IMIESA April 2011 final - · PDF fileTrenchless Pipe 240 000 metres of Successfully Installed...

240 000 metres of Trenchless Pipe

Successfully Installed

SASTTAwAA ard

ofExcellence2007 & 2009

Proud Supplier

Award WinnerInstallation of New Pipes By:• Horizontal Directional

Drilling

• Guided Rock Drilling

• Bores of 1200mm

• Lengths up to 400 metres

• Microtunnelling

C O U N T R Y W I D E 0 8 6 0 0 6 6 3 4 4C O U N T R Y W I D E 0 8 6 0 0 6 6 3 4 4

[email protected]

Renovate Existing Pipes By:• Pipe Bursting

• Sliplining

• CIPP UV Cure

• CIPP Ambient Cure

• Ribloc ® Expanda

• Ribloc ® Ribline

• Pipe Eating

Trenchless technologies2.indd 1 2010/11/22 03:04:01 PM

SASTT contact details:

Web: www.sastt.org.za

President: Andries Lötz

Tel: (011) 688 1483Fax: (011) 688 1524

E-mail: [email protected]

Honorary director: Joop van Wamelen

Tel: (012) 567 4026 Fax: 086 668 4026

E-mail: [email protected]

TRENCHLESS TECHNOLOGY

58 - IMIESA APRIL 2011


The future in horizontal directional drilling

COMMISSIONED AT A site in Ekhurleni, the TJ5415 S (pictured) has an impressive 5 400 Nm torque and 15 t back-pull. But the

commissioning site is in actual fact a work site, the Delphinium Water Replacement Project, which includes the replacement of an existing 300 diameter steel pipe with a 450 diameter high-density polyethylene (HDPE) pipe to be installed by horizon-tal directional drilling (HDD). The project involves the drilling of 164 m through a marshland and under the R59 to install the new 450 HDPE pipe.

Consol and cabinThere are many features that make the pow-erful TJ 5415 S HDD machine unique but

TECHNICAL DATA: TJ 5415 SPull-back/thrust force, max. 15/7.5 t 33 000/16 500 lbs Ø of the pilot bore 60 to 100 mm 2.5” to 4”Rated power output 74 kW (100 HP) 74 kW (100 HP) Maximum ø of backreaming* Ø 520 mm (manufacturer)/actual Ø 650 Ø 20”Torque:maximumtorque at double rpm

5 400 Nm2 700 Nm

4 000 ft.lbs2 000 ft.lbs

Maximum bore length 200 m 650 ft

Rotation speed of the drill rods:maximumat maximum torque

145 rpm62 rpm

145 rpm62 rpm

Drill rods:lengthdiameter

3.0 m55 m

10 ft2.16”

Drilling fluid:backreamingpilot bore

200 ℓ/min @ 25 bar92 ℓ/min @ 50 bar

53 gpm @ 360 psi

25 gsm @ 720 psi

Minimum bending radius** 35 m 115 ft

Drilling speed:quick gearat full load

12 m/min12 m/min

40 ft/min40 ft/min

Dimensions:lengthwidthheight with cabinheight without cabin

5.80 m2.10 m2.55 m2.38 m

19.1 ft6.9 ft8.4 ft7.9 ft

Pullback speed:quick gearat full load

12 m/min6 m/min

40 ft/min20 ft/min

Noise emission at operator’s ear:with cabinwithout cabin

70 dB (A)85 dB (A)

70 dB (A)85 dB (A)

Weight without cabin including 60 drill rods, ø 55 mm

6.9 t 15 200 lbs Guaranteed sound:power level Lwa 104 dB (A) 104 dB

(A)*depending on ground conditions **depending on rod size

Boasting a fully-computerised onboard touch-screen and the ability to drill up to 200 m continuously, Trenchless Technologies’ latest machine – the Terra-Jet 5415 S – was acquired to service both the civils (water and sewer) as well as the fibre optic market. Candice Landie was on site to witness the commissioning of this machine and learn more about the other machines within the Trenchless stable.

IMIESA APRIL 2011 - 59


especially impressive are its state-of-the-art, fully computerised consol and ergonomically designed drill cabin, ensuring optimum opera-tor comfort. The onboard computer saves all relevant machine data every two seconds, providing the operator with an update on the essential drilling elements, which is vital for effective service diagnostics. Additionally, a bore log indicating the grade, depth and dis-tance is printed for each bore, along with the machine protocol, which indicates the torque and thrust/pullback force during the entire operation. All main functions are operated via two multifunctional joysticks.

The cabin has all-round tinted glazing, with the machine side being glazed in a single uninterrupted panel. “This allows the operator to see every detail of the drilling machine,” explains Sam Efrat of Trenchless Technologies. “The operator sits in a comfortable operator’s seat, which can be adjusted to suit the body shape and weight of the operator. The operator’s cab is wide, allowing the seat to rotate 180˚. The drill operator can drill looking in the drilling

direction, or he can rotate the seat to be at right angles to the drill and observe every detail of the drilling machine.”

HydraulicsThe machine also features three separate hydraulic settings, namely thrust, rotation

TERRA MINI-JETModel Mini-Jet Mini-Jet/LV 1 712 CPull-back forceThrust force

8 t8 t

8 t8 t

12 t6 t

Rated power output 15 kW(20 HP)

15 kW(20 HP)

25 kW(34 HP)

Torque 1st speed2nd speed

1 400 Nm----

1 400 Nm----

1 700 Nm850 Nm

Rotation speed of drill rods

2nd speed1st speed

--110 rpm

--110 rpm

200 rpm100 rpm

Drilling fluid volumeDrilling fluid pressure

34 ℓ/min55 bar

34 ℓ/min55 bar

30 ℓ/min70 bar

Weight of drill rig 250 kg 425 kg 2.8 tØ of pilot bore 60 to 100 mm 60 to 100 mm 60 to 100 mmMaximum Ø of backreaming* Ø 260 mm Ø 260 mm Ø 360 mm (manufacturer) /actual Ø 440Maximum bore length*:technicaleconomical

50 mtr30 mtr

120 mtr120 mtr

200 mtr120 mtr

Drill rods Length Ø

0.5 mtr30/40 mm

1.5 mtr45 mm

3 mtr45/55 mm

Minimum bending radius** 15/25 mtr 25 mtr 25/35 mtrLV = long version *depending on ground conditions **depending on drill rods

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Contact Info: Call : 031—579 2240 Web : www.camjet.co.za Email : [email protected]

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and drilling fluid (bentonite¹). The drill-ing fluid pressure inside the drill rods is

TECHNICAL DATA: TJ 7520 DPull-backThrust force

20 t10 t

44 000 lbs22 000 lbs

Ø of the pilot bore 90 to 170 mm 3.5 to 6.7”

Rated power output 94 kW (132 HP)

94 kW (132 HP)

Maximum ø of backreaming*

Ø 800 mm (manufacturer)/actual Ø 1 200

ø 32”

Torque:1st speed2nd speed

7 750 Nm3 875 Nm

5 700 ft.lbs2 850 ft.lbs

Maximum bore length

400 m 1 300 ft

rpm of drill rods:maximum speed at no load2nd speed at full load1st speed at full load

130 rpm120 rpm60 rpm

130 rpm120 rpm60 rpm

Weight including 40 drill rods Ø 70 mm and 2 x AAS

8.0 t 17 600 lbs

Drilling fluid volumeoptionalMax. drilling fluid pressure

185 ℓ/min370 ℓ/min85 bar

49 gpm98 gpm1 230 gsm

Minimum bending radius**

45 m 150 ft

Max. drilling speed:backreaming at full loaddrilling at full loadquick gear

8 m/min16 m/min35 m/min

26 ft/min53 ft/min115 ft/min

Dimensions:lengthwidthheight

6.30 m2.00 m2.30 m

20.8 ft6.6 ft7.6 ft

Sound level at a distance of 7 m

70 dB (A) 70 dB (A) Drill rods:length diameter

3.0 m70 mm

10 ft2.75”

*depending on ground conditions **depending on drill rod size

automatically released before each drill rod change, preventing bentonite from being splashed onto the glazing. The torque and pullback force are produced by separate hydraulic circuits, allowing the maximum torque of 5 400 Nm and the maximum pull-back force of 150 KN (15 t) to be used simultaneously under full load – a rare ele-ment in HDD machines nowadays.

Automatic drilling controlThe TJ 5415 S is equipped with a second-generation automatic drilling and back-reaming system (ADBS). This patented system automatically adjusts the working speed of the drill to suit the ground condi-tions. In soft ground, the drill operates at maximum speed and in hard ground the ADBS automatically slows down the thrust of the drill. So, if the drill head hits an unexpected obstacle, the ADBS stops the

drilling speed immediately and drills very slowly through the obstacle. This allows the operator to operate the drill at maximum efficiency in a controlled and relaxed man-ner and prevents the drill rods and drilling tools from being overloaded.

Another new feature is the automatic drill rod greasing function, which is under-taken during each drill rod change by an electrically driven grease press attached to the driving saddle. “We anticipate cre-ating bores of up to 650 mm with the TJ 5415 S,” says Efrat.

Apar t from the TJ 5415 S, Trenchless Technologies has three other machines, namely the TJ 7520 S, the TJ 1712 B and the small TT 3100. The company has been an agent for Swiss-based Terra-AG since 1994 and began horizontal directional drill-ing back in 1997 when the first Terra-Jet 1712b machine, with 1700 Nm torque and 12 t backpull, was purchased. “Over the years, this machine proved to be extreme-ly reliable, capable of installing HDPE pipes up to 400 mm, and is still in daily operation today, 14 years later,” continues Efrat. “In 2008, we received our TJ 7520 machine, which has proved highly success-ful in under taking a large range of works, including the ABSA Sleeves Reticulation Contract, which involved installing 100 HDPE sleeves between 160 and 710 diam-eters, with 20 crossings being in solid rock.” This project won the SASTT Award of Excellence in 2009. The company con-structed a range of backreamers, allowing bores of up to 1 200 mm to be made using this machine.

¹ Bentonite is a type of clay that is used to keep the integrity of a hole, i.e. so it doesn’t collapse.

ABOVE The TJ 5415 S is equipped with a second-generation automatic drilling and backreaming system



EINSTEIN WAS ONCE quoted as say-ing: “We cannot solve our problems with the same thinking we used when we created them.” It is pre-

cisely this type of paradigm shift that was required to implement trenchless pipeline technology on a grand scale, in contrast with the previously favoured open-cut construc-tion practices. The widely publicised AC Pipe Replacement Project was one of these ini-tiatives – albeit a combination of trenchless and open-cut pipeline replacement method-ologies. It therefore came as no surprise that further innovation by the municipality concerned was to follow in the upgrading of its larger-diameter pipeline networks.

eThekwini once more took a bold step and looked to international solutions and techno-logical advancements for a feasible solution to its water network crisis. The Netherlands gov-ernment played an integral role in this regard and was pivotal in introducing compact pipe to South Africa. This innovative pipeline renova-tion solution makes use of a folded polyethyl-ene pipe (the pipe is folded along its length during manufacturing), which is inserted into the existing pipeline. Once in place, a com-bination of steam and later compressed air (used for cooling) is used to revert the folded pipe back to its circular shape and it subse-quently fits securely within the host pipe. This close-fit renovation system allows for continu-ous lengths of pipe to be renovated (lengths of 380 m were achieved) in quick succession and with minimal disruption or inconvenience to the immediate environment.

Compact pipe was first used in South Africa for the renovation of a section of a gas pipe-line owned by a private entity in Johannesburg. This project and other consequent installa-tions were undertaken by international con-struction companies experienced in the use of renovation system.

The project in Durban, however, is the cul-mination of a series of training exercises and

skills transfer practices that enabled South African specialist contractor TT Innovations to become a licensed installer of compact pipe. Various installations of the system in the Pinetown area proved its versatility and efficiency in these congested urban settings. The pipe solution provides a distinct advantage where working space and construction time are paramount, which is why it is a preferred reno-vation method in the highly competitive Asian markets: in Hong Kong, since 2004 50 km of gas and water mains have been reno-vated using this system.

Fur ther compact pipe installa-tions were

undertaken in Westville, Durban, where sec-tions of the existing 300 mm-diameter AC water main were earmarked for renovation. A three-tiered approach was applied to this project, which entailed a detailed inspec-tion and subsequent cost estimation of the deteriorated pipeline sections. As part of the second phase, the main contractor was appointed to perform all construction-related functions, including traffic accommodation, water shut-offs and tie-ins, and any rein-

statement requirements. The final stage comprised the actu-

al renovation of the pipeline, where

the main

Raise your glass!When a service provider realises that it requires urgent and immediate action to stem the flow of its unaccounted-for water, a holistic and often pioneering approach is required.

RIGHT Compact pipe drum trailer with reel



Our range of services include:

• Pipe Bursting

• Horizontal Directional Drilling

• Pipe Rehabilitation

• Slip Lining

• Pipe R ming

• CCTV Inspection

• Dewatering

• Industrial Pipe Cleaning

• HDPE Welding

• Deep Excavation and Shoring

• Underground Service Detection

• Close-fi t lining: COMPACT PIPE

For more information you can contact us: +27 (0)21 761 3474 F +27 (0)21 797 1151 E [email protected] www.tt-innovations.co.za

Trenchless Technology Specialists

contractor enlisted the services of spe-cialist trenchless pipeline contractor, TT Innovations.

This project provided the ideal platform for fully exploiting the unique capabilities of the system. Many sections of the pipe-line included slight misalignments as well as various bends, with the maximum bend angle being 90˚. The folded pipe was able to accommodate these direction changes easily, with the maximum single installation length achieved being approximately 380 m. With two-way traffic and confined spaces, this renovation system again proved invalu-able with its small site footprint. As a final validation of the system’s versatility and effi-ciency, the network owner was faced with a dilemma when the main feed to the reservoir was rendered redundant owing to various factors. The only solution was to have the

existing adjacent pipeline – which was still under construction – operational before the reservoir reserves were depleted. The folded polyethylene compact pipe was inserted into the L-shaped 170 m section of pipeline at approximately 10:00am. After insertion, the steaming and cooling process was initiated. The 170 m pipeline section was completely renovated and reconnected by 10:00 am the following morning. After testing and chlorinat-ing, the much-needed water was diverted through this newly renovated pipeline.

As a flagship project, various stakeholders, including contractors, consultants and other municipal representatives, were hosted at an open day event. A theory session detailing the compact pipe process followed by a site visit allowed the participants to witness the renovation system firsthand.

It is envisaged that this renovation sys-tem will further be used for the renovation of existing sewer pipelines. Other municipal service providers will do well to follow this revolutionary approach to future network cri-ses perpetuated by failing pipelines, block-ages and bursts. Innovation will again provide the necessary answers and allow for cost-effective alternatives to age-old problems. Local contractors embracing international technology will bring these proven solutions to your doorstep.

ABOVE Building a coffer dam alongside the banks of the Vaal DamRIGHT Delegates attending the compact pipe site demonstrationFAR RIGHT View of the steam kettle inside of the Steam Unit



THE CITY OF Cape Town introduced ‘cured-in-place pipe’ (CIPP) short repair liners as an innovative trenchless technology to reha-bilitate some of its deteriorating trunk clay sewers. This method was adopted for the Plumstead Sewer Project, proving very suc-

cessful, and sets the scene for application in similar gravity pipelines.

OverviewThe 3.0 km trunk sewer runs from Ottery Road to the Victoria Road Pump Station in Plumstead (a suburb of Cape Town). The sewer com-prises 375 mm-, 450 mm- and 525 mm-diameter vitrified clay pipes through the relatively narrow residential streets, at depths varying between 2 and 6 m.

Sewer assessment: In 2004 Vela VKE prepared a report based on CCTV inspections assessing the condition of the pipes. Some

Sewer project scoops coveted trenchless awardThe Plumstead Sewer Project earned Michael King of Vela VKE, Peter Salomons of Jetvac South Africa and Yusuf Ebrahim of the City of Cape Town the prestigious SASTT 2010 Award of Excellence.

serious defects were found that were generally cracks, fractures and displaced joints. Where these defects resulted in ground-water infiltration, there was the threat of loss of pipe bedding and support, leading to the failure of the pipe and dangerous sur face collapses.

It was found that these serious defects in clay pipes were never continuous between manholes but of an isolated nature and the rehabilitation of these sewers was a challenge. Point repairs would be costly and disruptive to the neighbourhood and environment. Full-length trenchless lining between manholes would also have been prohibitively expensive.

BELOW The application of short CIPP liners was applied in the Plumstead Sewer Project


Group Head Office +27 12 481 3800Email: [email protected]: www.velavke.co.za

VV

KE

/P

IPE

S01

Vela VKE is a truly South African, multi-disciplinary,consulting engineering company committed

to transformation.

Leaders in pipe renovation, with oversixty years of experience.

Vela VKE Board: left to right: Viwe Qegu, Arthur Taute, Mathews Phosa,Dave Gertzen, Tom Marshall, George Munyai, Job Mokgoro, Mothupi Malaka


Project planningIn 2008 the City of Cape Town’s Water and Sanitation directorate embarked on the implementation of phase 1 of this rehabilita-tion project. Vela VKE was able to confirm that short CIPP liners were becoming more widely used internationally and several South African trenchless contractors had demonstrated interest in applying the technology. Tender documents and specifications were drawn up accordingly.

Jetvac South Africa was awarded the construction contract, propos-ing to use a glass fibre material with silicate resin manufactured in Europe by Trelleborg Epros. The liner is wetted out on site, placed in the pipe on a bladder and inflated, and the resin cured under ambient conditions within hours or less. The scope of work was for the repair of 12 defects, most of which were short (approximately 2 m), with two being 10 and 13 m long. Each defect was inspected by CCTV before and after lining.

Another opportunity presented by this short CIPP technology was where defects could only successfully be completed by open excava-tion. Where defects included nearby connections or some surface settlement was evident, the section of pipe would first be lined; then excavations could be made onto the pipes and the connections remade or the trench backfill re-compacted safely.

The rehabilitation of the Plumstead Sewer was achieved by the use of short CIPP liners to repair the individual defects in the vitrified clay pipes effectively. The technique used in the project proved to be suit-able for the rehabilitation of defective clay sewer pipes, and adds to

the armoury of trenchless methods of pipe rehabilitation available. By introducing the technology as an innovative trenchless solution and proving it on a difficult project, the nomination actively contributed directly to the promotion, development and implementation of trench-less technology in Southern Africa.

ABOVE Winners of the SASTT 2010 Award of Excellence pictured with (left) Andries Lötz, Johannesburg Water and president of SASTT; Peter Salomons, Jetvac South Africa; Yusuf Ebrahim of the City of Cape Town (Water and Sanitation) and Michael King of Vela VKE Consulting Engineers



FUNDED BY THE Dutch government, the pilot project involves technology transfer and training for university learners and emerging contractors.

Called close-fit lining, this internationally recognised technique involves inserting a compact pipe or sleeve into an existing pipe. Once in position, the compact pipe or sleeve is steam heated. This causes it to expand to its original size and shape, filling the old pipe with a new structural interior lining. The compact pipe is made of high-density polyethylene (HDPE) and has an estimated 50-year lifespan.

A cutting-edge form of trenchless technology is being used to replace burst-prone asbestos cement pipes in Pinetown and Westville.

Local contractors, design consultants, emerging contractors and representatives of other municipalities have been invited to demonstrations of the process, which has not been used on water pipe replacement in Africa before. “We hope that as many peo-ple as possible will benefit from seeing this progressive technology at work,” says eThek-wini’s Asbestos Cement Pipe Replacement Project executive, Alan Kee. According to Kee, a socio-economic and cost/benefit analysis exercise is being conducted by BSc and MSc students from the University of KwaZulu-Natal. The feasibility study will take two years.

According to Aurecon’s lead project manag-er, Evan Smith, both the feasibility study and the on-site training are vital parts of the pilot

eThekwini’s world-class pilot project

ABOVE A demonstration of a new trenchless method of pipe laying was held in Westville near Durban recently. The demonstration, which was sponsored by the Dutch government and is part of a technology transfer programme, show-cased the uses of compact pipe. Here, local contractors and design consultants watch as the compact pipe moves into the mouth of the old asbestos cement pipe. Three consultants from Holland were on hand to inform delegates about the ben-efits of this form of trenchless technology

CONTACT NUMBERS:

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PRETORIA

CAPE TOWN

DURBAN+27 31 705 4983

PORT ELIZABETH+27 41 451 3556

+27 12 380 4600 (switchboard)+27 12 380 4692 (orders)+27 12 380 4603 (orders)+27 12 380 4712 (technical)

+27 21 512 2860

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DUCTILE IRON for bulk water

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project. “The study will provide a cost/benefit analysis of trenchless technology compared to more traditional methods, while the on-site training will enable established and emerging contractors to have first-hand access to this innovation,” says Smith.

The Dutch government is funding the train-ing and feasibility study components of the pilot project, with eThekwini paying for the insertion of new lining, which will be supplied by Wavin. The Dutch supply company will have experts on hand to deal with technical issues and provide on-site training.

“We believe that in a country like South Africa the benefits of trenchless technology must be carefully weighed against the need to create

jobs and develop communities,” says Kee. “However, in congested areas like the Pinetown CBD, the use of close-fit lining makes sense.”

According to Kee, the surface digging and consequent disruption to traffic are kept to

RIGHT Dutch compact pipe expert, Wim Elzink, explains the steaming process that causes compact pipes to expand and regain their original shape. Here, he is addressing local contractors and design consultants at a demonstration in Westville as part of a technology transfer programme sponsored by the Dutch government

a minimum as the process only requires the digging of a launch and connection pit. The process is extremely quick, which means that the excavations cause much less inconven-ience in busy areas.

JACKED PIPELINESWWW.JACKPIPE.CO.ZATEL: +27 11 206 2000

JACKED PIPELINES

QUALITY PROJECT DELIVERY

SINCE 1998

Pipe-jacking | Drilling | Auger boring | Grouting | Guniting

The Leader in Trenchless Technology construction operating throughout Southern Africa

Jacked Pieplines has extensive experience, specialised equipmentand skills in the offering of the following services:

CORPORATE MEMBERS OF



JACKED PIPELINES, a division of WK Construction, has been part of the South African trenchless society for more than 20 years. The company

specialises in pipe jacking, a technique of installing underground pipelines with-out disturbing surface activities and other underground services. Pipelines that can be installed in this manner range from a mini-mum of 900 mm-diameter concrete sleeves to 3 000 mm-diameter concrete sleeves and 3 500 mm concrete box culverts. Pipe jacking is mostly done through hand excavation, whereby miners enter the pipe sleeve to form a tunnel underground and advance the concrete pipe sleeve by means of hydraulic jacking of the concrete pipe into the void formed.

The company has now also added a new technology to its wide range of products on offer, by acquiring the latest model auger boring machine, stated as being the biggest such machine built to date, from American company Barbco. Jacked Pipelines acquired the second machine of its kind off the supplier’s production line. This boring unit

is capable of installing up to 2 100 mm-diameter steel sleeves. It is equipped with a 350 hp Caterpillar engine capable of some 300 000 ft.lbs (400 000 Nm) torque in first gear, with a thrust power of 1 180 t.

The company is currently using this machine on a Rand Water project where it is installing a 1 800 mm-diameter steel sleeve using auger boring, which will then be replaced by a 1 500 mm-diameter concrete sleeve. The crossings are approximately 60 m in

length. Production to date has been slower than anticipated but the machine is capa-ble of boring 12 m per day (some 32 m³ per day). The company also has a smaller auger boring unit capable of installing steel sleeves between 600 mm and 1 000 mm in diameter.

Trenchless company acquires ‘monster’ boring machine

BELOW New to the Jacked Pipelines stable: the latest model auger boring machine, the biggest of its kind

Tel: 011 906 8000 [email protected] www.rare.co.za

22 Old Vereeniging Road, Kliprivier, Midvaal. PO Box 124186, Alrode, 1451

Products:

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THE LIFELINE OF INDUSTRY

SWAG LININGTM



OVER THE PAST couple of years, the Rare Group has undertaken numer-ous swagelining projects for the mining sector across the continent.

Originally developed by British Gas and United Utilities in the 1980s, swagelining tech-nology was initially designed as a trenchless technology rehabilitation solution, providing an effective method of overcoming the problem of failing pipes in inaccessible or inconvenient areas, such as beneath busy main streets. This technology was further developed in the 1990s for the protection of new pipelines in the subsea industry, complemented by a new connection system, the WeldLink, for use in high-pressure carbon steel water injection applications.

In November 2009, the Glasgow-based Swagelining Limited (official sub-Saharan African partner to the South African-based Rare Group) acquired the intellectual property rights to the established swagelining technol-ogy. Swagelining Limited wanted to push the boundaries of the technology to extend its benefits from niche application to wider use in the pipeline industry globally.

How it worksSwagelining technology is used for corrosion prevention and life extension of new and exist-ing pipelines that are utilised in a range of industry applications, such as mining slurry, gas, potable water, sewage, water injection, crude oil, cement and chemicals.

The swagelining system is suitable for inserting liners into pipelines of up to 60” (1.52 m) in diameter for structural and non-structural applications. It works by installing a tight-fitting polymer liner into new or existing pipelines by designing and constructing a liner

Pipeline technology is a gold mineAfrica’s mining industry appears to be one of the first to be embracing swagelining polymer pipelining technology fully and reaping the benefits.

that has an outside diameter slightly larger than the inside diameter of the pipe to be lined. The aim is to maximise pulling lengths, which in turn leads to reduced numbers of connections and excavations.

The technique uses a naturally reverting recovery system after installation. The liner is installed into a host pipe by pulling it through a reduction die using a winch, which temporarily reduces its diameter, allowing for easy instal-lation. Once it is pulled completely through the pipe, the pulling force is removed and the liner returns to its original diameter, pressing tightly against the inside wall of the host pipe. The tight-fitting polymer liner results in a flow capacity close to that of the original pipeline.

The benefi tsThe Swagelining system uses high-density polyethelyne liners, which offer a range of benefits to the mining industry with regard to asset integrity. The polymer is highly abrasive resistant, which increases the lifespan of the pipeline. The smooth surface of the polymer liner decreases resistance, which reduces the overall power consumption required to run the pipe. By rehabilitating existing cor-roded pipelines with thick structural liners, the liner can take the working pressure off

the pipe. This can result in significant cost savings and operational efficiencies for the pipeline operator.

One of the latest projects secured by the Rare Group involves using Swagelining on a new 2 600 m-long, 450 m-diameter tailings slurry pipeline for the Iduapriem gold mine in Ghana.

Swagelining Limited is a true pioneer in the polymer lining solutions market, delivering industry-changing technologies to the world-wide pipeline community. With this much-talked-about life-extending technique offering unquestionable benefits, swagelining polymer liners look set to become an important way for the pipeline industry to lower its corrosion pre-vention costs in new pipelines or rehabilitate its existing pipelines at a fraction of the cost of new build systems.

ABOVE Swagelining technology is used for corrosion prevention and life extension of new and existing pipelines

HEAD OFFICE: 14 Atlas Road Anderbolt Boksburg (011) 306-0700 • e-mail: [email protected] • www.elbequipment.com

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DRAIN CLEANING - LIQUID WASTE SOLUTIONS - CCTV PIPE INSPECTIONS - PIPE REHABILITATION - PUMP HIRE


OFTEN THE CONDITION of a pipe is measured by its outer physical appearance. However, this does not give a true reflection of the

inner working condition, which is where, in most cases, the deterioration of the pipe occurs. To achieve this condition assess-ment, non-destructive equipment (NDE) must be applied.

CCTV inspection offers an internal visual inspection which, unlike many other NDE methods, provides a condition-based assess-ment that is not affected by interpretation. Modern CCTV inspection systems consist of a robotically controlled camera linked to a control unit and video screens. The camera can have a pan and tilt functionality with up

to 40 x optical zoom to provide detailed and precise video footage of over 460 vertical TV lines. The camera system is also linked to a PC, where the defects are recorded and graded on a specialised software package. The video footage and report can be pro-vided on DVDs or hard drives.

Until recently, a CCTV system could only provide a visual inspection. But with laser profiling, it now has the added advantage of physical measuring. A laser profiler is a CCTV camera with a small laser probe mounted in front of it. The laser provides a ring of light on the internal circumfer-ence of the pipe that is processed by the software to provide numerical data and accurate measured values on the internal

pipe profile. This is useful in measuring and creating 3D mapping of features, showing their deviation from the design bore of the pipe. These features could be corrosion, pipe deformation, out of round, wear, ero-sion and deposits.

JETVAC South Africa supplies both CCTV and laser profiling services for pipes rang-ing from 100 mm to 1.8 m in internal diam-eter, as well as a push rod camera system to access pipes and cavities as small as 25 mm in diameter. The company can be contacted for competitive rates on all CCTV requirements, and also specialises in pipe-line rehabilitation by means of CIPP liners and patches, which proves cost-effective and time saving in the repair of pipes.

Advanced systems for internal pipe monitoring



THERE IS NO SURPRISE that blackouts have serious financial implications for businesses. The blackouts expe-rienced during 2004 to 2006 made

national headlines, with the incidents being cited as “the worst crisis ever experienced”. At the time, Eskom was undergoing investiga-tions in Gauteng regarding the state of the net-works, but the Bedfordview blackout in 2007 sounded alarm bells, pushing the Edenvale to Bedfordview area reparations to the top of its priority list. Part of the project was also to ensure quality of supply and sustainability of the networks.

WetlandsSSI Environmental was appointed as an inde-pendent environmental assessment practi-tioner for Eskom Distribution, North Western Region, on all the underground distribution

Jannette Horn, project principal, and Malcolm Roods, project manager, of SSI received the Bronze CPR Award for the Eskom Benoni cablings project. Candice Landie takes a closer look at this project and the achievement.

Electric project sparks at CPR Awards

cable replacements in the Edenvale, Germiston and Bedfordview areas. During the initial plan-ning stages, the environmental control offic-er (ECO) discovered that the project would pass through nine watercourse areas, so the environmental impact had to be considered. Although the necessary mitigation measures had to be implemented, the work being under-taken would still have an effect on one of the most sensitive environments. Three cable route alignments were affected, namely:• Edenvale Industries Substation to North Rand

DS Substation (four watercourse crossings): A1: situated within Heartland Properties’ old explosive factory ash dumps A2: situated adjacent to the Gautrain/Modderfontein Road Crossing A3: situated next to the Spartan industrial areaA4: situated next to Kelvin Power Station (on the Edenvale side).

A better description of the crossings is: A 1: located north-east of the Modderfontein Golf Course, within Heartland Properties’ old ash dam property A2: situated directly south of the R25 Modderfontein Road and east of Founders Hill on Heartland Properties, adjacent to the Gautrain railway

A3: situated directly north of Sebenza Extension 6, and east of the Illiondale neighbourhood in Edenvale A4: situated directly west of Kelvin Power Station.

• Edenvale Industries Substation to Lombardy Substation (three watercourse crossings): B1 and B2: situated in Sebenza, imme-diately before the confluence into the Modderfontein Spruit B3: located north of Eastleigh urban area next to Aitken Road, within the major over-head transmission cable servitude.

• Lombardy Substation to Croydon Substation (two watercourse crossings):C1: located directly west of 1st Avenue at the Eastleighspruit Bridge Crossing, within the Protea Park C2: located within the Norwood Farm Park in the Edenvale CBD.

SSI Environmental undertook both a basic assessment and water-use licence appli-cation. The water use licence was grant-ed on 4 September 2010 and the envi-ronmental authorisation was issued on 24 August 2010.

Project detailsThe overall project consists of five phases, of which phases 1 and 2 are currently being undertaken. The scope of the project includes the upgrade of substations as well as the construction of approximately 48 km of under-ground distribution cables in the Edenvale and Bedfordview areas.

Because some cables were required to be installed under the highways, pipe jacking was the preferred method, from a munici-pal and technical perspective, to limit con-struction-related traffic impacts. Horizontal directional drilling (HDD) was the pre-ferred environmental method for crossing

PROJECT TEAMECO Charlotte Grobbelaar (SSI

Environmental)Project manager Frank van Heerden (Eskom)Environmental advisor Benito Williams (Eskom)Land & rights negotiator Stephen Nakanyane (Eskom)Senior engineer Modiri Seate (Eskom)Contractor CBI ElectricClerk of works Riaan Strydom

LEFT Construction of underground cables in the Edenvale and Bedfordview areas



wetlands and watercourses, but owing to geotechnical concerns this was not possible. “It is important to find a balance between the environmental, social and economic consid-erations of a development,” says Roods. “We believe that compliance monitoring and environ-mental best practice is crucial in any project to ensure sustainable development. By adopting best practice methods, we also managed to reduce rehabilitation costs and limit adverse impacts on the receiving environment.”

As with any project, there were a few chal-lenges along the way. One of the biggest issues was space constraints. “It was not just the cables that had to be upgraded but also the surrounding infrastructure,” explains Grobbelaar. “We experienced difficulty in find-ing available routes to work on in such con-gested areas.” Waiting for authorisation to cross waterways/wetlands also caused some delays on the project. However, given all the previous projects that the company has dealt with, the basic assessment and water licence application were processed in record time by authorities.

Corporate project responsibilityAccording to Roods, Eskom Distribution, North Western Region and SSI Environmental have always had a proactive relationship, with SSI advising its client on the environmental legal requirements, as well as where the company can assist from a corporate project responsi-bility (CPR) stance. “We ask ourselves: How can we help our clients think responsibly? How can we help make the project more sus-tainable? How can we help clients realise their CPR?” continues Roods. At SSI, three aspects

are always taken into consideration before embarking on any project: people, planet and profit. Project sustainability is one of the main driving forces behind the company’s five-year strategy.

Other examples of the company’s CPR initia-tives at work are shown in tables 1 and 2.

In light of CPR, SSI Environmental sug-gested that Eskom sponsor a Wetlands Day in George, with the aim of educating learners on the importance of saving and preserving wetlands. The theme of the Wetlands Day was ‘Caring for wetlands – an answer to climate change’ and SSI sponsored 150 T-shirts for learners participating in the initiative. The contractor also received training on the Environmental Management Plan provisions,

as well as recommendations. The project has been nominated as a finalist because of the awareness of the potential impact on wet-lands being elevated to the client, contractor and learners. “It is very important to empha-sise that the awards are based on what SSI has added to the overall sustainability of the project, as well as the added value to the cli-ent as a result of this sustainable approach,” stated Pieter van Niekerk, SSI COO for produc-tion, during the awards ceremony.

TABLE 1:Project SANI Pass upgrade: phase 2Client KZN Department of TransportProject description The project involves the reconstruction of the SANI Pass Road to an all-weather

hard surface from 14 km to 33 km (SANI Top) in the uKhahlamba Drakensburg World Heritage Park.

Project fees and CPR value Design: R21 million (CPR involved with all activities).CPR project CPR is interwoven with all activities on the project, from the type of material

selected to the way it was used.

TABLE 2:Project Eden emergency housing projectClient Eden District MunicipalityProject description The project was started after the regional flooding in 2007 that damaged houses

in the Zoar, Uniondale and Haarlem communities. The project was aimed at restoring the damaged houses, using labourers from the affected communities.

Project fees and CPR value Total fees of R46.6 million and CPR of approximately R920 000.CPR project All 178 workers received training in general building work. Building rubble was

used to stabilise erosion dongas in the area. The environmental sector carried the ECO work on the project that involved regular site inspections to ensure that environmental impact was minimised. A product called ‘skim plast’ was used to plaster house walls because by using this, the energy input is a lot lower than that required for cement and less waste is generated.

IMIESA April 2011 final - · PDF fileTrenchless Pipe 240 000 metres of Successfully Installed...

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