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SAN DIEGO COUNTY WATER AUTHORITY PIPELINE RELINING PROGRAM

Keeping the Water Flowing

• Misha Troyan, P.E., EPC Consultants

• Mike Kenny, SDCWA

• Jose Martinez, R.W. Beck

Panel Members

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Bio – Misha Troyan, P.E.

• San Diego Area Manager, EPC Consultants• B.S. Civil Engineering, University of California

at Berkeley• Construction Manager for 27,000 feet of

pipeline relining projects – EPC has been a prime or subconsultant

on four reline projects to date

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Bio – Mike Kenny

• Senior Construction Manager, SDCWA• Oversight on $130 million in current

construction projects• B.S. Construction Management, Colorado

State University• 18 years with SDCWA including Inspection

Manager of Construction Inspection Group• Member, CMAA Board of Directors, San Diego

Chapter

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Bio – Jose Martinez

• Construction Manager, R.W. Beck• B.S. Mechanical Engineering, United States

Naval Academy– Certified Naval Nuclear Engineer by the

Department of Energy• Construction Manager on recent design-

build & urgent pipeline relines

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Presentation Goal

• Who is the San Diego County Water Authority?

• What is PCCP?

• Why is the Water Authority relining its pipelines?

• How does relining work?

• When did relining work start and what is the future of the program?

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Regional Background

• More than 200 years of water development

• Major focus of dam construction at end of 19th century

• SDCWA organized in 1944 to meet area's wartime mission

• Fifth of five major pipelines completed in 1982

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Mission Dam was constructed by Spanish settlers in 1769.

SDCWA Regional Role

• Water wholesaler provides 90% of San Diego County’s water

• 24 member agencies serving a population of 3.7 million people

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• Active in state and federal government as advocate for regional water supply

Completed in 2003, Olivenhain Dam is the largest RCC dam in the world

Infrastructure Overview

• Key Components– 300 miles of pipe– 82.5 miles of PCCP

(gravity)– 48 to 108 inch

• Expanding treated water capability

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Prestressed Concrete Cylindrical Pipe (PCCP)

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Why Reline?

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Historical Failures

• February 1979 – 66” (1959)• December 1980 – 66” (1959)• May 1982 – 66” (1959)• October 1990 – 84” (1972)• November 1993 – 96” (1972)*• May 2006 – 66” (1959) *• October 2008 – 72” (1976)*

* High pressure section13

Aqueduct Protection Program (APP)

• Established by SDCWA Board in 1991 in response to failures and concern about pipeline condition

• Risk Management role– May 2006 Failure = $6 million– Feb 2008 Replacement = $1 million– May 2008 Carbon Fiber Urgent Repair = $530k

• $41 million over the next 30 years; 4 regular staff plus support staff (as of 2003)

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APP – What Does it Do?

• Monitors and mitigates corrosion related damage

• Identifies pipeline nearing end of service life and schedules rehabilitation/replacement

• Documentation• Determines remaining service life and pipeline

decay index (PDI) for analysis

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Condition Assessment Tools

• In Service– Failures– Acoustical Monitoring

• Out of Service– Visual/Sounding– Remote Field Eddy Current– Impact Echo (limited effectiveness)

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Acoustic Fiber Optics (AFO)

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• Real-time monitoring of prestressing wires – Hydrophone Arrays– Acoustic Fiber Optic Cable

• Authority Pipelines Currently Being Monitored– Pipeline 3 = 19,715 feet– Pipeline 4 = 20,167 feet– Pipeline 5 = 65,000 feet– Crossover Pipeline = 39,600 feet

Handwriting On The Wall

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Got Corrosion?

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Visual Inspection

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Visual Inspection

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Deformed Cylinder

Thin Mortar Lining Cracked and Exposed Steel Cylinder

Sounding

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• Examination of External PCCP Wires

• Sounding and removal of delaminated mortar coating

• Cleaning and inspection of pre-stressed wires

Remote Field Eddy Current

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• 30 broken wires estimated

• 27 broken wires found

Condition Assessment

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• Pipeline Decay Index (PDI)– Summary of all factors– Determines remaining service life– Determines maintenance schedule– Regular data reviews and updates

• Potential impacts via GIS maps– Watercourse, schools, homes, roads,

commercial zones, etc.

Lessons Learned

• In-Plant inspection is key– Proper coating and lining– Steel can condition

• Consider bedding and environment – San Diego has very corrosive soils high in chlorides– Rock backfilled against pipe cracks coating– Poor diapers at joints on older PCCP

• Effect of shutdowns on PCCP25

Relining Considerations• Costs:

– Average reline cost = $1,300/ft– New Steel Pipe = $1,462/ft (rural) & $2,055/ft (urban)– Carbon fiber repair = $7,500/ft• Time:– Reduced OOS duration– 24-hour work• Community impacts:– Out of sight, out of mind• Environmental:– Minimizes dust, noise and impacts to habitat

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Relining Background

• New steel pipeline within PCCP

• Process developed in early 1980s by SDCWA Assistant Chief Engineer, Buckley L. Ogden– Ogden’s pipe carrier

• Process used around the nation and at the Water Authority today

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Basic Relining Process

• Portal Development

• Liner installation & Welding

• Grouting

• Cement Mortar Lining

• Closure Pieces

• Portal Restoration

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Portal Development

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Portal Development

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Liner Installation

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Liner Installation

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Bell & Spigot Fit-up

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Welding

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Grouting

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Grouting

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Cement Mortar Lining

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Cement Mortar Lining

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Closure Pieces

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Closure Pieces

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Concrete Encasement

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Concrete Encasement

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Portal Restoration

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Portal Restoration

Emergency Repairs

• Emergency vs. Urgent Repairs

• Same Process, Compressed Timeline

• Additional Variables

• Communication

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Carbon Fiber Repair

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Reline Program Status

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• Total Budget: $787 million

• Spent to date: $100 million

• May 2006 Failure, $6 million

• AFO repairs

• Feb 2008 replacement,

$1 million

• May 2008 carbon fiber,

$530k

26%

74%

Relined To date Remaining

61 Miles

21.5 Miles

Anything Else?

Questions & Answers

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