Appendix 2 - Railway Crossing Calculation DN1050
Appendix 2 - Railway Crossing Calculation DN1050
Appendix 2 - Railway Crossing Calculation DN1050
Project: ABP
Calculation Title: Rail Crossing Calculation for ABP
Job No: 41-24306
Appendix 2 -
Railway Crossing Calculation
DN1050
Client: ARROW ENERGY APPENDIX 1
Project: ABP
Calculation Title: Rail Crossing Calculation for ABP Job No: 41-24306
Design Factor 0.72 0.72 is used for crossing calc as per AS2885.1-2007 Section 5.7.3 c) (i)
Installation Temperature 21 °C
Max Operating Temperature 60 °C
Min Operating Temperature -10 °C
Pipeline Options
Trenched Construction? Other
Soft to medium clays and silts with low to medium plasticities; loose
Soil Type / Description sands and gravels
Soil Unit Weight 18.9 kN/m3 Recommended value from RP1102: 18.9
Single or Double Track Crossing? Double
Pipeline Results
Cyclic Circumferential
stress S-Hr 52419 kPa
Cylic Long stress S-Lr 38097 kPa
Circumferential stress S-Hi 272538 kPa
Effective Stress Seff (T2Min) 347631 kPa
Seff (T2Max) 320599 kPa
% of Allowable / Limit
Effective stresses are within allowable limits. 99.6
Girth weld stresses are within fatigue limits. 78
Longitudinal weld stresses are within fatigue limits. 33.13
Client: ARROW ENERGY APPENDIX 1
Project: ABP
Calculation Title: Rail Crossing Calculation for ABP Job No: 41-24306
Earth Load tw
K He f ,E'
Circ stiffness factor K-he 3346 Obtained from figure 3 D
Earth Burial factor Be 0.54 Soil A Obtained from figure 4 H
Earth Excavation factor Ee 0.911 Obtained from figure 5
B e f
Bd
D Be 33398.3 kPa B d
E f
Earth Excavation factor Ee e
D
Live Load w 96.0 kPa 96KPa as per Section 4.7.2.2.1 1.45
Impact Factor Fi 1.711156667 DLA: Default calculated based on Figure 7 for railways, else use DLA (refer App W of
DR04561)
Railroad Cyclic Stresses
tw
Stiffness factor K-Hr 452.47 Obtained from figure 8 K Hh f ,Er
Geometry factor G-Hr 0.553161376 Obtained from figure 9 D
Circ Double Track factor N-Hr 1.274939429 Obtained from figure 10
Cyclic Circ stress S-Hr 52419.2 kPa
Long stiff factor K-Lr 472.22724 Obtained from figure 11
Long Geo factor G-Lr 0.380625017 Obtained from figure 12
Long Double Track factor N-Lr 1.290275333 Obtained from figure 13
Cylic Long stress S-Lr 38097.1 kPa
Internal Pressure Stress P (D tw )
S Hi
Circ stress S-Hi 272537.7551 kPa 2t w
Long fatigue endurance limit Sfl 172369 kPa Obtained from Table 3
check for S-Hr < Sfl x DF 124106 kPa Sfl x DF
Longitudinal Wel Stresses 41115.05346 kPa
Longitudinal weld stresses are within fatigue limits.
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
1. Introduction
Arrow Energy (the Principal), is proposing to develop a pipeline network in central eastern Queensland that
will deliver coal seam gas from its gas fields in the Bowen and Surat Basins to a proposed LNG facility to be
located on Curtis Island near Gladstone. The proposed network will be approximately 1,200km long and will
incorporate scraper stations and intermediate mainline valves.
A pipeline licence has been granted for the major part of the proposed pipeline from the Surat Basin,
however an environment impact assessment of the initial 100km at the start of this pipeline, to the Kogan
North Central Gas Processing Facility near Dalby in south-eastern Queensland, is required.
No part of the proposed pipeline from the Bowen Basin has yet been assessed and this preliminary
engineering is associated with the full extent of approx. 610km of pipeline length, the subject of a separate
report.
The ABP system will consist of a DN800 (32”), Class 600 buried steel pipeline.
This calculation also reflects a possible future upgrade of the ABP system to a DN1050 (42") pipe diameter.
The aim of this calculation is to determine the minimum pipeline wall thickness with respect to
penetration resistance by excavators.
The methods and equations will be used as they appear in the standard when determining the required
wall thickness for the design pressure of 10.2MPa(g). The wall thickness required to prevent full bore
rupture and limit the release rate to 10GJ/s will be a factor in the selection of pipe for high consequence
areas.
1
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
3. Assumptions
3.1 Code Related Inputs
B Factor - 1.3 for High Consequence Areas. A value of 1.3 has been
selected for conservatism over the equally credible value of 1.0
The expected gas composition used in this calculation was specified by Arrow Energy and
is in the Design Basis (08-GHD-3-02-0045). To be conservative, the rich gas composition
has been used.
2
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
4. Calculation Procedure
The calculation process requires numerous iterative steps. This calculation does not provide evidence of
the iterative steps undertaken to produce the finally selected pipe wall thickness, but does provide the
working for the selected thickness
AS 2885.1 outlines the method to evaluate the pipe's ability to resist penetration for standard excavator
sizes and bucket tooth types. The excavator sizes outlined in the standard are as follows: 5, 10, 15, 20,
25, 30, 35, 40 & 55 tonne machines. The documented bucket teeth types are ‘general purpose’, single
and twin 'tiger teeth’ and 'penetrating tooth'.
The pipe's resistance to penetration for excavator threats is calculated using Equation M3 (AS 2885.1).
The force exerted by a bucket (FBUCKET) is calculated using Equation M4. The ‘B’ factor is applied to
obtain the maximum force assuming the worst possible geometry (FMAX), which varies between 0.75 and
1.3. Refer Equation M2.
The maximum force exerted on the pipe from a bucket and excavator combination can then be
compared with the force required to penetrate the pipe, ultimately determining if the excavator's tooth
can penetrate the pipe.
The critical defect length (CDL) is the axial length of a defect that just exceeds the pipes ability to retain
a flaw, such that the defect grows causing the pipe to rupture. The critical defect length is dependent on
the pipeline parameters (diameter, grade, wall thickness) and the instantaneous operating pressure.
Calculating the critical defect length allows the type of failure mode to be determined by comparing the
critical defect length with the maximum defect length an excavator can produce (L max). If the critical
defect length is greater than the excavator defect length, then the defect will not grow and the failure
mode is LEAK. In contrast, if the critical defect length is smaller than the excavators defect length, then
the failure mode is RUPTURE. As per AS2885.1, the critical defect length must be at least 150% of the
maximum defect length for the pipe to be considered No Rupture.
The method used to calculate the critical defect length for lower toughness steels is given in Section
4.8.5 – Critical Defect Length (AS 2885.1). This approach is an iterative process. A MS Excel
spreadsheet was developed to solve the equations.
3
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
4.4.1 No Rupture
AS 2885.1 Clause 4.7.2 specifies that the pipeline shall be designed such that rupture is not a credible
failure mode for the following location classes: T1, T2, I, S (and HI areas with the potential for an
escalation in consequences). The Safety Management Study (risk assessment) will determine if the
pipeline route passes through any of the aforementioned High Consequence Areas.
Sensitive (S) locations shall be limited to 1 GJ/s, however these are not considered in this preliminary
calculation.
5. Calculation Results
5.1 Resistance to Penetration
The results of the resistance to penetration calculation, summarised and tabled below, show that the
High Consequence pipe cannot be penetrated by a 35T excavator irrespective of tooth type. The wall
thickness for pipe in High Consequence areas was set by the CDL requirements listed in Section 5.2
DN800
4
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
A 35 tonne excavator has been assumed to be the largest credible excavator size that could potentially
impact the pipeline using any of the four tooth types.
DN800
5
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
5.2.2 No Rupture
The No Rupture wall thickness for High Consequence pipe is tabulated below. Even though the pipeline
cannot be penetrated by a 35 tonne excavator, the No Rupture requirements for 150% CDL have been
applied. Consideration has not been given to Facilities and Road / Rail crossing pipe which can occur
within a High Consequence Area, however it is envisaged that wall thicknesses and subsequently CDL
would be larger.
It can be seen that the worst case is for single point contact from a general purpose or tiger tooth bucket
and it has been found that 12.5 mm thick pipe for the DN800 and 14.53 mm thick pipe for the DN1050
are required to (just) satisfy the 150% rule.
6
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
Calculations (shown in the appendix) to determine the energy discharge rate show that the hole size to
produce an energy discharge rate of 10 GJ/s, is approximately 144 mm, which is larger than the
maximum tooth diameter for a 35 tonne excavator. The equations and graphs used are valid for sales
quality natural gas at typical ambient air temperatures, discharged through an orifice under choked flow
conditions and have been taken from Appendix Y of AS2885.1. These equations are typically only used if
the hole size is less than 25% of the pipeline diameter as they become increasing conservative with
increasing percentage of hole size to diameter. As the results indicate that the hole size is less 25% of
the pipeline diameter the equations are approximately valid.
The hole size required to produce an energy dischage rate of 1 GJ/s, has been calculated to be
approximately 46 mm (shown in the appendix). The largest defect caused by a 35 tonne excavator
(equipped with twin tiger teeth) is 110 mm (refer to Table M3, Appendix M of AS 2885.1 – 2007), which
is clearly greater than the required hole size for limiting energy release rate of 46 mm in a T2 location
class zone. However the results above show that the pipeline is not penetrated for an excavator size of
up to 35 tonnes (the maximum credible threat) and as such the pipeline meets the requirements of
limiting energy release rates in a T2 location class zone.
Please note this calculation is not dependent on pipe size and is applicable to both the DN800 and
DN1050 pipe sizes.
Measurement length is defined in AS2885.1 as the radius of the 4.7 kW/m2 radiation contour for a full
bore rupture. It is calculated in accordance with Clause 4.10
The hand calculation appended uses the method of AS2885 Appendix Y to calculate a measurement
length of 900m. To be conservative, a measurement length of 1100m for the DN800 will be used in the
initial SMS workshop.
In addition, for a possible future upgrade of the ABP to DN1050 pipe size, the measurement length is
approximated to be 1250m.
6. Conclusion
The wall thicknesses summarised below meet the resistance to penetration requirements. Note that there is
some conservatism in this calculation.
DN800
Minimum Wall
Location Comments
Thickness
- No penetration
- No Rupture governs WT (for credible 35 tonne
High Consequence 12.5 mm excavator)
- Max discharge rates are acceptable
7
Client: Arrow Energy CALCULATION
Project: ABP
Calculation Title: Resistance to Penetration Job No: 41-24306
Minimum Wall
Location Comments
Thickness
- No penetration
- No Rupture governs WT (for credible 35 tonne
High Consequence 14.5 mm excavator)
- Max discharge rates are acceptable