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Design of a 120 in.-Diameter Steel Bifurcation with a Small Acute Angle for a
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High-Pressure Penstock

By: Henry H. Bardakjian P.E (1) and Mehdi S. Zarghamee Ph.D., P.E (2)

(1) Consulting Engineer, 1331 N. Maryland Ave, Glendale, CA 91207

Email: [email protected]
(2) Senior Principal, Simpson Gumpertz & Heger Inc.
41 Seyon St., Building 1, Suite 500, Waltham, MA 02453
Email: [email protected]

Abstract: The design of the shell and reinforcing members of a 120 in. x 120 in.
bifurcation (wye branch) for the Olivenhain-Lake Hodges Pumped Storage Project in
San Diego County, CA, was a major challenge because of the small acute angle of
34.6º and the high design pressure of 472 psi.

The project design criteria for the shell of the wye and reinforcing elements limit the
general membrane stresses to the lesser of 2/3 of yield strength or 1/3 of tensile
strength of the steel and the surface stresses at points of geometric discontinuities to 3
times the allowable membrane stress. Although AWWA Manual M11 design
procedure does not include calculation of discontinuity stresses, preliminary design of
the wye and reinforcing elements in conformance with AWWA procedures does not
lead to designs that are feasible to fabricate and transport due to the required
thickness and depth of the crotch plates.

Finite element analyses (FEA) were performed to verify a modified-preliminary

AWWA baseline crotch plate reinforcement design and to predict the membrane and
discontinuity stresses. Since the project allowable stresses of the baseline design
were exceeded, additional FEA analyses were conducted using different crotch plate
thicknesses and depths, different shell thicknesses, and additional localized
reinforcement schemes. Crotch plates with T cross-sections could not be used
because of the small acute angle.

The design assumptions and the FEA results are the focus of this paper. The
advantages of the nonlinear analysis due to the high discontinuity stresses will be
discussed and the supporting data presented. The use of a steel reinforcing pin at the
intersection of the crotch plates to reduce the maximum discontinuity effects is also
discussed.

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Introduction

The Lake Hodges to Olivenhain 40-megawatt pumped storage project is a part of the
San Diego County Water Authority’s $939 million Emergency Water Storage
Project. This project consists of a 5900 ft long, 120 in. diameter high pressure steel
pipeline tunnel starting at the Olivenhain reservoir and ending near Lake Hodges, 180
ft of 120 in. diameter above grade steel pipeline connected to the Lake Hodges tunnel
portal and a 120 in. diameter bifurcation connecting the pipeline to the Power/Pump
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House and Lake Hodges. The above grade pipe and the wye will be encased in
concrete; therefore, it was desirable to limit the maximum depth of the crotch plates
to avoid excessive concrete encasement.

The major challenges of the design of the shell and reinforcing members of the 120
in. x 120 in. bifurcation (wye branch) are due to the small acute angle of 34.6º
(typically a minimum 45º angle is used) between the branches and the high design
pressure of 472 psi. The project design criteria for the wye section are the provisions
of ASCE Manual 79 Steel Penstocks, which limits the maximum membrane and
discontinuity stresses.

Design of the crotch plates by the AWWA M11 procedure, which is based on the
design procedure developed by Swanson (1955), requires very thick and deep crotch
plates due to the small acute angle and high design pressure. Even though the
AWWA procedure does not account for discontinuity stresses, the resulting AWWA
designs were not practical or even feasible to fabricate due to the required thickness
(maximum thickness for continuous cast steel is about 5.5 inches and for ingot cast
steel to 7.5 inches) and the depth far exceeding the shell diameter. Therefore, new
additional reinforcing schemes were explored. Alternative designs and reinforcement
schemes are based on finite element analysis (FEA), using a special version of the
NASTRAN FEA program.

Design Criteria for the 120 in. Diameter Bifurcation and Reinforcement

The design of the shell of the wye and reinforcing members was based on the ASME
Pressure Vessel Code and ASCE Manual 79, which limit the general membrane
stresses ( m) to the lesser of 2/3 of yield strength ( y) or 1/3 of tensile strength ( T),
and the surface stresses ( s) at points of geometric discontinuity to 3 m ( s = 3 m).

The minimum yield, y, and tensile strength, T, of ASTM A516 Grade 70 steel used
for the fabrication of the shell and the crotch plates are 38,000 psi and 70,000 psi,
respectively. Therefore m and s are limited to 1/3 T = 23,333 psi, which is less
than 2/3 y = 25,333.3 psi, and 3 m =70,000 psi, respectively. The ASCE procedure
also allows a maximum membrane stress ( max) of 1.5 m = 1.5 x 23,333.3 = 35,000
psi provided this stress drops to 1.1 m (1.1 x 23,333 =25,667) within a distance not
to exceed R t where R is the radius of the shell and t is its thickness.

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Baseline Design of the Wye & Initial Linear Finite Element Analysis

The baseline design consists of a 120 in. x 120 in. x 34.6º angle wye with 3-plate
crotch plate design and dimensions and geometries as shown in Figure 1. The wye
has two120 in. x 84 in., 18 ft long reducing legs and 5 ft long 84 in. stubs. The design
pressure is 472 psi. The initial design did not include a pin at the three crotch plate
intersect region.
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Initial finite element linear analysis was conducted on the baseline model shown in
Figures 1, 2, and 3. The boundary conditions and applied loads, consisting of internal
pressure P applied to pipe elements along with dead end longitudinal PA forces at the
three ends of the model. The discontinuity and membrane stresses in the acute region,
flat region and intersect region, which are defined in Figure 3, all exceeded the
allowable limits.

0’’
5’-

Pipe wall = 1.25” thick 84’’ID

Crotch plates = 7.00” thick
’’
’-0
18

121½ ’’ID
’’
64½ ’’
52
36’- 84’’ID
’’ º-
’-3 34 150’’
16

Height of crotch plates over the pipe

surface is 30.0” at intersection point.

30’’

7’-6’’ 16’-3’’ 18’-0’’ 5’-0’’

Figure 1. Dimensions and baseline model geometry of the wye

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Intersect
A half-model was Region
analyzed utilizing
symmetry boundary Flat
Region
conditions on the XY
plane.
X
Acute
Region

Y
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Figure 2. Boundary Conditions Figure 3. Stress Regions

The maximum discontinuity stress was 80,000 psi > 70,000 psi and the maximum
membrane stress was 64,000 psi > 35,000 psi.

Since the allowable stresses were exceeded, the following parametric study was
performed to determine the effect of change of pipe and crotch plate thickness and
depth:

• The effects of increasing the pipe wall thickness from 1.25 inches to 1.50 inches
are:
• Discontinuity stress reduced by 5%.
• Membrane stress reduced by 5%.

• The effects of increasing the depth of the main crotch plate from 150 inches to
160 inches are :
• Discontinuity stress reduced by 4%.
• Membrane stress reduced by 3%.

• The effects of decreasing the crotch plate thickness from 7 inch to 6 inches are:
• Discontinuity stress increased by 15%.
• Membrane stress increased by 13%.

Finite Element Analysis with Additional Localized Reinforcement

Based on the preliminary finite element results, the following localized reinforcement
schemes were considered to provide a better load path through the structure:

• Redesign-1: Baseline model with a 7- inch thick stiffener at the crotch plate
intersection, and two 2 in. stiffeners on either side of the largest crotch plate.
• Redesign-2: Baseline model with a 7 in. thick stiffener at the crotch plate
intersection and only one 2 in. thick stiffeners on either side of the largest crotch
plate. Figure 4 depicts Redesign-2.

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• Redesign-3: Similar to Redesign-2 except 3/4 in. thick plates are welded on either
side of the acute angle.

Revised conceptusing a single

2” thick plate on each side ofthe
7” crotch plate

2” thick
plates (1
on each
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7”thick plate side of

crotch
plate)

Figure 4. Redesign – 2 Concept

The peak stresses for the base line model, Redesign-1, Redesign-2, and Redesign-3
are given in Table 1, and the results are summarized below.

Table1. Peak Stresses due to Additional Localized Reinforcement

P eak C om bined S tress (psi) P eak M em brane Stress (psi)
Acute Flat Intersect 7” Crotch Acute Flat Intersect 7” Crotch
Region Region Region Plates Region Region Region Plates

Baseline Model 79,179 51,390 81,612 63,632 63,609 28,338 26,060 63,383

Redesign-1 80,625 52,397 57,234 61,163 65,292 27,399 24,292 60,986

Redesign-2 71,175 54,001 57,140 59,722 61,291 27,413 24,318 59,530

Redesign-3 56,727 53,892 56,511 52,145 51,883 27,259 24,000 52,001

Summary of Results forRedesign-1

• Adding two new stiffener plates, 3 ft apart, in the acute region does not help
reduce the maximum discontinuity stresses in the acute region.
• Extending the 7 in. thick plate reduced the discontinuity stresses in the intersect
region below the design criteria (From 82 ksi to 57 ksi)

Summary of Results for Redesign-2

• Adding only one stiffener plate at the middle of the acute region reduced the
maximum discontinuity stresses in the acute region by 12% (from 81ksi to 71 ksi)
and the maximum membrane stress by 6% (from 65 ksi to 61 ksi).

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Summary of Results for Redesign-3

• Adding one new stiffener plate and strengthening the acute region reduces the
maximum discontinuity stress by 21% from 71 ksi to 56 ksi, and the maximum
membrane stress by 15% from 61 ksi to 52 ksi.

None of the above alternative schemes were satisfactory to control the peak stresses
within the design criteria except with the addition of the 7 in. stiffener at the crotch
intersection the stresses at the intersect region were controlled.
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The use of T-section crotch plates was not considered due to the lack of space in the
small acute region of the bifurcation.

Nonlinear Finite Element Model

Since the allowable discontinuity stresses are beyond the yield strength of the steel
and the stress-strain curve is not linear beyond the yield strength, the non linear
analysis was conducted to predict the actual strains and stresses. The nonlinear
analysis for the baseline model is similar to the linear analysis baseline model except
that the pipe wall elements and crotch plate elements yield at 38 ksi. Both materials
then undergo strain hardening with a plastic modulus that is defined by ultimate stress
and strain equal to 70 ksi and 20%, respectively. The nonlinear material response
given in Figure 5 is based on the true stress-strain diagram and not the engineering
stress-strain diagram.

Figures 6 and 7 depict the strains in the cylinder and crotch plates. The maximum
plastic strain in the cylinder and crotch plates, which occurs in the acute region, is
0.28% and 0.27%, respectively, compared to 0.13% strain at the onset of yielding
(see Figure5) and 20% at ultimate. The corresponding stresses varied between 38,200
psi and 38,800 psi. Figure 7 also shows that, besides the 0.27% localized plastic strain
at the bifurcation depicted in red color, the plastic strain on top of the main plate near
the intersect area depicted in green color also exceeded the elastic limit at 0.20%.

38
ksi E = 254 ksi

E = 29,000
ksi

1310 µ

Figure 5. Nonlinear Material Response

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Figure 6. Major Principal Strain in Outer Surface of Cylinder. Maximum

Strain in Acute Region is 0.0028<<0.20.

Figure 7. Major Principal Strain in Crotch Plates. Maximum Strain in

Acute Region is 0.0027<<0.20.

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Effect of a Tube (Pin) at Intersect Region

Based on earlier results and the advantage of the addition of a 7 in. stiffener at the
intersect region, it was decided to explore the effect of adding a pin at the intersection
of the three crotch plates.

The steel tube is 16 in. OD with a wall thickness of 1.59 in. and has the same
properties as the shell and crotch plate material. The tube is closed at the top and
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bottom by 1.25 in. thick disks. All other parameters of the finite element model were
the same as the model without the tube.

The results of the nonlinear FEA are shown in Figures 8, 9, and 10. Figure 8 shows
that the maximum discontinuity stress at the cylinder in the intersect region near the
pin is 38,671 psi which is less than the allowable 70,000 psi. The maximum stress in
the crotch plates is less than 35,000 psi, which is the allowable membrane stress.

Figure 8. Maximum Principal Stresses in Cylinder and Crotch Plates with 16 in.
Diameter Steel Tube at Intersect Region

As shown in Figure 9, the maximum plastic strain near the top of tube is 0.2%, and is
highly localized. Limited yielding may occur; however the equivalent stress will be
less than 39,000 psi which is less than the allowable 70,000 psi.

The maximum localized plastic strain at the bifurcation is 0.135% (Figure 10). Based
on the assumptions made, the elastic limit is 0.131%. Plastic strain may not occur
since the actual yield of the steel will usually be greater than 38,000 psi. The
maximum localized plastic strain without the tube, as shown in Figure 7, was 0.27%.
After the addition of the pin the plastic strain was reduced by 50 % to 0.135%. The
plastic strain of 0.2% strain at top of the plate without the pin, as shown in Figure 7,
was reduced to below the elastic limit (0.05 %) after the addition of the tube.

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i Strain near
Figure 9. Plastic i theiTube at Intersect
i Region

Plastic yielding on
upper edge is eliminated
by adding the tube

Figure 10. Plastic Strain in Crotch Plate (Maximum at Bifurcation = 0.135%).

Note Negligible Magnitude of Plastic Strain and its Localization

The addition of the 16 in. OD tube reduces the amount of plastic strain, and the
maximum principle stresses in the system.

Conclusions and Recommendations

• The AWWA M11 procedures for the design of large diameter, high pressure
bifurcations with small acute angles should be supplemented with finite element
analysis to check for membrane and discontinuity stresses. Typically, nonlinear
finite element analysis may be required to deal with the high discontinuity
stresses.

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• The parametric study, for this high pressure bifurcation with small acute angle
showed that the reduction of membrane and discontinuity stresses due to
changing the shell thickness and crotch plate thickness or depth is not significant.
The addition of localized stiffeners in the intersect region did reduce the stresses
in that region.
• The addition of a tube or pin at the intersections of the crotch plates for large-
diameter, high-pressure bifurcations reduces the amount of plastic strain and the
maximum principle stress, and facilitates welding of the plates.
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Fabrication of Wye

This 120 in. x 120 in. x 34.6º wye is being fabricated at Ameron’s Fontana Plant. See
Figure 11. The two 120 in. x 84 in. reducing legs were welded to check the fit up.
Due to weight and shipping limitations the two legs will be welded in the field; the
weight of the main crotch plate alone is 44 tons.

Figure 11. Fabrication of the Wye

References

American Water Works Association (2004), Manual of Water Supply Practices

AWWA M11, Steel Pipe - A Guide for Design and Installation, Denver, CO.

Swanson, H.S Et AL. (1955) “Design of Wye Branches for Steel Pipe,” J. Am. Water
Works Assoc., 47(6), 581-629.

American Society of Civil Engineers (1993), ASCE Manuals and Reports on

Engineering Practice No. 79, Steel Penstocks.

10

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