Bruce Power Pipeline Assessment Workshop. May 31, 2018
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1 Bruce Power Pipeline Assessment Workshop May 31, 2018
2 Pure Technologies Over 30 years of experience in pressure pipe assessment and management Provided inspection, assessment, and management of thousands of miles of pressure pipe Expertise includes non-destructive technologies, hydraulic transient monitoring, forensic evaluations, structural modeling, and life cycle assessment Inspection, assessment, and program management services for many large utilities Over 500 employees in 12 North American offices
3 AIA Portfolio Forensics Capital Planning Wall Thickness Testing Leak Detection Hidden Revenue Detection Water Loss Management Remaining Useful Life Estimates Structural Modelling Pipeline Condition Assessment Transient Monitoring Pipeline Risk Prioritisation Real Time Intelligence
4 Large Main Failure Cost Total Failure Cost = Direct Cost* + Societal Costs** Total Failure Cost = $500,000*** + ($5 x 15,000 pe x 5 days to repair) Total Failure Cost = $875,000 *Repair, engineering, flooding damage, landscaping/restoration, etc. **$5/day triple bottom line inconvenience charge per person for low pressure or no service Failure of a 600-mm feeder main in Calgary A large diameter rupture is a catastrophic event! A good estimate of the total cost of large diameter main breaks based on these data is $500,000. Flooding damage is the largest 30 large diameter (500-mm +) failures analyzed: repair average $1,700,000; mean $500,000. Analysis of Total Cost of Large Diameter Pipe Failures, American Water Works Association Research Foundation,
5 Managing Risk 5
6 1. Find the weak links 2. Repair 3. Manage pipeline
7 Failure Pressure
8 Risk Based Condition Assessment Strategy Priority of Pipeline LOW MEDIUM HIGH Assessment Techniques Hydraulic Study Corrosion Survey Inline Acoustic Survey Inline Pipe Wall Screening High Resolution Inline Scan Medium Resolution Inline Mapping Survey Test Pits Analysis Engineering Evaluation Structural Model Statistical Life Cycle Analysis RESOLUTION RELIABILITY COST
9 Leading Causes of Valve Failures Lack of Access Over Torqueing Lack of Training Lack of Exercise Lack of Lubrication Lack of Maintenance Gears out of Adjustment Wear and Tear on the Seat Gasket Valve Exercisers Out of Calibration Under-Designed: Light Duty Actuator
10 External Stops & Seats on Disc Seat Gasket on Disc
11 Seat Gasket & Disc Out of Adjustment Left Side of 72-inch BFV Disc Right Side 72-inch BFV Disc
12 12
13 Prestressed Concrete Cylinder Pipe 13
14 PCCP Construction Concrete core Steel Cylinder rubber gasket bell and spigot rings High strength wire Wrapped under tension Mortar coating Protect the prestressing wires
15 PCCP Design AWWA C301 Lined Cylinder PCCP (SP-5) Prestressing wires wrapped directly over steel cylinder 16-inch to 60-inch* AWWA C301 Embedded Cylinder PCCP (SP-12) Prestressing wires wrapped over concrete core 24-inch* to 244-inch
16 PCCP History Early concrete pressure pipe added a steel cylinder for water retention. (1929) First installation L-301 pipe 1942 First AWWA standard 1949 (C301) First installation E-301 pipe 1953 Used in 90 of the 100 largest municipalities >20,000 miles in N. America Long service life
17 PCCP History
18 Primary Failure Mechanisms Corrosion Loss in cross-sectional area of wire Wire breaks Tension released Causes Cracking and/or carbonation of the mortar coating Infiltration of corrosion products
19 Primary Failure Mechanisms Dynamic Strain Aging/Hydrogen Embrittlement Good Quality Wire
20 Primary Failure Mechanisms Dynamic Strain Aging/Hydrogen Embrittlement Poor Quality Wire
21 PCCP Management Inspection Leak Detection Visual and Sounding Electromagnetic Assessment Hydraulic Analysis Structural Evaluation Risk Analysis
22 Visual & Sounding Identifies pipes in a state of incipient failure Actual distances and features used to compile actual laying schedule
23 Design Manufacturin g and/or Materials Capacity Leak & Gas Pocket Detection
24 Acoustic Leak & Gas Pocket Detection Leaks are often precursors to failures Transmission main leaks major source of water loss Gas pockets may promote internal corrosion (force mains), compound the effects of hydraulic transients, and reduce capacity
25 Inline Acoustic Leak & Gas Pocket Detection Technologies SmartBall Sahara Free swimming All pipe materials 150mm diameter and greater +/- 1.5 m location accuracy 100mm insertion Inspection length up to 20 km Pipeline mapping available Tethered All pipe materials 300mm diameter and greater +/- 0.5 m location accuracy 50mm insertion Inspection length up to 1.5 km Pipeline mapping not available
26 SmartBall Leak and Gas Pocket Detection Technology
27 Leaks Per 150 km Inspected by Type DI 68 Steel 53 BWP 21 PVC 58 AC 81 PCCP 34 CI 211 Source: Free Swimming database
28 Types of Leaks Found by Pipe Type Barrel 1% Unknown 25% Joint 15% Unknown 22% PCCP Ductile Iron Feature 59% Unknown 36% Barrel 1% Barrel 22% Joint 12% Unknown 8% Steel Cast Iron Feature 51% Feature 31% Barrel 7% Joint 11% Feature 60% Joint 39% Source: Free Swimming database
29 SmartBall Case Study North Cowichan Insertion Setup (Hydrant)
30 SmartBall Case Study North Cowichan Extraction Setup (Hydrant) Tool Extraction (video)
31 SmartBall Case Study North Cowichan Overview Map with Leak Locations
32 SmartBall Case Study North Cowichan 150mm lateral or inline valve Leak #1 location: ~20m downstream of the 150mm lateral or inline valve Joints Magnetometer data Flow
33 Pipe Material Change and Un-documented Feature SmartBall data is used to locate possible pipe material changes and undocumented features by carefully looking for changes in the: Pipes natural magnetic field SmartBall rolling motion Background acoustic signature Asbestos Cement Poly Vinyl Chloride Poly Vinyl Chloride Ductile Iron Note: Not all pipe material changes or features will provide a noticeable signal change Adapter 33
34 Confirmation of Pipe Alignment SmartBall data is analyzed to identify and locate bends for the purpose of confirming pipeline alignment. Measured heading changes are correlated to elbows seen in drawings and or GIS Areas with discrepancies will be identified in a table and visual format Alignment discrepancies SmartBall Line GIS Utility Line
35 City of Ottawa Richmond Forcemain
36 Sahara Leak and Gas Pocket Detection Technology
37 Kingston Woodbine Road Watermain 300mm Ductile Iron Installed in 1990 Approximated 1km Average operating pressure of 90psi Only pipeline to subdivision which includes a school 37
38 CCTV 38
39 39
40 Condition Assessment Platforms for Wall Assessment PipeWalker PipeDiver PureRobotics PureMFL PCCP, BWP, Steel, DIP PCCP, BWP, Steel, DIP PCCP, BWP, Steel, DIP Steel, DIP Dewatered In-service Depressurized Dewatered
41 Large-Diameter Watermain Condition Assessment Electromagnetic - Free-Swimming 41
42 Large-Diameter Watermain Condition Assessment Electromagnetic - Free-Swimming 42
43 43
44 Electromagnetic Inspection AMPLITUDE PHASE
45 Electromagnetic Inspection Distress Man Hole
46 Pressure (psi) Structural Analysis inch ECP Water Main Mark 164 under 9 feet of cover Microcracking Visible Cracking Yield Strength Operational Pressure Operational+Surge Pressure Steel Cylinder Yield Strength Steel Cylinder Ultimate Strength Number of Wire Breaks
47 Transient Pressure Monitoring THE PURE PRECISION PLAYBOOK 47
48 Palo Verde Arizona Public Service owns a major stake (29.1%) in the Palo Verde Nuclear Generation Station and operates the facility. Construction began in There are three units, the last of which was completed in About 4 million people in California, Arizona, New Mexico and Texas receive power generated by the Palo Verde plant.
49 Palo Verde
50 Palo Verde Details Unit 1 Capacity Net MW(e) Generation in 2003 Megawatthours Capacity Factor in 2003 Type On-line Date License Expiration Date 1,243 10,587,107 97% PWR June 1, 1985 Dec. 31, 2024 Unit 2 Capacity Net MW(e) Generation in 2003 Megawatthours Capacity Factor in 2003 Type On-line Date License Expiration Date 1,243 8,439, % PWR April 24, 1986 Dec. 9, 2025 Unit 3 Capacity Net MW(e) Generation in 2003 Megawatthours Capacity Factor in 2003 Type On-line Date License Expiration Date 1,247 9,554, % PWR Nov. 25, 1987 March 25, 2027
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52
53 Circulating Water PCCP Ruptures on this piping are unacceptable Extended repair outages would also compromise the ability of the power plant to supply clients with electricity Proactive action assess the condition of this water piping detailed look at the design of the pipeline and the surrounding soil conditions
54 Water Reclamation line and Unit cooling and return lines inspected at least 4 times Distressed pipes identified Risk assessment taking place
55
56 Prestressed Concrete Cylinder Pipe EM provides a picture of the current state of prestressing wires AFO provides the rate wires break 56
57 Cable Installation Unanchored installation Fully anchored installation Splice Points
58 Data Acquisition Continuous monitoring Single DAQ up to 12.5 miles Dual DAQ up to 25 miles Requires 2 dedicated circuts Standard includes power backup (45mins)
59 Monitoring Process Acoustic Data Location Data Fiber Optic Cable Analysis DAQ
60 AFO Monitoring Fiber Optic Cable Data Acquisition System Data Analysis Notification
61 AFO Monitoring
62 AFO Monitoring
63 Metallic Pipelines 63
64 Electromagnetics (Metallic)
65 Project Overview PipeDiver inspection in April mm (32-in) steel water main 2.8 km (1.7 mi) 3 runs, 1 Butterfly valve Click here to watch video made by Evides
66 Inspection Results 4 pipes identified with wall loss 30% to 60% wall loss FOOT GOES HERE 66
67 Validations 3 pipes excavated for validation 2 areas of wall loss confirmed Unknown welded patch identified Location Expected Loss Actual Loss 1 60% Not Excavated 2 40% Welded Patch 3 30% 25% 4 30% 35% FOOT GOES HERE 67
68 Inspection Overview of Water Main Sahara Leak detection PureEM PipeDiver Condition Assessment Transient Pressure Monitoring Structural Engineering FEA
69 PureEM Results For internal use only
70 Sahara Video Validation Sahara Video Pipe 127 chosen for validation Large EM anomaly Visual indications in video PipeDiver EM Signal Contour Plot PipeDiver Video
71 Validation of Pipe 127 EM Anomaly
72 How did we do? Circumferential location Longitudinal location Estimate of size: Analysts: 2.83-inch 3 Actual: ~2.5-inch3 % % - %
73 How much deterioration before pipe fails? 2017 Pure Technologies 73
74 Pressure (psi) Pipe Performance Curves psi allowable for pipe with 20% wall loss 20% wall loss at current Operating Pressure 40 psi Yield Limit 40% allowable wall loss at 40 psi Strength Limit (Pipe Failure) Percent Wall Loss 2017 Pure Technologies 74
75 Mike Garaci Pure Technologies
Acoustic Fiber Optic Monitoring of PCCP and Pipelines of Other Materials. Stewart Day, Pure Technologies
Acoustic Fiber Optic Monitoring of PCCP and Pipelines of Other Materials Stewart Day, Pure Technologies 1 Presentation Outline PCCP Common failure modes Metallic pipe failure modes PCCP & metallic pipe
Acoustic Monitoring of Large Diameter Water Transmission Mains - City of Ottawa Case Study
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