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Annual Journal 48 – 2014

Themes, Authors, Abstracts, Keywords (Details)

From the 300-year-old iron pipes at the UNESCO World Heritage Site to the concepts of today – a lasting infrastructure for water management
By Harald Roscher and Jürgen Rammelsberg

A monument in the heart of Germany with impressive fountains fed by 300-year-old iron pipes, which has been designated a “World Heritage Site”, is the starting point of a fascinating historical story which stretches all the way to the system of ductile iron pipes, fittings and valves which we have today. It may well be that the technical progress between “then” and “now” has led to a remarkable improvement in performance, but there is nevertheless something which all generations of ductile iron pipe have in common: their superior sustainability.

Keywords: History, iron pipes, UNESCO World Heritage Site, lasting infrastructure, water management, Bergpark Wilhelmshöhe, Kassel, Hercules monument, cascades, Museumslandschaft Hessen Kassel, World Heritage Site, Riesenschloss, Octagon, cascades, Kassel Museum, Frontinus Gesellschaft e. V., Prof. Dr.-Ing. habil. Harald Roscher, socket pipes, length, age, German National Committee, ICOMOS – International Council on Monuments and Sites, authenticity, criterion, measures to restore and preserve, architectural, monument, 18th century, cascades, superstructure, construction period, preservation, renovation, old pipes, historic record, visits, inspection, iron pipe joint, iron pipeline, operation, garden, castle park, pieces of pipe, sand-cast, cast pipe, eggshell fracture, document, Fachgemeinschaft Guss-Rohrsysteme (FGR®) e. V., archives, European Association for Ductile Iron Pipe Systems · EADIPS®, research, cast iron pipe industry, Prussian state building authority, water features, historical development, municipal water pipe, Dillenburg Castle, river Dill, water pipe networks, London, Vienna, Germany, Hamburg, Berlin, Darmstadt, manufacture, application, E-book, website, www.eadips.org, publications, Langensalza, Jacobi and Rathaus fountains, water pipeline for the castle in Braunfels, sewer laying work, grounds of the Palace of Versailles, Zwinger Palace, Dresden, Weißeritz pipe, material, grey cast iron, steel, statistics of the German gas and water management association, Federal Republic of Germany, proportion of cast iron pipes, existing network, main area of use, fittings, valves, spheroidal graphite cast iron, corrosion protection, assembly techniques, restrained joints, trenchless technique, pipe generations, zinc-coated, protective finishing layer, cement mortar lining, PE coating, PUR coating, cement mortar coating, soils, low damage rate, sustainability, economic processes, resources, economic aspect, investment, cost, running costs, useful life, installation, operation, maintenance, decommissioning, connection and assembly technique, ecological aspect, material properties, diffusion-tight, contaminated soil, waste water and sewage, groundwater, linings, absolute hygienic safety of drinking water, recycling, iron and steel scrap, technical superiority, performance level, pressures, longitudinal bending, surface loads, savings, fire extinguishing lines, snow-making systems, hydroelectric power stations, security, internal pressures, production process, future generations.

The renaissance of the metallic sealing gate valve in the drinking water section
By Frank Endress

Difficult to believe but it’s true – a relic of the last century long believed dead and buried is celebrating its revival with lime precipitating waters: the metallic sealing gate valve. The metal wedge gate, which can be immersed in a valve sack, enables solid incrustations to be broken up and crushed. When the wedge gate opens, the fragments are flushed out. The other criteria meet modern technical standards: stem seal, corrosion protection and countersunk and sealed connecting bolts between the top and bottom parts.

Keywords: Metal sealing valves, drinking water applications, historical development, drinking water supply, standard isolation valves, stuffing box, features, externally located bolts, coating, soft-seated valves, rubberised wedge, casing, epoxy powder, corrosion protection, stuffing box packing, O-ring seal, spheroidal graphite cast iron, grey cast iron valves, advantage, breaking strength, casing material, whirl sintering process, “IRON PIPE SYSTEMS” E-book, pore-free coating, enamelling, wedge, incrustation, pipeline, valves, deposits, manganese, iron, calcium, closing function, valve bag, closure, closing device, construction, approved for drinking water, working life, epoxy resin coating, minimum thickness, sealing gland, permanently lubricated, top part, spindle on the inside, seat ring, brass, stainless steel, maintenance budget, civil engineering work, packing rings, spindle nut, sealing of top part, hexagon socket screw, back seal, sliding disk, thread adapter, retaining ring, EN-JS1030, EPDM, NBR, EN-JL1040, polyamide, plastic.

Butterfly valves “Made in Germany
By Johannes Neubert

As with gate valves, there is a remarkable history of development with the second major group of shut-off valves – the butterfly valves – in the area of materials and construction. The “sticking” of the rubber seals to the brass seal seating has been remedied with high-grade steel seal seating rings, the bearing bushes have been produced from a new composite material with Teflon and the disks have now been given a “double eccentric” arrangement. The new low-temperature cast iron with spheroidal graphite EN-GJS-400-18LT could open up new areas of application which were previously only covered by traditional steel casting. The perfection of the corrosion protection with seamless epoxy resin powder coating inside and out make extremely high working lifetimes possible.

Keywords: Butterfly valves, Made in Germany, look back, Keulahütte foundry, history, producer and processor of iron, manufacturer, valves, 19th century, metal sealing valves, the early days of extension, drinking water network, hydrants, drainage function, range, Keulahütte GmbH, Krauschwitz, resilient-seated butterfly valves, flange-mounted, single eccentric design, casing and seat ring, brass, nitrile seals, strength, material, stainless steels, construction features, development, DIN length, F4, GR 14, European standards, generations of valves, innovations, composite-layer bearing bushes, polytetrafluoroethylene (PTFE) layer, water network valve sector, heavy-duty valves, valve bearings, double-offset, wear, sealing fittings, working life, DIN-DVGW, construction material, EN-GJS-400-15, casting material, tensile strength, minimum elongation at break, tensile strength, security strategy, overloading, plastic deformation, breaking point, material properties, EN-GJS-400-18LT, very low temperature notched impact strength, ferritic cast iron, spheroidal graphite, corrosion protection, epoxy powder coating, development of processes and materials, type of protection, pipeline construction, coating, valve parts, installation, drive, control, waterworks, process parameters, quality parameters, integral corrosion protection, housing seating, valve seat, nominal coating thickness, adhesive strength, diffusion tightness, impact resistance, operating conditions, under-rusting, chemical resistance, suitability for drinking water, repair kits, touching up, damaged areas, use, valve casing, nominal width range, DN 1400, Scandinavia, PTFE coating, shaft bearing, joint areas, assembly areas, benefit, production chain, valve manufacturer, gearing, electrical drive, drive supplier.

New sewage pipe in ductile cast iron on the Bachweg in Seon
By Roger Saner

One sometimes comes across constraints in sewer pipeline construction which make the use of traditional building materials impossible. As little cover as possible combined with thesmallest gradient possible and an installation position between a drinking water pipeline and the road surface – everything that can create nightmares for a planner. So if he finds a piping system which can solve all his problems at a stroke then he will be forever grateful afterwards when he thinks about the ductile iron pipe system which got him out of a tight spot.

Keywords: Sewage pipeline, DN 250, DN 350, ductile cast iron, Bachweg, municipality of Seon, Aargauer Seetal, regional centre of Lenzburg, utility pipelines, road resurfacing, base course, general wastewater management plan, overloaded, structural condition, combined sewer, concrete pipes, DN 300, hydraulic capacity, cross-section, edge of the road, bedding depth, pipe covering, depth, gradient, sewerage system, elevation, connection point, gradient, choice of pipe material, criteria, pipe material, requirements, installation conditions, bedding, Swiss standard SIA 190, structural design, strength properties, inside surface, drag forces, open-channel sewer, maintenance costs, flushing, road cross-section, drinking water pipeline, rainwater conduit, receiving water course, sewage pipeline, piping system, socket joint, contamination, choice of material, planning engineer, client, operational safety, sustainability, security of investment, ductile iron pipe, reinforced coating, EN 598, pipe supplier, vonRoll ECOPUR, full protection pipe, lining, polyurethane (PUR), diametral stiffness, roughness coefficient, push-in joints, assembly, branch connections, corrosion protection, PUR coating, PUR lining, EN 15655, pore-free surface, pH values, deposits, incrustation, high-pressure flushing, test report, test institute, IRO – Institut für Rohrleitungsbau an der Fachhochschule Oldenburg e. V., high-pressure flushing capability, DIN 19523, EN 15189, soils, corrosion levels, covering of pipes, traffic loads, mechanical damage, deformations, underground, structural stability under load, fitness for purpose, height of cover, installation work, depth in the ground, resistance to high-pressure jet cleaning, connection line, building, tapping saddle, transition sleeve, plastic pipe, concrete bedding, gravel bottom, trench, pipe alignment laser, HYDROTIGHT, assembly work, feed lines, buildings, street drains, tapping, coating thickness, adhesive strength, cut pipes, advantage, cutting edges, 2-component epoxy resin, bedding and surrounding pipes, inspection manholes, shaft depth, manhole connectors, core drilling, flow channel, shoulder, ease of installation, simple, time-saving, cost-effective.

Replacement of the Schwarzbachtal waste water authority’s DN 800 and DN 1000 sewage pipeline between Bernau and the sewage treatment plant
By Werner Martin and Wolfgang Rink

The replacement of a worn-out sewer of nominal sizes DN 800 to DN 1000 is in itself no simple thing. But when thissewer is in a drinking water protection zone, when it is made of asbestos cement pipes and when it has to remain undisturbed and securely in operation during the replacement work, then a high degree of professionalism is demanded of all involved. However, with ductile sewage pipes the job could be done elegantly and safely.

Keywords: Sewage pipeline, DN 800, DN 1000, renewal, sewer, Schwarzbachtal wastewater association, residential district of Bernau, sewage treatment plant, sewage, municipality of Neunkirchen, town of Rappenau, district of Obergimpern, inspections, damage, damage class, asbestos cement pipes), pipe walls, bottom, mechanical wear, Bernau connection point, town of Neckarbischofsheim, drinking water protection zone III A,  water source, Mühlbach water supply association, section, drinking water protection zone II, Krebsbach intersection, planning, remedial measures, Werner Martin civil engineering and environmental protection service in Reichartshausen, renovation of the inside of the sewer, short pipe liners, wastewater drainage, volumes of wastewater, storm water outflows, area covered by the wastewater association, groundwater, prefabricated manholes, distances, reinforced concrete structures, manhole structures, ductile sewage pipes, manhole connectors, cast iron, TYTON® push-in joint, connection, retaining wastewater, reconnection, gradient, bedding depth, pumping station, height of the base of the sewage pipes, pumping station, sewer route, view of the site, longitudinal section, feeder pipe, sloping trench walls, shored trench walls, total length, profile of requirements, client, planning engineer, EN 598, push-in joints, zinc coating, cement mortar coating, EN 15542, high-alumina cement, stability margin, loads, length, length variations, internal pressures, negative pressures, articulated joint, aggressive soils, bedding material, stones, size, corrosive sewage, construction work, clay, alluvial loess, pipe bedding, bottom of the trench, geotextile, coarse gravel, mineral aggregate, groundwater level, open dewatering, pipe trench depth, L 549 road, reinforced concrete pipes, DN 1200, pipe jacking, River Krebsbach, crossing area, base profile, restricted space, work in incremental stages, open/close method, external protection, excavation material, encasing, mineral seal, groundwater protection, cohesive excavation material, backfilling, costs, removal, landfill, wastewater retention, pressure pipes, pipe couplings, hydraulic calculation, contaminated water, weather, equipment, pumps, generators, standby units, pressure testing, EN 1610, period.

Construction of a new drinking water supply pipeline between Pödelwitz and Neukieritzsch
By Mathias Renger, Stefan Präger, Renaldo Moritz and Uwe Hoffmann

Opencast lignite mining not only changes the outward appearance of the landscape, it also involves alterations to theentire infrastructure. Old roads disappear and new ones have to be built. Between Pödelwitz and Neukieritzsch, to the South of Leipzig, an embankment is due to be raised for the new main road, which is going to take quite some time to settle. This road will also take the main water transport pipeline between the two towns. Piping systems need to be selected for it which have sufficient reserves for all the loads associated with this – both planned and unforeseen. That means ductile iron pipe systems.

Keywords: Construction, new drinking water pipeline, DN 250, drinking water supply pipeline, location of Pödelwitz, district of Neukieritzsch, region of Borna, administrative district of Leipzig, drinking water, wastewater, Bornaer Land water/wastewater association, town of Borna, district, Thräna, Wyhra, Zedtlitz, Eula, Haubitz, Gestewitz, Kesselhain, industrial and commercial locations, Fernwasserversorgung Elbaue-Ostharz GmbH, drinking water regulation, lignite mining area, to the South of Leipzig, extraction field, Mitteldeutsche Braunkohlengesellschaft mbH (MIBRAG), project sponsor, main B 176 road, demolition, road connection, main drinking water supply pipeline, planning permission, planning, UKAM GmbH engineering office from Borna, design, execution, planning approval procedure, constraints of open-cast mining, pipe material, construction technology, residual inherent settlement, construction site, tipping of spoil material, below and above the working level, site plan, pipeline construction stages, settlement area, installation requirements, pipe system, loads, ground motions, technical working life, choice of pipe material, area of the route, geotechnical report, ductile iron pipes (GGG), EN 545, BLS® restrained push-in joints, thrust and tension resistance, nominal size, corrosion protection, zinc-aluminium coating, Duktus Zinc-Plus, epoxy resin finishing layer, horizontal movements, axis of the pipe, socket joints, deflectability, pipe length, deflection, deviation, axis, pipe, fitting, lock, catch, concrete thrust blocks, bends, sloped trench, permissible grain sizes, cover material, cover, grain size, zinc/bitumen, zinc/epoxy, zinc-alu/epoxy, cement mortar coating, safety margin, pipe joints, pulled apart, subsidence, variations in length, positive locking joint system, axial movement, strain, compression, thrust system, movements caused by mining subsidence, installation location, flow of forces, locking chamber, welded bead, spigot end, axial movement, direction changes, construction work, waiting time for the spoil embankment, pipe trenches, fibre optic control cable, protective tube, DVGW worksheet W 400-2, mining disposal area.

Construction of a new drinking water connecting pipeline from the Ramstein pumping station to the Dackenheid water tower
By Markus Steier

With a single 40-year-old DN 300 connecting pipeline in ductile iron pipes, the supply of drinking water to 18,000 clients of the Trier water authority was relatively insecure. It was not even possible to take it out of operation in order to produce a status report, let alone carry out repairs in case of damage. A reserve pipeline was urgently required. The technical, economic and administrative constraints for building a second pipeline were extremely difficult to overcome: geological and topographical requirements, the protection of the environment and monuments, the demands of operating and working safety and not least cost effectiveness resulted in the installation of a standby pipeline of the same length along a different route. After the completion of the new pipeline, the old pipes were finally able to be inspected. Apart from cleaning with pigging equipment, no further reinforcement was  necessary. Now the water authority has a secure second connection.

Keywords: Construction, new drinking water pipeline, DN 300, drinking water network connection, Ramstein pumping station, Dackenheid high-level tank, Trier-Land waterworks association, Trier-Land local authority association, district of Kordel, district of Butzweiler, alternative supply, water catchment area of Kylltal, pressure line, Sauer and Kyll rivers, central elevated tank, distribution network, border between Germany and Luxemburg, planning, deliver water, delivery volume, ductile cast iron, internal diameter, inspection, investigations, damage, bottlenecks, supply ensured, not with TYTON® restrained push-in joints, install, route, construction work, legal questions regarding nature conservation, “Lower Kyll and Kordel valleys” area subject to flora and fauna habitat protection guidelines, “Meulenwald and Stadtwald Trier” protected forest landscape area, natural spring, habitat, Federal nature conservation legislation, “Kylltal waterworks association” drinking water protection area, class II protection zone, class III A zone, plateau, “Roman long wall”, Rhineland Landesmuseum, routing, outstanding “Roman pathway” trail, forestry administration, preliminary planning, terrain, alternative routes, hydraulic calculations, length, pumps, forest and farm tracks, steep slope, gradients, topographical conditions, line crossings, pipes laid parallel, nature and monument conservation, geological and topographical conditions, sandstone walls, rocky outcrops, project location, Upper and Middle Bunter period, medium sandstone, fine sandstone, subsoil conditions, small ramming drillings, tests with heavy-duty penetrometer, sandstone rock, surface of the terrain, shallow depth, bedrock horizon, area investigated, soil class 7, approvals, Winter 2010/2011, clearing work, pipeline route, construction work, woodland, EN 545, cement mortar coating, EN 15542, external protection, bedding pipes in crushed materials, maximum grain size, reusing, material excavated from the trenches, economic and ecological advantages, pipe bedding material, transporting, soil and rubble, UVB company (Universal-Bau GmbH from Bitburg), pressure class C 50, ductile iron pipes, restrained (friction-locking) BLS® push-in joints, permissible operating pressure, concrete thrust blocks, bends, transport of concrete, drainage effect, trench, landslips, clay aprons, leaching out, washing away, topsoil, outline map, curve point, transition, assembling, direction of flow, stabilisation, jute mat, wooden pegs, stabilisation barriers, vegetation, excavator, Komatsu PC228USLC, engine rating, delivery head, valve shafts, pressure port, baseplate, riser, valves, pressure testing, completion, commissioning, investigation, renovation, pipe sections, North Rhine-Westphalia Material Testing Institute, condition, material properties, structure, test report, irregularities, protective coating, mechanical material properties, deposits, TV inspection, pigging, dry weather.

Construction of a new DN 500 main supply pipeline from HB Bromberg to Holzgerlingen
By Lothar Schütz and Alexander Bauer

An ageing DN 300 main pipeline was no longer able to cope with performance requirements and economic specifications and so it has been replaced with a modern pipeline in DN 500 ductile iron pipe. With well-trained teams and modern machine technology it is possible to achieve high pipe-laying speeds even in rural areas, meaning that with the technically superior ductile cast iron pipe system an economically sustainable solution can be found for the transport of drinking water.

Keywords: Construction, new main supply pipeline, DN 500, PN 16, Bromberg high-level tank, district of Holzgerlingen, site and contour map, planning approach, Ammertal-Schönbuchgruppe (ASG) association, drinking water, association, pipeline, ductile cast iron, nominal size, Zinc-Plus coating, grey cast iron, asbestos cement, DN 300, hydraulic calculations, Miltenberger und Schmid GmbH design office in Hechingen, reserves, increase in the consumption, communities supplied, drinking water supply pipeline, administrative district of Böblingen, Baden-Württemberg, preliminary planning, golf course operator, forestry administration, construction work, Max Wild GmbH company from Berkheim, Norbert Schütz GmbH & Co. KG from Boos, civil engineering, road construction, pipe laying work, Wild- Schütz consortium, earth moving, gravity pipeline, height difference, open pipe trench, humus, ductile iron pipeline, freezing, choice of pipe material, decision-making criteria, economic points of view, technical points of view, ecological points of view, complete solution, topographical conditions, height, length, performance, flow rate, pressure conditions, supply volumes, geographical conditions, price/performance ratio, piping system, pipe dimensions, useful technical life, durability, sustainability, operational safety, operational expenditures, types of joint, flexibility, assembly time, corrosion protection, quality, construction work, longitudinal section, requirements profile, installation site, space restrictions, use of machines, use of equipment, use of personnel, structure of the terrain, land, soil conditions, construction time, seasons, infrastructure, traffic, requirements of landowners, tendering costs, management costs, reports, guarantees, reimbursements, compensation payments, material processing, internal and external coating, quality assurance, works testing, jointing technology, welding, socket joints, operating pressure, pressure classes, compressive and tractive forces, flexibility, pipe lengths, transport, storage, pipe bedding, in-situ soil, grain sizes, pipe covering, energy consumption, CO2 balance, useful life, soil compaction, renaturalisation, recultivation, ductile iron pipe system, fittings, installation techniques, daily progress, EN 545, wall thickness, pressure class C 50, zinc-aluminium coating, non-restrained, TYTON®, restrained part, BRS®, friction-locking joint, locking and sealing function, TYTON SIT PLUS® gasket, EN 14901, DIN 3476, RAL GZ 662, epoxy resin powder, coating thickness, construction project, pipeline route, Schönbuch golf course, Buch/Sol industrial estate, piping and distribution network, manhole structures, employees, special machines, walking excavator, patented installation rig, cutting the ductile iron pipes, assembly of bends, assembly, hydraulic installation rig, pipe section, pipe trench, insertion, back-locking, adapter piece, patented advantages, semi-automatic iron pipe installation rig, grab jaws, securing and holding, assembly, retaining bracket, traction line, pipe insertion, socket, push-in marking, traction cylinder, finest adjustment, pushing force, spigot end, site personnel.

Status analysis for the piping network of the city of Vienna using non-damage-based data on ductile iron pipes
By Daniela Fuchs-Hanusch, Franz Weyrer and Christian Auer

In a large city like Vienna the service of supplying drinking water has been provided by iron pipes for more than 150 years. However, knowledge about the condition of the piping network is always patchy – it is repaired when damage occurs. An attempt has been made to assess and document the external condition as and when the opportunity arises, even when making a house connection for example. The status data obtained in this way can now be combined in a variety of ways with soil maps, areas with strikingly high damage rates, geoinformation systems, etc. The benefit for the pipe network operator could lie in an optimised replacement strategy and for the pipe manufacturer in a further optimisation of his protection systems.

Keywords: Status analysis, ductile iron pipes, piping network, city of Vienna, data, damage statistics, pipe renewal strategies, damage rates, instances of damage, analysis, predicted, working life, damage probabilities, operational time, probability, calculation models, DVGW, ÖVGW, findings, reference values, Vienna waterworks, network information system, damage recording, databanks, GIS (geo-information system), camera inspection, corrosion attack, assessing, piping network of Vienna, length, Austria, corrosion protection systems, pipe materials, asbestos, PE, PVC, grey cast iron, ductile cast iron, screwed joint, pipe generations, external coating, tar, zinc/bitumen, zinc/polyurethane, development, Tiroler Rohre GmbH, Technical University of Vienna, Technical University of Graz, piping system operators, manufacturers, renewal strategies, metallic materials, grey cast iron, grey cast iron pipes, budget control, renewal methods, influencing factors, bedding, installation, soil, laboratory tests, generations of coatings, area of drinking water, periods of use, performance capability, generations of ductile iron pipes, coating systems, assessment, pipe status, pipe uncovered, installing house connection lines, instructions, standard description, standard images, basis, status classes, perforation, questionnaire, pipe condition, pipeline condition, photo-documentation, trench, surrounding area, datasets, status analyses, previous damage, comparison, map, maps, pipelines, tar-based, protection system, score average, duplex coating systems, finishing layer, soil aggressivity, predictions, status mean value, districts of Vienna, type of coating, proportional sampling rate, sampling rate, correlation, pipeline renewal, working life tests, soil charts, small excavations.

Renewable energy in the land of the fjords – high performance application of ductile iron pipes for hydroelectric power stations
By Marc Winheim

Renewable energy from water power in Norway – an immense and not yet fully tapped potential stands ready to store surplus power from Europe’s wind and solar power stations in pumped-storage power plants. With its alpine structure of mountains and fjords, the country has water resources at great altitudes which, by means of penstock pipelines, are routed to turbines to produce power. Ductile iron pipe systems have already been making a significant contribution to this technology for decades. This article gives some basic information on the completion of different projects.

Keywords: Penstock pipelines, DN 200, DN 1000, renewable energy, land of the fjords, high performance applications, ductile iron pipes, hydroelectric power stations, Tverraga, Norway, energy source, energy store, CO2 reduction, electrical energy, generation, hydroelectric energy, power generation, European Union, excess capacity, energy sources, wind, solar power, European member states, pumped storage power plants, storage capacity, Europe, producer of hydroelectric power, China, Brazil, Canada, Federal Ministry for the Economy, work on the principles of osmosis, tide, wave power, price of electricity, power sources, lights, lighting, geographical location, Arctic Circle, winter, heating, power, consumption of electricity, output, micro power stations, mini power stations, small power stations, large power stations, hydro-power turbines, rainwater, hydro-power plants, turbines, mechanical energy, rotational energy, generators, construction types, Pelton turbine, falling from great heights, nozzles, water jet, high speed, rotor blades, impeller, speed, Pelton wheel, generator shaft, Francis turbine, run-of-river power plants, storage power plants, flow rates, stator, guide vanes, direction of flow, inflow, outflow, swirling momentum, turning moment, Francis flume type turbines, Francis spiral case turbines, Kaplan turbine, river, water volume, construction, shaft, ship’s propeller, rotary motion, dual regulation, flow of water, type of turbine, outflow, efficiency, turbine pipeline, supplying water, storage location, geodesic height difference, high point, water reservoir, low point, high-pressure lines, planning, operating pressures, 40 bar, 80 bar, turbine inlet, EN 545, advantages, ductile iron pipe systems, construction, operation, wall thicknesses, material, safety margin, pressure surges, weather, robust, length, steep gradients, rocky substrates, pipe joints, fittings, route, bends, substrate, cement mortar coating, external protection, backfilling, transporting, bedding material, types of joint, TYTON® push-in joint, seal, rubber compound, deflected, root penetration, bursting pressure, non-restrained joint, open trench, branches, reductions, thrust block, BLS®, installation aid, DIN 28603, locks inserted, restrained, type of use, locking segments, tractive forces, mountainous regions, concrete, pressure areas, pipeline component operating pressure (PFA), angle, concrete thrust blocks, internal pressure, ground, stress, circumferential direction, longitudinal stresses, resulting forces, skin friction, triaxial stress state, circumferential direction, longitudinal direction, radial direction, EN 15542, soils, DIN 50929, mechanical loads, anode backfill bedding, sand and gravel bedding, grain sizes, individual stones, backfilling, excavation and bedding materials, impact resistance, cement mortar layer, zinc-coated pipe, zinc coating, calculation, permissible pressures, minimum wall thickness, safety factor, tensile strength, pressure fluctuations, surge tanks, isolation valves, speed of closing, mean pipe diameter, nominal external diameter, minimum tensile strength, limit deviations, decentring, type tests, performance, pressure loading, test pressure, positive hydrostatic internal pressure, negative internal pressure, Positive hydrostatic external pressure, cyclical hydrostatic internal pressure, FEM analysis, accredited test institute, DIN EN 545, certificate, pipe store, waterfall, steep gradient pipeline, assembly.

Small hydroelectric power plant at Ossasco, in the Bedretto valley
By Roger Saner

Once again pipe systems in ductile cast iron are making a contribution to the production of renewable energy in small hydroelectric power plants. A variety of technical, economic and ecological advantages bear witness to the superior sustainability of ductile iron pipes and fittings in the sensitive ecosystem between Valais and Tessin.

Keywords: Penstock pipeline, DN 600, small hydroelectric power plant, Ossasco, Bedretto valley, Canton of Ticino, Airolo, Gotthard Pass, Nufenen Pass, Canton of Valais, Cristallina massif, company CEL Bedretto SA, Riale Cristallina, electricity, water extraction, pressure pipeline, production station, volume of water, static pressure, turbine shaft, dimensions, pressure surge, energy, Pelton turbine, vertical axis, water return, economical operation, vonRoll ECOPUR, hydraulic performance, choice of material, strength characteristics, ductile iron pipe system, vonRoll HYDROTIGHT restrained push-in joint, PUR lining, EN 15655, EN 15189, EN 545, full-protection pipes, internal diameter, polyurethane (PUR), wall thickness K 7 and K 9, PUR external protection, roughness coefficient, efficiency, energy conversion, pressure pipeline system, vonRoll ECOFIT fittings, full-protection epoxy resin coating,  EN 14901, RAL GZ 662, Gütegemeinschaft Schwerer Korrosionsschutz von Armaturen und Formstücken durch Pulverbeschichtung e. V. (GSK), PUR internal coating, manhole, overhaul work, double-socket tees with flanged 90° branches, final version, blank flange, baffle plate, rocky terrain, grain sizes, largest size, thrust protection, section, pressure stages, flow meter, volume of water, tightness, control opening, pressure losses, unpaved road, operating pressure, pipe joints, route, polyurethane coating, bedding pipes, steep face, rock, channel, steel frames, high pressure area, Fig. 2805, site, short pipes, weld beads, repairs, assembly, pipe installation, cableway, storage, helicopter, installation site, weight, helicopter transport, pipe assembly work, pressure pipeline system, pressure testing, water, months of construction delivery times, means of transport.

Hydroelectric power station in Nauders, Tyrol has gone into operation
By Roland Gruber

A small community in the tri-border area of Switzerland, Austria and Italy wanted to use its adequate supplies of water power and make a contribution to the production of renewable energy with a small hydroelectric power station.The topographical conditions were perfect, the planning was under way but it took 6 years of hard work to be able to put the commercial project into practice. In addition to the technical details, an experienced planning engineer also reports on the bureaucratic hurdles which need to be overcome with projects of this kind.

Keywords: Power station pipeline, DN 800, hydroelectric power station, district of Nauders, approval, Stiller Bach power station project, small hydroelectric power station, water catchment area, machine hall, pressure pipeline, ductile iron pipe, trial operation, normal year, electricity, three-border district, pipe store, design office of BERNHARD Ingenieure ZT GmbH – Hall in Tirol, route to be taken, power station plans, TIWAG (Tiroler Wasserkraft AG), feed water, topographical conditions, Labaunbach, flows into the Inn, sand trap, Reschenstraße (B 180), structure of the gallery, gallery, tunnel, turn, steep slope, gradient, bank of the Inn, pipeline route, rocky terrain, double-chamber sand trap, catchment structure, water quality, land, farmers’ cooperative of Nauders, hydroelectric power station operator, three-border region, requirements, volume of water used, subject of residual water, planning phase, readings, sewage treatment plant, pressure chamber, outflow from the sewage treatment plant, economy, water, environmental impact assessment, assessment procedure, official experts, riverbed extraction, Tyrolean intake, impoundment, joint-venture Inn power station, stretch of free-flowing water, environmental impact assessment obligation, planning permission, orders, site facilities, construction work, site, winter break, altitude, mountainous terrain, Reschen Pass, Finstermünz Pass, traffic, construction work , time frame, pipeline, Federal highway B 180, protection, rock fall, machine hall location, area of the route, hazard, geological construction supervision, hazard areas, rock fall protection measures, protective measures, cleft opening, dimensions, rock avalanche event of 2011, volume broken away, section of rock, electronic crack control equipment, optical and acoustic warning device, crack monitoring, accidents, damage, safety measures, ductile cast iron, PFA 25 bar, tendering process, pipe material, purpose, steel pipes, welding work, steel pipeline, flexibility, GRP, high operating pressures, substrate, bedding, capacity for movement, socket, angular deflection, fittings, installation, cement mortar lining, slope creep, geological conditions, special solution, geological, geotechnical, statics, fixed points, steep section, creep movements, longitudinal movements, expansion pieces, pipe manufacturer, socket at the top end, thrust resistance device, ground bearing vegetation, slope movements, slope creep pressures, pipe protection fleece, pipe joints, socket cones (socket protection sheets), VRS®-T/BLS® push-in joints, walking excavators (“spiders”), rope, truck, boom, assembly technique, storing materials, trench, pressure testing, hydraulic steel equipment, GMT Wintersteller GmbH, Kuchl district, hydraulic steel construction company, protection devices, screen, fine screen, steel pressure pipeline, DN 400, cement mortar, telescopic arm screen cleaning rig, cleaning range, steel cone, DN 1200, boring tool, electromechanical equipment, Troyer AG company from Sterzing, Pelton turbine, water flow rate, net head height, generator, HITZINGER GmbH – Linz, investment, single investment, return.

Trenchless replacement of a fire main using the burst lining technique
By Stephan Hobohm and Alexander Bauer

A fire extinguishing water system in an industrial port in which flammable liquids and gases are constantly being handled – a real challenge for any fire service! When extinguishing water pipelines in the nominal size range DN 300 to DN 500 need to be replaced while maintaining landside goods transport and the functional reliability of existing equipment, planning engineers and contractors are challenged to the extreme. The new pipes in ductile cast iron were installed under the severest constraints using the burst lining process. It’s worth a read – there is much to be learned!

Keywords: Burst lining, DN 300, DN 400, DN 500, trenchless replacement, fire extinguishing pipeline, BASF northern inland port, Ludwigshafen, transhipment point, combustible fluids, naphtha, methanol, gases, tankers, supply raw materials, goods transferred, harbour basin, control station, safety measures, pneumatic oil barriers, snake lines, quick-release system, in case of fire, foam-water extinguishers, steel pipelines, nominal sizes, water, leakages, piping system, safety requirements, burst lining process, TRACTO-TECHNIK, Lennestadt, constraints, security of supply, extinguishing equipment, works traffic, fire services, circulation areas, same route, working life, pressure stage, construction costs, planning, main pipelines, trenchless technique, traffic disruptions, hydrants, pipeline material, pipe cover, soil on site, non-cohesive, sand, operating pressure, excavations, section lengths, changes of direction, feeder branch lines, open trenches, fire extinguishing equipment, renewal possibilities, hydraulic performance, cross-section, ductile iron pipes, old pipeline, bursting head, upsizing stage, earth, dynamic and static processes, soil rocket, upsizing head, sewers, vitrified clay pipes, vibrations, fracturing ribs, pulling unit, overcut, DVGW Bulletin GW 323, requirements, tests, asbestos cement, grey cast iron, roller cutting heads, upsizing of nominal size, upsizing dimension, external diameter of the socket, minimum distances, parallel pipeline, crossing pipelines, EN 545, drinking water, restrained BLS® push-in joints, cement mortar coating, EN 15542, external protection, area of the joint, impurities, socket, spigot, rubber sleeve, shrink-on sleeve, protective cone, steel sheet, corrosion protection, sand bedding, length, TYTON® seal, lock, steel sheet cone, construction work, emergency water supply, the civil engineering work, Diringer & Scheidel GmbH & Co. KG – Mannheim branch, pipe pulling, machine pits, installation pits, Duktus Rohrsysteme Wetzlar GmbH – Wetzlar, internal diameter, external diameter, radius, upsizing dimension, upsizing, pipe length, working space, bursting equipment, front frame, safety loop, 250 tonne unit, 190 tonne unit, produced with corrugated sheeting, stability, difficulty of displacing soil, pull-in lengths, tractive forces thrust blocks, traction machine, in-situ concrete, reinforced concrete construction, GRUNDOBURST 190G, QuickLock bursting string, roller-knife, GrundoLog traction force measuring device, concrete thrust block, cable, data logger, wireless transmission, BASF SE – Ludwigshafen, dimensions, weight, permissible operating pressure (PFA), permissible traction, assembly times, pipe manufacturer, pipe string, bottom, DIN 28603, installation speeds, friction, machine technology, construction time, BLS® spigot, welded bead, flanged sockets, double socket tees with flanged branch, dismantling joints, leak tightness, system test pressure, branches, soil present on site, conventional laying, renovation, inliner, advantage, statics.

100 kilometres of ductile iron driven piles for the CSP power station – KaXu Solar One – in South Africa
By Erich Steinlechner

Desert regions with high and constant solar radiation can be a real torture for human existence, but they are predestined for the solar thermal generation of energy. The idea of a parabolic reflector in the equatorial sun-belt seems simple at first, but the actual implementation is complicated: gigantic reflector surfaces have to track the sun accurately to the degree, which means that they should not move under the severe influence of the winds which are always powerful here. The absolutely stable foundation of a parabolic reflector of this kind becomes a decisive factor and it is precisely here that ductile driven piles take the stage: more than 100 km of ductile piles are being driven for the first solar thermal power station between Pretoria and Johannesburg in order to stabilise some 10,000 m² of collector surface against winds of up to 140 km/h.

Keywords: Ductile iron driven piles, CSP power station (CSP = Concentrated Solar Power), KaXu Solar One, South Africa, parabolic mirror, pile system, Cape of Good Hope, Northern Cape region, Namibia, Kalahari Desert, output, energy supply, city of Johannesburg, city of Cape Town, ABENGOA company, Spain, Industrial Development Corporation (IDC), subsidiary ABEINSA EPC, Upington, supplier, Geopile company, piling points, stabilise, pile foundations, daily performance, pile lengths, construction site, area, total pile length, Austrian pile supplier, tests, test piles, random basis, “pulling” load case, own weight, position, wind speeds, East area, West area, wind breaks, height, wind flow, North-South area, earth mounds, length, break up, tolerances, total stations (electronic tachymeters), precision, DN 27 bolt, construction machines, sinking, cutting off, load bearing capacity, position, effectiveness deviation, production, requirements, deadline, solar radiation, solar thermal, reflectors, sun’s rays, receiver tube, heat transfer medium, thermal oil, water, energy, production, steam, heat, cold, electricity, steam turbine, solar thermal power station, potential, thermal energy, solar energy, fossil fuels, coal, coal deposits, sun, substation, end clients.

EADIPS®/FGR® member companies are training

The shortage of skilled workers is making itself felt in the construction industry. For this reason, EADIPS®/FGR® member companies are not only offering training in the narrower field of their own production, such as foundry mechanics. In fact they are extending their training activities into occupational areas in which their products should be properly processed, such as pipeline constructors for example. Naturally, these training courses are closely linked with the vocational promotion centre of the constructionindustry.

Keywords: EADIPS®/FGR®  member companies, training on offer, European Association for Ductile Iron Pipe Systems · EADIPS®, Fachgemeinschaft  Guss-Rohrsysteme (FGR®) e. V., pipes, fittings, ductile cast iron, valves, spheroidal graphite cast iron, taking on trainees, vocational fields, importance, production companies, electrical installation engineer, electronics engineer, electronics installation engineer, IT specialist, mould maker, foundry mechanic, industrial business manager, industrial mechanic, construction engineer, logician, mechanical engineer, machine and equipment operator, mechatronics engineer, polytechnician, production engineer, pipeline fitter, technical pattern maker, technical product designer, toolmaker, cutting machine operator, dual tertiary education, students, fields, engineering, industrial engineering, business administration, internships, technical college students, business, management, engineering, skilled personnel, pipeline construction, professional career, ductile iron pipe systems, plan, calculate, produce, install, company, training, website, www.eadips.org, E-book “Ductile iron pipe systems”, information, practical use, annual volume, newsletter “IRON PIPE SYSTEM NEWS”, logging on, Berufsförderungswerk der Bauindustrie NRW e. V., trainees, tasks, activities, individual parts, assembly, standard pipes, EN 545, EN 598, production, fitting of water pipelines, gas pipelines, oil pipelines, branch lines, shutoff devices, section of pipeline, tightness tests, types of corrosion protection, use in different soils, media, water, open and trenchless techniques, connections, installation and joining techniques specific to types of material, welding, screwing, bonding, site, excavation, pipe trench, stability, subsoil, secure, backfilling, earth, sinking, subsidence, civil engineering industry, pipeline construction, sewer construction, sewage disposal, hydraulic engineering, well production, employment opportunities, energy generation and distribution, oil, gas, energy supply, gas, water, district heating, at a glance, professional training legislation (BBiG), field, structural engineering, job training, specialisation, specific areas, specialist subjects, industrial operations, small businesses, construction and utility industry, civil engineering work, training qualification.