Flow Control Group recently completed a repair on a 24-inch (600 mm) carbon steel water transmission main for a municipal client. The project involved critical water infrastructure and had to be completed within a strict 24-hour shutdown window due to system capacity requirements and limited reservoir storage. Through careful planning, experienced crews, and efficient execution, the repair was completed safely while minimizing downtime and service interruptions.
Innovative Solution: Weld-On Encasement Sleeve
To meet the limited shutdown window, the project team selected a JCM 117 weld-on encasement-style sleeve. This repair system provided a much faster alternative to conventional methods, such as cutting out and replacing the damaged pipe section with a welded butt strap. That traditional approach was estimated to require approximately 72 to 96 hours.
The encasement-style sleeve also significantly reduced project costs. Its total cost was estimated at only 20% to 30% of the conventional repair method, largely because it minimized additional work and associated expenses, including:
- Larger excavation requirements
- Chamber removal and reinstatement
- Additional fittings and hardware
- Extended service interruptions
- Administrative costs
- Unplanned project expenses
The JCM 117 is designed to repair and reinforce in-service steel pipelines while reducing operational disruption. It is suitable for addressing weakened or leaking pipe sections affected by:
- Internal or external corrosion
- Physical damage, including dents and gouges
- Defective welds
- Material defects
Adjusting to On-Site Challenges: Switching to the JCM 417 Split Tee
As part of the project preparation, the upstream and downstream isolation valves were tested to verify they could provide a safe shutdown for the welding work. During testing, the team identified minor valve leakage, with approximately 5 gallons per minute (GPM) bypassing one of the valves.
To overcome this issue without delaying the project, the repair approach was modified by using a JCM 417 Type 1 Split Tee. Similar in design to the JCM 117 encasement sleeve, the JCM 417 includes an outlet connection that allowed the crew to:
- Cut an opening at the top of the pipeline
- Pump out water bypassing the isolation valve
- Keep the exterior of the pipe dry to maintain proper welding conditions
By quickly adapting to the field conditions, the team kept the project on schedule and successfully met the client’s shutdown requirements.
Enhancing Durability: NSF-Approved Epoxy Coating
Efficient Execution: Finishing 6 Hours Ahead of Schedule
A big thank you to everyone involved for their hard work and commitment to excellence!