ATTACHMENT - X
Document No. XXXXX
Uncased Track Crossing Design Calculation
36-inch Pipeline, API 5L X65 SAW
1 As per API RP 1102
2 Input Data
3 Pipe Material = API 5L X65 SAW
4 Pipeline design factor, D.F. = 0.50
5 pipe size, Outside Diam., D = 36 in 914 mm
6 Pipe nominal thickness, t = 20.6 mm
7 SMYS of linepipe material = 65300 psi
8 Longitudinal joint factor, Ej = 1
9 Allow. design factor for Eff. Stress, Fa = 0.72
10 Corrosion allowance = 1 mm
11 Corroded wall thickness, tw = 19.6
2
12 Design pressure, P = 70 barg 10197.16213 713801.3 kg/m 14.504 1015.26 psig
13 Design temperature (U/G), T2 = 65 deg C
14 Installation (backfill) temp., T1 = 13 deg C
2
15 Youngs modulus of steel, E = 2.07E+05 Mpa 101971.6213 2.111E+10 kg/m
16 Poisson ratio, ٧ = 0.3
17 Thermal expansion coefficient, a = 1.17E-05 per deg C
18 Soil density, g = 1927 kg/m3 18.9 kN/m3 Soil Type = Loose Sand
19 Modulus of soil reaction, E' = 3.40E+06 N/m2 3.47E+05 kg/m2
20 Soil resilient modulus, Er = 6.90E+07 N/m2 7.04E+06 kg/m
2
21 Depth of cover, H = 2000 mm
22 Bored diameter, Bd = 914 mm Construction type: Trenched
Trenched
23 Tandem Axle Load, Pt = 112 kN 11428.57 kg
24 Single Axle Load, Ps = 112 kN 11428.57 kg
25 Wheel contact area, A = 144 Inch2 0.093 m
2
26
27 Check for Allowable stress
28 Hoop stress Sh [ D.F x Ej x SMYS
29 Shi(Barlow) = PD/2tw = 23672.23 psi 0.00689 = 163.21 MPa
30 D.F x Ej x SMYS = 32650.00 psi Hence OK
31
32 Circumferential stress due to earth load SHe
33 Ref. Fig 3 tw/D = 0.021 KHe = 2709
34 Ref. Fig 4 H/Bd = 2.2 Be = 0.7
35 Ref. Fig 5 Bd/D = 1.00 Ee = 1.00
36 Ref. Equation 1 SHe = KHe x Be x Ee x g x D SHe = 3340368 kg/m2 9.81E-06 32.76 MPa
37
38 Check critical axle configurations (figure A-1)
39 Pavement
Pavement type : No Pavement
40 Critical Axle : Tandem Axles R = 1.1 L = 1.00 (Refer table 2)
41
42 Impact factor and applied surface pressure w
43 Ref. Fig 7 H = 2.00 Fi = 1.45
44 Applied pressure (w) = Pt /A
2
45 for Tandem Axles w = 123016.1 kg/m 9.81E-06 1.21 MPa
46
47 Cyclic circumferential stress ΔSHh
48 Ref fig 14 tw/D = 0.021 KHh = 13.90
49 Ref fig 15 GHh = 0.71
50 Ref. Equation 5 ΔSHh = KHh x GHh x R x L x Fi x w ΔSHh = 18.99 MPa
51
52 Cyclic Longitudinal stress ΔSLh
53 Ref fig 16 tw/D = 0.021 KLH = 9.70
54 Ref fig 17 GLh = 0.73
55 Ref. Equation 6 ΔSLh = KLh x GLh x R x L x Fi x w ΔSLh = 13.63 MPa
56
57 Circumferential Stress due to Internal Load, SHi
58 Ref. Equation 7 SHi = P(D-tw)/2tw SHi = 23164.60 psi 159.71 MPa
59
60 Principal stresses S1, S2, & S3
61 Ref. Equation 9 S1(max circum stress) = SHe + ΔSHh + SHi S1 = 211.46 MPa
62
63 Ref. Equation 10, S2 = Maximum longitudinal stress
64 S2 = ΔSLh - Ea(T2-T1) + ٧(SHe + SHi) S2 = -54.57 MPa
65
66 Ref. Equation 11, Radial stress S3 = -P S3 = -7 MPa
67
68 Ref. Equation 12, Effective stress Seff = [0.5 {(S1-S2) + (S2-S3) + (S3-S1)2}] 0.5
2 2
69 Seff = 245.73 MPa
70 Allowable effective stress (SMYS x Fa) = 324.16 MPa
71
72 Ratio of Seff / Allowable = 0.758 Result Design OK
73
74 Check for Fatigue
75 Girth weld fatigue endurance limit (SFG) = 82.74 MPa (from table 3 of API 1102)
76 Allowable SFG = SFG x D.F = 41.37 MPa
77 Refer Equation 17 ΔSLh < SFG x D.F
78 Ratio of Actual (ΔSLh)/ Allowable = 0.329 Result Design OK
79
80 Longitudinal weld endurance limit (SFL) = 82.74 MPa (from table 3 of API 1102)
81 Allowable SFL = SFL x D.F. = 41.37 MPa
82 Refer Equation 18 ΔSHh < SFL x D.F.
83 Ratio of Actual (ΔSHh) / Allowable SFL = 0.459 Result Design OK
84
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