14050642-100-PL-CAL-0002_Pipeline Road Crossing Calculation Report_Rev 1

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Class 1

Page Rev Date

1 of 15 1 09.05.2016

Effluent Water Treatment And Injection Plant (NK)

PROJECT

:

CONTRACT NO

: 14050642

OWNER

: KUWAIT OIL COMPANY

CONTRACTOR

: Dodsal Engineering & Construction Pte. Ltd.

DOCUMENT NO.

: 14050642-100-PL-CAL-0002

DOCUMENT REVISION STATUS

: 1

DOCUMENT TYPE

: E (Engineering Drawing/Document)

1

09.05.2016

Re-Issued for Design (14050642-KD-T-02947)

SV

AC

PC

0

17.12.2015

Issued for Design (14050642-KD-T-01167)

SV

AC

PC

A

01.07.2015

Issued for Approval

SV

AC

PC

Rev

Date

Description

Prepared By

Checked By

Approved By

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

2 of 15 1 09.05.2016

REVISION RECORD:

Revision No. A 0 1

Reason for Revision Issued for Approval Issued for Design Re-Issued for Design

Date 01.07.2015 17.12.2015 09.05.2016

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Class 1 PAGE INDEX Page B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

C

D

1

X X X X

Revision 2 3

Page B 49 50 51 52 53 54 55 56 57 58 59 60 61 62

C

D

1

Revision 2 3

Page Rev Date

3 of 15 1 09.05.2016

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

4 of 15 1 09.05.2016

TABLE OF CONTENTS 1.

GENERAL ............................................................................................................................... 5

2.

SCOPE .................................................................................................................................... 5

3.

REFERENCE DOCUMENTS AND DATA ................................................................................ 5

4.

DESCRIPTION ........................................................................................................................ 6

5.

METHODOLOGY..................................................................................................................... 7

6.

CALCULATION RESULT / SUMMARY ................................................................................... 9

7.

CONCLUSION ....................................................................................................................... 13

8.

APPENDICES ........................................................................................................................ 14

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

1.

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

5 of 15 1 09.05.2016

GENERAL Kuwait Oil Company (K.S.C), hereafter referred as COMPANY, as a major player of global oil and gas sector has a long term strategy for the development of North Kuwait (NK) Fields. North Kuwait Fields is located approximately 90kms from north of Kuwait city. The purpose of this project is to provide sufficient injection water to meet the requirements of the north Kuwait well injectors. For this, an effluent water treatment and injection plant shall be built in a location between the SABRIYAH and RAUDATAIN fields of north Kuwait having a treatment capacity of 1,045,000 BWPD with 550,000 BWPD for injection and balance 495,000 BWPD will be transferred to existing central processing injector facility (CIPF existing). The plant shall receive a continuous supply of effluent water from existing Gathering Centers GC-15, GC23, GC-24, GC-25 and an intermittent supply of effluent water from new GC-29, GC-30 and GC-31 (all routed from existing CIPF). For this purpose, the COMPANY has entered into a contract with DODSAL ENGINEERING & CONSTRUCTION

PTE LIMITED,

hereafter

referred as

CONTRACTOR,

for

Engineering,

Procurement, Construction and Related Activities, with a Contract No. 14050642.

2.

SCOPE The scope of this document is to provide Cased Asphalt Road, Highway, Rig Crossing / Uncased Track Crossing Calculations for Water Injection pipeline systems including Distribution lines, Manifold lines & Flow lines of Sabriyah, Raudatain fields and offsite pipelines.

3.

REFERENCE DOCUMENTS AND DATA

3.1 Codes, Standards and Referenced Documents KOC Documents: KOC-L-002

KOC Recommended Practice for the Protection of KOC Services: Clearance Requirements for Buried Pipelines, Cables, Underground Structures, Buildings and Housing Projects

015-IH-1002

Pipeline Design

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

KOC-L-015

Page Rev Date

6 of 15 1 09.05.2016

External Cathodic Protection of Underground Steel Pipelines &Piping Networks

International Codes and Standards: ASME B31.4

Pipeline Transportation Systems for Liquids and Slurries

ASME B31.8

Gas Transmission and Distribution Piping Systems

API 5L

Specification for Line Pipe

API RP 1102

Steel Pipelines Crossing Railroads and Highways

3.2 Project Documents: 14050642-700-PR-DBM-0001 - Process Design Basis and Design Criteria 14050642-700-PR-LST-0002 – Process Line List 14050642-100-PL-DBM-0001 - Pipeline Design Basis 14050642-100-PL-DAT-0001 – Pipeline Data Sheet

4.

DESCRIPTION The purpose of this calculation is to ensure safe design in compliance with Road crossing criteria defined in API RP 1102 (circumferential stresses, Cyclic stresses, effective stress and fatigue failure) and to confirm that the selected wall thickness of carrier pipe / casing pipe is sufficient. The following categories are considered for road / track crossing calculations: 1. Uncased Track Crossing - Open Cut. 2. Cased Asphalt Road / Highway / Rig track Crossing - Open Cut / Trenchless. The burial depths for the above crossing categories are listed below: Sl. No 1

Crossing

Uncased Track Crossing Cased Asphalt Road / Highway / Rig Track 2 Crossing *As per clause 17.3.8 of KOC-L-002

Burial Depth in M 1.2 1.2*

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

7 of 15 1 09.05.2016

The following wheel loadings were taken into account in determining the stresses imposed on the carrier pipe / casing pipe at each crossing: 

Asphalt Road / Highway / Track crossings: As per KOC specification 015-IH-1002, 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 Track crossings: The total load of rig is 1100 KN and the maximum Tandem axle wheel load is 550KN. The contact area, over which the wheel load is applied, shall be taken as 0.403 square meters.

5.

METHODOLOGY The methodology for crossing calculation (as mentioned in API 1102) is described briefly in the following steps: a. Begin with the wall thickness (calculated with design factor 0.6 for Fuel gas and design factor 0.72 for all other services as per the respective codes) 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. f.

Calculate the cyclic circumferential stress, ∆SH, and the cyclic longitudinal stress, ∆SL, live load.

due to

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 ∆SL against the girth weld fatigue limit, SFG x F.

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Class 1

Page Rev Date

8 of 15 1 09.05.2016

2. Check longitudinal weld fatigue by comparing, ∆SH against the longitudinal weld fatigue limit, SFL x F. Where,  Circumferential stress due to internal pressure: SHi (Barlow) = pD / 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: ∆SHh = 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: ∆SLh = 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 = p (D– tw) / 2tw (refer section 4.7.3 of API 1102)



Maximum circumferential stress: S1 = SHe + ∆SH + SHi (refer section 4.8.1.2 of API 1102)

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Class 1



Page Rev Date

9 of 15 1 09.05.2016

Maximum longitudinal stress: S2 = ∆SL – EsαT(T2 – T1) + vs(SHe + SHi) (refer section 4.8.1.2 of API 1102)



Maximum radial stress: S3 = –p =-MAOP or –MOP (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)

6.

CALCULATION RESULT / SUMMARY 6.1 Uncased Track Crossing Assessment: Wall thickness and stresses developing in the wall of the carrier pipe due to backfill soil weight and vehicle loading were calculated and assessed in accordance with API RP 1102 requirements. Circumferential, longitudinal and radial stresses developing in the wall of the pipeline under the road are calculated and combined by the Von Mises yield criterion and found to be within the allowable limits. Table 6.1A shows the results of carrier pipe wall thickness check at track crossing and that the stresses developed are within the allowable limits. Table: 6.1A- Uncased Track Crossing Calculation Results:

Pipeline

Water Injection System

Oily Water Fuel Gas

Carrier Pipe OD

DF

Nominal WT (tnom)

Corroded WT (tmin)

(mm)

Total Effective Stress Calculated

Total Effective Stress Allowable (90% of SMYS)

(mm)

(kPa)

(kPa)

%

Selected WT for Crossing (tsel)

Burial Depth

(mm)

(mm)

% Stress ratio

Design Check

inch

(mm)

6.625 8.625 10.75 12.75 14.00 20.00

168.3 219.1 273.1 323.9 355.7 508

0.72 0.72 0.72 0.72 0.72 0.72

9.53 12.3 15.88 19.05 20.62 28.3

9.53 12.3 15.88 19.05 20.62 28.3

9.53 12.3 15.88 19.05 20.62 28.3

1200 1200 1200 1200 1200 1200

307119 310140 300786 297630 302970 313752

373500 373500 373500 373500 373500 373500

82.2 83.0 80.5 79.7 81.1 84.0

Safe Safe Safe Safe Safe Safe

6.625

168.3

0.72

7.11

3.99

3.99

1200

119951

220500

54.4

Safe

6.625

168.3

0.6

7.11

3.99

3.99

1200

144187

220500

65.4

Safe

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

10 of 15 1 09.05.2016

Pipelines are also assessed for fatigue endurance (due to the cyclic loading conditions imposed by vehicles) as per API RP 1102 requirements and the results are presented in Table 6.1B.

Table: 6.1B- Uncased Track Crossing Fatigue Results:

Pipeline

Water Injection System

Oily Water Fuel Gas

Stresses Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress

Carrier Pipe OD (inch) 6.625 8.625 10.750 12.750 14.000 20.000 6.625 6.625

Value (kPa)

Allowable (kPa)

%

7941 10602 7882 9151 6853 8246 6329 7783 9818 11946 52471 20431 23654 18455 23654 18455

59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571

13.3 17.8 13.2 15.4 11.5 13.8 10.6 13.1 16.5 20.1 88.1 34.3 39.7 31.0 39.7 31.0

Design Check Safe Safe Safe Safe Safe Safe Safe Safe

This report checks that the selected carrier pipe wall thicknesses are adequate for use at uncased track crossings. This crossing calculation checks are performed for uncased track crossings in accordance with API RP 1102.

6.2 Cased Asphalt / Highway Crossing Assessment: Wall thickness and stresses developing in the wall of the Casing pipe due to backfill soil weight and vehicle loading were calculated and assessed in accordance with API RP 1102 requirements. Circumferential, longitudinal and radial stresses developing in the wall of the casing pipe are calculated and combined by the Von Mises yield criterion and found to be within the allowable limits. Table 6.2A shows the results of casing pipe wall thickness check at Cased Asphalt / Highway crossing and that the stresses developed are within the allowable limits.

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Class 1

Page Rev Date

11 of 15 1 09.05.2016

Table: 6.2A- Cased Asphalt / Highway Crossing casing Pipe Wall Thickness Results:

Pipeline

Casing Pipe OD

Water Injection System

Oily Water Fuel Gas Effluent Water Treated Water

DF

Nominal WT (tnom)

Corroded WT (tmin)

(mm) 9.53 9.53 9.53 9.53 9.53 9.53

Total Effective Stress Calculated

Total Effective Stress Allowable (90% of SMYS)

Selected WT for Crossing (tsel)

Burial Depth

(mm) 9.53 9.53 9.53 9.53 9.53 9.53

(mm) 9.53 9.53 9.53 9.53 9.53 9.53

(mm) 1100 1100 1100 1100 1100 1100

(kPa) 21756 23445 27743 30305 42066 67710

9.53

9.53

9.53

1100

% Stress ratio

Design Check

(kPa) 220500 220500 220500 220500 220500 220500

9.8 10.6 12.6 13.7 19.1 30.7

Safe Safe Safe Safe Safe Safe

21756

220500

9.8

Safe Safe

inch 12.75 14.00 16.00 18.00 20.00 26.00

(mm) 323.9 355.7 406 457 508 660

12.75

323.9

12.75

323.9

0.6

9.53

9.53

9.53

1100

21756

220500

9.8

22.00

559

0.72

9.53

9.53

9.53

1100

44708

220500

18.2

36.00

914

0.72

9.53

9.53

9.53

1100

43447

220500

17.7

0.72 0.72 0.72 0.72 0.72 0.72 0.72

Safe 1

Safe

Pipes are also assessed for fatigue endurance (due to the cyclic loading conditions imposed by vehicles) as per API RP 1102 requirements and the results are presented in Table 6.5B.

Pipeline

Water Injection System

Oily Water Fuel Gas Effluent Water

Table: 6.2B- Cased Asphalt / Highway crossing Fatigue Results: Casing Value Allowable Stresses Pipe OD (kPa) (kPa) (inch) 59571 Circumferential Cyclic Stress 17469 12.750 Longitudinal Cyclic Stress 12804 59571 Circumferential Cyclic Stress 18121 59571 14.000 Longitudinal Cyclic Stress 13107 59571 Circumferential Cyclic Stress 20043 59571 16.000 Longitudinal Cyclic Stress 13620 59571 Circumferential Cyclic Stress 20736 59571 18.000 Longitudinal Cyclic Stress 13838 59571 Circumferential Cyclic Stress 32643 59571 20.000 Longitudinal Cyclic Stress 21071 59571 Circumferential Cyclic Stress 52471 59571 26.000 Longitudinal Cyclic Stress 20431 59571 Circumferential Cyclic Stress 17469 59571 12.750 Longitudinal Cyclic Stress 12804 59571 Circumferential Cyclic Stress 17469 49642 12.750 Longitudinal Cyclic Stress 12804 49642 Circumferential Cyclic Stress 32827 59571 22.000 Longitudinal Cyclic Stress 21073 59571

% 29.3 21.5 30.4 22.0 33.6 22.9 34.8 23.2 54.8 35.4 88.1 34.3 29.3 21.5 35.2 25.8 55.1 35.4

Design Check Safe Safe Safe Safe Safe Safe Safe Safe Safe 1

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Class 1 Treated Water

Circumferential Cyclic Stress Longitudinal Cyclic Stress

36.000

24381 17486

Page Rev Date

59571 59571

12 of 15 1 09.05.2016 40.9 29.4

Safe 1

This report checks that the selected casing pipe wall thicknesses are adequate for use as casing pipes. This calculation checks are performed for cased Asphalt / Highway Crossing in accordance with API RP 1102.

6.3 Cased Rig Track Crossing Assessment: Wall thickness and stresses developing in the wall of the casing pipe due to backfill soil weight and vehicle loading were calculated and assessed in accordance with API RP 1102 requirements. Circumferential, longitudinal and radial stresses developing in the wall of the casing pipe under the rig crossing are calculated and combined by the Von Mises yield criterion and found to be within the allowable limits. Table 6.3A shows the results of casing pipe wall thickness check at cased rig track crossing and that the stresses developed are within the allowable limits. Table: 6.3A- Cased Rig Track Crossing Wall Thickness Results:

Casing Pipe OD

Pipeline

Water Injection System

Oily Water Fuel Gas

inch

(mm)

12.75 14.00 16.00 18.00 20.00 26.00

323.9 355.7 406 457 508 660

12.75

323.9

12.75

323.9

Total Effective Stress Calculated

Total Effective Stress Allowable (90% of SMYS)

(mm)

(kPa)

(kPa)

%

9.53 9.53 9.53 9.53 9.53 9.53

1100 1100 1100 1100 1100 1100

32131 34256 39804 42820 45667 73732

220500 220500 220500 220500 220500 220500

14.6 15.5 18.1 19.4 20.7 33.4

Safe Safe Safe Safe Safe Safe

9.53

9.53

1100

32131

220500

14.6

Safe

9.53

9.53

1100

32131

220500

14.6

Safe

Nominal WT (tnom)

Corroded WT (tmin)

(mm) 0.72 0.72 0.72 0.72 0.72 0.72 0.72 0.6

DF

Selected WT for Crossing (tsel)

Burial Depth

(mm)

(mm)

9.53 9.53 9.53 9.53 9.53 9.53

9.53 9.53 9.53 9.53 9.53 9.53

9.53 9.53

% Stress ratio

Design Check

Pipelines are also assessed for fatigue endurance (due to the cyclic loading conditions imposed by vehicles) as per API RP 1102 requirements and the results are presented in Table 6.3B. Table: 6.3B- Cased Rig Track crossing Fatigue Results:

Pipeline

Stresses

Casing Pipe OD (inch)

Value (kPa)

Allowable (kPa)

%

Design Check

Water Injection

Circumferential Cyclic Stress Longitudinal Cyclic Stress

12.750

30456 22323

59571 59571

51.1 37.5

Safe

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

System

Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress Circumferential Cyclic Stress Longitudinal Cyclic Stress

Oily Water Fuel Gas

14.000 16.000 18.000 20.000 26.000 12.750 12.750

31594 22851 34943 23746 36152 24126 36992 23878 59463 23153 30456 22323 30456 22323

Page Rev Date

59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 59571 49642 49642

13 of 15 1 09.05.2016 53.0 38.4 58.7 39.9 60.7 40.5 62.1 40.0 99.8 38.9 51.1 37.5 61.4 45.0

Safe Safe Safe Safe Safe Safe Safe

This report checks that the selected casing pipe wall thicknesses are adequate for use as casing pipes. This calculation checks are performed for cased rig crossings in accordance with API RP 1102. 6.4 Casing Pipe Details for Asphalt Road / Highway / RIG Track Crossing – Open Cut / Trenchless: The Wall thickness required for casing pipe at asphalt road, highway and Rig track crossings are tabulated below as per KOC Standard Drawing for Pipe sleeve, Drawing No 55-04-77 and also in accordance with minimum wall thickness for casing as per Annex-C of API RP 1102. The selected pipe for casing is API 5L Gr.B with STD wall thickness as per KOC Standard for Pipe Sleeves, Drawing No: 55-04-77. Casing pipe (sleeve) protection shall be as per clause 7.8.1 of KOC-L-015. Table: 6.3- Casing Pipe Details:

1

7.

Carrier Pipe Size in inch 6.625 8.625 10.750 12.750 14.000 16.000 20.000 30.000

Casing Pipe Size in inch 12.750 14.000 16.000 18.000 20.000 22.000 26.000 36.000

Casing Pipe Thickness in mm 9.53 9.53 9.53 9.53 9.53 9.53 9.53 9.53

CONCLUSION This calculation report conclusively show that the proposed pipeline design is adequate to withstand the applied earth load, track live load, Highway vehicle load, rig load, internal pressure load and fatigue failure.

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

8.

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

14 of 15 1 09.05.2016

APPENDICES

Appendix-1: Uncased Track Crossing Calculations for 20" Injection Water Pipeline Appendix-2: Uncased Track Crossing Calculations for 14" Injection Water Pipeline Appendix-3: Uncased Track Crossing Calculations for 12" Injection Water Pipeline Appendix-4: Uncased Track Crossing Calculations for 10" Injection Water Pipeline Appendix-5: Uncased Track Crossing Calculations for 8" Injection Water Pipeline Appendix-6: Uncased Track Crossing Calculations for 6" Injection Water Pipeline Appendix-7: Uncased Track Crossing Calculations for 6" Oily Water Pipeline Appendix-8: Uncased Track Crossing Calculations for 6" Fuel Gas Pipeline Appendix-9: Cased Asphalt / Highway Crossing Calculations for 20" Injection Water Pipeline Appendix-10: Cased Asphalt / Highway Crossing Calculations for 14" Injection Water Pipeline Appendix-11: Cased Asphalt / Highway Crossing Calculations for 12" Injection Water Pipeline Appendix-12: Cased Asphalt / Highway Crossing Calculations for 10" Injection Water Pipeline Appendix-13: Cased Asphalt / Highway Crossing Calculations for 8" Injection Water Pipeline Appendix-14: Cased Asphalt / Highway Crossing Calculations for 6" Injection Water Pipeline Appendix-15: Cased Asphalt / Highway Crossing Calculations for 6" Oily Water Pipeline Appendix-16: Cased Asphalt / Highway Crossing Calculations for 6" Fuel Gas Pipeline Appendix-17: Cased Rig Crossing Calculations for 20" Injection Water Pipeline Appendix-18: Cased Rig Crossing Calculations for 14" Injection Water Pipeline Appendix-19: Cased Rig Crossing Calculations for 12" Injection Water Pipeline Appendix-20: Cased Rig Crossing Calculations for 10" Injection Water Pipeline Appendix-21: Cased Rig Crossing Calculations for 8" Injection Water Pipeline

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) Project No. EF/1761 Class 1

CONTRACT NO. 14050642 PIPELINE ROAD CROSSING CALCULATION REPORT Doc. No. : 14050642-100-PL-CAL-0002

Page Rev Date

15 of 15 1 09.05.2016

Appendix-22: Cased Rig Crossing Calculations for 6" Injection Water Pipeline Appendix-23: Cased Rig Crossing Calculations for 6" Oily Water Pipeline Appendix-24: Cased Rig Crossing Calculations for 6" Fuel Gas Pipeline Appendix-25: Cased Asphalt / Highway Crossing Calculations for 16" Effluent Water Pipeline 1

Appendix-26: Cased Asphalt / Highway Crossing Calculations for 30" Treated Water Pipeline

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-1

Road Crossing Calculations for 20" Injection Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 508 28.3 331.00 API 5L L415/X60 SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 297,081

% SMYS 71.6%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

313,752

75.6%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 11,588 9,945

% SMYS 2.8% 2.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 1 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-1

DETAILED CALCULATIONS Bored Diameter

Bd =

508

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

158,579.41 415.00 Not Applicable

kPa Mpa

297,081 298,800

kPa kPa

380.00 0.680 0.831 2072.58

(from Fig. 3, for tw/D=0.056 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.056

MPa

H/B d =

2.36

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=2.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,204.3

Fi = K Hh = G Hh = ΔSHh =

1.500 4.390 1.140 9,945

K Lh = G Lh = ΔSLh =

5.450 1.070 11,588

kPa

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 7, for H = 1200 mm) (from Fig. 14, for tw/D=0.056 & Er=69 MPa) (from Fig. 15, for D = 508 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 16, for tw/D=0.056 & Er=69 MPa) (from Fig. 17, for D = 508 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

280,531

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

292,548

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-7,773

kPa

S3= -p = -MAOP or -MOP

S3 =

-33,100

kPa

Seff =

313,752

kPa

SMYS x Fe =

373,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

114,177

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 2 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-2

Road Crossing Calculations for 14" Injection Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture Design Factor

ASME B31.4 355.6 20.62 331.00 API 5L L415/X60 SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

(Enter values if available from Design Basis or LEAVE BLANK ) kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts

Description of soil (Modulus of Soil Reaction)

E' =

Stiff to very stiff clays and Silts; medium dense and gravels

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels γ= 19 kN/m3 (Based on Survey Report/Design Data) E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 285,411

% SMYS 68.8%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

302,970

73.0%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 11,946 9,818

% SMYS 2.9% 2.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 3 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-2

DETAILED CALCULATIONS Bored Diameter

Bd =

355.6

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

158,579.41 415.00 Not Applicable

kPa Mpa

285,411 298,800

kPa kPa

350.00 0.820 0.831 1611.38

(from Fig. 3, for tw/D=0.058 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = SHe = KHeBeEeγD

MPa

Soil Type = t w /D =

B 0.058

MPa

H/B d =

3.37

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,204.3

Fi = K Hh = G Hh = ΔSHh =

1.500 4.050 1.220 9,818

K Lh = G Lh = ΔSLh =

5.320 1.130 11,946

kPa

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 7, for H = 1200 mm) (from Fig. 14, for tw/D=0.058 & Er=69 MPa) (from Fig. 15, for D = 355.6 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 16, for tw/D=0.058 & Er=69 MPa) (from Fig. 17, for D = 355.6 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, S hi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

268,861

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

280,291

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-11,054

kPa

S3= -p = -MAOP or -MOP

S3 =

-33,100

kPa

Seff =

302,970

kPa

SMYS x Fe =

373,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

114,177

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 4 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-3

Road Crossing Calculations for 12" Injection Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 323.9 19.05 331.00 API 5L L415/X60 SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 281,393

% SMYS 67.8%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

297,630

71.7%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 7,783 6,329

% SMYS 1.9% 1.5%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 5 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-3

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

158,579.41 415.00 Not Applicable

kPa Mpa

281,393 298,800

kPa kPa

300.00 0.850 0.831 1304.08

(from Fig. 3, for tw/D=0.059 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.059

MPa

H/B d =

3.70

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.7 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 3.920 1.250 6,329

(from Fig. 7, for H = 1200 mm)

K Lh = G Lh = ΔSLh =

5.240 1.150 7,783

(from Fig. 16, for tw/D=0.059 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.059 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

264,843

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

272,476

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-16,514

kPa

S3= -p = -MAOP or -MOP

S3 =

-33,100

kPa

Seff =

297,630

kPa

SMYS x Fe =

373,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

114,177

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 6 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-4

Road Crossing Calculations for 10" Injection Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 273.1 15.88 331.00 API 5L L415/X60 SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 284,622

% SMYS 68.6%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

300,786

72.5%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 8,246 6,853

% SMYS 2.0% 1.7%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 7 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-4

DETAILED CALCULATIONS Bored Diameter

Bd =

273.1

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

158,579.41 415.00 Not Applicable

kPa Mpa

284,622 298,800

kPa kPa

350.00 0.910 0.831 1373.36

(from Fig. 3, for tw/D=0.059 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.058

MPa

H/B d =

4.39

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=4.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 4.050 1.310 6,853

(from Fig. 7, for H = 1200 mm)

K Lh = G Lh = ΔSLh =

5.320 1.200 8,246

(from Fig. 16, for tw/D=0.058 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.058 & Er=69 MPa) (from Fig. 15, for D = 273.1 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 273.1 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

268,072

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

276,298

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-15,062

kPa

S3= -p = -MAOP or -MOP

S3 =

-33,100

kPa

Seff =

300,786

kPa

SMYS x Fe =

373,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

114,177

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 8 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-5

Road Crossing Calculations for 8" Injection Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 219.1 12.3 331.00 API 5L L415/X60 SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 294,805

% SMYS 71.0%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

310,140

74.7%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 9,151 7,882

% SMYS 2.2% 1.9%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 9 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-5

DETAILED CALCULATIONS Bored Diameter

Bd =

219.1

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

158,579.41 415.00 Not Applicable

kPa Mpa

294,805 298,800

kPa kPa

380.00 0.995 0.831 1307.99

(from Fig. 3, for tw/D=0.057 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.056

MPa

H/B d =

5.48

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=5.5 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 4.390 1.390 7,882

(from Fig. 7, for H = 1200 mm)

K Lh = G Lh = ΔSLh =

5.450 1.300 9,151

(from Fig. 16, for tw/D=0.056 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.056 & Er=69 MPa) (from Fig. 15, for D = 219.1 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 219.1 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

278,255

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

287,445

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-11,122

kPa

S3= -p = -MAOP or -MOP

S3 =

-33,100

kPa

Seff =

310,140

kPa

SMYS x Fe =

373,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

114,177

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 10 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-6

Road Crossing Calculations for 6" Injection Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 168.3 9.53 331.00 API 5L L415/X60 SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 292,273

% SMYS 70.4%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

307,119

74.0%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 10,602 7,941

% SMYS 2.6% 1.9%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 11 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-6

DETAILED CALCULATIONS Bored Diameter

Bd =

168.3

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

158,579.41 415.00 Not Applicable

kPa Mpa

292,273 298,800

kPa kPa

360.00 1.070 0.831 1023.59

(from Fig. 3, for tw/D=0.057 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.057

MPa

H/B d =

7.13

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=7.1 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

Fi = K Hh = G Hh = ΔSHh =

1.500 4.240 1.450 7,941

K Lh = G Lh = ΔSLh =

5.400 1.520 10,602

kPa

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 7, for H = 1200 mm) (from Fig. 14, for tw/D=0.057 & Er=69 MPa) (from Fig. 15, for D = 168.3 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 16, for tw/D=0.057 & Er=69 MPa) (from Fig. 17, for D = 168.3 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

275,723

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

284,688

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-10,516

kPa

S3= -p = -MAOP or -MOP

S3 =

-33,100

kPa

Seff =

307,119

kPa

SMYS x Fe =

373,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

114,177

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 12 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-7

Road Crossing Calculations for 6" Oily Water Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 168.3 3.99 17.90 API 5L L245/B SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

60

°C

T des = E= T=

93 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 37,752

% SMYS 15.4%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

119,951

49.0%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 18,455 23,654

% SMYS 7.5% 9.7%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 13 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-7

DETAILED CALCULATIONS Bored Diameter

Bd =

168.3

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

144,789.90 245.00 Not Applicable

kPa Mpa

37,752 176,400

kPa kPa

1680.00 1.070 0.831 4776.74

(from Fig. 3, for tw/D=0.024 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.024

MPa

H/B d =

7.13

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=7.1 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 12.630 1.450 23,654

(from Fig. 7, for H = 1200 mm)

K Lh = G Lh = ΔSLh =

9.400 1.520 18,455

(from Fig. 16, for tw/D=0.024 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.024 & Er=69 MPa) (from Fig. 15, for D = 168.3 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 168.3 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

36,857

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

65,287

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-73,197

kPa

S3= -p = -MAOP or -MOP

S3 =

-1,790

kPa

Seff =

119,951

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

104,249

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 14 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-8

Road Crossing Calculations for 6" Fuel Gas Pipeline (Uncased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.8 168.3 3.99 46.60 API 5L L245/B SMLS

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.60

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

50

°C

T des = E= T=

93 1.00 1.0000

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

(Enter values if available from Design Basis or LEAVE BLANK ) kPa mm/mm/°C

Uncased Trenched Road H= 1200 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SMLS & ERW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 98,280

% SMYS 40.1%

Check OK

Limit 60.0%

Total Effective Stress (Seff )

kPa

144,187

58.9%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 18,455 23,654

% SMYS 7.5% 9.7%

Check OK OK

Limit 60% 60%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 15 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-8

DETAILED CALCULATIONS Bored Diameter

Bd =

168.3

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

144,789.90 245.00 1.0000

kPa Mpa

98,280 147,000

kPa kPa

1680.00 1.070 0.831 4776.74

(from Fig. 3, for tw/D=0.024 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x T x SMYS SHi (Barlow) = F x E x T x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.024

MPa

H/B d =

7.13

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=7.1 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 12.630 1.450 23,654

(from Fig. 7, for H = 1200 mm)

K Lh = G Lh = ΔSLh =

9.400 1.520 18,455

(from Fig. 16, for tw/D=0.024 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.024 & Er=69 MPa) (from Fig. 15, for D = 168.3 & H =1200 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 168.3 & H =1200 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

95,950

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

124,381

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

-31,250

kPa

S3= -p = -MAOP or -MOP

S3 =

-4,660

kPa

Seff =

144,187

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

49,642

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

86,874

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 16 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-9

Road Crossing Calculations for 20" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 660 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 3,508

% SMYS 1.4%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

67,710

27.6%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 20,431 52,471

% SMYS 8.3% 21.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 17 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-9

DETAILED CALCULATIONS Bored Diameter

Bd =

660

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

3,508 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

3420.00 0.525 0.831 18710.44

MPa

Soil Type = t w /D =

B 0.014

MPa

H/B d =

1.67

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.015 & E'=6.9 MPa) (from Fig. 4, for H/Bd=1.7 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 14.670 1.800 52,471

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

10.180 1.010 20,431

(from Fig. 16, for tw/D=0.014 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.014 & Er=69 MPa) (from Fig. 15, for D = 660 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 660 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

3,457

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

74,639

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

17,394

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

67,710

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 18 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-10

Road Crossing Calculations for 14" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 508 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,700

% SMYS 1.1%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

42,066

17.2%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 21,071 32,643

% SMYS 8.6% 13.3%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 19 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-10

DETAILED CALCULATIONS Bored Diameter

Bd =

508

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,700 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

2400.00 0.640 0.831 12319.97

MPa

Soil Type = t w /D =

B 0.019

MPa

H/B d =

2.17

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.019 & E'=6.9 MPa) (from Fig. 4, for H/Bd=2.2 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 14.410 1.140 32,643

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

9.910 1.070 21,071

(from Fig. 16, for tw/D=0.019 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.019 & Er=69 MPa) (from Fig. 15, for D = 508 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 508 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,649

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

47,612

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

15,874

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

42,066

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 20 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-11

Road Crossing Calculations for 12" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 457 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,429

% SMYS 1.0%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

30,305

12.4%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 13,838 20,736

% SMYS 5.6% 8.5%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 21 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-11

DETAILED CALCULATIONS Bored Diameter

Bd =

457

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,429 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

2100.00 0.680 0.831 10303.84

MPa

Soil Type = t w /D =

B 0.021

MPa

H/B d =

2.41

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.021 & E'=6.9 MPa) (from Fig. 4, for H/Bd=2.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 13.840 1.160 20,736

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

9.740 1.100 13,838

(from Fig. 16, for tw/D=0.021 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.021 & Er=69 MPa) (from Fig. 15, for D = 457 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 457 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,378

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

33,418

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

7,955

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

30,305

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 22 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-12

Road Crossing Calculations for 10" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 406.4 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,160

% SMYS 0.9%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

27,743

11.3%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 13,620 20,043

% SMYS 5.6% 8.2%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 23 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-12

DETAILED CALCULATIONS Bored Diameter

Bd =

406.4

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,160 176,400

kPa kPa

1800.00 0.725 0.831 8373.73

(from Fig. 3, for tw/D=0.024 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.023

MPa

H/B d =

2.71

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=2.7 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 13.040 1.190 20,043

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

9.500 1.110 13,620

(from Fig. 16, for tw/D=0.023 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.023 & Er=69 MPa) (from Fig. 15, for D = 406.4 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 406.4 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,109

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

30,526

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

7,077

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

27,743

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 24 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-13

Road Crossing Calculations for 8" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 355.6 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,890

% SMYS 0.8%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

23,445

9.6%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 13,107 18,121

% SMYS 5.3% 7.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 25 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-13

DETAILED CALCULATIONS Bored Diameter

Bd =

355.6

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

1,890 176,400

kPa kPa

1310.00 0.780 0.831 5736.97

(from Fig. 3, for tw/D=0.027 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.027

MPa

H/B d =

3.09

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.1 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 11.500 1.220 18,121

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.980 1.130 13,107

(from Fig. 16, for tw/D=0.027 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.027 & Er=69 MPa) (from Fig. 15, for D = 355.6 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 355.6 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,839

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

25,698

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

5,692

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

23,445

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 26 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-14

Road Crossing Calculations for 6" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 323.9 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,721

% SMYS 0.7%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

21,756

8.9%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 12,804 17,469

% SMYS 5.2% 7.1%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 27 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-14

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

1,721 176,400

kPa kPa

1100.00 0.820 0.831 4612.88

(from Fig. 3, for tw/D=0.03 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.029

MPa

H/B d =

3.40

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 10.820 1.250 17,469

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.620 1.150 12,804

(from Fig. 16, for tw/D=0.029 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.029 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,671

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

23,753

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

5,001

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

21,756

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 28 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-15

Road Crossing Calculations for 6" Oily Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 323.9 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,721

% SMYS 0.7%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

21,756

8.9%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 12,804 17,469

% SMYS 5.2% 7.1%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 29 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-15

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

1,721 176,400

kPa kPa

1100.00 0.820 0.831 4612.88

(from Fig. 3, for tw/D=0.03 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.029

MPa

H/B d =

3.40

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 10.820 1.250 17,469

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.620 1.150 12,804

(from Fig. 16, for tw/D=0.029 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.029 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,671

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

23,753

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

5,001

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

21,756

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 30 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-16

Road Crossing Calculations for 6" Fuel Gas Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.8 323.9 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.60

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00 1.0000

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

(Enter values if available from Design Basis or LEAVE BLANK ) kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Single Based on Table-1 of API RP 1102 No Pavement Ps = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,721

% SMYS 0.7%

Check OK

Limit 60.0%

Total Effective Stress (Seff )

kPa

21,756

8.9%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 12,804 17,469

% SMYS 5.2% 7.1%

Check OK OK

Limit 60% 60%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 31 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-16

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 0.65 82,737.08

S FL = SMYS = T=

82,737.08 245.00 1.0000

kPa Mpa

1,721 147,000

kPa kPa

1100.00 0.820 0.831 4612.88

(from Fig. 3, for tw/D=0.03 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x T x SMYS SHi (Barlow) = F x E x T x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.029

MPa

H/B d =

3.40

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Ps/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 10.820 1.250 17,469

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.620 1.150 12,804

(from Fig. 16, for tw/D=0.029 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.029 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,671

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

23,753

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

5,001

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

21,756

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

49,642

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

49,642

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 32 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-17

Rig Crossing Calculations for 20" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 660 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 3,508

% SMYS 1.4%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

73,732

30.1%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 23,153 59,463

% SMYS 9.5% 24.3%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 33 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-17

DETAILED CALCULATIONS Bored Diameter

Bd =

660

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

3,508 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

3420.00 0.525 0.831 18710.44

MPa

Soil Type = t w /D =

B 0.014

MPa

H/B d =

1.67

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.015 & E'=6.9 MPa) (from Fig. 4, for H/Bd=1.7 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 14.670 1.800 59,463

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

10.180 1.010 23,153

(from Fig. 16, for tw/D=0.014 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.014 & Er=69 MPa) (from Fig. 15, for D = 660 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 660 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

3,457

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

81,630

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

20,116

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

73,732

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 34 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-18

Rig Crossing Calculations for 14" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 508 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,700

% SMYS 1.1%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

45,667

18.6%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 23,878 36,992

% SMYS 9.7% 15.1%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 35 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-18

DETAILED CALCULATIONS Bored Diameter

Bd =

508

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,700 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

2400.00 0.640 0.831 12319.97

MPa

Soil Type = t w /D =

B 0.019

MPa

H/B d =

2.17

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.019 & E'=6.9 MPa) (from Fig. 4, for H/Bd=2.2 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 14.410 1.140 36,992

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

9.910 1.070 23,878

(from Fig. 16, for tw/D=0.019 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.019 & Er=69 MPa) (from Fig. 15, for D = 508 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 508 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,649

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

51,961

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

18,681

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

45,667

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 36 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-19

Rig Crossing Calculations for 12" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 457 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,429

% SMYS 1.0%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

42,820

17.5%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 24,126 36,152

% SMYS 9.8% 14.8%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 37 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-19

DETAILED CALCULATIONS Bored Diameter

Bd =

457

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,429 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

2100.00 0.680 0.831 10303.84

MPa

Soil Type = t w /D =

B 0.021

MPa

H/B d =

2.41

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.021 & E'=6.9 MPa) (from Fig. 4, for H/Bd=2.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 13.840 1.160 36,152

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

9.740 1.100 24,126

(from Fig. 16, for tw/D=0.021 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.021 & Er=69 MPa) (from Fig. 15, for D = 457 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 457 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,378

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

48,834

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

18,243

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

42,820

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 38 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-20

Rig Crossing Calculations for 10" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 406.4 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,160

% SMYS 0.9%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

39,804

16.2%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 23,746 34,943

% SMYS 9.7% 14.3%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 39 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-20

DETAILED CALCULATIONS Bored Diameter

Bd =

406.4

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,160 176,400

kPa kPa

1800.00 0.725 0.831 8373.73

(from Fig. 3, for tw/D=0.024 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.023

MPa

H/B d =

2.71

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=2.7 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 13.040 1.190 34,943

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

9.500 1.110 23,746

(from Fig. 16, for tw/D=0.023 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.023 & Er=69 MPa) (from Fig. 15, for D = 406.4 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 406.4 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,109

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

45,426

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

17,203

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

39,804

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 40 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-21

Rig Crossing Calculations for 8" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 355.6 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,890

% SMYS 0.8%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

34,256

14.0%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 22,851 31,594

% SMYS 9.3% 12.9%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 41 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-21

DETAILED CALCULATIONS Bored Diameter

Bd =

355.6

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

1,890 176,400

kPa kPa

1310.00 0.780 0.831 5736.97

(from Fig. 3, for tw/D=0.027 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.027

MPa

H/B d =

3.09

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.1 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 11.500 1.220 31,594

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.980 1.130 22,851

(from Fig. 16, for tw/D=0.027 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.027 & Er=69 MPa) (from Fig. 15, for D = 355.6 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 355.6 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,839

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

39,170

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

15,436

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

34,256

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 42 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-22

Rig Crossing Calculations for 6" Injection Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 323.9 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,721

% SMYS 0.7%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

32,131

13.1%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 22,323 30,456

% SMYS 9.1% 12.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 43 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-22

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

1,721 176,400

kPa kPa

1100.00 0.820 0.831 4612.88

(from Fig. 3, for tw/D=0.03 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.029

MPa

H/B d =

3.40

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 10.820 1.250 30,456

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.620 1.150 22,323

(from Fig. 16, for tw/D=0.029 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.029 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,671

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

36,740

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

14,520

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

32,131

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 44 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-23

Rig Crossing Calculations for 6" Oily Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 323.9 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,721

% SMYS 0.7%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

32,131

13.1%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 22,323 30,456

% SMYS 9.1% 12.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 45 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-23

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

1,721 176,400

kPa kPa

1100.00 0.820 0.831 4612.88

(from Fig. 3, for tw/D=0.03 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.029

MPa

H/B d =

3.40

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 10.820 1.250 30,456

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.620 1.150 22,323

(from Fig. 16, for tw/D=0.029 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.029 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,671

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

36,740

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

14,520

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

32,131

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 46 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-24

Rig Crossing Calculations for 6" Fuel Gas Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.8 323.9 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.60

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00 1.0000

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

(Enter values if available from Design Basis or LEAVE BLANK ) kPa mm/mm/°C

Cased Trenched Rig H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 550 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.403 Based on clause 4.7.2.2 of API RP1102 m

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 1,721

% SMYS 0.7%

Check OK

Limit 60.0%

Total Effective Stress (Seff )

kPa

32,131

13.1%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 22,323 30,456

% SMYS 9.1% 12.4%

Check OK OK

Limit 60% 60%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 47 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-24

DETAILED CALCULATIONS Bored Diameter

Bd =

323.9

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 1.0000

kPa Mpa

1,721 147,000

kPa kPa

1100.00 0.820 0.831 4612.88

(from Fig. 3, for tw/D=0.03 & E'=6.9 MPa)

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x T x SMYS SHi (Barlow) = F x E x T x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

MPa

Soil Type = t w /D =

B 0.029

MPa

H/B d =

3.40

B d /D =

1.00

Check :

OK

kPa

(from Fig. 4, for H/Bd=3.4 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,364.8

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 10.820 1.250 30,456

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

8.620 1.150 22,323

(from Fig. 16, for tw/D=0.029 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.029 & Er=69 MPa) (from Fig. 15, for D = 323.9 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 323.9 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

1,671

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

36,740

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

14,520

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

32,131

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

49,642

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

49,642

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 48 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-25

Road Crossing Calculations for 16" Effluent Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 559 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 2,971

% SMYS 1.2%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

44,708

18.2%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 21,073 32,827

% SMYS 8.6% 13.4%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 49 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-25

DETAILED CALCULATIONS Bored Diameter

Bd =

559

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

2,971 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

2800.00 0.600 0.831 14827.77

MPa

Soil Type = t w /D =

B 0.017

MPa

H/B d =

1.97

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.018 & E'=6.9 MPa) (from Fig. 4, for H/Bd=2 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 14.750 1.120 32,827

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

10.100 1.050 21,073

(from Fig. 16, for tw/D=0.017 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.017 & Er=69 MPa) (from Fig. 15, for D = 559 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 559 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

2,920

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

50,575

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

16,710

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

44,708

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 50 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-26

Road Crossing Calculations for 30" Treated Water Pipeline (Cased and with No Pavement) INPUT DATA Pipe and Operational Characteristics Pipeline Design Code Outside Diameter

D= tw =

Wall Thickness (minus corrosion allowance for carrier pipe)

p=

Design Internal Pressure Steel Grade Pipe Manufacture

ASME B31.4 914 9.53 1.01 API 5L L245/B SAW

mm mm barg

(If other material, fill following) Grade SMYS = MPa S FG = kPa S FL = kPa

0.72

Design Factor for Total Longitudinal Stress

F= FL =

0.90

(If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress

Fe =

0.90

Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature

T1 =

17

°C

Maximum Operating Temperature

T2 =

21

°C

T des = E= T=

21 1.00

°C

Es =

207000000.0

Design Factor

Design Temperature Longitudinal Joint Factor Temperature Derating Factor Pipe material properties Modulus of Elasticity of Steel

(Enter values if available from Design Basis or LEAVE BLANK )

Poisson Ratio

vs =

0.30

Co-efficient of Thermal Expansion

αt =

0.0000117

Installation and Site Conditions Type of Crossing Construction Method for Crossing Crossing Pipeline Cover under crossing Soil Type Description

kPa mm/mm/°C

Cased Trenched Road H= 1100 mm B = Dense to very dense sands and gravels; medium to very stiff clays and silts E' = Stiff to very stiff clays and Silts; medium dense and gravels

Description of soil (Modulus of Soil Reaction)

E r = Stiff to very stiff clays and silts;loose to medium dense sands and gravels 3 (Based on Survey Report/Design Data) γ= 19 kN/m E' = MPa (Enter values other than Appendix A or Er = LEAVE BLANK ) MPa SAW Tandem Based on Table-1 of API RP 1102 No Pavement Pt = 112 kN Based on clause 6.4 of 015-IH-1002 2 Ap = 0.093 Based on clause 4.7.2.2 of API RP1102 m .

Description of soil (Resilient Modulus of Soil) Unit Weight of Soil Modulus of Soil Reaction Resilient Modulus of Soil Type of Longitudinal Weld Axle Configuration Pavement Type Design Wheel Load Contact Area of Wheel Load

SUMMARY OF RESULTS Stress Results Variable Circumferential Stress SHi(Barlow)

Unit kPa

Value 4,858

% SMYS 2.0%

Check OK

Limit 72.0%

Total Effective Stress (Seff )

kPa

43,447

17.7%

OK

90.0%

Fatigue Results Variable Cyclic Longitudinal Stress Cyclic Circumferential Stress

Unit kPa kPa

Value 17,486 24,381

% SMYS 7.1% 10.0%

Check OK OK

Limit 72% 72%

Overall Road Crossing Stress Check

DESIGN IS SAFE

Page 51 of 52

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS ACCORDING TO API RP 1102 PROJECT: DOC NO:

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK) 14050642-100-PL-CAL-0002, APPENDIX-26

DETAILED CALCULATIONS Bored Diameter

Bd =

914

mm

Modulus of Soil Reaction (as per table A-1)

E' = Er =

6.90 69.00

R= L= S FG =

1.10 1.00 82,737.08

S FL = SMYS = T=

82,737.08 245.00 Not Applicable

kPa Mpa

4,858 176,400

kPa kPa

Resilient Modulus of Soil (as per Table A-2) Pavement Type Factor (as per Table 2) Axle Configuration Factor (as per Table 2) Fatigue Endurance Limit - Girth (as per Table 3) Fatigue Endurance Limit - Long. (as per Table 3) Specified Min. Yield Strength Temperature Derating Factor

Check Allowable Barlow Stress (as per clause 4.8.1.1) [SHi (Barlow)= pD/2tw] ≤ F x E x SMYS SHi (Barlow) = F x E x SMYS = Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1) Stiffness factor for circumferential stress from earth load K He = Be = Burial factor for earth load Ee = Excavation factor for earth load SHe = KHeBeEeγD SHe =

4410.00 0.310 0.831 19728.82

MPa

Soil Type = t w /D =

B 0.010

MPa

H/B d =

1.20

B d /D =

1.00

Check :

OK

kPa

(from Fig. 3, for tw/D=0.011 & E'=6.9 MPa) (from Fig. 4, for H/Bd=1.2 & Soil Type=B)

kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1) Applied design surface pressure,

w = Pt/Ap

w=

1,204.3

kPa

Fi = K Hh = G Hh = ΔSHh =

1.500 12.520 0.980 24,381

(from Fig. 7, for H = 1100 mm)

K Lh = G Lh = ΔSLh =

10.000 0.880 17,486

(from Fig. 16, for tw/D=0.01 & Er=69 MPa)

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4) Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1) Impact Factor Highway stiffness factor for cyclic circumferential stress Highway geometry factor for cyclic circumferential stress ΔSHh = KHhGHh RLFi w

(from Fig. 14, for tw/D=0.01 & Er=69 MPa) (from Fig. 15, for D = 914 & H =1100 mm)

kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2) Highway stiffness factor for cyclic longitudinal stress Highway geometry factor for cyclic longitudinal stress ΔSLh = KLhGLh RLFi w

(from Fig. 17, for D = 914 & H =1100 mm)

kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3) SHi= p(D-tw)/2tw

SHi =

4,807

kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2) S1 = SHe + ΔSHh + SHi

S1 =

48,917

kPa

S2 = ΔSLh - ESαT (T2 - T1 ) + vs (SHe + SHi)

S2 =

15,160

kPa

S3= -p = -MAOP or -MOP

S3 =

-101

kPa

Seff =

43,447

kPa

SMYS x Fe =

220,500

kPa

Check :

OK

Check for Fatigue Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F

SFG x F =

59,571

kPa

Check :

OK

Longitudinal Weld Fatigue As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F

SFL x F =

59,571

kPa

Check :

OK

Effective Stress, Seff (as per clause 4.8.1.3) Seff = √1/2[(S1-S2)2 + (S2-S3)2 + (S3-S1)2] Check for allowable effective stress: Seff ≤ SMYS x Fe

Page 52 of 52