1. Understanding International Standards for Pre-insulated Piping for District Cooling Piping Networks 1

2. About Perma-Pipe Design principles of buried district cooling systems International Standards Dissecting a Pre-insulated Pipe Casing End-Seals Insulation Carbon Steel Carrier Pipes Corrosion Protection Leak Detection Systems Field Joint Systems Conclusions Contents

3. Perma-Pipe established in 1961 Ricwil established in 1910 Division of MFRI, Inc. NASDAQ traded company $ 200 + million / year revenues Perma-Pipe Global manufacturer & engineering company providing piping systems & solutions $100+ million / year revenues District Heating & Cooling, Environmental, Industrial, and Oil & Gas Markets Largest supplier of pre-fabricated / pre-insulated piping systems in North America & the Middle East Installations all over the world About Perma-Pipe

4. Perma-Pipe Credentials Holds the Chairman position on the ASTM Task Group responsible for developing standardsfor pre-insulated piping standard for district heating & cooling. First member ofInternational District Energy Association (IDEA). Member since 1921. Products Certified to EN 253standards. Been supplying to the Middle East since 1975. Supplier of the worlds longest pre-insulated pipeline – 590 km from Rjaastan to Gujarat Products successfully in service for over 40 years!

5. Manufacturing Facilities Perma-Pipe, USA Lebanon, TN Manufacturing Facility

6. Manufacturing Facilities Perma-Pipe Oil & Gas New Iberia, LA Manufacturing Facility

7. Manufacturing Facilities Perma-Pipe Middle East (FZE) Fujairah, UAE Manufacturing Facility

8. Manufacturing Facilities Perma-Pipe India Ltd. Gujarat, India Manufacturing Facility

9. Manufacturing Facilities Bayou Perma-Pipe Canada, Camrose, Alberta, Canada

10. Manufacturing Facilities Perma-Pipe Saudi Arabia LLC

11. 2” – 72” service pipe diameters Any service pipe material Any insulation thickness Different types of insulation Any HDPE casing thickness With/without leak detection cables With/without end-seals HDPE Molded fitting Covers Extrusion welded fitting Covers Custom and standard spool fabrication Heat-tracing System Fabrication Blasting & anti-corrosion coating Manufacturing Capabilities

12. Design principles of buried district cooling pipe systems

13. Contraction/expansion of service pipe Friction between casing and soil Virtual anchors/restrained systems Pipe movement Hoop stress of pipe Stress analysis

14. When axial force from service pipe is less than the accumulated friction the pipe will be fully restrained. SYSTEM LAY OUT PRINCIPLES: Cold installation Pre-heated/pre-stressed systems Compensated systems

15. Expansion/contraction of pipe Expansion/contraction absorbed by elbows or expansion loops Expansion cushions Compensators/contraction joints Cushions at branches Anchors

16. EXPANSION CUSHIONS Elastomeric foam Closed cell Soft/flexible

17. Hoop stress from internal pressure Example: 10 bar system, 30” pipe, sch std Restrained stress Example: Operating temperature 5˚C, installation temperature 35˚C ΔT = 30˚C Accumulated stress

18. Bonding between pipe-foam-jacket Backfilling materials Pipe movement at branches Hoop stress is not the dominating stress factor Complex systems Fatigue of pipe Stress analysis is “a must” Design and verifications

19. Examples Proper installation Poor workman ship

20. International Standards European Standards Background Positives Quality Assurance Standardized System Negatives Based on all-case scenario Written for district heating NOT district cooling Based on cold & harsh European environment Limits innovation Over designed and adds unnecessary cost, especially for chilled water systems Thicker than required HDPE casing

21. North American Standards Background ASTM Standard for insulated pipe is under final development Negatives Allows all service pipes. Some service pipes are not as adequate for the application as steel pipe Positives Various pipe materials Designs are uniquely engineered to each project for innovative solutions Holds the insulated piping manufacturer responsible for the recommended solutions HDPE casing thickness engineered for project specific requirements International Standards

22. Peeling back the layers of a Pre-Insulated Pipe - Understanding the HDPE Casing

23. The outer casing has 2 main functions: Mechanical Protection During material handling at the plant and on-site During freight & transportation Vapor Barrier Preventing water ingress during installation due to trench flooding Isolating underground water during operation Significantly reduces diffusion of the blowing agent gas from the PU cell structure Understanding the Function of the HDPE Casing

24. Why does EN 253 require thicker than required HDPE casing? Foaming is exothermic – heat deforms the casing EN standards written based on process limitations of the injection system Thin casing damaged during storage & transportation especially for larger diameters piping Politically difficult to change, even with new technology

25. HDPE Casing – How thick is thick enough? Soda Ash Project in Colorado 12” pipe, 50 mm insulation - 150 km Less than 2mm jacket thickness Barmer to Salaya cross-country Pipeline (BSPL) Rajasthan to Gujarat, India 24” pipe , 90 mm insulation - 590 km Various rugged terrain including desert, marsh-land and forest Followed EN 253 quality standard but with 5 mm HDPE casing Typical jacket thickness for Western Canadian Oil & Gas market is 1.5 mm Supplied thousands of kilometers of thin wall jacket

26. Point Load Test Steel Rod (Penetrator) : 12.0mm MTS Machine Speed : 5.1mm/min Ambient Temperature : 24 C Relative Humidity : 52.9% Average Density of foam : 50 kg/m3 HDPE Jacket thickness specimens tested: 3mm & 4 mm Measured Peak Loads: 1516 – 1979 N

27. EN 253 vs. Recommended CasingThickness

28. Peeling back the layers of a Pre-Insulated Pipe - Other Casing Materials

29. Applications Above-ground applications Fire-retardant properties Options Spiral formed casing Cigarette wrap casings GI/Al Casing

30. Applications Above and Below-ground applications Fire-retardant properties Advantages Higher Temperatures Higher Strength Disadvantage Higher Cost GRP Casing

31. Peeling back the layers of a Pre-Insulated Pipe - End Seal

32. HDPE End-Seal – A Water Spread Limiting System Seamless HDPE Wind-Down End Seal Moisture contained to field joint or to one length of pipe

33. End Seal Certification Test Pressure Vessel Gauge Reading Test pressure is 11 PSI (76 KPa). Removing Test Specimen From Pressurized Testing Chamber

34. End Seal Certification Test CONCLUSION: No evidence of water . Ingression test establishing the functionality of a seamless end-seal.

35. Peeling back the layers of a Pre-Insulated Pipe - Understanding the Bonding Layer

36. Bonding is required to design the system as “strain based” with virtual anchors (buried pipes). Load transfer from pipe to insulation to jacket. Pipe, insulation and jacket move together as a unit. No water transfer longitudinal to the pipe. Why is Bonding Important?

39. Comparison of Injection vs. Spray Applied PU Foam Injected PU foam May have voids Not concentric Jacket may not bond to insulation Inconsistent density Inconsistent compressive strength Inconsistent thermal conductivity Predetermined thickness increments Higher cost Difficult inspection / lower quality Sprayed PU foam No insulation voids Fully concentric Jacket fully bonded to the insulation Consistent density Consistent compressive strength Consistent thermal conductivity Precise thickness Lower cost Easy inspection / higher quality

40. Understanding Polyurethane - Density Selecting the right density is important to strike the best possible cost-effectiveness ratio. The higher the density, the higher the thermal conductivity. The higher the density the higher the compressive strength. The higher the density, the higher the cost! Current EN 253 does not specify density.

41. Understanding Polyurethane – Thermal Conductivity (K Value) The k value is the most important parameter in determining the efficiency of the insulated piping system. This is what you pay for! The thermal conductivity of insulation materials decreases as the temperature falls. Temperature increases on the other hand result in a minimal increase in thermal conductivity. Aged k value is what should be considered in the design of an insulated piping system. It is important to note that all polyurethane insulations will age. The difference is the duration over which the insulation will age.

42. Thermal Conductivity vs. Density 0.24 0.20 0.16 0.12 Thermal Conductivity (BTU-in/hr-ft2-oF) 0 2 4 6 8 10 Density (lbs/ft3)

43. Understanding Polyurethane - Compressive Strength This parameter is the second most important consideration for designing insulated piping systems. PERCEPTION: The HDPE Jacket provides the loading properties of the system. FACT: Compressive Strength of the foam provides the loading characteristics of the system. Soil loading determines the required compressive strength.

44. Polyurethane Compressive Strength

45. Understanding Polyurethane - Closed Cell Content This parameter determines the water absorption characteristics of the polyurethane foam. Every step and effort must be taken to keep water out of the system. Wet insulation is no insulation. Water is the dielectric for corrosion The higher the closed cell content the slower the gas diffuses out of the foam and hence slower the aging. Note: Even though not listed in the revision changes this parameter was removed from latest version of EN 253. Previous EN 253 standards specified the requirement as 88%.

46. Polyurethane Foam – Blowing Agents K Factor The insulation properties of rigid polyurethane foam are determined by blowing agents. Thermal conductivity of foam made with various blowing agents.

47. Average Thermal Conductivity vs. Temperature HCFC 141b & HFC 245fa have much lower thermal conductivity than Cyclopentane (Data provided by Association of Home Appliances Manufacturers, AHAM, USA)

48. Average Aged Foam Thermal Conductivity Foam with HFC-245fa and R141b have lower K-Factors after aging than Cyclopentane.

49. Understanding Blowing Agents – Water Blown Foam (CO2) CO2 blown foam provides the worst thermal conductivity as compared to other blowing agents. CO2 has very small molecules that will diffuse into the air or into the cell walls and be replaced by Nitrogen molecules. The process of aging is hence the fastest in the case of CO2 blown foam.

50. Peeling back the layers of a Pre-Insulated Pipe - Anti-Corrosion Epoxy Coating

51. Insulation is a very good anti-corrosion coating because of its excellent electrical insulation value However, when wet, insulation no longer acts as a corrosion protection layer If leak from outside the water will be very corrosive Surface Preparation – Blasting to SA 2 ½, Epoxy Coating Case Study: Princess Noura University Heavy rains in Riyadh earlier this year Trenches flooded Water entered hundreds of joints during construction Corrosion Protection

52. Peeling back the layers of a Pre-Insulated Pipe - Understanding Carbon Steel Pipes

54. ID Corrosion: The water must be treated (non corrosive quality)Durable and ideal for higher pressure applications Welded construction - No risk of field joint leaks Relatively inexpensive Contractors are familiar with the welding and layout techniques Field joint weld quality can be verified with a variety of NDE methods (x-ray, ultrasonic, magnetic particle)

55. Pipe Thickness Considerations Water Quality Water quality used in the Middle East is not the same as what is used in Europe Water is mostly made from desalinated seawater so level of chlorides may be higher Longer Delivery Times Much lower availability of BS and EN standard pipes as compared to ASTM standard pipes – manufactured by fewer mills. Thin walled pipe is not carried by Middle East pipe stockists Corrosion Annual corrosion rate for steel must be calculated. Depends on O2 content Pipe Handling Thin wall pipe is lighter and hence may be easier to handle Thin wall pipe is much easier to damage during storage, transportation and handling

56. Steel Service Pipe Wall Thickness – EN 253 vs. Standard Weight Pipe

57. Understanding Fitting Manufacturing Processes

58. Fabrication Fabrication done in-house by trained, tested and certified welders MIG/TIG/SAW/GTAW/GMAW/FCAW/Plasma Cutting/Victaulic Grooving All required testing facilities on site Ultrasonic Testing (UT) Radiography Testing (RT/X-Ray) Magnetic Particle Testing(MT) Die Penetrant Testing(PT)

60. High quality

61. Lower costs

62. Ease of fabrication

64. Why use a Leak Detection System? Is it required can leaks be detected in other ways? To avoid corrosion? To avoid excessive loss of water? To avoid increased heat loss/gain?

65. Resistance (Nordic system) TDR /Capacitance system (Time Domain Reflectometry) Mechanical wires Pressure drop Heat sensitive camera (thermo graphic camera) Visual monitoring Leak Detection Principles

66. Important Features in Leak Detection Systems Ease of installation Ease of operation Connection to BMS Accuracy in locating leaks Monitor leaks Finding multiple leaks False alarms Price

67. Working Principles Nordic system Measuring resistance between 2 copper wires Electrons will travel through liquid and resistance will drop Works only in conductive liquids TDR system Send energy pulses in cables reading the reflections of energy Drop in energy reflection will show leak Will work with all liquids

68. Leak Detection Comparison Nordic system Will detect only one leak Sensitive to moisture Prone to give false alarms Difficult to find leaks (in-accurate) One wet joint will render the system useless. TDR Can detect multiple leaks Less sensitive to moisture but will sense water No false alarms Easy to find leaks Very accurate indications of where the leak is Mapping technology available

69. Time Domain ReflectometryPAL-AT TDR is a cable measuring technology related to sonar and radar. By sending energy pulses down the center conductor of a coaxial cable and measuring the reflected energy a map can be stored of the cable and monitored for change. When change occurs the type of alarm and its location is displayed on the panel.

70. TDR Trace of Dry Cable

71. TDR Trace with Leak Detected

72. TDRTrace of System with Wet Cable

73. TDR Trace Showing Growing Leak

74. Map 3 Response

75. Second Leak Detected

76. Monitoring with Liquid onthe Cable

77. Break Detected

78. Short Detected

79. Where does Perm-Alert differ from other systems? Mapping of reflection Multiple leaks can be found and monitored Reduced risk of false alarm Will give leak and location of leak immediately Set point follows the actual TDR response not as a fixed value More sensitive than other TDR systems Software will show location of leak on BMS

80. Palcom SoftwarePAL-AT and LiquidWatch Palcom allows remote control of up to 254 panels with the ability to review TDR traces, review the history of each unit and to pull down a CAD drawing for each system for location of leaks, breaks, shorts or probe activations.

81. Field Joint Systems

82. Application method Tubular Wrap around Sealent method Mastic/hot melt sealed Welded Material type Cross linked Non cross linked Field Joint Systems

83. Wrap Around Heat Shrink Sleeves Wrap Around Shrink Sleeves Can Be Installed After Welding Polyolyfin sheet, irradiated, stretched and mastic/hotmelt is then applied for sealing Applied by wrapping around the insulated joint and returning the sleeve to its original dimensions by the application of heat utilized from a torch Features Can be supplied as double sealed Does not require special tools/machinery Easy to inspect Easy to repair Does not require extensive training –easy to apply

84. Heat Shrink Casings Tubular sleeves are manufactured from a polyethylene material to the proper diameter and thickness The sleeve is then irradiated using gamma rays to create an “elastic memory”. After irradiation the sleeve is heated to its softening point, expanded and cooled down in the expander. Sealants are applied to the ends of the joint (or the sealant are supplied in form of strips) The joints can also be produced without irradiation, this will however make the sleeve very sensitive to heat and direct sunlight as it will start to shrink before the joint is applied.

85. Electro fusion welded sleeves are made of non cross linked polyethylene. The joint can be either shrinkable or non shrinkable The heat shrinkable joint is placed over the field joint area, heat is applied to shrink the sleeve and the ends are fused to the HDPE casing using electrical welding wires. The non shrinkable sleeve will have a longitudinal opening so it can be wrapped around the joint. The sleeve will be fitted tightly using straps and then fused to the HDPE casing using electrical welding wires, or extrusion welded. Electro-fusion Welded Sleeves

86. Factors Causing Failure of Electro-Fusion Joining Process Factors of human errors cleaning, clamping, cooling time, operation of welding equipment, gap between fitting and pipe Factors of equipment errors equipment performance variation, degradation of equipment, frequency of electricity, input voltage, excessive length of electric cable, capacity of portable power generator in field, loose connectors for fitting, contamination of connectors Note: Weld controlled by a computer with temperature sensor, in warmer climates the sensor is not accurate and will stop the welding process before the joint is completed leaving parts of the joint un welded. Factors of environment temperature, rain, dust Factors of installation bending

87. Factors Causing Failure by Electro-Fusion Joining Process Sometimes difficult to achieve a circumferential fit Alignment issues on site

88. Installation issues apply to all types of field joints Heat shrink sleeves are easier to install and hence have fewer problems during application Heat shrink sleeves have a much longer track record in the region than other alternatives Electro-fusion joints can be difficult to install, especially if too thick Field Joints - Summary

89. Conclusions

90. Conclusions Standards are useful as a quality assurance guidelines but specification should be written based on project requirements Spray insulation is far superior to the injection technique The K Factor is what you buy! End seals and leak detection are very cost-effective insurance policies

91. Thank You For Being A Wonderful Audience