The construction and laying of the above-ground pipeline infrastructure in mining operations involves a great deal of labour, time and costs. One of the biggest hurdles is the general safety of the pipes, which have to be weatherproof even in extreme areas. On the other hand, they should have as few connecting elements as possible, as these are inherently a weak point and encourage leaks, for example, that pose a security thread to the environment. However, if the terrain is particularly challenging, it may be necessary to lay more connections in order to adapt to the terrain without risking too much distance unnecessarily, which in turn increases the general project costs. However, in order to maintain operations, it is crucial that the pipes are laid quickly and with low manpower requirements. To achieve this, German manufacturer Rädlinger primus line GmbH has developed the Primus Line® Overland Piping system that considerably reduces the effort. One reason for this is the structure of the aramid-reinforced and composite liner with leak-free connectors which makes it much more durable and flexible than other piping at the same time. The system is specifically developed for above-ground piping of demanding and potentially hazardous media.
The biggest problem with mines is that they are often located in remote places whose terrain makes laying above-ground supply lines a particular challenge. “To keep mining operations running, water and other process media must be transported through a remote and rugged terrain, where the weather is often times extreme, the access is limited, and the risks are high. It is essential to have a reliable and durable pipeline system that can handle the challenges and deliver the targeted results”, explains engineer Heiko Manzke, Director Australia and New Zealand. HDPE pipes are still frequently used for this purpose, as they have proven themselves in many applications. However, it is particularly important to have as few connection points as possible, which can weaken the overall structural integrity of the lines and create weak points where problems such as leaks can occur if they are under constant stress from environmental influences. No matter which overland piping system is used: In the long term, these lead to materials degrading over time, which can only be prevented up to a certain point.
That is why Germany-based Rädlinger primus line GmbH has developed Primus Line® Overland Piping: an alternative that is considerably more safe and resistant, but at the same time can significantly shorten the installation work. “The lining of the flexible pipeline consists of thermoplastic polyurethane (TPU), a very durable polymer. Its outer layer, also made of TPU, offers maximum protection from UV-light and abrasion as well as the required flexibility for repeated installations and coiling of the reusable system”, explains Manzke.
Durability is ten times stronger than steel
Abrasion, impact, UV-light and other environmental stresses affect the outer layers of the pipe while they internally must be able to cope with abrasive materials and harsh chemicals. Therefore, Primus Line® Overland Piping has a three-layer structure to ensure high durability. While the outer TPU-layer protects against external influences, the aramid-reinforced middle layer ensures the necessary flexibility of the liner, making it reusable and bendable. The third and inner layer offers strong chemical resistance that even withstands contact with highly corrosive hydrocarbon compounds. “This design differentiates the solution from other systems resulting in a generally longer service life and ensuring a successful operation without leakage and environmental damage”, explains Manzke.
The choice of aramid as a core material was no coincidence: Its strength is ten times higher than that of steel and twice that of glass fibre or nylon. The aramid fabric therefore makes Primus Line® flexible and, in combination with the TPU layers, safe at the same time. “Based on the standard API 15LF, the burst pressure is at least two and a half times higher than the permissible operating pressure”, Manzke adds. In addition, this fabric gives the pipes an extremely high tensile strength that allows for a complete stand-alone absorption of even very high operating pressures.
Easy installation without heavy equipment or high manpower
One of its main advantages is the ease of installation, which does not require heavy equipment or high manpower. “The construction of 3.7 miles (6 km) of pipeline only takes about one to two days with a crew of three to four people. In comparison, it takes about 25 to 30 days to lay the same distance with a crew of four to six people using HDPE pipes”, Manzke describes. The situation is similar when it comes to removing the pipeline. This time saving is made possible, among other things, by coiling them flat on special transport reels that are delivered to the customer. Once on site, installation requires only a mini-excavator or winch and basic hand tools. This approach can minimize both logistical costs and the environmental impact associated with transportation. “Since no heavy trucks are needed to transport liquids, Primus Line® Overland Piping actively contributes to minimizing CO2 emissions”, Manzke adds.
However, flexibility does not only refer to the material of the pipes. Specially developed high-pressure end fittings with flanges or quick couplers compatible with Victaulic notch are used to link various flexible pipelines, allowing them to be laid out fast and easily in different layouts. They can also be connected to pumps or other pipeline assets. Either way, no hot work such as welding or butt fusion is required for installation. In addition to this quick connection system the overall number of necessary joints for the pipeline infrastructure was reduced since fewer joints mean less weak points. “We therefore provide installation lengths of 3,300 feet (1,000 metres) and more to reduce the number of necessary joints, especially when compared to HDPE pipe, thus making this solution particularly safe to use and operate.”, explains Manzke.
Pipe system is fully reusable
When developing the design, great care was taken to keep operating costs as low as possible. This cost advantage of Primus Line® Overland Piping results, in addition to the less complex laying, from its low storage requirements and reusability. Storage demand can be kept low because, depending on the diameter, up to 13´120 feet (4,000 metres) of the flexible pipe can fit on one transport reel. In comparison, storing HDPE pipe requires up to ten times more space. “The reusability of Primus Line® Overland Piping makes it not only a cost-effective solution, but also an environmentally friendly one since far less machinery is required during installation and transport. This significantly reduces the carbon footprint on site and allows installation through bushland, nature parks or waterways without damaging the environment”, Manzke concludes.
