16 - PROJECT #191 EMERGENCY WORK SANTA ANA FORCE MAIN 23RD FORCE MAINCosta Mesa Sanitary District
Protecting our community’s health and the environment by providing solid waste and sewer collection services cmsdca.gov COSTA MESA SANITARY DISTRICT . . .an Independent Special District
Memorandum To: Operations Committee Via: Scott Carroll, General Manager From: Robin B. Hamers, District Engineer Date: September 18, 2012 Subject: Emergency Work: Santa Ana Force Main
Repair & 23rd Force Main Repair _____________________________________________________________________ Summary The force mains for the Santa Ana Pumping Station and the 23rd Pumping Station
were electronically inspected on July 17-18, 2012 and the results indicate there is little to no remaining pipe wall thickness in multiple areas in both lines and a rupture may occur
at anytime. Staff Recommendation The Committee recommends to the Board of Directors approving the following action: 1. Ratify the General Manager’s declaration of the emergency condition
(Operations Code 4.04.120(a)) for each of the force mains due to the imminent failure of the force mains. Failure of either force main will lead to wastewater entering the Upper Newport
Bay (Back Bay) resulting in beach closures and fines levied against the District. 2. Transfer funding into the Capital Improvement Program by a budget adjustment for the repair of both
force mains in an amount still being determined. This will be furnished to the Board in advance of the Board meeting as soon as it is made available. 3. Award Spiniello Companies (the
licensee authorized to install NordiTube lining in the western United States) a lining contract for the force mains and award Schuler Engineering a separate contract for the force mains.
Spiniello Companies will be installing the NordiTube lining and Schuler Engineering will replace all the old piping from just outside the station to inside the station plus Schuler will
be providing access pits for Spiniello to install the lining. Schuler will also be providing traffic control and the bypass operation.
Operations Committee September 18, 2012 Page 4 of 4 Analysis After successfully cleaning each of the force mains through a pigging operation, the District entered into an electronic
inspection contract with PICA Corp. from Edmonton, Canada. The PICA technology is brand new and represents the first available technology to determine the remaining pipe wall thickness
from end to end of the line without excavation. The PICA inspection occurred on July 17-18, 2012 for the Santa Ana Force Main and the 23rd Force Main. The final report was previously
distributed to Board and Staff and the pipe wall thickness chart for each force main is attached hereto as Exhibit “A”. The column titled “Tmin1 RW%” is highlighted and represents the
remaining wall thickness expressed in percent at the thinnest point in each section of pipe (the pipe segments are each 18 feet long). The Santa Ana force main was installed in 1977
and the 23rd force main was installed in 1984. As can be seen in the wall thickness chart, many of the values are zero indicating the area is 100% graphitized (the metallic components
have corroded away and only graphite remains). Having a 100% graphitized area does not necessarily mean that the pipe is leaking though. Once the iron is completely leached out of the
material, the graphite matrix that is left behind still has some strength left. Usually, the weakened area has to grow in surface area to some size (say more than 1" diameter) before
a surge in pressure, or some ground movement (vehicles, tremors, water hammer, or even the soil simply drying out) will cause the graphite plug to pop out and cause a leak. Therefore,
time is of the essence in repairing the force mains. Installing structural liners in force mains is more specialized than installing liners in gravity sewers because the force main liners
must withstand the pressure of the pumps. Additionally, the liners must be very thin in order to maintain the original pipe diameter as close as possible. The District has past experience
with products from Sekisui and their pressure pipe lining company is NordiTube. Spiniello/NordiTube is providing the lining of the force mains from the outlet manholes to just outside
the pumping stations and Schuler Engineering is removing and replacing the old ductile iron pipe inside the stations. Together, all the older piping will have been either lined or replaced.
In order to insure the above proposal is cost effective, the lining cost will be compared to dig and replace costs. Strategic Plan Element & Goal This item complies with Strategic Plan
Element 1.0, Sewer Infrastructure and Goal No. 1.4 System Wide Sewer Replacement and Repair Program. The strategy for this Strategic Element is
Operations Committee September 18, 2012 Page 4 of 4 ”We will do this by the careful management of the collection infrastructure using prudent planning and maintenance, with financial
strategies to maintain sufficient capacity and respond to changing regulatory demands.” Legal Review District Counsel will review and approve contracts with NordiTube and Schuler Engineering
when the draft form of the contracts is finalized. Financial Review At the time this report was prepared, the final total cost was still being calculated by the contractors. The final
cost will be made available at today’s meeting. When the dollar value of the work is established, a budget adjustment will be needed as there are currently no funds set aside for this
emergency work. Public Notice Process Copies of this report are on file and will be included with the agenda packet for the September 18, 2012 Board of Directors regular meeting at District
Headquarters and on the District’s website. Alternative Actions 1. Do not award and emergency contract to Spiniello Companies and Schuler Engineering 2. Refer the matter back to staff
for additional information