1204 Hydropower E Web

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Hydropower Pipelines


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From the Beginning to this Day...

Hydropower Right from the StartWhat is good enough for the automotive, aircraft and ship-building industries must also be suitable for us, thought theengineers at a Swiss dye works in the 1950s and started tomake the rollers they used for winding fabrics round duringthe dyeing process out of glass reinforced plastic (GRP).The centrifugally cast rollers had an even outer surface andwere resistant to both chemicals and corrosion virtuallypredestined therefore also for use as pipes to transportwater. No sooner said than done: the rst industrial appli-cation for HOBAS Pipes was as intake lines for a hydro-electric power station in the early 1960s. In the steep,rugged terrain of Switzerland's Binn Valley, the HOBASPressure Pipeline its installation can be seen on theright has proved so reliable that it has been in servicefor over 50 years now.

A great success, but the Swiss did not rest on theirlaurels. On the contrary: they continued to develop ma-terials, manufacturing, joining and installation methods,constantly expanded the product line and opened plantsall over the world making HOBAS one of the most uni-versal suppliers of pipe systems today. Whether potablewater supply, wastewater disposal, irrigation, hydropowerplant pipelines or industrial applications, experts round theglobe set great store by HOBAS Products.

Proven Manufacturing ProcessThe centrifugal casting process developed at that time hasbasically remained the same today: standard HOBAS GRPPipe Systems are made of unsaturated polyester resins,chopped glass ber and mineral reinforcing agents. The pipe

wall is built up step by step from the outside inwards in arotating mold. Once all the materials have been fed into themold, the speed of rotation is increased. Spinning at a pres-sure of 30 to 70 bar presses the material against the mold wall,which removes the gas, compacts and cures it. This centrifugalcasting process ensures that the pipes are circular, void free andhave a uniform wall thickness over their entire length.


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Sophisticated Pipe Wall Structure for Your Benet

HOBAS Pipes' unique wall structure offers a whole range of advantages:

Minimal friction and pressure loss due to the extremely smooth innerpipe surface

Less water hammer than with metal pipe materialsResistance to UV lightLow weight enabling high installation rates even in less accessible terrainHigh abrasion resistanceCorrosion resistanceVariable lengths as pipes can easily be shortened on siteDimensionally accurate outside diameterAngular deection possible in couplings

Consistently high quality with complete internal and external qualitycontrol (testing of material properties, pressure tests, etc.)

Low operating and maintenance costsLong service life of up to 100 yearsTechnical service

Our HOBAS Experts are here to support you throughout your project.From inspecting the planned pipe route, selecting the right diameter andcreating a digital installation plan through constant supervision of installationactivities on the construction site by our pipe consultants you havea reliable and experienced partner at your side with HOBAS.

Pipe Wall Structure*

1 External protective layer

2 Outer reinforced layer

(glass ber, polyester resin)

3Transition layer (glass ber,

polyester resin, sand)

4 Reinforcing layer (sand,

polyester resin, glass ber)

5Transition layer

6 Inner reinforced layer

7 Barrier layer

8 Inner pure resin layer

*Schematic illustration of in reality seamless-

ly merged pipe wall construction. Layer

design is adapted to suit requirements set by

e.g. the conveyed medium, installation method,

pressure, external forces, etc.


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Specications

StandardsISO 10467ISO 10639EN 1796EN 14364N B 5161ONR 25161

ApprovalsDVGW approvalVGW-GRIS approvalSVGW approvalTV OktagonISO 9001 certicate

ISO 14001 certicate

Our ServicesSupport in dimensioning and routing pipelinesHydraulic calculationsDrawing up a veriable structural design to

ATV A127 and NORM B 5012Support in dimensioning bedding, anchoring

and thrust blocksConsulting on the construction site

Physical Properties

Density ~ 2000 kg/cm3

Linear thermal expansion coeff ~ 26 - 30 x 10-61/K

Thermal conductivity 0.5 - 1.0 W/m/K

Elastic modulus 10,000 - 15,000 MPa

Roughness k (to Colebrook) 0.01 - 0.016 mm

Hazen-Williams owcoefcient

~ 155

Shock wave propagation speed ~ 450 m/s


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hPipe Systems

HOBAS Hydropower Plant Pipes are available in the following standard sizes:

* Other sizes on request.

Depending on the size, HOBAS Hydropower Plant Pipes are produced in most pressure classesup to PN 32 and in lengths of 1, 2, 3 and 6 meters (tolerances to company standards). Other pipelengths can also be supplied on request.

We also have a wide range of GRP Fittings to t the various pipes. Thanks to the exibility of HOBAS

Products, we can manufacture custom designs to your specications.

System BuildinghProducts

Tee

MasonryCoupling

Structural Adapterwith Thrust Ring

Reducer

Tee withLoose Flange

Bend

FlangedSpigot

Available diameter DN | Dein mm*

150 | 168 400 | 427 650 | 650 960 | 960 1400 | 1434 1937 | 1937 2555 | 2555

200 | 220 450 | 478 700 | 718 1000 | 1026 1500 | 1499 2000 | 2047 3000 | 2999

250 | 272 500 | 501 750 | 752 1100 | 1099 1535 | 1535 2160 | 2160 3600 | 3600

300 | 324 500 | 530 800 | 820 1200 | 1229 1600 | 1638 2200 | 2250

350 | 376 550 | 550 860 | 860 1280 | 1280 1720 | 1720 2400 | 2400

400 | 401 600 | 616 900 | 924 1350 | 1350 1800 | 1842 2400 | 2454


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Time [s]0 100 200

343

340

337

2

0.25

-1.5

In-andoutfow[

m/s]

Water-table[m]

Water-table after valve closure

In- and outow in surge tank during and

after valve closure

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hSurge Tank

Surge tanks separate the pipeline into an area ofmass oscillation and an area of pressure oscil-lation. This reduces on the one hand the risk ofvacuum as consequence of water hammer andthe amplitude of water hammer on the other.HOBAS GRP Surge Tanks offer a lot of benefits:the made-to-measure design and fast as well aseconomic installation due to prefabricated unitsare only a few. The well-thought-out double

chamber surge tank moreover provides advantageous pressure and waterstorage properties.

In cooperation with the Graz University of Technology HOBAS has de-veloped a special software program which makes sure that each surgetank perfectly matches individual parameters such as of the pipeline, theterrain, turbine closing times, etc. Our specialists will also gladly supportyou in calculating the pressure surge and dimensioning the surge tankwith the characteristics method.


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hAngular Cut System

An efcient pipe joint must provide for angular deection and exibility

in the connection. The HOBAS FWC Coupling differs from conventionaljointing systems in that it has a full width EPDM gasket seal which ispermanently tted in a GRP sleeve. In combination with HOBAS Pipes,

the FWC coupling has exceptional characteristics. Making use of thenormal deection possible within the joint, you can create curved pipe-lines with larger radii, while if you use shorter pipes, you can also achievesmaller curves and do not require pipe bends or thrust blocks.

When the pipeline is curved, there is automatically a coupling gap withright-angled tube sheets. This is not a problem for normal wastewater sys-tems. It is however important to prevent any loss in hydropower pipelines.The HOBAS Angular Cut System enables coupling gaps to be eliminatedto a large extent and therefore optimal hydraulic conditions to be created without the need for expensive ttings.

*Deection in the Joint in

StandardDeection

Two-Sided Angular Cuts

PN 1 PN 6 PN 10 PN 16

DiameterDN

2555 0.5 ** ** ** **

Benets of the HOBAS Angular Cut System

Improved pipeline efciency, as practically nohydraulic losses occur compared with seg-ment bends

Optimal route thanks to high adaptability topipeline and terrain structures

No need for segment bends and concretethrust blocks

Easier, more cost-efcient and much faster

installation, as segment bends and concretethrust blocks are not requiredLess adaptation required on the construction

site, fewer pipe cuts on site

* Maximal deection

achieved if both pipes are

cut angularly

** on request

One-Sided

Angular Cut

HOBAS Pipe DN 1600

PN 6; angular cut onone end with permis-sible deection of 3

- no coupling gap

3.0


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hPipe Joints

HOBAS Pipes are supplied with a coupling premounted at the factory. There is a choice of the following types:

hPipe Installation -Whenever and Wherever You Want

No matter when and where you want to build your pipeline, HOBAS Pipesand Couplings are quick to install irrespective of the weather and sitesituation. You will nd an overview of our installation methods here:

Open cut with steel clampsOpen cut on concrete supportsBuriedJacking

ReliningInstallation in tunnels

1 FWC coupling

2Assembly coupling

3 Flush FWC coupling

4 FWC-L coupling (restrained)

5 Laminated joint

6Transition from HOBAS

GRP Pipe to steel pipe

with pre-welded spigot

1

4

2

5

3

6


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In the early 1960s, Gommerkraftwerke in the Binn Valley in the Swiss canton of Valais was search-ing for a suitable material for the pressure pipeline to its hydropower plant. Around the same time,Swiss mechanical engineers were thinking about other applications for their textile dyeing rollers. Itwas to be a stroke of luck, as when Gommerkraftwerke heard about the pipes' excellent proper-ties and low weight, the choice of material was clear and they used the centrifugally cast GRPpipes for the three-kilometer-long, very steep sloping DN 1000 pipeline. At that time, the pipeswere green inside and joined with bell sleeves. Because the material is so light, they only neededrelatively simple equipment to install the pipeline quickly.

Plant director Bernhard Truffer is still highly satisfied with the HOBAS Products today, "especiallywhen you consider that the walls are very thin at 7 mm for a diameter of 1,000 mm", says Trufferextremely pleased with the experience that the company has had with the pipes over the past50 years. HOBAS can justifiably be proud of producing quality for generations and contributing toclean power generation.

Fmd: [email protected]

Year of Construction

1961

Total Length of Pipeline

> 3 km

Diameter

DN 1000

Pipe Specics

Pressure pipeline,

wall thickness 7 mm

Installation Method

Open cut

Client

Gommerkraftwerke AG

Special Features

Low weight, easy instal-

lation, low wall thick-

nesses, long service

life, excellent

hydraulic

properties

Pioneers from the Very Beginning

The FirsthHydropower Plant Pipeline in 1961, CH
mailto:hobas.poland%40hobas.com?subject=HOBAS%20PipeLine%20Special%20Jackingmailto:hobas.poland%40hobas.com?subject=HOBAS%20PipeLine%20Special%20Jacking


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High-Quality Hydropower in Austria

Curves without Bends usinghAngular Cuts

With its many mountain torrents, Austria is ideal for generating greenelectricity. The micro hydroelectric power station in Schwarzach (East Tyrol)is designed for a maximum turbine output of 9.9 MW and a ow rate of

4.6 m3/s. To achieve this output, a 4-km-long DN 1600, SN 10000, PN 10-16 pipeline had to be installed.

As early as the tender phase, GRP pipes clearly had signicant advantages

over other materials. HOBAS Pipe Austria gave the client detailed adviceon the benets of HOBAS Products: 3 meter long pipes, 2.2 angular cuts

at the pipe ends and angular deection in the couplings meant that small -er radii could be used. This enabled the company to use 41 fewer bendsand thrust blocks than in the tender, thus reducing construction time.Using a computer planning system, HOBAS generated a bill of materialsand an exact CAD plan. The pipe route was simulated on the computerand an installation plan created. Successful pressure testing rounded offthe project to the complete satisfaction of everyone involved and thehydropower plant now supplies some 15,000 households with greenelectricity.

Anti-AginghPipes Produced in 1987

Built by Salzburg AG in the 1980s, the Wald hydropower plant is locatedat the edge of the Hohe Tauern National Park. It has been in operationsince 1988 to meet the rising energy demand in the area. After 18 yearsof service, the sand ushing pipeline in the hydropower plant consisting

of DN 1600, PN 1 HOBAS Pipes was examined during an inspection inMarch 2006. The experts were very pleased that they hardly found anysigns of wear on the pipeline, even after it had been in use for nearly twodecades. Despite the abrasive medium water with sand and glacial sedi-ment the inner pure resin layer that is also responsible for the hydraulicproperties of HOBAS Pipes was neither pitted nor worn away. Also in theinvert area of the pipes the resin layer was completely intact.

Just how aggressive glacial sediment is compared with most materials

can be seen from the fact that the power plant's turbine had to be re-placed several times over the same period the HOBAS Pipeline how-

ever shone like new against the light and only showed slight signs ofmechanical abrasion on the markings. The hydropower plant operators

will denitely be able to count on HOBAS Pipes over the coming

decades.


Stiffness Class

SN 2500 - 10000

Special Features

Abrasion and corrosion

resistance, long service

life, excellent hydraulic

properties

Stiffness Class

SN 10000

Special Features

Angular cuts on the

pipes and angular

deection in the

couplings, excellent

hydraulic

properties


1987 - 1988

Length of Pipeline

1,143 m

Pipe Specics

DN 1200 - 2200PN 1 - 8.5


2005 - 2006

Length of Pipeline

4 km

Pipe Specics

DN 1600

PN 10 + 16


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Norway can meet most of its electricity demand with the hydropowergenerated in the country. The Helleren power plant, for example, lies northof the Arctic Circle on the River Helleren and had been in operation witha DN 2500 wooden penstock since 1958. Leaks in the penstock werehowever leading to escalating maintenance costs and reduced plant out-put. At low temperatures, the water leaking from the penstock causedice to form and increased its weight considerably. The wooden structurecould have given way under the load and caused the pipeline to collapseat any time.

A long-lasting, low-maintenance alternative to the wooden penstock wastherefore sought. The pipes had to be installed both in a trench and aboveground on supports where they have to withstand great uctuations in

temperature. In addition, there was hardly any room for storage on site.A good logistics concept was therefore important. HOBAS Pipes havethe advantage of virtually no thermal expansion and low weight theclient was delighted and nothing now stood in the way of replacing theold penstock with long-lasting, maintenance-free HOBAS GRP Pipesin DN 2500.

Filled with water, each pipe weighs 32 tons when the pipeline is inservice. A substructure has to bear this weight in the part of the pipelineinstalled above ground. Each support therefore sat on a precast reinforcedconcrete base. The upper part of the support was cast in situ as soon asthe pipe was in position. As there was hardly any room for storage on theconstruction site, HOBAS delivered the pipes just-in-time straight to thesupports. Not only is the outer surface UV and abrasion resistant but alsothe pure resin layer ensures that the elements cannot do the productsany harm. The HOBAS FWC Coupling System enables the large pipes tobe joined quickly and securely.

Investors in the hydropower sector know that they are building thefuture. HOBAS Products guarantee that the pipeline will functionreliably and durably for the coming decades and are consequently alsoinvolved in the production of clean energy. Welcome to the future


Promising Investment

hPipes North of the Arctic Circle, NOR


2008

Total Length of Pipeline

114 m

Pipe Specics

DN 2500, PN 6, SN 5000

Installation Method

Above ground on sup-

ports, open trench

Special Features

Temperature resistance,

low weight, long service

life, low maintenance,

quick and easy instal-

lation with HOBAS

Couplings

EEngineering GmbH

Responsible for content: Friedrich Moser, Christoph Voutsinas | Texts & Layout: Sabine Friesser, Alexandra Dobnigg

Publication: 03/2011 | Updated: 04/2012 | Print: Carinthian Druck Beteiligungs GmbH 04/2012

All rights reserved. No part of this document may be reproduced or utilized in any form or by any means without our prior written permission. All informa-

tion in the document is correct at the time of going to press. However, we reserve the right to make changes without notice, in particular to technical data.

The data given is not binding and must therefore be checked in each individual case and revised as appropriate.

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We develop and manufacture HOBAS Products conserving natures

resources and with respect for our environment. Visit our website to

fnd out more about the HOBAS Environmental Policy.

EGroup Worldwide

HOBAS manufactures and markets HOBAS GRP Pipe

Systems. The HOBAS Network includes HOBAS Production

Facilities and Sales Organizations in Europe and throughout

the world.

EEngineering Austria

Pischeldorfer Strasse 128

9020 Klagenfurt | Austria

T +43.463.48 24 24 | F +43.463.48 21 21

[email protected] | www.hobas.com

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