Relining Project in Turkey proves successful By Hans Juergen Koenig and Jens Kirste

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Relining Project in Turkey proves successful By Hans Juergen Koenig and Jens Kirste The Trolining process for no-dig pipe renovation has proven successful for decades.

1 Relining Project in Turkey proves successful By Hans Juergen Koenig and Jens Kirste The Trolining process for no-dig pipe renovation has proven successful for decades. Lately, the grouted-in-place pipe (GIPP) method can also be successfully applied as shown on a recent project in the City of Eregli, Turkey, for a pressure pipeline that required relining a 690-m, steel pipe with a diameter of 1,800 mm. Key to the project s success was the close relationship between Trolining GmbH, Troisdorf, Germany, and its partner Gezer Industrial Construction A.S., Gebze, Istanbul together they tackled the project, which involved rehabilitating a seawater pipeline for industrial use. Eregli is located in northern Turkey at the Black Sea. Seawater provides a valuable contribution, in this case for a steel manufacturer, as an energy source for cooling purposes. Since the 1960s, the worldwide-leading steel producer Erdemir has transported the seawater by steel pipelines. The seawater is extracted from the Black Sea and transported over several hundred meters to a steam turbine. At the same time, the water is cleaned of living shell larva through filters. Problem The steel line in question was an underground in a concrete tunnel that was built in the 1960s. The pipeline is located at the shoreline from the steel plant in order for salt water to be delivered from the Black Sea. Due to the corrosive medium, the ½-in. steel wall was affected considerably inside and showed partial pitting. Moreover, it was necessary to shut down the steel line in order to clean shell incrustations. It was the project s goal to solve both these problems with an appropriate renovation technique. Figure 1: Up to 70% reduction of cross section due to mussel growth From the beginning it was clear that in considering the conditions, application of Trolining s basic system appeared to be the most reasonable method to correct the problem from both a technical and economical point of view. The core of the basic Trolining system is a HDPE hose with anchors on the outside of the Inliner, which serves as a spacer to the inner surface of the pipe. The annular void created by the stud texturing is filled with a high-strength, cementitious grout leading to a statically self-supporting composite system. Page

Figure 2: Design of the TROLINING Basic-System Project Engineering In March 2004, the first meeting with the customer Erdemir took place in Turkey.

2 Figure 2: Design of the TROLINING Basic-System Project Engineering In March 2004, the first meeting with the customer Erdemir took place in Turkey. In reviewing the project, it became evident that the pipeline that needed rehabilitation could not be shut down for assessment of the current condition. After viewing the site plans, an evaluation of the number of bends, admissions, blind flanges, ventilation valves and inspection covers of different kinds and sizes was made. Since the steel line could not be shut down prior to renovation, the exact geometry of the available bends remained unclear and the plans provided insufficient information in this respect. Therefore, a flexible relining technique was chosen, enabling adaptation of the liner to the actual pipe geometry. At this phase of the project, material requirements, transportation volume and the exact time schedule was defined and an offer was presented to Erdemir. After evaluating the different renovation methods, the Trolining Basic System was chosen for the project. The partnership between Trolining and Gezer became official in April Project execution was scheduled between November and December 2004, enabling the engineers of both companies to familiarize themselves with the technical conditions and develop a detailed plan for the necessary pre-construction work. Manufacturing of the HDPE Inliner took place at the end of September 2004 at the Trolining production facility in Germany. For the renovation distance of 690 m, 10 separate, studded liner hoses were manufactured; six of which were made at a length of 85 m. Transparent HDPE sealing sheets, with a wall thickness of 2.5 mm and 19 mm studs, were considered for this purpose. The sheets were welded together with a double-welding seam to the requested circumference. Page

Figure 3: Roller for large size HDPE-hoses up to dia. 2000mm For the bend relining, HDPE segmental plates were chosen with a wall thickness of 8 mm and 13 mm studs.

Nine trucks were necessary for transportation of the coils, with the 10 rolled-up liner hoses, 134 tons of grout (shipped in sacks), the necessary equipment and the other material and accessories

3 Figure 3: Roller for large size HDPE-hoses up to dia. 2000mm For the bend relining, HDPE segmental plates were chosen with a wall thickness of 8 mm and 13 mm studs. Connection of the laterals to the relining system was planned with smooth, fabric backed HDPE plates that were adhered to the steel wall of the host pipe with epoxy resin prior to liner insertion. Nine trucks were necessary for transportation of the coils, with the 10 rolled-up liner hoses, 134 tons of grout (shipped in sacks), the necessary equipment and the other material and accessories from Germany to Turkey. Prior to liner insertion and after the scheduled shutdown of the pipeline on Nov. 1, 2004, Gezer handled several pre-construction tasks, which included: - Opening the underground pipe, which consisted of prefabricated reinforced concrete in six areas at a length of 4 m each in order to guarantee entry to the host pipe - Breaking the steel line in the area of the openings - Cleaning the steel line, primarily removing the shell incrustations and corrosion products - Localizing and sealing of the corroded and damaged spots of the steel pipe - Welding grouting ports for grouting of the annular void - Attaching fabric-backed HDPE plates in the outflow area, as well as at both ends of the planned sanitation area with the purpose to weld the liner hoses Figure 4: Opening for cleaning and installation purposes Page

One after the other, the liners were inserted through the openings using a tensile-forth, controlled rope. For renovation of a 255-m section length, it required insertion of three 85-m hoses.

4 Since the water demand for the steel plant would be covered by a parallel pipe during project execution, set up of a bypass was not necessary. Liner Insertion After completing the pre-construction work, insertion of the Trolining liner began. One after the other, the liners were inserted through the openings using a tensile-forth, controlled rope. For renovation of a 255-m section length, it required insertion of three 85-m hoses. After insertion of the HDPE hoses, they were temporary sealed at each end with inflatable bags in order to lift the liners by compressed air. In this position, the liners could be connected to each other by radial extrusion welding. The annular void between the liner and host pipe was also sealed during this step by welding each renovation end to the HDPE plates. Figure 5: Inserted HDPE Inliner dia. 1800mm The 255-m long, self-contained liner was then closed on each end by special sealing bags. By means of bypass openings in the core of the sealing bag, the Inliner was filled with water, building-up a water column of 8 m. This water column acted as internal sustaining pressure against the exterior grout pressure during annular void grouting. At the same time, the water column acted as proof for leak tightness. Figure 6: Closing of the HDPE Inliner dia. 1800mm with an inflatable sealing plug for pressurization by compressed air Page

The 19 mm annular void between liner and host pipe was filled with Trolining- Injektor via the welded-on filling ports (DA 90 mm) on the outside of the steel pipe at a distance of 30 m.

After a 24-hour hardening phase, the supporting pressure was released and the quality of the process could be proven. The four available bends were relined in segments.

5 The 19 mm annular void between liner and host pipe was filled with Trolining- Injektor via the welded-on filling ports (DA 90 mm) on the outside of the steel pipe at a distance of 30 m. The low viscous grout was continuously mixed with water in four mixing units and filled into the annular void under hydrostatic pressure. After a 24-hour hardening phase, the supporting pressure was released and the quality of the process could be proven. The four available bends were relined in segments. After adapting and welding the HDPE plates, a specially assembled, wooden casing served as support medium during the annular void grouting. After re-insertion of the removed pipe parts and complete lining of the whole 690-m long steel pipe with the HDPE liners, the following work was performed: - Connection of the outflows by means of PE welding - Transition from the liner system to the steel pipe by means of additional steel rings at the upper and the lower head of the renovation section - Closing of the concrete pipe by re-insertion of the previously removed concrete precastings Figure 7: Lateral connection dia. 900mm to the TROLINING-System Figure 8: Transition from the TROLINING-System to the steel pipe Due to the excellent knowledge in plastic welding by the Turkish technicians, all PE connections were completed at the highest quality standard. The local staff was readily trained in all the other phases of the relining process and at the end of the initial two partial sections, all further work was completed by them. Page

6 After only six weeks, the pipe rehabilitation was completed and the pipeline was released to the customer. Figure 9: Visual inspection of the relined steel pipe Conclusion After three days of operation, Erdemir shut down the line in order to review the quality of the work. No deficiencies were found. With the success of this project, the Trolining system set another milestone in the development of its renovation technique especially the choice of a local partner proved to be ideal since its knowledge and skills were decisive for the successful outcome of the project. Pre-manufactured Inliner hoses for renovation of large dimension pressure pipes were successfully put into practice and proved their suitability in this project. On account of the high material flexibility the application range can now be extended to the drinking water area. Both Trolining and Gezer can now successfully apply the gained experience to future shoreline projects of similar range. Hans Jurgen Koenig is the sales and marketing director and Jens Kirste the international sales manager with Trolining GmbH, which is headquartered in Troisdorf, Germany. Page

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