th

Proceedings of the 17 Plastic Pipes Conference

PPXVII
September 22-24, 2014, Chicago, Illinois, USA

PE-RT FOR INDUSTRIAL AND OIL & GAS APPLICATIONS:

NEW OPPORTUNITIES WITH NEW STANDARD

Daniel Libert Pierre Belloir

Total Refining & Chemicals – Polymers Europe Total Refining & Chemicals – Polymers Europe
Seneffe, Belgium Seneffe, Belgium

ABSTRACT
PE-RT is now well established in the Hot & Cold market with various pipe designs and associated standards. For
many years, PE-RT has found a good place in Under Floor Heating applications in many places around the world. The
comprehensive testing performed on raw materials led to a better knowledge of high temperature performance and
resistance to adverse environment such as chlorine based disinfectants. This knowledge benefits industrial applications
where operating conditions are outside the ones defined for the transport of gas and drinking water. In consequence, it
was decided to revise the ISO15494 standard dedicated to such applications. The revised version was circulating for final
vote current 2013 and an update on its publication will be given at the conference. What can PE-RT bring to industrial
applications? Most requirements of this industry will be commented in the paper ; this will include the pipe designs
considered, the expected polymer processing behavior, the multiple operating conditions, the chemical resistance, the
fusion compatibility, the method of extrapolation from the ISO9080 regression curves, the slow crack growth performance
as well as the fatigue and rapid crack propagation resistance. A walk-through to use ISO15494 with PE-RT will be shown.
Some insight will also be given on how PE-RT is being introduced for new applications such as plastic pipes and liners to
be used in conventional and unconventional Oil & Gas projects. Design temperature and pressure, pipe sizes and
potential applications are defined at the disposal of project managers around the globe.

INTRODUCTION
PE-RT is a material that has been on the market for many years as an alternative to other polymers for Hot & Cold
(H&C) piping applications, especially Under Floor Heating. Monolayer and multilayer P-type pipes as well as multilayer
M-type pipes have been produced with PE-RT in accordance with relevant product standard. Its applications have been
extended further with the arrival of Type II products for which new reference curves were defined and added in the last
revision of the standard. The knowledge brought by the comprehensive testing performed on all these new materials led
to a better knowledge of high temperature performance as well as their behavior in adverse environment such as
chlorinated disinfectants. PE-RT Type II, of higher strength, naturally became a good candidate for industrial applications.
The scope of such applications will be reviewed here. The Oil & Gas industry can also find new opportunities in their high
demanding applications.

KEY LEARNINGS FROM H&C STANDARDS

The starting point of the H&C standards is the publication of the reference curves in the ISO 24033:2009. This
second edition cancels and replaces the first edition (ISO 24033:2006), which is extended to cover PE-RT materials, Type
II, which have a higher hoop stress performance at higher temperatures than Type I. The first edition dealt only with PE-
RT materials, currently designated Type I [1]. Those curves tend to give the expected strength of PE-RT pipes when
submitted to internal pressure at high temperature. The extrapolation limits (the end points of the reference lines) are
based on an experimentally determined life at 110 °C and an Arrhenius equation for the temperature dependence with an
activation energy of 110 kJ/mol (≈ 26 kcal/mol) [1]. It shows, for example, a minimum expected hoop strength value of 5,1
MPa for a continuous use at 70°C during a period of 50 years for a pipe made of PE-RT Type II. Commercial PE-RT raw
materials need, of course, to show conformity with those reference curves by submitting pipes for a yearlong hydrostatic
pressure testing in an accredited laboratory. For example, one PE-RT Type II showed a minimum expected hoop strength
value of 5,44 MPa in the same operating conditions (70°C, 50 years) [2].

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 The second standard to take into consideration is the ISO 22391-1:2009 defining the general requirements for PE-RT
plastics piping systems for hot and cold water installations. This part of ISO 22391 covers a range of service conditions
(classes of application), design pressures and pipe dimension classes, and also specifies test parameters and defines
terms [3]. The classification of service conditions detailed in Table 1 of this standard is exactly the same for all plastics
piping systems (PEX, PB, PP and PVC-C). The material from which the pipes are made shall be in accordance with ISO
22391-2:2009 defining the pipe characteristics. The material, as said in clause 4.2, shall be evaluated in accordance with
ISO 9080 in order to determine the σLPL values. The σLPL value thus determined shall be at least as high as the
corresponding values of the reference curves given in ISO 24033:2009 over the complete range of times [4].

Part 2 of ISO 22391 defines also, besides the raw material properties, all other pipe characteristics such as diameter,
wall thickness and tolerances calculated for each classes of application and associated service conditions. The Table 2
from this standard is given below in Figure 1. It shows the calculated diameter to wall thickness ratios for each application
classes. The pipe dimensions will then be chosen within the given pipe series as long as it meets the required maximum
allowed diameter to wall thickness ratio. The maximum allowed stress allowing the calculation of the minimum thickness
for each given operating pressure is added below the Table ; this value comes from the reference curves of the relevant
material, PE-RT Type II in this case applying a given safety factor.

Figure 1: Pipe geometry for applications classes and various operating pressure according to ISO 22391-2:2009

In review of the previous example with a minimum expected hoop strength value of 5,1 MPa for a continuous use at
70°C during a period of 50 years for a pipe made of PE-RT Type II, considering class 2 service conditions represent the
best these conditions, we see that the standard recommends a maximum stress of 3,4 MPa instead of the 5,1 MPa
expected from the reference curve ; there is indeed a applied safety factor of 1,5 giving much confidence for a service life
of 50 years.

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 Other requirements from ISO 22391-2:2009 include the longitudinal reversion and the thermal stability by hydrostatic
pressure testing with testing up to 1 year minimum at 110°C.

Additional requirements are also defined in ISO 21003-2:2008 dedicated to multilayer pipes for H&C. Such pipes
must be tested for the resistance of mounted assemblies to temperature cycling ; no failure should be observed after 5000
cycles (2500 h) at 10bar / 20 to 95°C. This challenging test may be compared to a fatigue test where all components are
subject to mechanical stresses due to temperatures cycling.

Chlorine resistance is also required where this disinfectant is used and the reference standard is ASTM F2023.
Failure times are extrapolated to 50 years and the results are expressed as a maximum operational temperature for 50
years oxidative resistance in contact with 4.3 ppm chlorinated water (concentration kept constant during the test by
dynamic operating conditions). Products that perform well in the application show a maximum temperature of 75°C, in
excess of the 60°C required for ASTM Class 5.

APPLICATION TO THE INDUSTRIAL STANDARD

All these testing required by the H&C industry are all benefits for the industrial applications where operating conditions
are outside the ones defined for the transport of gas and drinking water. In consequence it was decided to revise the ISO
15494 standard dedicated to such applications.
st
The new edition is replacing the 1 version of 2003. The main novelty is the introduction of PE-RT and PEX besides
the PE, PP and PB. The ISO/TC138/SC3/WG7 is leading this work ; the enquiry on DIS draft version was closed on 4
September 2013 and the document was approved by the majority of ISO member countries. The comments on ISO/DIS
15494:2013 were examined and discussed. The final draft should be subjected to enquiry as reported at the last TC155
plenary meeting of May 2014.

Before it is officially published, the ISO/DIS 15494:2013 can already be reviewed and examined how the
characteristics of PE-RT can be used to answer the needs of industrial applications. Basically the standard requires the
components to withstand the mechanical, thermal and chemical demands to be expected and to be resistant to fluids
being conveyed [6]. Knowing each project in industrial field has specific requirements in terms of temperature, pressure,
nature of the fluid conveyed, the standard gives guidelines for the design of the plastic pipes rather than predefined
service conditions and associated dimensions such as in H&C standards. Each project should be studied case by case
and use the tools of ISO 15494 for proper piping design.

The key points of ISO 15494:2013, focusing on PE-RT requirements, are the following [6] :

 The hydrostatic strength properties of the material must be in conformity with the relevant product standard, ISO
24033:2009 for PE-RT ; this is a basic but fundamental requirement as the regression curves of the raw material
must be above the reference lines defined in the product standard.
 The control of the mechanical characteristics of components is aligned on ISO 22391-2 (control points with up to
1000 hours testing at 95°C)
 The color of the components depends on the material and the associated product standard ; if a PE100 is used,
then the color must be black ; if a PE-RT is used, no color is specified meaning all colors are allowed providing
the requirements of the PE-RT product standard are met ; non pigmented pipes can be used provided UV-
protection is not needed. The choice of color for pigmented pipes shall be agreed between manufacturer and
purchaser providing good pigment dispersion is achieved (≤ grade 3 according to ISO 18553).
 UV resistance: Components for external above ground installations shall be adequately protected against UV-
radiation or the material shall be resistant to UV radiation for the intended application. For products which are
usually stored outside in direct sunlight prior to installation, the effect of UV radiation shall be taken into account.
To assess materials for resistance to UV radiation for storage purposes, pipe is subject to a cumulative radiant
exposure of > 3.5 GJ/m2 in accordance with ISO 16871. Following this exposure the pipe is assessed for any
significant change in mechanical properties.
 Thermal stability : same requirement as in ISO 22391-2
 Resistance to Rapid Crack Propagation (RCP) if a compressible gas is conveyed

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  Fitness for purpose and performance of joints : as it is common practice in gas and water standards, the fusion
compatibility of the PE-RT material must be assessed to ensure the performance of all jointing techniques (butt
fusion, electrofusion, socket and saddle fusion jointing)
 Chemical characteristics: Where fluids other than water are to be conveyed, guidance is given in ISO/TR 10358
or by the component manufacturer. If it is necessary to evaluate the chemical resistance of the pipe for a
particular application, then the pipe can be classified in accordance with ISO 4433-1:1997 and ISO 4433-2:1997.
These tests consist of an immersion of test samples at 80°C / 4 weeks followed by the measure of tensile strength
change (must be < 5%) and weight change (must be < 10%)

Once the performance of the PE-RT is demonstrated to be in conformity with all above requirements, the design of
the thermoplastics piping system for industrial applications can proceed. For the design of a piping system (e.g.
determination of the maximum allowable pressure), the following parameters should be taken into account:

 Temperature, usually constant, if changing, then ISO 13760 Miner's Rule should be used;
 Pressure, usually constant, if changing, then ISO 13760 Miner's Rule should be used;
 Lifetime, usually 25 years;
 Stress, calculated with the equations given in Figure 1
 Resistance to Rapid Crack Propagation for pipe for transport of air or a compressible gas;
 Chemical resistance of the material against the fluid;
 Required design coefficient, C; (minimum values of C are given in ISO 12162)
 Influence of wear and abrasion by solid matters in fluids;
 Influence of changing of length (caused by temperature, swelling, internal pressure);
 Kind of installation (fixed, floating, etc.);
 Supporting distances in the installed piping system.

With these parameters, together with the minimum required hydrostatic strength curves, the design of a piping system
can be carried out, taking into account the national and/or local requirements, where appropriate, complemented by
experimental design methods.

Example 1: an alkaline solution at a constant temperature of 70°C must be conveyed in a 250mm diameter pipe at a
pressure of 5 bar ; an expected lifetime of 25 years is considered ; can PE-RT be used and which pipe design to select ?
PE-RT has an excellent chemical resistance to such solution ; the reference curves of Type II material taken from ISO
24033 show a maximum stress of 6 MPa after 25 years at 70°C ; taking into account a safety factor of 1,5 we can
recommend a maximum stress of 4 MPa ; therefore a wall thickness of 14.7mm is suitable (SDR17). Such pipes can be
easily welded together by butt fusion technique for a cost effective installation. A PE-RT raw material with good sag
behavior will have to be selected to allow the extrusion of such a 14.7mm wall thickness pipe.

Example 2: methane / ethane gas at a temperature of 60°C must be conveyed in a long distance pipe; what is the
maximum allowable pressure when using PE-RT Type II material ? 50 years lifetime is considered here. The reference
curves show a maximum stress of 5.8 MPa; this time a safety factor of 2 is used such as in the gas industry; the
recommended maximum stress is thus 2.9 MPa. A maximum operating pressure (MOP) would be 3.6 bar if an SDR 17
pipe is used ; this MOP increases to 5.8 bar with an SDR 11 and up to 9.0 bar with an SDR 7.4. Attention is drawn on the
resistance to Rapid Crack Propagation for such pipe transporting a compressible gas and moreover flammable ; this
property will have to be checked on the final dimension (diameter and thickness) either by the pipe or the raw material
manufacturer ; we may suggest to follow the requirements of the ISO 4437-2:2013 [7] where the critical pressure (Pc)
must greater than 1.5 the MOP (Pc ≥ 1.5 MOP) at 0°C. Therefore the RCP performance of the selected PE-RT will
determine the MOP.

Example 3: a PE liner for corrosion protection is submitted to high temperature without stress being applied; what is
the maximum temperature allowed and what is the lifetime expectancy of such a liner ? Although the no stress situation is
difficult to achieve, a very low stress condition will lead the material to fail eventually in a thermo-oxidative mode ; this
mode being stress independent, the lifetime expectancy will be extrapolated from the testing data generated at the highest
temperature (110°C) taking into account the limits defined by the ISO 9080. The one year requirement at 110°C allows an
extrapolation of 18 years at a continuous temperature of 80°C but if the testing of the selected PE-RT is successfully
continued beyond the minimum required, the lifetime expectancy can be extended to 40 years at a continuous

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temperature of 80°C or 13 years at a continuous temperature of 90°C (data calculated from continued pressure testing
performed on a PE-RT Type II resin [9]).

NEW APPLICATIONS OF PE-RT IN OIL & GAS INDUSTRY

HDPE has been used for years in the oil & gas industry with precautions applied from this industry. An example of
conditions for using HDPE is given below:
 Onshore application
 1 to 16 inches diameter pipe (25 to 625mm)
 Effluent is water or gas
 Maximum design temperature of 40°C
 Maximum design pressure below 25 bar
 No cyclic loads expected

We can of course challenge such conditions for the use of HDPE but it is better to reconsider those conditions in
regard of the PE-RT properties and define a new scope of utilization for this material.

In parallel, to answer the growing demand of hydrocarbons, the search for new sources of oil & gas led to the
development of new “unconventional” production technologies such as shale gas & oil, tight gas, coal bed methane (also
called coal seam gas), … Those techniques have in common “out of the box” operating conditions which need to
reconsider the choice of the materials used.

Figure 2: Schematical view of various geological traps for gas [10].

For coal bed methane developments in places around the world, HDPE pipes are an interesting option in terms of
corrosion resistance and cost for low pressure piping networks. The expected service conditions being more stringent
than usual, it is necessary to consider the use of PE-RT as this material is suited for high temperature applications. Based
on design reference curves and manufacturing experience limitations (in particular in terms of maximum wall thickness),
guidance is given for maximum design pressure and pipe diameter limitations. In some scenarios studied by the industry,
such coal bed methane fields would need a low pressure gathering piping network with a maximum pressure of 3.5 bar
and a temperature above the usual limitations of HDPE. PE-RT is an excellent candidate for such projects. Two scopes
of utilization are defined: one for gas and one for water; each of them gives recommendations for a maximum design
pressure for 50 years lifetime, a maximum pipe diameter for different maximum design temperatures.

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 PE-RT materials should also be considered for some oil fields with unconventional production techniques used to
improve the extraction of heavy or extra-heavy oil. The most "conventional" scenario in the field of extra-heavy oil offers
key advantages such as a better energy balance than thermal recovery projects. On the downside, however, these
projects post the lowest recovery rates – on the order of 8 to 10%. There is hope that such technologies could as much as
double that performance [11]. In some cases, injection of water at potentially high temperature is required and therefore
the use of PE-RT has interest.

Figure 3: Various technologies for the production of extra-heavy oils [12].

In the frame of such projects, the use of polymer liners is considered by some oil companies to provide internal
corrosion protection to water injection flowlines. Such liners need to provide long term internal corrosion protection for the
water injection flowlines and ensure there is no degradation through the pipeline system. The operating temperatures in
the flowlines could be higher than current industry practice where standard HDPE is used. Therefore the use of PE-RT
was selected for the pre qualification tests (PQT); PE-RT was preferred to other polymers offering high temperature
resistance thanks to the experience gathered with HDPE liners at lower temperature in terms of processability according
to the selected lining technology, toughness, diameter range experience, weldability by butt fusion and last but not least
the cost of the raw material. A selected PE-RT material is currently being tested in the frame of a formal PQT; this
includes material testing (chemical compatibility with water additives, stress strain curves, tensile creep and relaxation at
high temperature …), butt fusion behavior, liner properties after installation, reeling capability …

CONCLUSION
The extensive knowledge of the mechanical properties at high temperature acquired on PE-RT for the Hot & Cold
market benefits for the industrial applications where operating conditions vary as much as there are projects. The ISO
15494 was revised with the introduction of PE-RT and references to appropriate product standards. This opens the doors
to new applications, especially for the Oil & Gas industry where the growing demand for hydrocarbons requires the use of
“unconventional” production technologies. Those new technologies have in common operating temperatures above the
current industry practice where PE-RT becomes the ideal material taking into account the experience already gathered
with standard HDPE and, besides the mechanical properties at elevated temperature, characteristics such as the
weldability, the access to much larger diameters than allowed by Hot & Cold product standards, the flexibility, creep
resistance, toughness, … in one word, all the advantages of HDPE accessible at higher temperature.

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REFERENCES
[1] : ISO 24033:2009, Polyethylene of raised temperature resistance (PE-RT) pipes — Effect of time and temperature
on the expected strength
[2] : Determination of the long-term hydrostatic strength, ISO 9080:2003-evaluation of the PE-RT Type II pipe grade
HDPE XRT70 from Total Petrochemicals, Exova testing report P-12/25 (2012)
[3] : ISO 22391-1:2009, Plastics piping systems for hot and cold water installations — Polyethylene of raised
temperature resistance (PE-RT) — Part 1: General
[4] : ISO 22391-2:2009, Plastics piping systems for hot and cold water installations — Polyethylene of raised
temperature resistance (PE-RT) — Part 2: Pipes
[5] : ISO 21003-2:2008, Multilayer piping systems for hot and cold water installations inside buildings — Part 2: Pipes
[6] : ISO 15494:2013, Plastics piping systems for industrial applications — Polybutene (PB), polyethylene (PE) and
polypropylene (PP) — Specifications for components and the system — Metric series
[7] : ISO 4437-2:2013, Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE) — Part 2: Pipes
[8] : ISO 9080:2012, Plastics piping and ducting systems, Determination of the long-term hydrostatic strength of
thermoplastics materials in pipe form by extrapolation
[9] : Hydrostatic pressure testing, continued pressure testing of the PE-RT Type II pipe grade HDPE XRT70 from Total
Petrochemicals, Exova testing report P-13/68 (2013)
[10] : “Unconventional gas, resources for the future” on http://total.com/en/brochure-gnc-en consulted on 10/06/2014
[11] : “Improving the Recovery of Extra-heavy Oil” on http://total.com/en/energies-expertise/oil-gas/exploration-
production/strategic-sectors/eho/innovation/Improving-Recovery-Rates consulted on 10/06/2014
[12] : “Three Categories of Heavy Oil” on http://total.com/en/energies-expertise/oil-gas/exploration-
production/strategic-sectors/eho/challenges/presentation consulted on 10/06/2014

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