BURIED FLEXIBLE PIPELINES

The Design Process- Boundary Conditions Design Fundamentals-AS2566.1 Materials Installation AS 2566.2 Tips, Tricks & Traps
C.Eng FIMechE; CP Eng FIEAust RPEQ

Presented by Geoffrey D Stone

Principal Blenray Pty Ltd ( Design Detail & Development)

geoffrey.stone@yahoo.co.uk 0402 35 2313

THE DESIGN PROCESS Boundary Conditions

Soils & Soil Data Trench Width & Depth Structural Response to Loading Trench Details Stiffness Thrust Blocks Structural Interfaces

Water Table Design Loads Trench & Embankment Fill Superimposed Live Loads Other Superimposed Loads

Soils & Soils Data

Native Soil
Classify Modulus

Backfill
Type Compaction

Bedding
Type

Piles
Testing
Field Laboratory

Embedment
Material Compaction Geo-textile Water Table

Trench Width & Depth

AS 2566.1 Minimum Embedment or Embankment Shape of trench

Trench Dimensions

Structural Response to Loading

Stiffness AS 2566.1
2 year values of pipe stiffness suitable for good soils 50 year values of pipe stiffness should be used for poor soils, uncontrolled installations or other higher risk applications

Stiffness AS 2566.1

Thrust Blocks
Not required for fully welded systems as in ABS, PP, PVC-U, PB or PE Required for rubber ring systems as used for DICL, MSCL, GRP & PVC-U/O/M Design basis

Steady state pressure Unsteady state pressure spikes Hydrostatic test pressure

Structures Interfaces

Differential Settlement Soil swelling Water Retaining Shear Loading Thermal Loading Chaffing Water seal in concrete

Water Table
Water hydrostatic level applies load onto pipe-refer AS2566 Rising water applies uneven load onto pipe and the pipe may buckle or exceed its strain limit Water may cause flotation of empty pipe and special embedment may be necessary High water table increases construction difficulty Safety Dewatering Quality

Loading
Design loads due to trench & embankment fill External hydrostatic loads Internal pressure Superimposed dead loads Superimposed live loads Other unsustained loads

Design Loads due to Trench & Embankment Fill

Superimposed Live Loads

Superimposed Live Loads

Other Unsustained Loads

1. 2.

3.
4.

Specialist Engineering National Codes Local Conditions Risk

Likelihood Consequences Responsibility Safeguarding

Earthquake Vibration/Shock Differential Settlement Thermal Strain Subsidence Airport runways Railways

DESIGN FUNDAMENTALS
AS2566.1 Buried Flexible Pipelines-Design

Deflection Strength Internal Pressure Combined Loading Buckling

Hoop Stress Ring Bending Strain Creep Temperature Other Considerations

Deflection
Short term Long term Vertical & Horizontal

Considered equal Effect of excess side compaction

Modulus to use Acceptance criteria Measurement during installation

Strength
Loads cause strain in pipe wall Ring compression strains << ring bending strains AS 2566.1 predicts maximum tensile ring bending strains A Shape Factor adjusts strain values

True Ellipse Shape Factor Df=3.0 horizontal < vertical Shape Factor Df > 3.0

Internal Pressure
Steady State Unsteady State

AS 2566.1 Requirements 1.25 AS 2885 Requirement 1.10 Other codes requirements

Combined Loading
Combined external load and internal pressure Re rounding effect

Buckling
Ovalization Buckling External Pressure No substantial soil support-Timoshenko Substantial soil support I.D. Moore

Hoop Stress
Stress in the wall due to pressure Only criteria used for pipe class selection Does not take into account other stresses Basis of the Pipe Class System Relaxes with time for thermoplastic pipes Never Constant

Ring Bending Strain

Importance of Strain Comparison of allowable strain in materials 1. ABS 1% 2. GRP 0.18 to 0.6 % 3. PE 4.0% 4. PVC-U 1% 5. PVC-M 1% 6. PVC-O 1.3%

Creep
Variation of Properties in Time Long term loading/Stress relaxation Reverse loading/Stress magnitude Repetitive loading/Fatigue

Temperature
The design temperature may vary due to:Ambient diurnal temperature variations Flow rate Fluid temperature range Process conditions Installation ambient temperature Wall thickness

Other Considerations
Anchor forces Differential Settlement Earthquake Subsidence Testing conditions Corrosion

Mass of pipe contents Thermal Strain Local buckling Fatigue Pavement settlement

Materials Selection
Types Costs Class Characteristics Fittings & Valves

Modulus GRP Modulus Thermoplastic Pipes

Materials - Types
GRP ABS PE PVC-U, PVC-M, PVC-O DICL MSCL

Materials Selection

Costs Supply
1. Pipe 2. Fittings 3. Supports

Costs - Whole of Life

1. Safety 2. Availability 3. Maintenance 4. Energy 5. Risks

Costs Installation
1. 2. 3. 4. 5. Standard of trades Equipment Jointing Access Testing

Costs - Standards
1. Authority 2. Industry 3. Acts

Selection of Pipe Class

Design Pressure Steady State Design Pressure Unsteady State Vacuum Conditions Industry Application & Environment

Soil/Pipe Structure Design Standardization Risk Likelihood Consequences Responsibility

Typical Material Characteristics

Fittings & Valves

Valve classes do not meet all pipe classes Injection moulded fittings- Size Limitation Manufactured fittings-Larger Sizes
Tees Bends

Jointing Gaskets Expansion Bellows Saddles Valves

Isolation Check Air release Control

Modulus-GRP Pipes
Manufacturers establish values by test & calculation Axial & longitudinal modulus differs Values at various temperatures required for design Strain rate changes values Standards such as ISO 14692

Modulus-Thermoplastic Pipes
Published figures normally are strain rate at 20C Value determined by ASTM test Standard dog bone test specimen Fixed strain rate Values at various temperatures required for design Strain rate changes values

INSTALLATION
Trench Excavation Trench Shields Laying & Jointing Embedment & Compaction

Thrust Blocks Hydrostatic Testing

Trench Excavation
Excavator bucket width Excavated depth Soil removal, testing and stockpile Shape of trench Pockets for pipeline projections Thrust block preparation Dewatering Welding machine access Adjacent pipes

Trench Shields

When to use Remove in stages Affect on compaction Geotextile fabric Over excavation Wide trench

Trench Shields

Laying and Jointing

Join on the bank and lay Lay in trench and join Rubber ring joints PVCU, PVC-M, PVC-O, GRP, DICL & MSCL Solvent welded jointsABS, PVC-U & PVC-M Fusion butt weld-PE, PB & PP Electro-fusion couplings-PE

Wrapped joints-GRP Welded joints-steel Flanges & Mechanical Joints-All Alignment & Bending Adjacent parallel pipes Crossing Pipelines Removal of temporary pegs and supports

Embedment & Compaction

Materials Dewatering Bedding Side Support Overlay Migration of fines

Pipeline Protection Prevention of floatation Compaction trials Compaction controls Deflection controls Gauging

Thrust Blocks

Hydro-testing

Establish test pressure Test standard Prepare test equipment Prepare ITPs Prepare test points

Source of test water Disposal of test water Selection of test lengths Owners witness Records

Hydrotest Methods
Constant pressure test (No water loss) DICL, MSCL, GRP & PVC Constant pressure test (water loss) PE, ABS, PP & PB Pressure decay PE & PB Pressure rebound- DN DN315 ABS, PB & PE

Tips, Tricks & Traps

Design Installation Testing Product

quality Completion In Service leaks

Tips, Tricks & Traps - Design

Design pressure may not include surge Temperature profile not defined Pipeline route/soils not adequately surveyed Consultant expects sub contractor or material supplier to do the detail design Lower pipe class than necessary specified Temporary facilities not designed

Tips, Tricks & Traps - Installation

Variations from design not engineered Surfaces not cleaned Aged solvent cement Pipe ends bevelled Damaged pipe UV degradation

Physical damage Solvent damage to internal surface Use of incorrect solvent Incorrect slings Foreign matter not removed from trench

Tips, Tricks & Traps - Installation

No detail drawings Insufficient joints for erection Incomplete insertion in joints Inadequate time for welds or lay ups Differential settlement

Resources Poor trench conditions Poor native soil Soil properties not measured routinely Inadequate access Water ingress Cleanliness

Tips, Tricks & Traps -Testing

Lack of planning & procedure Standard provisions not understood Inexperienced testers Test pressure unknown Equipment not isolated Procedure not agreed beforehand

Records of test not prepared Person to witness test not available Resources not available
Water supply Pump Gauges Data logger Temperature instrument Trained personnel

Tips, Tricks & Traps -

Product Quality Inspection or QA

Non conformance with drawings Pipe ovality Lining thickness Socket dimensions Surface defects Fabricated fittings Cracks at weld Dimensions Orientation

Tips, Tricks & Traps -Completion

Resources & budget Site clean up Reinstatement Handover to owner Records Work as Executed Drawings Quality Assurance Sign-Off Certificate of Practical Completion

Tips, Tricks & Traps -

In Service Leaks & Failures

Pipe burst Flanged joints leak Solvent welds leak Rubber ring joints leak Fusion welds leak Fittings

Buckling of thin wall pipe Thrust blocks Waterhammer Over pressure Pipe shear Fatigue & vibration

Questions
1.

2.
3. 4.

Is AS 2566 mandatory? Can AWWA M45 be used? Is FEA a viable alternative? Who designs pipelines Civil, structural or mechanical engineers?