General information 1:101 - Powerpipe

General information 1:101
Preface
This catalogue introduces Powerpipe Systems AB and presents the product program and services which the
company offers. Product specifications are completed with important information with regards to handling and
installation of the products. Per definition, applicable technical standards are referred to in the catalogue as well as
quality control systems and their daily influence on our operations.
Powerpipe is the brand name for the products manufactured and services rendered by Powerpipe Systems AB and
Powerpipe AS.
Standards and other local regulations have been considered to the extent that they are valid at the date of issue of
the catalogue.
The specifications of the catalogue are subject to change without previous notification.
Disposition
This general information briefly gives information about the company Powerpipe Systems AB, its preinsulated pipe
systems as well as our technical specifications, technical standards, quality and environmental policies.
In the following chapters, detailed product specifications are given together with instructions on how to order these
items.
Finally, you will find chapters on the design of district heating systems based on the Powerpipe technology, as well
as instructions on how to handle Powerpipe products and installation of the same.

General information 1:102
Powerpipe
Powerpipe represents more than 20 years of experience in the field of development, design, manufacturing and
marketing of preinsulated pipe systems. The Powerpipe systems and technologies have been sold to and installed
at customers in Europe and Asia.
Powerpipe has the documented experience and capacity for managing deliveries ranging from complete turn-key
projects for complete distribution systems to the supply of components. Our preinsulated systems can be used for
a wide range of applications such as district heating distribution systems, district cooling distribution systems and
industrial processes.
Continuous research and development in close co-operation with our customers, raw materials suppliers, the
Swedish District Heating Association, universities and testing institutes guarantees a high quality of our products
based on state of the art technology.
Powerpipe was certified according to the international quality standard ISO 9001:2000 and the international
environmental standard ISO 14001:2004 by Bureau Veritas.
When designing a system for preinsulated district heating pipes, the forces exposed to the system has to be
considered. Such forces formed by thermal expansion and friction will vary depending on the conditions under
which the system is installed. In order to secure a long life of the system, these forces (stresses) should be
calculated and compared to given limits.
Powerpipe has developed a unique PC based, static calculation program to help the designer make these
calculations. For further information, please contact our sales staff.
preinsulated pipe system
Powerpipe products are built up as a bonded system using a normal steel service pipe surrounded by a
polyurethane foam and with an outer impact-proof polyethylene casing pipe (PEH). The service pipe is centred in
the PEH casing by means of distance holders.
The Powerpipe system is built up from straight pipes and curved pipes together with fittings like bends, T-pieces,
valves, compensators, anchor units etc. All products are, as standard, equipped with two copper alarm wires for
connection to an electronic moisture surveillance system. Of couse, other surveillance systems can be delivered
upon request. Powerpipe optionally offers the electronic surveillance system and its installation as part of the
system.
By use of the Powerpipe components, most customer specific demands on the system layout can easily be met.
The Powerpipe components are designed and type certified according to the standards EN253, EN448, EN488
and EN489.
Insulation
In 1989 Powerpipe pioneered the first commercially available, technically approved, completely CFC-free foam for
preinsulated pipes. The technology was at the time a CO2 based insulation foam.
During the 1990s Powerpipe followed the market development for PUR foam, which was merely concentrated on
attempts to develope CFC-free foams. As Powerpipe already had developed CFC-free foam, we concentrated our
research on improving foam thermal and mechanical resistance, insulation capacity and other important foam
characteristics.
After further advanced research and extensive test procedures, Powerpipe introduced in 1998 a high performance
pentane based PUR insulation foam for preinsulated pipes with, excellent technical characteristics.

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Norms and Standards
Powerpipe´s products are manufactured according to the European standards for preinsulated pipes and fittings.
These are:
District heating systems – Prefabricated thermally insulated pipe-in-pipe assemblies for underground hot water
networks, comprising a steel service pipe from DN20 to DN900, rigid polyurethane foam insulation and an outer
casing of polyethylene.
EN253:2003 Preinsulated bonded pipe systems for underground hot water networks – Pipe assembly of steel
service pipes, polyurethane thermal insulation and outer casing of polyethylene.
EN448:2003 Preinsulated bonded pipe systems for underground hot water networks – Fitting assemblies of
steel service pipes, polyurethane thermal insulation and outer casing of polyethylene (PE).
EN488:2003 Preinsulated bonded pipe systems for underground hot water networks – Steel valve assembly
for steel service pipes, polyurethane thermal insulation and outer casing of polyethylene.
EN489:2003 Preinsulated bonded pipe systems for underground hot water networks – Joint assembly for
steel service pipes, polyurethane thermal insulation and outer casing of polyethylene.
EN14419:2003 District heating pipes - Preinsulated bonded pipe systems for directly buried hot water
networks - Surveillance systems.
EN1394:2003 Design and installation of preinsulated bonded pipe systems for district heating.
In addition to the above standards, there are sometimes local domestic standards, which might differ from the
above European standards. Powerpipe can, on demand and after having evaluated any economic consequences
resulting from application of such special regulations, deliver products that fully comply with such special
regulations.

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Technical Specifications
Service pipe (Steel)
Unless otherwise stated in the order, in request or quotation, the following steel qualities are delivered as standard.
Straight pipes Longitudinally or spirally welded steel pipe
Insulation (PUR)
Materials: P235GH according to EN10216-2, EN10217-2 or EN10217-5.
For small dimensions P235TRI according to EN10217-1 or EN10217-2
can be accepted according EN253:2003/A2:2006.
Certificate: According to EN 10204/ 3.1.B
( can be delivered with each shipment provided our
customer forwards this requirement with the order )
Standard: EN253:2003
Seamless steel pipe ( can be delivered on request )
Materials: Normally P235GH in accordance with EN10216-2.
Certificate: According to EN 10204/ 3.1.B
( can be delivered with each shipment provided our
customer forwards this requirement with the order )
Standard: EN253:2003
Powerfoam, the brand name for Powerpipe insulation, is a hard polyurethane foam with extremely low thermal
conductivity, superior mechanical and ageing performance.
Materials: polyurethane foam produced by polyols and
isocyanate. Blowing agent is C-pentane.
Mixing and dosage takes place in a modern
high pressure system.
Standards: EN253
Typical data for Requirements
Powerfoam CP-99 EN253
Cell size, mm 0.27 = 88
Core density, kg/m3 73 = 0.30
Water absorption, %
Axial shear strength, MPa
3.50 = 0.12
+230C, aged 0.14 >= 0.12
+1400C, new 0.22 >= 0.08
+1400C, aged 0.13 >= 0.08
Thermal conductivity, W/mK 0.027

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Technical Specifications
Casing pipe (HDPE)
All preinsulated pipes and fittings are produced from PEH casing pipes produced by Powerpipe according to
standards issued by the Swedish Plastic Pipe Manufacturers Association.
All casing pipes are treated by corona directly in our extrusion process.
Fittings
Materials: High density polyethylene (HDPE)
Density: ≥ 944 kg/ m3
Standard: EN253:2003
Pipe wall thickness: According to EN253:2003
The material, fulfilling all functional requirements specified in EN253, is stabilised to withstand
thermal, chemical and oxidative degradation. It has a high impact strength and weather
resistance even at low temperatures. Other features are excellent welding characteristics
and high resistance against stress corrosion.
Note: preinsulated pipes with a casing diameter > 560 mm are to be handled with care at
outdoor temperatures between 0 and – 20 0C. Should the outer temperature fall below -20 0C, such pipes shall not be handled without prior instruction from Powerpipe.
All fittings meet the functional requirements specified in EN448:2003 and are designed to meet all normally
upcoming loads in a district heating net.
Steelbends are delivered as bended or welded. Material is normally P235GH according to EN 10217-2.
Preinsulated closing valves withstand the yield strength (300MPa) of connecting steel pipe with full controllable
functions.

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Technical Specifications
Joints
Powerpipe offers a complete range of field joints to suit different installation conditions and customer demands.
The jointing methods fulfil the technical demands specified in the standard and has passed the so called sand
box test with positive result.
The field joints for preinsulated district heating pipes can be divided into 3 different types:
● Electro welding joint
● Heat-shrinkable casing
● Oversized casing
The joints are manufactured from high density polyethylene (HDPE).If not otherwise specified, the heat shrinkable
materials are manufactured from expanded high density polyethylene or cross linked material. The HDPE jointing
sleeves can optionally be delivered with an inside coating of mastic or hot melt to increase the performance of the
joint.
Most of our joints are installed using a gas flame torch. For installation of the electro welding joints, an electric
welding unit combined with a hand extruder is used.

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Quality
Powerpipe Systems AB works according to a Quality Management concept, which ensures the quality performance
during all stages of the operations, ranging from Research & Development to delivery and installation of complete
systems. In 1997 Powerpipe was awarded the Bureau Veritas certificate for ISO 9001.
The quality system gives a guarantee that contractual demands as well as applicable standards and norms are
fulfilled.
Quality Policy
● Powerpipe shall produce products in accordance with demands from customer and valid EN-standards.
● By continously improve our production processes, procedures, material an educational level reduce number
of failure to zero.
● Deliveries of products and services in due time at expected level of quality.
Quality System
Powerpipe´s quality system is aimed at structuring and developing the use of a well-documented system based on
ISO9001:2000. This will guarantee that the company always fulfils its contractual agreements.
The quality system includes the organisation of the company, its routines as well as the use of processes and
resources, so that these interact in a harmonised way, ensuring that the products are delivered at the agreed time
as well as have a quality, which is defined in the quality policy.
ISO
9001

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Testing
Powerpipe has routines for continuous supervision and testing of products.
This, combined with documented routines for the calibration of processes and machinery, is our way of ensuring
the delivery of products of a high and even quality.
Our internal quality control system performs and is documented as follows:
● visual inspection of the products and checking of the alarm wire during 100% of the production.
● continuous checking in our laboratory of foam density and HDPE-quality for pipes and fittings produced.
● at least twice a year, tests according to EN253 on pipes and fittings including
- axial shear strength
- yield strength
- water absorption
- compressive strength
- voids and bubbles
- cell size
Steel welds for fittings are checked according to EN253 or according to agreement with the customer.
Official tests
Powerpipe Systems AB´s internal continuous control system is supervised by the National Swedish Testing
Institute (SP). Twice a year, SP performs an audit of our manufacturing process as well as performs external tests
on our products according to EN253. The result of such tests are published in official reports.
Powerpipe Systems AB is awarded a P-mark for the Swedish market and a LT-mark for the Finish market. These
awards are based on regulary check from testing institutes that the products follows all demands in the standards
EN253:2003, EN448:2003 and EN488:2003.

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Environment
Ever since Powerpipe was established in 1987, the company´s policy has been to develop environmentally friendly
products and production processes.
In 1989, Powerpipe pioneered the introduction of the first commercially available, technically, approved completely
CFC-free foam for preinsulated pipes. This excellent innovation influenced the Swedish Government as the first
country in the world to change the law.
The new law, which came into force on 1st July 1991, banned all import, production or use in Sweden of CFC
foam insulation in preinsulated pipes for district heating.
Powerpipe´s environmentally friendly profile and policy has resulted in a number of projects, having a positive
influence on the environment.
Environmental Program
The environmental program at Powerpipe is based on ISO 14000:2004.
The program also includes a control plan for the external environment. The plan describes the activites, discharges
and permitted discharges, inspections, waste handling including waste utilitation and reports procdures internal
and to authorities.
The local environmental autohority inspects the business twice a year.
Recycling
During the production of preinsulated pipes and fittings, different types of waste materials are produced. Such
waste comes from the start up of the process and sometimes also from products rejected by our quality control.
Powerpipe has defined routines for how to handle these waste materials.
● PEH is re-granulated and re-used
● Steel pipes are re-used, when possible, in our own production or else sent as steel scrap for re-melting.
● PUR foam is sent to an incineration plant where it is burned (generates district heating)
● Alarm wire will be sent as scrap for re-melting
● In case some dangerous waste occurs it will be collected in a separate storage and be sent to refuse
incineration.
Environmental policy
Powerpipe Systems AB develops, produce and offer environmental products for district heating and industrial
applications. Due to the supply to the Society with high-insulated products, which intend to give a good long-term
energy supply. We are convinced that an activity regarding environmental issues is creating a competitive strength
on long term and will strengthen our reputation on the market.
We achieve it with:
● Prevent pollution in air, ground and water.
● The Transports internal as external shall encourage for a decreased influencing on environment.
● To do constant improvement in production facilities which leads to effectiveness in increased use of energy
and material.
● Laws and regulation will be followed and provided.

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