72in Telescoping Bypass

Internal SEALFAST™ inflatable seals visible on the center elbow section were used to allow the two bypass end sections to be pulled back into the elbow during installation to provide seal around the ends.

External SEALFAST™ inflatable seals shown that sealed to the existing concrete piping ends during installation. Also visible are guide rollers and come-along attachment points for bypass manipulation and support during installation.

Internal supports were added to prevent elbow buckling due to water weight and flow thrust while lifting bypass from above.

72in Telescoping Bypass

THE CHALLENGE

We were tasked with the analyzing the acquired survey data and flow calculations to provide an easy to install and dependable working-solution in a very short timeframe. We began by checking the prepared flow calculations and existing thrust block / piping geometry. MRD modeled the entire vault in Solidworks® CAD and developed a bypass and installation procedure that was to meet the customer capabilities and requirements. Design function and lifting loads were analyzed with FEA software and a complete design package was delivered to the customer. After review, MRD was able to move quickly to the fabrication process.

Several hundreds of millions of dollars worth of contract construction were hinging upon a quick feasibility study, design, and fabrication solution.

FLEXIBLE, HIGH FLOW SOLUTIONS!

High flow, telescoping bypasses for installation under flow — made to fit almost any size and length.

THE SOLUTION

MRD utilized in-stock heavy profile inflatable seals and in-stock steel, burning, welding, and fabrication resources to quickly fabricate the bypass. Cranes were utilized to attach to load-rated lifting points on the bypass to support the bypass water weight load during installation. The unit was shipped overnight to the customer and was installed immediately. The customer installed the bypass specifically to our installation procedures and were able to begin construction demolition and repair within a day. Work occurred on three shifts over two weeks including the pouring and set-up of critical concrete structures. After successful completion the bypass was removed and the customer was able to move on to the remainder of their construction schedule.

The customer installed the bypass specifically to our installation procedures and were able to begin construction demolition and repair within a day.

CAD model explosion of the primary bypass components detailing the two end sections that passed into the existing pipe sections. The center elbow was dropped in thereafter. All components were held in place with come-alongs until they could evenually be pulled together and locked in place with turnbuckles. Internal and external SEALFAST® inflatable seals can be seen on each section which were actuated after all sections were locked into place.

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