NJWEA FALL 2019 TECH TRANSFER 10/17/2019HydroBurst HB100, PP70 Power Pack, Specialized Tooling...

NJWEA FALL 2019 TECH TRANSFER 10/17/2019

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Pipebursting: Static, Pneumatic, Splitting & Laterals

Gregg Conklin, Regional Sales ManagerNortheast Regional Manager,

HammerHead

Deteriorating Infrastructure

• Worldwide deterioration of underground infrastructure– Water lines

– Sewer lines

– Gas lines

• Congested urban areas

• Beneath buildings, roadways and landscaping

Sanitary and Storm Sewer Systems

• Offset pipes

• Deterioration

• Root intrusion

• Crowned or cracked

• Leaking

• Under capacity

• Rain infiltration/inflow

Water Distribution Systems

• Encrusted

• Corroded

• Leaking (loss up to 40%)

• Under capacity

• Drinking Water Infrastructure over 700,000 Miles

Gas Distribution Systems

• Regulations require cast iron lines be replaced

• Cathodic protection failing, in turn steel lines are corroding and failing

• Leaking

• Under capacity

Sewer and Water Main Bursting Market

• $1 Trillion– Next 20 years

• Water

• Sewer

• More than 60 million feet to date

• 50% annual growth


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Pipe Bursting

• The breaking of an existing pipe, expanding the broken pipe shards into the surrounding soil while simultaneously pulling in the “NEW” carrier line, usually polyethylene pipe (HDPE).

Pipe Bursting• Eliminates up to 85% of

excavation • Damage prevention:

Follows the path of the existing utility reducing risks of utility strikes

• Especially cost effective when compared to an open cut utility relocation design

• Reduced traffic disruption• Minimal surface

disruption

Pipe Bursting

• Sometimes classified as a repair versus new construction

• Often reduces engineering costs

• Permitting needs, requirements, costs and time required from planning, construction to final completion are impacted

Pipe Bursting

• Install same size or larger diameter pipe

• Pipe bursting is often more cost effective than other methods when long term owner costs and capacity needs are considered.

Brief History of Pipe Bursting

• Developed by British Gas in the late 70’s when they were faced with deteriorating gas lines in severely congested and developed areas.

• Open cutting to replace these lines was cost prohibitive and sometimes not an option.

• Directional Drilling had difficulty due to the lack of knowing where the existing utilities were.

• In conjunction with a utility contractor, British Gas developed the patented the process of Pipe Bursting to replace fracturablepipes including water, sewer & gas. (Patents Expired April 2004)

• Utilizing the existing easement and path of existing utilities, pipe bursting proved a very effective method of replacement.

PROJECT CONSIDERATIONS


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What materials can be burst?

Fracturable PipesCast iron, clay tile, concrete, reinforced concrete, asbestos cement, etc.

Non-fracturable PipesDuctile iron, steel, galvanized (require use of specialized tooling and static bursting machines.

ClassDepth of Pipe

Existing Pipe

Diameter

New Pipe Diameter Options

BurstLength

<12 ft 4” – 12”Size for Size to 1 upsize

0 – 350 ft

>12 ft < 18 ft 12” – 20” 2 upsizes 350 – 450 ft

> 18 ft 20” – 36”3 or more upsizes

> 450 ft

IPBA Project Classification

Project classifications per IPBA (International Pipe Bursting Association) pipe bursting specification.

A

B

C

Upsizing – Expansion (where it goes)

Approximately 90% of compaction occurs upwards from the existing line.

Depth of Cover

8” DIPS Burst HeadExpander OD – 11.50”

6” Clay PipeExisting Pipe ID – 5.94”

General rule is one (1) foot of cover for every inch of expansion

Note: any compaction recedes over time. The deeper the line, the less chance of surface disruption

Upsizing: A Closer Look

Note: the above illustrations assume flow line remains the same.

Upsizing and Depth

• Has flow monitoring been completed?

• Is upsizing necessary if I/I is eliminated?

• A minimum of 4’ (1.2m) of cover should be used when upsizing 1 size

• Greater cover should be used if upsizing more than one size

Note: any compaction recedes over time. The deeper the line, the less chance of surface disruption


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Flow Comparisons - HDPE

Cast Iron Pipe AC Pipe New DIPS HDPE SDR17 pipe

4" ID = 96 gpm 4" ID = 109 gpm 4" = 132 gpm; 6" = 299 gpm



10" ID = 511 gpm 10" ID = 583 gpm 10" = 706 gpm; 12" =997gpm

12" ID = 723 gpm 12" ID = 824 gpm 12" = 997 gpm

Summary: Significant increased flow rate with HDPE

Soil Conditions

What is the Soil Surrounding the Existing Pipe?

• Sand?

• Clay?

• Cobble?

• Rock?

Going the Distance

• Static Energy– Increase Pulling Pressure

• Impact Energy– Use the largest Hammer for the job

• Soil Memory – Race against time

• Pipe Friction– Lubrication– Tractor Effect– Entry Pit Length

Depth of Existing Line

• Entrance and exit pit depths?

• Can we dig an entry pit?– Entry pit length is minimum 2 ½ times depth

– With pipes larger than 12” diameter length of entry pit will increase

• Can we manhole exit?– 8, 10 & 12” single upsize

• Can we dig an exit (receiving) pit?

Length of Burst

• How Long is the Burst?– Bypass Needed?

– Number of Services?

– Has One Call been Contacted?

– How close are the are the other Utilities?


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New Pipe Questions

• What kind of new pipe?

• IPS or DIPS? (OD)– Important for burst head adaptability

– Existing clay to DIPS is a single upsize

• What is the SDR Rating– Recommend a minimum of SDR17 for pipe

bursting with HDPE

New Pipe Material

• HDPE is preferred pipe when pipe bursting

• Fusible PVC, Terrabrute, Ductile and Clay have been used successfully but require additional project and site considerations.

Use of Lubrication (Lube Manifold)

Small Dia. (6”-10”) Good Soil

Medium Dia. (12-16”)

Large Dia. (16” and larger)

Large Dia.Poor Soil

Large or long bursts: lubrication can increase production and the bursting distance capability

Current Video Available

• Current video is very important

• Scenario: We have a video, but it is 2 years old.

• Problem: What has happened to the line in the last 2 years.– Point repair on clay line with ductile repair section

and steel bands

Current Video

• Is there a dip in the line?

• Is there a swell in the line?

• Is a point repair needed prior to bursting?

Common questions

1. What about pipe scratches on the new HDPE2. How do you go around bends3. What about damage to other utilities with the expansion that takes place4. Our plans are bad for old lines, how do you deal with this5. How does the equipment work if there is a line repair6. How long can you burst7. How big can you burst8. We need to chlorinate the pipe after it is installed and wait 2 days to

hook people back on service9. How do you connect to existing pipe materials and services10. Who around here is doing this, I don’t want to be first11. I am concerned about taking the risk of trying something new and don’t

want the responsibility


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System Selection

• Pneumatic systems

• Static systems

• Compact systems PIPE BURSTINGTypes of Systems

Pneumatic Pipe Bursting MethodA constant tension winch keeps a pneumatic hammer attached to a burst head online to burst pipe and pull in new pipe.

Shown - 8, 10 & 12” single upsize bursts – PATENTED manhole exit method

Live Burst Video

Manhole Exiting

• Manhole exits save time and money

• Maneuverability to set up in difficult terrain

*Manhole exiting is a patented process of Earth Tool Company LLC, US PATENT: US 6,299,382 B1

Static Pipe Bursting MethodHigh tonnage pull back force pulls on rod attached to a bursting head or slitter and breaks existing pipe, expands surrounding soil and pulls in new pipe.

Small tonnage systems (up to 50 tons) available for 2 – 8” pipeLarge tonnage systems (up to 300 tons) available to burst 4 – 24” pipe and largerSpecialized equipment available to split steel and ductile pipes.


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Live Static Burst Video

Static Pipe Bursting Systems

• Static systems provide the opportunity to replace non fracturable pipe with the use of slitters

• 2 – 16” host pipe– Ductile iron

– Steel

– Cast iron

Lateral Pipe Bursting MethodCompact static systems pull cable or chain attached to bursting head or puller that breaks existing pipe and pulls in new pipe.

Live Lateral Burst Video

Why Pipe Bursting for Lateral Replacement?

• Proven method• Reduces excavation

and surface disruption• Installs HDPE pipe

– New Pipe– No-joints– Superior flow

characteristics

• Low initial equipment investment

PIPE BURSTING CASE STUDIES


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Project

Product/Footage

Equipment

City

of C

alga

ry, A

lber

ta, C

anad

a Pneumatic Pipe Bursting

Sewer main replacement

315 feet of 24” Clay Tile to 24” SDR17 HDPE

20” HammerHead bursting hammer, 26” bursting head, HydroGuide HG20 winch, 24” pipe pilot

Project

Product/Footage

Equipment

Nor

thpo

rt, M

aine

Pneumatic Pipe Bursting


150’ of 10” VCP to 10” HDPE

8” HammerHead bursting hammer, HydroGuide HG12 winch, 10” burst head, manhole exit method

Project

Product/Footage

Equipment

Plan

o, T

exas

Pneumatic Pipe Bursting

Sanitary sewer replacement

24” RCP to 32” HDPE, 817 feet

20” and 24” HammerHead pipe bursting hammers, Hydroguide HG20 winch

Project

Product/Footage

Equipment

Balti

mor

e, M

aryl

and Pneumatic Pipe Bursting

Sanitary sewermain replacement

1,550 feet of 18” VCP to 24” IPD HDPE

20” HammerHead bursting hammer, HydroGuide HG20 winch, 20” burst head, 24” tractor head

Project

Product/Footage

Equipment

Orla

ndo,

Flo

rida Static Pipe Bursting with

Pre-Chlorination Method

Water main replacement

15,000 feet of 4 & 6” AC & Cast Iron replaced with 6” HDPE

HydroBurst HB5058, PP20 Power Pack, Ductile Slitter

Project

Product/Footage

Equipment

Jagu

ariu

na, B

razi

l Static Pipe Bursting


47,000 meters replaced from 2002 to 2008 work is ongoing.

HydroBurst HB5058, PP20 Power Pack


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Project

Product/Footage

Equipment

Chon

gqin

g, C

hina

Static Pipe Bursting


70 meters of 4” Cast Iron to 110 mm HDPE

HydroBurst HB5058, PP20 Power Pack

Project

Product/Footage

Equipment

Mel

bour

ne, A

ustr

alia Static Pipe Bursting


2,000 feet of 250 mm AC/Ductile Repairs to 315 mm HDPE

HydroBurst HB80, PP73 Power Pack, 10” Ductile Slitter, 12” Expander

Project

Product/Footage

Equipment

Mal

mst

rom

AFB

, Mon

tana

Static Pipe Bursting


2,500 feet of 8” Concrete lined with CIPP and Sliplinedreplaced with 8” HDPE

HydroBurst HB100, PP70 Power Pack, Specialized Tooling

Project

Product/Footage

Equipment

Ypsi

lant

i, M

ichi

gan Static Pipe Bursting


7,000 LF of 8” & 12” Cast to 12” FPVC™

HydroBurst HB125, PP73 Power Pack, HammerHead tooling

Project

Product/Footage

Equipment

City

of L

ondo

n, O

ntar

io, C

anad

a Lateral Pipe Bursting

Municipal sewer lateral replacement program

4” and 6” pipes replaced with 4 & 6” HDPE

PortaBurst PB30 Gen 2, Quick Grip burst heads, PP13 Power Pack

Project

Product/Footage

Equipment

Mar

ion,

Iow

a Lateral Pipe Bursting

Sewer lateral replacement under school parking lot

116 feet of 6” Orangeburg to 6” HDPE

PortaBurst PB30 Gen 2, 6” Quick Grip burst head, PP13 Power Pack


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Project

Product/Footage

EquipmentSale

m, M

assa

chus

etts Lateral Pipe Bursting

Private sewer lateral replacement

4” VCP to 4” HDPE

PortaBurst PB30 Gen 2, 4” Quick Grip burst head, PP13 Power Pack

Project

Product/Footage

Equipment

Lync

hbur

g, V

irgin

ia Lateral Pipe Bursting

Private sewer lateral replacement

4” PVC to 4” HDPE

PortaBurst PB30 Gen 2, 4” Quick Grip burst head, PP13 Power Pack, Connectra® fusion machine.

Project

Product/Footage

Equipment

Wau

kesh

a, W

I: M

ay, 2

010 Hydroburst HB 125

South West St., Waukesha, WIC.W. Purpero

1500’ of 10” Cast replaced w/ 10” DIPS HDPE DR 11

HB 125 Longest Pull: 980’

PO Box 3 • Oconomowoc, WI 53066 USA • Phone: 800-331-6653 • Int: +1 262-567-8833Fax: 262-567-5068 • Web: www.hammerheadtrenchless.com

Thank You

NJWEA FALL 2019 TECH TRANSFER 10/17/2019HydroBurst HB100, PP70 Power Pack, Specialized Tooling...

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Transcript of NJWEA FALL 2019 TECH TRANSFER 10/17/2019HydroBurst HB100, PP70 Power Pack, Specialized Tooling...