Duplication Scheme

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Introduction

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The aim of the DVA Duplication Project is to provide a second clean water pipeline between Kings Corner and Church Wilne.

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The project involves inserting a PE liner through 9.3km of steel 39” pipe. The host pipe that was installed in 1937 has been out of service for several years and cannot be put back into service in its existing condition.

Duplication

Project Team

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Framework Manager

Nick Parker

Environmental Advisor

Denise Bacon

Design ManagerMark Sherwood

Commercial Manager

Gary Jackson

Health & SafetyAdvisor

Gareth Williams

Planning Manager

Nick Harrington

Procurement Manager

Mike Holmes

Customer Services Management

John Esslemont

Office & Plant Managers

Adele DunneDave Bertie

Project ManagerRussell Boyd

Pipeline Designer

Brent Eastell

Environment Assistant

Steve Brown

Assistant QSLaura Woodward

Senior EngineerGraham Potts

Construction Manager

Kevin Barnett

Project PlannerRob Richards

Procurement Assistant

Jenny Earnshaw

Document Control

Nadine Tovey

As Built Surveyor

Greg Whitworth

DesignEngineer

Lewis Allesbrook

Shared Support

Project Team

Project TeamsMultiple Projects

DVA DUPLICATION

DVA DUPLICATION Project TeamJune 2013

Site EngineerRichard Holloway

Assistant Engineer

Robert Link

Pipeline AgentRichard Shaw

Student EngineerSam Blackburn

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Different options of replacing / renewing the pipe were considered at feasibility stage including full open cut replacement.

The preferred solution was to opt for a roll down pipe liner installation of a PE100 - 937mm diameter liner pipe inserted into the 39” steel host main.

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Subline is an innovative process, for the installation of close-fit polyethylene (PE) liners inside existing pressure pipelines.

The process comprises:

•Butt fusion welding of pipe sticks

•Cold-folding of the PE pipe into the Subline shape.

•Maintaining the shape using temporary restraining bands.

•Insertion of the folded liner into the existing host pipe.

•Reversion of the liner to close fit with the host pipe by pressurisation with water.

The key benefits to the Subline system

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•To avoid disruption to the local environment by reducing the amount of excavation required compared to open cut techniques

•Long length installation capability

•Fast installation speeds

•Slip lining-type insertion process does not disturb adjacent services

•Close-fit of lining maximises water carrying capacity

•Smooth bore of PE liner pipe minimises friction

•Provides Leakage benefit by sealing leaks, gaps at joints and corrosion holes

•Solves water quality problems arising from internal pipeline corrosion of water mains

•50+ year design life

Progress to date

Started on site – September 2012

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Haul Roads

Excavations – September 2012

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Pipe cut out Pipe pieced back in

Subline – October 2012

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Butt Fusion welding Roll down

Insertion Winching

Valve Houses – November 2012

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Bespoke lifting frame

Removing valve

5 valve houses on Duplication

Under Pressure Tee – March 2013

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Drilling of UPT

Pressure Testing – May 2013

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Pressure test end restraint frame

Ecology & Archaeology

Using the Subline method has led to;

• reduce the amount of excavation required compared to open cut techniques by 42,650 m3

• reduced 21,500 tonnes of material going to landfill.

• a full working easement for the full length of the pipe line has not been required reducing the environmental impact on 215,000 m2 of land take.

• 8,370 tonnes of pipe bedding material is no longer required

• refurbish rather than replace all the existing inline and air valves.

•  Overall, a reduction in the region of 541,000 Kg of co2 has been achieved for the project.

• also reduced the impact of 2000 HGV vehicle movements on the local roads has been mitigated.

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Environmental Impact

Great Crested Newts 

• Great Crested Newts (GCN) found at 2 areas near Spondon Wood which affected four of the ponds surveyed.

• After a European Protected Species Licence was obtained, a specialist contractor installed temporary and permanent amphibian fencing to enable EMEC to trap out newts.

• Once the working area had been confirmed as newt free and the temporary amphibian fencing removed, the project was able to work in these areas.

• Regular GCN toolbox talks are given to site personnel re GCN working method statement to ensure optimum awareness of the risks in the working area.

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Client Interface

Site Visits

• Andrew Duff (Chairman STW)

• Pipeline Industries Guild

• Severn Trent Sewage

• Balfour Beatty H&S

• STW accounts dept.

• STW quality audits

• STW Safety audits

• LOR internal quality audits

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Client Interface

• Asset owner – Kevin Bacon• Designers – Laing O’Rourke• 71 land boundaries and 25 landowners• Risk & Contingency Plans – completed by Atkins• Current Status of R&C plans

• Overall Duplication Project – (Complete)• North Connection UPT – (Complete)• South Connection UPT – (Currently being reviewed by STW)• Commissioning Plan – (Currently being reviewed)

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Challenges & Good Practice

NovoGrips• The host pipe is an early type of

steel pipe being manufactured around 80 years ago and being coated in bitumen, the Novo Siria end restraint fitting being used offers;

• flexibility in use allowing higher than normal tolerances in terms of diameters encountered.

• ‘one size fits all’ fitting for the entire project.

• Clamps PE liner to host pipe

• PN16 flange allows fitting to ductile

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DVA Burst – 15/02/13

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Severn Trent and Laing O’Rourke working as one team, this repair was completed within 24 hours

Programme

Programme Synopsis

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• Start date – September 2012

• Project Duration – 17 months

• Construction Completion – February 2014

• Pressure Testing – May 2013 – November 2013

• Commissioning – November 2013 – February 2014

Programme

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