TECHNIQUES, MATERIALS AND DESIGN CONSIDERATIONS: REHABILITATION & STRENGTHENING OF WATER AND WASTEWATER PIPELINES. Solutions & Case Studies
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1 TECHNIQUES, MATERIALS AND DESIGN CONSIDERATIONS: REHABILITATION & STRENGTHENING OF WATER AND WASTEWATER PIPELINES Solutions & Case Studies Mike Larsen Senior Manager Pipeline Solutions
2 Specialty contracting State of the art construction products Engineering support services Turnkey Solutions that integrate products, engineering, and construction
3 Specialty Contracting Repair Services Concrete Repair Strengthening PT Repairs Force Protection Moisture Control & Waterproofing Building Envelope Historic Restoration Pipe Rehabilitation Corrosion & Cathodic Protection Industrial & Power Generation Delayed coking units Sulfur recovery units Fluid catalytic cracking units Vacuum structures Cooling towers Water intake structures Secondary containment Equipment foundations Chimneys and stacks Tanks Silos Flue gas path structures Intake structures Boilers Pipe supports Circulating water systems Hyperbolic cooling towers Mechanical draft cooling towers Industry Leading Specialty Contracting Services
4 Comprehensive Repair and Strengthening Solutions Products & Technologies V-Wrap FRP Composite Systems VSL Post-Tensioning Systems Tstrata Enlargement Systems DUCON Micro-Reinforced Concrete used in blast hardening of structures
5 Repair and Strengthening Solutions Structural Upgrade with V-Wrap TM FRP Systems Light-weight, thin materials with high strength-to-weight ratio Rapid installation process Code approval - ICC Report (ESR-3261) Comprehensive design support Fully trained installation crews with extensive experience since 1994
6 Repair and Strengthening Solutions V-Wrap TM FRP surface preparation Primer 2.Dustless grinding & vacuum Open pores for mechanical bond 1.Abrasive blast 3.Water blast & dry
7 Material Selection Epoxy highlights o Two-part o Ambient cure thermoset o 100% solids o VOC compliant
8 Repair and Strengthening Solutions V-Wrap TM FRP saturation process FRP Sheet Installation
9 Repair and Strengthening Solutions V-Wrap TM FRP QA/QC ASTM D4541 ASTM D3039
10 Pipe, Culvert & Tunnel Rehabilitation Products XPT TM Post-Tensioning System V-Wrap TM Carbon Fiber System StrongPIPE TM Hybrid FRP XPT PT System V-Wrap Carbon Fiber System StrongPIPE FRP Hybrid System
11 CFRP Repair of Pipe + Widely preferred method + No excavation + Standalone + Fast + Targeted or continuous repairs + Emergency repairs - Specialty repair in confined space - Environmental controls - Cost
12 CFRP Liner Installation Environmental Controls Laydown Area Typical Mix-Tent
13 CFRP Liner Installation
14 CFRP Liner Installation Termination Detail
15 CFRP Liner Installation Termination Detail
16 CFRP Liner Installation
17 Project Overview: 102-inch PCCP NRG Limestone Station Unit 1 Jewett, TX o Coal Fired Power Station o 1706 MW o 102-inch PCCP CWS o 35 PSI operating pressure. o No condition assessment performed on CWS. o 2010 added Surge Tower to alleviate transient pressures.
18 Project Overview: 102-inch PCCP NRG Limestone Station Unit 1 Jewett, TX o Dec. 2014: Unplanned Outage Due to Pipe Failure on CWS. o Emergency pipe inspection performed. o Phase 1: Dec 18- Dec 24, 2014 V-Wrap Carbon Fiber utilized for Emergency Repairs on initial 2 segments, grew to 7 segments of 102-inch PCCP.
19 Project Overview: 102-inch PCCP & 72-inch Steel NRG Limestone Station Unit 1 Jewett, TX Phase 2: Spring 2015 Internal CFRP repairs of 7 sections of 102 PCCP & one section of 72 carbon steel pipe. Inspection of pump pit wall leaks and development of repair options for remediating leakage. Chemical grouting and concrete repair at the pump pit walls. 18 days Total Project Cost: $1.56M
20 Project Overview: 24-inch Carbon Steel Exelon Generation Muddy Run Internal Pipe Repair: Carbon Steel Penstock Drain Line
21 Project Overview: 24-inch Carbon Steel Exelon Generation Muddy Run Internal Pipe Repair: Carbon Steel Penstock Drain Line
22 Project Overview: 18-inch RCP to Steel NRG Etiwanda Station External Pipe Repair: Reinforced Concrete to Steel Pipe Connection
23 Project Overview: 18-inch RCP to Steel NRG Etiwanda Station
24 Project Overview: 18-inch RCP to Steel NRG Etiwanda Station
25 Rehab Options: StrongPIPE Hybrid FRP System o StrongPIPE is used when pipe cannot be excavated and is ideally suited for extended runs requiring fully structural repair.
26 StrongPipe Cross Sectional View StrongPIPE system utilizes a continuously wound high strength deformed steel wire embedded in a epoxy matrix, placed inside the existing pipe. StrongPIPE System Legend 1. 1 st Glass FRP Layer (longitudinal) 2. High Str. Steel Wire 3. Polymer Matrix Existing Pipe nd Glass FRP Layer (longitudinal) 1 5. Flexible Topcoat
27 StrongPIPE Hybrid FRP System Installation Installation Overview Reinforcing Steel
28 Project Overview: 78-inch PCCP Mill Creek Generating Station: Jefferson County, KY o o o During their spring outage the client inspected their 78 pipeline and noticed a large crack with water spraying into the pipeline and another large bulge in the line about 60 away The crack and bulge were caused by piles being driven into the ground Client decided to go with the full 60 repair (3 x 20 long pipe sections)
29 Project Overview: 78-inch PCCP Mill Creek Generating Station: Jefferson County, KY o We stopped the water by chemical injection and then client personnel welded a plate over the crack.
30 Project Overview: 78-inch PCCP Mill Creek Generating Station: Jefferson County, KY o o We installed StrongPIPE wire system which took 2 days. Full project duration was under 2 weeks long.
31 Carbon Fiber Technical Overview Design Considerations Overview o Internal working pressure o Internal working-plus-transient pressure o Weight of pipe and fluid o Earth load above the pipe o Live loads at the ground surface o External pressure due to groundwater above the pipe o Negative pressure inside the pipe Full-scale testing o Thrust o Combined loading effect o Thermal effect o Joint details o Differential stiffness near wire break zone (PCCP) o Other Considerations o Water-tightness What is the desired service life?
32 Resources Specialty Products Design Support Construction Budgets Forensic Support Specifications and Material Selection Contracting Services Concrete Repair & Strengthening Post Tensioning Systems Corrosion Prevention Systems Moisture Control Systems Building Envelope Repairs
33 Questions? Current Projects? Thank You!
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