Mechanical pipe joining specialist Victaulic offers a safe and sustainable alternative for pipework in biogas energy plant infrastructure development, explains Paul Herman, vice president for the UK energy market at Victaulic.
Global energy demand is increasing rapidly, with the World Energy Outlook predicting that 50% more energy will be needed worldwide by 2050. More energy plants are required, and with that will come a greater need for essential pipework. As a global provider ofmechanical pipe joining solutions for the most complex piping applications, Victaulic plays a pivotal role in developing safe and sustainable energy plant infrastructure.
Every energy plant possesses extensive pipework essential to its operation. This pipework consists of critical systems for cooling water, instrument air, and other important service lines needed to run the plant. Whatever the facility – be it biogas or hydrogen production, carbon capture or waste to energy – it needs reliable systems for it to run. The need for high-speed, high-quality piping is critical in an industry that is growing rapidly. While welding in pipework is seen by many as an industry staple, grooved pipe joining provides a robust solution to welding and flanged alternatives and helps to reduce the pipe joining and maintenance challenges that come with them, such as accommodating misalignments, system accessibility, and constructability.
An energised market
Energy production from biogas continues to increase in Europe. The European biogas plant market was valued at approximately €1.56 billion ($1.67 billion) in 2020 and is expected to reach €3.24 billion ($3.47 billion) by 2028. This holds significant potential. As demand for renewable energy grows, there will be increased opportunities for constructing biogas plants. Construction expertise is required to design facilities that efficiently convert organic waste into energy and ensure their long-term operational viability.
One of the main challenges is ensuring that constructed facilities meet the rigorous standards required for biogas production. This includes managing the complexities of integrating biogas systems with existing infrastructure and ensuring consistent quality control throughout the construction process. The growth will drive innovation in construction techniques and materials, which should be seen as an opportunity for more sustainable building practices.
A proven pipeline build strategy
Victaulic solutions have become synonymous with faster and easier installation that can be implemented across diverse industry applications and can significantly improve efficiency and reduce the total installed cost in the construction of energy plants’ utility lines. Grooved pipe joining also does not require open flames in its installation process, enhancing site safety and eliminating hazardous emissions. Though welding or flanging can still be utilised in specific circumstances, such as in very high-pressure, extreme high-temperature pipelines, grooved piping can become a game-changing alternative for over 40% of pipe installations in new energy plant construction projects.
Constructability of piping systems is significantly increased when using Victaulic Installation-Ready™ Technology. This provides a single-unit coupling design, enabling the installer to install couplings by simply inserting them onto the grooved end of a pipe and tightening the nuts. Because the coupling housings, nuts, bolts, and gaskets do not need to be disassembled, the installation process is expedited and reduces the number of loose parts that could potentially be dropped or misplaced. It can be installed in less than half the time of standard grooved couplings, six times faster than flanged joints and 10 times faster than welded joints.
Grooved joints also provide full restraint, eliminating the need for thrust blocks, which can involve extensive digging and concrete, or restraint systems which require complex welding and time-consuming disassembly.
Sustainable solutions at every stage
Time efficiencies directly impact energy consumption. Victaulic has embedded sustainability as a mindset. In energy plant construction, as elsewhere, sustainability challenges necessitate innovative approaches, as traditional methods often consume significant energy and may not deliver long-term value.
Victaulic offers a versatile and sustainable solution. A grooved system takes less time to install and, unlike welding, produces zero emissions during installation, with products made from up to 98% recycled content using the cleanest technology.
Grooved systems are fully reconfigurable and reusable, allowing pipes, fittings, and couplings to be disassembled, cleaned, repurposed, or entirely recycled at the end of their lifecycle. This reduces waste and eliminates the need for new raw materials. Victaulic couplings also feature a pressure-responsive gasket that is designed for multiple reuses.
These advantages align with, and extend beyond, net-zero mandates. The Victaulic coupling system requires only two bolts for connections up to 24 inches and four bolts for those up to 60 inches, significantly reducing the number of bolts compared to flanged connections. It results in less waste throughout the process and facilitates easy maintenance and modifications, as the system is easy to access or to dismantle.
If this sounds simple, then that’s because it is. Simple but extremely effective. Victaulic is an easy-to-learn system, as opposed to welding, which requires skilled construction professionals. It currently takes four years to train to become a welder, with a significant 20-year industry training gap due to the insufficient influx of newly trained professionals entering the field. There is currently a skilled labour shortage throughout the UK and Europe. A report by the Learning and Work Institute has predicted that the UK skills shortage will cost the country £120 billion by 2030, with a shortfall of 2.5 million highly skilled workers and an oversupply of 8.1 million people with traditionally intermediate or low skills. This is a labour problem that Victaulic can help solve. The simple coupling, with only two bolts and nuts, saves on time and labour during installation. Victaulic offers world-class customised training tailored to individual business needs, helping to upskill the workforce, and ensures quality control and first-rate service with all applications.
Collaboration is crucial. Construction and engineering teams must work closely to design and build energy plants that are not only efficient but also scalable and adaptable. Early engagement in the concept or FEED (Front-End Engineering Design) stage ensures that both teams understand project goals and constraints. Furthermore, the industry must stay informed about advancements in technologies, more efficient processes, and innovations in solutions. Keeping up with these advancements can improve plant efficiency and output.
It is essential to maintain a dialogue with key partners and continue to advocate how the Victaulic sustainable and efficient approach can offer a reduction in energy consumption and waste. In this way, Victaulic can continue to support both environmental goals and long-term operational efficiency for biogas plant projects.
