Proceeding of Marine Safety and Maritime Installation (MSMI 2018)

The Implementation of API RP 1102 Code to Evaluate

Gas Pipeline Road Crossing
Nurhadi Siswantoro1,a,*, Muhammad Badrus Zaman1,b, Semin1,c, and Dwi Priyanta1,d
1
Department of Marine Engineering, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia
a. [email protected], b. [email protected], c. [email protected],
d. [email protected]
*corresponding author

Keywords: API RP 1102; Gas Pipeline; Road Crossing; and Stress Analysis

Abstract: This paper discussed about evaluation stress on gas pipeline. A pipeline
transports LPG (Liquefied Petroleum Gas) from jetty to storage tank area along 1200
meters. The pipeline has nominal pipe size (NPS) 10 inches and buried in areas with high
population levels (areas with high consequences). At KP 800 meter the segment of pipeline
has road crossing conditions, where vehicles such as heavy vehicles pass across above.
Pipeline has operated during about 8 years, it necessary study to evaluate the integrity or
strength. One of the methods to evaluate buried and road crossing pipelines is determining
stress occurs. Stress analysis for pipeline road crossing is evaluated using code API RP
1102 (Pipelines Crossing Railroads and Highway). Based on these standards, the pipeline
road crossing is evaluated by stress components such as (a) Circumferential Stress, (b)
Longitudinal Stress, (c) Radial Stress. The calculation will be analysed using spreadsheet
modelling. Based on the stress analysis in existing operational condition, the segment in KP
800 is Acceptable according Standard API 1102. All parameters show acceptable,
furthermore the pipeline is concluded in satisfactory condition.

1. Introduction

Terminal LPG company involved in the services of receiving, stockpiling and distributing the
LPG. The company has responsible for ensuring its assets in high integrity. The process of
receiving, stockpiling and distributing the LPG. The company has responsible for ensuring its assets
in high integrity. The process of receiving, stockpiling and distribution starts from the Jetty head,
which functions to carry out receipts from Tanker. In the jetty head there is a marine loading arm
equipment that serves to connect the manifold pipe of the tanker with a pipe from the ground and
transport LPG into a storage tank. The LPG pumping from the tanker uses a 10-inch diameter pipe
along 1200 meters before entering the tank. The pipe is able to flow LPG from tankers up to 300
MT / hour.
Pipe is the main asset in transporting LPG from the process of reception (jetty head) to storage
tank. At KP 00 + 800 meters from the jetty head, pipes crossing the road. The greatest load due to

Published by CSP © 2018 the Authors 240

the crossing when the heavy vehicle passes over. The heavy equipment that passes over the pipe is
Komatsu PC-200 type with loads greater than 20 tons.
To ensure the integrity of the LPG pipeline that has been operating for 8 years, it is necessary to
evaluate the strength of the pipeline. Pipe stress analysis is the most important method for
convincing and numerically determining that piping systems in engineering are safe, or a method of
stress calculation on pipes caused by static loads and dynamic loads that are the resultant effects of
gravity, temperature change, pressure inside and outside the pipe, changes in the amount of fluid
discharge flowing in the pipe and the effect of seismic forces [1].
API RP 1102 Steel Pipeline Crossing Railroad and Highways is one of the methods / standards
to evaluate the strength of pipes that have undergone road crossing. In this standard, pipe will be
evaluated based on longitudinal stress, circumference stress / Hoop stress, and radial stress [2].

Figure 1: (a) Burried pipeline and before road crossing ; (b) Pipeline arrise after buried

2. Methodology

In evaluating the strength of the pipe, inspection is required to obtain the data for consideration in
the calculation. Here are some documentation:
• Complete design and fabricarion drawing / as buid drawing.
• Manufacture data.
• Inspection Report.
• History records.
• A sketch showing the location of the thickness measurement.
• All records and repair performed along with procedures and test records.
Can be seen in Figure. 2, it shows flowchart methodology API calculation RP 1102. Based on the
API 1102 standard, the road crossing pipeline is evaluated with concern to longitudinal stress,
circumference stress / Hoop stress, and radial stress. Here are the stress components calculated on
the road crossing pipeline:
a. Circumferential Stress
Circumferential Stress is affected by the following components:
• Circumferential stress due to earth load

𝑆𝐻𝑒 = 𝐾𝐻𝑒 𝐵𝑒 𝐸𝑒 𝛾𝐷 (1)

Where,
𝑆𝐻𝑒 = Circumferential stress due to earth load
𝐾𝐻𝑒 = Stiffness factor for circumferential stress from earth load

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𝐵𝑒 = Burial factor for earth load circumferential stress
𝐸𝑒 = Excavation factor for earth load
𝛾 = Soil unit weight
𝐷 = Pipe outside diameter

Begin
Pipe data, operational,
installation condition,
and site characteristics

Internal Load
External Load

Earth load Live load

Calculate circumference stress
Calculate circumference Calcuate wheel load, w due to internal pressure
stress due to earth load and impact factor, Fi (Equation 3)
(Equation 1) (Figure 4)

Calculate circumference stress

Calculate cyclic due to internal pressure using
circumference stress Barlow formua.
due to live load (Equation 9)
(Equation 2)
Calculate cyclic
longitudinal stress due
Shi Barlow allowable
to live load Fails
(Equation 5)
Pass

Calculate the principal stresses,

S1, S2, S3
(Equation 4, 6, 7)

Calculate effective stresses, Seff

(Equation 8)

Fails Check for allowable Seff

(Equation 11)

Pass

Fails Check for fatigue

(Equation 12, 13)

Pass

Satisfactory design

End

Figure. 2: Flowchart stress analysis pipeline road crossing based on API RP 1102

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 • Circumferential stress due to internal pressure

𝑝(𝐷−𝑡𝑤 )
𝑆𝐻𝑖 = (3)
2𝑡𝑤

Where,
𝑆𝐻𝑖 = Circumferential stress due to internal pressure
𝑝 = Maximum operating pressure
𝐷 = Pipe outside diameter
𝑡𝑤 = Wall thickness

• Maximum circumferential stress

𝑆1 = 𝑆𝐻𝑒 + ∆𝑆𝐻 + 𝑆𝐻𝑖 (4)

b. Longitudinal Stress
Longitudinal Stress is affected by the following components:
• Longitudinal stress due to highway vehicular load

∆𝑆𝐿𝑘 = 𝐾𝐿𝑘 𝐺𝐿𝑘 𝑅 𝐿 𝐹𝑖 𝑤 (5)

Where,
∆SLk = Longitudinal stress due to highway vehicular load
K Lk = Highway stiffness factor for cyclic longitudinal stress
GLk = Highway geometry factor for cyclic longitudinal stress
R = Highway pavement type factor
L = Highway axle configuration factor
Fi = Impact factor
w = Applied design surface pressure

𝑆2 = ∆𝑆𝐿 − 𝐸𝑠 𝛼 𝑇 (𝑇2 − 𝑇1 ) + 𝑉𝑠 (𝑆𝐻𝑒 + 𝑆𝐻𝑖 ) (6)

where,
∆𝑆𝐿 = Longitudinal stress due to highway vehicular load
𝐸𝑠 = Young's modulus of steel
𝛼𝑇 = Coefficient of thermal expansion of steel
𝑇2 = Maximum or minimum operating temperature
𝑇1 = Temperature at time of installation
𝑉𝑠 = Poisson ratio of steel
𝑆𝐻𝑒 = Circumferential stress due to earth load
𝑆𝐻𝑖 = Circumferential stress due to internal pressure

c. Radial Stress
Radial Stress is affected by internal pressure.

𝑆∃ = −𝑃 (7)

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Where,
𝑆∃ = Radial stress
𝑃 = MOP (Maximum Operating Pressure)

3. Result and Discussion

3.1.Pipe Data

The basic technical data of pipes from jetty head to storage tank are as follows:
a. Service : LPG
b. Material/Schedule : API 5L Gr.B/Sch 40
c. SMYS : 35000 psi
d. Nominal Diameter : 10 inches
e. Outside Diameter : 10.75 inches
f. Inside Diameter : 10.02 inches
g. Thickness Nominal : 0.365 inches
h. Type Joint : ERW
i. Operating Pressure : 130 psi
j. Operating Temperature : 24.8 - 77 oF
k. Valve rating : 300#
l. flange rating : 300#
m. Design Factor : 0.5 (Class Location 3)

3.2.Stress Calculation

1. Area condition of pipeline road crossing

The soil condition in the road crossing area is soft to medium clay category, and loose sand and
gravel. The pipeline is located in an area with a density of > 46 buildings and industrial, and as
according to ASME B31.8 belongs to Class Location category 3 [3,5,6]. Maximum vehicle load
received by pipe is Komatsu PC-200 with load more than 20 tons. Pipe buried with a depth of 2.7
meters. The specifications of Komatsu PC-200 can be seen in Figure. 3.

Figure 3: (a) (b) The specification of Komatsu PC-200

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 2. Wheel load
Wheel loads by ground-contact Komatsu PC-200 at a depth of 2.7 meters shall be correlated
with Impact Factor values. Impact Factor for highways 1 – 1.5 and decreased 0.03 per ft (0.1 per m)
to depths below 5ft (1.5 m). Because of the burried pipe depth of 2.7 m, the impact factor ± 1.4. The
impact factor graph can be seen in Figure 4.

Figure 4: Recommended impact factor versus depth

For Komatsu PC-Bego 200 used the value of impact factor of 1.4, it becomes the size of wheel
loads is 6.97 lb/in2.

3. Circumference stress
Circumference stress is caused by earth load, vehicular load, and internal pressure. The
circumference stress calculation uses (1), (2), and (3).
• Earth Load
Table 1 is the summary calculation on circumference due to earth load (SHe) based on (1).

Table 1: Summary Calculation Circumference due to Earth Load

 D 𝑺𝑯𝜽
𝑲𝑯𝜽 𝑩𝜽 𝑬𝜽 3
(lb/in ) (inch) (psi)
800 1.3 1 0.069 10.75 771.42

• Vehicular Load
Table 2 is a summary of calculations on circumference due to vehicular load (SHh) based on
(2).

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 Table 2: Summary Calculation Circumference due to Vehicular Load
𝑲𝑯𝒌 𝑮𝑯𝒌 R L 𝑭𝒊 W ∆𝑺𝑯𝒌
(lb/in2) (psi)
11 0.85 1.1 1 1.4 6.97 100.39

• Internal Pressure
Table 3 is summary calculation on circumference due to internal pressure (S Hi) based on (3).

Table 3: Summary Calculation Circumference due to Internal Pressure

𝑝 D tw SHi
(psi) (inch) (inch) (psi)
130 10.75 0.365 1849.38
Total of circumference stress is sum of earth load, vehicular load and internal pressure.
From the calculation, total of circumference stress is 2721.19 psi.
4. Longitudinal stress
Longitudinal stress, caused by vehicular load. The calculation of longitudinal stress using (5).
After calculating the longitudinal load due to vehicular load, then maximum longitudinal stress may
be used in the (6). Table 4 is summary calculation on longitudinal stress.

Table 4: Summary of Calculation of Maximum Longitudinal Stress

w ∆𝑺𝑳𝒌
𝑲𝑳𝒌 𝑮𝑳𝒌 R L 𝑭𝒊 (lb/in2) (psi)
10.5 1 1.1 1 1.4 6.97 112.74
The maximum of longitudinal stress from calculation based on (6) is 2339 psi
5. Radial stress
Radial stress, caused by internal pressure. By the data of pipe, the maximum operating pressure
(MOP) is 130 psi. So, the radial stress is equivalent with the MOP -130 psi.
6. Effective stress
After the total of maximum stress, the next step is continued to calculate total effective stress
from (8).

S eff =
1
2

(S1 − S 2 )2 + (S 2 − S3 )2 + (S3 − S1 )2  (8)

Where,
S1 = Maximum circumferential stress, psi
S2 = Maximum longitudinal stress, psi
S3 = Maximum radial stress, psi
From this formula, total effective stress (Seff) is 2681 psi.

7. Check for calculation stress

From previous calculation, the next steps are checked for the maximum stress based on Barlow
Formula and Effective Stress.

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▪ First check for circumferential stress (Barlow formula)
Checking for the safety at internal pressurization is accomplished by assuring that the
circumferential stress due to internal pressure calculated by Barlow formula is less than the factored
specified minimum yield strength [3,4]. Barlow stress formula is shown in (9).

SHi (Barlow) = pD/2tw (9)

The calculation of SHi (Barlow) is 1914 psi. Stress level is acceptable if:

SHi (Barlow) ≤ F x E x T x SMYS (10)

Where,
F = Design factor
E = Longitudinal joint factor
T = Temperature derating factor
SMYS = Specified minimum yield strength

From this calculation of F x E x T x SMYS = 17500 psi. Since SHi (Barlow) less than 17500
psi, then SHi (Barlow) is Acceptable.

▪ Second check for total effective stress

The check against yielding of the pipeline is accomplished by assuring that the total effective
stress is less than the factored specified minimum yield strength.
The calculation of total effective stress is 2681 psi. Stress level is acceptable if:

Seff ≤ F x SMYS (11)

From this calculation of F x SMYS = 17500 psi. Since Seff less than 17500 psi, then Seff is
Acceptable.

8. Check for fatigue

The check for fatigue is accomplished by comparing a stress component normal to weld in the
pipeline againts an allowable value of this stress, referred to as a fatigue endurance limit.

▪ First check for potential fatigue in girth weld

The cyclic stress that must be checked for potential fatigue in a girth weld located beneath a
roadcrossing is the longitudinal stress due to live load. The design check is accomplished by asuring
that the live load cyclic longitudinal stress is less than the factored fatigue endurance limit. The
girth weld check is given by the following

∆SLh ≤ SFG x F (12)

From this calculation of SFG x F = 6000 psi, and ∆SLh from Table 4 is 112.74 psi. Since ∆SLh
less than 6000 psi, then potential fatigue in girth weld is Acceptable.

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▪ Second check for potential fatigue in longitudinal weld

The cyclic stress that must be checked for potential fatigue in a girth weld located beneath a
roadcrossing is the circumferential stress due to live load. The design check is a accomplished by
asuring that the live load cyclic circumferential stress is less than the factored fatigue endurance
limit. The longitudinal weld check is given by the following

∆SHh ≤ SFL x F (13)

From this calculation of SFL x F = 10500 psi, and ∆SHh from Table II is 100.39 psi. Since ∆SHh
less than 10500 psi, then potential fatigue in longitudinal weld is Acceptable.

4. Conclusions

The Pipeline transports LPG from jetty to storage tank area along 1200 meters. The pipeline has
nominal pipe size (NPS) 10 inches and buried in areas with high population levels (areas with high
consequences). At KP 800 meter the segment of pipeline has road crossing conditions. Based on the
stress analysis in existing operational condition, the segment in KP 00+800 is Acceptable
according Standard API 1102. From the calculation and checking all parameters the segment in KP
00+800 is Acceptable by checked for four parameters:
▪ Acceptable by checked circumference stress (Barlow Stress),
▪ Acceptable by checked total effective stress,
▪ Acceptable by checked potential fatigue in girth weld,
▪ Acceptable by checked potential fatigue in longitudinal weld.
All parameters show acceptable, so it can be concluded that the pipeline is in satisfactory
condition.

References

[1] Liang-Chuan and Tsen-Loong, Pipe Stress Engineering. New York: USA, 2009.
[2] The American Petroleum Institute, API RP 1102, Steel Pipelines Crossing Railroads and Highways. Washington
DC: USA, 2007.
[3] The American Society of Mechanical Engineer, ASME B31.8 Gas Transmission and Distribution Piping Systems.
New York: USA, 2007.
[4] The American Petroleum Institute, API 570 Piping Inspection Code Second Edition : Inspection, Repair, Alteration,
and Rerating of In-service Piping Systems. Washington DC: USA, 2012.
[5] The American Society of Mechanical Engineer, ASME B36.10M Welded and Seamless Wrought Steel Pipe. New
York: USA, 2004.
[6] Alkazraji, Duraid, A Quick Guide to Pipeline Engineering. Abington Cambridge: UK, 2008.

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