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L-0288 - CS Pipe Wall Thickness Calculation - Rev.1

The document is a revised calculation of the wall thickness for carbon steel pipes used in the construction of a new pumping station at Jabel Hafet Base in Abu Dhabi, United Arab Emirates. It includes references to codes, standards, and previous correspondence. It addresses comments provided by the client and consultant regarding input parameters, equations, and justification of material grades and wall thicknesses selected for pipes of various diameters and pressure ratings. The calculations determine the minimum required wall thickness to withstand internal pressure and buckling based on pipe dimensions, material properties, design pressures, and soil conditions according to industry standards.

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0% found this document useful (0 votes)
373 views16 pages

L-0288 - CS Pipe Wall Thickness Calculation - Rev.1

The document is a revised calculation of the wall thickness for carbon steel pipes used in the construction of a new pumping station at Jabel Hafet Base in Abu Dhabi, United Arab Emirates. It includes references to codes, standards, and previous correspondence. It addresses comments provided by the client and consultant regarding input parameters, equations, and justification of material grades and wall thicknesses selected for pipes of various diameters and pressure ratings. The calculations determine the minimum required wall thickness to withstand internal pressure and buckling based on pipe dimensions, material properties, design pressures, and soil conditions according to industry standards.

Uploaded by

unnicyriac
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 16

To, Your reference: N16297-TECH-0155-21

M/s. Arcadis Design & Consultancy Our reference: N16297-HPE-KH-OL-0288


P.O. Box : 2774
Abu Dhabi, United Arab Emirates Department: Operations
Ph: +971 2 566 4000 Name Eng. Unni Cyraic
Fax : +971 2 635 9109
Contact Details ucyraic@hydropower.ae
Kind Attn: Project Manager
Date 01.04.2021

PROJECT: N-16297 – Construction of New Pumping Station at Jabel Haffet Base

SUBJECT: CS Pipe Wall Thickness Calculation - Rev.01

References:

1) HYD Letter Ref. – N16297-HPE-KH-OL-0214 Dated 01.03.2021


2) ADC Letter Ref. – N16297-TECH-0155-21 Date 14.03.2021

Dear Sir,

With reference to the above-mentioned subject, please find enclosed herewith the revised CS Pipe
Wall Thickness Calculation.

Description CS Pipe Wall Thickness Calculation


Submittal No. N16297-GE-M00-EN-S011-01
Revision 01

Thanking You,
For Hydropower Energy and General Construction LLC

Tanay Kumar
Project Manager

Encl: As Stated Above.

Cc: Project Manager – Transco

Answers Required (Yes / No)


DOCUMENT – COMMENT SHEET – RESPONSE SHEET

CS PIPE WALL THICKNESS CALCULATION


Comment Sheet Ref: N - 1 6 29 7- T E CH - 0 15 5- 2 1 Date of Comment: 14.03.2021

Incoming Submittal Ref: N1 6 29 7 - HP E- K H- O L- 0 21 4 Date of Receipt: 01.03.2021

ARCADIS / TRANSCO Comments HPE Reply


1. Section 3.1.6, Please correct allowable stress of Corrected, Reference included in section 3.1.5
DN200 DP 1.6 Mpa pipes to 138 n/mm².
Furthermore, please include reference for allowable
stress values.
2. Please justify reason for selecting API 5L Gr X52 API 5L Gr X52 is selected avoid higher/non standard
grade for DP 15 Mpa pipes. wall thickness for higher pressure pipelines
3. Quality Factor mentioned in section 3.1.1 is E=1.0. Noted, As per the technical levers 1 & 2 , Welded pipe
However, adopted value for calculation in section are allowed for suction pipes and Green Mubazara
3.1.6 is 0.94. Please clarify. Quality factor in discharge pipeline. So E=1. Will be used for all pipes
accordance with ASME B31.3 Table A-1B shall be except DN300suction line and DN300 Discharge line
1.00 for seamless pipes. Furthermore, in accordance to green mubazarah.
with W-P-SS-012, the pipe shall be manufactured by
seamless process up to size DN 400 mm (14" NB).
4. Section 3.1.6- Please clarify why higher thickness Noted, Standard and easily available pipe wall
selected for PN16 pipes (DN300,200,150 & 100 thickened are used.
pipes) even though calculated thickness is very less.
Even after considering mill tolerance of 12.5%,
selected thickness seems high. Please verify.
5. Section 2.1 Tensile Strength & Yield Strength values Corrected
shall be updated in accordance with ASME B 31.3
Table A-1. In addition, reference to this specification
shall be mentioned in this section
6. Section 4.1 – In accordance with AWWA M11, the Corrected.
summation of external loads shall be equal to or less
than the allowable buckling pressure. Please rephrase
wordings of section 4.1.
7. Section 4.1 Buckling - Please consider modulus of soil Corrected.
reaction (E’) as 700 psi (4830 kpa) in accordance with
AWWA M11 Table 6-1 for pipes buried between 0.06
and 1.5 [m] considering 90 [%] compactions.
8. Section 4.1.1- Reference to Modulus of elasticity of Noted, the reference is included in section 2.6
internal and external coating used for calculation shall
be mentioned in the calculation
9. Section 4.1.1 - Please verify value of “Transverse Corrected
moment of inertia per unit length for pipe wall (I)”.
Same is written as 0.08 inch³. However same shall be
0.007 inch³ as per AWWA M11 formula I= t³/12
10. Section 4.1.1 - Value pipe wall stiffness (EI) seems Corrected.
incorrect. Please verify.
11. Section 4.1.1 & Section 4.2.1 – Please clarify how Reference made to project scope of work SP-0001,
Vertical soil load on pipe per unit length (Wc) is page 46/86 and the equation Eq 5-3 of AWWA
calculated. Equation for Wc in accordance with Standard 5th edition
AWWA M11 shall be mentioned in this calculation.
Vertical soil load/unit length is Wc= w x Hc/12 X Dc
w- Soil density (lb./ft3)
H- Height of fill above pipe (feet)
DC- Outside Diameter(inch)
12. Section 4.1.1- Please clarify the reference for internal Internal vacuum pressure is the -0.5 barg ( 7.25 psi) ,
vacuum pressure value of 7.25 psi Maximum allowable negative pressure during
transient condition
13. Section 4.1.1 & Section 4.2.1 - Please clarify the Reference made to AWWA M11 chapter 5 Table 5.1
reference for Live load (Wl) 400 lbs/feet² (for height of cover 4 ft minimum)
14. Section 4.2.1 – Please clarify the formula for “load per Reference made to AWWA M11 chapter 5 Eq 5-4, for
unit of pipe length(W)=Wc + Wl X Dc/144”. Please load per unit of pipe length(W)=Wc/12 + Wl X
mention reference. Dc/144”.
Where Wc is the Vertical soil load/unit length and Wl I
live load as per AWWA M11 chapter 5-chapter 5
Table 5.1
15. Please include calculation sheet in excel format with Will be included
next submission.
16. Reference for all formulas used for calculation shall be Will be included
mentioned. (Eg: Buckling, Deformation etc)
17. Please clarify radius values mentioned in Section r = (Dc – t – tL – tC) / 2 , reference made to AWWA
4.2.1. M11 chapter 5 Eq 5-4 ,
Where
Dc – opter dia ,
t – wall thickness
tL -internal lining thickness
tC – coating thickness

Note: The above comments and/or approvals do not relieve the Contractor from his obligation in the contract to ensure conformance to the specifications. Any
specification deviations found subsequent to approval are to be corrected by the Contract to the satisfaction of the OWNER/ENGINEER.

STATUS CODE: Not Approved – Re-submit

Signed: Signed:
For Arcadis Consulting Middle East Ltd for TRANSCO
Client Project: Consultant

N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

Contents
1. INTRODUCTION ............................................................................................................................... 3
1.1. Purpose of Document ......................................................................................................... 3
1.2. Description of Project ......................................................................................................... 3
1.3. Abbreviations ...................................................................................................................... 4
1.4. References .......................................................................................................................... 5
1.5. Codes and Standards........................................................................................................... 5
2. BASIC DESIGN DATA ........................................................................................................................ 5
2.1. Minimum tensile strength & Specified minimum yield strength of material ..................... 5
2.2. Design pressure of pipe line (P) .......................................................................................... 6
2.3. Outer Diameter of the Pipe................................................................................................. 6
2.4. Corrosion allowance (c) ...................................................................................................... 7
2.5. Mill Tolerance ..................................................................................................................... 7
3. Design against Internal pressure..................................................................................................... 7
4. Design of Pipe line against external pressure ................................................................................. 9
4.1. Buckling ............................................................................................................................... 9
4.2. Deformation ...................................................................................................................... 12

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CS Pipe Wall Thickness Calculation N16297-GE-M00-EN-S011-01 01
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Client Project: Consultant

N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

1. INTRODUCTION

1.1. Purpose of Document

This document provides the calculated wall thickness of the CS pipe/Pipe line
which is to be constructed newly in this project

As stipulated in the project scope of work , contractor shall carry out wall
thickness calculations and confirm the required wall thickness.

The wall thickness calculation shall cover selection of the minimum wall
thickness. More over integrity of buried pipe work against external pressure
also will be checked

1.2. Description of Project

Contractor is newly awarded with the TRANSCO EPC project (N-16297) for
New Pumping Station at Jabel Hafeet Base. This project is for replacement of
existing base pump station

Client/Owner Abu Dhabi Transmission & Despatch Company


(TRANSCO)
Consultant Arcadis consultants .
Existing means all existing equipment, works and installations,
which must be interconnected to or integrated with the
new project. This is especially valid for the existing
TRANSCO/AADC/others’ pipelines, and the existing
pumping stations.

Final Design Means the detail design to be performed by the


Contractor in compliance with the requirements stipulated
in the Tender/Contract Document

Main Contractor Hydropower Energy and General Construction LLC

New Means all new equipment, works and installations which are part
of the Project, including the extensions or modifications to
existing equipment, works and installations

Party Company, Engineer, Contractor, Engineering


Subcontractor, Subcontractor or Vendor as the context
implies

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Client Project: Consultant

N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

Pipeline Means the complete entity of the particular transmission


pipeline for the System, including all branch lines, line
sections and segments complete with all the related
appurtenant structures.

Project New Pumping Station at Jabel Hafeet Base

Shall Indicates a mandatory requirement

Should Indicates a strong recommendation to comply with the


requirements of this document

Station Piping Means the complete pipe works within the


Pumping Station Boundary / Plot.

Tie-in Point Means all works related to a specific location along


the system

Vendor A Party to whom another Party has issued an RFQ and/or


PO based on a Material Requisition for supply of

Works Means all supplies, works and activities to be


performed by the contractors for the implementation and
completion of the project materials/services to the Project

1.3. Abbreviations

P Design Pressure
MAOP Maximum Allowable operating pressure
CS Carbon Steel
ASME American Society of mechanical Engineers
WT Wall thickness
TRANSCO Abu Dhabi Transmission & Despatch Company
HPE Hydropower Energy and General construction
DI Ductile iron
AWWA American water works association
API American petroleum institute

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N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

1.4. References

Doc. No. Title


N-16297-SP-0001 Scope of Work
N-16297 SP-0101 Specification for Supply of Carbon Steel
Pipes
N-16297-GE-P00-CN-D001 Jabel Hafeet Base pump station
N16297-GE-P00-CN-D013 Jabel Haffet Base Pumping Station Proposed
DN200 C.S Discharge Pipeline Plan and
Profile
N16297-GE-P00-CN-D012 Jabel Haffet Base Pumping Station Proposed
DN300 C.S Discharge Pipeline Plan and
Profile
N16297-GE-P00-CN-D011 Jabel Haffet Base Pumping Station Proposed
DN300 C.S Suction Pipeline Plan and Profile

1.5. Codes and Standards

Doc. No. Title


ASME B31.3 2020 Process Piping
ASME B31.4 2019 Pipeline Transportation Systems for Liquids
API 5L: 45th Edition Pipeline Transportation Systems for Liquids and
Slurries
ASME B36.10 Specification for Line Pipe
AWWA M11 5th Edition Steel Pipe—A Guide for Design and Installation

2. BASIC DESIGN DATA

2.1. Minimum tensile strength & Specified minimum yield strength of material

Grade Minimum Specified


tensile minimum yield
strength, σ strength
(N/mm2) (N/mm2)
API 5L, Gr B 414.00 241.00
API 5L, Gr X42 414.00 290.00
API 5L, Gr X46 434.00 317.00
API 5L, Gr X52 455.00 359.00
API 5L, Gr X60 517.00 414.00

Ref: Table A-1M Basic Allowable Stresses in Tension for Metals

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N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

2.2. Design pressure of pipe line (P)


Pipeline

Pressur

Coating

Coating
Pressur

Externa
Design

Internal
Design
Sl. no

(bar)
eP

(Mpa)
Size

mm
OD
eP

l
1 Main Suction DN300 16.0 1.6 323.80 FBE 3LPE
pipeline 400micron
2 Individual DN150 16.0 1.6 168.30 FBE FBE
suction line 400micron 400micro
(transfer and n
distribution
pump)
3 Individual DN100 150 15.0 114.30 FBE FBE
transfer pump 400micron 400micro
discharge line n
4 Individual DN100 16.0 1.6 114.30 FBE FBE
distribution 400micron 400micro
pump n
discharge line
5 Recirculation DN150 150.0 15.0 168.30 FBE FBE
line Transfer 400micron 400micro
pump n
6 Recirculation DN150 16.0 1.6 168.30 FBE FBE
line distribution 400micron 400micro
pump n
7 Discharge main DN200 150.0 15.0 219.10 FBE 3LPE
line Transfer 400micron
pump
8 Discharge main DN300 16.0 1.6 323.80 FBE 3LPE
line Distribution 400micron
pump

2.3. Outer Diameter of the Pipe

Pipe DN Outer Diameter (mm) (D)


DN100 114.30
DN150 168.30
DN200 219.10
DN300 323.80

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N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

2.4. Corrosion allowance (c)

No corrosion allowance required as per–Project scope of work

2.5. Mill Tolerance

A negative mill tolerance of 12.5 % considered as per the industrial standard.

2.6. Modulus of elasticity

Material Modulus of Modulus of


elasticity (Gpa) elasticity (psi)
Low carbon steel (Es) 200.00 29007547.54
Epoxy (EL) 4.53 657021.00
Poly Ethelene (EC) 0.959 139091.19

Reference: http://www.matweb.com/

3. Design against Internal pressure

Station piing will be design against internal pressure as pee the code ASME
B31.3 clause 304.1.2

Calculated wall thickness


𝑃𝐷
𝑡=
2(𝑆𝐸𝑗𝑊 + 𝑃𝑌)

3.1.1. Quality factor (Ej)

Proposed pipes will be Electric fusion welded pipe, 100% radiographed, So


quality factor E = 1.0, as per Table A-1B of ASME B31.3

3.1.2. Weld joint strength reduction factor(W)

For Carbon steel below 427 °C Weld joint reduction factor W =1. As per Table
302.3.5 of ASME B31.3

3.1.3. Coefficient (Y)

For Ferritic steels below 482 °C, Y = 0.4, As per Table 304.1.1 of ASME B31.3

3.1.4. Slenderness Ratio (D/t)

Slenderness Ration must be Less than 130 as per Section IV/I.B.4 –Project
Particular Specification for Carbon Steel Station Piping and Pipeline Works

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STATION AT JABEL HAFEET BASE

3.1.5. Allowable stress

Grade Allowable Stress


(S)
(N/mm2)
API 5L, Gr B 138
API 5L, Gr X42 138
API 5L, Gr X46 145
API 5L, Gr X52 152
API 5L, Gr X60 172

Ref: Table A-1M Basic Allowable Stresses in Tension for Metals

3.1.6. Calculation sheet

Unit DN200 DN150 DN100 DN300 N200 DN150 DN100


Design Pressure ( Mpa 15.00 15.00 15.00 1.60 1.60 1.60 1.60
P)
Design ℃ 52.00 52.00 52.00 52.00 52.00 52.00 52.00
Temperature ( T)
Material API 5L, API 5L, API 5L, API 5L API 5L API 5L API 5L
Gr X52 Gr X52 Gr X52 Gr B Gr B Gr B Gr B
Min Tensile N/mm2 460.00 460.00 460.00 415.00 415.00 415.00
Strength (σ) 415.00
Allowable Stress N/mm2 152.00 152.00 152.00 138.00 138.00 138.00
(S) 138.00
Weld joint 1.00 1.00 1.00 1.00 1.00 1.00 1.00
strength
reduction
factor(W)
Quality factor (Ej) 1.00 1.00 1.00 0.94 1.00 1.00 1.00
Coefficient (Y) 0.40 0.40 0.40 0.40 0.40 0.40 0.40
Outside mm 219.10 168.30 114.30 323.80 219.10 114.30
Diameter(D) 168.30
Corrosion mm - - - - - - -
allowance(c)
Calculated mm 10.40 7.99 5.43 1.99 1.26 0.97 0.66
Thickness(t')
Mill Tolerance % 12.50 12.50 12.50 12.50 12.50 12.50 12.50
Selected Wall mm 12.70 10.97 8.56 9.53 8.18 7.11 6.02
thickness (tm)

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N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

Minimum wall mm 11.11 9.60 7.49 8.34 7.16 6.22 5.27


thickness
tm-t mm 0.71 1.61 2.06 6.35 5.89 5.25 4.61
Slenderness Ratio 17.25 15.34 13.35 33.98 26.78 23.67 18.99
(D/t)

4. Design of Pipe line against external pressure

Main suction Line DN300, discharge lines (Transfer pump DN 200 &
Distribution pump DN300) will be subjected to external loading including live
load. Minimum cover of 8 feet is considered for live load

4.1. Buckling

The summation of external loads shall be equal to or less than the allowable
buckling pressure

1 𝐸𝐼
𝑞𝑎 = √32 × 𝑅𝑤 × 𝐵′ × 𝐸′ × 3
𝐹𝑆 𝐷

(Ref: SP-0001 – scope of work page 45 / 86)

Were

qa – allowable buckling pressure

FS – design factor = 2.0

Rw – water buoyancy factor = 1-0.33×(hw/H), 0 < hw < H

hw – height of water surface above top of pipe

H – height of fill above pipe

B’ – empirical coefficient of elastic support = 1/(1 + 4e(-0.065H)).

E’ – modulus of soil reaction

Es – modulus of elasticity of Steel

Ec – modulus of elasticity of external coating

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STATION AT JABEL HAFEET BASE

EL – modulus of elasticity of internal lining

t = pipe wall thickness

tC = external coating thickness

tL -= Internal lining thickness

I – transverse moment of inertia per unit length of pipe wall = t3 /12

IC – transverse moment of inertia per unit external coating = tC3 /12

IL – transverse moment of inertia per unit external coating = tL3/12

EI – pipe wall stiffness = ES X I + EC X IC + EL X IL

D – outside diameter of pipe

External loads are

hw – height of water above conduit

γw – specific weight of water

Pv – internal vacuum pressure ( Maximum vacuum pressure allowed -0.5


barg)

Wc – vertical soil load on pipe per unit length = w x H/12 X D (Eq 5-3 of AWWA
Standard 5th edition)

Where w- Soil density (lb./ft3)

H- Height of fill above pipe (feet)

WL- Live load (Ref: AWWA Manual M11 Table 5-1 Live-load effect)
nual M11

Acceptance Criteria

ɣw x hw + Rw x Wc/(Dx12) + Pv < qa (without live load)

ɣw x hw + Rw x Wc/(Dx12)+ WL/(D*144) < qa (with live load)

(Ref: SP-0001 – scope of work page 46 / 86)

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STATION AT JABEL HAFEET BASE

4.1.1. Calculation sheet

Parameter Unit DN200 PN150 DN300 PN16


Allowable buckling pressure
calculation
Outside Diameter(D) mm 219.10 323.80
inch 8.63 12.75
Design factor (FS) 2.00 2.00
Height of fill above pipe (H) m 1.20 3.36
feet 3.94 11.02
Height of water surface above top of m - -
pipe(hw)
feet - -
inch - -
water buoyancy factor (Rw) 1.00 1.00
empirical coefficient of elastic 0.24 0.34
support(B’)
modulus of soil reaction(E') psi 700.00 700.00
Pipe line wall thickness (t) mm 11.11 8.34
inch 0.44 0.33
Internal lining thickness (tL) mm 0.40 0.40
inch 0.02 0.02
External coating thickness (tc) mm 3.90 3.90
inch 0.15 0.15
Transverse moment of inertia per unit inch3 0.00698 0.00295
length for pipe wall, I
transverse moment of inertia per unit inch3 0.0000003 0.0000003
length for (internal coating), IL
transverse moment of inertia per unit inch3 0.00030 0.00030
length for (external coating) IC
Modulus of elasticity of Steel (Es) psi 29,007,547.54 29,007,547.54
Modulus of elasticity of internal psi 657,021.00 657,021.00
coating (El)
Modulus of elasticity of external psi 139,091.19 139,091.19
coating(Ec)
pipe wall stiffness (EI) in-lb. 202,467.40 85,574.87
allowable buckling pressure (qa) psi 656.65 279.84
External loading
specific weight of water(γw) N/m3 9,789.00 9,789.00

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STATION AT JABEL HAFEET BASE

lbs./in3 0.04 0.04


internal vacuum pressure psi 7.25 7.25
Soil density Kg/m3 1,800.00 1,800.00
lb./ft3 112.37 112.37
Vertical soil load on pipe per unit lbs./ft 318.01 1,315.95
length ( Wc)
external load case covering dead load psi 10.32 15.85
and vacuum inside the piping(L)
Live load (Wl) lbs./feet2 400.00 400.00
external load case covering dead load psi 3.39 8.82
and live load (L)
Buckling check (L<qa) PASS PASS

4.2. Deformation

The estimated horizontal deflection of a buried pipe can be calculated by the


Iowa deflection formula, as follows:

horizontal deflection of pipe

𝐾×𝑊×𝑟 3 ×
∆𝑥 = 𝐷𝑖 × (Ref: (Eq 5-4) AWWA M11)
(𝐸𝐼+0+0061×𝐸′×𝑟 3

Were

DI – deflection lag factor (1.0 – 1.5)

K – bedding constant (0.1)

𝑊𝑐 𝐷
W – load per unit length of pipe = + 𝑊𝑙 × (Ref (Eq 5-4) AWWA
12 144
M11)

r – radius (in.) = (D – t – tL – tC) / 2 (Ref: (Eq 5-4) AWWA M11)

E X I – pipe wall stiffness

E – modulus of elasticity

I – transverse moment of inertia per unit length of pipe wall

E’ – modulus of reaction

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N 16297 CONSTRUCTION OF NEW PUMPING


STATION AT JABEL HAFEET BASE

Acceptance Criteria

For all pipes this deformation shall be limited to 5% of the pipe diameter

(Ref” project Scope of work)

4.2.1. Calculation sheet

Parameter Unit DN200 PN150 DN300 PN16


Deflection lag factor (Dl) 1.00 1.00
Bedding Constant(K) 0.10 0.10
Outside Diameter(D) mm 219.10 323.80
inch 8.63 12.75
Mean Radius of pipe(r) inch 4.01 6.13
Height of fill above pipe (H) m 1.20 3.36
feet 3.94 11.02
Soil density Kg/m3 1,800.00 1,800.00
lb./ft3 112.37 112.37
load per unit of pipe lbs./in 50.46 145.07
length(W)=Wc/12+WlXDc/144
pipe wall stiffness (EI) in-lb. 202,467.40 85,574.87
Deflection ∆x inch 0.0016 0.0350
allowable deflection ∆x' (0.05XD) inch 0.43 0.64
Deflection Check ∆x < ∆x' PASS PASS

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