Mainline Pipe Rehabilitation Using Cured-in-Place Pipe (CIPP) & Folded Pipe Technology

Transcription

1 2007 Pumper & Cleaner Environmental Expo International Wednesday February 7, 2007 Mainline Pipe Rehabilitation Using Cured-in-Place Pipe (CIPP) & Folded Pipe Technology

2 What is Cured-In-Place Pipe (CIPP) A resin saturated fabric liner that is installed into a deteriorated pipeline and then cured using Heat, Ambient or Ultra Violet Light WITHOUT EXCAVATION

3 What is Folded Pipe (FP) A factory manufactured pipe that is folded for easy delivery in coils then reheated and installed into an existing pipeline WITHOUT EXCACATION

4 Where Can CIPP or Folded Pipe Be Used? Municipal sewers, laterals, water mains and drainage pipes, outfall pipes, force mains, etc Industrial, sewer,water, drainage, gas mains, process pipes, downspouts, air vents Highway & railroad culverts Other piping systems

5 Pipeline Solutions With CIPP Structural renewal Structural reinforcement Infiltration reduction Inflow reduction of.. M.H. M.H. Lining Lateral pipe lining Sectional Lining Sizes 4-120

6 Pipeline Solutions With Folded Pipe Structural renewal Structural reinforcement Infiltration reduction Inflow reduction of.. M.H. M.H. Lining Sizes 4-24

7 Typical CIPP Liner Materials Resins Polyester Vinyl Ester Epoxy Materials Liner Fabric Fiberglass Carbon Fiber Kevlar Installation Coatings Urethane Polyethylene PVC

8 The Cured CIPP Product The typical product consists of either a polyester fabric, fiberglass or combination liner saturated with either a polyester, vinylester or epoxy thermoset resin. The product can be cured using hot water, steam, ultra-violet light or ambient temperatures

9 Typical CIPP Thermoset Resins Polyester Most common for typical sewer applications Vinyl ester Industrial or special waste applications Higher corrosion resistance Pressure applications Epoxy Industrial & potable water applications Pressure applications Higher temperature applications Epoxy Vinyl Ester Polyester

10 Polyester Fabric Liner Preparation A felt liner is fabricated of polyester needled, woven or knit fabric and coated with an impervious film such as polyethylene, polyurethane or PVC. Just prior to installation, the fabric liner is saturated with a heat activated resin using a vacuum impregnation process. All excess resin is removed by pulling the liner through a specially designed set of rollers. The saturated liner can be stored in a refrigerated truck for several days until installation into the host pipe.

11 Polyester Fabric Resin Impregnation A Vacuum is created on the custom manufactured liner to remove air and to ensure thorough resin distribution Resin, with dye, is pumped into the liner and displaces the evacuated air saturating the inside of the liner

12 Fiberglass Liner Preparation Fiberglass Liners are manufactured several ways: 1. A liner is fabricated of a specially designed fiberglass material and encased in impervious film such as polyethylene, polyurethane or PVC. The fiberglass liner is saturated with either a heat activated or UV Light activated resin. All excess resin is removed by pulling the liner through a specially designed set of rollers 2. UV Light activated resin is saturated into the raw fiberglass material then spirally wound into a round tube. No vacuum impregnation is required 3. UV Light activated resin fiberglass liners typically have an extended shelf life of up to six (6) months without refrigeration

13 Typical Folded Pipe Materials Folded Pipe material are thermoplastic in nature. The material can typically be re-heated several times to accommodate installation into an existing pipeline Materials include: High Density Polyethylene (HDPE) Modified Polyvinyl Chloride (PVC) Type #1 Polyvinyl Chloride (PVC) Type #2

14 Folded Pipe (HDPE) Typically manufactured in a U shape 4 4 to 24 and in some cases larger Coiled on large vertical drums References ASTM F-F 1533, ASTM F-1606F

15 Folded Pipe (PVC) Type #1 PVC Based Products Type #1 Reference ASTM F-F 1504 & F-1947F 4 to 15 diameters

16 Folded Pipe (PVC) Type #2 PVC Based Products Type #2 Reference ASTM F-F 1871 & F-1867F 4 to 24 and larger

17 Cured-In-Place Pipe (CIPP) & Folded Pipe (FP) Typical Project Execution

18 CIPP & Folded Pipe Technology Requirements The liner materials must be designed and selected for the specific application (sewer, water, industrial, etc) The installer must be experienced in the technology (minimum number of installations, years of experience, etc)) Installation technique and equipment specific to the technology and curing technique applied (equipment should be integral part of technology) The Installed product must be tested and certified to meet the specification requirements

19 Pre-Project Data Collection Document size, length and condition of line(s) (using PACP standards) Document pipe material(s) Document size change(s) within a line section Verify line and grade of pipe Identify necessary pipe repairs to be done before liner installation Identify all infiltration into the pipe and repair major leaks or install a pre-liner Determine peak flow volumes in pipe Determine traffic maintenance requirements Identify all service connections as active or inactive

20 Lateral Connection Identification Quantity to be reinstated Locations to be documented Abandoned services identified

21 Pre-Installation Considerations Equipment staging area is required at or near access manhole The existing pipe must be pretelevised and surveyed to determine its condition Some excavation may be required for larger diameter liners or for point repairs All existing flows in the pipe must be plugged or by-passed The existing pipe must be cleaned to remove ALL debris, silt, roots, sand, etc

22 Heat Cured CIPP Liner Installation The resin impregnated tube is either inverted, using air or water pressure or pulled into the old pipe through the existing access or manhole structure

23 CIPP Curing with Hot Water Once in place and properly inflated the liner is cured using hot water heat. Cure temperatures are monitored at access points and at each end of the installation Boiler Truck Circulation Pump

24 CIPP Curing With Steam Once in place and properly inflated the liner is cured using steam heat. Cure temperatures are monitored at access points and at each end of the installation

25 U V Light Cured Liner Installation A fiberglass liner is pulled into the host pipe. A light train & CCTV is inserted in one end and pulled to the opposite end recording the pre-cure condition of the liner. The light train is then pulled back through the inside of the liner, at a regulated speed, with the CCTV camera recording the actual curing of the liner.

26 CIPP Curing With Ultra-Violet Light Once in place and inflated the liner is cured using ultra Violet Light. Infrared sensors record the entire liner cure

27 Folded Pipe Liner Installation Folded pipe is pulled into the existing pipe The pipe is then heated and unfolded to fit tightly within the existing pipe Steam is typically used to process to liner

28 Folded Pipe Processing With Steam Folded Pipes are typically re-heated, to various degrees, to accommodate installation requirements Steam and pressure are typically used to expand and process the pipe to fit tight within the existing pipe

29 Manhole Termination Existing Pipe Pipe Seal New CIPP Pipe A seal can be installed between the newly installed liner and the existing pipe to prevent groundwater migration into the manhole. Seals can be either hydrophilic or grout

30 Installed CIPP or Folded Pipe The installed pipe should be free of wrinkles or other defects that will prevent the proper operation of the pipeline The installed pipe should have the projected longevity as specified

31 Lateral Re-Connection Identify lateral connection dimples from CCTV inspection and/or preliner installation measurement Cut opening each live lateral connection Leave each abandoned connection closed as directed by the customer Lateral Connection Dimple

32 Post Installation Documentation The specified design requirements must be verified after the liner has been installed and cured in the field The thickness of the liner is measured The physical properties of the installed material are tested The chemical resistance verified The water tightness is verified The physical appearance is recorded

33 CIPP ASTM Standards ASTM F1216 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube ASTM F1743 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by Pulled in-place Installation of Cured-in-Place Thermosetting Resin Pipe (CIPP) ASTM D Standard Specification for Cured-In-Place Thermosetting Resin Sewer Piping Systems ASTM F2019 Standard Practice for the Rehabilitation of Existing Pipelines and Conduits by the Pulled in Place installation of Glass Reinforced Plastic (GRP) Cured-In-Place Thermosetting Resin Pipe (CIPP)

34 Folded Pipe ASTM Standards HDPE Based Products ASTM F-1533 F & ASTM F-1606F PVC Based Products Type #1 ASTM F-1504 F & ASTM F-1947F PVC Based Products Type #2 ASTM F-1871 F & ASTM F-1867F

35 Why Use CIPP or Folded Pipe Technology? Typically no excavation required No disruption of adjacent utilities or surface pavement Installed through existing manholes Lengths over several thousand feet can be installed in a continuous joint-less section Can be installed in a variety of pipe crosssections Flow characteristics are typically improved and future maintenance is reduced Lateral pipes are reconnected robotically

36 Why Use CIPP or Folded Pipe Technology? Designed for specific applications Many years of successful installations Significantly lower in cost than traditional excavation and replacement Long design life when properly installed and tested Fast installations Minimal social impact Unique Installations

37 Conclusion Trenchless Pipe RenewalTechnologies are not magic but are tools that need to be properly utilized. Projects must be evaluated, good engineering practice applied and the correct technologies selected to achieve the desired end result

38 Any Questions Contact Gerhard Gerry P. Muenchmeyer, P.E. Director of Engineering & Operations Reline America, Inc Saltville, VA Irv Gemora Executive Director NASSCO Web

39 Credits & Disclaimer Material contained in this Presentation has been obtained and compiled from various related industry manufacturers, contractors, engineers, installers and end users. All parties involved acknowledge the need to disseminate relevant information to promote (trenchless technology) product advantages and rehabilitation techniques for the benefit of all concerned. This slide presentation shows products and systems made by specific companies. This is not intended as an endorsement of these products and systems or to imply that there are not other products and systems which perform the same functions.