fusible pvc pipe presentation€¦ · industrial uses. - process has great promise for municipal...
TRANSCRIPT
Fusible PVC® PipePresentation
Contemporary Topics in Water/Wastewater Construction Seminar
Goldsboro, NC
December 4, 2018
Company Confidential
Today’s Discussion…• Aegion Infrastructure Platform Products
• Background and History of Butt-Fused PVC Pipe
• Understanding Fusion of PVC Pipe
– Process
– Data Logging Joints
– Certification of Technicians
• Multi-layered Product QA
– In Plant
– Independent Lab
• Benefits of Fusible PVC® Pipe; Comparison to HDPE
– Material characteristics
– ID/OD relationship
– Flexibility & toughness
– Practical field differences
• Primary Application – Horizontal Directional Drilling, Design & Case Study
• Other Applications – Sliplining, Jack & Bore, Pipe Bursting & Open Cut
Infrastructure Platform Products• There are four business units of the Infrastructure
Platform for new construction or rehabilitation of deteriorating water and wastewater pipelines.
- Cured-in-place pipe rehabilitation for gravity sewer lines, of which several billion
dollars’ worth installed.
- Insitumain is a CIPP liner designed specifically to rehabilitate pressure mains from 6”
to 36” diameter, for pressures upto 200 psi.
- Insitumain can be a fully structural element, designed to replace the existing main
should it corrode and fail entirely.
- For more information, review and download the information at
http://www.aegion.com/InfrastructureSolutions/PipeLiningsWater/InsituMain
- Fibrwrap developed the process of carbon reinforce polymer lining of large pressure
mains over 20 years ago.
- Repaired many discreet sections of pipe since that time.
- Process requires man entry and can be effective for diameters larger than 36” and
pressures over 400 psi.
- Fibrwrap system is meant for spot repairs, wherein a few lengths of pipe within a longer
section may need reinforcement.
- For more information, review and download the information at
http://www.aegion.com/InfrastructureSolutions/PipeLiningsWater/FRP
- Developed Tite Liner® to offer a corrosion
control solution in the oil and gas patch, and for
industrial uses.
- Process has great promise for municipal
wastewater force mains with beginning or
moderate stages of internal H2S corrosion.
- Corrosion in these force mains can be stopped
dead with this thin HDPE liner available from,
and installed by, UPS, as long as the underlying
main has adequate structural capacity to
perform the remainder of its design life.
- Diameters available up to 54”.
- For more information:
http://www.aegion.com/CorrosionProtection/Pipe
Linings/Tite-Liner
Bringing Innovation to Underground Infrastructure• Fastest growing underground infrastructure product-line in
North America
– Leak free, restrained joint pipe systems
– Trenchless installation modes that reduce contractor costs
– Rehabilitation capabilities for difficult high pressure water pipe
applications
– “Trenchless Project of the Year 2010 & 2013” “Honorable Mention 2007 & 2014” – Trenchless Technology magazine
• Over 11,000 successful projects installed to date with over 12,000,000 feet
in service worldwide
– In 50 states, Canada, Latin America, New Zealand, Australia
– Over 5,000 HDD’s (horizontal directional drills) completed
– Over 8,500 separate pull-in instances (HDD, Slipline, Pipe Burst, Open-Cut)
• Pipe meets relevant industry pipe standards
– AWWA C900, C905, C605, NSF-61, NSF-14, PPI-TR2, ASTM Cell Classification
12454
– Utilizes standard PVC and ductile iron fittings
– Available in all water industry configurations
Company Confidential
Fusible PVCTM Products – 40’ or 45’ Lengths, plain end x plain end; extruded by NAPCO and Northern to UGSI formula and quality standards
Pipe TypeSizes
(Nominal OD)
DIPS or IPS or
Schedule
Dimension Ratios (DR)
Uses Color
Fusible C-900® 4” – 12” DIPSDR 14, 18,
25
Potable Water
AWWA C900Blue
Fusible C-905® 14” – 36” DIPSDR 14, 18,
21, 25, 32.5, 41
Potable Water
AWWA C905Blue
FPVC® 4” – 36”DIPS, IPS,
or Schedule
DR 14,17,18, 21, 25, 26, 32.5, 41
and Sch.80
Non-Potable Water or Potable
Water Applications not
in C900/C905 Dimensions
Blue, Purple, Green, White,
Grey
* Not all diameters are extruded to all listed DR’s.
The Underground Solutions® PVC Fusion Process: Utilizes Industry Standard Fusion Equipment
Internal Bead not a flow restriction– friction losses are negligible (‘C’-factor of 150) and are significantly less than mechanically joined pipe.
Company Confidential
Fusible C-900®, Fusible C-905® And FPVC ® : Fusion Process Is Tightly Controlled• Qualified fusion technicians are trained and
retrained every year by Underground Solutions
– Initial 3 day course
• Fusion equipment must meet minimum company 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
Growth in Carolinas Region
• NC > 485,000• SC > 311,000
NCDOT Standards -2012
Fusible PVCTM is the Most Tested PVC Pipe in the Industry with Four Levels of Quality Control to Help Ensure Flawless Installations: Over 10,000 Specimens Tested by 3rd Party Labs
Test AWWA
Requirements
UGSI Requirements UGSI Lot
Acceptance
Testing
Fusion Joint QC
Data
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
Hydrostatic
Pressure Test
Per AWWA
C900/C905
Per AWWA
C900/C905
Impact Test ASTM D2241;
ASTM D2444
Heat Reversion ASTM F1057 ASTM F1057
Ash/Inert Content (LOI) ASTM D2584
Joint Fusion
Parameters
Temperature
Pressure, Location, Other
Licensed Operator Unique Operator ID
Thousands of Hours and Thousands of Individual Sample Tests by Independent Sources further Verify Mechanical Properties of UGSI Fusible PVCTM
• Tensile Strength – >1000 fused samples verify fused joint strength ~ 7000 psi ultimate tensile strength or typically 95-105% of the un-fused pipe strength (within the variability found in commercial PVC pipe)
• 1000 Hour Sustained Pressure Test - per ASTM D1598 at 500psi (DR18) for 10x the ASTM threshold of 1000 hours – UGSI test duration was 10,000 hours – fused and un-fused pipe
• 1,000,000 Cycle Pressure Test – (94-188psi for DR18) demonstrating cyclic surge on a fused joint system per ASTM F1674 – simulating a severe duty cycle (3.5 million completed)
• 5000 Hour Scratch/Pressure Test – Gouge depths of 5-10% on samples under 500psi (DR18) pressure were successfully tested (pipe and fused joint)
Fusible PVC® Pipe Physical / Mechanical Material Properties Are Very Different From HDPE Pipe
Property Specification PVC PE80 PE4710 Diff.
Tensile Strength (psi) ASTM D638 7,000 3,000 3,000 >2X
Safe Pulling Stress (psi) (w/SF = 2.5) 2,800 1,200 1,200 >2X
Specific Gravity ASTM D1505 1.40 0.94 0.95
Hydrostatic DesignBasis At 73º F (psi)
ASTM D2837 4,000 1,600 2.5X
Modulus of Elasticity (psi)
ASTM D638 400,000 110,000/28,200* 3.6X
Hardness(Rockwell R)
ASTM D785 117 52 2.25X
Coefficient of Linear Expansion In./In. deg F
ASTM D6960.3 x 10-4
.36”/ 100’/ 10°F
1.2 x 10-4
1.44”/ 100’/ 10°F0.25X
* PPI – PE Handbook – Long term Modulus of Elasticity = 28,200 psi.
Bending differences • HDPE is More Flexible Than PVC…
But, PVC is Stronger and Requires Less Wall Thickness for a Given Design…
OD= 13.20"ID= 11.65"
OD= 15.30"
PE
PVC
ID= 11.70"
12” DR18 PVC (DIPS)14” DR9 HDPE (DIPS)
Fixed ID and Pressure Rating Yields this Result for 24” ID, 200 psi
24” ID 24” PVC DR 21SF = 2.0
30” PE DR 9SF = 2.0
PVC % Advantage
OD (inches) 25.80 30.00 16%
Volume per Foot (ft3) 3.63 4.91 35%
Wall Thickness (inches) 1.23 3.33 171%
ID (inches) 23.19 22.93 1%
Pressure Rating (PSI) 200 200 0%
Weight (lbs./ft.) 61.49 121.62 98%
OD= 25.80"ID= 23.19"
OD= 30.00"
PE
PVC
ID= 22.93"
Borehole Comparison
HDD – Connection Points (PPI Recommends for HDPE…)
A typical pullout prevention technique is to restrain the transition connection and
several non-PE bell and spigot joints down line from the transition connection as
shown in Figure 26. From Plastics Pipe Institute Literature (Technical Note 36)
Connection Suggestion For Fusible PVC®
Fusible PVC™Mechanical Joint
Ductile Iron Solid Sleeve
EBAA Megalug® or Equal EBAA Megalug® or Equal
Joint Deflections,
only
Fusible PVC™
Fusible PVC™
Fusible PVC™ Mechanical Joint
Ductile Iron Bend
EBAA Megalug® or Equal
EBAA Megalug® or Equaldd
Open Cut DIP or PVC
Open Cut DIP or PVC
High Creep HDPE Typically Fused for Connections and Taps & Repairs
Scraper to prep surface for coupling Hammering on electrofusion coupling
Saddle fusion for tap or puncture repairMJ Adapter w/stiffener
Low Creep Fusible PVC® pipe uses industry standard couplings, MJ fittings and tapping procedures
Mechanical Joint Fittings:
Same Piping Size
Connecting to Fittings & Pipe Tapping Machines/Procedures
Pictures from various manufacturers of fittings: JCM, Smith Blair, EBAA Iron, Mueller.
HorizontalDirectional
Drilling
• 55%of UGSI Fusible PVC® installed by directional drilling techniques–Pulls of over 7,000 ft accomplished (AWWA C905 – 16”)–Pulls of over 7,000 ft accomplished (AWWA C905 – 30”)–Over 3,000 separate pull-ins–Pipe diameters of 4” - 36” installed
• 25% of UGSI Fusible PVC® installed in slip lining applications–Pull of over 7,000 ft accomplished with 14” pipe–Pull of over 3,500 ft accomplished with 12” pipe–Pull of over 1,800 ft accomplished with 24” pipe–Pipe diameters of 4”- 30” installed
• 15% of UGSI Fusible PVC® installed in direct-buryapplications
•5% of UGSI Fusible PVC® installed in pipe bursting applications
–- Pulls of over 2,000 ft accomplished with 8” and 10” pipe
PipeBursting
Open-Trench/Direct Bury
Sliplining
Underground Solutions Fusible PVC® is installed through two generic installation methods: Trenchless and Open-Cut
Fusible C-900 ®, Fusible C-905 ® and FPVC® Pipe Lower Costs
• Guided pilot hole is drilled along a bore path
• Drilling fluids are injected into the hole to stabilize and lubricate – fluids suspend and transport cuttings to the surface
• Back reamer is used to enlarge the pilot hole – Multiple passes are required to
accommodate pipe OD
– Drilled bore hole is typically enlarged to 1.5 x OD of new pipe
HorizontalDirectional
Drilling
Considerations
• Insertion trench is configured to meet bend radius of the pipe
• 120’ small pipe culvert crossings, or…• 7,000’ x 16” DR18 pulled in a single
continuous drill operation• No relaxation period required –
immediate connections possible• Higher density of Fusible PVC®
reduces buoyant forces to reduce pull-in forces
• Longer pull-ins possible – recommend water ballasting and rollers to reduce drag
HorizontalDirectional
Drilling
30” HDD Bore in Wilmington, NC 2012
Company Confidential
HDD –Entry/Exit Angles, Borepath & Radius
Slope or Tangent Portion
(8° to 15° - 20% is 11°)
Radius
Level Run (depends on obstacle crossed)
Depth
Company Confidential
HDD – Setbacks, Depth, Connection Points
Setback
Connection Point
Company Confidential
HDD – Radius Based on Rig Size
ASTM F1962 Guide for Maxi-Directional Drilling suggests 1200 times the
drill rod radius to determine minimum radius of drill stem:
• For 40,000# class rigs with 2.5” rods, that is 250’ radius
• For 100,000# class rigs with 4” rods, that is 400’ radius
• For 300,000# plus class rigs with 6” rods, that is 600’ radius
Rig size for your project depends on:
• Product pipe diameter
• Length and depth of drill shot
• Soils type or presence or rock
• Site conditions
• Local contractor capability
Company Confidential
HDD – Radius Check on Product Pipe
Fusible PVC™ pipe bend radii ranges (DIPS OD):
• 4” – 100’
• 6” – 144’
• 8” – 189’
• 12” – 275’
• 16” – 363’
• 20” – 450’
• 24” – 538’
• 30” – 667’
• 36” – 798’
Horizontal Directional Drilling with Fusible PVC® Pipe -
Columbia, SC- Mill Creek Forcemain
• HorizontalDirectional
Drilling
Client:
City of Columbia
1,665’ – 30” DR21
The final reaming pass used 42” rock bore tooling directly
in front of the 32” outside diameter product pipe.
Horizontal Directional Drilling with Fusible PVC® Pipe -Okatie, SC
Client:
Beaufort Jasper
1,300’ – 36” DR21
One Intermediate
Fusion
HorizontalDirectional
Drilling
North Topsail Waterline RehabNorth Topsail, NC
Onslow Water and Sewer Authority(Completed January 2018)
North Topsail Waterline Rehab
37
-35 yr old 10” DIP on Bridge
-Prolonged exposure to coastal
environment
-Corrosion, water leaks, and joint
deterioration
-Main water feed to Island
North Topsail Waterline Rehab• WK Dickson design
• 2 options for construction: short HDD and open cut or long HDD
• Approximately 2,025 ft. of HDD across ICWW
• Upsized line to 12”
• Tidal environment
• Approximately 20+ ft. below ICWW bottom
• Entry and Exit angles adjusted for topo
North Topsail Waterline Rehab
• 2,025’ – 12” in Single Pull
• Drill pipe entry angle about 12º, exit angle 10º
• Wire line tracing used to steer
• 9” Pilot drill took 6 days
• Swabbing pass to clean hole and set slurry cake took 5 days
• Ready to connect and pull pipe mid-December 2017
North Topsail Waterline Rehab
North Topsail Waterline Rehab
•Drilling Operations – Sandy’s Hauling
•330 k-lbs machine
•ParaTrack survey and guidance system utilized
North Topsail Waterline Rehab
Fusion required 45
joints over 6 days
Rollers supported pipe at 40’ intervals
Pipe String to
Driveway
North Topsail Waterline Rehab
•Took 60 days from NTP to test (150 psi/2 hrs) and reconnect
•Minimal impact to ICWW and wetlands
•70+ HDDs over 2,000 ft.
Compromised Host Pipe Has a Continuous Length of Fusible PVCTM Pulled Into Place
• 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
• Grouting of the annular space between the existing and new pipe is usually required
Sliplining
Sliplining Project Considerations
• Video inspection of host pipe – condition, deflections, vertical profiles and stranded appurtenances
• Layout area for fused pipe – as well as entrance pit constraints – possibility for “fuse & pull” or in pit fusion
• Recommended difference between ID of host pipe and OD of Fusible PVCTM is about 2”
• Ability to dig out connections before sliplining
• Effect of abrasion on pipe surface – plastic 10% gouge depth before de-rating
• Traffic management – night activity or “fuse & pull” in tight areas
Sliplining
Client: DC Water
Consultant – CDM Smith
Sliplining with Fusible C-900® Pipe – M Street Water Main
• 1,800LF of 30” DR 25 Fusible C-905® pipe in 36” PCCP Host
• Pipe pulled in with Grundoburst 800G
Sliplining
DC Water-M Street WM
Fusible PVC C-905 vs HDPESliplining
DC Water-M Street WMWell designed Pit for Fusion
Sliplining
DC Water-M Street WMRoom to Maneuver & Perform Fusion Tasks
Sliplining
DC Water-M Street WM Static Machine Provides Pulling Force with Steel Rods
Sliplining
DC Water-M Street WM Pipe installed awaiting annular space grouting
Sliplining
Fusible PVC™ pipe is well suited to Jack & Bore installation
• Bore pits are dug on each side of the crossing
• Casing pipe is jacked into place while spoils are removed through the casing
• Carrier pipe is installed inside of new casing
http://www.energy.ca.gov
Jack & Bore
24" DR 18 FPVC®
inside 36" Steel Casing
OD= 25.80"
Casing ID= 35.00"
24" RJ Ductile Iron
inside 42" Steel Casing
w/ Casing Spacers
Pipe OD= 25.80"
Casing ID= 40.50"
Bell OD= 30.25"
45°30°
2" Conduit
45°30°
2" Conduit
Runner Height = 3.75"Runner Height = 1.50"
Jack & Bore with Fusible PVC® Pipe – Napa, CA
• 300 LF of 24” DR 18
• Jack & Bore crossing of Highway 221
• This section of pipeline provided approximately $50,000 in savings compared with other design options
Client: Napa Sanitation DistrictJack & Bore
Jack & Bore with Fusible PVC® Pipe – Eastvale, PA
• 24” DR 25 in a 42” steel casing
• Jack & Bore crossing under Norfolk Southern Railway
• By bundling Fusible PVC™ with the small diameter carrier pipes, the contractor was able to utilize a smaller diameter steel casing than with other pipe materials
Client: Beaver Falls Municipal AuthorityJack & Bore
Fusible C-900®, Fusible C-905®, And FPVC ® Pipe Attached to the Bursting Head and Pulled into the Existing Pipe
• Static Hydraulic Method is used
• Burst head is pulled through existing line - fracturing or cutting the pipe
• Fractured or split pipe is pushed into the surrounding soil
• New pipe is pulled in immediately behind the burst head
PipeBursting
Client: Greensboro Water Resources
City Wide Water Pipe Bursting ProgramPipe
Bursting
•Greensboro, NC
•58,000’ water main (to date)
•2, 4 & 6” Cast Iron to 6 & 8” Fusible
PVC™
•Through cast iron hubs and tees
•GrundoBurst 800G (over 160 tons of
pull)
•KRG Utility Performed Work
Pipe Bursting with Fusible PVC® pipe- Wilmington, NC
• 5039’ of 20” DR18 FPVC® Pipe- Longest Pull 900LF
• Replaced Corroded 20” Ductile Iron Pipe
• Performed in 5 months late 2014, early 2015
Client: Cape Fear Public Utilities Authority
Consultant: Kimley-HornPipe Bursting
Length of Fused Pipe with Pullhead and Expander Attached – up to 900 LF
Pipe String In Place for Pullback
Tooling Consists of Three Cutters, Each Subsequent One Larger than Last One
Removing Final Vestiges of Ductile Iron Pipe
Aegion Pressure Pipe Capabilities
62
4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 36" 42" 48" 54" 60" 66" 72"
InsituMain 258 195 160 255 220 195 175 161 256 227 190 165 145 130 115 108 100
Fusible PVC 305 305 305 305 305 305 305 305 305 235 200 200
Tite Liner 252 202 202 202 161 161 161 126 126 126 112 101 101 81 64
HDPE Slip Lining 333 333 333 333 333 333 333 333 333 333 250 200 125 125 125
Tyfo 450 450 450 450 450 450 450 450
0
50
100
150
200
250
300
350
400
450
500
Aegion Product Matrix by Maximum Internal Operating Pressure
Questions?
THANK YOU! Geoffrey Burdick, PERegional Sales Manager
TM