distribution maintenance & repair techniques to avoid ......• system shutdown –boil orders...
TRANSCRIPT
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Distribution Maintenance &
Repair Techniques to Avoid
System Shutdown
Line Tapping ● Line Stopping ●Valve
Insertion
Presented by: Fred Haines
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• Fire hydrants without auxiliary valves
• Broken valves that need to be replaced
• Sections of your system that can not be isolated
• Old water main that needs to be replaced
• Repairs that require system shutdown
to complete
System O&M Challenges…
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• A shut-off valve is
broken or, worse
yet, does not
exist?
The Problem…
• A hydrant repair
becomes hydrant
replacement?
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Turn off the water supply and suffer the consequences later!!!
Old Technique…
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• System pressure drops
• Large portion of the community without water
• Possibility of boil orders due to contamination
• Loss of fire protection
• Loss of water revenue
• Possible EPA involvement
Eliminate Health & Safety Risk with a Line Stop or Valve Insertion
Impacts & Challenges of Shut Down…
Community Impact
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– Difficulty locating underground or under-
pavement valves
– Determining whether all valves work
– Unsafe working environment
– Purge Air and Flushing
– Overtime / Comp time issues
– Cleaning plugged meters
Eliminate Health & Safety Risk with a Line Stop or Valve Insertion
Impacts & Challenges of Shut Down…
Work Challenges
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• Larger pipe sizes, greater water
pressure and greater volume of water
• More demands on your time, smaller
staffing
• Age of pipe, valves, and hydrants
• Attitudes of society have changed –
impatient. Social media “blitz”.
Why Change Now?
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• New regulations – more stringent
water quality standards
• Regulation enforcement
• Water conservation
• Operator safety
• Budget Considerations
Why Change Now?
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Project Constants:
➢ Excavation
➢ Material (valve, hydrant,
etc.) labor,
Inherent to any process, no
matter how you handle
your shutdown problem.
The True Cost to Shut Down…
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➢ Time to read the maps…if
they are correct
➢ Locate and turn valves
➢Break a valve
➢ Advertise the shutdown
➢ Overtime
➢ Loss of fire protection
➢ Increased liability
➢ Backflow problems
The True Cost to Shut Down…
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➢ Compliance with rules and regulations
➢Issuing of boil orders
➢Sampling
➢Lab costs
➢Additional notification
➢Media fallout
➢Re-chlorinization and de-chlorinization
➢ Loss of treated water
➢Gallons lost draining
➢Gallons lost purging➢ Loss of water revenue
The True Cost to Shut Down…
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Line Stopping
Never shutdown…
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Use a line-stop/insert valve system…instead of
shutting down
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Required – Line tapping machine (typical below)
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Side Tapping (illustrated)
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• Establishes a connection
to an existing pipeline
• Utilizes a valve, fitting,
and sealed tapping
machine to cut a hole
into pipeline without loss
of pressure or contents
• Available sizes: 4″
through 20″
• Also known as hot
tapping
Line Tapping Explained…
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Traditional Tapping Methods
Traditional tapping methods provides a means for
coupon retention which allows for inspection,
evaluation and verification.
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Line Stopping Machine (illustrated)
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• Developed over 50 years
ago; introduced to water
industry in 1980
• Utilizes the line tapping
process with the addition
of flow stopping
• Temporarily stops flow to
allow repairs or
maintenance without
disrupting service
Line Stopping Process Overview
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Line Stopping Animation
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• Effectively used in:
– Rural water systems
– Public and private utilities
– Gas distribution systems
– Industrial systems
• Used by 1000’s of
municipalities: Domestic and
International
Line Stopping
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➢ Commonly used when:
➢ Inserting, changing or
repairing valves
➢ Adding, changing or
repairing hydrants
➢ Tying in new lines or
services
➢ Performing repairs
➢ Changing large meters or
backflow preventers
➢ Abandoning, cutting or
capping lines
Line Stopping
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Example: Hydrant Valve Installation
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Example: Hydrant Valve Installation
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Example: 6” Tuberculated Pipe 80psi
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Line Stopping with Bypass
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Example of Line Stopping Heads
A Line-Stop Head
– Flexible rubber stopper easily handles moderate pressures, tuberculated lines
– Provides 95-100% flow stoppage at the point of repair
– Available from 4″ to 12″
– Good for pressures up to 100 PSI (7 bar)
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Example of Line Stopping Heads
Bullet Head
– Ideal for use with higher pressure systems, bypass lines
– Available from 4″ to 20″
– Good for pressures up to 250 PSI (17 bar)
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Line Stopping Heads
Pivoting Head
– Used for larger size mains, higher pressures
– Used primarily to 12” line size
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Example of Line Stopping Heads
Folding Head
– Ideal for large diameter cast iron, ductile iron, steel, and concrete pipes with average pressure (under 150 PSI)
– Enables smaller diameter tap to be performed
– Diameters to 60” are readily available through specialized line stop contractors
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An Example of Line Stop Fittings
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Line Stop Fittings – typical Bill of Material
Line Stop Fitting
Test and Working Pressures: 375 psi test
pressure max. 250 psi working pressure.
Stainless Steel Construction: Offers improved
corrosion resistance and durability.
Made in the USA – May be required to comply
with AIS and Buy American Project Requirements
NSF 61 and NSF 372 Classified - NSF/ANSI
Standard 61 and NSF/ANSI Standard 372 to meet
the regulatory requirements for the U.S. and
Canada assuring safe use in drinking water
systems.
Factory Pressure Test – Recommended
pressure tested and serialized for traceability
before leaving manufacturing facility.
Line Stop Fitting
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• Designed to achieve workable shutdown.
• Provides 95-100% stop at point of repair
• No service interruptions
• No loss of fire protection
• Reduced labor costs – less overtime, fewer man-hours
to complete
• Contamination and backflow eliminated
• Reduced loss of treated water and associated water
revenue
• Safer working conditions
Benefits of Line Stopping
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Insertion Valve (illustrated)
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Insertion Valve Installation Animation
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Insertion Valve Bill of Materials
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Operating Nut:
Steel, Cast
Standard Black
indicates open left
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Operating Nut:
Steel, Cast
Optional Red indicates
open right
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Bonnet Hardware:
304 Stainless SteelDomestic 304 Stainless Steel
Option available
Body Mounting Hardware:
304 Stainless SteelDomestic 304 Stainless Steel
Option available
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Valve Bonnet:
Standard Epoxy
Coated Carbon Steel
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Valve Bonnet:
Optional 304 Stainless Steel
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Valve Body:
304 Stainless Steel
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Completion Plug Pins:SAE GRADE 8 STEEL, ZINC COATED Completion Pin Plugs:
SAE GRADE 8 STEEL, ZINC COATED
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Upper and Lower Body
Sealing Gaskets:
BUNA-N Rubber
Body Armor Shields:
16 gauge
304 Stainless Steel
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Completion Plug O-ring:
BUNA-N RubberFlange O-Ring:
BUNA-N Rubber
Not Pictured:
Valve Stem O-Ring
BUNA-N Rubber
Quad O-ring
Seals
Valve Bonnet O-Ring:
BUNA-N Rubber
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Cartridge Wipe Seal:
EDPM
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Valve Cartridge
Wipe Seal
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6” IV 250 Patriot
Resilient Wedge
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Exploded 6” Resilient Wedge Seat
Rubber
Layers
Mesh
Layers
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Resilient Wedge
Front View
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Cross section of resilient wedge.
Rubber
Mesh
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Resilient Wedge BEFORE compression
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Resilient Wedge DURING
compression
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Resilient Wedge AFTER compression
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Completion Plug:
Reinforced
Composite Polymer
Stem Collar:
No Lead Brass
Conforms to NSF 372
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Heavy Duty Valve Stem:
304 Stainless Steel
4”-8” valves - 1.5” Diameter
10” & 12” valves – 2”
Diameter
Valve Stem O-ring:
BUNA-N Rubber
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Insertion Valve Basic Specifications
Insertion Valve
Cut-away
Test and Working Pressures: 375 psi test
pressure max. 250 psi working pressure.
Stainless Steel Construction: Offers improved
corrosion resistance and durability.
Made in the USA – May be required to comply
with AIS and Buy American Project Requirements
NSF 61 and NSF 372 Classified - NSF/ANSI
Standard 61 and NSF/ANSI Standard 372 to meet
the regulatory requirements for the U.S. and
Canada assuring safe use in drinking water
systems.
Factory Pressure Test – Recommended
pressure tested and serialized for traceability
before leaving manufacturing facility.
![Page 59: Distribution Maintenance & Repair Techniques to Avoid ......• System Shutdown –Boil orders –Complicated planning –Loss of fire protection –Large street excavation and street](https://reader035.vdocument.in/reader035/viewer/2022081620/610980ba74057e6c0b1c4f5e/html5/thumbnails/59.jpg)
IV 250 – Sealing Surface
IV 250 valve cartridge
designed to seal on
engineered sealing
surface within the valve
body.
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IV 250 – Resilient Wedge Seal
Resilient wedge
seal
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• Insertion Valves
– Constant flow
– System control
– Immediate results
– In place working
valve
– Value added options
– Safe working
conditions
– Water conservation
• System Shutdown
– Boil orders
– Complicated planning
– Loss of fire protection
– Large street excavation and
street patches (5’x5’)
– Working in unsafe
trenching and knee-high
mud
– Reaming the pipe wall or
completely severing the
pipe
– Need for heavy equipment
on-site
Insertion Valve versus System Shutdown
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16” Insertion Valve An Inside Look
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16” Insertion Valve An Inside Look
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Open Position Closed Position
16” Insertion Valve An Inside Look
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16” Insertion Valve An Inside Look
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20” and 24” Insertion Valve
➢ Permanent asset
➢ Ductile iron valve
construction with fusion-
bonded epoxy coating
➢ Resilient wedge valve
cartridge
➢ Stainless-steel hardware
➢ Fast installation
➢ Tried and true installation
process
Integrated temporary gate
valve
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20” and 24” Insertion Valve
Installation Process
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20” and 24” Insertion Valve
Valve Closure
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Asbestos cement pipe
Cast/ductile iron pipe
PVC pipe (IPS or C-900)
Steel pipe
Insertion Valves & Line-Stop Pipe Compatibility
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AWWA Standards➢ There are no AWWA standards covering
insertion valves.
➢ AWWA C509-15 (Resilient-Seated Gate Valves
for Water Supply Service) is the closest
standard which applies to insertion valves.
➢ Some material specifications of C509-15 are
met depending on the manufacturer.
➢ The important part of C509-15 are the
performance standards or the “Proof of Design”
tests.
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➢C509-15 Proof of design consists of 4
separate tests.
➢Hydrostatic Gate Test
➢Torque Test
➢Leakage Test
➢Hydrostatic Shell Test
Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Insert Valve Testing
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Old 12”
Valve12”
Insert
Valve
Installed
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Applications:
Valve Installation in Pump
Station(s)
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Applications: Versatility -
Multiple Lines
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Applications: Versatility -
Multiple Lines
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Insertion Valve Installation Flexibility
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Insertion Valve Service Providers
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• Premier Contract
Services utilizing The
Hydra-Stop System are
offered through Hydra-
Stop’s nationwide
network of Premier
Service Providers.
• Hydra-Stop offers the
largest and most
experienced Service
Provider network in the
industry.
Hydra-Stop Premier Service Providers Contract
Services
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• Product required (line-stop or insertion
valve)
• Type of Pipe (material)
• Pipe O.D.
• Pressure
• Scope of Work
• Location of Work
• Number of Mobilizations
• Number of Days on Line
What you need to know for an insertion valve of line
stop…
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Contact: Jason Chase or Fred Haines
Telephone: (203) 693-3740
Email: [email protected]
Website: www.Harper-Haines.com
Thank you for attending!