23
For inspection purposes only. Consent of copyright owner required for any other use. EPA Export 22-06-2016:01:37:43
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
1
Smartply Europe
Firewater Retention Pond
Testing and Repair CQA Report
6th April 2016
Smartply Europe
Belview Slieverue Co. Kilkenny
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
2
Issue, Revision and Control
Revision Date Originator Checker Approver Status
0 06/06/16 C Byrne L Griffin Issued
This document is issued for the party which commissioned it and for specific purposes connected with the titled project only. It should not be relied upon by any other party or used for any other purpose. We accept no responsibility for the consequences of this document being relied upon by any other party, or being used for any other purpose, or containing any error or omission which is due to an error or omission in data supplied to us by other parties. This document contains confidential information and proprietary intellectual property. It should not be shown to other parties without consent from us and from the party which commissioned it.
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
3
Table of Contents 1. Introduction .......................................................................................................................................... 4
1.1 Scope of Project ............................................................................................................................ 4
2. Welding and Testing ............................................................................................................................. 4
2.1. Air Pressure Testing ...................................................................................................................... 4
2.2 Vacuum Box Testing ...................................................................................................................... 5
2.3 Repairs .......................................................................................................................................... 5
2.4 HVET Spark Testing ....................................................................................................................... 6
3. Installation Records .............................................................................................................................. 7
3.1 Air Testing Records ....................................................................................................................... 7
3.2 Extrusion Test Summary ............................................................................................................... 9
3.3 Trial Weld Summary .................................................................................................................... 11
3.4 Destructive Test Summary .......................................................................................................... 12
4. As-built Panel Placement Drawing ...................................................................................................... 13
5. Photographic Records ......................................................................................................................... 14
Appendix A - Tensiometer Calibration Certificate ..................................................................................... 22
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
4
1. Introduction
1.1 Scope of Project
Lining Tech (LT) were engaged by Smartly Europe to carryout testing and remediation works to
the existing geomembrane lined firewater retention pond at Belview, Co. Kilkenny. The existing
2.5mm HDPE pond lining system was installed in 1996. It was suspected that there may be a leak
in the exiting lining system. It was decided to empty the firewater retention pond during an
operational shutdown period to enable the lining system to be tested to identify any defects.
Cleaning works to remove sludge from the base of the pond were required to be carried out
prior to testing of the lining system. The testing works included re-testing of existing wedge
welded seams via air pressure testing, vacuum box testing of existing extrusion welds and
vacuum box testing of wedge weld seams where no air channel was found. Any defects
identified were repaired prior to conducting a final overall HVET spark test of the entire pond
lining surface to test for any defects in the liner material and welds. The testing and repair works
were commenced on 22/03/16 and were completed on 25/03/16.
2. Welding and Testing
2.1. Air Pressure Testing
All fusion welds were tested by air pressure testing. The fusion seams consist of a dual track
weld of the overlapped liner panels, with a small air channel present between each of the
welds. To test the fusion welds, the air channel was blocked off at either end of the seam by
grinding off the top layer of liner over the air channel at the block location and extrusion
welding a bead over the channel to create a blockage. When the extrusion weld block cooled
sufficiently, an air pressure testing needle is inserted into the air channel. The air testing kit
comprised of a test needle, an air pressure gauge, a shut off valve and a pump. The seams were
pumped up to between 200-240kpa, the valve closed off and the air pressure allowed to
settle. The reading on the air pressure gauge was recorded noted. The seams were required to
maintain the air pressure in the channel for 5 minutes, with the pressure loss after 5 minutes
not exceeding 15kPa.
On satisfactory passing of the test, the pressure in the air channel was then released at the
opposite end to where the measurement has taken place to check that the entire length of
the air channel has been subjected to pressure test. On seams where there was no obvious loss
of pressurised air when the opposite end was released, this indicated a blockage in the air
channel. The length of seam can be if necessary split into two with a block welded midway along
the seam to try identify the location of the blockage. If the air channel is found to be block
continuously along the seam, the top flap of the weld in question was trimmed off and vacuum
box testing of the overlapped seam carried out to identify any defects in the weld.
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
5
2.2 Vacuum Box Testing
Existing and new extrusion welds were tested using a vacuum box. To Vacuum Box test an
extrusion weld, an adequate amount of soapy water was used to cover the test area. The
vacuum box was placed down over the centre of the weld, ensuring there are no points where
air can enter the test area. The vacuum motor was then turned on to create a negative pressure
over the weld. The vacuum pressure should be chosen according to the material thickness. A
vacuum of minimum 35kPa was pulled into the box. The geomembrane was examined for 10 to
15 seconds. The weld is deemed to have passed this test if no air bubbles form along the weld
during the test. The presence of air bubbles indicates a defect in the weld.
2.3 Repairs Failed Air Tests
During the air pressure testing of the fusion welded seams a number of issues were identified. In
some cases the welded seams could not hold an air pressure test. The defective areas of the
welds were identified and repaired locally by extrusion welding. The seam on either side of the
localised repairs were then tested via air pressure testing.
Seam With No Air Channel
During the air pressure testing it was found that a significant proportion of the seams did not
contain a free air channel from one end of the seam to the other. The dual track welds breached
across the air channel to create a one solid weld. This is generally as a result of an issue with the
feather on a fusion wedge welder. In cases like this, the top flap on the welded seam was
trimmed off and the weld from the top sheet to the bottom sheet tested via vacuum box
testing.
Holes in the Liner
One hole at elevated location on panel P22. A localised build up of water under the liner on the
floor directly below this defect was noted also. This water should dissipate naturally and will
have no affect on the integrity of the HDPE lining system. This were repaired by extrusion
welding a patch over the area with the hole. A destructive sample was also taken from the base
of the pond and was repaired by patching. Two small pin holes were also visually identified.
These were repaired by extrusion welding a bead over the pin holes.
Patch Over Old Outlet Pipe
The old outlet pipe at low level in the lagoon was not required any longer. The PVC pipe was
cut back flush with the concrete pad surrounding the pipe. A patch of protection geotextile
was placed over the concrete and pipe prior to welding a patch over the entire concrete area
to fully seal the HDPE liner at the outlet.
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
6
Large Rocks Beneath HDPE liner at Panel 25
A number of large rocks were discovered under the HDPE liner at panel 25. It is though the
blinding beneath the liner may have washed away over time to leave these rocks. The HDPE
liner was still intact in this area. The HDPE liner was cut and the rocks removed by hand where
possible. A patch of geotextile was placed in position and the entire area was patched over
with HDPE liner.
2.4 HVET Spark Testing
On completion of air and vacuum box testing and the repair of any defects identified, a full HVET
(High Voltage Electromagnetic Insulation Testing) spark test was carried out over the entire
pond liner area. Electrodes were installed below and above the liner, producing a potential
difference for carrying out the test. The equipment was earthed outside the anchor trench
during the testing and the lagoon was divided into a grid for testing. Testing was carried out by
moving the testing probe over the geomembrane liner in a controlled grid approx 25mm above
the liner, ensuring that the geomembrane liner was at all times in contact with the underlying
soil. A decrease in the electrical resistance results in a spark being generated when a defect in
the lining system is traversed. Any defective areas are be marked up and repaired by extrusion
welding patch repairs.
A HVET spark testing of the entire area of the FWR pond was carried out on 25/03/16. We can
confirm that no further defects were identified. The pond lining system is deemed to be intact
and operating effectively.
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
7
3. Installation Records
3.1 Air Testing Records
Liner Installation Air Test Summary
Project Name Smartply FWR Pond Material 2.5mm HDPE
Project Nr 15128
TEL: 051 307021 EMAIL: [email protected] WEB: www.liningtech.ie
Date Seam
Ref
Start
Time
Start
Pressure
End
Time
End
Pressure
Pass /
Fail
Test
By
Reason For Non-
conformance
22/03/16 P16/P17 9.40 2.5 9.45 2.5 P JM
22/03/16 P12/P11 11.37 2.5 11.42 2.5 P JM
22/03/16 P12/P13 11.25 2.6 11.30 2.6 P JM
22/03/16 P17/P18 N/A 0 N/A 0 F JM Hole found in seam
22/03/16 P23/P24 2.10 2.8 2.15 2.6 P JM
22/03/16 P24/P25 2.20 2.8 2.25 2.8 P JM
22/03/16 P25/P1 2.20 2.8 2.25 2.6 P JM
22/03/16 P2/P23 N/A 0 N/A 0 F JM No air channel in
seam
22/03/16 P3/P27 3.15 2.6 3.20 2.5 P JM
22/03/16 P2/P27 3.01 3.0 3.06 2.9 P JM
22/03/16 P4/P27 N/A 0 N/A 0 F JM No air channel in
seam
22/03/16 P4/P5 N/A 0 N/A 0 F JM Hole found in seam
22/03/16 P4/P6 4.47 2.6 4.52 2.6 P JM
22/03/16 P6/P7 5.15 3.0 5.20 3.0 P JM
22/03/16 P2/P3 5.21 3.1 5.26 3.1 P JM
23/03/16 P2/P3B N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P3/P4B 8.4 2.8 8.45 2.8 P JM
23/03/16 P4/P5 N/A 0 N/A 0 F JM Hole found in seam
23/03/16 P5/P6 8.55 3.1 9.00 3.1 P JM
23/03/16 P1/P2B 9.10 2.7 9.15 2.7 P JM
23/03/16 P4/P5B 9.25 3.0 9.3 3.0 P JM
23/03/16 P27/P23 N/A 0 N/A 0 F JM No air channel in
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
8
seam
23/03/16 P23/P22 N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P22/P27A 11.06 2.6 11.11 2.6 P JM
23/03/16 P22/P27B 11.20 2.6 11.25 2.6 P JM
23/03/16 P21/P28 N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P21/P22 N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P21/P29 N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P21/P20 N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P20/P30 N/A 0 N/A 0 F JM No air channel in
seam
23/03/16 P19/P30 1.40 3.0 1.45 3.0 P JM
23/03/16 P19/P15 3.06 2.6 3.11 2.6 P JM
23/03/16 P19/P16 3.09 3.0 3.14 3.0 P JM
23/03/16 P14/P31 3.35 2.5 3.40 2.5 P JM
23/03/16 P14/P15 3.45 0 3.50 0 F JM Seam Fail
23/03/16 P31/P13 4.00 2.6 4.15 2.5 P JM
23/03/16 P14/P13 4.05 2.5 4.10 2.4 P JM
23/03/16 P13/P11 4.20 2.6 4.25 2.6 P JM
23/03/16 P31/P32 N/A 0 N/A 0 F JM No air channel in
seam
25/03/16 P10/P29B N/A 0 N/A 0 F JM No air channel in
seam
25/03/16 P29/P30B N/A 0 N/A 0 F JM No air channel in
seam
25/03/16 P10/P9B N/A 0 N/A 0 F JM No air channel in
seam
25/03/16 P29/P28B N/A 0 N/A 0 F JM No air channel in
seam
25/03/16 P9/P29 N/A 0 N/A 0 F JM No air channel in
seam
25/03/16 P9/P8 N/A 0 N/A 0 F JM No air channel in
seam
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
9
3.2 Extrusion Test Summary
Liner Extrusion Test Summary
Project Name Smartply FWR Pond Material 2.5mm HDPE
Project Nr 15128
TEL: 051 307021 EMAIL: [email protected] WEB: www.liningtech.ie
Date Seam
Ref
Extrusion
Temp Preheat
Vac
Test
Spark
Test
Pass /
Fail
Test
By
Reason For Non-
conformance
22/03/16 P2/P23 230 240 YES P JM
22/03/16 P4/P27 230 240 YES P JM
22/03/16 P4/P5 230 240 YES P JM
22/03/16 P17/P18 230 240 YES P JM
23/03/16 P4/P5 230 240 YES P JM
23/03/16 P2/P3B 230 240 YES P JM
23/03/16 P27/P23 230 240 YES P JM
23/03/16 P23/P22 230 240 YES P JM
23/03/16 P21/P28 230 240 YES P JM
23/03/16 DS1 230 240 YES P JM
23/03/16 P21/P22 230 240 YES P JM
23/03/16 P21/P29 230 240 YES P JM
23/03/16 P21/P20 230 240 YES P JM
23/03/16 P20/P30 230 240 YES P JM
23/03/16 Inlet Pipe 230 240 YES P JM
23/03/16 Patches
11&12 230 240 YES P JM
23/03/16 P15/P16 230 240 YES P JM
23/03/16 P16/P18 230 240 YES P JM
23/03/16 P31/P32 230 240 YES P JM
23/03/16 P14/P15 230 240 YES P JM
24/03/16 P26/P11 230 240 YES P JM
24/03/16 P26/P10 230 240 YES P JM
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
10
24/03/16 P10/P9 230 240 YES P JM
24/03/16 P9/P8 230 240 YES P JM
24/03/16 P8/P7 230 240 YES P JM
24/03/16 P7/P27 230 240 YES P JM
24/03/16 P8/P27 230 240 YES P JM
24/03/16 P8/P28 230 240 YES P JM
24/03/16 P9/P28 230 240 YES P JM
24/03/16 P9/P29 230 240 YES P JM
24/03/16 P10/P29 230 240 YES P JM
24/03/16 P10/P30 230 240 YES P JM
24/03/16 P26/P30 230 240 YES P JM
24/03/16 P26/P32 230 240 YES P JM
24/03/16 P26/P11 230 240 YES P JM
24/03/16 P32/P30 230 240 YES P JM
24/03/16 P31/P30 230 240 YES P JM
24/03/16 P30/P29 230 240 YES P JM
24/03/16 P29/P28 230 240 YES P JM
24/03/16 P28/P27 230 240 YES P JM
24/03/16 Patches
1-10 230 240 YES P JM
24/03/16 Patches
13-15 230 240 YES P JM
24/03/16 5 Beads 230 240 YES P JM
24/03/16
Patch
over old
outlet
pipe
230 240 YES P JM
25/03/16 P10/P29B 230 240 YES P JM
25/03/16 P29/P30B 230 240 YES P JM
25/03/16 P10/P9B 230 240 YES P JM
25/03/16 P29/P28B 230 240 YES P JM
25/03/16 P9/P28 230 240 YES P JM
25/03/16 P9/P8 230 240 YES P JM
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
11
3.3 Trial Weld Summary
Liner Installation Trial Weld Summary
Project Name Smartply FWR Pond Material 2.5mm HDPE
Project Nr 15128
TEL: 051 307021 EMAIL: [email protected] WEB: www.liningtech.ie
Date Time Machine
Nr Welding
Tech
Wedge/
Extrudate
Temp °C
Speed/
Preheat
°C
Ambient
Temp °C Wind
(s/l/m)
Nr
Peel
Test
Nr
Shear
Test
Trial
Seam
Accept.
22/03/16 9.00 LTE8 JP 230 240 9 L 5 0 JM
23/03/16 8.30 LTE8 JP 230 240 12 L 5 0 JM
24/03/16 12.30 LTE8 JP 230 240 10 M 5 0 JM
25/03/16 12.40 LTE8 JP 230 240 12 L 5 0 JM
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
12
3.4 Destructive Test Summary
Liner Installation Destructive Test Summary
Project Name Smartply Material 2.5mm HDPE
Project Nr 15128 Tensiometer Nr.
TEL: 051 307021 EMAIL: [email protected] WEB: www.liningtech.ie
DS Nr
Seam Ref
Temp
Speed/ Temp
Machine ID
Date of Test
Units Peel Test
Peel Test Shear
Tab Nr A B DS1 P28/P21 N/A N/A N/A 23/03/16 1 764 824
2 929 940 No air channel in seam
3
4 5 P/F P P
1
2 3
4
5
P/F
1
2
3
4
5
P/F
1
2
3
4
5
P/F 1 2 3 4 5 P/F
MINIMUM TENSIOMETER VALUES Newtons/25.4mm wide sample (one inch)
Thickness of Membrane 0.5mm 0.75mm 1.0mm 1.5mm 2.0mm 2.5mm
HDPE Shear Strength 178 267 356 534 712 890 Peel strength (Fusion) 133 200 267 400 534 667 Peel Strength (Extrusion) 116 174 231 347 463 578
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
13
4. As-built Panel Placement Drawing
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
14
5. Photographic Records
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
15
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
16
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
17
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
18
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
19
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
20
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
21
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
Smartply FWR Pond Testing and Repair CQA
22
Appendix A - Tensiometer Calibration Certificate
For
insp
ectio
n pur
pose
s only
.
Conse
nt of
copy
right
owne
r req
uired
for a
ny ot
her u
se.
EPA Export 22-06-2016:01:37:43
