Flow restored and repairs averted on a critical water main
Problem: A critical 2-mile raw water main in De Soto, Kansas, was experiencing reduced flow, leading to water shortages. The 16-inch ductile iron pipeline, installed in the 1940s, was the city’s primary water source. Population growth and ongoing development increased the demands for water. The objectives for American Pipeline Solutions (APS) and Blue Water Solutions Group were to improve the flow rates and conduct a condition assessment of the raw water main.
Solution: To remove sediment and debris that had reduced the effective diameter of the pipe from 16 inches to 12 inches, pigs in different sizes and densities were launched into the pipeline and propelled by water pressure. When there wasn’t enough water pressure to propel the pig effectively during the day, the team quickly adapted by switching operations to nighttime hours. Following this, APS conducted a pipeline condition and integrity assessment using i2i’s SmartFoam Pig. Equipped with eddy current sensor technology, the smart pig assessed the pipe’s internal conditions, including corrosion, geometry and wall thickness.
Result: Flow rates and operating pressures were restored to satisfactory levels, ensuring that the city could meet the demands. Data from the smart pig’s condition assessment confirmed the pipeline was in overall good condition, with no leaks and minimal levels of corrosion and debris. The pipeline was deemed to have decades of remaining service life, negating the need for immediate rehabilitation or costly repairs.
201-525-0088; www.americanpipelinesolutions.com
Underground camera system now includes machine learning analytics
Problem: TREKK Design Group operates from 11 offices in Missouri, Kansas, Nebraska, Arkansas and Tennessee, employing 227 professionals on public and private sector water resources, civil and transportation projects. TREKK needed machine learning-capable analytics software to power its Waterspout data collection and delivery system that collects data from its PreView underground storm and sanitary sewer pipe viewing technology.
Solution: Some members of the TREKK team were already familiar with infinitii ai flowworks from previous jobs. It’s renowned for its ability to easily accept varying internal and public data inputs and outputs, from underground camera images tied to sensor data, to satellite weather data inputs from far overhead. After a successful project to integrate infinitii flowworks with TREKK PreView, Waterspout powered by infinitii ai has been rolled out to 11 TREKK clients that include municipalities and other engineering services companies.
Result: “With machine learning capability, it’s no longer ‘out of site, out of mind,’” says TREKK President Trent Robinett. “We can pinpoint and avoid problems without having to send crews into sometimes dangerous environments. This new way of doing things completely replaces the old way of delivering a PDF report of a site inspection that might have been done a month ago and isn’t relevant anymore. We’re excited by the ability to help clients operate based on live data that can include predictive analytics – what could happen versus what did happen.”
778-379-0275; www.infinitii.ai
High-build lining allows rapid emergency repair of splitter box
Problem: Positioned early in the wastewater treatment process, splitter boxes are subject to significant abrasive force and exposure to highly corrosive influent. At the Lake City (Florida) Wastewater Treatment Plant, a splitter box’s prior coal tar epoxy lining system failed, resulting in widespread pitting of the underlying steel. An immediate repair was necessary, and plant managers sought to minimize the impact of any potential disruptions that would result.
Solution: Plant managers chose the spray application of Carboline’s Hydroplate 6500. Hydroplate 6500 is a premium-grade, ultra-durable epoxy lining suited for use on both concrete and steel surfaces in aggressive, hydrogen-sulfide-rich municipal and industrial wastewater environments. Two features were crucial to this project: First, its rapid-cure formula minimized the length of time plant operators needed to partially shut down the splitter box. Second, it achieves film builds as high as 250 mils on a single pass at comparatively low pump pressures — around 3,000 psi, and often less than that. The result is a significant reduction in fatigue of spray applicators, leading to overall faster and higher quality work for time-sensitive projects.
Result: Only short partial shutdowns of the splitter box were necessary. With no full shutdown, there were no disruptions to wastewater treatment.
800-848-4645; www.carboline.com
Three construction firms join forces to deploy large pipe plug at theme park
Problem: Universal Studios is developing Universal Epic Universe, a new theme park in Orlando, set to open in 2025. The project faced a significant challenge: replacing 18 underground chiller line valves in the parking lot. This complex task involved three specialized companies: Comprehensive Energy Services for mechanical contracting, National Trench Safety for trench and traffic safety equipment, and GPH Services for site development and underwater installations. The valves, buried 18-25 feet deep, required excavation near a major drainage pipe, demanding innovative solutions for water flow management and safety. NTS provided the necessary equipment to block the storm drain, CES handled the valve servicing, and GPH, subcontracted by CES, managed the underwater aspects of the installation, ensuring the project’s success despite the challenging conditions.
Solution: NTS acquired a 72- to 120-inch Cherne I-Series Test Ball Plug for a project and rented it to Comprehensive Energy Services, who hired GPH Services for its installation due to their diving expertise. GPH ensured the plug’s correct placement, vital for CES’s repair work. This plug, notable for its size and made from 100% natural rubber, is designed for durability and conformity to pipe surfaces, making it ideal for underwater use. GPH’s preparation included extensive testing and cleaning of the pipe to prevent damage. The installation, conducted by a diver in zero visibility, emphasized safety, using a five-point harness and backup air supplies, with constant team communication. The plug remained installed for four months, successfully providing the necessary access for repairs.
Result: Cody Crawford, vice president of operations for GPH Services, praised the plug’s performance, saying, “The plug worked great, just like any other Cherne plug. Its performance was exceptional, and it met all our expectations.” Similarly, Tim Kelce, an account manager for National Trench Safety, expressed excitement about a significant project, saying, “I’m installing the largest plug in the world, and that’s a pretty big deal.” The project, notable for its use of premium materials and strict safety measures, set a new standard for future large-scale engineering projects.
800-843-7584; www.cherneind.com
CIPP solution stops groundwater leaks at dam
Problem: The Barkley Dam Power Plant in Grand Rivers, Kentucky, faced a serious issue when groundwater began leaking into the powerhouse tunnel through eight rigid steel conduits. These conduits had been installed by an electrical contractor, but the steel couplings became compromised, allowing water to seep into the conduits and the tunnel. This posed a significant risk to the power plant’s operations, requiring an immediate and effective solution to stop further water intrusion. The conduits in question were extremely narrow, with diameters ranging from only 1 to 2 inches. This small size made accessing and lining the pipes extremely challenging. Additionally, the conduits were located 350 feet from the tunnel entrance, complicating access and debris removal during cleaning.
Solution: To resolve the issue, NuFlow Services utilized NuDrain CIPP technology, which involved lining the conduits to create a watertight barrier. The conduits were first cleaned using high-pressure air abrasive blasting with a silica carbide aggregate. Evacuating the debris posed a challenge due to the 350-foot distance from the tunnel entrance, but a 2-inch suction hose was used to successfully remove the debris. Once the cleaning was complete, eight NuDrain liners were consecutively installed within the leaking conduits. To successfully rehabilitate the pipes, the application and curing pressures exceeded 100 psi, ensuring a durable, watertight seal despite the challenging pipe configuration.
Result: All conduit lines were fully lined, and the tunnel wall was sealed effectively, addressing both the initial groundwater intrusion and the unexpected tunnel wall leak. The electrical contractor was highly satisfied with the innovative and swift solution provided by NuFlow Services. The final inspection by the U.S. Army Corps of Engineers confirmed the repair met all standards, with no wrinkling in the conduit bends and minimal loss of internal diameter, ensuring the cables had sufficient space to pass through.
866-430-2134; www.nuflow.com
Lining system allows for swift and silent sewer rehab
Problem: The wastewater pipes under an apartment complex in Hollywood, Florida, had to be repaired. The challenge was that there was only one access point available for the 68-foot section.
Solution: Pipelining Technologies rehabilitated the wastewater pipes in the building using BRAWO SYSTEMS equipment, installing BRAWOLINER using the BRAWO Magnavity SX light-curing system. The wastewater pipes to be rehabilitated were first thoroughly cleaned to ensure optimum adhesion of the liner. Then the liner was inverted into the pipe through the single access point. The liner was cured using special lighting technology that ensured that the liner cured quickly and evenly within 60 minutes.
Result: The rehabilitated wastewater pipe could be put back into operation quickly. Using only one access point and not having to carry out any demolition work, the tenants and residents of the apartment complex were hardly disturbed. There was no construction site noise to speak of.
240-796-5007; www.brawosystems-usa.com
Lift station retrofit into existing footprint
Problem: Santa Barbara County needed a wastewater lift station retrofit to effectively replace an existing lift station. A nearby restaurant sewer flowed into this station, creating difficult water conditions with the potential for grease and other suspended solids. The site was small and could not be excavated without becoming prohibitively expensive. The lift station retrofit needed to handle medium flows of municipal sewer from two inlet lines and make use of limited site space without a huge excavation plan.
Solution: The low head conditions were met with 2 hp BJM submersible shredder pumps in a duplex configuration. These pumps were needed to handle difficult water conditions from the nearby restaurant. Pump maintenance and accessibility were improved through the addition of a Thern Commander 1000 crane to lift the 150-pound pumps from the well. This is useful for dealing with clogs in the pumps or other service needs. The retrofit utilized a fiberglass insert to install directly into the existing well. This prevented site excavation where there was limited space and difficult dewatering requirements. In addition, the fiberglass acted as a new coating, providing an extra level of protection for the existing structure. A separate valve vault comprises check valves, shut-off valves and an accessible pumping port for emergency bypass pumping. Romtec Utilities also provided the retrofit control panel for this system with a tie-in for a mobile generator.
Result: Romtec Utilities met these requirements and developed a retrofit specification while keeping the project on budget, completing the project with limited space, difficult water conditions and dewatering requirements. This all allowed the retrofit lift station to work seamlessly.
541-496-9678; www.romtecutilities.com
Asset management and maintenance play vital role in water treatment protocol
Problem: Located in Vermont, Champlain Water District is nationally recognized for excellence in drinking water treatment. It operates as a wholesale water supplier of water to 12 municipal water systems located in eight communities covering approximately 70 square miles, accounting for approximately 24,000 connections with 75,000 customers. Over the past few years, proactive asset management and maintenance has become a cornerstone to management and maintenance of key assets in the treatment and distribution system.
Solution: USG Water Solutions was charged with restoring CWD’s 15 water tanks to like-new condition and maintaining them over the long term. Its success encouraged the district to explore using asset management for other parts of its water treatment system, and today, USG is also responsible for asset management and maintenance covering the three adsorption clarifiers and eight filters that are critical components in CWD’s water treatment system.
Result: Regarding the CWD’s experience with asset management and maintenance programs, Joe Duncan, P.E., general manager of CWD, noted, “We strongly recommend looking at this model. Putting aside money for future repairs doesn’t always work as the money that’s been put away might be diverted to other needs. I believe this model has extreme value, because you know that once you’re in the program, maintenance and repairs will move forward.”
855-526-4413; www.usgwater.com
Epoxy resin used to rehab large corroded pipes
Problem: The San José-Santa Clara Regional Wastewater Facility had 1,800-plus feet of massive 120- and 102-inch-diameter pipes with severe crown corrosion. Several areas had extensive concrete spalling with exposed rebar. An assessment estimated the remaining service life of the pipe between 0 and 12 years. A high priority was given to coating the pipes to lengthen their life span.
Solution: As part of the WTP Yard Piping Improvements Phase 2 project, Michels Pipeline patched badly deteriorated spots with cementitious geopolymer material, followed by coating the pipes with Neopoxy high-strength corrosion-resistant NPR-5303 Epoxy Resin. The project owner decided to line only the top 200 degrees of the pipe due to the more serious corrosion in that area. The Michels crew applied epoxy at a thickness of 150-250 mils using plural component spray equipment.
Result: The project was completed successfully. The coating successfully passed spark and pull testing. Several of the pull test results were over 1,500 psi (project specs required 250 psi minimum), with a clean concrete break rather than a separation of the coating and substrate. The pipes were back in service within a few days. Through the application of the Neopoxy NPR-5303, the life span of the large-diameter pipe was extended by approximately 50 years.
510-782-1290; www.neopoxy.com
PVC liner the choice for city’s sanitary sewer rehabilitation
Problem: Murrysville, Pennsylvania, was facing the deterioration of its 50-year-old terra-cotta sewer pipes, causing sanitary overflows during rain events. With joints every 4 feet, these pipes were prone to blockages and failure points, taxing the wastewater treatment plant. The Franklin Township Municipal Sanitary Authority needed a solution to prevent inflow and infiltration. Complicating matters, the project required working through a forested area, making conventional trenching methods impractical.
Solution: The municipality selected IPEX’s NovaForm PVC liner, a trenchless, expand-in-place solution that repairs pipes without the need for excavation. Unlike CIPP methods, NovaForm does not rely on chemical curing or styrene, making it environmentally friendly. The product offers a joint-free, durable liner that can handle various pipe materials, including terra-cotta and asbestos cement, and install depths of up to 30 feet. It also allows fast installation, with up to 800 feet of pipe relined per day.
Result: NovaForm was installed quickly with minimal disruption, eliminating the need to dig and preserving the forested area. The project provided immediate results, reducing system strain and preventing overflows. Murrysville has used NovaForm multiple times, with public works officials praising its efficiency and durability.
800-463-9572; www.ipexamerica.com
