My presentation on PVC Pipes in India, Past, Present and future in PDF format

1. UPVC Pipe:
Past, Present and Future in India
iPVC 2014
4th December 2014
Siddhartha Roy
Plastics commonly used for Piping
• In India the commonly used Polymers for
manufacturing Pipes and fittings, arranged in order
of Tonnage used, are:
–UPVC
–HDPE
– LLDPE
– CPVC
– PPR
• Other polymers like ABS, Acrylics, Polybutylene,
PEX etc. have been used for pipes abroad, but are
used very little in India
Pipe Characteristics Comparison
Polymer Critical Properties Main
Application
areas
Strength
(Hoop)
Operating
Temp.oC.
Chemical
Resistance
UPVC 500-
600
60-70 Acids & Alkalis
++
Solvents --
Water Supply, Agri
Pipes, SWR, Chem.
Plants, Bore wells, Ducts
HDPE 350-
400
90-100 Solvents &
Hydrocarbons
++
Water Supply, Gas,
Effluents, Sprinkler
Irrigation, Large Drains
LLDPE 300-
350
80-90
Rarely used
For
Chemicals
Mainly Drip Irrigation
Laterals.
CPVC 500 90-100 Hot Water systems.
PPR 300 100-110 Hot Water systems.
Comparison of Wall Thickness of PVC &
HDPE Pipes of 110 mm PN 6
Material Standard Min. Wall
Thickness mm
As % of
UPVC
UPVC BIS 4985:01 3.70
HDPE
(PE 63)
BIS 4984:95 7.70 208%
HDPE
(PE 80)
BIS 4984:95 6.30 170%
HDPE
(PE 100)
BIS 4984:95 5.00 135%
Jointing Systems
Polymer Types of Joints Pros & Cons
UPVC Threaded Solvent
Cement
Rubber
Ring
+Very Convenient
-Poor Quality Solvent
Cement failures
HDPE Butt
Welded
Electro
Fusion
Extrusion
Welded
-Cumbersome
-Needs special Tools
-Power Dependent
LLDPE But
Welded
Press
Fitted
+Drippers can be
press fitted.
CPVC Solvent
Cement
+Very Convenient
-Poor Quality Solvent
Cement failures
PPR Butt
Welded
-Cumbersome
-Needs special Tools
History of PVC Pipe
Development in India

2. 1970s
• PVC Conduits caught on early 70s
• RC-100s and single screw extruders used
• Large twin screw Extruders for BIS-4985 pipe
installed by a handful of PVC Pipe majors.
• Supplies to Government Water Supply Schemes
mainly catered to by these few firms.
• Growth of Capacity for pipe sizes up to 110
meters affected as it was reserved for small scale
only.
– Multiple High capacity modern twin screw lines
beyond the purview of Small Scale.
1980s
• Rapid Capacity expansion for water supply pipes to cope
with World Bank funded Water supply schemes
• PVC Edges out HDPE because of field failures with
HDPE
• PVC Agri Pipes well accepted in Maharashtra and
gradually spread to neighbouring states.
• Many Extrusion lines airlifted to meet demand.
• Individual plant capacities of 15-20KTA becomes
common
• Intense competition sets in
• Mindless filler addition resorted to
• Smaller Pipe companies start to fail
• Shakeout in Manufacturing:
– Larger firms consolidate
– Buy up capacity of failed firms.
1990s
• High capacity Twin screw Extruder manufacture now well
established in India, Imports taper off.
• Other PVC pipe applications like SWR, Casing. Plumbing
and column pipes flourish.
• LLDPE and HDPE pipe based Drip and Sprinkler
Irrigation systems get established. Fiber Optic Cable
conduits catch on.
• Firms offering good quality lead in the new markets.
• As more firms enter SWR, High filler loading and thin
walling disease strikes the rapidly expanding SWR
market.
• Injection moulded Fittings for SWR become widely
available, majority Tin Stabilized.
• More small & medium size pipe units collapse as market
share eroded due to poor quality.
21st Century
• Industry self corrects on filler loading issues, large capacity
units with good quality discipline expand their markets
• Drip and Sprinkler irrigation gets big boost from Govt.
Subsidies
• PVC Pipes maintains a healthy growth rate throughout the
decade peaking in the end of the decade.
• Local PVC production unable to keep up with demand,
Market Volatility in PVC prices affect firms with long term
supply contracts.
• Gas transmission with HDPE/MDPE Pipes does well.
• A few firms introduce Foam Core Pipe, Hollow Core Pipes
• CPVC Pipes are well accepted for hot water plumbing.
Scores over PPR because of easier laying and jointing.
PVC Pipes is the dominant sector
in PVC.
PVC Sectors: Estimated Consumption
Unit KT
2005-
06
2006-
07
2007-
08
2008-
09
2009-
2010
2010-
11
Pipes& Fitting 760 830 948 975 1305 1400
Calendering 96 97 100 100 128 138
Films & Sheets 90 91 101 101 103 110
Wires & Cables 80 81 83 83 86 90
Footwear 38 38 39 39 40 41
Profiles 38 39 43 43 44 48
Others 38 39 50 50 70 73
Total 1140 1214 1364 1391 1776 1900
Overall Giowth 6% 12% 2% 28% 7%
Share of PVC Pipes 67% 68% 70% 70% 73% 74%
PVC Pipe Growth 9% 14% 3% 34% 7%
End-use PVC Consumption
UPVC
Pipes
Footwear
Films
W & Cable
Calender
Profiles
Compounding
and Others

3. Main Manufacturing Factors
• Extrusion Equipment
–Extruders
–Pipe Sizing
–Downstream
• Formulation and Mixing
–Raw Material Quality
–Stabilizers and additive balance.
–Fillers
• Technical Innovations
Extrusion Equipment
-Extruder Type
• Single Screw..
– Pumps melt by Induced
Flow.
– High Temperatures needed
(180oC+).
– Mixing and fluxing not
adequate.
– Prone to surging.
– Good quality Pipe need
expensive Flow Promoters
and Impact Modifiers.
– Low Filler Tolerance.
– Low Capital Costs.
– High Running Costs.
– Low Maintenance.
• Twin Screw.
– Pumps melt by Positive
Displacement.
– Lower Temperatures (160-
180C).
– Excellent Mixing.
– Constant Melt Flow.
– Good quality w/o Impact
modifiers and flow
promoters.
– High Filler Tolerance.
– High Capital Costs
– Low running costs
– High Maintenance
Extrusion Equipment
- Pipe Sizing
• Pressure Sizing.
– Pipe contacted with
Sizing Sleeve by
Internal Air Pressure.
– Lower running cost.
– Suited for Large
Diameter Pipes.
– Gloss is Better.
– Sizer Tube scratches
prominent. (Plate
out)
– Weight control range
coarser.
• Vacuum Sizing.
– Pipe Contacted with
Sizing Sleeve by
External Vacuum.
– Higher Running
Cost.
– Best for Small Dia.
Pipes.
– Gloss is poorer.
– Sizer scratches less.
– Good weight control.
Downstream Equipment
• Cooling Tanks
– Spray Cooling tanks have replaced water bath
tanks.
– HDPE & PPR pipes need much more cooling.
• Haul off
– Servo drives replacing DC drives
– Separate Haul offs recommended for twin strand.
• Saw
– Digital measurement cutting trigger replacing Limit
Switches.
• Sawdust removal systems.
Formulation and Mixing
• Once Extrusion Equipment is the
correct type, PVC Formulation plays a
major role in Pipe Quality.
• The Popularity of One Pack
Stabilizer/ Lubricant systems has
made matters a lot simpler.
• The Filler loading used has a major
bearing on Pipe Quality.
• It’s effects are not clearly understood.
PVC Pipe Formulation and
Processing trends Worldwide
• The European Approach
– Followed in India, as our exposure to German
PVC Technology is well entrenched thanks to
the K Fairs.
– Japan, Korea, Taiwan, South Africa, Australia.
• The American Approach
– The Americas, Canada and parts of South
America
• The Chinese Approach
– Low Cost Manufacturing

4. The European Approach
Stabilization Systems
Predominantly Lead One Pack Systems
Shifting to Ca-Zn due to environmental
pressures
In India, Tin Stabilizers are preferred for Fittings,
while in Europe Leads and Ca-Zns are the norm.
Extrusion Preference
Parallel Twin Screw outnumber Conical Screw
Single screw extruders hardly ever used
Single Screws only used in Injection mouldings,
hence costlier formulations.
Sturdy, Costly, Screw life 30,000 hrs..+
The European Approach
Filler Levels
Pressure Pipes limited to 8-10 PHR
Non Pressure Drainage can go up to 40 PHR, though 20
– 25 PHR levels used by discerning manufacturers.
Impact Modifiers and Flow Promoters
In India, hardly used for bulk of PVC Pipe production.
Exceptions are Column Pipe, Wavihole type pipes and
specialties
Colour of Pipe
In India, Pressure Pipe- Light Grey, Column Pipe- White
Non Pressure Pipe- Dark Grey
The American Approach
Stabilization Systems
Predominantly Tins, high efficiency methyl tins very
popular
Extrusion Preference
Very late to switch over from Single Screw to Twin Screw
Twin Screws are now universal. Strong dependence on
German technology.
Filler Levels
Reasonable, up to 10 PHR for pressure and ~20 PHR for
non Pressure
Impact Modifiers and Flow Promoters
Usage has decreased on shifting to Twin screw.
Colour of Pipe
White. PVC Pipes are a major market for Titanium
Dioxide.
The Chinese Approach
Stabilization Systems
Predominantly Lead based for pipes and fittings.
Extrusion Preference
Predominantly Conical Twin Screw
Low cost, screw life ~10,000 hrs.
Price Ratios-Chinese 1, Indian 1.5, European 2.5-3
Filler Levels
Pressure pipe- 10-15 PHR
Non Pressure- Very high. 50-100 PHR the norm. Up to
200 PHR has been reported
Impact Modifiers and Flow Promoters
Key ingredients in highly filled pipe
Impact modifier of choice- CPE 3.5-4 PHR
Flow Promoter- ACR 1-1.5 PHR
Colour of Pipe – White/Cream for all applications.
Filler level and Pipe Quality
• Precipitated and Coated Calcium Carbonate is
the most widely used filler.
– Purity, fine particle size and Coating are very
important.
– Ground Calcium Carbonate making inroads but
machine life suffers. Recent advances in Wet grinding
technology has reduced this problem.
• Up to 6-8 PHR Filler addition actually improves
PVC Pipe quality. Better flow and Impact
strength.
• It is when filler loadings are higher that the
problems start.
• Before going into cost reduction by mindless filler
addition, other approaches should be adopted.
Other Avenues ooff CCoosstt rreedduuccttiioonn
• Tight OD and Wall Thickness control can get
Cost savings comparable to High Filler
Loadings.
• Reduction of Wastage and Spillage:
– Automated Material Handling
– During Mixing.
– Startup, Shutdown and size changes.
– Lowering power costs by newer Technology.
– Reducing or eliminating Rejections.
• Twin Strand Extrusion for smaller Dia Pipes
• Eliminating Goods returned.

5. Precision in Extrusion.
• Wall thickness Control
– What is the Weight difference of a 90mm 2.5
Kgf pipe made at max. and min. dimensions
specified?
Mean
Outside
Diameter
Pipe Weight
Gms./Mtr.
Class 1
0.25 MPa
Max. Min. Min. Max. Max Min
%
Diff.
Wall Thickness
Pipe Weight
Gms./Mtr.
Class 2
0.4 MPa
Min. Max. Max Min
%
Diff.
Class 3
0.6 MPa
Pipe Weight
Gms./Mtr.
Min. Max. Max Min
%
Diff.
90 90.3 1.3 1.7 691 529 23% 2.1 2.6 1046 847 19% 3.1 3.7 1470 1236 16%
110 110.4 1.6 2.0 995 796 20% 2.5 3.0 1478 1233 17% 3.7 4.3 2093 1804 14%
125 125.4 1.8 2.2 1243 1017 18% 2.9 3.4 1903 1624 15% 4.3 5.0 2762 2381 14%
140 140.5 2.0 2.4 1520 1266 17% 3.2 3.8 2383 2008 16% 4.8 5.5 3406 2977 13%
160 160.5 2.3 2.8 2026 1664 18% 3.7 4.3 3081 2653 14% 5.4 6.2 4389 3830 13%
Technology for Precision Extrusion
• Retrofitting Twin Screw Extrusion lines
with latest technology
– Microprocessor Controls
– Modern Variable Frequency AC drives
– Precise Synchronization of Screw speed
Haul Off.
– High Volume Die Heads
– Vacuum Sizing is preferred
– On Line Wall Thickness measurement
– Precise Length Cutting
Technology for Precision Extrusion
• Modifying Melt Rheology of PVC
Formulation for smooth extrusion
– Selection of most suitable One Pack System
• Considerable experimentation is required
– Balancing with High performance
Lubricants
• High melting Polyethylene waxes instead of
Hydrocarbon Waxes
– High Bulk Density Low Porosity PVC Resin.
– Limiting Filler levels
• Selection of good quality filler. Treated gives
smoothest flow.
CPVC Piping
Systems
SSSiiiddddddhhhaaarrrttthhhaaa RRRoooyyy
28
CPVC Piping Systems
• The major property improvement of CPVC over
PVC is increase in Heat resistance.
• While the maximum operating temperature of
PVC is 60oC and softening point is 70oC, for
CPVC it is 85oC and 100oC respectively.
• Mechanical properties and chemical resistance
are comparable.
• CPVC thus opens the market for hot water
systems in plumbing and hot, corrosive liquids in
Chemical Plants, which was previously shut to
PVC. 29
Flammability Performance
• CPVC is one of the safest polymers from
the flammability hazard pint of view.
• The chlorine content may go up to 70% in
some grades of CPVC.
• It does not need any additional fire
retardant additives and no flammable
plasticizers are used in its compounding.
• Only the Fluorinated Polymers like PTFE
have better flammability performance.
30

6. Limiting Oxygen Index of some
Polymers
MATERIAL LIMITING OXYGEN
INDEX
POM 15
PMMA 17
PP 17
LDPE 17
HDPE 17
PS 18
PC 26
PVC 45
C-PVC 80
PTFE 95
31
CPVC Piping is used in emergency Sprinkler piping because of this
Metal Hot Water Plumbing Systems
• The Traditional materials used for
Plumbing Piping in Construction are:
• Galvanized Iron Pipes
–Extensively used in many countries
• Copper Pipes
–Used extensively in the Americas.
–Suited to the Wooden Frame Homes.
–Water Pressure provided by pumps, not
rooftop tanks. 32
Plastic Hot Water Systems
• There are 3 leading polymers which are used for
hot water piping systems in construction:
• Chlorinated PVC
– Most popular in India
• PPR (Random Poly Propylene Copolymer)
– Used extensively in China, Far East and Europe
• Polybutadiene
– Floor embedded Hot Water heating systems in
cold climates like North America and Europe.
• The reasons for this regional preference will be
explained later.
33
How CPVC Pipes have evolved in India
• The Eighties:
– Modest amounts imported in the early Eighties when I was
handling the indenting of Geon CPVC from BF Goodrich.
These were mainly used to extrude Chemical Plant Piping.
• The Nineties:
– PVC pipes had already made inroads on the traditional GI
Pipes, but were not suitable for hot water.
– Gradual penetration of CPVC in Plumbing starts.
– GI Fittings predominate with problems of adaptation with
plastic pipes.
• The Noughties:
– A large number of injection moulded fittings became
available.
– Big boost for CPVC Piping installations.
• In the current decade, CPVC has eclipsed PPR and has become
the pipe of choice and is used for Hot and cold water for
convenience of stocking one type of pipe.
34
Hot Water Pipe System
Comparison
CPVC Copper GI PP-R
35
Hot Water Pipe System
Comparison
CPVC Copper GI PP-R
36

7. Pros and Cons of CPVC Pipes
Strengths Limitations
Superior corrosion
resistance
Good heat resistance (up to
100-110°C)
High pressure resistance (3
bars at 90°C)
Inert to most mineral acids,
bases and salts, as well as
aliphatic hydrocarbons
Self-extinguishing and
relatively low smoke
generation
Poor impact resistance
Opaque
Poor resistance to aromatic
solvents, ketones and esters
High cost, compared with
PVC and PPR
37
New Stabilizer Systems
• Worldwide there is a move to shift from
the very efficient Lead systems for
environmental reasons.
• The alternatives are
–Mixed Metal systems (Mainly Calcium-
Zinc)
–Organ tin systems (Methyl Tin and Butyl
Tin)
–Organic Metal Free systems (OBS)
Light Weight PVC Pipes
• For non Pressure Application:
–Foam Core PVC Pipes
– “Wavihole” type Hollow Core Pipes
• For Pressure Pipes
M-PVC
O-PVC
Foam Core PVC Pipes
• 3 Layer Coextruded Pipe
– Stiffness and properties not compromised much
– Dramatic Weight Reductions possible
Solid PVC Skin Layer
Foam PVC Core Layer
Solid PVC Skin Layer
3 Layer Pipe Extrusion Die head
Solid PVC
Foam PVC

8. Foam Core PVC Pipes
Cheapening with Foam
Cheapening with Foam
Rs.90.00
Rs.85.00
Rs.80.00
Rs.75.00
Rs.70.00
Rs.65.00
Rs.60.00
Rs.55.00
Rs.50.00
R s . K g
Rs.90.00
Rs.85.00
Rs.80.00
Rs.75.00
Rs.70.00
Rs.65.00
Rs.60.00
Rs.55.00
Rs.50.00
V o lum e C o s t R s ./L t r
Solid 100%
10 PHR
Solid 80%
20% Foam
Solid 70%
30% Foam
Solid 60%
40% Foam
Solid 50%
50% Foam
Solid 40%
60% Foam
Solid 30%
70% Foam
Formulation Cost Rs/Kg Rs.46.53 Rs.65.33 Rs.64.51 Rs.63.68 Rs.62.85 Rs.62.03 Rs.61.20
Volume Cost Rs/Ltr. Rs.67.94 Rs.85.06 Rs.78.95 Rs.72.83 Rs.66.71 Rs.60.59 Rs.54.47
Foam Core Pipe Applications
• Non Pressure Pipe with good Wall Thickness:
– DWV Pipes of larger Diameter
– Cable Ductings
– Casing Pipes??
Hollow Core PVC Pipes
• Instead of Foam, the core
can be hollowed.
• A closely spaced set of
oval holes running
through the length of the
pipe are formed by the
“Wavihole Process”.
• The cross section of the
Pipe wall resembles an
interconnected series of
I Beams
Modern light weight PPrreessssuurree PPiippeess
( Data obtained from the Chemsons Website)
1. M-PVC
Impact modified known as M-PVC in Australia or
PVC-A in UK where A is an abbreviation for Alloy.
Provides increased toughness and ductility which
allows for reduced wall thickness
2. O-PVC
Stretched in line and then oriented biaxially or
oriented off line in a blowing system. Provides
strength and toughness from chain orientation
under controlled conditions, which allows for
reduced wall thickness
TTeecchhnniiccaall rreeqquuiirreemmeennttss MMooddiiffiieedd MM--PPVVCC PPiippeess
Product Requirements :
1. M-PVC pipe is processed with either CPE or
acrylic impact modifiers at melt temperatures
in excess of 200°C. This is to meet the high
energy impact level from 20 meters drop .
2. O-PVC pipe has the 3 heat phases
– Thick wall extrusion pre form,
– Re heating inside and outside for stretching
– Re heating for integral joint forming.
20 meter dart dropping rig

9. MMooddiiffiieedd MM--PPVVCC PPiippeess
MPVC Pipes should not shatter on impact
Formulation M-PVC
SPVC K66/68 100
One Pack Stabilizer 3.0
*Calcium Carbonate 5.0 *2 micron
coated
Blue pigment 0.25
Impact Modifier 5.0
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SSiiddddhhaarrtthhaa RRooyy
614 A K.P. Tower-2, Fatimanagar, Pune 411013
Mobile: 9890366632, Phone: 020-26860723
Email: royplastech@rediffmail.com