CIP Liner rehabilitation technology for high-pressure pipelines
Jul 27, 2006
Since the beginning of the 1990's, procedures for trenchless renewal and rehabilitation have been increasingly developed due to environmental issues and economic factors. In particular, German medium-sized construction companies were able to recognize the need for technical developments and their implementation.
Description of the rehabilitation of high-pressure pipelines
Although the starline®20000 material development was completed within the framework of the E.ON Ruhrgas project, the installation process itself was not part of the project. This installation process is based upon the starline®2000 procedure for rehabilitation of gas distribution pipelines, which has been performed successfully in over 600 km. Here, the liner filled with resin is inverted into the cleaned pipeline section to be rehabilitated by applying air pressure. This, however, is the only common ground between the starline®20000 technology and the wellestablished fabric hose relining system because completely new technical solutions have become necessary in order to realize the installation objectives for highpressure gas and water transmission pipelines.
The starline®20000 system is a reliable and safe rehabilitation technology in order to:
- restore operational safety in the event of corrosion damage,
- limit localized damages, and
- in particular, with drinking water pipelines it permanently restores sanitary requirements.
- Prevent corrosion: In the vicinity of underground gas storage systems, natural gas may become humid. In gas transmission pipelines, fabric hose relining prevents internal corrosion.
- Seal inaccessible locations: Pipeline leakages in locations difficult to access, such as culverts, railway underpasses or nature reserves, which could only be repaired at great expense using the open-cut method.
- Tightness after welding seam fractures: Other problems are high-pressure gas pipelines in earthquake and submergence of ground areas (e.g. mining areas, etc.). The earth movements may cause welding seams to break. With fabric hose relining, the pipelines' safety is assured for a certain period of time until the pipeline can be depressurized and the damage repaired.
Karl Weiss focused on three specific areas relating to the installation during the starline®20000 HPL development: inspection procedure prior to and after lining up to 1000 m; extended inversion procedure up to 600 m; resin mixing/supply and application system for resin batches of more than 2 t/h. The equipment used so far only allows for inspection lengths up to max. 180 m, inversion lengths up to max. 240 m and manually handled resin batches up to max. 0.5 t/h.
- Inspection system for visual and metrological inspection of the pipeline. This process is designed for inspection lengths up to 1000 m and nominal diameters from 200 mm – 1200 mm. Prior to rehabilitation (inspect degree of cleaning) and after liner installation and curing (quality control of full bonding and installation of liner), the pipeline is visually inspected and the internal pipeline diameter is measured using a caliper. The result of the caliper measurement is recorded to determine the internal diameter profile. It also indicates: inadmissible deviation automatically.
- Resin mixing and measuring system. The system processes up to 2 tons resin per hour without bubbles. For these resin batches, the equipment must be air-conditioned (Figure 3).
- Liner application with resin filling and distributing system. This system consists of a height-adjustable liner holder as well as an air-conditioned transport and unwinding unit. The filling process of the resin is also performed without bubbles.
- Inversion equipment. In order to extend the inversion sections to 600 m, the pressure drum had to be designed completely new and ancillary equipment had to be changed fundamentally. The pressure drum is designed such that the maximum diameter for intake of the maximum liner length is utilizable in relation to the minimum height of the flat-bed trailer as well as the maximum possible bridge clearance (i.e. for pipes up to 600 mm diameter, the liner inversion length is up to 600 m, with pipes ≥ 600 mm – 1200 mm diameter, the inversion length is reduced accordingly by folding the liner longitudinally). The pressure drum is equipped with all-terrain caterpillar tracks.
The starline®20000 procedure is a CIP liner system certified by DVGW for rehabilitation of potentially corroded highpressure pipelines for pressures up to 30 bar in gas pipelines. The system has a tested service life of at least 50 years and bridges corrosion damage with diameters up to 50 mm. Using materials certified for use in drinking-water applications with the appropriate material strength, water pipelines with an operating pressure up to 40 bar can be rehabilitated. Such rehabilitation considerably extends the remaining useful life of potentially corroded high-pressure pipelines and thus markedly reduces material and energy consumption. It also leads to an increase or restoration of the pipelines' operational safety. Furthermore, the number of pits as well as construction noise, emissions caused by machinery and traffic and other adverse effects on people and the environment are considerably reduced.
- Seal all leakages in the pipe section lined and increase or restore operational safety
- Restore sanitary condition required in drinking water pipelines
- Prevent internal corrosion
- Seal welding seams
- Seal leakages at inaccessible locations and road crossings, in ecologically sensitive areas, on rocky ground, etc.
- No problem with access rights and no need to work under cramped conditions
- Support utility in adhering to safety regulations
- Cost-effective procedure reduces risks and improves pipelines' state of preservation.
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