Pacific Northwest Section, AWWA Vancouver 2008 Conference Fusible Polyvinylchloride Pipe: Expanding...
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Transcript of Pacific Northwest Section, AWWA Vancouver 2008 Conference Fusible Polyvinylchloride Pipe: Expanding...
Pacific Northwest Section, AWWA Vancouver 2008 Conference Pacific Northwest Section, AWWA Vancouver 2008 Conference
Fusible Polyvinylchloride Pipe: Expanding Thermoplastic Fusible Polyvinylchloride Pipe: Expanding Thermoplastic Trenchless Applications and BeyondTrenchless Applications and Beyond
May 2May 2ndnd, 2008, 2008
Richard (Bo) Botteicher, Richard (Bo) Botteicher, PEPE
2
Fusible Polyvinylchloride Pipe - Fusible PVC ™Fusible Polyvinylchloride Pipe - Fusible PVC ™
Where has this stuff been??– Technology developed to create a close-fit “C909”
slipline rehabilitation solution– Thermal fusion was used to join pipe lengths
together– The fusion technology was then developed and
refined as a stand-alone technology– Fusible PVC™ procedure requires appropriate pipe
and the proper fusion procedure
Where is it going?– More than 500 successful projects installed to date– Projects in over 34 states, Canada and Mexico
®
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Fusible Polyvinylchloride Pipe Technology OverviewFusible Polyvinylchloride Pipe Technology Overview
Fusible Polyvinylchloride Pipe Technology– Formulation– Fusion Procedure
Design– Water Systems– Connections– Trenchless Construction
Installation Options– Trenchless Techniques– Direct Bury / Traditional Techniques– Case Studies
®
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Fusible PVC™ TechnologiesFusible PVC™ Technologies
Two significant developments were required to produce Fusible Polyvinylchloride Pipe:
– Formulation for PVC extrusion.
– Butt-fusion procedure.
®
5
• Meets requirements of ranges for components designated in PPI-TR2.
• NSF-61 certified.
• Meets ASTM Cell Classification 12454 – Industry Standard PVC Plastic for water and wastewater use.
FormulationFormulation
®
Fusible PVC™ TechnologiesFusible PVC™ Technologies
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PVC Classification and CompliancePVC Classification and Compliance
PPI-TR2
ASTM D1784Cell Class 12454
Range Formulation for PVC Pipe
Calculates HDB For Plastic Pipe
PPI-TR3
Hydrostatic Design Basis of 4000 psi
AWWA C900/905
Requires PPI-TR3, ASTM D1784 CellClass 12454, NSF 61
Minimum StandardsFor Drinking Water
PVC Pipe
®
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• Uses standard thermal fusion equipment.
• Equipment readily available within infrastructure construction industry.
• Pressure, temperature, and time (duration of each step) unique to PVC.
• Process time approximately the same as HDPE.
Fusion ProcedureFusion Procedure
®
Fusible PVC™ TechnologiesFusible PVC™ Technologies
8
PVC Fusion Process: Utilizes Industry Standard Fusion EquipmentPVC Fusion Process: Utilizes Industry Standard Fusion Equipment
Internal and External Bead Removal is Optional – friction losses are negligible (‘C’-factor of 150) andare significantly less than mechanically joined pipe (i.e. for 8” DR18 with 1000gpm in a length of 1000LF, flow loss is 0.173 gpm and a head loss of 0.013 ft) and pipe tensile strength is not impaired (extra material in bead)
®
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Fusible PVC™: Fusion Process Is Tightly ControlledFusible PVC™: Fusion Process Is Tightly Controlled
Qualified fusion technicians are trained and must be retrained every year
– Initial 3 day course
Fusion equipment must meet minimum standards to be approved for PVC fusion
Data loggers record critical fusion datafor each joint– Provide real time feedback on joint integrity– Provide record of entire project for proof of
system integrity Fusion conditions logged by technician and “as-
built” fusion joint record is developed for owner as necessary
30111
Myrtle Beach 20" Force Main Diversion
Myrtle Beach, SC
Eric Kerner
Eric Kerner
Pipe DR
DR 25
Piston
Area (in2)
15.32
A. Pressures (psi) B. Ambient Conditions / Start Time
Heat
Fusion
Drag AM
AM
C. Heating Plate Temperature & Extrusion Marking
Left Face Temperature - °F Right Face Temperature - °F
Record extruder pipe marking (near fusion joint) and pipe length above.
Fusion Technician
Pipe Dia. (in)
Jobsite Location
Pipe Description
PIPE DETAILS
Color Extruder
Pull No.
21462810604-1172
NAPCO FPVC™20004
MDL3-0241
Green
C09247
Data Logger Serial No.
Heat Plate Serial ID
EQUIPMENT IDENTIFICATION
57Temp. (°F)
20
sunnyWeather
IR Pyrometer Serial No.
50
564
T-900
Project No.
Joint Number
20004
Nov. 29, 2007
Fusion Machine Identification
131
Joint No.
Fusion Date
Project Name
Project Engineer
399
15 Sept 07 @ 11:23 12 Nov 07 @ 17:47
412
399
402
410
402 395403
10:52
End Time 11:29
Start Time
235188
Piv
ot
12:00
3:00
6:00
9:00
12:00
3:00
6:00
9:00
®
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Joint StrengthJoint Strength
• Hauser Labs, Boulder, CO has performed 3rd party testing.
• Testing to date includes tensile strength, flattening, acetone immersion column buckling, 3-point bending, and burst testing, among others.
• Tensile tests performed on 1000’s of samples in sizes from 4” to 36”
• Results representative of full pipe strength.
Fused Joint
®
Fusible PVC™ TechnologiesFusible PVC™ Technologies
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Fusible PVCFusible PVCTMTM is the Most Tested PVC Pipe in the Industry with Four Levels is the Most Tested PVC Pipe in the Industry with Four Levels of Quality Control to Help Ensure Flawless Installationsof Quality Control to Help Ensure Flawless Installations
Test VendorQualification
Required VendorTesting
UGSI LotAcceptanceTesting
Fusion Joint QCData
Fusion Tensile ASTM D638
Pipe Tensile ASTM D638
Pipe Dimensions Per AWWA C900/C905
Per AWWA C900/C905
Pipe Burst Per AWWA C900 Per AWWA C900
Flattening Per AWWA C900/C905
Per AWWA C900/C905
Per AWWA C900/C905
Acetone Immersion ASTM D2152 ASTM D2152 ASTM D2152
HydrostaticPressure Test
Per AWWA C900/C905
Per AWWA C900/C905
Impact Test ASTM D2241;ASTM D2444
ASTM D2241;ASTM D2444
Heat Reversion ASTM F1057 ASTM F1057 ASTM F1057
Ash/Inert Content(LOI)
ASTM D2584 ASTM D2584Per UGSI Request
Joint FusionParameters
TemperaturePressure, Location,Other
Licensed Operator Unique Operator ID
Note: Bold highlights indicate required AWWA tests ®
12
Independent Laboratory Testing: Prior to Acceptance for ProjectsIndependent Laboratory Testing: Prior to Acceptance for Projects
Flattening Test:
– Pipe compressed to 40% of specified O.D. with no splitting, cracking or breaking
Extrusion Quality Tests:– Acetone Immersion: Poor fusion
quality (fusion of resin mix) is evident when flaking and disintegration is displayed
– Heat Reversion: A number of fail conditions including excess moisture and poor vacuum control on the extrusion line – as exhibited by blistering or wall separation
FlatteningPass
Flattening Fail
Heat Reversion
Fail
®
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Designing Water System Infrastructure with Fusible PVC™Designing Water System Infrastructure with Fusible PVC™
Identical PVC Plastic…– ASTM D1784 – for PVC plastic Cell
Classification (12454)– NSF 61 certified– AWWA C900 & C905 compliant– IPS, and Schedule sizing available as
well– Available in white and purple colors as
well
New Joining Technique…– Thermal butt fusion joints provide the
same strength as the pipe wall.– No gaskets.– No exfiltration or leakage.– No over-deflection, over-seating, or
rolled gaskets possible at joints. – Compatible with raw water sources –
brackish water, high solids content, etc.
Distribution and Raw Water Piping
®
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Designing Water System Infrastructure with Fusible PVC™Designing Water System Infrastructure with Fusible PVC™
Critical Infrastructure– Under rivers, major streets and other
problem areas– Will not leak at joints– Fully restrained at joints– May eliminate bends and some fittings– Very good contamination resistance,
including gasoline
Repair and Maintenance– Standard waterworks repair fittings for
PVC pipe– Standard industry knowledge– No special equipment needed– No specialized training needed
Design of Critical Pressure Piping and Ongoing Maintenance
®
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Designing Water Systems - Restrained JointDesigning Water Systems - Restrained Joint
Conventional Gasketed & Restrained PVC to PVC Connections12” Example
Fusible C-900®, Fusible C-905®®, FPVC™ Low Profile Restrained Joint
TerraBruteTM
Barrel = 13.2”Bell = 16.75”
Certa-LokTM
Barrel = 13.2”Bell = 15.83”
Barrel = 13.2”Bell = 16.75”
Restraining Hardware = 19.45”
Barrel and Fused Joint Have Consistent O.D. = 13.2” ®
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Designing Water Systems - Industry standard couplings and Designing Water Systems - Industry standard couplings and fittings for connections and reconnectionsfittings for connections and reconnections
Connecting to Fittings
Mechanical Joint Fittings:
Flanged Joint Fittings:
Connecting to Pipe
Same Piping Size:
Different Piping Size:
Pictures from various manufacturers of fittings: JCM, Smith Blair, EBAA Iron, Romac Industries, American Pipe.
®
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Designing Pressure Piping Infrastructure with Fusible PVC™Designing Pressure Piping Infrastructure with Fusible PVC™
Horizontal and Vertical Layout – uses standard line and grade installation
Three additional Design Factors:– Allowable Bend Radius– Tensile Capacity of PVC Plastic– Thermal Expansion and Contraction
®
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Trenchless Installation and Rehabilitation Methods May Trenchless Installation and Rehabilitation Methods May Dramatically Reduce Project CostsDramatically Reduce Project Costs
Traditional Direct-Bury, Open-Cut or Exhume & Bury pipe installation methods can be disruptive, impractical and limiting – especially in rehabilitation efforts
Trenchless methods reduce:– Project costs– Business interruption costs– Political costs
An estimated 25% of water line rehabilitation is done utilizing trenchless technologies
Hard Project Costs are Potentially Reduced Hard Project Costs are Potentially Reduced by 20-40% through use of Trenchless by 20-40% through use of Trenchless
MethodsMethods
®
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Installation Design with Fusible PVC™Installation Design with Fusible PVC™
Existing System Rehabilitation or Alternative Installation Techniques Available– Pipe Bursting and Sliplining Rehabilitation– Horizontal Directional Drilling
Utilizes the Tensile Capacity of the PVC Plastic, Bend Radius and consistent Outer Diameter of the pipe
®
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HDD Design Considerations with Fusible PVC™HDD Design Considerations with Fusible PVC™
No relaxation period required – immediate connections possible
Higher density of Fusible PVC™ reduces buoyant forces to reduce pull-in forces
The favorable PVC plastic weight to tensile strength ratio allows longer, higher pressure installation by HDD, between steel pipe and HDPE pipe
5,120 ft 10” DR14 pulled in a single continuous drill operation
4,400 ft 24” DR 18 pulled in a single continuous drill operation
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
®
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HDD Design Considerations with HDD Design Considerations with Fusible PVC™Fusible PVC™
® Pit Layout and Design
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
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Horizontal Directional Drilling with FPVCHorizontal Directional Drilling with FPVCTMTM - -
Broomfield, COBroomfield, CO
2,420 linear feet of FPVC™
24” DR25 FPVC™ purple pipe for reclaim water line
Client: City and County of Broomfield, COHorizontalHorizontalDirectionalDirectional
DrillingDrilling
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
®
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Horizontal Directional Drilling with FPVCHorizontal Directional Drilling with FPVCTM TM - Beaufort, SC- Beaufort, SC
5,120 linear feet of 10” DR 14 FPVC™
Longest pull of thermoplastic pipe in the water & wastewater industry
Client: Beaufort Jasper Water & Sewer Authority for Secession Golf Course
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
®
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Insertion SideInsertion Side
Beaufort River Crossing AlignmentBeaufort River Crossing Alignment
All mapping provided by Google®
Drill SideDrill Side
Beau
fort
Riv
er
Beau
fort
Riv
erB
eauf
ort R
iver
Bea
ufor
t Riv
er
Secession Secession Golf CourseGolf Course
®
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Project consists of 60,000’ of 24” water main in 4 divisions
Supply from CWS through St. John's Water Company system to wholesale users
19,000’ designed as HDD, including 4,260’ under the Stono River
4,400’ of 24” DR18 Fusible C-905® laid out
Client: St. John’s Water Company Stono River Crossing (Div. IV)
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
HorizontalHorizontalDirectionalDirectional
DrillingDrilling
®
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Provides maximum flow with an independent fully structural solution
Results in a smaller I.D. than the host pipe
Improvement in internal friction often minimizes flow loss– “C” factor of 150 with internal
bead
®
Slipline Design Considerations with Fusible Slipline Design Considerations with Fusible PVC™PVC™SlipliningSlipliningSlipliningSliplining
27
Slipline Design Considerations with Fusible Slipline Design Considerations with Fusible PVC™PVC™
Cleaning and video inspection recommended to ensure acceptable clearance prior to insertion
Recommended difference between ID of host pipe and OD of Fusible PVCTM is 2” at a minimum
Grouting or other treatment of annular space is advised
– Eliminate void space, nuisance water, and potential future collapse around new sliplined pipe
– Fully support and fix new sliplined pipe in place This process can be employed with new casings
– Casing spacers may be utilized– Annular space treatment may be utilized
Fusion may be done in the access pit 3,510 ft 12” DR18 pulled in one operation
SlipliningSlipliningSlipliningSliplining
®
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Slipline Design Considerations with Slipline Design Considerations with Fusible PVC™Fusible PVC™SlipliningSlipliningSlipliningSliplining
®
Pit Layout and Design
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Client: United Water
Sliplining with Fusible C-900Sliplining with Fusible C-900®® – Harrisburg, PA – Harrisburg, PA
3,510 linear feet of Fusible C-900®
Host Pipe – 16” cast iron
12” DR 18 for water line under the Susquehanna River
SlipliningSlipliningSlipliningSliplining
®
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Client: Horseshoe Construction for Zaragosa Boulevard
Sliplining with Fusible C-905Sliplining with Fusible C-905®® – El Paso, TX – El Paso, TX
16,300 linear feet of Fusible C-905®
Host Pipe – 36” Prestressed Concrete-Lined Cylinder Pipe (PCCP)
24” DR25 for water line under Zaragosa Boulevard
SlipliningSlipliningSlipliningSliplining
®
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Client: Horseshoe Construction for Zaragosa Boulevard
Businesses along Zaragosa Rd remained open with minimal access issues
Texas Council of Engineering Companies 2008 Silver Medal Award winner
SlipliningSlipliningSlipliningSliplining
®
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Static Hydraulic Method is used Typically done in 300 - 500’ increments (~1 hour pull-back) Utilizes existing alignment – less engineering cost to locate adjacent
utilities
Fusible PVCTM
Pipe Bursting Design Considerations with Pipe Bursting Design Considerations with Fusible PVC™Fusible PVC™
PipePipeBurstingBurstingPipePipe
BurstingBursting
®
33
Ductile iron, cast iron, asbestos-concrete and steel are typical water pressure pipe materials that are burst – high production rates are possible (recent project in Florida - 500 LF in 1 hour)
Static hydraulic bursting/splitting method is used vs. pneumatic method (typically used in sewer work)
High density and hardness of Fusible PVCTM results in excellent scratch and abrasion resistance
Isolation of pipe from burst hardware prevents rebound when force changes rapidly
Pre-chlorination method – removes need for bypass line installation – required disinfection is done above ground prior to burst/pull-in (24 hour sampling per AWWA)
– Pits for lateral connections dug prior to pull-in– Once new pipe is pulled-in, laterals are connected using standard PVC
tapping and connection techniques– 20% less cost than dig-and-replace
PipePipeBurstingBurstingPipePipe
BurstingBurstingPipe Bursting Design Considerations with Pipe Bursting Design Considerations with
Fusible PVC™Fusible PVC™
®
34
Ypsilanti, MI Ypsilanti, MI
M-17 (Ecorse Road) Water Main Replacement Project
8”,12”, and 16” Water Main Pipe Bursts8”,12”, and 16” Water Main Pipe Bursts
PipePipeBurstingBurstingPipePipe
BurstingBursting
®
35
Project Details
800 LF of 16” 5200 LF of 12” 2000 LF of 8”
Pre-fused Fusible PVC™ by Midwest Trenchless
Pre-fused lengths for pulls ranged:– 780 LF down to– 320 LF
Ypsilanti, MI - M-17 Water Main Replacement Project
PipePipeBurstingBurstingPipePipe
BurstingBursting
®
36
Sample Installation Sequence
Ypsilanti, MI - M-17 Water Main Replacement Project
PipePipeBurstingBurstingPipePipe
BurstingBursting
®
1. 3.2.
5.4.
37
Potable Water Mains Michigan DOT and Michigan DEQ
approvals required Pre-chlorinated Pipe Bursting and
Horizontal Directional Drilling
Ypsilanti, MI - M-17 Water Main Replacement Project
PipePipeBurstingBurstingPipePipe
BurstingBursting
®
38
Results Successfully installed and tested Minimized public impact
– Minimal traffic closure– Minimal commercial impact
Ypsilanti, MI - M-17 Water Main Replacement Project
PipePipeBurstingBurstingPipePipe
BurstingBursting
®
39
Fusible PVCFusible PVCTMTM is an efficient and elegant leak-free design in open-trench is an efficient and elegant leak-free design in open-trench installation, and also delivers a fully restrained, corrosion free jointinstallation, and also delivers a fully restrained, corrosion free joint
Open-Trench/Open-Trench/Direct BuryDirect Bury
Open-Trench/Open-Trench/Direct BuryDirect Bury
®
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Direct Bury with FPVCDirect Bury with FPVCTMTM – Naples, FL– Naples, FL
33,000 LF of 30”, 24”, 16”, 12”, 8” FPVCTM
Raw water collection system for 12 MGD brackish water RO Facility
Client: Collier County, FL Open-Trench/Open-Trench/Direct BuryDirect Bury
Open-Trench/Open-Trench/Direct BuryDirect Bury
®
41
Direct Bury with Fusible C-900Direct Bury with Fusible C-900®® – Sunnyvale, CA – Sunnyvale, CA
4,200 LF Direct Bury
12” DR18 Fusible C-900® for new water line
Towne Center ProjectPotable Water LineDirect Bury/HDDDirect Bury/HDDDirect Bury/HDDDirect Bury/HDD
®
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Selected National A&E Firms Specifying Fusible C-900™/Fusible C-905Selected National A&E Firms Specifying Fusible C-900™/Fusible C-905®®/FPVC™ /FPVC™
Arcadis Army Corp of Engineers Austin Civil GroupBanner AssociatesBartlett –WestBKFBolton-MenkBonestrooBowen-CollinsBP BarberBrelje and RaceBrown and CaldwellCarolloCarter and BurgessConklin, Porter and HolmesCDMCH2M HillDudekEarth TechGC Wallace
Greeley And HansenHarris and AssociatesHDRInterstate EngineeringKennedy JenksKimley-HornMetcalf and EddyMWHMoore EngineeringNolte Assoc. Parsons EngineeringRBFRMC WaterStantecPBS&JTetra TechWinzler and KellyWilson & CompanyURSUtility Services
®
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Fusible Polyvinylchloride Pipe for Water System PipingFusible Polyvinylchloride Pipe for Water System Piping
Fusible Polyvinylchloride Pipe Technology requires:– PVC piping that can create integral, full-strength
fusion joints– The correct fusion procedure
Water System Design will benefit from:– Tough, reliable, accepted PVC thermoplastic
material – Leak free pipe system– Integral restrained joint– Acceptance of standard PVC/DIP fittings and
methods Suitable for varied and demanding Installation
Techniques– Horizontal Directional Drilling– Sliplining Rehabilitation– Pipe Bursting– Direct Bury
®
Questions?Richard (Bo) Botteicher, PE
(303) 521.2618
Underground Solutions, Inc.Poway, CA
www.undergroundsolutions.com858-679-9551