Featured Projects
Featured Projects
Gas Pipeline – Victoria.
Brief
The pipeline owner/operator had constructed a new line from an existing pipeline to a new site, however no gas was getting through the new line. It was apparent that water had entered at some point of the pipeline during construction and was preventing the gas getting to the new connection.
Challenge
The construction team did not want to cut into the pipeline due to the presence of gas and the possibility of an explosion. The experienced technicians from the alliance partnership of Clearflow Australia and Horizon Industrial Pty Limited were consulted, and were faced with not only locating the blockage but the additional problem of removing the water from the pipeline. It was necessary to determine a source of propulsion to initially get the pig into the line, then travel through the pipeline, locate the blockage, and then remove the blockage at the same time.
Action
The team decided to use compressed air as the best course of action. Our expertise in air scouring and pigging of pipelines was invaluable in determining our calculations. Consideration to the length and diameter of the gas line, the amount of air to not only get the pig into the pipeline but to propel it through the pipe at precise speed and momentum to meet the blockage, get through and remove it, and clean and remaining debris.
Result
The blockage was removed along with excess debris and the pipeline dried of water residue, allowing a clean flow of gas into the new connection.
Another successful project delivered by our team of experts.
SA WATER – Adelaide Hills, SA.
Brief
The pipeline owner/operator had been experiencing operational problems with their DN200 x 7.5 kilometre long Sewer Mains such as service interruption, pumping inefficiencies and pipeline failures due to the steady build-up of debris in the internal bore of the pipeline.
Action
In order to reduce costly repairs and ongoing maintenance it was decided to clean the pipeline using experienced Pigging Services technicians from the alliance partnership of Clearflow Australia and Horizon Industrial Pty Limited.
High-efficiency “Jetting” Pigs were employed to clear choking debris from the mains and the location of pigs could be confirmed at any point along the pipeline using state-of-the-art Pig Locating and Tracking Equipment. “Jetting” technology creates turbulent flow which prevents ‘compacting’ and blockages occurring in the pipeline ahead of the pig. The majority of collected solids are retained in suspension as Pipeline Pigs travel through the line.
Result
After two Pigging runs, the majority of debris had been cleared from the pipeline and the pumping efficiencies had returned to peak levels. The project was completed in two days and within budget.
DUARINGA SHIRE – Dawson River, QLD
Brief
The 150 mm diameter pipeline is ten kilometres in length, pumping raw water from the Dawson River to the treatment plant to service parts the Duaringa Shire, Queensland. Clearflow Australia was contracted to remove the internal debris and weed growth built up in the pipeline over a period of ten years.
Challenge
Due to the location of the site and the urgency of the program, Clearflow Australia worked purely on telephone communication and faxed documents in order to fabricate a pig launcher to suit the conditions onsite. There was no confident local knowledge of the pipeline and the only map available was a longitudinal section map. Most of the pipeline is located in bush terrain with difficult access, and had a number breaks in certain sections and unknown debris in the pipe. As the pipeline had no offshoot sections or designed breaks it was necessary for the pig to travel the entire ten kilometres and achieve the desired result. If the wrong type of pig is used and too much debris is dislodged too early the pig could jam up in the pipe. On the other hand, if the pig is too soft it may break up during the run. Or if the pig travels too quickly we may not get a true idea on the condition of the pipe or the type and amount of debris that is in the pipe to be removed. At the time of fitting the launcher the pipeline showed signs of encrustation with a large amount of weed slime and sludge – the aftermath of pumping raw water.
Action
Clearflow’s normal procedure on the first run is to try and determine the condition of the pipe. The first run took approximately four hours to travel the pipe, removing large amounts of sludge and slime.
This initial run was not without complications. The pig did jam up with the amount of debris in the pipe and it was decided to release the pressure in the pipe. In doing so, Clearflow drained some of the pipe to get another run with the pig and to try and dislodge the debris.
Under normal conditions the first-run pigs or proving pigs will float, however, in this case, when they were finally discharged from the pipe they were so full of sludge and slime that they just settled on the bottom of the discharge pond. They were stuck in the sludge and at the bottom of the pit.
It is necessary when refurbishing pipelines to try and control the speed of the pigs through the pipeline. After two proving runs Clearflow was confident the pipeline was reasonably true and launched the working pig; a harder compound, poly-foam pig. This purpose of running this pig was to remove all of the debris of weed sludge and slime as well as any harder encrustation.
Result
Clearflow not only removed large amounts of raw water slime sludge and weed growth, but also the heavy scale evident in the bottom of the discharge pit. There were also signs of manganese mixed up with the weed growth. The pig launcher that was specially fabricated and adapted for the existing fittings is now a permanent fixture of the pipe at the river end.
The final analysis was improved water quality delivery with increased flow rate to the dam of 60 per cent. This alone decreased the operating costs of pumping water.
SUNSTATE CEMENT LTD. – Brisbane, QLD
Brief
Sunstate Cement Ltd was experiencing the build up of hardened cement deposits and repeated blockages in the plant’s extraction pipelines, resulting in shutdowns and considerable downtime. All previous attempts to rectify the problem by water blasting had failed, and the only alternative was pipe replacement at an estimated cost of $40K-$50K. Clearflow Australia was contracted to remove the cement deposits from the internal bore.
Challenge
The material build up on the internal bore was hardened concrete. There was also considerable cement deposit on the bends. Clearflow’s assessment was to design a pig strong enough to withstand the hardness of the cement, but allowing flexibility to negotiate the bends affected by the hard cement deposits, whilst being propelled through the pipeline.
Action
After inspection and a considerable amount of consultation and analysis, Clearflow Australia designed and fabricated special pigs suitable for the operation. Over a limited timeframe allocated during a programmed shut-down, approximately 450 metres of affected pipeline were progressively pigged.
Result
De-scaling and removal of hard cement deposits and wastewater sludge resulted in an increase of 15% in production of each cycle, which equates to 3 hours on a 24 hours cycle, and improved product quality. Savings were also achieved in power consumption (considerable in operating a plant of this size), wear and tear on compressors, diesel motors and other equipment. The operation saved the company over $70K in pipeline replacement and production downtime.
“ … a very impressive operation – for an increase in production cycles as high as 15% is a great saving to plant operations .. we fully endorse this method of increasing flow rates and cost savings in daily production!”
Mr Michael Sygrove
Consulting Engineer – Connell Wagner, Brisbane
“If you told me your process was going to save me 15% per cycle I would have told you to go away, and stop kidding yourself.”
Mr Mark Tonkin
Operations Supervisor – Sunstate Cement Ltd
TWEED SHIRE COUNCIL – NSW
Brief
The Tweed Shire Council decided to employ a continuous Preventative Maintenance Programme and contracted Clearflow Australia to implement this programme in conjunction with their Water Department.
Action
The scope of works undertaken by Clearflow Australia included:
• Hydrant and Valve Refurbishment
• Hydrant and Valve Maintenance
• Cleaning of water mains via Air Scouring or Pigging Methodologies
The combination of these programmes has been advantageous to the Council, as the hydrants and valves were located, tested, refurbished or replaced, and maintained prior to the cleaning process.
Result
This Preventative Maintenance Programme ensured that all equipment was being maintained to optimal condition by a continuous and diligent schedule of works. This also allowed for records to be maintained and updated whilst being able to determine any problems. It also resulted in reducing dirty water complaints and minimised chemical use.
Reference:
Mr Peter Haywood
Water Engineers Management – Tweed Shire Council, NSW