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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER

TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING


JAYA, SELANGOR DARUL EHSAN

1.0 INTRODUCTION

The work has been awarded to Haluan Prisma Ang Yoke Lian
Construction J.V. with start date of 6th February 2007 and
scheduled to be completed by 12th February 2007.

The original scope of works involved the followings: -

a) Carry out Noise Logger Correlation test


b) Construct working pit
c) Carry out repair work using internal physical inspection
method
d) Provide traffic management
e) Provide report by Independent Consultant
f) Construction of manhole chamber

The work was awarded to Haluan Prisma Ang Yoke Lian


Construction J.V. with understanding that LINE A was leaking
somewhere underneath the highway and the best method of
repair was to avoid open excavation and repair work to be done
from inside of the pipe. The duration given was also based on
this understanding as well as that the repair work could be done
immediately with minimum time frame of a week.

When the works started, the contractor was facing the problem
in detecting the pipe. Based on as-built drawings received from
SYABAS, the pipes should be about 2-3 meter below ground level.
Pilotings were done but the pipes could be not located.
Eventually, the pipes were detected at depth of 7.8 meter and
8.6 meter after large trenches were dug up.

This created another problem as this situation requires the


construction of coffer dam. After the requirement of coffer dam
issue was solved, the contractor was facing with another problem
that was the pipeline could not be totally emptied due to
upstream leaking at the butterfly valve at Bukit Dengkil
Reservoir. The contractor only managed to inspect the inside of
the pipe after the leaked butterfly valve was replaced.
Subsequently, the contractor also faced another surprise as no
leak was found in LINE A. Thus contractor was asked by SYABAS
to do additional work to identify leakage in LINE B.

The full proposed method to repair the pipe is as describe in


detail under SECTION 2.0 below. The details of works already

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

done are described in detail under SECTION 3.0. Meanwhile,


SECTION 4.0 gives detail of the revised scope of works and
SECTION 5.0 shows the reasons and duration of extension of
time required.

2.0 METHOD REPAIR WORKS OF INTERNAL WELDING AT THE


LEAKING SPOT (MINOR LEAKAGE REPAIR)

This method will only entail a minor traffic management

a) Locate the leak/s thru Noise Logger & Correlation Method.

b) From step (a) above we can further narrow down the area where
the leak is. Measure the distance of the leak from the shoulder of
the road towards Puchong.

c) Install barricade, hoarding and traffic signals along the area to be


excavated to the requirement of authorities.

d) Excavate a pit of size 12 m x 8 m x 10 m depth to expose both


the 1800mm (Line A and B) pipes. Excavation to be continued
until the twin 1800mm pipes are exposed. Once its exposed,
the coffer dam size of 11m x 6m (refer APPENDIX 2) is
constructed as a protection to the pit.

e) Upon reaching the pipes concerned, confirm with SYABAS


Petaling which is the right pipe as there are two 1800mm pipes
running parallel towards the reservoir. Once the right pipe is
confirmed, SYABAS Petaling will dewater the pipe, and an access
tee measuring 800mmx450mm long will be installed to the
pipe.

f) Once the pipe is emptied, all air valves will be removed. An


electrical blower (size 600mm) will be used at the air valve tee
in the Bukit Dengkil Reservoir to blow the air and suction blower
to be placed at the new access tee to suck the air out from the
pipes to provide ventilation to the pipe.

g) Chlorine vapour test of the pipe will be carried out to determine


the safety level before the inspection team; comprising SYABAS
and Contractor, mobilize into the pipe to carry out the inspection
of the pipe. The chlorine Vapour Test equipment is carried all the
time once they are inside the pipe. Once the beep sound is
heard all inspectors/workers must come out of the pipe.

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

h) The team will measure the distance previously determined and


check for leakage at the location and carry out further check
along the internal pipe if necessary.

i) Once the leakage location has/have been found and the cause of
the leak is/are determined and the leakage is considered minor
by the inspection team, the internal welding method will be used.

j) For leakage such as minor cracks on the welding joint of the pipe
or due to socket plug damaged, the cement lining around the
spot concerned will be removed.

k) Then the existing joint will be grind to remove the damage


welded joint and redo the welding joint internally. Then grind by
fibre grinder to a level the surface to install the internal collar
(200mm wide x 10mm thick) for double protection and will then
be fillet welded to cover the leaking spot which had been filled.

l) For minor crack on the welded joint along the longitudinal


section, the whole section longitudinal welded joint will be
removed similar method as step (k) above. Add a plate (10mm
thick) of 200mm width and length as the exiting section of the
pipe which will be curve to the shape of the metal shell covering
100mm both sides of the repaired section and minimum of
50mm both side lapping to the next section of the pipe and fillet
weld to the body of the pipe adjacent to it.

m) For small puncture on the pipe, we assume that there will be


rusty and some small part of the pipe must be removed. Since
the road is above the pipe, we will be required to strengthen the
soil surrounding the leakage point to avoid erosion or sink hole.
Pressure grouts the external of the pipe to fill up the void created
and to strengthen the surrounding soil.

n) Once the soil surrounding the pipe is strengthen, the pipe body
will be cut to remove the rusty and damaged section. Then a
piece of steel plate slightly smaller in size to the opening and
butt weld the plate to the pipe body adjacent to the opening and
then add internal collar to the spot as per step (k) above.

o) Upon completion of the repair works, the cement lining with


rapid hardener will be used to repair the damaged lining.

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

p) The access tee will then be closed with blank flange. A chamber
will be constructed at the access tee for future used.

3.0 REPORT ON THE WORKS DONE

3.1 Locating the twin 1800mm pipeline (LINE A and LINE B)

Piloting works and pipe detection works has been carried out
started on 6th February 2007. Piloting works have been carried at
several locations but failed to detect the twin pipes.

Photo No. 1 & 2 : The piloting works at several location have been
carried out

The contractor has engaged a licensed surveyor to demarcate the


R.O.W. and mobilise the utilities detection team to locate the twin
pipes. On 3rd March 2007 the twin pipes were discovered at 7.8meter
and 8.6 meter depth respectively.

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

Photo No. 3 & 4 : The twin 1800mm pipes was located at 7.8m and
8.6m depth respectively

3.2 Change in site condition Bulk excavation

Due to the changes of the site condition, where the depth of


pipes is located more than 8 meter depth, the Contractor has to
carry out bulk excavation to expose the twin pipelines. The
excavation was carried out in 2 tiers to reach at 8 9meter
depth.

3.3 Construction of coffer dam

The construction of cofferdam size of 11 m x 6 m x 10 m depth


has to be constructed due to extreme depth of the excavated
area and for the safety reason.

Photo No. 5 & 6 : The construction of the cofferdam

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

3.4 Leaking of existing 1600mm butterfly valve at Bukit Dengkil


Reservoir (LINE A)

The method of repair is to physically inspect and repair the pipe


internally. Thus, in order to go into the pipeline, the pipeline must
be free from combustible gases i.e. chlorine, methane and etc.
The leaking from the 1600mm diameter butterfly valve has
caused the pipeline will be continuously has a running water,
therefore the internal repair works cannot be carried out.

It was agreed by SYABAS to change the existing 1600mm


butterfly valve, before the physical access to the pipe can be
done. The contractor has installed an end cap before the butterfly
valve in order to stop the water flowing back to the pipeline. Due
to the ERP (Emergency Response Plan) reason where pipe burst
was occurred at CH7000m of 1600mm pipe (LINE A) at
Cyberjaya on 15th May 2007, the works were postponed and only
continued been carried out on 16th June 2007.

Photo No. 7 & 8 : Replacement of the existing 1600mm butterfly


valve (LINE A) at Bukit Dengkil Reservoir

3.5 Repair Works for LINE A

From the internal inspection, it was found that there is no leaking


in the LINE A. Physical inspection to the internal pipe cannot find
any severe damage to the pipe. But there are 2 spots where the
cement lining of the pipe were damaged and the pipes shell

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

were corroded. The location of the damage is illustrated in the


sketch below at Point B.

Photo No. 9 & 10 : 2 spots of damage cement lining and corroded


pipes shell detected at CH 75m and CH 78m

The spots has been grinded and applied with epoxy paint. Then the
300mm x 300mm x 10mm thick of ms plate is used to patch the
damage area by welding to the pipes shell. Then the epoxy paint is
applied again before cement lining with fast hardening admixtures is
carried out which flush with the existing pipes cement lining.

Photo No. 11 & 12 : 2 spot of damage have been repaired and cement
lined

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

A part of the above, the pipeline was filled up with debris, small rocks
and other waste materials. The contractor has cleaned up the internal
pipe and further physical inspection is carried out and no further
damage was found in the pipeline.

Photo No. 13 & 14 : The pipe was filled up with debris and after the
pipe was cleaned up

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

12mm End Cap


POINT D (CH 121 m)
Access tee (Air Valve) 8 nos tie rod

Existing
Chamber at
Bukit
Dengkil
Reservoir
POINT A (CH 0 m) POINT B (CH 75 & CH 78)
700mm dia. Access Tee 2 damage cement lining
and corroded pipes shell
has been repaired
Existing 1600mm BV
has been replaced

45 deg. Vertical bend

POINT C (CH82m to Ch 92m)


Debris i.e. small rocks, sand,
welding rod have been cleared

40 deg. Horizontal bend

Existing 1800mm dia. Pipe (LINE A)

Sheet piles (Coffer dam)

SKETCH OF THE LONGITUDINAL SECTION FOR 1800mm PIPELINE (LINE A)

4.0 PART 1 : TECHNICAL REPORT REVISED SCOPE OF WORKS

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

Based on the available data and information, the location of the


pipes was located beside the Puchong and Bukit Jalil Highway
before reaching Bukit Dengkil Reservoir.

The original scope of works has been differed due to the existing
site condition. The change of the scope of works is elaborated as
follows:

4.1 Locating the twin 1800mm pipeline (LINE A and LINE B)

Based on the as-built drawing given by SYABAS, it was estimated


both pipeline are having about 2-3 meter depth of cover to the
crown of pipes. However, after piloting and mobilized utilities
detection team the pipe cannot be located. Contractor has
engaged a licensed surveyor to demarcate the R.O.W. and
carried out utilities detection team to locate the exact location
and depth of the pipes.

Thus, the contractor has carried out piloting works within the
demarcated R.O.W. and bulk excavation and discovered the twin
pipes are buried at 7.8 meter and 8.6 meter depth respectively.

Photo No. 15 & 16 : The survey and piloting works has been carried out

4.2 Change in site condition Bulk excavation

The depth of original scope of works is to excavate the pipe


trench about 3 4 meter depth (based on the as-built drawing)
to exposed the twin 1800mm pipes. Due to the changes of the
site condition and the pipes are detected at more than 8 meter

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

depth. Contractor has carried out bulk excavation to expose the


twin pipelines. The excavation was carried out in 2 tiers to reach
at 8 9meter depth.

Photo No. 17 & 18 : The utilities detection was carried out inside the
trench and bulk excavation works

4.2 Construction of coffer dam

The construction of the coffer dam is an additional works to the


original scope of works. The reason is the depth of the trench is
increase drastically and due to the safety reason the construction
of the coffer dam is necessary.

Photo No. 19 & 20 : The construction of cofferdam and access tee

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

4.3 Leaking of existing 1600mm diameter butterfly valve at Bukit


Dengkil Reservoir (LINE A)

The method of repair is to physically inspect and repair the pipe


internally. Thus, in order to go into the pipeline, the pipeline must
be free from combustible gases i.e. chlorine, methane and etc.
The leaking from the 1600mm diameter butterfly valve has
caused the pipeline will be always has a running water, therefore
the internal repair works cannot be proceeded.

It was decided to change the existing 1600mm diameter butterfly


valve, before the physical access to the pipe can be done. The
contractor has installed an end cap before the butterfly valve in
order to stop the water flowing back to the pipeline. Due to the
few reason i.e. burst 1600mm diameter pipe (LINE A) at
Cyberjaya (same pipeline) on 15 th May 2007, the works only can
be carried out and completed on 17th June 2007.

Photo No. 21 & 22 : Leakage at 1600mm diameter BV and temporary


end cap and additional tie rod have been installed

4.5 Location of Leaking

Based on the earlier information, it was suspected that LINE A


has been detected leaking. However, after physical inspection
has been carried out, there are no sign of leaking. Thus, the
result of leaking that produced by the Noise Logger Correlation
Test carried out is suspected come from leaking in LINE B.

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

The same procedure will be implemented to inspect and detect


the leaking in LINE B.

Photo No. 23 & 24 : Spotted damage to cement lining but not leaking
and existing condition full of debris in LINE A

Photo No. 25 & 26 : Damaged cement lining and debris have been
repaired and cleaned

4.6 Construction of chambers

Due to the depth and size of the trench, a new reinforced


concrete chamber has been proposed for the purpose of future
maintenance as the Sg. Besi-Puchong Highway has became a
very busy road with extremely high traffic volume and will be
difficult to carry out the maintenance/repair of the pipes using
open trench excavation on the highway should any unforeseen
circumstances happen to the pipes underneath the highway.

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

Further the one side of the highway adjacent to Bukit Dengkil


Reservoir is on slope, any deep excavation might disturb the
stability of the slope.

The size of the chamber is 7 meter x 9 meter x 10 meters in


depth.

5.0 PART 2 : EXTENSION OF TIME DUE TO THE CHANGES IN


SCOPE OF WORKS

Due to the above reason, the contractor has required additional


time to complete the works. Thus, the Extension of Time No. 1
was submitted for SYABAS approval. Followings are the reasons
for the extension of time: -

i) The original contract period (7 days) awarded to the


contractor are not sufficient as the period was mainly for
implementing the repair works only. The piloting works,
construction of chamber and reinstatement works are not
included in the original contract period.

ii) Delay in locating existing twin 1800mm diameter pipeline

It was learnt that this pipeline was completed in 1986 by


Jabatan Bekalan Air Selangor. Due to rapid development in
the vicinity and insufficient information available in
SYABAS, the locating of this pipeline has taken so much
time and effort.

The piloting works has been carried out at five (5) different
locations but failed to detect the twin pipes. Contractor has
to appoint license surveyor to carry out the utilities
detection and demarcated the pipeline Right of Way
(R.O.W.). Finally, the pipes were located at 7.8m and 8.6m
depth. The works has contributed 23 days of delay.

iii) Change in site condition

The development of the surrounding area has cause the


pipeline reserve was backfill with the additional earth and
the pipeline was buried more than eight (8) meter depths.
The contractor has to carry out major excavation to reach

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

the bottom of pipelines. Thus, the contractor requires 23


days for the additional time for bulk excavation.

iv) Noise Logger Correlation Test

The location of the leaking is located at the median of the


very heavy traffic highway. Thus, the piloting method to
identify the leakage is not viable. Therefore, Noise Logger
Correlation Test has been carried out by SYABAS Petaling
to identify and narrow down the location and which
pipeline is leaking. The overall test procedures have
contributed 44 days in delay.

v) Construction of coffer dam

Site condition has changed and the depth of the


excavation has varies extremely to the depth of 8 - 9
meters depth. Therefore, the construction of coffer dam
has been introduced due to safety reason. This
construction takes 28 days to complete.

v) Existing 1600mm diameter Butterfly Valve (Inlet) Bukit


Dengkil Reservoir leaking

The method of repair is to physically inspect and repair


the pipe internally. Thus, in order to go into the pipeline,
the pipeline must be free from combustible gases i.e.
chlorine, methane and etc. The leaking from the 1600mm
diameter butterfly valve has caused the pipeline will be
always has a running water, therefore the internal repair
works cannot be implemented.

It was decided to change the existing 1600mm diameter


butterfly valve, before the physical access to the pipe can
be done. The contractor has installed an end cap before
the butterfly valve in order to stop the water flowing back
to the pipeline. This works has contributed 97 days in
delay.

vi) Location of Leaking

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

Based on the earlier information, it was suspected that


LINE A has been detected leaking. However, after
physical inspection has been carried out, there are no
sign of leaking.

Thus, the Noise Logger Correlation Test was once again


has been carried out and detected / suspected that LINE
B is probably has a leak.

It was decided that the same procedure / method of


inspection and repair for LINE A will be implemented to
inspect and detect the leaking in LINE B. Thus the period
for the detection of leaking and repair will takes 39 days.

vii) Construction of chambers

Due to the depth and size of chamber, the new reinforced


concrete chamber has been proposed. The construction
of chamber takes 91 days to complete.

viii) Postponed on the replacement of the existing 1600mm


dia BV

The works has been postponed due to ERP (Emergency


Response Plan) where the the downstream of the same
pipeline was burst near to Cyberjaya CH 7000m on 15 th
May 2007. The replacement of BV was rescheduled on
17th June 2007. This works has contributed 97 days in
delay.

ix) Additional requirement by Safety and Health Department,


SYABAS

Safety and Health Department, SYABAS has implemented


the Confined Space Entry Regulations. This regulation has
contributed 7 days of delay.

6.0 CONCLUSION

After throughout inspection of the two pipes and further study


of the system, the leakage has been stop.

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EMERGENCY REPAIR WORKS ON THE TWIN 1800MM DIAMETER
TREATED WATER PIPELINE AT BUKIT DENGKIL RESERVOIR, PETALING
JAYA, SELANGOR DARUL EHSAN

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