Repairing critical pipe leaks with Hydro Stop encapsulation collar in Southern Italy

Eight major leaks in the DN3000 pipeline were repaired using encapsulation collars.

The largest and most important pipeline in southern Italy, Adduttore Sinni, were in critical need of repair. The DN3000 pipeline supplying fresh water to Apulia and Lucania, serving about 4.5 million people had several leaks. The pipeline goes from the Sinni dam to the western part of Taranto district, covering a distance of about 133 kilometres.

Leaks on the pipeline means physical loss of water, and also unnecessary consumption of energy for producing and pumping clean water that is finally lost through the leaks.

Eight critical leaks; eight customised collars

There were several leaks on the old joints, so it was essential to plan the repair without causing any water stoppage on this important distribution line. Additionally the E.I.P.L.I.’s technicians had identified eight critical leaks in the pipeline that needed particular attention and so Hydrocos was invited to inspect them to provide a specific solution for each of them. The situation was, the DN3000 flanges that connected the pipes, as well as the expansion joints, were worn out and had started to leak severely. Considering the disruption of water supplies would potentially involve the large population in the area, the only possible way to perform any repair was by using our Hydro Stop socket encapsulation collars.

For the eight leaks, eight different variants of Hydro Stop collars capable of working not only as encapsulation and repair collars but also as expansion joints were designed.

Challenging installation conditions

Seven days after the first inspection of the pipeline, the first Hydro Stop was installed at location where the most severe leak was detected. In the following months, additional collars were manufactured and installed on the remaining leaks to reduce water losses.

Severe conditions faced during installation

The most challenging installation was performed in the Montescaglioso district, where the pipeline crossed hillside. This special circumstance caused a pressure increase from an average of 10 to 16 bar up to a peak of 24 bar; a very high pressure for such an enormous pipeline! Stopping this leak was a real challenge, so; to oversize the collar to ensure the highest possible reliability over time was the best solution.The largest collars installed to date.

What surprised E.I.P.L.I. management was the flexibility and reliability of our product, and to date, these DN3000 collars are the largest socket-encapsulating collars ever installed.

Product Details - Hydro Stop encapsulation collars

The Hydro Stop socket encapsulation collar is a universal repair collar designed to seal and encapsulate a leakage on the sleeve of a pipe as well as leaking or displaced spigot/socket joints - all while the pipeline is under pressure.

The shaped carter can accommodate any type of pipe socket, including joints connecting two pipes of different materials, flange connections on steel pipes as well as remnants of any previous repairs. The collar features up to 40mm pipe OD tolerance, and is a good and safe solution even when the pipe OD has not been correctly detected, and in case of oval or other ways damaged pipes.

Contact us to learn more about Hydro-Cos solutions, Hydro Stop range of products and your local possibilities.

Hydro Stop is availaible in different sizes DN250 - DN3000.

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Encapsulation Collars

An introduction to our range of encapsulation collars and case stories.