the introduction to seismic resilient ductile iron pipe

Introduction to Seismic Resilient Ductile Iron Pipe Technology

Presenter: Todd Randell

Co-Authors:

Akira Yabuta Kurimoto Ltd, Japan

Norio Matsuki Pino & Co. NZ

This presentation will review

▪ Introduction

▪ Global review of large-scale disasters

▪ Pipeline performance during these disasters

▪ Seismic Resilient Ductile Iron Pipe (SRDIP) Technology▪ Range▪ Coatings & Linings▪ Standards

▪ Unique design features of SRDIP

▪ Evidence of the fault free performance of SRDIP in Japan

▪ USA Case Study –▪ Adoption of SRDIP in high-risk locations in the

United States of America

▪ A New Zealand Case Study

Introduction

▪Water Infrastructure pipelines are vulnerable assets

▪Water is fundamental to residential, commercial and industrial functions

▪Our communities will not function without water

▪ Traditional pipeline materials installed in NZ generally don’t survive severe Natural Disasters

▪At the time of the Christchurch sequence of events it was considered

“Nothing was earthquake proof”

Introduction

▪ In Japan, SRDIP pipe technology has survived many great earthquakes including:▪ The Great Hanshin-Awaji Earthquake Japan (17th January 1995)

▪ Well known internationally as the “KOBE Quake”

▪ The Great East-Japan Earthquake & Tsunami (11th March 2011)

▪ Northern Osaka Earthquake Japan (18th June 2018)

Introduction

▪ Global view of tectonic plates

▪ USA and NZ share the Pacific Plate Boundary known to us as

“The ring of fire”

…which also passes close by Japan’s coastline

Source; United States Geological Service – www.usgs.gov

Introduction

▪ Hundreds of active fault lines run the length of NZ

▪ Several Major faults run alongside the North Island Fault system including the Wairarapa and Wellington Faults

▪ The Marlborough fault system is quite fractured

▪ Scientists have been predicting a major earthquake within the next 40 years – likely produced by the Alpine Faultline

Source : https://en.wikipedia.org/wiki/North_Island_Fault_System

Review of “Great International Earthquakes”

Northridge California USA 17th January 1994

• 6.7 Mw event - The epicenter was located 40km north west of Los Angeles

• 57 Died

• Severe damage to:• 60 Transmission pipelines• 1100 Distribution pipes• 7 Water reservoirs• 160,000 homes and businesses were without water

• Repair costs of U.S $40m to repair the 1100 distribution pipes alone

• Nineteen years later …and following an in-depth scientific study on earthquake proofing LA’s high-risk locations authorities adopted SRDIP Technology


Kobe Quake Japan 17th January 1995

• 7.3 Mw event

• 6434 Died

• 43,792 Injured

• 250,000 building damaged. Many beyond repair

• Damage to waste and water pipelines included:a) 43km Raw Water Conduitsb) 260 kms Transmission Mainsc) 4000kms Distribution Mainsd) 650,000 Utility Service Pipeline Connections

▪ Although installed, there were ‘no reports’ of damage or leakage to SRDIP pipe systems

Source: Kobe earthquake DN700 SRDIP remains in service (leak free) after the Great Hanshi-Awaji quake. (Photo: Japan DI Pipe Assn (JDPA))


Kobe Quake Japan 17th January 1995

The type of pipeline failures included:

▪ Disconnected pipe joints (to unrestrained socket spigot pipes)

▪ Deformed and buckled Flexible Pipes

▪ Damage to seals

▪ Over compressed pipe-spigots into pipe-sockets

These failure modes are common to what NZ has experienced over the past 30 years


CONCLUSIONS made by the

Kobe Municipal Waterworks Bureau

• A reliable emergency water supply system was required

• Future pipeline systems must be:

• Easy to repair• Disaster resistant

• Mandatory specification of SRDIP technology adopted in construction of all critical assets

Japanese Water Pipe Market Breakdown by material

Type (2017) (Source: JDPA)

vSRDIP Market Share Development in Japanese DIP Market


The Great East-Japan Earthquake & Tsunami (11th March 2011)

• The event was:• The most powerful earthquake ever recorded in Japan• The fourth in the world

• 9.0 Mw event – The epicenter located off the North East Coast of Japan

• 1599 Died

• 6157 Injured

• 2529 people are still missing, considered dead

• Tsunami wave height reported to be 40m high

• All near by Port Cities and villages were destroyed

• Traditional unrestrained waste and water pipelines were “washed out” and/or damaged

• There were ‘no reports’ of damage to SRDIPvSRDIP “Type NS” restrained Ductile Iron pipe water pipeline

remains operational following the Great East-Japan

Earthquake 2011 (Photos: JDPA)


Northern Osaka Earthquake 18th June 2018

▪ 6.1 Mw event – The epicenter was located at Takatsuki area of North Osaka

▪ 4 died

▪ Hundreds were injured

▪ Traditional unrestrained waste and water pipelines were dis-connected and/or damaged

▪ A crucial twin DN1200 welded rigid Steel transmission pipeline burst

▪ There were ‘no reports’ of damage to SRDIPSource; Twin Mild Steel Transmission pipelines (2 x DN1200) damaged following the 6.1Mw Osaka earthquake of 2018 (Photo: Kurimoto Ltd, Japan)

Seismic Resilient Ductile Iron Pipe

Background

▪ This technology was first developed in the mid 1970’s

▪Evidence shows it has survived many large-scale natural disasters since 1975

▪ Including surviving earthquakes up to 9.0Mw


Where SRDIP is best installed

▪ Near Fault lines

▪ Liquefiable ground

▪ Tsunami prone locations

▪ Artificially deformed areas such as road embankments

▪ Pipelines servicing critical water supply points such as▪ Hospitals, civil-defense head quarters, shelters, public facilities

▪ Fire fighting or hydrant water supply

▪ Difficult to repair pipelines

▪ Bridge-mounted pipelines


Diameter & Range

▪DN100 - 450▪ Joint Type NS

▪DN500 - 1000▪ Type NS – Mechanical Joint

▪DN1100 – 2600▪ Type UF – Mechanical Joint

▪ Fittings▪ These are mainly a mechanical Type NS/UF


Manufacturing Standard

▪Ductile Iron Pipes JIS G 5526

▪Ductile Iron Fittings JIS G 5527

▪Epoxy Powder Coating

(Fusion Bonded Epoxy or FBE)

for interior of Ductile Iron Pipe and Fittings JIS G 5528


Unique Design Features

▪Expansion and contraction

▪Angular deflection 6-8 degrees – during an event



▪Slip out resistant technology

▪ Joint separation prevention▪ Force = 3 x DN(kN)

▪ Worked example: DN300 = 900kN

▪Pipeline expansion during an event ▪ = ±1% of pipeline (L)

Expansion range Contraction range



▪Chain-link-structure

Source; Examples of chain-link-structure using compressed chain-links and extended chain-links (Photo: T Randell - Hynds)

Compressed Chain

Extended Chain

DIP Chain-link-structure Animation & Video

Self Healing Corrosion Protection Coating


▪ External Coating replaces the need to fit PE Sleeve

▪ Design Conditions Apply – Refer to the guidelines provided within AWWA C105 – 10 Polyethylene encasement for Ductile Iron Pipe systems”

Synthetic Resin

Sealing Primer 23

Zinc Metal Spray1

Layer Coating process Material & coating

thickness

1 Zinc Metal Spray Zn alloy (Al-Si-Mn)

Not less than 220 g/m2

2 Sealing Primer Silica compound sealing

agent

Not less than 50 g/m2

3 Synthetic resin Synthetic resin

Not less than 80 μm

1

2

3

Source: Porirua Branch Pipeline Extension near Wellington NZ. Photo: (V. Cham - Hynds)


▪ Internal lining Fusion Bonded Epoxy (FBE) Powder

(Oven baked)Thickness = >0.3mm

▪ Lower internal surface friction than when compared to cement mortar lining▪ Hazen-Williams’ C = 130▪ Mannings’ n = 0.010 All references made are for clean water applications

▪ FBE has similar friction values as PE & PVC Pipes

Unique Design Features Internal Coating

Internal Coating Test Traditional Grey Cast or

Ductile Iron (unlined) pipe

Seismic Resilient Ductile Iron

Pipe

Internal coating Mortal lining Epoxy powder coating

Corrosion

Resistance

Average Excellent

Water quality Average

・Raised pH value

・Reduced residual chlorine

Excellent

・Keep pH value

・Keep residual chlorine

Lower surface

section

Average

・4～10 mm

Excellent

・0.3 mm

・10～20 % higher than Mortar

lining

Red Water



Internal Coating

▪Corrosion protectionSalt spray test in accordance with JIS Z 2371 “Methods of salt spray testing ” that was published based on ISO 9227 is performed.

[Kurimoto’s special coating]①Zn alloy (Al-Si-Mn) : 130 g/m2

②Sealing treatment

[Traditional coating]①Zn spray : 130 g/m2

15 Days Later350 Days LaterCorrosionNo corrosion


Expected Asset Life

State over 100-year life before any major rehabilitation or maintenance

Internal

Lining

External

Coating

SRDIP

OVER

100 years+ =Ductile Iron

Thickness +


▪ Some thrust preventing methods are required due to thrust forces at fittings (bends, tees and valves) in pipeline.

Tee

Reducer

Valve & Cap

Thrust block construction is time and cost consuming

Bend

In the case of Traditional DIP



▪ Total “Anchor-block-free” pipeline technology

1. Applied force due to water pressure

2. In-Trench/Soil friction resistance created by force applied

q

qf

f

A

A

PP1

P2M

θ2

2P2

δ1 δ

δ2

LP

LP

θ

θ

Thrust force and resistance force acting on a bend part (Source: JDPA)

1

2

2




DI LinerRubber

Pipes socket interface with Bend

Spigot must be fixed by inserting

“liner = rubber”

Fittings are

permanently fixed.

Sockets on fittings are fixed they can not move or deflect DI Liner & Rubber for

centering liner




Result:

= Quicker construction time

v

Flow chart of calculating integrated length (Source: JDPA)


Pipe Product Range

▪ DN75 – DN2600

▪ 3 Pipe Joint Types▪ Type NS

– DN75 to 450▪ Type NS Mechanical

– DN500 to 1000▪ Type S Mechanical

– DN1100 to 2600

▪ All SRDIP fittings are mechanical jointed – full range available

Rubber gasket

Rubber for centring lock ring

Lock ring

Joint structure of Type NS pipe joint (DN75~450) (Source: JDPA)

Gland T-bolt and nut

Rubber gasketBackup ringLock ring

Joint structure of Type NS pipe joint (DN500~1000) (Source: JDPA)

Bolt and nutGrand

Split ringRubber gasket

Lock ring

Backup ring

Joint structure of Type S pipe joint (DN1100~2600) (Source: JDPA)

1

2

3

1

2

3


USA Case Study & Research

▪ About a decade ago Los Angeles Power & Water Dept earthquake engineers began studying SRDIP and its performance dating back to the 1995 Kobe quake

▪ LAPWD’s study could not uncover any reported failures

▪ They chose to complete a series of pilot installations which began in October 2014

▪ Since 2014 the use of SRDIP technology has increased

▪ For high risk locations it has become normal to install this pipe technology

Source: Installation at Northridge California (near the public Hospital. Photo: Los Angeles Times)


NZ Case Study – Porirua Branch Pipeline Extension Kurimoto SRDIPAir valve

With PE Sleeves

Start of SRDIP

End of SRDIP

Source: Wellington Water Ltd

Without PE Sleeves

Source: Pipe installation at Porirua. Photo: by A. Yabuta Kurimoto Ltd Japan

Source: Pipe installation at Porirua. Photo:mage by A. Yabuta Kurimoto Ltd Japan


NZ Case Study – Porirua Branch Pipeline Extension Kurimoto SRDIP

1. No Thrust Blocks installed

2. No PE Sleeves fitted

Source: Installation of SRDIP bend at Porirua (NZ) Branch Pipeline extension. (Photo: A Yabuta. Kurimoto Ltd, Japan)

Past Lessons Learned

John Black once stated….:▪ Seismic events break the weak links ▪ Brittle pipes perform poorly▪ DI pipes with Traditional RRJ - acceptable performance▪ Areas of large PGD need special attention▪ Avoid lateral spread areas▪ Design for flexibility and fixability

▪ “The adoption of SRDIP pipe technology in Japan has proven this is a failure free system during some of the worlds largest natural disasters”

Today’s Lessons Learned

▪ Earthquake proof pipelines do exist▪ Installed in Japan since the 1970’s

▪ Installed in USA since 2013

▪ Installed in NZ in 2019

▪ “The adoption of SRDIP pipe technology internationally has provided hard evidence that it is a failure free pipeline technology that can be trusted”.

Conclusions

▪ Resilience is one of the most critical requirements for the success of societies today

▪ No reported failures of SRDIP installed in the past 45 years

▪ Less physical resourcing due to “anchor-block-free” and PE-sleeve-Free” design features

▪ Can provide NZ water pipeline industry sustainably and long-life asset management

▪ Overall contribution to safety and wellbeing of citizens in the event of natural disasters

▪ Potable water still available after a catastrophic event

▪ No reports have been made of damage or leakage to any SRDIP joint

▪ SRDIP technology could be considered-to-be the only “Earthquake Proof” pipeline technology available - internationally.

Acknowledgements

▪ The team at - Wellington Water Ltd▪ John Duggan, Gary Cullen, James Craig & Laurence Edwards

▪ G.P. Friel Ltd – Wellington▪ Gerry Friel & Ray Dunn

▪ Kurimoto Ltd, Japan▪ Takao Yamanaka▪ Akira Yabuta – Co-Author▪ Yasuhiro Kawashima

▪ Pino & Co. New Zealand▪ Norio Matsuki – Co-Author

QUESTIONS

Thank You

the introduction to seismic resilient ductile iron pipe

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