Trenchless technology such as the Primus Line Rehab offers significant cost and time savings in the rehabilitation of fire water mains.
Fire suppression systems are critical to the safety of public, residential and industrial buildings and must perform reliably in an emergency. Their failure can have serious consequences for people and the environment, so regular maintenance and repair is essential.
In the industrial sector, such as refineries, chemical plants or airports, functional fire-extinguishing systems are a prerequisite for operating licences. To maintain this, operators regularly test their fire water pipework. Any weak points or damage must be repaired to ensure that the pipes function properly in the event of a fire.
Technical challenges for operators
Fire water mains need to be checked regularly for leaks. Above-ground pipelines require flow and volume measurements, while underground pipelines are at risk of rupture during pressure testing.
Damaged, ageing or corroded pipelines often fail to withstand increased pressure, leading to further damage.
The use of seawater or salt water in firefighting can exacerbate corrosion, especially in steel or cast-iron pipes without a cement lining, rendering them unable to withstand operating pressures.
Accessibility is another challenge in industrial plants, where pipelines are often buried under roads, asphalt surfaces or concrete.
The presence of numerous other transport and utility lines adds to the complexity.
Traditional open trench methods using heavy equipment can be costly and disruptive due to the industry’s strict safety regulations and protocols.
Sudden damage repairs are expensive and usually offer only short-term solutions.
Operators also must consider permits, scheduling of repairs and the impact on operations. These factors complicate the maintenance and repair process, making efficient solutions crucial.
Trenchless systems preferred
Trenchless methods such as Primus Line Rehab offer a practical alternative. They require only small construction pits at the beginning and end of the rehabilitation section.
These pits can be created with minimal equipment, such as a pulling winch, reducing the need for large crews and heavy machinery. The insertion speed of up to ten metres per minute further minimises installation times.
In emergencies, quick rehabilitation is possible, especially when flexible pipes such as Primus Line Rehab are stored on site.
Regular maintenance can also be carried out within short-notice maintenance windows without external personnel, as Rädlinger Primus Line trains the operator’s maintenance staff for such tasks.
There are no follow-up costs after a Primus Line rehabilitation, as the product is designed for a service life of 50 years.
Its durability has been proven in various installations, such as at an Austrian airport where a refinery’s fire water pipework rehabilitated with Primus Line Rehab almost twenty years ago is still functioning perfectly.
Adaptability and safety
Primus Line Rehab is flexible enough to handle multiple bends within a single section, making it suitable for complex pipeline layouts.
Installation crews can adapt to site conditions, even when as-built plans are out-of-date or inspections with a camera prior to rehabilitation start are not permitted.
Safety is paramount for industrial operators, and Primus Line Rehab has undergone extensive fire resistance testing in the presence of independent testing companies.
When filled with fire water, the pipe remains functional even under direct heat, with only the outer layer showing scorch marks while the inner layer and reinforcing aramid fabric remain undamaged.
The bottom line
The benefits of trenchless systems such as
Primus Line Rehab are reflected in significant
cost reductions.
A study by a refinery operator found that trenchless rehabilitation cut the cost per metre in half and increased the number of metres rehabilitated per month by a factor of 10 to 15 in total.
Over 13 years, the operator had accumulated repair costs in the low tens of millions for numerous leaks.
Using Primus Line Rehab would reduce the rehabilitation period to five years, cut the investment by a third and eliminate follow-up costs.
Primus Line Rehab increases efficiency, lowers capital and operating costs and extends the service life of fire water mains, making it a compelling trenchless rehabilitation option.
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This feature also appears in the September edition of The Australian Pipeliner.