JP-8 Pipeline Replacement - Charleston, SC

Pond performed this design-build, fast track project to relocate a section of 8” JP-8 fuel transfer line from DFSP Charleston to Charleston Air Force Base (AFB), which was 8 miles long. The section was directly under Interstate 26 (I-26), an active 8-lane freeway. Pond’s engineers finished a work plan and design within a month, and construction began shortly thereafter.

Work included the installation of new fuel piping outside the limits of the new Remount Road overpass, draining and gas freeing the existing line, tie-in connections between new and existing, testing and flushing, and proper abandonment of the existing piping section under I-26. Work was performed in phases to allow continuous operation of the pipeline until draining for the tie-in. Phasing was coordinated with DFSP and Charleston AFB. The operational capability of the existing line could not be disrupted for more than seven consecutive days.

Project included the following:

  • Clearing, grubbing and erosion control.
  • Installation of dewatering wells and equipment.
  • Shoring and excavation of Microtunnel and jacking and receiving pits.
  • Microtunnel and jacking of a 24” casing pipe under I-26.
  • Fabrication and installation of 8” carrier pipe for section located within casing under I-26.
  • Radiographic inspection and weld testing (pneumatic test) for piping section located within casing.
  • Installation of casing end seals and wax fill (flowable) interstitial space.
  • Fabrication of carrier pipe from casing seals to tie-in points on east and west side of I-26.
  • Radiographic inspection of welds.
  • Construction of isolation valve pit and low point drain pit, and installation of associated valves and piping.
  • Pneumatic testing and cleaning (pigging) of new piping section (prior to tie-in).
  • Draining and pigging of existing piping system to remove fuel and vapor free piping section prior to cutting piping.
  • Cutting existing pipeline and performing tie-in connections.
  • Start-up and flushing of transfer pipeline.
  • Removal of approximately 200 LF of piping between tie-in points and I-26.
  • Pipe section under I-26 to be abandoned with ends filled with grout.
  • Site cleanup and demobilization.

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