Pipeline Technology Conference 2015

1. Introduction
Most power plants require a circulating water system to transfer the waste heat
generated by steam cycle into the ambient environment. Recently three kinds of p
ipe
materials have been used widely; these are steel, GRE (Glass Reinforced Epoxy),
and HDPE materials.
HDPE pipe is selected for the Ras Djinet Combined Cycle Power Plant Project to
intake sea water from the intake head located 1 km away shoreline. Ultra large s
ize
of 2500 mm diameter of HDPE pipeline was successfully installed by Daewoo
Engineering & Construction Co., Ltd. through rigorous analysis with respect to d
esign
and installation. A bird's-eye view of the project is shown in Figure 1. This pa
per
covers the design of HDPE pipeline and the procedures of its installation.
Figure 1. A Birds-Eye View of the project
2. Material and Design Consideration
The seawater intake system of a power plant has the function of delivering cooli
ng
water to condenser and auxiliaries. The objective of the design process for pipe
line of
intake and outfall system is therefore to determine the size of pipeline which e
nsure
flow rate which systems required. The intake system for the project is designed
to
intake seawater of 108,240 m3 per hour with HDPE pipeline and finally designed t
o
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Pipeline Technology Conference 2015

162,360 m3 per hour considering safety factor of 1.5. The design velocity in the
each
pipeline is limited less than 2.5 m/sec and leads to the size of diameter 2500 m
m with
4 pipelines.
2.1 Material Selection
The HDPE pipeline adopted for the project has been increasingly used for various
marine applications such as water intake, effluent outfalls, river and lake cros
sings,
apart from oil and gas industries. There are various benefits of HDPE such as
immunity to galvanic corrosion, light weight and flexibility, which have become
excellent solution for water intake system in power plant.
Table 1 and Table 2 present the key characteristics of the as designed HDPE pipe
line
and material properties, and Figure 2 presents its schematic configuration.
Table 1. HDPE Pipeline Key Design Characteristics
Description
Intake Pipeline
A Intake Pipeline B
Type

SDR30
SDR26
Material

HDPE
HDPE
Material Grade

PE100
PE100
mm
2500
2500
Service

Raw Sea Water

Raw Sea Water

Pressure Regime

LP
LP
mm
83.3
96.2
bar(g)
5.5
6.4
Design Temperature
C
40
40
Operating Temperature
C
24
24
MPa
10
10
Pipeline Outer Diameter
Wall Thickness
Design Pressure
Minimum Required Strength (MRS)
Table 2. High Density Polyethylene Properties for HDPE100
Property
Value
Unit
Density

960
kg/m
Tensile Yield Strength
23
MPa
Elongation at Yield
8
%
2
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Pipeline Technology Conference 2015

Tensile Break Strength
37
MPa
-4
2.4x10
m/m /C
Poissons Ratio
0.4
Minimum Required Strength at 20C (MRS)
10.0
MPa
Hydrostatic Design Stress at 23C (HDS)
7.7
MPa
Coefficient of Thermal Expansion
Figure 2. Schematic of HDPE pipeline with concrete collar
Upper concrete collar
2500 HDPE pipeline
Anchor bolt
Lower concrete collar
2.2 Design Issues
After completion of pipeline sizing, the mechanical design is performed so that
the
pipeline could be protected from internal and external loads. General key design
tasks performed in this project can be summarized as follows:
1. Wall Thickness Design
2. On-Bottom Stability
3. Pipeline ree-Span Analysis
4. Concrete collar structural analysis
5. Sinking Analysis
International codes and standards are applied to these design tasks such as DNV,
DEP, AWWA, API and CEM (Coastal Engineering Manual). Each of these design
activities for the pipeline is discussed in more detail in the following subsect
ions of
the paper.
2.2.1 Wall thickness design
The wall thickness of pipeline is core resistant factor to endure internal press
ure and
external loads. While this task involves various technical aspects related to di
fferent

design cases, primary design loads relevant to the containment of the wall thick
ness
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Pipeline Technology Conference 2015

for HDPE pipelines are as follows:
Bursting criteria under internal pressure
Pipe ring deflection under hydrostatic pressure
Compressive stress under burial load and buckling criteria under installation
load.
The wall thickness of SDR 30 and 26 pipes is checked to be enough margins to the
wall thickness calculated based on the pressure containment because water intake
system does not require high internal pressure.
To check the pipes reaction to external load, the pipe must be within its safe
allowable limit for each of these three reactions deflection, buckling and ring
compression. Ring deflection is a crucial response of flexible pipes to soil loa
d. The
modified Iowa ormula is used as specified in the AWWA Manual. or non-pressure
applications, a 7.5 percent deflection limit provides a large safety factor agai
nst
instability. The ring deflection in the pipe caused by the applied external pres
sure of 2
m soil cover depth is 3.29 %, which is within the limit of recommended deflectio
n
7.5%. Compressive hoop wall stress was calculated to 2.70 MPa and is less than t
he
allowable long-term compressive stress of 3.53 MPa.
2.2.2 On-bottom stability
HDPE pipeline resting on the seabed are significantly subjected to the forces in
both
the horizontal and vertical directions due to wave and current loads. If a pipel
ine is
not stable then it will move under the actions of waves and currents. In the ini
tial
stages after finishing installation of HDPE pipeline before backfilling, the pip
eline is
exposed to the risk of these movements which may cause damage to pipeline.
On-bottom stability was performed to keep the pipeline safely no movement based
on DNV standards. The pipeline on-bottom stability analysis comprises of both la
teral
and vertical stability of the pipelines during their design life. The lateral st
ability
analysis is carried out to determine the concrete ballast weight (i.e., concrete
collars)
required to make pipeline stable during installation and operation against the
environmental loading caused by waves and currents. The vertical stability analy
sis is
carried out to assess the floatation and/or settlement potential of the pipeline
.
The absolute lateral static stability method is a design wave approach, i.e. it
ensures absolute static stability for a single design (extreme) wave-induced
oscillation. Absolute lateral static stability approach is based on force equili
brium
ensuring that the hydrodynamic loads are less than the soil resistance under a
design extreme oscillatory cycle in the seastate considered for design.
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Pipeline Technology Conference 2015

In order to keep the pipelines stable vertically, the submerged weight of the pi
peline
shall be enough large with the safety factor of 1.1 to avoid floatation refer to
DNV.
(ref). Settlement of the pipeline in the seabed should be then checked not to si
nk into
the seabed, considering with maximum content density, e.g. water-filled. If the
specific weight of the pipe is less than that of the soil (including water conte
nts), no
further analysis is required to document the safety against sinking.
The concrete collar volume is designed to 6.7 m 3 with 6 m span which is equival
ent
to 135 mm of concrete coating thickness all the way along the pipeline. rom onb
ottom stability analysis, the vertical stability both upward and downward meets
the
requirements and lateral stability also is above required safety factor as shown
Table
3.
Table 3. On-bottom Stability Example Results
Load Case Water Depth
(m)
Installation
Operation
15
15
Specific
Gravity
Lateral
Stability
(Vertical)
7.272
14.247
1.251
1.251
Lateral
Stability
(Lateral)
2.485
4.528
Collar
Volume (m3)
6.7
6.7
2.2.3 ree-span analysis
Pipeline spans are caused by a variety of seabed features, the most common of
which is an uneven seabed on the selected route. The route for HDPE pipeline was
trenched and leveled before installation, but the concrete collars inevitably ma
ke
spans between them. The allowable span lengths are calculated to maintain the
pipelines within the allowable stress limit and to prevent the onset of vortex i
nduced
vibrations (VIV).

The maximum span length based on static stress considerations are governed by
self-weight of the pipe and coatings and the environmental loads. The allowable
static span length for a pipeline is calculated by limiting the equivalent stres
s in the
span to allowable bending stress based on the Von Mises equation incorporating t
he
axial stress.
The second mode of failure for spans is a fatigue failure due to vortex-induced
vibrations (VIV). Vibrations may occur in the pipeline due to vortex shedding be
cause
of the flow of water passing a free span. Normally two types of oscillations are
encountered:
Oscillations in line with the velocity vector (in-line).
Oscillations perpendicular to the velocity vector (cross flow).
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Pipeline Technology Conference 2015

or certain flow velocities the vortex shedding frequency may coincide with or b
e a
multiple of the harmonic or sub harmonic excitations. The span length will be
selected such that the harmonic frequency or natural frequency of the span will
be
less than the vortex shedding frequency either for in-line or cross flow oscilla
tions.
The pipelines are designed such that no oscillation is allowed and to that effec
t, the
maximum allowable span for the VIV criteria shall be less than that for the onse
t of
in-line oscillation requirements. As in-line oscillations are not allowed, a fat
igue
analysis will not be required. The static and dynamic free spanning analysis is
performed for installation condition because backfilling will be followed to ins
tallation.
or conservative approach, fully restraint condition is considered. The summary
of
free span analysis for installation case is presented in Table 4.
Table 4. ree Span Analysis Results
Description
Unit
Max. Allowable Static Span Length
Max. Allowable Dynamic Inline flow VIV
Span Length
Cross flow VIV
Governing Span Length
Recommended Allowable Span
m
m
m
m
m
Design Condition
Installation
Hydrotest
10.42
10.42
33.72
34.74
34.66
35.68
10.42
10.42
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6
2.2.5 Concrete collar Structure Analysis
Previously explained, the concrete collar is attached on the pipeline with 6 m s
pan by
combining upper and lower parts of precast concrete collar.
The standards of CBA 93 and BAEL 91 are applied for design concrete structures.
The type of cement was determined to CPA with C3A to be contained less than 10 %
considering full immersion conditions for seawater. The concrete is designed to
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MPa of the compressive concrete strength and 2.55 ton/m 3 of dry density.
To prohibit that the pipe is rotating when floating on the water surface, the bo
ttom
part of the collar should be heavier than the upper part. Accordingly, the concr
ete
collar volume comprises 2.4 m3 in the upper part and 4.0 m3 in the lower part.
The blocks are attached on the pipes with 4 bolts. Bolt forces are controlled by
means of measuring the compression of the rubber compensators on each bolt. In
order to secure that the block will not slide on the pipe during the submersion
of the
pipes a sliding test was performed. A minimum bolt force at the assembly of coll
ars
on the pipes is expected to be around 8 ton. But, based on 0.5 friction coeffici
ent
between rubber pad and HDPE pipe, considering more than 4 times safety factor fo
r
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Pipeline Technology Conference 2015

uncertainty during bolt tightening & sinking pipe and etc., a maximum bolt force
at the
assembly of blocks on the pipes is designed to be around 33.5 ton (335kN). As a
result M33 size of bolt is used.
The overall structure modeling and analysis are performed using Midas Civil, fin
ite
element analysis ( EA) software. rom the concrete collar structural analysis, i
t could
be learned that the most critical engineering parts are not concrete structure i
ntegrity
such as bending moment, shear stress, and crack is not critical, but the bolts
combining each parts of the collar and rubber part making the gap between the pi
pe
and concrete. These parts are shown in the figure 3.
igure 3. Precast Concrete Collar
2.2.6 Installation Analysis
The HDPE pipeline installation method for this project adopted the float-and-sin
k
method, so-called, Rentis installation. It has been used widely for near shore
underwater pipeline installation. In traditional Rentis method, the required pip
e string
length is fabricated onshore and fitted with buoyancy devices at a given spacing
,
then is launched and finally towed to the desired offshore location. After posit
ioning
and aligning of the pipe string, the buoyancy devices are stripped in a control
manner
so that the pipeline settles to seabed due to its own weight in a controlled man
ner.
The main difference between HDPE pipeline and traditional Rentis installation is
that
HDPE dont have to consider buoyancy devices because HDPE is buoyant itself.
Critical issues are therefore to attach concrete collar to submerge pipeline and
pump
water into the pipeline to change it from positive buoyancy to negative. Accordi
ngly
pipeline settles on seabed due to its own weight including concrete collar in a
controlled manner.
The commercial software Orcaflex was used to perform the analysis of Rentis
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Pipeline Technology Conference 2015

installation. Orcaflex developed by Orcina have been used widely for static and
dynamic analysis of a wide range of offshore systems including all types of mari
ne
riser, floating facilities, moorings, installation and towed systems. Orcaflex i
s a fully
3D non-linear time domain finite element program capable of dealing with arbitra
rily
large deflection of the flexibles from the initial configuration.
The sinking analysis model consists of HDPE pipeline, concrete collar, buoyancy
tank and winch as shown igure 4. As Orcaflex is limited to simulate change of p
ipe
content from empty to flooded condition, Pipeline was modeled as flooded status
with
seawater in the beginning but attached additional buoyancy tanks to compensate t
he
initial flooded water weight inside the pipe. Analysis was then performed by rem
oving
the attached buoyancy tanks, which could simulate sinking of HDPE pipeline in th
e
offshore site. The weather condition is assumed as Calm-day working.
As a result of analyses minimum bending radius along pipeline length is larger t
han
50m of the pipeline as shown in igure 5. According to AWWA Manual (Ref), the
minimum short-term bending radius shall be larger than 20 times pipe OD i.e., 50
m
for this project in a short-term period. Maximum von-Mises stress was calculated
to
21.2 MPa which is within the tensile yield strength of 23 MPa refer to igure 6.
These
results are based on the tension from pulling boat with the magnitude of 70 ton.
igure 4. Simulation Progress with Time
(a) Initial floating out
(b) Sinking gradually by remove buoyancy tank
(c) Sinking completion
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Pipeline Technology Conference 2015

igure 5. Maximum/Mean/Minimum Curvature along Offshore Intake Pipeline Length
igure 6. Maximum/Mean/Minimum von Mises Stress along Offshore Intake Pipeline L
ength
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Pipeline Technology Conference 2015

3. Construction and Installation
3.1 Manufacturing of 2500mm OD of HDPE & Accessories
The manufacture and production of long module 2500m OD HDPE pipe and
accessories required for the project were carried out by PipelifeNorge The pipes
are
produced in Norway where fabrication yard is located and then delivered to Alger
ia.
3.2 Towing of pipe from factory, receiving and storage
The pipelines are towed to the port near the site in Algeria under responsibilit
y of
Pipelife. The towing plan was prepared to ensure that pipes to be towed are free
from
damages and not exposed to extreme hazards during transport. To increase visibil
ity
of the cargo, a standard yellow color is painted every 5 meters on the HDPE pipe
and
blinking light at the end of the tow is attached as shown in igure 7. Tug boat
usually
travels with the speed under 7~8 knots and a 1 knot per minute acceleration woul
d
be permitted for increasing the speed.
igure 7. Towing of HDPE Pipeline (PIPELI E)
When long module HDPE pipes approach to the port, the harbor authority grants
permission to proceed. The harbor tug holds the pipes and the assisting vessels
position and secure them.
3.4 Installation of concrete weights
The concrete weight production was carried out in parallel with the delivery of
HDPE
pipe by pre-cast method. The upper collar and the lower collar were fixed to the
HDPE pipe by using a lift frame. The lifting frame will then be loaded with a se
t of the
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Pipeline Technology Conference 2015

collar weight, the upper and the lower section, and then it is carefully lowered
to the
marked area on the HDPE where the collar weights will be put in place. The upper
collar will then be slowly lowered to connect the two sections by hot dip galvan
ized
bolts and nuts. This procedure is repeated until installation of all collar weig
hts is
completed. igure 8 shows the installation of concrete collar performed in the s
ite. .
igure 8. Setting of Collar using Lift frame
3.5 Sinking process of weighted HDPE pipe
After installation of concrete collar with other required accessories to the lon
g module
pipe, it was towed from the port to the site. The most important thing is to kno
w the
local weather condition because sea condition must be calm to sink the HDPE
pipeline.
The pipeline to be sunk is positioned in the designated route by the use of tug
boats,
barges and small boats. The inmost end is connected to the flange, and there mus
t
be an entry pipe so that seawater can be allowed to enter during sinking. The
outmost end is fitted with a hose connected to the compressor to serve controlli
ng air
pressure inside the pipe if required.
To be ready to sink, the location of the pipe route should be pre-determined and
marked by buoys using GPS equipment. The first end to be sunk is the inmost part
and it is anchored to concrete anchors by the use of a wire to the end flange of
the
pipe. This is to ensure inmost end of the pipe string settles to a suitable dist
ance from
the end of the onshore distance.
The flooding of the pipe start by opening one of the valves for inflow of water,
and as
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Pipeline Technology Conference 2015

the water flows into the pipe, the inshore end become sink down to rest on the
seabed. Initial stage of the sinking shows an inverse J-figure and continuous in
flow of
water inside of the pipe leads gradually to the shape of S-bend configuration. T
he
configuration of the pipeline is controlled to maintain curvature above 60 OD us
ing
the valve and pulling force. It is very important that pull on the offshore is m
aintained
to prevent the sudden significant increase of curvature to the pipe. Maintaining
the
pull force applied at the offshore end will control the buckling failure to the
pipe.
When the air in the pipe are fully evacuated, and the offshore end of the pipe i
s fully
submerged, the pulling force applied is gradually reduced until the offshore end
of
pipe reaches the seabed, and the installation of the pipe could be said to be
successful. The configuration during sinking of the HDPE pipeline and process ar
e
shown in igure 9 and igure 10.
igure 9. S-shape Configuration of HDPE Pipeline
igure 10. Initial Sinking
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Pipeline Technology Conference 2015

3.6 Spool piecing and connection works
To connect the two pipe strings which are inshore and offshore section respectiv
ely,
the pipe spools are required. The length is measured before as per the actual
distance between the ends of the pipe to be spool pieced. There must be a cleara
nce
for the spool piece in between flanges but not wide, the gap shall be minimized
in
order to prevent excessive longitudinal strain to the pipe in the flanging opera
tion
when bolts are tighten.
Sinking of spool piece to join submerged pipe carried by the use of barge with c
rane.
The bolts were completely tightened by pneumatic type under water.
4. Conclusion
There are many advantages to use HDPE pipeline for seawater intake and outfall i
n
power plant projects. Continuous manufacture of long module has the pipeline mor
e
integrity by reducing the welding joint in the site and contributes saving time
requiring
installation.
The engineers should make a careful assessment in design and installation for
HDPE to be installed with no harm and keep safe during its operation. In terms o
f
design large diameter HDPE pipeline might adopt traditional offshore pipeline
engineering procedures. But on-bottom stability analysis is to be performed most
critically when assessing the pipeline movement underwater. or rigorous approac
h
the projected area of submerged concrete collar should be considered in calculat
ing
the force caused by currents and waves. These forces are not much small to be
neglected. The connection between lower and upper part of concrete collar is als
o be
stringently checked because of possibility to breaking and loosening of bolts in
the
harsh condition. Daewoo Engineering & Construction Ltd., have been conducting
research about optimizing concrete collar and miscellaneous parts.
In addition to design, the installation of HDPE pipeline should be analyzed and
investigated previously before start up the sinking so that it could be controll
ed
delicately. The results of simulation could provide information such as what ten
sion
would be required to hold the pipeline to keep the S-shape and to avoid buckling
.
These meticulous engineering analyses and controlling performed in the site lead
the
pipeline to be finally said installed successfully.
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