3 TM Scotchkote TM Spray in Place Pipe 269 Coating. Case Study: Syracuse, New York

Transcription

1 3 TM Scotchkote TM Spray in Place Pipe 269 Coating Case Study: Syracuse, New York

2 Client: City of Syracuse Department of Water 101 North Beech Street Syracuse, NY Contact: Eric Murdock, P.E. Chief Engineer PH: (315) Location: East Seneca Turnpike below East Brighton Avenue Two lane rural road with highway overpass Active commercial and residential connections Heavy traffic flow Significant grade increase from West to East (toward East Brighton Avenue)

3 Water Main Detail 10 Cast Iron Original installation 1928 Approximately 1,400 linear feet Significant history of breaks over the past decade Significant tuberculation (Pre-cleaning images of East Seneca Tpke Syracuse, NY)

4 Work Completed: 1,342 linear feet of 10 water main was cleaned, lined and inspected Increased flow by removing tuberculation Enhanced structural performance of the main Prevents tuberculation from returning

5 The Process Pre-Work Site visit and planning The city provided detailed drawings of the main, but a physical site visit is critical to establishing optimal pit sites to avoid traffic issues or difficulties for residents or local businesses Pit excavation was completed by Syracuse Water Department preferred vendor JJ Lane Construction Inc. Bypass piping The Syracuse Water Department was responsible for establishing, testing, and maintaining bypass piping Note: This should be scheduled early enough to complete testing protocol before lining process is to start Traffic Management and Worker Safety The water main is located under the west-bound lane of East Seneca Turnpike. Traffic cones and barrels were used to close that lane of traffic. Flag men were used to allow for both directions of traffic to utilize this route throughout the lining process

6 Excavation Two pits are required per lining section (with multiple linings, as in this case, the exit pit will become the entrance pit for the next section) Pits should be approximately 5 x 7 with the water main centered. There should be at least 2 of material removed below the water main to prevent water from re-entering pipe All local codes for shoring were followed

7 A 36 section of pipe was cut and removed to allow for cleaning and lining

8 The section away from the lining was capped to prevent water from entering Submersible pumps were placed in the pit to remove flush water (storm sewer was utilized to remove flush water)

9 Cleaning Rack feed boring process o This process utilizes a powerful drive motor and hydraulic system to insert and spin 5 meter carbon steel rods into the pipe o Each section is connected to the next to allow for cleaning of up to 600 feet from either direction o A set of two flail heads are attached to a boring head located at the front of the first rod o As the flail heads traverse the pipe and spin they mechanically remove tuberculation from the pipe o The flail heads can flex to accommodate protruding connections, angles, and pipe diameter changes due to repair

10 The equipment is positioned below the first pit

11 During the cleaning process the pipe is continually flushed to remove all loosened debris resulting in severe water discoloration

12 A thorough flush is completed after the rack feed cleaning process Water will return to clean flow Following the final flush a swabbing process is used to remove last debris and remove all standing water o This process consists of using a bung to supply air pressure that pushes large foam pigs down the pipe o Multiple pigs are used until the final pig comes out mostly clean and dry

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14 Camera Inspection A tractor (crawler) camera is used to inspect the cleaned pipe This camera is equipped with a pan and tilt head so that a 360 degree inspection is possible This step is to ensure: o The pipe is properly cleaned and free of standing water o There are no major cracks, breaks or defects in the pipe o There are not protrusion, snags, or other issues that could damage or stop the lining equipment

15 Each connection is inspected to ensure that it is open and free of debris If the connection is found to be blocked multiple solutions available o For loose dirt and debris the connection can be blown back from the house or business o For heavy corrosion cameras can be equipped with a boring/cutting tool that can remove corrosion and tuberculation from the interior of the connection

16 The Lining Process Once the pipe is clean, dry and inspected the lining process can be started Equipment: o Lining rig this specialized trailer consists of two heated material tanks, a heavy duty pumping system, an umbilical hose wound on a drum, a drive motor and a PLC (computer) that controls the entire process

17 o Application head This consists of an application cone, an air motor to drive the cone, a static mixer element and centering devices

18 o Ancillary equipment 25 kva generator 375 cfm compressor Process steps o Step 1: The umbilical is spooled out through the pipe o Step 2: The application head is attached to the umbilical o Step 3: The pumping system is started and the spin up process is started

19 o Step 4: The application head is launched into the pipe o Step 5: The rig automatically applies the material to a uniform thickness of 3.5 millimeters through the pipe

20 o Step 6: The spray head is retrieved at the opposite end of the pipe Post Lining Inspection The material sets in 10 minutes, so camera inspection is immediately following the spray head retrieval This final inspection is to ensure that the lining is satisfactory and that all connections are still open

21 Reconnection The main is ready for reconnection and charging Post Lining Upon completion of each lining section a documentation package is completed and delivered to the customer The package includes o Post cleaning inspection DVD o Post lining inspection DVD o Application equipment physical print out The application equipment prints out a physical reading for all critical statistics every 3 seconds (lining thickness, speed, temperature, et al) Important Notice: All statements, technical information, and recommendations related to 3M's products referenced herein are based on information believed to be reliable, but the accuracy or completeness is not guaranteed. Before using this product, you must evaluate it and determine if it is suitable for your intended application.