State of Technology Report for Force Main Rehabilitation, Final ...

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