INNOVATIONS IN TRENCHLESS REHABILITATION

“PRESSURE PIPELINE REHABILITATION USING CIPP LINING- ONSLOW RD STORMWATER

UPGRADE”

ByRaad Dali

General Manager Advanced Pipeline Services Ltd.

July 2010

ONSLOW CATCHMENT-WELLINGTON

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• Storm water run-off from the Onslow Rd Catchment in Hutt City / Wellington has historically resulted in considerable problems and damage to the road and / or its environment .

• Due to the uncoordinated nature of the upgrading , some of the measures simply transferred the problems to the downstream sections.

• Council Engineers were unwilling to proceed with an further upgrade work until investigation, evaluation, and/or mitigation of the risks of transferring the design flow to the lower sections of the storm water main were completed.

PROJECT BACKGROUND

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The project represented Stage 5 of a 6 Stage upgrade.

This section of the storm water outfall that need to be upgraded runs

beneath Hutt Rd

PROJECT LOCATION

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PROJECT LOCATION

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The North Island Main Railway line, the Wairarapa Railway line

PROJECT LOCATION

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and under Wellington Urban State Highway 1

PROJECT LOCATION

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to the sea outfall

PROJECT DESIGN

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Conventional upgrade options available included the installation of a larger diameter pipe ( or a duplicate) by open cut or by microtunelling would have been very risky due to the variable ground conditions and the potential for disruptions to the major transportation links serving Wellington City was high.

Preliminary cost estimates for these options run in several million of dollars.

Thinking Innovatively ( both economically and technically) the consultant CPG proposed the alternative of lining the existing pipeline including the manholes with a Cured in Place Pipe ( CIPP liner) to create a continuous pressurized pipeline taking advantage of the upstream gradient and potential hydraulic energy to discharge more water through the existing pipeline.

PROJECT REQUIREMENTS

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The technical requirements for the project included the following:

• The CIPP liner should be a fully structural liner capable of withstanding all loads from soil, traffic loads and ground water in its own rights .

• The minimum effective life of the CIPP liner would be 50 years.

• The lining system should not reduce the diameter of the existing pipe by more than 5%

• The CIPP lined section should withstand a test up to 30m

• The curing water should be disposed to an approved site.

PROJECT CONSTRAINTS

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Several Lining options are available for the rehabilitation of similar diameter pipelines .However these methods are not suitable in this particular project. Inherent difficulties included :

• The requirement to overcome two transitions in the diameter of the pipeline from 675mm to 750mm, and 750mm to 900mm. Continuous lining through the two transitions in the liner is something not attempted before internationally.

• There are several vertical and horizontal bends in the existing stormwater line.

• Limited access to the installation sites as access points were located in a private property, near a historic trough, in the rail reserve and with one buried manhole located in the middle of the main state highway to Wellington City.

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PROJECT CONSTRAINTS

PROJECT CONSTRAINTS

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• A Steep installation , there is a significant static head of approx 10m between upstream manhole and down stream sea outlet.

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PROJECT PROPOSAL

• Advanced Pipeline Services Ltd proposed the use of Insituform Pressure Pipe Liner (PPL) custom engineered cured in place pipe product. The specific PPL ordered for this project was designed to flexibly negotiate the existing horizontal and vertical bends in the existing pipeline.

Insituform PPL is an advanced, proven and non-disruptive technology that is specially designed to withstand a wide range of system operation conditions, and because it is installed inside the existing main there was no risk of damage or disturbance to adjacent utilities or infrastructures.

As the installation is a fully trenchless technique the process reduces transport and subsequent commercial disruption, site noise, pollution and safety concerns to limited access

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PPL LINER

Vinlyester -Epoxy/Fibreglass Structure•Number of Layers dependent on diameter and internal pressure

Vinlyester-Epoxy/Polyester Felt Structure •Provides external load capacity•Layer thickness can be varied depending on the loading conditions

PE coating•Water contact surface•Coating provides water barrier for installation process and impregnation

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PPL LINER

DESIGN THICKNESS•The liner was designed according to the ASTM standard F1216-07 with a factor of safety of 1.5 for external loading and a factor of safety of 3 for any vacuum loading.•The design revealed a liner thickness of 12mm

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Sketch of liner design showing transitions

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DETAIL OF OUTFALL END TO CONTAIN LINER AND CURING WATER

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INSTALLATION OF THE PPL LINER-STEP 1 LINER IMPREGNATION

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STEP 1-LINER IMPREGNATION

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STEP 1-LINER IMPREGNATION

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STEP 2- THE LINER IS PACKAGED FOR TRANSPORT TO SITE

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STEP 3-LINER INSTALLATION

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STEP 3-LINER INSTALLATION

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STEP 3- SUPPORTING LINER INSIDE MANHOLE

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OUTFALL END

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TESTING OF LINER

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TESTING OF LINER

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END OF PROJECT

OTHER CIPP LINING PRESSURE APPLICATIONS-INSITUMAIN TM

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InsituMainTM Product Characteristics

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ANSI- American National Standards InstituteNSF- National Science Foundation

InsituMainTM Technical Envelope

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InsituMainTM Applications

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InsituMainTM Design

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InsituMainTM Manufacturing

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Installation Process- Bypass and Pipeline Access

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InsituMainTM Installation

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Service Connection Reinstatement

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Restoring Service

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Future Connections

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Potable Water Case Study

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InsituMainTM Product Benefits

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OTHER NON-POTABLE PROJECTS COMPLETED IN NZ USING PRESSURE LINERS

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•Repair of Gulf Harbour-Whangaparaoa Rising main

•640 mm GRP Hobas pipe

•35m repair due to physical damages

•Working pressure 50 psi

•Vinylester- Kevlar reinforced lining system

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Mangere Sewage Treatment plant-Watercare Services Ltd.

•250mm Cement lined Steel pipe

•25m repair due to corrosion.

•Working pressure 60 psi

•Testing pressure 90 psi

•Epoxy- Kevlar reinforced lining system

•Installation time 12 hours

OTHER NON-POTABLE PROJECTS COMPLETED IN NZ USING PRESSURE LINERS