Zektin Group

407 Royal Parade

Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION TABLE OF CONTENTS
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 2 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
Calculations
page
1 Wall thickness Calculation for Design internal pressure 3
2 Road Crossing Calculation - 1200mm Cover 4-6
3 Road Crossing Calculation - 1500mm Cover 7-9
4 Road Crossing Calculation - State Controlled Crossing 1200mm Cover 10-12
5 Road Crossing Calculation - State Controlled Crossing 1500mm Cover 13-15
6 Road Crossing Calculation - Unformed infrequent use 16-18
7 Resistance to Penetration Calculation 19
8 Pipe Ovality 20
9 Wall thickness Summary 20
10 Wall thickness Calculation for Design internal pressure of bends 21
11 Buoyancy of Pipe 22
12 Permissible External Pressure 23
Attachments
1 American Lifelines Alliance: Guidelines for the design of Buried 34 pages
Steel Pipe, July 2001. Sections 1-6
2 Density of soils: Marks' Standard Handbook for Mechanical 1
Engineers, 8th Ed, pg 6-8

G
G
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 3 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
1. Required Wall thickness Calculations as per AS2285.1
Design Pressure P
D
= 10.2 MPa
Nominal Pipe Outside Diameter D = 1067 mm
Design Factors F
D
= 0.8 Below Ground Pipe - Option 1
F
D
= 0.72 Below Ground Pipe - Option 2
F
D
= 0.67 Pipeline Assemblies - Above ground Pipe
Design Temperature (Below Ground Pipe) T
d1
= 65
o
C
Design Temperature (Above Ground Pipe) T
d2
= 85
o
C > 65
o
C therefore derate of yield strength
required as per AS2885.1 3.4.3
Below Ground Piping:
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Specified Min Yield Strength API5L X80
YX80
= 555 MPa API5L - 2007 Standard Table 7
Above ground Piping
Reduction in yield = 0.07%/
o
C by which the design temperature exceeds 23
o
C
therefore reduction in yield = 4.34 %
Specified Min Yield Strength API5L X70
YX70
= 463.95 MPa
Specified Min Yield Strength API5L X80
YX80
= 530.91 MPa
1.1. Wall Thickness for design internal pressure (t
p
) AS2285.1 section 5.4.3
equation 5.4.3
For Design Factor F
D
=0.8 (Below Ground Pipe):
Wall thickness for design internal pressure for API5L X70 t
pX70
= 14.03 mm
Wall thickness for design internal pressure for API5L X80 t
pX80
= 12.26 mm
For Design Factor F
D
=0.72 (Below Ground Pipe):
Wall thickness for design internal pressure for API5L X70 t
pX70
= 15.58 mm
Wall thickness for design internal pressure for API5L X80 t
pX80
= 13.62 mm
For Design Factor F
D
=0.67 (pipeline assembly sections - Above Ground Pipe) :
Wall thickness for design internal pressure for API5L X70 t
pX70
= 17.51 mm
Wall thickness for design internal pressure for API5L X80 t
pX80
= 15.30 mm
Summary - Calculated wall thickness requirements for internal pressure:
Grade FD
Nominal
Thickness (mm)
API5L X70 0.80 14.10
API5L X70 0.72 15.60
API5L X70 0.67 17.60
API5L X80 0.80 12.30
API5L X80 0.72 13.70
API5L X80 0.67 15.30

Y D
D
p
F
D P
t
2
=
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 4 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
2. Road Crossings as per AS2885.1 Clause 5.7.3 and API RP 1102 Section 4.
All road crossing except for state controlled road crossings, ie council controlled, maintained access roads crossings.
Design Pressure P
D
= 10.2 MPa
Nominal Pipe Outside Diameter D = 1067 mm
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Specified Min Yield Strength API5L X80
YX80
= 555 MPa API5L - 2007 Standard Table 7
Pipe Wall Thickness for API5L X70 pipe t
wX70
= 18.00 mm (min required)
Pipe Wall Thickness for API5L X80 pipe t
wX80
= 15.20 mm (min required)
Temperature Derating Factor T = 1 AS2885.1 Section 3.4.3, T<65
o
C (Underground Sections)
Design Factor F = 0.72 AS2885.1 5.7.3(i)
Longitudinal joint factor E = 1
Installation Depth H = 1200 mm (Min required at road crossings, AS2885.1 fig 5.8.8(B)
Bored diameter Bd = 1067 mm (Assume = D for trench construction)
Modulus of soil reaction E' = 3.4 MPa (Table A-1 Soft/medium clays/silts, loose sands and gravels)
Resilient Modulus Er = 34 MPa (Table A-2 Soft to medium clays and silts)
Soil Density = 18.9 kN/m
3
(Recommended value 4.7.2.1)
2.1 Circumferential Stress due to Earth Loads API RP 1102 4.7.2.1
Stiffness factor for circumferential stress from earth load K
HeX70
= 3500 figure 3 t
w
/D = 0.017
K
HeX80
= 4550 figure 3 t
w
/D = 0.014
Burial Factor for Earth load B
e
= 0.37 figure 4 H/B
d
= 1.125
Excavation Factor E
e
= 1 figure 5 B
d
/D = 1.000
Circumferential Stress due to earth load on API5LX70 pipe S
HeX70
= 26.12 MPa
Circumferential Stress due to earth load on API5LX80 pipe S
HeX80
= 33.95 MPa
2.2 External Live Load - Road Crossing
Determine critical load case:
The design wheel load shall be either the maximum wheel load from a trucks single axle or the maximum wheel load from a trucks tandem
axle. The critical design case shall be determined as follows:
W80 wheel loading and A160 Axle loading - Single Axle:
Applied vehicle design surface pressure w = 800 kPa (W80 wheel loading and A160 axle loading AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.22 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 0.65 Table 2
M1600 Moving Traffic loading - Tandem Axle:
Applied vehicle design surface pressure w = 750 kPa (M1600 moving traffic loading. AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.18 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 1 Table 2
Critical load case is the maximum of : (Based on equation 5 where F
i
= 1+DLA)
A160 = 698
M1600 = 974
Therefore the critical vehicle load case for design is the tandem axle load case - M1600 moving traffic loading.

D E B K S
e e He He
=
( ) w DLA L R + 1
G
G
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 5 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
2.3 Cyclic Stresses API RP 1102 4.7.2.2.4.1
The cyclic circumferential stress due to highway vehicular load: (5)
Highway stiffness factor cyclic circumferential stress API5L X70 K
HhX70
= 20.4 (figure 14)
Highway stiffness factor cyclic circumferential stress API5L X80 K
HhX80
= 20.7 (figure 14)
Highway geometry factor for circumferential stress G
Hh
= 0.95 (figure 15)
Highway pavement factor R = 1.1 Table 2 (Tandem axle no pavement)
Highway axle configuration factor L = 1 Table 2 (Tandem axle)
Impact Factor F
i
= 1.18 (1+DLA)
Cyclic circumferential stress for API5L X70 S
HhX70
= 18.87 MPa
Cyclic circumferential stress for API5L X80 S
HhX80
= 19.14 MPa
The cyclic longitudinal stress due to Highway vehicular load: (6)
Highway stiffness factor cyclic longitudinal stress API5L X70 K
LhX70
= 15 (figure 16)
Highway stiffness factor cyclic longitudinal stress API5L X80 K
LhX80
= 15.1 (figure 16)
Highway geometry factor for longitudinal stress G
Lh
= 0.77 (figure 17)
Highway pavement factor R = 1.1 Table 2
Highway axle configuration factor L = 1 Table 2
Impact Factor F
i
= 1.18 (1+DLA)
Cyclic longitudinal stress for API5L X70 S
LhX70
= 11.24 MPa
Cyclic Longitudinal stress for API5L X80 S
LhX80
= 11.32 MPa
Cyclic stress due to internal pressure: (7)
Cyclic stress due to internal pressure API5L X70: S
HiX70
= 297.22 MPa
Cyclic stress due to internal pressure API5L X80: S
HiX80
= 352.91 MPa
2.4 Principal Stresses S
1
,S
2
,S
3
API RP 1102 4.8.1.2
Maximum circumferential Stress: (9)
Maximum circumferential Stress API5L X70: S
1X70
= 342.20 MPa
Maximum circumferential Stress API5L X80: S
1X80
= 406.00 MPa

w RLF G K S
i Lh Lh Lh
=
( )
w
w
Hi
t
t D p
S
2

=
Hi Hh He
S S S S + + =
1
w RLF G K S
i Hh Hh Hh
=
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 6 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
2.4 Principal Stresses S
1
,S
2
,S
3
Cont..
Maximum Longitudinal Stress: (10)
Youngs Modulus of steel E
S
= 201138 MPa
@55
o
C
B31.3 Table C-6
Coefficient of thermal expansion
T
= 0.00001108
per
o
C @55
o
C
B31.3 Table C-5
Installation temperature T
1
= 10
o
C
Min Ground Temp as per BOD
Maximum operating temperature T
2
= 55
o
C
Max Gas Temp at CPP outlet
Poisson's Ratio of Steel
S
= 0.3
Maximum Longitudinal Stress API5L X70: S
2X70
= 7.96 MPa
Maximum Longitudinal Stress API5L X80: S
2X80
= 27.09 MPa
Maximum Radial Stress: S
3
= -P = -MAOP (11)
S
3
= -10.2 MPa
2.5 Total Effective Stress API RP 1102 4.8.1.3
The total effective stress: (12)
The total effective stress must satisfy : S
eff
< SMYS x F where F = 0.72 as per AS2885.1 5.7.3 (d)(i)
Total Effective Stress API5L X70 S
effX70
= 343.68 MPa < 349.2 MPa PASS
Total Effective Stress API5L X80 S
effX80
= 398.87 MPa < 399.6 MPa PASS
2.6 Check for Fatigue in Welds API RP 1102 4.8.2.1
Cyclic stress in girth Weld: (14)
Fatigue endurance limit of girth weld S
FG
= 82740 kPa Table 3
Cyclic longitudinal stress for API5L X70 S
LhX70
= 11.24 MPa < 59.57 MPa PASS
Cyclic Longitudinal stress for API5L X80 S
LhX80
= 11.32 MPa < 59.57 MPa PASS
Cyclic Stress in longitudinal weld: (20)
Fatigue endurance limit of longitudinal weld S
FLX70
= 89635 kPa Table 3 (SAW to be conservative)
Fatigue endurance limit of longitudinal weld S
FLX80
= 96530 kPa Table 3 (SAW to be conservative)
Cyclic circumferential stress for API5L X70 S
HhX70
= 18.87 MPa < 64.54 MPa PASS
Cyclic circumferential stress for API5L X80 S
HhX80
= 19.14 MPa < 69.50 MPa PASS

( ) ( )
Hi He S T S Lh
S S T T E S S + + =
1 2 2
( ) ( ) ( ) [ ]
2
1 3
2
3 2
2
2 1
2
1
S S S S S S S
eff
+ + =
F S S
FG Lh

F S S
FL Hh

Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 7 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
3. Road Crossings as per AS2885.1 Clause 5.7.3 and API RP 1102 Section 4. - 1500mm Cover
All road crossing except for state controlled road crossings, ie council controlled, maintained access roads crossings.
Design Pressure P
D
= 10.2 MPa
Nominal Pipe Outside Diameter D = 1067 mm
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Pipe Wall Thickness for API5L X70 pipe t
wX70
= 18.00 mm (Wall thickness selected)
Temperature Derating Factor T = 1 AS2885.1 Section 3.4.3, T<65
o
C (Underground Sections)
Design Factor F = 0.72 AS2885.1 5.7.3(i)
Longitudinal joint factor E = 1
Installation Depth H = 1500 mm (Max Cover at road crossings
Bored diameter Bd = 1067 mm (Assume = D for trench construction)
Modulus of soil reaction E' = 3.4 MPa (Table A-1 Soft/medium clays/silts, loose sands and gravels)
Resilient Modulus Er = 34 MPa (Table A-2 Soft to medium clays and silts)
Soil Density = 18.9 kN/m
3
(Recommended value 4.7.2.1)
3.1 Circumferential Stress due to Earth Loads API RP 1102 4.7.2.1
Stiffness factor for circumferential stress from earth load K
HeX70
= 3500 figure 3 t
w
/D = 0.017
Burial Factor for Earth load B
e
= 0.45 figure 4 H/B
d
= 1.406
Excavation Factor E
e
= 1 figure 5 B
d
/D = 1.000
Circumferential Stress due to earth load on API5LX70 pipe S
HeX70
= 31.76 MPa
3.2 External Live Load - Road Crossing
Determine critical load case:
The design wheel load shall be either the maximum wheel load from a trucks single axle or the maximum wheel load from a trucks tandem
axle. The critical design case shall be determined as follows:
W80 wheel loading and A160 Axle loading - Single Axle:
Applied vehicle design surface pressure w = 800 kPa (W80 wheel loading and A160 axle loading AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.18 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 0.65 Table 2
M1600 Moving Traffic loading - Tandem Axle:
Applied vehicle design surface pressure w = 750 kPa (M1600 moving traffic loading. AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.15 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 1 Table 2
Critical load case is the maximum of : (Based on equation 5 where F
i
= 1+DLA)
A160 = 672
M1600 = 949
Therefore the critical vehicle load case for design is the tandem axle load case - M1600 moving traffic loading.

D E B K S
e e He He
=
( ) w DLA L R + 1
G
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 8 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
3.3 Cyclic Stresses API RP 1102 4.7.2.2.4.1
The cyclic circumferential stress due to highway vehicular load: (5)
Highway stiffness factor cyclic circumferential stress API5L X70 K
HhX70
= 20.4 (figure 14)
Highway geometry factor for circumferential stress G
Hh
= 0.83 (figure 15)
Highway pavement factor R = 1.1 Table 2 (Tandem axle no pavement)
Highway axle configuration factor L = 1 Table 2 (Tandem axle)
Impact Factor F
i
= 1.15 (1+DLA)
Cyclic circumferential stress for API5L X70 S
HhX70
= 16.06 MPa
The cyclic longitudinal stress due to Highway vehicular load: (6)
Highway stiffness factor cyclic longitudinal stress API5L X70 K
LhX70
= 15 (figure 16)
Highway geometry factor for longitudinal stress G
Lh
= 0.68 (figure 17)
Highway pavement factor R = 1.1 Table 2
Highway axle configuration factor L = 1 Table 2
Impact Factor F
i
= 1.15 (1+DLA)
Cyclic longitudinal stress for API5L X70 S
LhX70
= 9.68 MPa
Cyclic stress due to internal pressure: (7)
Cyclic stress due to internal pressure API5L X70: S
HiX70
= 297.22 MPa
3.4 Principal Stresses S
1
,S
2
,S
3
API RP 1102 4.8.1.2
Maximum circumferential Stress: (9)
Maximum circumferential Stress API5L X70: S
1X70
= 345.04 MPa

w RLF G K S
i Lh Lh Lh
=
( )
w
w
Hi
t
t D p
S
2

=
Hi Hh He
S S S S + + =
1
w RLF G K S
i Hh Hh Hh
=
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 9 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
3.4 Principal Stresses S
1
,S
2
,S
3
Cont..
Maximum Longitudinal Stress: (10)
Youngs Modulus of steel E
S
= 201138 MPa
@55
o
C
B31.3 Table C-6
Coefficient of thermal expansion
T
= 0.00001108
per
o
C @55
o
C
B31.3 Table C-5
Installation temperature T
1
= 10
o
C
Min Ground Temp as per BOD
Maximum operating temperature T
2
= 55
o
C
Max Gas Temp at CPP outlet
Poisson's Ratio of Steel
S
= 0.3
Maximum Longitudinal Stress API5L X70: S
2X70
= 8.08 MPa
Maximum Radial Stress: S
3
= -P = -MAOP (11)
S
3
= -10.2 MPa
3.5 Total Effective Stress API RP 1102 4.8.1.3
The total effective stress: (12)
The total effective stress must satisfy : S
eff
< SMYS x F where F = 0.72 as per AS2885.1 5.7.3 (d)(i)
Total Effective Stress API5L X70 S
effX70
= 346.46 MPa < 349.2 MPa PASS
3.6 Check for Fatigue in Welds API RP 1102 4.8.2.1
Cyclic stress in girth Weld: (14)
Fatigue endurance limit of girth weld S
FG
= 82740 kPa Table 3
Cyclic longitudinal stress for API5L X70 S
LhX70
= 9.68 MPa < 59.57 MPa PASS
Cyclic Stress in longitudinal weld: (20)
Fatigue endurance limit of longitudinal weld S
FLX70
= 89635 kPa Table 3 (SAW to be conservative)
Cyclic circumferential stress for API5L X70 S
HhX70
= 16.06 MPa < 64.54 MPa PASS

( ) ( )
Hi He S T S Lh
S S T T E S S + + =
1 2 2
( ) ( ) ( ) [ ]
2
1 3
2
3 2
2
2 1
2
1
S S S S S S S
eff
+ + =
F S S
FG Lh

F S S
FL Hh

Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 10 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
4. Road Crossings as per AS2885.1 Clause 5.7.3 and API RP 1102 Section 4. - State Controlled Road Crossing 1200 mm Cover
Design Pressure P
D
= 10.2 MPa
Nominal Pipe Outside Diameter D = 1067 mm
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Pipe Wall Thickness for API5L X70 pipe t
wX70
= 23.50 mm (Wall thickness selected)
Temperature Derating Factor T = 1 AS2885.1 Section 3.4.3, T<65
o
C (Underground Sections)
Design Factor F = 0.72 AS2885.1 5.7.3(i)
Longitudinal joint factor E = 1
Installation Depth H = 1200 mm (Max Cover at road crossings
Bored diameter Bd = 1067 mm (Assume = D for trench construction)
Modulus of soil reaction E' = 3.4 MPa (Table A-1 Soft/medium clays/silts, loose sands and gravels)
Resilient Modulus Er = 34 MPa (Table A-2 Soft to medium clays and silts)
Soil Density = 18.9 kN/m
3
(Recommended value 4.7.2.1)
4.1 Circumferential Stress due to Earth Loads API RP 1102 4.7.2.1
Stiffness factor for circumferential stress from earth load K
HeX70
= 2220 figure 3 t
w
/D = 0.022
Burial Factor for Earth load B
e
= 0.37 figure 4 H/B
d
= 1.125
Excavation Factor E
e
= 1 figure 5 B
d
/D = 1.000
Circumferential Stress due to earth load on API5LX70 pipe S
HeX70
= 16.56 MPa
4.2 External Live Load - Road Crossing
Determine critical load case:
The design wheel load shall be either the maximum wheel load from a trucks single axle or the maximum wheel load from a trucks tandem
axle. The critical design case shall be determined as follows:
W80 wheel loading and A160 Axle loading - Single Axle:
Applied vehicle design surface pressure w = 800 kPa (W80 wheel loading and A160 axle loading AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.22 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 0.65 Table 2
M1600 Moving Traffic loading - Tandem Axle:
Applied vehicle design surface pressure w = 750 kPa (M1600 moving traffic loading. AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.18 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 1 Table 2
Critical load case is the maximum of : (Based on equation 5 where F
i
= 1+DLA)
A160 = 698
M1600 = 974
Therefore the critical vehicle load case for design is the tandem axle load case - M1600 moving traffic loading.

D E B K S
e e He He
=
( ) w DLA L R + 1
G
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 11 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
4.3 Cyclic Stresses API RP 1102 4.7.2.2.4.1
The cyclic circumferential stress due to highway vehicular load: (5)
Highway stiffness factor cyclic circumferential stress API5L X70 K
HhX70
= 18.5 (figure 14)
Highway geometry factor for circumferential stress G
Hh
= 0.95 (figure 15)
Highway pavement factor R = 1.1 Table 2 (Tandem axle no pavement)
Highway axle configuration factor L = 1 Table 2 (Tandem axle)
Impact Factor F
i
= 1.18 (1+DLA)
Cyclic circumferential stress for API5L X70 S
HhX70
= 17.11 MPa
The cyclic longitudinal stress due to Highway vehicular load: (6)
Highway stiffness factor cyclic longitudinal stress API5L X70 K
LhX70
= 14 (figure 16)
Highway geometry factor for longitudinal stress G
Lh
= 0.77 (figure 17)
Highway pavement factor R = 1.1 Table 2
Highway axle configuration factor L = 1 Table 2
Impact Factor F
i
= 1.18 (1+DLA)
Cyclic longitudinal stress for API5L X70 S
LhX70
= 10.49 MPa
Cyclic stress due to internal pressure: (7)
Cyclic stress due to internal pressure API5L X70: S
HiX70
= 226.46 MPa
4.4 Principal Stresses S
1
,S
2
,S
3
API RP 1102 4.8.1.2
Maximum circumferential Stress: (9)
Maximum circumferential Stress API5L X70: S
1X70
= 260.14 MPa

w RLF G K S
i Lh Lh Lh
=
( )
w
w
Hi
t
t D p
S
2

=
Hi Hh He
S S S S + + =
1
w RLF G K S
i Hh Hh Hh
=
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 12 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
4.4 Principal Stresses S
1
,S
2
,S
3
Cont..
Maximum Longitudinal Stress: (10)
Youngs Modulus of steel E
S
= 201138 MPa
@55
o
C
B31.3 Table C-6
Coefficient of thermal expansion
T
= 0.00001108
per
o
C @55
o
C
B31.3 Table C-5
Installation temperature T
1
= 10
o
C
Min Ground Temp as per BOD
Maximum operating temperature T
2
= 55
o
C
Max Gas Temp at CPP outlet
Poisson's Ratio of Steel
S
= 0.3
Maximum Longitudinal Stress API5L X70: S
2X70
= -16.89 MPa
Maximum Radial Stress: S
3
= -P = -MAOP (11)
S
3
= -10.2 MPa
4.5 Total Effective Stress API RP 1102 4.8.1.3
The total effective stress: (12)
The total effective stress must satisfy : S
eff
< SMYS x F where F = 0.72 as per AS2885.1 5.7.3 (d)(i)
Total Effective Stress API5L X70 S
effX70
= 273.74 MPa < 349.2 MPa PASS
4.6 Check for Fatigue in Welds API RP 1102 4.8.2.1
Cyclic stress in girth Weld: (14)
Fatigue endurance limit of girth weld S
FG
= 82740 kPa Table 3
Cyclic longitudinal stress for API5L X70 S
LhX70
= 10.49 MPa < 59.57 MPa PASS
Cyclic Stress in longitudinal weld: (20)
Fatigue endurance limit of longitudinal weld S
FLX70
= 89635 kPa Table 3 (SAW to be conservative)
Cyclic circumferential stress for API5L X70 S
HhX70
= 17.11 MPa < 64.54 MPa PASS

( ) ( )
Hi He S T S Lh
S S T T E S S + + =
1 2 2
( ) ( ) ( ) [ ]
2
1 3
2
3 2
2
2 1
2
1
S S S S S S S
eff
+ + =
F S S
FG Lh

F S S
FL Hh

Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 13 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
5. Road Crossings as per AS2885.1 Clause 5.7.3 and API RP 1102 Section 4. - State Controlled Road Crossing 1500 mm Cover
Design Pressure P
D
= 10.2 MPa
Nominal Pipe Outside Diameter D = 1067 mm
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Pipe Wall Thickness for API5L X70 pipe t
wX70
= 23.50 mm (Wall thickness selected)
Temperature Derating Factor T = 1 AS2885.1 Section 3.4.3, T<65
o
C (Underground Sections)
Design Factor F = 0.72 AS2885.1 5.7.3(i)
Longitudinal joint factor E = 1
Installation Depth H = 1500 mm (Max Cover at road crossings
Bored diameter Bd = 1067 mm (Assume = D for trench construction)
Modulus of soil reaction E' = 3.4 MPa (Table A-1 Soft/medium clays/silts, loose sands and gravels)
Resilient Modulus Er = 34 MPa (Table A-2 Soft to medium clays and silts)
Soil Density = 18.9 kN/m
3
(Recommended value 4.7.2.1)
5.1 Circumferential Stress due to Earth Loads API RP 1102 4.7.2.1
Stiffness factor for circumferential stress from earth load K
HeX70
= 2220 figure 3 t
w
/D = 0.022
Burial Factor for Earth load B
e
= 0.45 figure 4 H/B
d
= 1.406
Excavation Factor E
e
= 1 figure 5 B
d
/D = 1.000
Circumferential Stress due to earth load on API5LX70 pipe S
HeX70
= 20.15 MPa
5.2 External Live Load - Road Crossing
Determine critical load case:
The design wheel load shall be either the maximum wheel load from a trucks single axle or the maximum wheel load from a trucks tandem
axle. The critical design case shall be determined as follows:
W80 wheel loading and A160 Axle loading - Single Axle:
Applied vehicle design surface pressure w = 800 kPa (W80 wheel loading and A160 axle loading AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.18 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 0.65 Table 2
M1600 Moving Traffic loading - Tandem Axle:
Applied vehicle design surface pressure w = 750 kPa (M1600 moving traffic loading. AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.15 AS5100.2 Section 6.7.2
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 1 Table 2
Critical load case is the maximum of : (Based on equation 5 where F
i
= 1+DLA)
A160 = 672
M1600 = 949
Therefore the critical vehicle load case for design is the tandem axle load case - M1600 moving traffic loading.

D E B K S
e e He He
=
( ) w DLA L R + 1
G
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 14 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
5.3 Cyclic Stresses API RP 1102 4.7.2.2.4.1
The cyclic circumferential stress due to highway vehicular load: (5)
Highway stiffness factor cyclic circumferential stress API5L X70 K
HhX70
= 18.5 (figure 14)
Highway geometry factor for circumferential stress G
Hh
= 0.83 (figure 15)
Highway pavement factor R = 1.1 Table 2 (Tandem axle no pavement)
Highway axle configuration factor L = 1 Table 2 (Tandem axle)
Impact Factor F
i
= 1.15 (1+DLA)
Cyclic circumferential stress for API5L X70 S
HhX70
= 14.57 MPa
The cyclic longitudinal stress due to Highway vehicular load: (6)
Highway stiffness factor cyclic longitudinal stress API5L X70 K
LhX70
= 14 (figure 16)
Highway geometry factor for longitudinal stress G
Lh
= 0.68 (figure 17)
Highway pavement factor R = 1.1 Table 2
Highway axle configuration factor L = 1 Table 2
Impact Factor F
i
= 1.15 (1+DLA)
Cyclic longitudinal stress for API5L X70 S
LhX70
= 9.03 MPa
Cyclic stress due to internal pressure: (7)
Cyclic stress due to internal pressure API5L X70: S
HiX70
= 226.46 MPa
5.4 Principal Stresses S
1
,S
2
,S
3
API RP 1102 4.8.1.2
Maximum circumferential Stress: (9)
Maximum circumferential Stress API5L X70: S
1X70
= 261.18 MPa

w RLF G K S
i Lh Lh Lh
=
( )
w
w
Hi
t
t D p
S
2

=
Hi Hh He
S S S S + + =
1
w RLF G K S
i Hh Hh Hh
=
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 15 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
5.4 Principal Stresses S
1
,S
2
,S
3
Cont..
Maximum Longitudinal Stress: (10)
Youngs Modulus of steel E
S
= 201138 MPa
@55
o
C
B31.3 Table C-6
Coefficient of thermal expansion
T
= 0.00001108
per
o
C @55
o
C
B31.3 Table C-5
Installation temperature T
1
= 10
o
C
Min Ground Temp as per BOD
Maximum operating temperature T
2
= 55
o
C
Max Gas Temp at CPP outlet
Poisson's Ratio of Steel
S
= 0.3
Maximum Longitudinal Stress API5L X70: S
2X70
= -17.27 MPa
Maximum Radial Stress: S
3
= -P = -MAOP (11)
S
3
= -10.2 MPa
5.5 Total Effective Stress API RP 1102 4.8.1.3
The total effective stress: (12)
The total effective stress must satisfy : S
eff
< SMYS x F where F = 0.72 as per AS2885.1 5.7.3 (d)(i)
Total Effective Stress API5L X70 S
effX70
= 274.98 MPa < 349.2 MPa PASS
5.6 Check for Fatigue in Welds API RP 1102 4.8.2.1
Cyclic stress in girth Weld: (14)
Fatigue endurance limit of girth weld S
FG
= 82740 kPa Table 3
Cyclic longitudinal stress for API5L X70 S
LhX70
= 9.03 MPa < 59.57 MPa PASS
Cyclic Stress in longitudinal weld: (20)
Fatigue endurance limit of longitudinal weld S
FLX70
= 89635 kPa Table 3 (SAW to be conservative)
Cyclic circumferential stress for API5L X70 S
HhX70
= 14.57 MPa < 64.54 MPa PASS

( ) ( )
Hi He S T S Lh
S S T T E S S + + =
1 2 2
( ) ( ) ( ) [ ]
2
1 3
2
3 2
2
2 1
2
1
S S S S S S S
eff
+ + =
F S S
FG Lh

F S S
FL Hh

Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 16 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
6. Road Crossings as per AS2885.1 Clause 5.7.3 and API RP 1102 Section 4
6.1 Crossing at unformed roads/tracks used infrequently:
Design Pressure P
D
= 10.2 MPa
Nominal Pipe Outside Diameter D = 1067 mm
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Specified Min Yield Strength API5L X80
YX80
= 555 MPa API5L - 2007 Standard Table 7
Pipe Wall Thickness for API5L X70 pipe t
wX70
= 14.10 mm Wall thickness (design factor = 0.8)
Pipe Wall Thickness for API5L X80 pipe t
wX80
= 12.30 mm Wall thickness (design factor = 0.8)
Temperature Derating Factor T = 1 AS2885.1 Section 3.4.3, T<65
o
C (Underground Sections)
Design Factor F = 0.9 AS2885.1 5.7.3(i)(B) (Applies to locations with unformed roads)
Longitudinal joint factor E = 1
Installation Depth H = 650 mm (Min depth of cover for pipeline - 100mm to be conservative)
Bored diameter Bd = 1067 mm (Assume = D for trench construction)
Modulus of soil reaction E' = 1.4 MPa (Table A-1 Soft/medium clays/silts with high plasticities)
Resilient Modulus Er = 34 MPa (Table A-2 Soft to medium clays and silts)
Soil Density = 18.9 kN/m
3
(Recommended value 4.7.2.1)
Note: Values for soil reaction and reslilient modulus are chosen
as most conservative option.
6.2 Circumferential Stress due to Earth Loads API RP 1102 4.7.2.1
Stiffness factor for circumferential stress from earth load K
HeX70
= 6000 figure 3 t
w
/D = 0.013
K
HeX80
= 7000 figure 3 t
w
/D = 0.012
Burial Factor for Earth load B
e
= 0.18 figure 4 H/B
d
= 0.609
Excavation Factor E
e
= 1 figure 5 B
d
/D = 1.000
Circumferential Stress due to earth load on API5LX70 pipe S
HeX70
= 21.78 MPa
Circumferential Stress due to earth load on API5LX80 pipe S
HeX80
= 25.41 MPa
6.3 External Live Load - Road Crossing
Determine critical load case:
The design wheel load shall be either the maximum wheel load from a trucks single axle or the maximum wheel load from a trucks tandem
axle. The critical design case shall be determined as follows:
W80 wheel loading and A160 Axle loading - Single Axle:
Applied vehicle design surface pressure w = 800 kPa (W80 wheel loading and A160 axle loading AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.3025 AS5100.2 Section 6.7.2 (interpolated value)
Highway pavement factor R = 1.2 Table 2 (no pavement)
Highway axle configuration factor L = 0.8 Table 2
M1600 Moving Traffic loading - Tandem Axle:
Applied vehicle design surface pressure w = 750 kPa (M1600 moving traffic loading. AS2885.1 Section V4)
Dynamic Load Allowance DLA = 0.235 AS5100.2 Section 6.7.2 (Interpolated value)
Highway pavement factor R = 1.1 Table 2 (no pavement)
Highway axle configuration factor L = 1 Table 2
Critical load case is the maximum of : (Based on equation 5 where F
i
= 1+DLA)
A160 = 1000
M1600 = 1019
Therefore the critical vehicle load case for design is the tandem axle load case - M1600 moving traffic loading.

D E B K S
e e He He
=
( ) w DLA L R + 1
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 17 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
6.3 Cyclic Stresses API RP 1102 4.7.2.2.4.1
The cyclic circumferential stress due to highway vehicular load: (5)
Highway stiffness factor cyclic circumferential stress API5L X70 K
HhX70
= 20.4 (figure 14)
Highway stiffness factor cyclic circumferential stress API5L X80 K
HhX80
= 20.2 (figure 14)
Highway geometry factor for circumferential stress G
Hh
= 1 (figure 15)
Highway pavement factor R = 1.1 Table 2 (Tandem axle no pavement)
Highway axle configuration factor L = 1 Table 2 (Tandem axle)
Impact Factor F
i
= 1.235 (1+DLA)
Cyclic circumferential stress for API5L X70 S
HhX70
= 20.79 MPa
Cyclic circumferential stress for API5L X80 S
HhX80
= 20.58 MPa
The cyclic longitudinal stress due to Highway vehicular load: (6)
Highway stiffness factor cyclic longitudinal stress API5L X70 K
LhX70
= 15.1 (figure 16)
Highway stiffness factor cyclic longitudinal stress API5L X80 K
LhX80
= 15 (figure 16)
Highway geometry factor for longitudinal stress G
Lh
= 0.75 (figure 17)
Highway pavement factor R = 1.1 Table 2
Highway axle configuration factor L = 1 Table 2
Impact Factor F
i
= 1.235 (1+DLA)
Cyclic longitudinal stress for API5L X70 S
LhX70
= 11.54 MPa
Cyclic Longitudinal stress for API5L X80 S
LhX80
= 11.46 MPa
Cyclic stress due to internal pressure: (7)
Cyclic stress due to internal pressure API5L X70: S
HiX70
= 380.84 MPa
Cyclic stress due to internal pressure API5L X80: S
HiX80
= 437.31 MPa
6.4 Principal Stresses S
1
,S
2
,S
3
API RP 1102 4.8.1.2
Maximum circumferential Stress: (9)
Maximum circumferential Stress API5L X70: S
1X70
= 423.40 MPa
Maximum circumferential Stress API5L X80: S
1X80
= 483.31 MPa

w RLF G K S
i Lh Lh Lh
=
( )
w
w
Hi
t
t D p
S
2

=
Hi Hh He
S S S S + + =
1
w RLF G K S
i Hh Hh Hh
=
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 18 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
6.4 Principal Stresses S
1
,S
2
,S
3
Cont..
Maximum Longitudinal Stress: (10)
Youngs Modulus of steel E
S
= 201138 MPa
@55
o
C
B31.3 Table C-6
Coefficient of thermal expansion
T
= 0.00001108
per
o
C @55
o
C
B31.3 Table C-5
Installation temperature T
1
= 10
o
C
Min Ground Temp as per BOD
Maximum operating temperature T
2
= 55
o
C
Max Gas Temp at CPP outlet
Poisson's Ratio of Steel
S
= 0.3
Maximum Longitudinal Stress API5L X70: S
2X70
= 32.04 MPa
Maximum Longitudinal Stress API5L X80: S
2X80
= 49.99 MPa
Maximum Radial Stress: S
3
= -P = -MAOP (11)
S
3
= -10.2 MPa
6.5 Total Effective Stress API RP 1102 4.8.1.3
The total effective stress: (12)
The total effective stress must satisfy : S
eff
< SMYS x F where F = 0.9 as per AS2885.1 5.7.3 (d)(i)(B)
Total Effective Stress API5L X70 S
effX70
= 414.10 MPa < 436.5 MPa PASS
Total Effective Stress API5L X80 S
effX80
= 466.33 MPa < 499.5 MPa PASS
6.6 Check for Fatigue in Welds API RP 1102 4.8.2.1
Cyclic stress in girth Weld: (14)
Fatigue endurance limit of girth weld S
FG
= 82740 kPa Table 3
Cyclic longitudinal stress for API5L X70 S
LhX70
= 11.54 MPa < 74.47 MPa PASS
Cyclic Longitudinal stress for API5L X80 S
LhX80
= 11.46 MPa < 74.47 MPa PASS
Cyclic Stress in longitudinal weld: (20)
Fatigue endurance limit of longitudinal weld S
FLX70
= 89635 kPa Table 3 (SAW to be conservative)
Fatigue endurance limit of longitudinal weld S
FLX80
= 96530 kPa Table 3 (SAW to be conservative)
Cyclic circumferential stress for API5L X70 S
HhX70
= 20.79 MPa < 80.67 MPa PASS
Cyclic circumferential stress for API5L X80 S
HhX80
= 20.58 MPa < 86.88 MPa PASS

( ) ( )
Hi He S T S Lh
S S T T E S S + + =
1 2 2
( ) ( ) ( ) [ ]
2
1 3
2
3 2
2
2 1
2
1
S S S S S S S
eff
+ + =
F S S
FG Lh

F S S
FL Hh

Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 19 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
7. Resistance to penetration Calculation (AS2885.1 Clause 4.11.3)
As per AS2885.1 clause 4.11.3, the effectiveness of resistance to penetration may be determined using calculations as per Appendix M
As per Appendix M, In principle, penetration should not occur if: R
p
>BxF (M2)
Where:
R
p
is the force required to penetrate the pipe (kN): (M3)
F is the maximum force applied to the pipeline by the machine (kN): (M4)
Factor B as per table M5. B = 1
Pipe wall thickness required for API5L X70 t
wX70
= 11.60 mm (min required)
Pipe wall thickness required for API5L X80 t
wX80
= 11.00 mm (min required)
Ultimate tensile Strength of API5L X70
UX70
= 570 MPa API5L-2007 Table 7
Ultimate tensile Strength of API5L X80
UX80
= 625 MPa API5L-2007 Table 7
Based on the excavator tooth dimensions provided in AS2885.1 table M3, the following R
p
and F
bucket

forces are
calculated for various excavator sizes:
Excavator
Weight (t)
L at point W at point R
pX70
R
pX80 BxF L at point W at point R
pX70
R
pX80 BxF
5.0 51.0 4.0 327.2 327.7 36.4 6.0 5.0 138.8 139.0 36.4
10.0 56.0 14.0 509.6 510.3 70.5 8.0 7.0 167.0 167.2 70.5
15.0 63.0 13.0 547.4 548.2 102.4 11.0 9.0 197.0 197.3 102.4
20.0 76.0 13.0 630.7 631.6 132.0 13.0 10.0 214.4 214.7 132.0
25.0 89.0 18.0 754.8 755.9 159.4 11.0 17.0 224.3 224.7 159.4
30.0 102.0 21.0 861.2 862.4 184.5 12.0 20.0 236.6 236.9 184.5
35.0 121.0 23.0 1004.0 1005.5 207.4 14.0 22.0 253.5 253.9 207.4
40.0 127.0 24.0 1051.3 1052.9 228.0 16.0 25.0 271.5 271.9 228.0
55.0 143.0 30.0 1191.5 1193.3 276.4 17.0 25.0 278.5 279.0 276.4
As per the table above. The wall thickness calculated for both the X70 and X80 pipe is sufficient to provide resistance to penetration
for excavators up to and including 55t weight using buckets with general purpose, single point penetration or twin pointed tiger teeth.
This applies to areas where penetration resistance can be reasonably relied on to satisfy the requirements of the safety management study
ie where B = 1 or less as per table M5.
For high consequence areas where penetration must never occur:
Factor B as per table M5. B = 1.3
Pipe wall thickness required for API5L X70 t
wX70
= 15.00 mm (min required)
Pipe wall thickness required for API5L X80 t
wX80
= 14.20 mm (min required)
Excavator
Weight (t)
L at point W at point R
pX70
R
pX80 BxF L at point W at point R
pX70
R
pX80 BxF
5.0 51.0 4.0 423.1 423.0 47.3 6.0 5.0 179.5 179.5 47.3
10.0 56.0 14.0 658.9 658.8 91.7 8.0 7.0 215.9 215.9 91.7
15.0 63.0 13.0 707.8 707.7 133.1 11.0 9.0 254.8 254.7 133.1
20.0 76.0 13.0 815.5 815.4 171.6 13.0 10.0 277.2 277.2 171.6
25.0 89.0 18.0 976.0 975.8 207.2 11.0 17.0 290.1 290.0 207.2
30.0 102.0 21.0 1113.6 1113.3 239.9 12.0 20.0 305.9 305.9 239.9
35.0 121.0 23.0 1298.3 1298.1 269.6 14.0 22.0 327.8 327.7 269.6
40.0 127.0 24.0 1359.5 1359.2 296.4 16.0 25.0 351.0 351.0 296.4
55.0 143.0 30.0 1540.7 1540.4 359.3 17.0 25.0 360.2 360.1 359.3
In high consequence areas where penetration must never occur, the wall thickness calculated for the X70 and X80 pipe above are
sufficient to provide resistance to penetration for excavators up to and including 55t weight using buckets with general purpose teeth,
single point penetration or twin pointed tiger teeth.

General Purpose Teeth Single Point penetration tooth and twin pointed tiger teeth
General Purpose Teeth Single Point penetration tooth and twin pointed tiger teeth
( )( ) |

\
|
+
+ + =
14 . 3
4 . 22 410 0007 . 0
W
W
L t R
U w p

( )
2
045 . 0 5 . 7
OP OP
W W F =
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 20 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
8. Pipe ovality As per Guidelines for the design of Buried Steel Pipe, American Lifelines Alliance. (Appendix 1)
Outside Diameter of Pipe D = 1067 mm
Deflection lag factor D
l
= 1.5 4.2.1
Bedding constant K = 0.1 4.2.1
Soil Load on pipe P
v
= 0.0142 MPa (Soil Density x Depth. Based on values used in section 2. )
Soil Load on pipe P
v2
= 0.0227 MPa (Soil Density x Depth. Based on values used in section 2. )
Modulus of Soil Reaction E' = 3.4 MPa (Table A-1 Stiff clays, medium dense sands and gravels)
Youngs Modulus of Steel E
S
= 200500 MPa
@65
o
C
Depth of Soil above pipe C = 750 mm (Worst Case, for traffic crossing at unformed roads)
Depth of Soil above pipe C
2
= 1200 mm (Min Depth for crossings at formed roads)
Load at surface (Road Crossings) P
s
= 12232 kg (120kN load as per M1600 moving traffic. AS2885.1 V4)
Offset Distance from pipe to line of
application of surface load d = 0 mm
External load transmitted to pipe
(4-1)
For unformed roads: P
p
= 0.1019 MPa
For formed roads: P
p2
= 0.0398 MPa
Unformed Road: Total load on pipe (P
v
+ P
p
F) P = 0.1313 MPa (Where F is impact factor as per table 4.1-2) F = 1.15
Formed Road: Total load on pipe (P
v
+ P
p
F) P = 0.0625 MPa (Where F is impact factor as per table 4.1-2) F = 1
Pipe ovality due to earth and live loads:
(4-2) Where R = pipe radius
Note: effects of internal/external lining
have been ignored.
Wall
thickness
(mm)
Area Moment
of inertia (I)
mm
4
Ovality (dy/D)
Vertical
Deflection
of pipe (dy)
mm
14.10 233.60 0.038 40.74
15.60 316.37 0.032 33.62
18.00 486.00 0.011 11.77
12.30 155.07 0.048 50.99
13.70 214.28 0.040 42.86
15.30 298.46 0.016 16.62
As per AS2885.1 Section V6, the guideline usually adopted is that deflection of the pipe should not exceed 5% of the pipe diameter. This criteria will be
applied to buried pipe for sections that are not regular road crossings and therefore heavy wall pipe is not used i.e. 0.8 and 0.72 design factor pipe.
Design Criteria for API RP 1102 is based on a maximum vertical deflection of 3% of the vertical diameter. This criteria is applied to the Heavy Wall pipe
that is to be used at all regular road crossings. As per the table above, deflection of ppe is within the allowable limits and therefore ok.
9. Wall thickness Calculation Summary
Pipeline Pipeline
Pipeline
Assemblies Pipeline Pipeline
Pipeline
Assemblies
API5L X70 API5L 70 API5L X70 API5L X80 API5L X80 API5L X80
R1,R2 R1,R2 R1,R2 R1,R2 R1,R2 R1,R2
0.8 0.72 0.67 0.8 0.72 0.67
14.03 15.58 17.51 12.26 13.62 15.30
14.03 15.58 17.51 12.26 13.62 15.30
0.00 0.00 0.00 0.00 0.00 0.00
14.10 15.60 17.60 12.30 13.70 15.30

High
Consequence
Areas and
API5L X70 API5L X80
11.60 11.00 11.60
T1,T2,S,I
0.67
15.30
11.00
Material
11.60 15.00
High Consequence Areas
and crossings
T1,T2,S,I
0.67
17.51
thickness for penetration
resistance (mm)
tn (mm) 18.00 15.30
round up round up round up round up round up
Hydrotest and
constructability round up
14.20 11.00
15.20 N/A N/A N/A N/A 18.00
tw (mm)
Allowances (mm)
round up
N/A
round up
0.00
18.00 15.30
0.00
N/A
X80 F
D
=0.72 - Soil Load Only
X80 Heavy Wall - Soil and External Loading
Thickness required at
road crossings (mm)
X70 F
D
=0.8 - Soil Load Only
X70 F
D
=0.72 - Soil Load Only
X70 Heavy Wall - Soil and External Loading
X80 F
D
=0.8 - Soil Load Only
Location
F
D
tp (mm)
Yes
Yes
Yes
Deflection acceptable
Unformed Road (dy/D < 0.05)
Formed Road (dy/D<0.03)
Yes
Yes
Yes
5 . 2
2
2
1 2
3
(
(

\
|
+
=
C
d
C
P
P
S
P

\
|
+
=

' 061 . 0
3
E
R
EI
KP D
D
y
l
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 21 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
10. Wall Thickness for design internal pressure of bends (t
p
) AS2285.1 section 5.4.4
The minimum wall thickness for design internal pressure of bends shall be determined by:
equation 5.4.4(1)
Where at the extrados of the bend: Where at the intrados of the bend:
Where R = Bend radius at centreline of pipe = 6402 mm (6D)
Wall thickness used in bend manufacture:
API 5L X70 Heavy Wall Pipe t
X70
= 18.00
API 5L X80 Heavy Wall Pipe t
X80
= 15.30
Material Yield Strength of Bend After Forming:
Min Yield Strength of bend API5L X70
YX70
= 450 MPa (Assumed to be SMYS - 5ksi)
Min Yield Strength of bend API5L X80
YX80
= 520 MPa (Assumed to be SMYS - 5ksi)
Bends may be used above ground therefore de-rate yield strength for above ground temperature:
Min Yield Strength for bend design API5L X70
YX70
= 430.5 MPa
Min Yield Strength for bend design API5L X80
YX80
= 497.4 MPa
mean pipe wall radius for API5L X70 heavy wall pipe r
mX70
= 524.50 mm
mean pipe wall radius for API5L X80 heavy wall pipe r
mX80
= 525.85 mm
For extrados: F
PX70
= 0.96
F
PX80
= 0.96
For intrados: F
PX70
= 1.04
F
PX80
= 1.04
Minimum allowable thickness of bend after forming (F
D
=0.8 - Above Ground)
Minimum thickness of extrados for API5L X70 t
pX70
= 15.20 mm
Minimum thickness of intrados for API5L X70 t
pX70
= 16.51 mm
Minimum thickness of extrados for API5L X80 t
pX80
= 13.16 mm
Minimum thickness of intrados for API5L X80 t
pX80
= 14.29 mm
Actual bend thickness after forming:
Thinning allowance for bend 6.8 % (Based on 6D bend)
Thickness of API5L X70 bend after forming 16.78 mm
Actual design factor of bend 0.75
Thickness of API5L X80 bend after forming 14.26 mm
Actual design factor of bend 0.77

Y D
P D
p
F
DF P
t
2
=
( )
m
m
p
r R
r R
F
+
+
=
2
2
( )
m
m
p
r R
r R
F

=
2
2
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 22 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
11. Buoyancy of Pipe As per Guidelines for the design of Buried Steel Pipe, American Lifelines Alliance Section 6.
Upward force on straight buried pipe from water table being above the pipe is:
Depth of soil cover C = 750 mm Minimum depth of cover
Distance from top of pipe to ground water table h
w
= 750 mm (Worst Case)
Pipe Density
p
= 7800
kg/m
3
Water buoyancy factor R
W
= 0.67 (3-2, R
w
=1-0.33(h
w
/C))
Dry density of backfill.
d
= 1600
kg/m
3
(dry sand, gravel,packed, Appendix 2)
Density of Water
w
= 1000
kg/m
3
Safety Factor SF = 1.2
Weight of water displaced by bare pipe per meter W
W
= 1073.0 kg/m W
w
= (PI*D
2
/4)*
w
xSF
Effective Weight of soil above pipe W
s
= 857.9 kg/m W
s
= (R
w

d
C)*D
Wall
thickness
(mm)
Weight of
Pipe. W
p
kg/m
Buoyancy
force on pipe
F
B
(kg/m)
Concrete
coating
required?
Concrete
coating
required?
14.10 364 -149 Not Required Yes
15.60 402 -187 Not Required Yes
18.00 463 -248 Not Required Yes
12.30 318 -103 Not Required Yes
13.70 354 -138 Not Required Yes
15.30 394 -179 Not Required Yes
Calculate concrete coating thickness required:
Coating
Thickness
(mm)
Weight of
Water
Displaced
by Coated
Pipe (kg/m)
Weight of
Concrete
kg/m
Design
Buoyancy
force on pipe
(kg/m)
Actual
Buoyancy
force on
coated pipe
(kg/m)
154 1782.2 1418 0 -297
147 1744.1 1342 0 -291
135 1683.3 1221 0 -281
163 1828.1 1510 0 -305
156 1792.4 1439 0 -299
148 1751.7 1357 0 -292
Note: Concrete density assumed to be 2400kg/m
3
in calculation of required thickness. Thickness calculated by iteration of concrete coating thickness
until design buoyancy force on pipe is zero. The safety factor is applied to the weight of water displaced to ensure sufficient negative buoyancy.

X80 F
D
=0.8
X80 F
D
=0.72
X80 Heavy Wall
X70 F
D
=0.8
X70 F
D
=0.72
X70 F
D
=0.8
X70 F
D
=0.72
X70 Heavy Wall
X80 F
D
=0.8
X80 F
D
=0.72
Buoyancy Force on pipe (no
soil cover) (kg/m)
709
671
X70 Heavy Wall
610
755
719
679 X80 Heavy Wall
P S W B
W W W F =
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet 23 of 23
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
12. Permitted External Line Pipe Pressure AS2285.1 section 5.4.5
The permitted external pressure shall be determined from the following equation:
equation 5.4.5(1)
Where:
equation 5.4.5(2)
equation 5.4.5(3)
equation 5.4.5(4)
equation 5.4.5(5)
Nominal Pipe Outside Diameter D = 1067 mm
Minimum Pipe Diameter Dmin = 1059.0 mm (At installation = -0.75%D ovality as per pipe spec)
Maximum Pipe Diameter Dmax = 1075.0 mm (At installation = +0.75%D ovality as per pipe spec)
Youngs Modulus of Steel E = 201138 MPa @65
o
C B31.3 Table C-6
Poisson's ratio = 0.3
Specified Min Yield Strength API5L X70
YX70
= 485 MPa API5L - 2007 Standard Table 7
Specified Min Yield Strength API5L X80
YX80
= 555 MPa API5L - 2007 Standard Table 7
t
w
F
D
D
M
f
o
P
P
P
EL
P
EXT
Equ 5.4.5(1)
(mm) (mm) MPa MPa MPa
X70 FD=0.8 14.1 0.80 1052.90 0.015 10.39 1.06 0.890 0.03
X70 FD=0.72 15.6 0.72 1051.40 0.015 10.36 1.44 1.160 0.03
X70 Heavy Wall 18.0 0.67 1049.00 0.015 11.15 2.23 1.694 0.05
X80 FD=0.8 12.3 0.80 1054.70 0.015 10.36 0.70 0.613 0.02
X80 FD=0.72 13.7 0.72 1053.30 0.015 10.39 0.97 0.823 0.03
X80 Heavy Wall 15.3 0.67 1051.70 0.015 10.82 1.36 1.113 0.03
Note: Iterate P
EXT
in table above until Equ 5.4.5(1) = 0
The permitted External Pressure (P
EXT
) on the pipeline is therefore summarised in the table below:
t
w
P
EXT
(mm) MPa
X70 FD=0.8 14.1 0.890
X70 FD=0.72 15.6 1.160
X70 Heavy Wall 18.0 1.694
X80 FD=0.8 12.3 0.613
X80 FD=0.72 13.7 0.823
X80 Heavy Wall 15.3 1.113
0
5 . 1
1
2
= +
|
|

\
|
|
|

\
|
+ +
p EL EXT EL
w
o
p EXT
P P P P
t
D f
P P
( )
3
2
1
2
|
|

\
|

=
M
w
EL
D
t E
P

|
|

\
|
=
M
w
y D P
D
t
F P 2
D
D D
f
o
min max

=
w M
t D D =
Zektin Group
407 Royal Parade
Parkville VIC 3052
Ph: (61) 3 8480 1000
Fax: (61) 3 8480 1055
CALCULATION
DOCUMENT No : P09QGC02-000-CAL-L-002
PROJECT / JOB TITLE : QCLNG E05 Pipeline QGC Doc No: QCLNG-BG00-PLE-CAL-000002
CLIENT : Queensland Gas Company JOB No. P09QGC02
Sheet
CALCULATION TITLE: Pipe Wall Thickness Calculations to AS2885.1
Attachments