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Calculation Cover Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
Elec File Location 0002_0.xlsx

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Calculation Objective
To determine if the DN100 CPF to Refinery Crude Oil Pipeline can withstand the worst anticipated highway vehicular loads at a
minimum depth of cover of 900 mm.
1) Design pressure: 10.2 MPag
2) Nominal wall thickness: 5.56 mm (fully corroded)
3) Material: API Spec 5L GrB Electric Resistance Welding (ERW) pipe

Calculation Method
The method described in Section 4 of API RP 1102 has been used as permitted by Section 5.7.3.2 of AS/NZS 2885.1. The calculations
were done for transverse loads over unsealed road crossings of an open cut and uncased pipe. The API RP 1102 impact factor was
used instead of the AS 5100.2 dynamic load allowance.

Assumptions
1) Nominal diameter has been used conservatively rather than outside diameter for values obtained from Table 2 in API RP 1102
2) The Type A soil model has been used to simulate the worst case scenario in the absence of geotechnical information on the site.
3) Vehicular loads based on AS 5100.2 A160 and M1600 load cases have been used with additional conservatism applied as
recommended by Section G4 (ii) of AS/NZS 2885.1.
4) Full loss of corrosion allowance.
5) Installation temperature is the average temperature.

Software Used
Title Version Validation (Y / N / N/A)
Nil

References
1) AS/NZS 2885.1 - 2018 - Pipelines - Gas and liquid petroleum - Part 1: Design and construction
2) API RP 1102 - 7th ed - Steel Pipelines Crossing Railroads and Highways
3) API Spec 5L - 46th ed - Line Pipe
4) ASME B31.8 - 2016 - Gas Transmission and Distribution Piping Systems
5) AS 5100.2 - 2017 - Bridge design: Design loads
6) ASME B36.10M-2018 - Welded and Seamless Wrought Steel Pipe
7) 411001-0035-04-PL-CAL-0001 - DN100 AS/NZS 2885.1 Wall Thickness Calculation
8) 411001-0035-04-PL-CRT-0001 - Pipeline Design Criteria

Conclusions
For the DN100 CPF to Refinery Crude Oil Pipeline to be able to withstand the worst anticipated highway vehicular loads at unsealed
open cut crossings, the total effective stress and fatigue (at girth and longitudinal welds) criteria shall be met.

The calculations performed to the method described in API RP 1102 indicate that at 900 mm and 1200 mm depth of covers, the DN100
CPF to Refinery Crude Oil Pipeline will be able to withstand the anticipated highway vehicular loads, at such crossings.

Related to a Safety Critical System? No Status of Supplier Data used N/A

0 30-01-20 Issued for Use T Doan M Nichols R Zadeh


Rev Date Description By Checked Approved
This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared
solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for
any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Checklist

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-
Elec File Location PL-CAL-0002_0.xlsx

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Please check boxes for all applicable items checked or mark as "N/A" if not appropriate:

Originator Checker

Calculation number assigned and registered. refer to project numbering system or Document Number Standard (DPP-
Y Y
0031-COR-EN) for format.
Y Y All required information on Cover Sheet provided.
Revision history box complete and signed. (Typed names (minimum of first initial and last name e.g. A. Wood)
Y Y
of Originator, Checker, Approver; to be initialled beside at sign-off) (Dates in standard format (DD-MM-YY)

Y Y Table of Contents.

Y Y Appropriate stamp for preliminary issues.

Y Y Source of input data stated (with revision number and date if relevant).

N/A N/A Customer's requirements included/addressed.

Y Y Approach used is appropriate for problem being solved.

Y Y Method clear and easy to follow.

Y Y Input data correct.

Y Y Calculation arithmetically correct OR software previously verified and reference to verification checked.

Y Y Calculation result within expected limits.

N/A N/A Calculation tolerances stated if significant.

Y Y Units used as required by customer. Unit conversions correctly performed.

Y Y Appropriate cross-references.

Y Y Sketches included and clearly labelled, where required.

Y Y Appendices included and referenced, as required.

N/A N/A Considered design reviews, HAZOP actions, customer input, safety and environmental issues, etc.

N/A N/A Safety in Design (SID) and Sustainable Design are addressed. Refer relevant SID Discipline Standard.

Y Y Conclusions and recommendations are appropriate.


Checking Records:
Y Checked and annotated copy of calculation filed (use "Doc Check Print" stamp).

Y Corrections made as required and calculation dated and signed on cover sheet by checker.

Y Alternative method calculation and/or representative check performed and filed, as required.
Revisions:
Changes clouded.
Revision history block updated.
Calculation re-checked if required.

0 30-01-20 Issued for Use T Doan M Nichols R Zadeh


Rev Date Description By Checked Approved
This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and
prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees
assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-
Elec File Location 00035-04-PL-CAL-0002_0.xlsx

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Rev Date By Checked Rev Date By Checked Rev Date By Checked
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Table of Contents
Page
1.0 Calculation Method 4
2.0 Non-Location-Specific Input Data 5
3.0 Location-Specific Input Data 6
4.0 Derived Variables 6
5.0 Location-Specific Variables Selected from Graphical Data 7
6.0 Stiffness Factors Selected from Graphical Data 7
7.0 Variables Selected from Tabulated Data 8
8.0 Stress Calculations 10
9.0 Fatigue Calculations 17
10.0 Summary or Results 18
11.0 Conclusions 18

Appendices
Pages
A API RP 1102 Graphs 5
B API RP 1102 Tables 2

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their
respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-
Elec File Location 00035-04-PL-CAL-0002_0.xlsx

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1.0 Calculation Method
The flow diagram for performing this calculation (shown below) has been reproduced from API RP 1102.

Figure 1: Flow diagram of design procedure for uncased road crossings

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor
their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-
Elec File Location 00035-04-PL-CAL-0002_0.xlsx

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Rev Date By Checked Rev Date By Checked Rev Date By Checked
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2.0 Non-Location-Specific Input Data
The key non-location-specific data used in this calculation and their sources are listed in Table 1 below.

Parameter Symbol Value Units Source


Crossing type Open cut 411001-00035-04-PL-CRT-0001
Fluid type Crude Oil 411001-00035-04-PL-CRT-0001
Maximum operating pressure p 10200 kPa.g 411001-00035-04-PL-CRT-0001
Installation temperature T1 35 °C 411001-00035-04-PL-CRT-0001
Minimum operating temperature T2 5 °C 411001-00035-04-PR-BOD-0001
Maximum operating temperature T2 65 °C 411001-00035-04-PR-BOD-0001
Temperature derating factor T 1 Section 3.5.3, AS/NZS 2885.1
External load cyclic Table 5.7.7, AS/NZS 2885.1
F 0.72
circumferential stress factor
External load cyclic longitudinal Table 5.7.7, AS/NZS 2885.1
F 0.72
stress factor
External combined load stress Table 5.7.7, AS/NZS 2885.1
F 0.9
factor
Nominal diameter DN 100 411001-00035-04-PL-CRT-0001
Pipe outside diameter D 114.3 mm ASME B36.10M
Wall thickness (inc. Corrosion tw 6.96 mm 411001-00035-04-PL-CAL-0001
Allowance)
Pipe material B 411001-00035-04-PL-CAL-0001
Specified minimum yield strength SMYS 245 MPa ASTM A106, Table 2
Longitudinal weld type ERW 411001-00035-04-PL-CRT-0001
Longitudinal joint factor E 1
Young's modulus of steel Es 203000 MPa @ 21⁰C, ASME B31.8
Poisson's ratio or steel νs 0.3 Table A-3, API RP 1102
Coefficient of thermal expansion αT 0.0000117 °C-1 Table A-3, API RP 1102
Resilient modulus of soil Er 34 MPa Table A-2, API RP 1102
Modulus of soil reaction E' 1.4 MPa Table A-1, API RP 1102
Soil unit weight γ 18.9 kN/m3 Section 4.7.2.1, API RP 1102
Pavement type No pavement API RP 1102

Table 1: Non-location-specific input data

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their
respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
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30-01-20 T Doan M Nichols
3.0 Location-Specific Input Data
The location-specific data used in this calculation and their sources are listed in Table 2 below.

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Depth to top of pipe 900 1200 1800 2400 3000 mm Based on standard drawings
Ballast 0 0 0 0 0 mm No build up over finished surface
Single axle wheel load Ps 80 80 80 80 80 kN A160, Section G4(i), AS/NZS 2885.1
Tandem axle wheel load Pt 120 120 90 90 90 kN M1600, Section G4(ii), AS/NZS 2885.1
Single axle wheel contact area A ps 0.093 0.093 0.093 0.1 0.1 m2 Section G5 AS/NZS 2885.1
Tandem axle wheel contact area A pt 0.093 0.093 0.093 0.08 0.08 m2 Section G5, AS/NZS 2885.1
Table 2: Location-specific input data

4.0 Derived Variables


The parameters or variables derived form the input data used in this calculation shown in Table 3 below.

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Depth to top of pipe H 900 1200 1800 2400 3000 mm
Wall thickness to diameter ratio t w/D 0.061 0.061 0.061 0.061 0.061
Bored diameter Bd 114.3 114.3 114.3 114.3 114.3 mm
Depth to bored diameter ratio H /B d 7.87 10.50 15.75 21.00 26.25
Bored diam. to pipe diam. ratio B d /D 1.00 1.00 1.00 1.00 1.00
Table 3: Derived data

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 7 of 18
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30-01-20 T Doan M Nichols
5.0 Location-Specific Variables Selected from Graphical Data
The location-specific variables read from graphs are shown in Table 4 below.

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Stiffness factor for earth load Figure 3, API RP 1102
K He 200 200 1500 1500 1500
circumferential stress
Soil type A A A A A Figure 4, API RP 1102
Burial factor for auger bored earth Figure 4, API RP 1102
Be 1.25 1.33 1.12 1.18 1.26
load circumferential stress
Excavation factor for auger bored Section 4.7.2.1, API RP 1102
Ee 1 1 1 1.11 1.11
earth load circumferential stress
Impact factor Fi 1.50 1.50 1.47 1.41 1.35 Figure 7, API RP 1102
Highway geometry factor for cyclic Figure 15, API RP 1102
G Hh 1.49 1.49 1.03 0.84 0.65
circumferential stress
Highway geometry factor for cyclic Figure 17, API RP 1102
G Lh 1.75 1.75 1.02 0.94 0.80
longitudinal stress
Table 4: Location-specific data from API RP 1102 graphs (refer to Appendix A)

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-
Elec File Location 00035-04-PL-CAL-0002_0.xlsx

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30-01-20 T Doan M Nichols
6.0 Stiffness Factors Selected from Graphical Data
The non-location-specific variables read from graphs are shown in Table 5 below.

Parameter Symbol Value Units Source


Highway stiffness factor for cyclic Figure 14, API RP 1102
K Hh 4.0
circumferential stress
Highway stiffness factor for cyclic Figure 16, API RP 1102
K Lh 7.50
longitudinal stress
Table 5: Non-location-specific data from API RP 1102 graphs (refer to Appendix A)

7.0 Variables Selected from Tabulated Data


The variables obtained from tabulated data sets are shown in Table 6 below.

Parameter Symbol Value Units Source


Girth weld fatigue endurance limit, all Table 3, API RP 1102
welds S FG 12000 psi

Longitudinal weld fatigue endurance Table 3, API RP 1102


limit, all welds S FL 21000 psi

Table 6: Data from API RP 1102 Table 3 (refer to Appendix B)

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor
their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
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Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Highway Pavement Type and Axle Configuration Factors
Depth to top of pipe H 900 1200 1800 2400 3000 mm
Pipe outside diameter D 114.3 114.3 114.3 114.3 114.3 mm
Highway pavement type factor, Table 2, API RP 1102
Tandem axle R 1.10 1.10 1.10 1.10 1.10

Axle configuration factor, Tandem axle Table 2, API RP 1102


L 1.00 1.00 1.00 1.00 1.00

Highway pavement type factor, Single Table 2, API RP 1102


axle R 1.20 1.10 1.10 1.10 1.10

Axle configuration factor, Single axle Table 2, API RP 1102


L 0.80 0.65 0.65 0.65 0.65

Table 7: Data from API RP 1102 Table 2 (refer to Appendix B)

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
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8.0 Stress Calculations

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Circumferential Stress due to Earth Load
Wall thickness to diameter ratio t w/D 0.061 0.061 0.061 0.061 0.061 Eqn 1, SS 4.7.2.1, API RP 1102
Modulus of soil reaction E' 1.4 1.4 1.4 1.4 1.4
Stiffness factor for earth load
K He 200 200 1500 1500 1500
circumferential stress
Soil type A A A A A
Depth to bored diameter ratio H /B d 7.87 10.50 15.75 21.00 26.25
Burial factor for auger bored earth
Be 1.25 1.33 1.12 1.18 1.26
load circumferential stress
Bored diam. to pipe diam. ratio B d /D 1.00 1.00 1.00 1.00 1.00
Excavation factor for auger bored
Ee 1.00 1.00 1.00 1.11 1.11
earth load circumferential stress
Soil unit weight γ 18.9 18.9 18.9 18.9 18.9 kN/m3
Pipe outside diameter D 0.1143 0.1143 0.1143 0.1143 0.1143 m
Circumferential stress due to
S He 0.5 0.6 3.6 4.2 4.5 MPa
earth load

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 11 of 18
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0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Applied Design Surface Pressure
Single axle wheel load Ps 80 80 80 80 80 kN Eqn 2, SS 4.7.2.2, API RP 1102
Tandem axle wheel load Pt 120 120 90 90 90 kN
Single axle wheel contact area A ps 0.093 0.093 0.093 0.1 0.1 m2
Tandem axle wheel contact area A pt 0.093 0.093 0.093 0.08 0.08 m2
Applied design surface pressure,
ws 860.2 860.2 860.2 800.0 800.0 kPa
single axle
Applied design surface pressure,
wt 1290.3 1290.3 967.7 1125.0 1125.0 kPa
tandem axle

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to
or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 12 of 18
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0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Cyclic Circumferential Stress due to Highway Vehicular Load
Wall thickness to diameter ratio t w/D 0.061 0.061 0.061 0.061 0.061 Eqn 5, SS 4.7.2.2.4.1, API RP 1102
Resilient modulus of soil Er 34 34 34 34 34 MPa
Highway stiffness factor for cyclic
K Hh 4 4 4 4 4
circumferential stress
Depth to top of pipe H 900 1200 1800 2400 3000 mm
Pipe outside diameter D 114.3 114.3 114.3 114.3 114.3 mm
Highway geometry factor for cyclic
G Hh 1.49 1.49 1.03 0.84 0.65
circumferential stress
Impact factor Fi 1.50 1.50 1.47 1.41 1.35
Highway pavement type factor,
single axle R 1.20 1.10 1.10 1.10 1.10

Axle configuration factor, single


axle L 0.80 0.65 0.65 0.65 0.65

Applied design surface pressure,


ws 860.2 860.2 860.2 800 800 kPa
single axle
Highway pavement type factor,
tandem axle R 1.10 1.10 1.10 1.10 1.10

Axle configuration factor, tandem


axle L 1.00 1.00 1.00 1.00 1.00

Applied design surface pressure,


wt 1290.3 1290.3 967.7 1125.0 1125.0 kPa
tandem axle
Cyclic circumferential stress
ΔS Hh 12.7 12.7 6.4 5.9 4.3 MPa
due to highway vehicular load

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 13 of 18
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0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Cyclic Longitudinal Stress due to Highway Vehicular
Wall thickness to diameter ratio t w/D 0.061 0.061 0.061 0.061 0.061 Eqn 6, SS 4.7.2.2.4.2, API RP 1102
Resilient modulus of soil Er 34 34 34 34 34 MPa
Highway stiffness factor for cyclic
K Lh 7.5 7.5 7.5 7.5 7.5
longitudinal stress
Depth to top of pipe H 900 1200 1800 2400 3000 mm
Pipe outside diameter D 114.3 114.3 114.3 114.3 114.3 mm
Highway geometry factor for cyclic
G Lh 1.75 1.75 1.02 0.94 0.80
longitudinal stress
Impact factor Fi 1.5 1.5 1.47 1.41 1.35
Highway pavement type factor,
single axle R 1.20 1.10 1.10 1.10 1.10

Axle configuration factor, single


axle L 0.80 0.65 0.65 0.65 0.65

Applied design surface pressure,


ws 860.2 860.2 860.2 800.0 800.0 kPa
single axle
Highway pavement type factor,
tandem axle R 1.10 1.10 1.10 1.10 1.00

Axle configuration factor, tandem


axle L 1.00 1.00 1.00 1.00 1.00

Applied design surface pressure,


wt 1290.3 1290.3 967.7 1125.0 1125.0 kPa
tandem axle
Cyclic longitudinal stress due
ΔS Lh 27.9 27.9 12.0 12.3 9.1 MPa
to highway vehicular load

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 14 of 18
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
API RP 1102 Circumferential Stress due to Internal Pressurisation
Maximum operating pressure p 10200 10200 10200 10200 10200 kPa Eqn 7, SS 4.7.3, API RP 1102
Pipe outside diameter D 114.3 114.3 114.3 114.3 114.3 mm
Wall thickness tw 6.96 6.96 6.96 6.96 6.96 mm
Circumferential stress due to
S Hi 78.7 78.7 78.7 78.7 78.7 MPa
internal pressurisation

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 15 of 18
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Principal Stresses
Circumferential stress due to earth Eqns 9, 10 & 11,
S He 0.5 0.6 3.6 4.2 4.5 MPa
load SS 4.8.1.2, API RP 1102
Cyclic circumferential stress due
ΔS Hh 12.7 12.7 6.4 5.9 4.3 MPa
to highway vehicular load
Cyclic longitudinal stress due to
ΔS Lh 27.9 27.9 12.0 12.3 9.1 MPa
highway vehicular load
Circumferential stress due to
S Hi 78.7 78.7 78.7 78.7 78.7 MPa
internal pressurisation
Young's modulus of steel Es 203000 203000 203000 203000 203000 MPa
Coefficient of thermal expansion αT 0.0000117 0.0000117 0.0000117 0.0000117 0.0000117 °C-1
Poisson's ratio or steel νs 0.3 0.3 0.3 0.3 0.3
Installation temperature T1 35 35 35 35 35 °C
Minimum temperature T2 5 5 5 5 5 °C
Maximum temperature T2 65 65 65 65 65 °C
Maximum operating pressure p 10.200 10.200 10.200 10.200 10.200 MPa
Principal stress 1 S1 91.9 91.9 88.7 88.8 87.5 MPa
Principal stress 2, tensile S2 123.0 123.0 107.9 108.4 105.3 MPa
Principal stress 2, compressive S2 -19.6 -19.5 -34.6 -34.1 -37.2 MPa
Principal stress 3 S3 -10.2 -10.2 -10.2 -10.2 -10.2 MPa

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 16 of 18
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Total Effective Stress
Principal stress 1 S1 91.9 91.9 88.7 88.8 87.5 MPa Eqns 12 & 13, SS 4.8.1.3, API RP 1102
Principal stress 2, tensile S2 123.0 123.0 107.9 108.4 105.3 MPa
Principal stress 2, compressive S2 -19.6 -19.5 -34.6 -34.1 -37.2 MPa
Principal stress 3 S3 -10.2 -10.2 -10.2 -10.2 -10.2 MPa
Total effective stress S eff 120.7 120.7 113.1 112.8 113.7 MPa
Specified minimum yield strength SMYS 245.0 245.0 245.0 245.0 245.0 MPa
External combined load stress
F 0.90 0.90 0.90 0.90 0.90
factor
Allowable stress 220.5 220.5 220.5 220.5 220.5 MPa
S eff ≤ SMYS x F Pass Pass Pass Pass Pass

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
Elec File Location \\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-00035-04-PL-CAL-
0002_0.xlsx
Page 17 of 18
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0 30-01-20 T Doan M Nichols
9.0 Fatigue Calculations

Values
Parameter Symbol Units Source
Case 1 Case 2 Case 3 Case 4 Case 5
Girth Weld Fatigue
Cyclic longitudinal stress due to Eqn 17, SS 4.8.2.1.2, API RP 1102
Δ S Lh 27.9 27.9 12.0 12.3 9.1 MPa
construction vehicular load
Girth weld fatigue endurance limit,
S FG 82.7 82.7 82.7 82.7 82.7 MPa
all welds
External load cyclic longitudinal
stress factor F 0.72 0.72 0.72 0.72 0.72

ΔS Lh ≤ S FG x F Pass Pass Pass Pass Pass


Longitudinal Weld Fatigue
Cyclic circumferential stress due Eqn 20, SS 4.8.2.2.3, API RP 1102
ΔS Hh 12.7 12.7 6.4 5.9 4.3 MPa
to construction vehicular load
Longitudinal weld fatigue
S FL 144.8 144.8 144.8 144.8 144.8 MPa
endurance limit, all welds
External load cyclic circumferential
stress factor F 0.72 0.72 0.72 0.72 0.72

ΔS Hh ≤ S FL x F Pass Pass Pass Pass Pass

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be
disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Calculation Sheet

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev 0\411001-
Elec File Location 00035-04-PL-CAL-0002_0.xlsx

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10.0 Summary of Results

Summary of Results
Location Case 1 Case 2 Case 3 Case 4 Case 5
S Hi ≤ SMYS Not required as per Section 5.7.3.2 of AS/NZS 2885.1
S eff ≤ SMYS x F Pass Pass Pass Pass Pass
ΔS Lh ≤ S FG x F Pass Pass Pass Pass Pass
ΔS Hh ≤ S FL x F Pass Pass Pass Pass Pass
`
11.0 Conclusions
For the DN100 CPF to Refinery Crude Oil Pipeline to be able to withstand the worst anticipated highway vehicular
loads at unsealed open cut crossings, the total effective stress and fatigue (at girth and longitudinal welds) criteria
shall be met.

The calculations performed to the method described in API RP 1102 indicate that at 900 mm and 1200 mm depth of
covers, the DN100 CPF to Refinery Crude Oil Pipeline will be able to withstand the anticipated highway vehicular
loads, at such crossings.

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor
their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix A
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Appendix A
API RP 1102 Graphs
5 Pages

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants
nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix A
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Case 1
Case 2

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants
nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix A
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

Case 1
Case 2

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants
nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix A
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants
nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix A
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants
nor their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix B
Rev Date By Checked Rev Date By Checked Rev Date By Checked
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Appendix B
API RP 1102 Tables
2 Pages

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor
their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.
Appendix

Customer Oil Search Limited Proj No 411001-00035


Project Title Kutubu Refinery Repair and Upgrade FEED Calc No 04-PL-CAL-0002 / 500-CAL-P-0002
Calculation Title DN100 Transverse Load Calculation Phase/CTR FEED / 1-4-100
\\aubriwpdfs02v\brisbane\Projects\411001\00035 PRJT - OSL Refinery Upgrade\10.0 Engineering\10 PL-Pipelines\CAL - Calculations\Transverse Load Calculation\Rev
Elec File Location 0\411001-00035-04-PL-CAL-0002_0.xlsx

Appendix B
Rev Date By Checked Rev Date By Checked Rev Date By Checked
0 30-01-20 T Doan M Nichols

This Calculation represents the work of Worley performed to recognized engineering principles and practices appropriate for the terms of reference provided by Worley contractual Customer. This Calculation is
confidential and prepared solely for the use of the Customer. The contents of this Calculation may not be disclosed to or relied upon by any party other than the Customer, and neither Worley, its subconsultants nor
their respective employees assume any liability for any reason, including, but not limited to, negligence, to any other party for any information or representation herein.

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