Pipe Installation Though Existing Tunnel Assessment
Project Overview
PDL was engaged by the client to assess the feasibility of installing a Flexsteel pipeline through an existing service tunnel as part of a major infrastructure project. The installation route involved a series of challenging tunnel geometries, including multiple bends, shafts and access points, creating uncertainty around the loads imposed on the pipe during installation. PDL used advanced global dynamic analysis techniques to verify the installation methodology and provide confidence that the pipe could be installed safely without exceeding manufacturer limits.
Our Solution
Our engineers deployed a comprehensive suite of simulation tools, including ANSYS Mechanical for structural analysis and ANSYS Fluent for thermal-fluid interaction. We developed a detailed 3D model of the component, applying realistic boundary conditions and material properties. Key aspects of our solution included:
Material Characterization : Incorporating advanced material models to accurately represent behavior under irradiation and high temperatures
Topology Optimization : Identifying optimal material distribution to reduce weight while maintaining structural integrity.
Thermal-Structural Coupling : Simulating the interaction between temperature fields and structural deformation.
Fatigue Life Prediction : Performing high-cycle and low-cycle fatigue analysis to predict component lifespan.
The analyses demonstrated that the proposed installation method could be completed without exceeding the manufacturer's allowable tension or bend radius limits. Across all assessed scenarios, the pipe maintained acceptable structural margins, with the most onerous tension load remaining below the allowable installation limit and the minimum bend radius remaining within acceptable limits. By completing the assessment during the planning phase, PDL provided the project team with confidence in the installation strategy and identified the key areas requiring attention during execution. The work reduced installation risk, supported informed project decision-making and provided an engineering basis for progressing the pipeline installation with confidence. Recommendations were also provided for additional verification activities and testing to further reduce project risk prior to execution.
Client: Undisclosed
Sector: Nuclear
Service Provided: Global Dynamic Analysis, OrcaFlex, Installation Engineering
Challenge: Verifying the safe installation of a flexible pipeline through a complex existing tunnel network
Outcome: Confirmed installation feasibility, demonstrated compliance with manufacturer limits, reduced installation risk prior to execution
