Pipe Bursting. Size for Size and Upsizing Mains Replacement with PE pipes. Matthew Izzard (Business Development Director Tracto Technik UK)

Transcription

1 Pipe Bursting Size for Size and Upsizing Mains Replacement with PE pipes Matthew Izzard (Business Development Director Tracto Technik UK)

2 Pipe Replacement Techniques: Static Pipebursting Dynamic Pipe Bursting Pipe Extraction / Pulling Insertion

3 A Brief History of Pipe Bursting: Developed in late 1970s by D J Ryan & British Gas Patents granted worldwide for both method & equipment between 1980 & 1985 Originally used for gas main replacement Since adopted for water & sewer replacement Courtesy Norman Howell Associates

4 Pipe Bursting Method: New Pipe Expander with blade ledges Old Pipe Rods Typical sizes 90mm (3 ) -180mm (8 ), larger systems up to 600mm (24 ) Word Record c. 1,200mm (48 ) Typical distances from 10m (30ft) - 100m (300 ft), larger systems up to 400m (1,200 ft). World Record c. 1,000m (3,000ft)

5 Applications: Gas Pipe Bursting Technique & Applications: Clean Water *Dynamic pipe bursting exhaust Sewer, including gravity Drainage Insertion (Tight Fit) Re-rounding Cleaning Only trenchless process where it is possible to replace size for size or upsize an existing pipe. Both static & dynamic bursting can be stop start process (pipe welding). Pipe material old pipe or new pipe generally irrelevant in terms of process. Ground has to be physically displaceable.

6 Geotechnical Displacement: Expander Ø New Pipe Ø Old Pipe Ø 10 x Displacement Factor Old Pipe Blade & Expander New Pipe Displacement factor Existing annulus from old pipe

7 Pipe Bursting Design & Risk Mitigation: Pipe Wall Damage & Drag: Expander selection guideline 20% - 40% larger than final pipe, bentonite fluid option to reduce friction & stablise fragments. Ground Heave: Displacement factor critical when expanding Effects around 10 x diameter of upsize in surrounding ground.

8 Pipe Bursting Design & Risk Mitigation: EXISTING PIPE SIZE NEW PIPE (OD) IN MM (INS) (MM) u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u

9 Geotechnical Requirements: Cohesive Soils: Firm to soft clays: Ideal Hard clays: Greater displacement power is needed to achieve required soil compaction Non-Cohesive Soils: Dry sand: Most difficult conditions Wet sand: Provides problems for hydraulically powered machines Rock: Limits upsizing capabilities Ground water: High water tables can cause problems for both pneumatically & hydraulically powered machines

10 Pipe Bursting Design & Risk Mitigation: Site Access & Layout: - Static Equipment: Rig, Rod Packs, Power Pack, Hoses, Tooling - Dynamic Equipment: Hammer, Winch, Compressor, Hoses, Tooling Pipe entry point & method Coil, sticks or sections Overall replacement distance can be broken down into less disruptive distances - 100m lengths typical on smaller diameters generally based on pe coils. Fast replacement speed better for consumers as shorter streetworks and disruption but longer disconnection time. Static bursting quiet night time work, dynamic pipe bursting has noise factor - Both processes can be start/stopped but static better for this. Use of bentonite or grout can be considered for pipe fragment stabilisation

11 Pipe Bursting Design & Risk Mitigation: Considerations that may prevent successful application: Proximity for other utility services Repair fittings & clamps Reinforced concrete pipes Concrete beds Concrete surrounds Substantial quantities of concrete adjacent to the pipeline at connections & chambers

12 Static Pipe Bursting Overview:

13 Static Pipe Bursting Stitching :

14 Pipe Bursting Rig Selection: Nominal Diameter Old Pipe Minimum Static Pipe Bursting Rig ND 250mm (10 ) > ND 250mm (10 ) - ND 400mm (16 ) > ND 400mm (16 ) - ND 600mm (24 ) > ND 400mm (16 ) - ND 800mm (32 ) > ND 600mm (24 ) - ND 1000mm (39 ) 40 Tonne (44 Ton) kn (62-90 kip) 80 Tonne (88 Ton) kn (58-173kip) 125 Tonne (138 Ton) kn ( kip) 200 Tonne (220 Ton) kn ( kip) 250 Tonne (275 Ton) kn ( kip)

15 Static Pipe Bursting - Rods: Cable: Screw Rods: QuickLock Rods:

16 Static Pipe Bursting - Blades: Roller Blade - Ductile Cutter - PE Delta Blade - Brittle Bursting Head / Expander - Brittle

17 Blades for Old Pipe Material: Old Pipe Static Pipe Bursting Rollerblade Hook knife Bursting head Grey cast iron pipes X X Ductile cast iron pipes Steel pipes X X PE / PP pipes X PVC pipes Asbestos / fibre cement pipes Vitrified clay pipes Concrete / reinforced concrete pipes GFRP pipes Brickwork X X X X X X X Inliners X X

18 Pipe strings Polyethylene pipes Steel Short Length pipes Polyethylene Polypropylene UPVC Clayware pipes Replacement Pipe Options:

19 Data Logging & Load Sensing: Data Logger

20 Data Logging & Load Sensing:

21 Case Study 1: Grundoburst 400G Salisbury, England Client: Wessex Water Contractors: Huxter Plant Date: 9 th January 2018 Length: 3.1 miles (5 kilometres) in 100m (328ft) shots. Existing pipe: 4 (125mm) Ø Cast Iron. Access: Two lane road, open access. Pipe Condition: Leaking and partially corroded pipe. Replace with: 125mm (5 ) SDR17.6 polyethylene 100m (328 ft) coil.

22 Case Study 1: Reception Pit: Continuous coil 125mm (5 ) Ø MDPE 100m (300ft) Launch Pit: Bursting Rig launch pit

23 Case Study 1: The bursting rig being lowered into position in line with the old main.

24 Case Study 1: The rods are then pushed up the main and a standard delta blade for cast iron fitted for the pull back.

25 Case Study 1: The continuous coil pe pipe is then pulled into the hole from a pipe coil trailer.

26 Case Study 1: Quicklock rods are then pulled back with the blade and expander breaking out the old pipe.

27 Case Study 1: The pre-chlorinated pipe is then pulled into the docking port and the new main commissioned.

28 Case Study 2: Grundoburst 2500G Glogow, Poland Client: PWIK w Glogowie Contractors: ZISBD Date: 23 rd April 2017 Length: 170m (558 ft) Existing pipe: 500mm (19 ) Ø Ductile iron with cement coating Replace with: 500mm (19 ) Ø Polyethylene with polypropylene coating. Speciality: Usage of GrundoLog 1250kN to measure the tensile forces on the new installed pipe.

29 Case Study 2:. Poland

30 Case Study 2: GrundoBurst 250 rig with reception frame and power pack.

31 Case Study 2: Rollerblade for ductile iron and coated pipe, expander and pipe being installed.

32 Case Study 2: The pipe is then installed using a load sensing data logger to record pulling forces.

33 Case Study 2: Load sensing data was then supplied to the client proving the stress factors on the installed pipe were below the manufacturers tolerances.

34 Manhole Operation Sewer Rehab:

35 Case Study 3: Grundoburst 400S Cardiff, Wales Client: Welsh Water Contractors: Lakewell Utilities Date: 3 rd May 2017 Length: 23m (75 ft) Existing pipe: 6 (150mm) Clayware Access: Both chambers 1200mm (4 ft) wide. Upstream 5m (16 ft) deep, downstream 3.5m (12 ft) deep. Pipe Condition: Partially collapsed / blocked, causing occasional upstream overflow / flooding. Replace with: 160mm (8 ) Ø, 750mm (29.5 ) long Demco screw together short section pipe.

36 Case Study 3: Upstream Chamber: Demco pipe drawn in from this Chamber with Spanfix Downstream Chamber: Grundoburst launch pit

37 Case Study 3: Upstream Chamber Downstream Chamber (Launch Chamber)

38 Case Study 3: Equipment set up and Quicklock Rods pushed into receiving Chamber in 1 ½ hours

39 Case Study 3: Equipment all on one trailer & vehicle

40 Case Study 3: Short section pipes, clamped together with Spanfix tensioning system

41 Case Study 3: Bursting Head arrives in the Chamber pulling the new 160mm (9 ) Ø pipe

42 Case Study 3: Bursting Head and tooling dismantled leaving the new sewer pipe

43 Dynamic Pipe Bursting:

44 Dynamic Pipe Bursting: Old Pipe GRUNDOCRACK New PE-HD Brittle pipes only! *reinforced concrete Winch rope Front Expander Broken Shards Of Old Pipe

45 Dynamic Pipe Bursting:

46 Old Pipe Materials: Old Pipe Stoneware (Stz) Concrete (B) Cast Iron (GG) Polyvinylchlorid (PVC) Fibre Cement (FZ) Asbestos-Cement (AZ) Masonry Channels Stahl (St) Polyethylene (PE), Polypropylene (PP) Fibre Glass Reinforced Plastic(GRP) Dynamic Bursting Process X X X X X X X X (conditioned) X (conditioned) Ductile Cast Iron (GGG) - Already Rehabilitated Pipelines(Liner) - -

47 Case Study 4: Client: City of Riyadh Water and Sewerage Dept, KSA Main Contractors: Bin Jarallah Existing Pipe Material: 10 (250mm) AC Sewer Pipe Depth of existing pipe: 3m (10 ft) Ground conditions: Dry, loose sand with small stone

48 Case Study 4:

49 Case Study 4:

50 Case Study 4:

51 Dynamic Pipe Bursting - Manhole:

52 Case Study 5: New sewer pipe Expander Hammer (inside pipe) Winch cable

53 Case Study 5:

54 Case Study 5:

55 HDD Pipe Bursting Case Study: Existing Pipe: Combined sewer 8 (200mm) VCP Collapse caused 2m (6 ft) diameter void Pipe 7.5m (25 ft) below pavement Groundwater Table: -West End: 3m (10 ft) above existing 8 (200mm) VCP -East End:.75m (2 ft) below 40m (130 ft) Distance

56 HDD Pipe Bursting Case Study: Seattle, WA, United States of America 2.5m (8 ft) Collapse Site Location Courtesy Staheli Trenchless Consultants

57 HDD Pipe Bursting Case Study: HDD Rig set back : 12m (40ft) Courtesy Staheli Trenchless Consultants

58 HDD Pipe Bursting Case Study: Courtesy Staheli Trenchless Consultants

59 Today & Tomorrow No joints: Provides long term leakage benefits. Standard pipe materials are used which allows new Connections to be fitted easily. No pre-cleansing required. Minimal disruption to customers during installation works. Can be operated from within existing manholes. Can be used to replace pumping mains. Substantial time saving possible on projects.

60 Today & Tomorrow Pipe capacity can be maintained or increased. A new pipe is provided with at least a 50 year asset life. Improved safety for operatives and the public due to reduced open excavation. Direct cost savings due to reduced excavation, backfill and reinstatement. Indirect cost savings as social & traffic disruption are minimized. Reduced risk of damage to other utility plant.

61 Today & Tomorrow Natural resources are conserved & the impact on the environment is less due reduced need for quarried materials. Wessex Water: 2017 saved more than 47,000 tonnes the same weight as USS Roosevelt!

62 Thank you for your time Matthew Izzard T: M: E: Handbook of Pipe Bursting Practice Pipe bursting terms and application range Host pipe and new pipe materials Planning and design guidelines Pipe Bursting equipment and accessories Jobsite reports