Design Considerations for Selection of Pipe Material for Large Diameter CSO Force Main
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1 Design Considerations for Selection of Pipe Material for Large Diameter CSO Force Main Pacific Northwest Clean Water Association 2010 Conference Presented By M. Patty Nelson, City of Portland Phil Roppo,, Brown and Caldwell Mark Havekost,, Jacobs Associates
2 Presentation Overview Project Overview Design Requirements Pipe Materials Considered Pipe Material Evaluation Selection Project Update Questions
3 PROJECT OVERVIEW
4 Willamette River Combined Sewer Overflow (CSO) Program
5 Portsmouth Force Main Deliver 120 mgd From Swan Island CSO Pump Station to Existing Portsmouth Tunnel Meet ASFO Deadline of December 2011
6 Segment 1 Swan Island Alignment Single 66 Inch Force Main 3,000 linear feet 84-inch Microtunnel 4 Microtunnel Shafts 6,800 linear feet Open Cut Steel Pipe with Polyurethane Liner
7 Segment 2 Bluff Alignment Single 66 Inch Force Main inside a 10 Foot Tunnel 200 linear feet - Open Cut 6,000 linear feet - Deep Tunnel 2 Tunnel Shafts Fiberglass Reinforced Pipe
8 Profile Considerations Force Main: Sloped to Drain Segment 1: Conflicting Utilities Segment 2: Deep Connection
9 Design Requirements 120 mgd,, peak 140 mgd Single 66-Inch Diameter Corrosion Resistant Handle Hydraulic Transient Conditions
10 Pipe Materials Considered Welded Steel Pipe (WSP) with polyurethane lining Fiber-Reinforced Polymer Pipe (FRPP) Ductile Iron (DIP) with PROTECTO 401 (ceramic epoxy lining) Reinforced Concrete Cylinder Pipe (RCCP)
11 Pipe Material Eliminated Ductile Iron (DIP) Insufficient Size Reinforced Concrete Cylinder Pipe (RCCP) Corrosion concerns with concrete lining
12 Pipe Materials Evaluated Fiber-Reinforced Polymer Pipe (FRPP) ASTM D foot length Push on joints 225 to 300 lbs per linear foot
13 Pipe Materials Evaluated Welded Steel Pipe (WSP) AWWA C200 Polyurethane lining 40 foot length Double-welded lap joints 600 lb per linear foot
14 Evaluation Criteria Cost Maintenance Constructability Installation Risk Structural Design Sewer Operation Durability
15 Cost Considerations Direct Costs Production Rates Restraint Requirements Number Welds/Joints Weight/Handling Corrosion Resistant Coating Maintenance Access for Lined Pipe
16 Cost Comparison Segment 1 Segment 2 WSP million million FRP million million Thrust Restraint Required Poor soils Maintenance Access Intermediate Shaft
17 Constructability Considerations Space requirement - Shoring Ease of Installation - Handling Length Pipe - # Joints Restraint Requirement Weight of Pipe Backfill Requirements
18 Constructability Comparison Segment 1 Segment 2 WSP FRP Double Welded Lap Joints Prep/Patch Lining at Joints Shoring system for external joint welds Push-on Joints Careful attention required for backfill Single welded lap joint Careful fit for welding Prep/Patch Lining at Joints Push-on Joints Specialized bracing for backfilling in tunnel External thrust restraint system
19 Structural Design Considerations Loading Internal Pressures External Pressures Ability to handle ground movement
20 Structural Design Comparison Both WSP and FRP were designed to handle: Internal Pressure 45 psi operating, 63 psi peak Full Vacuum Installation Loads Backfill Loads
21 Durability Considerations Internal Corrosion Resistance External Corrosion Resistance Abrasion Resistance Fatigue
22 Durability Comparison Segment 1 & 2 WSP Internal Corrosion: Lining External Corrosion: Tape Wrap Abrasion: Polyurethane Highest Fatigue: Resistant FRP Pipe material Corrosion Resistant Abrasion: High Resistance Fatigue: Designed using higher pressure class to extend pipe life
23 Maintenance Considerations Access for Repairs & Cleaning Method of Repairs Historical Maintenance Issues
24 Maintenance Comparison Segment 1 Segment 2 WSP FRP Shallow force main Air/Vac Access Vaults Lining repairs anticipated Repairs sensitive to workmanship & environment Shallow force main Air/Vac Access Vaults Repairs using fiberglass and resin laminations controlled environment Deep force main Requires Intermediate Shaft for Access Lining repairs anticipated Repairs sensitive to workmanship & environment Deep force main Repairs using fiberglass and resin laminations controlled environment
25 Installation Risk Considerations Excessive loads due to: Pipe floatation High grouting pressures Poor Joints Damage from Installation
26 Installation Risk Comparison Segment 1 Segment 2 WSP Lining damage during installation Double Joints Protect Lining damage during installation Pipe grouted within tunnel FRP Pipe damage during backfill Joint Leakage Pipe damage during backfill Joint Leakage
27 Summary of Pipe Comparison Segment 1 Segment 2 Pipe Cost WSP FRPP Constructability Neutral FRPP Structural Design Neutral Neutral Durability FRPP FRPP Maintenance Neutral FRPP Installation Risk WSP WSP
28 System Operation Considerations Low Pressure Wet Weather Operation Only Avoid Full Vacuum Air/Vacuum Relief & Access
29 Air/Vacuum Relief Valves Locations needed for Air/Vacuum Relief Must vent to surface Hydraulic Transient Analysis to Determine Location
30 Pipe Material Considerations in Hydraulic Transient Analysis Different Pipe Materials = Different Wave Speeds Wave Speed impacts Transient Analysis FRP = Higher Wave Speed than Steel Reviewed combinations of pipe type Seg 1 & Seg 2 Objective Avoid Full Vacuum Condition
31 Transient Analysis: Steel Vs FRP Pressure (psig) Flow Exiting Pump Station Maximum Pressure All FRP Option 7A: Segment 1: Fiberglass Pipe (wave speed 1,400 ft/s) Segment 2: Fiberglass Pipe (wave speed 1,400 ft/s) Vent-O-Mat Locations: 7 Steady-State Pressure ,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,00 11, Force Main STA (ft) PS Discharge ~ STA Tunnel Section 12,00 0 Minimum Pressure 13, ,00 0 P Steady-State (psig) Pressure Max (psig) Pressure Min (psig) Vent-O-Mat Location 15, % Design Profile 16, , ,00 0 Pressure (psig) Flow Exiting Pump Station Steel + FRP Maximum Pressure Option 6A: Segment 1: Steel Pipe Segment 2: Fiberglass Pipe (wave speed 1,400 ft/s) Vent-O-Mat Locations: 7 Steady-State Pressure ,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,00 11, Force Main STA (ft) PS Discharge ~ STA Tunnel Section 12,00 0 Minimum Pressure 13, ,00 0 P Steady-State (psig) Pressure Max (psig) Pressure Min (psig) Vent-O-Mat Location 15, % Design Profile 16, , ,00 0 Selection: Segment 1 Steel + Segment 2 FRP
32 Fear Factor Poor Experience with Plastic Pipe Major Facility Single Force Main Tunnel Limited Access
33 Case History FRP Pipe Owner Project Application Size (inches) Length (LF) Pipe Installation Method City of Charleston, South Carolina Harbor Tunnel, Ashley River Tunnel (2006) Cooper River Tunnel (2007) Pressurized Sewer Siphon ,000 9,500 18,100 HOBAS Carrier Pipe in Tunnel Jackman Penstock Replacement (1982, 2003, 2007) Jackman Penstock Replacement (1982, 2003, 2007) Hydropower penstock 84 3,900 Flowtite HOBAS Open Cut City and County of Honolulu Hart Street Force Main (2000) Sewer Force Main 51 2,100 HOBAS Pipe Jacking City of Abilene Buck Creek Force Main Sewer Force Main 36 26,000 HOBAS Open Cut Goochland County, Virginia Goochland/Henrico Regional FM Sewer Force Main 48 44,800 Flowtite Open Cut
34 THE DECISION
35 Segment 1 Pipe Material 10,000 LF 66-Inch Steel AWWA C200 Polyurethane Liner Tape Wrap
36 Segment 2 Pipe Material 66 inch FRPP HOBAS ASTM D3754
37 WHERE ARE WE NOW?
38 Segment 1 Update
39 Segment 2 Deep Tunnel
40 QUESTIONS?
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