BIOSECURITY PIPE SYSTEMS - Pipex px ® - … · 1. SYSTEMS INTRODUCTION 1.1 Background: Pipex px® are the leading company supplying worldwide engineering projects with proprietary

For the safe, fully sealed transmission of bio-hazardous fluids, gases and wastes, including human & animal infectious diseases in high containment level ACDP & SAPO CL3 & CL4 licensed facilities.

Plymouth: +44 (0)1752 581200 Glasgow: +44 (0)1698 818222 Email: [email protected] www.pipexpx.com

BIOSECURITY PIPE SYSTEMS

CONTENTS 1. Pipex px® BIOSAFE® Pipe Systems Introduction: 1.1 Background 1.2 Systems Description 1.3 Systems Bio-Security Features & Advantages 1.4 Pipex px® Technical Services 2. Pipex px® BIOSAFE® Pipe Systems Data: 2.1 Materials Properties & Characteristics 2.2 Bio-Security Containment Options 2.3 Product Data – Dual Contained Pipe 2.4 Product Data – Dual Contained Pipe Fittings 2.5 Product Data – Dual Contained Manholes & Chambers 2.6 Product Data – Dual Contained Floor Drains 2.7 Product Data – Dual Contained Floor Channels 2.8 Product Data - Bio-secure Manhole Cover Systems 2.9 Product Data – Bio-secure Jointing Systems 2.10 Integral Maintenance Access Trench Options. 3. Pipex px® BIOSAFE® Pipe Systems Information: 3.1 Pipex px® Completed Projects Case History List. 3.2 Applicable Standards 3.3 References & Abbreviations 4. Pipex px® CSR & Environmental Commitment 4.1 Environmental Product Innovation.


PIPEX px® BIOSAFE® BIOSECURITY PIPE SYSTEMS

1. SYSTEMS INTRODUCTION 1.1 Background: Pipex px® are the leading company supplying worldwide engineering projects with proprietary corrosion resistant pipe systems, structures & construction products manufactured in premium grade thermoplastic, stainless steel & FRP composite materials, suitable for a diverse range of specialist applications ranging from wastewater through to warships. Wherever a risk of chemical pollution exists, such as in laboratory or water treatment facilities, then a range of guidelines & regulations such as the Pollution Prevention Guidelines require designers & facility owners to ensure that pipe systems are installed & maintained in a manner to ensure that hazardous substances shall be conveyed in a safe & controlled fashion to prevent chemical pollution. Pipex px® CHEMSAFE® chemical pipe systems to BS EN 1852 as standard are the industry standard to deliver this requirement for the secure transmission of corrosive chemical fluids, gases & trade effluent wastes, including in extreme pipe environments with high temperatures and aggressive cleaning agents present. Additionally wherever a risk of serious biological pollution or contamination exists, such as at nuclear or life sciences facilities, then additional legal requirements exist. For example in the research of infectious animal pathogens like Foot & Mouth disease, the Specified Animal Pathogen Order (SAPO) sets out additional legislative requirements for the licensing of laboratory facilities, and stipulates the way in which specified animal pathogens covered by a particular licence must be handled to ensure their safe operational containment and disposal. Specified animal pathogens are currently classified into four categories by DEFRA, with category or containment level 4 (CL4) highly hazardous pathogens being subject to particularly stringent containment level (CL) controls. Pipex px® BIOSAFE® biosecure pipe systems are the proven solution to meet bio-secure containment level requirements for pipe systems & infrastructures, including ACDP & SAPO CL 3 & 4 licensed laboratory facilities for the safe, fully sealed transmission of bio-hazardous fluids and gases, including human & animal infectious diseases. Pipex px® are wholly & demonstrably committed in our business operations to provide high quality products whilst ensuring the protection of the natural & built environment locally, nationally & globally. Pipex is rare for an SME, holding all 3 principle business management system accreditations 9001, 18001 & 14001 – we manage excellence.



1.2 Description: Pipex px® BIOSAFE® bio-secure pipe systems are designed for enhanced bio-security and high containment level (CL) & HAZOP safety integrity level (SIL) applications, in relation to the threat to humans health, animal health or to the natural environment from biological infection, contamination or pollution. Pipex px® BIOSAFE® Pipe Systems are the industry standard for the fully sealed, secure transmission & high containment level of human and animal infectious diseases & pathogens in SAPO (Specified Animal Pathogen Order) & ACDP (Advisory Committee Dangerous Pathogens) CL3 & CL4 licensed research laboratory facilities, and for the transmission & high containment levels of extremely bio-hazardous substances such as radioactive media at nuclear power plants. Additionally Pipex px® BIOSAFE® Pipe Systems are applied to provide enhanced layers of environmental protection to specific critical elements of otherwise standard industrial single or double contained pipe systems at points of increased sensitivity or threat from the risk of pollution, for example where industrial pipe systems make river crossings or are in proximity to water courses or aquifers. Pipex px® BIOSAFE® Pipe Systems are an evolution of standard Pipex px® CHEMSAFE® double contained piping products, providing additional enhanced & unique bio-security design features & operational performance. Pipex px® BIOSAFE® Pipe Systems are bespoke fabrications, supplied tailored to meet the exact bio-security requirements of individual end user operators and facility owners. The systems are metric and consist of a primary “carrier” pipe located within, and integral to, a secondary outer “containment” pipe providing the basis of a robust & bio-secure “jacket” system.

(Cross-section through typical

Pipex px® BIOSAFE® Pipe Systems unique BIOSEAL multi barrier bio-secure joint

system)



1.3 Bio-Security Features & Advantages:

Designed for maximum visual inspection & minimum physical man-entry maintenance during operational service life.

Provides several robust but affordable bio-security barriers for multi-layer protection of installed systems. Wet or dry jacket containment options, and various continuous validation management options, mean that in the event of a system failure any bio-hazardous media can be effectively contained, located, isolated, identified & dealt with as required - this allows site & system specific bio-security SOP’s & HAZOP’s to be accurately produced & implemented.

Manufactured from latest generation, premium grade heavy wall alpha-nucleated homopolymer polypropylene thermoplastic materials, providing enhanced material safety margins, corrosion resistance, mechanical properties & traceability, and therefore optimal performance & longevity of

installed systems.

Unique, robust multi-layer protection BIOSEAL™ jointing systems for optimal bio-secure protection.

Meets the fully welded & sealed requirements as stated in 2007 HSE report into foot & mouth outbreak i.e. “*) demonstrably leak proof *) airtight; or negatively pressured *) proofed against ingress and egress of insects *) isolated from flooding.”

Materials of manufacture prohibit propagation of pathogens or bio-fouling by micro-organisms, and due to excellent corrosion resistance properties are suitable for use with aggressive cleaning agents like peracetic acid and sodium hypochlorite, and for operational and maintenance temperatures to 140ºC.

Smooth bore fittings are factory manufactured swept to flow i.e. 91.5º bends etc all factory pipe joints are constructed using fully automated welding equipment, for seamless welds & crevice free systems welded by skilled operatives certified to TWI CSWIP-PW-6-96.

Structural integrity test (Negative internal pressure test): - to BSEN 13598-2:2009: Pipex BIOSAFE® chamber tested and approved at a pressure of -0.6 bar vacuum for 1000 hours in BBA approved test.

Durability test: - to BSEN 13598-2:2009, Pipex BIOSAFE® chamber tested and approved for 1000 hours, at 80 ± 2°C. Test pressure (max) = -0.1 x H/R bar.

Impact resistance Test: to BSEN 13598-2:2009, 1kg 50mm striker dropped from 2.5 meters; temperature 23 ± 2°c.

Vertical load test: - (BS 7158:2001, Clause 7.7). Vertical load of 15kN (Class A15) applied and horizontal deflection measured and should not exceed 6% of the chamber diameter. Pipex BIOSAFE® chambers are suitable for use up to D400, providing the chambers are installed to manufacturer’s instructions.



1.4 Pipex px® Technical Support Services

Pipex px® offer one stop design & build services in accordance with LRQA accredited ISO9001 quality, OHSAS18001 health & safety & ISO14001 environmental business management systems, including:

DESIGN: Site surveys. Full insurances held, including professional indemnity insurances, for complete systems & process

design. Alternatively Pipex can work to a client or designers general arrangement design. Material corrosion resistance checks & selections. 2D & 3D AutoCAD libraries available for all system product component parts. Effluent Treatment Plant (ETP) design & installation available if required.

PROJECT MANAGEMENT: Offsite or site based expert project managers. Project coordination & delivery. Project technical standards compliance. Project records and documentation, including O&M Manuals, for complete traceability.

STATE OF THE ART MANUFACTURING: All factory & site manufacturing & welding activities conducted by TWI certificated welders to BS

EN 13067 & CSWIP standards, and all itemised factory tested prefabricated spools supplied with supporting individual test certification & data sheets for full traceability.

Manhole & chamber BBA certificates confirm testing & manufacture to BS EN 13578 - UNIQUE.

SITE INSTALLATION & COMMISSIONING: Conducted by experienced & expert Pipex Field Service Engineers who understand SAPO & ACDP

systems specific documentation and quality standards, that are key to any successful installation.

SERVICE VALIDATION TESTING & MAINTENANCE: 3rd party training



2. SYSTEMS INFORMATION

2.1 Materials Properties & Characteristics

Polypropylene (PP) is a generic term for a wide range of PP thermoplastic corrosion resistant materials that are available in different “grades”, with each PP grade performing differently due to varying materials properties and characteristics, therefore making each PP grade suitable for different types of industrial operational pipe system applications. Correct material and materials grade selection is vital.

Pipex px® BIOSAFE® Pipe Systems are typically supplied in premium grade PP-H alpha-nucleated polypropylene materials (PX PP-H 100 α+), providing the following extensive bio-secure materials advantages:

Fine crystalline structure equals improved hydraulic properties due to lower surface roughness (i.e. enhanced smoothness) of the internal pipe surfaces. The extremely low surface roughness makes internal pipe bores less susceptible to incrustation or accumulation of bacteria, micro-organisms or “bio-fouling”, with reduced maintenance requirements due to ultra smooth surfaces. Materials are also available with integral anti-bacterial agents to prevent MRSA etc.

Increased toughness and enhanced rigidity of the materials provides greater functionality along with improved safety margins especially at high or low temperatures.

Superior creep structure strength resistance to slow crack growth as measured in the FNCT (Full Notch Creep Test) enhances materials & systems safety margins. Greatly improved resistance to slow crack growth equals longer service life & significantly enhanced reliability.

Annealing processed during materials manufacture reduce residual stress and thus lower internal stress potential.

Enhanced chemical resistance, stable morphology & superior enhanced stress crack resistance as a result of highly stable crystalline structure reducing materials related stress failure factors i.e. internal or external chemical attack at critical system points like weld seams etc. Operational reliability, chemical versitilty and safety is enhanced.

Excellent welding properties & stable materials morphology reduce the potential level of stress concentrations in the notch root of welds, significantly enhance welding and jointing procedures, the overall seamless quality & integrity of the assembled parts and the safety margin of the installed system. This enables a demonstrably air and fluid leak proof system for bio-security.

Additional material combinations are available for specific corrosion, pressure or temperature resistance requirements including GRE, FRP PVDF, CPVC, ECTFE & stainless steel materials; Pipex will confirm materials selection case by case with clients.

Pictured Above: grades of PP-H materials viewed under microscope

Top Left: PP-H non-nucleated

Top Right: PP-H mildly nucleated.

Bottom Left: PP-H β beta-nucleated.

Bottom Right: PP-H 100 α+ alpha-plus-nucleated, as used by Pipex

BIOSAFE®



Pipex px® use high grade homogenous materials for all parts throughout for a fully welded/sealed system, typically alpha

nucleated PP-H grade polypropylene giving significantly enhanced resistance to chemicals & corrosion compared to other plastics.



2.2 Systems Bio-Security Containment Design Options:

Different methods can be adopted for containment and early warning alarm systems:

Option

Option

1. Dry jacket system “option” for integral leak detection probes located at strategic points withinthe secondary containment annular void, see Fig 1.

2. Dry jacket system “option” with additional surge probe to detect full flows or blockages withinprimary drain, see Fig 2.



3. Wet jacket system “option” for continuous pressurised fluid validation within the secondarycontainment annular void i.e. inert dyes, see Fig 3.

4. Wet jacket system “option” for neutralising agents to be in continual circulation within thesecondary containment annular void, with PH monitoring instrumentation for constantvalidation of the agent, see Fig 3.

Other non standard options are available, including Wet/Dry system option for deluge of neutralising agents into the secondary containment annular void, and dry jacket system “option” for continuous pressurised air validation within the primary and/or secondary containment annular void i.e. monitored & recorded vacuum negative air pressures.

Option

Option



2.3 Product Data – Heavy Gauge Dual Contained Pipe

The system typically comprises a secondary containment pipe either SDR33 for dry systems and SDR17.6 for wet (pressurized) containment systems, the primary containment pipe is SDR17.6 for both options in either gravity or pressurized applications.

The internal and external surfaces of pipes and fittings shall be smooth, clean and free from grooving, blistering, impurities and pores. Pipe ends shall be cleanly cut and the ends of fittings shall be square to their axis. Colour – Beige Grey (RAL 7037).

(Pipex px® BIOSAFE® Pipe Systems material combinations: thermoplastic, stainless steel or FRP primary containment pipe options )

Table 1 Nominal Design Sizes & Pressure Ratings

Size O.D. Size N.B. Secondary SDR Primary SDR

90x40 75x32 SDR17.6 - 7.5 Bar SDR17.6 - 7.5 Bar

90x50 75x40 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

110x63 100x50 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

160x90 150x75 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

160x110 150x100 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

225x160 200x150 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

315x225 300x200 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

315x250 300x225 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar

400x315 375x280 SDR 17.6 – 7.5 Bar SDR17.6 - 7.5 Bar



Typical Pipe Fitting Features

1. Secondary containment (SDR17.6)2. Primary carrier drain (SDR17.6)3. Branch butt fusion joint4. Reducing plate butt fusion joint5. End of secondary containment butt fusion joint6. Spacer welded to primary drain7. Jointing length dimension8. Secondary branch route and speed/extrusion weld9. Position of spacer for site butt fusion joint10. Jointing length dimension (tail length)

2.4 Product Data – Dual Contained Fittings







(Internal Pipe Work & Valves)

(Containment Manhole Covers)

2.5 Product Data – Dual Contained Manholes & Chambers

Pipex x® manufacture bespoke dual contained manholes to BS EN 13598:2. The detail below indicates the standard requirement for the design and fabrication of a bio-secure drainage system. The manholes can be manufactured from materials with integral anti-bacterial agents if required i.e. anti-MRSA.

1. Manhole fabricated & tested to BS EN 13598:22. Reinforcement rib3. Lifting Lugs4. Reinforced base5. Manhole step to BSEN13101:20026. Butt fusion primary drain fittings7. PN10 Access flange assembly8. Dual contained branch connection9. Hydraulic loop connection with valve10. Test and drain nipples11. Primary drain surcharge probe (optional)12. Manhole leak detection probe13. Cable duct entry with watertight cable glands14. Bolted secondary inspection cover with gasket

seal15. Threaded dosing port with ‘o’ ring seal16. Shuttering welded to manhole for concrete sur-

round17. Viewing port, stainless steel, borosilicate glass18. Insect Screen (if applicable)19. Embossed finish for bonding to concrete and

damp proof membrane.20. Stainless steel lifting handle to containment cover21. Concrete base



PIPEX

2.6 Product Data – Dual Contained Floor Drains

Dual contained floor drains are located within containment rooms for the safe disposal or wash down of contaminated trade effluent waste. The floor drains are manufactured from heavy gauge PP-H. Machine Butt Fusion welding processes are used for the assembly of the individual components to provide a fully welded containment sealed component. The trap is formed with a removal dip tube and nitrile ‘o’ ring sealing ring, the dip tube when removed facilitates access for rodding the interconnecting drainage system.

Red = Primary Pipe Layer Blue = Secondary Pipe Layer



2.7 Product Data - Dual Contained Floor Channels

(BIOSAFE® Dual Contained Floor Channels With FRP Non Corrosive Grating Covers)

Red = Primary Pipe Layer Blue = Secondary Pipe Layer

Pipex px® unique BIOSAFE® dual contained floor channels are the ideal solution for the secure transportation of hazardous materials. These innovative channels ensure that hazardous materials remain securely contained.



2.8 Product Data – Bio-Secure Sealed Manhole Covers & Validation Ports

(Fully sealed manhole covers and validation points available on all Pipex BIOSAFE® & CHEMSAFE® products)

Pipex px® unique CHEMSAFE®

& BIOSAFE® stainless steel manhole covers and PP-H

manhole chambers are fully sealed air tight units with

integrated test validation ports, ensuring the safe containment of

hazardous materials & gases.



2.9 Product Data - Bio-Secure Joint Systems

Pipex px® bio-secure site joint is a fully welded homogenous dual contained joint that provides robust multi-layer bio-secure protection with crack free smooth internal bores. The sequence detail below describes the 5 general stages to completing the joint on site.

Joint Stage 2

Joint Stage 1

PIPEX BIOSAFE® BIOSECURITY PIPE SYSTEMS



Joint Stage 3

Joint Stage 4



(Assembled Bio-Secure joints inside a Pipex BIOSAFE® Tank)

Joint Stage 5



2.10 Integral Maintenance Access Trenches:

To avoid buried systems Pipex px® can provide the pipe system contained within a modular trench systems complete with sealed access covers:

(Pipex px® FRP solid top HD grating cover, used to protect cables and pipe work running the length of the facility,

whilst allowing easy maintenance access)



3. SYSTEMS INFORMATION

3.1 Pipex px® SAPO & ACDP Projects Case History List

Wyeth Medica, Dublin, Ireland. GSK Dartford, Stevenage, Worthing & Coleford Sites, UK. MSD Hoddesdon UK Pfizer Sandwich, Kent, UK. Fisheries Research Centre, Aberdeen Piwet Veterinary labs, Poland Institute for Animal Health – Pirbright UK. Institute for Animal Health – Compton UK. MAFF DEFRA Veterinary Laboratories Agency (VLA) CVL – Weybridge UK. Merial Pirbright UK. DSTL, Porton Down Pfizers Pegasus Sweden Centrecor, Ireland. Bio-Gen, Denmark Lonza Genetech, Spain Genzyme, Spain AWE Aldermaston BNFL, Sellafield BNS DML Devonport Dockyard Nuclear Submarine Facility

Any Many More!

(Pfizers Pegasus Sweden GRE materials for Pipex px® SAPO-SAFE System with integral SS gullies)

(Bespoke BIOSAFE® manholes incorporating stainless steel isolation valves, viewing ports, leak detection system and chemical dosing port. Guaranteed fully

sealed bio-secure drainage system; tested at 2 bar for 24 hours including HSE acceptance)



3.2. Applicable Standards:

BS EN 13598:2009 Plastics piping systems for non-pressure underground drainage and sewerage. Unplasticized poly(vinyl chloride) (PVC-U), polypropylene (PP) and polyethylene (PE). Specifications for manholes and inspection chambers in traffic areas and deep underground installations.

BS 4994: 1987 Specification for design and construction of vessels and tanks in reinforced plastics.

BS EN 12573: 2000 Welded static non-pressurized thermoplastic tanks.

BS EN 752: 2008 Drains and Sewers Outside Buildings.

BS 8000: Part 14:1989 Workmanship on building sites. Code of practice for below ground drainage

BS EN 13067 Plastics Welding Personnel - Qualification testing of welders - thermoplastics welded assemblies

Building Regulations Section H

Building Regulations Section L

CDM Regulations

DIN 8077 and DIN 8078 – Metric dimensions and properties for polypropylene (PP-H)

DIN 16962

TWI CSWIP-PW-6-96 - Certification of Plastic Welders

BS EN 1610: 1998 Construction & testing of Drains & Sewers.

DVS 2210-1

BS EN 61511-1:2004 Functional safety. Safety instrumented systems for the process industry sector. Framework, definitions, system, hardware and software requirements

BBA Certificate No. 02/3927

BS EN 1852-1:2009 Plastics piping systems for non-pressure underground drainage and sewer-age. Polypropylene (PP). Specifications for pipes, fittings and the system

BS EN 7158:2001Plastics inspection chambers for drains and sewers



3.3 Abbreviations

BBSRC Biotechnology & Biological Sciences Research Council BREEAM BRE Environmental Assessment Method CDM ` Construction, Design & Management DEFRA Department for Environment, Food & Rural Affairs HSE Health & Safety Executive IAH Institute for Animal Health facilities at Pirbright & Compton in Surrey, UK. PPG Pollution Protection Guidelines PP-H α+ - Homopolymer alpha plus polypropylene PPS Pipex Project Services SIL Safety Integrity Level VLA Veterinary Laboratories Agency, UK



4. Pipex px® Environmental Commitment

4.1 Environmental Product Innovation

(Pipex px® Passive Rainwater Harvesting Systems)

(Pipex px® Carbon Abatement Systems - Free Cooling Technology)

For more information on our innovative, environmentally sustainable products please visit our website or contact us on 01752 581200

Pipex px® investment 5% of total profits to Corporate Social Responsibility projects including:

Pipex Project Services division is funding, managing & delivering the restoration of an indigenous ancient woodland site at a 55 acre plantation site on Smithswood on Dartmoor as part of our carbon offset commitment.

Pipex px® as a corporate supporter of local DWT, are funding the restoration of indigenous wetlands in North Devon as part of our carbon offset commitment.



Documents

BIOSECURITY PIPE SYSTEMS - Pipex px ® - … · 1. SYSTEMS INTRODUCTION 1.1 Background: Pipex px® are the leading company supplying worldwide engineering projects with proprietary