ATTACHMENT - X

Document No. XXXXX

Uncased Track Crossing Design Calculation
36-inch Pipeline, API 5L X65 SAW
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As per API RP 1102

Input Data
Pipe Material
Pipeline design factor, D.F.

=
=

API 5L X65 SAW

0.50

pipe size, Outside Diam., D

Pipe nominal thickness, t
SMYS of linepipe material
Longitudinal joint factor, Ej

=
=
=
=

36
20.6
65300
1
0.72
1
19.6
70
65
13
2.07E+05
0.3
1.17E-05
1927
3.40E+06
6.90E+07
2000
914
112
112
144

Allow. design factor for Eff. Stress, Fa =

Corrosion allowance
Corroded wall thickness, tw
Design pressure, P
Design temperature (U/G), T2
Installation (backfill) temp., T1
Youngs modulus of steel, E
Poisson ratio,
Thermal expansion coefficient, a
Soil density, g
Modulus of soil reaction, E'
Soil resilient modulus, Er
Depth of cover, H
Bored diameter, Bd
Tandem Axle Load, Pt
Single Axle Load, Ps
Wheel contact area, A

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

in
mm
psi

914 mm

mm
barg

10197.16213

2
713801.3 kg/m

deg C
deg C
Mpa

101971.6213

2
2.111E+10 kg/m

18.9

N/m2
N/m2

3.47E+05
7.04E+06

mm
mm
kN
kN
Inch2

psig

= 23672.23
= 32650.00

KHe =
Be =
Ee =
SHe =

Check critical axle configurations (figure A-1)

Pavement type : No Pavement
Pavement
Critical Axle :
Tandem Axles

Soil Type = Loose Sand

kg/m2
2
kg/m

psi
psi

=
Hence

0.00689

2709
0.7
1.00
3340368

R = 1.1

Impact factor and applied surface pressure w

Ref. Fig 7
H =
2.00
Applied pressure (w)
= Pt /A
for Tandem Axles

kN/m3

Construction type: Trenched

Trenched
11428.57 kg
11428.57 kg
2
0.093 m

Circumferential stress due to earth load SHe

tw/D
Ref. Fig 3
=
0.021
Ref. Fig 4
H/Bd
=
2.2
Ref. Fig 5
Bd/D
=
1.00
SHe = KHe x Be x Ee x g x D
Ref. Equation 1

kg/m2

L = 1.00

163.21
OK

MPa

32.76

MPa

1.21

MPa

9.81E-06

(Refer table 2)

Fi = 1.45
2
w = 123016.1 kg/m

Cyclic circumferential stress SHh

tw/D
Ref fig 14
=
0.021
Ref fig 15
SHh = KHh x GHh x R x L x Fi x w
Ref. Equation 5

KHh =
GHh =
SHh =

13.90
0.71
18.99

MPa

Cyclic Longitudinal stress SLh

tw/D
Ref fig 16
=
0.021
Ref fig 17
SLh = KLh x GLh x R x L x Fi x w
Ref. Equation 6

KLH =
GLh =
SLh =

9.70
0.73
13.63

MPa

Circumferential Stress due to Internal Load, SHi

SHi = P(D-tw)/2tw
Ref. Equation 7

SHi = 23164.60 psi

Principal stresses S1, S2, & S3

S1(max circum stress) = SHe + SHh + SHi
Ref. Equation 9

S1 =

211.46

MPa

Ref. Equation 10,

S2 = Maximum longitudinal stress
S2 = SLh - Ea(T2-T1) + (SHe + SHi)
S2 =

-54.57

MPa

-7

MPa

Ref. Equation 11, Radial stress S3 = -P

S3 =

Allowable effective stress (SMYS x Fa)

= [0.5 {(S1-S2) + (S2-S3) + (S3-S1)2}] 0.5

Seff =
245.73 MPa
=
324.16 MPa

Ratio of Seff / Allowable

Check for Fatigue

Girth weld fatigue endurance limit (SFG)
=
Allowable SFG = SFG x D.F
=
SLh < SFG x D.F
Refer Equation 17
Ratio of Actual (SLh)/ Allowable
=
Longitudinal weld endurance limit (SFL)
Allowable SFL = SFL x D.F.
SHh < SFL x D.F.
Refer Equation 18
Ratio of Actual (SHh) / Allowable SFL

1015.26

per deg C
kg/m3

Check for Allowable stress

Sh [ D.F x Ej x SMYS
Hoop stress
Shi(Barlow) = PD/2tw
D.F x Ej x SMYS

Ref. Equation 12, Effective stress Seff

14.504

=
=
=

9.81E-06

159.71

MPa

0.758

82.74
41.37

Design OK

Result

Design OK

Result

Design OK

MPa (from table 3 of API 1102)

MPa

0.329
82.74
41.37

Result

MPa (from table 3 of API 1102)

MPa

0.459

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