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.
More News and Articles
Mar 24, 2023
Innovative technologies remove pharmaceutical residues from wastewater
Every year on 22 March, World Water Day reminds us of the importance of one of the most important resources of life. Almost two-thirds of our planet is covered with water, but not even three percent is drinkable freshwater. Every …
Mar 22, 2023
Delivering sustainable solutions to solve water challenges
With British Water’s conference on creating a more sustainable water sector approaching, Stephen Kennedy, head of digital and innovation at MWH Treatment shares his views on celebrating recent successes in creating a more sustainable sector while also discussing the challenge …
Mar 20, 2023
Supporting the National Water Strategy through scientific research
This month, the federal government of Germany introduced the first National Water Strategy. “With this strategy, the federal government is shining a spotlight on the necessity of integrated water resource management, serving as a leading example of resource use in …
Mar 17, 2023
Trenchless manufacturer celebrates installation of 100,000th liner
SAERTEX multiCom®’s trenchless pipe relining product, SAERTEX-LINER, has been installed for the 100,000th time.
Mar 13, 2023
Spring collaborates with Microsoft and Impact X on water innovation
The water sector’s innovation centre of excellence – Spring - is collaborating with Microsoft and Impact X on a new initiative to make tools and funding available for start-ups to accelerate their companies.
Mar 10, 2023
State of Global Water Resources report informs on rivers, land water storage and glaciers
WMO reports on freshwater availability in a changing climate
Mar 08, 2023
Australia: Centenarian sewer gets after-dark upgrade
Over 100 years since its inception, Brisbane’s S1 Main Sewer has undergone a seven-year upgrade.
Mar 06, 2023
UKWIR gives access to hundreds of water sector research reports
UK Water Industry Research (UKWIR) is providing free access to over 1,000 of its water sector research reports aimed at helping to improve water and wastewater services for customers, and protecting the environment.
Mar 03, 2023
Sector must challenge public misconceptions through engagement
The water sector must tackle “unfair criticisms” by sharing more about the great work it delivers, Yorkshire Water’s chief executive, Nicola Shaw, told attendees at British Water’s Better Together reception in Hull.
Mar 01, 2023
World-first project to ‘self heal’ cracked concrete using sludge could save $1.4 billion repair bill to Australia’s sewer pipes
Water treatment sludge could be used to prevent 117,000 kilometres of sewer pipes in Australia from cracking in future, without any intervention by humans, helping to save $1.4 billion in annual maintenance costs.
Feb 27, 2023
Delaware Water Treatment Plant Opts for Penetron to Protect New Concrete Structures
The final 2022 commissioning of the Doe Run Road Water Treatment Plant enables the city of Newark, Delaware (USA), to increase the quantity and quality of the city's drinking water to better meet growing demand – and EPA guidelines. PENETRON …
Feb 24, 2023
Aussie Trenchless: the future of pipe rehabilitation solutions
Aussie Trenchless has been passionate about progressing future infrastructure opportunities and accomplishing superior outcomes since it was founded in 2014.
Dipl.-Ing. Andreas Hüttemann
+49 (0)30 80 97 00 0
+49 (0)30 80 97 00 90