michelangelo ed. 02-2016 - Kiasma, The dredging pipeline ... Pipes Michelangelo.pdf · Michelangelo Ed. 02 - 2016 ... knowledge in the production of underwater pipeline, ... production

Michelangelo Ed. 02 - 2016

KIASMA® Group

1. Dredging

2. Sinking line ( sea – ports ) for dredging pressure

3. Sewage of the treatment plan (sea)

Dewatering water (shore)

4. Fall pipe for vessels

5. Electric dams

HDPE PIPES

High Pressure – Big Diameters

HDPE PIPE

HIGH PRESSURE

BIG DIAMETERS FOR DREDGING

DREDGING

KIASMA® Group

DREDGING

INTRODUCTION

To reduce the cost per cubic meter of dredged material, the Ship builders, in the last years

are turning their interests in building CSD (Cutter Suction Dredger) and TSHD (Trailing

Suction Hopper Dredgers) of large dimension.

The evolution in the '60s saw installed diesel power of 10,000 kW to reach 13,000 KW of

power in the 70s, to then continue in the 80s with 15,600 KW of power to 20,500 KW

power in the 90s, growing to 22,400 KW of power in the 2000, to eventually reach a power

of 27,000 KW in the year 2015.

In the near future dredging work will be characterized by the production requirements

(large volumes at low cost) and by the geographical peculiarity and the climatology in the

sites that has to be dredged ( temperature, climate, storms, waves, escape ways, etc.).

Only the large CSD & TSHD will be able to meet these types of job requirements.

Currently the dredging fleet in the world includes about 40 large CSD-TSHD.

To meet the increasing worldwide demand for high pressure and large diameter discharge

pipes KIASMA has developed innovative HDPE piping systems for the dredging industry

to resist to pressures much higher than 10 bar.

KIASMA® Group 1

RAW MATERIAL

The raw material used for the production of polyethylene pipes are classified in MRS (

Minimum Required Strength ).

MRS is the strength value of the material against the inner pressure along 50 years of

work at 20°.

The Safety Coefficient is determined according to the class of the raw material and the

conditions of the network. Networks and all calculations are made according to this

coefficient.

Safety Coefficient is C=1,25 for potable water distribution lines.

PE100 Ø1200mm PN16 pipe wall thickness 109,1mm

DREDGING

CHARACTERISTICS OF POLYETHYLENE

CALCULATION OF WALL THICKNESS

Calculation of wall thickness required for PE pipe (Nominal

Pressure) is performed using the pipe calculation formula in

ISO 161-1.

PN : Nominal pressure (bar),1 bar = 0,1 N/mmq

s : Wall thickness (mm)

σs

: Hoop stress (N/mmq)

SDR : Stabdard dimension Ratio SDR= da/s = 2S+1

da : Pipe Outer diameter (mm)

According to this, minimum wall thickness is as

follows.

It is dependent to hoop stress safety coefficient

and safety coefficient shall be taken into account

for calculation.

MRS: Minimum Required Strenght

KIASMA® Group 2

Safety coefficient, safety factor is expressed as total operation coefficient in ISO 12162

and has numerous functions. Primarily, safety shall be ensured in case of accuracy of

pipe calculations ( measurements ) and increase of nominal pressure inside the pipe.

For wall pipe = cmin

= 1,25

DREDGING

ABRASION HDPE PIPE FOR

DREDGING

Hydrophilic HDPE, which Reduces

interaction between the transported

material and the pipe wall, ensures

high abrasion resistance, thus allowing

the pumping of abrasive materials like

sands, gravels and mud.

In the test case performed in

Darmstadt, samples of sands and

gravel (60% concentration), with

thickness of 2.0 – 8.4 mm and water

(40% concentration) were used; the

dredged material tested by the U.S.

Army Engineers varied (fine sand,

pebbles and coarse sand).

In the presence of linear motion, it has

been verified that most abrasion occurs

in the sliding surface of the HDPE pipe

through which most of the material

passes. With turbulent motion,

abrasion occurs in a completely

different way.

DREDGINGDREDGING

THERMAL EXTENSION( ELONGATION IN LENGTH DUE TO

TEMPERATURE VARIATION)

Elongation in length due to temperature

variation shall be taken into consideration

while laying HDPE (PE80, PE100) pipes. In

the case that the temperature is increased

elongation will occur in length and

contraction will occur in case of decrease in

temperature.

At 1 m of PE pipe, for temperature variation

for each «K» number (1K=1°C), 0,18mm

elongation or contraction will occur.

∆L = α x L x ∆T (∆L =m. k. mm/m.K-1 )

For instance, in case of elongation or

contraction dependent to temperature, in

length in a line built with PE piping, pipe will

move from the turning point instead of the

fixed point. Assume that for a 12 m pipe

normal operating temperature Tv= 20°C,

maximum pressure T2=10°C. According to

this, variations in length dependent to

temperature are calculated as follows.

Elongation dependent to temperature

increase:

+ ∆L = Lx ∆T1xd= 12,45x0,18=97,2mm

Calculation dependent to temperature

decrease:

-∆L = Lx ∆T2xd= 12,10x0,18=21,60mm

Ls= Fixing distance (mm)

d = Pipe outer diameter (mm)

k = factor 26 for HDPE,

30 for PP,

33,5 for PVC

If it is ∆L=97,2mm for a PE pipe with

diameter of Ø63mm, factor is 26 and clamp

distance is as follows.

3KIASMA® Group

Roughness Value for Varius Pipe Lines

Lyne Tipe Roughness k (mm)

Steel, new 0,01��.0,1

Ductile pipe, new 0,0001��.1

Ductile pipe, old 0,03��.0,2

Plastic pipe (general) 0,01��.0,1

HDPE 0,007��...0,1

Concrete pipe, new 1,0��...2,0

Ceramic pipe 0,1��1,0

Old pipe,operated with

aggressive fluid

2,0


Coefficients of Elongation in length for varius Plastic Materials

HDPE PP PVDF PB PVC GFK

α Coefficient

mm/m.K

0,18 0,15 0,14 0,12 0,07 0,02

DREDGING

WATER HAMMER

Water hammer occurs when valve or

pump is turned on/off. For this following

formula is used theoretically.

a : propagation speed of pressure ware (m/sec)

V : flow speed of the fluid (m/sec)

ρ : fluid density (Kg/mc)

In practice Ps value can be negative or

positive:

Positive: taps can occur when turning off

the pump or while turning it on;

Negative: when turning off the pump or in

presence of a sudden change of

hydraulic property ( ex. sudden reduction

of flow speed )

Propagation speed of pressure wave is

calculated according to the following

formula:

Short term elasticity module shall be used in this

formula(Er=800_1200N/mm2)

Short term pressure changes and water

hammer effect does not cause damage in

HDPE pipes. Following example table

indicates the rate of increase of new

pressure value which is generated by

short term water hammer under 20°C

temperature for the varius safety factor

according to the nominal pressure.

Pressure increase occurring within

values does not damage the pipe.

DREDGINGDREDGING

BENEFIT OF “KFC” SYSTEM

FLOW MOTION CHANGE

"KFC" Flow Motion Change (patent)

can be used to reduce the problem of

water hammer by creating a turbulent

flow sufficient to propel the fluid in a

uniform manner along the entire

circumference of the tube.

In this way, it reduces the accumulation

of sediment that often causes the

water hammer. Also the entire

thickness of the piping is subject to a

uniform abrasion with benefits in terms

of longevity of of the same pipes.

When suitably positioned inside the

pipe, the "KFC" motion changer, varies

the motion of mixtures from linear into

turbulent motion.

Abrasion decrease

Allows the flow to return to a situation

similar to that of pseudo-homogeneous

Newtonian fluid motion in which the

suspended particles flow inside the

pipes.

Increase in pressure along the

discharge line with a consequent

decrease in the consumption of diesel

fuel for the pump.

As shown in the graph below, the KFC

turbulent motion line is represented as

using less energy than the turbulent

motion line and permits a greater

discharge distance to be reached at

equivalent upstream loads.

4KIASMA® Group

Safety Factor – Water Hammer Relation in PE Pipes

Total Operatin Coefficient C (safety factor) Rate of Pressure Increase to Norminal Pressure Under Effect of Short

Term Water Hammer

1,25 50%

1,6 100%

STEEL PIPE = FOR 1 MILLION CM (SOLID) = abrasion 0,9mm

HDPE PIPE = FOR 1 MILLION CM (SOLID) = abrasion 0,7mm

HDPE PIPE + SYSTEM KFC = FOR 1 MILLION CM (SOLID) = abrasion 0,4mm


DREDGINGDREDGINGDREDGING

DIMENSION - HDPE PIPES FOR DREDGING

5KIASMA® Group

PE 100 Pipes

ISO 4427-2

EN 12201-2

SDR 41 SDR 33 SDR 26 SDR 21 SDR 17

PN 4 PN 5 PN 6 PN 8 PN 10

OD

mm

INC

OD

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

500 20 12,30 19,00 15,30 23,40 19,10 28,90 23,90 35,70 29,70 43,80

560 22 13,70 23,60 17,20 29,40 21,40 36,20 26,70 44,70 33,20 54,80

630 24 15,40 29,90 19,30 37,10 24,10 45,90 30,00 56,50 37,40 69,40

710 28 17,40 38,00 21,80 47,20 27,20 58,40 33,90 72,00 42,10 88,00

800 32 19,60 48,10 24,50 59,70 30,60 79,90 38,10 91,20 47,40 112,0

900 36 22,00 60,90 27,60 75,60 34,40 93,40 42,90 115,0 53,30 141,0

1000 40 24,50 75,20 30,60 93,10 38,20 115,0 47,70 143,0 59,30 175,0

1200 48 29,40 108,0 36,70 134,0 45,90 166,0 57,20 205,0 71,10 250,0

1400 56 34,40 147,0 42,90 183,0 53,50 226,0 66,70 279,0 83,00 341,0

1600 64 39,20 192,0 49,00 238,0 61,20 295,0 76,20 365,0 94,80 453,0

1800 72 44,00 246,0 55,10 306,0 68,80 379,0 85,80 467,0 106,6 573,0

2000 80 48,90 303,0 61,20 378,0 76,40 467,0 95,30 577,0 118,4 707,0

2250 90 55,00 385,0 68,90 478,0 86,00 592,0 107,2 724,0

2500 100 61,20 475,0 76,50 584,0 95,60 730,0 119,1 900,0


6KIASMA® Group

DIMENSION - HDPE PIPES FOR DREDGING

PE 100 Pipes

ISO 4427-2

EN 12201-2

SDR 13,6 SDR 11 SDR 9 SDR 7,4

PN 12,5 PN 16 PN 20 PN 25

OD

mm

INC

OD

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

500 20 36,80 53,30 45,40 64,50 55,80 77,30 68,30 91,80

560 22 41,20 66,90 50,80 80,80 62,50 97,00

630 24 46,30 84,60 57,20 102,0 70,30 125,0

710 28 52,20 107,0 64,50 130,0 79,30 160,0

800 32 58,80 136,0 72,60 166,0 89,30 202,0

900 36 66,10 173,0 81,70 210,0

1000 40 73,50 211,0 90,80 259,0

1200 48 88,20 304,0 109,1 375,0

1400 56 102,8 423,0

1600 64 117,5 552,0

1800 72

2000 80

2250 90

2500 100


KFC SYSTEM – TURBULENT MOTION INSIDE THE PIPES

7KIASMA® Group

KFC system inside the HDPE pipes

The conveying of the fluids in the discharge networks under pressure takes place in a way

defined as "linear motion".

When the fluid is flowing within the network, the slope of the line energy decreases more

steeply due to the deposit of the transported material on the bottom of the pipe.

Consequently the liquid section reduces because of the sedimentation and the flow

dissipates most energy to carry the same scope.

The linear motion is characterized by the formation of a bed that causes abrasion on the

bottom of the pipe with a problems of durability of the pipeline (this fact is proved by the

abrasion test conducted in accordance with EN 295-3,

With Kiasma KFC System the problem is limited as it gives the mixture a radial and an

axial motion (Pseudo-homogeneous motion for Newtonian fluids).

The radial motion forces the mixture to rotate in the whole circumference of the pipe, the

axial motion carries in suspension all mixture of small particle size (sand-clay-mud-gravel,

rock, coral).

Here is that the entire inner surface of the pipe is subjected to a uniform abrasion, with

benefit in terms of life of the pipe.

The load loss that the KFC System Kiasma generates inside the pipe is of an order of

0.0017 Pascal, lower than the one generated by a normal pipe which dissipates the

energy while pushing the mixture that continually tends to deposit in the sliding surface of

the pipe.

uniform abrasion inside the pipe

Pseudo-omogeneous flow for newtonian fluids


8KIASMA® Group

WELDING HDPE STUB END ON THE HDPE PIPE

Big welding machine T/T for Big diameters HDPE pipes

WELDING HEAD TO HEAD STUB END /PIPE

WELDING COLLAR ELECTROFUSION STUB END /PIPE

SELF - CERTIFICATION

NORM UNI 10520:2009 – Welding Head To Head

The norm is applied for the welding process done by contact, related to thermal elements

for the realization of junctures head-head of pipe and/or polyethylene joints needed for the

transportation under pressure of fuel gas, water and other fluids. The norm also

defines the methods for the welding preparation and execution, the essential

requirements of the equipment in use and also the various inspections that have to be

carried out in order to verify the final quality.


NORM UNI 9737 – Operator

The welding head to head is executed by an operator in possession of a certificate of

attendance as per Norm UNI 9737


NORM UNI 10521 –Electrofusion Collar

The norm UNI 10521 is related to the welding of plastics done by electrical fusion of pipes

and joints needed for the transport under pressure of fuel, gas and water.

Control of the weld is reposted in the form.


FLOATS FOR HDPE PIPES

9KIASMA® Group

1. Rotationally Polyethylene R 210 Yellow – Linear polyethylene high density

2. Safety Form for R 210 Yellow ( production )

CERTIFICATE

TEST METHOD

Breaking load ISO 527

Yield strength ISO 527

Falling weight – 20°C ISO 6603/2

CERTIFICATE

M.F.I. (190 °C / 2.16 Kg ) UNI 1133

1 Substances identification

2 Dangers identification

3 Ingredients information

4 First aid intervention

5 Fire – fighting measures

6 Storage

7 Exposure check of raw materials

8 Ecological information

9 Disposal

3. Polyurethane CR 761 – CR 775

Polyol

4. Safety Form

TEST METHOD

Density ISO 845 Kg/dm3

1 Substances identification

2 Ingredient

3 Dangers identification

4 First aid intervention

5 Fire – fighting measures

6 Handling – storage

7 Exposure check

8 Physical and chemical properties

9 Ecological information

10 Disposal

Polyurethane injection

Floating stock


10KIASMA® Group

PLACEMENT AND BLOCKING FLOATS IN THE HDPE PIPE

Float blocked

Dime blocking float

Collars HDPE - electrofusion

Assembly and welding of collar by electrofusion

Float blocked


HDPE PIPE FOR HIGH PRESSURES

FOR DREGDING APPLICATION

11KIASMA® Group

KIASMA for the dredging sector, offers a range of discharge pipes in HDPE for pressure

up to 25 Bar ( 360 PSI), with diameters up to OD1200mm (40’’), for floating and shore

lines.

Photo from prodution

Container flat rack

HDPE PIPE HIGH PRESSURE

BIG DIAMETERS FOR DREDGING

SELF SINKING ( SEA – PORT )

KIASMA® Group

DREDGINGDREDGINGSELF SINKING ( SEA – PORT )

INTRODUCTION

12KIASMA® Group

KIASMA SRL is specialized in the marine sector of Dredging as a worldwide leader in

HDPE discharge shore and floating pipeline.

Thanks to a Joint Venture with a worldwide leader in manufacturing of HDPE with a deep

knowledge in the production of underwater pipeline, Kiasma is able to offer suitable

HDPE self sinking pipes even for dredging sector.

Kiasma R & D department knows how to work with the line and project designers.

The R & D laboratory with product tests and experts in subsea pipe laying, coordinate the

production of suitable HDPE pipes up to a diameter of 1200 mm (40 ") and working

pressure up to 25 Bar.

CHARACTERISTICS OF POLYETHYLENE : EN12201 and ISO 4427

Advantages of Polyethylene Piping

* They have high flexibility, accept bending radius down to 20 x OD .

Thus them are reliable during of installation. Elongation at break is minimum 350%.

* They are not affected from underground movements, they do not break.

* They have high resistance and crack propagation resistance.

* Since they have low interior surface roughness, they ensure significant advantages

while selecting diameter during project design.

* They are suitable for installation on sea , they are not affected from sea water and sea

movements.

* Black colored pipes are resistant to UV rays.

* They are not affected from harmful substances which are contained in the structure of

soil that cause abrasive effects. Therefore, cathode protection is not required.

* They are resistant to chemical substances.

* They do not change odor and taste of water, therefore, fit for health.

* It is not possible for plant and tree roots to penetrate inside the pipes.

* Buoyancy in sea water

* Almost unlimited lifetime underwater

* Weldable by butt fusion


13KIASMA® Group

INSTALLATION HDPE PIPES IN LONG LENGHTS

METHODOLOGY

Before sinking there has to be worked out a sinking procedure taking into account all

relevant conditions that can occur during installation.

A submarine pipeline is built by welding individual 11,8 m to 35,4 m lengths of pipe into a

string or "section" or by continuous extension of long lengths at the factory.

A string or section should be as long as possible, but its overall length depends on the

space available at the site. In general, lengths practically possible to handle are 500 m

depending on pipe diameter and the towing conditions (open sea, weather conditions).

The pipes should be weighted with concrete weights. The weights can be attached before

the pipe is launched into the sea, or on a barge if it is delivered in long lengths. Pipes

towed to a job site should be stored in a floating position, at a location protected from wind

and waves, and the sections should be securely anchored.

Pipeline systems are sunk in the direction from shore to the outer end.

Normally the whole pipe is sunk in one operation.

After one section is sunk, its sealed flange end rests on the sea bed. In a period with calm

weather, the pipe is filled with air to lift its end to the surface, and the sinking proceeds, as

soon as the next section in connected to the flange. During connection there must be

applied a pulling force to avoid buckling.

The sinking speed shall be checked and recorded during sinking.

A tug boat or other vessel should be available to supply the necessary pulling force.

DREDGINGDREDGINGSELF SINKING ( SEA – PORT )

BENDING RADIUS

14KIASMA® Group

MAXIMUM BENDING RADIUS PE PIPES

R: Bending radius (mm) Dm: Average pipe diameter (mm)

E: Pipe elasticity module (N/mm2) σ : Stress (N/mm2)

Admissible small bending radius shall not

drop under the value indicated in the

below table.

Bending radius for PE Pipes:

Admissible small

bending radius

Pipe

rawmaterial

Installation

temperature

SDR

17

SDR

11

PE80 and

PE100

20°C 30 x da 20 x da

10°C 50 x da 35 x da

0°C 75 x da 50 x da

Breaking possibility constitutes the critical

point in calculation of bending radius for

thin walled pipes. In thick walled pipes,

stresswarping limit constitutes the critical

point while calculation the diameter for

dending process. The following formula is

applied while calculating the admissible

radius of bending for thin walled pipes:

rm

: Average pipe radius (mm)

s : Wall thickness (mm)

Following formula is applied for

calculation (by considering stress-

warping) of the admissible radius of

bending for thick walled pipes:

ra: Pipe outer radius (mm)

e : Stress-Warping (%)

Stress-Warping rate shall not

exceed 2,5%

Bending radius for PE Pipes according to

SDR : 20°C

Pipe

series

SDR Admissible Bending Radius R

s=Pipe Outer Diameter

20 41 50 d

16 33 40 d

12,5 26 30 d

8 17 30 d

5 11 20 d

3,2 7,4 20 d


15KIASMA® Group

PHOTO GALLERY

Sea transport of «cigars» of HDPE pipesOD1400mm – 3000 meters

Installation of concrete blocks

Ancor blocks in cement

Submerging HDPE pipes

HDPE PIPE BIG DIAMETERS

FOR

- SELF SINKING SEWAGE OF TREATMENT PLANT (SEA)

- DEWATERING WATER (SHORE)

SEWAGE OF THE TREATMENT PLANTS

KIASMA® Group


16KIASMA® Group

INTRODUCTION





knowledge in the production of underwater pipeline, Kiasma is able to offer suitable HDPE

self sinking pipes even for sewage of treatment plant (sea) and dewatering water ( shore ).

Kiasma R & D department knows how to work with the line and project designers.

The R & D laboratory with product tests and experts in subsea pipe laying and experts in

laying excavation in trenches, coordinate the production of suitable HDPE pipes up to a

diameter of ID 2500 - 2700 - 3600 mm (144 ").

HDPE PIPES APPLICATION SELF-SINKING - SEWAGE

Sea Discharge application with HDPE pipes

Waste water sewage lines are discharged to the sea in coastal settlements. since the

seas are being polluted more every other day and aqueous life being threatened, these

settlements shall subject waste to treatment process and they shall be discharged to seas

upon being rendered harmless for the aqueous life.

In some projects, sewage lines are

required to pass through water in

areas such as river, lake, sea and

swamps.

HDPE pipes are the most economical

solution with their convenience and

permanent durability for such critical

area applications. The most ideal

pipe for the delivery of waste waters

which will be discharged to the sea is

HDPE pipe which is not affected by

sea water, water movements and

ensuring definite leak-proof.

In sea discharge applications, pipes are extended from the final manhole on the shore to

the streaming open sea, treated waste water is discharged to the deep stream of the sea.

HDPE pipes are submersed on the sea bottom and fixed with concrete blocks since their

density is lower than water. pipes in long discharge lines are jointed on the shore in 250 to

500 meters sections and their ends are covered with blind flanges, concrete connections

are made they are conveyed to the application field by floating. At the application field,

floating segments are jointed together at their flanged points from the land. Air inside the

floating pipes are displaced with sea water from land to sea in a controlled manner and

pipes are submersed on the sea bottom. In sea discharge lines, end section of the pipe is

closed to prevent sedimentation of waste on the mouth of the pipe, diffuser application

shall be ensured at the point where the waste is discharged to water to ensure a

homogenous distribution. Diffuser outputs shall be realized in an oppositely crosswise

fashion on the top 120° circumference of the pipe. Filtered special diffuser application

shall be realized in critical project.

SELF SINKING


17KIASMA® Group

INSTALLATION


Each time a chain ( sinking section of

pipeline ) is concluded, it’s transported to

the storage zone, waiting to be sinked in its

definitive location.

Once the pipe is placed in the sinking area

where the globes placement starts.

The globes control the pulling force to the

chain of the sea outfall during the sinking.

They increase the structural resistance of

the pipeline and they make easier the

jointing of two different chains because the

radius of curvature during the sinking is

much higher thanks to the globes.

When the chain is in the right position with

the globes placed it’s necessary to open the

valve for water entry in one end of the chain

and one for air exit on the opposite side.

While the water gets inside the chain the

HDPE line starts sinking.

SELF SINKING


18KIASMA® Group

The pipeline section is sunk up to an

approximate level of – 4 meters depth and

remains in balance in that depth, full of

water and supported by the sinking globes.

In this position the provisional blind

flanges can be recovered.

Finally the air of the globes it’s taken off

following a well calculated sequence which

allow the pipeline to successfully sink up

to its definitive depth

The two pipelines come close also thanks

to the globes and the connection of two

chains starts by using pneumatic tools.

SELF SINKING


19KIASMA® Group


After the connection of two chains the

emptying of the rest of the globes starts in a

controlled way

ACCESSORIES

Concrete ballast calculated and designed in

one piece to proceed to its placement and

fixation to the pipeline

Valves of water

entry and air exit

SELF SINKING


20KIASMA® Group

INSTALLATION SUBMARINE TRENCHA submarine pipeline will normally be installed as a combination of trench installation and

directly laying on the seabed installation.

Whenever the water tables is higher than the center of a PE pipe, the pipe may be

subjected to buoyancy forces when it is partly filled with water.

The buoyancy forces must be overcame by the backfilling and the concrete weights.

The backfill materials on top of pipe combined with

the concrete weights provide the weight that

counterbalances the uplift due to buoyancy,

preferable with a safety factor not less than 2,0.

Note that the specific gravity of soil is diminished

when it is submerged in water.

Compaction under water is not possible.

Is required using gravel of compaction.

When in position, the pipe is filled with water and

will sink to bottom of trench. The backfilling can now

start.

If the water is deep and the trench can not be seen

from surface position, the route has to be marked

with buoys.

Trenching in soft soil under water may be done

using air or water jets to remove material, which is

then sucked up while the trench is flushed.

The trench depth depends on pipe diameter.

Sea bed material (deposits) or gravel should be

used for backfilling. After the pipe is laid, bed above

it should be restored to its original condition.

Otherwise, waves and ocean currents will erode the

changed profile. In areas where the seabed is

exposed to erosion, gabions filled with gravel should

be used for protection.

To protect the pipe, it is recommended that the top of a trench shall be covered with a

layer of concrete cast under water. The layer of concrete should be reinforced and

anchored. Otherwise the lifting forces generated by wave action might remove the

concrete.

SELF SINKING


21KIASMA® Group


WALL STRUCTURE AND EXTERIOR PROFILE TYPES HDPE PIPES

HDPE pipe ID2700mm

Wall section and technical

structure corrugate


structure single

Layer profile supported


structure double

Layer profile support


structure single

Compact layer profile

supported


structure triple

Layer profile supported

SELF SINKING


22KIASMA® Group

SYSTEM OF CONNECTION BETWEEN PIPES HDPE

System welding electrofusion System welding T/T fusion

System Flanged

BUOYANCY AND CONCRETE SUPPORT CALCULATION

Pipes must be anchored with concrete clamps for underwater application such as sea

discharge or extremely high groundwater for underground application in order to project

pipes from buoyancy of water.

In calculation of the assembly intervals of said concrete clamps, is should be ensured that

pipes will not be bent due to buoyancy of water.

Stability calculation for pipes:

Filled pipe calculation formula

Empty pipe calculation formula

Maximum support (concrete clamp) distance:

Fv: Lifting force (N)

da: pipe external diameter (mm)

DN: pipe internal diameter (mm)

yd: Specific density of lining (Kg/dm3)

LR: support interval (m)

LA: maximum support dis. (mm)

fLA: bending factor (0,80) (-)

Ec: Elasticity modulus (N/mm2)

JR: moment of inertia of the pipe (mm4)q: Lifting load (N/mm)

SELF SINKING


23KIASMA® Group

DEWATERING WATER (SHORE)

Innovative solutions for the disposal of larger quantities of water.

These pipelines are resistant up to a pressure of 1.5 bar.

Fast coupling system through male/female joints

- HDPE inside

- Galvanized steel

- HDPE outer

- Norm UNI 11434

ID mm Thickness mm OD mm joint

400 2,5 474

500 3,0 588

600 3,5 700

700 4,0 810

800 4,5 940

900 4,8 1045

1000 5,0 1160

1100 5,0 1270

1200 5,0 1400

1300 5,0 1524

1400 5,0 1661

1500 5,0 1773

1640 5,5 1880

1800 6,0 2111

2000 7,0 2344

2200 7,0 2582

2400 7,0 2813


24KIASMA® Group

Different types of fittings available:

For large quantities, the pipeline can be produced directly on site


25KIASMA® Group

The pipes are obtained thanks to a process of spiral winding of polyethylene and an omega

– shaped steel profile. Therefore, pipes consist of an inner layer in polyethylene, an outer

structured wall in polyethylene and a core of galvanized steel completely covered by a

polyethylene-based primer, which ensures a perfect blending with the two walls.

The combination of the two materials, along with the use of an omega-shaped profile,

ensures a performance that is by far better than other structured pipes in fiber glass,

concrete, cast iron or clay available on the market.

The presence of the steel has several advantages:

- higher resistance to pressure (up to 20 kN/m2), unequalled by other pipes in

thermoplastic material

- a better long-term performance, with particular reference to deformation under

constant load and a creep ratio lower than other pipes made exclusively in

polyethylene

Ring stiffness classes according to EN ISO 9969:2008:

Class A (= 8 kN/m2) corresponding to SN 8

Class B (= 12 kN/m2) corresponding to SN12

Class C (= 16 kN/m2) corresponding to SN16



26KIASMA® Group

CREEP test

The blend of different types of material - HDPE and steel - determines a reinforcing effect

of polymeric materials and alters the mechanical characteristics and working conditions.

Steel, in particular, reduces the CREEP effect

The pipe, therefore, in spite of its deformable structure, which means less rigid than the

surrounding soil, is extremely more resistant to ovalisation in comparison with an ordinary

structured thermoplastic pipe.

JUNCTION SYSTEM

Junction is made thanks to a male-female connection consisting of a female weld socket

and a male component equipped with an EPDM seal (complying with UNI EN 681

standard), housed in a preset slot, assuring the water-tightness of the junction system

(up to 1,2 bar pressure/0.3 bar in vacuum) according to UNI EN 1277 standard.

“Male” and “female” components feature a structured spiral wall profile, smooth inside and

corrugated outside, reinforced with an omega-like profile in galvanized steel (DX51D +

ZF/Z class) complying with UNI EN 10346 requirements and entirely embedded into the

pipe wall.

These manufacturing properties ensure a higher ring stiffness and increase product

resistance in the most critical sections of the pipeline - connections - thus reducing the

deformation of the inside diameter as much as possible.


27KIASMA® Group

PHYSICAL/MECHANICAL CHARACTERISTIC OF MATERIALS

The pipes combine the typical properties of polyethylene - resistance to abrasion, light

weight, minimum frictional resistance, resistance to chemical agents, versatility and ease of

installation – with the properties of steel, featuring an elastic modulus 200 times higher

than the polyethylene

ABRASION

The pipe inner surface is made of polyethylene and this ensures a high resistance to

abrasion.

As a result, pipelines may be also used for high flow speed and slope (max speed up to

10 m/s) without producing relevant abrasion effects on the inner surface.

The diagram shows how polyethylene pipes are more resistant to abrasion than other

pipes manufactured with other materials (concrete, coated concrete, fiber glass, clay, PVC

etc.)



28KIASMA® Group


29KIASMA® Group


Thanks to the smooth surface of their polyethylene inner walls, PALADEX pipes have an

excellent water conductivity if compared to all other drainage pipes on the market

(concrete, cast iron, steel, clay, fiber glass).

The excellent surface smoothness allows the design of draining lines that reach high flow

rates at very low longitudinal slopes.

The low hydraulic resistance prevents the presence of debris inside the pipelines, thus

avoiding periodical cleaning.

TRANSPORT AND HANDLING

Loading, transport, downloading and all related operations must be carried out with great

care, by using means and devices appropriate to the type of pipes and taking all the safety

measures in order to avoid breaks, cracks, or damages


30KIASMA® Group

Pipes will be stored in a flat and safe area.

The first row of pipes that is placed on the ground must be arranged so as to avoid

possible damages to the outer surface, bending and deformation.

Stacked pipes must be protected with appropriate wedges in order to prevent sudden falls.

LAYING

European standards UNI EN 1610 legislation specifies that trenches designed to house

sewers must comply with precise requirements.

As far as dimensions are concerned, UNI EN 1610 standard states that the minimum width

should be no less than the upper value among those specified in the tables below, where

OD represents the outer diameter of the pipe (in meters).


31KIASMA® Group


LAYING BED

It is recommended to use sand and avoid the use of materials with sharp edges that can

damage pipes. The laying surface, in any case, will work as a permanent and stable

support to the pipeline.

The UNI EN 1610 prescribes that the thickness of the laying bed is not below:

1100 mm in normal soil conditions;

150 mm in hard ground conditions (rocks/stones).

Junctions will be carried out by testing pipe alignment, the correct position of seals and

examining the inside of the pipe for extraneous materials/debris

Backfilling and soil compaction are operations to

accomplish in an accurate way, since they can

affect the duration and the whole performance of the

pipeline

The table that follows, included in UNI EN 1046

standard, summarizes the recommended thickness

for every soil layer and the number of steps required

to obtain the different classes of compaction,

depending on the type of equipment and the filling

materials.


32KIASMA® Group

SOLUTION A : HDPE PIPES BIG DIAMETERS

SOLUTION B : HDPE PIPES BIG DIAMETERS WITH GRP

outer layer

FALL PIPE FOR VESSELS

KIASMA® Group


KIASMA® Group


33


KIASMA® Group

DIMENSION OF HDPE PIPES

PE 100 Pipes

ISO 4427-2

EN 12201-2

SDR 41 SDR 33 SDR 26 SDR 21 SDR 17

PN 4 PN 5 PN 6 PN 8 PN 10

OD

mm

INC

OD

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

500 20 12,30 19,00 15,30 23,40 19,10 28,90 23,90 35,70 29,70 43,80

560 22 13,70 23,60 17,20 29,40 21,40 36,20 26,70 44,70 33,20 54,80

630 24 15,40 29,90 19,30 37,10 24,10 45,90 30,00 56,50 37,40 69,40

710 28 17,40 38,00 21,80 47,20 27,20 58,40 33,90 72,00 42,10 88,00

800 32 19,60 48,10 24,50 59,70 30,60 79,90 38,10 91,20 47,40 112,0

900 36 22,00 60,90 27,60 75,60 34,40 93,40 42,90 115,0 53,30 141,0

1000 40 24,50 75,20 30,60 93,10 38,20 115,0 47,70 143,0 59,30 175,0

1200 48 29,40 108,0 36,70 134,0 45,90 166,0 57,20 205,0 71,10 250,0

1400 56 34,40 147,0 42,90 183,0 53,50 226,0 66,70 279,0 83,00 341,0

1600 64 39,20 192,0 49,00 238,0 61,20 295,0 76,20 365,0 94,80 453,0

1800 72 44,00 246,0 55,10 306,0 68,80 379,0 85,80 467,0 106,6 573,0

2000 80 48,90 303,0 61,20 378,0 76,40 467,0 95,30 577,0 118,4 707,0

2250 90 55,00 385,0 68,90 478,0 86,00 592,0 107,2 724,0

2500 100 61,20 475,0 76,50 584,0 95,60 730,0 119,1 900,0


34


KIASMA® Group

DIMENSION OF HDPE PIPES

PE 100 Pipes

ISO 4427-2

EN 12201-2

SDR 13,6 SDR 11 SDR 9 SDR 7,4

PN 12,5 PN 16 PN 20 PN 25

OD

mm

INC

OD

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

Th

mm

Kg

m

500 20 36,80 53,30 45,40 64,50 55,80 77,30 68,30 91,80

560 22 41,20 66,90 50,80 80,80 62,50 97,00

630 24 46,30 84,60 57,20 102,0 70,30 125,0

710 28 52,20 107,0 64,50 130,0 79,30 160,0

800 32 58,80 136,0 72,60 166,0 89,30 202,0

900 36 66,10 173,0 81,70 210,0

1000 40 73,50 211,0 90,80 259,0

1200 48 88,20 304,0 109,1 375,0

1400 56 102,8 423,0

1600 64 117,5 552,0

1800 72

2000 80

2250 90

2500 100

35


KIASMA® Group

Solution A : HDPE pipe with steel cone

The particular nature of the material that will be discharged inside the pipes ( rock

dumping, ex rock Eclogite ) forced us to be very uncompromising with the type of polymer

that we would have to use for the production of these pipes.

Our offer proposes pipe made of virgin HDPE PE 100, EN12201 – ASTM4710 PLUS

ISO4427-2 –Type BL, very resistant to crack test which also prevents the propagation of

the fractures.

description Quantity

No.

Price EXW

euro

Amount

EXW Euro

ex:

HDPE PE100 Type BL according to EN12201

international standard

OD1200mm thickness 43,4 mm ID 1113,20

mm working pressure 6 Bar SDR26

flanged on only one side with galvanized steel

flange DN1200 PN10 UNI 1092

including:

1. Gasket

No E

PipesEuro/pipe

E..

Euro

�..


36


KIASMA® Group


No.

Price

EXW

euro

Amount

EXW Euro

ex:Galvanized steel cone, thickness 8 mm ,

flanged DN1200 PN10 UNI 1092

Color yellow

Lenght EEE.

No E Euro/cone

E..

Euro

EE

Solution B: HDPE pipe with GRP and steel cone

The pipeline in HDPE – Type BL ( crack resistant ) is externally coated with a layer of GPR (

Glass Reinforced Plastic ) processed by Filament winding.

- INNER LAYER IN HDPE PE100 Type BL = resistant to cracks propagation and

abrasion

- OUTER LAYER IN GRP = Filament winding

The fall pipe is constantly full of water. This fact help to counteract the negative hydrostatic

pressure acting externally on the circumference of the pipe.

It’s therefore suggested to always execute the Buckling Test Verification and obtain a safety

coefficient > 1 ( see enclosed file ).

With the characteristic of the HDPE pipe you required we obtain a safety coefficient of 0,3.

To obtain a coefficient >1 we have to coat the HDPE pipes with an external layer of GRP

also obtaining a reduced bending of the pipe.

OUTER LAYER IN GRP= Resistant to high pressures , resistant to shocks and

compensate for the intrinsic flexibility of the polyethylene pipeline.

The GRP outer layer Filament Winding, not subject to the attack of salt water, provides high

pressures and shocks resistance to conduct.

GRP thickness which is wrapped the HDPE pipe is designed according to the needs of the

yard work and responding to regulations ISO,EN,ASTM,ANSI, AWWA.

The possibility to vary the angle of wrapping of the glass (main component that ensures the

mechanical resistance of the product) allows pipes which have a modulus of axial elasticity

or circumferential the most appropriate to the application request

37


KIASMA® Group

Average values for the principal physical-mechanical properties of laminated in Filament

Winding:

breaking load traction circumferential : 2000 ÷ 4000 Kg/cm2

breaking load axial tensile : 400 ÷ 1200 Kg/cm2

elastic modulus traction circumferential : 100000 ÷ 300000 Kg/cm2

elastic modulus axial tensile: 50000 ÷ 125000 Kg/cm2

breaking load cut : 600 Kg/cm2

breaking load of compression : 2200 Kg/cm2

specific weight: 1,9

coefficient of linear expansion: 20,10 m/m °C

resilience : 220 Kg/ cm/cm2

electrical resistivity: 10 ohm cm

thermal conductivity: 0,2 Kca l/ (m2 h °C)

Pipeline “HDPE +GRP SYSTEM”


38


KIASMA® Group

JUNCTION SYSTEM

The junction is carried out by flanging.

The flat base of the stub flange is the location for the seal, o-ring

The joint between tube and tube, occurs between in polyethylene surfaces in order to

maintain the continuity of the line.

The layer of GRP cover the pipe and the welding between the pipe and stub end, and gets

to the flange.


No.

Price EXW

euro

Amount

EXW Euro

EX:

HDPE PE100 Type BL according to EN12201

international standard +GRP

OD1200mm thickness 43,4 mm ID 1113,20

mm working pressure 6 Bar SDR26

With external unlayer GRP thickness 22 mm

flanged on only one side with galvanized steel

flange DN1200 PN10 UNI 1092

including:

1. Gasket

No E.

PipesEuro/pipe

EE..

Euro

EE.


No.

Price EXW

euro

Amount

EXW Euro

EX:

Galvanized steel cone, thickness 8 mm ,

flanged DN1200 PN10 UNI 1092

Color yellow

Lenght EE

No E. Euro/cone

EE

Euro

EE

39


KIASMA® Group

JOINT SYSTEM BETWEEN THE PIPES

To help the joint of the pipes they have a cone on top of them

For the joint of the pipes in HDPE + GRP system the joint is the same.

A flanged cone from one side joins the flange of the pipe and the other side is conical with an

angle dimension able to fit the upper pipe and allow the inclination of it of 15 – 20° avoiding

the upper pipe to get out of its position.


40


KIASMA® Group

BUCKLING TEST

41

HDPE PRESSURE PIPES

LARGE DIAMETER FOR ELECTRICAL DAMS

ELECTRIC DAMS

KIASMA® Group


KIASMA® Group

ELECTRIC DAMS

INTRODUCTION




knowledge in the production of underwater pipeline, Kiasma is able to offer suitable HDPE

pipe for transmission lines which portable water. KIASMA R & D department knows how

to work with the line and project designers.

The R & D laboratory with product tests and experts in subsea pipe laying, coordinates the

production of suitable HDPE pipes up to a diameter of 4000 mm (160 ") and working

pressure up to 25 Bar.

The response to the growing demand of high pressure pipes for big diameters was the

development of an innovative pipe system able to resist to a working pressure up to 25

Bar with a diameters range from 800 mm to 4000 mm.

These pipes are mostly characterized by their low weight, a quick and easy installation,

besides their unique joining system, the electro fused socket.

Moreover the system provides a high resistance to chemical agents, UV, rays, rodents,

micro organisms and termites and also features good hydraulic properties.

42


KIASMA® Group

ELECTRIC DAMS

PIPE DIMENSION NORMS ISO/CD 29561-2 ASTM F2720

Large diameter pipe behind the dam wall

43

PN6 bar SIDR47

SN 2.0 kN/m2

PN8 bar SIDR35

SN 4.5 kN/m2

PN10 bar SDR27

SN 10 kN/m2

PN12.5 bar SDR21

SN 18 kN/m2

Nominal

inside Dia

ID(mm)

Wall thick

s(mm)

Weight

(kg/m)

Wall thick

s(mm)

Weight

(kg/m)

Wall thick

s(mm)

Weight

(kg/m)

Wall thick

s(mm)

Weight

(kg/m)

800 17,3 52,5 23,1 68,3 29,4 85,8 37,3 112,0

1000 21,7 78,8 28,9 105,0 36,7 133,0 46,6 173,3

1200 26,0 112,0 34,7 150,5 44,0 194,3 56,0 250,3

1400 30,3 150,5 40,5 206,5 51,4 264,3 65,3 341,3

1600 34,7 201,3 46,3 269,5 58,7 344,8 74,6 446,3

1800 39,0 253,8 52,1 341,3 66,1 441,0 84,0 565,3

2000 43,3 311,7 57,9 421,8 73,4 542,5 93,3 703,3

2200 47,7 375,0 63,6 514,5 80,7 656,3 102,6 850,5

2400 52,0 451,7 69,4 612,5 88,1 778,8 111,9 1012

2600 56,3 526,7 75,2 717,5 95,4 911,8 121,3 1197

2800 60,7 607,5 81,0 833,0 102,7 1055 130,6 1390

3000 65,0 700,0 86,8 955,5 110,1 1208 139,9 1607

3200 69,3 805,0 92,6 1096 117,4 1397 149,3 1829

3400 73,7 903,3 98,4 1237 124,8 1573 158,6 2065

3600 78,0 1010 104,1 1386 132,1 1759 167,9 2319

3800 82,3 1120 109,9 1545 139,4 1974 177,2 2602

4000 86,7 1253 115,7 1726 146,8 2184 186,6 2884


KIASMA® Group

PIPE DIMENSION NORMS ISO/CD 29561-2 ASTM F2720

Large diameter pipe that bringsWater to the turbines

44

PN16 bar SIDR17

SN 36 kN/m2

PN20 bar SIDR13

SN 73 kN/m2

PN25 bar SDR10,5

SN 137 kN/m2

Nominal

inside Dia

ID(mm)

Wall thick

s(mm)

Weight

(kg/m)

Wall thick

s(mm)

Weight

(kg/m)

Wall thick

s(mm)

Weight

(kg/m)

800 47,5 143,5 60,8 187,3 77,0 243,0

1000 59,4 224,0 76,0 294,0 96,0 382,0

1200 71,3 323,8 91,2 425,3 115,0 553,0

1400 83,2 441,0 106,4 579,3 134,0 758,0

1600 95,1 581,0 121,6 763,0 153,0 969,0

1800 107,0 736,8 136,8 974,8 172,0 1264,0

2000 118,9 917,0 152,0 1202 191,0 1566,0

2200 130,8 1110 167,2 1468

2400 142,6 1330 197,6 1899

2600 154,5 1561

2800 166,4 1829

3000 178,3 2098

3200 190,2 2394

3400

3600

3800

4000


KIASMA® Group

ELECTRIC DAMS

RAW MATERIAL

The Pipe is made up from of HDPE; Glass Fibre and compound materials.

The pipes inner and outer surface is made up from HDPE, while the middle layer is made

up from a composite structure.

Production of pipes

Joining with electrofusion system

Installation

Besides joining by the electrofusion

method, this pipe system can also be

joined by using normal flange connections.

This time saving joining method makes it

possible to connect several pipes

simultaneously and to install the pipes in

very narrow tranches in very short time.

This pipes don't break or crak, even under

30% deformation.

This means that, even if the pipes deform

up to 30%, the there will be no decrease in

the performance the system

45

Type A : Bayonet connection

Type B : Female ring connection

Type C : Release system to the discharge pipeline

QUICK COUPLING

KIASMA® Group


KIASMA® Group 46

QUICK COUPLING

Type A : Bayonet connection

Bayonet connection (6 claws)

The female part with claws will be a cast part with a 10 mm thickness

The male part is provided with a bayonet ring, which can be rotated separately.

The seal is provided by a sturdy lip seal, similar to what is used in the bayonet ball joints.

This seal has been used for over 60 years in the dredging industry and provides optimal

sealing, even in wearing and corrosive circumstances.


KIASMA® Group 47

Type B : Female ring connection

Two shares male flanged

A female ring connecting the two male parts

The seal is provided by a sturdy lip seal. This seal provides optimal sealing, even in

wearing and corrosive circumstances


KIASMA® Group 48

QUICK COUPLING

Type B : Release system to the discharge pipeline

Quick coupling and release system to the discharge pipeline

Hydraulic control with a lever ( connectable to the control unit of the pump )

KIASMA SRL Via Monte Adamello,31/H 31059 Zero Branco (TV) ITALY

Tel. 0039 0422 97620 Fax 0039 0422 487447

www.kiasmasrl.it [email protected]

KIASMA® Group

Documents

michelangelo ed. 02-2016 - Kiasma, The dredging pipeline ... Pipes Michelangelo.pdf · Michelangelo Ed. 02 - 2016 ... knowledge in the production of underwater pipeline, ... production