What does a 4,000 BC mud hut, the Roman Coliseum, 1953 Corvette, bullet proof vest, and a Boing 787 have in common? They all were cutting edge applications of composite materials.
Composite material is achieved through the combination of two or more materials of different constituency. Together, they create a stronger and more durable product. Humans have been combining various materials together to improve strength and durability for millennia. But modern chemistry and technology have allowed more advances in the last 50 years than in all of history combined.
One such invention is thermoplastics. Thermoplastics have unique characteristics that make it a highly useful material, particularly for piping. Its ability to be extruded into various diameters, and wall thickness combined with its exceptional anti-corrosion properties have quickly made thermoplastic pipe the material of choice for most liquid and gas substances particularly anything corrosive or abrasive. The challenge for thermoplastic pipe is its pressure capacity is achieved through its wall thickness. Thicker walls equate to higher costs and installation challenges.
Parallel with advances in thermoplastics, a new material was developed, fiberglass. Thin strings of glass fibers have tremendous tensile strength, particularly when grouped together. Scientists and engineers began looking for viable applications in the mid-20th Century. Fiberglass reinforced hard epoxy plastics have been used for everything from cars to airplanes.
As with all great discoveries, it takes people looking at problems from the outside to see the opportunities. The first composite plastic pipe was devised in 1935. But it took more than 75 years for that process to be perfected. This is what Composite Piping Technology has accomplished. MaxDR is the world’s first large diameter, fusible composite poly pipe. Through our patented process of creating a cohesive fiberglass wrap that is heat fusion bonded with traditional poly pipe.
Composite Pipe Materials – Better Together
Historically, pipe has been made from a single material. This is due in part to the fact that you must connect multiple joints of pipe together to build a pipeline, e.g., welding steel, fusing HDPE, or gluing PVC and fiberglass. In the case of composite pipe, it is extremely difficult to combine different materials together, especially in the middle of nowhere in dusty, dirty conditions. This is the single biggest challenge that must be overcome when engineering pipe that has different layers of material.
Over the decades, there have been numerous attempts (successful and failed) at combining multiple materials, such as fibers and resins to create a pipe with superior strength and performance, that is able to handle higher pressures and temperatures, as well as resistance to corrosion and abrasion. By leveraging the strengths of each component, these pipes can surpass the individual capabilities of any single material. However, at the end of the day, you have to connect joints of pipe to have a pipeline.
This article provides a perspective on the benefits of composite piping that addresses the challenges of transporting liquids, gases, and slurries that require larger diameters and have corrosive or erosive properties while also maintaining the ability to be easily joined in the field.
Various forms of composite piping include:
Steel-plastic composite pipes. These pipes combine the durability of steel with the flexibility of corrosion-resistant plastic. They are widely used in various industries for transporting caustic or corrosive fluids. While these pipes exhibit high pressure capacity, their joint connections present a weak point for corrosion and joining.
Reinforced Thermoplastic Pipe – Recently, composite pipes have included varying layers of thermoplastics pressure barrier and woven fiberglass layers, and in some cases thin layers of steel, all combined to create a spoolable composite pipe. While this pipe has benefits for smaller volumes and high pressures, these spoolable pipes are limited in diameter to less than 10 inches. In addition, the joint connections are difficult to install and present long-term cyclical integrity issues.
Fiber Reinforced Plastic/Glass Reinforced Plastic pipe (FRP/GRP). Generally referred to as fiberglass pipe, this product has strands of fiberglass embedded in a hardened epoxy matrix. Fiberglass pipe exhibits strong anti-corrosive attributes and can handle higher temperatures and pressures but is difficult to join and is a much higher cost than other pipe material.
Fusible Composite Poly Pipe (HDPE). Composite poly pipe, utilizing high-density polyethylene (HDPE) as its core pipe, is a versatile and durable material that is commonly used in numerous sectors due to its excellent properties. The core pipe is wrapped with a continuous poly-fiberglass reinforcement tape (PFRT) that is heat fusion-bonded to the pipe along with a protective HDPE cover. Because the PFRT is cohesive with the core pipe and very thin, the joint connection is heat fusion bonded utilizing the same equipment and procedures as traditional HDPE.
Composite Pipe Applications
Composite pipes find extensive use in various industrial sectors due to their exceptional performance and versatility:
Oil & Gas. Composite pipes are employed in oil and gas exploration, production, and distribution, offering resistance to corrosion and the ability to withstand harsh environments on land, subsurface or in deepwater ocean.
Water Midstream. In water transportation and distribution networks, composite pipes ensure reliability and longevity, making them ideal for long-distance conveyance of water and wastewater.
Industrial and Mining. Composite pipes are widely used in chemical processing plants, mining operations, and other industrial applications where resistance to aggressive chemicals and abrasion is crucial. Plastics are typically used for the interior pipe, acting as a sacrificial buffer for abrasive materials like slurry.
Water and Wastewater. Composite pipes serve as durable and leak-free solutions for transporting clean water and managing wastewater effectively. Additionally, plastic or ceramic inner pipes are more durable than other materials in resisting contaminants like hydrogen sulfide (H2S).
Advantages of Fusible Composite Poly Pipe (HDPE)
Fusible composite HDPE poly pipe is versatile and durable. Some of the key features and characteristics of composite HDPE poly pipe include:
- High Density Polyethylene (HDPE) material. HDPE is a thermoplastic polymer made from ethylene monomer molecules. It has a high strength-to-density ratio and is known for its toughness, chemical resistance and UV resistance, making it suitable for a wide variety of applications.
- Composite structure. Composite poly pipes consist of multiple layers, typically with a core layer of HDPE 4710, PE-RT or MDPE, and additional protective layers. The additional layers can be made of various materials, such as adhesive, barrier coatings or reinforcement, depending on the specific requirements of the application.
- Corrosion resistant. Composite HDPE pipes are highly resistant to corrosion, rust, and chemical attacks, making them an excellent choice for transporting corrosive fluids or chemicals.
- Despite their enhanced strength, composite HDPE poly pipes are often lighter than traditional materials like steel, GRE or concrete. This lower weight facilitates easier transportation, handling, and installation, reducing overall project costs.
- Long service life. Composite HDPE pipes have a 50-year service life due to their resistance to degradation from environmental factors, including UV radiation and harsh chemicals. They can often outlast other types of pipes, reducing maintenance and replacement costs.
- Environmental performance. Composite HDPE poly pipe uses less material than standard poly and its lightweight nature of composite pipes reduces the carbon footprint associated with transportation and installation. Additionally, their corrosion resistance and leak-free design contribute to better environmental protection.
- HDPE composite poly pipes are used for a wide range of applications, including produced water gathering, water supply and distribution, natural gas distribution, irrigation systems, sewer and wastewater management, mining operations, and industrial fluid transport.
- Smooth interior surface. Composite HDPE pipes often have a smooth interior surface, which reduces friction and flow resistance, leading to improved flow rates and reduced energy consumption.
- Reduced leaks and spills. Composite pipes are joined using heat fusion bonding methods that create leak-free connections, minimizing the risk of leaks, spills, and environmental contamination.
- Cost-effective. Composite poly pipes generally offer a total lower cost when compared to the same internal dimension and pressure rated pipe due to less material and lower handling/installation costs along with their long-term benefits, including reduced maintenance, extended service life, and improved efficiency, often lead to overall cost savings.
Overall, the use of composite pipes provide a reliable and efficient solution for various industries, contributing to improved performance, reduced operational costs, and a more sustainable approach to infrastructure development.
MaxDR™ Fusible Composite Poly Pipe
MaxDR from Composite Piping Technology (CPT) is the first large diameter, fusible composite poly pipe reinforced by multiple layers of fiberglass cohesively bonded to the HDPE core pipe. MaxDR offers pipeline designers, builders and operators all of the benefits of HDPE poly pipe with the strength of composite materials.
Key features of MaxDR include:
- Large diameters.Available in diameters ranging from 12″ to 24″.
- Enhanced pressure performance.Delivers 2-3x greater pressure performance while remaining lightweight and strong.
- High-pressure applications.Available for applications of 350, 550 and 750 psi service, dramatically expanding the performance envelope of lightweight, fusible HDPE poly pipe.
- MaxDR joints are fused together using existing HDPE fusing equipment.
- Corrosion resistant. Suitable for transporting highly corrosive gases, liquids and slurries.
- Compliance with standards.Manufactured to ASTM and API standards applicable to traditional HDPE 4710 pipe.
- Full traceability.Embedded with RFID tags aids digital traceability.
MaxDR Benefits
MaxDR offers A Material Difference in Performance and Value™. As a lighter, less expensive pipe for the same application, MaxDR composite poly pipe delivers these benefits:
- Use poly pipe where it has never been used before. MaxDR enables the use of lightweight, easy to use, durable poly pipe in applications where ordinary HDPE cannot due to pressure constraints.
- Lower installation and capital costs. MaxDR is substantially lighter than alternative steel pipes for higher-pressure applications, reducing transportation, handling and installation costs. The ability to use existing poly pipe fusing equipment enables faster installation.
- Decreased operating cost. Leak-free operation eliminates spills and the need for costly cathodic protection and anti-corrosion chemicals.
- Reduced carbon intensity. Composite pipes use fewer resources, promoting sustainability and resource conservation.
- No leak fusion joint. Easy to use and MaxDR segments are joined using existing HDPE fusing technology for a leak-free connection, mitigating risk and improving environmental performance.
- Easy to use. Retains the properties of HDPE, making them familiar and user-friendly.
Summary
Composite materials have played a critical role in lowering costs while increasing performance on projects while making them more sustainable. Composite pipes offer several significant benefits over traditional piping materials, making them an attractive choice for various industrial and municipal applications.
MaxDR is the first large diameter fusible composite HDPE poly pipe, opening the door to new possibilities for pipeline designers, builders and operators. MaxDR offers users in Oil & Gas, Industrial & Mining, Water & Wastewater and CO2 gathering and processing sectors a sustainable solution with the lowest total cost of ownership.
Contact CPT today at info@compositepiping.com or (903) 309-1158 to learn more about the MaxDR innovation and how it can help you boost economic returns with improved sustainability and lower carbon intensity.
