Pipe User Group

Tuesday March 14, 2017

Walnut Creek, CA

Matt Wassam720-333-4500

Agenda• AWWA M-28 liner definitions brief overview• What information is required to bid a project?• Technology Overview

– Transmission Mains: Compressive Fit– Distribution: CIPP

• Trenchless vs. Open Cut Economics

• Two categories of pressure pipe liners– Independent – liner is

designed for all applicable loads independent of the host pipe

– Interactive – semi-structural liner relies on radial support from host pipe to handle internal loads without failing

INDEPENDENTloose-fitting and close-fitting

INTERACTIVE

Pressure Liner Classifications

Design Liner Classification (AWWA M 28 Manual)

Class I Linings Non Structural

Class II Linings Semi Structural

Class III Linings Semi Structural

Class IV Linings* Fully Structural or Structurally Independent

1. A long term (50-year) internal burst strength, when tested independently from the host pipe, equal to or greater than the MAOP of the pipe to be rehabilitated

2. The ability to survive any dynamic loading or other short-term effects associated with sudden failure of the host pipe due to internal pressure loads

*

Why are you considering a trenchless project?

• Economics– Pipe depth? – Host pipe material? AC pipe?– Surface restoration cost? – Traffic disruption? – Environmental? Wetlands? Contaminated

soil?– Construction timing?

Questions to ask

• Is your product 3rd party verified– Psi rating / material properties / safety

• Detailed instructions for installing future repairs / taps / connections

• Long-term performance testing

What information is needed?

Pipe Diameter (exact?)

Pipe materialInternal corrosion (cleaning requirements)

Service connection detailsTemp bypass requirements

• Adjacent utilities• Pit locations and

sizes• Traffic control • Process water

discharge requirements

• Permitting

Procurement / Bidding

• Pilot Project: Sole Source• Bid against other competing technologies• Bid against conventional open cut• Design Build

Plans for bidding project

• Standard Utility Drawings

• Adjacent Utilities• Bypass

Requirements

Project Plans #2

Lining Project Economics

• Pit Frequency– 300’ for CIPP– 800’ for CFPE

• Construction restrictions– Work hours / days?

• Internal Corrosion

• Bypass requirements– Commercial

bypass?– Impact envelope

• Surface Restoration

Compressive Fitting HDPE

• 6”-48” Transmission Mains

• Very Long Pulls: 2,000’-3500’

• Hazen-Williams= 150• Over 10 million feet

installed • Class IV or Class III

• Large access pits• Service connections

require excavation• Must know exact ID• Future connections

History of Compressed Fit Lining

• Method originally developed by British Gas in 1970’s• Partnership with industry to advance the technology with

companies such as DuPont• Widely used in the oil, gas and mining industries• Over 10,000,000’ installed globally over the past 40

years• Numerous recent advancements and patents (end

fittings, flange connections, monitoring, industry specific, etc.)

Engineering and Design HDPE Pipe

• Methods of Joining•Butt fusion - Butt fused joint 20% stronger than rest of pipe

–Electrofusion–Mechanical joints

Liner Pipe Fusion

• PE pipe is manufactured in joint lengths of up to 60’

• Smaller diameters can be provided on reels

• Butt fusion process

Host Pipeline Cleaning and Calibration

MAXIMUM PENETRATION 1/16”

Liner Pipe Installation

• Cable strung through pipeline

• Sizing plate pulled• Cable attached to pulling

head• Pipe pulled through

reduction rollers and host pipe

HDPE Engineering – Pulling

• “Yield strength”• Closely monitored

and logged

Termination End Fittings Installed

• Stub Ends• Bolt Up• Compression Rings

Fittings

Termination Fittings

• Mechanical• www.isco-pipe.com

Fittings

Ft. Collins, Colorado 6,000 x 27”

Ft. Collins, Colorado 6,000 x 27”

• 2,400 x 27” in a single pull

• DR 26 Fully Structural pressure rated replacement

Ft. Collins, Colorado 2,400 x 27”

Ft. Collins, Colorado 6,000 x 27”

Ft. Collins, Colorado 6,000 x 27”

Amarillo, TX Case Study

Challenge 3,100 feet of 30” Cast Iron Water

Transmission Main installed in 1927 Leaking lead joints Tight easement, close to homes and

through busy roads Shut down limited to dry weather

conditions Flow capacity needed to be

maintained

Solution Several Methods Analyzed –

with CFPE selected to maximize flow capacity, limit excavation, follow the existing utility path and speed of installation

Liner System Design 32” Outside Diameter DR

32.5 HDPE DR 4710 1,200 feet pull distances to

minimize connections

Amarillo, TX Case Study

HDPE layout

3,100’ installed in 2 days Total project cost 50% of

open cut estimate Project design completed in

less than a month 4 joints in 3,100 feet of pipe

Amarillo, TX Case Study

Project Scope

• 525’ of 24” Ductile Iron Pipe at 180 psi.

• Lined with 24” DR 26 HDPE PE3408

Project Scope

• 540’ of 19” Steel Pipe at 180 psi. • Lined with 19.13” DR 26

Case Studies• Mississippi

– 45,000 ft– 3 inch to 12 inch steel pipe– 2,250 psi– CO2 injection

Case Studies

• Colorado– 72,000 ft– 12 inch steel – 2220 PSI– Produced water

Case Studies• PHMSA Regulated Pipeline

– 55 miles 8” steel pipe– 70 year old pipeline– Oil transmission– Heavy urban setting– 500 psi

Case Studies• Mexico

– 8” – 12” steel pipe– 27,000 ft– <1,000 psi

CIPP For Distribution Mains• 6”-18”• 2.5 million feet

installed• Services

reconnected robotically

• Temp bypass installed

• Relatively short runs: 300-500’

• Must know the exact ID and internal condition

Class IV CIPP Water Main Renewal

1. Locate the pipe2. Excavate access pits3. Clean the pipe4. CCTV inspection5. Install service connection plugs6. Install the structural CIPP7. Hydrostatic pressure test8. Robotically reinstate services9. Reconnection & civil work10. Disinfect the pipe11. Site restoration

Temporary Bypass

Water Main RenewalBasic Project Steps

Clean to bare metal Dry surface

Pipe Cleaning:

Water Main RenewalLiner installation

Polyester woven liner impregnated with epoxy resin Cured with hot water @ 65°C (150°F)

Water Main RenewalLiner installation

Pulled-in-place

Water Main Renewal Liner installation

Pig ReceiverPig Launcher

Reconnection

Breckenridge, CO

• 5,100’ x 6 and 8 inch• Cast Iron Pipe• 9-11 feet deep• History of circumferential beam

breaks

Breckenridge, COCOS T

EA $0.00EA $12,589.50EA $3,503.16EA $0.00EA $0.00EA $0.00EA $0.00EA $955.80EA $4,421.10EA $0.00EA $0.00EA $0.00EA $99,833.69LF $1,188.64EA $1,453.48EA $1,629.48LF $6,320.45LF $125,464.47EA $0.00EA $0.00EA $0.00EA $15,650.52LF $320,549.90LF $12,298.56

# # # # # # # #1.24 Sewer Main Replacement 0 $0.00 $0.00 92 $133.68

S UBTOTAL $ 4 8 0 , 0 7 8 . 0 6

1.21 Reconnect t o Exist ing Fire Hydrant 1 $5,263.16 $5,263.16 0 $0.001.22 Tie int o Exist ing Main 0 $0.00 $0.00 4 $3,912.631.23 Cure- in-Place 2940 $145.29 $427,152.60 2165 $148.06

1.18 8" DIP 0 $0.00 $0.00 1437 $87.311.19 6" Plug 0 $0.00 $0.00 0 $0.001.20 8" Plug 0 $0.00 $0.00 0 $0.00

1.15 8" Bend 0 $0.00 $0.00 4 $363.371.16 8" 900 Bend 0 $0.00 $0.00 3 $543.161.17 6" DIP 0 $0.00 $0.00 83 $76.15

1.12 6" MJ Cap 0 $0.00 $0.00 0 $0.001.13 Fire Hydrant Assembly 3 $11,141.05 $33,423.15 11 $9,075.791.14 Insulat ion 0 $0.00 $0.00 68 $17.48

1.9 6"x6" Tee 5 $652.63 $3,263.15 10 $442.111.10 8"x6" Tee 0 $0.00 $0.00 0 $0.001.11 8"x8" Tee 0 $0.00 $0.00 0 $0.00

1.6 Vert ical Bends 0 $0.00 $0.00 0 $0.001.7 8"x4" Reducer 0 $0.00 $0.00 0 $0.001.8 8"x6" Reducer 0 $0.00 $0.00 4 $238.95

$0.00 $0.00 2 $1,751.581.4 4" Solid Sleeve 0 $0.00 $0.00 0 $0.001.5 6" Solid Sleeve 0 $0.00 $0.00 0 $0.00

Aqua - P i peBAS E BI D ALT B ADDI TI ON TO BAS E B I D ALT B

BI D I TEM

I TEM DES CRI P TI ONUNI T QUANTI TY

UNI T COS T

COS TQUANTI TY

UNI T COS T

Wat er Main

1.1 4" Gat e Valve 0 $0.00 $0.00 0 $0.001.2 6" Gat e Valve 7 $1,568.00 $10,976.00 10 $1,258.951.3 8" Gat e Valve 0

Breckenridge, CO

Breckenridge, CO

Breckenridge, CO

Loveland, CO

• 6,400’ of 6-12”• 1,500’ of open cut• Public bid against open

cut• Project Completion July

2016

Loveland, CO

Loveland, CO

Loveland, CO

• $747,740 savings over open cut

• 6,200’ of lining completed in 6 weeks

• $177,008 savings in asphalt fees

Loveland, CO

Old Market Project

Old Market Project

Specifics: Lined over 2500’ of 10” and 12” CILJ water main 20% less than bursting and open cut Eliminated 20 (18) service reconnection

excavations. (2 had to be dug up after lining.) Avoided about 10,000 ft2 of brick removal 24 calendar days to clean and line ½ mile of

mains (including small service reinstatements).- 86 calendar days total on-site- vs. 145 days (est.) for replacement

Old Market Project

Old Market Project