Success Stories
It is not uncommon to double flow (and more) in old lines.
Reduced Pumping Costs:
Power saving can be dramatic in large lines.
Cleaner Product:
Impurities such as Red Water can be eliminated.
Satisfied Customers:
Due to good results and minimum service downtime.
In the case of removing heavy build-ups from pipes
a “progressive” pigging method is used
which maximises cleaning safety
A selection of projects which presented some unique challenges with successful results include:
- Sunstate Cement
- Tenterfield Shire Council
- Orange City Council
- Cootamundra Shire Council
- Broadsound Shire Council
SUNSTATE CEMENT – 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.
TENTERFIELD SHIRE COUNCIL – NSW
Brief:
The Council was experiencing a recurring dirty water problem, despite being previously cleaned.
Challenge:
On inspection, it was recommended that due to the heavy manganese deposit build-up on the internal bore of the large feeder lines, they should first be Pigged, to allow an Air Scouring operation to be implemented on the smaller feeder lines, otherwise the desired results of a cleaning programme would not be achieved. In addition, during the subsequent Air Scouring programme it was discovered many inoperable hydrants, and outdated Council plans.
Action:
Clearflow specially designed and fabricated launchers which were cut into the existing pipelines as permanent fixtures to facilitate future pigging programmes and reduce costs.
Clearflow also were able to compile a report on a programme of replacement and refurbishment of hydrants, valves and lines, and update the Councils plans.
Result:
The Pigging operation successfully removed the manganese build-up from the main lines from the treatment plant, allowing the Air Scouring operation to be more effective. With inspection and restoration of the existing hydrants and valves, the result was cleaner water quality and improved water pressure. The Council reported that the successful combination Maintenance Package of pigging the larger mains and allowing the smaller pipelines to be air scoured proved most effective and very economical.
ORANGE CITY COUNCIL – NSW
Brief:
Clearflow was contacted to address a problem the Council was experiencing with the delivery of raw water through a cast-iron pipeline from the weir to the treatment plant.
Challenge:
The pipeline was 375mm in diameter and approximately 2.7km in length. It was commissioned in 1930 and had never been cleaned, and in addition the pipeline was constructed using lead joints. The likelihood of debris buildup was considerable, restricting flow, with the likely debris from an unlined cast iron pipe amounting to accumulated slime, sludge, iron leach, manganese, mussel shell, weed growth, metal nodules and general encrustation.
Action:
After inspection and consultation with the council, it was the recommendation by Clearflow to Progressively Pig the pipeline. Consideration was given to the age, size, condition of the pipeline including lead joints, distance the pig needed to travel, type of pig used and the speed at which it was essential to run to successfully clean the line. The site conditions with the discharge of debris, and the amount of debris was also considered.
It was decided to pig this line against the regular flow, therefore new fixtures and additional connections were required both at the treatment plan and the pump station. Clearflow specially designed and fabricated a launcher which was cut into the existing pipeline as a permanent fixture to facilitate future pigging programmes and reduce costs.
Result:
After running four pigs covering the full length of the pipeline, the resulting discharge was an oily black consistency, and the debris collected was six 200 litre drums of mussel shell, weed growth and encrustation. After the operation, there was a 25% increase in the pump cycle.
COOTAMUNDRA SHIRE COUNCIL – NSW
Brief:
Clearflow was contacted as the Council was experiencing dirty water problems.
Challenge:
On inspection, numerous problems with the reticulation system such as unknown locations and non-operational stop-valves were encountered.
Action:
Clearflow implemented a Air Scouring programme, with thorough logging of areas of concern so the Council was able to update their records and schedule all remedial works required.
Result:
Due to the success of the initial programme, the Council has implemented a more structured Maintenance Program, with an annual Air Scouring programme under sequential planning and within the parameters of the Council’s budget.
Brief:
To conduct an air scouring programme in the western mining towns of Dysart and Middlemount.
Challenge:
The Town of Middlemount did not have sufficient valves or hydrants fitted in the system to successfully conduct the operation. To do so meant the entire township would have unnecessary and extended water disruptions over the period of the operation (envisaged 14 days) with limited results. Due to isolated location, delivery of materials was difficult, so a programme of this magnitude required sound planning and expertise.
Action:
Clearflow was contracted to increase the number of valves and hydrants into the reticulation system, so the Air Scouring operation could proceed. Using existing water reticulation plans, Clearflow implemented the changes, supplying and installing a total of 46 units of varying sizes cut into the existing pipeline system, with minimal disruption to the town supply. The entire operation covered two months in one-month blocks. The second stage included the long-awaited Air Scouring operation for Middlemount.
Result:
The entire water reticulation system was improved to meet normal maintenance standard and water quality was enhanced. Clearflow was involved in the entire process, from initial planning through to the cleaning operation and completion.