14050642-100-pl-cal-0002_pipeline road crossing calculation report_rev 1

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EFFLUENT WATER TREATMENT AND INJECTION

PLANT (NK)

Project No. EF/1761

Class 1

CONTRACT NO. 14050642 of 15

PIPELINE ROAD CROSSING CALCULATION REPORT Rev 1

Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

PROJECT :Effluent Water Treatment And InjectionPlant (NK)

CONTRACT NO : 14050642

OWNER : KUWAIT OIL COMPANY

CONTRACTOR : Dodsal Engineering & Construction Pte. Ltd.

DOCUMENT NO. : 14050642-100-PL-CAL-0002

DOCUMENT REVISION STATUS : 1

DOCUMENT TYPE : E (Engineering Drawing/Document)

1 09.05.2016Re-Issued for Design

(14050642-KD-T-02947)SV AC PC

0 17.12.2015Issued for Design

(14050642-KD-T-01167)SV AC PC

A 01.07.2015 Issued for Approval SV AC PC

Rev Date Description Prepared By Checked By

Approved

By




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

REVISION RECORD:

RevisionNo.

Reason for Revision Date

A Issued for Approval 01.07.2015

0 Issued for Design 17.12.20151 Re-Issued for Design 09.05.2016




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

PAGE INDEX

Page Revision Page Revision

B C D 1 2 3 B C D 1 2 31 492 503 514 525 536 547 558 569 57

10 5811 X 5912 X 6013 X 6114 6215 X 161718192021222324252627282930313233343536373839404142434445464748




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

TABLE OF CONTENTS

1.

GENERAL ............................................................................................................................... 5

2.

SCOPE .................................................................................................................................... 5

3.

REFERENCE DOCUMENTS AND DATA ................................................................................ 5

4.

DESCRIPTION ........................................................................................................................ 6

5.

METHODOLOGY ..................................................................................................................... 7

6.

CALCULATION RESULT / SUMMARY ................................................................................... 9

7.

CONCLUSION ....................................................................................................................... 13

8.

APPENDICES ........................................................................................................................ 14




PLANT (NK)

Project No. EF/1761

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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

1. GENERAL

Kuwait Oil Company (K.S.C), hereafter referred as COMPANY, as a major player of global oil and gas

sector has a long term strategy for the development of North Kuwait (NK) Fields. North Kuwait Fields is

located approximately 90kms from north of Kuwait city.

The purpose of this project is to provide sufficient injection water to meet the requirements of the north

Kuwait well injectors.

For this, an effluent water treatment and injection plant shall be built in a location between the SABRIYAH

and RAUDATAIN fields of north Kuwait having a treatment capacity of 1,045,000 BWPD with 550,000

BWPD for injection and balance 495,000 BWPD will be transferred to existing central processing injector

facility (CIPF existing).

The plant shall receive a continuous supply of effluent water from existing Gathering Centers GC-15, GC-

23, GC-24, GC-25 and an intermittent supply of effluent water from new GC-29, GC-30 and GC-31 (all

routed from existing CIPF).

For this purpose, the COMPANY has entered into a contract with DODSAL ENGINEERING &

CONSTRUCTION PTE LIMITED, hereafter referred as CONTRACTOR, for Engineering,

Procurement, Construction and Related Activities, with a Contract No. 14050642.

2. SCOPE

The scope of this document is to provide Cased Asphalt Road, Highway, Rig Crossing / Uncased Track

Crossing Calculations for Water Injection pipeline systems including Distribution lines, Manifold lines &

Flow lines of Sabriyah, Raudatain fields and offsite pipelines.

3. REFERENCE DOCUMENTS AND DATA

3.1 Codes, Standards and Referenced Documents

KOC Documents:

KOC-L-002 KOC Recommended Practice for the Protection of KOC Services: Clearance

Requirements for Buried Pipelines, Cables, Underground Structures, Buildingsand Housing Projects

015-IH-1002 Pipeline Design




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KOC-L-015 External Cathodic Protection of Underground Steel Pipelines &Piping Networks

International Codes and Standards:

ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries

ASME B31.8 Gas Transmission and Distribution Piping Systems

API 5L Specification for Line Pipe

API RP 1102 Steel Pipelines Crossing Railroads and Highways

3.2 Project Documents:

14050642-700-PR-DBM-0001 - Process Design Basis and Design Criteria

14050642-700-PR-LST-0002 – Process Line List

14050642-100-PL-DBM-0001 - Pipeline Design Basis

14050642-100-PL-DAT-0001 – Pipeline Data Sheet

4. DESCRIPTION

The purpose of this calculation is to ensure safe design in compliance with Road crossing criteriadefined in API RP 1102 (circumferential stresses, Cyclic stresses, effective stress and fatigue failure)and to confirm that the selected wall thickness of carrier pipe / casing pipe is sufficient.

The following categories are considered for road / track crossing calculations:

1. Uncased Track Crossing - Open Cut.

2. Cased Asphalt Road / Highway / Rig track Crossing - Open Cut / Trenchless.

The burial depths for the above crossing categories are listed below:

Sl.No

Crossing Burial Depth inM

1 Uncased Track Crossing 1.2

2 Cased Asphalt Road / Highway / Rig TrackCrossing

1.2*

*As per clause 17.3.8 of KOC-L-002




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

The following wheel loadings were taken into account in determining the stresses imposed on thecarrier pipe / casing pipe at each crossing:

Asphalt Road / Highway / Track crossings: As per KOC specification 015-IH-1002, 112kN per

wheel at 900mm centers with maximum of four (4) wheels per axle. Contact area per API RP

1102 is 0.093 square meters, giving surface pressure = 1204 kN/m2.

Rig Track crossings: The total load of rig is 1100 KN and the maximum Tandem axle wheel load

is 550KN. The contact area, over which the wheel load is applied, shall be taken as 0.403 square

meters.

5. METHODOLOGY

The methodology for crossing calculation (as mentioned in API 1102) is described briefly in thefollowing steps:

a. Begin with the wall thickness (calculated with design factor 0.6 for Fuel gas and design factor0.72 for all other services as per the respective codes) for pipeline of given diameter approachingthe crossing. Determine the pipe, soil, construction and operational characteristics.

b. Use the Barlow formula to calculate the circumferential stress due to internal pressure, SHi (Barlow). Check SHi against the maximum allowable value.

c. Calculate the circumferential stress due to earth load, SHe.

d. Check the critical axle configuration as per figure A-1 Annex. A of API 1102.

e. Calculate the external live load, w, and determine the appropriate impact factor, Fi.

f. Calculate the cyclic circumferential stress, ∆SH, and the cyclic longitudinal stress, ∆SL, due tolive load.

g. Calculate the circumferential stress due to internal pressure, SHi

h. Check effective stress, Seff , as follows:

1. Calculate the principal stresses, S1 in the circumferential direction, S2 in longitudinaldirection, and S3 in the radial direction.

2. Calculate the effective stress, Seff .

3. Check by comparing Seff against the allowable stress, SMYS x F.

i. Check weld for fatigue as follows:

1. Check with weld fatigue by comparing ∆SL against the girth weld fatigue limit, SFG x F.




PLANT (NK)

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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

2. Check longitudinal weld fatigue by comparing, ∆SH against the longitudinal weld fatiguelimit, SFL x F.

Where,

Circumferential stress due to internal pressure:

SHi (Barlow) = pD / 2tw (refer section 4.8.1.1 of API 1102)

Circumferential stress due to earth load:

SHe = KHe Be Ee γ D (refer section 4.7.2.1 of API 1102)KHe is the stiffness factor for circumferential stress from earth load.Be is the burial factor for earth load.

Ee is the excavation factor for earth load.γ is the soil unit weight.

Surface pressure due to Live load:

w = P / AP (refer section 4.7.2.2 of API 1102)P may be Design single wheel load PS or Design tandem wheel load PT

AP is the contact area over which the wheel load is applied

Cyclic circumferential stress due to highway vehicular load:

∆SHh = KHhGHhRLFiw (refer section 4.7.2.2.4.1 of API 1102)KHh is the highway stiffness factor for cyclic circumferential stress.GHh is the highway geometry factor for cyclic circumferential stress.R is the highway Pavement type factor.

L is the highway axle configuration factor.Fi is the impact factor.w is the applied design surface pressure.

Cyclic longitudinal stress due to highway vehicular load:

∆SLh = KLhGLhRLFiw (refer section 4.7.2.2.4.2 of API 1102)KLh is the highway stiffness factor for cyclic longitudinal stress.GLh is the highway geometry factor for cyclic longitudinal stress.R is the highway pavement type factor.L is the highway axle configuration factor.Fi is the impact factor.w is the applied design surface pressure.

Circumferential stress due to internal pressure:

SHi = p (D – tw) / 2tw (refer section 4.7.3 of API 1102)

Maximum circumferential stress:

S1 = SHe + ∆SH + SHi (refer section 4.8.1.2 of API 1102)




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

Maximum longitudinal stress:

S2 = ∆SL – EsαT(T2 – T1) + vs(SHe + SHi) (refer section 4.8.1.2 of API 1102)

Maximum radial stress:

S3 = –p =-MAOP or –MOP (refer section 4.8.1.2 of API 1102)

Total effective stress:

Seff = [0.5 (S1 – S2)2 + (S2 – S3)

2 + (S3 – S1)2]0.5 (refer section 4.8.1.3 of API 1102)

6. CALCULATION RESULT / SUMMARY

6.1 Uncased Track Crossing Assessment:

Wall thickness and stresses developing in the wall of the carrier pipe due to backfill soil weight andvehicle loading were calculated and assessed in accordance with API RP 1102 requirements.Circumferential, longitudinal and radial stresses developing in the wall of the pipeline under the roadare calculated and combined by the Von Mises yield criterion and found to be within the allowable

limits.

Table 6.1A shows the results of carrier pipe wall thickness check at track crossing and that thestresses developed are within the allowable limits.

Table: 6.1A- Uncased Track Crossing Calculation Results:

Pipeline Carrier Pipe OD DF

NominalWT

(tnom)

CorrodedWT (tmin)

SelectedWT for

Crossing(tsel)

BurialDepth

TotalEffectiveStress

Calculated


Allowable(90% ofSMYS)

%Stressratio

DesignCheck

inch (mm) (mm) (mm) (mm) (mm) (kPa) (kPa) %

WaterInjectionSystem

6.625 168.3 0.72 9.53 9.53 9.53 1200 307119 373500 82.2 Safe

8.625 219.1 0.72 12.3 12.3 12.3 1200 310140 373500 83.0 Safe

10.75 273.1 0.72 15.88 15.88 15.88 1200 300786 373500 80.5 Safe

12.75 323.9 0.72 19.05 19.05 19.05 1200 297630 373500 79.7 Safe

14.00 355.7 0.72 20.62 20.62 20.62 1200 302970 373500 81.1 Safe

20.00 508 0.72 28.3 28.3 28.3 1200 313752 373500 84.0 Safe

OilyWater

6.625 168.3 0.72 7.11 3.99 3.99 1200 119951 220500 54.4 Safe

FuelGas

6.625 168.3 0.6 7.11 3.99 3.99 1200 144187 220500 65.4 Safe




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Project No. EF/1761

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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

Pipelines are also assessed for fatigue endurance (due to the cyclic loading conditions imposed byvehicles) as per API RP 1102 requirements and the results are presented in Table 6.1B.

Table: 6.1B- Uncased Track Crossing Fatigue Results:

Pipeline StressesCarrier

Pipe OD(inch)

Value(kPa)

Allowable(kPa)

%DesignCheck


Circumferential Cyclic Stress6.625

7941 59571 13.3Safe

Longitudinal Cyclic Stress 10602 59571 17.8Circumferential Cyclic Stress

8.6257882 59571 13.2

Safe Longitudinal Cyclic Stress 9151 59571 15.4


6853 59571 11.5Safe

Longitudinal Cyclic Stress 8246 59571 13.8


6329 59571 10.6Safe



9818 59571 16.5Safe



52471 59571 88.1Safe


Oily WaterCircumferential Cyclic Stress

6.62523654 59571 39.7


Fuel GasCircumferential Cyclic Stress

6.62523654 59571 39.7


This report checks that the selected carrier pipe wall thicknesses are adequate for use at uncasedtrack crossings. This crossing calculation checks are performed for uncased track crossings inaccordance with API RP 1102.

6.2 Cased Asphalt / Highway Crossing Assessment:

Wall thickness and stresses developing in the wall of the Casing pipe due to backfill soil weight andvehicle loading were calculated and assessed in accordance with API RP 1102 requirements.Circumferential, longitudinal and radial stresses developing in the wall of the casing pipe arecalculated and combined by the Von Mises yield criterion and found to be within the allowable limits.

Table 6.2A shows the results of casing pipe wall thickness check at Cased Asphalt / Highwaycrossing and that the stresses developed are within the allowable limits.




PLANT (NK)

Project No. EF/1761

Class 1



Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

Table: 6.2A- Cased Asphalt / Highway Crossing casing Pipe Wall Thickness Results:

Pipes are also assessed for fatigue endurance (due to the cyclic loading conditions imposed byvehicles) as per API RP 1102 requirements and the results are presented in Table 6.5B.

Table: 6.2B- Cased Asphalt / Highway crossing Fatigue Results:

Pipeline StressesCasing

Pipe OD(inch)

Value(kPa)

Allowable(kPa)

%DesignCheck



17469 59571 29.3Safe


Circumferential Cyclic Stress

14.000

18121 59571 30.4

Safe

Longitudinal Cyclic Stress 13107 59571 22.0Circumferential Cyclic Stress

16.00020043 59571 33.6



20736 59571 34.8Safe



32643 59571 54.8Safe



52471 59571 88.1Safe



12.75017469 59571 29.3


Fuel Gas Circumferential Cyclic Stress 12.750 17469 49642 35.2 Safe Longitudinal Cyclic Stress 12804 49642 25.8

EffluentWater


32827 59571 55.1 Safe


Pipeline Casing Pipe OD DF

NominalWT

(tnom)

CorrodedWT (tmin)

SelectedWT for

Crossing(tsel)

BurialDepth


Calculated


Allowable(90% ofSMYS)

%Stressratio

DesignCheck

inch (mm) (mm) (mm) (mm) (mm) (kPa) (kPa)

Water

InjectionSystem

12.75 323.9 0.72 9.53 9.53 9.53 1100 21756 220500 9.8 Safe

14.00 355.7 0.72 9.53 9.53 9.53 1100 23445 220500 10.6 Safe

16.00 406 0.72 9.53 9.53 9.53 1100 27743 220500 12.6 Safe

18.00 457 0.72 9.53 9.53 9.53 1100 30305 220500 13.7 Safe

20.00 508 0.72 9.53 9.53 9.53 1100 42066 220500 19.1 Safe

26.00 660 0.72 9.53 9.53 9.53 1100 67710 220500 30.7 Safe

OilyWater

12.75 323.90.72

9.53 9.53 9.53 1100 21756 220500 9.8 Safe

FuelGas

12.75 323.9 0.6 9.53 9.53 9.53 1100 21756 220500 9.8 Safe

EffluentWater

22.00 559 0.72 9.53 9.53 9.53 1100 44708 220500 18.2Safe

TreatedWater

36.00 914 0.72 9.53 9.53 9.53 1100 43447 220500 17.7 Safe




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

TreatedWater

Circumferential Cyclic Stress 36.000 24381 59571 40.9 Safe


This report checks that the selected casing pipe wall thicknesses are adequate for use as casingpipes. This calculation checks are performed for cased Asphalt / Highway Crossing in accordancewith API RP 1102.

6.3 Cased Rig Track Crossing Assessment:

Wall thickness and stresses developing in the wall of the casing pipe due to backfill soil weight and

vehicle loading were calculated and assessed in accordance with API RP 1102 requirements.Circumferential, longitudinal and radial stresses developing in the wall of the casing pipe under therig crossing are calculated and combined by the Von Mises yield criterion and found to be within theallowable limits.

Table 6.3A shows the results of casing pipe wall thickness check at cased rig track crossing and thatthe stresses developed are within the allowable limits.

Table: 6.3A- Cased Rig Track Crossing Wall Thickness Results:

Pipelines are also assessed for fatigue endurance (due to the cyclic loading conditions imposed byvehicles) as per API RP 1102 requirements and the results are presented in Table 6.3B.

Table: 6.3B- Cased Rig Track crossing Fatigue Results:

Pipeline Stresses

Casing

Pipe OD(inch)

Value(kPa)

Allowable(kPa)

% DesignCheck

WaterInjection


30456 59571 51.1Safe


Pipeline Casing Pipe OD DF

NominalWT

(tnom) CorrodedWT (tmin)

SelectedWT for

Crossing(tsel)

BurialDepth

Total

EffectiveStress

Calculated

TotalEffective

StressAllowable

(90% ofSMYS)

%Stressratio

DesignCheck

inch (mm) (mm) (mm) (mm) (mm) (kPa) (kPa) %


12.75 323.9 0.72 9.53 9.53 9.53 1100 32131 220500 14.6 Safe

14.00 355.7 0.72 9.53 9.53 9.53 1100 34256 220500 15.5 Safe

16.00 406 0.72 9.53 9.53 9.53 1100 39804 220500 18.1 Safe

18.00 457 0.72 9.53 9.53 9.53 1100 42820 220500 19.4 Safe

20.00 508 0.72 9.53 9.53 9.53 1100 45667 220500 20.7 Safe

26.00 660 0.72

9.53 9.53 9.53 1100 73732 220500 33.4 Safe

OilyWater

12.75 323.90.72

9.53 9.53 9.53 1100 32131 220500 14.6 Safe

FuelGas

12.75 323.9 0.6 9.53 9.53 9.53 1100 32131 220500 14.6 Safe




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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

System Circumferential Cyclic Stress 14.000 31594 59571 53.0 Safe Longitudinal Cyclic Stress 22851 59571 38.4


34943 59571 58.7Safe



36152 59571 60.7Safe



36992 59571 62.1Safe



59463 59571 99.8Safe



12.75030456 59571 51.1

Safe


Fuel GasCircumferential Cyclic Stress

12.75030456 49642 61.4


This report checks that the selected casing pipe wall thicknesses are adequate for use as casingpipes. This calculation checks are performed for cased rig crossings in accordance with API RP1102.

6.4 Casing Pipe Details for Asphalt Road / Highway / RIG Track Crossing – Open Cut / Trenchless:

The Wall thickness required for casing pipe at asphalt road, highway and Rig track crossings are

tabulated below as per KOC Standard Drawing for Pipe sleeve, Drawing No 55-04-77 and also inaccordance with minimum wall thickness for casing as per Annex-C of API RP 1102.

The selected pipe for casing is API 5L Gr.B with STD wall thickness as per KOC Standard for PipeSleeves, Drawing No: 55-04-77.

Casing pipe (sleeve) protection shall be as per clause 7.8.1 of KOC-L-015.

Table: 6.3- Casing Pipe Details:

Carrier Pipe Sizein inch

Casing Pipe Sizein inch

Casing Pipe Thicknessin mm

6.625 12.750 9.538.625 14.000 9.53

10.750 16.000 9.53

12.750 18.000 9.53

14.000 20.000 9.53

16.000 22.000 9.53

20.000 26.000 9.53

30.000 36.000 9.53

7. CONCLUSION

This calculation report conclusively show that the proposed pipeline design is adequate to withstandthe applied earth load, track live load, Highway vehicle load, rig load, internal pressure load andfatigue failure.




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Project No. EF/1761

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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016

8. APPENDICES

Appendix-1: Uncased Track Crossing Calculations for 20" Injection Water Pipeline






Appendix-7: Uncased Track Crossing Calculations for 6" Oily Water Pipeline

Appendix-8: Uncased Track Crossing Calculations for 6" Fuel Gas Pipeline

Appendix-9: Cased Asphalt / Highway Crossing Calculations for 20" Injection Water Pipeline






Appendix-15: Cased Asphalt / Highway Crossing Calculations for 6" Oily Water Pipeline

Appendix-16: Cased Asphalt / Highway Crossing Calculations for 6" Fuel Gas Pipeline

Appendix-17: Cased Rig Crossing Calculations for 20" Injection Water Pipeline








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Doc. No. : 14050642-100-PL-CAL-0002 Date 09.05.2016


Appendix-23: Cased Rig Crossing Calculations for 6" Oily Water Pipeline

Appendix-24: Cased Rig Crossing Calculations for 6" Fuel Gas Pipeline

Appendix-25: Cased Asphalt / Highway Crossing Calculations for 16" Effluent Water Pipeline

Appendix-26: Cased Asphalt / Highway Crossing Calculations for 30" Treated Water Pipeline



PROJECT:

DOC NO:

INPUT DATA

Pipe and Operational Characteristics

Pipeline Design Code ASME B31.4

Outside Diameter D = 508 mm

Wall Thickness (minus corrosion allowance for carrier pipe) t w = 28.3 mm (If other material, fill following)

Design Internal Pressure p = 331.00 barg Grade

Steel Grade API 5L L415/X60 SMYS = MPa

Pipe Manufacture SMLS S FG = kPa

Design Factor F = 0.72 S FL = kPa

Design Factor for Total Longitudinal Stress F L = 0.90 (If required by Pipeline Design Basis)

Design Factor for Allowable Effective Stress F e = 0.90 Based on Table 403.3.1-1 of ASME B31.4

Installation Temperature T 1 = 17 °C

Maximum Operating Temperature T 2 = 60 °C

Design Temperature T des = 93 °C

Longitudinal Joint Factor E = 1.00

Temperature Derating Factor T =

Pipe material properties

Modulus of Elasticity of Steel E s = 207000000.0 kPa

Poisson Ratio v s = 0.30

Co-efficient of Thermal Expansion α t = 0.0000117 mm/mm/°C

Installation and Site Conditions

Type of Crossing Uncased

Construction Method for Crossing Trenched

Crossing Road

Pipeline Cover under crossing H = 1200 mmSoil Type Description B =

Description of soil (Modulus of Soil Reaction) E' =

Description of soil (Resilient Modulus of Soil) E r =

Unit Weight of Soil γ = 19 kN/m3

Modulus of Soil Reaction E' = MPa

Resilient Modulus of Soil E r = MPa

Type of Longitudinal Weld SMLS & ERW

Axle Configuration Tandem Based on Table-1 of API RP 1102

Pavement Type No Pavement

Design Wheel Load Pt = 112 kN Based on clause 6.4 of 015-IH-1002

Contact Area of Wheel Load A p = 0.093 m2 Based on clause 4.7.2.2 of API RP1102

.

SUMMARY OF RESULTS

Stress Results

Unit % SMYS Check Limit

kPa 71.6% OK 72.0%

kPa 75.6% OK 90.0%

Fatigue Results


kPa 2.8% OK 72%

kPa 2.4% OK 72%

Cyclic Longitudinal Stress 11,588

Cyclic Circumferential Stress 9,945

Overall Road Crossing Stress Check DESIGN IS SAFE

Circumferential Stress SHi(Barlow) 297,081

Total Effective Stress (Seff ) 313,752

Variable Value

(Based on Survey Report/Design Data)

(Enter values other than Appendix A or

LEAVE BLANK )

Variable Value

Stiff to very stiff clays and silts;loose to medium dense sands

and gravels

(Enter values if available from Design

Basis or LEAVE BLANK )

Dense to very dense sands and gravels; medium to very stiff

clays and silts

Stiff to very stiff clays and Silts; medium dense and gravels

Road Crossing Calculations for 20" Injection Water Pipeline (Uncased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-1

EFFLUENT WATER TREATMENT AND INJECTION PLANT (NK)

ACCORDING TO API RP 1102

CASED/UNCASED PIPELINE ROAD CROSSING CALCULATIONS

Page 1 of 52



PROJECT:

DOC NO: 14050642-100-PL-CAL-0002, APPENDIX-1




DETAILED CALCULATIONSBored Diameter B d = 508 mm Soil Type = B

Modulus of Soil Reaction (as per table A-1) E' = 6.90 MPa t w /D = 0.056

Resilient Modulus of Soil (as per Table A-2) E r = 69.00 MPa H/B d = 2.36

Pavement Type Factor (as per Table 2) R = 1.10 B d /D = 1.00

Axle Configuration Factor (as per Table 2) L = 1.00

Fatigue Endurance Limit - Girth (as per Table 3) S FG = 82,737.08 kPa

Fatigue Endurance Limit - Long. (as per Table 3) S FL = 158,579.41 kPa

Specified Min. Yield Strength SMYS = 415.00 Mpa

Temperature Derating Factor T = Not Applicable

Check Allowable Barlow Stress (as per clause 4.8.1.1)

[SHi (Barlow)= pD/2tw] ≤ F x E x SMYSSHi (Barlow) = 297,081 kPa

F x E x SMYS = 298,800 kPa Check : OK

Circumferential Stress due to Earth Load SHe (as per clause 4.7.2.1)

K He = 380.00 (from Fig. 3, for tw/D=0.056 & E'=6.9 MPa)

Burial factor for earth load B e = 0.680 (from Fig. 4, for H/Bd=2.4 & Soil Type=B)

Excavation factor for earth load E e = 0.831

SHe = KHeBeEeγD SHe = 2072.58 kPa

Impact Factor, Fi, and Applied Design Surface Pressure, w (as per clause 4.7.2.2.1)

Applied design surface pressure, w = Pt/Ap w = 1,204.3 kPa

Cyclic Stresses, ΔSHh and ΔSLh (as per clause 4.7.2.2.4)

Cyclic circumferential stress, ΔSHh (as per Clause 4.7.2.2.4.1)

Impact Factor F i = 1.500 (from Fig. 7, for H = 1200 mm)

Highway stiffness factor for cyclic circumferential stress K Hh = 4.390 (from Fig. 14, for tw/D=0.056 & Er=69 MPa)

Highway geometry factor for cyclic circumferential stress G Hh = 1.140 (from Fig. 15, for D = 508 & H =1200 mm)

ΔSHh = KHhGHh RLFi w ΔSHh = 9,945 kPa

Cyclic Longitudinal Stress, ΔSLh (as per clause 4.7.2.2.4.2)

Highway stiffness factor for cyclic longitudinal stress K Lh = 5.450 (from Fig. 16, for tw/D=0.056 & Er=69 MPa)

Highway geometry factor for cyclic longitudinal stress G Lh = 1.070 (from Fig. 17, for D = 508 & H =1200 mm)

ΔSLh = KLhGLh RLFi w ΔSLh = 11,588 kPa

Circumferential stress due to internal Pressurisation, Shi (as per clause 4.7.3)

SHi= p(D-tw)/2tw SHi = 280,531 kPa

Principle Stresses, S1, S2, S3 (as per clause 4.8.1.2)

S1 = SHe + ΔSHh + SHi S1 = 292,548 kPa

S2 = ΔSLh - E SαT (T2 - T1 ) + vs (SHe + SHi) S2 = -7,773 kPa

S3= -p = -MAOP or -MOP S3 = -33,100 kPa

Effective Stress, Seff (as per clause 4.8.1.3)

Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 313,752 kPa

Check for allowable effective stress:

Seff ≤ SMYS x Fe SMYS x Fe = 373,500 kPa Check : OK

Check for Fatigue

Girth Weld fatigue as per clause 4.8.2.1, ΔSLh ≤ SFG x F SFG x F = 59,571 kPa Check : OK

Longitudinal Weld Fatigue

As per clause 4.8.2.1 Table 3, ΔSHh ≤ SFL x F SFL x F = 114,177 kPa Check : OK

Stiffness factor for circumferential stress from earth load

Page 2 of 52



PROJECT:

DOC NO:

INPUT DATA



Outside Diameter D = 355.6 mm




















Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 68.8% OK 72.0%

kPa 73.0% OK 90.0%

Fatigue Results


kPa 2.9% OK 72%

kPa 2.4% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-2


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 3 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-2

DETAILED CALCULATIONS

Bored Diameter B d = 355.6 mm Soil Type = B























Highway geometry factor for cyclic circumferential stress G Hh = 1.220 (from Fig. 15, for D = 355.6 & H =1200 mm)




Highway geometry factor for cyclic longitudinal stress G Lh = 1.130 (from Fig. 17, for D = 355.6 & H =1200 mm)

ΔSLh = KLhGLhRLFi w ΔSLh = 11,946 kPa








Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 302,970 kPa



Check for Fatigue





Page 4 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road








Axle Configuration Single Based on Table-1 of API RP 1102


Design Wheel Load Ps = 112 kN Based on clause 6.4 of 015-IH-1002


SUMMARY OF RESULTS

Stress Results


kPa 67.8% OK 72.0%

kPa 71.7% OK 90.0%

Fatigue Results


kPa 1.9% OK 72%

kPa 1.5% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-3


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 5 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-3

DETAILED CALCULATIONSBored Diameter B d = 323.9 mm Soil Type = B


















Applied design surface pressure, w = Ps/Ap w = 1,204.3 kPa


















Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 297,630 kPa



Check for Fatigue





Page 6 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 68.6% OK 72.0%

kPa 72.5% OK 90.0%

Fatigue Results


kPa 2.0% OK 72%

kPa 1.7% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-4


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 7 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-4





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 300,786 kPa



Check for Fatigue





Page 8 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 71.0% OK 72.0%

kPa 74.7% OK 90.0%

Fatigue Results


kPa 2.2% OK 72%

kPa 1.9% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-5


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 9 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-5
























Highway geometry factor for cyclic circumferential s tress G Hh = 1.390 (from Fig. 15, for D = 219.1 & H =1200 mm)













Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 310,140 kPa



Check for Fatigue





Page 10 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 70.4% OK 72.0%

kPa 74.0% OK 90.0%

Fatigue Results


kPa 2.6% OK 72%

kPa 1.9% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-6


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 11 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-6





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 307,119 kPa



Check for Fatigue





Page 12 of 52



PROJECT:

DOC NO:

INPUT DATA






Steel Grade API 5L L245/B SMYS = MPa

















Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 15.4% OK 72.0%

kPa 49.0% OK 90.0%

Fatigue Results


kPa 7.5% OK 72%

kPa 9.7% OK 72%




Road Crossing Calculations for 6" Oily Water Pipeline (Uncased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-7


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 13 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-7





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 119,951 kPa



Check for Fatigue





Page 14 of 52



PROJECT:

DOC NO:

INPUT DATA















Temperature Derating Factor T = 1.0000








Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 40.1% OK 60.0%

kPa 58.9% OK 90.0%

Fatigue Results


kPa 7.5% OK 60%

kPa 9.7% OK 60%




Road Crossing Calculations for 6" Fuel Gas Pipeline (Uncased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-8


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 15 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-8











[SHi (Barlow)= pD/2tw] ≤ F x E x T x SMYSSHi (Barlow) = 98,280 kPa

F x E x T x SMYS = 147,000 kPa Check : OK

























Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 144,187 kPa



Check for Fatigue





Page 16 of 52



PROJECT:

DOC NO:

INPUT DATA







Pipe Manufacture SAW S FG = kPa














Type of Crossing Cased


Crossing Road







Type of Longitudinal Weld SAW





.

SUMMARY OF RESULTS

Stress Results


kPa 1.4% OK 72.0%

kPa 27.6% OK 90.0%

Fatigue Results


kPa 8.3% OK 72%

kPa 21.4% OK 72%




Road Crossing Calculations for 20" Injection Water Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-9


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 17 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-9


































S2 = ΔSLh - E SαT (T2 - T1 ) + vs (SHe + SHi) S2 = 17,394 kPa

S3= -p = -MAOP or -MOP S3 = -101 kPa


Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 67,710 kPa



Check for Fatigue





Page 18 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 1.1% OK 72.0%

kPa 17.2% OK 90.0%

Fatigue Results


kPa 8.6% OK 72%

kPa 13.3% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-10


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 19 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-10





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 42,066 kPa



Check for Fatigue





Page 20 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 1.0% OK 72.0%

kPa 12.4% OK 90.0%

Fatigue Results


kPa 5.6% OK 72%

kPa 8.5% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-11


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 21 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-11





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 30,305 kPa



Check for Fatigue





Page 22 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 0.9% OK 72.0%

kPa 11.3% OK 90.0%

Fatigue Results


kPa 5.6% OK 72%

kPa 8.2% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-12


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 23 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-12





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 27,743 kPa



Check for Fatigue





Page 24 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 0.8% OK 72.0%

kPa 9.6% OK 90.0%

Fatigue Results


kPa 5.3% OK 72%

kPa 7.4% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-13


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 25 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-13





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 23,445 kPa



Check for Fatigue





Page 26 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 0.7% OK 72.0%

kPa 8.9% OK 90.0%

Fatigue Results


kPa 5.2% OK 72%

kPa 7.1% OK 72%





14050642-100-PL-CAL-0002, APPENDIX-14


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 27 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-14





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 21,756 kPa



Check for Fatigue





Page 28 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 0.7% OK 72.0%

kPa 8.9% OK 90.0%

Fatigue Results


kPa 5.2% OK 72%

kPa 7.1% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts


Road Crossing Calculations for 6" Oily Water Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-15




Page 29 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 21,756 kPa



Check for Fatigue





Page 30 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












SUMMARY OF RESULTS

Stress Results


kPa 0.7% OK 60.0%

kPa 8.9% OK 90.0%

Fatigue Results


kPa 5.2% OK 60%

kPa 7.1% OK 60%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts


Road Crossing Calculations for 6" Fuel Gas Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-16




Page 31 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 21,756 kPa



Check for Fatigue





Page 32 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












.

SUMMARY OF RESULTS

Stress Results


kPa 1.4% OK 72.0%

kPa 30.1% OK 90.0%

Fatigue Results


kPa 9.5% OK 72%

kPa 24.3% OK 72%




Rig Crossing Calculations for 20" Injection Water Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-17


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 33 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-17





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 73,732 kPa



Check for Fatigue





Page 34 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












.

SUMMARY OF RESULTS

Stress Results


kPa 1.1% OK 72.0%

kPa 18.6% OK 90.0%

Fatigue Results


kPa 9.7% OK 72%

kPa 15.1% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts



14050642-100-PL-CAL-0002, APPENDIX-18




Page 35 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 45,667 kPa



Check for Fatigue





Page 36 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












.

SUMMARY OF RESULTS

Stress Results


kPa 1.0% OK 72.0%

kPa 17.5% OK 90.0%

Fatigue Results


kPa 9.8% OK 72%

kPa 14.8% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts



14050642-100-PL-CAL-0002, APPENDIX-19




Page 37 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 42,820 kPa



Check for Fatigue





Page 38 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












.

SUMMARY OF RESULTS

Stress Results


kPa 0.9% OK 72.0%

kPa 16.2% OK 90.0%

Fatigue Results


kPa 9.7% OK 72%

kPa 14.3% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts



14050642-100-PL-CAL-0002, APPENDIX-20




Page 39 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 39,804 kPa



Check for Fatigue





Page 40 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












.

SUMMARY OF RESULTS

Stress Results


kPa 0.8% OK 72.0%

kPa 14.0% OK 90.0%

Fatigue Results


kPa 9.3% OK 72%

kPa 12.9% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts



14050642-100-PL-CAL-0002, APPENDIX-21




Page 41 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 34,256 kPa



Check for Fatigue





Page 42 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












.

SUMMARY OF RESULTS

Stress Results


kPa 0.7% OK 72.0%

kPa 13.1% OK 90.0%

Fatigue Results


kPa 9.1% OK 72%

kPa 12.4% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts



14050642-100-PL-CAL-0002, APPENDIX-22




Page 43 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 32,131 kPa



Check for Fatigue





Page 44 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












SUMMARY OF RESULTS

Stress Results


kPa 0.7% OK 72.0%

kPa 13.1% OK 90.0%

Fatigue Results


kPa 9.1% OK 72%

kPa 12.4% OK 72%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts


Rig Crossing Calculations for 6" Oily Water Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-23




Page 45 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 32,131 kPa



Check for Fatigue





Page 46 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Rig












SUMMARY OF RESULTS

Stress Results


kPa 0.7% OK 60.0%

kPa 13.1% OK 90.0%

Fatigue Results


kPa 9.1% OK 60%

kPa 12.4% OK 60%






Variable Value



LEAVE BLANK )

Variable Value


and gravels




clays and silts


Rig Crossing Calculations for 6" Fuel Gas Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-24




Page 47 of 52



PROJECT:









































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 32,131 kPa



Check for Fatigue





Page 48 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 1.2% OK 72.0%

kPa 18.2% OK 90.0%

Fatigue Results


kPa 8.6% OK 72%

kPa 13.4% OK 72%




Road Crossing Calculations for 16" Effluent Water Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-25


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 49 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-25















Burial factor for earth load B e = 0.600 (from Fig. 4, for H/Bd=2 & Soil Type=B)






















Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 44,708 kPa



Check for Fatigue





Page 50 of 52



PROJECT:

DOC NO:

INPUT DATA























Crossing Road












.

SUMMARY OF RESULTS

Stress Results


kPa 2.0% OK 72.0%

kPa 17.7% OK 90.0%

Fatigue Results


kPa 7.1% OK 72%

kPa 10.0% OK 72%




Road Crossing Calculations for 30" Treated Water Pipeline (Cased and with No Pavement)

14050642-100-PL-CAL-0002, APPENDIX-26


and gravels




clays and silts




LEAVE BLANK )

Variable Value



Variable Value




Page 51 of 52



PROJECT:

DOC NO:




14050642-100-PL-CAL-0002, APPENDIX-26





































Seff = √1/2[(S1-S2)2+ (S2-S3)

2 + (S 3-S1)

2] Seff = 43,447 kPa


