Distribution Maintenance & Repair Techniques to Avoid ......• System Shutdown –Boil orders...

Distribution Maintenance &

Repair Techniques to Avoid

System Shutdown

Line Tapping ● Line Stopping ●Valve

Insertion

Presented by: Fred Haines

• 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…

• A shut-off valve is

broken or, worse

yet, does not

exist?

The Problem…

• A hydrant repair

becomes hydrant

replacement?

Turn off the water supply and suffer the consequences later!!!

Old Technique…

• 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

– 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

• 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?

• New regulations – more stringent

water quality standards

• Regulation enforcement

• Water conservation

• Operator safety

• Budget Considerations

Why Change Now?

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…

➢ 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…

➢ 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…

Line Stopping

Never shutdown…

Use a line-stop/insert valve system…instead of

shutting down

Required – Line tapping machine (typical below)

Side Tapping (illustrated)

• 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…

Traditional Tapping Methods

Traditional tapping methods provides a means for

coupon retention which allows for inspection,

evaluation and verification.

Line Stopping Machine (illustrated)

• 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

Line Stopping Animation

• 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

➢ 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

Example: Hydrant Valve Installation

Example: Hydrant Valve Installation

Example: 6” Tuberculated Pipe 80psi

Line Stopping with Bypass

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)

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)

Line Stopping Heads

Pivoting Head

– Used for larger size mains, higher pressures

– Used primarily to 12” line size

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

An Example of Line Stop Fittings

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

• 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

Insertion Valve (illustrated)

Insertion Valve Installation Animation

Insertion Valve Bill of Materials

Operating Nut:

Steel, Cast

Standard Black

indicates open left

Operating Nut:

Steel, Cast

Optional Red indicates

open right

Bonnet Hardware:

304 Stainless SteelDomestic 304 Stainless Steel

Option available

Body Mounting Hardware:

304 Stainless SteelDomestic 304 Stainless Steel

Option available

Valve Bonnet:

Standard Epoxy

Coated Carbon Steel

Valve Bonnet:

Optional 304 Stainless Steel

Valve Body:

304 Stainless Steel

Completion Plug Pins:SAE GRADE 8 STEEL, ZINC COATED Completion Pin Plugs:

SAE GRADE 8 STEEL, ZINC COATED

Upper and Lower Body

Sealing Gaskets:

BUNA-N Rubber

Body Armor Shields:

16 gauge

304 Stainless Steel

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

Cartridge Wipe Seal:

EDPM

Valve Cartridge

Wipe Seal

6” IV 250 Patriot

Resilient Wedge

Exploded 6” Resilient Wedge Seat

Rubber

Layers

Mesh

Layers

Resilient Wedge

Front View

Cross section of resilient wedge.

Rubber

Mesh

Resilient Wedge BEFORE compression

Resilient Wedge DURING

compression

Resilient Wedge AFTER compression

Completion Plug:

Reinforced

Composite Polymer

Stem Collar:

No Lead Brass

Conforms to NSF 372

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

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.

IV 250 – Sealing Surface

IV 250 valve cartridge

designed to seal on

engineered sealing

surface within the valve

body.

IV 250 – Resilient Wedge Seal

Resilient wedge

seal

• 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

16” Insertion Valve An Inside Look

16” Insertion Valve An Inside Look

Open Position Closed Position

16” Insertion Valve An Inside Look

16” Insertion Valve An Inside Look

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

20” and 24” Insertion Valve

Installation Process

20” and 24” Insertion Valve

Valve Closure

Asbestos cement pipe

Cast/ductile iron pipe

PVC pipe (IPS or C-900)

Steel pipe

Insertion Valves & Line-Stop Pipe Compatibility

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.

➢C509-15 Proof of design consists of 4

separate tests.

➢Hydrostatic Gate Test

➢Torque Test

➢Leakage Test

➢Hydrostatic Shell Test

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Insert Valve Testing

Old 12”

Valve12”

Insert

Valve

Installed

Applications:

Valve Installation in Pump

Station(s)

Applications: Versatility -

Multiple Lines

Applications: Versatility -

Multiple Lines

Insertion Valve Installation Flexibility

Insertion Valve Service Providers

• 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

• 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…

Contact: Jason Chase or Fred Haines

Telephone: (203) 693-3740

Email: jchase@harper-haines.com

fhaines@harper-haines.com

Website: www.Harper-Haines.com

Thank you for attending!