Session 1 - Hawaii Water Environment Association

hwea.org

Session 1 - Hawaii Water Environment Association

HWEA – Collection Sy

ystems Conference

Hawai Hawai‘i i Pacific University Hal lekou Lift Station and Force

Main Project: j A Project j Case e Study y Involving g HDD and

Fusible PVC

November 1 13 th 13 , 2009

David Bills, PE –Bil Bil lls Engineering Inc.

Rob Craw – Undergro ound Solutions, Inc.


Project Overview

• HPU has been on Private WWTP sinc ce campus inception

• Master Planned Growth, the age of thhe

WWTP and growing environmental

concerns associated with the operattion

and maintenance of a POTW

mandated change.

• The proposed change was a connecttion

to the City and County of

Honolulu Wastewater Collection Sys stem 5,000 5 000 linear feet way way. The hurdle

was the intervening Conservation lannds,

City and County lands, private

property and a federal highway.

• There were 3 major elements to the pproject:

– Permitting

– Design g

– Construction

2


Permitting

• Conservation District Use Permit from m DLNR

• Subdivision Application for easemennt

acquisition for portion(s) of sewer

on City property

• Easement acquisition for portion of ssewer

crossing under private lands

• Use and Occupancy Agreement with State DOT for portion of sewer under

H-3 Freeway (Halekou Interchange) aand

freeway access roads

3


Force Main Alignment Overview

Halekou

Pump Station

State, County and

Private Lands

Interstate H-3

Project Alignment

HPU Campus

(Conservation Lands)

Pali Golf Course

(City Lands)

HPU Pump

Station

4


Design

• 44,000 000 linear feet of Force Main

• Duplex Wet Well Mounted Pump Stattion

(Gorman Rupp) with engine

driven (LPG) back-up back up power

5


Fusible PVC TM Products are Segmented

900 ® , Fusible CC-905

905 ® 900 , usbe C 905 and a d FPVC C

Sizes

Pipe Type (Nominal

OD)

DIPS or

IPS or

Schedule

F ibl C 900 ® Fusible C-900 4” 12” DIPS

® 4” – 12” DIPS

Fusible C-905 ® 14” – 36” DIPS

FPVC TM 4” – 36”

* Not all diameters are extruded to all listed DR’s.

D Dimension

Ra atios (DR)

D DR 14, 14 18, 18

DIPS, IPS, 221,

25, 26,

or 322.5,

41, 51*

Schedule annd

d SSch.40, h 40

Sch.80

into Three Product Lines: Fusible CC-

D DR 14, 14 18, 18 Potable Water

25 AWWA C900

D DR 14, 14 18, 18 Potable Water

211,

25, 32.5,

41, 51* AWWA C905

Uses Color

Non Non-Potable Potable

Water or Potable

Water

Applications pp not

in C900/C905

Dimensions

Bl Blue

Blue

Blue, Purple,

Green, White,

Grey

®

7


The Underground Solutions ® PVC Fusio on Process: Utilizes Industry Standard

Fusion Equipment q p

Internal and External Bead Removal is Optional – frriction

losses are negligible (‘C’-factor of 150) and

are significantly less than mechanically joined pipe (i.e. for 8” DR18 with 1000gpm in a length of 1000LF,

fl flow l loss i is 00.173 173 gpm and d a hhead d l loss of f 00.013 013 ft) aand

d pipe i tensile t il strength t th i is not t iimpaired i d

(extra material in bead)

®

8


Fusible C-900 C 900 ® , Fusible CC-905

905 ® And

d FPVC: Fusion Process Is

Tightly Controlled

• Qualified fusion technicians are train ned and

retrained every year by Undergroundd

Solutions

– Initial 3 day course

• Fusion equipment must meet minimum

company

standards to be approved for PVC fuusion

• DData t loggers l record d critical iti l fusion f i d

ata t

for each joint

– Provide real time feedback on jooint

integrity

– Provide record of entire project for f proof of

system integrity

• Fusion conditions logged by techniccian

and “as-

built” fusion joint record is develope ed for owner as

necessary

Fusion Date

Project Name

Jobsite Location

Project Engineer

Fusion Technician

Joint No.

20004

Nov. 29, 2007

Project No.

Myrtle Beach 20" Force Main Diversion

Myrtle Beach, SC

Pull No.

Eric Kerner

Eric Kerner

Piston

Area (in 2 EQUIPMENT IDENTIFICATION

Heat Plate Serial ID

)

15.32

C09247

30111

Pipe Dia. (in) Pipe DR

PIPE DETAILS

Color Extruder

Pipe Description

20 DR 25 Green

NAPCO FPVC

Fusion Machine Identification

T-900

Data Logger Serial

No.

MDL3-0241

IR Pyrometer

Serial No.

21462810604-1172

A. Pressures (psi) B. Ambient Conditions / Start Time

Heat

131

Temp. (°F)

57

Fusion

564

Weather

sunny

Drag 50

Start Time

10:52 AM

End Time 11:29 AM

C. Heating Plate Temperature & Extrusion Marking

Left Face Temperature - °F Right Face Temperature - °F

412 410

12:00

402 9:00

3:00 403

402 9:00

3:00 395

6:00

399

Joint Number

20004

12:00

15 Sept 07 @ 11:23 12 Nov 07 @ 17:47

188

Record extruder pipe marking (near fusion joint) and pipe length above.

Pivot

235

6:00

399

®

9


Fusible PVC TM is the Most Tested PVC P Pipe in the Industry with Four Levels

of o oof Quality Qua ty Co Control t o to to Help ep Ensure su e Flawle a e ess Installations sta at o s

Test Vendor

Qualification

Fusion Tensile ASTM D638

Pipe Tensile ASTM D638

Pipe Dimensions Per AWWA

Per AWWA

C900/C905 C900/C905

Pipe Burst Per AWWA C900 Per AWWA C900

Flattening Per AWWA

C900/C905

Required VVendor

UGSI Lot

Testing

Acceptance

Testing

Per AWWA

C900/C905

AAcetone t IImmersion i ASTM D2152 ASTM D215

52 ASTM D2152

Hydrostatic

Pressure Test

Per AWWA

C900/C905

Per AWWA

C900/C905

Impact Test ASTM D2241;

ASTM D22441;

ASTM D2444 ASTM D244

44

Heat Reversion ASTM F1057 ASTM F10557

ASTM F1057

Ash/Inert Content

(LOI)

Joint Fusion

Parameters

Licensed Operator

ASTM D2584 ASTM D25884

Per UGSI RRequest

Note: Bold highlights indicate required AWWA tests

Per AWWA

C900/C905

Fusion Joint QC

Data

Temperature

Pressure, Location,

Other

Unique Operator ID

®

10


Fusible PVC pipe uses industry s standard couplings and fittings

for reconnection to existing system ms

Connecting to Fittings

Mechanical Joint Pressure Fittings:

Non-Pressure, Gravity Fittings:

Connecting to Pipe

Same Piping Size:

Different Piping Size:

Pictures from various manufacturers of fittings: JCM, Smith BBlair,

EBAA Iron, Romac Industries, Royal Trends Pipe

Systems, and Inserta Tee®.

®

11


PVC vs. HDPE

HDD / Direct Bury

HPU – Halekou Seewer

Force Main

• Originally designed with HDPE –

5,000’

• HDD - 2 sections of 14” casing annd

10” carrier

• Fusible PVC evaluated to originnal

HDPE

consideration

• It was determined the Fusible PVCC

provided

the lowest overall installed price

®

12


Required Force Main

HDD / Direct Bury

HPU – Halekouu

Sewer Force Main

• Approximately 5,000’ 5 000’ of Pipe Re

quired

• HDD # 1 – 2,200’ 12” casing and

pipe

• HDD # 2 – 620’ 12” casing and 8”

carrier pipe, both Fusible PVC

pipe

• Open Cut Section – 8” Fusible PPVC

pipe

8” carrier pipe, both Fusible PVC

®

13


Force Main Alignment Overview

Lift Station

HDD # 1 – H3 Hwwy

Crossing

HDD # 2 -

Kamehameha Hwy

CCrossing i

Existing Treatment

Facility (abandoned)

Fusion and

Laydown Area

14


HDD # 1 – Crossing H3

• 12” DR 18 FPVC Casing pipe

• 8” DR 14 FPVC Carrier pipe

• Fusion layout and staging occurred iin

the golf course area along

Kamehameha Hwy ROW

• 12” 12 casing installed followed by 8” 8

• Pull Stats – 12” casing peaked at 34,0000

lbs of pull back force required

compared p to safe pull p force of 80,300 , 0 lbs. for 12” pipe pp

15


HDD # 1 – Halekou Force Main, HI

2,200 LF HHDD

H-3 Crossinng

®

16


HDD #1 – Halekou Force Main, HI

12” Casing Pipe

Horizontal Directional

Drill undeer

H-3 and

Utiliities

8” Carrier Pipe

®

17


HDD # 2 – Crossing Kamehameha

• 8” DR 18 FPVC Carrier pipe

• Fusion layout and staging occurred oon

HPU property

• 12” casing installed followed by 8”

Hwy

• Pull Stats - 12” casing peaked at 27,0000

lbs of pull back force required

compared to safe pull force of 80,330 80 330 0 lbs lbs. for 12 12” pipe

18


HDD # 2 – Halekou Force Main, HI

620 LF HDD

8” FPVC

Kamehameha Hwy

CCrossing i

®

19


HDD #2 – Halekou Force Main, HI

12” 12 Casing Pipe

Horizontal Directional

Drill under

Kamehameha Hwy

8” Carrier Pipe

®

20


Open Cut – Halekou Force Main, H HI

1500 LF Open Cut

8” FPVC

Existing Treatment

Facility (abandoned)

®

21


Open Cut – Profile - Halekou Force

e Main, HI

End of HDD # 2 under

Kamehameha Hwy

8” FPVC Pipe

Lift Station and

Abandoned

Treatment Facility

®

22


Project Sequence

23


HWEA – Collection Sy

ystems Conference

Hawaii Pacific University Hal ekou Lift Station and Force

Main Project: j A Project j Case e Study y Involving g HDD and

Fusible PVC

November 1 13 th 13 , 2009

David Bills, PE –Bil Bil ls Engineering, Inc.

Rob Craw – Undergro ound Solutions, Inc.

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