Sep Cross Country Piping

DEVELOPMENT CONSULTANTS LIMITED
STANDARD ENGINEERING PROCEDURE

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STN GRP SL CLASS Sg1 Sg2 Sg3
RIAS CAT #

SEP NONE NONE NONE

DOC #

01201-SEP-M-133 E-MEDIA
ARCHIVED

TITLE

Design and Optimization of Cross-Country Water Piping

AUTHOR

Technology Control Cell, Mechanical

ABSTRACT
This document discusses various activities towards finalization of major
parameters of cross-country water piping and aims to indicate the
procedure for optimizing the system.

KEYWORDS 1

MS Pipe
2
Optimization

3

DI Pipe
4 FRP Pipe

5

6

2
1
0 FIRST ISSUE
REV # STATUS REV. DESCRIPTION

ENDORSEMENTS
2
1
0 30.08.12 Sanchari
Paul
DSM DSM
Initial Signature Initial Signature Initial Signature
REV # DATE PREPARED REVIEWED APPROVED

This document contains proprietary information of Development Consultants Limited and is to be returned upon
request. The contents may not be copied, disclosed to third parties, or used for other than the express purpose
for which it has been provided, without the written consent of Development Consultants Limited.


# 01201-SEP-M-133

TITLE : DESIGN AND OPTIMIZATION OF CROSS-
COUNTRY WATER PIPING
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1.0.0 INTRODUCTION

Cross-country pipeline is primarily a transmission line for transporting bulk
quantity of fluids over large distances. The transmission distance may be
a few kilometers, or even hundreds of kilometers. For example, in India,
cross-country pipeline for LPG transportation from Jamnagar, in Gujrat, to
Loni, in Pubjab, covers a distance of about 1300 km, whereas, the HBJ
pipeline covers a distance of almost 2300 km.

Cross-country pipeline has also been extensively used for transport of
water, as, often, water source is not available in close vicinity to consumer
point. Such pipeline may run thru land, rivers, marshy areas, roads,
forests etc.

This Standard Engineering Practice discusses the various activities
towards finalization of major parameters of a cross-country water piping
system and aims to indicate procedures for optimizing the cross-country
piping system related to material of construction of pipe, thickness,
corrosion protection and laying of pipe.

2.0.0 PRE-PROJECT ACTIVITIES

The pre-project activities during preparation of feasibility report and TEFR
should have already identified the source of water for meeting the
requirement of the proposed plant. For such identification, the Project
Authority needs to discuss with irrigation dept. to ensure the availability of
required quantity of water, the seasonal fluctuation, if any, examining
recommendations, such as, constructing weir to enhance assurance of
available water etc.

During execution of cross-country water project, the initial activities that
the Project Authority needs to be advised is to appoint a bathymetric
surveyor, who will interact with irrigation department to re-examine
availability of water. The bathymetric surveyor will also identify the
configuration of intake system whether on-shore or off-shore, location of
intake well / intake pump house and low water level / high water level of
the intake structure which will be subsequently utilized for preparing the
GA dwg. of intake well / intake pump house.


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On reassurance of water availability, the Project Authority also needs to
examine the seasonal fluctuation, if any, and the mitigating measures
such as making a raw water reservoir at plant site, to ensure availability of
required quantity of water for the plant, even when supply from source
(river or lake) has reduced or altogether stopped.

The next step that the Project Authority needs to be advised is to appoint
a surveyor for conducting the route survey. There can be many
alternatives for routing the pipeline from supply point to consumer point. It
is necessary to work out techno-economic comparisons of various routes
taking care of the route length, the nature of obstacles along the route etc.
Ideally, the pipe should run close to existing roads so that the erection and
maintenance activities can be carried out conveniently.

Once the route from supply to consumer point has been identified, the
route survey is intended to further furnish data such as :

a) Spot-level survey at every 50 to 100 metres & at least over 10 m on
either side of the probable route.

b) Soil conditions in the form of bore-logs, trial pits, chemical tests on
subsoil & ground water etc.

c) Alignment map with lengths, bearings, angles etc. to know the exact
route & the total length of the pipe-line.

d) Details of the route and their locating dimensions with respect to sea,
roads (crossing and along the route) rivers, nallas, pipe-lines, bridges,
rail-tracks, transmission lines, underground services including cables/
pipes etc., hills and mountains, buildings, plantation, forests,
agricultural land etc.

e) Cadestral Survey The route may be passing thru so many lands
belonging to private owners, farmers, govt. authorities, defence wings
etc. En-route information and data has to be collected for such land
pieces. Such data will include :

- Type of land and the owners name
- Length of the route thru the land
- Problems in acquiring Right of Way (R.O.W.)
- Authority which will permit/grant ROW.
- Survey maps for the land available from the local Land Authority
(such as Collector, Tahasildar, Gram-Panchayat etc.)
- Land records regarding the title and ownership of the land
- Approx. compensation required for acquiring the R.O.W.

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- Status of Habitation on the land
- Similar information of the adjacent plots on 50 to 100 m on either
side of the route
- Plans for future installations by others on the proposed route and/or
in the vicinity such as roads/rail-tracks/buildings/pipe-lines etc.

f) Availability of construction materials, labour & facilities.

[Since the pipe-line has to pass thru different areas and over a long
distance, it is essential to know the availability of construction Labour
and Materials on the way such as excavation labour, transport
facilities, access roads, construction material like stones, aggregrates,
sand, cement, steel structurals, workshop facilities etc. This
information will be useful in working out the project schedule and cost
estimates and assessing the problems during construction.]

g) Soil Resistivity Survey required for design of cathodic protection
system.

h) Names and addresses of the statutory and public bodies required to be
contacted for acquiring ROW, construction permission, blasting
licenses, interfering with the public facilities (Roads, rivers, rail-tracks
etc.) and cathodic protection work, power supply/water supply etc.

[Such authorities include the following but not limited to the listed ones.

Local land authorities Distr. Collector, Municipal Corporation,
Tahsildar, Owners of the respective land.
P.W.D. Authorities Local Office
Irrigation Department
Electricity Supply Agencies / Bodies / Boards
Water-supply and Public Health Department
Controller of Explosive and use of Hazardous Chemicals
Industrial Development Corporations
Railway Authority
Marine and Port Authority
Salt-commissioner and Controller
Competent Authorities for Land and ROW acquisition
State and Central Govt. for necessary permission, licenses,
clearances etc.
Import/Export rules / regulations authorities
Controller of Quarrying and Mining
Navy/Army/Air force (Defence Authorities)
Plants for future installations
MOEF ]

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3.0.0 PROJECT ACTIVITIES

Based on various data collected as in 2.0.0 and the cost estimates, over
all project schedule has to be prepared based on past experience, and
specific problems unique to the project under consideration. This schedule
should cover only broad activities to serve as a guide line for preparation
of detail activity schedule.

This should generally include :

a) Preliminary survey / data collection.
b) Finalising the route
c) Cost estimates / budget sanctions.
d) Acquisition of R.O.W. and land
e) Basic engineering package
f) Detail engineering work
g) Construction work (Civil/Mech./Piping/Elect., Marine Crossing, River
Crossing etc. / Cathodic Protection).
h) Testing / Flushing / Pigging
i) Commissioning and hand over

This will establish the overall completion time for the entire project work.

4.0.0 BASIC ENGINEERING

Once the route survey and bathymetric survey document is available, the
Basic Engineering can be started.

The first step required for Basic Engineering is to finalize the pipe
parameters with regard to MOC, diameter, thickness (or class), corrosion
protection and laying requirements. The life cycle cost of various
alternatives will be compared to arrive at the final selection. The basic
guideline for calculating these parameters are furnished in the subsequent
clauses.

5.0.0 MATERIAL OF CONSTRUCTION

Popularly used Material of Construction for cross-country pipe line used to
be MS. Generally, spirally welded factory made SAW type MS pipes are
preferred. The methodology of manufacture of such pipe ensures better
quality of welding with in-built 100% radiographic testing facility. Such
improvement in quality of pipes is achieved at a very normal incremental
cost and, hence, should be recommended.

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Ductile Iron pipes has been another popular MOC for cross-country water
pipes. Invented in 1949, it retains the corrosion resistance of Cast Iron, but
has more than double the tensile strength of cast iron and even more than
MS. Impact resistance, also, is quite high and comparable with MS pipe.

Fiberglass pipe, commonly called as FRP or GRP pipes, made from glass
fiber reinforcements embedded in , or surrounded by thermosetting resin
is also becoming popular as pipe material for water transportation. A few
years back, GRP pipes used to be costly and, hence, application of GRP
pipes used to be considered only as corrosion-resistant alternative to
protect steel, stainless steel or other exotic materials. However, presently,
large scale bulk use of GRP pipes have attracted many manufacturers
producing GRP pipes. This, coupled with rapid improvement in
manufacturing technique, has brought down the prices of GRP pipes and
has become highly competitive with MS or DI pipes.

A brief comparison of pipes with above 3 material of construction is
indicated below :

MILD STEEL PIPE vs. DUCTILE IRON PIPE vs. FRP PIPE

Sl.
No.
Criteria
Mild Steel
pipeline
Ductile Iron
pipeline
Fiberglass
Reinforced
pipeline
1 Friction loss
C* = 120
Hence, friction
loss is maximum
C = 140
Hence, friction
loss is less than
MS but more than
FRP
C = 150
Hence, friction
loss is least
2 Total energy cost
Maximum, since
friction loss is
maximum
Less than MS.
More than FRP
Least
3
Corrosion
resistance
Susceptible to
corrosion. Hence,
inner and outer
lining is required
More Corrosion
resistant
compared to
MS.However,,
inner lining and
external painting
is required.
Highly resistive to
corrosion. Hence,
no lining is
required


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Sl.
No.
Criteria
Mild Steel
pipeline
Ductile Iron
pipeline
Fiberglass
Reinforced
pipeline
4 Maintenance
Outer lining may
peel off with time.
Hence, periodical
maintenance is
required
Outer painting
may erode off
with time. Hence,
periodical
maintenance is
required,but
frequency is less
than MS pipe.
Lesser
maintenance is
required
compared to MS
and DI pipes
5 Life of pipeline
Pipeline is
designed for 10-
15 years life
Pipeline is
designed for 15-
20 years life
Pipeline is
designed for 50
years life.
However, being
applied only in
recent times, it is
not yet time-
tested.
6 Design
Obtained in
standard sizes
Obtained in
standard sizes
Optimized design
can be effected
by the
manufacturer
depending upon
requirement
7
Weight &
handling
Specific gravity =
7.85
Hence, it is about
4.4 times heavier
than FRP pipes
and thereby
difficult to handle
than FRP pipes
Specific gravity =
7.05
Hence, it is about
4 times heavier
than FRP pipes
and thereby
difficult to handle
than FRP pipes
Specific gravity =
1.8 to 1.9
Hence, it is easier
to handle due to
its lighter weight
as compared to
MS & DI pipes
8
.Thrust Block
requirement
Thrust Block
requirement is
not there,as
welded
connection is
provided
As spigot /socket
tipe connection is
provided,thrust
block requirement
is there.
Special
connection can
eliminate
requirement of
thrust block.

*C-Hazen Willims Constant


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6.0.0 CALCULATION PROCEDURE FOR OPTIMIZATION OF PIPE
DIAMETER/THICKNESS FOR DIFFERENT MOCs

[In the calculation, the pipe diameter / thickness, buried piping has been
considered as per the normal practice followed for cross-country piping,
unless rock is encountered at close to top soil level.

Reasons behind this are :

1. With buried piping, cost of laying and supporting system become
economic.
2. Obtaining ROW becomes easier and compensation against such ROW
with buried piping is much less compared to overhead piping routing.]

The calculation procedure works out the design parameters and
subsequently works out the capitalized life cycle cost for each of the
alternatives and ultimately selects the most optimum choice. In case of
long cross-country water piping of length exceeding 20-30 km.,
segmenting the piping system with one/multiple no. of booster stations
may result in overall economy, as there can be substantial saving in cost
of piping. Such option for long distance piping needs to be examined.

6.1.0 Basic Inputs for Calculation

The basic input data required for the calculation are as follows:

i) System Design Flow rate
ii) Plant life
iii) Trench dimensions including height of ground cover and water
cover over the pipe crown
iv) Length of pipeline
v) Pump & motor efficiencies
vi) Pump & motor set cost[Based on the capacity,Head and Motor KW
to be calculated ]
vii) Static head and pumping station loss
viii) Number of hours the pumps will run in a year
ix) Number of working pumps
x) Prevailing power tariff
xi) Escalation of power tariff per year
xii) Civil costs (cost of excavation & backfilling)
xiii) Interest rate
xiv) Maintenance cost


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xv) Lining thickness (if any) / corrosion allowance *
xvi) Cost of material, lining (if any), fabrication, pipe laying.

* For guideline of degree of wrapping/coating, recommendations in
clause no. 8.2 of IS 10221-2008 may be referred.

6.2.0 Calculation Procedure

The procedure for calculation, in order to determine the most suitable and
optimum pipe material, size and wall thickness for a given application, is
elaborated below. The procedure is based on the guidelines laid down in
AWWA M-11, AWWA M-45 and IS 8329 for MS Pipes, FRP Pipes and DI
Pipes respectively.

6.2.1 Mild Steel Pipe

6.2.1.1 The calculation begins with the assumption of pipe NB and pipe thickness
(t), from IS 3589.

6.2.1.2 Pipe OD is determined from IS 3589.

6.2.1.3 Pipe ID is calculated as,
ID = OD 2t 2t
L

Where, ID = Internal diameter of pipe,mm
OD = External diameter of pipe,mm
t = Pipe thickness,mm (assumed)
t
L
= Internal liner thickness (IS 3589, Annexure A-
6.2, Table 8),mm

6.2.1.4 Check 1 : Checking for velocity :

Velocity of flow is calculated as,

V = Q / A

Where, V = Velocity of flow through pipeline,M/Sec
Q = System Design Flow rate,M3/Sec
A = Cross-sectional area of pipeline,M2
= (/4) * (ID/1000)
2


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The velocity of flow should not be less than 1.2 m/s to prevent from
precipitation of solid particles.This should also not exceed 2.5 M/Sec. in
order to maintain the flow without the generation of vibration. With the
initial assumption, if the above condition fails, pipe size and/or thickness
are revised and the above calculations are repeated to satisfy the
condition.There may be multiple diameters which will maintain the velocity
criteria within the acceptable range.

6.2.1.5 Check 2 : Checking against failure due to internal pressure :

Head loss due to friction (h
f
) is calculated using Hazen Williams equation
(Ref. AWWA M-11, eqn. (3-2M)). For MS pipe, friction co-efficient in
Hazen Williams equation, C, shall be considered as 120.

Total pump head is thus,
H
p
= h
f
+ h
fm
+ H
s
+ h
L

Where, H
p
= Total pump head
h
fm
= Margin on head loss due to friction
H
s
= Static head
h
L
= Pumping station loss

Design internal pressure, P
D
shall be considered as 120% of total
pump head (H
p
) to take care of shut-off Condition.

Maximum allowable internal pressure that can be withstood by the pipe,
with the selected diameter and thickness, is calculated using the Barlow
formula (Ref. AWWA M-11, (eqn. 4-1)), with, t = assumed pipe wall
thickness, and p = Maximum allowable internal pressure.

The following condition is checked, P
D
< p

On failure of the above condition, the pipe thickness is revised and the
selected thickness is now applied in clauses 6.2.1.3 and 6.2.1.4 above to
fine-tune the results. The selected thickness should also be checked as
per clause 104.1.2 of ASME B 31.1 2001 (code for pressure piping) and
higher value of thickness shall be considered.

6.2.1.6 Check3 : Checking against buckling due to internal vacuum / live
load :

Allowable buckling pressure is calculated using eqn. (6-7), in AWWA M-
11.


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Total external load on a buried pipe subjected to internal vacuum is
calculated using eqn. (6-8), in AWWA M-11. In buried pipe applications,
it is recommended to consider that the pipeline is subjected to full
internal vacuum.

Total external load on a buried pipe subjected to live loads is calculated
using eqn. (6-9), in AWWA M-11. Live load effect is obtained from Table
6-3. However, simultaneous application of live-load and internal
vacuum transients need not normally be considered. For calculation
of allowable buckling pressure, value of modulus of Soil Reaction is
furnished in Table 6.10/AWWA M-11. However it should be
considered as 500 psi (3450 kPa), unless specifically advised.

The total external load, as calculated above, should be less than the
allowable buckling pressure. If the condition fails, the pipe wall thickness is
revised and the previous calculations in clause 6.2.1.3 through 6.2.1.6 are
repeated to satisfy the condition.

6.2.1.7 Check- 4 : Checking against failure due to stresses due to handling :

Minimum wall thickness for handling are based on the eqns. (4-5), (4-6),
or (4-7) of AWWA M-11.

6.2.1.8 Check- 5 : Checking against deflection due to external pressure :

Load per unit of pipe length, W = W
DL
+ W
LL

Where, W
DL
= Dead load per unit length of pipe
= W
P
+ W
L
+ W
W
W
P
= Weight of bare pipe per unit length
W
L
= Weight of internal + external lining per unit
length
W
W
= Weight of water-filled pipe per unit length
W
LL
= Live load per unit length of pipe, as per
AWWA M-11, Table 6-3.

Horizontal deflection of pipe is calculated using eqn. (6-5) of AWWA M-11.

Allowable deflection is preferably 2% of pipe OD, for mortar lined and
coated, 3% of pipe OD for mortar lined and flexible coated and 5% of pipe
OD for flexible lined and coated.


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Horizontal deflection, as calculated above, should be less than the
allowable deflection. In case the above condition fails, the pipe thickness
is revised and the previous calculations in clauses 6.2.1.3 through 6.2.1.8
are repeated until the condition is satisfied.

6.2.1.9 Check- 6 : Checking against failure due to pressure surge :

Pressure rise above normal, due to water hammer, is calculated using
eqn. (5-2M) and (5-3M) of AWWA M-11.

The total pressure during the surge is the normal working pressure plus
the pressure rise above normal (as calculated above). In case this total
pressure exceeds the maximum allowable internal pressure (as calculated
in Cl. 6.2.1.5), either pipe thickness needs to be increased or surge
suppression device needs to be incorporated. In cross-country pipeline
applications, it is more economical to use surge suppression device
to take care of the pressure surge instead of increasing pipe wall
thickness.

6.2.1.10 Cost Analysis : From the above calculations, applicable pipe size(s) and
thickness(s) are selected for the particular buried pipe application. For
every set of selected pipe size and thickness, the following steps are
undertaken to evaluate the cost of each pipe.

Capitalization factor is calculated as, CF = 1-C
Lc

1-C

Where, C = 1 + (E
p
/ 100)
1 + (R
f
/ 100)
E
p
= Escalation of power tariff per year (%)
R
f
= Interest rate (%)
L
c
= Plant life (years)

Total piping cost, C
pipe
= C
BP
+ C
L
+ C
CW
+
C
LAY

Where, C
BP
= Cost of the entire length of bare pipe
C
L
= Cost of internal and external lining for entire
pipe
C
CW
= Cost of civil works (excavation & backfilling) **
C
LAY
= Cost of laying of pipe


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** Cost of civil works (excavation & backfilling) shall be evaluated
considering a standard trench, as shown below :

3D
o

1
0
0
0

D
0

3
0
0

2D
o

Total energy cost, C
E
= P * N * T * CF

Where, P = Power consumed in pumping
N = Number of hours the pumps work in a year
T = Power tariff
CF = Capitalization factor (as calculated above in in
this clause)

Total evaluated cost, C = C
pipe
+ C
E
+ C
P+M
+ C
M

Where, C
P+M
= Cost of pump set (pump + motor)
C
M
= Maintenance cost (May be considered as 5%
of C
E
)

For every selected set of pipe size and thickness, the above calculations
are done and the optimized set is determined. The optimized set is the
one having the least value of Total evaluated cost, C.

D

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6.2.2 Ductile Iron Pipe

6.2.2.1 The calculation begins with the assumption of pipe size (NB), from IS
8329, and pipe class (K7 / K8 / K9 / K10).

6.2.2.2 Pipe OD is determined from IS 8329, Table 2.

6.2.2.3 The internal lining (Cement-mortar) thickness is obtained from IS 8329.
The wall thickness of pipe is calculated using eqn (1) of IS 8329, Cl. No.
4.3.

6.2.2.4 Pipe ID is calculated as in Cl. 6.2.1.3.

6.2.2.5 Check- 1 : Checking for velocity : This checking is done as indicated in
Cl. 6.2.1.4.

On failure of the condition, the pipe size and class is revised and the
previous calculations are repeated to satisfy the condition. There may be
multiple sets of NB and class which will maintain the velocity criteria within
the acceptable range.

6.2.2.6 Check- 2 : Checking against failure due to internal pressure :

Head loss due to friction is calculated using Hazen Williams equation
(Ref. AWWA M-11, eqn. (3-2M)). For DI pipe, friction co-efficient in Hazen
Williams equation, C, shall be 140.

Total pump head and Design Internal Pressure is calculated as in Cl.
6.2.1.5.

The Allowable operating pressure (maximum allowable internal pressure)
for the selected pipe size and class is then obtained from IS 8329,
Annexure-E, Table 1.

The following condition is checked,
Design internal pressure < Allowable operating pressure
On failure of the above condition, the pipe class is revised and the above
calculations in clauses 6.2.2.4, 6.2.2.5 and 6.2.2.6 are repeated to satisfy
the condition.

6.2.2.7 Check-3 : Checking due to failure against pressure surge : This
checking is done as in Cl. 6.2.1.9.


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6.2.2.8 Cost Analysis : From the above calculations, applicable pipe size(s) and
pipe class(s) are selected for the particular buried pipe application. For
every set of selected pipe size and class, the following steps are
undertaken to evaluate the cost of each pipe.

Capitalization factor, Total piping cost, Total energy cost and Total
evaluated cost is calculated as in 6.2.1.10.

For every selected set of pipe size and pipe class, the above calculations
are done and the optimized set is determined. The optimized set is the
one having the least value of Total evaluated cost, C.

6.2.3 FRP Pipe

6.2.3.1 Apart from the inputs mentioned in Cl. 6.1.0, the design of FRP pipe
requires the following additional inputs :

i) Nominal pipe size (ref. IS 12709, Table 1 or Table 2).
ii) Hydrostatic design basis (manufacturers data)
iii) Long term ring bending strain (manufacturers data)

6.2.3.2 The calculation begins with the assumption of pipe NB, Pressure class,
P
C
, (ref. IS 12709, Cl. 4.1.1) and pipe reinforced wall thickness, t.

6.2.3.3 If ID series pipes are used, then, pipe ID, for the assumed pipe NB, is
obtained from IS 12709, Table 1. If OD series pipes are used, then, pipe
OD is determined from Table 2 and pipe ID is calculated as in Cl. 6.2.1.3.
The internal lining thickness for FRP pipes is obtained from
manufacturers data. It is generally between 1-1.2mm.

6.2.3.4 Check-1 : Checking for velocity : This checking is done as indicated in
Cl. 6.2.1.4. On failure of the condition, the pipe size and wall thickness is
revised and the calculations in clauses 6.2.1.3 (pipe ID) and 6.2.1.4 are
repeated to satisfy the condition. There may be multiple sets of pipe sizes
& thickness which will maintain the velocity within the acceptable range. It
is to be noted here, that the maximum velocity that can be allowed for safe
operation of FRP pipe is determined using eqn. (4-1) of AWWA M-45. the
minimum velocity to maintain the flow shall be 1.2 m/s.

6.2.3.5 Check-2 : Checking Pressure class : The acceptability of the selected
pressure class, P
C
, is checked using eqn. (5-1) or eqn. (5-2) of AWWA M-
45. In case the condition fails, the pressure class and pipe wall thickness
is simultaneously revised and above calculations are repeated to satisfy
the condition.


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6.2.3.6 Check-3 : Checking against failure due to internal pressure :

Head loss due to friction is calculated using Hazen Williams equation
(Ref. AWWA M-11. eqn. (3-2M)). For FRP pipe, friction co-efficient in
Hazen Williams equation, C, shall be 150.

Total pump head and design internal pressure is calculated as in Cl.
6.2.1.5.

The eqn. (5-3) of AWWA M-45 is checked with Pw being the calculated
design internal pressure. In case the condition fails, the pipe wall
thickness and pressure class is simultaneously revised and the above
calculations in clauses 6.2.3.4, 6.2.3.5 & 6.2.3.6 are repeated until the
condition is satisfied.

6.2.3.7 CHECK 4 : Checking against failure due to pressure surge :

Pressure surge above normal is calculated using eqn. (4-21) of AWWA M-
45. Here, a full instantaneous change in velocity equal to the flow velocity
in the pipe shall be considered.

The eqn. (5-4) of AWWA M-45 is checked. In case the condition fails, the
pressure class and wall thickness is simultaneously revised and the above
calculations in clauses 6.2.3.4, 6.2.3.5, 6.2.3.6 & 6.2.3.7 are repeated until
the condition is satisfied. The pressure surge for FRP piping will be lower
compared to MS/DI Pipe for same parameters.

6.2.3.8 Check-5 : Checking for maximum allowable deflection due to ring-
bending :

Pipe stiffness class, PS, is assumed (Ref. AWWA M-45, Table 5-1).

From eqn. (5-5) or eqn. (5-6) of AWWA M-45, the maximum allowable
long-term vertical pipe deflection is calculated.

For proper design, maximum allowable long-term vertical pipe deflection,
as calculated above, should be greater than the permitted deflection
(generally 5%). In case the above condition fails, the pressure class, wall
thickness and pipe stiffness are simultaneously revised and the above
calculations in clauses 6.2.3.4 through 6.2.3.8 are repeated until the


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6.2.3.9 Check-6 : Checking against failure due to deflection :

Vertical soil load, W
C
, is calculated using eqn. (5-9) of AWWA M-45, Cl.
5.7.3.5 and Live Loads on pipe, W
L
, as per the guidelines in Cl. 5.7.3.6 of
AWWA M-45..

Constrained soil modulus, M
S
, is calculated as per Cl. 5.7.3.8 of AWWA
M-45.

The predicted deflection is calculated using eqn. (5-8) of AWWA M-45. In
case the predicted deflection is greater than permitted deflection, the pipe
stiffness, pressure class and wall thickness is simultaneously revised and
the above calculations in clauses 6.2.3.4 through 6.2.3.9 are repeated
until the condition is satisfied.

6.2.3.10 Check-7 : Checking against failure due to combined loading of
internal pressure and deflection : The checking is done as per Cl. 5.7.4
of AWWA M-45. In case the condition fails, the pressure class, wall
thickness and pipe stiffness class is simultaneously revised and the above

6.2.3.11 CHECK 8 : Checking against buckling due to internal vacuum or live
load :

Allowable buckling pressure is calculated using eqn. (5-24a) of AWWA M-
45. Here, EI is calculated using eqn. (5-18) of AWWA M-45.

Total external load on a buried pipe subjected to internal vacuum is
calculated using eqn. (5-25) of AWWA M-45. In buried pipe
applications, it is recommended to consider that the pipeline is
subjected to full internal vacuum.

Total external load on a buried pipe subjected to live loads is calculated
using eqn. (5-26). Live load is calculated as per Cl. 5.7.3.6 of AWWA M-
45. However, simultaneous application of live-load and internal
vacuum transients need not normally be considered.

The total external load, as calculated above should be less than the
allowable buckling pressure. If the condition fails, the pressure class, wall
thickness and pipe stiffness is simultaneously revised and the above


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6.2.3.12 Cost Analysis : From the above calculations, applicable pipe sizes with
pressure class, reinforced wall thickness and stiffness class are selected.
For every selected pipe, the following calculations are done to evaluate
the cost of each pipe.

Capitalization factor is calculated as in Cl. 6.2.1.10.

Total piping cost is, C
pipe
= (U * L) + C
CW

Where, C
CW
= Cost of civil works (excavation & backfilling)
(Calculated as in Cl. 6.2.1.10)
U = Unit rate of pipe (Rs/m) (manufacturers data)
L = Length of pipe

Total energy cost, C
E
, and, Total evaluated cost, C, is calculated as in Cl.
6.2.1.10.

For every selected pipe, the above calculations are done and the
optimized pipe is determined. The optimized pipe is the one having the
least value of Total evaluated cost, C.

7.0.0 RESULT

Based on the analysis above, the optimum choice of diameter / class
(thickness) and MOC can be found out. Such optimized parameters will
form the basis of subsequent procurement activity.

8.0.0 REFERENCES

1. AWWA M 11 : Steel Water Pipe : A Guide for Design and
(Fourth Edition) Installation.

2. AWWA M 45 : Fiberglass Pipe Design
(Second
Edition)

3. IS 3589 : Steel Pipes for Water and Sewage (168.3 to
(Third revision) 2540mm outside diameter specification)


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4. IS 12709 : Glass Fiber Reinforced Plastics (GRP) Pipes,
(First revision) Joints and Fittings for use for Potable Water
Supply Specification

5. IS 8329 : Centrifugally Cast (Spun) Ductile Iron Pressure
(Third revision) Pipes for Water, Gas and Sewage Specification

6. FLOWTITE Test Report on Hydrostatic Design Basis (strain)

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