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DWGOM-GP 02-1019
Applicability
DWGOM
Date
Draft
DWGOM-GP 02-1019
DWGOM
SITE TECHNICAL PRACTICES
BP America Inc.
501 Westlake Park Boulevard
Houston, Texas 77079
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CONTENTS
Introduction................................................................................................................. 1
B.1
B.2
B.3
Recommendations ...................................................................................... 18
B.3.1 Design Procedure .....................................................................................18
B.3.2 Documentation ..........................................................................................18
B.3.3 Operations .................................................................................................19
B.3.4 Using JETCAP ..........................................................................................20
B.4
B.5
B.6
References ................................................................................................... 23
APPENDIX A.............................................................................................................. 24
Derivation of the Required Conductor Length, L................................................24
APPENDIX B.............................................................................................................. 27
Example Calculation: Landing Load ...................................................................27
APPENDIX C.............................................................................................................. 29
Example Calculation: Required Conductor Length...........................................29
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INTRODUCTION
The importance of a sound structural foundation cannot be overemphasized. In the past decade,
there has been a significant amount of research regarding the design and installation of jetted
conductors. Yet, despite the lessons learned, seven conductors on BP wells subsided in 2002. In
each of these cases, at least one of the recommended design/installation techniques presented in
this section was ignored.
The earliest jetted conductors were designed by sampling and analyzing Gulf of Mexico (GOM)
soil properties. Using these soil analyses, lower and upper bound immediate capacities for
conductor setting depths were calculated1. The designs were then configured for the length of the
conductor casing, application of donut weights, and bottom hole assemblies.
Reciprocation was avoided by having enough weight available during jetting. This was achieved
by the use of donut weights, which were cylindrical weights of steel that were stacked up on the
drill pipe.
The key advantage of this method was that the weight of the donuts used was greater than the
weight to be landed on the conductor. If the conductor was able to carry such weight immediately
after installation, then the conductor was essentially proof-loaded against the weight to be landed.
This provided certainty that the wellhead would not move when landing of subsequent strings took
place.
The main limitation of this method was that it was not possible to drill ahead after jetting was
completed. The BHA had to be retrieved, the donut weights removed, a new BHA assembled, and
drill pipe run back in the hole again before drilling could resume. As water depths continued to
increase, this disadvantage became such a significant cost factor that this method was eventually
abandoned.
The main issue at hand was that none of these earlier practices calculated the increase in unit
friction along the conductor with time, nor did they sufficiently account for soil properties. Well
failures were not adequately studied to determine the causal factors and relationships
(e.g., conductor penetration lengths or reciprocation stroke lengths). Considering the high cost of
drilling deepwater wells, these and other factors needed to be addressed.
Through various studies and collaborations, BP recommends this standardized approach for the
design, setup, and installation of deepwater conductors. It is now no longer common practice for
BP to collect site-specific soil data to determine conductor setting depths for exploration wells in
the GOM. Therefore, the proposed method for setting depth design of a conductor assumes
reasonable conditions. The BP model has been strengthened by the lessons learned from failure
studies, and the final result reduces both setup time and material cost.
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CONDUCTOR CAPACITY
Setup calculations have recently been facilitated by the implementation of the Jetting Capacity
(JETCAP) program and by the recent studies performed on various GOM deepwater wells. BP
has determined that donut weights are too time consuming and, therefore, too costly. In order to
determine conductor capacity, the following recommendations and equations are presented.
(B.1)
where:
Q0 = Conductor capacity immediately after jetting (t = 0.01 days)
WOBlast = Last weight on bit recorded during installation
R = WOB utilization ratio, should be between 0.8 and 1.0
Wcond = Weight of the conductor in water
WWH = Weight of the wellhead housing in water
WDC = Weight of the drill collars in water
WCADA = Weight of the CADA tool in water
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t =
Qt - Q0
()(D )( L )( Suave )
(B.2)
where:
Dat = Setup factor; measures the change in average friction factor along the conductor, at time = t
Site
Conductor
Length
(ft)
Conductor
Diameter
(in.)
Immediate
Capacity
(kips)
Setup
Time
Measured
Capacity
(kip)
Calculated
Dat
135
30
135
4 hr
>170
0.07
65
30
91
1 day
125
0.11
175
36
130
5 days
>300
0.15
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0.18
0.16
0.14
Calculated Da
0.12
0.1
Data
Best Fit
0.08
0.06
0.04
0.02
0
0.01
0.1
10
Time (days)
Plotting the line through the data in Figure B-1 results in the following equation:
Dat = (0.055)[2 + log(t)]
(B.3)
Immediately after jetting the conductor, the soil in the immediate vicinity around the conductor
begins to set up and regains strength, resulting in an increased capacity of the conductor with time.
The Da is a measure of this healing process and can be used to predict the capacity of the
conductor as a function of time after jetting.
(B.4)
where:
t = time, in days < 10 days
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CONDUCTOR DESIGN
Su AVE = Su 0 + Su1 z
Suo
(ksf)
Su1
(ksf/ft)
-0.0268
0.0034
0.0191
0.0043
0.0635
0.0052
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
Lower
50
Ave
Depth z (ft)
100
Upper
150
200
250
300
350
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(B.5)
(B.6)
where:
Wlanded = landing load
Wsurf = air weight of surface casing
Wcmt = air weight of cementing string (the drill pipe below the mudline)
Wcmt-fld = weight of fluid inside cementing string
Wcmt-surf-fld = weight of fluid occupying the volume between the outside of the cementing string and
the inside of the surface casing.
Wsurf-fld = weight of fluid displaced by the surface casing
This formulation assumes that the weight of the cementing string is part of the landing load.
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Wlanded
Fluid inside surface
casing
Wsurf
Wcmt
Fluid outside surface
casing
Fy = 0 = Fhook Wdp PtAt + PbAb + Wlanded + PxoAxo Wsurf PziAzi PziAdp + PzoAzo
(B.7)
Wlanded = -Fhook + Wdp + PtAt + PbAb - PxoAxo + Wsurf + PziAzi + PziAdp - PzoAzo
(B.8)
It is important to note that areas At and Ab are not equal. At includes the cross-sectional area at the
top of the surface casing, whereas Ab only considers the area exposed between the inside of the
surface casing and the outside of the drill pipe.
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Fhook
+
PtAt
Wlanded
PbAb
Wsurf
Wdp
PxoAxo
PziAzi
PzoAzo
PziAdp
Figure B-4Pressure-Area Technique to Determine the Landing Load with Drill Pipe
The influence of the drill pipe can be removed from the analysis in order to obtain a simplified
solution for the landing load. An example landing load calculation is included in Appendix B.
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(B.10)
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+
PtAt
Wlanded
PbAb
Wsurf
PxoAxo
PziAzi
PzoAzo
Figure B-5Pressure-Area Technique to Determine the Landing Load without Drill Pipe
When computing the landing weight, consider designing for the case during the cement job when
the lighter weight spacer fluid is in the open hole and the cement is in the inner cement string, if
appropriate.
L=
(B.11)
where:
L = Required conductor length below mudline
A = (0.055)[2 + log(t)](p)(D)(Su1)
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The ultimate choice of safety factor remains with the user, but it is recommended that the setting
depth be determined using a minimum safety factor of 1.3 against the weight to be landed
(i.e., FS1=1.0 and FS2=1.3). The available GOM data suggests that Eq. B.11 may be valid for
conductors installed both with and without reciprocation, provided the jet nozzles are 12 to 18
above the conductor tip and the reciprocation strokes are not excessive.
The WOB utilization ratio, R, should be kept less than 1.0 to avoid compressive stresses in the
BHA and running string, as well as to prevent buckling. The immediate capacity is arbitrarily
defined at a time equal to 0.01 day (on the log cycle graph). This corresponds to roughly
14 minutes, and is consistent with past practices.
This method is inherently conservative since the setup curves are lower bounds based on proof
load tests and not on load tests to failure. In addition, any drag due to hole deviation and/or
doglegs reduces the weight to be landed. However, the recommended average shear strength
profile may or may not be conservative depending on the site location. Also, keep in mind that
this method does not account for any hydraulic fracture requirements, which may dictate a deeper
setting depth.
(B.12)
The WOB profile from the mudline to the point where reciprocation starts can be calculated using
Eq. B.13. The shear stress term is reduced by one-half to compensate for the reduced friction
between the conductor and the disturbed soil moving past the conductor. A reduction factor of 0.5
is generally a good representation of this phenomenon.
WOBno recip = D
( 2z ) (Su
+ Su1 z )
(B.13)
Once the depth is reached (zrecip) where the WOB calculated from Eq. B.13 is equal to one-half the
useable WOB, the WOB profile should increase linearly so as to reach the maximum allowable
WOB at target depth. Eq. B.14 can be used to predict the depth where reciprocation should begin.
Be very careful to use a consistent set of units when using Eqs. B.13 and B.14. An example is
illustrated in Figure B-6.
zrecip =
B-12
-0.5Suo +
usable
)
(0.5Suo )2 + ( Su1WOB
D
Su1
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where:
WOBno recip = Recommended WOB up to a depth of zrecip
WOBusable = Maximum usable WOB during jetting
z = Depth below mudline
zrecip = Depth below mudline where reciprocation begins
Recommended Weight on Bit (kips)
0
20
40
60
80
100
120
140
50
Depth (ft)
100
150
200
Note:
Dashed line indicates no reciprocation
Solid line indicates reciprocation
250
Figure B-6Recommended WOB profile During Jetting Operation
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Figure B-7 illustrates a good WOB record. Note that the recommended profile uses an assumed
soil shear strength at the site, which explains the slight difference between the predicted and actual
WOB profiles before reciprocation starts.
Figure B-7An Example of a Good Conductor Jetting WOB Record and Comparison with the
Recommended Profile
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Figure B-8 illustrates poor WOB profiles during jetting. Either the WOB is maximized too soon,
in which case no friction is gained from the lower part of the soil profile, or the WOB is not
maximized at all, which means that the immediate capacity calculated using the described method
grossly overestimates the actual immediate capacity. Although both conductors were installed to
target depth, their load bearing capacity has been reduced from what is calculated by the methods
presented here.
Recommended WOB (kips)
0
20
40
60
80
100
120
140
50
Depth (ft)
100
150
200
250
Figure B-8Examples of Poor WOB Profiles
B.2.5 RECIPROCATIONS
The purpose of reciprocations is to remove friction along the outside of the conductor to allow
penetration. Current weights of the conductor and BHA are not sufficient for full penetration
without reducing friction. The amount of friction reduction is, at least in part, a function of the
amount and stroke length of reciprocation.
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ed
sir
De
B
WO
ge
ra n
WOB
Excessive soil
damage Conductor capacity
effected
It is desirable to reciprocate such that some of the friction is reduced without causing extreme
damage to the soil, while at the same time ensuring that the conductor does not get stuck or build
an unacceptable angle before the desired penetration is met. This is illustrated qualitatively in
Figure B-9. The red area to the left of the recommended WOB profile represents a condition
where the soil will be extremely damaged, which will result in slow soil healing times (reduced
Da values) and perhaps a permanent loss of soil strength. The red area to the right of the WOB
profile represents conditions where the conductor may be unable to be pulled free or excessive
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angles from the vertical may build in the conductor. The desired WOB profile should fall between
these two red regions as shown in Figure B-9.
Work performed by the Norwegian Geotechnical Institute suggests that GOM soils with a ratio of
the undrained shear strength to the effective vertical stress less than one-half (Su/sv<0.5) will tend
to squeeze into an open hole. This implies that soil would be scraped away on the downward
reciprocation stroke causing a reduction in lateral stresses and inducing shear stresses in the soil at
points away from the conductor-soil interface. A reduction in lateral stresses will impact the
immediate capacity of the conductor. Furthermore, the induced shear stresses will cause pore
water pressures to increase and will result in longer healing (setup) times. Since reciprocation is
necessary for conductor installation, it is recommended that the length of the reciprocation stroke
be minimized and kept less than 10 ft, measured at the mudline (10 ft up and 10 ft down). By
minimizing the length of the open hole, it is possible that the stresses in the soil may arch around
the open hole, thus minimizing any squeezing of the soil into the open hole.
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RECOMMENDATIONS
If available, use site-specific soil boring data. If soil boring data is not available, review
high-resolution seismic data over the well area. If data do not show signs of active or
relic geohazards such as faults, landslides, buried channel, or erosion, capable of
influencing the soil shear strength in the top 300 ft, then use the average GOM soil
properties given in Table B-2. If active geological processes are suggested, an
experienced geotechnical engineer should modify the soil profile. A soil boring may be
required for extreme cases.
2.
Calculate the weight to be landed using Eq. B.6. The density of the fluid in the open hole
should be carefully considered to take full advantage of the buoyancy provided by the
mud. However, consider designing for the load case during the cement job when the
lighter weight spacer fluid is in the open hole and the cement is in the inner cement
string.
3.
Calculate the required conductor setting depth using Eq. B.11. A minimum safety factor
of 1.3 is recommended (i.e., FS1=1.0 and FS2=1.3).
4.
Using Eqs. B.12, B.13, and B.14, construct a WOB profile to be followed during jetting.
B.3.2 DOCUMENTATION
It is recommended to carefully document each conductor installation. The following list describes
the minimum data that should be recorded.
B-18
1.
2.
WOB profile from mudline to final depth, including pump volume and rates,
reciprocation length and intervals.
3.
Setup time between end of jetting and landing of the first string.
4.
Mud weight in the hole prior to landing, with indication of depths (if any) where the well
might be flowing.
5.
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B.3.3 OPERATIONS
Based on the available data, there appears to be no single aspect of the conductor jetting process
that clearly causes a conductor to subside. However, back analysis of available data trends,
coupled with conventional soil mechanics principles, suggests the following recommendations.
Each recommendation listed below alone may not result in conductors that do not subside.
However, it is expected that small changes in design and operations will make the difference
between success and failure.
1.
Follow the recommended WOB profile. Of the seven conductors that have failed in
2002, none have followed the recommended WOB profile. A drill string with higher
over pull capability should allow for more aggressive jetting. Contractors involved in the
operational aspects of the jetting procedure indicated the last 100 ft of jetting is difficult,
and they are fearful of sticking the conductor. Because of the fear of sticking the pipe,
the conductor is jetted in using excessive reciprocation. Jetting the conductor with a drill
string capable of providing more over pull may alleviate the problem of getting the
conductor stuck.
2.
3.
4.
The average GOM shear strength data given in Table B-2 should be used with caution.
In fact, the data in Table B-2 should only be used if site-specific soils data is not available
and geophysical information does not indicate anomalous features.
5.
Cement the surface casing prior to landing the full weight of the surface casing on the
conductor. This will reduce the fully landed weight by about 25% due to the extra
buoyancy provided by the cement.
6.
7.
8.
Minimize the pump rate to less than 1,000 gpm and pressures below 2,000 psi.
9.
10. Assume the smallest conductor diameter when running the calculations (e.g., use a 36-in.
diameter when determining the jetted length for a 36-in. x 38-in. conductor).
11. Following the recommended WOB profile can result in compressive loads in the BHA
above the mudline. There has been some concern that this may build angle in the
conductor as the jetting process continues, but three recent jetting operations have been
performed, all following and some even exceeding the recommended WOB profile. All
three conductors were successfully jetted within acceptable vertical limits.
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2.
When computing the landing load, consider designing for the peak loading case. If
appropriate, use a combination of drilling mud and lighter weight spacer fluids in the
open hole and cement inside the inner string. Typically, landing weights are computed
assuming 12.0 to 12.5-ppg mud in both the open hole and inner string that results in
underestimating the peak landing load by about 15 percent.
3.
For conductors greater than 220 ft in length, UTG should be consulted regarding conductor
design and jetting procedures.
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WELL FAILURES
Despite the lessons learned, seven conductors on BP wells subsided in 2002. These include:
1.
2.
3.
4.
The jetted lengths for these conductors range from 210 ft to 314 ft, with the majority of the jetted
lengths greater than 260 ft. In each of these failures, none of the installations followed the
recommended WOB profile discussed in section B.2.4.
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GLOSSARY OF TERMS
BHA
Bottomhole assembly
BOP
Blowout preventer
CADA
JETCAP Design program designed by UTG, used to compute lengths and weights
B-22
POOH
ROP
Rate of penetration
ROV
WOB
Weight on bit
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REFERENCES
1.
Beck, R.D.; Jackson, C.W.; and Hamilton, T.K. (1991) Reliable Deepwater Structural
Casing Installation Using Controlled Jetting.
2.
Frugo Limited.
3.
4.
Jeanjean, P.; Trevor, T.; and Hampson, K. (1999) BP Amoco UTG Recommended
Practice for Jetted Conductor Setting Depth for Gulf of Mexico Deepwater Applications,
Report No. 9921CEH001.
5.
Jeanjean, P. (2002) SPE 77357, Innovative Design Method for Deepwater Surface
Casings.
6.
7.
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APPENDIX A
DERIVATION OF THE REQUIRED CONDUCTOR LENGTH, L
The capacity of the jetted conductor can be expressed as:
Qt = Q0 + SETUP = WOBlast + 0.055[2 + log(t)](DL)(SuAVE)
(A.1)
with:
t = Time, in days
Qt = Conductor capacity at time = t
WOBlast = Weight on bit measured at final penetration
D = Conductor diameter
L = Conductor length below mudline
SuAVE = Average undrained shear strength over the length of the conductor
The last WOB measured is assumed to be proportional to the available weight during jetting. The
constant of proportionality, called the WOB utilization ratio, is noted R. As discussed in the main
text, R should be close to 0.8 as per past practice. It should not exceed 1.0 in order to maintain
tension in the jetting assembly.
Therefore:
Q0 = WOBlast = R(Wcond + WWH + WDC + WCADA)
(A.2)
with:
Q0 = Conductor capacity immediately after jetting (t = 0.01 days)
WOBlast = Last weight on bit recorded during installation
R = WOB utilization ratio, should be equal to 0.8
Wcond = Buoyed weight of the conductor, in water
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(A.3)
with:
w1 = Weight per unit length of upper conductor section in water
L1 = Length of upper conductor section (usually equal to 80 ft)
w2 = Weight per unit length of lower conductor section in water
WDC = wDCL
(A.4)
with:
wDC = Weight per unit length of drill collars in water
Combining A.3 and A.4 into A.2 gives:
Q0 = R[w1L1 + w2(L - L1) + WWH + wDCL + WCADA]
(A.5)
The average shear strength along the conductor length L can be expressed as:
SuAVE = Su0 + Su1L
(A.6)
with:
Su0 equals 0.0191 ksf for an average GOM soil profile
Su1 equals 0.0043 ksf/ft for an average GOM soil profile
Combining A.5 and A.6 into A.1 gives the total capacity:
Qt = R[w1L1 + w2(L - L1) + WWH + wDCL + WCADA] + 0.055[2 + log(t)](DL)(Su0 + Su1L)
(A.7)
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with:
LOAD = Load to be resisted by the conductor
Wlanded = Load to be landed on conductor (do not include self-weight of conductor)
FS1 = Safety factor on weight of conductor and wellhead
FS2 = Safety factor on weight to be landed
If the quantities Wlanded, FS1, FS2 are given, the load to be resisted is also a function of one
unknown, L.
Since the load and resistance are equal:
Qt = LOAD
(A.9)
Substituting Eqs. A.7 and A.8 into A.9 and re-arranging yields the following quadratic equation:
AL2 + BL + C - (FS2)(Wlanded) = 0
(A.10)
with:
L = Required conductor length below mudline
A = 0.055[2 + log(t)](pD)(Su1)
B = R(wDC + w2) + 0.055[2 + log(t)](pD)(Su0) - FS1w2
C = R[WWH + WCADA + L1(w1 w2)] - (FS1)(WWH) + (FS1)[L1(w2 - w1)]
The solution to Eq. A.10 can be expressed as follows, all quantities as previously defined:
L=
(A.11)
The required conductor length below mudline is a function of the square root of the weight to be
landed on the conductor.
B-26
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B P
U T G
D R I L L I N G
T E C H N O L O G Y
P R O J E C T
APPENDIX B
EXAMPLE CALCULATION: LANDING LOAD
Given the following data, calculate the landing load.
Water Depth: 3,775 ft
Drill pipe cementing/landing string OD: 5-in.
Drill pipe cementing/landing string ID: 4.276-in.
Drill pipe actual weight: 22.6 lbf/ft
Surface casing:
Draft D, 12/11/02
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B-27
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D R I L L I N G
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P R O J E C T
METHOD ):
The difference between the two solutions is due to the formulations used by both methods. The
volume displacement method was formulated to take into account the weight of the cementing
string, whereas the pressure area method was not. Either method can be reformulated to consider
the most appropriate condition.
B-28
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P R O J E C T
APPENDIX C
EXAMPLE CALCULATION: REQUIRED CONDUCTOR LENGTH
Given the following conductor data below, calculate the required conductor length to
accommodate an estimated 230 kip landing load with 3 days of healing time. Use a safety factor
of 1.5 on the weight to be landed, and a utilization ratio of 0.8.
CADA tool = 3,500 lbf (in air)
Wellhead housing = 10,000 lbf (in air)
Drill collars = 209 ppf (in air)
Water Depth: 3,775 ft
Conductor casing:
S OLUTION :
A = 0.055[2 + log(t)](pD)(Su1)
A = 0.055[2 + log(3)](p)(3 ft)(4.3 lbf/ft3) = 5.52 lbf/ft2
B = R(wDC + w2) + 0.055[2 + log(t)](pD)(Su0) - FS1w2
wDC = 1-
w2 = 1-
Draft D, 12/11/02
8.6
209 = 182 ppf
65.44
8.6
374 = 325 ppf
65.44
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B-29
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P R O J E C T
wWH = 1-
8.6
10, 000 = 8, 686 lbf
65.44
8.6
3,500 = 3, 040 lbf
65.44
wCADA = 1-
w1 = 1-
8.6
727 = 632 lbf/ft
65.44
L=
L=
B-30
2 (5.52)
DWGOM-GP 02-1019
= 242 ft
Draft D, 12/13/02