Ductile iron pipe systems for turbine penstocks. - TRMtrm.at/fileadmin/userdaten/dokumente/Downloads/Folder/TRM_Turbine...TRM – Tiroler Rohre GmbH Ductile iron pipe systems for turbine

Ductile iron pipe systems forturbine penstocks.

ductile iron technologieswww.trm.at

2 | Ductile iron pipe systems for turbine penstocks TRM – Tiroler Rohre GmbH TRM – Tiroler Rohre GmbH Ductile iron pipe systems for turbine penstocks | 3

„Planning, construction methods and the choiceof sustainable materials

are all esential for a moderate,reasonable and eco-friendly use of

hydropower.“

TRM – Tiroler Rohre GmbH Ductile iron pipe systems for turbine penstocks | 3

Turbine penstocks from TRM - a pillar for small hydro power plants

In Austria alone, around 2,800 small hydropower plants supply approx. 1.7m households with electric energy – that's more than half of all the country's households. Compared to the generation of electricity from fossil fuels, this saves around 4.1m tons of carbon emissions1. This means that small hydropower plants are going a long way to help achieve the EU's 20-20-20 targets.Planning, construction methods and the choice of sustainable materials are all esential for a moderate, reasonable and eco-friendly use of hydro power. Pipe systems made of ductile cast iron from TRM have been a key part of this for decades. Compared to other materials, ductile cast iron pipes from TRM offer much greater safety and reliability. This means that unexpected impacts during the lifetime of the plant, such as settlements,

land slides and ingrowth of vegetation are usually no threat to TRM pipes. This saves the operator downtimes and repair work. At the end of their life cycle, TRM ductile cast iron pipes can be fully recycled and this saves valuable raw material resources. Due to many years of experience and collaboration with strong industry partners, solutions from TRM also offer economic advantages. Any problems during project execution, especially liability matters, can be addressed by experienced staff with a strong local presence. TRM has now delivered a total of almost 1,000 kilometers of turbine pipelines, that's approximately the distance from Florence to Berlin. Working together with other main contractors, a small hydro power plant with TRM pipe systems can be set up for decades of reliable operation.

Decentralized energy supply is a cornerstone of current reforms in Energy supply("Energiewende"). Small hydropower plants – with a power of up to 10MW – arenot just a highly flexible method of power generation, but are also cheaper interms of production costs compared to all other alternatives.

1 Data according to: www.kleinwasserkraft.at (September 2014).

4 | Ductile iron pipe systems for turbine penstocks TRM – Tiroler Rohre GmbH

A pipe system is much more than just pipesand fittings. Comparing of different manufacturers, project owners value especially the ability to integrate turbine pipelines into the overall plant, as well as a smooth construction process.TRM staff work directly with customers, engineering and construction firms on site in order to resolve problems even before they occur. One can rely on our many years of experience in this industry and technical experts at our home office in Hall, Tyrol – during all phases of your project, from germits to commissioning. This creates the real economic benefit that goes beyond euros per meter.If necessary, we will take care of theboundary conditions, co-ordinate work withother contractors and include all pipelinecomponents.

This service is becoming increasingly important for customers, especially when talking about liability issues:After all, who solves problemswhen the worst comes to the worst, forinstance, in an environmental disaster, suchas earthquakes and landslides? Who is responsible for the reliability of the overall pipe system if many single components are bought from various traders instead of from an OEM? Do project owners have the professionalism and strength necessary to enforce claims for damages against a major foreign corporation? Power plant operators are considering this today in their purcharing deasious and are opting for real solutions – made by TRM, made in Austria.

TRM pipe systems fully integrated into the plant

„TRM connects theturbine penstocks to other equipment and

components.“

engineering turbine electrical systems

constructionwork

TRMpipe systems

hydraulic steelstructures

TRM – Tiroler Rohre GmbH Ductile iron pipe systems for turbine penstocks | 76 | Ductile iron pipe systems for turbine penstocks TRM – Tiroler Rohre GmbH

Turbine penstocks from TRM – fully integrated into the plant

Inlet coneInflow opening into the ductile cast iron pipe.

Wall flangeplaced in the

retaining wall.

Shut-off valveprevents damage to the ductile cast iron

pipe when operations are disrupted.

Venting valveensures that the ductile cast iron pipe is filled and that

trapped air can escape. This also prevents negativeinternal pressure when the cast iron pipe is drained.

Flange pipeA cast iron component with a flange at both ends.

This can be used to create a restrained joint forspecial parts.

Manholeprovides an entry

opening into the duc-tile cast iron pipe. This

allows pipe inspections and repair work.

F piecepipe fitting with

flange and spigot.Used as a connector

piece between flange and socket

components.

MK fittingBend with socket and

spigot. Different angles are available.

Fixing point made of reinforced concreteused to absorb forces

caused by internal pressure.

Expansion - jointto absorb slope

movements.The insert length of the

lower socket islonger than usual. The

spigot inserted canmove in the fitting and

hence absorb slopemovements.

TRM – Tiroler Rohre GmbH Ductile iron pipe systems for turbine penstocks | 76 | Ductile iron pipe systems for turbine penstocks TRM – Tiroler Rohre GmbH

MMK fittingBend with two

sockets. Differentangles are available.

Pipe supportto provide a stable

base for ductile cast iron pipes.

EU fittingwith flange and socket. Used to connect flange

fittings with a spigot of the pipe.

Drain valveEnables safe

drainingof penstocks.

FFR fittingNominal width reduction with a

flange at both ends or a transitionpiece made of steel.

TurbineHydraulic energy is

converted to mechanical energy and ultimately to

electricity.

Adapter and expansion pieceUsed to compensate

for building tolerances when ductile cast iron pipes are

fitted and to enable easier dismantling of pipe parts in case of maintenauce.


Ductile means formable. The endurance test shows the mechanical capabilitiesand reserves that are unique to cast iron – the top choice for turbine penstocks.This means additional safety and reliability even in extreme situations, such aslandslides, settlements and earthquakes.

VRS®-T / BLS® connection and the mechanicalproperties of the material are the top choice forturbine penstocks

At full power!

Ductile means formable. Simple. Fast. Restrained. Safe.

retaining chamber

lock

weld bead

VRS®-T / TYTON® gasket

SOCKET

In order to ensure that these safety reserves aremet by the entire pipe system, operators rely onthe restrained VRS®-T / BLS® joint. In this way, individual pipes are connected to form one sys-tem – without the need for time-consuming wel-ding, testing, later surface treatment or keeping pipe trenches open.This simple laying not only saves constructiontime, but in most cases it also can be carried out by theconstruction company itself.Due to the tensile forces absorbed by theconnection, concrete thrust blocks are no longerneeded at bends or to absorb downhill forces.Detailed information for planning can be foundin our ductile cast iron pipe systems manual that can be downloaded at: www.trm.at.

TRM offers a consistent system from DN 80 toDN 1000 along with an extensive range of fit-tings and accessories.

This also includes special products which areoften needed for the transition to existingpipes or to connect to turbines.Our local sales staff and engineering team will be pleased to advise you during all phases of your project in order to develop a customized, economically efficient solution.

Special component - MMA DN 1000


System pressures (penstock and special fitting) up to DN 1000 with restrained joint VRS®-T /BLS®

For pipes with non-restrained TYTON®joint, the following maximum pressures are possible. In this case, the pipe system must be secured using concrete thrust blocks.

DN PFA [bar] Connection Max. deflection [°] Lock perm. tensile

force[kN]

80 100 VRS®-T 5° 2 locks + catch 115

100 100 VRS®-T 5° 2 locks + catch 150

125 100 VRS®-T 5° 2 locks + catch 225

150 100 VRS®-T 5° 2 locks + catch 240

200 100 VRS®-T 4° 2 locks + HD lock + catch 350

250 100 VRS®-T 4° 2 locks + HD lock + catch 375

300 85 VRS®-T 4° 4 locks + 2 catches 380



600 40 BLS® 2° 9 segments 1525

700 25 BLS® 1,5° 10 segments 1650

800 25 BLS® 1,5° 10 segments 1460

900 25 BLS® 1,5° 13 segments 1845

1000 25 BLS® 1,5° 14 segments 1560

Higher pressures available on request!

DN 80 100 125 150 200 250 300 400 500 600 700 800 900 1000

PFA [bar] 205 177 178 155 138 127 100 98 82 70 76 68 48 38

Deflection [°] 5 5 5 5 5 5 5 4 3 3 3 3 3 3

Higher pressures available on request!

TRM solutions create value by integrating individual components!

T R M - S o l u T i o n S

Thanks to good cooperations with experts in steel construction, TRM is in a position to offer holistic solutions for turbine penstocks. The parts are individually designed and produced. This ensures a perfect integration and the on-time delivery of the envire pipe system.

understand produce integrate complete


The right coating Protecting the mechanical advantagesof the ductile cast iron pipeDuctile cast iron pipes are supplied with internal and external coating. The rightcoating maintains the superior mechanical properties for decades.

The most important influences when choosing the right coating are:

•transportedfluid •soilandgroundwatercorrosiveness •grainsizeofthebeddingmaterial •temperatureofthefluid •ambienttemperature •installationmethod •influenceofelectricitycurrents

i n T E R n A l C E M E n T l i n i n G

C E ME n T M o R TA R C o AT i n G ( Z M u )

C A S T I R O N P I P E


Different cement mortar linings are available for the internal coating depending on the fluid, for instance, for particularly soft or acidic water. The following options are available for the external coating:

Zinc coating with PUR or epoxy cover coating.TRM ductile cast iron pipes are normally supplied with a zinc coating of 200g/m2 and PUR orepoxy cover coating.

Irrespective of the cover coating of the pipe, fittings are sand-blasted and have an epoxy powdercoating. This means that they can be used in soils of any degree of corrosiveness.Detailed information on all cover coatings and their areas of application can be found in the TRMmanual for ductile cast iron pipe systems. Please also contact our sales staff.

ZMU cement mortar coating. PREMIUM protection for the premiums pipe.ZMU, the most robust outer coating, protects:• against mechanical forces, for instance during transport, under rough installation conditions

and when using coarse bedding materials.• against chemical attack, for instance from acidic soil.

That's why ZMU pipes provide best value:• Long-term corrosion protection and hence a long working life (according to DVGB up

to 140 years).• No soil replacement or additional pipe bedding required: excavated material can be reused.

No delivery of bedding material required.• Saves time and money because there is no need to remove and store excavated material.

ZMU. Premium protection for a premium pipe.

cast wall

zinc coating

annealing skin

local damage

precipitation of zinc salts

(self-healing effect)

PUR coating (open pores)

zinc ions Zn++

cathode (small area)

anodes (large area)

The protective effect of the zinc coating with cover hasbeen tried and tested on ductile cast iron pipes and avoids theneed for additional cathodic protection for the pipe.

This protection results from:•theelectrochemicaleffectofthezinc•thereductionofpost-diffusionoftheattacking

medium due to the inert zinc reaction products that are formed

•theanti-bacterialeffectofzincsalts


from TRM.

For more than 50 years, ductile cast iron pipe systems from TRM have been used in alpine regious. They became an integral component of the expansion of small hydropower plants and part of a true success story. More than 1,000 kilometers of pipes have now been installed which is approximately the distance from Florence toBerlin. Ductile cast iron pipes are now the material of choice, especially in difficult terrain. They provide safety, simple installation and unparalleled working life.

It is not just the outstanding material properties that make TRM ductile cast iron pipes the pipe of choice for turbine pipelines, but also the unique connection system: The socket joint enables fast and secure fitting. Numerous types of fittings and bends are available. Moreover, larger pipeline radiuses are easily possible thanks to the deflection capability in the socket joints. One huge advantage here is that the connection system permits the so-called "open-close laying method". This means that the construction team opens the trench for just one pipe and then closes it immediately, so that pipes can be laid even under bad weather conditions and narrow spaces. From an ecological perspective, this method of laying also has advantages because the top soil can be quickly restored which ensures fast recultivation.

Economic efficiency winsIn 2011, a sensational project was implemented at the foot of the Passo dello Stelvio. What was exciting about installing the penstock for Rio Furcla power station, however, was not just the pipe dimension of DN 400 but even more so the spectacular laying work in the high alpine terrain at gradients of up to 65°. The many changes

in direction along the 1.2-kilometer pipeline were largely mastered by the deflection capability in the sockets joints.In Styria, and specifically in Gaal in the Niedere Tauern mountains, an approximately 4-km long penstock, DN500, made of TRM ductile cast iron pipes, was laid in 2012 for Vorwitzbach power plant. The entire pipeline was installed without fixed points.In the case of Strickeralmbach power plant which was commissioned in 2012, the outer coating was particularly important. Around 350 meters of the 1.7-km long DN 500 penstock was fitted with pipes with a cement mortar coating in order to ensure maximum protection against the acidic soil.Kanzingbach hydropower plant is one of thebiggest projects in Northern Tyrol in 2014. Since this DN 600 project involves particularly soft water, the operators opted for a pipe lining made of alumina cement. Moreover, TRM was the only manufacturer able to meet the customer's special project requirements in terms of the material´s fracturing characteristics.Easy laying, outstanding safety in turbineoperations and maximum working life. Thesethree points say it all when it comes to ductile cast iron pipes made in Hall, and can besummed up in three letters: TRM.

Key element of small hydropower plants siner decades2.

Turbine pipelines

2 According to ZEK Hydro 04/2014 with amendments and new projects by TRM.


„Rio Furcla power plant –outstanding adaptability of the

pipeline system with VRS®-T connectionin high alpine terrain.“


References

Puni hydropower plant


TWKW Trieben/Steiermark, Trieben:

TWKW Hölln/Salzburg, Bischofshofen:

TWKW St.Johann/Salzburg, St.Johann/Pongau:

TWKW Stainach/Steiermark, Stainach:

KW Nötschbachquelle/Kärnten, Bad Bleiberg:

TWKW Köflach/Steiermark, Köflach:

TWKW Wölfernquelle/Salzburg, Bruck/Zell am See:

KW Mooserbach/Kärnten, Maria Luggau:

KW Mattlinggraben/Kärnten, Lesachtal:

KW Brandgraben/Salzburg, Maria Pfarr:

KW Cadipietra/South Tyrol, Steinbach am Brenner

KW Dorfergraben/Salzburg, Zederhaus:

TWKW Marbachquelle/Salzburg, Flachau:

KW Lobnigbach/Kärnten, Eisenkappel:

KW Mühlbach/Salzburg, Lessach:

KW Großer Gößbach/Steiermark, Leoben:

KW Reichensteinquelle/Steiermark, Eisenerz:

KW Rite 1 / Italy, Belluno:

KW Kanzingbach/Tyrol, Flaurling:

KW Uttendorf/Salzburg, Uttendorf ÖBB:

KW Siflitzbach/Kärnten, Kleblach Lind:

KW Rite 2 / Italy, Belluno:

KW Gosalda / Italy, Belluno:

KW Unterberg / South Tyrol, Sarentino:

KW Niedergail/Kärnten, Lesachtal:

KW Dorferbach/Tyrol, Prägraten:

KW Rio Puni / South Tyrol, Val Venosta:

KW Monno / Italy, Brescia:

KW Calamento / Italy, Trient :

KW Spinelle / Italy, Trento:

KW Tröpolach/Kärnten, Kelag:

KW Rosenbach/Kärnten, Rosenbach ÖBB:

KW Finsing/Tyrol, Finsing:

DN 150 – PN 50 bar

DN 200 – PN 20 bar

DN 200 – PN 17 bar

DN 200 – PN 40 bar

DN 250 – PN 26 bar

DN 250 – PN 40 bar

DN 300 – PN 8.5 bar

DN 300 – PN 14 bar

DN 300 – PN 26 bar

DN 300 – PN 28 bar

DN 300 – PN 63 bar

DN 400 – PN 22 bar

DN 400 – PN 8 bar

DN 400 – PN 20 bar

DN 400 – PN 27,5 bar

DN 500 – PN 40 bar

DN 500 – PN 50 bar

DN 500 – PN 30 bar

DN 600 – PN 54 bar

DN 600 – PN 20 bar

DN 600 – PN 22 bar

DN 600 – PN 20 bar

DN 600 – PN 50 bar

DN 700 – PN 6 bar

DN 800 – PN 77 bar

DN 800 – PN 25 bar

DN 800 – PN 28 bar

DN 900 – PN 16 bar

DN 900 – PN 32 bar

DN 1000 – PN 26 bar

DN 1000 – PN 8 bar

DN 1000 – PN 25 barKanzingbach hydropower plant

Finsing hydropower plant

Val Senales hydropower plant

Vorwitzbach hydropower plant

Calamento hydropower plant

DN 600 | 500 | 300 – PN 32 bar

TRM is a full member of EADIPS®/FGR® www.eadips.org

Date:10/2014•Im

ages:istock,TirolerRohre,ZEK

Tiroler Rohre GmbH develops, produces and markets high quality systems for transporting water and for deep foundations of structures – made of ductile cast iron.

The durable properties of the material, innovative product technologies and a proven track record in the applications of our customers make us the leading provider of water and foundation engineering solutions.

Our products and servicesOur products are efficient, durable and robust. They are known especially for their ecological and economic benefits. Thanks to the properties of ductile cast iron and our expertise in the areas where our products are used, we are able to overcome extreme challenges. We are known for our skill, network of industry partners and reliability. Thanks to their long service life and the careful use of resources, our products and services help to protect precious water resources.

ContactTIROLER ROHRE GMBH

Innsbrucker Strasse 51 6060 Hall in Tirol Austria T +43 5223 503 0 F +43 5223 43619 E [email protected] www.trm.at

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Ductile iron pipe systems for turbine penstocks. - TRMtrm.at/fileadmin/userdaten/dokumente/Downloads/Folder/TRM_Turbine...TRM – Tiroler Rohre GmbH Ductile iron pipe systems for turbine