March | April 2012 PipeLine · 2012-03-16 · keep weather-dependent lamination on site to a minimum HOBAS opted for just-in-time deliveries of prefabricated pipe spools. The 10 to

h Industrial Pipe Systems 1 | Escondida Copper Mine in Chile Equipped with h Pipes

3 | h CC-GRP Cooling Water Pipes Employed for CCPP in Germany

5 | h Industrial Pipe Systems - an Adequate Solution to Every Requirement

6 | h Industry Products for Special Applications

8 | h Social Media Presentation | Info

PipeLine

E Engineering GmbH | Pischeldorfer Str. 128 | 9020 Klagenfurt | Austria

T +43.463.48 24 24 | F +43.463.48 21 21 | [email protected] | www.hobas.com

Taking the h Motto “Make things happen” at Face Value - Escondida Copper Mine in Chile Equipped with h Pipes

Beginning of December 2011, 18 workers from HOBAS Kunststofftechnik installed roughly 800 meters of HOBAS GRP Pipe with CPVC liner in the world’s biggest copper mine. The line has been completed within four days only and under extremely challenging working conditions in the

Chilean Atacama desert 3200 m above sea level.

3200 meters above sea level in the middle of the Chilean Atacama desert lies Minera Escondida, the world’s biggest copper mine.

Atacama is the driest desert as well as one of the regions with the most mineral reserves around the world. It makes Chile the richest country for copper on earth, with almost a quarter of the global reserves. This is why Chile is also the interna- tionally leading copper producer – 5.42 million tons in 2010. As the copper prices multiplied by four and due to Asia’s great demand it seems that copper mining in Chile will be profitable also in the future.

Copper is won by various methods. One of those applied at Minera Escondida is the oxide method in which large areas of crushed rocks are treated with sulfuric acid. Pipes then trans-port the extracted copper sulfate to electrolysis that produces plates of pure copper. A total of one million tons of rock are

daily moved and 20,000 people work at the mine. This and the long distances that need to be overcome over the vast terrain

pose great challenges to logistics.

Material ChoiceThe medium, a high concentration of sulfuric acid and other chemi-

cals at temperatures around 50°C and above, makes high demands on the piping material. The client had initially filed a tender for pure CPVC-

Schedule-80 pipes. However, 600 mm in diameter CPVC pipes installed on supports would have been very difficult to work on. Barbara Prommeg-ger, Sales Director of HOBAS Latin America seized the opportunity and

March | April 2012

h PipeLine | March/April 2012 | Page 02

convinced the client that HOBAS Pipes would clearly be the better choice. After a comparison of materials with comprehensive documentation in Spanish as well as a presentation of and tests on the material, that was new to the mine, HOBAS and the local partner Buildtek were assigned for the job in February 2011. HOBAS delivered a total of 800 m of pipe with CPVC liner.

“Purely CPVC pipes would have weighed 97 kg per meter whereas HOBAS Pipes merely weigh 38. The wall thickness of CPVC would mea-sure 31 mm which is difficult to weld and the design for HOBAS Pipes only requires 12 mm”, summarizes Barbara Prommegger. The GRP Pipes delivered by HOBAS have an internal chlorinated PVC layer and therefore withstand temperatures up to 80°C. Moreover, the outside pipe surface is extremely resistant; an important factor regarding the high concentration of acid in the fog prevailing in the hall during the process.

Production and InstallationThe pipes for the mine were produced at the German production sites in Stade and Goslar and then transported to Antofagasta in Chile. Here a team of HOBAS Kunststofftechnik and Buildtek prepared as long as pos-sible spools to be transported into the mine to minimize works in the mine. A standstill in the mine costs 1.5 million US-Dollars per day and the avail-able installation time was therefore accordingly short.

The starting signal for the works was given beginning of December 2011. In record time of merely 4 days 18 welders and laminators of HOBAS Kunststofftechnik installed 800 m of HOBAS Pipe welding and laminating almost 60 joints. The result is even more impressive in regard of the dif-ficult conditions in the dessert. Neither the great variations in temperature nor the altitude, wind, dry air or the for safety reasons very detailed paper work could stop the HOBAS Team. On the contrary: the job was final-ized ahead of schedule and the project was a great success. “The client, partner as well as all third-party companies involved are impressed. The installation of a second section is already being planned”, says Barbara Prommegger rightly pleased with the first job from Chile. HOBAS. Make things happen.

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Year of construction

2011

Scope of products

800 m HOBAS GRP Pipes

with CPVC liner

Diameter

DN 600

Pressure class

PN 6

Application

Pipes for the transporta-

tion of copper sulfate

Medium

concentrated sulfuric acid

Temperature of

the medium

up to 50°C

Installation method

above ground, on supports

Client

Minera Escondida

Installation team

HOBAS Kunststofftechnik

Advantages

low weight, compact wall

thickness, resistance to

high temperatures under

exposure to sulfuric acid

even up to 80°C, chemical

resistance to sulfuric acid,

competent advice from

HOBAS Experts, profes-

sional and fast installation

by HOBAS Laminators

and Welders

h PipeLine | March/April 2012 | Page 03

In May 2011 the turnkey EPC (Engineering, Procurement and Construc-tion) contracting partner, German Siemens AG, assigned HOBAS for the design, production, delivery and installation of an underground cooling water line for one of the world’s most modern combined-cycle power plants (CCPP). Erected next to Statkraft’s existing power plant in Knapsack nearby Cologne in Germany the plant is designed to have a gener-ating capacity of about 430 MW and an efficiency of almost 60 percent.

HOBAS GRP Pipes have been standing their ground regard-ing high performance and quality in a vast field of applica-tions for more than half a century. This as well as the ser-vice and expertise HOBAS offers can be exemplified by a cooling water line project implemented in the context of the construction of Statkraft’s new combined-cycle power plant at the chemical park Knapsack in Hürth, Germany.

Winning BenefitsHOBAS not only trumped with a high tensile strength CC-GRP (centrifugally cast glassfiber reinforced plastics) pipe system comprising DN 1800 (De 1842), SN 5000, PN 2.5 and 5 pipes bends and tees designed for working temperatures up to 40 and 50 degrees but clearly aced out competing bidders thanks to comprehensive quality measures and proof as well a rigorous group-wide quality management system that ensures unvarying high quality at every single HOBAS Production Plant. A further advantage unique to centrifugally cast GRP pipes is the possibility to apply the 1 mm thick vinyl ester internal pipe layer required by the client Siemens.

HOBAS from A to ZApart from stringent product tests on the pipes, bends, tees and lami-nated joints which were conducted in-house as well as by independent experts such as the TÜV to verify compliance with standards and project requirements, the job comprised an array of supplementary work such as planning, engineering, site management, installation, and the final pressure test. Furthermore, HOBAS attached great importance to adhering to waste disposal, health and safety measures not least due to accumulations in the soil from a former coking plant. Trained personnel and instructions to the workforce in regard of these issues therefore formed a requisite part of the responsibilities at site.

Preparation and InstallationFor an exact installation of the cooling water line and optimal future service of the pipe, HOBAS made sure that the pipe trench and bedding were prepared strictly in accordance with standards and client require-ments. Since the soft sandy soil of the terrain would easily wash out

Powered by hh CC-GRP Cooling Water Pipes Employed for Combined Cycle Power Plant

h PipeLine | March/April 2012 | Page 04

Year of construction

2011

Total length of pipes

130 m

Pressure class

PN 2.5 and PN 5

Diameter

DN 1800

Service temperature

40-50° C

Installation

open trench

Application

Cooling water line

Client

Statkraft

Contractor

SIEMENS AG, Energy

Sector – Fossile Power

Generation, D-Erlangen

Engineering

HOBAS Germany

Advantages

smooth interior surface,

comprehensive quality

system

from beneath the pipe, geotextiles were used forming a gravel cushion beneath the pipe and to envelope several layers of backfill material.

Every step was documented in detail.

Given the restricted space, parallel construction works and to keep weather-dependent lamination on site to a minimum HOBAS opted for just-in-time deliveries of prefabricated pipe spools. The 10 to 12 meter-long spools were one after the other aligned and joined by lamination respecting tight lateral, horizontal and vertical tolerances of 25 to 30 mm per spool.

Site Inspections, Tests and FinalizationStrict inspections and tests at site were conducted through-out the whole installation. Checkpoints along the line for instance served to double check the line’s correct position.

Pipes as well as raw materials and joints underwent strict tests such 24 hour creep tests on pull-out drilled laminate

cores by third party experts, and general inspection by the client in respect of dew point, bonding, hardness to Barcol, ovalization,

general condition, etc.

Once the two parallel underground cooling water pipes were completed and the trench backfilled end of November the HOBAS Pipe was ready to pass its final test: The hydro test that served to prove the pipes’ leak tightness and perfect bonding of the laminated joints lasted more than 70 hours to 1.1 times the design pressure. With this the job was suc-cessfully finalized to the complete satisfaction of the client who will consider HOBAS as reliable partner also in future industry projects. After the completion of the CCPP planned for mid-2013 the plant will supply up to 500,000 households with electricity.

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The final hydro test served to prove the pipes’ leak tightness and

perfect bonding of the laminated joints. With this the job was success-

fully finalized to the complete satisfaction of the client.

h PipeLine | March/April 2012 | Page 05

Be it a line for carbon dioxide for Omya, a process pipeline for well-known car pro-ducers or a lean gas line for the world’s biggest and most modern fine paper

producer Sappi – HOBAS Pipe Systems are based on more than 3 decades of experience in a large variety of industrial sectors and comply with

highest clients’ requirements.

HOBAS Pipe Systems for the Chemical IndustryThe chemical industry ranks amongst the world’s most impor-

tant and most dynamic economic sectors, and in no other European region are there as many industrial production sites as in the German Ruhr area. One of the largest indus-trial parks in Germany is the chemical park Marl. This is where international companies such as Evonik Degussa GmbH, Nova Innovene, Sasol, Vesolit, etc. produce petrochemical raw materials as well as base and special chemicals. The sewer network beneath the park spans 290 km needs to be kept in best condition and has to comply with strictest safety regulations – for the chemi-cal park has two discharges into the river Lippe. In order to comply with the safety standards, the pipe needs to be resistant to contaminated sewage and temperatures

up to 60°C. Company DOMMEL Sanierungstechnik GmbH therefore drew up a system solution with HOBAS

Products for stormwater discharge. Within less than 3 months 480 m HOBAS SewerLine DN 1200 and DN 1800

as well as HOBAS Relining Pipes De 960 including special units such as shafts, reductions and tailored fittings have been

installed. The high chemical resistance and the outstanding hydraulic properties of the HOBAS System were decisive criteria

in this project.

One of the oldest industrial projects realized with a HOBAS Pipe System

was the rehabilitation of a sewage sys-tem of a soda production plant belonging

to the German Solvay sites in Rheinberg, Germany. When it came to ma-terial choice end of the 1980s, high process related temperatures with peaks around 80°C as well as a pH-value of 1-14 had to be taken into consideration. Since the effluents of the plant contain large amounts of sand, abrasion resistance was of major importance. The abrasion resistant inner pipe wall and the HOBAS Pipes’ excellent chemical resistance convinced the client and made the project a complete success.

HOBAS Jacking Pressure Pipes for the Pharmaceutical IndustrySituated in Basel, Switzerland, the company Novartis is one of the world’s leading providers of pharmaceutical products. 2009 the industrial complex of the St. Johann area with its research and produc-tion sites, office buildings and the international headquarters have been converted into an ultra-modern center for research, development and

h Industrial Pipe Systems - an Adequate Solution to Every Requirement

Solvay WerkeYear of Construction

1986-1990

Diameter

DN 200 bis DN 1200

Pressure Class

PN 1

Stiffness Class

SN 10000

Client

German Solvay Sites

Contractor

German Solvay Sites

Advantages

abrasion resistant inner

pipe wall and excellent

chemical resistance of

HOBAS Pipes

Chemical Park MarlYear of Construction

2007-2008

Diameter

DN 1000 bis DN 1800

Pressure Class

PN 1

Stiffness Class

up to SN 32000

Client

DOMMEL Sanierungs-

technik GmbH

Contractor

Infracor GmbH Marl

Advantages

high chemical resistance

of HOBAS Pipes, high

stiffness classes

h PipeLine | March/April 2012 | Page 06

NovartisYear of Construction

2009

Total Length of PipeLine

433 m

Pipe Specifics

PN 10, De 1499, SN 160000

Client

Novartis Basel, CH

Contractor

Implenia AG, CH

Advantages

Jacking under the Rhine

with high groundwater

level, direct jacking of

pressure pipes

management. Due to changes in the technical requirements the existing water treatment facilities of the plant had to be connected via a pipeline running underneath the Rhine River. HOBAS Jacking Pressure Pipes PN 10 with an outer diameter of 1499 mm have been installed for this purpose. A further challenge which has been mastered with the help of HOBAS Products was to jack the pipes on a curve with a 1000-m-radius. Reason for the curve was the course of the country border between Switzerland and France.

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Centrifugally cast HOBAS Pipes together with filament wound pipes from HOBAS Kunststofftechnik open up a broad application spectrum for clients of the HOBAS Group. Corresponding to individual customer requirements the properties of pipe, vessels and specialized units can be tailored to match a large variety of applications. Diameters ranging from DN 25 to DN 4000, in certain cases also beyond, from the standard HOBAS Inliner through PVC, HDPE to MFA, from pipe through vessel to tailored fittings, there are almost no boundaries set to production options. Out of respect for our clients’ wish we will not mention customers in the following text; you can obtain further information about the projects at [email protected].

In Saudi Arabia pipes and several headers were demounted and replaced with HOBAS GRP Products DN 25 to DN 4000 at a chlor-alkali plant. HOBAS set high value on a comprehensive service: From taking measu-res by HOBAS Experts on site through exact isometric drawings (installa-tion drawings) to accompanying the installation, HOBAS Technicians were always present playing a leading role.

If You Need Something Specialh Industry Products for Special Applications

h PipeLine | March/April 2012 | Page 07

At one of Europe’s biggest incineration plants for special waste HOBAS Pipes DN 1500 convey waste gas and withstand not only negative pres-sure but also temperatures up to 130° C. In order to fit round onto square HOBAS Kunststofftechnik manufactured a special reducer to connect the two differently shaped lines. The installation was swiftly completed without obstructions.

A mixer is used not only for cooking but also in seawater desalination plants. In the latter case the mixer is manufactured by HOBAS. It serves to optimally mix the water with additives and therefore plays an important role in water conditioning.

In Germany HOBAS Tanks have been employed for biological water treatment. One of these tanks is 10 meters high and 4 meters wide in diameter and has been in reliable service since 2011. In the graphic to the left you can see a pre-evaporator constructed by HOBAS that has been installed in a waste incineration plant and serves to separate hydrofluoric acid. HOBAS. Make things happen.

Receive further examples of possible applications at [email protected] and click the window below to watch our HOBAS Industry Clip (currently German; soon available also in English and Spanish).

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InfoFor all HOBAS Production Facilities in Europe the TÜV certificates to ISO standards have been extended to pipe systems up to 3600 mm in dia-meter. In March HOBAS Central has success-fully passed its audits to ISO standards 9001, 14001, etc. by TÜV. Congratulations to everyone involved!

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You would like to know more about HOBAS and stay up to date regarding the HOBAS World? No problem.

Already 15 years ago when we launched our first HOBAS Website we held a cutting edge in the sector. This has not changed for today we are still in the front line and offer to keep you posted about the latest deve-lopments at HOBAS through our social media platforms. Via Twitter, the mass message service of the internet, merely 140 characters make sure you are updated also between our newsletters. On Facebook, the world-wide largest social network with more than 850 million active users, we bring HOBAS within your reach and supply you with interesting as well as fun information about the company. You prefer pictures in motion? In this case we recommend our channel on YouTube, the world’s largest video portal. Here you will find short films about Products, Projects and HOBAS at Trade Shows. It would also be a pleasure for us to stay in touch with you and to share technical discussions on LinkedIn.

Have we aroused your interest? Follow us on Twitter, Facebook, YouTube and LinkedIn!

h Social Media Presentation