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Introduction to Seismic Resilient Ductile Iron Pipe Technology
Presenter: Todd Randell
Co-Authors:
Akira Yabuta Kurimoto Ltd, Japan
Norio Matsuki Pino & Co. NZ
This presentation will review
▪ Introduction
▪ Global review of large-scale disasters
▪ Pipeline performance during these disasters
▪ Seismic Resilient Ductile Iron Pipe (SRDIP) Technology▪ Range▪ Coatings & Linings▪ Standards
▪ Unique design features of SRDIP
▪ Evidence of the fault free performance of SRDIP in Japan
▪ USA Case Study –▪ Adoption of SRDIP in high-risk locations in the
United States of America
▪ A New Zealand Case Study
Introduction
▪Water Infrastructure pipelines are vulnerable assets
▪Water is fundamental to residential, commercial and industrial functions
▪Our communities will not function without water
▪ Traditional pipeline materials installed in NZ generally don’t survive severe Natural Disasters
▪At the time of the Christchurch sequence of events it was considered
“Nothing was earthquake proof”
Introduction
▪ In Japan, SRDIP pipe technology has survived many great earthquakes including:▪ The Great Hanshin-Awaji Earthquake Japan (17th January 1995)
▪ Well known internationally as the “KOBE Quake”
▪ The Great East-Japan Earthquake & Tsunami (11th March 2011)
▪ Northern Osaka Earthquake Japan (18th June 2018)
Introduction
▪ Global view of tectonic plates
▪ USA and NZ share the Pacific Plate Boundary known to us as
“The ring of fire”
…which also passes close by Japan’s coastline
Source; United States Geological Service – www.usgs.gov
Introduction
▪ Hundreds of active fault lines run the length of NZ
▪ Several Major faults run alongside the North Island Fault system including the Wairarapa and Wellington Faults
▪ The Marlborough fault system is quite fractured
▪ Scientists have been predicting a major earthquake within the next 40 years – likely produced by the Alpine Faultline
Source : https://en.wikipedia.org/wiki/North_Island_Fault_System
Review of “Great International Earthquakes”
Northridge California USA 17th January 1994
• 6.7 Mw event - The epicenter was located 40km north west of Los Angeles
• 57 Died
• Severe damage to:• 60 Transmission pipelines• 1100 Distribution pipes• 7 Water reservoirs• 160,000 homes and businesses were without water
• Repair costs of U.S $40m to repair the 1100 distribution pipes alone
• Nineteen years later …and following an in-depth scientific study on earthquake proofing LA’s high-risk locations authorities adopted SRDIP Technology
Review of “Great International Earthquakes”
Kobe Quake Japan 17th January 1995
• 7.3 Mw event
• 6434 Died
• 43,792 Injured
• 250,000 building damaged. Many beyond repair
• Damage to waste and water pipelines included:a) 43km Raw Water Conduitsb) 260 kms Transmission Mainsc) 4000kms Distribution Mainsd) 650,000 Utility Service Pipeline Connections
▪ Although installed, there were ‘no reports’ of damage or leakage to SRDIP pipe systems
Source: Kobe earthquake DN700 SRDIP remains in service (leak free) after the Great Hanshi-Awaji quake. (Photo: Japan DI Pipe Assn (JDPA))
Review of “Great International Earthquakes”
Kobe Quake Japan 17th January 1995
The type of pipeline failures included:
▪ Disconnected pipe joints (to unrestrained socket spigot pipes)
▪ Deformed and buckled Flexible Pipes
▪ Damage to seals
▪ Over compressed pipe-spigots into pipe-sockets
These failure modes are common to what NZ has experienced over the past 30 years
Review of “Great International Earthquakes”
CONCLUSIONS made by the
Kobe Municipal Waterworks Bureau
• A reliable emergency water supply system was required
• Future pipeline systems must be:
• Easy to repair• Disaster resistant
• Mandatory specification of SRDIP technology adopted in construction of all critical assets
Japanese Water Pipe Market Breakdown by material
Type (2017) (Source: JDPA)
vSRDIP Market Share Development in Japanese DIP Market
Review of “Great International Earthquakes”
The Great East-Japan Earthquake & Tsunami (11th March 2011)
• The event was:• The most powerful earthquake ever recorded in Japan• The fourth in the world
• 9.0 Mw event – The epicenter located off the North East Coast of Japan
• 1599 Died
• 6157 Injured
• 2529 people are still missing, considered dead
• Tsunami wave height reported to be 40m high
• All near by Port Cities and villages were destroyed
• Traditional unrestrained waste and water pipelines were “washed out” and/or damaged
• There were ‘no reports’ of damage to SRDIPvSRDIP “Type NS” restrained Ductile Iron pipe water pipeline
remains operational following the Great East-Japan
Earthquake 2011 (Photos: JDPA)
Review of “Great International Earthquakes”
Northern Osaka Earthquake 18th June 2018
▪ 6.1 Mw event – The epicenter was located at Takatsuki area of North Osaka
▪ 4 died
▪ Hundreds were injured
▪ Traditional unrestrained waste and water pipelines were dis-connected and/or damaged
▪ A crucial twin DN1200 welded rigid Steel transmission pipeline burst
▪ There were ‘no reports’ of damage to SRDIPSource; Twin Mild Steel Transmission pipelines (2 x DN1200) damaged following the 6.1Mw Osaka earthquake of 2018 (Photo: Kurimoto Ltd, Japan)
Seismic Resilient Ductile Iron Pipe
Background
▪ This technology was first developed in the mid 1970’s
▪Evidence shows it has survived many large-scale natural disasters since 1975
▪ Including surviving earthquakes up to 9.0Mw
Seismic Resilient Ductile Iron Pipe
Where SRDIP is best installed
▪ Near Fault lines
▪ Liquefiable ground
▪ Tsunami prone locations
▪ Artificially deformed areas such as road embankments
▪ Pipelines servicing critical water supply points such as▪ Hospitals, civil-defense head quarters, shelters, public facilities
▪ Fire fighting or hydrant water supply
▪ Difficult to repair pipelines
▪ Bridge-mounted pipelines
Seismic Resilient Ductile Iron Pipe
Diameter & Range
▪DN100 - 450▪ Joint Type NS
▪DN500 - 1000▪ Type NS – Mechanical Joint
▪DN1100 – 2600▪ Type UF – Mechanical Joint
▪ Fittings▪ These are mainly a mechanical Type NS/UF
Seismic Resilient Ductile Iron Pipe
Manufacturing Standard
▪Ductile Iron Pipes JIS G 5526
▪Ductile Iron Fittings JIS G 5527
▪Epoxy Powder Coating
(Fusion Bonded Epoxy or FBE)
for interior of Ductile Iron Pipe and Fittings JIS G 5528
Seismic Resilient Ductile Iron Pipe
Unique Design Features
▪Expansion and contraction
▪Angular deflection 6-8 degrees – during an event
Seismic Resilient Ductile Iron Pipe
Unique Design Features
▪Slip out resistant technology
▪ Joint separation prevention▪ Force = 3 x DN(kN)
▪ Worked example: DN300 = 900kN
▪Pipeline expansion during an event ▪ = ±1% of pipeline (L)
Expansion range Contraction range
Seismic Resilient Ductile Iron Pipe
Unique Design Features
▪Chain-link-structure
Source; Examples of chain-link-structure using compressed chain-links and extended chain-links (Photo: T Randell - Hynds)
Compressed Chain
Extended Chain
DIP Chain-link-structure Animation & Video
Self Healing Corrosion Protection Coating
Unique Design Features
▪ External Coating replaces the need to fit PE Sleeve
▪ Design Conditions Apply – Refer to the guidelines provided within AWWA C105 – 10 Polyethylene encasement for Ductile Iron Pipe systems”
Synthetic Resin
Sealing Primer 23
Zinc Metal Spray1
Layer Coating process Material & coating
thickness
1 Zinc Metal Spray Zn alloy (Al-Si-Mn)
Not less than 220 g/m2
2 Sealing Primer Silica compound sealing
agent
Not less than 50 g/m2
3 Synthetic resin Synthetic resin
Not less than 80 μm
1
2
3
Source: Porirua Branch Pipeline Extension near Wellington NZ. Photo: (V. Cham - Hynds)
Seismic Resilient Ductile Iron Pipe
▪ Internal lining Fusion Bonded Epoxy (FBE) Powder
(Oven baked)Thickness = >0.3mm
▪ Lower internal surface friction than when compared to cement mortar lining▪ Hazen-Williams’ C = 130▪ Mannings’ n = 0.010 All references made are for clean water applications
▪ FBE has similar friction values as PE & PVC Pipes
Unique Design Features Internal Coating
Internal Coating Test Traditional Grey Cast or
Ductile Iron (unlined) pipe
Seismic Resilient Ductile Iron
Pipe
Internal coating Mortal lining Epoxy powder coating
Corrosion
Resistance
Average Excellent
Water quality Average
・Raised pH value
・Reduced residual chlorine
Excellent
・Keep pH value
・Keep residual chlorine
Lower surface
section
Average
・4~10 mm
Excellent
・0.3 mm
・10~20 % higher than Mortar
lining
Red Water
Seismic Resilient Ductile Iron Pipe
Unique Design Features
Internal Coating
▪Corrosion protectionSalt spray test in accordance with JIS Z 2371 “Methods of salt spray testing ” that was published based on ISO 9227 is performed.
[Kurimoto’s special coating]①Zn alloy (Al-Si-Mn) : 130 g/m2
②Sealing treatment
[Traditional coating]①Zn spray : 130 g/m2
15 Days Later350 Days LaterCorrosionNo corrosion
Seismic Resilient Ductile Iron Pipe
Expected Asset Life
State over 100-year life before any major rehabilitation or maintenance
Internal
Lining
External
Coating
SRDIP
OVER
100 years+ =Ductile Iron
Thickness +
Seismic Resilient Ductile Iron Pipe
▪ Some thrust preventing methods are required due to thrust forces at fittings (bends, tees and valves) in pipeline.
Tee
Reducer
Valve & Cap
Thrust block construction is time and cost consuming
Bend
In the case of Traditional DIP
Seismic Resilient Ductile Iron Pipe
Unique Design Features
▪ Total “Anchor-block-free” pipeline technology
1. Applied force due to water pressure
2. In-Trench/Soil friction resistance created by force applied
q
qf
f
A
A
PP1
P2M
θ2
2P2
δ1 δ
δ2
LP
LP
θ
θ
Thrust force and resistance force acting on a bend part (Source: JDPA)
1
2
2
Unique Design Features
▪ Total “Anchor-block-free” pipeline technology
Seismic Resilient Ductile Iron Pipe
DI LinerRubber
Pipes socket interface with Bend
Spigot must be fixed by inserting
“liner = rubber”
Fittings are
permanently fixed.
Sockets on fittings are fixed they can not move or deflect DI Liner & Rubber for
centering liner
Seismic Resilient Ductile Iron Pipe
Unique Design Features
▪ Total “Anchor-block-free” pipeline technology
Result:
= Quicker construction time
v
Flow chart of calculating integrated length (Source: JDPA)
Seismic Resilient Ductile Iron Pipe
Pipe Product Range
▪ DN75 – DN2600
▪ 3 Pipe Joint Types▪ Type NS
– DN75 to 450▪ Type NS Mechanical
– DN500 to 1000▪ Type S Mechanical
– DN1100 to 2600
▪ All SRDIP fittings are mechanical jointed – full range available
Rubber gasket
Rubber for centring lock ring
Lock ring
Joint structure of Type NS pipe joint (DN75~450) (Source: JDPA)
Gland T-bolt and nut
Rubber gasketBackup ringLock ring
Joint structure of Type NS pipe joint (DN500~1000) (Source: JDPA)
Bolt and nutGrand
Split ringRubber gasket
Lock ring
Backup ring
Joint structure of Type S pipe joint (DN1100~2600) (Source: JDPA)
1
2
3
1
2
3
Seismic Resilient Ductile Iron Pipe
USA Case Study & Research
▪ About a decade ago Los Angeles Power & Water Dept earthquake engineers began studying SRDIP and its performance dating back to the 1995 Kobe quake
▪ LAPWD’s study could not uncover any reported failures
▪ They chose to complete a series of pilot installations which began in October 2014
▪ Since 2014 the use of SRDIP technology has increased
▪ For high risk locations it has become normal to install this pipe technology
Source: Installation at Northridge California (near the public Hospital. Photo: Los Angeles Times)
Seismic Resilient Ductile Iron Pipe
NZ Case Study – Porirua Branch Pipeline Extension Kurimoto SRDIPAir valve
With PE Sleeves
Start of SRDIP
End of SRDIP
Source: Wellington Water Ltd
Without PE Sleeves
Source: Pipe installation at Porirua. Photo: by A. Yabuta Kurimoto Ltd Japan
Source: Pipe installation at Porirua. Photo:mage by A. Yabuta Kurimoto Ltd Japan
Seismic Resilient Ductile Iron Pipe
NZ Case Study – Porirua Branch Pipeline Extension Kurimoto SRDIP
1. No Thrust Blocks installed
2. No PE Sleeves fitted
Source: Installation of SRDIP bend at Porirua (NZ) Branch Pipeline extension. (Photo: A Yabuta. Kurimoto Ltd, Japan)
Past Lessons Learned
John Black once stated….:▪ Seismic events break the weak links ▪ Brittle pipes perform poorly▪ DI pipes with Traditional RRJ - acceptable performance▪ Areas of large PGD need special attention▪ Avoid lateral spread areas▪ Design for flexibility and fixability
▪ “The adoption of SRDIP pipe technology in Japan has proven this is a failure free system during some of the worlds largest natural disasters”
Today’s Lessons Learned
▪ Earthquake proof pipelines do exist▪ Installed in Japan since the 1970’s
▪ Installed in USA since 2013
▪ Installed in NZ in 2019
▪ “The adoption of SRDIP pipe technology internationally has provided hard evidence that it is a failure free pipeline technology that can be trusted”.
Conclusions
▪ Resilience is one of the most critical requirements for the success of societies today
▪ No reported failures of SRDIP installed in the past 45 years
▪ Less physical resourcing due to “anchor-block-free” and PE-sleeve-Free” design features
▪ Can provide NZ water pipeline industry sustainably and long-life asset management
▪ Overall contribution to safety and wellbeing of citizens in the event of natural disasters
▪ Potable water still available after a catastrophic event
▪ No reports have been made of damage or leakage to any SRDIP joint
▪ SRDIP technology could be considered-to-be the only “Earthquake Proof” pipeline technology available - internationally.
Acknowledgements
▪ The team at - Wellington Water Ltd▪ John Duggan, Gary Cullen, James Craig & Laurence Edwards
▪ G.P. Friel Ltd – Wellington▪ Gerry Friel & Ray Dunn
▪ Kurimoto Ltd, Japan▪ Takao Yamanaka▪ Akira Yabuta – Co-Author▪ Yasuhiro Kawashima
▪ Pino & Co. New Zealand▪ Norio Matsuki – Co-Author
QUESTIONS
Thank You