Engineering Calculation Pipeline

HABSHAN-MAQTA-TAWEELAH (HMT) GAS PIPELINES PROJECT

Project No. 5272 Agreement No. 13527201

EPC CONTRACTOR

Page 2 of 30

PIPELINE ENGINEERING CALCULATION REPORT

Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

REVISION RECORD:

Revision No.

Reason for revision Date

0 Issued for Construction 19.12.2012

C Re-Issued for Approval incorporating Client comments 09.12.2012

B Issued for Approval incorporating Client comments 06.11.2012

A Issued for Client Review 16.10.2012



EPC CONTRACTOR

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Date 19.12.2012

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TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................... 5 1.1. Background ......................................................................................... 5 1.2. Project Description ............................................................................... 5

2. DEFINITIONS ................................................................................................... 5

3. SCOPE ............................................................................................................. 6

4. REFERENCE CODES, STANDARDS AND SPECIFICATIONS ....................... 6 4.1. General ................................................................................................ 6 4.2. International Codes and Standards ...................................................... 6 4.3. Project Documents .............................................................................. 6

5. PIPELINE DESIGN DATA ................................................................................ 7

6. DESCRIPTION / METHODOLOGY - WALL THICKNESS CALCULATION...... 8 6.1. General ................................................................................................ 8 6.2. Pipe Thickness Check for Stress Value ............................................... 9 6.3. Minimum Elastic Bending Radius ......................................................... 11 6.4. Bend Thinning Requirements .............................................................. 11

7. DESCRIPTION / METHODOLOGY - UPHEAVAL BUCKLING CALCULATION 12 7.1. General ................................................................................................ 12 7.2. Methodology ........................................................................................ 12 7.3. Calculation for Axial Force (P) ............................................................. 12 7.4. Imperfection Length ............................................................................. 13

8. DESCRIPTION / METHODOLOGY – ROAD CROSSING CALCULATION ...... 14 8.1. General ................................................................................................ 14 8.2. Methodology ........................................................................................ 14

9. CALCULATION RESULT / SUMMARY ............................................................ 17 9.1. Result for Wall Thickness Calculation .................................................. 17 9.2. Result for Upheaval Buckling Calculation ............................................ 21 9.3. Result for Crossing Calculation ............................................................ 22 9.4. Result for Anchor Load, Active length, free end expansion and Buoyancy 23 Corroded Condition......................................................................................... 24

ATTACHMENT-1A & 1B: WALL THICKNESS CALCULATIONS (CORRODED & NEW CONDITION) .......................................................................................................................... 26

ATTACHMENT-2: UPHEAVAL BUCKLING CALCULATION ........................................ 27

ATTACHMENT-3: CROSSING CALCULATIONS .......................................................... 28



EPC CONTRACTOR

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ATTACHMENT-4: PIPELINE BUOYANCY CALCULATION .......................................... 29

ATTACHMENT-5: ANCHOR LOAD, ACTIVE LENGTH & FREE EXPANSION CALCULATION 30



EPC CONTRACTOR

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Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

1. INTRODUCTION

1.1. Background

Abu Dhabi Gas Industries Limited (GASCO) intends to supply sales gas to Emirates Aluminium (EMAL) for their second expansion requirements, to MASDAR for their new Carbon Capture & Storage Project Requirements and other new consumers identified by ADNOC as part of their next five year gas supply plan in Taweelah Area. DODSAL ENGINEERING & CONSTRUCTION PTE LIMITED is EPC Contractor for the project of Habshan – Maqta -Taweelah Gas Pipelines Project abbreviated to HMT Gas Pipelines Project. The Owner Company for this project is Abu Dhabi Gas Industries Ltd. (GASCO).

1.2. Project Description

Two (2) Nos. new 52” pipelines from Habshan to Maqta premises (approx. 125 km.each) with Scraper Launcher, Scraper Receiver and intermediate Block Valve Stations.

One (1) No. new 52” pipeline from Maqta to Taweelah KM42 point (approx. 42 km.) with Scraper Launcher, Scraper Receiver and intermediate Block Valve Stations.

One (1) No. new 42” pipeline from Taweelah KM42 point to ADWEC CRS (approx. 11 km.) with Scraper Launcher and Receiver Stations. Scraper receiver station at ADWEC CRS shall include ROV, FCV, Filters, Metering skid and PRS for custody transfer to Khalifa Port (KIZAD). Scraper Receiver station shall also include plot area provision for future filters, Custody Transfer/Metering and PRS for ADWEC (Taweelah) and MASDAR (with ADWEC).

Supervisory and Monitoring Systems for the new pipelines and upgrading of the existing SMC system to include new facilities.

Associated Civil, Electrical, Instrumentation, Telecom and Cathodic Protection works

Demolition of existing 30” pipeline from Bab to Maqta manifold.

Demolition of existing 24” pipeline from Maqta to Taweelah Consumer Receipt Station.

2. DEFINITIONS

In this document following words and expressions shall have the meanings hereby assigned to them except where the content otherwise requires:

COMPANY : Abu Dhabi Gas Industries Ltd. (GASCO) CONTRACTOR : Dodsal Engineering & Construction Pte. Ltd. PMC : Engineers India Limited.



EPC CONTRACTOR

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Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

3. SCOPE

This document covers the Calculations for Pipeline Wall Thickness, Upheaval buckling,

Buoyancy, Crossing, Anchor load, Active length and Free expansion for “Habshan-Maqta-

Taweelah (HMT) Gas Pipelines Project”. The thickness will be verified as per ASME B31.8 for gas

pipelines.

4. REFERENCE CODES, STANDARDS AND SPECIFICATIONS

4.1. General

These pipeline calculations were performed in conformance with the current issue, amendments and Project Addendum of the following codes, standards and specifications prevailing on the effective date of the contract.

4.2. International Codes and Standards

The following codes and standards form the basis for the pipelines calculations.

ASME B 31.8 Ed 2010 Gas Transmissions and Distribution Piping Systems

PD 8010-1:2004 Code of Practice for Pipelines Part 1 - Steel Pipelines on Land

API 5L 44th Edition Specification for Line Pipe

API RP 1102 7th Edition Steel Pipeline Crossing Rail, Roads and Highways

4.3. Project Documents

5272-PP-GEN-00-001 Process Design Basis.

5272-RT-GEN-95-001 Pipeline Design Basis

5272-ADD-9550-004 Addendum to DGS Flexibility analysis (Pipeline)

5272-ADD-9550-003 Addendum to DGS for Pipeline Hydrostatic Testing

5272-ADD-9550-002 Addendum to DGS Pipeline Construction

5272-RT-GEN-17-004 Geotechnical survey report



EPC CONTRACTOR

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5. PIPELINE DESIGN DATA

Parameters Thammama C - Maqta Maqta – KM 42 KM 42 –

Taweelah

SV2 to Yas

island tie-in

Pipeline diameter. NB 52 52 42 16

Outside Diameter mm 1320.8 1320.8 1066.8 406.4

Design Code, ASME B31.8 B31.8 B31.8 B31.8

Design Pressure, bar (g)

63.5 63.5 63.5 63.5

Corrosion Allowance, mm

1.5 1.5 1.5 1.5

Maximum Design Temp. Above Ground (ºC)

100 100 100 100

Maximum Design Temp. Below Ground (ºC)

65 65 65 65

Warmest or Coldest Operating Temp. (ºC)

65 65 65 65

Minimum Design Temp. of pipeline system (ºC)

0 (Note 1) 0 (Note 1) 0 (Note 1) 0 (Note1)

Max. Temp. at 1m depth of soil (ºC)

38 38 38 38

Minimum Tie-in Temp., underground section (ºC)

13 13 13 13

Minimum Tie-in Temp., aboveground section (ºC)

5 5 5 5

Flange Rating, ASME Class

600 600 600 600

Min burial depth to top of pipe (normal terrain), m

1 1 1 1

Material Grade, API 5L X 65MS, PSL 2 X 65MS, PSL 2 X 65MS, PSL 2

X 65MS, PSL 2

Material SMYS, MPa 450 450 450 450

Design Factor, F CLASS 1 CLASS

3 CLASS

4 CLASS 3 CLASS 4 CLASS 3 CLASS 3



EPC CONTRACTOR

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Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

Parameters Thammama C - Maqta Maqta – KM 42 KM 42 –

Taweelah

SV2 to Yas

island tie-in

Mainline 0.72 0.5 0.4 0.5 0.4 0.5 0.5

Track/Asphalt Road/Rig Crossings

0.5 0.5 0.4 0.5 0.4 0.5

0.5

Stations (SVs & Launcher/receivers)

0.5 0.5 0.4 0.5 0.4 0.5 0.5

Co-efficient of Thermal Expansion, mm/deg C

11.7 x 10-6 11.7 x 10-6 11.7 x 10-6 11.7 x 10-6

Elastic Modulus E, Mpa 207.0 x 10³ 207.0 x 10³ 207.0 x

10³ 207.0 x

10³

Internal coating thickness

60 – 100 microns 60 – 100 microns 60 – 100 microns

Not applicable

External Coating 3 Layer Polyethylene 3 Layer Polyethylene 3 Layer

Polyethylene

3 Layer Polyethylen

e

Minimum External Coating Thickness, mm (FBE+Adhesive+PE)

3.55 3.55 3.55 3.05

Note 1: Min. Design temperature is confirmed as per depressurization study.

6. DESCRIPTION / METHODOLOGY - WALL THICKNESS CALCULATION

6.1. General

Pipelines wall thickness is calculated based on the internal design pressure and in accordance

with the Design codes for gas pipelines as described below. Calculations are done for location

class 1, 3 and 4 of gas pipeline with design factors of 0.72, 0.5 and 0.4 respectively.

The wall thickness for the CS pipe shall be initially calculated by following expression.

As per ASME B31.8 clause 841.1.1, the formula for the wall thickness calculation of gas pipeline

is:

tmin = [PD D / (2FSET)] + A

where,

PD = Design pressure for the pipeline



EPC CONTRACTOR

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5272-NC-GEN-95-001 Rev 0

S = Specified Minimum Yield Strength (SMYS)

tmin = Calculated Minimum Wall thickness

D = Outside diameter of pipe

F = Design factor (Ref Table 841.1.6-1 of ASME B31.8)

E = Longitudinal joint factor (Ref Table 841.1.7-1 of ASME B31.8)

T = Temperature derating factor (Ref Table 841.1.8-1 of ASME B31.8)

A = Corrosion Allowance

The Thickness calculated from above is then checked for acceptability of the ratio of diameter to thickness for final thickness selection and it should not exceed 96.

6.2. Pipe Thickness Check for Stress Value

The stresses are calculated for the pipe wall thickness as per equations given below:

a) Hoop Stress

Hoop stress, SH = PDD / 2t (Clause 805.2.3 of ASME B31.8)

b) Longitudinal Stress

Longitudinal stress due to pressure:

For restrained pipe: SP = 0.3 SH (Clause 833.2 (a) of ASME B31.8)

For unrestrained pipe: SP = 0.5 SH (Clause 833.2 (b) of ASME B31.8)

Longitudinal stress due to thermal expansion in restrained pipe (thermal stress):

ST = E (T1 – T2) (Clause 833.2 (c) of ASME B31.8)

Longitudinal stress due to bending:

SB = M / Z (Clause 833.2 (d) of ASME B31.8)

Longitudinal stress due to axial loading other than thermal expansion and pressure:

SX = R / A (Clause 833.2 (f) of ASME B31.8)

The net longitudinal stress:



EPC CONTRACTOR

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For restrained pipe: SL = SP + ST + SB + SX (Clause 833.3 (a) of ASME B31.8)

For unrestrained pipe: SL = SP + SB + SX (Clause 833.6 (a) of ASME B31.8)

Where:

E = Modulus of elasticity at ambient temperature

= Thermal expansion coefficient

T1 = pipe temperature at the time of installation, tie-in or burial

T2 = Warmest operating temperature

M = Bending moment across the pipe cross-section

Z = Pipe section modulus

R = External force axial component

A = Pipe metal cross-sectional area

c) Combined / Equivalent Stress

The combined/equivalent stress of the restrained pipe is evaluated using the calculation in

either (1) or (2) below (Ref clause 833.4(a) of ASME B31.8):

(1) SE1 = SH – SL

(2) SE2 = [SH2 + SL

2 - SH SL] ½

d) Criteria

The calculated stress needs to fulfill the criteria given below:

The net longitudinal stress, SL:

For restrained pipe (Ref clause 833.3(b) of ASME B31.8): SL ≤ 0.9 SMYS x T

For unrestrained pipe (Ref clause 833.6(b) of ASME B31.8): SL ≤ 0.75 SMYS x T

The combined / equivalent stress for restrained pipe (Ref clause 833.4 of ASME B31.8),

SE1 and SE2 ≤ k x SMYS x T, where k ≤ 0.9 for load of long durations



EPC CONTRACTOR

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5272-NC-GEN-95-001 Rev 0

6.3. Minimum Elastic Bending Radius

The route and profile of any fully restrained section of pipelines should be controlled to ensure

that the elastic bend limit or minimum allowable elastic bending radius is not exceeded.

The minimum elastic bending radius is determined as explained below.

1. The net longitudinal stress SL in section 6.2(b) shall be calculated in terms of SB

2. By substituting the calculated SL in terms of SB into combined / equivalent stress equation

6.2 (c), SE is derived in terms of SB.

3. Based on criteria mentioned in section 6.2 (d), combined / equivalent stress shall be less

than 90% of SMYS for k = 0.9 and T = 1. Hence, maximum allowable margin for bending

stress can be derived by substituting the values of combined / equivalent stress SE in terms

of SB into the criteria.

By adjusting the Minimum Elastic Bending Radius (R) in below equation, we can ensure that

Bending Stress is within the allowable margin to meet the above criteria.

R = ED / 2SB

For pipelines assuming a natural curvature that incurs a permanent elastic bending stress, the

minimum bending radius as per the calculation specified in Attachment-1 for respective wall

thickness shall be followed.

6.4. Bend Thinning Requirements

Wall thickness check, also takes into account the bend thinning requirements in accordance

with Clause 6.2.2.3 of PD 8010-1:2004. This is in the case of subjecting the pipe to field

bending or cold bending having a minimum bend radius of 40D and Factory hot bends with a

bend radius of 5D.

The wall thinning as a percentage is given by following empirical formula.

Wall thinning % = 50 / (n +1)

Where n = inner bend radius divided by pipe diameter.

By equating the calculated pipe thickness and bend thickness after bending, the calculated

thickness for design pressure = (1- thinning %) x pipe thickness before bend.

Pipe thickness before bending = (Calculated thickness for design pressure) / (1 – Thinning %)

The bend wall thinning allowance considered for the project shall be verified / confirmed by Hot

Bends Supplier.



EPC CONTRACTOR

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7. DESCRIPTION / METHODOLOGY - UPHEAVAL BUCKLING CALCULATION

7.1. General

The simplified method presented in OTC Paper 6335 by A.C. Palmer, C. P. Ellinas, D.M.

Richards and J. Guijt (presented at 22nd Annual OTC in Houston, Texas, May 7-10, 1990) is

used to check that the selected depth of cover for pipeline is adequate to prevent upheaval

buckling.

The calculation is done for both new and corroded condition of pipes.

7.2. Methodology

The required downward force to prevent upheaval buckling of pipe is a function of pipe flexural

rigidity (EI) and the axial compressive force due to pressure and temperature load. The equation

12 of OTC paper 6335 gives the required download for stability in the operating condition:

W = [1.16 – 4.76 (EI Wo / δ) 0.5 / P P (δWo / EI) 0.5 …………. (1)

Where, W = Required download force to prevent upheaval buckling

E = Young’s modulus of steel

I = Section modulus for pipe

δ = Allowable Imperfection height

P = Effective axial force in operation

Wo = Weight of pipe + Weight of content + Weight of corrosion coating

per unit length

The vertical download force that resists uplift of pipeline is related to the profile imperfection and

therefore a term imperfection height is appearing in the above formula. The soil resistance also

changes with increase in imperfection height. Upheaval buckling check has been carried out for

various imperfection heights from 0.1 to 0.5m.

7.3. Calculation for Axial Force (P)

The axial force on buried pipeline section will include following forces:

a) Axial tensile stress due to hoop stress = ٧Sh

Where, ٧ = Poissons ratio i.e. 0.3 for steel pipe

Sh = Hoop stress (PD x D)/2t



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b) Axial Compressive stress due to internal pressure = 0.3 x Sh

c) Axial Compressive force due to temperature change = Eα(T2-T1)

Where, E = Modulus of elasticity

α = Thermal expansion coefficient

T2 = Design temperature for underground section

T1 = Installation temperature

The Axial Force,

P = PD*Ai + A*{E α (T2-T1) - ٧Sh } …………. (2)

Where, Ai = Area corresponding to internal cross-section of Pipe

A = Cross-Section area of Pipe

PD = Design pressure

Axial force calculated above is considering fully restrained condition of pipeline (more

conservative scenario)

The soil above the buried pipeline will provide an uplift resistance, (as per OTC paper Eq 13),

Q = H*D* Ƴ*[1+f *H / D] …………. (3)

Where, Q = Uplift Soil resistance per unit length

H = pipe cover

D = Pipe outside diameter

Ƴ = Soil density

f = Uplift coefficient (0.1 for loose material &

0.5 for dense material)

To prevent the upheaval buckling of pipeline, |W| < |Wo + Q|

7.4. Imperfection Length

Maximum downward force per unit length required to stabilize the pipeline at the crest of the

profile imperfection (as per OTC paper Eq 4 )

W = 2*δ* P*(π/Limp)2 – 8*δ*E*I*((π/Limp)

4 …………. (4)



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where, Limp = Imperfection Length

Limp shall be calculated by solving the quadratic equation as follows

(π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0

8. DESCRIPTION / METHODOLOGY – ROAD CROSSING CALCULATION

8.1. General

The purpose of this calculation is to ensure satisfactory and optimal design in compliance with

criteria (circumference stress due to internal pressure as per Barlow formula, effective stress

and fatigue) defined in API RP 1102, and to determine whether wall thicknesses heavier than

the selected wall thickness would be required at road crossing.

The following wheel loadings were taken into account in determining the stresses imposed on

pipeline.

Asphalt Road/ Highway /Track crossings: 112kN per wheel at 900mm centers with

maximum of four (4) wheels per axle. Contact area per API RP 1102 is 0.093 square

meters, giving surface pressure = 1204 kN/m2.

Rig crossings: 2200 kN on a single axle (2 wheel set) and the maximum single axle wheel

load is 1100kN. The contact area, over which the wheel load is applied, shall be taken as

0.403 square meters.

8.2. Methodology

The methodology for track/asphalt road/rig crossing calculations (as mentioned in API 1102) is

described briefly in the following steps:

a. Begin with the wall thickness (calculated with design factor 0.5 for Class 1 and 3 and design

factor 0.4 for Class 4) for pipeline of given diameter approaching the crossing. Determine

the pipe, soil, construction, and operational characteristics.

b. Use the Barlow formula to calculate the circumferential stress due to internal pressure, Shi

(Barlow). Check Shi against the maximum allowable value.

c. Calculate the circumferential stress due to earth load, SHe.

d. Check the critical axle configuration as per figure A-1 Annex. A of API 1102.

e. Calculate the external live load, w, and determine the appropriate impact factor, Fi.



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f. Calculate the cyclic circumferential stress, ΔSH, and the cyclic longitudinal stress, ΔSL, due

to live load.

g. Calculate the circumferential stress due to internal pressure, SHi

h. Check effective stress, Seff, as follows:

1. Calculate the principal stresses, S1 in the circumferential direction, S2 in longitudinal

direction, and S3 in the radial direction.

2. Calculate the effective stress, Seff.

3. Check by comparing Seff against the allowable stress, SMYS x F.

i. Check weld for fatigue as follows:

1. Check with weld fatigue by comparing ΔSL against the girth weld fatigue limit, SFG x F.

2. Check longitudinal weld fatigue by comparing, ΔSH against the longitudinal weld fatigue

limit, SFL x F.

where,

Circumferential stress due to internal pressure,

Shi (Barlow) = PDD ⁄ 2tw (refer section 4.8.1.1 of API 1102)

Circumferential stress due to earth load,

SHe = KHe Be Ee γ D (refer section 4.7.2.1 of API 1102)

KHe is the stiffness factor for circumferential stress from earth load. Be is the burial factor for earth load. Ee is the excavation factor for earth load. γ is the soil unit weight.

Surface pressure due to Live load,

w = P ⁄ AP (refer section 4.7.2.2 of API 1102)

P may be Design single wheel load PS or Design tandem wheel load PT

AP is the contact area over which the wheel load is applied

Cyclic circumferential stress due to highway vehicular load,



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ΔSHh = KHhGHhRLFiw (refer section 4.7.2.2.4.1 of API 1102)

KHh is the highway stiffness factor for cyclic circumferential stress. GHh is the highway geometry factor for cyclic circumferential stress. R is the highway Pavement type factor. L is the highway axle configuration factor. Fi is the impact factor. w is the applied design surface pressure.

Cyclic longitudinal stress due to highway vehicular load,

ΔSLh = KLhGLhRLFiw (refer section 4.7.2.2.4.2 of API 1102)

KLh is the highway stiffness factor for cyclic longitudinal stress. GLh is the highway geometry factor for cyclic longitudinal stress. R is the highway pavement type factor. L is the highway axle configuration factor. Fi is the impact factor. w is the applied design surface pressure.

Circumferential stress due to internal pressure,

SHi = PD (D– tw) ⁄ 2tw (refer section 4.7.3 of API 1102)

Maximum circumferential stress,

S1 = SHe + ΔSH + SHi (refer section 4.8.1.2 of API 1102)

Maximum longitudinal stress,

S2 = ΔSL – EsαT(T2 – T1) + νs(SHe + SHi) (refer section 4.8.1.2 of API 1102)

Maximum radial stress,

S3 = –p = –PD (Design Pressure) (refer section 4.8.1.2 of API 1102)

Total effective stress,

Seff = [0.5 (S1 – S2)2 + (S2 – S3)

2 + (S3 – S1)2]0.5 (refer section 4.8.1.3 of API 1102)



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9. CALCULATION RESULT / SUMMARY

For calculation details, refer to Attachments - 1, 2, 3, 4 and 5.

Based on the calculation results, the selected wall thicknesses for pipelines as listed below are

found adequate for the anticipated design pressures and temperatures, combined / equivalent

stresses, upheaval buckling and withstand the expected traffic / wheel loadings at Track,

Asphalt Road/ Highway and Rig crossing at the specified depth.

9.1. Result for Wall Thickness Calculation

Wall thickness of Pipeline

52” Sales Gas

Pipeline, API 5L X65

42” Sales Gas


16” Sales Gas


Location

Class

Calculated

WT (mm)

Selected

WT (mm)

Calculated

WT (mm)

Selected

WT (mm)

Calculated

WT (mm)

Selected

WT (mm)

4 24.8 25.2 NA NA NA NA

3 20.1 20.5 16.5 16.9 7.2 14.7

1 14.4 14.7 NA NA NA NA

Wall thickness check for 40D field/cold bends

52” Sales Gas


42” Sales Gas


16” Sales Gas


Location

Class

Calculated

WT (mm)

Selected

WT (mm)

Calculated

WT (mm)

Selected

WT (mm)

Calculated

WT (mm)

Selected

WT (mm)

4 25.1 25.2 NA NA NA NA

3 20.4 20.5 16.8 16.9 7.3 14.7

1 14.6 14.7 NA NA NA NA



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Wall thickness of Mother pipes for 5D Factory Hot bends

52” Sales Gas


42” Sales Gas


16” Sales Gas


Location

Class

Calculated

WT (mm)

Selected

WT (mm)

Calculated

WT (mm)

Selected

WT (mm)

Calculated

WT (mm)

Selected

WT (mm)

4 27.3 28.0 NA NA NA NA

3 22.1 25.2 18.2 18.8 8.0 14.7

1 15.9 20.5 NA NA NA NA

Check for D/t ratio

Description Class - 4 Class -3 Class -1 Class-3 Class-3

Pipeline Diameter , inch 52 52 52 42 16

Pipeline Outer Diameter D, mm 1320.8 1320.8 1320.8 1066.8 406.4

Selected Wall Thickness t, mm 25.2 20.5 14.7 16.9 14.7

D/t Ratio 52 64 90 63 28

D/t < 96 OK OK OK OK OK



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Result for Stresses and minimum elastic bending radius (Non-Corroded condition)

52” (Location

Class 4)

52”

(Location

Class 3)

52”

(Location

Class 1)

42”

(Location

Class 3)

16”

(Location

Class 3)

Selected Wall

Thickness (mm) 25.2 20.5 14.7 16.9 14.7

Combined /

Equivalent

Stress of

unrestrained

section in MPa

(% of SMYS)

144.1(32.02%) 177.2

(39.37%)

247.1

(54.91%)

173.6

(38.57%)

76

(16.89%)

Combined /

Equivalent

Stress of

Restrained

section in MPa

(% of SMYS)

238.6

(53.02%)

265.3

(58.95%)

321.8

(71.51%)

262.4

(58.31%)

183.6

(40.8%)

Margin for

Bending Stress

in MPa (% of

SMYS)

166.6

(37.02%)

139.9

(31.08%)

83.4

(18.53)

142.8

(31.73)

221.6

(49.24)

Min. Elastic Bend

Radius (m) 796 948 1589 750 184



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Result for Stresses and Minimum Elastic Bend Radius (Corroded Condition)

52” (Location

Class 4)

52”

(Location

Class 3)

52”

(Location

Class 1)

42”

(Location

Class 3)

16”

(Location

Class 3)

Selected Wall

Thickness (mm) 25.2 20.5 14.7 16.9 14.7

Corroded wall

thickness (mm) 23.7 19.0 13.2 15.4 13.2

Combined /

Equivalent

Stress of

unrestrained

section in MPa

(% of SMYS)

153.2

(34.04%)

191.1

(42.46%)

275.1

(61.13%)

190.5

(42.33%)

84.7

(18.82%)

Combined /

Equivalent

Stress of

Restrained

section in MPa

(% of SMYS)

246 (54.66%) 276.6

(61.46%)

344.5

(76.55%)

276.1

(61.35%)

190.5

(42.33%)

Margin for

Bending Stress

in MPa (% of

SMYS)

159.2(35.37%) 128.6

(28.57%)

60.7

(13.48%)

129.1

(28.68%)

214.7

(47.71%)

Min. Elastic Bend

Radius (m) 832 1031 2184 829 190

Minimum elastic bending radius to be considered for Construction shall be as per the value calculated in corroded condition.



EPC CONTRACTOR

Page 21 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

9.2. Result for Upheaval Buckling Calculation

Calculation for Non-Corroded & Corroded Conditions Result

Size Location

Class

Wall Thickness

(mm)

Depth of Cover

(m)

52” SALES GAS

PIPELINE, API 5L X65

4 25.2 1.5 OK

3 20.5 1.0 OK

1 14.7 1.0 OK

42” SALES GAS

PIPELINE, API 5L X65 3 16.9 1.0 OK

16” SALES GAS

PIPELINE, API 5L X65 3 14.7 1.0 OK



EPC CONTRACTOR

Page 22 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

9.3. Result for Crossing Calculation

Crossing

52” SALES GAS

PIPELINE, API 5L

X65

42” SALES GAS

PIPELINE, API 5L

X65

16” SALES GAS

PIPELINE, API 5L X65

Wall Thick.

(mm)

Burial

Depth

(m)

Wall

Thick.

(mm)

Burial

Depth

(m)

Wall

Thick.

(mm)

Burial

Depth (m)

Location Class = 4

Track Crossing 25.2 2 NA NA NA NA

Asphalt Road

Crossing/

Highway

Crossing

25.2

(Note-1) 2 NA NA NA NA

Rig Crossing 25.2 2 NA NA NA NA

Location Class = 3

Track Crossing 20.5 1.5 16.9 1.5 14.7 1.5

Asphalt Road

Crossing/

Highway

Crossing

20.5 (Note-

1) 2

16.9

(Note-1) 2 NA NA

Rig Crossing 20.5 2 16.9 2 NA NA

Location Class = 1

Track Crossing 20.5 1.5 N/A N/A NA NA

Asphalt Road

Crossing/

Highway

Crossing

20.5 (Note-

1) 2 N/A N/A NA NA

Rig Crossing 20.5 2 N/A N/A NA NA

Result OK OK OK

Note 1: The value of Wall thickness for NDRC will be re-validated by NDRC Contractor.



EPC CONTRACTOR

Page 23 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

9.4. Result for Anchor Load, Active length, free end expansion and Buoyancy

Non Corroded Condition

52”

(Location

Class 4)

52”

(Location

Class 3)

52”

(Location

Class 1)

42”

(Location

Class 3)

16”

(Location

Class 3)

Selected Wall

Thickness (mm) 25.2 20.5 14.7 16.9 14.7

Free End

Expansion (Non-

compacted) (mm)

495

(Note-1)

440

(Note-1) N/A

366

(Note-1)

259

(Note-1)

Free End

Expansion

(Compacted) (mm)

445

(Note-1)

395

(Note-1) N/A

328

(Note-1)

232

(Note-1)

Anchor Load in

Tonne

1616

(Note 3)

1384

(Note 3) N/A

916

(Note 3)

256

(Note 3)

Active Length

(Non-compacted)

(m)

753.86 659.5 N/A 549.8 407.78

Active Length

(Compacted) (m) 678.59 592.41 N/A 493 365.23

Factor of Safety

against floatation

0.573

(Note-2)

0.468

(Note-2)

0.337

(Note-2)

0.477

(Note-2)

1.068

(Note-2)



EPC CONTRACTOR

Page 24 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

Corroded Condition

52”

(Location

Class 4)

52”

(Location

Class 3)

52”

(Location

Class 1)

42”

(Location

Class 3)

16”

(Location

Class 3)

Selected Wall

Thickness (mm) 25.2 20.5 14.7 16.9 14.7

Corroded wall

thickness (mm) 23.7 19 13.2 15.4 13.2

Free End

Expansion

(Compacted)

(mm)

429

(Note-1)

379

(Note-1) N/A

311

(Note-1)

214

(Note-1)

Anchor Load

(tonne)

1542

(Note 3)

1310

(Note 3) N/A

857

(Note 3)

234

(Note 3)

Active Length

(Compacted)

(m)

651.51 564 N/A 463.65 336

Factor of Safety

against

floatation

0.540

(Note-2)

0.434

(Note-2)

0.303

(Note-2)

0.436

(Note-2)

0.963

(Note-2)

Anchor load shall be considered based on non corroded condition. However, the value obtained

from approved stress analysis shall be used for design of anchor block.

Notes:

1) Values less than 25mm at A/G U/G transition point can be accepted and these can be

accommodated in A/G portion of the pipeline with sliding supports in the pig trap. Values

greater than 25mm are not acceptable and should be reduced by anchoring in the U/G

section of the pipeline as per the stress analysis report.

2) It is not anticipated that construction will be carried out in ground water because where

ground water is encountered; the pipeline will be installed on filled ground above the water

table in accordance with the typical drawings for Sabkha Construction. However, Anti-

buoyancy calculation is carried out to check pipeline stability in case pipeline installation

inside the water table is approved by COMPANY in unavoidable circumstances. The



EPC CONTRACTOR

Page 25 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

calculation result FOS value less than 1.0 indicates that the pipeline is buoyant. A FOS

value greater than 1.1 is recommended to prevent pipe floatation against negative buoyancy

in case pipeline is laid inside water table.

3) Anchor load will be confirmed after Pipeline Stress Analysis.



EPC CONTRACTOR

Page 26 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

ATTACHMENT-1A & 1B: WALL THICKNESS CALCULATIONS (CORRODED & NEW CONDITION)

(No. of Sheets – 10+5)



EPC CONTRACTOR

Page 27 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

ATTACHMENT-2: UPHEAVAL BUCKLING CALCULATION

(No. of Sheets – 10)



EPC CONTRACTOR

Page 28 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

ATTACHMENT-3: CROSSING CALCULATIONS




EPC CONTRACTOR

Page 29 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

ATTACHMENT-4: PIPELINE BUOYANCY CALCULATION




EPC CONTRACTOR

Page 30 of 30


Date 19.12.2012

5272-NC-GEN-95-001 Rev 0

ATTACHMENT-5: ANCHOR LOAD, ACTIVE LENGTH & FREE EXPANSION CALCULATION


1

2 DESIGN INPUT

3 Design Codes and standards ASME B31.8, API 5L

4 Pipeline Size / Nominal O.D D 52 in 1320.8 mm

5 Corrosion Allowance A 1.5 mm

6 Location Class 4

7 Design Factor F 0.4

8 Steel Coefficient of Expansion α 0.0000117 per deg C 6.50E-06 in/in/ oC

9 Modulus of Elasticity E 2.01E+05 MPa 2.91E+07 Psi

10 Pressure and Temperature Data

11 Design Pressure P 63.5 bar g 921.0 psi g

12 Installation Temp. T1 13oC 55.4

oF

13 Aboveground Design Temp. T2 100oC 212.0

oF

14 Underground Design Temp. T3 65oC 149.0

oF

15 Weld joint factor E 1

16 Temperature Derating Factor T 1

17 Max. factor for load of long durations k 0.9

18

19 A. WALL THICKNESS

20 Grade X65

21 SMYS of Line Pipe S 65300 psi 450 MPa

22 Wall Thickness Calculated tmin 24.8 mm 0.976 inch

23 tmin = PD / (2SFET) + A

24 Selected wall thickness t 25.2 mm 0.992 inch

25 D/t Check ( Should be < 96) 52

26

27 B. COMBINED / EQUIVALENT STRESS CHECK FOR NEW PIPE CONDITION

28 Wall thickness (t) 25.2 mm 0.992 inch

29 Hoop Stress = SH = PD/2t 166.4 MPa 24136 psi

30

31 B.1 Restrained Pipe (Underground)

32 Thermal Stress = ST = α (T1 - T3) E -122.1 MPa -17711 psi

33 Longitudinal Stress due to pressure = SP = 0.3 SH 49.9 MPa 7241 psi

34

35 Longitudinal Stress, SL

36 SL = SP + ST + SB + SX ≤ 0.9 x SMYS x T = 406 MPa 58770 psi

37

38 Without considering SB (Bending stress) and SX (Axial stress due to external loading):

39 SL = SP + ST -72.2 MPa -10471 psi

40 Longitudinal Stress check : SL ≤ 0.9 x SMYSxT hence OK

41

42 Combined Stress, SE

43 SE1 = | SH - SL | SE1 238.6 MPa 34606 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 211.9 MPa 30739 psi

45 SE = Max (SE1, SE2) ≤ k x SMYS xT = 406 MPa SE 238.6 MPa 34606 psi

46 Combined/Equivalent Stress check : SE ≤ 0.9 x SMYSxT hence OK

47

48 B.2 Unrestrained Pipe (Aboveground)


50


52 SL = SP +SB + SX ≤ 0.75 x SMYS x T = 338 MPa 48975 psi


54 SL = SP 83.2 MPa 12068 psi


56


58 SE1 = | SH - SL | SE1 83.2 MPa 12068 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 144.1 MPa 20902 psi



62

63 C. MINIMUM BENDING RADIUS

64 Minimum bending radius for underground section is calculated from margin for elastic bending,

65 = (0.9 x SMYS x T) - SE 166.6 MPa 24163 psi

66 R (Minimum Bend Radius) = E D / (2 |Sb|) 796 m

67

68

69

70

71

72

73

74

75

ATTACHMENT - 1A - Non Corroded condition

Document No. 5272-NC-GEN-95-001 Rev. 0

Wall thickness calculation and minimum elastic bend radius for 52" Pipelines at Location Class 4

Page 1 of 10

1

2 DESIGN DATA

3 Design Codes and standards ASME B31.8, PD 8010-1, API 5L

4 Pipe outside diameter D 1321 mm

5 Grade X65

6 SMYS of Line Pipe S 65300 psi

7 Design pressure P 921.0 psi(g)

8 Design factor F 0.4


10 Temp. derating factor T 1


12

13 A. CHECK ON THINNING FOR FACTORY HOT BENDS: BEND RADIUS = 5 D

14 Calculated required thk, t 24.8 mm

15 t = P x D / (2x Sx Fx E x T) + A

16 Selected Mainline Wall Thickness 25.2 mm

17 n, Inner Bend radius divided by diameter 4.5

18 9.1 %

19 Pipe Thk. Before bending (cal thk)/(1-thinning %) 27.3 mm

20 Selected thickness for bend making 28.0 mm

21 Adequacy Check (Pipe thk before bending < Available thk) OK

22

23

24 B. CHECK ON THINNING FOR FIELD OR COLD BENDS: BEND RADIUS = 40 D

25 Inner bend radius divided by diameter, (n) 39.5

26 1.23 %

27 Pipe thk. before bending = cal thk/(1-thinning %) 25.1 mm

28 Available thickness for bending (= Selected thk) 25.2 mm


30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

As per Cl 6.2.2.3 of PD 8010-1:2004,% of wall thinning

(50)/(n+1)



Bend thinning calculation for 52" Pipelines at Location Class 4


(50)/(n+1)

Page 2 of 10

1

2 DESIGN INPUT




6 Location Class 3







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -60.7 MPa -8811 psi


41


43 SE1 = | SH - SL | SE1 265.3 MPa 38480 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 240.8 MPa 34919 psi



47



50




54 SL = SP 102.3 MPa 14835 psi


56


58 SE1 = | SH - SL | SE1 102.3 MPa 14835 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 177.2 MPa 25694 psi



62





67

68

69

70

71

72

73

74

75




Page 3 of 10

1

2 DESIGN DATA



5 Grade X65







12



15 t = P x D / (2x Sx Fx E x T) + A



18 9.1 %




22

23



26 1.23 %




30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55


(50)/(n+1)





(50)/(n+1)

Page 4 of 10

1

2 DESIGN INPUT




6 Location Class 1







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -36.5 MPa -5299 psi

40 Combined/Equivalent Stress check : SL ≤ 0.9 x SMYSxT hence OK

41


43 SE1 = | SH - SL | SE1 321.8 MPa 46674 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 305.2 MPa 44264 psi


46 Combined Stress check : SE ≤ 0.9 x SMYSxT hence OK

47



50




54 SL = SP 142.6 MPa 20688 psi


56


58 SE1 = | SH - SL | SE1 142.6 MPa 20688 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 247.1 MPa 35832 psi



62





67

68

69

70

71

72

73

74

75




Page 5 of 10

1

2 DESIGN DATA



5 Grade X65







12



15 t = P x D / (2x Sx Fx E x T) + A



18 9.1 %




22

23



26 1.23 %




30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55


(50)/(n+1)





(50)/(n+1)

Page 6 of 10

1

2 DESIGN INPUT




6 Location Class 3







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -62.0 MPa -8991 psi


41


43 SE1 = | SH - SL | SE1 262.4 MPa 38059 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 237.6 MPa 34455 psi



47



50




54 SL = SP 100.2 MPa 14534 psi


56


58 SE1 = | SH - SL | SE1 100.2 MPa 14534 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 173.6 MPa 25174 psi



62





67

68

69

70

71

72

73

74

75




Page 7 of 10

1

2 DESIGN DATA


4 Pipe outside diameter D 1066.8 mm

5 Grade X65







12



15 t = P x D / (2x Sx Fx E x T) + A



18 9.1 %




22

23



26 1.23 %




30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55


(50)/(n+1)





(50)/(n+1)

Page 8 of 10

1

2 DESIGN INPUT




6 Location Class 3







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -95.8 MPa -13892 psi


41


43 SE1 = | SH - SL | SE1 183.6 MPa 26623 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 159.0 MPa 23064 psi



47



50




54 SL = SP 43.9 MPa 6365 psi


56


58 SE1 = | SH - SL | SE1 43.9 MPa 6365 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 76.0 MPa 11025 psi



62





67

68

69

70

71

72

73

74

75




Page 9 of 10

1

2 DESIGN DATA


4 Pipe outside diameter D 406.4 mm

5 Grade X65







12



15 t = P x D / (2x Sx Fx E x T) + A



18 9.1 %




22

23



26 1.23 %




30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55


(50)/(n+1)





(50)/(n+1)

Page 10 of 10

1

2 DESIGN INPUT




6 Location Class 4







oF


oF


oF




18


20 Grade X65






26

27 B. COMBINED /EQUIVALENT STRESS CHECK FOR CORRODED PIPE CONDITION



30




34



37


39 SL = SP + ST -69.0 MPa -10012 psi


41


43 SE1 = | SH - SL | SE1 246.0 MPa 35676 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 219.7 MPa 31872 psi



47



50




54 SL = SP 88.5 MPa 12832 psi


56


58 SE1 = | SH - SL | SE1 88.5 MPa 12832 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 153.2 MPa 22225 psi



62





67

68

69

70

71

72

73

74

75

ATTACHMENT - 1B - Corroded condition



Page 1 of 5

1

2 DESIGN INPUT




6 Location Class 3







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -55.9 MPa -8108 psi


41


43 SE1 = | SH - SL | SE1 276.6 MPa 40120 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 253.3 MPa 36743 psi



47



50




54 SL = SP 110.4 MPa 16006 psi


56


58 SE1 = | SH - SL | SE1 110.4 MPa 16006 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 191.1 MPa 27723 psi



62





67

68

69

70

71

72

73

74

75




Page 2 of 5

1

2 DESIGN INPUT




6 Location Class 1







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -26.8 MPa -3888 psi


41


43 SE1 = | SH - SL | SE1 344.5 MPa 49966 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 331.9 MPa 48139 psi



47



50




54 SL = SP 158.8 MPa 23039 psi


56


58 SE1 = | SH - SL | SE1 158.8 MPa 23039 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 275.1 MPa 39904 psi



62





67

68

69

70

71

72

73

74

75




Page 3 of 5

1

2 DESIGN INPUT




6 Location Class 3







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -56.1 MPa -8142 psi


41


43 SE1 = | SH - SL | SE1 276.1 MPa 40041 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 252.7 MPa 36655 psi



47



50




54 SL = SP 110.0 MPa 15950 psi


56


58 SE1 = | SH - SL | SE1 110.0 MPa 15950 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 190.5 MPa 27626 psi



62





67

68

69

70

71

72

73

74

75




Page 4 of 5

1

2 DESIGN INPUT




6 Location Class 3







oF


oF


oF




18


20 Grade X65






26




30




34



37


39 SL = SP + ST -92.8 MPa -13458 psi


41


43 SE1 = | SH - SL | SE1 190.5 MPa 27636 psi

44 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 165.0 MPa 23936 psi



47



50




54 SL = SP 48.9 MPa 7089 psi


56


58 SE1 = | SH - SL | SE1 48.9 MPa 7089 psi

59 SE2 = [ SH2 + SL

2 - SH SL ]

1/2 SE2 84.7 MPa 12278 psi



62





67

68

69

70

71

72

73

74

75




Page 5 of 5

Document No. 5272-NC-GEN-95-001 Rev.0

123

4

5 Input Data Unit Unit

6 Pipe diameter, D = 1.321 m 52 inch

7 Nominal pipe thk, tn = 0.0252 m 25.2 mm

8 Corrosion Allowance = 0.0015 m

9 Pipe thk, t = 0.0252 m

10 Ext. coating thickness, tcor 0.0036 m 3.550 mm

11 Design pressure, PD = 647520 kg/m2

63.5 barg

12 Steel density = 7850 kg/m3

13 Soil density, Y = 1800 kg/m3

14 Ext. coating density, ρcor = 900 kg/m3

15 Youngs modulus of steel, E = 21108121200 kg/m2

207000 MPa

16 Poisson ratio, n = 0.3

17 Thermal expansion, a = 0.0000117 Per oC

18 Installation (backfill) Temp, T1 = 13oC

19 Design Temp (U/G), T2 = 65oC

20 Pipeline Cover depth, H = 1.5 m

21 Fluid density = 0 kg/m3

(Consider zero for conservative reason)

22 Uplift coefficient, f = 0.1 (for loose soil or 0.5 for dense material)

23 Pipe Properties

24 Pipe Internal Cross-Sectional Area Ai π/4(d2) = 1.267566788 m

2

25 Pipe cross sectional area, A = π/4(D2-d

2) = 0.102570236 m

2

26 Corrosion coating area, Acor = π/4((D+2tcor2)-D

2) = 0.014770017 m

2

27 Pipe Section modulus, I = π/64(D4-d

4) = 0.021529677 m

4

28 Pipe flexural rigidity = EI = 454451032.9 kg-m2

29 Weight of pipe = Sect area x density = 805.176349 kg/m

30 Weight of corrosion coating, Wcor Sect area x density = 13.2930155 kg/m

31 Pipe contents sectional area = π/4(D-2t)2

= 1.267566788 m2

32 Weight of contents = Sect area x density 0 kg/m

33

34 Pipeline Axial force P = PD*Ai + A{Eα(T2-T1) - ٧Sh }

35 Axial stress due to hoop stress = ٧(PDD)/(2t) = 5090737.898 kg/m2

(+)

36 Axial force due to pressure = PD*Ai = 820774.4156 kg/m2

(-)

37 Thermal stress = Eα(T2-T1) = 12842180.94 kg/m2

(-)

38 So the Axial force P = = 1615841.754 kg

39

40 The required down force from OTC Paper Eq 1241

42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43

44 The Uplift resistance from Soil and Pipe weight from OTC Paper Eq 13

45 Q = HDY [1 + f H / D]

46 Wo = Weight of Pipe + Weight of Corrosion Coating + Weight of Contents 47

48 Maximum downward force required in terms of imperfection length L imp from OTC Paper Eq. 4

49 W = 2δP(p/Limp)2 - 8δEI(p/Limp)

4

50 Imperfection length is calculated by solving the quadtratic equation as follows

51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0

52 Condition for Stability = |W| < |Wo + Q|

53

54

Req. Down force

W

Uplift soil

resistance

Q

Wo Q + WoImperfection

Length Limp (m)

55

56 -3100.46 3971.16 818.47 4789.63 53.891

57 -2770.97 3971.16 818.47 4789.63 63.514

58 -2518.15 3971.16 818.47 4789.63 69.769

59 -2305.01 3971.16 818.47 4789.63 74.472

60 -2117.23 3971.16 818.47 4789.63 78.257

61

62

63

64

65

66

67

68

69

70

0.1

0.2

0.3

0.4

0.5

ATTACHMENT - 2 - Non Corroded condition

Upheaval Buckling Calculation (52" - 25.2 mm WT Pipeline, Location Class = 4)

As per OTC Paper 6335 by A.C. Palmer, C.P.Ellinas, D.M. Richards and J.Guijt, 1990

Imperfection height,

δ (m)

Stable

Stable

Stability

Stable

Stable

Stable

Page 1 of 10


123

4





9 Pipe thk, t = 0.0205 m



63.5 barg





207000 MPa





20 Pipeline Cover depth, H = 1 m




23 Pipe Properties


2


2) = 0.083742765 m

2


2) = 0.014770017 m

2


4) = 0.017703224 m

4





= 1.286394258 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -2512.09 2557.44 670.67 3228.11 53.889

57 -2230.30 2557.44 670.67 3228.11 63.480

58 -2014.07 2557.44 670.67 3228.11 69.700

59 -1831.78 2557.44 670.67 3228.11 74.368

60 -1671.18 2557.44 670.67 3228.11 78.116

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 2 of 10


123

4





9 Pipe thk, t = 0.0147 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.060317542 m

2


2) = 0.014770017 m

2


4) = 0.01286357 m

4





= 1.309819481 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -1778.62 2557.44 486.79 3044.23 53.796

57 -1555.57 2557.44 486.79 3044.23 63.300

58 -1384.42 2557.44 486.79 3044.23 69.434

59 -1240.13 2557.44 486.79 3044.23 74.014

60 -1113.02 2557.44 486.79 3044.23 77.674

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 3 of 10


123

4





9 Pipe thk, t = 0.0169 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.055742252 m

2


2) = 0.011937243 m

2


4) = 0.007682506 m

4





= 0.838089741 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -1574.84 2100.24 448.32 2548.56 48.123

57 -1343.23 2100.24 448.32 2548.56 56.523

58 -1165.51 2100.24 448.32 2548.56 61.899

59 -1015.69 2100.24 448.32 2548.56 65.879

60 -883.69 2100.24 448.32 2548.56 69.031

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 4 of 10


123

4





9 Pipe thk, t = 0.0147 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.018089259 m

2


2) = 0.003923292 m

2


4) = 0.000347415 m

4





= 0.111627856 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -274.37 911.52 145.53 1057.05 28.126

57 -101.08 911.52 145.53 1057.05 32.025

58 31.89 911.52 145.53 1057.05 34.045

59 143.99 911.52 145.53 1057.05 35.220

60 242.75 911.52 145.53 1057.05 35.930

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 5 of 10


123

4




8 Corrosion Allowance = 0.0015 m 1.5 mm

9 Pipe thk, t = 0.0237 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.096576548 m

2


2) = 0.014770017 m

2


4) = 0.020317655 m

4





= 1.273560475 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -2913.26 3971.16 771.42 4742.58 53.895

57 -2599.00 3971.16 771.42 4742.58 63.510

58 -2357.86 3971.16 771.42 4742.58 69.756

59 -2154.56 3971.16 771.42 4742.58 74.449

60 -1975.46 3971.16 771.42 4742.58 78.225

61

62

63

64

65

66

67

68

69

70

ATTACHMENT - 2 - Corroded condition




δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 6 of 10


123

4





9 Pipe thk, t = 0.0190 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.077704781 m

2


2) = 0.014770017 m

2


4) = 0.01646413 m

4





= 1.292432242 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -2323.19 2557.44 623.28 3180.72 53.877

57 -2056.61 2557.44 623.28 3180.72 63.453

58 -1852.05 2557.44 623.28 3180.72 69.657

59 -1679.60 2557.44 623.28 3180.72 74.308

60 -1527.66 2557.44 623.28 3180.72 78.039

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 7 of 10


123

4





9 Pipe thk, t = 0.0132 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.054224895 m

2


2) = 0.014770017 m

2


4) = 0.011590517 m

4





= 1.315912129 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -1587.55 2557.44 438.96 2996.40 53.741

57 -1379.66 2557.44 438.96 2996.40 63.207

58 -1220.14 2557.44 438.96 2996.40 69.302

59 -1085.66 2557.44 438.96 2996.40 73.844

60 -967.18 2557.44 438.96 2996.40 77.466

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 8 of 10


123

4





9 Pipe thk, t = 0.0154 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.050867286 m

2


2) = 0.011937243 m

2


4) = 0.007030362 m

4





= 0.842964707 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -1429.38 2100.24 410.05 2510.29 48.100

57 -1212.97 2100.24 410.05 2510.29 56.476

58 -1046.91 2100.24 410.05 2510.29 61.827

59 -906.91 2100.24 410.05 2510.29 65.782

60 -783.57 2100.24 410.05 2510.29 68.908

61

62

63

64

65

66

67

68

69

70





δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 9 of 10


123

4





9 Pipe thk, t = 0.0132 m



63.5 barg





207000 MPa









23 Pipe Properties


2


2) = 0.01630562 m

2


2) = 0.003923292 m

2


4) = 0.000315474 m

4





= 0.113411495 m2


33



(+)


(-)


(-)


39


42 W = [1.16 – 4.76 (EI Wo / δ)0.5

/ P] P ( δ Wo / EI) 0.5 kg/m

43


45 Q = HDY [1 + f H / D]




4


51 (π / Limp)4 – [P / 4*E*I] (π / Limp)

2 + [ W / 8δEI ] = 0


53

54

Req. Down force

W

Uplift soil

resistance

Q


Length Limp (m)

55

56 -244.47 911.52 131.53 1043.05 28.135

57 -86.40 911.52 131.53 1043.05 32.014

58 34.89 911.52 131.53 1043.05 34.011

59 137.14 911.52 131.53 1043.05 35.165

60 227.23 911.52 131.53 1043.05 35.856

61

62

63

64

65

66

67

68

69

70

ATTACHMENT - 2 - Non Corrroded




δ (m)Stability

0.1 Stable

0.2 Stable

0.3 Stable

0.4 Stable

0.5 Stable

Page 10 of 10


1

2 Input Data

3 Pipe Material = API 5L X65 LSAW

4 Pipeline design factor, D.F. = 0.50

5 pipe size, Outside Diam., D = 16 in 406.4 mm

6 Pipe nominal thickness, t = 14.7 mm

7 SMYS of linepipe material = 65300 psi8 Longitudinal joint factor, Ej = 1

9 Allow. design factor for Eff. Stress, Fa = 0.72

10 Corrosion allowance = 1.5 mm11 Corroded wall thickness, tw = 13.2 mm

12 Design pressure, P = 63.5 barg 10197.16213 647519.8 kg/m2

14.504 920.99 psig13 Design temperature (U/G), T2 = 65 deg C

14 Installation (backfill) temp., T1 = 13 deg C

15 Youngs modulus of steel, E = 2.07E+05 Mpa 101971.6213 2.111E+10 kg/m2

16 Poisson ratio, ٧ = 0.3

17 Thermal expansion coefficient, a = 0.0000117 per deg C

18 Soil density, g = 1800 kg/m3

17.65 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/m2

21 Depth of cover, H = 1500 mm

22 Bored diameter, Bd = 406.4 mm Construction type: 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 m2

26

27 Check for Allowable stress28 Hoop stress Sh < D.F x Ej x SMYS

29 Shi(Barlow) = PD/2tw = 14177.66 psi 0.00689 = 97.75 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 = 0.032 KHe = 1279

34 Ref. Fig 4 H/Bd = 3.7 Be = 0.96

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83

36 Ref. Equation 1 SHe = KHe x Be x Ee x g x D SHe = 745414.1 kg/m2

9.81E-06 7.31 MPa

37

38 Check critical axle configurations (figure A-1)

39 Pavement type :

40 Critical Axle : R = 1.1 L = 1.00 (Refer table 2)

41

42 Impact factor and applied surface pressure w43 Ref. Fig 7 H = 1.50 Fi = 1.5

44 Applied pressure (w) = Pt /A

45 for Tandem Axles w = 123016.1 kg/m2

9.81E-06 1.21 MPa

46

47 Cyclic circumferential stress ΔSHh

48 Ref fig 14 tw/D = 0.032 KHh = 9.80

49 Ref fig 15 GHh = 1.05

50 Ref. Equation 5 ΔSHh = KHh x GHh x R x L x Fi x w ΔSHh = 20.48 MPa

51

52 Cyclic Longitudinal stress ΔSLh

53 Ref fig 16 tw/D = 0.032 KLH = 8.10

54 Ref fig 17 GLh = 1.0455 Ref. Equation 6 ΔSLh = KLh x GLh x R x L x Fi x w ΔSLh = 16.77 MPa

56

57 Circumferential Stress due to Internal Load, SHi

58 Ref. Equation 7 SHi = P(D-tw)/2tw SHi = 13717.16 psi 94.58 MPa

59

60 Principal stresses S1, S2, & S361 Ref. Equation 9 S1(max circum stress) = SHe + ΔSHh + SHi S1 = 122.37 MPa

62

63 Ref. Equation 10, S2 = Maximum longitudinal stress64 S2 = ΔSLh - Ea(T2-T1) + ٧(SHe + SHi) S2 = -78.60 MPa

6566 Ref. Equation 11, Radial stress S3 = -P S3 = -6.35 MPa

67

68 Ref. Equation 12, Effective stress Seff = [0.5 {(S1-S2)2 + (S2-S3)

2 + (S3-S1)

2}]

0.5

69 Seff = 176.32 MPa

70 Allowable effective stress (SMYS x Fa) = 324.16 MPa

71

72 Ratio of Seff / Allowable = 0.544 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 MPa77 Refer Equation 17 ΔSLh < SFG x D.F

78 Ratio of Actual (ΔSLh)/ Allowable = 0.405 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 MPa82 Refer Equation 18 ΔSHh < SFL x D.F.

83 Ratio of Actual (ΔSHh) / Allowable SFL = 0.495 Result Design OK

84

NOTE:

1. This spread sheet is only for LOOSE SAND soil type.

2. Exact data are only available for depth in beetween 3 ft (0.9m) to 10 ft (3m). Extrapolation has been done for any unavailable data.

ATTACHMENT - 3

16-inch Pipeline, Location Class 3, API 5L X65 LSAWAs per API RP 1102

No Pavement

Tandem Axles

Uncased Track Crossing Design Calculation

No Pavement

Trenched

16

Page 1 of 1


1

2 Input Data



5 pipe size, Outside Diam., D = 42 in 1067 mm










17 Thermal expansion coefficient, a = 1.17E-05 per deg C


17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2


22 Bored diameter, Bd = 1118 mm Construction type: Bored




0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.8 Be = 0.61

35 Ref. Fig 5 Bd/D = 1.05 Ee = 0.91

36 Ref. Equation 1 SHe = KHe x Be x Ee x g x D SHe = 5105103 kg/m2

9.81E-06 50.06 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.66



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59

60 Principal stresses S1, S2, & S3

61 Ref. Equation 9 S1(max circum stress) = SHe + ΔSHh + SHi S1 = 283.84 MPa

6263 Ref. Equation 10, S2 = Maximum longitudinal stress

64 S2 = ΔSLh - Ea(T2-T1) + ٧(SHe + SHi) S2 = -34.92 MPa


67


2 + (S3-S1)

2}]

0.5

69 Seff = 305.48 MPa


71


73





79




84

ATTACHMENT - 3


Flexible Pavement

Tandem Axles

Asphalt Road Crossing Design Calculation

Flexible Pavement

Bored

42

Page 1 of 1


1

2 Input Data







10 Corrosion allowance = 1.5 mm11 Corroded wall thickness, tw = 19 mm


14.504 920.99 psig

13 Design temperature (U/G), T2 = 65 deg C






17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.5 Be = 0.53

35 Ref. Fig 5 Bd/D = 1.04 Ee = 0.89


9.81E-06 52.67 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.5450 Ref. Equation 5 ΔSHh = KHh x GHh x R x L x Fi x w ΔSHh = 13.89 MPa


53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59



62



67


2 + (S3-S1)

2}]

0.5

69 Seff = 307.82 MPa


71


73





79




84

ATTACHMENT - 3


Flexible Pavement

Tandem Axles


Flexible Pavement

Bored

Page 1 of 1


1

2 Input Data















17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.5 Be = 0.53

35 Ref. Fig 5 Bd/D = 1.04 Ee = 0.89


9.81E-06 52.67 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.54



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59





67


2 + (S3-S1)

2}]

0.5

69 Seff = 307.82 MPa


71


73





79




84

ATTACHMENT - 3


Flexible Pavement

Tandem Axles


Flexible Pavement

Bored

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.017 KHe = 3742

34 Ref. Fig 4 H/Bd = 1.5 Be = 0.53

35 Ref. Fig 5 Bd/D = 1.04 Ee = 0.89


9.81E-06 41.15 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.017 KHh = 14.80

49 Ref fig 15 GHh = 0.54



53 Ref fig 16 tw/D = 0.017 KLH = 10.10




59






67


2 + (S3-S1)

2}]

0.5

69 Seff = 263.06 MPa


71


73





79




84

ATTACHMENT - 3


Flexible Pavement

Tandem Axles


Flexible Pavement

Bored

Page 1 of 1


1

2 Input Data







10 Corrosion allowance = 1.5 mm11 Corroded wall thickness, tw = 15.4


14.504 920.99 psig





17 Thermal expansion coefficient, a = 0.0000117 per deg C


17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2


22 Bored diameter, Bd = 1067 mm Construction type: Trenched




0.403 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.9 Be = 0.63

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 47.16 MPa

37


39 Pavement type :


41



45 for Single Axle w = 278367.9 kg/m2

9.81E-06 2.73 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.66


51


53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59



62



67


2 + (S3-S1)

2}]

0.5

69 Seff = 309.74 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Single Axle

Rig Crossing Design Calculation

No Pavement

Trenched

42

Page 1 of 1


1

2 Input Data







10 Corrosion allowance = 1.5 mm11 Corroded wall thickness, tw = 19


14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.403 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.6 Be = 0.56

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 51.90 MPa

37


39 Pavement type :


41




9.81E-06 2.73 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.54



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59






67


2 + (S3-S1)

2}]

0.5

69 Seff = 313.48 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Single Axle


No Pavement

Trenched

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.403 m2

26

27 Check for Allowable stress28 Hoop stress Sh <D.F x Ej x SMYS



31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.6 Be = 0.56

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 51.90 MPa

37


39 Pavement type :


41




9.81E-06 2.73 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.54



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59






67


2 + (S3-S1)

2}]

0.5

69 Seff = 313.48 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Single Axle


No Pavement

Trenched

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.403 m2

26




31


33 Ref. Fig 3 tw/D = 0.017 KHe = 3742

34 Ref. Fig 4 H/Bd = 1.6 Be = 0.56

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 40.55 MPa

37


39 Pavement type :


41




9.81E-06 2.73 MPa


48 Ref fig 14 tw/D = 0.017 KHh = 14.80

49 Ref fig 15 GHh = 0.54



53 Ref fig 16 tw/D = 0.017 KLH = 10.10




59



62



67


2 + (S3-S1)

2}]

0.5

69 Seff = 268.65 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Single Axle


No Pavement

Trenched

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.5 Be = 0.53

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 39.67 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70

49 Ref fig 15 GHh = 0.85



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59





67


2 + (S3-S1)

2}]

0.5

69 Seff = 302.77 MPa


71


73





79




84

ATTACHMENT - 1


No Pavement

Tandem Axles


No Pavement

Trenched

42

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26

27 Check for Allowable stress28 Hoop stress Sh [ D.F x Ej x SMYS



31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.2 Be = 0.44

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 40.78 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59


62



67


2 + (S3-S1)

2}]

0.5

69 Seff = 304.51 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Tandem Axles


No Pavement

Trenched

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.014 KHe = 4789

34 Ref. Fig 4 H/Bd = 1.2 Be = 0.44

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 40.78 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.014 KHh = 14.70



53 Ref fig 16 tw/D = 0.014 KLH = 10.10




59



62



67


2 + (S3-S1)

2}]

0.5

69 Seff = 304.51 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Tandem Axles


No Pavement

Trenched

Page 1 of 1


1

2 Input Data









14.504 920.99 psig







17.65 kN/m3



3.47E+05 kg/m2


7.04E+06 kg/m2






0.093 m2

26




31


33 Ref. Fig 3 tw/D = 0.017 KHe = 3742

34 Ref. Fig 4 H/Bd = 1.6 Be = 0.56

35 Ref. Fig 5 Bd/D = 1.00 Ee = 0.83


9.81E-06 40.55 MPa

37


39 Pavement type :


41




9.81E-06 1.21 MPa


48 Ref fig 14 tw/D = 0.017 KHh = 14.80



53 Ref fig 16 tw/D = 0.017 KLH = 10.10




59


62



67


2 + (S3-S1)

2}]

0.5

69 Seff = 263.56 MPa


71


73





79




84

ATTACHMENT - 3


No Pavement

Tandem Axles


No Pavement

Trenched

Page 1 of 1

1

2 Input Parameters

3 Pipe OD, Do 52 in 1.3208 m

4 Pipe Wall thickness, tp 0.992 in 0.0252 m

5 Corrosion Allowances, tca 1.5 mm 0.0015 m

6 Water Density, γw 1025 kg/m3

7 Dry Soil/ Backfill Density, γd 1800 kg/m3

8 Pipe Density, γp 7850 kg/m3

9 Pipe Content Density, γc (Assumed zero for conservative case) 0 kg/m3

10

11 Calculations

12 Check for Non-corroded condition

13 Outside Area of Pipe, Ao = p Do2/ 4 1.3701 m

2

14 Inside Area of Pipe, A i = p D i2/ 4 1.2676 m

2

15 Effective Area of Pipe, A e = p (Do2 - Di

2)/ 4 0.1026 m

2

16

17 Weight of water displaced by pipe per unit length of pipe, Ww

18 Ww = γw . Ao 1404.39 kg/ m

19 Weight of pipe per unit length of pipe, Wp

20 Wp = γp . Ae 805.08 kg/ m

21 Weight of pipe contents per unit length of pipe, Wc

22 Wc = γc . A i 0.00 kg/ m

23 Factor of safety against flotation

24 FS = Wp/ Ww 0.573

25

26 Check for Corroded condition


2


2


2)/ 4 0.0966 m

2

30


32 Ww = γw . Ao 1404.39 kg/ m


34 Wp = γp . Ae 758.03 kg/ m


36 Wc = γc . A i 0.00 kg/ m


38 FS = Wp/ Ww 0.540

39 Assumptions:

40 1- To simplify calculations, the adherence of the soil to the pipe walls is neglected.

41 2- Pipeline content considered to be empty in order to calculate largest upward force.

42

Attachment-4

52'' Pipeline Buoyancy Check (WT - 25.2mm)Check for Pipeline Stability in High Water Areas


Page 1 of 5

1

2 Input Parameters

3 Pipe OD, Do 52 in 1.3208 m







10

11 Calculations



2


2


2)/ 4 0.0837 m

2

16


18 Ww = γw . Ao 1404.39 kg/ m


20 Wp = γp . Ae 657.31 kg/ m


22 Wc = γc . A i 0.00 kg/ m


24 FS = Wp/ Ww 0.468

25



2


2


2)/ 4 0.0777 m

2

30


32 Ww = γw . Ao 1404.39 kg/ m


34 Wp = γp . Ae 609.91 kg/ m


36 Wc = γc . A i 0.00 kg/ m


38 FS = Wp/ Ww 0.434

39 Assumptions:



42

Attachment-4

52'' Pipeline Buoyancy Check (WT - 20.5mm)

Check for Pipeline Stability in High Water Areas


Page 2 of 5

1

2 Input Parameters

3 Pipe OD, Do 52 in 1.3208 m







10

11 Calculations



2


2


2)/ 4 0.0603 m

2

16


18 Ww = γw . Ao 1404.39 kg/ m


20 Wp = γp . Ae 473.70 kg/ m


22 Wc = γc . A i 0.00 kg/ m


24 FS = Wp/ Ww 0.337

25



2


2


2)/ 4 0.0543 m

2

30


32 Ww = γw . Ao 1404.39 kg/ m


34 Wp = γp . Ae 425.88 kg/ m


36 Wc = γc . A i 0.00 kg/ m


38 FS = Wp/ Ww 0.303

39 Assumptions:



42

Attachment-4




Page 3 of 5

1

2 Input Parameters

3 Pipe OD, Do 42 in 1.0668 m







10

11 Calculations



2


2


2)/ 4 0.0557 m

2

16


18 Ww = γw . Ao 916.18 kg/ m


20 Wp = γp . Ae 437.35 kg/ m


22 Wc = γc . A i 0.00 kg/ m


24 FS = Wp/ Ww 0.477

25



2


2


2)/ 4 0.0508 m

2

30


32 Ww = γw . Ao 916.18 kg/ m


34 Wp = γp . Ae 399.08 kg/ m


36 Wc = γc . A i 0.00 kg/ m


38 FS = Wp/ Ww 0.436

39 Assumptions:



42

Attachment-4




Page 4 of 5

1

2 Input Parameters

3 Pipe OD, Do 16 in 0.4064 m







10

11 Calculations



2


2


2)/ 4 0.0181 m

2

16


18 Ww = γw . Ao 132.96 kg/ m


20 Wp = γp . Ae 142.00 kg/ m


22 Wc = γc . A i 0.00 kg/ m


24 FS = Wp/ Ww 1.068

25



2


2


2)/ 4 0.0163 m

2

30


32 Ww = γw . Ao 132.96 kg/ m


34 Wp = γp . Ae 128.00 kg/ m


36 Wc = γc . A i 0.00 kg/ m


38 FS = Wp/ Ww 0.963

39 Assumptions:



42

Attachment-4




Page 5 of 5

Attachment-5

1

2

3 In put Data Unit Conv.fact Unit

4 Pipe diameter, D = 1.321 m

5 Nominal pipe thk, t = 0.0252 m

6 Corrosion allowance, CA = 0.0015 m

7 Effective Wall Thickness tc = 0.0252 m

8 Design pressure, PD = 63.5 Barg 10197.16213 6E+05 Kg/m2

9 Steel (pipe) density = 7850 kg/m3


11 = 207000 MPa 101971.6213 2E+10 kg/m2


13 Thermal expansion, a = 0.0000117 Per Deg C

14 Installation Temp, T1 = 13 Deg C

15 Design Temp, T2 = 65 Deg C


17 Fluid density = 0 kg/m3 (Consider zero for conservative reason)

18 Coefficient of friction, m = 0.3


2

20 Pipe cross sectional area π/4(D2-d

2) = 0.1026 m

2

21 Weight, Wg A x density(pipe) = 805.30 kg/m

22

23 Pipeline Axial force P = PD*Ai + A*{Eα(T2-T1) - ٧(PDD)/(2t)}

24 Axial stress due hoop stress = ٧Sh = ٧(PDD)/(2t) = 5091509.8 kg/m2

25 Axial Force due to pressure PD.Ai = 821033.04 kg

26 Thermal stress Eα(T2-T1) = 12842184 kg/m2

27 So the Axial force P = 1616144.2 kg

28

29 The Axial frictional force f=m (2g DH + Wg) = 2143.83 kg/m

30

31 Pipeline Active length La=(P) / f = 753.86 m

32

33 End expansion due to pressure effect

34 ΔLp = [(0.5 – ٧) Sh x La] / E = 36.37 mm

35

36 End expansion due to temperature effect

37 ΔLt = α (T2-T1) x La = 458.65 mm

38

39 Toal expansion at A/G end

40 (ΔL) = ΔLp + ΔLt = 495.02 mm

41

Anchor Load, Active Length and Free Expansion Calculation

(52-inch - 25.2mm, Non-Compacted Soil, Non-Corroded Pipeline)


Youngs modulus of steel,E

Page 1 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.1026 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 32.74 mm

35


37 ΔLt = α (T2-T1) x La = 412.86 mm

38


40 (ΔL) = ΔLp + ΔLt = 445.59 mm

41



(52-inch - 25.2mm, Compacted Soil, Non-Corroded Pipeline)


Page 2 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0966 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 33.42 mm

35


37 ΔLt = α (T2-T1) x La = 396.38 mm

38


40 (ΔL) = ΔLp + ΔLt = 429.80 mm

41



(52-inch - 25.2mm, Compacted Soil, Corroded Pipeline)


Page 3 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0838 m

2


22





27 So the Axial force P = 1384619 kg

28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 39.11 mm

35


37 ΔLt = α (T2-T1) x La = 401.24 mm

38


40 (ΔL) = ΔLp + ΔLt = 440.35 mm

41





Page 4 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0838 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 35.13 mm

35


37 ΔLt = α (T2-T1) x La = 360.42 mm

38


40 (ΔL) = ΔLp + ΔLt = 395.55 mm

41





Page 5 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0777 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 36.09 mm

35


37 ΔLt = α (T2-T1) x La = 343.18 mm

38


40 (ΔL) = ΔLp + ΔLt = 379.28 mm

41





Page 6 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0603 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 44.36 mm

35


37 ΔLt = α (T2-T1) x La = 326.35 mm

38


40 (ΔL) = ΔLp + ΔLt = 370.71 mm

41





Page 7 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0603 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 39.74 mm

35


37 ΔLt = α (T2-T1) x La = 292.34 mm

38


40 (ΔL) = ΔLp + ΔLt = 332.08 mm

41





Page 8 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0542 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 41.49 mm

35


37 ΔLt = α (T2-T1) x La = 274.10 mm

38


40 (ΔL) = ΔLp + ΔLt = 315.59 mm

41





Page 9 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0557 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 31.94 mm

35


37 ΔLt = α (T2-T1) x La = 334.50 mm

38


40 (ΔL) = ΔLp + ΔLt = 366.44 mm

41





Page 10 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0557 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 28.64 mm

35


37 ΔLt = α (T2-T1) x La = 299.95 mm

38


40 (ΔL) = ΔLp + ΔLt = 328.60 mm

41





Page 11 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0509 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 29.56 mm

35


37 ΔLt = α (T2-T1) x La = 282.09 mm

38


40 (ΔL) = ΔLp + ΔLt = 311.64 mm

41





Page 12 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0181 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 10.38 mm

35


37 ΔLt = α (T2-T1) x La = 248.10 mm

38


40 (ΔL) = ΔLp + ΔLt = 258.47 mm

41





Page 13 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0181 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 9.29 mm

35


37 ΔLt = α (T2-T1) x La = 222.20 mm

38


40 (ΔL) = ΔLp + ΔLt = 231.50 mm

41





Page 14 of 15

Attachment-5

1

2









11 = 207000 MPa 101971.6213 2E+10 kg/m2









2


2) = 0.0163 m

2


22






28


30


32


34 ΔLp = [(0.5 – ٧) Sh x La] / E = 9.52 mm

35


37 ΔLt = α (T2-T1) x La = 204.39 mm

38


40 (ΔL) = ΔLp + ΔLt = 213.91 mm

41





Page 15 of 15