The most complete solutions in GRP PIPES AND FITTINGS. ABRERA WATER TREATMENT PLANT (Barcelona) PROJECT REPORT DWTP 2010 / D - 7

Transcription

1 The most complete solutions in GRP PIPES AND FITTINGS 1 ABRERA WATER TREATMENT PLANT (Barcelona) 2010 / D - 7 PROJECT REPORT DWTP

2 ABRERA DRINKING WATER TREATMENT PLANT Project Managers Plant Owner: Aigües del Ter de Llobregat Contractor: Sacyr Sadyt Joint Venture Project Manager: Jordi Burguera Team Manager: Raúl Lemes Pipe Data Pipes: Glass Fiber Reinforced Polyester (GRP) ALPHASAND and ALPHACOR DN PN SN: From 150 to 1500mm. 10 bar N/m 2 and 5000 N/m 2 Joints: Bell & Spigot, Flanges and Laminated Joints 2

3 ABRERA WATER TREATMENT PLANT PROJECT REPORT DWTP PROJECT DESCRIPTION 3 The expansion and improvement of the Abrera Drinking Water Treatment Plant (Barcelona), included in the Spanish A.G.U.A programme as part of the improvement of water resource management, will provide the water supply for 20% of Barcelona s metropolitan area. The plant s main objective is to reduce the levels of salt and bromide in particular in the drinking water, in order to bring them within the limits set by current legislation. The water originates from the river Llobregat. The main project was developed in order to expand the plant s filtration and active carbon systems, including the innovation of incorporating an EDR desalination system instead of the better known reverse osmosis system. Now that the work is finished, the Water Treatment Plant is the largest in the world using electrodialysis technology, allowing for the production of a volume of 200,000 cubic metres of treated water per day, which is sufficient to supply a population of 800,000 people.

4 SCOPE OF SUPPLY. GRP The scope of the services provided by PROTESA for this project is as follows: The study and design of each of the GRP elements required for the project, based on the graphic documentation and technical specifications provided by the contractor. The manufacture and installation of: Main GRP intake pipes for the EDR plant. Modules for the EDR Treatment Building. Intake and discharge pipes from the chemical treatment to the EDR section. Installation of valves and external elements to the GRP pipes. Flange assembly. Technical assessment in the study and installation of the support system. Hydraulic Pressure Tests. The installation of Tramex safety flooring. 4

5 ABRERA WATER TREATMENT PLANT PROJECT REPORT DWTP DESIGN AND MANUFACTURING SYSTEM. GRP The design and manufacturing processes of the pipes used for the project were carried out in the following stages: 1) Structural design: PROTESA s Technical Department designed each of the pipes based on the system s requirements and the characteristics of the installation, differentiating between underground and aboveground pipelines. The manufacturing process used by PROTESA is known as Crossed Filament Winding and consists of continuous filaments of glass fiber roving, previously impregnated with resin, being wound onto a rotating metal mold, which has already been covered with a corrosion-proof barrier. This system allows the winding angle to be varied, in order to produce the required mechanical properties. The following types of pipe were produced for this project: 5 ALPHASAND structures with the incorporation of aggregate loads in the structural layer (giving the pipe greater Hoop Stiffness) and a winding angle of almost 70º, for underground pipelines subject to local loads and external factors. ALPHACOR structures made exclusively and entirely of continuous filament, glass fiber and resin. These pipes have a winding angle of around 55º, giving them greater Axial Tensile Strength, which makes them able to withstand the spans required by the installation. 2) Technical Assessment for Approval of Supports: providing the necessary mechanical properties for each diameter, pressure and type of installation and analysing the design and positioning of each of the supports. 3) Material Supply: in accordance with the material list drawn up for the project. 4) Pipeline Installation: PROTESA has an independent and completely qualified assembly team to carry out all of the installation work, finishing this within the required deadlines and to the client s complete satisfaction.

6 PROJECT DEVELOPMENT Filtration Stage. Cartridge Filters. Having already been pre-treated, for safety reasons it is also necessary for the river water to be filtered before reaching the EDR system. This filtration guarantees that any small particles in suspension are completely eliminated. 6

7 ABRERA WATER TREATMENT PLANT PROJECT REPORT DWTP Main GRP intake and discharge pipes for the EDR system: These are the pipes connected to the EDR modules as well as those used for transporting the desalinated product water and waste brine. These pipes are made entirely of GRP. The desalinated water is transported to a tank, in order to be re-mineralized by means of a calcite bed, and is then finally distributed via the supply network. The installation of the pipes was a complex operation, as this had to be carried out in a very reduced space due to the fact that the area available for the expansion was restricted to the limits of the existing plant. The design and size of these pipes needed to be suitable for both the chemical and installation requirements (allowable span, pressure etc.) and for that reason, PROTESA s Technical Department worked in close conjunction with the Joint Venture s own Technical Team. 7

8 Modules of the EDR Treatment Building: The pipes for the pumping system are made entirely of GRP. The water is pumped into the EDR modules, where the desalination process takes place. From this operation two types of water are obtained, the product water, which is then put through a pre-treatment process before being distributed via the drinking water supply network and the waste product, which is highly concentrated brine. 8

9 ABRERA WATER TREATMENT PLANT PROJECT REPORT DWTP Pump Connection. EDR Modules. 9

10 Chemical area pipes for cleaning pumps and the main intake and discharge lines for the chemical cleaning of the EDR system: The chemical cleaning process is an operation that is carried out periodically, in order to eliminate accumulations of dirt in the membranes after long working periods or plant shut-downs, and has the aim of lengthening the life-span of the filtration system. The process consists of re-circulating the cleaning solution through the membranes at high speed and transporting the waste water to the waste tank. As both the cleaning product and waste product obtained during the desalination process are highly corrosive, Glass Fiber Reinforced Polyester pipes have been used for all of these pipelines. 10

11 ABRERA WATER TREATMENT PLANT PROJECT REPORT DWTP PROJECT COMPLETION Each project milestone was completed to deadline, with entirely satisfactory results at each stage of commissioning. Both the Project Management and the Plant Owners expressed their satisfaction, congratulating PROTESA s team for the work carried out and the service provided. The largest EDR plant in the world using calcite beds for re-mineralization. Protesa s efficient performance in the ABRERA project earned it a distinction at the GLOBAL WATER AWARDS

12 ABRERA (BARCELONA) WATER TREATMENT PLANT Esther Mazuela Project Manager Industrial Plant Division c/ Industria, 3-5 Polígon Industrial Anoia SANT ESTEVE SESROVIRES (Barcelona - España) Tel. (+34) Fax (+34) protesa@protesa.es