Api RP 1102 - 1993

PIPELINE ENGINEERING
ASSIGNMENT II
Nadia Handayani 4210 100 053
Jurusan Teknik Sistem Perkapalan
FTK ITS
Surabaya - 2013

Nadia Handayani 4210100053
Pipeline Engineering Assignment 3
FTK - ITS

API RP.1102 - 1993
STEEL PIPELINES CROSSING
RAILROADS AND HIGHWAYS
No. Key Issue Description Value/Formula Reference
1. SCOPE
General This code covers - Design
- Installasion
- Inspection
- Testing
Para. 1.1
Application - This practice applies to welded steel pipelines
- The construction of pipelines crossing under
railroads and highways
Para. 1.2
2. SYSMBOLS, EQUATIONS, DESCRIPTIONS
Equations All stresses below have units of psi or kPa
a. Earth Load

Para. 2.2
Eq. 1
b. Live Load
-

Para. 2.2
Eq. 2 - 6
c. Internal Load

a. Natural Gas
[
()
]
b. Liquids
[
()
]

Para. 2.2
Eq. 7 8b
d. Limits of Calculated Stresses a. Circumferential
S
1
= S
He
+ S
H
+ S
Hi
b. Longitudinal
S
2
= S
L
E
S
T
(T
2
T
1
) + s (S
He
+ S
Hi
)
c. Radial
- S
3
= p = MAOP or MOP
Para. 2.2
Eq. 9 20
FTK - ITS

-
[(
]
-

- R
F
S
Lr
N
L
S
FG
F
- S
Lh
S
FG
F
- S
H
S
FL
F
- S
Hr
N
H
S
FL
F
- S
Hh
S
FL
F
3. PROVISIONS FOR SAFETY
Applicable regulation Federal, state, municipal or other regulating bodies Shall be observed during the installation of a crossing Para. 3.1
The hazards involved Guards (watch persons) should do - Should be posted and placed :
Warning signs, Lights, and flares
- Should be provided and maintained :
Temporary walkways, fences, and barricades
Para. 3.2
Drainage ditches Should be maintained to avoid flooding or erosion Para. 3.6
4. UNCASED CROSSINGS
Type of Crossing Focuses specifically on the design of uncased carrier
pipelines
Para. 4.1
General The carrier pipe shall be welded In accordance with :
- API Standard 1104
- ASME B31.4 or B31.8
Para. 4.2
Location and Alignment The angle of intersection between a pipeline crossing and
the railroad or highway
- Near to 90 degrees
- Not less than 30 degrees
Para. 4.3.1
Vertical and horizontal clearances Must be sufficient to permit maintenance Para. 4.3.3
Cover Railroad Crossings Location :
a. Under track structure proper
b. Under all other surfaces within the right-of-way
or from the bottom of ditches
c. For pipelines transporting HVL, from the
bottom of ditches
Min. Cover :
a. 6 ft (1.8 m)
b. 3 ft (0.9 m)
c. 4 ft (1.2 m)
Para. 4.4.2
Highway Crossings Location :
a. Under highway surface proper
Min. Cover :
a. 4 ft (1.2 m)
b. 3 ft (0.9 m)
Para.4.4.3
FTK - ITS

bottom of ditches
c. 4 ft (1.2 m)
Design Design procedure :
(shown schematically in Figure 2)
a. Determine the pipe, soil, construction, and operational
characteristics
b. Calculate S
Hi
(Barlow)
c. Calculate S
He

d. Calculate w and determine Fi
e. Calculate S
H
and S
H

f. Calculate S
Hi

g. Check effective stress (S
eff
)
- Calculate S
1,
S
2,
S
3

- Calculate S
eff

- Check by comparing Seff < SMYS x F
h. Check welds for fatigue
- Grith weld : S
Lh
SFL x F
- Longitudinal weld : S
Hh
SFL x F
i. If any check fails, modify from step b through h
Para. 4.5
Loads A carrier pipe at an uncased crossing will be subjected to
:
- Internal load from pressurization
- External loads from earth forces (dead load) and
- Train or highway traffic (live load).
Para. 4.6.1
A result of temperature fluctuations caused by : - Longitudinal tension due to end effects
- Fluctuations associated with pipeline operating conditions,
unusual surface loads associated with specialized equipment
- Ground deformations arising from various sources
Para. 4.6.2
- External Loads a. Earth Load
The force resulting from the weight of the overlying soil that is
conveyed to the top of pipe
b. Live Load
- Railroad Crossing : the load from a single train
- Highway Crossing : the loads from two trucks traveling in
adjacent lanes
Para. 4.6.2.2
- Internal Load - Produced by internal pressure, p (Psi or kPa)
- MAOP and MOP should be used
Para. 4.6.2.3
Stresses a. Stresses Due to External Loads

Where :
- = 120 lb/ft
3
(18.9 kN/m
3
) of 0.069 lb/in
3

-
accounts for t
w
/D and E
Para. 827
FTK - ITS

-
or equals to 1.0
b. Stresses Due to Live Load a. Surface Live Loads
- External rail load
Cooper E-80 loading of w = 13.9 psi (96 kPa)
External highway load (See. Figure 6)
Single axle loading
Tandem axle loading
Para. 4.7.2.2.1
b. Impact Factor (See. Figure 7)
- For railroad : 1.75
- For highway : 1.5
Para. 4.7.2.2.2
c. Railroad Cyclic Stresses
- The cyclic circumferential stress (See. Figure 8)

- The cyclic longitudinal stress (See. Figure 9)

Para 4.7.2.2.3
d. Highway Cyclic Stresses
- The cyclic circumferential stress (See. Figure 10 and 14)

- The cyclic longitudinal stress (See. Figure 11- 13 and 15)

Para 4.7.2.2.4
c. Stresses Due to Internal Load

Para. 4.7.3
Limits of Calculated Stresses See. Figure 16 and 17
See Table 2
Para. 4.8

Check for Allowable Stresses
(Specified by 49 Code of Federal Regulations
Part 192 or Part 195)
a. Natural Gas
[
()
]
b. Liquids
[
()
]

Para. 4.8.1
The principal stresses a. Circumferential
S
1
= S
He
+ S
H
+ S
Hi
b. Longitudinal
S
2
= S
L
E
S
T
(T
2
T
1
) + s (S
He
+ S
Hi
)
Para. 4.8.1.2
FTK - ITS

c. Radial
S
3
= p = MAOP or MOP (Max. Radial Stress)

Table A-3, in Annex A gives typical values for Es, vs and T.
The total effective stress (Seff)
[(
]
Para. 4.8.1.3
Check for Fatigue Fatigue endurance limit determined from :
- S-N (fatigue strength versus number of load cycles)
- Min. ultimate tensile strengths as given in API 5L
Para. 4.8.2
a. Grith Weld - The fatigue endurance limit (
) = 12,000 psi (82,740 kPa)

- See. Table 3
-

Para. 4.8.2.1
a. Railroads Crossing (See. Figure 18A and 18B)
- For L
G
5 ft (1,5m) =

- For L
G
5 ft (1,5m) = R
F
S
Lr
N
L
S
FG
F

b. Highways Crossing
- S
Lh
S
FG
F
Para. 4.8.2.1
b. Longitudinal welds
S
H
S
FL
F
(See. Table 3 )
Para. 4.8.2.2
c. Railroads Crossing (See. Figure 18A and 18B)
- S
Hr
N
H
S
FL
F
- N
H
= 1.00 for single track crossing

d. Highways Crossing
- S
Hh
S
FL
F
Para. 4.8.2.2
Orientation of Longitudinal
Welds
The optimal location of all longitudinal welds is at the
45, 135, 225, or 315 degree position with the crown at
the zero degree position
Para. 4.9
Location of Girth Welds at
Railroad Crossings
L
G
, at least10 ft (3 m) from the centerline of the track for
a single track crossing
Para. 4.10
5. CASED CROSSINGS
Carrier Pipe Installed within The material and design requirements - Latest edition of ASME B31.4 or B3.1.8 Para. 5.1
FTK - ITS

a Casing - Casings may be coated or bare
Casings for Crossings Suitable materials for casings - New or used line pipe
- Mill reject pipe
- Other available steel tubular goods, including longitudinally
split casings.
Para. 5.2
Minimum Internal Diameter
of Casing
The casing pipe should be at least two nominal pipe sizes
larger than the carrier pipe
Para. 5.3
Wall Thickness - Bored Crossings Shown in Annex C. Para. 5.4.1
- Open Trenched Crossings The requirements of 5.7 Para. 5.4.2
General The casing pipe should be : - Free of internal obstructions
- As straight as practicable
- Have a uniform bedding
- Installed with an overbore as small as possible
- Steel casing pipe should be joined completely
Para. 5.5
Location and Alignment It should extend : - Min. of 2 ft (0.6 m) beyond the toe of slope or base grade
- 3 ft (0.9 m) beyond the bottom of the drainage ditch
Para. 5.6.1
Additionally for railroad crossings, the casing pipe
should extend :

- When casing is sealed at both ends
Min. distance of 25 ft (7.6 m) each side from centerline of
outside track
- when casing is open at both ends
Min. distance of 45 ft (13.7 m) each side of the centerline of the
outside track
Para. 5.6.2
Cover - Railroad Crossings :
a. Under track structure proper, except secondary
and industry tracks.
b. Under track structure proper for secondary and
industry tracks.
c. Under all other surfaces within the right-of-way
or from bottom of ditches.
d. For pipelines transporting HVL, from the
bottom of ditches.

Minimum Cover :
a. 5.5 ft (1.7 m)
b. 4.5 ft (1.4 m)
c. 3 ft (0.9 m)
d. 4 ft (1.2 m)

Para. 5.7.1
- Highway Crossings :
a. Under highway surface proper.
bottom of ditches
Minimum Cover :
a. ft (1.2 m)
b. 3 ft (0.9 m)
c. 4 ft (1.2 m)
Para. 5.7.2
FTK - ITS

Mechanical Protection Mechanical protection shall be installed
Installation Carrier pipe installed in a casing should be : - Properly designed supports, insulators, or other devices,
- No external load will be transmitted to the carrier pipe
- Accomplished by building up a ring of layers of coating and
outer wrap, or by a concrete jacket.
- Manufactured insulators should be uniformly spaced and
securely fastened to the carrier pipe
Para. 5.8
Casing Seals The casing should be : - Fitted with end seals at both ends
- It formed with a flexible material
Para. 5.9
Casing Vents Vents are not required on casings Para. 5.10
One or two vent pipes may be installed, if used : - D 2 in. (51 mm)
- Should extend 4 ft (1.2 m) above the ground surface
- Fitted with suitable weather caps on the top
Para. 5.10
Insulators Insulators electrically isolate the carrier pipe from the
casing
By providing a circular enclosure Para. 5.11
Inspection and Testing - The section of carrier pipe inspected visually for
defects
- All girth welds should be inspected by radiographic
or other nondestructive methods
Para. 5.12
6. INSTALLATION
Trenchless Installation Percussive molding D < 6 in. (150 mm) Para. 6.1.1
The bored hole, B
d
B
d
= D Para. 6.1.2
The following provisions apply to bored, jacked, or
tunneled crossings :
B
d
2 in. (51 mm) the outside diameter of the carrier pipe
(including coating)
Para. 6.1.3
Open Cut or Trenched
Installation
- Backfill should be placed in : layers of 12 in. (305 mm) or less (uncompacted thickness) Para.6.2.2
- Casing Requirements Under Railroads, Highways,
Roads, or Streets
shown in Table 841.114B Para. 6.2.3
General Welding (See. API Standard 1104) - For uncased crossings :
NDT be required for girth welds within a horizontal distance of
50 ft (15 m) from either the outside or inside rail and from
either the outside or inside highway pavement line.
- For cased crossings:
The same applies for welds within 50 ft (15 m) of the end seals
of the casing
Para. 6.3.3
Pressure Testing Accordance with 49 CFR, Part 192 or Part 195 requirements Para. 6.3.4
FTK - ITS

Pipeline Markers and Signs API Recommended Practice 1109 Para. 6.3.5
7. RAILROADS AND HIGHWAYS CROSSING EXISTING PIPELINES
Adjustment of Pipelines at
Crossings
If adjustments are required the pipeline crossing should
be :
- Lowered
- Repaired
- Reconditioned
- Replaced, or
- Relocated
Para. 7.1
Adjustment of In-service
Pipelines
Lowering Operations Accordance with API Recommended Practice 1117 Para. 7.2.1
Split Casings When stress due to external loads of the railroad or highway
necessitates casing of a pipeline
Para. 7.2.2
Temporary Bypasses Suitable mechanical means to isolate the section to be adjusted Para. 7.2.3
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Api RP 1102 - 1993

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PIPELINE ENGINEERING

) = 12,000 psi (82,740 kPa)

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