CarboSeal® References

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2023

Södertörns Fjärrvärme AB

Tullinge, Sweden

Swedish energy company SFAB which operates the district heating network in Tullinge, Stockholm, planned to rehabilitate a section of a DN 250 pipe in their heating network. The traditional excavation method was considered too time-consuming and expensive, as road suspensions, welding, and digging would all add to the cost.

The pipe section ran underneath one of the municipality’s busiest roads, so a solution involving excavation would have had a significant impact on traffic, including a large number of blue-light rescue vehicles using the road on a daily basis.

The rehabilitation using CarboSeal® only took four days, and the heating system was recommissioned in the same week.

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2023

Pražská Teplárenská

Prague, Czech Republic

In November 2022, the primary district heating pipe on Zálesí Street in the southeastern part of Prague suffered a severe DN 500 pipe burst, leading to disruptions in the heating service for PTAS’s customers. Since the leakage occurred, most of the affected section of the pipe was replaced using traditional excavation methods. However, one section running underneath the main road was not replaced, as doing so would have rendered the road non-operational during the replacement process. This is when PTAS reached out to CarboSeal®. A CarboSeal® liner was installed through two smaller trenches on either side of the road, with one pit being five meters deep. This was done without affecting traffic during the rehabilitation.

The installation was carried out during a short planned energy distribution stop over the weekend, and the pipe was back in service the following working day. This approach circumvented the need to activate a reserve heating plant, which would have incurred costs exceeding 100,000€ per day.

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2023

Sundvalls Energi

Sundsvall, Sweden

The Swedish district heating network owner Sundsvall Energi, which operates the city of Sundsvall’s network, discovered a leak in one of the district heating pipes running underneath a road in the middle of a residential area.

The rehabilitation of two pipes, each being just over 100 m in length, took a total of four days. During this time, only negligible disruptions hindered the accessibility of residential parking lots and roads to the buildings.

Following an approved leakage test using air, the pipes were recommissioned and back in by the following workday.

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2022

RWE

Aachen, Germany

Large amounts of hot water escaped from a leak in RWE’s main district heating line under the A44 in Aachen! In order to get this accident under control, tankers commuted day and night in a two-shift shuttle service between the Aachener Kreuz and the power plant in Weisweiler. What a hassle!

In the course of coping with this accident, PPR Deutschland was able to support by installing the district heating liner CarboSeal® into a 128 meter long pipeline in DN 500 under the motorway. After brief consultation with Fischer Teamplan Ingenieurbüro GmbH and RWE, they were able to start installation just five weeks after the order was placed. They received valuable support from the companies Quabus GmbH, BKP Berolina Polyester GmbH & Co. KG, KURT Kanal- und Rohrtechnik GmbH and PPR Sweden AB.

RWE was the first company in Germany to use a CarboSeal® liner of this dimension and length in a district heating main. It once again underscores its innovation and openness to new solutions.

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2022

E.ON

Örebro, Sweden

E.ON Örebro discovered a leaking district heating pipeline section under the railroad, close to the Örebro station. The pipes were emptied of water and inspected via video. CarboSeal liners were installed in the feed and return pipes over four days without any effect on the rail bound traffic during the rehabilitation. The work was conducted via two minimal excavation pits, one on each side of the railroad.

Even though the video inspection showed that the pipes had several smaller dimension changes of approximately 10 mm, the CarboSeal liners were easily adaptable.

Steered drilling was considered as an alternative repair method for the project. However, the need for large support structures/barricades in connection with massive excavation pits, together with the substantial requirements for ground level measurements prior to, during and after the completed work, made this alternative complex and expensive. The alternative solution would also have cost three times as much as the relining work using CarboSeal.

Sveriges Radio report (Swedish)

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2022

KELAG Energie & Wärme

Pinkafeld, Austria

In the city of Pinkafeld, Austria, local network owner Kelag Energie & Wärme conducted a renewal of the district heating network upon identifying multiple leaks. One DN 100 section of the pipe system passed under a railroad track and was difficult to excavate without disturbing the rail traffic. Quabus and PPR Deutschland installed CarboSeal liners in both the feed and the return and cured both at the same time.

Both rail and road traffic remained unaffected during the pipe renovation period, and the pipe was ready to be recommissioned after four days.

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2022

Vilniaus šilumos tinklai

Vilnius, Lithuania

Vilniaus šilumos tinklai, a company operating the city district heating system in Vilnius, Lithuania, faced a challenge: a DN 500 pipe system embedded in a concrete bridge structure needed renovation. This heavily used bridge contained six traffic lanes, including several electrical trolleybus lines and sidewalks for pedestrians and cyclists. It spanned a 10-track railway yard heading in and out from the city’s central station.The pipes were built into the bridge structure, due to which legislation banned all interventions of the bridge while it was in use. Therefore, if the pipe system had been renewed using traditional replacement methods, city traffic would have been severely affected, and complex and costly alternative rerouting options would have been needed.

Rehabilitation of the pipe system was carried out using CarboSeal DN 500 in September 2022. The liner was introduced to the pipes though a four metre deep chamber with a manhole entrance from the sidewalk. The sidewalk was slightly narrowed down but kept continuously open for pedestriansand cyclists. The vehicle lanes were completely unaffected during the installation.

The installation of CarboSeal took two days, and the entire operation took five days. The Lithuanian company Poli conducted the installation with the help of PPR personnel on-site.

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2022

Veolia UK

Sheffield, UK

In the city centre of Sheffield, UK, a 42 m long DN 400 pipe section needed repair. A traditional excavation solution was not possible because the pipes ran below a street with heavy traffic load, including several bus lines.

The pipes were reached though chambers on each side of the road. One chamber had a depth of ca. 4 m. This did not give rise to any extra issues during the installation and proved that CarboSeal could be installed through such access points.

The recognized benefits from the installation company and network owner were:

Minimal Excavation.
No excessive welding/weak spots in the pipeline.
Public Sector benefits i.e. no road closures or disruption.
Design life in excess of steel pipes.
Saving on this scheme of approx. £120,000 based on alternative methods.
Lining activity can be undertaken in 1 day. Civils element dramatically reduced.
The liner can withstand pressures up to 24bar.
The system can be operational 2 days after the lining works has been completed (depending on site conditions/extent of renewal works).

The UK Distrcit Energy Association awarded this project as “Innovation of the Year 2023”.

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2022

Korea District Heating Corp.

Yongin, South Korea

The South Korean district heating company KDHC installed a 30 m long DN 200 CarboSeal® liner in the district heating system of Yongin City. The installation was done by the Korean company Litech and supervised by PPR on-site. The relined pipe section was recommissioned the day after the installation was completed. All in all, the installation took five days.

KDHC saw CarboSeal® as a method of prolonging the life of the district heating network and minimising the risk of sudden ruptures and leaks, which could potentially result in dangerous situations depending on the location of the pipe.

CarboSeal® can be transported to any country and is a solution for district heating pipes worldwide, as demonstrated by the installation in South Korea. PPR has full knowledge of how the liner needs to be shipped and stored according to the necessary handling and installation parameters and is thus able to facilitate simple and smooth installations.

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2022

AGFW e.V.

Neumünster, Germany

PPR got the opportunity to install a CarboSeal liner in an above ground DN 200 test pipe in Neumünster, Germany. The testing site was prepared by AGFW and their project partners, and it was connected to the Neumünster district heating network. The pipe section was closed off and drained during the installation process.

A prechosen 40 m long straight section of the DN 200 test pipe was equipped with three 12 mm diameter holes and multiple slits, both axially and radially, to represent defects in the steel pipe. CarboSeal® was installed without any issues, and the pipe section was reconnected to the district heating network once the end seals were in place and the pipe access openings were closed.

After almost a year of trial runs under real conditions, the test track in Neumünster, in which a 40-meter-long CarboSeal by PPR liner was installed in March 2022, was opened. During the subsequent inspection of the pipe section, no changes or abnormalities could be found either in the condition of the liner or in other parameters relating to the installation.

The relined section will be in operation in the district heating network for an undefined period of time.

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2021

E.ON

Malmö, Sweden

In Malmö, Sweden, energy company E.ON operates a district heating system in the area around Södra Grängesbergsgatan. The pipe system had previously undergone rehabilitation, and the trenchless method of controlled drilling had been chosen to minimize the impact on the traffic-intense intersection. However, the new pipe, a PE foam-insulated twin pipe holding two DN 100 district heating pipes, had sustained damage in the section joints of the polymer jacket. Thus, groundwater had been degrading the pipes, causing leakage. E.ON was forced to stop using the pipe for five years. Installing a CarboSeal liner would allow the company to recommission it.

The steered drilling process had positioned the twin pipe in an arc shape with a ca 5-m vertical deviation between the lowest and highest points, with the lowest point located about halfway into the section. As steam condensates during the steam-curing cycle, water naturally accumulates at the lowest point. This water must be removed continuously during the curing process so that the curing is not affected. During the manufacture of the liner, a thin draw wire was placed inside the liner, which allowed the condensate hose to be pulled into the low point, 25 m into the liner from the exit, without causing damage.

The AMEX type 10 end seals, which are normally used together with CarboSeal, have a minimum diameter of DN 150. Thus, they were too large for the DN 100 pipes. In collaboration with the end seal manufacturer, AMEX Sanivar, a new, narrower end seal was developed. To test and verify this product, a small test rig was made to cure the DN 100 liner and subsequently test the new type of end seal.

Following successful testing and verification of the DN 100 liner and end seal, the actual installation was planned. During four days in November 2021, the feed and return in the twin pipe were cured at the same time without disturbing the intersection traffic above. The pipes were pressure-tested, and the pipe section was recommissioned by the network owner.

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2021

E.ON

Sundbyberg, Sweden

Energy network owner Norrenergi operated a district heating network in Sundbyberg, north of Stockholm, Sweden. The network pipes were ageing and needed repair. As the system capacity exceeded the existing energy consumption, diameter reduction was implemented when installing new pipes. This reduced the pipes from DN 400 to DN 300 in most of the system.

One section running under Rissneleden, a main road to Sundbyberg, had not been replaced, as an excavation would have significantly impacted traffic. Trenchless rehabilitation using CarboSeal® was proposed, but it came with a few challenges. Because of the dimension changes and the fact that an inaccessible compensator chamber was located several metres below the roadway, a unique solutionwas required. Additionally, there wasa 12°bend in relation to the chamber exit.

PPR came up with a solution to cure a DN 300 CarboSeal liner inside a full-length DN 300 dimensioned burst bag and proposed it to Norrenergi and project coordinator Fjärrvärmeprojekt Sverige AB. The DN 300 liner was naturally to be laying at the bottom of the old DN 400 pipe. Burst bag versions were developed and tested to verify that they would endure the installation process, and an aramid burst bag was chosen. A test rig was constructed off-site to mimic the dimension changes, the bend and the free-standing liner setup. Installation trials in the test rig verified the solution, and the actual installation was planned.

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