Steel Water Pipe Products

Steel pipe fitting consisting of (6) fabricated pieces of 108″ diameter carbon steel pipe. Included as part of this assembly were (2) 108″ 4-piece 45 degree fabricated elbows, (1) 108″ true wye reinforced with a 3-piece crotch plate that was 4″ thick, (1) 108″ lateral with a 2-piece crotch plate that is 4″ thick and (2) straight pieces of 108″ diameter pipe. One of the straights has a shop-welded internal domed head for field hydro-testing. These fittings were built to AWWA C200 and C208 requirements.

Field connections for these pieces were furnished as 2-piece butt straps. The lower half of these were shop-welded to the pipe to aid in installation. One butt strap connection located off the lateral was placed at a 45 degree angle to the pipe in order to keep the shipping width of the lateral as narrow as possible. The 108″ wye had a shipping width of 16′-0″. Normal widths for truck freight is 8′-6″ wide. Shipping distance from the fab shop to the jobsite was 1400 miles with full escort for the entire trip.

The steel pipe was coated and lined with polyurethane per AWWA C222. The pipe was designed and reinforced for 150# test pressure.

This pipe project was a key component for increasing the Oklahoma City Water District’s water flow to 150 million gallons of water per day.

Our company completed this large high pressure pipe project, which consisted of over 1100 lineal feet of mostly 96″, 84″, 72″ & 60″ diameter pipe, with a pipe wall thickness of 5/8″ & 1/2″. The designed pressure required four large wye outlet fittings, reinforced with (4) – sets of 1-3/4″ thick Crotch Plates that required numerous weld passes in the intersecting outlets. Lift lug ears were also designed into the crotch plates for ease of handling & installation purposes. This system starts with a 96″ dia. suction header with (6) – 36″ dia. lateral outlets, that runs parallel to the 84″ dia. discharge header with (6) – 36″ lateral outlets. All outlets required 3/8″ wall reinforcement welded collars, which lead to each new pump. The different elevations & layout required over (26) – miter welded elbows & (18) – rolled & welded reducers. This large pipe also had (24) – sets of welded harness restraint ring systems, to restrain the large flex couplings, which allow for angular deflection at different levels.

Unfortunately, we were unable to capture the true validity of this project in a photo, since most pipe was inside a confined concrete structure & the remaining pipe was buried.

This AIS Compliant (“American Iron & Steel” provision act) steel pipe project was coated with 25 mils of polyurethane and 1/2″ thick cement lining, for an extensive life of service. The pipe project specifications consisted of strict guidelines for all steel fabrication phases & nondestructive testing of this pipe system.

Square to Round Steel Transition:
73″ O.D. x 1/2″ thick Square End x 72″ O.D. x 1/2″ thick Round End.

Reinforcement:
(6) 3/4″ thick x 10″ tall Stiffener Ribs to keep the fabricated transition piece from collapsing during concrete encasement.

Three individual Hydrostatic Tests completed at 35psi for 15 minutes per each test.

Pump Discharge Header
Pipe:
1/4″ Thick x 32″ OD x 40′-4″ Long
‘E’ Flanged End for Dished Head x ‘F’ Flange

Flanged Outlets:
4 Typical 14″ OD ‘E’ Flanged Outlets x 1/4″ thick with 1/4″ thick collar plates

The 67″ diameter elbow shown in the photograph extends from a 111″ diameter header that is buried underground to line up with the pipe that extends from the building. Double flexible coupling and a small closure piece (not shown in picture) were to make the connection. The fabrication had to be precise in order for this connection to be made as space was very limited. All the buried pipe received a polyurethane coating. As the pipe rose out of the ground, the pipe received a zinc primer coating and was finished being painted in the field. All pipe in the photograph was cement lined per AWWA standards.

This product is a 108-inch x 108-inch 45° Wye with a 0.529-inch thick cylinder and 4.5-inch thick broken crotch plate 13 feet 1-3/4 inches wide that weighs 37,850 pounds. The cylinder outside diameter is 111 inches and overall length is 24 feet 3 inches. One crotch plate segment is 19 feet 2-1/2 inches long while the other is 8 feet 3-5/16 inches in length. The piece features a welded temporary internal 108-inch bulkhead 1-1/8 inches thick for hydrostatic testing purposes. The Wye has a 1-inch thick mortar lining and 35-mil polyurethane coating.

The piece took over 600 man-hours to fabricate. Each crotch plate segment was made by welding two 4-1/2″ thick steel plates together, since no 13-foot wide steel plate was available. The two welded segments were then fit to the cylinder, welded together at their intersection and sent for stress-relieving to 1100°F per ASME Boiler and Pressure Vessel Code Section VIII Division 1. After heat treatment, the run cylinder and branch cylinder were welded to the crotch plates. All complete joint penetration welds were ultrasonically examined and all fillet welds were examined using magnetic particle. The Wye was mortar-lined using a shotcrete process in two courses; the first application was applied to the bottom half. After the mortar was steam cured overnight, the piece was rotated 180 degrees, mortar was applied to the remaining half and cured. The piece was abrasive blast cleaned to near-white metal (NACE No. 2/SSPC-SP 10) and a 3.5 mil profile before applying the 35 mils of polyurethane coating.

The Wye weighs 77,970 pounds and has a footprint of 18.38 feet wide by 13.15 feet high by 24.25 feet long. Due to its size and weight, it required a special permit to ship as well as special cranes at both the load and unload locations. It is one of four wyes being built and installed on the Integrated Pipeline project.

The UV disinfection plant receives treated water from a 144″ line that feeds into (2) 108″ manifolds through a 144″ x 144″ x 144″ true wye and (2) 144″ x 108″ eccentric reducing 45 degree elbows. The elbows were drawn in 3-D Autocad and then 3-D printed to scale as proof of concept.

The inset picture shows the scale of the 144″ x 144″ wye during fabrication. The wyes were transported in one piece as special wide loads 23 ft. (two lanes) wide.

Each manifold has (8) 48 risers that feed the (16) UV disinfection trains. The picture shows the discharge manifold being installed and the only visible portion of the supply manifold which was installed first, are the valve boxes.

After installation of the manifolds, the building slab was poured and the (16) treatment trains were installed. Each train required (16) 48″ flanged spools for a total of 256 spools.

The name of this project is the Lake Scranton Finished Water Tunnel. This project consisted of approximately 4,730 feet of 42″ x 0.750″ steel pipe. The pipe was coated on the exterior with AWWA C222 polyurethane with an abrasion resistant overcoat (ARO). The pipe was lined on the ID with polyurethane in accordance with AWWA C222. The pipe was provided in lengths of 50 feet and the joints were a mixture of lap weld, butt weld and harnessed end joints in conjunction with flexible couplings.

The Lake Scranton Finished Water Tunnel project was first proposed by Pennsylvania-American Water in an effort to improve the reliability of water service to customers in the Scranton area. This new main would providing a secondary water feed from the treatment plant to customers. The project consisted of drilling a pilot hole through East Mountain from the treatment plant to the residential area west of East Mountain. The bulk of the 4,730 feet of 42″ pipe was butt welded together and installed through the pilot hole by means of horizontal directional drilling (HDD). The success of this project helped Pennsylvania-American Water install a more secure water source for its customers without the negative impacts of open-cut construction.

The name of this project is the Eastern Parkway 48″ Transmission Main Rehab – Phase 1. This project consisted of approximately 11,203 feet of 42″ OD x 0.375″ steel pipe. Approximately 10,100 feet of this quantity was slip-lined inside existing 48″ cast iron pipe. The pipe was coated on the exterior with AWWA C222 polyurethane in the open cut sections and was left bare in the slip lining sections. The annular space between the bare steel pipe and the existing 48″ pipe was grouted after installation. The pipe was lined on the ID with cement mortar lining in accordance with AWWA C205. The pipe was provided in a mixture of lengths including 25 foot, 20 foot, 18 foot, 10 foot and 8 foot joints as requested by the installing contractor. All of the joints were lap welded on the ID after installation.

This project (Phase 1) was 2.1 miles of a 6.4-mile construction project along Eastern Parkway in Louisville, KY. This slip lining project’s purpose was to extend the life of one of Louisville Water Company’s oldest water mains. The original 48″ cast iron water main was installed sometime between 1923 and 1930. This transmission main is a critical water line used to transport an average of 15 million gallons of drinking water per day to important areas of Louisville. Renovating and repairing this large transmission main was a complex project because the pipe runs along a historic, heavily traveled parkway bordered by established neighborhoods, businesses and popular recreation areas. Slip-lining the majority of this existing 48″ main helped minimize environmental impacts and neighborhood disruptions, while increasing the lifespan of this critical water main.

Low lake level pump station discharge piping from (22) vertical pumps supplied by others 36″ in size.

These 36″ lines feed (2) 84″ headers that increase in size to 108″, continue to a concrete surge tank. (2) 84″ discharge headers from the remaining (12) pumps increase in size from 84″ to 108″ and then again to 144″ in size before tying into pipe furnished by others. The total footage on these lines are approximately 2300’.

The headers were laid in a trench and concrete encased in the field. These pipe sections were also cement mortar lined in the field as well. Pipe design was for a field hydro-test pressure of 340#. AWWA C-200 and C-208 specifications were used in the fabrication of this pipe.

Baker WTP was built by the Irvine Ranch Water District as a state of the art surface water treatment plant with a concentration on low greenhouse gas emissions. The plant is built on a hillside in a residential neighborhood and required extensive modeling to fit all of the processes in the plant so they would not be visible to any of the neighbors.

The construction was staged to minimize disruption the neighborhood which required detailed coordination and timing of delivery.

The steel process pipe varied in diameter from 4″ to 48″ and all pipe was finish coated in the shop. As can be seen in the picture, the design also included aesthetics in addition to efficiency.

Dam rehabilitation included field fabricating an irregular steel gate chamber lining connected to 66″ pipe outlets within an existing dam and with very limited access. The existing concrete gate chamber transitioned from a 15′ tall by 7′ wide rectangular shape progressively tapering down to a 66″ diameter round inlet and outlet. The concrete chamber was cut back to allow installing a steel lining which matched the original liner geometry. The challenge was assembling this 1″ thick lining using 12″ wide steel plate strips which was necessary to enable lowering the strips through the gate shaft. The annular void between the lining and concrete chamber was approximately 4″ which limited the assembly access to the interior only.

All welds were Ultrasonically Inspected to ASME standards and the project was completed on an expedited schedule to beat the winter conditions at the 9000′ elevation site.