Alliance Annual MeetingDecember 6th 2017HDPE 101 Performance Characteristics, Features and CasesPeter Dyke, Murray Sullivan

SPECIAL THANKS

Jimmy Dang, PE

SPECIAL THANKS

Murray Sullivan

Alliance Membership

LEAK-FREE CONVEYANCE

6

LEAK FREE SYSTEM

CORROSION RESISTANT

REDUCED MAINTENANCE

LONG SERVICE LIFE

TOUGH/DUCTILE/FLEXIBLE

Why Use HDPE?

SUPERIOR SEISMIC RESISTANCE

RECENT EARTHQUAKES: IMPLICATIONS FOR U.S. WATER UTILITIES (#4408, 2012)

JOHN EIDINGER G&E ENGINEERING SYSTEMS INC., OAKLAND, CA 94611

CRAIG A. DAVIS LOS ANGELES DEPARTMENT OF WATER & POWER

Water Research Foundation

WRF IS THE WORLD'S LARGEST AND MOST WELL-RESPECTED RESEARCHORGANIZATION DEVOTED TO DRINKING WATER RESEARCH …..….HELPSWATER UTILITIES, PUBLIC HEALTH AGENCIES AND OTHER PROFESSIONALORGANIZATIONS....

Concepcion, Chile 2010• History of quakes w/ significant damage

8.8 earthquake• 3000 pipelines severely damaged• Essbio began replacing pipelines in 2001

HDPE Pipes survived while other systems did not

• Water System: 1700 line breaks in 1700 km• CBD leveled, Extensive liquefaction • New HDPE lines did not fail. All nearby pipelines failed• 170 km PE gas lines all survived

FOUR 6.0 QUAKES IN 15 MONTHS 2010-11

CHRISTCHURCH, NZ

HDPE PIPES SURVIVED ALL 4 QUAKES

• Fault displacement up to 260 vertical feet (O’Rourke)• Shaking lasted 3 – 5 min w/ 10 – 25 cm, world axis shift• Most Pipe failures caused by pulled joints• 600 million times more

powerful than Hiroshima

9.0 EARTHQUAKE AND TSUNAMI

TOHUKU PREF, JAPAN

NO HDPE FAILURES

• THOUSANDS OF DEATHS

• BILLIONS IN DAMAGE

• SEVERE PIPE DAMAGE

Water Research FoundationCommon Denominators

NO reported HDPE failures

NAPA CA 2014

US SEISMIC PERFORMANCE

6.0 Earthquake caused 132 bell and spigot Breaks……Napa Sanitation had many miles of HDPE and NO HDPE failures

Napa does not use HDPE

THIRD PARTY VERIFICATIONCORNELL UNIVERSITY

• Dr. Thomas O’Rourke

Expert: - geotechnical engineering- earthquake engineering; - construction technology, - authored over 350 publications

IF IT WORKS IN A QUAKE………

SEISMIC FLEXIBILITY

4’ Shift

35’ PIPE

Large Scale Fault

Rupture Simulation

Four foot fault event

16” DR 11

SEISMIC FLEXIBILITY

The experimental evidence confirms… HDPEpipelines… accommodate severe deformationassociated with earthquake-induced groundrupture……Cornell Report

HIGH PERFORMANCE WATER PIPE

“SEISMICALLY RESISTANT”

HDPE IN THE NEWS

HDPE IN THE NEWS

HDPE IN THE NEWS

HDPE IN THE NEWS

Corporate Use

De Halve Maan: Enough beer to fill 12,000 bottlesan hour is flowing in a 2 mile HDPE beer mainunder the medieval streets of Bruges, Belgium

BEER MAIN

De Halve Maan: Enough beer to fill 12,000 bottlesan hour is flowing in a 2 mile HDPE beer mainunder the medieval streets of Bruges, Belgium

Fusion

CORROSION FREE

HIGH PERFORMANCE WATER PIPE

DIP w/ HDPE Wrap

Photo by Chuck Seal

Flexible

SURGE IS ADDITIVE

HDPE AND SURGE

670 psi up to 335 psi DR7

0

100

200

300

400

500

Pres

sure

(psi)

1.5 X

2.0 X

e.g. DR11

ENGINEER’S PACKAGE

Bead Removal

Situational

Bead Removal

Pipe Gets Hot

1. PE has Higher Coefficient of Thermal Expansion (ɑ) than other Piping Materials2. PE Has Lower Modulus of Elasticity than other Piping Materials3. PE Thermal Expansion ≈ 1 in/10°F/100 ft

Piping Material Coeff. Thermal

Exp/Cont, (α) in/in-oF

ElasticModulus

(E)psi

Stressσ=αEΔT

psi

Carbon Steel 6.1 x 10-6 29 x 106 177ΔTStainless Steel 9.1 x 10-6 28 x 106 255ΔTPolyethylene 80 X 10-6 0.065 x 106 5.2ΔT

Force to Required to Prevent Thermal Expansion?

• PE 4710 resin recognized from 4” to 65” for Potable Water use.

• Pipe and fittings are considered leak free

• Safety Factor Change

• Working pressures are recognized to 335 psi.

• Enhanced surge capability • 1.5 times pressure for regular surges and • 2 times pressure class for occasional surges

C906-15 an American National StandardC 906-15

AWWA C-901 Standard for ½” – 3” water serviceAWWA C-906 Standard for 4” – 65” water serviceAWWA M-55 Design and Installation of HDPE Pipe

Standards, Notes & GuidelinesAWWA

ASTM ASTM F714 Standard Spec for HDPE Pipe based on Outside DiameterASTM D3035 Standard Spec for HDPE Pipe based on Controlled Outside DiameterASTM F2620 Standard Practice for Heat Fusion (Butt Fusion) of HDPE PipeASTM D3350 Standard Spec for PE Plastic Pipe and Fittings MaterialsASTM F1055 Standard Spec for Electrofusion Type Polyethylene Fittings

PPI Handbook of Polyethylene Pipe, 626 pages, www.plasticpipe.orgPPI EF Manual 2015 <12”PPI TN-34 Guidellines for EF couplingsPPI TN-41 High Performance HDPE for Municipal WaterPPI TN-44 Long Term Resistance of HDPE to DisinfectantsPPI TN-49 Service Tubing GuidelinesPPI TN-54 Squeeze Off Guidelines

NSF

Plastic Pipe Institute

NSF/ANSI 61 Standard for Drinking Water Components – Health EffectsNSF/ANSI 14 Standard for Plastics Piping System Components and Related Material

PPI – plasticpipe.org

Handbook of Polyethylene Pipe Material PropertiesPipe and FittingsSpecs and TestingDesignUndergroundJoiningHDD, Lining, Bursting

Alliance for PE PipeResources

RT 132 Transmission Main Replacement

– Towns of Cambridge and White Creek NY

– Phase I - 5700’– Replacing 8” Steel with 12”

HDPE– Open Cut, Drilling– Butt Fusion, ElectroFusion

Trench Width Requirements

Nominal Pipe Size Trench Width<3" 12"

3 - 24" OD + 12">24" OD + 24"

e.g. 10” IPS needs

22” Trench

10 + 12 = 22” min(24” bucket typ.)

ASTM D2321

Greenlee Marker Balls – Spaced Every 20’ – 1’ Above Pipe

Nominal Pipe Size Max Particle Size2 - 4" 1/2"6 - 8" 3/4"

10 - 15" 1">= 16" 1.5"

e.g. 10” IPS permitsMax 1” particle size

ASTM D2321

HDPE Embedment Requirements

Embedment

Pipe Laying

Horizontal Directional Drilling• Controlled borepath horizontal drilling• Used for crossing rivers, lakes, roads, etc., and where open cut is

not feasible or cost effective• ASTM F 1962; PPI Handbook, 2nd Ed., Ch. 12• PPI BoreAid Software – www.plasticpipe.com

FixedPositionReelPipeCoil

PipeStraightener/Rerounder

DirectionalBoringMachine

Bore-Aid

Installation Loads• Bore path curvature generally controlled by drill rod• Pipe pulling load depends on

– friction between pipe and ground at entry– pipe to bore hole friction– weight of pipe / buoyancy (air vs. water filled)– frictional drag due to slurry

Under I-5

Sliplining

• Pull, push, or push/pull new PE into deteriorated main

• Pressure: insertion renewal• Non-pressure: sliplining

Sliplining

Gouges

Pipe Bursting Defined?The breaking of an existing pipe, expanding the broken pipe shards into the surrounding soil ………

while simultaneously pulling in the new HDPE line

Pipe Bursting Benefits

• Installs a new seamless pipe

• Ability to upsize• Eliminates up to 85% of excavation • Follows the path of the existing

utility

• Less disturbance to traffic patterns • Often more cost effective than

open trench replacement • Proven technology with 70,000,000

feet installed worldwide

Key Pipe Bursting Benefit

20% - 40% less costly

Depth of Cover• A minimum of 4 foot of cover

should be used when upsizing 1 size

• Greater cover should be used if upsizing more than one size

• Or, do the math yourself: Head is 3” larger in Dia. then add upsize inches

• Head + upsize = X

X * 10” = proper cover depth

Impact Zone Formula

• Head + upsize = X

X * 10” = proper cover depth

HOST

PRIMARY

80%

SECONDARY

e.g. 1 Upsize w/ 6” Host Pipe and 8” HDPE.

Head = 3” + 2” = 5” 5 x 10” = 50” vertical impact

Host Materials• Cast Iron• Clay tile• PVC

• Concrete• Reinforced

Concrete• Asbestos Cement

• Ductile Iron • Steel

IPBA Project Classification

Class Depth of Pipe

Existing Pipe

Diameter

New Pipe Diameter Options

Burst Length

Class A <12 ft 4” – 12”Size for Size to 1 upsize

0 – 350 ft

Class B >12 ft < 18 ft 12” – 20” 2 upsizes 350 – 450 ft

Class C > 18 ft 20” – 36” 3 or more upsizes > 450 ft

Upsizing

Soil Conditions

Pneumatic Bursting Job Site Layout

Pneumatic Burst

Bursting Setup – Push out rod

Attach Tooling/Pipe

Pull Back

Shuttle Rods

Equipment Selection

• High tonnage static pull back force

Ø 38 ton (2” – 6” pipe)Ø 58 ton (2” – 8” pipe)Ø 80 ton (3” – 12” pipe)Ø 100 ton (3” – 18” pipe)Ø 125 ton (4” – 20” pipe)Ø 175 ton (6” – 32” pipe)

Static Pipe Bursting Systems

• Ductile SlitterØDuctile ironØSteel

In the Field

Operational Video

Double Blade Set vs Cast Iron Valve