IDBE-WO-YCCAL-En0002 Road and Rail Crossing Analysis Rev.0

______________________________
Banyu Urip Project

_______________________________
Road and Rail Road Crossing Analysis
IDBE-WO-YCCAL-EN0002
17 Dec. 07
ISSUED FOR CONSTRUCTION
MD
ST&ARA
PF
14 Nov. 07
ISSUED FOR APPROVAL
MD
ST&ARA
PF
17 Sept 07
ISSSUED FOR COMMENT
MD
ST&ARA
PF
Rev
Rev Date
Description
Prepared
By
Checked
By
JPK
Approved by
MCL
Reviewed
by
BANYU URIP PROJECT
Mobil Cepu Limited
Non-Technical Document Management

Procedure
IDBU-ED-BPDCC-000002
9th April 2007
Rev 0
MPI: COMPANY USE ONLY
Page 2 of 26
BANYU URIP PROJECT
ROAD AND RAIL ROAD CROSSING ANALYSIS

17 Dec. 2007
Rev 0
Page 2 of 21
REVISION MODIFICATION LOG
Revision
Section
A
B
0
All
All
All
Description
Issued for Comment

Issued for Approval
Issued for Construction
BANYU URIP PROJECT

17 Dec. 2007
Rev 0
Page 3 of 21
Table of Contents
1.0
2.0
3.0
4.0
INTRODUCTION
1.1
General
1.2
Scope of Document
1.3
Abbreviations
1.4
Units
SUMMARY, CONCLUSION AND RECOMMENDATION
2.1
Summary & Conclusion
2.2
Recommendation
DESIGN DATA
3.1
Pipeline Data
3.2
Pressure and Temperature Parameters
3.3
Installation and Site Characteristic
3.4
Design Factor, F
3.5
Weld Joint Factor, E
METHODOLOGY
4.1
General
4.2
Circumferential Stress due to Internal Pressure (SHi)
4.3
Circumferential Stress due to Earth Load (SHe)
4.4
Surface Live Loads
10
4.5
Cyclic Circumferential (SHh) and Longitudinal Stresses (SLh) due to Live Load
10
4.6
Internal Load Stress (Barlow) Check
12
4.7
Effective Stress (Seffi) Check
12
4.8
Fatigue Welds Check
13
4.9
Maximum Vehicle Load Across Buried Pipeline Maximum
14
4.10 Analysis Step
15
4.11 Assumptions
15
5.0
RESULT
16
6.0
REFERENCES
21
ATTACHMENTS
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Attachment A
UNCEASED PIPELINE ROAD CROSSING CALCULATIONS
Attachment B
UNCEASED PIPELINE RAIL ROAD CROSSING CALCULATIONS
Attachment C
MAXIMUM VEHICLE WEIGHT CALCULATIONS
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1.0
INTRODUCTION
1.1
General
Banyu Urip is an oil and gas field located in the Cepu Block in Central Java, Indonesia. The
expected peak production is 185 kbpd (165 kbpd annual average) of sour crude and associated
gas from four well pads. The field development will involve conventional onshore oil and gas
facilities (including well pads, Central Processing Facility (CPF), flowline, water disposal and gas
injection) and an export pipeline to transport processed crude oil to a Floating, Storage and Offloading (FSO) facility. The crude oil will be sweetened in CPF and sent via onshore and offshore
pipelines to a FSO vessel located 23 km off of the north coast of Java near the city of Tuban.
JP Kenny has been appointed to update the original 2001 Front End Engineering Design (FEED)
for onshore and offshore export pipelines and develop Front End Execution Plan (FEEP).
1.2
Scope of Document
This document presents the results of the road and rail road crossing analysis for the 20-inch
export pipeline. The export pipeline road and rail road crossing analysis has been assessed in
accordance with API RP 1102 [Ref. 1].
1.3
Abbreviations
API
ASME
American Society of Mechanical Engineers
CPF
Central Processing Facility
ERW
Electric Resistance Welded
FEED
Front End Engineering Design
FEEP
Front End Execution Plan
FSO
Floating, Storage and Off-loading
OD
Outside Diameter
SAW
Submerged Arc Welded
SI
International System of Units
SMYS
WT
1.4
American Petroleum Institute
Specified Minimum Yield Strength

Wall Thickness
Units
Unless otherwise noted, the international system of units (SI) will be used.
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2.0
SUMMARY, CONCLUSION AND RECOMMENDATION
2.1
Summary & Conclusion

The analysis is performed for road crossing and railroad crossing without a casing pipe.
The circumferential stress due to earth load and internal pressure, cyclic circumferential and
longitudinal stresses due to live load and weld fatigue are checked against the requirements of API
RP 1102 [Ref. 1].
The analysis considered minimum pipe burial depth of 1.5m for a road crossing and railroad
crossing. Where the burial depth is not sufficient a deeper burial was analyzed.
The onshore pipeline road and railroad crossing analysis have been performed for the following
conditions:
Installation un-corroded pipeline;
Hydrotest un-corroded pipeline at hydrotest pressure, and
Operation corroded pipeline at mechanical design pressure and temperature.
Based on API RP 1102 methodology, burial depth of minimum 1.5 m is sufficient for road crossing
with wall thickness (WT) 9.53mm, but not sufficient for a single track railroad crossing. To meet
code requirements there are two possibilities:
A burial depth of 2m is required with wall thickness 12.7mm, even when the operating pressure
is reduced to 6.89 MPa (1000 psi)
A burial depth of 2m is required with wall thickness 9.53mm under un-corroded condition and
girth weld is located more than 1.5m from the centreline of the railroad track.
The detailed result is presented in Section 5.
2.2
Recommendation
The following minimum burial depths and crossing pipe wall thickness are recommended:
1.5m for road crossing with 9.53mm WT.
2.0m for railroad crossing with 12.7mm WT
The maximum load allowed to cross buried pipeline are:

Table 2.1 Maximum Load on Pipe Tandem Axle
Wall
Thickness
Pressure
Depth of
Cover
Max Load
Pressure
Max Wheel
Load
Max Axle Load

(Tandem)
Max Vehicle
Weight
(MPa)
(mm)
(m)
(kPa)
(tonnes)
(tonnes)
(tonnes)
9.53 (corroded)
9.31
1.2
806
7.6
30.6
38.2
9.53 (corroded)
6.89
1.2
1432
13.6
54.3
67.9
However, it is not advisable to cross the buried line without surface protector, such as concrete slab
or steel plate, since the soil condition may not be capable to withstand the concentrated wheel load
imposed.
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3.0
DESIGN DATA
3.1
Pipeline Data
Table 3.1 Pipeline Parameters
Parameter
Value
Unit
Reference
20
in
[4]
mm
[5]
Pipeline OD
Wall thickness
9.53
12.7
Steel Material
API 5L X60
[3]
Type
SAW/ERW
414
MPa
[3]
MPa
[4]
SMYS
Young Modulus of steel
2.07 x 10
Poisson Ratio
0.3
[4]
Thermal Heat
Coefficient
1.17 x 10-5
/oC
[3]
1.6
mm
[4]
Corrosion Allowance
3.2
Pressure and Temperature Parameters

The design pressure and temperature parameters used in this analysis are presented in Table 3.2.
Table 3.2 Pressure and Temperature Parameters
Phase
Installation Case
Parameter use
Value use
Reference
Pressure
0 MPa
[4]
Temperature
Wall Thickness
Hydrotest
[4]
Pressure
11.64 MPa(1688 psig)
[4]
Temperature
28.4oC
[4]
(Corroded/non
corroded)
Mechanical Design Pressure
9.53mm
[4]
12.7mm
Wall Thickness
Operational
28.4 C
9.53mm
12.7mm
[4]
9.31 MPa (1350 psig)
[4]
Mechanical Design
Temperature
Wall Thickness
88 C
9.53mm
[4]
12.7mm
[4]
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3.3
Installation and Site Characteristic

The installation and site characteristics are presented in Table 3.3.
Table 3.3 Installation and Site Characteristic
Parameter
Value
Road Crossing burial depth to the

top of pipe
1.5(1)
Railroad Crossing burial depth to

the top of pipe
1.5(2)
Installation method
Unit
Reference
[4]
[4]
[1]
[4]
Open trenched for road crossing

Bored for railroad crossing
o
Installation Temperature
28.4
Soil Unit Weight ( )(3)
18.9
kN/m3
[1]
Modulus Soil Reaction ( E ' )(4) (5)
1.4
MPa
[1]
Resilient modulus of soil ( E r )(4) (5)
34
MPa
[1]
no pavement, flexible pavement, and

rigid pavement
[1]
Tandem Axle Loading (road

loading)(4)
479
kPa
[1]
Rail road loading(3)
96
kPa
[1]
Rail road condition
Single Track
Pavement Type
Notes:
1. Minimum burial depth in accordance with Government Regulation of Republic of Indonesia Number 34 of 2006.
2. Minimum burial depth in accordance with Government Regulation, Decree of Minister of Transportation Number: KM
53 of 2000.
3. Recommended by Ref.1.
4. An analysis of soil based on USCS (Unified Soil Classification System) [Ref.6&7] from Geotechnical report [Ref.8]
found that soft to medium clays and silts with high plasticity are exist in a number of boreholes. As it is the
conservative value, it will be used for the analysis.
5. Specific analysis to borehole 11 (BH PL-11) located in railroad crossing showing that the soil is soft with high
plasticity. Therefore this value will be used for rail road crossing analysis.
3.4
Design Factor, F
Design factor (F) for installation and operation is 0.72, refer to ASME B31.4 Par. 402.3.1(a) [Ref.2].
Design factor (F) for hydrotest is 0.9, refer to ASME B31.4 Par. 437.4.1(a). Design factor (Fc) for
effective stress is 0.9, refer to ASME B31.4 Par. 402.3.2(e) [Ref.2]
3.5
Weld Joint Factor, E

The weld joint factor (E) for submerged arc welded and electric resistance welded pipe is 1.0, refer
to ASME B31.4 Table 402.4.3 [Ref.2]
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4.0
METHODOLOGY
4.1
General
To ensure safe operation of the pipeline, the circumferential and longitudinal stresses affecting the
uncased pipeline due to earth load, road (highway) live load, rail road load, circumferential due to
internal pressure, girth weld fatigue and longitudinal welds fatigue need to be checked
comprehensively in accordance with API RP 1102 [Ref. 1].
4.2
Circumferential Stress due to Internal Pressure (SHi)

Determine the circumferential stress due to internal pressure and check against the maximum
allowable value.
S
Hi
p. D t
2t
where:
=
circumferential stress due to internal pressure, MPa
internal pipe pressure which is taken as equal to design pressure, MPa
pipe wall thickness, mm
4.3
Hi
Circumferential Stress due to Earth Load (SHe)

Calculate the circumferential load due to earth load.
S
He
He
.B .E . .D
e e
where:
SHe
circumferential stress due to earth load, kPa
stiffness factor for circumferential stress due to earth load (Fig. 3 of

Ref. [1])
burial factor for circumferential stress due to earth load (Fig. 4 of Ref.
[1])
excavation factor for circumferential stress due to earth load (Fig. 5

of Ref. [1])
unit weight of soil, kN/m3
Pipe outside diameter of pipe, m
KHe
Be
Ee
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4.4
Surface Live Loads

Vehicular load (w), applied at the surface of the crossing. Based on API RP1102 it is recommended
for external vehicle load is Ps = 53.4 kN (single axle) and Pt = 44.5 kN (tandem axle). For rail load
is recommended that Cooper E-80 loading of w = 356kN be used.
The applied design surface pressure (w) determined as follows:
P
Ap
where:
P = either the design single wheel load (Ps) or the desing tandem wheel load (Pt) (kN)
Ap = the contact area over which the well load is applied. Ap is taken as 0.093 m2
There for, the applied design surface pressure are as follows:
Single axle loading: w = 574 kPa. (Ref.[1])
Tandem axle loading: w = 479 kPa. (Ref.[1])
4.5
Cyclic Circumferential (SHh) and Longitudinal Stresses (SLh) due to Live Load
Calculate the cyclic circumferential and cyclic longitudinal stresses due to live load based on
appropriate impact factor. For highway road crossing are:
S
S
Hh
Lh
Hh
Lh
.G
.G
Hh
Lh
.R.L.F .w
i
.R.L.F .w
i
where:
S
cyclic circumferential stress from road highway vehicular load, MPa
K
K Hh
Lh
=
=
G
G Hh
Lh
=
=
R.Lh
=
=
stiffness
stress
form
highway
vehicular
(Fig.
14
stiffness factor
factor for
for cyclic
cyclic circumferential
longitudinal stress
from
highway
vehicular
loadload
(Fig.
16 of
of
Ref.
[1])
Ref. [1])
geometry
stress
form
highway
vehicular
(Fig.
15
geometry factor
factor for
for cyclic
cyclic circumferential
longitudinal stress
from
highway
vehicular
loadload
(Fig.
17 of
of
Ref.
[1])
Ref. [1])
cyclic
longitudinal
from highway
highway
pavementstress
type factor
(Table 2 vehicular
of Re. [1])load, MPa
highway axle configuration factor (Table 2 of Ref. [1])
F
i
impact factor (Fig. 7 of Ref. [1])
applied design surface pressure, MPa
Hh
For rail road crossing are:

S
Hr
Lr
Where:
Hr
Lr
.G
.G
Hr
Lr
.N
.N
. F .w
i
.F .w
i
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S
Hr
cyclic circumferential stress from railroad load, MPa
Hr
railroad stiffness factor for cyclic circumferential stress (Fig. 8 of Ref. [1])
Hr
railroad geometry factor for cyclic circumferential stress (Fig. 9 of Ref. [1])
Railroad single or double track factor for cyclic circumferential stress
1 for single track
Cyclic longitudinal stress due to rail road, MPa
Lr
Railroad stiffness factor for cyclic longitudinal stress (Fig. 11 of Ref. [1])
Lr
Railroad geometry factor for cyclic longitudinal stress (Fig. 12 of Ref. [1])
Railroad single or double track factor for cyclic longitudinal stress
1 for single track
F
i
impact factor (Fig. 7 of Ref. [1])
applied design surface pressure, MPa
G
N
S
K
G
4.6
Lr
Internal Load Stress (Barlow) Check

S Hi F E SMYS
Where:
=
circumferential stress due to internal pressure, MPa
Design Factor refer to ASME B31.4 Par. 402.3.1(a) [Ref. 2]
Longitudinal Joint Factor
4.7
Hi
SMYS = Specified Minimum Yield Strength

Effective Stress (Seffi) Check
S
eff
0.5
S1 S 2 2 S 2 S 3 2 S 3 S1 2
SMYS.F
C
S1 S He S H S Hi
S 2 S L E S T (T2 T1 ) s ( S He S Hi )
S3 p
Where:
S
eff
S ,S ,S
1 2
3
total effective stress, MPa
principal stresses in pipe, MPa
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4.8
S1
maximum circumferential stress
S2
maximum longitudinal stress
S3
maximum radial stress
F
C
effective stress design factor = 0.9 [Ref. 2]
SMYS
Specified Minimum Yield Strength, MPa
Fatigue Welds Check

For road crossing fatigue check analysis based on API RP 1102 are:
S
Hh
Lh
FL
FG
.F
.F
where:
S
S
Hh
FL
S
S
Lh
FG
cyclic circumferential stress from road highway vehicular load, MPa
fatigue endurance limit of longitudinal weld (Table 3 of Ref. [1]) = 12,000 psi
(API 5L X60)
cyclic longitudinal stress from highway vehicular load, MPa
fatigue endurance limit of girth weld (Table 3 of Ref. [1]) = 12,000 psi (API 5L
X60)
Design Factor
For railroad crossing fatigue check analysis based on API RP 1102 are:
S
N
Hr S
S
N
Lr S
FL
FG
.F
.F
Where:
S
N
Hr
FL
cyclic circumferential stress from railroad load, MPa
Railroad single or double track factor for cyclic circumferential stress
1 for single track
fatigue endurance limit of longitudinal weld (Table 3 of Ref. [1]) = 12,000 psi
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(API 5L X60)
S
N
Lr
FG
F
4.9
cyclic longitudinal stress railroad load, MPa
Railroad single or double track factor for cyclic longitudinal stress
1 for single track
fatigue endurance limit of girth weld (Table 3 of Ref. [1]) = 12,000 psi (API 5L
X60)
Design Factor
Maximum Vehicle Load Across Buried Pipeline Maximum

To determine the maximum applied design surface pressure for external vehicle load that can cross
the buried pipeline based on API RP 1102 are:
Ps
single axle load

tandem axle load
Pt
2
4
or
where:
Ps = single axle wheel load.
Pt = Tandem axle wheel load.
Assuming distribution ratio 4:1 for rear axle and front axle, the weight of vehicle is:
Wvehicle P 1 P 4
Wvehicle 5 P
The maximum load will be checked against the bearing capacity of the soil backfill.
The formula to calculate the soil bearing capacity is based on Meyerhof formula.
_
Vertical Load: q ult cN c s c d c q N q s q d q 0.5B ' N s d

_
Inclined Load: q ult cN c d c ic q N q d q i q 0.5B ' N d i
tan
tan 2 45
Where: N q e
N c N q 1 cot
N N q 1 tan 1.4
s c 1 0 .2 K p
B
for any
L
s q s 1 0.1K p
B
for >100
L
s q s 1 for otherwise.
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d c 1 0.2 K p
D
for any
B
d q d 1 0.1 K p
D
for >100
B
d q d 1 for otherwise.
0
ic iq 1 0 for any
90
0
i 1 0 for >00
90
i 0 otherwise
K p tan 2 45
2
4.10
Analysis Step
Step for crossing analysis are:
1. Verify API RP 1102 requirements for depth of cover regulated by the authorities.
2. If verification fail, whether burial depth will be deepened or wall thickness will be increased or
both, until it is acceptable by the code.
3. In addition to item 2, additional load cases performed by reducing design pressure to Maximum
Operating Pressure.
4.11
Assumptions
The assumptions made during the onshore pipeline road crossing (Table 3.3) analysis are:
The angle of intersection between the pipeline crossing and the highway (road) to be crossed
is assumed 90o.
The soil is soft to medium clays and silt with high plasticy.
Overall coating of pipe is not considered for conservatism and simplicity
Longitudinal stress reduction factor for fatigue is 1 for conservatism.
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5.0
RESULT
The results from the onshore pipeline road crossing analysis are presented in Table 5 .4, Table 5.2,
Table 5.3, Table 5.4, and Table 5.5 below.
Table 5.4 Detail Result of 20 inch (9.53 mm WT) Onshore Pipeline Road Crossing Analysis
for SAW and ERW pipe
Case
Hi
Phase
(MPa)
Unity
Check
Barlow
Check
eff
(MPa)
Unity
Check
Fatigue Check
eff
Check
Lh
Unity
Check
(MPa)
No
Pavement
Flexible
Pavement
Rigid
Pavement
Girth
Welds
Unity
Check
Unity
Check
(MPa)
ERW
SAW
Hh
Lon
W
Installation
PASS
31.05
0.08
PASS
11.22
0.19
PASS
15.77
0.14
0.26
PA
Hydrotest
304.42
0.82
PASS
309.82
0.83
PASS
11.22
0.15
PASS
15.77
0.11
0.21
PA
Operational
293.55
0.98
PASS
365.54
0.98
PASS
11.85
0.20
PASS
17.43
0.15
0.29
PA
Installation
PASS
29.82
0.08
PASS
10.20
0.17
PASS
14.33
0.13
0.24
PA
Hydrotest
304.42
0.82
PASS
308.65
0.83
PASS
10.20
0.14
PASS
14.33
0.1
0.19
PA
Operational
293.55
0.98
PASS
364.56
0.98
PASS
10.78
0.18
PASS
15.84
0.14
0.27
PA
Installation
PASS
28.59
0.07
PASS
9.18
0.15
PASS
12.90
0.11
0.22
PA
Hydrotest
304.42
0.82
PASS
307.48
0.82
PASS
9.18
0.12
PASS
12.90
0.09
0.17
PA
Operational
293.55
0.98
PASS
363.57
0.98
PASS
9.7
0.16
PASS
14.26
0.12
0.24
PA
API RP 1102 criteria are passed for road crossing with 1.5m burial depth.
The detailed calculations are presented in Attachment A.
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Case
Hi
Phase
(MPa)
Unity
Check
Barlow
Check
Fatigue Check
eff
(MPa)
Unity
Check
eff
Check
Lr
(MPa)
Unity
Check
Girth
Welds
Unity
Check
Unity
Check
(MPa)
ERW
SAW
Hr
Long
We
Depth Cover 1.5m
Railroad
Crossing
Single
Track
Installation
PASS
84.25
0.23
PASS
69.55
1.17
FAIL
67.28
0.59
1.13
FA
Hydrotest
304.42
0.817
PASS
352.74
0.95
PASS
69.55
0.93
PASS
67.28
0.47
0.90
PA
293.55
0.985
PASS
389.60
1.05
FAIL
81.65
1.37
FAIL
71.06
0.62
1.19
FA
243.48
0.817
PASS
336.12
0.90
PASS
69.55
1.17
FAIL
67.28
0.59
1.13
FA
Operational
(Corroded)
Operational
(UnCorroded)
Depth Cover 1.8m
Railroad
Crossing
Single
Track
Installation
PASS
81.12
0.22
PASS
64.56
1.08
FAIL
62.46
0.55
1.05
FA
Hydrotest
304.42
0.817
PASS
350.78
0.94
PASS
64.56
0.87
PASS
62.46
0.44
0.84
PA
293.55
0.985
PASS
390.13
1.05
FAIL
75.79
1.27
FAIL
65.96
0.58
1.11
243.48
0.817
PASS
335.62
0.90
PASS
64.56
1.08
FAIL
62.46
0.55
1.05
FA
Operational
(Corroded)
Operational
(UnCorroded)
FA
Depth Cover 2.0m
Railroad
Crossing
Single
Track
Installation
PASS
76.74
0.21
PASS
60.06
1.01
FAIL
57.37
0.50
0.96
PA
Hydrotest
304.42
0.817
PASS
347.05
0.93
PASS
60.06
0.81
PASS
57.37
0.4
0.77
PA
293.55
0.985
PASS
387.82
1.04
FAIL
70.5
1.18
FAIL
60.60
0.53
1.02
FA
243.48
0.817
PASS
333.20
0.89
PASS
60.06
1.01
FAIL
57.37
0.50
0.96
PA
Operational
(Corroded)
Operational
(UnCorroded)
Table 5.2 Detail Result of 20 inch (9.53mm WT) Onshore Pipeline Railroad Crossing
Analysis for SAW and ERW Pipe
Analysis for SAW and ERW Pipe
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Case
Hi
Phase
(MPa)
Unity
Check
Barlow
Check
Fatigue Check
eff
Unity
Check
eff
Check
(MPa)
Lr
Unity
Check
(MPa)
Girth
Welds
Hr
(MPa)
Unity
Check
Unity
Check
ERW
SAW
We
Long
Depth Cover 1.5m
Railroad
Crossing
Single
Track
Installation
PASS
69.74
0.19
PASS
65.02
1.09
FAIL
57.46
0.50
0.97
PA
Hydrotest
226.98
0.609
PASS
267.78
0.72
PASS
65.02
0.87
PASS
57.46
0.40
0.77
PA
208.38
0.699
PASS
297.60
0.80
PASS
68.04
1.14
FAIL
61.99
0.54
1.04
FA
181.54
0.609
PASS
267.38
0.72
PASS
65.02
1.09
FAIL
57.46
0.50
0.96
PA
Operational
(Corroded)
Operational
(UnCorroded)
Depth Cover 1.8m
Railroad
Crossing
Single
Track
Installation
PASS
66.23
0.18
PASS
60.35
1.01
FAIL
53.33
0.47
0.90
PA
Hydrotest
226.98
0.609
PASS
265.42
0.71
PASS
60.35
0.81
PASS
53.33
0.37
0.72
PA
208.38
0.699
PASS
297.17
0.80
PASS
63.16
1.06
FAIL
57.54
0.50
0.97
PA
181.54
0.609
PASS
266.86
0.72
PASS
60.35
1.01
FAIL
53.33
0.47
0.89
PA
Operational
(Corroded)
Operational
(UnCorroded)
Depth Cover 2.0m
Railroad
Crossing
Single
Track
Installation
PASS
62.17
0.17
PASS
56.14
0.94
PASS
48.99
0.43
0.82
PA
Hydrotest
226.98
0.609
PASS
262.03
0.70
PASS
56.14
0.75
PASS
48.99
0.34
0.66
PA
208.38
0.699
PASS
295.14
0.79
PASS
58.75
0.99
PASS
52.86
0.46
0.89
PA
181.54
0.609
PASS
265.12
0.71
PASS
56.14
0.94
PASS
48.99
0.43
0.82
PA
Operational
(Corroded)
Operational
(UnCorroded)
The detailed calculations are presented in Attachment B.
Table 5.4 Detail Result of 20 inch Onshore Pipeline Railroad Crossing Analysis for
SAW and ERW Pipe (Pressure = 6.89 MPa (1000 psi))
Case (Operational
Condition)
Hi
Unity
Check
Barlow
Check
eff
Unity
Check
Fatigue Check
eff
BANYU URIP PROJECT
17 Dec. 2007
Rev 0
Page 18 of 21
(MPa)
(MPa)
Check
Lr
(MPa)
Unity
Check
Girth
Welds
Unity
Check
Unity
Check
(MPa)
ERW
SAW
Hr
Long
We
Depth Cover 1.5m

9.53mm WT Corroded
217.40
0.729
PASS
322.15
0.87
PASS
81.65
1.37
FAIL
71.06
0.62
1.19
FA
9.53mm WT Uncorroded
180.32
0.605
PASS
281.05
0.75
PASS
69.55
1.17
FAIL
67.28
0.59
1.13
FA
12.7mm WT Corroded
154.33
0.518
PASS
250.90
0.67
PASS
68.04
1.14
FAIL
61.99
0.54
1.04
FA
134.45
0.451
PASS
227.27
0.61
PASS
65.02
1.09
FAIL
57.46
0.50
0.96
PA
Depth Cover 1.8m

9.53mm WT Corroded
217.40
0.729
PASS
322.88
0.87
PASS
75.79
1.27
FAIL
65.97
0.58
1.11
FA
180.32
0.605
PASS
280.78
0.75
PASS
64.56
1.08
FAIL
62.46
0.55
1.05
FA
12.7mm WT Corroded
154.33
0.518
PASS
250.72
0.67
PASS
63.16
1.06
FAIL
57.54
0.50
0.97
PA
134.45
0.451
PASS
227.02
0.61
PASS
60.35
1.01
FAIL
53.33
0.47
0.89
PA
FAIL
60.60
0.53
1.02
FA
Depth Cover 2.0m

9.53mm WT Corroded
217.40
0.729
PASS
320.78
0.86
PASS
70.50
1.18
180.32
0.605
PASS
278.60
0.75
PASS
60.06
1.01
FAIL
57.37
0.50
0.96
PA
12.7mm WT Corroded
154.33
0.518
PASS
248.95
0.67
PASS
58.75
0.99
PASS
52.86
0.46
0.89
PA
134.45
0.451
PASS
225.55
0.60
PASS
56.14
0.94
PASS
48.99
0.43
0.82
PA
Case
Hi
Phase
(MPa)
Unity
Check
Barlow
Check
Fatigue Check
eff
(MPa)
Unity
Check
eff
Check
Unity
Check
Unity
Check
(MPa)
ERW
SAW
PASS
67.28
0.59
1.13
FA
0.63
PASS
62.46
0.55
1.05
FA
0.61
PASS
57.37
0.50
0.96
PA
Unity
Check
Girth
Welds
69.55
0.62
64.56
60.06
Lr
(MPa)
Hr
Long
We
Depth Cover 1.5m

Railroad
Crossing
Single
Track
Operational
(UnCorroded)
243.48
0.817
PASS
336.12
0.90
PASS
Depth Cover 1.8m

Railroad
Crossing
Single
Track
Operational
(UnCorroded)
243.48
0.817
PASS
335.62
0.90
PASS
Depth Cover 2.0m

Railroad
Crossing
Single
Track
Operational
(UnCorroded)
243.48
0.817
PASS
333.20
0.89
PASS
Analysis for SAW and ERW Pipe with Reduction Factor
Pipe with wall thickness 12.7mm are complying with API RP 1102 and ASME B 31.4 requirement
for rail road crossing at the minimum burial depth of 2m under pressure 9.31 MPa and 88degC.
These conditions satisfy for both corroded and un-corroded condition.
BANYU URIP PROJECT
17 Dec. 2007
Rev 0
Page 19 of 21
Pipe with wall thickness 9.53mmm are not met API RP 1102 and ASME B 31.4 requirement for rail
road crossing to the depth of 2m under pressure 9.31 MPa and temperature 88degC. Reducing
pressure to 6.89 MPa(1000psi), it still fail in fatigue check.
By locating girth weld at least 1.5m from centreline of rail track, the longitudinal fatigue check are
passed API RP 1102 and ASME B 31.4 requirement for pressure 9.31 MPa, un-corroded at
minimum 2m burial depth.
Table 5.6 Maximum Load on Pipe Tandem Axle
Wall
Thickness
(mm)
9.53
corroded
9.53
corroded
Depth of
Cover
Max Load
Pressure
Max Wheel
Load
Max Axle Load

(Tandem)
Max Vehicle
Weight
(m)
(kPa)
(tonnes)
(tonnes)
(tonnes)
9.31
1.2
806
7.6
30.6
38.2
6.89
1.2
1432
13.6
54.3
67.9
Pressure
(MPa)
Corroded pipe with 9.53 mm and 1.2m burial depth is capable to withstand external load pressure
up to 1432 kPa (Operating pressure 6.89 MPa) and 806 kPa (operating pressure 9.31 MPa).
However an analysis of soil bearing capacity suggested that the maximum external load is 37 kPa
which allowed wheel load 0.3 ton (tandem axle load 1.4 ton, vehicle load 1.7 ton). Therefore soil
surface protection such as concrete slab or steel plate shall be provided above buried pipe for
vehicle to cross buried line.
BANYU URIP PROJECT

17 Dec. 2007
Rev 0
Page 20 of 21
6.0
REFERENCES
1.
API,RP1102 Steel Pipelines Crossing Railroads and Highways, Sixth Edition, April 1993.
2.
ASME, B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids, 2006.
3.
API, 5L Specification for Line Pipe, 43rd Edition, March 2004.
4.
Pipeline Design Basis Doc. No. IDBE-WO-YBDES-000001.
5.
Decree of Minister of Transportation Number: KM 53 of 2000, Crossing And/Or Approaching

Railways and Other Constructions.
6.
ASTM,D2487-06 Standard Practice for Classification of Soils for Engineering Purposes

(Unified Soil Classification System)
7.
NAVFAC,Appendix B-The Unified Soil Classification System,FM 5-472/NAVFAC MO

330/AFJMAN 32-1221(I)
8.
ITSKemitraan,Final Report on MCL-Onshore Pipeline Surveys Banyu Urip-Palang

Geotechnical Investigation, Doc. No. IDBE-IT-YBSIT-EN0004 Rev.A
BANYU URIP PROJECT

17 Dec. 2007
Rev 0
ATTACHMENT A
UNCASED ONSHORE PIPELINE ROAD CROSSING CALCULATIONS
BANYU URIP PROJECT

17 Dec. 2007
Rev 0
ATTACHMENT B
UNCASED ONSHORE PIPELINE RAILROAD CROSSING CALCULATIONS
BANYU URIP PROJECT
17 Dec. 2007
Rev 0
ATTACHMENT C
MAXIMUM VEHICLE WEIGHT CALCULATIONS
BANYU URIP PROJECT
17 Dec. 2007
Rev 0
Document Checklist
Project:
Banyu Urip Project
Job No:
140099.01
Document Title:
Road and Rail Road Crossing Analysis
Document Number:
Date:
17 Dec. 2007
Issue / Revision:
Rev. 0
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Banyu Urip Project

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BANYU URIP PROJECT

Mobil Cepu Limited

Non-Technical Document Management

MPI: COMPANY USE ONLY

BANYU URIP PROJECT

ROAD AND RAIL ROAD CROSSING ANALYSIS

REVISION MODIFICATION LOG

Issued for Comment

BANYU URIP PROJECT

ROAD AND RAIL ROAD CROSSING ANALYSIS

SUMMARY, CONCLUSION AND RECOMMENDATION

Summary & Conclusion

Pressure and Temperature Parameters

Installation and Site Characteristic

Weld Joint Factor, E

Circumferential Stress due to Internal Pressure (SHi)

Circumferential Stress due to Earth Load (SHe)

Surface Live Loads

Internal Load Stress (Barlow) Check

Effective Stress (Seffi) Check

Fatigue Welds Check

Maximum Vehicle Load Across Buried Pipeline Maximum

4.10 Analysis Step

BANYU URIP PROJECT

ROAD AND RAIL ROAD CROSSING ANALYSIS

MPI: COMPANY USE ONLY

UNCEASED PIPELINE ROAD CROSSING CALCULATIONS

UNCEASED PIPELINE RAIL ROAD CROSSING CALCULATIONS

MAXIMUM VEHICLE WEIGHT CALCULATIONS

ROAD AND RAIL ROAD CROSSING ANALYSIS

BANYU URIP PROJECT

MPI: COMPANY USE ONLY

American Society of Mechanical Engineers

Central Processing Facility

Electric Resistance Welded

Front End Engineering Design

Front End Execution Plan

Floating, Storage and Off-loading

Submerged Arc Welded

International System of Units

American Petroleum Institute

Specified Minimum Yield Strength

ROAD AND RAIL ROAD CROSSING ANALYSIS

BANYU URIP PROJECT

MPI: COMPANY USE ONLY

SUMMARY, CONCLUSION AND RECOMMENDATION

Summary & Conclusion

Installation un-corroded pipeline;

Hydrotest un-corroded pipeline at hydrotest pressure, and

Operation corroded pipeline at mechanical design pressure and temperature.

The detailed result is presented in Section 5.

1.5m for road crossing with 9.53mm WT.

2.0m for railroad crossing with 12.7mm WT

The maximum load allowed to cross buried pipeline are:

Max Axle Load

ROAD AND RAIL ROAD CROSSING ANALYSIS

BANYU URIP PROJECT

MPI: COMPANY USE ONLY

Pressure and Temperature Parameters