CIPP RELINING FOR

HIGH PRESSURE PIPE

 Abstract

During the 1980s Japanese gas companies decided, in view of the

frequent earthquakes in their country, to use the CIPP concept to secure
their pipeline networks.
In 1984 Norditube, a CPT company, produced Tubetex, an interactive
CIPP liner for the lining of partially deteriorated low pressure gas mains or
for medium pressure water mains. Over 20 years of experience and more
than 2,600 kilometres installed confirms the long term durability of lining
with this product.
To meet the new requirements of water authorities, who wish to create
a new pipe within an old one, CPT has developed two new liners for the
pressure pipe relining market:
An interactive liner, used mainly for medium pressure gas mains (up to
PN 32), and
An independent liner, used mainly for high pressure water mains
(between PN 20 and 60).
This paper describes in detail the design, present stage of development
and main testing conducted on the independent liner for high pressure
water mains Nordipipe.
It also presents three projects, highlighting the application of the
 Introduction

The use of Cured In Place Pipe (CIPP) for the rehabilitation of pressures
mains has been employed since the 1980s. During this period Japanese gas
companies decided, in view of the frequent earthquakes in their country, to
use the CIPP concept to secure their pipeline networks.
In 1984 Norditube, a CPT company, developed TUBETEX, an
interactive CIPP liner for the lining of partially deteriorated low pressure gas
mains or for medium pressure water mains. Since this development more
than 2,600 kilometres have been installed over 20 years, confirming the
long term durability of lining with this product.
To meet the new requirements of authorities, who wish to create a New
pipe within an old one, CPT has developed two new liners for the pressure
pipe relining market:
An interactive liner, used mainly for medium pressure gas mains (up to
PN 32), and
An independent liner, used mainly for high pressure water mains
(between PN 20 and 60).
It is becoming increasingly common that the rehabilitation of high
pressure pipelines is being sought after, rather than going through the
expense and inconvenience of replacement.
 CIPP relining for high pressure pipe

Since 1980 diverse interactive CIPP liners were developed for the
rehabilitation of pressure pipe:
For low pressure gas main (100 mbar)
For medium pressure gas main (6 bar with extension to 32 bar in
Germany)
For water medium pressure pipe (7bar)
2600 kilometres installed at the end of 2005 confirms the long term
durability of this CIPP rehabilitation system.
Due to technical evolution, at the present time, 2 types of CIPP liners
are available on the market.
The Interactive solution, mainly used for the rehabilitation of high
pressure gas main (up to 32 bar), transfer the internal pressure to the
existing pipe and do not withstanding the total external load (like TUBETEX
supplied by Norditube a CPT company)
The Independent solution, mainly used for the rehabilitation of water
pressure pipe (up to 60 bar), withstanding the total internal and external
load without considering the host pipe (like Nordipipe - supplied by
Norditube a CPT company)
 Products - Design

The Nordipipe independent liner for high

pressure mains is based on a stable and
strong composite material. Made of several
polyester needle felt layers and an external
coated protective tight layer, it is reinforced
with Bi-axial fiberglass yarn. This product is
assembled in circular position (see Figures 1
and 2)
This means that as long as the
thermosetting resin remains uncured, the Figure 1: Liner Structure
liner is flexible and can expand to reach the
host pipe's section under the eversion
pressure. Due to its elasticity, this liner
Once the liner is in position and the resin cured it imposes a completely
follows the host pipe more closely in the
fixed structure in which the previous sliding layers are firmly bound together,
curves and bends ensuring fewer wrinkles.
enabling the composite to withstand external and high internal pressures.
 CIPP relining for high pressure pipe
Obviously, a hard and stiff resin with the highest possible E modulus
has to be selected for this purpose, with the ability to be accepted for
drinkable water pipe rehabilitation when necessary.

Figure 2: Liner Design Figure 3: Patented Fiberglass

Design
The patented fibreglass design is based on a bi-axial oriented
structure. See Figure 3.
Production Range and Technical Data

Available diameter: from 115 to 1100 mm

Available thickness: from 5.5 mm to 23 mm
Maximum length: Up to 1000 m dependent of thickness and diameter
 Installation
After cleaning and CCTV inspection, the liner produced in the Norditube
factory is delivered to the job site or to the impregnation plant.
Due to using epoxy resin, the impregnation is usually made on the job
site.
The method consists in inserting a flexible (water or gas-tight) hose
liner impregnated with a two-component epoxy resin into the damaged pipe.
The eversion is done with a water column or with compressed air at a
controlled speed. Special equipment is required for air eversion to achieve
perfect contact between the sleeve/resin system and the wall of the pipe
(see Figures 4 and 5).

Figure 4: Eversion and Figure 5: Eversion and heating by water

heating by air
 Testing
Based on high-modulus glass fibre, the main characteristics and the
performance of the Nordipipe are considerably higher than all other liners.
For example:
Internal pressure resistance (Short time burst test, see Figure 6)
Diameter 200 mm 81 bar
Diameter 400 mm 41 bar

Figure 6: Burst test

Breaking extension: less than 0.38% - no transfer of pressure to the

host pipe
E modulus based on 3 point bending test between 3800 and 4200
MPa
Vacuum resistance
External pressure resistance, depending from the wall thickness.
Thinner liner and lower polyester or epoxy resin consumption
Long term creep test. Ring bending test. See 100 000 hours result (see
 Testing (continue)

Figure 7: Creep test

Figure 8: Nominal Pressure

Nominal pressure
resistance following burst
pressure test (see Figure
8)
 Approvals
In case of drinking water pipe rehabilitation, this type of liner complies with
the requirements of the main Water Authorities.
At present for example:
Canada (Qubec) BNQ agreement
UK Water Regulation Advisor Scheme (WRAS) test of effect on water
quality BS 6920
Hong Kong BS 6920
Austria Austereiche Hygiene Institut
 Case Studies
This paper present three project highlight the application of the technology throughout
the diverse environments of Asia, Europe and North America
Hong Kong
Completed January 2005
Contractor CPR
Duration 2 week
Length and Diameter 600m of 600 mm diameter, in 3 sections
Service Pressure 15 bar
Test Pressure 22 bar
For this job site, the cleaning was made by water high pressure jet (1000 bar), the
impregnation of epoxy resin on site, the liner eversion by air and the curing by steam.
The pipe end finishing where made in this case with rubber gasket bounded with
Stainless steel strips. The reason of this type of finishing is to protect the edges of the
installed liner in case of mounting or dismounting, and prevent water flow between pipe
and liner after curing.
Vienna (Austria)
Completed 2005
Contractor Rabmer
Length and Diameter 3000m of 250mm diameter, in -160m sections
3300m of 200mm diameter, in -160m sections
Service Pressure 16 bar
Test Pressure 24 bar
This presentation shows the main step over:
On site epoxy resin impregnation
Air eversion and crossing through 45 bend
Pipe end finishing with steel bend without rubber Pressure test up to 24 bar
House connection directly fit on the cured liner
 Case Studies (continue)

Gatinau (Quebec)
Completed October 2005
Contractor Aqua Rehab
Length and Diameter 300m of 250mm diameter (140m and 160m
sections)
Service Pressure 15 bar
Test Pressure 22 bar
This presentation shows:
On site epoxy resin impregnation
Air eversion
Liner introduction, eversion and curing condition
 Conclusions

Based on more than 20 years of experience, CIPP pressure pipe

rehabilitation is the best solution to extend life of your pipes.
Perfectly tailored to water distribution and high pressure gas mains,
this system offers a fast, economic and non disruptive solution against
replacement.