Department of Energy uses Fusible PVC™ Pipe to Rehab Water Lines

The U.S. DOE was faced with the need to replace or repair ductile iron fire and process water pipelines at its Oak Ridge, TN facility. The lines had been in service for over 50 years and had suffered numerous failures in recent years due to corrosion. UGSI was contacted initially regarding the use of Fusible PVC™ pipe, and ultimately a solution utilizing Duraliner™ - UGSI's close-fit, structural pipeline renewal system - was selected for the project. The Duraliner™ system provided the largest ID possible (inside the existing iron pipe) with a fully pressure rated 200 psi rehabilitated pipe. The on-site fabricated Duraliner™ pipeline system was slipped into the existing host pipe, filled with water, heated, and pressurized to expand as a close-fit solution within the ID of the compromised host pipe.

The project presented several unique challenges. The existing waterlines were located in extremely crowded areas of the DOE complex. DOE engineers would allow only minimum disturbance of the soil envelope around the existing pipelines. These conditions ruled out pipe bursting and normal sliplining (or CIPP) procedures. These methods would have resulted in an ID that was too small or a pressure rating that was too low. The Duraliner™ pipe was custom sized to a wall thickness and OD so that, when fully expanded and installed in the host pipe, it provides the maximum ID and the required pressure rating.

UGSI's fusion technicians worked closely with Contract Management personnel to install and expand the liner under the coordinating eye of DOE field installation supervisors. All digging of entry, exit, and connection pits was done by DOE personnel. Installation went smoothly under very difficult (limited access) conditions and all pipe was pressure tested before putting the system back in service.

Pipe Joint Fusion

Expansion Vehicle

Pipe Expansion on Site