Trenchless rehabilitation of water mains using the Primus Line system

Transcription

1 Andreas Gross M.Sc., Head of International Business Development Trenchless rehabilitation of water mains using the Primus Line system

2 Company Introduction The Rädlinger Group Overview Foundation: 1963 Ownership Structure: family-owned company Annual Performance 2016: approx. 300 million Euro Employees: approx Locations: 12 Large construction company in Bavaria approached by Ruhrgas (later Open Grid EUROPE) to develop a solution for trenchless rehabilitation of high pressure gas pipes 2

3 Trenchless Rehabilitation Currents aspects Current aspects of trenchless rehabilitation Difficult to access pipes River crossings (siphons) Disturbance of shipping-traffic Land permits and private terrain Environmentally protected areas Emphasis on sustainability 3

4 Trenchless Rehabilitation Currents aspects Current aspects of trenchless rehabilitation Congested cities, traffic jams Disturbance of street- and railroad-traffic Working space and time windows Current approach: HDD drill for river crossings (expensive, time consuming, risky) New-lay (highly intrusive in city environments, noise emissions, lengthy and possibly costly process) Relining with HDPE (limitations regarding bends, pressures, hydraulic capacity losses)

5 The Primus Line system Technology and benefits

6 Parts The Primus Line system consists of... a flexible high-pressure liner and patented end fittings 6

7 Composition of the Primus Liner Composition of the Primus Liner External Layer Abrasion-resistant PE Protection of the fabric during insertion Internal Layer DN 150 DN 500 Based on PE or TPU NSF/ANSI 61, KTW W 270, AS/NZS 4020:2005 Kevlar Seamless, woven aramid fabric Accommodates the operating pressure independently from host pipe Wall thickness of 6 mm Liner is not glued to host pipe (no steaming or curing processes) Installed with annulus space 7

8 Primus Line connection techniques Primus Line End Fitting Low Pressure connector Medium Pressure connector DN 150 DN 300 Nominal pressure design PN 25 PN 12 Mechanical installation DIN or ANSI flanges available 8

9 Primus Line connection techniques Primus Line End Fitting Low Pressure connector Medium Pressure connector Steel Jacket (malleable) Valve for Resin Injection External Sleeve Primus Liner Internal Core 9

10 Primus Line connection techniques Primus Line End Fitting Low Pressure connector Medium Pressure connector Steel Jacket (malleable) Valve for Resin Injection External Sleeve Primus Liner Internal Core 10

11 Easy installation Installation technique Reel with Primus Liner Cable winch Host pipe Start pit Destination pit 11

12 Primus Line Benefits Why use Primus Line Renewal of water mains with a high consequence of failure Increase operating pressure independently from host pipe Avoid cost for disposal of asbestos cement water mains Maintain hydraulic capacity with PN 16 compared to HDPE Reduce the amount of land permits (1,000 m and more) Minimize disruption (400 m per hour and small pits) Reduce the amount of excavation (bends of up to 45 degree) Completely manufactured and quality controlled at factory 12 Minimum life span of 50 years

13 Primus Line in practice Special projects and references

14 Increase the pressure rating on existing pipe network Pressure upgrade of a DN 225 PVC pipe in Australia Transported Medium: Potable water Pipe Diameter: DN 225 Class 9 Length: 460 m (two sections of 170 m and 290 m) Upgrade the existing pressure level to PN 16 Maintain hydraulic capacity (Primus Line with ID = 191 mm vs. HDPE with ID = 147mm ) Installation time: 2 working days 15% more expensive than HDPE Installed price: 210 EUR/m (198 GBP/m) During project phase, no variation because of 15 degree bends that were unaccounted for

15 Skip land permits due to long insertion lengths Rehabilitation of a DN 500 trunk main in Spain Transported Medium: Potable water Pipe Diameter: DN 500 Pipe Material: Cast iron trunk main Land permits were not available (time consuming and difficult to obtain) Length: 2,562 m installed in five sections of 713 m, 558 m, 528 m, 305 m and 458 m Installation through existing maintenance chamber and access pits on public ground Installation time: less than 3 weeks (including cleaning, CCTV inspection) Cost saving of 30% compared to second bid (CIPP) Installed price: 270 EUR/m (232 GBP/m)

16 Renovate difficult to access pipes Rehabilitation of a river crossing in Germany Transported Medium: Potable water Pipe Diameter: DN 250 Pipe Material: PE 80 from 1970 Length: m installed in one section with protracted bend of 30 degrees Operating pressure: 10 bar Insertion time liner: 3 hours Pulling force: 1,75 t Installation time: 8 working days Installed price: 171 EUR / m 16

17 Thank you for attending Rädlinger primus line GmbH Kammerdorfer Str Cham, Germany