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Presented by Daniel Williams, P.E. May 1, 2008

Constructing Anacortes’ 36-inch Welded Steel Waterline Replacement Project and its two 1,500-foot-long Horizontal Directional Drills underneath the Skagit River and the Swinomish Channel. Presented by Daniel Williams, P.E. May 1, 2008. Project Overview.

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Presented by Daniel Williams, P.E. May 1, 2008

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  1. Constructing Anacortes’ 36-inch Welded Steel Waterline Replacement Project and its two 1,500-foot-long Horizontal Directional Drills underneath the Skagit River and the Swinomish Channel Presented byDaniel Williams, P.E.May 1, 2008

  2. Project Overview • Replacement of 12 miles of 1920’s-vintage 24-inch Pipeline • $22M in new 36-inch and 24-inch Pipeline Construction • Two major Waterway Crossings (1,300 feet each) by Horizontal Directional Drill • Several Bore and Jack crossings of State and County Roadways, wetlands, and Irrigation Ditches

  3. City of Anacortes Population 16,170

  4. City of Anacortes – Gateway to San Juan Islands

  5. Padilla Bay

  6. City of Anacortes Downtown

  7. City of Anacortes – Ship Building

  8. Oil Refineries (Tesoro and Equilon)

  9. Oak Harbor Pop. 2,841

  10. Naval Air Station, Whidbey Island

  11. Town of La Conner Pop. 900

  12. Skagit County Agriculture

  13. History of Existing System • 1920’s – Original 24-inch Waterline and Raw Water Intake on Skagit River Constructed. • 1950’s – Parallel 36-inch Waterline Constructed to serve new Oil Refineries and provide redundancy. • 1971 – WTP Constructed to Replace Pressure Filter Plant and Rainey Well System. • 1995 – Planning for 24-inch Waterline Replacement Begins • 1999 – 2007: Phased Design and Construction of new 36-inch Pipeline.

  14. Customers of Anacortes Water Supply • Equilon Oil Refinery (Texaco) – 7 MGD (38%) • Tesoro Oil Refinery (Shell) – 5 MGD (28%) • Oak Harbor / Naval Air Station – 2.3 MGD (13%) • City of Anacortes – 1.7 MGD (10%) • Skagit County PUD – 1.6 MGD (9%) • Town of La Conner – 0.4 MGD (2%) • Swinomish Tribal Community – 0.07 MGD (0.4%)

  15. Planning and Design Team • City of Anacortes • MWH – Design and Construction Management • Landau Associates – Geotechnical Engineer • Reid Middleton – Surveying • LBS – Surveying • Pharos Corporation – Right-of-way Acquisition • Staheli Trenchless – Trenchless Design • Evergreen Aquatic Resources – Environmental and Permitting

  16. Agency Approvals • State Department of Health (DOH) • State Department of Transportation (WSDOT) • State Department of Ecology • U.S. Army Corps of Engineers • Skagit County • Diking Districts

  17. Construction Contractors • 2001 – Segment 3A – R.L. Alia • 2001 – Segment 3B – Tri State Construction • 2002 – Segment 1 – Robison Construction Co. • 2002 – Segment 2 – Robison Construction Co. • 2004 – Segment 4 – James W. Fowler • 2007 – Segment 5 & 6 – Tri State Construction • Welded Steel Pipe Supplier – Northwest Pipe • Ductile Iron Pipe Supplier – American CI Pipe Co.

  18. Construction Costs • Segment 3A – 9,500 LF 36” WSP – $2.5M • Segment 3B – 2,940 LF 36” WSP – $1.0M • Segment 1 – 14,400 LF 36” WSP – $3.4M • Segment 2 – 1,300 LF HDD – $1.0M • Segment 4 – 5,200 LF 24” DI – $2.8M • Segment 5 – 17,000 LF 36” WSP (Pipe) – $2.5M • Segment 5/6 – 17,000 LF 36” WSP (Install) – $9.2M Total Construction Cost = $22.4M

  19. Design Criteria -- Hydraulics • Design Flow Rate – 27.5 MGD • Velocity – 6 fps • Typical Operating Pressure – 120 psi to 180 psi • Maximum Design Working Pressure – 250 psi • Maximum Transient Design Pressure – 332 psi

  20. Design Criteria -- Pipe • Steel Pipe – AWWA C200, mortar-lined, tape coated, double-welded lap joints • Steel Pipe – Minimum D/t Ratio – 240 • Ductile Iron Pipe – AWWA C151, mortar-lined, asphaltic coating, restrained joints • Typical Modulus of Soil Reaction (E’) = 700 • Very High Groundwater in Winter • Liquifaction possible in some reaches during seismic events.

  21. Trenchless Methods for River Crossings • Pipe Bridge (Swinomish Channel Crossing) • Microtunnel • Horizontal Directional Drill (HDD) HDD was selected based on cost savings, suitable soils, and room to lay out pipe.

  22. Other Issues • Twin Bridges Marina Repairs at low, low tide • Restraint of Joints on Existing 36-inch Pipeline constructed with Sleeve-type Coupling Joints • Agricultural soil preservation/restoration • WSU Agricultural Station and Skagitonians for Agricultural Preservation.

  23. Other Issues Continued • Army COE and Diking Districts’ Approval for Skagit River Crossing (entry and exit points were placed adequately back from Dikes, plus grout plugs). • WTP Tie-in and HDD geometry. • Easements, Landowner Notification, and Property Restoration

  24. Swinomish Channel Crossing – Overview • Length – 1,300 feet • Depth Below Channel Bottom – 36 feet • Maximum Depth Below Ground Elevation – 60 feet • Pipe Diameter – 36-inch Welded Steel, Polyurethane Lined and Coated

  25. Swinomish Channel Crossing – Overview • Length – 1,300 feet • Depth Below Channel Bottom – 36 feet • Maximum Depth Below Ground Elevation – 60 feet • Pipe Diameter – 36-inch Welded Steel, Polyurethane Lined and Coated

  26. Swinomish Channel Crossing –Construction Sequence • Drill 12-inch Diameter Pilot Hole • Pull 24-inch Ream back through Pilot Hole • Push 50-inch Ream through 24-inch Hole • Pull 50-inch Swab back through 50-inch Hole (to Verify that Hole is Clean) • Pull back 36-inch Diameter Pipe

  27. Swinomish Channel Crossing – Drill 12-inch Diameter Pilot Hole • Start Pilot Hole: 8/7/02 • Finish Pilot Hole: 8/12/02 • Advance Rate: 2 to 3 feet/min.

  28. Swinomish Channel Crossing – Push 24-inch Ream through Pilot Hole • Started Ream: 8/15/02 • Finished Ream: 8/17/02 • Advance Rate: 1 foot per min.

  29. Swinomish Channel Crossing – Push 50-inch Diameter Ream through 24-inch Hole • Start 50-inch Ream: 8/17/02 • Finish 50-inch Ream: 8/19/02 • Advance Rate: 30 feet per hour • Worked 24 hours per day to compete 50-inch Ream

  30. Swinomish Channel – Pull Back 36-inch Pipe • Start Pull Back: 7:00 a.m. • Finish Pull Back: Midnight • Pull Back Rate: 30-feet every 10 minutes • Pulling Force at Drilling Machine was 170,000 to 180,000 pounds

  31. Swinomish Crossing – Misc Photos

  32. Skagit River HDD Crossing – Installed 2007 • Length: 1,540 feet • Depth Below River: 45 feet • Depth below Grade: 75 feet • Pipe: 36-inch welded steel

  33. 36-inch Steel Pipe Prior to Pull

  34. Skagit River HDD -- Timeline • Set up Drill Machine – Aug 27th • 8-inch Pilot Hole – Sept 3rd • 24-inch Ream back through Pilot Hole – Sept 7th • 44-inch Ream back – Sept 14th • 54-inch Ream back – Sept 18th • Pulled 36-inch pipe beginning 10:00 a.m. and ending at 5:00 p.m., September 22nd. Note: Pulling force reached 300,000 lbs

  35. 36-inch Steel Pipe prior to Pull

  36. Ready to Pullback 36-inch Pipe

  37. Cranes Support 36-inch Pipe during Pull

  38. Cranes Support 36-inch Pipe during Pull

  39. WTP Tie-in – 36-inch Fittings and Couplings

  40. Dewatering Well Construction

  41. Pipeline Installation aided by Dewatering

  42. Dewatering Wells and Vacuum Header Pipe

  43. Hot Tap tie-in to 24-inch Ductile Iron Pipe

  44. 36-inch Steel Pipe prior to Installation

  45. Pipe resting on Sand Supports

  46. Bell and Spigot Lap Joint prior to Welding

  47. 36-inch Pipe Installation

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