Part of egeplast Group 2022/2023 EN Standard and multifunctional Polyethylene pipe systems - Pressure pipes - Gravity pipes - Pipe fittings - Pipes for relining - Insulated pipes - Cable protection pipes
3 Since April 2020, Extena is part of the German group egeplast, which for decades has been Europe’s leading manufacturer of polyethylene pressure pipe systems. egeplast is also a specialist in multifunctional multilayer pipes with unique properties for safer and better pipe systems. This means that Extena is now a complete supplier of high quality polyethylene pipe systems in the Nordic market. We can offer a wide range of pipes made of polyethylene in both small and large dimensions and an extensive range of pipe fittings, for both small and large projects. Together with our customers, we create optimal conditions for a better environment and clean water for future generations. Extena is now the leader in pressure pipes and polyethylene pipe fittings in the Nordic region. Part of egeplast Group
4 Extena has long been Sweden’s leading manufacturer of pressure pipe systems in PE100 RC. When Extena became part of egeplast, we also became experts in multilayer pipe systems, with an extensive range of sheathed pipes for different applications and alternative installation methods. egeplast is a specialist in homogeneous polyethylene pipes in general and multilayer pipes in particular – and also offers a wide range of polyethylene pipe fittings, which is now being made available to the Swedish market. PE100 RC as standard We manufacture our standard pipes in PE100 RC, which is the best raw material for a safe and economical pressure pipe system with a long service life. For example, our PE100 RC material, certified by PAS 1075, has 17 times higher requirements than the standard for resistance to slow crack growth (SCG). Starting with PE100 RC as the base material, we add a variety of features depending on the application – such as protective layers (sheathed pipes), colour marking for the location of scratches and damage detection with online monitoring. By choosing PE100 RC, you will achieve faster installation, a longer and safer service life and better overall cost efficiency. 40% higher requirements than the standard At Extena, we specialize in manufacturing the best polyethylene pipe systems on the market. We therefore place tougher requirements on the pipe systems we manufacture than those specified in European standards. By cooling the pipes for a longer period and stabilizing them during the cooling process, we can set higher requirements and significantly tighter tolerance levels regarding ovality than the standard permits. In fact, we have 40% higher requirements in terms of ovality than specified in the standard. A complete package – for safe and secure procurement Extena takes responsibility for everything. With Extena, you get a complete range of polyethylene pipes and fittings from a single supplier. As a complete supplier, we can also offer complete quotations for safe and secure procurement. We manufacture our products at our own factories in Sweden, Germany and the UK, which means that we have full control of the manufacturing process and can guarantee the highest possible quality. Project service Extena is a safe partner throughout the procurement process as well as the design phase. We offer advice, planning and, if necessary, drawings of project-specific pipe fittings. We can also advise on the choice of pipe and provide recommendations for laying pipes in installations close to traffic, for example. A complete range of pressure pipes and polyethylene pipe fittings from a single manufacturer
5 Sheathed pipes Type 3 for optimal protection Extena’s sheathed pipes in PE100 RC are tested and approved according to PAS 1075, a requirement standard developed under the auspices of the German standards institute DIN (Deutsches Institut für Normung). The standard is divided into three classes as described below: Type 1 includes standard pipes made of PE100 RC material. Type 2 includes homogeneous 90/10 pipes with an integrated PE100 RC surface layer representing 10% of the material thickness. Type 3 includes pipes with a minimum sheath thickness of 0.8 mm. In order to meet the Type 3 requirements, therefore, the protective sheath must be at least 0.8 mm thick. Our sheaths are 1 to 5 mm thick for optimal protection and must not be confused with the thin layer of less than 1 mm that some pipes on the market are fitted with. All of Extena’s sheathed pipes easily exceed the requirements of PAS 1075 Type 3. Extena is leading development in Sweden Extena is the manufacturer in the Nordic region that is most forcibly driving the issue of building pipe systems with better raw materials, which significantly increase resistance to slow crack growth. At an early stage, we saw the benefits of PE100 RC pipe systems, a material that enables more cost effective pipelaying methods with a longer and safer service life – resulting in better overall cost efficiency. The pipes are a relatively low cost option, in most cases representing only 5-15% of the total cost. It should therefore be an obvious choice to use the highest quality pipes. egeplast has long recognized the benefits of using the modern PE100 RC material. As both Extena and egeplast have a clear focus on offering the highest quality and use the PE100 RC as the main raw material in production, our respective product ranges fit very well together. egeplast – expert in multilayer pipes For decades, egeplast has led the way in Europe in the development and manufacture of polyethylene pressure pipes and fittings in general and multilayer pipes in particular. Research and development have a long tradition at egeplast and over the years the company has become a recognized innovation hub. This technical leadership includes more than 60 patents for products and manufacturing processes. egeplast was founded in 1908, and its products can now be found in various technical supply systems across the globe. The head office is located in Greven, Germany, where the company operates Europe’s most modern polymer pipe system plant. The Group also has its own factory in the UK and now also includes Extena with its development and manufacturing facility in Norsjö. Together with egeplast, Extena is a leading manufacturer of pipe systems with different functions. With our multilayer pipes, we can offer systems with e.g. an impermeable barrier, online damage control monitoring and resistance to extra high pressures. Introduction
6 Safe supplier for large projects We have extensive experience of large projects and know how important the time aspect and reliability of supply are when working with many subcontractors. Since we have our own modern, large capacity production facility and a complete range of polyethylene pressure pipes and pipe fittings, we are now a reliable supplier to large projects all over Sweden. We are a safe partner in marine pipeline projects and the expansion of municipal water supply systems, for example. Quality you can trust Large pipeline projects require careful coordination of all the processes in order to meet the budget and achieve the desired end result. The fact that the pipes are of consistently high quality is therefore particularly important for larger projects. By cooling the pipes for a longer period and stabilizing them during the cooling process, we can set higher demands and significantly tighter tolerance levels regarding ovality than the standard permits. Among other things, this makes the jointing process simpler and more efficient, optimizing operating costs when carrying out large projects. Our pipes are also made of PE100 RC, a modern material that is extra resistant to cracking. Complete range and in-house manufacturing Extena provides a complete range of polyethylene pipes and fittings. As a complete supplier, we can also offer complete quotations for safe and secure procurement. We manufacture our products at our own factories, which means that we have full control of the manufacturing process and can guarantee the highest possible quality. Coordination of shipments We know how important it is for our clients that the right product is delivered to the right place at the right time. We have therefore built up a strong organization with a high level of competence to coordinate shipments. When you work with Extena, you can be sure that your products will be delivered as planned. Project support Extena is a safe partner throughout the procurement process as well as the design phase. We offer advice and, if necessary, drawings of project-specific pipe fittings. We can also advise on the choice of pipe and provide recommendations for laying pipes in installations close to traffic, for example. Introduction
7 Large dimensions – up to 1600 mm We extrude pipes in dimensions up to 1,600 mm. The pipes are manufactured from PE100 RC, which gives discharge pipes, pressure sewers and raw water pipelines, etc. a long service life. Over-sizing the pipeline from the outset gives you a future-proof, large capacity pipe system that can easily be supplemented with fittings and connections when needed. 4,600 m marine pipelines Extena and egeplast have supplied pipes for several large marine pipeline projects, such as the renovation of the water treatment plant at Grebbestad in Bohuslän county north of Gothenburg. For this extensive project, where the goal was to improve the efficiency of the municipal water treatment plant, we supplied a total of 4,600 metres of marine pipeline. Each welded and immersed segment is 500 metres long and weighs 250 tonnes, which placed very high requirements on the quality of both pipes and joints. In order to cope with the harsh demands and the tough conditions, PE pipes with a dimension of 710 mm SDR 17 were used together with polyethylene pipe fittings from egeplast. Logistics and installation went according to plan and Grebbestad now has a very efficient water treatment plant with a long and safe service life. Drinking water for future generations Another large project that we have been involved in is the construction of a new water supply in Skellefteå in northern Sweden. The project included 50 km of pipeline, for which Skellefteå Municipality and the general contractor chose to use PE100 RC pipes from Extena. The water that is transported from the water treatment plant to Skellefteå’s 45,000 inhabitants is distributed in double pipes with a diameter of 560 mm. By adding double pipelines from the start, Skellefteå Municipality has ensured that it will be able to cope with any increased future demands.
8 Introduction The development of pressure pipes has gone from the HDPE (high density polyethylene) pipes of the 1950s via PE63 and PE80 to today’s PE100 and PE100 RC. The increasing classification of materials meets the market’s demand for increased transport efficiency, which requires pipes that can operate under ever higher pressures. At the same time, new pipelaying techniques are being requested that are more cost effective than traditional open trench excavation. This has resulted in alternative installation methods such as pipe splitting, directional drilling and relining. These pipelaying methods, which pull the pipe through the ground, place high stress on the pipe systems with increased risk of scratches and pressure damage to the pipe walls. The increased demands for more efficient pipelaying have also led to an increased use of existing soils as backfill material. This process also increases the risk of the pipes being damaged by sharp stones that push against the pipeline. Studies and tests conducted by RISE have shown that the impact of a potential scratch or damage on a pipe cannot be assessed solely by its depth and sharpness. “In order to assess the impact of the scratch on the performance of the pipe, account must also be taken of the material from which the pipe is made and the safety factor by which it has been dimensioned. Extensive pressure testing shows that pipes made of modern materials can withstand scratches in the pipe surface much better than pipes made of older materials.” (Acceptance criteria for scratches and indentations in plastic pipes, RISE) Alternative installation methods New alternative installation methods and maximum service life requirements require pipes made from the best possible raw material. At Extena we therefore recommend that you always choose pipe systems made of PE100 RC, where RC stands for Resistance to Cracks. Extena’s PE100 RC material, certified according to PAS 1075, has 17 times higher requirements for resistance to slow crack growth (SCG) compared to the materials that the Swedish AMA (General material and work descriptions) bases its recommendations on. By choosing PE100 RC, you will not only have pipe systems with maximum service life, but also faster and more cost effective pipelaying. This is due to significantly improved installation, since PE100 RC permits the use of backfill material with a higher fraction. And by adding a high strength protective sheath to the pipe, you will create the best conditions for a pipeline to achieve the longest possible service life. All Extena’s sheathed pipes meet the requirements of PAS 1075 Type 3, i.e. the highest grade (pipes with a higher strength sheath). New installation methods, faster pipelaying and maximum service life demand the best pipe design
Därför rekommenderar vi alltid PE100 RC för ekonomisk läggning och säkrare livslängd 9 Introduction Polyethylene (PE) is lightweight and durable and has been the dominant raw material in pressure pipe systems for decades. The material, which provides reliable systems for the safe transportation of drinking water, waste water and process water, has been developed and launched in a number of versions over the years. As the demands for more cost effective pipe systems are constantly increasing, the material PE100 RC was launched in 2005 with more and stronger bonding between the molecules. The result is a raw material and pressure pipe system with significantly higher resistance to slow crack growth. We therefore recommend that you always choose pipes made of PE100 RC, which provides a safer and more cost effective pipe system. More bonding molecules PE100 RC is polymerized with longer side chains/branches or even more side branches especially in the longer chains. These branches result in stronger entanglement in the amorphous parts and increase the resistance against slow crack growth (SCG). This improvement guarantees an intact lifetime even when using tough modern no-dig technologies. “Slow Crack Growth” Resistance to slow crack formation. SCG MRS “Minimum Required Strength” Minimum required pipe strength. RCP “Rapid Crack Propagation” Resistance to rapid crack formation. PE100 RC PE100 More facts about polyethylene and PE100 RC New alternative installation methods and maximum service life requirements require pipes made from the best possible raw material. Extena’s PE100 RC material, certified according to PAS 1075, has 17 times higher requirements for resistance to slow crack growth (SCG) compared to the materials that the Swedish AMA (General material and work descriptions) bases its recommendations on. By choosing PE100 RC, you will not only have pipe systems with maximum service life, but also faster and more cost effective pipelaying. Read more about polyethylene and PE100 RC in our brochure. This is why we have chosen to manufacture virtually all our pipes in PE100 RC
10 Introduction Homogeneous inner pipe in PE100 RC with wall thickness according to EN standard. One or more intermediate layers with different functions. High strength outer sheath in PEplus corresponding to 20-30% of the pipe’s wall thickness. There is confusion in the market around homogeneous pipes and multilayer pipes and the difference between them. In simple terms, a homogeneous pipe consists of a single layer inside and out, while a multilayer pipe consists of a main pipe and an outer sheath. Between this outer sheath and the main pipe, additional layers can also be added to provide the pipe with various functions, such as an impermeable barrier, online damage control monitoring and the ability to withstand extra high pressures, or a combination of these. The confusion usually occurs when homogeneous pipes are supplied with colouration on the outermost part of the pipe. This colouration, however, which is intended to facilitate the location of any scratches and cracks that may occur during pipelaying, is not a layer in itself, but a part of the main pipe. Another big difference between these pipe types is how they are handled during jointing. For example, homogeneous pipes must never be stripped during arc welding (a homogeneous pipe simply does not have an outer layer that can be stripped). PE sheath corresponding to e.g. 25% of the thickness at dimension 250 mm Sheathed pressure pipes, also known as “coated pipes”, are equipped with an outer sheath that may be made of various materials, the most common of which are polypropylene (PP) and polyethylene (PE). Extena’s sheathed pipes have a PEplus sheath made of high density polyethylene. The thickness of the sheath increases with the dimension of the pipe, from 1 to 5 mm. In dimensions up to 355 mm/SDR17, the sheath thickness corresponds to approximately 20-30% of the pipe’s wall thickness. In dimensions over 355 mm, the thickness is a slightly lower percentage, but the thickness of the sheath in mm is in fact larger. Pipes with high strength Extena sheaths must not be confused with the thin coats of less than 1 mm that some pipes on the market are fitted with. Since both pipe and sheath are made of polyethylene, the sheath does not need to be removed during butt welding (SLM® 3.0) but can be integrated into the joint, reducing the risk of the sheath being ripped off when performing alternative installation methods such as directional drilling, pipe bursting and pipe splitting. Recovery (regranulation) is also simplified as the sheath does not need to be separated from the main pipe. However, when using an arc welding sleeve, the outer sheath must always be removed. PE sheath offers 60% less wear than PP PEplus is a patented HD-PE with a higher molecular weight that makes the coating more scratch resistant compared to conventional grades. We have chosen this durable, scratch resistant material because the sheath is only a protective layer that is not included in the dimension of the pipe. Tough tests have shown that our PEplus sheath offers 60% less wear on the outer layer of the pipe compared to a polypropylene sheath. Abrasion tests according to DIN EN ISO 15527 show that a sheath made of patented PEplus with a higher molecular weight has 60% less impact than a sheath made of polypropylene PP. PEplus sheath PEplus sheaths have 60% less impact than PP sheaths. PP sheath Polyethylene pipes with PP sheath. 60% less impact Pipes with an extra thick sheath in PEplus Homogeneous pipes and multilayer pipes – what’s the difference?
11 High strength sheath in PEplus corresponding to 20-25% of the pipe’s wall thickness provides optimal protection. (Example in dim 250 mm/SDR 17)
12 Quality at the highest level With requirements that exceed the standard. Today, more and more buyers of pressure pipe systems are looking for pipelines with a service life of 150 years. However, this demand is not in harmony with the commonly used standard EN 12201, which tests the product for a service life of 50 years at a temperature of 20 °C. EN 12201 and EN 1555 have been developed by the European Committee for Standardization (CEN) and are the most widely used standards for polyethylene pressure pipe products in Europe. These European standards also specify external factors affecting the pipe system and its service life – such as root penetration, frost limit, corrosion, load and media temperature – which must be taken into account when laying new pipelines. The joints are often the weak point Even if the material is certified according to EN 12201 and EN 1555, it is important to remember that the joints are usually the weak point in a piping system. These must therefore have at least the same high quality and long service life as the rest of the pipe system to ensure that the pipeline will last and deliver over time according to the specifications. In terms of joint quality, the roundness of the pipes plays a key role. Thanks to our manufacturing process, Extena has been able to set higher requirements and significantly tighter tolerance levels for ovality than the standard allows. Class B with tighter tolerance levels than EN 12201. According to ISO 11922, the tolerances for the pipe’s mean outside diameter are divided into three classes: A, B and C. It is important to know that arc welding parts are manufactured to ISO 11922 class B. Compared to EN 12201, i.e. the standard that applies to pipes, tolerances in many dimensions are tighter (class B) compared to EN 12201. This is particularly true in dimensions over 630 mm. We have therefore chosen to manufacture our pipes with the tighter tolerances specified for class B. In this way, our pipes are better placed to fit well with arc welding parts, which results in safer joints. We are following Germany’s lead The modern PE100 RC material is widely used in Europe and especially in Germany, which is at the forefront of the development of new pipelaying methods for pressurized pipe systems. Today, the majority of the pipes for the German market are manufactured from PE100 RC material. It is important to point out that neither EN 12201/EN 1555 nor the Nordic Poly Mark certification institute (INSTA-CERT) have yet to meet higher requirements for RC pipes in their respective certification documents, despite the fact that PE100 RC offers significantly higher resistance to slow crack growth compared to PE100. However, a change in the EN standard has been announced, which will probably replace PAS 1075. Germany is also way ahead when it comes to welding PE pipes. The German organization DVS (Die Verbindungs Spezialisten/German Welding Society) produces a comprehensive manual for welding PE pipes that is valued by welders throughout Europe, including Sweden. All Extena’s sheathed pipes meet the requirements of PAS 1075 Type 3 (pipes with a higher strength sheath). Quality marks and standards In addition to EN 12201 and EN 1555 (gas), several quality marks and standards are currently used in the market for pressurized pipe systems. Some common examples, which we use at Extena and egeplast are Nordic Poly Mark, PAS 1075, DK-Vand, FI, Kiwa and TÜV. Third party certifications and tests We regularly conduct quality tests on our pipes and fittings to ensure that they meet the pipe requirements in the Nordic region and Europe, but above all that they fulfil our own even higher expectations. The tests are carried out by ourselves and a third party such as RISE. Introduction
PAS 1075 13 Nordic Poly Mark Nordic Poly Mark is a Nordic quality mark for plastic pipe products. This quality stamp has been developed jointly by the Nordic countries in order to maintain a high level of quality plastic pipe products for the Nordic market. Extena’s PE100 RC pipes meet all the requirements for Nordic Poly Mark by a very good margin. However, we believe that the present requirements of Nordic Poly Mark are too low with regards to RC material and slow crack growth (SCG). PAS 1075 As EN 12201 and EN 1555 still lack specific higher requirements for pipes and fittings made of PE100 RC, manufacturers have instead tested materials and finished products according to PAS 1075. This is a requirement standard developed under the auspices of the German standards institute DIN (Deutsches Institut für Normung) for polyethylene pressure pipes in PE100 RC. PAS 1075 places significantly higher demands on slow crack growth (SCG) than the current EN 12201 and EN 1555 and has a basic requirement that the raw material must have a service life of at least 100 years. The raw material used for Extena’s PE100 RC pipes is tested and approved according to PAS 1075. The current EN standard is currently being updated. This will allegedly contain higher requirements for PE100 RC. All Extena’s sheathed pipes meet the requirements of PAS 1075 Type 3 (pipes with a higher strength sheath). KIWA Kiwa is one of the world’s 20 largest companies specializing in inspection, testing and certification. Kiwa provides a variety of services such as technical consultation and training. Kiwa was founded in 1948 in the Netherlands but over the years has grown to become a leader in its field. In 2008, Kiwa acquired the Swedish SWEDCERT and thereby expanded into the Swedish market. Kiwa currently employs more than 4,500 people in over 40 countries, mainly in Europe, Asia and South America. DK-VAND DK-VAND is a product certification system, which ensures that certified products meet the strict requirements of the Danish Ministry of Environment and Food’s regulations and additional requirements for drinking water pipes. Pipes used for the distribution of drinking water must not contain substances in concentrations which may be harmful. FI The FI certification ensures that the product has been tested and approved by a third party and shows that the pipes meet the requirements of the Finnish Ministry of the Environment for use in drinking water pipe systems. TÜV Founded 150 years ago, the Germany-based TÜV (Technischer Überwachungsverein) is one of the world’s leading providers of independent tests, inspections and certifications. TÜV tests and certifies technical systems and products such as pressure pipe systems according to European and international standards. Germany is currently at the forefront in terms of both technical product requirements and hygiene requirements for the protection of people and the environment. DVGW DVGW is a reputable German standardization body active in the gas and water industries. Since the mid 19th century, DVGW has been working to ensure the highest possible quality and safety in the transport and supply of water and gas to the general public. Inspection certificate 3.1 according to EN 10204 EN 10204 is a European standard that regulates the design of Inspection certificate 3.1. By issuing an Inspection Certificate 3.1 according to EN 10204, we certify that the product we are supplying meets the customer’s requirements. Pipes and pipe fittings from the same batch for full traceability Our pipes and customized pipe fittings are available from the same batch and are supplied with 3.1 certificates. Introduction
14 Introduction The joints are most often the weak link in the pipe system. One of the more important requirements from contractors and pipeline owners, therefore, is good conditions for safe jointing. In order to produce safe joints, the pipes must be of high quality in all respects, both in terms of raw materials and the manufacturing process. Round pipes with low ovality are an important part of this. Manufacturing process that produces round pipes During manufacture of a PE pipe, stress is created in the pipe wall when the pipe is cooled down. This built-in stress causes the ends of the pipes to bend into the pipe when they are cut, known as toe-in. This phenomenon, as well as stacking and storage, affects the ovality of the pipe. To eliminate the effect of bending in, Extena uses a unique method where the pipes are cooled down over a longer period and stabilized during the cooling process. The pipes are then stored in a cassette where they are allowed to cool before being bundled. We have therefore been able to set higher requirements and significantly tighter tolerance levels for ovality than the standard allows. We have the same requirements for pipes in dimensions over 250 mm as specified by the standard for pipes in dimensions between 90-250 mm (see table). Requirements diameter value Dimension 90-250 mm >250 mm EN 12201:2 Permissible difference between maximum and minimum value 0.02xDy 0.035xDy Extena’s minimum requirements Permissible difference between maximum and minimum value according to Extena’s minimum requirements 0.02xDy 0.02xDy We regularly perform quality tests on our pipes and fittings to ensure that they meet our high standards. Minimal ovality is a condition for safe joints and efficient operation. Round pipes are essential for secure jointing We therefore have higher requirements than the standards to ensure minimum ovality. We have 40% higher requirements in terms of ovality than specified in the standard!
15 The Swedish AMA (General material and work descriptions) regulates the laying of pressure pipes. However, AMA does not take into account new materials such as PE100 RC and its positive properties with, among other things, significantly higher resistance to slow crack growth (SCG) caused by point loads. AMA has also not taken into account sheathed pipes, which also provide additional protection. According to AMA, the backfill may have a maximum fraction of 31.5 mm, but thanks to the use of PE100 RC, it is possible to use backfill material with a fraction up to 50% of the pipe diameter, but no more than 64 mm. You should also avoid allowing frozen material and sharp stones to come into direct contact with the pipe. Our recommendation is to always use normal backfill under and around the pipe, which according to AMA must be 0-32 mm in the support packing zone. We all have to set higher requirements! At Extena, we have higher requirements with significantly tighter tolerance levels regarding ovality than specified by the standard EN 12201. High quality joints require minimal ovality in the pipe. It is important, therefore, that the client also places high demands on the pipes they order. It is also important that the pipes are manufactured from the best possible raw material PE100 RC. The best raw material for the best overall cost efficiency When it comes to the production and installation of a pipe system, the pipes themselves represent a relatively low percentage of the cost, in most projects about 5 to 15% of the total cost. We therefore recommend our customers to always choose the best pipe, although initially the pipe cost may be somewhat higher. By choosing PE100 RC, you will achieve faster installation, a longer and safer service life and better overall cost efficiency. Pipelaying regulations do not take into account new raw materials and pipes with protective sheaths
16 APPLICATION AREAS From water and sewage to gas and extremely demanding applications Extena offers the market’s widest range of polyethylene pressure pipe systems, developed for a variety of applications. To make it easier to find the right type of pipe, we have chosen to highlight the most common application areas. Water & Sewage Water and sewage is our largest business area and we have been a major supplier to municipal water supply systems for many years. Since the transport of drinking water is an essential social function, it is particularly important that all parts of water and sewage systems maintain a high level of quality throughout their lifetime. We therefore manufacture our pipes for water and sewage from PE100 RC, which is the best raw material for this type of pipe system. Compared to traditional pipe materials, PE100 RC has 17 times higher requirements for slow crack growth, which is the property that has the greatest impact on the service life of the pipe. We have a wide range of pipes and pipe fittings for the transportation of water and sewage. Certain conditions may require the use of pipe systems with special functions, such as a permeation barrier for the protection of drinking water when the pipe is laid in contaminated soil, and the protection of sensitive environments where the pipe transports waste water or other contaminated substances close to a water source. Another common special function is pipes with a high strength sheath for extra protection in alternative pipelaying methods. The joints are the weak point in a pipe system. A prerequisite for good joints is round pipes with low ovality. By cooling the pipes for a longer period using our “anti-stress” production method, and stabilizing them during the cooling process, we can set higher demands and significantly tighter tolerance levels regarding ovality than the standard permits. In fact, we have 40% higher requirements in terms of ovality and toe-in than specified in the standard. We have extensive experience of large projects and know how important the time aspect and reliability of supply are when working with many subcontractors. Since we have our own modern, large-capacity production facility and a complete range of polyethylene pressure pipes and pipe fittings, we are now a reliable supplier to large projects in all Nordic countries. Gas Gas transportation can have devastating consequences for both humans and the environment in the event of a leakage or breakdown. The transportation of gas is therefore a highly Introduction
17 Introduction controlled area requiring certified pipes of the highest quality and traceability of both product and raw material. Our gas pipes are used for the transportation of e.g. natural gas and biomethane. Extena was quick off the mark to develop systems for maximum control and traceability and today offers Inspection certificate 3.1 according to EN 10204 for customers who require it. Our traceability makes it easy to trace e.g. suppliers of raw materials, pipes and pipe fittings, including the extrusion line and date of manufacture. The aim is to ensure that our customers are confident in their choice and know that their gas pipelines are of the highest quality. We offer pipes for gas pipelines installed in trenches (standard pipe 90/10) as well as for alternative installation methods (SLM®). Our range of gas pipes also includes the unique multilayer pipe HexelOne®, which can withstand a gas pressure of 16 bar. We can also offer pipes and pipe fittings from the same batch and with 3.1 certificates. • Gas can be fatal • Gas pipelines with maximum control • High traceability • EN 10204 Inspection certificate 3.1 • EN 1555 • Option to order pipes and pipe fittings from the same batch The manufacture of gas pipes is defined in various standards and directives such as EN 1555. SS-EN 10204 is a European standard that regulates the design of Inspection certificate 3.1. We can supply pipes with Inspection certificate 3.1 according to EN 10204 for customers who require it. Swedish Gas Association and EGN 2020 Extena is a member of the Swedish Gas Association (Energigas Sverige), an organization for stakeholders in the energy gas industry. Members of the association include grid operators, gas suppliers, manufacturers and suppliers of gas equipment, installation companies, consulting companies, etc. Grid operators that are members of the Swedish Gas Association have undertaken to comply with these standards. A central part of the association’s activities is to promote the safe use of energy gases (natural gas, biogas, LPG, vehicle gas and hydrogen). This involves drawing up standards and instructions. The regulations up to 4 bar for natural gas, biogas and LPG in the gas phase are coordinated in EGN 2020. The construction, inspection and operation of distribution systems for gas, natural gas, biogas and LPG in the gas phase as well as associated installations according to EGN ensure compliance with the reasonable precautions clauses of the legislation on flammable and explosive materials. Industry Plastic pipes have many applications in industry, which means that requirements vary significantly. Extena offers probably the widest range of high quality pipes and pipe fittings on the market, including various special pipes adapted for special functions and conditions. We offer pipes for every demand – for high pressures and temperatures as well as large flows, abrasive media and heavy external loads. Plastic pipe systems have many advantages, including the fact that they are corrosion resistant and that they are highly resistant to a large number of chemicals and aggressive media. Plastic pipe systems also provide high operational reliability because they are both robust and flexible. Combining polyethylene pipes with another type of plastic or metallic material such as aluminium creates new functions and application options. Permeation tightness, high pressure resistance and extra durability for transporting heavy media are just some of the functions that can be achieved with these material combinations.
18 Mines The working environment in mines is extremely tough, not only for the miners, but also for all the tools and products used in the mining industry. Raw surfaces, blasting dust, coarse media and crushed rock transported and removed by heavy vehicles expose the environment to excessive wear and damage. Large level differences In addition to the external impact on pipes and pipe systems, the mine’s level differences also mean that high pressures are required to pump media from low to high points. Mining environments therefore require durable pipes that can withstand high pressure both inside and outside. Extena has two pipe systems specifically designed for high pressure applications: Extena homogeneous high pressure pipes and HexelOne®. Drill cuttings and slurry The transportation of e.g. drill cuttings and slurry (tailings and mine water) requires extra strong pipelines that can withstand both high pressures and excessive wear on the inside. Drill cuttings consisting of crushed rock with a grain size of up to 6 mm place great stress on the inside of pipes. Our durable, homogeneous multilayer pipe egeSlurry® with a protective inner layer is perfect for these types of demanding conditions. Static electricity In mines, static electricity is also generated when pumping dry and flammable media, for example. For these applications, we have developed egeStatic®, a co-extruded homogeneous pipe made of PE-EL that reduces the risk of static electricity generation. Prefabricated pipelines We can also offer prefabricated pipes with pre-assembled flange joints, which facilitates the jointing and installation of pipe systems in the mine. These pipes are joined on site and are available in dimensions up to 1600 mm. In addition, we offer several other types of pipes and pipe fittings that meet all the requirements of the mining industry. High pressures In mountain environments, mines and structures with large level differences, pipes are required to withstand high pressures. For this type of environment, we offer pipes that can withstand high internal pressures and which also have a high ring stiffness to withstand high external loads. The traditional method of handling high pressures in pipe systems is to increase the thickness of a standard pipe. However, Extena and egeplast can offer the unique and innovative multilayer pipe HexelOne®. HexelOne® consists of a main pipe made of PE100 RC, two reinforcement layers of PE100 and a protective sheath of 100% high strength PEplus. The result is a pipe system with a normal wall thickness that can withstand up to twice the pressure of traditional pipes (30 bar for water and sewage and 16 bar for gas). HexelOne® is therefore easier to handle and the high strength sheath also protects the pipe from external impact. Extena offers two high pressure pipe systems: Homogeneous standard pipes Pipes with increased thickness for high pressures. Available in dimensions 16–630 mm for 20, 25 or 30 bar. HexelOne® HexelOne® is a multilayer pipe with a main pipe made of PE100 RC, two reinforcement layers of PE100 and a protective sheath of 100% high strength PEplus. The result is a pipe that can withstand up to twice the pressure (30 bar for water and sewage and 16 bar for gas). High strength sheath protects against external impact. The Boliden mine uses pipes supplied by Extena. Introduction
19 Introduction Extena manufactures pipe systems for a wide variety of special applications, such as fish farms, industry, mines and ski resorts. The requirements of a pipe system vary depending on the application. In some cases, pipes with a high resistance to abrasion, chemicals or static electricity are required, while other systems require permanent monitoring or the ability to handle high pressures. In many cases, a combination of several properties is required. Extena meets these diverse needs by offering customized pipes and pipe fittings combining five different layers of functionality to create systems with the required properties. For a complete pipe system, we also offer pipe fittings to match the functions of the pipe, as well as customized pipe fittings according to drawing. As the demands for the safety and service life of pipe systems are constantly increasing, it is becoming more common for pipes and pipe fittings to be ordered from the same supplier. Extena meets these requirements by offering pipes and pipe fittings from the same batch together with Inspection certificate 3.1 according to EN 10204 for maximum traceability. Our pipes can be built with up to 5 different layers, with each layer designed to meet the customer’s needs. 1. The media pipe can be adapted to the current application. For example, it could be a standard pipe, an anti-static pipe, or a pipe that resists high temperatures up to 95°C. 2. Reinforcement layer for high pressure. 3. Intermediate or outer layers which can be used as an indicator layer, an abrasion resistant outer layer or a layer offering protection against UV radiation, etc. 4. Metallic layer for maximum permeation resistance to protect media against soil toxins and the environment when transporting harmful chemicals. This layer can also be given a monitoring function. 5. High strength sheath protects against external impact. Special applications and customized pipes and pipe fittings Project-specific pipes and fittings from the same batch For this manufacturer of fish farming equipment in Norway, we supplied pipes with a dimension of 500 mm SDR13.6 for the double floating rings and dimension 140 mm SDR11 for the rail.
2 3 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qu nac 2 3 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qu nac Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitä nachw 2 3 20 Contents Standard pipe for installation in trenches PE100 RC Pipe system made of PE100 RC Dim 16-1600 mm page 26-29 All media pipes are made of PE100 RC with resistance to slow crack growth Pipe properties PE100 RC Homogeneous pipe Coloured surface approx. 10% of total wall thickness Sheathed pipe with PEPlus coat Built-in function test Withstands extra high pressure Permeation resistant “Online” function check Pipe fittings Range of arc welding parts Range of PE pipe fittings: – Injection moulded parts – Seamless bends – Machined parts – Segment welded Range of flange joints Special pipe fittings adapted for this pipe type Customized pipe fittings according to drawing Suitable for mechanical couplings Standard pipes for installation in trenches Standard pipe made of PE100 RC X X X X X X X X X X X Standard pipe PE100 RC “90/10®” with approx. 10% coloured surface X X X X X X X X X X X X Pipe for installation in trenches, trench-free installation and alternative installation methods SLM® - Sheathed pipe X X X X X X X X X X X SLM® DCT - With function test + sheath X X X X X X X X X X X X SLM® DCS - With online function check and protective sheath X X X X X X X X X X X X X Pipes for extra high pressure HexelOne® - Pipes for extra high pressure + sheath X X X * * X X X Permeation resistant pipes SLA® - Permeation resistant layer + sheath X X X X * X X X X X X X X Pipes with permanent function check 3L® - With online function check + permeation resistant layer + sheath X X X X X X X X X X X X X X Pipe type Contents Polyethylene pipes PE100 RC for water, sewage and gas. * Made to order Resistant to point load a slow crack growth Standard pipes 90/10® PE100 RC Pipe system with approx. 10% of the pipe thickness in a different colour Dim 16–1600 mm page 26-29
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Schacht 7 8 Werksgeprüfte Qualität Wurzelfeste Verbindung Schacht zu Schacht Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Di usionsdicht Lecküberwachung Close tLining Kamerabefahrung 2-Lippendichtung High Pressure 7 8 4 5 6 3 4 5 6 Kratz-/Riefen beständig Punktlastbeständig Kratz-/Riefen beständig Punktlastbeständig Kratz-/Ri fen beständig Punktlastbeständig Kratz-/Ri fenbestä di Punktlastbeständig Kratz-/Riefen beständig Qualitäts nachweis Di usionsdicht Lecküberwachung High Press re 3 4 5 6 Kratz-/Riefen beständig Punktlastbeständig Kratz-/Riefen beständig Punktlastbeständig Kratz-/Riefen beständig Punktlastbeständig Kratz-/Ri fenbestä di Punktlastbeständig Kratz-/Riefen beständig Qualitäts nachweis Di usionsdicht Lecküberwachung High Press re Kr tz-/Riefenbeständig Punktlastbest n i Kratz-/Riefenbeständig Punktlastbest dig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbest dig Kratz-/Riefenbe tändig Qualitätsnachw is Di usions dicht Lecküberwachung High Pressure 3 4 5 6 2 3 4 5 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Ri fenbeständi Pu be Qualitätsnachweis Di usionsdicht 2 3 4 5 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Ri fenbeständi Pu be Qualitätsnachweis Di usionsdicht Punktlastb st di Kr tz-/Riefenbeständig Punktlastb ständi Kratz-/R efenbeständig Punktlastb ständi Kratz-/Riefenbeständig Pu Quali ätsnachweis Di usionsdicht 2 3 4 5 7 3 4 5 6 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionsdicht Lecküberwachung High Pressure Close tLining 3 4 5 6 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Ri fenbeständi Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionsdicht Lecküberwachung High Pressure Close tLining 7 Punktlastst i Kratz-/Riefenbes ändig Punktlastst i Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastst n i Kratz-/Riefenb tändig Qualitätsnachweis Di usionsdicht Lecküberwachung Close t Lining High Pressure 7 3 4 5 6 2 3 4 Punktlastbeständig Kra z-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachw is Di usionsdicht 2 3 4 Punktlastbeständig Kra z-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionsdicht Punktlast beständig Kra z /Riefenbeständig Punktlast beständig Kratz-/Riefenbeständig Punktlast beständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionsdicht 2 3 4 Riefendig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbes ndig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbe tändig Qualitätsnachw is Di usio sdicht Lecküberwachu g High Pressure Clo Lin 3 4 5 6 Riefendig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbes ndig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbe tändig Qualitätsnachw is Di usio sdicht Lecküberwachu g High Pressure Clo Lin 7 2 3 Punktlastbeständig Kr tz-/Riefen beständig Punktlastbeständig Kratz-/Riefe bes ändig 2 3 Punktlastbeständig Kratz-/Riefen beständig Punktlastbeständig Kratz-/Riefe bes ändig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefen beständig 2 3 Punktlastbeständig Kr tz-/Riefen beständig Punktlastbeständig Kratz-/Riefen beständig Punktlastbeständig Kratz-/Ri fenbestä di Punktlastbeständig Kratz-/Ri fenbe tänd g Qualitä s nachw i Di usio - dicht Lecküber wachung 2 3 4 5 Punktlastbeständig Kr tz-/Riefen beständig Punktlastbeständig Kratz-/Riefen beständig Punktlastbeständig Kratz-/Ri fenbestä di Punktlastbeständig Kratz-/Ri fenbe tänd g Qualitä s nachw i Di usio - dicht Lecküber wachung 2 3 4 5 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionsdicht Leckü wachu 2 3 4 5 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionsdicht Leckü wachu Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di usio sdicht Lecküber wachu g 2 3 4 5 7 3 4 5 6 Punktlas - beständig Kratz-/Riefenbestä dig Punktlas - beständig Kratz-/Riefenbeständig Punktlas - beständig Kratz-/Riefenbeständig Punktlas - beständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionscht Lecküberwachung High Pressure Close tLining 3 4 5 6 Punktlastbeständig Kratz-/Riefenbestä dig Punktlas - beständig Kratz-/Riefenbeständig Punktlas - beständig Kratz-/Riefenbeständig Punktlas - beständig Kratz-/Riefenbeständig Qualitätsnachweis Di usionscht Lecküberwachung High Pressure Close tLining Werk Qua 7 Werk Qua Punktl stbeständig Kratz-/Riefen beständig Punktl stbeständig Kratz-/Riefe - beständig Punktl stbestä dig Kratz-/Riefenbeständig Punktl tbeständig Kratz-/Riefenbeständig Qualitätsachweis Di usionsdicht Lecküberwachung Close tLining High Pressure 7 3 4 5 6 2 3 Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständ g Kratz-/Ri f b stä ig 2 3 Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständ g Kratz-/Ri f b stä ig Punktlastbeständig Kratz-/Riefenbestä dig Punktlastbes änd g Kratz-/Riefen beständig 2 3 2 3 4 5 Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständig Kra z-/Riefenbeständig Qualitätsnachweis Di usionsdicht Lecküber wachung 2 3 4 5 Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständig Kratz-/Riefe - beständig Punktlastbeständig Kra z-/Riefenbeständig Qualitätsnachweis Di usionsdicht Lecküber wachung Punktlastbeständig Kra z-/Riefenbeständig Punktla tbes ändig Kra z-/Riefenbeständig Punktlastbestä dig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Qualitätsachweis Di usionsdicht L cküberwachu g 2 3 4 5 2 3 4 5 6 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kr tz-/Riefenbeständig Punktlastbeständig Kratz bestä Punktlastbeständig Kratz-/Riefenbes ändig Qualitätsnachwei Di usionsdicht Lecküberwachun 2 3 4 5 6 Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kr tz-/Riefenbeständig Punktlastbeständig Kratz bestä Punktlastbeständig Kratz-/Riefenbes ändig Qualitätsnachwei Di usionsdicht Lecküberwachun Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/Riefenbeständig Punktlastbeständig Kratz-/ bestän Punktlastbeständig Kratz-/Riefenbeständig Qualitätsnachweis Di sionsdicht Lecküb rwachung 2 3 4 5 6 21 Contents HexelOne® For extra high pressure and with protective sheath page 46-49 For extr high pr ss re Resistant to point load a d slow crack growth Resistant o scratchi g Ada ted for high pressure “Online” function check Multilayer pipe with high strength sheath SLM® 3.0 SLM® DCT With protective sheath page 30-33 Built-in function test and protective sheath page 30-31, 34-35 SLM® DCS With online function check and protective sheath pag 30-31, 36-37 Resistant to point load an slow crack growth Resistant to scratching Resista t to point load and slow crack growth Resis ant to scratchi g Function test after installation Resistant to point load a slow crack growth Resistant to scratching Permeation resi tant pipe SLA® Barrier Pipe 3L® Leak Control With online function check and protective sheath page 42-45 Permeation resistant pipe system and protective sheath page 38-41 Permanently monitored Resistant to point load a slow crack growth Resistant to scratchi g Impermeable layer Resistant to poi t load an slow crack growth Resistant to scratchi g Impermeable layer “Online” u ction check
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