TECHNICAL STUDIES OF ELIGIBILITY DESIGN ON

CROSSING PIPELINE AREA UNDER RAILWAY AT GAS

NETWORK PIPE

Septian Firdaus Yoga Pratama

0814040064

Supervisor 1 Supervisor 2
R. Dimas Endro W, ST., MT. Abdul Gafur, ST., MT.
 INTRODUCTION

Pipeline design Pipeline Crossing

lifetime prediction Under Railway

Pipe Bending
degree
 MAIN PROBLEM

What is the stress value due to ground load, live load, internal load and
effective stress on the pipeline crossing railway based on API RP 1102?

What is the value of wall thickness pipe before and after bending
process?

What is the stress value in overall pipeline crossing based on

modelling with software?

Does the design of pipeline crossing able to survive with the specified
design lifetime?
 SCOPE OF PROBLEM

The design and data of pipeline analysis taken from PT. Depriwangga
Engineering in South Jakarta area.

The rule parameters used for this research are API 1102 for pipeline
crossing railway analysis and ASME B31.8 for pipeline bending
analysis and stress analysis overall design.

The pipe material used for this research is API 5L Gr. B, NPS 8 inch
sch. 40 (OD = 219.10 mm, ID = 202,74 mm, t = 8,18 mm).

Fatigue analysis on pipes is only to determine the number of cycles

and cycle types as well as to estimated lifetime of the pipe.

In the bending pipe analysis only for manual calculation for wall
thickness calculation
 RESEARCH DATA

Pipe Characteristic Process Data

Description Unit Value Description Unit Value
Outside Diameter inch 8.625
Operating Pressure psig 125
Thickness inch 0.322
Material - API 5L Design Pressure psig 200
Steel Grade - B Maks. Operating Pressure psig 150
Design Factor - 0.5
Hydrotest Pressure psig 280
Longitudinal Joint Factor - 1
Type of Longitudinal Weld - ERW
Operating Temperature °F(°C) 85.17 (29.54)
Specified Minimum Yield Strength 35000
Psi

Specified Minimum Tensile Strength 60000 Design Temperature °F(°C) 200(93.3)

Psi
Steel Density kg/m3 7850
Young Modulus Mpa 207000 Maks. Operating Temperature °F(°C) 100 (37.8)
Thermal Expansion Coefficient 1/°C 1.12x10-5
Poisson Ratio - 0.3 Fluid Density lb/ft3 0.485

Installation & Site Characteristic

Description Unit Value
Depth m 2
Soil Type - Loose Land
Bored Diameter Inch 10.75
Unit Weight kg/m3 1920.99
Modulus of Soil Reaction (E') kN/m2 3447.37
Resilient Modulus (Er) kN/m2 68947.57
Poisson Ratio Soil - 0.25
Railroad Loading - E-80
Seismic acceleration - 0.4
 PIPELINE CROSSING
CALCULATION BASED
ON API 1102

Stress Due To Internal Load

Depth (mm) Shi (Barlow) (psi) Minimum Yield Strength Factor (psi) Keterangan

2000 2678.571 17500.000 Accept

Stress Due To Dead Load

Depth (mm) tw/D H/Bd Bd/D Khe Be Ee She

2000.000 0.037 7.325 1.246 900.000 1.230 1.280 843.268

Stress Due To Live Load ( Circumferential & Longitudinal)

Circumferential
Depthn (mm) Khr Ghr Nh Fi w ΔSHr
2000 190 1.054 1.09 1.69 13.9 5127.695

Longitudinal
Kedalaman (mm) Klr Glr Nl Fi w ΔSLr

2000 250 1 1.02 1.69 13.9 5990.205

 PIPELINE CROSSING
CALCULATION BASED
ON API 1102

Principal & Effective Stress

S1
Depth (mm) She SHr Shi S1

2000 843.268 5127.695 2578.571 8549.535

S2
El
SLr E (psi) α T1 (F) T2 (F) v SHe SHi S2
(mm)

2000 5990.205 30002280 6.95E-06 85.17 80.6 0.3 843.268 2578.571 6063.84

S3
Depth (mm) P (psi) S3

2000 200 -200

Effective Stress
Depth (mm) (S1-S2)² (S2-S3)² (S3-S1)² Seff (psi)

2000 6178682.6 39235685 76554364.4 7809.249

 PIPELINE CROSSING
CALCULATION BASED
ON API 1102

Check For Allowable Stress Based on API 1102

Seff ≤ SMYS x F

Kedalaman (mm) F SMYS Seff (psi) Allowable Stress Keterangan

2000 0.5 35000 7809.24876 17500 Accept

Based on calculation, the effective stress of the pipeline is under the value of
allowable stress based on API 1102. So, the pipeline can be installed safely.
BENDING PIPE CALCULATION
(FIELD COLD BEND METHOD)
 BENDING PIPE CALCULATION
ANALYSIS & RESULT
(FIELD COLD BEND METHOD)

Maksimum Angle of Bend & Thinning Percentage :

L pipe = 12 m ; Tg = 2 m

Thinning
Radius Tg (m) Lb (m) H (Inch) B (deg) G (Point) Cbmax (deg)
Percentage (%)

30 2 8 10 2.21 31 68.6 19

From table we know that thinning have 19%. So we can calculate:

Thin Nominal = 19% x 0.322 inch.
= 0.061 inch
Thikcness pipe after bend = 0.322 – 0.061
= 0.261 inch
From the calculation the thickness after bend is 0.261 inch , but the needed
thickness from min. thickness calculation is 0.025 inch. So the bending pipe is
safely for installation
 Modelling Overall
ANALYSIS & Pipeline
RESULT
Crossing With Software

Ideal Without Load From Field Calculation

C = 6000 mm R = 18D = 4000 mm
G = 30 degree H = 0.5 x 30 = 15 degree
D = 35000 mm F = 12000 mm
E = 10392 mm
A = 12304 mm
B = 12304 mm
K = tan 15 x 4000 = 1071 mm
M = 12304 - 1071 = 11233 mm
N = 12304 - 1071 = 11233 mm

P = 12000 - (2 x 1.071) = 9856 mm

Ideal With Load

 BENDING PIPE CALCULATION
ANALYSIS & RESULT
(FIELD COLD BEND METHOD)

Eksisting Without Load

From Field Calculation
C = 6000 mm H = 0.5 x 30 = 15 degree
G = 30 degree A = 12304 mm
D = 35000 mm B = 12304 mm
R = 30D = 6572.25 K = tan 15 x 6572.25 = 1761
mm mm
M = 12304 - 1761 = 10542
F = 12000 mm mm
N = 12304 - 1761 = 10542
E = 10392 mm mm
P = 12000 - (2 x 1761) = 8477
mm

Eksisting With Load

 Lifetime Prediction

For Lifetime Prediction Based on API 570 we can get the corrosion rate
from measurement of pipeline wall thickness which have operation more
than 3 month and hava s same specification data process.

(tmax) = 8.168 mm
(tmin) = 8.021 mm
 Conclusion

1. Based on Calculation of NPS 8” Sch. 40 based on API 1102 So stress due to earth load is 843.268 Psi,
and stress due to live load (circumferential) is 5127.695 Psi and longitudinal is 5990.205 Psi, and stress
due to internal load is 2578.571 Psi, and finally the effective stress is 7809.25 Psi. From the calculation the
effective stress value is not more than allowable stress value so the pipeline is safely based on API 1102.
2. Based on calculation for determine the thickness value based on ASME B31.8 so the inimum thickness
of the pipe is 0.025 inch. From the min. thickness so can choose the pipe thickness from API 574 and get
the thickness of the pipe is 0.322 inch, next after we calculate the thickness pipe after bending process, the
thickness of the pipe decrease untill 19%, so the thickness of the pipe is 0.26 inch. From the calculation the
thickness pipe is safely because the min. thickness after bending not more than min. thickness needed. So
the pipe is safely for bending.
3. Based on modelling with software ANSYS 18.2 the stres value in overall pipeline with ideal design and
eksisting design will got it. The stress value of ideal design without load is 2152 Psi, and The stress value
of ideal design with load is 7564.2 Psi. Next for The stress value of eksisting design without load is 4679.6
Psi, The stress value of eksisting design with load is 10021 Psi. From the result of modelling pipeline, the
pipeline is safely because all the stress value not more than allowable stress material (31500 Psi).
4. Based on the pipeline lifetime prediction based on API 570 and data of measurement pipeline wall
thickness with have same specification data. From the corrosion rate of the pipeline, the lifetime of the
pipeline is 22 years. So the pipeline is good because have a lifetime more than 20 years based on client
demand.
THANK YOU