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Annual Journal 45 – 2011

Themes, Authors, Abstracts, Keywords (Details)

Heat recovery in the home using ductile iron pipes
by Roger Saner

International climate conferences are calling for steps to be taken to reduce CO2 emissions. National subsidy schemes are prompting innovative solutions: a Swiss property owner and energy specialist is extracting heat from the waste air and waste water from his home with the help of ductile iron pipes and is recovering it to heat rooms and hot water, thereby making it energy self-sufficient.

Keywords:Heat recovery, DN 125, DN 200, ductile iron pipes, home, alternative energies, energy efficiency, buildings, CO2 reduction targets, thermal insulation, energy savings, solar collectors, heat pumps, biomass boilers, energy self-sufficiency, ecological footprint, energy schemes, Switzerland, scheme for buildings, rehabilitation from the point of view of energy, energy standard, Minergie, heat demand for heating, Minergie-P, energy consumption, scheme for buildings, renewal of air, heat recovery ducted ventilation system, air-tight building envelopes, additional cost, buildings complying with both the standards, waste heat, PlusEnergy house, Rebstein, St. Gallen, Otto and Bernadette Mattle-Hofstetter, owners, engineering consultant’s office, photovoltaic system, net excess of energy, average over the year, electricity, public grid, heat for the heating, oil-fired heating system, gas-fired heating system, wood-fired heating system, heat pump heating system, radiators, underfloor heating system, air, obtaining energy, PML Ingenieurbüro AG, thermal conductivity, frictional flow resistance, polyurethane (PUR) lining, geopur sewer pipes, transmitting heat, plastic pipes, push-in joint, (gas)-tight, ductile iron pipe systems, EN 598, (sewage) pressure pipelines, component operating pressures, operation, fresh air, geothermal heat collector, waste air, heat exchanger, air pipeline, ducted ventilation system, temperature, cool, air-conditioning system, total length, entrance to the garage, outside parking space, ductile iron as material for the pipes, stress-resisting properties, encased in concrete, cost, excavation work, materials, transport, choice of material, use of heat from sewage and wastewater, thermal energy, sewage and wastewater pipeline, bedding, refrigerant circuit, wall roughness, fall, EN 15655, coefficient of friction, manhole, municipality’s main sewer, wall of ductile iron, pipeline of copper, plastic-coated, circulating refrigerant, services room, properties of the material, residential buildings. »

Dismantling type butterfly valves for flexible use in pipe networks and plant construction
by Thomas Hammer

There is always a potential for improvement, even in highly sophisticated products: valve designers have responded to the suggestions from experts in the fields of plant construction and pipeline laying, and a dismantling type butterfly valve with a loose flange has been developed. This will enable the usual dismantling joint to be dispensed with. It will also mean that the time taken by replacement work will be considerably shorter and this, at the end of the day, will mean greatly improved economy.

Keywords: Butterfly valves, dismantling type, dismantling type butterfly valves, flexible use, pipe networks, plant construction, double-eccentric butterfly valves, plant construction, pipeline laying, economical products and procedures, standard of quality, economy, cost, components, expenditure, accessories, hours that have to be worked, special tools, fitting, replacement, valves, dismantling joints, length correction, inspection, cost, time spent, fitting, connecting parts, deal with, alternative solution, restrained loose flange, planned, developing the new valve, combination, fixed flange, site, ERHARD ROCO, DN 400, vertical pipeline, supporting from below, end carrying the fixed flange, secured against twisting out of position, tilting, side on which the gearbox is situated, chocking, correctly orientated, compression, flange seal or gasket, special tools, splitters, flange spreaders, damage, corrosion protection, face-to-face dimensions, change in the position, ends of the pipes, special tool, hydraulic compression tool, bolt-holes in the flanges, EN 558, permitted tolerances, design of the loose flange, fouling, availability, advantages, considered holistically, savings, DN 250 gate valve, inspection work, Landeswasserversorgung Baden-Württemberg, valve flange, pipe flange, accessibility, installation situations, pipe trench, product range, ROCO Premium butterfly valve, nominal sizes from DN 150 to DN 500, pressure ratings from PN 10 to PN 16, enamelling, epoxy coating, coating thickness, slider-crank actuating mechanism, installation of new valves, storage space, logistics.   »

Full protection by an epoxy-coated round thread for the sealing elements
by Hansjörg Portmann

Although the task of optimising valves has been largely completed, there are still cost-saving improvements that can be seen. The usual metric thread used to fasten the bronze spindle sealing element in place in the ductile iron top part of the body of a gate valve is being replaced by a round thread which lends itself well to coating. Having been machined, the round thread in the top part of the body can be given a continuous epoxy coating which gives perfect corrosion protection.

Keywords: Something new in valves, epoxy-coated round thread, VS 5000 resilient-seated gate valve, water supply, gas supply, useful life, underground shut-off valves, supply networks, damage due to idle state, thick epoxy coating, rules of the GSK, thickness, full corrosion protection, design must lend itself well to coating, plastic tapering guides, state of the art, connecting member, sealing member, top part of the body, spindle, threaded bushes, sealing elements, slide gate body, fully protected gate valve, metric standard threads, turns, coating material, threads, corrosion problems, development, connection, bayonet joints, threaded connections, idle for long periods, closing torques, tolerances on castings, tolerances on the thickness of coatings, process parameters, snap ring, groove, production and fitting, ductile iron, standard process, epoxy powder, machining operations, use in practice, long-term corrosion protection, nominal sizes from DN 65 to DN 300, pressure ratings of PN 10 and PN 16, DN 65 to DN 150 – PN 25. »

A new cast of ideas – shortening the time for successful development of demanding designs
by Torsten Stein

In the past, castings were developed to production standard in a laborious series of individual steps. The pattern and gating system were gradually optimised by modifications and trial casts until the quality of the castings was within acceptable limits. With simultaneous engineering, these steps can be overlapped in time and shortened by means of computer-assisted design, finite element methods and casting and solidification simulation. The casting, together with its gate and feeder system, is seen in a true to-life form on the computer before the actual casting pattern is produced. This optimisation phase would previously take weeks or months but now, given suitable experience, it can be shortened to a few days.

Keywords: Product development, fittings, valves, ductile iron, simultaneous engineering, development time, costs, castings of demanding designs, components of demanding designs, customer’s benefit, sub-processes, start of production (SOP), interactive implementation, CAD (computer-aided design), calculation of strength, finite element methods (FEM), simulation of mould filling and solidification, how much information is available, more work, errors, phase of development, development processes, cast components, integrated development, casting simulation, choice of materials, casting process, foundry, scheduling of work, logistics, 3D models, engineering procedures, time, quality, DN 150 type 4004 FL-FL gate valve, completion, 3D design data, model, models, molten iron, mould cavity, gating and feeder system, passages, pouring cup, sprue, runner, gates, molten metal, feeder, casting, mould, loss of volume, castability, know-how, layout of the model, process, hot-spots, iron, casting flaws, simulation software, results, optimum from the point of view of casting, trial casts, advantages, benefit. »

Wall-thickness classes and pressure classes in EN 545 – Comparison between the 2007 and 2010 versions
by Jürgen Rammelsberg

It can be a challenge for users when fundamentally new technical rules and new ways of looking at things are introduced in to standards that have been in place for years. It is necessary for the user to ‘bridge’ the content of the old standard to that of the new one. This article looks at the wall thicknesses, which form an axis to which the new pressure classes of ductile iron pipes and their wall-thickness classes can both be referred.

Keywords: Technical rules, wall-thickness classes (K classes), pressure classes (C classes), comparison, EN 545, innovation, pressure pipelines, pressure classifications, EN 14801, classification of products, pipelines, water, wastewater, installation parameters, external loads, installation conditions, pipe materials, transporting of drinking water, transporting of wastewater, EN 805, water pipelines, EN 1610, wastewater pipelines, product standards, calculation methods, internal pressure, pressure class C 40, dimensioning of components, ductile cast iron, national foreword, method of dimensioning, ductile iron pipes, process control, centrifugal casting, wall thickness, scatter, nominal wall thicknesses, equation, minimum wall thicknesses, allowable limit deviation, resistance, longitudinal bending resistance, nominal diameters, minimum diametral stiffness, restrained joints, trenchless installation techniques, maximum permitted tractive force, DVGW, GW 320 ff, trenchless replacement techniques, positive locking joints, welding bead, spigot end, length which can be pulled in, pipe string, distance between installation pits, economical, allowable component operating pressure PFA, Barlow’s formula, minimum tensile strength, safety factor, pipe external diameter, part from DN 80 to DN 200 of the nominal size range, limit for minimum wall thickness, drinking water distribution networks, wall thickness class K 9, range of nominal diameters from DN 40 to DN 2000, standard products, nominal diameter of DN 400, pressure class 40, point of reference, bedding conditions, ground subsidence, settlement, bending stresses, bending moments, stresses, earth loads, traffic loads, ovalisation, restrained joints, ductile iron pipe industry, opportunities for making savings, optimisation, resources used, raw materials, energy, weight for transport, ruggedness, demands for sustainability, new standard. »

Examination of ductile iron pipes with cement mortar coating after a period of three decades in operation
by Wolfgang Rink

To investigate the durability which can be achieved in practice by ductile iron pipes with a cement mortar coating, test digs were made at various points. The parameters examined included the corrosion nature of the soil, the state of the outer surface of the coating and the surface of the cast iron pipes below the coating. After a period of three decades in operation, the state of all the pipes was as good as new, even under extremely unfavourable conditions. The assumption of a technical operating life of 100 to 140 years which has been made for 25 years was confirmed.

Keywords: Sustainability, quality, long life, examination, ductile iron, cement mortar coating (ZM-U), period in operation, Buderus Aktiengesellschaft, Duktus Rohrsysteme Wetzlar GmbH, specifications, DIN 28600, DIN 30674-2, zinc coating, glass fibres, coating of synthetic resin (a two-component epoxy), coating of bitumen, process whereby a bandage is wrapped on, checks on coatings, stand up, test digs, sections of pipeline, surfaces of the pipes, samples, native soils, beddings materials, DIN 50929-3, projects, Heilbronn, Böllinger Höfe, Wannenäckerstrasse, ductile iron drinking water pipes, DN 400, DIN 28610, surface of the ductile iron, year of installation, epoxy bonding layer, no evidence of corrosive attack, embedded, slightly aggressive soil, rating figure, soil class I, soil class Ib, part of the route, embedding material, test dig, state as good as new, certainly, Grundäckerstrasse, DN 500, anode backfill, bedding of neutral sand, operating life, Zweckverband Mittelhessische Wasserwerke ZMW, connection to Gladenbach, Lohra section, DN 300, soil tests, bottom of pipe, gravel, ground water, vertical inhomogeneity, backfill at the sides, top of the pipe, corrosive cohesive soil, differential aeration cells (corrosion cells), conditions encountered at installation, soil conditions, properties as a material, operation, list of the main results. »

Replacement and relaying of DN 200 to DN 800 drinking water pipelines in Leipzig
by Andrea Bauer and Wolfgang Rink

Leipzig’s drinking water network is more than 100 years old and is being replaced, redesig ned, optimised and adapted over several years to meet present-day requirements. The pipe manufacturers, planners and installing companies continue to show outstanding expertise as they develop and adapt products and techniques to meet local requirements. This is an ongoing task as the demographic of the area is constantly changing.

Keywords: Pipeline replacement and relaying, DN 200 to DN 800, drinking water pipelines, Leipzig, cross, Max-Liebermann-Strasse, Olbrichtstrasse, ground below the surface, pipelines, sewers, cables, road-building work, relocation, re-design, pipeline systems for drinking water, DN 100 to DN 400 supply pipelines, DN 500 supply main, “Probstheida” central water distribution station, trunk main, “Schwarzer Berg” high-level service reservoir, “Möckern” pressure-raising station, pipeline pressure, adjoining area, outgoing pipelines, network of supply pipelines, road-building work on the “Mittlerer Ring Nord” ring-road, decision, proportion of drinking water, waterworks (Canitz, Thallwitz, Naunhof 1 & 2), Kommunale Wasserwerke Leipzig (KWL), own water, existing pipelines, pipeline connections, directions of flow, valves needed to be installed, tangle of pipelines, task for the planners, timetable, supply, interim pipelines, bypass pipelines, combined sewers, utilities, clear space needed, age of the existing pipeline network, DN 300, pipe systems, ductile iron, EN 545, fittings, restrained push-in joints, friction locking, BLS®, external protection, zinc coating, epoxy finishing layer, cement mortar, connecting, companies, building and installation period, experience, schedule. »

Replacement of a water pipeline in the structure of an arch bridge in Swiss Steel AG’s works at Emmenbrücke near Lucerne
by Roger Saner

Mains for process water in the steel industry require the very highest levels of safety and reliability – in itself this may be something of a nightmare for a pipe network engineer. When a main of this kind has to be replaced in a very narrow, almost inaccessible, services duct in an architecturally attractive steel arch bridge then there is really only one solution that can be considered: ductile iron pipes of the type which, with individual laying lengths, can be produced to an accuracy measured in centimetres. Read the story of a masterpiece of Swiss precision!

Keywords: Replacement, water pipeline, DN 300, arch bridge, Swiss Steel AG, Emmenweid, Emmenbrücke, city of Lucerne, Switzerland, steel works, water supply, production processes, steel production, cooling, smelting and casting processes, steel billets, rolling mill, event of a fire, sufficient fire-extinguishing water, sprinkler system, supply of fire-extinguishing water, hydrants, drinking water, water for the toilet facilities, water supply system, pumping stations, extracting ground water, pumping capacities, pumps, stations, transporting pipeline, “Listrig” reservoir, reserve of fire-extinguishing water, reserve of water for works consumption, volume of water pumped, works consumption, security, drinking water network, hydrant system, municipality of Emmen, pressure on the steelworks‘ network, emergency water supply system, cooling water circuits, lateral, mains network, “Kleine Emme” river, parts of the network, access route to the works, material, heavy goods vehicles, goods trains, loads, weather, surfacing of the carriageway, replacement of the carriageway, footway, grey cast iron pipeline, packed socket joints, operating pressure feeder pipeline, main body of the bridge, concrete abutment, pipes, ductile iron, screwed socket joints, construction drawings, installation situation, trapezoidal duct for the works pipeline, restricted access openings, pipes with packed sockets, cramped conditions, wooden supports, prefabricated concrete slabs, covering of asphalt, maintenance or refurbishment work, selection of the pipes, standard openings, requirements, external dimensions, corrosion protection, ecopur fully protected pipe, EN 15655, EN 15189, polyurethane (PUR), ecopur pipe, PUR coating, EN 545, chemical attack, mechanical damage, advantage, changes in length, vibration, railway traffic, installation work, standard spacing of the bridge’s suspension rods, edge of the bridge, when the pipes were being produced, hydrotight joint, pipe clips, base plates, concrete duct, fixing in place with bolts, auxiliary formwork, special mortar, restrained joints, fittings, external thrust resistance system, anchoring clamp, restrained, pressure pipeline, protect it from frost, glass wool, bituminous felt, work of installing the pipes, works traffic. »

Replacement of the Wilkau-Hasslau connecting pipeline belonging to Wasserwerke Zwickau GmbH
by Thomas Mühlmann

An aging steel pipeline showing signs of damage needs to be replaced and adjusted to the fall in the demand for water, guaranteeing a secure water supply for the population of 235,000 people in this part of the town of Zwickau. In open trenches, 3,080 m of DN 400 ductile iron pipes are being laid in three sections right next to the existing pipeline and the fourth section will be completely replaced along the same route. The BRS® restrained joint is providing the optimum economic solution.

Keywords: Replacement of part of pipe network, DN 400, ductile iron pipes, connecting pipeline, Wilkau-Hasslau, Wasserwerke Zwickau GmbH, pipe network, area supplied, Crimmitschau region, Kirchberger region, inhabitants, towns, municipalities, drinking water, feeder main, “Vielau” high-level service reservoir, infeed point, Bürgerschachtstrasse, gravity pipeline to the “Hermann-Krasser-Strasse” high-level service reservoir, equalising reservoir, pipeline, section on which work was planned, DN 600 steel pipes, layout plan, section concerned, pressure, pipe bursts, pitting corrosion, hydraulic conditions, security of supply, financial reasons, refurbishment measures, sub-sections, declining consumption, cross-section of the pipeline, interim pipeline, route, study of possible variants, internal refurbishment, laying of a new pipeline, pipes of different materials (steel, ductile cast iron, HDPE), layout of the pipeline, on same route, parallel, analysis, BRS® restrained push-in joint, form the joint would take, tender, internal protection, EN 545, cement mortar lining, DIN 2880, zinc coating, epoxy finishing layer, installation work, existing pipeline, interim supply, farming and pasture land, installation work, nominal pressure of PN 10, width of the installation site, unsurfaced land, installation in parallel, HSE-Bau GmbH, clear distance, bedding for the pipes, DVGW-Arbeitsblatt W 400-2, EN 1610, bedding condition type 1, commissioning, DVGW-Arbeitsblatt W 346, gasification with CO2, pH, soft drinking water, carbonation, “Burkersdorf” waterworks. »

Trenchless replacement of asbestos cement pipes by special ductile iron pipes in Berlin
by Lutz Rau

Strict regulations don’t always stop innovation. Due to the fear of releasing asbestos fibres, asbestos cement pipelines are often replaced by the burst lining technique but the fragments are left in the ground for ever. In Berlin, this is not permitted. The press-pull technique was specially developed to meet this demand but it would overstress softened asbestos cement pipes and it is possible that pieces may remain behind in the ground. Recently, it has been possible to strengthen asbestos cement pipes from inside with plastic pipes and concrete, thus enabling them to be removed from the ground leaving nothing behind.

Keywords: Trenchless replacement, press-pull technique, DN 200 nominal size, asbestos cement pipes, special ductile iron pipes, Berlin, sewage disposal, Berlin’s Müggel Hills, asbestos cement, sewage pressure pipeline, burst lining technique, fragments of old pipes, dumping costs, nature of the soil, material, pipe replacement techniques, ZMU-PLUS, BLS® restrained push-in joints, DVGW-Arbeitsblatt GW 322-1, auxiliary pipe technique, DVGW-Arbeitsblatt GW 322-2, removed, fittings, valves, house connections, hydraulic rams, bedding, installation pit, composition of the water, strength, thrust, DN 250, technical requirements, BWB (Berliner Wasserbetriebe), external protection, cement mortar coating, fully cylindrical outer circumference, new pipes, Josef Pfaffinger GmbH installing company, special tender, installation technique, traffic flow, environmental requirements, safety at work, machinery and installation pits, distance between pits, intersecting pipelines, exposed sections of the pipeline, plastic pipes, spacers, traction string, annular space, inner wall, outer wall, special mortar, function of strengthening and supporting, old pipe, pressing operation, expander cone, safety requirements, stored temporarily, suitable dump, mist of water, asbestos fibres, annular space, bursting process, protective big bag, expander cone, mist of sprayed water, asbestos cement particles, mortar filling, as the bursting progressed, fast installation, tractive forces, pulling process, fragments of old asbestos cement pipes, sustainable pipeline installation. »

With special ductile iron pipes through Berlin’s Müggel Hills
by Olaf Brucki and Lutz Rau

Relaying a sewage pressure pipeline in a popular recreational area of forest and lake close to a big city automatically makes for a technically and logistically demanding installation. Ductile iron pipes of an entirely cylindrical shape, produced by an extra thick cement mortar coating, have been installed by a technique developed in Berlin for trenchless relaying using auxiliary tubes and a pilot bore. The pipes and the installation technique demonstrate further stages of development that have resulted from mutually beneficial collaboration between the client, contractor and pipe manufacturer.

Keywords: Trenchless laying of a new pipeline, DN 250, trenchless replacement, complex terrain, special ductile iron pipes, Berlin’s Müggel Hills, recreational area, Müggelsee lake, Köpenick district, catchment area for drinking water, capital, sewage disposal, Berliner Wasserbetriebe (BWB), Müggelheimer Damm, pressure sewage pipeline, Max Bögl group of companies, “Müggelheimer Damm” consortium, trenchless techniques, pressure sewage pipeline, period for installing, new pressure sewage pipeline, village of Müggelheim, Köpenick sewage pumping station, site equipment, ductile iron pipeline, edge, main traffic artery, forested land, trees and roots everywhere, route, requirements, open trench sections, auxiliary pipe technique, steered pilot bore, DVGW-Arbeitsblatt GW 322-2, ZMU-PLUS pipes, landscape, nature, interference, flow of traffic, re-routeings of traffic, Siberian temperatures, installation work, clearing the route, relaying of other pipelines, laying out the installation pits, Sandschurrepfad, “Müggelsee Terrassen Rübezahl” restaurant, DVGW-Arbeitsblatt GW 301, group GN 1, machinery pit and pit for connection work, steel pipes (auxiliary pipes), drilling head, feed augers, protective steel pipes, bore which is being drilled out, bore, oversize, spoil, upsizing head (the hole opener), cast iron pipes cylindrical on the outside, restrained joints, frictional forces, ZMU-PLUS pipes, restrained BLS® push-in joints, sealed gap, sections of pipeline, forest, biotopes, traffic routes, innovations, re-thought, conditions of use, replacement techniques for drinking water pipes, coarse-grained and non-cohesive soils, BLS® restrained joints, external outline of the socket, cement mortar, cylindrical shape externally, cement mortar coating, DIN 15542, thickness of the coating, tolerances in the plus direction, BLS® locks, end-face of the socket, spigot end, flexible material, special adhesive tape, proceed smoothly, EN 598, wall thickness class K 9, accessories for the restrained joints, gap at the socket, logistical demands, installation timetables, twin DN 250 pipelines, area of a bend, punctual deliveries, signs and barricades for traffic, connections, transfer structures. »

Horizontal directional drilling technique used for pipe-by-pipe pulling-in of DN 900 ductile iron pipes in Belgium
by Steffen Ertelt

Belgium and the Netherlands have been pioneers in the installation of ductile iron pipes by the horizontal direction drilling technique. The technique of assembling the pipe string from individual pipes in a very small area during the pulling-in has also been perfected there. Had the laying of 342 m of DN 900 pipes right next to an important waterway been carried out in open trenches, costly predraining provisions would have been necessary. This is done much more efficiently in Belgium with the HDD technique and ductile iron pipes.

Keywords:Horizontal directional drilling technique, DN 900, ductile iron pipes, pipe-by-pipe pulling-in, Belgium, built-up areas, roads, routes, replace, install, pipeline systems, open trench technique, trenchless installation techniques, machinery, restrained joints, positive locking BLS® / VRS®-T push-in joint, angular deflection, sockets, radiuses, spigot end, welding bead, metal locking segments, locking chamber, HDD technique, horizontal directional drilling, cement mortar coating, EN 15542, external protection, locks, locking segments, pushed in, openings, end-face of the socket, axial tractive forces, internal pressure, trenchless pulling-in technique, fixing clip, TYTON® gasket, fully assembled pipe string, pipe-by-pipe connection, length of a pipeline which can be pulled in, permitted tractive force, DVGW-Arbeitsblatt GW 321, Duktus manual, type tests, internal pressure tests, product standard EN 545, nominal size, angular deflection, allowable operating pressure PFA, basis for calculation, wall thickness classes K 9 and K 10, pipelines follow straight routes, high-pressure locks, drinking water pipeline, Pidpa, Flemish water suppliers, pipeline network, municipality of Grobbendonk (Belgium), Albert Canal, waterway, town of Liège, town of Antwerp, construction of a new bridge, relaying of existing pipeline, water would have had to be pre-drained, DN 600, town of Ghent, drilling, drilling rig, widened bore, upsizing heads, connecting ramp, traction head, force-measuring equipment, traction string, barrel reamer, circumference of the pipe, steel, as the pipe is pulled in, shrink-on material, sheet-metal cone, shrink-on sleeve, economical and cast-saving installation. »

Klagenfurt replaces water pipelines by the burst lining technique
by Stefan Koncilia

The drinking water network in Klagenfurt, which uses grey cast iron and PVC pipes, is showing its age and increasingly frequent signs of fracturing on parts of certain streets. The replacement technique and materials for the new pipes are being selected on the basis of sustainability: economic factors (= very low costs) and ecological considerations (= reduction of exhaust gas, noise and dust). The work will be carried out using an optimum installation technique and materials, and in a socially responsible fashion by minimising the nuisance to local residents (= shortest possible installation time). Replacement by burst lining using ductile iron pipes is in line with this strategy.

Keywords: Burst lining for DN 100 pipes, Klagenfurt, water pipelines, burst lining technique, age and material, drinking water network, area of the town, fractures, grey cast iron pipelines, PVC pipelines, replacement work, Glanfurtgasse, DN 80 PVC, house connections, length, Krassnigstrasse, DN 100 grey cast iron, Toni Strugger Weg, planning phase, Stadtwerke Klagenfurt AG, hydraulic calculations, minimum size, parts, question of cost, traffic situation, environmental requirements, criteria which would decide, how the work was done, pipeline rehabilitation specialists SWIETELSKY-FABER, economical method of replacement, nature of the ground, test digs, coarse gravel, type of soil, mechanical stresses, selecting the pipe material, butt-welded polyethylene pipes, protective sheath, ductile iron pipes, BLS® / VRS®-T restrained joints, calculations to compare, permitted tractive stress, burst lining work, small amount of space needed, installing pipes, EN 545, class K 9, cement mortar lining (ZM-A), cement mortar coating (ZM-U), socket areas, sheet-metal cones, locks, high-pressure lock, permitted tractive force, positive locking push-in joints, 400 G bursting rig, old pipes of almost any material, asbestos cement, steel, grey cast iron, polyethylene, vitrified clay, concrete, hydraulic traction unit, bursting string, cutting and expanding head, old pipe, fragments, soil, cross-section, DVGW-Merkblatt GW 323, installation pits, machinery and pipe installation pits, old pipeline, TV inspection unit, route, drawings, old pipeline does not have to be cleaned, static burst lining technique, TRACTO TECHNIK company, total tractive force, pit measurements, roller cutting blades, expander cone, widening, re-contraction, diameter, pulling-in process, plot of tractive force, electronic data logger, pulling-in process, operator of the machine, plots, permitted stress, short connecting times, installation rate, open-trench work, total length, journeys by lorries, town, noise and dust, later study, overall installation time, reduction in costs, environment, sustainability. »

Installation of a DN 200 ductile iron pipeline by the burst lining technique – The “Ithbörde” installation project in Germany’s Weser Uplands
by Bernd Richter and Karl-Wilhelm Römer

The burst lining technique is a proven technique for the trenchless replacement of pipelines of brittle materials – and now of ductile materials too. A conical displacing body at the head of the new pipeline is pulled through the old pipeline and bursts it open. When the operation has been completed, the new pipeline is surrounded in the ground by the fragments of the old pipes which have been displaced radial ly. It is clear from this that the new pipes have to be extremely rugged to withstand the tractive forces and equally resistant to the sharp edges of the fragments of old pipe past which they are pulled. Ductile iron pipes with a cement mortar coating and BLS® restrained joints are an ideal combination for this tough job!

Keywords: Burst lining for a DN 200 pipeline, ductile iron pipeline, burst lining technique, “Ithbörde” installation project, Weser Uplands, KURT Kanal- und Rohrtechnik GmbH company of Chemnitz, replacement, drinking water transporting pipeline, replacement of the pipeline, HDPE pipes, grey cast iron pipes, open trench technique, cement mortar coating, EN 15542, ductile cast iron, cement mortar lining, zinc coating, EN 545, pipes, BLS® restrained push-in joint, external protection, strong, protective effect, zinc coating, pierced, iron, pipes impermeable to diffusion, coating of tar, safety margins, loads, trenchless installation techniques, longitudinal scoring, point supports, safe operation, operating life, plastic, farmers road, route of the pipeline, bundles of pipes, static burst lining technique, hydraulic bursting rig, new pipeline, target pit, string of rods, old pipeline, starting pit, bursting head, rubber collar, sheet-metal cone, stored pipes, tractive forces, pulling-in, DVGW-Merkblatt GW 323, levels permitted, sections, individual lengths, ends of the pipeline, intermediate pits, changes of direction, range of fittings, installation time, areas of agricultural land, restore the surface to its former state, crop harvesting, bursting system, hydraulic unit, control, pipe connection pipe, budget. »

Fire protection for five cereal mill complexes in Turkmenistan
by Claudia Mair

For a long time now, ductile iron pipe systems have been in service as safe and reliable pieces of equipment for fire-fighting in road and railway tunnels and in industrial plants. Further proof of their safety and reliability can now be seen in cereal mills in earthquake prone areas of post-Soviet Turkmenistan, where they are used by European installed systems for fighting fires.

Keywords: Fire-fighting pipelines, Turkmenistan, DN 80 to DN 200, fire protection, cereal mill complexes, ductile iron pipes, ductile iron fittings, accessories, Austria, difficult transport, landlocked state, location, development, Central Asia, Caspian Sea, Iran, Afghanistan, Uzbekistan, Kazakhstan, provinces, Ahal province, Balkan province, Dasoguz province, Lebap province, Mary province, agriculture, imports, exports, cotton, grapes (for wine), wheat, area of the country, farmland, irrigation projects, Soviet Union, Karakum (or Qaraqum) Canal, Amu Darya, Aral Sea, irrigated areas, light industry, producing textile products, producing foodstuffs, oil business, gas business, Russia, China, European partners, UNIONMATEX, wheal mills, textile factory, industrialisation, modernisation, areas of investment, petrochemicals, construction industry, terms of tender, main items of equipment, manufacturers, Germany, Switzerland, quality, long life, ductile iron pipe systems, layer of flour, flour dust explosion, fire protection system, Total Walther GmbH company, backshop, capital Ashgabat, Ruhabat, Serdar, buried pipeline, external hydrants, GOST standard, Russian state standard, underground hydrants, hydrant system, water supply, buried ring pipeline, DN 80, DN 100, DN 150, ISO 2531, EN 545, minimum depth, diameter of the pipeline, laterals, internal hydrants, buildings, fire brigade, fight fires, connection, isolating gate valves, nature of the soil, earthquake zone, Mercalli scale, BLS® / VRS®-T push-in joint, restrained against both thrust and traction, DN nominal size, lengths of pipe, FM approval, DN 500, safety and security, area subject to earthquakes, angular deflectability, safety factor, pipelines for fire-extinguishing water, fire-extinguishing water, safety margins, internal pressure, pressure surges, fire-fighting and fire-extinguishing systems, airports, railway tunnels, road tunnels, autobahn tunnels, industrial plants, technical advantages, allowable operating pressures, pipe wall, connecting systems, heat-resistant non-combustible pipeline material, fire resistant, environmental advantages, recycled materials, lining, cement, sand, drinking water, economic advantages, installation rates, laying length, not requiring any welding, working life, coating, Turkmenabat, Dasogus, Mary, bakery products, pasta, emergency, fire, production plants, economically viable, safety equipment.

Water supply for the expansion of Frankfurt am Main Airport
by Jolanda Rosenberg and Heinz-Jörg Weimer

Fraport (Frankfurt Airport), Germany’s largest airport, is being given a third terminal. The infrastructure is being brought up to world standards, so the level of functionality and long term reliability has to be very high. For the water supply alone – drinking water, clean water for other purposes and fire-extinguishing water – some 9,000 m of ductile iron pipes of nominal sizes ranging from DN 150 to DN 300 are being installed. Experience over several decades has made planners at Fraport aware of the high reliability provided by ductile iron supply networks so for them there was no other pipe material worth considering.

Keywords: Water supply, DN 150 to DN 300 pipes, expansion, Frankfurt am Main airport, US air base, aprons, Terminal 3, public works approval decision, locations for buildings, infrastructure, handling aircraft, ducts for electrical and telecommunications cables, manholes, pipelines for drinking and other water, hydrants, intercepting sewers for storm water, fuel hydrant system, aprons, laid in concrete, taxiways, asphalt, supply fire-extinguishing water, needed, stages, ductile iron pipes, system for supplying the fire-extinguishing water, DN 250, connections, existing pipelines, ensure, security of supply, phases of construction, ring pipeline for drinking water, main building, mobile concrete mixing plant, branch, connecting in a hydrant, branch pipeline, underground hydrant, network pressure, external loads, wall-thickness class K 9, BRS® restrained joint, external protection, zinc coating, finishing layer, EN 545, DIN 30674-3, blue pipes for drinking water, green pipes for other water, reliability, availability, repair work, expansion work, very best quality.

Laying of new penstock pipelines for small hydroelectric power stations
by Andreas Moser

Many European governments are aiming to increase production of energy from renewable sources in order to reduce CO2 emissions. Payments in the form of a feed-in tariff act as an incentive for the building of small hydroelectric power stations. The penstock pipelines needed by these stations are a new field for ductile iron pipe systems, which has been on the increase in recent years and demonstrates how wide the field of application for these pipes is.

Keywords: Penstock pipelines, DN 300, DN 1000, ductile iron pipe systems, high Alpine terrain, laying of new penstock pipelines, small hydroelectric power stations, turbine pipelines, high operating pressures, ductile iron ones, material, demands, working, safety, system components, laying, BLS® restrained push-in joint, welding, weld, time saving, range of fittings, connecting situations, valve manholes, joints can be deflected, fittings, connecting time, changes in direction, pressure surges, butterfly valves, faulty closing times, concrete thrust blocks, ground, coating systems, corrosion protection, practical examples, perform, range of nominal sizes, client, Vernagtsee hydroelectric power station, South Tyrol, Energie Schnals GmbH, Schnals, Italy, Ingenieur Team Pohl, Kastellbell-Tschars, installing company, Marx AG, Schlanders, installation time, DN 500, DN 700, DN 800, ductile iron pressure pipes, wall thickness classes, K 9, K 12, length of pipeline, head, water intake structures, water, storage tank, capacity, yield of water, bottom of the storage tank, drawdown pipeline, turbine house, pH, high-alumina cement mortar, DIN 2880, pipe bridge, time slot for installation, pieces of construction machines, sea level, pipe clips, Dorferbach hydroelectric power station, East Tyrol, TIWAG, TIWAG Hydro-Engineering, Alpine Mayreder, Lienz, cement mortar lining, K 18, test pressure, blank flange, end of the pipeline, Taurus electric locomotives, flange for connection to the turbine, Furkelbach hydroelectric power station, Municipality of Trafoi, Dipl.-Ing. Hochschwarzer, Plöstl GmbH, Partschings, DN 400, K 14, route, blasted out, cable car, laying point, impassable terrain, steepest parts, sloped, pipe installation, brought in, slope, Holzerbach hydroelectric power station, Konsortialgesellschaft Prettau, Exact-Ingenieure, Brixen, Brunner und Leiter GmbH, Weissenstein, take-offs from the pipeline, watercourse, water rights, generate electricity, pipelines for sprinkler irrigation systems, fire protection facilities, hydrant connections, items of measuring equipment, technical data, excavated, narrow trenches, can be re-used, material excavated, push-in joints, bad weather, recultivation, strength properties, restrained push-in joint, trouble-free operation, power station pipelines, safe from the technical point of view, economic and sustainable type of material.

What’s new in ductile iron pipe systems?
by Jürgen Rammelsberg

In April 2010, college and university teachers specialising in the water sector, supply technology and construction, and installation were guests of the Association in the Lusatia region to hear the latest about ductile iron pipe systems. The Lusatia region had been chosen because one of Germany’s oldest foundries, the Keulahütte foundry of Krauschwitz, has its home there and had issued an invitation to a works inspection. At the same time the guests were also able to see one of the greatest transformations of a landscape, namely the conversion of the Lusatia region‘s one-time brown coal mining district into a modern residential and recreational area with water everywhere close at hand.

Keywords: Fachgemeinschaft Guss-Rohrsysteme (FGR®) e. V. / European Association for Ductile Iron Pipe Systems • EADIPS®, 2010 Conference for College and University Teachers, Großräschen, what’s new, ductile iron pipe systems, Fördergemeinschaft zur Information der Hochschullehrer für das Bauwesen (FIHB) e. V., industrial trade associations, colleges, universities, Lusatia region, Seehotel Großräschen, Prof. Dr. Rolf Kuhn, IBA (Internationale Bauausstellung Fürst-Pückler-Land 2000-2010 GmbH), talks, conference programme, excursions, inspection, Keulahütte GmbH, Krauschwitz, Lusatia region’s lignite (brown coal) mining district, Eisenhammer Keula, iron foundry, products, water industry, custom castings, machinery and automotive industries, conference attendees, foundry production, “Ilse” mine, “Victoria” coal briquetting plant, brickworks, open-cast mining activities, flooding, open-cast mine workings, Lake Ilse, IBA terraces, pier, IBA-Auftaktgebiet Großräschen-Süd, IBA Fürst-Pückler-Land GmbH, landscape is being transformed, mining of lignite, landscape, triangle of land defined by the towns of Senftenberg, Hoyerswerda and Spremberg, lakeland, lakeside terraces, open-cast mining of lignite at Welzow-Süd, floating homes at Geierswalde, landmark for the Lusatia lakeland, navigable canals, tourism, marinas, harbours, water sports, leisure activities, viewing platform, Cortene steel which has a natural rust-like appearance, Boxberg, Schwarze Pumpe and Jänschwalde power stations, energy generation, Welzow Energy Landscape, growing of biomass and use of biomass, wind turbines, solar panels, depopulation, civil engineers, hydraulic engineers, pipes, fittings, valves, Ulrich Päßler, Prof. Dr.-Ing. Prof. h. c. Wolfgang Krings, Udo Müller, developments, material, spheroidal graphite cast iron castings, small steps aimed at optimisation, micro-alloyed material, vehicle construction, wall thicknesses, fatigue strength, silicon, spheroidal graphite, material for valve bodies, low-temperature use, railway axle boxes, information technology, 3D design, rapid prototyping, simulation of solidification, development times, hydrants, gate valves, butterfly valves, non-return valves, valves for house connections, René Pehlke, product development, hydrant for football stadiums, corrosion protection systems, how they work, where they can be used, Uni. Prof. DI Dr. Paul Linhardt, Vienna University of Technology, cloud of volcanic ash, Ewald Titze, Dr. Norbert Klein, coatings, properties as materials, thickness, ground, metallic materials of the pipes, corrosive reaction, isolate electrically, active synergistic coatings, difference in potential, zinc, iron, electrolytes in the soil, products of reaction, finishing layer, processes by which iron can be corroded, product standards, external protection, internal protection, commissioning, linings, cement mortar, based on inorganic material, drinking water, cleaning, flushing, disinfection, pressure testing, “air-pulse process”, section to be flushing, compressed air, static pressure for the system, air bubbles, stream of water, blocks of water, blocks of air, turbulent flow, deposits, amount of water needed, flushing speed, pipeline network operator, Zweckverband Fernwasser Südsachsen, connecting pipeline, DN 1200, steel pipes, cement mortar lining, bypass, supply of water, rehabilitation work, Wolfgang Rink, Applications Engineering Division of Duktus Rohrsysteme Wetzlar GmbH, DN 600, squared timbers, bypass pipeline, rehabilitation, steel pipeline, interim pipeline, water pressure, signs of wear, economical use, pipeline for transporting water, DN 500, Sonnenberg tunnel, Lucerne, Roger Saner, vonRoll hydro (suisse) ag, cancelled flight, Michael Schulz, co-CEO, vonRoll hydro (deutschland) gmbh, Prenzlau, range of products, polyurethane lining, EN 15655, polyurethane coating, EN 15189, fluidised bed powder coating process, epoxy resin, GSK guidelines (GSK – Quality Association for the Heavy Duty Corrosion Protection of Powder Coated Valves and Fittings), butterfly valves, non-return valves, tapping saddles, installation sets, accessories, event. »