Savings of up to 50% in time and 40% in installation costs were achieved compared to traditional steel piping.
The new fire main at Borealis' production site in Porvoo, Finland serves a fire fighting water curtain and sprinklers at a new loading station for highly flammable liquid petroleum gas (LPG) and butadiene. To ensure total operating reliability at all times, engineering company Neste Jacobs Oy required a water pipe system capable of offering a long working life despite the exceptionally tough physical conditions at Porvoo.
Key challenges for a fast and economical turnaround included highly rocky terrain and a busy railway line under which part of the pipeline would run. Rail services could not be disrupted by the installation project, meaning no-dig directional drilling was required to lay the pipe system. The excessive ground vibrations caused by heavy rail-yard traffic and completion of the project during the harsh winter months of November to February, where temperatures fall as low as -15°C, placed further demands on the chosen pipe's performance both during installation and over the long-term.
Neste Jacobs, the project installer Destia, and pipe manufacturer KWH Pipe evaluated BorSafe HE3490-LS-H as the most viable alternative to traditional steel in meeting the tough demands of this project.
BorSafe HE3490-LS-H is a latest generation high density polyethylene (HDPE) pipe material. The PE100-RC material, classified as MRS 10.0, was developed specifically to complement faster, more economical pipe-laying techniques in tough conditions with high environmental stress.
A product of the advanced performance and processing benefits created by Borealis' bimodal Borstar® process, BorSafe HE3490-LS-H offers low notch sensitivity and superior resistance to point loading and slow crack growth (SGC). The RC (resistance to crack) material avoids the potential for pipe tears even when point loads caused by rocks occur.
Non-corrodible by chemicals, this adds to the outstanding durability that enables BorSafe HE3490-LS-H-based pipes to deliver a service life in excess of 100 years.
Its consistent toughness and high quality makes BorSafe HE3490-LS-H particularly suitable for pipes subject to the aggressive conditions associated with modern, trenchless laying techniques. The lack of soft, sandy bedding in directional drilling, pipe bursting and ploughing-in techniques makes robust pipe material a definite requirement.
At Porvoo, the pipes were laid at a depth of 2 metres to avoid potential climatic damage. Thanks to the robust profile of the BorSafe HE3490-LS-H based pipes some of the rough excavated rocky soil could be used as trench backfilling. This reduced the amount of excavated material to be removed from the site and the volume of finer material to be brought on-site for pipe bedding, thus reducing time, cost, and environmental impact.
"Using PE provided a major reduction in installation time compared with traditional steel piping," comments Ville Lilja, Borealis Project Manager. "It allowed the pipes to be joined by butt fusion welding which offers a 50 % time saving on steel welds, as well as a 40 % cost saving," adds Jarmo Aho, NesteJacobs Construction Manager.
Borealis (borealisgroup.com) is a leading provider of chemical and innovative plastics solutions that create value for society. With sales of EUR 4.7 billion in 2009, customers in over 120 countries, and 5,200 employees worldwide, Borealis is owned 64% by the International Petroleum Investment Company (IPIC) of Abu Dhabi and 36% by OMV, the leading energy group in the European growth belt. Borealis is headquartered in Vienna, Austria, and has production locations, innovation centers and customer service centers across Europe and the Americas. Through Borouge, a joint venture between Borealis and the Abu Dhabi National Oil Company (ADNOC), one of the world’s major oil companies, the company’s footprint reaches out to the Middle East, Asia Pacific, the Indian sub-continent and Africa. Established in 1998, Borouge employs approximately 1,400 people, has customers in more than 50 countries and its headquarters are in Abu Dhabi in the UAE and Singapore.
Building on the unique Borstar® technology and their experience in polyolefins of more than 50 years, Borealis and Borouge provide innovative, value creating plastics solutions for the infrastructure (pipe systems and power and communication cables), automotive and advanced packaging markets. In addition, Borealis offers a wide range of base chemicals from melamine and plant nutrients to phenol and acetone.
Today Borealis and Borouge manufacture over 4 million tonnes of polyolefins (polyethylene and polypropylene) per year. Borouge (borouge.com) is currently tripling its polyolefins manufacturing capacity to 2 million tonnes per year (t/y) by mid-2010 and an additional 2.5 million t/y is scheduled for 2013. The companies continue to invest to ensure that their customers throughout the value chain, across the globe, can always rely on product quality, consistency and security of supply.
Borouge and Borealis are committed to the principles of Responsible Care® and proactively contribute to addressing the world’s water and sanitation challenges through their Water for the World™ (waterfortheworld.net) initiative.