Product / project title:
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Joint Booster Pump Station (JB3)
Tarrant Regional Water District and City of Dallas, TX
PRODUCT/PROJECT DESCRIPTION AND SPECIAL FEATURES:
This 45 degree lateral was fabricated for the JB3 Booster Pump Station in Ennis, Texas. This fabrication has a weight after polyurethane coating and 3/4" thick cement lining of over 100,000 pounds. The overall dimensions of this fabrication 17'-0 wide x 14'-5 tall and 26'-0 long.
In order to withstand the high-test and working pressures for the fabrication, the three crotch plates are 3 1/2" thick. The weight of the crotch plates by themselves is over 22 tons.
To have the ability to lift the piece and move it into position, lifting lugs had to be added. One lifting lug was added to each crotch plate, each large enough and strong enough to support the weight of the entire fabrication. The lugs we cut to fit the curvature of the crotch plates. At 2 1/2" thick, each lug weights over 200 pounds.
In order to get the width down to 17' -0”, the outlet from the lateral was cut at an angle to reduce the overall width. A butt strap halve was added to the bottom on the outlet so that the adjoining piece could be easily set into place. The plastic end covers were removed to better display the unique configuration of this fabrication.
210” Siphon Repair
Navajo Agricultural Products Industry
On Friday, May 13th, the 210-inch diameter Kutz Siphon exploded, cutting off the irrigation water to 72,000 acres of farmland. Faced with millions of dollars in crop losses, the Navajo Agricultural Products Industry needed replacement pieces to the 40 feet of 210 inch pre-stressed concrete cylinder pipe (PCCP) quickly. The original PCCP was manufactured onsite in the early 1970s, as transporting the pipe would have been a significant challenge. Needing the repair pieces in a timely manner, the manufacturer worked closely with the Bureau of Reclamation to design a solution for which material acquisition, manufacturing, and delivery could be completed in a timely manner. The design solution was to use steel plate to roll up the replacement pieces in short segments that could be hauled as over-width loads, eliminating any over-height issues. Reclamation provided a previously used detail for connection to the existing PCCP. The repair pieces joints were designed as butt-straps in lieu of banded bells to facilitate joining of pipe in field. A port was provided for access and ventilation during installation.
Manufacturing was completed in a one week period after receipt of the materials. Special transportation permits were issues by the States of Arizona and New Mexico at the request of the President of the Navajo Nation to allow the pieces to be hauled over the Memorial Day weekend. Field installation and welding was completed in less than 2 weeks. Water was released back into the system on Friday, June 10th, 4 weeks from the date of the break in the pipeline.
Calumet Tarp Pump Station Improvements
City of Chicago
7’ -2” x 7’ -5”
54” x 36”
This fitting is a 54" x 36" eccentric reducing 90 degree elbow. The fitting material is carbon steel, 3/4" thick with an elaborate support/ stiffener ring design to withstand the high pressure required by this system.
Granby Hydropower Plant
Northern Water Hydropower Water
27’ -10 7/16”
½” to 2”
The pipe piece pictured is a 31”O.D. x 31” O.D. x ½” thick x 37’-0 long bifurcation pipe with a 2” thick crotch plate for reinforcement that weighs approximately 5 tons in combined steel, with the 2” crotch plates weighing just over 2 tons by themselves. This piece was designed and built to accommodate the size and angle needed to fit into an existing 10’ diameter x 500’ long concrete tunnel that slopes down to the Colorado River beneath the Granby Dam. This bifurcation pipe is designed to meet two individual water supply needs. While the upper pipe supplies water flow to approximately 900’ of steel water pipe to generate clean energy at the newly built Granby Hydropower Plant, the lower pipe connects to a jet valve that is used to oxygenate the water supplied to the Colorado River.
Long Beach Storm Main Pump Plant Facility Upgrades
County Sanitation District #2 of Los Angeles County
Long Beach, CA
18” to 42”
We provided the 42", 36", 24", 18" and 12" Pump suction piping and discharge piping with new carbon and stainless steel piping. The challenge was due the Historical Nature of the building. All of the pipe had to connect at the existing locations, while bringing the Pump Station up to modern standards.
The exterior has retained its historical appearance while the interior is a modern pump station.
Much of the original pipe and fittings was cast specifically for this project. This required a very creative approach to the design and fabrication.
Wylie WTP Plant 2 Clearwell & Disinfection Improvements
North Texas Municipal Water District
110” to 62”
This large diameter steel pipe project is one of the key components of the North Texas Municipal Water District, with a new surface water treatment capacity plant of 280 million gallons of water per day. It is designed to store & distribute water from two new 5 million gallon clearwells in which the 110 3/4" & 98 3/4" diameter pipe is cast into the concrete walls & then connects to the existing clearwells & other high service pump stations. Seven massive valves control these buried pipe lines that are about 25 feet below grade. The pipe on each side of these seven valves were designed with 5/8" x 6" welded stiffener rings to reinforce the earth load, for proper valve rotation.
Our company completed the various pipe sizes ranging from 110-3/4" to 86-3/4" diameter, including the meter vault piping consisting of 92-3/4", 86-3/4" & 62-3/4" diameter pipe. The 3/4" to 5/8" thick steel wall of each pipe was coated with 3/4" thick cement mortar & a heavy reinforcement wire. The interior was lined with a minimum of 1/2" thick cement mortar. Each of the six large clearwell pipes were fabricated with two sets of oversized, & welded steel Carnegie type slip joints, which holds two rubber type O-rings, for sealing. This dual joint design would allow for angular deflection & settlement, of the large pipe at the clearwell structures.
Another unique design, was 1 inch thick x 2 foot wide reinforced cement bands on sections of pipe, which would allow some pipe to be slid thru about an 84 foot casing tunnel. This helped accelerate the installation process in that area. This project included twelve fabricated long radius mitered elbows & outlets, along with five large diameter concentric reducers. This pipe required special freight permits for each state and a lot of these pipe freight loads were specially permitted for excessive loads near 63,000 pounds and required 70 different freight trucks to deliver all the pipe to its final destination.
This 2020 lineal feet of large steel water pipe will allow for a more efficient and effective pumping of treated water to the North Texas Municipal Water District's members & surrounding Texas cities. Our scope consisted of strict guidelines for all steel fabrication phases & nondestructive testing of this welded pipe, too numerous to list, and in compliance with the North Texas Municipal Water District specifications. It’s truly hard to appreciate the validity of this large steel pipe project, since it is buried below ground.
Interconnect Section 2/Section 12, IPL
Trwd, City of Dallas
108” / 90” / 72” / 60”
½” to 3/8”
Detail, Detail and more Detail. This project entailed the most diverse piping system in a given steel pipe project yet encountered by our group. Critical to the time-line and the installation process were the tie in to existing Carnegie joints to the 90" and 72" pipes and crotch plated Tee's, 100% UT and hydro-tested. These lines are the key to uninterrupted supply of water.
The second phase of the project entailed difficult mortar overcoats to polyurethane coating for piping through the tunnels. With a microscopic approach to cathodic protection and coating integrity, this was an extremely critical component of the project.
The third stage of the project involved 108" x 90" Crotch plated Tee and 90" x 60" Tees. The crotch plate up to 2" thick made it extremely difficult to fit, handle and weld the pieces. In addition the coating process for these required extremely careful handling and completion of these pieces.
Last but not least, the transition to the above ground piping required skip welding of very sensitive monolithic isolation joints and repeated testing demonstrated that they were installed above and beyond the customer’s expectations. In fact, the resistance values were so good that the inspectors had not seen them this high over several projects. Change in the lining/coating from below ground to above ground requiring special lining material created another transition challenge successfully overcome by our engineering/coating group.
Overall a highly prestigious project, completed successfully for our customer.
Tulalip Water Pipeline Segment 2
The Tulalip Tribes
44” & 37”
.625” & .250”
This project consisted of two different segments. The first segment of this project required the pipe in be installed at a depth of over 100 feet. The 37" pipe had to be installed using a horizontal directional drilling method. The pipe had to pass under a busy street intersection and under several railroad lines and spurs.
The 2300' lineal feet of 37" x 5/8" wall thickness pipe was fabricated with end matched cut for butt-welds to be made in the field. The pipe was fusion bond epoxy coated and lined. The pipe sections were laid end to end and welded. The joint coating and lining were pre-formed before the pull could begin. The pipe was raised into position using fourteen cranes and several dirt ramps to achieve the proper entry angle into the tunnel. In one pull, lasting over 24 hours the pipe was successfully installed.
The 5500' lineal feet of 44" x 1/4" wall thickness was laid using bell and spigot joints. This pipe had to be cement lined and polyethylene tape wrapped. Several special fittings were had to made, in order to avoid the buried utilities and accommodate existing field conditions.
Horse Creek Flume Rehabilitation Project
Ft. Lyon Canal Company
Las Animas, CO
11’ – 1 ¼”
10' – 4”
PRODUCT/PROJECT DESCRIPTION AND SPECIAL FEATURES:
ALL 316SS SPECIAL EXPANSION JOINT FOR HORSE CREEK FLUME
The Horse Creek Flume consists of an elevated 123" inside diameter steel pipe with an approximate length of 392 ft. The function of the flume is to carry water from the Ft. Lyon Canal across Horse Creek. The existing flume has significant corrosion and the purpose of this work is to furnish and deliver to the work site for the Owner new steel pipe, structural steel supports and miscellaneous metals for replacement of the existing flume.
The expansion joint is a sleeve type joint. Steel for the joint was fabricated from plate meeting the requirements of ASTM A240, Stainless Steel Type 316. The stainless steel packing gland is used to compress the packing.
Working Pressure: 150 PSI
Test (Surge) Pressure: 225 PSI
Longitudinal Pipe Welds NDT 100% Radiography
Circumferential Fillet Welds 100% Magparticle tested
Movement: Up to 10" Movement