Cured-in-place pipe (CIPP) Rehabilitation of AC water mains

James GardnerCRC-P Program Manager on behalf of SEW

15 October 2019

CRC-P Melbourne Industry Update

This presentation is for individual reference only, do not reproduce materials or publish without permission from WSAA.

Why Lining Technology?

- High risk and old water mains – pipe cracking not possible

- Increasing risk to 3rd party assets and social impacts

- 1,600 kms of AC pipes (20% of network).

- $10M p.a. $40M p.a. by 2040

- Pipe Cracking - HDD on new alignment

- Abandoned AC = legacy issue

- Renewal alternatives to combat legacy and increasing cost:

• use existing assets• lower cost rehab

methods

Why CIPP?

Drivers for South East Water- New structural pipe (min

50 year life)- Minimise disruption to

customers - Suitable for 100 mm and

150 mm AC mains- Easy to maintain- Minimise potential

exposure of asbestos- Reduce future liability- Reduced cost of

rehabilitation

Field Trials

CIPP field trial – Springvale, VictoriaInitial small scale test using both products.First installation in AC pipe in Australia.Used abandoned AC mains.DN100 and DN150.Field tests ensure realistic installation environment.Approx. 200 m lined –32 samples tested.

Lessons LearnedKey Lessons

- AC main size (ID) investigation required as quite variable.

- QA records and procedures required improvement (though this is a trial so this was expected).

- Efficiencies need improving to make it cost competitive - It is much more costly to renew mains in America and

Europe where they must be deeper to get under the frost zone, making lining more attractive.

- SEW < $400 p/m for HDD.

Installed Products

Live Trial Site – Seebeck Road, Rowville Vic

• Site renewed with HDPE in 2017

• 2km of abandoned AC mains- 1km per product• Offline replacement minimises

customer disruption• Lined main to be live with

network through cross connections

Trial Aims: - Productivity/Economics- Maintainability- Sample Testing- Ongoing Testbed

Product 1Product 2

ChallengesSafety - Site layout and placement of equipment

- Depth and size of AC Mains

- Excavation at power poles for tee’s and fittings

Delays- Varying ID and OD of AC mains

- Equipment faults and failures- Compressors, refrigeration trucks, wet

out equipment.

- Equipment availability - 100mm camera/cutter required to be

returned to US for electrical modifications.

- Crew’s first time doing lengthy job

- Developing new documentation (ITP’s, reporting, data collection)

- Large differential ID at burst repairs is difficult for the camera equipment to pass. AC ID ≈86mm, PVC repair ID ≈109mm

ChallengesCommunity - Customer interactions -

being disturbed twice (renewal of mains then trial works).

Quality Assurance- Products require AS4020

certification (contact with dinking water) and water quality testing for initial installations important for verification.

Successes Wins- Achieved a double shot

(two lines in one day) - Lined around a 150mm

90° bend - Created a baseline for

QA documentation for CIPP delivery

- Crews are becoming more accustomed to roles and responsibilities

- Have been able to line through burst repairs successfully Successful lining around a 90° bend

Lessons Learned- QA and Safety documentation is key

- ITP for pressure testing - Resin quantities- Record of service plugging - CCTV- Relevant SWMS and SOP’s for

task

- Involve all relevant areas of business

- Expect teething issues with equipment and crews

- Record keeping of delays, positives, customer interactions, program, etc.

- Manufacturer expertise very handy to have on site

- Program flexibility- One equipment issue can see the

program change completely, can the contractor accommodate this change?

Overall SEW are happy with the progress of the project.

-Complete liner installation in all areas (late-2019 to early-2020).

-Following completion of works:-Open relined pipes to network.-Undertake additional testing, e.g. a burst repair on the liner.

Next Steps

-CT scans of AC pipe showed generally even internal corrosion and quite different rates of external corrosion.

-When looking at the bonding of the liner to the host pipe consideration was given that the bond not be too strong – this is to prevent a broken back failure in the host pipe applying a point load to the liner.

-Service connections-Ferrule (sticks out into the pipeline), these can be seen, plugged before lining and cut out after lining.-Tapping bands – insert a plug with a light on it before lining, then after lining send down the robotic cutter and it can find the light to cut out the connection.-Robot cutters are currently difficult to use in DN100 AC pipes as after lining the diameter can get as small as 77mm.

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