IEEES-1

Proceedings of the First International Exergy, Energy and Environment Symposium

13-17 July 2003, Izmir, Turkey
Paper No.

PIPELINES AND PIPING NETWORK IN GEOTHERMAL DISTRICT HEATING SYSTEMS

A.Caner Şener1, Gülden Gökçen1

1
İzmirInstitute of Technology Mechanical Engineering Department
Gülbahçe – Urla, 35437 İzmir, Republic of Turkey
Fax: +90.232.4986505 E-mail:[email protected], güldengö[email protected]

ABSTRACT heating systems show that, pipes are usually primary

In geothermal district heating project construction of source of problems during operation.
transmission pipeline system is required to transport
the hot water from source to user. In most of the In geothermal district heating systems piping may be
geothermal district heating projects piping constitutes divided into two categories. Geothermal transmission
the biggest part of capital investment cost. Since the pipeline which carries geothermal fluid from wells to
properties of geothermal water, infrastructure of cities heat stations and city distribution network which
and economic criterion are different for each country, distributes hot water from heat stations to customers.
standards and methods may change country to
country. Factors such as pipe sizing, pipe material, This study investigates the basic principles of route
insulation, installation, head loss, heat loss, and service selection, sizing, material selection, installation and
points should be considered before final decision. In maintenance in Turkish geothermal district heating
this study, general methods and international standards systems.
used in geothermal piping and district heating piping
will be reviewed. Then suitable methods and standards ROUTE SELECTION
and their applicability will be discussed for the Turkey Generally route of pipeline follows the shortest path
case. from geothermal well to customers. Although it is the
best solution most of the times, it may not be always
INTRODUCTION possible to follow the shortest path. Highways, land
Turkey is one of the richest countries in geothermal owners, military zones, rivers and other utility networks
potential which is mostly located at the western part of are the main obstacles in front of the pipeline route. In
the country. Characteristics of the geothermal most of the times overcoming these obstacles requires
resources in Turkey are mostly suitable for heating. The heavy bureaucracy and time. It is possible to gain time
use of medium temperature (30 to 150 oC) geothermal if applicatios are made at the very beginning of the
resources as a heat source in Turkish district heating project for a necessary permissions.
systems and greenhouses has been accelerating since
1980’s. Considering the geothermal district heating Geological structure of the area from where geothermal
projects, which are in the phase of conceptual planning pipeline passes is also important. According to the
and construction, it is obvious that geothermal energy geological structure of the region pipes may be burried
will be started to use widely for the heating purposes in or above ground pipeline system considered. In Turkish
the next decade. [1] geothermal district heating systems both geothermal
pipeline and city distribution network are burried.
Considering the fact that transmission and distribution Although city distribution networks have always been
piping generally constitute the biggest portion in a cost burried in all over the world, it is not the case for
of geothermal system. “For district heating systems, the geothermal transmission pipelines. If there is no dense
cost associated with the distribution network is settlement between wells and heat station, then both
frequently 40 - 60% of the overall capital cost of the options underground and above ground piping should
project. [2]” One of the most important factors be analysed. The primary decisive factor is cost of
influencing the success of geothermal project is proper installation for most of the cases, however external
piping from material selection to installation and corrosion risk should also be analysed.
maintenance. Since characteristics of geothermal
resources, weather conditions and infrastructure of PIPE SIZING
each city are different from each other. Each The pressure loss per unitary length is a common sizing
geothermal project is unique. Therefore there is no parameter. If the pressure loss is high, then the
standard way of piping for all geothermal district heating investment in the pipe is well utilised, but the operating
systems. cost is high. On the other hand, if the pressure loss is
low, the investment is badly utilised, but the pumping
In Turkish geothermal projects, piping has not been cost is low [3].
considered with enough attention at the beginning.
However, experiences in Turkish geothermal district The target head loss in the design of a new pipeline
system varies from 5 to 20 mm/m. While deciding target
head loss, future expansion scenarios of the system sizes. Steel is the material most familiar to pipe fitters
should be considered. If the geothermal reservoir and and installation crews. The joining method for small
customer potential are promising for the future, then it is sizes (<50 mm) is usually threading, with welding used
wisefull to lower the target pressure loss. for sizes above this level. For underground installations,
all joints are typically welded when unlined piping is
Pipe sizing is an optimisation problem. As stated before used.
each geothermal project has different conditions.
Selection of target head loss directly influences the The most important disadvantage of steel piping is
feasibility of the all project. Figure 1 shows the variation corrosion. In many geothermal fluids, there are various
pipe cost and pumping cost with target head loss for a concentrations of dissolved chemicals or gases that can
sample Turkish district heating system which is located result in corrosion. If the potential exists for this type of
at Aegean region and serves approximately 3000 attack, or if the fluid has been exposed to the air before
dwellings. However the scene in Figure 1 may entering the system, carbon steel should be the
completely change for different climates or pipe costs. material of last resort. Steel piping is used primarily on
the clean loop side of the isolation heat exchanger,
although in a few cases it has been employed as the
350,000 70,000 Annual pumping cost (Euro) geothermal transmission line material. A distinct
300,000 60,000
disadvantage in using steel pipe is that the buried pipe
Total pipe cost (Euro)

250,000 50,000 is also subject to external corrosion unless protected

200,000 40,000 with a suitable wrapping or cathodic protection [4]. For
150,000 30,000 instance, the distribution system at Balçova-Narlıdere
100,000 20,000 GDHS consists of carbon steel pipe with polyurethane
Total pipe cost
50,000 10,000 foam insulation wrapped with insulating coat (glass
Annual pumping cost
0 0 fibre) to provide a seal. The water seal degraded with
0 5 10 15 20 25 time (approximately 5 years) and allowed ground water
Target head loss (mm/m) to contact the pipe. External corrosion resulted in a
number of failures, which cause significant amount of
leakage from the system.
Figure 1: Target head loss selection
Consideration of non-metallic pipes in Turkish
PIPE MATERIALS geothermal projects is rather new. Local manufacturers
There are numerous types of piping materials which have just started to compete with steel pipe
greatly vary in cost and durability for geothermal manufacturers in terms of price. However, non-metallic
heating systems. The main classification is made pipes cannot be used at temperatures higher than 90oC
between metallic and non-metallic pipes. Among and it is still the main disadvantage. Also cost of non-
metallic pipes steel pipes (slip-joint steel (STL-S) and metallic pipes is still higher than steel pipes.
welded steel (STL-W)) are most commonly used. Types Considering the fast improvement of composite pipes, it
of non-metallic pipes can be listed as: gasketed is expected that the non-metallic pipes will be started to
polyvinyl chloride (PVC-G), solvent welded PVC (PVC- use more commonly in future geothermal projects.
S), chlorinated polyvinyl chloride (CPVC), polyethylene
(PE), cross-linked polyethylene (PEX), mechanical joint INSTALLATION
fibreglass reinforced plastic (FRP-M), FRP epoxy Installation and maintenance of pipelines can be
adhesive joint-military (FRP-EM), FRP epoxy adhesive investigated in 9 steps. [5]
joint (FRP-E), FRP gasketed joint (FRP-S), and
threaded joint FRP (FRP-T). The temperature and 1. Receipt, handling and storage
chemical quality of the geothermal fluids, in addition to 2. Excavation of trench
cost, are the decisive factors in the selection pipe 3. Installation of pipes and components
materil. Both metallic and non-metallic piping can be 4. Welds
considered for geothermal applications. Carbon steel is 5. Leak and pressure tests
the most widely used metallic pipe and has an
6. Installation of joints
acceptable service life if properly applied. [4]
7. As-built survey
8. Related work
Since metallic pipes used in higher temperatures
9. Backfilling of trench
compared to non-metallic pipes, they are commonly
used in most of the geothermal applications. In addition,
Typically preinsulated pipes and components are
its properties and installation requirements are familiar
delivered from the manufacturer’s store or plant by the
to most installation crews. The advantage of non-
manufacturer. The owner takes delivery of the goods at
metallic materials is that they are virtually impervious to
a temporary storage area or directly at the pipe trench.
most chemicals found in geothermal fluids. However,
the installation procedures, particularly for fibreglass
The owner should carry out inspection on arrival of the
and polyethylene are, in many cases, outside the
materials. An inspection on arrival should include.
experience of typical labourers and local code officials.
[4]

In Turkish GDHSs the most common selection is

carbon steel pipes (welded). Steel pipe is available in • Inspection of bill of quantaties
almost all areas and manufactured in wide range of
• Inspection of quality of materials including check for Welds can be subjected to a leak test by one of the
transport damage. following methods.
• Inspection of possible certificates
• Test with water applied at 1.3 times maximum
Any handling, transportation and storage of pipes and operating pressure with simultaneous visual
fittings, etc. must be done in consideration of the inspection of the welds for leaks.
properties of the different materials and current external • Test with air at 0.2 bar over-pressure or 0.65 bar
conditions, in order to avoid the components being below atmospheric pressure where the tightness of
subjected to harmful impacts and in order to avoid the weld is checked by application of a suitable
impurities etc. in pipes and fittings. [5] indicator fluid.
• 100% radiographic inspection of steel service pipe
Figure 2 shows a typical cross-section of the trench with where the weld seams are made up of a minimum
safety fence between the work space and the traffic at of 2 passes and if start/end positions of the two
one side, and a marked safety area to the other side of passes are mutually displaced.
the trench.
A leak test with air must be performed before the pipes
have been water-filled, e.g. for flushing or pressure test.

Once buried the only information on the location of

pipes and components are the drawings and listings
based on a survey of the executed work. [5]

This information is essential when it comes to later re-

excavation of the trench in situations such as:

• Evidence of leakage into the pipes

• Connection of new pipe sections or branches to the
Figure 2: Section of trench and surrounding speace pipes.
requirements [5] • Planning of excavation for other underground utility
networks.
When pipes and fittings are transported to the trench
site, precautions must be taken to avoid damage of the
pipes. At the trench site pipes and components are A high level of accuracy of the survey is essential for
arranged and prepared for laying and welding. [5] the effective later use of the information. Each metre of
inaccurate excavation when accessing the buried pipes
The contractor must monitor the quality of piping work is costly and so are the costs of repair of pipes, which
by establishing and maintaining a quality assurance have been damaged due to incomplete and inaccurate
system with reference to EN 729-3 (Quality information on their exact location.
requirements for welding). Welding should preferably
only take place in dry weather. Where the work is The trend is to survey the co-ordinates of the pipes and
performed during unfavourable weather conditions the components in a common local co-ordinate system.
work site must be covered with tents or equivalent. [5] However, in a transitional period co-ordinates to fixed
objects as mentioned above should also be measured
A complete visual inspection must be carried out in order to calculate measurements for finding the
throughout the entire welding process by the contractor, pipeline. Within a few years it must be expected then
the owner’s supervisors and sometimes by an external GPS (Global Positioning System) will be used. [5]
specialist consultant. [5]
The objects of the pipe systems to be exactly identified
In co-operation with the contractor the supervisor and located are for example [5]
selects the welds for non destructive testing welding
inspection. The welds are divided into inspection • Bends
sections so that welds in the same section are unlikely • Branches
to have differences in qualty. [5]
• Joints
• Valves
The leak test is compulsory and the pressure test is
• Connections of electronic surveillance system
optional and can be specified according to local
authorities or the requirements of the owner. [5] • Other special components
• Crossing of other utility cables or pipes
The main emphasis is laid on the leak test in order to
find any penetrating pinholes, which will result in
subsequent failure. [5] Installation of preinsulated bonded pipes often involves
work of another character than just fitting of
preinsulated pipes. This could include concrete works,
or work on other utilities in the trench. In many cases
the intended functioning and service life of preinsulated
pipes also depend on the execution and quality of the leakage is one of the traditional problems of Turkish
related work. Related work may include valve chambers geothermal district heating systems, however, leak test
and fixpoints, drainage and sewerage work. have never been applied in one of the Turkish
geothermal district heating projects.
The assembled pipe system must be subjected to a
final inspection by the owner’s supervisor and the Although skipping most of the standard piping
contractor prior to backfilling of the pipe trench. procedures at the beginning may decrease the
investment cost of the project, it definetely raises the
The excavation is to be backfilled in layers. Each layer maintenance cost and decrease the life of the system.
is to be completely compacted before the next layer is
laid. Where mechanical compaction is permitted, There is no question that the local contractors can
backfilling should be performed in layers of max. 300 provide sufficient level of piping standards if they are
mm which are then compacted. In the case of manual required. The project owner should be aware of the fact
compaction the height of layers is to be max. 150 mm. that quality of piping determines the future of the all
[5] project. Even the smallest deviations from standards
may result in collapse of the all project. Geothermal
Sand and gravel materials can be added directly into project owners which are generally municipalities and
the excavation using grabbing crane. If they are to be local governments should have ready list of conditions
tripped, the materials have to be unloaded at the side of to give to the contractors. These list of conditions
the excavation. Materials must never be tipped into the should be prepared by geothermal specialists and
excavation. accepted by the contractor at the beginning of the
project.
CONCLUSION
In this study higlights of the district heating piping REFERENCES
standards were given. These procedures are accepted 1. A.C. Şener, Importance of load based automatic
as minimum standards in European district heating control in geothermal energy systems, 3rd IFAC
systems. Unfortunately, there is no standard piping Workshop DECOM-TT 2003, 225-231 (2003).
approach in Turkish district heating projects. At some 2. K. Rafferty, Piping materials for geothermal district
points like reception of pipes Turkish Standards are heating systems, Geo-Heat Centre Publications.
referred, however especially at the installation level (1996).
there is no standard approach. 3. T. Karlsson, Geothermal district heating the Iceland
experience, United Nations University Geothermal
In Turkey geothermal district heating projects are Training Programme Report 1982-4, 11
mostly financed by municipalities or local governments. 4. K. D. Rafferty, Geothermal direct use engineering
In both cases the financial sources are very limited. and design guidebook, Piping, Geo-Heat Center,
This case affects the quality of piping work. In addition Klamath Falls, OR 97601, Editor in chief: J. W.
to the lack of money, geothermal district heating Lund, 1998, p.241.
projects have limited time schedule, mainly because of 5. European District Heating Manufacturers
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Experiences show that the vital points especially at the
installation phase are generally neglected. For instance,