Kenilworth Rehab of PCCP with Steel pipelines...
Transcript of Kenilworth Rehab of PCCP with Steel pipelines...
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Structural Rehabilitation of the Kenilworth PCCP Transmission
Main with Steel Slipliner
Jeffrey Peluso, PEProject Manager, Baltimore County Dept. of Public WorksRon BrownSales Representative, Northwest Pipe Company
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Presentation OverviewJeffrey Peluso, PEProject Manager
§ Baltimore Water System/Kenilworth Transmission Main
§ Significant Events§ First Investigation/Repairs§ Forensic Analysis§ Second Investigation§ Advanced Condition Assessment
Techniques§ Replacement or Rehabilitation?
Ron BrownSales Representative
§ Criteria for Solution Selection§ Construction Methods and
Material Evaluation§ Project Design§ Project Bid, Award and Pipe
Manufacture§ Installation§ Conclusion
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Baltimore Water System
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48” Kenilworth Transmission Main
• 48,854 LF (PCCP)
• Serves the Towson 4th Zone and 5 Upper Pressure Zones
• Conduit between Towson Pumping Station and Mays Chapel Reservoir
• Built in four (4) phases between 1970 and 1991
• 30” Redundant Source
48” Kenilworth Transmission Main
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July, 2003, the trouble begins …
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April, 2004 … the Main Fails Again, Approximately 4000 LF From the First Break
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• 7800’-48” PCCP ECP (SP-12)
• Manufactured by Interpace Corporation w/Class IV Wire (1977)
• 4 Design Classes
Break 2
Break 1
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Condition Assessment #1: November, 2004
Manned-Sounding P-Wave™
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Condition Assessment Findings
• Inspected 394 sections• 16% had wire breaks• 16 sections with >50 wire
breaks• 4 sections with longitudinal
cracks and hollows• Recommended 4 sections to
be replaced• Re-inspect in 5 years
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Subsequent Action Taken• 4 pipe sections were replaced
in May, 2005• Forensic analysis done on all • 3 out of 4 sections correlated
well with the P-Wave™ results• The other pipe had several
wire splices which created EM anomalies similar to breaks
• 2 pipes were incorrect design class and, consequently, under designed for existing conditions
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Rate of Deterioration Using New Technology
• Hydrophone array launched Summer, 2005
• First commercial installation of a fiber optic acoustic monitoring system launched at the same time.
• 90 day trial• 14 wire breaks• Good correlation between
the systems• Trial discontinued after 90
day trial
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Condition Assessment #2: October, 2010
Manned-Sounding P-Wave™
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Condition Assessment Findings
• Inspected 386 sections• 16% had wire breaks• 40 sections with 5-75 wire
breaks• 5 sections with longitudinal
cracks and hollows• Pipes with wire breaks in
2004 continue to deteriorate
• Existing pipe does not meet current AWWA design standards
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Risk Curve Analysis
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What Do We Do Now??
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Fix, Repair, Rehab, Replace?Criteria for Solution Selection
Critical Design Path Decision: (1)system, (2) Pipe Selection
1. A Fully Structural, Permanent Repair2. Overall Cost of the Solution /
Technology3. Minimum 100-year Service Life4. Length of Construction Time5. Minimize Hydraulic Flow Loss in Host
PCCP6. Minimize Social & Traffic Cost Impacts
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Rehabilitation Methods and Materials Considered
1 2
3 4
1. Remove-and-Replace
2. Carbon Fiber Reinforced Polymers (CFRP)
3. HDPE Sliplining
4. Steel Cylinder Sliplining
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§ Excavation of distressed sections followed by replacement with new pipe
§ Fully Structural: YES§ Overall Cost: High§ Min 100 yr Svc Life: YES (with proper
corrosion control)§ Construction Time: High, Pipeline
Alignment Under Pavement of Busy Roadway and in Shoulders
§ Hydraulic Flow: Same as host pipe§ Traffic Disruption: Very High, in Congested
Suburban Locale – Shopping Centers and Large Mall Close by
§ Resident Inconvenience: Very High
Rehab Option – Remove and Replace
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Rehab Option – Carbon Fiber Composites (CFRP)§ Manual Application of Layers of CFRP and GFRP wet
lay-up System, Internally. Trenchless
§ Fully Structural: NO§ Overall Cost: Very High (only 33 sections of host
PCCP repair would cost $2.5 million)§ Min 100 yr Svc Life: ?? (first known CFRP in pipes
used less than 15 yrs ago)§ Construction Time: High, CFRP Technology is suited
for repair of short individual sections … therefore full section of Kenilworth Pipelines would take a long time
§ Hydraulic Flow: Minimal loss§ Traffic Disruption: Minimal, only need man-ways into
host pipe, and surface space for Ventilation and Other Equipment
§ Resident Inconvenience: Low
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Rehab Option – High Density Polyethylene (HDPE)§ Insertion of continuous sections of HDPE pipe with
butt-fused joints
§ Fully Structural: YES (if grout applied in annulus)§ Overall Cost: Moderate§ Min 100 yr Svc Life: POSSIBLY (use of AWWA 3408
HDPE in water systems in US less than 25 years service)
§ Construction Time: Moderate, dependent on joint butt-fusion
§ Hydraulic Flow: High Loss of ID (42-inch DR 11 HDPE would have an ID of only 33.905, resulting in loss of almost 10-inches in the ID)
§ Traffic Disruption: High (large staging areas needed on surface for making long strings of butt-fused HDPE, as well as space for entry and exit pits)
§ Resident Inconvenience: High
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Rehab Option – Steel Pipe Sliplining§ Continuous insertion of sections of Steel Pipe
(“cartridge” system … no continuous chains of pipe sections)
§ Fully Structural: YES§ Overall Cost: LOW compared to other options
considered§ Min 100 yr Svc Life: YES§ Construction Time: Moderate / Relatively Low§ Hydraulic Flow: Very Low Loss of ID (ID of steel pipe
sliplining system would be 40-inch minimum for the 42-inch host PCCP pipe)
§ Traffic Disruption: Low compared to other technologies considered (space needed on surface only for entry and exit pits)
§ Resident Inconvenience: Low
§ Use of welded joints would result in ZERO-leakage.
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Final Technical Solution Selected
PCCP REHAB OPTIONS
Relining with Steel
PipeSliplining with Steel Pipe Selected because it met all selection criteria:
1. A Fully Structural, Permanent Repair YES
2. Overall Cost of the Solution / Technology LOW
3. Minimum 100-year Service Life YES
4. Length of Construction Time LOW
5. Minimize Hydraulic Flow Loss in Host PCCP LOW
6. Minimize Social Cost Impacts YES
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Project Design
§ County and NWP worked together to develop Sliplining Specification
§ Geotechnical and sub-surface Conditions, Host PCCP Condition, Staging areas, Entry/Exit Pits, Steel Cylinder Strength to withstand Jacking Forces, etc. were determined
§ Host PCCP was 48-inch Diameter§ 7,800 LF of 40-inch ID Steel Pipe Cylinders
w/ 41 ¾-inch OD designed per AWWA M11 and AWWA C200 Steel Water Pipe standard
§ Working Pressure 120 psi, Test Pressure 180 psi
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Project Design§ Cylinders designed as a fully structural
solution, to withstand: Internal Pressure, External Earth Loads, and External Hydrostatic Pressures from Ground Water, per AWWA M11
§ Cylinder also had to withstand Grouting Pressure (of grout applied in annular space between cylinders and host PCCP)
§ Since this was first project with Steel Sliplining, the County chose to be conservative against possibility of buckling of cylinder due to improper grouting procedures … used 3/8-inch thick cylinder (approx. 2X the needed thickness per M11). Therefore also handled 2X the required internal pressure
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Project DesignCorrosion Control
Sliplining Cylinders§ Cylinder Outside was left bare … corrosion
control provided by use of Low Weight Cementitious Grout, combined with Corrosion Inhibitor
§ Internal Lining provided with ½-inch thick Cement Mortar Lining
Pipe Sections§ For corrosion protection of Welded Steel
Pipe sections in open-cut areas, bonded 80-mil thick dielectric tape-coating was applied per AWWA C214 and field installed Cathodic Protection
§ Internal Lining was ½-inch thick CML
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Spiral Welded Steel Pipe Manufacture
Each Cylinder hydro-tested to 75% Min. Yield of Steel. For 41.5-inch OD pipe w/ 0.375-inch Wall, Test Pressure was 566 psi
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Installation / Construction§ Exit/Entry Pits: 10 Pits, including tie-in
locations … sized to accommodate full pipe lengths and equipment.
§ Locations based on bends from as-builts, pushing distance and connection areas
§ Annular Spacing: Casing Spacers utilized to center steel slipliner pipe into the host PCCP --- 20-ft sections had 3 casing spacers, 10-ft sections had 2 casing spacers
§ Jacking Equipment: Jacking machine with connection sled used, instead of rail system. Bases of removed PCCP sections in pits served as tracks
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Installation / Construction§ Jacking: Jacking limitation was 800-ft. For longer push
lengths of up to 1000-ft, excavator facilitated movement upstream while jacking machine continued to push
§ Reconnections: Mechnical couplings used to connect to new and existing pipe, and to valves, meters and other appurtenances.
§ Butt straps used to join sliplining pipe “trains” together in adjacent pits.
§ Corrosion protection at joints completed in field using heat-shrink sleeves, AWWA C216, and hand-tape, AWWA C209
§ Welding: Each joint was internally lap-welded§ Per AWWA C206 (field welding procedures) and AWS
B2.1 (welding qualifications)§ QC – Magnetic Particle Testing (per ASTM E709)
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Installation / Construction§ Grouting§ Light-weight Cellular Foam with High
PH Grout Mix Used§ 28-day Compressive Strength of
Grout per ASTM C495/C796 Greater than 100 psi§ Grouting performed from pit-to-pit§ Low grout pressure of 5psi resulted in
100% of annulus being filled§ Grout Ports, though specified, were
not used due to nature of selected Grout
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CONCLUSIONS§ The 48-inch Kenilworth Transmission Main, after failing a couple of
times and undergoing several condition assessment and forensic analysis using various technologies, underwent a permanent structural rehabilitation using Steel Pipe Sliplining
§ Other technologies considered for rehabilitation included Slipliningwith HDPE, Remove-and-Replace with PCCP, and CFRP (Carbon Fiber composites) Lining
§ Project was completed with Steel Pipe in timely fashion, w/o disruption to traffic/ community and as planned by Baltimore County