State of Technology Report for Force Main Rehabilitation, Final ...
State of Technology Report for Force Main Rehabilitation, Final ...
State of Technology Report for Force Main Rehabilitation, Final ...
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<strong>Technology</strong>/Method Hose Liner/Pulled in Place<br />
Pressure Capacity, 493 psi <strong>for</strong> 6 inches (150 mm), 218 psi <strong>for</strong> 20 inches (500 mm) <strong>for</strong> single layer <strong>of</strong><br />
psi<br />
woven fabric; higher with double layer <strong>of</strong> woven fabric<br />
Temperature Range,<br />
o<br />
F<br />
60 o C<br />
Renewal Length, feet Up to 6,000 feet (3,000 feet more common)<br />
Other Notes Certified <strong>for</strong> drinking water in Germany, but not in North America.<br />
III. <strong>Technology</strong> Design, Installation, and QA/QC In<strong>for</strong>mation<br />
Product Standards KTW and W270 <strong>for</strong> drinking water in Europe, Deutsche Vereiniging des Gas und<br />
Wasserfaches (DVGW) Testing Basis VP 643, June 2004<br />
Design Standards None. Raedlinger’s rated pressure <strong>of</strong> the Primus Liner provides a short-term factor<br />
<strong>of</strong> safety <strong>of</strong> 2.5 against the burst pressure. Raedlinger’s literature states that longterm<br />
creep pressure tests are conducted, in accordance to DIN 16887 and ISO<br />
9080, with a safety coefficient <strong>of</strong> 2.0 applied to the extrapolated 50 year strength.<br />
Design Life Range Minimum service life <strong>of</strong> 50 years<br />
Installation Standards None<br />
Installation<br />
The existing pipe is first CCTV inspected. The inspection device is fitted with<br />
Methodology tools suitable <strong>for</strong> grinding <strong>of</strong>f sharp edges at pipe transitions or welded seams.<br />
The pipe is then cleaned using a mechanical pig. Sharp edges can damage the<br />
outer PE coating so a special fitting is needed to guide the liner into the host pipe.<br />
The Primus Line is pulled from a reel into the pipeline that has been prepared. A<br />
special pulling head is fitted to the end <strong>of</strong> the Primus Line <strong>for</strong> attaching the cable<br />
<strong>for</strong> pulling. Rate <strong>of</strong> installation <strong>of</strong> up to 1200 feet per hour possible. The<br />
maximum pulling <strong>for</strong>ce is 100 kN. A load cell with recorder is required to<br />
monitor and document the pulling <strong>for</strong>ce. With the Primus Line in final position,<br />
special connectors are fitted on the ends and after curing <strong>of</strong> the injected resin<br />
(Scotchcast Cable Resin No. 1471), the connector is used to join the Primus<br />
Line via a welded or flanged connection to the original pipe or an adapter.<br />
QA/QC The host pipe is CCTV inspected <strong>for</strong> anomalies. The inspection device is fitted<br />
with a grinding tool <strong>for</strong> removal <strong>of</strong> any sharp edges which could damage the<br />
Primus Liner during insertion or operation. After the liner has been completely<br />
installed and connecters fitted to the end, the line is hydrostatically pressure tested<br />
to ensure leak tightness. Raedlinger recommends a test pressure <strong>of</strong> 1.1 times<br />
working pressure, or a minimum <strong>of</strong> 30 psi (2 bar) over working pressure.<br />
IV. Operation and <strong>Main</strong>tenance Requirements<br />
O&M Needs None identified.<br />
Repair Requirements Raedlinger did not state what procedures need to be followed to repair a section<br />
<strong>for</strong> Rehabilitated that has been lined with Primus Line. It would appear that a damaged section<br />
Sections<br />
would have to be removed and two new special couplings used to install a<br />
replacement section.<br />
V. Costs<br />
Key Cost Factors • Time and cost savings<br />
• Only coarse cleaning <strong>of</strong> the old pipe is necessary; no bonding <strong>of</strong> the Primus<br />
Liner is required<br />
• Fast installation process and fast restart <strong>of</strong> pipeline operation<br />
• Savings through minimum construction costs<br />
• Reduction <strong>of</strong> excavation work to a minimum; minimal disruption <strong>of</strong> public<br />
life, no destruction <strong>of</strong> vegetation, no disturbance <strong>of</strong> road, rail and shipping<br />
traffic<br />
Case Study Costs The cost <strong>for</strong> the installation was reported to be about a 70% cost savings versus<br />
conventional replacement construction.<br />
VI. Data Sources<br />
References Primus Line brochure “Innovative High-Pressure Pipelines <strong>for</strong> Trenchless Pipe<br />
Renewal”; Reference data sheets (8 selected projects)<br />
Pressure Rates; Scope <strong>of</strong> delivery; Installation manual (December 2008);<br />
Installation manual connectors<br />
A-65