DESIGN CALCULATIONS SHEET - 18"

HORIZONTAL DIRECTIONAL DRILLING

INPUT VALUES
Sl .No. Parameter Symbol Value Unit
1 Pipe O.D. D 0.457 m Given
2 Wall thickness t 0.0111252 m Given
3 Pipe I.D. d 0.4349496 m Calculated
Pipe Grade Pgr API 5L Gr X Given
4
70
5
Specified Min. Yield Strength (SMYS) SMYS 482.63 Mpa(N/mm2) For X70 Gr Pipe

6 Hydrostatic test pressure - pre Hydtpr-pre 231 Kg/cm2 Given

Hydrostatic test pressure - post Hydtpr 155 2 Given
7 Kg/cm
8 Modulus of Elasticity E 200000 Mpa Standard
9 Weight of empty pipe in air Wt 122.39 Kg/m Given

Coefficient of friction downhole µ 0.4 Standard

10

11 Coefficient of drag/ mud cohesion δ 239 N/m2 Standard

12 Proposed min. radius of curvature R 500 m Calculated
13 Angle of entry α 8 Degree Std. practice

14 Angle of exit β 8 Degree Std. practice

15 Length of crossing L 236.66 m Calculated
16 Max. allowable stress (% of SMYS) % 90 % Given
17 Design pressure Dpr 10.783 N/mm2 Given
Poisson’s ratio/ Coefficient n 0.3 Standard for
18 Steel

Linear coefficient of thermal expansion α’ 0.0000117 /0C Standard for

19
Steel
Design temperature TD 65 0 Given
20 C

Ambient temperature TA 35 0 Taken/

21 C
Assumed
Temperature Difference ΔT 30 0 Calculated
22 C

23
Mud density/ Density of drilling fluid dm 1200 Kg/m3 Standard/
Assumed
24 Minimum Cover hlbl 7.00 m Given

25 0.2 Assumed
Coefficient of Friction on Rollers µR
26 Safety Factor for drill rig capacity S.F. 1.25 Assumed
27 Roller Spacing LR 24 m Taken
28 Max depth of installed pipe from rig level hrig 8 m Drawing
29 Column height from water level to pipe top hw 0.00 m Drawing
30 Column height from bed to pipe top hs 0.00 m Assumed
ds 1470 3 Standard
31 Soil Density - dry Kg/m
dw 1000 3 Standard
32 Water Density Kg/m

Document: CS-BTR/01 , HDD Design CIPL Page 1

1- Crossing Design

CONTRACT INFORMATION
Contractor AMPS Crossing Ch 39 Road & canal Crossing Owner IOCL

PIPE CHARACTERISTICS
Pipe Steel Grade API 5L X Gr 70 Diameter(") 18.00

Specific gravity
Diameter(mm) 457 Thickness(mm) 11.1252 7.85
(g/cm3)

External coating 3LPE Internal coating None

Thickness(mm) 3.20 Spec. Gravity 960 Kg/m3
WEIGHT CALCULATION(Kg/m)
Bare pipe 122.3869199 Kg/m
External Coating

Thickness of coating= 3x1mm = 0.003 m

External diameter of coating = Pipe OD+ (Coating Thickness x 2) = 0.4632 m

Internal Diameter of Coating = 0.4572 m

Area of Coating = π/4 (OD2- ID2)

= 0.004335084 m2
Weight of Coating = Density x Volume
= 4.16168064 Kg/m = 4.2 Kg/m
Total weight of Pipe = Bare weight + Weight of Coating
= 126.5869199 Kg/m

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

2
Buoyancy in drilling fluid = B = π D dm/4
= 202.1100941 Kg/m
Net Weight of Pipe Downhole = NWt= Weight of empty pipe in air - B
= -75.52 Kg/m
Maximum Bending Moment
Bmax = (Modulus of Elasticity x Moment of Inertia)/ Radius of Curvature = E I/R
Where, I = π/64 (D4-d4)
4
= 0.00038783 m
Bmax = 155132.00 Nm
Maximum Allowable Stress
Maximum allowable stress, Asmax = 90% of SMYS
Asmax = 434.37 N/mm2

Document: CS-BTR/01 , HDD Design CIPL Page 2

2-Pull Force

CONTRACT INFORMATION
Contractor AMPS Crossing Ch 39 Road & canal Crossing Owner IOCL

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

PIPE WEIGHT DOWNHOLE (Kg/m, negative when floating)
Mud density 1200 Buoyancy in drilling mud 202.1100941 Net weight of empty pipe downhole -75.52

OTHER PULLING PARAMETERS

FRICTION COEFFICIENT-MUD-COHESION-GRAVITY- (STANDARD VALUES)
Friction coefficient downhole 0.4 Gravity 9.81
Friction coefficient on rollers 0.20 Mud cohesion (N/m2) 239
PULL FORCE CALCULATION
FORCE TO COUNTER BUOYANCY
µ = Coefficient of friction downhole
N Wt = Net weight of empty pipe downhole
L = Length of pipe downhole F1 = µ. NWt. L
F1 = Force to counter buoyancy F1 = 70,134.91 N
FORCE TO COUNTER CURVATURE
Bmax = Max. bending moment
R = Radius of curvature
α = Entry angle F2 = 4.µ.Bmax.360
β = Exit angle π.R.(α+β)
F2 = Force to counter curvature F2 = 3557.17 N
FORCE TO COUNTER COHESION
δ = Coefficient of drag

D = External diameter of pipe F3 = δ.π.D.L

L = Length of pipe F3 = 81200.49 N

F3 = Force to counter cohesion

TOTAL PULLING FORCE REQUIRED

TF = Total pulling force (Kg) TF = F1+F2+F3 154892.56 N

TF = 15789.25 Kg
Min. capacity of drill rig required (taking safety factor) = T.F. x S.F. = 15.79 15.80 Ton
The Pull Force Required to pull the 89mm Conduit = 0.80 x 1.50 = 1.20 Tonns 1.20 Ton
The Total Force Required to pull both the product Pipe string and 89 mm conduit 17TON

32 Ton Rig will be deployed for executing the work , Drill Rig pulling capacity is more than the calculated total pull force
required for 18" + 89mm pipe Pulling, hence design is safe.

Document: CS-BTR/01 , HDD Design CIPL Page 3

3- Stress Analysis
CONTRACT INFORMATION
Contract AMPS Crossing Ch 39 Road & canal Crossing Owner IOCL

DEFINITIONS
Se Equivalent stress St Stress due to pull force Sz Bending stress
Sx Longitudinal stress Sy Hoop stress
The circumfrencial stress and longitudinal stress are usually much larger for pressure vessels ,and so far thin walled instances,
radial stress is usually neglected.
PIPELINE CHARACTERISTICS
E Youngs modulus 200000 Mpa DPR Design pressure (N/mm2) 10.783
D Pipe dimeter 457 mm SMYS Specified min. yield strength (Mpa) 482.63
t Pipe wall thickness 11.1252 mm AS Cross sectional area mm2 = π/4 ( D2-d2)
R Min. radius of curvature 500 m = 15582.79
/0
α Coeff. of thermal expansion 0.0000117 C Asmax Max. allowable stress (N/mm2) 434.37
Sf Safety factor 1.25 n Poisson coefficient 0.30

EQUIVALENT STRESS DURING PULLING

TF = 154892.56 N
2
St = TF/As = 9.94 N/mm
2
Sz = ED/2R = 91.44 N/mm Se < ASmax
2
Sx = St+Sz+nSy = 101.38 N/mm
Se = √Sx2+Sy2-Sx.Sy = 101.38 N/mm
2

EQUIVALENT STRESS DURING OPERATION

2
Sy = DPR x D/2t = 221.57 N/mm
2
Sz = ED/2R = 91.44 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 87.71 N/mm or -95.17 N/mm
Se = √Sx2+Sy2-Sx.Sy = 193.27 or 281.49 N/mm
2

2
Taking Larger Value, Se = 281.49 N/mm

EQUIVALENT STRESS DURING PREHYDROTEST ON ROLLERS

In this case we assume that δT = 0 for thermal stresses, as pipe is tested at ambient temp. due to canal flow.
LR = Roller spacing (m) = 24 Pipe Weight with water on rollers = 275.17 Kg/m
BM = Max. bending moment (Nm) = Wt . LR2 / 10 155486.1494 1,55,486.15
Z = Section modulus (mm3) = 2.I/D = 1696544.182
Sz = Stress due to roller spacing = BM /Z = 91.65 N/mm2
2
Sy = HYDTPR-pre.D/2t = 465.64 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 231.34 N/mm or 48.04 N/mm
Se = √Sx2+Sy2-Sx.Sy = 403.26 N/mm
2
or 443.57 N/mm
2

2
Taking Larger Value, Se = 443.57 N/mm

EQUIVALENT STRESS DURING POST HYDROTEST (AFTER PULLING)

In this case we assume that δT = 0 for thermal stresses, as pipe is tested at ambient temp. due to canal flow.
HYDTPR = Specified hydrotest pressure
2
Sy = HYDTPR.D/2t = 312.44 N/mm
2
Sz = ED/2R = 91.44 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 185.17 N/mm or 2.29 N/mm
Se = √Sx2+Sy2-Sx.Sy = 272.13 N/mm
2
or 311.30
2
Taking Larger Value, Se = 311.30 N/mm

Document: CS-BTR/01 , HDD Design CIPL Page 4

 EQUIVALENT STRESS DURING PULLING ON ROLLERS
LR = Roller spacing (m) = 24 Pipe Weight on rollers = 126.5869199 Kg/m
BM = Max. bending moment (Nm) = Wt . LR2 / 10 71528.69859 71528.7

Z = Section modulus (mm3) = 2.I/D = 1696544.182

Sz = Stress due to roller spacing = BM /Z = 42.16141304 N/mm2
St = µroller. L.Wt/As = 3.77 N/mm2 Se < ASmax
Sx = St+Sz+nSy = 45.93 N/mm2 Here, Sy =0
Se = √Sx2+Sy2-Sx.Sy = 45.93 N/mm2
MIN. RADIUS OF CURVATURE
Rmin = Min. radius of curvature (m) = E.(D/2) / 90% of SMYS = 105.26
Taking multipication factor of 1.85, Minimum elastic bend radius = 1.85 x Rmin.
= 194.7247374 m
POST INSTALLATION -
Rmin = Min. radius of curvature (m) = E.(D/2) / (90% x Df x SMYS - D.Hydtpr/4t)
Df = Design factor = 1 As per ANSI B31.8
Rmin (m) = 164.37

Our proposed Min. Radius of Curvature is 500 Mtr is more than the calculated Min. Radius of Curvature .

OVERBURDEN PRESSURE AND COLLAPSE PRESSURE

Collapse Pressure, Pc' (determined from theoretical elastic curve equation)
Pc' = 2E / [(1-n2)(D/t)(D/t-1)2]
Here, Pipe Dimension Ratio, D/t = 41.10
2
Pc' = 6.65 N/mm
2
Maximum allowable overburden pressure, Pc = 0.75 of Pc' = 4.99 N/mm

Maximum possible overburden pressure, Po

Po = (hrig*dm + hs*ds + hw*dw)g
2
Po = 0.09 N/mm

Po/Pc = 1.89% Since overburden is only 1.89% of maximum allowable overburden pressure, empty pipeline is
safe.

STRESS UNDER VERTICAL LOAD DUE TO SOIL LOOSENING AND ITS COLLAPSE ON PIPE
Vertical load per unit length of pipeline, Wv (factor of hole diameter, soil properties and pipe design)
Wv = K * B2 * Dsw
Here, K = Load factor depending on soil properties and pipe design
K= pi() [1+f-(D/B)^2/(4*b) Load factor for elliptical
Here, f = 0.05
B= Bore diameter = 0.71 m
b= bulking factor = 0.4 (0.1 to 0.15 for sand and gravel and 0.15 to 0.4 for silt and clay)
K= 2.49
3
Dsw = Sat. soil density = g * dsw 24.23 kN/m

Thus, Wv = 30.48 kN/m

Check for Buckling -

Horizontal % deflection in the pipe because of vertical load - Wv =
% deflection = (0.162 * DL * Wv)/(E * (t/D)3 + 0.0915 X M)
Here, DL = Deflection lag factor = 1
M= Modulus of soil reaction = 3.50 Mpa
% deflection = 0.002 m
= 0.34% of pipe dia Since deflection is less than 3%, buckling will not occur.

Document: CS-BTR/01 , HDD Design CIPL Page 5

Check for Flexural Stress -
Flexural Hoop Stress, SF = C * K * (D/B)2 * Dsw * D * DL
Here, C = Pipe Stiffness factor = (0.5 * E * (t/D) + 0.0053 * (D/t)2 * M)/(E * (t/D)3 + 0.0915 * M)
C= 769.76
SF = 8.77 Mpa SF < ASmax

COATING STRESSES
DIRAX sleeves used for HDD. To avoid damage to coating, low friction drilling mud will be used.
2
PE coating adhesive force = 25,000 kg/m
Longitudinal Soil Stress, Sx = N(2-sinɸ)tanɸ
Normal force on pipeline due to net buoyancy, NWt = 75.52 kg/m
Angle of friction, ɸ = 29.5 degree
N= NWt/(ɸ/360*pi() D)
N= 641.66 kg/m2
Therefore, Sx = 547.30 kg/m2

Since longitudinal soil stress is only 2.19% of PE coating adhesive force, coating is safe.

SUMMARY
As the above calculated stresses are well below the max. allowable stress, therefore the design is safe.

Document: CS-BTR/01 , HDD Design CIPL Page 6