A Complex Lining Project in Brooklyn’s Gowanus Canal Led to Creative Solutions
By: Mario Carbone, COO, Progressive Pipeline Management (PPM)
Publication: Trenchless for Gas Infrastructure - Spring 2024
The pipeline inside the tunnel dates back to the 1920’s.
Since 2002, Progressive Pipeline Management has been installing the Starline® Cured-In-Place-Lining trenchless technology for natural gas main renewal. The trenchless pipeline renewal technology is proven to be an effective alternative to conventional replacement methods for cast iron and steel pipelines.
Cured-in-Place-Lining relies on engineering, whether it is a conventional lining application, or when there are multiple complications. Rehabilitating natural gas pipelines requires a collaborative team with hands-on expertise of both natural gas and lining. Engineering innovation emerges from a need to solve a problem.
Every lining project, no matter how small or how complicated, requires up front engineering. Preparing the projects involves a knowledge of both gas procedures as well as lining applications. The two disciplines merge into a subject matter expertise and the ability to create new engineering processes. The 30-inch turnkey project in Brooklyn’s Gowanus Canal challenged what we thought was possible. There were several times we wondered, can it be done? With the creative engineering and ingenuity of National Grid and Progressive Pipeline Management, the challenges became a catalyst for multiple innovations.
Can It be Done?
There was nothing conventional about this project. The drawings showed a pipe configuration I had never seen. The 30-inch cast iron pipeline started above the ground and turned straight down 40 feet. It bended again, entered a tunnel for 200 feet, turned sharply with a 36-inch drip and up the other side of the canal. Access points to the pipe were extremely limited. The process of cleaning the pipeline’s interior had to be redesigned. The challenge of lifting the debris 40 feet to a vacuum truck, had to be overcome. A completely new approach to connecting the lining fitting to the pipe would need to be invented and engineered. Almost every lining standard and procedure would have to be redesigned, tested, and implemented.
After weeks of internal discussion within PPM’s engineering group, we worked through options and recommendations with National Grid’s engineers, pipeline and construction experts. Our collective expertise encompasses the best of rehabilitation technology, pipeline construction, gas engineering and distribution. Each scenario was considered and debated.
Even as we discussed possible solutions, I knew from experience to expect the unexpected. In lining, like chess, you can’t see the challenges all at once. At best you see the next one or two moves. As each new challenge appeared, we would have to face it head on and then be ready for the next one.
the best-laid plans
After many weeks, we had a project design for the Gowanus Canal, on paper. When we got on site and entered the tunnel where the pipe travels under the Gowanus waterway, it was obvious that everything on paper needed to change. Although National Grid’s drawings were accurate, what we found was much more complicated.
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““Gowanus Tunnel pipeline was one of the most complex projects we faced. The cast iron pipe was installed in the 1920’s. Lining involved a challenging inversion through the vertical section in the access shaft, and complex custom fittings to align to the existing pipe. Teamwork, PPM’s engineering and expertise were invaluable to the success of this job.”
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About PPM: Progressive Pipeline Management is a full service contractor and team of highly skilled infrastructure renewal specialists. For over twenty two years, PPM has been improving the safety and longevity of pipeline infrastructure. They hold the exclusive licensee in North America for the Starline® Cured-in-place-lining. PPM’s specialized expertise includes gas pipeline rehabilitation, restoration of damaged or leaking infrastructure, PIPES ACT 2020 compliance and trenchless technology.
