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Constructed in the late 1920s, the existing riveted joints and welded steel pipelines were becoming increasingly troublesome, springing numerous leaks at the weld seams, at the steel plates, and creating two major main breaks.
According to an annual report from the Springfield Water and Sewer Commission, the final straw for the steel pipelines came on May 20, 2010 when a significant leak was discovered in the north 36-inch diameter pipeline. Painters working on the nearby South End Bridge noticed a plume in the river, and divers were used to discover a 2- by 4-inch hole in the pipe.
A short-term fix was identified and implemented until full-scale repair work could begin on July 5, 2011.
To rejuvenate the pipeline, the Springfield Water and Sewer Commission turned to the flexibility and durability of high-density polyethylene (HDPE) pipe as the solution. Weather and logistics made the installation unique and challenging, but the reward of a leak-free system was worth the effort for the Commission; contractor P. Gioioso and Sons; lining subcontractor W. Walsh Company; and pipe supplier and fusion subcontractor VARI-TECH.
In the case of Springfield, typical slip line procedures were slightly altered. Often, the new lining pipeline would be fused together in a long length and pulled through the existing line using a horizontal directional drilling rig or other tooling. Because of the limited space along Connecticut River and a heavily traveled road near the site, constructing the pipelines in the full 1,300 foot length was impossible.
Instead, workers constructed an entry pit approximately 30 feet deep and 60 to 70 feet long for each pipeline with sheet pile supports and steel beams. These pits served as work areas that were large enough to house a pipe fusion machine and one stick of pipe. As needed, a 50-foot stick of 30-inch IPS DR 11 piping was maneuvered into place, with careful choreography by the crane operator and workers around the pit. Each stick was guided through the supporting structure of the pit, placed into the fusion machine and butt fused onto the longer length of pipe. On the other side of the river, equipment pulled the pipelines after each fusion joint to make room for the next stick of pipe.
Taking pipe fusion operations a step further, VARI-TECH’s director of engineering Bill Haines recommended a set-up called "piggybacking" that uses the cooling time of the fusion process as an advantage to prepare and perform a fusion joint on a second fusion machine. Only one technician is required to run both fusion machines. At the Springfield site, walking to the other fusion machine wasn’t that simple. Fusion technician Scott DesRosiers climbed up and down a series of ladders up to 21 times a day to complete fusion joints inside the two work pits.
Each pit was equipped with a TracStar® 900 fusion machine provided through VARI-TECH and the Certified McElroy Rental program. The TracStar 900 fuses pipes from 12-inch IPS to 36 inches OD. The tracked chassis of the fusion machine allowed DesRosiers to make slight adjustments under the pipeline to ensure fusion operations were performed to the highest standard. The mobility of the tracked fusion unit was critical as the pipe was pulled through the existing pipeline as each new length of pipe was added to the new pipeline.
“We were very satisfied with the pipe installation and fusing machine,” said Martin Lobik, project engineer for the Springfield Water and Sewer Commission. “The flexibility of the machine was critical.”
The project used Certified McElroy Rental machines that are billed as the industry’s most reliable fusion rentals. Certified McElroy Rental machines are checked after each rental and only use genuine McElroy parts for any repairs. All parts of the machine are checked, from top to bottom by factory-trained employees, to ensure rental fleets, like VARI-TECH’s, meet the customer's highest expectations.
With the high expectations for the future HDPE pipeline, several quality assurance tools were used to ensure that proper fusion procedures were followed. DesRosiers fused every joint with the help of McElroy DataLoggers®, which are used for recording and verifying fusion operations. The DataLogger consists of a rugged handheld computer that serves as a recording device. It is attached to a data collection device that records the heater temperature and fusion pressure profile over time. All data can be transferred to a desktop computer for archiving.
While fusion operations went smoothly, Mother Nature became the project’s biggest challenge. Hurricane Irene struck New England in late August, flooding the two entry pits and stopping work for some time. The excess water was pumped out and work restarted, unaffected by nature until an October Nor’easter dumped record amounts of snow on Massachusetts. The resulting thaw almost flooded the pits again, requiring all equipment to be removed until the pits were clear.
“The biggest challenge was the drastic changes in the Connecticut River’s water elevation,” said Lobik. “There were periods of inactivity due to the (water) topping of our sheet pipe supporting system.”
Despite the road blocks thrown their way by Mother Nature, the job is on target for a February 24th substantial completion date.
Sincerely,
Tyler Henning
P.S. – Do you have an interesting job site that you would like to share? McElroy is always looking for fusion job sites where HDPE is being used and fused to solve an infrastructure problem. Contact Tyler Henning, public relations specialist at (918) 831-9286 or by email at thenning@mcelroy.com
 Contractors that want a lightweight, but sturdy fusion option for 2-inch IPS through 8-inch DIPS (63mm to 225mm) fusion operations can turn to the DynaMc™ 28 Hand Pump (HP). The fusion machine comes in 2- and 4-jaw models, each with a sturdy and powerful electric facer that can be loaded from either side of the fusion machine. Designed to fit into the tightest of spaces, the DynaMc 28 HP has a detachable easy-lift cradle that can be removed for an even smaller footprint.The fusion machines use a double-action hand pump and high-velocity cylinders to create fast carriage speeds for opens and closes during the fusion process. A great rental option, the DynaMc 28 HP is available through your local McElroy distributor.
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Professionals in the underground construction market will descend on San Antonio on January 24th for the annual Underground Construction Technology International Conference and Exhibition. The three-day event offers engineers, contractors, manufacturers and utility owners an opportunity to meet and see the latest technologies in the industry.
McElroy will be located at Booth #240 and will have these new innovations on hand:
- Guided Side-Bend Tester
- In Field™ Tensile Tester
- Pit Bull® 26 fusion machine
- TracStar® 412 with Hydraulic Clamping retrofit
- Information on Certified McElroy Rentals
For more information, visit uctonline.com
For more than 30 years, McElroy has been the only pipe fusion machine manufacturer to offer advanced training. McElroy University's course offerings are designed to enhance your efficiency, productivity and safety in the proper use of McElroy equipment. The class schedule for 2012 is loaded with opportunities in February, March and April. The classes take place at McElroy's Technical Center in Tulsa, Oklahoma, and registration can be completed online in minutes. Here's a look at the courses available in the coming months:
Small Diameter Operator Qualification: February 6-8 - Mid-Range Operator Qualification: February 8-10
- Inspector Qualification: February 21-23
- TracStar Troubleshooting and Rebuild: March 6-9
- Large Diameter Troubleshooting and Rebuild: March 13-16
- Large Diameter Operator Qualification: March 26-30
- Small Diameter Troubleshooting and Rebuild: April 16-18
- Mid-Range Troubleshooting and Rebuild: April 18-20
A.H. McElroy's Ryan Ethier sends in these pictures from Delta, British Columbia, Canada where a large group of seagulls were supervising fusion operations. This McElroy TracStar® 618 was working on an expansion of a methane gas collection system.
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Thank you to Ryan and A.H. McElroy for these pictures.
If you have photos from a jobsite, we'd love to see them! Yours may be chosen for the next issue of McElroy Connections. Simply email your photos to Tyler Henning, at thenning@mcelroy.com.
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It's Time to Rethink Pipe Jan 20th |
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Here's a very interesting article about the use of horizontal directional drilling and #HDPE for geothermal loop systems.... Jan 9th |
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Great youtube video from http://www.pepipe.org. Why wouldn't you use #HDPE? Jan 9th |
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Great to see #HDPE being used for a water line at Cobbins Air Reserve Base! They chose HDPE for dependability and safety.... Jan 9th |
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Want to know more about #HDPE (polyethylene pipe) and why you should use it for water? Check out this video: http://ow.ly/8jjvS Jan 5th |
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Great to see Brownsville, Washington turning to #HDPE for a sewer replacement project! http://ow.ly/8ii5m Jan 4th |
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We recently visited a very interesting job site in Springfield, Mass., with two TracStar® 900s, two DataLoggers®, and an In Field™ Tensile Tester. The job required sliplining and two pits for the fusion work. How's that for getting down and dirty? Dec 20th |
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Great to see another community turn to #HDPE! http://ow.ly/84vBU Dec 19th |
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