PROJECTO EXECUTIVO PARA A REPARAÇÃO DA BARRAGEM DO CALUEQUE, ANGOLA CONDUTAS BOMBAGEM NORTE E BOMBAGEM SUL

Transcription

1 PROJECTO EXECUTIVO PARA A REPARAÇÃO DA BARRAGEM DO CALUEQUE, ANGOLA CONDUTAS BOMBAGEM NORTE E BOMBAGEM SUL REPORT ON THE VISIT TO THE GRP PIPE FACTORY in ZARAGOZA, SPAIN JANEIRO 2014 BKS Part of the AECOM Group 1 P a g e

2 PROJECTO EXECUTIVO PARA A REPARAÇÃO DA BARRAGEM DO CALUEQUE, ANGOLA CONDUTAS BOMBAGEM NORTE E BOMBAGEM SUL REPORT ON THE VISIT TO THE GRP PIPE FACTORY in ZARAGOZA, SPAIN INDEX 1. Introduction Purpose and Objectives PROTESA Company Profile Factory Visit at Zaragoza Introduction Factory Tour (raw materials) Factory Tour (pipe manufacturing process) Factory Tour (manufacturing of special fittings) Factory Tour (Quality Control and Records) General Discussion Demonstration of Pipe Assembly Specific Items Discussed re GRP Products Design of GRP Pipes Handling and Installation of GRP Pipes Specific Discussion on GRP Pipes for Calueque Project Drawings Method Statement for Pressure Testing of Pipeline Records of manufacturing, control and shipment of GRP Pipes Training of Pipe Layers Field Visit of GRP Pipe Installation Introduction Remote Management of Zaragoza Water Supply GRP Pipe Performance in the System Documentation (Quality Dossier and Mechanical Calculation) Summary of Project Team Conclusion P a g e

3 PROJECTO EXECUTIVO PARA A REPARAÇÃO DA BARRAGEM DO CALUEQUE, ANGOLA CONDUTAS BOMBAGEM NORTE E BOMBAGEM SUL REPORT ON THE VISIT TO THE GRP PIPE FACTORY in ZARAGOZA, SPAIN JANEIRO Introduction The Project Barragem de Calueque Angola inter alia consists of the supply and installation of 2800 m (approximate) of DN 1600mm PN 4 GRP pipes at the south pump station and 7600 m (approximate) of DN 1800mm PN 10 / PN 16 GRP pipes (a dual pipeline of app m) at the north pump station that will terminate at the two north bank reservoirs. The Contractor has indicated that all GRP pipes and special fittings would be procured from a manufacturer in Spain. As per normal quality control procedure in large projects to inspect such materials before it is delivered to site, AURECON has decided to send a delegation to the GRP pipe manufacturer s plant. The delegation that was nominated to visit the manufacturing plant in Zaragoza, Spain consisted of; James van der Linde (Chief Engineer: Construction Management and Supervision, Calueque, Angola) Jacques Mulder (Technical Director, AURECON) The Contractor s representative, Mr Mario Ferraz from TUBO Ambiente (also representing LYON) accompanied the AURECON delegation to Zaragoza. 2. Purpose and Objectives The purpose of the visit to the manufacturing plant was to inspect the complete manufacturing process of the GRP pipes and special fittings, to confirm that material used and manufacturing process is complying with specifications, and to ensure that the associated quality controls and procedures are followed and recorded. The objective also was to get acquainted with the manufacturer's design methodology and the storage, handling and installation requirements and procedures. Knowledge on specific issues/activities that would require special attention, care and quality monitoring and control during storage, handling and installation was to be discussed. 3 P a g e

4 3. PROTESA Company Profile PROTESA is a Spanish company founded in 1959 with the aim of researching, designing, producing, marketing and installing GRP (Glass Fiber Reinforced Polyester) pipes and fittings produced using the Crossed Filament Winding system, also known as the Reciprocal Filament Winding Method. PROTESA was a pioneer in the production of GRP pipes in Spain and was the first company in the sector to export to some of the most demanding countries in terms of quality and service, such as Germany, the USA, Canada and Australia, amongst others. PROTESA has its headquarters in Barcelona, Spain, with facilities in Zaragoza, Spain; Pune, India and Jorf Lasfar, Morocco. Over the years, PROTESA has acquired great experience in the GRP market, which has enabled them to reach a leading position within the sector, providing a high-quality product. The main sectors in which the Company is active are sewage networks, wastewater treatment plants, water supply networks, transmission lines, irrigation networks, purification plants, power plants, desalination plants, fire protection systems, industry, etc. In 2013, Future Pipe Industries Group (FPIG), as part of the execution of its global growth strategy, has acquired 100% of Protecciones Plásticas, S.A., which carries on business under the trading name "PROTESA". Today, PROTESA works throughout the world, carrying out projects in Australia, Chile, Algeria, Morocco, Panama, Israel, the UK, France, Switzerland, etc. Furthermore, the company has a network of international agents in Germany, France, the Netherlands, Italy, Bulgaria, the UK, Switzerland, the Czech Republic, Israel, Portugal, Australia, etc. Photo 1: Production center in Ejea de los Caballeros near Zaragoza (Spain). 4 P a g e

5 4. Factory Visit at Zaragoza 4.1 Introduction The production center near Zaragoza (Spain) is located in Ejea de los Caballeros. It is just 70 km away from the city of Zaragoza and 300 km from the ports of both Barcelona and Bilbao. There are approximately 90 technical workers on this site as well as the administrative offices. The delegation from PROTESA that was introduced was as follows: o o o o José Antonio Barón (Director Civil Works) David Tello Lorente (Operations Manager) Juan Pedro (Quality Control Engineer) Pedro Monsalve Moreno (Design Engineer from Barcelona) After introducing each other and providing some background information on PROTESA and AURECON, a short historic background of the Calueque Project was given. After these introductions a tour of the factory was conducted. Photo 2: Mario and José Antonio Photo 3: Juan Pedro and Pedro Monsalve 4.2 Factory Tour (raw materials) Glass fiber reinforced polyester (GRP) belongs to the group of materials known as 'composites'. Composites are made up of a continuous phase (a matrix of thermostable resins) and a fibrous phase (glass fiber), which provides their mechanical characteristics. The raw materials (resins and fiber) are sourced from elsewhere and stored on site. Various different types of glass fiber are used to manufacture the pipes and fittings. In the structure of the pipe, three different layers can be clearly distinguished, each of which has a specific set of properties and is composed of certain raw materials. 5 P a g e

6 4.3 Factory Tour (pipe manufacturing process) PROTESA specializes in the manufacture of GRP pipes by means of the application of continuous glass fibers onto a metallic mould (or mandrel). These fibers are wound onto the mould either circumferentially or helically. At the time of the visit, a DN 1600mm pipe was on the mould and in process of Cross Filament Winding, or the winding of continuous glass fibers onto a mould. Photo 4: This DN 1600mm pipe in the photo is scheduled for the Calueque Project. Photo 5: GRP pipes ready for final finishes. The winding process is automated to comply with the specific design parameters of that pipe section (thickness of pipe wall, density and angle of winding, stiffness, number/ thickness of layers, etc). All 6 P a g e

7 of the phases of this complex manufacturing process, from the design of the mould and its subsequent use to finish of the product are described below. 0. Preparation of the mould (Phase 1). 1. Application of a polyester film applied over the entire surface of the mould. 2. Fabrication of the first layer of the GRP pipe, also known as the liner. 3. Drying. 4. Fabrication of the mechanical layer including ID tag (Phase 2). 5. Curing. 6. Calibration (Phase 3). (Marking and then cutting the ends of the pipe where the Bell begins and the Spigot ends, rectifying the thickness of the Spigot and cutting grooves in it). 7. De-moulding: Extracting the mould by machine (Phase 4) 8. Final finishes, ie painting the calibrated parts with resin and, for pipes with a Bell and Spigot joint, inserting the check valve into the Bell. 9. Remove pipe to storage yard, stack in single layer on wood cradle. 10. Final quality control by individual inspection of each pipe. The person responsible for Quality Control will authorize the shipment of the pipe, based on both the internal Inspection Point Program (IPP) and also the external Program (that which is agreed with the client). Photo 6 & 7: Pipes ready for shipment to Calueque 7 P a g e

8 4.4 Factory Tour (manufacturing of special fittings) All the pipe specials, flanged and plain ended, are handmade to design specifications. Smoothing, cutting, drilling of flanges, etc, are all done by hand. Each pipe special has an identification tag (fixed into resin) and is numbered in numerical format for ease of installation. 4.5 Factory Tour (Quality Control and Records) Before the pipe is taken to storage, the final finishes are made. Only after the final Quality Control and inspection will shipment be authorized. The pipe identification tag on each pipe displays the following information: Client s Name and Project Name Article Description and Resin Reference Product Number, Specific Section Number and Date of Manufacture Nominal Diameter (ND) and Nominal Pressure (NP) Nominal Stiffness (SN) and Nominal Length (NL) Bar Code Number Photo 8: Identification tag of a 12m pipe destined for Calueque (Ref T011785/350) 8 P a g e

9 4.6 General Discussion After the factory tour we had short discussion on a number of technical points that was raised during the tour. Items discussed were sourcing of and quality of raw material (type of fiber material and sheets, resin, application method, etc). We also discussed quality control on pipe sections with respect to deflection (vertical and horizontal) and pressure tests of joints. 4.7 Demonstration of Pipe Assembly After lunch a practical demonstration of pipe assembly was attended. A Bell and Spigot joint of 1000mm dia and 12 m pipe sections, was demonstrated. The two O-rings (double seal) were placed in the grooves and lubricant was applied. Nylon slings were fixed some 3m from the ends of the pipes, attached to winches on either side of the pipe. It took two personnel approximately 8 minutes to complete the insertion of the spigot end into the bell end. Then the pressure test of the joint, to confirm the joint is not leaking, was done in a further 7 minutes. (With properly trained workers and proper preparation of the trench bed and alignment of the pipes, jointing and testing should not take longer than say 30 minutes on larger pipes.) Photo 9 & 10: Example of double O-ring seals in Bell and Spigot joint. Also visible is the test valve. 5. Specific Items Discussed re GRP Products 5.1 Design of GRP Pipes Physical Characteristics (Corrosion resistance, conductivity, resistance, expansion, density) Mechanical Characteristics (Pipe stiffness, allowable vertical and horizontal deflection) Hydraulic Characteristics (Water pressure, velocity, negative pressure and water hammer). 9 P a g e

10 5.2 Handling and Installation of GRP Pipes Loading use nylon slings, protect pipe ends Storing to be stored on wood pieces Joints clean bell and spigot, use O-ring with lubricant Laying proper compacted bedding, pipe aligned straight. Backfilling ensure proper compaction in primary fill and next to pipe. Joints into structures ensure solid connection. Joint testing test each joint individually. Pressure testing first test to be a shorter section. Training trained pipe layers are essential. Maintenance and repairs - very little failures, on-site repair with chemicals. 6. Specific Discussion on GRP Pipes for Calueque Project 6.1. Drawings During the detailed discussion of the design of GRP pipes for Project Barragem de Calueque, it was noted that PROTESA was not in possession of the latest/ approved project drawings of the two pipelines. The drawings at PROTESA did not show any special fittings (valves, etc) nor did it show any chambers on the pipelines. There were also no detail of GRP pipe connections to steel, no detail of special fittings at the beginning and at the end of the pipeline, no detail of special fittings (Tpieces for scour and air valves), and no indication of special pipe pieces (bends, etc) for change in alignment. There also was no detail on connecting GRP pipe section into concrete structures, eg at chambers. PROTESA was advised to obtain the approved design drawings for both pipelines. 6.2 Method Statement for Pressure Testing of Pipeline Control testing of the pipe installation was thoroughly discussed. Each bell and spigot joint should be individually tested before commencing with the joining of the next pipe section. With regards to pressure testing of the pipeline, no specific methodology was tabled. It is essential that the Method Statement for Pressure Testing of Pipeline be compiled (stating lengths to be tested, type of temporary pipe end closure and thrust support) and submitted as soon as possible, in order to manufacture any special GRP fittings for the DN 1600mm and DN 1800mm pipes which may be required for the testing operation. 10 P a g e

11 6.3 Records of manufacturing, control and shipment of GRP Pipes According to PROTESA, a total number of 362 pipe sections (12m in length each) of DN 1800mm have already been manufactured to date. See Final Product Report (sheet) below. Photo 11: Final Product Report example sheet 11 P a g e

12 The first shipment of pipe sections has been already shipped to Angola. This shipment should arrive in the Port of Namib shortly, from where the pipe sections will be transported by road to the construction site at Calueque. The next shipment is scheduled to leave Spain within a month. 6.4 Training of Pipe Layers As mentioned earlier, training of pipe layers is very important. It is essential that a Method Statement for Training of Pipe Layers be submitted and that the Training Schedule is planned in advance, not to delay project implementation. Training should be comprehensive and should include all aspects such as handling, storing, transporting, laying, testing, backfilling, etc. No pipe installation should commence unless the pipe layers have received proper training by PROTESA. Bad experiences with GRP pipe failures in South Africa were due to sub-optimal workmanship and not adhering to specifications and procedures. 7. Field Visit of GRP Pipe Installation (Zaragoza and Surrounding Water Supply and Management) 7.1 Introduction There are 800,000 inhabitants in Zaragoza water supply district and along the banks of the rivers Ebro, Jalon, Huerva, and Gallego. These areas are supplied with good quality water directly from the Pyrenees Mountains. Water is conveyed through a canal system (for irrigation) and a pipe system over a distance of more than 76 km to Zaragoza. In 2006 the previous water supply system was reinforced by the installation of GRP pipes over a distance of 13,2 km to provide a dual supply system between Sora and La Loteta Dam. These pipes were DN 2000mm and PN 6 and PN 10 bar. Couplings were of bell and spigot type, but flanges and laminated joints for special fittings at scour points (spillway) and at air valves were also used. 7.2 Remote Management of Zaragoza Water Supply. The whole of the Zaragoza and surrounding water supply is operated and managed via a very impressive scada and monitor display system at one central office. This central station is manned 24 hours a day and all activities and fault signals are logged here. It is recommended that the Calueque Dam and pumping scheme also be managed and operated in a similar way (opening and closing of sluice gates, valves, etc) 12 P a g e

13 Photo 12: Central Management of Zaragoza Water Supply Photo 13: Central Management of Zaragoza Water Supply 7.3 GRP Pipe Performance in the System. The GRP pipes in the water supply system (13,2 km in total, DN 2000mm) were installed in In the past 8 years there were only 2 incidents of malfunction (leakages) on the total GRP section of the pipeline. 13 P a g e

14 The pump station at the La Loteta Dam has 4 vertical pumps, each with capacity 1,5 m3/s. The pumping line is approximately 4000 m and connected to two balancing dams, from where the water gravitates further down the pipeline. These balancing dams are lined earth reservoirs with concrete inlet / outlet and overflow structures.. This setup is very similar to the Calueque north pump station and north bank reservoirs. Photo 14: Pump station Photo 15 & 16: Lined reservoir Photo 17: Overflow and outlet structure 14 P a g e

15 8. Documentation (Quality Dossier and Mechanical Calculation) The Quality Dossier (hard copy file and e-format) received from PROTESA consists of the following documents: Dossier Revision Report. Inspection Points Programme Raw Materials Control Product Specifications Raw Materials Control Certificates of Conformity End Product Standard Control Tests Calibration Certificates. These documents are also in e-format, a total of 43,5 Mb in 172 pdf pages. Attached as Annexure A are the first 12 pages of this file. The document referred to as Mechanical Calculation of Underground Piping with all design data and calculations have also been received. These two documents will be filed on the Aurecon.Calueque disc drive as soon as I am back in Calueque. 9. Summary of Project Team The Contractors for the pipe laying operation will be LYON, (for the alignment, embedment, assembly, jointing, testing and quality control of the pipe sections) and MOTA-ENGIL will execute the trench excavation and provide bedding material. They will also do the trench backfilling and primary and secondary compaction. The Pipe Manufacture and Pipe Supplier is PROTESA of Spain, a member of Future Pipe Industries. The factory is in Zaragoza, Spain. The pipes will be shipped to the site of the works by sea and road transport via Port of Namib in Angola. Supervision of construction of the GRP pipeline at Calueque will be done by AURECON, represented by Eng James van der Linde and the Resident Engineer s supervising team. 15 P a g e

16 10. Conclusion. It is my view that PROTESA is a highly effective/ efficient company who strive for 100% customer satisfaction, and value proper training and knowledge of the product of utmost importance for a successful implementation. Properly trained pipe layers and knowledge sharing with and capacity building of Contractor s personnel and Client s representatives are essential. In summary, the following points should be noted: a) The pipeline installer/ pipe layer/ contractor should be properly trained by PROTESA, and should have PROTESA's technical support whenever required. b) The procedures and approved methodology of the pipe manufacturer should be followed at all times. No alternatives or non-approved materials or methods should be allowed. c) Only approved drawings should be used for ordering of materials. d) A Method Statement for Pressure Testing of Pipeline is required. e) A Method Statement for Training of Pipe Layers is required. f) The first shipment of pipes will arrive at the Port of Namib shortly. Loading and transportation should be done with care. g) A remote computerised management system will eventually be required for efficient operation of the Calueque scheme. James van der Linde (Pr Eng, M Eng Water Services) Chief Engineer: Construction Management and Supervision AECOM AFRICA (Calueque, Angola) BKS Part of the AECOM Group 16 P a g e