PROJECT NAME: PROCUREMENT, LAYING, JOINTING, TESTING &

COMMISSIONING OF FEEDER MAINS FOR

OVERHEAD TANKS AND DESIGN, CONSTRUCTION,
TESTING & COMMISSIONING OF OVERHEAD TANKS
& BULK WATER MANAGEMENT SYSTEM INCLUDING
SCADA UNDER INDORE WATER SUPPLY SYSTEM
PLUS 10 YEARS OPERATION & MAINTENANCE
CLIENT:

SUPERINTENDING ENGINEER
INDORE MUNICIPAL CORPORATION
PROJECT ‘AMRUT’ INDORE-452001

PMC :

DRA CONSULTANTS LTD,

NAGPUR

EPC CONTRACTOR:
M/S RAMKY INFRASTRUCTURE LTD.
A-101, NEW YORK TOWNSHIP, NR. TURBO
COLLEGE AB BYPASS ROAD, INDORE-452012

TITLE: APPROVAL STAMP:

DESIGN OF 1900MM DIA MS PIPE

DOCUMENT NO. REVISION:

AMRUT-RAMKY-IMC-MSD-1900 R0
JOB NO.
AMRUT/RAMKY/IMC/2017-18/001
COMMENTS: (No. of Pages) 0 0 1 To 0 0 8

REVISION STATUS:
REVISION DATE DESCRIPTION DESIGNED BY CHECKED APPROVED
BY BY
R0 23-12-2017 For Approval RS SK RS

This document is not to be reproduced, copied or used for any purpose other than that for which it is
prepared.
 UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

CASE- 1 M SOIL COVER ABOVE THE PIPE

A DESIGN DATA
1 Finished Internal Dia of MS Pipe = 1860 mm
2 Factory Test Pressure = 12.00 Kg/cm2
3 Design Working Pressure (including surge as 10% of wkg. Pr = 6.60 Kg/cm2 At chainage-
4 Working Pressure as per survey data, considered on max. side = 6.00 Kg/cm2 6210 of Rau
by-pass
5 Site Test Pressure 6.60 Kg/cm3
6 Density of compacted filling earth = 1800 Kg/m3
7 Height of earth fill above pipe = 1 m
8 Vacuum Pressure = 0.35 Kg/cm2
9 Modulus of Elasticity of Steel = 2100000 Kg/cm2
10 Modulus of Elasticity of Cement Mortar = 280000 Kg/cm3
11 Soil Modulus of Fill = 50 Kg/cm2
12 Thickness of outer coating = 30 mm
13 Thickness of inner Lining = 20 mm
14 Internal Diameter = 1900 mm
15 Outer metal Diameter (Without Coating) = 1924 mm
16 Outer Diameter (After external coating) = 1984 mm
17 Site Clearance of Trench = 300 mm
18 Density of coating material = 2100 Kg/m3
19 Width of trench = 2.584 m
20 Density of water = 1000 Kg/m3
21 Yield stress of pipe material = 2500 Kg/cm2

B DESIGN
1 Thickness of MS plate considered = 12 mm
2 Maximum % of deflection allowed = 5%
(For flexible lining and coating)
C VACUUM PRESSURE
Collapse pressure on account of Vacuum (As per IS 5822-1986 clause A 3.1) states that the pipe
shall be strong enough to with stand the effect of partial vacuum (Partial vacuum corresponding to
1/3 of atmospheric pressure i.e.1/3 of 1 Ksc = 0.334Ksc 0r 0.35 Ksc). Refer Page No. 22
of IS 5822-1986
D PERMISSIBLE STRESSES
Yield Stress (fy) as per IS :2062 table 2 page No.5 is 2500Kg/cm2. The permissible stress in the
pipe shell shall as per Clause 1 page 1 of IWWA manual M1 be related to yield stress (fy) of pipe
material making due allowance for weld efficiency of the joint.
a) Working stress for combined bending and direct tensile stress shall not exceed 60% of yield
stress of the material making due allowance for efficiency of weld joint.

b) Working stress for combined bending and direct compressive stress shall not exceed 50% of
yield stress making due allowance for weld efficiency.

c) For field welded joint, efficiency factor of 80%, whilst for shop welded joints 90% efficiency
is allowed as per IWWA manual M1 page 2 clause 1
Permissible Stress are :
2
In compression = 2500 x (50/100) x (90/100)= 1125 Kg/cm
2
In tension = 2500 x (60/100) x (90/100)= 1350 Kg/cm
E Moment of Inertial

Moment of Inertial
4
1/12x(12/10)^3 Is = 0.14400 Cm
4
1/12x(20/10)^3 IL = 0.66667 Cm
4
1/12x(30/10)^3 IC = 2.25000 Cm
EI= EsIs+ELIL+EcIc = 1119067 Cm-Kg
2100000*0.14+2,80,000.00*0.666666666666667+280000*2.25 = 1119067 Cm-Kg

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 UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

F Fill Load
Weight of steel pipe = 565.83 Kg/Rm
PI()x(1900/1000+12/1000)x12/1000x7850

Weight of Inner Lining = 248.06 Kg/Rm

PI()x(1860/1000+20/1000)x20/1000x2100

Weight of coating Material = 386.74 Kg/Rm

PI()x(1924/1000+30/1000)x30/1000x2100

Weight of water = 2717.16 Kg/Rm

PI()/4x(1860/1000)^2x1000

Total weight 3917.79 Kg/Rm

2,717.16+248.06+565.83+386.74

As per clause no 2 of IWWA Publication No. M1, the load due to pipe shell, lining and water is
partially transmitted to the ground and therefore only 50% of this load is considered in the design

Ws = 1958.90 Kg/Rm
Earth fill load 3,917.79*0.5
Considering the desired earth fill
Bc- out side dia of the pipe = 1.984 m
H/Bt = 0.39
Ct from Fig. 4 of IS 783 = 0.4

We = Ct x Earth Load x Bc x Bt = 3691.19 Kg/Rm

Total dead load 1,958.90+3,691.19 = 5650.09 Kg/Rm

Live Load
Wheel Load shall not be considered in the design as per clause No. 10.6.2 (Vol. II),
however, the same has been considered in the design to have the safe designs
Wl = Cp x P x F

P = Axial Load(Class A loading as per IRC) = 13200 Kg

L = Effective length of pipe = 1m
F = Impact Factor =1.0 as per IS 783 table 1 Page No 19 1

Bc/2H = 0.9920

L/2H = 0.5000

From Fig. 3 of IS 783 Cp = 0.47

Wl = = 6204 Kg/Rm
Total Load = 11854.09 Kg/Rm
5,650.09+6204
CASE 1- Working Pressure (incl. Surge + Self Wt + Water Wt + Earth + Live Load
2
Considering 10% allowance for surge pressures = 6.6000 Kg/cm

Deflection
a) For external load and partial vacuum pressure

Deflection Deltax = De x Ke x We x R3
EI + 0.061e'R3 - 2PeR3Ke
Where
De = Deflection lag factor varies from 1.0 to 1.5 as per Page No. 59 of AWWA M11
manual and Page No. 83 of AWWA Steel Pipe manual, Adopt De= 1.00

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 UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

Ke = Bedding constant and is 0.10 as per Page No. 59 of AWWA M 11 manual

and 0.096 as per IWAA manual M1 Page 8, Table 1 for 90 deg angle of load
spread. Adopt value of Ke = 0.1

We = Total Load in Kg/cm = 118.54 Kg/cm

R = Radius of pipe in cm = 936 cm
E = Young's Modulus of Steel = 2100000 Kg/cm2
I= Moment of Inertia = 1119067 Cm-Kg
e' = Soil Modulus of fill in Kg/cm2 = 50 Kg/cm2
Pe = External radial pressure = 6.60 Kg/cm2

Delta x = 3.83 Cm
(1*0.1*11,854.09/100*((1860+12)/20)^3)/(11,19,066.67+0.061*50*((1860+12)/20)^3-2*0.35*0.1*((1860+12)/20)^3) =38.3mm
38./(1900+12x2)x100 = 1.98 % of OD of pipe

The allowable deflection as per AWWA M11 manual page 60 and IWWA M1 manual page 15 is
2% of pipe diameter in case of pipes with mortar lining and mortar coating coating. Hence safe.

b) For external load as above and with internal pressure

Deflection Delta x = De x Ke x We x R3
EI + 0.061 e' R3 + 2 PiR3Ke

Delta x = 2.07 Cm
(1*0.10*118.5409*((1,860.00+12.00)/20)^3)/(11,19,066.67+0.061*50.00*((1860+12)/20)^3+2*6.60*0.10*((1,860.00+12.00)/20)^3)
= 20.67 mm
20.67/(1900+12x2)x100 = 1.07 % of OD of pipe

The allowable deflection as per AWWA M11 manual page 60 and IWWA M1 manual page 15 is
2% of pipe diameter in case of pipes with mortar lining and mortar coating coating. Hence safe.

Compressive Stress

External load with side supports and partial vacuum

Moment Mb = Kb x We x R x EI
EI + 0.061 e' R3-2 Pe R3 Ke
Where
We = Self Wt + Wt of Water + Earth Load + Live Load = 118.5409 Kg/cm
Kb = Bending Constant and is 0.1570 as per page 89 of IWWA M 1 manual

Moment Mb = 147.86 Kg cm
0.157*(11,854.09/100)*((1860+12)/20)*21,00,000*0.14/((11,19,066.67+0.061*50*((1,860+12)/20)^3)-2*0.35*((1,860.00+12)/20)^3*0.10)

3
Section Modulus = Moment of Inertia /extreme fiber = 0.2400 cm

Compressive Stress fb = Mb/Section Modulus

2
147.86/0.24 = 616.07 Kg/cm

Hoop Stress f hoop = Pe x d/(2xts)

2
(0.35*1860/10)/(2*12/10) = 27.1 Kg/cm
Total Compressive Stress = fb + f hoop
2
616.07+27.13 = 643.19 Kg/cm
2
< 1125 Kg/cm
Safe

Tensile Stresses

Tensile stress ft = Kb x We x R x E x ts
2 x (EI + 0.061e' R3 + 2 Pi R3 Ke)

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 UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

2
ft = 466.743 Kg/cm
(0.157*(11,854.09/100)*((1860+12)/20)*2100000*(12/10))/(2*(11,19,066.67+0.061*50*((1860+12)/20)^3+2*6.60*0.10*((1860+12)/20)^3))
Hoop Stress f hoop = Pi x d/(2xts)
2
= 511.5 Kg/cm

Total Tensile Stress = ft + f hoop

2
= 978.24 Kg/cm
2
Allowable 1350 Kg/cm
Safe

CASE 2- Site Test Pressure + Self Wt + Water Wt + Earth Load

Deflection
a) For external load and partial vacuum pressure

Deflection Deltax = De x Ke x We x R3
EI + 0.061e'R3 - 2PeR3Ke
Where
De = Deflection lag factor varies from 1.0 to 1.5 as per Page No. 59 of AWWA M11
manual and Page No. 83 of AWWA Steel Pipe manual, Adopt De= 1.00

Ke = Bedding constant and is 0.10 as per Page No. 59 of AWWA M 11 manual

and 0.096 as per IWAA manual M1 Page 8, Table 1 for 90 deg angle of load
spread. Adopt value of Ke = 0.096

We = Total Load in Kg/cm = 56.50 Kg/cm

R = Radius of pipe in cm = 93.6 Cm
E = Young's Modulus of Steel = 2100000 Kg/cm2
EI = Moment of Inertia = 1119067 Cm-Kg
e' = Soil Modulus of fill in Kg/cm2 = 50 Kg/cm2
Pe = External radial pressure = 6.60 Kg/cm2

Delta x = 0.165 Cm
1.65 mm
1.65/(1900+12x2)x100 = 0.09 % of OD of pipe

The allowable deflection as per AWWA M11 manual page 60 and IWWA M1 manual page 15 is
2% of pipe diameter in case of pipes with mortar lining and mortar coating coating. Hence safe.

b) For external load as above and with internal pressure

Deflection Delta x = De x Ke x We x R3
EI + 0.061 e' R3 + 2 PiR3Ke

Delta x =0.95 Cm
9.55 mm
9.55/(1900+12x2)x100 = 0.50 % of OD of pipe
The allowable deflection as per AWWA M11 manual page 60 and IWWA M1 manual page 15 is
2% of pipe diameter in case of pipes with mortar lining and mortar coating coating. Hence safe.

Compressive Stress

External load with side supports and partial vacuum

Moment Mb = Kb x We x R x EI
EI + 0.061 e' R3-2 Pe R3 Ke
Where
We = Self Wt + Wt of Water + Earth Load = 56.50 Kg/cm
Kb = Bending Constant and is 0.1570 as per page 89 of IWWA M 1 manual

Moment Mb = 70.43 Kg cm

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UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

3
Section Modulus = Moment of Inertia /extreme fiber = 0.240 cm

Compressive Stress fb = Mb/Section Modulus

2
= 293.45 Kg/cm

Hoop Stress f hoop = Pe x d/(2xts)

2
= 27.1 Kg/cm

Total Compressive Stress = fb + f hoop

2
= 320.58 Kg/cm
2
Allowable 1125 Kg/cm
Safe
Tensile Stresses
Tensile stress ft = Kb x We x R x E x ts
2 x (EI + 0.061e' R3 + 2 Pi R3 Ke)
Where
We = Self Wt + Wt of water + Earth Load = 56.50 Kg/cm
2
Pi = Site test Pressure = 6.600 Kg/cm
2
ft = 224.534 Kg/cm

Hoop Stress f hoop = Pi x d/(2xts)

2
= 511.5 Kg/cm

Total Tensile Stress = ft + f hoop

2
= 736.03 Kg/cm
2
< 1350 Kg/cm
Safe
Critical Collapse Pressure
Any steel tube having t/d ratio less than 0.02 will fail by buckling when p = 4.62x 106 (t/d)3
as per page No. 22 of IS 5822 - 1986

2 3
As per AWWA M11 Pc = 2E/(1-mue ) x(t/d)
3
= 66000000 x (t/d) as per formula 403 at page no. 39 of AWWA
M11, where Pc is collapsing pressure in psi. To convert Pc in psi
to Ksc multiply by 0.07
3
Pc = 66000000 x 0.07 x (t/d)
6 3
= 4.62 x 10 x (t/d)
It is the Critical Collapsing pressure as per AWWA M11 manual and PHED.

Atmospheric pressure on account of vacuum (IS 5382 clause A 9.4) states that the pipes shall be
strong enough to withstand the effect of partial vacuum (Partial vacuum corresponding to 1/3 of
atmospheric pressure)

Atmospheric pressure up to elevation above 500 m from mean sea level is 1.03 Ksc.

One third of Atmospheric pressure = 1/3*(1.03)= 0.34 Ksc

As per AWWA M 11 manual page No. 39 any steel tube having t/d ration less than 0.023 will
fail by buckling when collapsing pressure Pc = 4.62 x 106 x (t/d)3

Ratio of thickness to diameter = t/d

= 0.0062
Where
t = thickness of MS plate
d = Outside diameter of pipe

2
Allowable Critical Collapsing Pressure Pc = 1.12 Kg/cm
> 0.34 Safe
Collapsing pressure on account of Vacuum is less than Critical collapsing pressure. Hence the
thickness provided is safe for collapse

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UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

Buckling
Pipe embedded in soil may collapse or buckle from elastic instability resulting from loads and
deformations. The summation of external loads should be equal to or less than the allowable
buckling pressure. The allowable buckling pressure qa may be determined by equation given in
AWWA M11 manual using formula 6-7 at page No. 61 clause No. 6.3

qa = (1/FS) x (32Rw B' E' x EI/D3)1/2

Where
FS = design factor
= 2.5 for h/D>=2
3 for h/D< 2
h/D 0.538
FS = 3

hw = height of water surface above top of pipe

Rw = Water buoyancy factor

= 1-0.33(hw/h)
hw = 1 Assumed

Rw = 0.67
B' = Empirical coefficient of elastic support
= (1/(1+4e-0.065H))
Where
H = Height of fill above pipe in ft

B' = 0.236
2
E' = 300000 Kg/m
2
qa = 8738.97 Kg/m

Check of pipe against buckling

As per AWWA M11 manual page 61 clause No. 6.3 formula 6-8

a) Load Combination 1
Water Pressure + Earth Pressure + Vacuum Pressure

2
Gamaw x hw + Rw (Wc/D)+Pv <=qa 5812.69 Kg/m
Allowable 8738.97
Safe in buckling
b) Load Combination 2
Water Pressure + Earth Pressure + Pressure due to Live Load

2
4518.99 Kg/m
2
Allowable 8738.97 Kg/m
Safe in buckling

Handling
Minimum plate or sheet thickness for handling are based on two formulae of AWWA M11
manual page No. 40, clause No. 4.5 equations (4-5) and (4-6)

ts = D/288

Minimum thickness of plate required for handling is

ts = 6.54 mm
and in no case shall the shell thickness be less than 14 gauge ( 0.0747 inch or 1.90 mm)
Hence pipe is safe in Handling

So the thickness adopted shall be 12 mm

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UNDER GROUND FEEDER MAIN STRESS ANALYSIS OF 1900MM MS PIPE

PIPE LINE -1900MM DIA

Hydraulic Test Pressure

As per IS - 3589 the maximum test pressure shall be

P = 2st
D
Where
S= 4100 Minimum Tensile Strength
&S= 40% of minimum Tensile strength

P = 2 x 0.4 x 4100 x 1.2

140
P = 28.114 kg/cm2 > 16.0 kg/cm2 Hence O.K.

Total design thickness of pipe = 12 mm

Adopted thickness of pipe = 12 mm

Adopted thickness of MS plate is 12 mm.

Hence total thickness of MS plate to be adopted in fabrication of MS pipes & specials in case of
6.60 Kg/cm2 field test pressure and 1 m over burden condition is 1212 mm

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