DESIGN CALCULATIONS SHEET - 18"

HORIZONTAL DIRECTIONAL DRILLING

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

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

7 Hydrostatic test pressure - post Hydtpr 155 Kg/cm2
8 Modulus of Elasticity E 200000 Mpa
Weight of empty pipe in air Wt 122.39 Kg/m
9
Coefficient of friction downhole µ 0.4
10

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

12 Proposed min. radius of curvature R 500 m
Angle of entry α 8 Degree
13
14 Angle of exit β 8 Degree
15 Length of crossing L 236.66 m
16 Max. allowable stress (% of SMYS) % 90 %
17 Design pressure Dpr 10.783 N/mm2
Poisson’s ratio/ Coefficient n 0.3
18

Linear coefficient of thermal expansion α’ 0.0000117 /0C

19
Design temperature TD 65 C
0
20

Ambient temperature TA 35 C
0
21
Temperature Difference ΔT 30 C
0
22
Mud density/ Density of drilling fluid dm 1200 Kg/m3
23

24 Minimum Cover hlbl 7.00 m

0.2
25 µR
Coefficient of Friction on Rollers
26 Safety Factor for drill rig capacity S.F. 1.25
27 Roller Spacing LR 24 m
28 Max depth of installed pipe from rig level hrig 8 m
29 Column height from water level to pipe top hw 0.00 m

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 30 Column height from bed to pipe top hs 0.00 m
31 Soil Density - dry ds 1470 Kg/m3
32 Water Density dw 1000 Kg/m3

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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/m 3

WEIGHT CALCULATION(Kg/m)
Bare pipe 122.386919867 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
= 126.586919867 Kg/m

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

Buoyancy in drilling fluid = B = π D2dm/4
= 202.11009408 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)
= 0.00038783 m4
Bmax = 155132.00 Nm
Maximum Allowable Stress
Maximum allowable stress, Asmax = 90% of SMYS
Asmax = 434.37 N/mm2

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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 202.11009408 Net weight of empty pipe downhole

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/m )2
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

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.

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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)
D Pipe dimeter 457 mm SMYS Specified min. yield strength (Mpa)
t Pipe wall thickness 11.1252 mm AS Cross sectional area mm2 =
R Min. radius of curvature 500 m =
α Coeff. of thermal expansion 0.0000117 C
/0 Asmax Max. allowable stress (N/mm2)
Sf Safety factor 1.25 n Poisson coefficient

EQUIVALENT STRESS DURING PULLING

TF = 154892.56 N
St = TF/As = 9.94 N/mm2
Sz = ED/2R = 91.44 N/mm2 Se < ASmax

Sx = St+Sz+nSy = 101.38 N/mm2

Se = √Sx2+Sy2-Sx.Sy = 101.38 N/mm2

EQUIVALENT STRESS DURING OPERATION

Sy = DPR x D/2t = 221.57 N/mm2
Sz = ED/2R = 91.44 N/mm2 Se < ASmax

Sx = nSy-EαδT±Sz = 87.71 N/mm 2

or -95.17 N/mm2
Se = √Sx2+Sy2-Sx.Sy = 193.27 or 281.49 N/mm2
Taking Larger Value, Se = 281.49 N/mm2

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
BM = Max. bending moment (Nm) = Wt . LR2 / 10 155486.1494129 155,486.15
Z = Section modulus (mm3) = 2.I/D = 1696544.181977
Sz = Stress due to roller spacing = BM /Z = 91.65 N/mm2
Sy = HYDTPR-pre.D/2t = 465.64 N/mm2 Se < ASmax

Sx = nSy-EαδT±Sz = 231.34 N/mm2 or 48.04 N/mm2

Se = √Sx +Sy -Sx.Sy
2 2
= 403.26 N/mm 2
or 443.57 N/mm2
Taking Larger Value, Se = 443.57 N/mm2

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
Sy = HYDTPR.D/2t = 312.44 N/mm2

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 Sz = ED/2R = 91.44 N/mm2 Se < ASmax

Sx = nSy-EαδT±Sz = 185.17 N/mm 2

or 2.29 N/mm2
Se = √Sx2+Sy2-Sx.Sy = 272.13 N/mm2 or 311.30
Taking Larger Value, Se = 311.30 N/mm2

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 EQUIVALENT STRESS DURING PULLING ON ROLLERS
LR = Roller spacing (m) = 24 Pipe Weight on rollers = 126.586919867
BM = Max. bending moment (Nm) = Wt . LR2 / 10 71528.69859235 71528.7

Z = Section modulus (mm3) = 2.I/D = 1696544.181977

Sz = Stress due to roller spacing = BM /Z = 42.1614130418 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 = √Sx +Sy -Sx.Sy
2 2
= 45.93 N/mm 2

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.

= 194.72473738 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
Pc' = 6.65 N/mm 2

Maximum allowable overburden pressure, Pc = 0.75 of Pc' = 4.99 N/mm2

Maximum possible overburden pressure, P o

Po = (hrig*dm + hs*ds + hw*dw)g
Po = 0.09 N/mm2

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
Dsw = Sat. soil density = g * dsw 24.23 kN/m3

Thus, Wv = 30.48 kN/m

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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.

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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.
PE coating adhesive force = 25,000 kg/m2
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.

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Given
Given
Calculated
Given

For X70 Gr Pipe

Given
Given
Standard
Given

Standard

Standard
Calculated
Std. practice

Std. practice
Calculated
Given
Given
Standard for
Steel

Standard for
Steel
Given

Taken/
Assumed
Calculated

Standard/
Assumed
Given
Assumed

Assumed
Taken
Drawing
Drawing

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Assumed
Standard
Standard

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IOCL

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 IOCL

-75.52

the calculated total pull

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 IOCL

n walled instances,

10.783
482.63
π/4 ( D2-d2)
15582.79
434.37
0.30

ASmax

ASmax

ue to canal flow.
Kg/m

ASmax

)
ue to canal flow.

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ASmax

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 Kg/m

ASmax

rvature .

overburden pressure, empty pipeline is

SE ON PIPE

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Document: CS-BTR/01 , HDD Design CIPL Page 17
adhesive force, coating is safe.

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outside dia 323.8 mm
outside radius 161.9 mm
inside radius 150.77 mm
internal dia 301.54 mm
wall thickness 11.13 mm
coating thickness 3.2
concrete thickness
concrete thickness outside
section modulus 825841.251830167 mm3
young modulus 200333
smys
pipe wall area 10927.253694 0.010927254
coating wall areA 0.004335084 4335.084
CONCRETE WALL AREA
density of pipe
density of coating
density of concrete
density of bentonite 1200 kg/m3
density of fluid
pipeline length 132
radius of curvature down hole 500
radius of curvature on over bend 450
maximum depth of profile 7m
conveyor spacing
roller spacing 10
friction factor on conveyor fc 0.2
friction factor downhole fd 0.4
coefficient of drag 0.000239 239
poision ratio 0.3
pre installation test pressure 215 bar
post installation test pressure 137 bar
weight of bare pipe 122.386919867
weight of coating 4.2
weight of water in pipe
weight of empty pipe 126.586919867
weight of pipe filled with water on convey 275.17 kg/m
byount force 202.11009408
pipe down hole empty -75.52
spanning stress
pipe filled 91.65
pipe empty 42.1614130418

curvature stress

pipe down hole empty 64.8678254

on conveyor 72075.3615555556

on conveyor
pull force 3.3418946845

tensile stress 2.9991791557

pull force -down hole empty

pull force 7324.0282723365 7.324028272 71775.48

tensile stress 6.5684827203

moment of inertia 0.0001337037 m4

53570.5261318367 107141.0523 N-M

PULL FORCE to counter curvature 59198.4940755467

tensile stress- counter drag

pull force to counter drag 3.239285544

stress 2.9644095714

external pressure based on experimental of bentonite

external pressure 12600 kg/m2 0.0126

hoop stress external 1.8328301887

longitudinal stress 0.5498490566

hoop stress -pre hydro test 312.7448337826

longitudinal stress 156.3724168913

hoop stress post hydro test

hoop stress 199.2839173405

longitudinal stress 99.6419586703

2997145.37843695
entry angl 0.175
exit angle 0.157 0.3238
0.0032 0.327

14.54627

75.78
 od+2ct lxfdd
3987.624 1.036828 31548 3336.405

171425.7
0.332 0.008722 2.895778