Slides penstock latam 2013 (English)

Ing. Andreas Moser

PENSTOCKS

HIGH PRESSURE, HIGH SLOPES, NO NEED FOR CONCRETE BLOCKS

European Experience in penstocks made in cast iron pipes with BLS® Plug&Play

Ing. Andreas Moser

IN THIS SLIDE PRESENTATION, WE WILL INTRODUCE

A TECHNIQUE FOR PENSTOCKS CONSTRUCTION, THAT:

• DO NOT require concrete blocks (till very high pressure). Not even in elbows.

• DO NOT require welding.

• DO NOT require trench (but it can be buried)

• DO NOT suffer corrosion and DO NOT need cathodic protection

• LOW head lost

• QUICK and EASY laying

• DO NOT suffer breakdowns. DO NOT require any maintenance procedure

OUR FIVE ARGUMENTS:

1. MATERIAL1. MATERIAL

2. PLUG & PLAY2. PLUG & PLAY

3. INSIDE LINING3. INSIDE LINING

4. OUTSIDE COATING4. OUTSIDE COATING

5. FULL TECHNICAL SERVICE5. FULL TECHNICAL SERVICE

&

We are German. We are Spanish

2008Changes into an

independent medium-sized group of

companies

1731Buderus company

founded by Johann Wilhelm

Buderus

1901First cast iron socket pipe

1927Use of centrifugal casting process

begins

1947Tiroler Röhren- und Metallwerke

founded

1958The pipes become ductile

1986Production of piles begins at

TRM

1978Cement mortar coating (ZMU)

introduced

1996TRM becomes

part of the Buderus Guss

Group

1975Restrained socket joints and cement mortar lining

introduced

2003Taken over by Robert Bosch

GmbH

2005A fresh start: The

Bosch Group sheds

considerable parts of its casting

business

2010Process of assuming a

new, common corporate identity completed

DUKTUS, A GLOBAL COMPANY

1. MATERIAL1. MATERIAL2. PLUG & PLAY

3. INSIDE LINING

4. OUTSIDE COATING

5. FULL TECHNICAL SERVICE


• Ductile Cast Iron: an ancient material, but innovative

• Tradicionally working with a Safety Factor of 3.0. This means WARRANTY

• Ductile means deformable. It is not rigid like GRP or some types of steel.

• Its microstructure allows it to yield, performing well under high pressure.

Properties of the material:• Minimum tensile strength 420 N/mm²• Elongation at break 10%• Compressive strength 550 N/mm²• Stress at 0.2% non-proportional elongation 300 N/mm²

Drinking water pipes EN545

Sewage pipes EN598


QUALITY CERTIFICATES

Calidad superior servida 1. MATERIAL1. MATERIAL

IT IS NOT JUST A KIND OF PIPESIt is a complete construction system

1. MATERIAL

2. PLUG & PLAY2. PLUG & PLAY3. INSIDE LINING

4. OUTSIDE COATING


2. PLUG & PLAY

Left lock x 2 Right lock x 2

Catch (EPDM)

BLS® DN 80-500


Locking chamber

2. PLUG & PLAY

BLS® DN 80-500


2. PLUG & PLAY 2. PLUG & PLAY2. PLUG & PLAY

BLS® DN600-1000

Calidad superior servida 2. PLUG & PLAY2. PLUG & PLAY

• BLS® is a retaining system flexible and with no bolts

• Equivalent to a welding work, but set in minutes.

•Suitable for steep slopes

• High productivity, up to 300 meters per team a day.

• High qualified staff not required

• More than 100 bar pressure (depending on diameter).

• Tensile force up to 2.273 kN (depending on diameter).

• Flexible. Up to 5º angular deflection in joints.

• DO NOT require concrete blocks neither other elements.

• Layable with NO trench if needed (e.g. rocky ground).

• High reliability. NO-Disconnection warrantied.


BLS® locking makes unnecesary the

use of concrete blocks.


VERSATILE¡THE POWER OF THE ¡THE POWER OF THE

IDEAS!IDEAS!


Easy laying means high performance when building.

Special fittings are joint in the same way (BLS®) and are placed quick and safely.

Right after laid the pipe-line is ready for use.

In hydro stations, often penstock laying is one of the critic tasks in the schedule. So that, an easy and quick laying technology is appropriated.


TYTON® Gasket

• Vulcanized rubber, according to DIN EN 681 (Elastomeric seals for joints in pipework and pipelines)

• Rubber depending on characteristics of water:

• Rubber with two hardness values (IRHD , ISO 48): 85±5 y 55±5

• The more pressure, the more sealing

• Lifetime of 200 years

Temperature Seal material

WA Drinking water up to 50ºC EPDM

WC Non drinking / Residual / Acid / Sea Watercontinuous up to 45ºC

not continuous up to 95ºCPerbunan®

WF Non drinking / Residual / Acid / Sea Water up to 110 ºC Isobutileno

Water characteristics

Calidad superior servida

No leaks because of disconection


Real case in Alps, The slope detachment caused by a strong river flood did not cause the destruction of the line under the slope. The pipe-line remained in use despite of the lost of ground around it. A few months later, finally it was restored.

Calidad superior servida

It is therefore useful in areas at risk of soil loss


DN200 deflection 0° DN 200 deflection 5°

DN 200 deflection 15° DN 200 deflection 20º DN 200 deflection 24°


Earthquake test performed for a

customer at factory.

Strong deformation can be suffered by pipe before breaking down.

1. MATERIAL

2. PLUG & PLAY

3. INSIDE LINING3. INSIDE LINING4. OUTSIDE COATING


3. INSIDE LINIG3. INSIDE LINIG

CEMENT MORTAR

o Set by centrifugation, at 50g

o High compacity. High density.

o PHYSICAL and CHEMICAL protection

o Inorganic. Immune to bacterial attack

o Low roughnesso Absolute roughness: ≈ 0,030 mmo C (Hazen-Williams): ≈ 158o n (Manning): ≈ 0,0088o Unchanged in time

o High resistance to abrasion

o Flow velocity up to 10 m/s without degradation

o Durability

o Gasket area is protected

Our standard


CEMENT MORTAR

o Set by centrifugation, at 50g

o High compacity. High density.

o PHYSICAL and CHEMICAL protection

o Inorganic. Immune to bacterial attack

o Low roughnesso Absolute roughness: ≈ 0,030 mmo C (Hazen-Williams): ≈ 158o n (Manning): ≈ 0,0088o Unchanged in time

o High resistance to abrasion

o Flow velocity up to 10 m/s without degradation

o Durability

o Gasket area is protected

Our standard


200 250 300 400 500 600 700 800 900 1000

50 10,08 3,31 1,32 0,34 0,11 0,05 0,02 0,01 0,01 <0,01

100 37,25 12,06 4,77 1,20 0,40 0,17 0,08 0,04 0,02 0,01

150 80,92 25,98 10,20 2,53 0,85 0,35 0,17 0,09 0,05 0,03

200 x 45,00 17,58 4,34 1,44 0,59 0,28 0,15 0,08 0,05

250 x 69,09 26,89 6,60 2,19 0,89 0,43 0,22 0,12 0,07

500 x x x 24,62 8,05 3,25 1,54 0,81 0,44 0,26

750 x x x 53,76 17,43 7,00 3,30 1,72 0,94 0,56

1.000 x x x 93,94 30,31 12,11 5,68 2,96 1,61 0,96

1.250 x x x x 46,65 18,57 8,69 4,51 2,45 1,45

1.500 x x x x 66,46 26,39 12,32 6,38 3,46 2,05

1.750 x x x x 89,73 35,56 16,57 8,56 4,64 2,74

2.000 x x x x x 46,07 21,43 11,06 5,98 3,54

2.250 x x x x x 57,92 26,90 13,87 7,49 4,42

2.500 x x x x x 71,12 32,99 16,99 9,17 5,41

2.750 x x x x x 85,66 39,70 20,42 11,01 6,49

3.000 x x x x x x 47,02 24,17 13,01 7,67

3.250 x x x x x x 54,95 27,52 15,18 8,94

3.500 x x x x x x 63,49 31,78 17,52 10,31

FL

OW

(l/s

)

(*) Using standard wall thickness. Elbows not considered in calculation. Using Colebrook-White formula

DIAMETER (mm)

HEAD LOSS (m) PER 1000 m PENSTOCK (*)

Calidad superior servida 3. INSIDE LINIG3. INSIDE LINIG

SUITABLE FOR 90% OF PENSTOCKS

Blast Furnace Cement (BFC) Mortar

High Alumina Cement (HAC) Mortar

pH 5,5 3

aggressive CO2 up to 15 mg/l No limited

Sulfate (SO42-) up to 3.000 mg/l No limited

Magnesium (Mg++) up to 500 mg/l No limited

Ammonium (NH4+) up to 30 mg/l No limited

Human Supply Water YES YES (1)

Desalinated Water (2) YES (3) YES

Sea Water (2) NO YES

Brine NO YES

(1) Aluminium in w ater to be controlled (2) According to DIN 2880 and DUKTUS experience (3) Only remineralized

Calidad superior servida 3. INSIDE LINIG3. INSIDE LINIG

CHEMICHAL PREVENTION

Just a PHYSICAL PROTECTION is NOT enough against corrosion (like inside lining made in polyurethane, rubber or other). A CHEMICAL ALLIANCE with water is required.

Minimum requirement (according to DIN EN 476) is a thickness loss of 0.6 mm after 100,000 cycles. HAC mortar cement inside lining of DUKTUS resut is below 0.1 mm.Event after 400.000 cycles the thickness loss is much lower of allowed value, and much better than any other material.

ABRASION RESISTANCEComparison of several abrasion diagrams of different materials: Darmstadt Test (DIN 295-3)

3. INSIDE LINIG3. INSIDE LINIG

1. MATERIAL

2. PLUG & PLAY

3. INSIDE LINING

4. OUTSIDE COATING4. OUTSIDE COATING5. FULL TECHNICAL SERVICE


To be chosen according to soil agressivity

ZINK + BLACK BITUMEN ZINK + BLUE EPOXY ZMU(a)

Zn 200 g/m 2

+5 mm of cement reinforced by plastic fibre

pH > 6 > 6 Any pH value

Above w ater table >1500 Ω·cm Sobre capa freática >1000 Ω·cm ALL TYPE OF SOILS

Below w ater table >2500 Ω·cm Bajo capa freática >1500 Ω·cm

Even stray currents

Filling material up to100 mm Trench can be f illed w ith exavation materials

Suitable for NO DIG technologies

(a) Spigot-Socket union area can be covered by a rubber sleeve, retractable polyethylene or Ergelit mortar tape

Contaminated soils (free of refuse, cinders, slags or industrial eff luents)

Without stray currents

Filling material up to 32 mm

Expoxy 250 μm or enamel, that guarantees protection against all levels of corrosionFittings

Laying

SO

IL

Resistivity

Chracteristics

Even strongly agressive soil, such as refused, cinder or slag containing ones,

volcanic, peaty or marshy soils.

Zn 200 g/m 2

+ Bitumen 70 μm

TYPE OF COATING

Zn 200 g/m 2

+ Epoxy ≥100 μm

Homogeneous soils


Zinc coating provides an electrochemical protection that prevents iron rusting. The soil or mortar coating, due to moisture, act as an electrolite. Iron wall acts as a cathode. Zinc layer, as an anode. Cations (Zn++) move and cover the iron surface in the case it is exposed because of any damage.

Therefore, cathodic protection is not required


The outside coating is usually the key to have a long or a short lifetime...

According to Paper W401 (by DVGW, Deutscher Verein des Gas und Wasserfaches) whose title is Advide to decide in rehabilitation of dring water pipes, a line lifetime depends strongly on material and outside coating.

The material with the longest lifetime is zin coated ductil iron, specially with ZMU coating

1. MATERIAL

2. PLUG & PLAY

3. INSIDE LINING

4. OUTSIDE COATING


Calidad superior servida 5. FULL TECHNICAL SERVICE5. FULL TECHNICAL SERVICE


SPECIALIZED STAFF

Civil engineers (speciality in hydraulics)

Agronomic engineers

Mechanical engineers

Chemical engineers

ANY PROJECT

STAGE

Prefeasibility Studies

Feasibiliy Studies

Detailed project

Materials quality control

Management

DIFFERENT WAYS TO PARTNERSHIP

Directly with owner or constructor

Help and advise to project consultants

In-site advisement

EPC


FOR EVERY PROJECT:

• Installation and Operation Manual

• Training for assembling workers

• Monitoring site operation

• Attendance and monitoring of pressure tests


FACTORY GUARANTEE

• All products included

• Covering property damage, personal injury and financial and operating costs arising from failure in pipeline.

• 5 years, renewable

• Up to € 10 million per claim. Up to € 20 million per year.


Quality does not end in design or manufacturing. A right delivery to site, free of damages, is a must.

We consider logistics a way to add value to our product, avoiding damages and setbacks.

DUKTUS LOGISTICS DEPARTMENT• Worldwide shipments

• Maximum efficency. Intermodal transport.

• Container o bulk cargo

• Specific Stowage Handbook

• Prompt CIF quotation

PACKAGING

• Minted timber for pipes transport settlement, facilitating transport and on site storing.

• Fiber-protected ropes.

• Clamping strips, when necessary.

• Caps to prevent dirt inside pipes.


Minimum requirements according to EN 545:2010

Standard

Test results:Elastic limit

Tensile strengthElongationHardness

QUALITY CONTROL ACCORDING TO CUSTOMER NEEDS

DIN EN 10204:• 2.2.• 3.1.• 3.2.

Some picturesof our projects

Extreme slopes.

Difficult access places

SwitzerlandDN250

GuatemalaDN700

Extreme slopes.


ItalyDN300

Extreme slopes.


Ground adaptation

AustriaDN600

GuatemalaDN700

Ground adaptation

Ground adaptation

SwitzerlandDN500

Flange connection to any other

element

FranceDN1000

GuatemalaDN700

Flange connection to any other

element

Very high pressure. Pressure Test at 93 bar

for DN800 pipeline.

AustriaDN800

Workable at any weather

AustriaDN400

Easy work in hard places

SpainDN800

All kind of transport

possibilities

SpainDN900


possibilities

GermanyDN1000


possibilities

Canary IslandsDN400

For complex sites: skyline, spider and

even copter

ItalyDN400

GuatemalaDN700


even copter


even copter

NorwayDN200


even copter

AustriaDN300

Fittings

SpainDN800

Elbows without concrete blocks.

SpainDN1000

Elbow

GuatemalaDN700

Elbows without concrete blocks.

IntakeChannelSand trap and chamber

Penstock

Powerhouse

USUAL SCHEME

Intake (with a small sand trap)

Penstock (buried if required)

DUKTUS SCHEME

Powerhouse

Full environmental integration

ItaliaDN500

NorwayDN800

Full environmental integration

A good material and a good organization are the key for a good project.

THANK YOU FOR YOUR ATTENTION

Slides penstock latam 2013 (English)

Business

Transcript of Slides penstock latam 2013 (English)