HDD DESIGN CALCULATION

HDD DESIGN CALCULATION FOR CONSTRUCTION

FOR MARKET AREA CROSSING FROM CH 11+564 TO 11+701
PROJECT : LAYING OF 3 LPE COATED CS PIPE LINE FOR AUTHORIZED GA OF WEST BENGAL CLUSTERS.

Section : HPCL Auto care to Champadanga (schedule-04) From CH 0.000 to 21.000 KM.

CLIENT: HINDUSTAN PETROLEUM CORPORATION LIMITED. CONTRACTOR: SUMIT GAS AGENCIES PVT.LTD
CONSULTANT: TRACTEBEL ENGINEERING PVT.LTD.
DOCUMENT NO : HPCL/TEPL/SGAPL/HDD/DWG_33
A. INPUT VALUES AND PARAMETERS:
1 Pipe Dia D 21.91 cm Given
2 Wall Thickness t 0.64 cm Given 6.4 mm
3 Internal Dia 20.63 cm Calculated
4 Pipe Grade X 52 Grade Given
5 Specified Min. Yield Strength S 3655.96 kg/cm2 Given X 52 KSI
6 Cross Sectional Area As 42.77 cm2 Calculated
7 Moment of Inertia I 2,420.67 cm4 Calculated
8 Section Modulus of Pipe Z 220.96 cm3 Calculated
9 Weight of empty Pipe in air Wp 0.34 kg/cm Calculated
10 Weight of Water Filled Pipe in air Ww 0.670 kg/cm Calculated
11 Modulus of Elasticity E 2038902 kg/cm2 Given
12 Soil Friction Angle 30 Degrees Standard
13 Design Pressure 49 kg/cm2 Given 3670.992
14 Pre Hydrotest Pressure Prh 73.50 kg/cm2 Calculated
15 Post Hydrotest Pressure Poh 73.50 kg/cm2 Calculated
16 Operating Pr. Of Pipeline Pop 45.00 kg/cm2 Given
17 Length of Crossing L 13718 cm Calculated
18 Entry Angle 8 Degrees Designed
19 Exit Angle 8 Degrees Designed
20 Poisson's ratio m 0.3 Standard
21 Fluid drag coeff (betn slurry and pipe) f 0.00352 kg/cm2 Standard
22 Coeff of friction between pipe and soil f' 0.3 Standard
23 Buoyant weight of pipe w 0.0979 kg/cm calculated
24 Density of mud used Db 0.00115 kg/cm3 Standard (Density of bentonite)
25 Max depth of crossing h 360 cm Given
26 Column height from water level to Bed Level Hw 0 cm Given
27 Maximum ht. of soil above pipe Hs 360 cm Given
28 Soil Density Ds 0.00185 kg/cm3
29 Water Density Dw 0.001 kg/cm3 Standard
30 Coeff of Linear Expansion a 0.0000117 /oC Standard
31 Difference in Temperature during operation D 10 Assumed
32 Proposed ROC R 29300 cm Calculated
33 Hoop Stress Limitation 0.9 of SMYS Given
34 Bending Stress limitation 0.9 of SMYS Given
35 Surface Area of Pipe 944241.4 cm2 Calculated
36 Rig Pulling Capacity 32 Tons To be Used
37 OFC OD 4.00 cm Given
38 OFC w.t. 0.00 cm Given
39 OFC weight 0.00 Kg/cm Given
40 OFC net Bouyancy 0.01445 Kg/cm Calculated
41 Roller Spacing 1200 cm
Notes & Calculations

A. GIVEN:
To Install 21.91 cm x 0.64 cm W.T. API 5L Gr. X 52 steel pipelines by Horizontal Directional
Drilling technique as per ASME B31.8

B. PURPOSE:
Pipelines to be used for gas transmission. P = 45.00 kg/ cm2

C. REFERENCE:
i) Specifications, ASME B31.8 for Gas Transmissions in Pipelines
ii) Angle of Soil Shearing resistance ASTM D-3080 methods (30 degrees)
iii) Average coeff of friction between pipe & soil; recommended values between 0.21 to 0.30 (Maidla)
Maidla, EE: “Borehole friction assessment and. application to oilfield casing design in directional. wells”,
Ph.D. Thesis, Louisiana State University (1987)
iv) Drag Coeff of Friction taken as 0.05 psi (Empirical)
NEN 3650 - Requirements for steel pipeline transportation system. Dutch Standard – 1993
v) Soil Investigation data

D. CALCULATIONS:

1 OVERBURDEN PRESSURE AND COLLAPSE PRESSURE

The collapse pressure is determined from the theoretical elastic curve equation
Pc = 2E / [(1-µ2)(D/t)(D/t-1)2 ]
Where: D/t = 21.91 / 0.64 = 34.23
= 118.51 kg/cm2
The collapse pressure, Pc = 118.51 kg/cm2

The maximum overburden pressure

Po = (h*Db + hs*Ds + hw*Dw)
Po = 360 x 0.00115 + 360 x 0.00185 + 0 x 0.001
= 1.08 kg/cm2
Po/Pc = 0.91%
Since Overburden is only 0.91% of Collapse Pressure, Pipe is safe

2. BOUYANCY OF PIPE
Pipe Volume
Displacement of pipeline in drilling mud where volume
V, = 3.14 (D)(D)/4
D = 21.91 cm
V = 377.03 cc/linear cm.
Buoyancy
Buoyancy in drilling mud where mud density
B = Volume of Mud Displacement by pipe x mud density
= V x Db
B = 377.03 x 0.00115
= 0.434 kg/cm
Net Buoyancy
Net buoyancy when pipeline is empty and fully submerged
= B-W or 0.434 - 0.336
= 0.098
= 0.0979 kg/cm force

3 COATING STRESSES
The maximum shear stress in the pipeline coating during installation depends upon relative movements
of the pipeline and the surrounding soil. Using bentonite mud, the low-friction soil-coating interface
will be at a minimum.
Coating Failure Check
PP coatings Resistance = 2.5 kg/sq.cm. Std. Peel Test Value
Longitudinal Soil Stress. t = t = N(2-sin d)tan d
 where ,
N is the force normal to the pipeline due to buoyancy
= 0.0979 kg/ cm
Friction Angle (d) = 30 (as per soil investigation report)
N = N/(30/360*3.14*D)
= 0.0171 kg/sq.cm.
2-sin 30o = 1.5
t = (N x 1.5 x tan(30)
= 0.0148 kg/sq.cm.
Which is negligible as compared to the adhesive force of 2.5 kg/sq.cm that is 0.591%
So, Coating is safe.

4. Max Tensile Stress During Pull

Allowable stress = 90 % of SMYS
T = 0.9 x S x As
= 1,40,715.44 kg
Check for Tensile Stress
Max long stress that can be applied by Rig = 32 Tons
= 32000 / As
= 748.26 kg/sq.cm.
Percentage of SMYS = 20.47% of SMYS
Since Max. Tensile Stress is within limits and thus SAFE
Check for Bending Stress
For Long Bending Stress During installation at ROC = 29300 cm
= Ec/r E = modulus of elasticity
= 762.33 kg/cm2 c = distance of natural axis from edge of section
Percentage of Total SMYS = 20.85% of SMYS r = radius of curvature (ROC)

Hence Long. Bending Sress at above radius is safe.

5. Radius of Curvature Calculations

A. Before Installation
Pulling Load = 0 kg
Bending Load = 90 % of SMYS during Overbend or on rollers
Hoop Stresses = 90 % of SMYS on ground before overbend

Before Installation
Min Radius for Temporary Pipe Handling
Limiting SMYS = 90%
Bending Stress S = Ec/2/r
or R = 6431 cm
= 64.31 meters
B. During Installation

Max Pulling Load = 32 Tons

P=F/As = 748.260 kg/sqcm
Bending Stress Radius 29300 cm
= 762.33 kg/sqcm
Hydrotest Stress = 0.00 kg/sqcm
TOTAL Stress = 1510.59 kg/sqcm
Total Percent of SMYS = 41.32%

C. After Installation (Post Hydrotesting will be done at this stage)

Bending Stress at ROC = Ec/2/R
Longitudinal Stress at Test Pressure = pd/4t
Pulling Load = 0
Min Radius for Permanent Pipe Installation
As per ANSI B 31.4 factor of 1.85
Permanent Radius of Curvature - R = Ec/(0.75.S.SMYS-pd/4t)
Where S is design factor of 0.72
= 22336171.41 / [ 1974.22 - 629.06 ]
= 16604.80 cm
= 166.047952 meters
Taking 10% higher ROC = 182.7 meters
Permanent Radius Calc Check:
Bending Stress at ROC = Ec/2/R
= 762.33 kg/sqcm

Longitudinal Stress at Test Pressure = pd/4t

= 629.06 kg/sqcm

Total Stresses = 1391.38 kg/sqcm

Stresses as Percent of SMYS = 38.06%

6. Combined Equivalent . Stresses

A: Before Installation

Hoop Stress Sh = pd/2t

Test Pressure Pt = 73.50 kg/sqcm
= 1258.11 kg/sqcm
= 34.41% of SMYS

Bending Moment for Pipe at 1200 cm Supports

= Ww.L2/8
= 80,400.00 kg-cm
Bending Stress Sb = BM/Polar MI
= 363.859 kg/sqcm

Combined Long Stress Sl1 = m x Sh + Sb Or m x Sh - Sb

= 377.43 + 363.86 = 377.43 - 363.86
= 741.29 kg/cm2 = 13.58 kg/cm2

Resultant Eq. Stress

Resultant 1 = Sqrt (Sl12- Sl1xSh+Sh2) Or Sqrt (Sl12- Sl1xSh+Sh2)
= 1095.32 kg/cm2 1251.38 kg/cm2
= 29.96% of SMYS 34.23% of SMYS

B: After Installation
Pressure at Final Hydrotest = 73.50 kg/cm2
Hoop Stress Sh = 1258.11 kg/cm2
Bending stress at give radius Sb = Ec/2/r
= 762.33 kg/cm2
Combined Long Stress Sl1 = m x Sh - Ea.dT + Sb
= 377.43 - 0.00 + 762.33
= 1139.76 kg/cm2

Combined Long Stress Sl2 = m x Sh - Ea.dT - Sb

= 377.43 - 0.00 - 762.33
= -384.89 kg/cm2
Resultant Eq. Stress
Resultant 1 = Sqrt (Sl12- Sl1xSh+Sh2) VON MISES' EQUATION
= 1203.31 kg/cm2
= 32.91% of SMYS
Resultant 2 = Sqrt (Sl22- Sl2xSh+Sh2)
= 1488.36 kg/cm2
= 40.71% of SMYS

C: During Operation
 Operating Pressure = 45.00 kg/cm2
Hoop Stress Sh = pd/2t
= 770.27
Bending stress at give radius Sb = Ec/r
= 762.33 kg/cm2
Combined Long Stress Sl1 = m x Sh - Ea.dT + Sb
= 231.08 - 238.55 + 762.33
= 754.86 kg/cm2

Combined Long Stress Sl2 = m x Sh - Ea.dT - Sb

= 231.08 - 238.55 - 762.33
= -769.80 kg/cm2
Resultant Eq. Stress
Resultant 1 = Sqrt (Sl12- Sl1xSh+Sh2)
= 762.68 kg/cm2
= 20.86% of SMYS
Resultant 2 = Sqrt (Sl22- Sl2xSh+Sh2)
= 1333.74 kg/cm2
= 36.48% of SMYS

7 ROLLER SPACING DURING PULL

Allowable Bending Moment for Roller Spacing = 90% SMYS
= 3290.37 kg/cm2
Max Tensile force that can be applied = 32 tons
P=F/As = 748.26 kg/cm2

Available Stress for Bending Fb = 2542.11 kg/cm2

Bending Moment = Z*Fb

5,61,716.09 kg-cm
This bending moment will determine the roller spacing

For Simple spans (In between Rollers) BM = wL2/8

Where w is the weight of pipe in air
Max spacing between rollers = L = sqrt ( 5,61,716.09 x 8 / 0.336 )
= 4480.90 cm
= 44.809 meters max

For Cantilever (On last Roller) BM = wL2/2

Where w is the weight of pipe in air
Max spacing between rollers = L = sqrt ( 5,61,716.09 x 2 / 0.336 )
= 1829.32 cm
= 18.2932 meters max

8 PULLING REQUIREMENTS
Pulling loads is divided into 3 main forces. Viz:
= Fluid Drag Resistance + Soil Drag Resistance + Fluid Weight on Pull Head
= pDLf + f'wL + DbhA
= 3323.72981 + 402.78 + 156.1
= 3882.60 kg
= 3.88 Tons

Total Pulling Force Required = 4.27 Tons cosidering safety factor 1.1
% of Force Required to Rig Capacity = 13.35%