DESIGN DEPARTMENT

Thrust Block Design

Thrust Block Design

1) INTRODUCTION
- Piping systems are subjected to unbalanced thrust forces resulting from static and dynamic fluid action on the pipe.
- These forces must be balanced if the piping system is to maintain its integrity.
- Unbalanced thrust forces occur at change in directions of flow such as elbows, tees,reducers, valves and dead ends.
- Reactive forces can be provided in the form of thrust blocks, or transmitting forces to the pipe wall by restrained, harnessed,
flanged or weldedjoints(forces from the pipe shell tranferred to the soil).

2) BASIC THEORY
2.1) FUNDAMENTAL EQUATIONS OF FLUID DYNAMICS
1) Conservation of mass:-
mass flow entering = mass flow leaving
Qentering = Qleaving …….(1) …. Form fluid dynamics

2) Conservation of energy
p1 v12 p2 v22
+ + z1 = + + z2 + hf + hl …….(2)
ρg 2g ρg 2g
.... Bernoulli's Equation
Here
p= Pressure ρ = Density of the fluid at all points in the fluid
v = Velocity of fluid g = Gravitational Acceleration
z = Elevation of the point above a reference plane

3) Conservation of momentum
F = mdv /dt δF =ρQ (v2-v1) ……(3)
Here …. Fundamental concept of physics
F = Force, v = Velocity, t = time
m = mass, ρ = density, Q= flow

2.2) CALCULATION OF THE FORCES

1.Pressure forces Rpx = pxA ……... From Eq.(2)

2.Momentum forces Rx= ρQ(V2x-V1x ) ……... From Eq.(3)
3.Reaction forces R=Σ (Rpx+Rx)

2.3) BEARING AREA OF THE THRUST BLOCK

A = R / Pbearing
Here …… From thrust restraint design for ductile iron pipe DIPRA
A = Bearing area of thrust block
R = Total thrust force
Pbearing = Bearing Capacity of soil
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Thrust Block Design

2.4) GUIDE LINE FOR BEARING CAPACITY OF SOIL

…… From thrust restraint design for ductile iron pipe DIPRA

2.5) PICTURES OF THE THRUST BLOCK

3) THRUST BLOCK FOR HORIZONTAL BEND

Steps involved in Calculation Procedure

3.1) Select the axis
3.2) Determine the pressures, velocities and flow rates at the specific point
3.3) Determine the forces using the funamental equations of fluid dyanmics
3.4) Calculate thrust block dimensions

3.1) SELECTION OF THE AXIS

 DESIGN DEPARTMENT

Thrust Block Design

Y (Vertical axis)

X (Horizontal axis)
Z X (Horizontal axis)

3.2) DETERMINATION OF THE PRESSURE, VELOCITIES AND FLOW RATE AT THE SPECIFIC POINT

On the basis of given pipe size and flow through pipe we have to find out the velocity inside the pipe at
that point.
V= Q/A
Here Q = flow through pipe
A = cross sectional area of the pipe
V= velocity of fluid through pipe

If there is an juction and pipe dia is changing the new pressure, can find out by appling the Bernoulli's
Equation at that point. And if pipe diameter is not changing the same pressure can be use to find out
the pressure force at the bend or the specific point

3.3) DETERMINATION OF THE FORCES ON BEND

3.3.1) Resulting force due to Mass flow and Flow Velocity

The resulting force in x-direction due to mass flow and flow velocity can be expressed as:
Rx = m v (1 - cosβ)         (1) ……. By applying the momentum equation
 DESIGN DEPARTMENT

Thrust Block Design

    = ρ A v2 (1 - cosβ)         (1b)
    = ρ π (d / 2)2 v2 (1 - cosβ)         (1c)
where
Rx = resulting force in x-direction (N)
m = mass flow (kg/s)
v = flow velocity (m/s)
β = bend angle
ρ = fluid density (kg/m3)
d = internal pipe diameter (m)
π = 3.14...
The resulting force in y-direction due to mass flow and flow velocity can be expressed as:
Ry = m v sinβ         (2) ……. By applying the momentum equation
    = ρ A v2 sinβ         (2b)
    = ρ π (d / 2)2 v2 sinβ          (2c)   
where
Ry = resulting force in y direction (N)

The resulting force on the bend due to force in x- and y-direction can be expressed as:
RF = (Rx2 + Ry2)1/2         (3)
where
RF = resulting force on the bend (N)

3.3.2) Resulting force due to Static Pressure

The pressure and the end surfaces of the bend creates resulting forces in x- and y-directions.
The resulting force in x-direction can be expressed as
Rpx = p A (1- cos β)         (4)   
    = p π (d / 2)2 (1- cos β)         (4b)
where
Rpx = resulting force due to pressure in x-direction (N)
p = gauge pressure inside pipe (Pa, N/m2)

The resulting force in y-direction can be expressed as

Rpy = p π (d / 2)2 sinβ         (5)
where
Rpy = resulting force due to pressure in y-direction (N)

The resulting force on the bend due to force in x- and y-direction can be expressed as:
Rp = (Rpx2 + Rpy2)1/2         (6)
where
Rp = resulting force on the bend due to static pressure (N)

3.3.3) Resulting thrust force on the Bend

R = ((RF)2 + (Rp)2)1/2 
where
RF = resulting momentum force on the bend (N)
Rp = resulting force on the bend due to static pressure (N)
 DESIGN DEPARTMENT

Thrust Block Design

3.3.4) Thrust Block Bearing Area

Bearing Area Required = (Thrust force/ Safe horizontal bearing capacity of soil) x Safety factor

A = R x S.F. / Pbearing

A =Bearing area of thrust block (m2)

R = Total thrust force (kN)
Pbearing = Bearing Capacity of soil (kPa or kN/m2 )
S.F. = Safety Factor

3.3.4.1) Sizing of Concrete Block

A) Criteria

1) The Sizing procedure is for horizontal or downward thrust only

2) Height of the thrust block must be equal to or less then1/2 the depth from the ground surface to the block
3) The thrust block bearing face is approximately reactangular
….. From APWA Specifications
B) Calculation Equations for Sizing

a) Area of Concrete (A) = Bearing area Required to resist the thrust force
b) Maximum Height of thrust Block (h) = Depth of tranch (Ht) / 2
c) Width of concrete thrust block (b) = [(Width of thranch)-(outside Dia of pipe)] / 2
d) Maximum Length of thrust block = Area of Concrete (A) / Maximum Height (h)

3.4) EXAMPLE

PROBLEM
Calculate the size of concrete block for a 45° bend in an 8" cast iron water main, themaximum test
pressure in the pipe will be 300 PSI and the soil condition in the area indicates sand and gravel.The
flow through pipe is 226 m3/h
Given
Q = flow through pipe 4375 m3/h
V = flow velocity 38.70 m/s
ρ = fluid density 1010 kg/m3
ß = bend angle 90 °
d = internal dia of pipe 0.2 m
p = pressure in pipe 145.0378 PSI
1000000.4293 Pa

Resulting force due to Mass flow and Flow Velocity

The resulting force in x-direction due to mass flow and flow velocity can be expressed as:

  Rx  = ρ π (d / 2)2 v2 (1 - cosβ)         (1c)

1010 x 3.14 x ( 0.2/2)^2 x 38.71^2 x(1 - cos90 )
= 47505.38 N

The resulting force in y-direction due to mass flow and flow velocity can be expressed as:

  Ry  = ρ π (d / 2)2 v2 sinβ          (2c)   

1010 x 3.14 x ( 0.2/2)^2 x 38.71^2 xsin90
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Thrust Block Design

= 47505.38 N

The resulting force on the bend due to force in x- and y-direction can be expressed as:

RF = (Rx2 + Ry2)1/2         (3)

((47505.39)^2 +(47505.39)^2))^1/2
= 67182.76 N

Resulting force due to Static Pressure

The pressure and the end surfaces of the bend creates resulting forces in x- and y-directions.

The resulting force in x-direction can be expressed as

  Rpx  = p π (d / 2)2 (1- cos β)         (4b)

4375 x 3.14 x ( 0.2/2)^2 x (1 - cos90 )
= 31400.01 N

The resulting force in y-direction can be expressed as

Rpy = p π (d / 2)2 sinβ         (5)

4375 x 3.14 x ( 0.2/2)^2 x sin90 )
= 31400.01 N

The resulting force on the bend due to force in x- and y-direction can be expressed as:

Rp = (Rpx2 + Rpy2)1/2         (6)

((31400.02)^2 +(31400.02)^2))^1/2
= 44406.32 N

Resulting thrust force on the bend

R = ((RF)2 + (Rp)2)1/2 
((67182.76)^2 +(44406.33)^2))^1/2
= 80532.26 N
= 80.53 KN
 DESIGN DEPARTMENT

Thrust Block Design

Thrust Block Bearing Area

Bearing Area Required = (Thrust force/ Safe horizontal bearing capacity of soil) x Safety factor

A = R x S.F. / Pbearing
A =Bearing area of thrust block m2
R = Total thrust force 80.53 KN
Pbearing = Bearing Capacity of soil 200 KN/m2
S.F. = Safety Factor 1.5

A = R x S.F. / Pbearing
A = 0.6040 m2

Calculation Equations for sizing

Given
Depth of tranch Ht = 1 m
Width of tranch = 0.92 m
Out side Dia of pipe = 355.6
0.3556 m

a) Area of Concrete (A) = Bearing area Required to resist the thrust force
= 0.6040 m2

b) Maximum Height of thrust Block (h) = Depth of tranch (Ht) / 2

= 0.5 m

c) Width of concrete thrust block (b) = [(Width of thranch)-(outside Dia of pipe)] / 2

= [(0.92-0.3556)/2]
= 0.2822 m
d) Maximum Length of thrust block = Area of Concrete (A) / Maximum Height (h)

= 1.208 m
HENCE SIZE OF CONCRETE BLOCK IS = 1.3 x 0.3 x 0.5 m3

4) THRUST BLOCK FOR VERTICAL BEND (GRAVITY BLOCK)

Steps involved in Calculation Procedure
4.1) Select the axis
4.2) Determine the pressures, velocities and flow rates at the specific point
4.3) Determine the forces using the funamental equations of fluid dyanmics
4.4) Calculate thrust block dimensions

4.1) SELECTION OF THE AXIS

 DESIGN DEPARTMENT

Thrust Block Design

Y (Vertical axis)

X (Horizontal axis)
Z X (Horizontal axis)

4.2) DETERMINATION OF THE PRESSURE, VELOCITIES AND FLOW RATE AT THE SPECIFIC POINT

On the basis of given pipe size and flow through pipe we have to find out the velocity inside
the pipe at that point.

V= Q/A

Here Q = flow through pipe

A = cross sectional area of the pipe
V= velocity of fluid through pipe

If there is an juction and pipe dia is changing the new pressure, can find out by appling the
Bernoulli's Equation at that point. And if pipe diameter is not changing the same pressure
can be use to find out the pressure force at the bend or the specific point

4.3) DETERMINATION OF THE FORCES ON BEND

 DESIGN DEPARTMENT

Thrust Block Design

Here, the Horizontal Component of the thrust force i.e. Rx and Rpx is must be resisted by
the bearing of the right of the block against the soil. Analysis of this aspect will follow
like the above section on bearing blocks.

3.3.1) Resulting force due to Mass flow and Flow Velocity

The resulting force in y-direction due to mass flow and flow velocity can be expressed as:
Ry = m v sinβ         (2) ……. By applying the momentum equation
    = ρ A v sinβ         (2b)
2

   Ry = ρ π (d / 2)2 v2 sinβ          (2c)   

where
Ry = resulting force in y direction (N)
m = mass flow (kg/s)
v = flow velocity (m/s)
β = bend angle
ρ = fluid density (kg/m3)
d = internal pipe diameter (m)
π = 3.14...

3.3.2) Resulting force due to Static Pressure

The resulting force in y-direction can be expressed as

Rpy = p π (d / 2)2 sinβ         (5)
where
Rpy = resulting force due to pressure in y-direction (N)
p = gauge pressure inside pipe (Pa, N/m2)

3.3.3) Resulting thrust force on the Bend

R = ((Ry)2 + (Rpy)2)1/2 
where
Ry = resulting momentum force on the bend (N)
Rpy = resulting force on the bend due to static pressure (N)

3.3.4) Required Volume of Gravity Thrust Block

Volume of Gravity Block = Saftey factor x thrust force in y direction / density of block material

Vg = R x S.F. / Wm
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Thrust Block Design

Vg =Volume of Gravity block (m3)
R = Total thrust force in Y direction (kN)
Wm = Density of Block material (kg/m3
S.F. = Safety Factor
 FORCE ON PIPE

Input Data

Sl no. Parameter Legend Value Unit

1 Pipe ID D 800 mm => 0.8 m
2 Fluid Density r 1000 kg/m3 = 1000 kg/m3
3 Flow in pipe Q 4375 m3/hr ==> 1.215 m3/sec
4 Gravity Acceleration g 9.81 m/s2 = 9.81 m/s2
5 Pressure in pipe p 100 MWC ==> 100000.00 kg/m2
6 Angle between pipes - Bending angle Θ 90 Degree. = 90 Degree
7 Area of pipe A 0.503 m2 => 0.503 m2
8 Velocity in pipe v 2.418 m/s = 2.418 m/s
9 Resulting Force F acting on the pipe ( from bellow formula) F 71509.86 KG ==> 701.27221 kN

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