Long Length Pipes and Marine Installations Presentation - Pipelife ...

Pipelife Norge AS - StathelleAdvantages and Experiences of the Use ofLong Length PE Pipes for Marine Pipeline Construction&Installation Techniques for Flexible PE PipesbyTrygve BlomsterExport ManagerPipelife Norge AS

Who is Pipelife• One of the world’s leading producers of plastic pipes& fittings• Wide range of products and materials forall major pipe & fitting markets• Headquarters in Vienna, Austria• A fully owned subsidiary of Wienerberger AG,Austria

Facts and Figures about Pipelife• LocationsworldwideRegion USRegion CentralEastern Europe(CEE)Region West &NordicSales Offices 2011: 27 CountriesProduction Sites 2011: 27Employees 2011 (average) : 2.651PlantSales OfficeHeadquarters

Pipelife in NorwayHead office:SurnadalProduction sites:SurnadalStathelleMarketing departments:SurnadalStathelleOsloTrondheimOrder / sales office:SurnadalSurnadalStathelle

Continuously Extruded Long Length PE PipesFrom Pipelife Norge AS, Stathelle, NorwayProtected location in anarrow fjordContinuous extrusioninto the fjordTransport by tugboat tothe marine destination

Part of Scandinavian PE Pipe HistoryPE pipe production started in 1960Due to lack of proper welding methods at that time, the pipeshad to be made as long as possible.From there the long length pipe concept has been developed

PE Pipe Range from OD 20 mm up to OD 2500 mmPipelife can offer:-PE pressure pipes in therange from OD 20 mmto OD 2500 mm in SDRclasses from 41 to 7.4(SDR21 for the largest ones)- Continuously extrudedPE pipes in lengths upto 550 - 600 m

PE Pipe Range from OD 20 mm up to OD 2500 mmThe range of products includeall accessories needed for acomplete pipe system:-PE segment welded bends-PE welded T-branches-PE reducers-PE stub ends-Steel loose backing rings-Diffusers-Manholes

Important Characteristics of PE Pipes-Light in weight, density 0,95 - 0,96 kg / dm 3-Buoyancy in sea water-Flexible, accept bending radius down to 20 x OD-Non-corrosive-Non-toxic, potable water approved-High abrasion resistance-High chemical resistance-High strength-High resilience to shocks-High fatigue strength-Permanent low head loss-Weldable, by butt fusion-Almost unlimited lifetime underwater

Quality Control on PE PipesPipelife Norge AS is certified according to ISO9001 and ISO14001Main standards used: ISO 4427:E and EN12201ISO 9001 CertificateTypical Quality Control Plan

Quality Control on PE PipesControl of the raw materialDensityISO1183Melt Flow Rate (MFR)ISO1183Oxidation Induction Time (OIT)EN728The results of the tests are shown on the resin suppliers material certificates.

Quality Control on PE PipesControl on Ready Made Pipe•Same raw material control is also made on the ready made pipe,i.e. (Density, MFR and OIT)•The use of an inert gas, (nitrogen) in the pipe manufacturingensures the quality of the material performance (anti oxidants)in the finished pipe is high and more stabile.

Appearance and dimensions:•Appearance ISO4427:E / EN12201•Diameter ISO4427:E / EN12201•Ovality ISO4427:E / EN12201Quality Control on PE PipesControl on Ready Made PipeGravimetric controlMeasuring of the pipe diameter

Quality Control on PE PipesHydrostatic TestHydrostatic strength ISO4427:E / EN12201PE80: +80ºC / 4,5 MPa / 165 h and +80ºC / 4,0 MPa / 1000 hPE100: +80ºC / 5,4 MPa / 165 h and +80ºC / 5,0 MPa / 1000 h

Quality Control on PE PipesTensile strength test on weldISO 13953 - 2001Machining of test sampleTensile strength testConditioning: test piece in air for a min. 6 h at 23C + 2C , testing not be carried out less than 24h after thebutt fusion og the joint.Procedure: Record the maximum force applied and the type of failure as ductile or brittle, as characterized bythe ductile and brittle failure modes. Only failures at the butt-fusion joint shall be taken into account

Quality Control on PE PipesCertification Requirements on Welding Machines and WeldersOwn experienced, certified welding specialists, (here welding a ø2100 mmpipe with 70 mm wall, a brine outfall for a desalination plant, 2012)

Tow PreparationTraditional Tow Preparation with End Plugs and Towing ClampsWelding of end plug on 1600 mm pipe,(Tay Region, Scotland, 1999)Pipes ready with towing clamps, hawsersand front cones, (Fylde, the U.K. 1995)

Tow PreparationTow with Flange Connections Ready Assembled at the FactoryWelding of stubend on 2100 mm pipe,Assembly of blind flange and protectivetyre on 1600 mm pipe,

Tow PreparationThe design of the towing gears is controlled by internationally recognized certifying bodiesDeparture of 1400 mm pipe tow, 10 pipesá 480 m, (Cartagena, Spain, 2005)Departure of 1200 mm pipe tow,(Cork, Ireland, 2001)

Towing in the Open OceanPipelife Norge AS long length deliveries includetowing transport and transport insuranceTowing of 1400 mm pipes,(Reykjavik, Iceland, 2001)Towing of 1000 mm pipes,(Split, Croatia, 2001)

Inspection and Control at ArrivalThe delivery is always jointly inspected by representatives fromthe Contractor, Project Consultant and Pipelife2000 mm pipes in storage, (Aveiro,Portugal, 2008)Mooring and inspection of 1200 mmpipes, (Sibenik, Croatia, 2002)

Advantages with Supply of PE Pipes in Long LengthsWhich are the mainadvantages with the longlength pipe concept?•No or very little welding work•Low transport costs•Substantial time and costsavings for the contractor, asnormally no land based worksite and storage area isrequired•Less risk for damages duringhandling, transport andstorage

Installation of flexible PE Pipes in Long LengthsMethodology•Surface preparation with concrete weights•Surface assembly of long sections•Surface positioning along lay route•Installation in a continuous operation•Surface to seabed transfer utilizing the PE pipe’s flexibleproperties•Submersion by water filling / air evacuation•The operation can be reversed if required•Fast, practical sinking speed 500-1000m/hour•No sophisticated equipment required

Installation of flexible PE Pipes in Long LengthsB U O YAN C YAIR FILLED P IP ELIN EAIR VEN TP U LL FO R C ER2C O N C R ETE B LO C KSD O W N D R AFT W ATER C O LU M NEQ U ILIB R IU M LEVELR1D IS P LAC EM EN TW ATER FILLED P IP ELIN ES EAB EDS - LAY IN S TALLATIO N O F FLEXIB LE P IP ELIN ES

Installation of flexible PE Pipes in Long LengthsImportant Parameters•Water filling method; pressure-, gravitation•Sinking speed / equilibrium pressure•Inlet arrangement / flow capacity•Relative pressure / hydrostatic buckling•S-curve / critical bending radius•Longitudinal pulling force•Concrete weight slide / bolt torque•Time- / stress factor during temporary stops•Weather conditions / positioning control•Contingency actions

Installation of flexible PE Pipes in Long LengthsLongitudinal pulling force•Assists positioning along lay route•Compensates wind- and wave action•Provides safety margin for S-curve bends•Maintains control when offshore end dives, (SJconfiguration), (water in / air out)•Achieves safe landing of end arrangement on seabed

Concrete Ballast WeightsVarious concrete weight designs, depending if thepipeline is installed on the seabed or in trenchLoudden, Stockholm, Sweden - ø630 mmReykjavik, Iceland - ø1400 mmStobrec, Split, Croatia - ø1000 mmMontpellier, France - ø1600 mmLimassol, Cyprus - ø1600 mm

Concrete Ballast WeightsConcrete weight bolts,rubber compensatiors,EPDM rubber frictionstraps and sacrificalanodesReykjavik, Iceland - ø1400 mmAntalya, Turkey - ø1600 mm

Concrete Ballast WeightsAssembly of the concrete weights on the PE pipe. Various methods.Lough Mahon, Cork, Ireland - ø1200 mmReykjavik, Iceland - ø1400 mmSödertälje, Sweden - ø1000 mmPorto de Suape, Recife, Brazil - ø1600 mm

Submerging of flexible PE pipelinesAntalya, Turkey - ø1600 mmTerga, Algeria – ø2000 mmCarrigrennan, Cork, Ireland - ø1600 mm

Submerging of flexible PE pipelinesXove, Spain – ø2000 mmMontpellier, France - ø1600 mmSibenik, Croatia - ø1200 mm

Submerging of flexible PE pipelinesOffshore surface connections of pipe stringsMontpellier, France - ø1600 mm

Submerging of flexible PE pipelinesPipeline end detailsCompressed air hose connected to the pipe end(Stobrec, Croatia - ø1000 mm)Towing end ø1600 mm for ocean towingof the ready weighted pipes

Diffuser solutions328 m long tapered diffuser 1600 / 500 mmwith 120 diffuser ports in ø160 mm forAntalya sea outfall - main pipeø1600 mm, (Turkey)Ø500 mm diffuser risers to be assembled onthe ø1400 mm main outfall - Accra, GhanaTotally 78 numbers of 160 mmdiffuser risers on the ø1600 mmmain pipeline - Montpellier, France

Special accessoriesø1600 mm Embedded spool piece3D tailor made fitting ø800 mm PN10for Fortum, StockholmFlanged 57 degree ø2000 mm bendfor Insuamar - SpainØ1400 mm intakes on ø2000 mmmain pipe - Insuamar - Spain

Reference projectsFylde Sea Outfall, the U.K. - 1995Pipe diameter 1400 mm (5200 m + 1100 m)Assembly of concrete weights & submerging

Reference projectsAntalya Sea Outfall, Turkey - 1997Pipe diameter 1600 mm (5400 m)Submerging of the sea outfallDiffuser section

Reference projectsAveiro Sewerage Project, Portugal - 1998-99Pipe diameter 1400mm (2780 m) and 1600 mm (1800 m)Sea transport of pipes and Concrete weight assembly

Reference projectsSantander Sea Outfall, Spain - 1999Pipe diameter 1400 mm (2690 m)Pipe welding and concrete weight assembly

Reference projectsLarnaca Desalination Plant Project, Cyprus - 1999 / 2000Pipe diameter 1200 mm (1050 m) and 1000 mm (1500 m)Tow departure from NorwayPipes stored in the port of Limassol

Reference projectsLevenmouth Sea Outfall, the U.K. - 2000Pipe diameter 1600 mm (1036 m)Production of diffuser sectionsTow preparation

Reference projectsCooling Water Intake, Södertälje, Sweden - 2000Pipe diameter 1000 mm (6134 m)Pulling of 500 m pipe length over the lock Concrete weight assembly

Reference projectsReykjavik Sea Outfall, Iceland - 2001Pipe diameter 1400 mm (5690 m), 1200 mm (155 mm) and 1000 mm (400 m)Assembly of concrete weights, jointing of pipe sections and submerging

Reference projectsBekkelaget Sea Outfall, Oslo, Norway - 2001Pipe diameter 1200 mm , twin pipe2 x 370 m + diffuserPreparation of diffuser for laying suspended2 m above the sea bottom submergingSubmerging of the first outfall pipe

Reference projectsStobrec Sea Outfall, Split, Croatia - 2001Pipe diameter 1000mm length 2932 m, including a 204 m long diffuserSinking of thedeep sectionTowing of the pipesPipe installation

Reference projectsLough Mahon Crossings, Cork, Ireland - 2001Pipe diameter 1200mm twin pipeline total length 7064 mPipestorageCollar assemblyGRP couplingCoupling assembly tool

Reference projectsCarrigrennan Sea Outfall, Cork, Ireland - 2002Pipe diameter 1600 mm Pipe length 800 mPipe installation

Reference projectsTermopernambuco Cooling Water Outfall, Recife, Brazil - 2002Pipe diameter 1600 mm total length 1624 mDeparture fromStathelleThe power plantWeighted pipes in Suape port

Reference projectsLoudden Waste Water Pumping Main, StockholmSweden – 2003Pipe diameter 630 mm total length 6820 mConcrete weight assemblyTowing of the pipes throughthe archipelago of StockholmThe power plant

Reference projectsMontpellier Sea Outfall, France – 2003Pipe diameter 1600 mm total length 10.827 mAssembly of the GRP coupling and pipe submersionWelding ofPE stubend

Reference projectsSibenik Sea Outfall, Croatia – 2003 and 2004Pipe diameter 1200 mm total length 5134 mInstallation of the first 1500 m sectionMooring of the pipes inSibenikThe power plant

Reference projectsSubmarine Cooling Water Pipeline, Stockholm, Sweden – 2004Pipe diameter 800 mm PN10 total length 2100 mThe PE pipes are lifted over the lock inSödertälje for further towing to siteThe power plantSpecial bends, re-inforced withGRP around the butt welds inorder to get PN10 rating

Reference projectsWater Pipeline for Paper Mill, Halden, Norway – 2004Pipe diameter 1400 mm total length 1490 mWelding of the OD 1400 x 66,7 mmSDR21 PE pipe at site.The power plantInstallation of the marine part of thepipeline in a river.

Reference projectsSchola Green Outfall Relining, Morecambe, the U.K. – 2004Pipe diameter 1400 mm total length 967 mDeparture of the tow with the 967 mlong PE pipe OD 1400 mm SDR26The power plantInstallation of the PE pipe into the oldconcrete lined steel pipe

Reference projectsKorle Lagoon Outfall, Accra, Ghana – 2004Pipe diameter 1400 mm total length 1800 mTow departure from Stathelle with the 4numbers of diameter 1400 mm pipeMooring of the pipes inSekondi The harbour, power plant Ghana

Reference projectsDrinking Water Pipeline, Kalmar, Sweden – 2004Pipe diameter 710 mm PN10 total length 7920 mThe OD 710 mm SDR17 PN10 PE pipe,500 m long, is pulled into the layingposition with a forest tractorThe power plantThe pipe is in position. The trenchshall be excavated to the right ofthe pipe

Reference projectsBrine outfall from a desalination plant, Cartagena, Spain – 2005Pipe diameter 1400 mm total length 4800 mDeparture of the tow with 10 x 480 mlong PE pipes OD 1400 mmThe pipeline is ready forsubmerging – buoyancy required

Reference projectsSea water intakes for a fish farm, Galicia, Spain – 2005Pipe diameter 2000 mm total length 2230 mDeparture of the tow with 4 pipes,Pipe submerging in Xove harbour2 x 630 m + 2 x 485 m long PE pipesOD 2000 mm SDR30 and SDR26 PE80

Reference projectsSea outfalls for Zadar and Biograd, Croatia – 2006Pipe diameter 1200 mm total length 2810 mPipe diameter 630 mm total length 3419 mPipes in storageSubmerging of the ø1200 mm PE pipes inZadar

Reference projectsSea water intakes for Abutaraba desalination, Libya – 2006Pipe diameter 1400 mm total length 1288 mSinking of the OD 1400 mm SDR26 PE80 pipes in Abutaraba in August 2006

Reference projectsSea water intakes and brine outfall for Hamma desalination,Algiers, Algeria – 2006Pipe diameter 1600 mm total length 1348 mInstallation of one ø1600 SDR26 sea water intake

Reference projectsTangier sewer outfall, Morocco – 2006/2007Pipe diameter 1400 mm total length 2195 mArrival of the second delivery to TangierMED harbour in March 2007Ready weighted pipes in storage

Reference projectsTetouan sewer outfall, Morocco – 2006/2007Pipe diameter 1200 mm total length 3100 mBallast weight assemblyTetouan – Submerging of the ø1200 mmpipeline

Reference projectsSea water intakes and brine outfall for Chennai desalination,India – 2007Pipe diameter 1600 mm total length 1700 mWelding and ballasting of the pipeline in Chennai.

Reference projectsCooling water outfall for a power plant, Ireland – 2007Pipe diameter 2000 mm total length 437 mWelding of the PE stubend to the ø2000SDR33 pipe on site in Cork.Ø1200 mm PE manhole assembledon the ø2000 mm pipe on site.

Reference projectsSea water intakes for the MIRA fish farm, Portugal – 2007/2008Pipe diameter 2000 mm total length 5308 mPipe submergingoutside MiraDeparture of the second tow with 6numbers of ø2000 SDR26 pipes.Concrete ballast weightingin the port of Aveiro

Reference projectsSea water intakes for the Barcelona desalination plant, Spain –2007/2008Pipe diameter ø1400 mm – 1330 m and ø1800 mm - 4320 mDirectional drilling operation under ariver – 1400 mm SDR21 PE pipeDeparture of the second tow with 10numbers of ø1800 SDR26/30 pipes.

Reference projectsSewer outfall for the city of Rabat, Morocco – 2008Pipe diameter 2000 mm total length 1365 mSubmerging of the ø2000 SDR26 diffuser pipein Rabat .Concrete ballast assembly

Reference projectsSewer outfall for the city of Tripoli, Lebanon – 2008Pipe diameter 1600 mm total length 1473 mAssembly of ø710 mm diffuser risers in theport of Tripoli .Concrete ballast assembly

Reference projectsSewer outfall for the city of Lisbon, Portugal – 2009Pipe diameter 1400 mm total length 1364 mArrival of the ø1400 SDR26 PE pipe deliveryto Lisbon .

Reference projectsSea water intakes & outfall for the Fouka desalination plant,Algeria – 2009Pipe diameter ø1600 mm – 1800 m and ø1200 mm - 380 mDeparture of the tow with thepipes for Fouka, (7 pipes), and forLisbon, (3 pipes).Assembly of concrete weightsin the port of Algiers .

Reference projectsCooling water intakes for the Terga power plant, Algeria – 2009Pipe diameter ø2000 mm – 3790 mDeparture of the tow with the 11ø2000 mm SDR26 pipes.Ready weighted pipes in theArzew port .

Reference projectsSewer outfall for Gdynia, Poland – 2009Pipe diameter 1300 mm total length 2480 m + diffuserDeparture of the tow with the 4 numbersø1300 mm SDR26 pipes and the diffuser.Arrival of the pipe delivery toGdansk .

Reference projectsCartagena sewer outfall, Colombia – 2009Pipe diameter 2000 mm total length 4321 mDeparture of the tow from Stathelleon May 17, 2009Arrival of the tow to Cartagena de Indiason July 16, 2009

Reference projectsCarboneras sea water intake for a desalination plant, Spain – 2009Pipe diameter 2000 mm total length 1007 mPipe arrival in the port ofCarboneras, south of SpainManhole asembly

Reference projectsSea water intake and brine outfall for a desalination plant –Limassol, Cyprus - 2010Pipe diameter: 1400 and 1200 mm – total length 2250 mTow preparationTow departure from Stathelle

Reference projectsTa’Barkat sewer outfall – Malta - 2010Pipe diameter: 1600 mm – total length 1000 mConcrete weight assemblyReady installed outfall pipeline, with diffuserrisers equipped with Tideflex valves.

Reference projectsEl Jadida sewer outfall , Morocco - 2010Pipe diameter: 900 mm total length 2160 mPipes ready for departure to El Jadida & Malta

Reference projectsSubmarine casings pipelines for a wind mill park,Norderney islands, Germany- 2010Pipe diameter: 450 and 250 mm total length 5690 mInstalled pipelinePulling operation

Reference projectsShoreham sewer outfall, Brighton, the U.K. - 2010Pipe diameter 1400 mm – total length 1658 m + tapered diffuserDeparture of the tow together withready made diffuser.Pulling the pipes over the pier towardsdesignated mooring place.

Reference projectsPipes for deep sea supports for oil pipelines, Luanda, Angola - 2010Pipe diameters: 900 and 1100 mm – total length 845 mThe pipes in the assembly hall in Antwerp

Reference projectsTailings outfall pipes for a copper mine – Batu Hijau, Indonesia - 2010Pipe diameter: 1000 mm – total length 3690 mStored pipes ready to be shippedLoading of pipes on the cargo vesselchartered by the Buyer.

Reference projectsOdessa sewer outfall, Ukraine - 2011Pipe diameter 2000 mm – total length 4307 mDeparture of the tow fromStathelle.The tow is passing the Bosphorus inIstanbul on the way to Odessa

Reference projectsStorm water outfalls, Doha, Qatar - 2011Pipe diameter 1400 and 1800 mm – total length 2551 mPipe submergingPipe welding on site in Doha

Reference projectsJeddah outfalls, Jeddah, Saudi Arabia – 2011 -12Pipe diameter 2000 mm – total length 1102 mThe pipeline is floated out on the seaPipe welding on site in Jeddah

PE Pipes in Long Lengths from PipelifeThank You for Your AttentionTrygve Blomster