RAILWAY CROSSING DESIGN REPORT - Casing Pipe 24" & 6"

Document No: A357-0000-PL-DO-CAL-R-0003 Rev : C

S.No. INPUT DATA Symbols Units 24" - 9.6 mm 6" - 6.4 mm Formulae / Reference

1 Line pipe material IS3589 FE410 API 5L Gr.B IS 3589

2 Type of crossing CASED CASED

3 Nominal diameter of pipe D mm 609.6 168.3

4 Wall thickness of pipe tw mm 9.6 6.4

5 Unit weight of soil γ kN/m 3

18.9 18.9

6 Soil type A A

7 Young’s modulus of elasticity Es MPa 2.07E+05 2.07E+05

8 Coefficient of thermal expansion αT per 0C 1.75E-05 1.75E-05

9 Poisson's ratio of steel νs 0.3 0.3

0
10 Installation Temperature T1 C 21 21

T2 0
11 Max. operating temperature C 30 30

2
12 Max operating pressure p N/mm 0 0

13 Depth of burial H mm 1700 1700

14 Bored diameter Bd mm 660.4 219.1

15 Specified minimum yield strength SMYS N/mm2 235 245 IS 3589 (Table 4)

16 Design factor F 0.4 0.4

17 Design factor for equivalent stress F' 0.9 0.9

STRESSES DUE TO EXTERNAL LOAD

STRESSES DUE TO EARTH LOAD , SHe (As per cl. 4.7.2.1)

1 Wall thickness to diameter ratio tw/D 0.016 0.038

2 Modulus of Soil reaction E' MPa 3.4 3.4

3 Earth load stiffness factor KHe 3800 722 Fig 3

4 Ratio of pipe depth to bored diameter H/Bd 2.57 7.76

5 Burial factor for earth load Be 0.78 1.25 Fig 4

6 Ratio of bored diameter to pipe diameter Bd/D 1.08 1.30

7 Earth load excavation factor Ee 0.96 1.40 Fig 5

kPa 32783.57 4019.03

8 Circumferential stress due to earth load SHe SHe=KHe Be Ee y D
MPa 32.78 4.02
 STRESSES DUE TO LIVE LOADS

i) CYCLIC CIRCUMFERENTIAL STRESS (RAILROADS) , ΔSHr

1 Applied design surface pressure w kPa 96 96 As per cl.4.7.2.2

2 Impact factor for Railway Fi 1.73 1.73 As per cl.4.7.2.2.2

3 Soil Resilient modulus Er MPa 69 69

4 Railroad stiffness factor for cyclic circumferential stress KHr 337.5 187.5 Fig 8

5 Railroad geometry factor for cyclic circumferential stress GHr 0.79 1.09 Fig 9

6 Railroad track factor NH 1.17 1.08 Fig 10

kPa 51437.51 36594.4

7 Cyclic circumferential stress ΔSHr ΔSHr = KHr GHr NH Fi w
MPa 51.44 36.59

ii) CYCLIC LONGITUDINAL STRESS (RAILROADS) , ΔSLr

1 External Railway load applied at the surface of crossing w kPa 96 96 As per cl.4.7.2.2

2 Impact factor for Railway Fi 1.73 1.73 As per cl.4.7.2.2.2

3 Soil Resilient modulus Er MPa 69 69

4 Railroad stiffness factor for cyclic longitudinal stress KLr 337.5 260.0 Fig 11

5 Railroad geometry factor for cyclic longitudinal stress GLr 0.82 1.29 Fig 12

6 Railroad track factor NL 1.01 1.02 Fig 13

kPa 46398.28 56498.93

7 Cyclic longitudinal stress ΔSLr ΔSLr = KLr GLr NL Fi w
MPa 46.40 56.50

STRESS DUE TO INTERNAL LOAD

1 Circumferential stress due to internal load SHi N/mm2 0.00 0.00 SHi =p(D-tw)/2tw

ALLOWABLE STRESS CHECK

The principal stresses S1,S2 and S3 are calculated as follows :

i) Maximum circumferencial stress S1

2
1 Circumferential stress due to internal pressure SHi SHi N/mm 0.00 0.00 SHi =p(D-tw)/2tw

2 ΔSH = ΔSHr for Railroads ΔSHr MPa 51.44 36.59

3 Maximum circumferential stress S1 MPa 84.22 40.61 S1 = SHe + ΔSH + SHi

ii) Maximum longitudinal stress S2

1 ΔSL = ΔSLr for Railroads ΔSLr MPa 46.40 56.50

2 Maximum longitudinal stress S2 MPa 23.63 25.10 S2 = ΔSLr – ES αT(T2-T1) + VS(SHe+SHi)

iii) Maximum radial stress S3

1 Maximum radial stress (-P, operating or design pressure) S3 MPa 0.00 0.00 S3 = -P

2 2 2 1/2
Total effective stress Seff MPa 75.24 35.50 Seff = (0.5[(S1-S2) + (S2-S3) + (S3-S1) ])

0.32 0.14
Ratio of Seff / SMYS should be less than Design factor(F'=0.9) Seff / SMYS
SAFE SAFE
 CHECK FOR FATIGUE

i) Girth weld

1 Design factor for fatigue Check Fg 0.4 0.4

2 Reduction Factor RF 0.625 0.475 Fig 18-A

3 Railroad track factor NL 1.01 1.02

4 Fatigue endurance limit of girth weld SFG MPa 82.74 82.74 SFG= 12000 psi

SFG x F 33.096 33.096

5 Cyclic longitudinal stress ΔSLr MPa 46.40 56.50

6 RF ΔSLr / NL 28.71 26.31

7 Design check against girth weld fatigue SAFE SAFE RFΔSLr/NL ≤ SFGxF

i) Longitudinal weld

1 Design factor for fatigue Check Fg 0.4 0.4

2 Railroad track factor NH 1.17 1.08

3 Fatigue endurance limit of Longitudinal weld SFL MPa 144.789 144.789 SFL= 21000 psi (ERW)

SFL x F 57.9156 57.9156

4 Cyclic Circumferential stress ΔSHr MPa 51.44 36.59

ΔSHr/NH 43.96 33.88

5 Design check against longitudinal weld fatigue SAFE SAFE ΔSHr ≤ SFL x F