DIPLOMA IN GAS ENGINEERING TECHNOLOGY

TOPIC: THEORY ASSIGNMENT T4

POLYMER (HDPE)

ENGINEERING MATERIAL
DKV20243

PREPARED BY:

NO. NAME NO. IC

1. HAZRIN SYAZILLAH BT MUHAMAD RIZAL 030511-01-0460
2. MUHAMMAD YUSUF IQMAL BIN MOHAMAD 030221-08-1017
ROSLI
3. MOHAMAD HAZIQ DANIAL BIN ABDUL 030613-01-0699
MANAF

LECTURER:
FADZIL NOOR BIN ROSE
 TABLE OF CONTENT

NO. TITLE PAGES

2
1.0 SUMMARY

We are grateful because we manage to complete our Engineering Material

assignment within the time given by our lecturer Mr. Fadzil Noor bin Rose. This
assignment cannot be completed without the effort and co-operation from our group
members, Hazrin Syazillah binti Muhamad Rizal, Muhammad Yusuf Iqmal bin
Mohamad Rosli, Mohamad Haziq Danial bin Abdul Manaf. We also sincerely thank
our lecturer of Engineering Material, for the guidance and encouragement in finishing
this assignment and for teaching us in this course.

The topic we choose for our assignment is “Polymer” (High-Density Polyethylene).

We choose this topic because as we know that the main ingredient in producing a
product especially in the manufacturing industry.

HDPE pipe is a type of flexible plastic pipe used for fluid and gas transfer and is
often used to replace ageing concrete or steel mains pipelines. Made from the
thermoplastic HDPE (high-density polyethylene), its high level of impermeability and
strong molecular bond make it suitable for high pressure pipelines. HDPE pipe is
used across the globe for applications such as water mains, gas mains, sewer
mains, slurry transfer lines, rural irrigation, fire system supply lines, electrical and
communications conduit, and stormwater and drainage pipes.

3
2.0 INTRODUCTIONS

A polymer is any of a class of natural or synthetic substances composed of very

large molecules, called macromolecules, which are multiples of simpler chemical
units called monomers. Polymers make up many of the materials in living organisms
and are the basis of many minerals and man-made materials.

HDPE stands for high-density polyethylene, which is a polymer with ethylene as its

monomer. It's a thermoplastic with a high strength-to-weight ratio. HDPE is a highly
adaptable plastic with a wide range of uses, from pipes to storage bottles. The
melting point of high-density polyethylene is relatively high when compared to other
polymers.

Polyethylene (PE) is a common polymer in plastics. It was widely used in our daily
life for many different purposes. PE is usually produced in different grade for different
usage. HDPE or high-density polyethylene was composed of mostly linear polymers.
This linear form has the better characteristic on tighter, denser, and more organized
structures compare to Medium-density polyethylene (MDPE) and Low-density
polyethylene (LDPE). HDPE is a harder plastic with a high melting point and sinks in
the alcohol-water mixture. HDPE is also good at electrical insulation, cold resistance,
chemical stability, resistant to corrosion, wear resistance and high tensile strength.
This material is commonly recycled and has an SPI resin ID code of 2. HDPE can be
produced in a different color but the original is translucent. It is widely used in
today's, piping, geomembranes, containers, plastic lumber (PL)Popular HDPE piping
usage includes gas transportation, water supply, sewage & drainage system,
agricultural irrigation, chemical, oil, and telecommunication field.

4
3.0 OBJECTIVE

At the completion of this assignment, students should be able to

i. Investigate the properties and processes involved for the materials used in
gas piping system; and
ii. Demonstrate competence in communication and writing skills.
iii. Learn that one of the major materials in those special disposable suits is
high-density polyethylene or HDPE. 

5
4.0 BODY CONTENT

4.1 MATERIAL AND MICROSTRUCTURE

High-density polyethylene (HDPE) is a thermoplastic polymer with ethylene as

its monomer unit. The hydrocarbon ethylene, often known as ethene (IUPAC
nomenclature), has the formula C2H4. PEHD (polyethylene high density), alkathene,
and polythene are all terms for high-density polyethylene.

STRUCTURE - HDPE is a type of polyethylene, the most common plastic which

accounts for over 34% of the global plastic market. It is a polymer made up of a huge
number of repeating units (known as monomers), and its chemical formula can be
generalized as (C2H4) n. The branching in high density polyethylene is of a relatively
low degree (when compared to other categories of polyethylene). The general
structure of HDPE is illustrated below.

High density polyethylene is a hydrocarbon polymer that can be prepared from

ethylene via a catalytic process. Some common catalysts used here include Ziegler–
Natta catalysts, chromium/silica catalysts (Phillips catalyst), and metallocene
catalysts.

Generally, in the polymerization process, these catalysts form free radical at the end
of the growing polyethylene molecules. They also add new ethylene monomers at
the end of the molecules thereby forming a long linear chain.

HDPE mostly features a low degree of branching where the linear molecules or the
polymer chains are packed together tightly. The presence of a strong intermolecular

6
force results in a dense, highly crystalline material. However, the true mechanism of
the synthesis of high-density polyethylene is still a debated topic.

5.0 MANUFACTURING PROCESS

Diagram above step-by-step process of making a high density polyethelyne pipe

5.1 ACCUMULATION OF RAW MATERIAL

The raw material forms the most integral part of the manufacturing process because
without the inclusion and availability of raw material, it would be impossible for a
manufacturer to produce pipes. The raw material which goes into making an HDPE
pipe is HDPE granules and carbon black. The HDPE granules are small chunks of
high-density polyethylene which are blended with carbon black in a high temperature
container.

5.2 MELTING THE RAW MATERIAL

Before the pipe is brought into shape by using the extrusion machine and further
processes, the raw material is kept in a container and subjected to a high
temperature wherein it is held until it melts.

5.3 EXTRUSION AND DYING

This is where things begin to get interesting. HDPE pipes make use of different types
of extrusion machines with the help of which they shape the melted raw material into
a pipe. Apart from that, dying of the pipe is also carried out during

5.4 VACUUM AND PRESSURE CALIBRATION

Among the other important processes, the pipe has to go through this process as
well. The vacuum and pressure calibration of the pipe allows the HDPE pipe
manufacturers to know what kind of pressure the pipe can withstand.

7
5.5 COOLING BATH

It is obvious that the HDPE coil pipes are going to be hot as hell when they come out
of the above-mentioned processes. That is why, it is important that they undergo a
cooling bath process which makes them go through a uniformly distributed water
shower so that every curve of the pipe is covered well.

5.6 HAUL OFF UNIT

It is the second last stage of manufacturing the pipe and after the pipe that has been
cooled down undergoes this stage, it qualifies for the final stage of the process which
is known as the cutting unit.

5.7 CUTTING UNIT

The pipes are given a distinct length by cutting them off. Most of the pipes are
usually 3 meters, 6 meters and 9 meters long, but in the case of HDPE pipes, this
length is usually higher.

8
6.0 FINAL PROPERTIES

HDPE pipe is suitable and the preferred solution for oil and gas distribution
applications. It is manufactured in black color compound under the highest quality
standards and using cutting edge technology equipment.

HIGH DENSITY-POLYETHYLENE (HDPE) GAS PIPELINE

The diagram above shows the HDPE pipe used in gas pipe line.The pipe that has
yellow stripes on the pipe is gas pipe.There are also HDPE pipe which has different
stripes color like blue stripes for water pipe, red stripes for fire extinguishers suply
pipe,etc.

9
6.1 PROPERTIES OF HIGH-DENSITY POLYETHYLENE

I. HDPE Melting point: 120-140°C

II. Density of HDPE: 0.93 to 0.97 g/cm3
III. High Density Polyethylene Chemical resistance:
IV. Excellent resistance to most solvents
V. Very good resistance to alcohols, dilute acids and alkalis
VI. Moderate resistance to oils and greases
VII. Poor resistance to hydrocarbons (aliphatic, aromatic, halogenated)
VIII. Continuous temperature: -50°C to +60°C, relatively stiff material with useful
temperature capabilities
IX. Higher tensile strength compared to other forms of polyethylene
X. Low-cost polymer with good processability
XI. Good low temperature resistance
XII. Excellent electrical insulating properties
XIII. Very low water absorption
XIV. FDA compliant

10
6.2 TYPE OF PIPE USE IN GAS PIPELINE SYSTEM

a. HDPE PIPE LINING

This pipe commonly used for underground piping.Most common usage can be
soft in installations of underground LPG bulk tank piping system.
b. HDPE PIPE THERMOMATIC COMPOSITE PIPE (TCP)

This pipe was made to handle a pressure below atmosphere level.Common

use on deep sea gas piping installations.

11
7.0 APPLICATION OF HIGH-DENSITY POLYETHYLENE

1) Packaging Applications – High Density Polyethylene is used in several

packaging applications including crates, trays, bottles for milk and fruit
juices, caps for food packaging, jerry cans, drums, industrial bulk containers
etc. In such applications HDPE provides the product a reasonable impact

strength.

2) Consumer Goods – Low cost and easy processability make HDPE a

material of choice in several household/ consumer goods like garbage
containers, housewares, ice boxes, toys etc.

3) Fibers and Textiles – Thanks to its high tensile strength, HDPE is widely
used for agricultural applications, such as in ropes, fishing and sport nets,
nets as well as industrial and decorative fabrics.

12
8.0 How Does HDPE Compare to Other Types of Pipe Materials?

The demand for high-density polyethylene pipe fittings is growing. The pipe market
alone is expected to reach a value of more than $25 billion by 2025 from no more
than $18 million in 2017. Between 2018 and 2025, the compound annual growth rate
(CAGR) will be at 5%. To appreciate the real value of HDPE, however, it’s best to
compare it with other common pipe materials.

Galvanized Steel vs. HDPE

Both HDPE and galvanized steel are common materials for pipes and pipe fittings.
They also have two similarities: they are both durable and anti-corrosion. These
make them popular options for water delivery, such as irrigation.

Between the two, however, HDPE is more lightweight since it is still plastic. In other
words, it can be less costly to make, transport, and install. It also saves its users time
and labor. It’s also possible to repair HDPE pipes when they are above the ground.
You can cut the damaged part and then connect both ends through a process called
butt fusion.

When galvanized iron suffers the same fate, it’s best to replace it since damage can
also erode the zinc layer, which makes it rust-free. In turn, it may be more expensive
to work with galvanized steel pipe than an HDPE in the long run.

13
 PVC vs. HDPE

PVC stands for polyvinyl chloride, and like HDPE it is a type of plastic. Compared to
other vinyl types, this is perhaps the strongest. That’s why it’s also a known material
for pipes and pipe fittings.

One of the distinct advantages of PVC is it’s cheap than galvanized steel and
sometimes against HDPE. You may also be able to submerge this material
underwater.

Meanwhile, HDPE is more likely to handle shock better, which means it can cope
with stress more effectively. It can also deal with heat, which is why HDPE pipe
fittings can also be used in compression systems.

14
 Copper and HDPE

HDPE tends to promote bacterial growth, although other types of piping systems
such as PVC can also experience it. With proper monitoring too, the chances are
slim to none. But this challenge makes copper an appealing alternative.

Copper has been a pipe material for hundreds of years, tracing back to the times of
the Egyptians. In other words, it’s a tried-and-tested one. It discourages microbial
growth, so some still use it for delivery of potable water.

However, this one is not corrosion free. Once it starts to rust, it can leach into the
water supply, contaminating it. What’s more, you may have to run the water freely for
at least 30 seconds before you drink it as leaching can also happen when water
remains idle. That’s some waste of water and effort.

In conclusion, There’s no perfect material for pipes and pipe fittings. Each has its
pros and cons, but it’s a matter of choice after considering the factors that matter to
you. If there’s one thing clear, it’s the fact HDPE can give some of the other common
pipe materials a good fight.

15
9.0 CONCLUSION

Overall,despite HDPE is not the strongest material for piping,it does what it
supposed to do.Using HDPE also saving the earth by slowly exterminated using
earth elements as a main piping material.HDPE also reducing the total amount of
cost that need to be consume to build a gas pipeline. Furthermore,HDPE is very
economical and recyclable.Having HDPE as the material used in gas pipeline also
reducing the cost to an installation of cathodic protection to protect pipe from
corrosion in underground piping.

After all,HDPE is good material and we were honoured to make a report about
it.Perhaps this report somehow eliminate the misunderstanding about usage of a
plastic pipe mainly on HDPE.

16
10 REFERENCE

10.1 INTERNET

1) T. (2019, June 13). Compare HDPE to Other Pipe Materials. The Earth
Awards. https://www.theearthawards.org/how-does-hdpe-compare-to-other-
types-of-pipe-materials/?amp
2)

17