Conference PaperPDF Available

THE SPIRAL WOUND PIPELINE REHABILITATION TECHNIQUE FOR PIPE NETWORKS: AN APPLICATION AND EXPERIENCE IN MOSCOW CITY

Authors:

Abstract and Figures

Spiral-wound pipe lining trenchless process is the advanced technology for re-laying and rehabilitation for water and sewer pipelines in dense urban areas. The basic principle of spiral-wound pipe (SWP) rehabilitation is that the old or destroyed pipe section is repaired using an endless PVC-U or HDPE profile strip. This profile strip is fed into the pipe through an open manhole and joined by a spiral-winding machine installed in the pipe. The main advantages of this technique are: flexible liners of practically any length, diameter and shape; continuous working; and no excavations. The spiral-wound pipe serves as a formwork for a new, inner concrete shell of the old pipe and provides a reliable protective layer for the concrete structure. In the present article, the authors present the experience of the early years of application of spiral-wound pipe lining trenchless technique in Moscow's specific urban environment. The flowchart for implementing one of modifications of this technology is outlined as an example to restore the 420 dia sewer pipe section in Moscow. Presented, also, is a list of renovated areas using this spiral-wound method for domestic and rainwater drainage systems rehabilitation in a wide range of diameters and lengths.
Content may be subject to copyright.
Paper 2.16 - 1
International No-Dig 2013
31st International Conference and Exhibition
______________________________________________________
Sydney, Australia
14 September 2013
Paper 2.16
THE SPIRAL WOUND PIPELINE REHABILITATION TECHNIQUE FOR PIPE NETWORKS: AN
APPLICATION AND EXPERIENCE IN MOSCOW CITY
Ramil Ishmuratov1, Vladimir Orlov2 and Alexey Andrianov2
1 Metalplast-S, Moscow, Russia
2 Moscow State University of Civil Engineering, Moscow, Russia
ABSTRACT: Spiral-wound pipe lining trenchless process is the advanced technology for re-laying and
rehabilitation for water and sewer pipelines in dense urban areas. The basic principle of spiral-wound pipe (SWP)
rehabilitation is that the old or destroyed pipe section is repaired using an endless PVC-U or HDPE profile strip.
This profile strip is fed into the pipe through an open manhole and joined by a spiral-winding machine installed in
the pipe. The main advantages of this technique are: flexible liners of practically any length, diameter and shape;
continuous working; and no excavations. The spiral-wound pipe serves as a formwork for a new, inner concrete
shell of the old pipe and provides a reliable protective layer for the concrete structure.
In the present article, the authors present the experience of the early years of application of spiral-wound pipe lining
trenchless technique in Moscow’s specific urban environment. The flowchart for implementing one of modifications
of this technology is outlined as an example to restore the 420 dia sewer pipe section in Moscow. Presented, also, is
a list of renovated areas using this spiral-wound method for domestic and rainwater drainage systems rehabilitation
in a wide range of diameters and lengths.
1. INTRODUCTION
The spiral-wound pipe lining method can be attributed to one of the most advanced and most popular trenchless
technologies of the last decade (Orlov, 2010; Kuliczkowski et al, 2010; Pinguet and Meynardie, 2006; Schmager,
2011). This technology is used in many countries around the world to enable the rapid restoration of damaged
pressure and non-pressure pipelines with minimal materials costs, as well as minimal environmental impact.
The basic principle of the spiral-wound pipe lining method is that the existing damaged sewer pipe is repaired using
prefabricated endless profile strip (spiral-wound pipe) which forms a new high-strength pipe inside the old pipe
section. A winding machine is put in place in the sewer to join strip edges using the tongue and groove technique
and to form a continuous waterproof lining within the restored sewer (Freimuth, 2011). This technology uses PVC-
U or HDPE ribbed stripping, which is fed into the sewer through an open manhole by rotating the drum located near
its roof.
Paper 2.16 - 2
2. INSTALLATION PROCESS
For the spiral-wound repair of sewer pipelines, four modifications are usually used: SPR™, SPR™ PE, SPR™ EX
and SPR™ ST. This rehabilitation method can be performed in partial liquid filling (water level up to 40 %) and in
flow velocity of up to 5 m/s. The characteristics of each system and winding workflow are shown below. In Russia,
the SPR™ and SPR™ PE technologies are used most widely.
The SPR™ winding process consists of feeding a profile strip through a manhole, at the start of the repair area, to
the winding machine located in the restored pipeline in the side of the starting well. The winding machine gives the
desired shape to the PVC profile and interlocks the strips to form a new watertight pipe. Winding continues until it
reaches the end of the restored sewer section. The winding machine can be stationary or mobile (moving towards the
next (final) chamber Figure 1).
Figure 1. A fragment of sewer pipeline being renovated by spiral-wound technology using a mobile winding
machine: 1 drum with endless profile strip; 2 host pipe, 3 liner inside old pipe; 4 self-propelled winding
machine; 5 mobile device for continuous feeding of an adhesive resin to the locks
After the winding process is complete, a bracing system is put into place, which fixes a new liner while filling-up
the annular space with grout. Fixing elements are put into the pipe through manholes. Prior to the grouting process,
each grout section is sealed with quick-setting cement or a similar material. The grouting process is divided into two
stages: feeding a potting compound (grout) in the annular space between the old pipe and PVC liner, and
vulcanization (setting) of a high-strength bonding slurry. A unique ribbed profile structure ensures efficient adhesion
to the potting compound (Figure 2). Then the fixing system elements are removed and the repaired pipeline is put
into operation.
Figure 2. The fragments of ribbed polymeric strip without (left) and with (right) reinforcement.
Depending on site conditions, two methods of winding can be used: a pushed or a self-propelled hydraulic
winding machine. A push (stationary) machine does not require an operator. The machine is placed in an existing
manhole and creates an SPR liner, which is fed into the repaired section of the old pipeline. The winding machine
remains stationary. The self-propelled hydraulic machine, on the other hand, is run by an operator, who also feeds
the strip into the machine. First, the machine is placed into the existing manhole, and the spiral-wound profile forms
the new pipe (10-15 mm less in diameter than the old one) while gradually moving forward, toward the rehabilitated
sewer. This pushmachine is able to line round pipelines with diameters ranging from 200 mm to 1500 mm. All
types of machines can be disassembled so that they can fit through existing manholes. The winding rate depends on
Paper 2.16 - 3
the diameter of the pipe, its configuration, and degree of damage. The strip feed rate into the winding machine is
about 5 10 m/min.
There are two types of "self-propelled" winding methods: one for circular pipelines; and the other for non-circular
cross-sections (oval, ovoid, horseshoe, etc.), which repairs pipelines with a diameter greater than 550 mm (Figure 3).
Figure 3. Strip feeding and the formation of the spiral-wound coating inside the ovoid pipe.
The SPR™ lining technology can produce a self-supporting static pipe that is used to repair old pipe-lines with
diameters from 150 to 1800 mm.
The essential difference of this process is that after installation, the new pipe is fits tightly against the old pipe.
SPR™ EX technology is specifically designed for maximum hardness and ability to withstand stress, for efficient
use in areas with seismic activity, subsiding, and dumps. The PVC profile used is similar in class to the material
used for new pipelines. This material can withstand high temperatures of the transported liquid.
This liner can be installed two ways (types S and L). In version S, profile S-PVC is mounted in the old pipeline with
a diameter up to 750 mm with minimal loss of space through the local expansion of the installed liner. The
installation process continues while the liner moves from the starting well inside the old pipe against the water flow
to the terminal well. In the SPR™ EX process, the profile strips are joined together by two sets of locks the
primary with a lubricant sealer, and the secondary with hot molten adhesive (Schmager, 2011). The expansion
process begins after locking (affixing) the end of the liner in the terminal well and the special cutting wire is pulled
out from the locking mechanism. This wire cut the secondary locking mechanism, therefore the pipe increases in
diameter. Thus, the new pipe fits snugly against the inside of the old section and the operational cross section
remains practically unchanged. Version L with the L-PVC profile, is used for pipes with a diameter of 800 mm or
greater. In this process, the liner is formed by manually moving the winding machine and fitting the lining tightly to
the inner surface of the old pipeline in advance.
3. APPLICATION
One of the case studies of the successful implementation of spiral-wound pipe lining technology in Moscow is
describe below. The rehabilitation of 420 mm ceramic sewer was conducted in Solncevo district (Lukinskaya St., 7)
by “Metaplast-S” company. The repaired pipe is located at a depth of 3 m and the length of the repair area was 42
meters. The repair was carried out in December of 2012, and required the installation of heated enclosures in the
starting and terminating wells.
Paper 2.16 - 4
Renovation of the sewer was required to restore its capacity, which was disturbed by wrinkling of polymer sleeves
installed in the pipe several years ago. The initial diameter of liner formed from S-PVC profile strip was 350 mm,
and after the expansion process, it became 400 mm.
The sequence of operations of spiral-wound pipe rehabilitation is presented on Figures 4-8.
Figure 4. The process of simultaneous feeding of the PVC profile strip into the starting manhole (left) and cutting
wire inside the locking device (right), the formation of new liner shell (inside the well).
Figure 5. Feeding a cutting wire from a reel (left) and the endless strip from the drum (right) located into the
warming enclosure above the manhole.
Paper 2.16 - 5
Figure 6. Managing the spiral winding process from the cab of an especially equipped vehicle.
Figure 7. The winding process at work, and moving from the starting to the terminal well (a photo from the
computer display).
Paper 2.16 - 6
Figure 8. The end of the liner manually locked (affixed) by a pinchbar in the terminal well, with the purpose of
providing a beginning of the process of increasing pipe diameter (left) and the overall view of a new pipe.
In Moscow, the Russian company “Metaplast-S”, in partnership with the German company SWP, was among the
first to master the spiral-wound technology and successfully apply it to various sewerage network renovation
projects. Over the past few years, the following sites were renovated using the spiral-wound pipe lining method by
State Unitary Enterprise “Mosvodostok”:
1. Sewer collector 362 m long and 1300 mm in diameter (Timur Frunze St);
2. Sewer collector 149.16 m long and 1200 mm in diameter (Turchaninov lane.)
3. Sewer collector 232 m long and 1500-1700 mm in diameter (Novuye Cheryomushki district);
4. Storm water culvert 118.5 m long and 2500 mm in diameter (on the intersection of the Moscow Ring Road);
5. Rainwater collector with ellipsoid cross-section 1000x700 mm and 408 m long;
6. Culvert 98 m long and 1500 mm in diameter (under federal highways M-7 and A-151);
7. Sections of the rainwater pipeline network with ellipsoid cross-section and total length of 159.5 m and dimensions
500x650 and 600x900 mm;
8. Rainwater collector 380 m long and 400 mm in diameter (CITY-2);
9. Rainwater collector 125 & 32 m long and 1000 & 400 mm in diameter respectively (Vypolzov lane), collector
308 m long and 1500 mm in diameter (Ostrovityanova St), collector 90 & 150 m long and 700 & 1000 mm in
diameter respectively (Butyrskiy district).
Overall, spiral-wound pipe lining technology has restored over 2570 meters of pipeline networks in Moscow,
ranging in diameters from 400 to 2500 mm.
4. CONCLUSIONS
The authors present an overview of the implementation of the spiral-wound pipe lining method. The benefits of this
trenchless technology are: high efficiency of pipeline rehabilitation in a wide range of diameters and lengths, a slight
change in the effective cross-section of the restored pipeline, the ability to carry out repairs in the presence of liquid
flow, and no welding work on the construction site, among others.
The ranges of technical capabilities of different types of the spiral-wound pipe lining technology for renovation of
pipelines with different cross-sections and materials are presented as basic information for builders and designers,
who must choose the optimal trenchless methods to rehabilitate old pipes in water and wastewater network systems.
A list of sites using spiral-wound pipe lining technology in Moscow is presented.
5. REFERENCES
Paper 2.16 - 7
Bürger, J. (2000). “Verfahren zur Sanierung bzw. Renovierung von Abwasserleitungen und -kanälen” (Method for
redeveloping or renovating sewer drains and sewer ducts), DE patent, WO 00/006932.
Freimuth, B. (2011) “Long pipe lining of sewage pipes ‘Tight-in-Pipe’ in the city of Salzgitter”, Proceedings of the
International No-Dig 2011 29th International Conference and Exhibition, ISTT, May 2-5, Berlin, Germany, Paper
4B-3.
Kuliczkowski, A., Kuliczkowska, E. and Zwierzchowska, A. (2010). “Technologie beswykopowe w inzeynierii
srodowiska” (Trenchless technologies in environmental engineering), Wydawnictwo Seidel-Przywecki Sp.
Orlov, V.A. (2010). “Construction and reconstruction of engineering networks and facilities”, Moscow, Academia.
Orlov, V.A., Michaylin, A.V. and Orlov, Е.V. (2011). “Technologies of trenchless renovation of pipelines”,
Moscow, ASV.
Pinguet, J.-F. and Meynardie, G. (2006). “Reseaux d'assainissement: du diagnostic a la rehabilitation”, Eau,
industry, nuisances, No 295, pp. 39-43.
Schmager, K-D (2011) “Overview of Spiral Wound Pipe Lining Technologies”, Proceedings of the International
No-Dig 2011 29th International Conference and Exhibition, ISTT, May 2-5, Berlin, Germany, Paper 2B-4.
Sekisui Chemical Corporation (Japan) presentations and promotional materials.
... ?????? ?????????? ?????????????? ???????? ?????? ????? ???????? ???????????? ??????????? ?????????? ??????????, ? ????? ?????? ?????????????, ??????? ?????? ???????????? ???????? [7][8][9][10][11][12][13][14][15][16][17][18][19][20]. ??? ????????? ???????? ???? ???????????? ???????, ? ...
... Modern polymer materials and copper pipelines which hold up to corrosion are preferable when reconstructing and replacing outdated fittings of a building [7][8][9][10][11][12][13][14][15][16][17][18][19][20]. This will allow increasing the operation life of the system and reducing wasteful expenditures (leak) in the building and as a result saving a large amount of clean drinking water. ...
... Open trench techniques, which can damage the environment and waste resources, are no longer feasible for buried pipeline maintenance and repair. Many trenchless pipeline rehabilitation methods, such as sliplining, pipe bursting, fold-and-form lining, deformed-and-reformed pipeline renewal, cured-in-place pipe (CIPP) lining, machine spiral wound lining, and splice segmental lining [3][4][5][6][7], have been developed in recent years to maintain and repair buried drainage pipes. CIPP technology is widely used because it has the advantages of needing no grouting, rapid curing, and short construction time [8,9]. ...
Article
Full-text available
Frequent accidents caused by underground pipeline damage are a widespread societal concern. Trenchless rehabilitation methods, particularly cured-in-place pipe (CIPP) lining, are increasingly used for pipeline repair with great success. Existing research is mainly concerned with practical improvements in rehabilitation and evaluating the performance of rehabilitation. In this study, the model of corroded buried concrete pipeline that had been rehabilitated with CIPP was established using numerical methods, and the Mesh-based parallel-Code Coupling Interface (MpCCI) was used to investigate multifield coupling effects of soil pressure, traffic load, and fluid-structure interactions. Moreover, the influences of corrosion depth, corrosion width, traffic load, cover depth, and water quantity on CIPP wall thickness were compared and analyzed. The result shows that maximum principal stress and vertical displacement of pipeline markedly decreased after CIPP rehabilitation, and thus the new CIPP can carry loads in a deteriorated pipe. Stress and displacement of the composite pipe liner were positively correlated with corrosion depth and negatively correlated with corrosion width. Increase in traffic load rapidly increases von Mises stress of CIPP, and increase in cover depth rapidly increases maximum principal stress of pipeline. Water flow has little effect on the pipe liner, and flow capacity increases slightly after CIPP rehabilitation. CIPP wall thickness was positively correlated with corrosion depth, traffic load, cover depth, and water quantity and negatively correlated with corrosion width.
... To restore the structure of inner walls and initial characteristics of old pipelines as well as reduce or prevent corrosion processes we can use trenchless rehabilitation. One of the most advanced and most popular trenchless technologies for pipelines recovery is spiral-wound pipe lining (Ishmuratov et al., 2013). The principle of this method is that the existing damaged pipe is repaired using prefabricated endless profile strip (spiral-wound pipe) which forms a new high-strength pipe inside the old pipe section. ...
Conference Paper
The purpose of this study was to determine the role of drinking water quality and water treatment technology on steel pipe corrosion and water quality deterioration in old distribution systems. The analyses were based on drinking water quality monitoring in Moscow water network over the past 12 years. The results show that improving of water treatment leads to better water quality at end-users, but discoloration risk s steal high due to active corrosion processes in old pipes. Morphological and physicochemical characteristics of steel corrosion scales were systematically investigated in this work. The corrosion scales were characterized by SEM and EDS. A significant contribution of iron-reducing and iron-oxidization bacteria to corrosion processes, tubercles and corrosion scale microstructure was suggested. Studying the organic matter distribution in corrosion scales helps us to understand microbiological processes in pipe deposits. A wide range of trenchless rehabilitation techniques are used in drinking water distribution system in Moscow. A long-term experience of water distribution system operation has been useful to select best techniques for old steel pipes renovation.
Article
Full-text available
Introduction. The co-authors analyze the process of malodor formation inside pipelines of non-pressure sewer networks (channels) and their efficient elimination using physicochemical, biological, catalytic, thermal, electric discharge, civil engineering and other methods. Materials and methods. The co-authors have analyzed literary sources, studied the most advanced malodor registration methods (broken down into malodor identification and intensity control) using specialized malodor detectors; they have also considered potential methods for malodor elimination or intensity reduction, as well as prevention of malodor formation and micro-climate preservation in sewer networks. Results. The co-authors have identified the reasons for the formation of malodors inside non-pressure pipelines of sewer networks and a number of negative factors that contribute to the formation of gases. The co-authors offer an overview of methods and technologies preventing the formation of anaerobic conditions inside sewer networks. They describe the cases of several cities where malodors were emitted inside sewer networks, as well as the actions aimed at their suppression in particular environments. The co-authors present specific malodor prevention actions using various methods applied in some countries of the world. Conclusions. The practical implementation of a number of actions aimed at the elimination of malodors in sewer networks is a costly project in terms of capex and operating expenses. Mobile, efficient and economically expedient methods of eliminating specific sources of malodors have been identified. The right choice of actions, technologies, design and device-focused solutions (equipment choice) need a detailed examination in terms of malodor emissions and pipeline systems as a whole, as well as consistent exploratory, research and development efforts.
Article
Full-text available
The proposed method of calculation takes into account the impact on the biogas yield and quality of the categories of organic waste sent for recycling. To calculate the biogas plants are given sposb determining daily rainfall volume generated from urban wastewater, large livestock complexes and farms. The proposed method of engineering calculation makes it possible to determine the volume of digesters and gas holders. It allows more reliable predicting of biogas reproduction and choosing proper equipment for conversion organization.
Article
The article reviews up-to-date technical solutions of percolation units use for mechanical treatment of waste water. The review describes various types and advantages of units which have positive impact at the entire treatment process. Amoung these advantages are: wet precipitate amount reduction; versatility for wide scope of waste water treatment plants speaks in favour of the use of this type of equipment.
Verfahren zur Sanierung bzw Renovierung von Abwasserleitungen und -kanälen " (Method for redeveloping or renovating sewer drains and sewer ducts), DE patent
  • J Bürger
Bürger, J. (2000). " Verfahren zur Sanierung bzw. Renovierung von Abwasserleitungen und -kanälen " (Method for redeveloping or renovating sewer drains and sewer ducts), DE patent, WO 00/006932.
Technologie beswykopowe w inzeynierii srodowiska
  • A Kuliczkowski
  • E Kuliczkowska
  • A Zwierzchowska
Kuliczkowski, A., Kuliczkowska, E. and Zwierzchowska, A. (2010). "Technologie beswykopowe w inzeynierii srodowiska" (Trenchless technologies in environmental engineering), Wydawnictwo Seidel-Przywecki Sp.
Technologies of trenchless renovation of pipelines
  • V A Orlov
  • A V Michaylin
  • Е V Orlov
Orlov, V.A., Michaylin, A.V. and Orlov, Е.V. (2011). " Technologies of trenchless renovation of pipelines ", Moscow, ASV.
Long pipe lining of sewage pipes 'Tight-in-Pipe' in the city of Salzgitter
  • B Freimuth
Freimuth, B. (2011) " Long pipe lining of sewage pipes 'Tight-in-Pipe' in the city of Salzgitter ", Proceedings of the International No-Dig 2011 29th International Conference and Exhibition, ISTT, May 2-5, Berlin, Germany, Paper 4B-3.
Construction and reconstruction of engineering networks and facilities
  • V A Orlov
Orlov, V.A. (2010). " Construction and reconstruction of engineering networks and facilities ", Moscow, Academia.
Overview of Spiral Wound Pipe Lining Technologies
  • K-D Schmager
Schmager, K-D (2011) "Overview of Spiral Wound Pipe Lining Technologies", Proceedings of the International No-Dig 2011 29th International Conference and Exhibition, ISTT, May 2-5, Berlin, Germany, Paper 2B-4. Sekisui Chemical Corporation (Japan) -presentations and promotional materials.
Reseaux d'assainissement: du diagnostic a la rehabilitation
  • J.-F Pinguet
  • G Meynardie
Pinguet, J.-F. and Meynardie, G. (2006). "Reseaux d'assainissement: du diagnostic a la rehabilitation", Eau, industry, nuisances, No 295, pp. 39-43.
Renovierung von Abwasserleitungen und -kanälen" (Method for redeveloping or renovating sewer drains and sewer ducts), DE patent
  • J Bürger
Bürger, J. (2000). "Verfahren zur Sanierung bzw. Renovierung von Abwasserleitungen und -kanälen" (Method for redeveloping or renovating sewer drains and sewer ducts), DE patent, WO 00/006932. Freimuth, B. (2011) "Long pipe lining of sewage pipes 'Tight-in-Pipe' in the city of Salzgitter", Proceedings of the International No-Dig 2011 29th International Conference and Exhibition, ISTT, May 2-5, Berlin, Germany, Paper 4B-3.