DESIGN CALCULATIONS SHEET - 12.

75"
HORIZONTAL DIRECTIONAL DRILLING

INPUT VALUES
Sl .No. Parameter Symbol Value Unit
1 Pipe O.D. D 0.324 m Given
2 Wall thickness t 0.0112 m Given
3 Pipe I.D. d 0.30145 m Calculated
Pipe Grade Pgr API 5L Gr Given
4
46
5 Specified Min. Yield Strength (SMYS) SMYS 317.158 Mpa(N/mm2) Given
6 Hydrostatic test pressure - pre (90%) Hydtpr-pre 200 Kg/cm2 Given
7 Hydrostatic test pressure - post (90%) Hydtpr 114 Kg/cm 2 Given
8 Modulus of Elasticity E 200000 Mpa Standard
9 Weight of empty pipe in air Wt 86.36 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 360 m Calculated
13 Angle of entry α 10 Degree Std. practice

14 Angle of exit β 10 Degree Std. practice

15 Length of crossing L 157.37 m Calculated
16 Max. allowable stress (% of SMYS) % 90 % Given
17 Design pressure Dpr 4.89 N/mm2 Assumed
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
C Given
20

Ambient temperature TA 35 0
C Taken/
21
Assumed
Temperature Difference ΔT 30 0
C Calculated
22
Mud density/ Density of drilling fluid dm 1200 Kg/m3 Standard/
23
Assumed
24 Depth from lowest bed level hlbl 5.10 m Given

25 0.2 Assumed
Coefficient of Friction on Rollers µR
26 Safety Factor for drill rig capacity S.F. 1.5 Assumed
27 Roller Spacing LR 10 m Taken
28 Max depth of installed pipe from rig level hrig 7.06 m Drawing
29 Column height from water level to pipe top hw 0.00 m Assumed
30 Column height from bed to pipe top hs 0.00 m Assumed
31 Soil Density - dry ds 1470 Kg/m 3 Standard
32 Water Density dw 1000 Kg/m3 Standard

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

1- Crossing Design

CONTRACT INFORMATION
Contractor CIPL Crossing CS-BTR/01 Owner IOCL

PIPE CHARACTERISTICS
Pipe Steel Grade API 5LGr 46 Diameter(") 12.75

Specific gravity
Diameter(mm) 323.85 Thickness(mm) 11.2 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 86.35668132 Kg/m
External Coating

Thickness of coating= 3x1mm = 0.003 m

External diameter of coating = Pipe OD+ (Coating Thickness x 2) = 0.32985 m

Internal Diameter of Coating = 0.32385 m

Area of Coating = π/4 (OD2- ID2)

= 0.003078927 m2
Weight of Coating = Density x Volume
= 2.95576992 Kg/m = 3 Kg/m
Total weight of Pipe = Bare weight + Weight of Coating
= 89.35668132 Kg/m

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

Buoyancy in drilling fluid = B = π D2dm/4
= 102.4905632 Kg/m
Net Weight of Pipe Downhole = NWt= Weight of empty pipe in air - B
= -13.13 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
= 0.00013452 m
Bmax = 74733.33 Nm
Maximum Allowable Stress
Maximum allowable stress, Asmax = 90% of SMYS
Asmax = 285.44 N/mm2

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

2-Pull Force

CONTRACT INFORMATION
Contract CIPL Crossing CS-BTR/01 Owner IOCL

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

PIPE WEIGHT DOWNHOLE (Kg/m, negative when floating)
Mud density 1200 Buoyancy in drilling mud 102.4905632 Net weight of empty pipe downhole -13.13

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 = 8,110.44 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 = 1904.03 N
FORCE TO COUNTER COHESION
δ = Coefficient of drag

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

L = Length of pipe F3 = 38246.65 N

F3 = Force to counter cohesion

TOTAL PULLING FORCE REQUIRED

TF = Total pulling force (Kg) TF = F1+F2+F3 48261.13 N

TF = 4919.58 Kg
Min. capacity of drill rig required (taking safety factor) = T.F. x S.F. = 7.38 7.40 Tons
The Pull Force Required to pull the 89mm Conduit = 0.80 x 1.50 = 1.20 Tonns
The Total Force Required to pull both the product string and 89 mm conduit = 1.20 + 7.40 =8.6 Tonns

Since Drill rig pulling capacity is more than total min capacity required for 12.75" & 89mm pipe, hence design is safe
against pulling force.

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

3- Stress Analysis
CONTRACT INFORMATION
Contract CIPL Crossing CS-BTR/01 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) 4.89
D Pipe dimeter 323.85 mm SMYS Specified min. yield strength (Mpa) 317.16
t Pipe wall thickness 11.2 mm AS Cross sectional area mm2 = π/4 ( D2-d2)
R Min. radius of curvature 360 m = 10995.28
/0
α Coeff. of thermal expansion 0.0000117 C Asmax Max. allowable stress (N/mm2) 285.44
Sf Safety factor 1.5 n Poisson coefficient 0.30

EQUIVALENT STRESS DURING PULLING

TF = 48261.13 N
2
St = TF/As = 4.39 N/mm
2
Sz = ED/2R = 89.96 N/mm Se < ASmax
2
Sx = St+Sz+nSy = 94.35 N/mm
Se = √Sx2+Sy2-Sx.Sy = 94.35 N/mm
2

EQUIVALENT STRESS DURING OPERATION

2
Sy = DPR x D/2t = 70.70 N/mm
2
Sz = ED/2R = 89.96 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 40.97 N/mm or -138.95 N/mm
Se = √Sx2+Sy2-Sx.Sy = 61.48 or 184.74 N/mm
2

2
Taking Larger Value, Se = 184.74 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) = 10 Pipe Weight with water on rollers = 160.73 Kg/m
BM = Max. bending moment (Nm) = Wt . LR2 / 10 15767.36419 15,767.36
Z = Section modulus (mm3) = 2.I/D = 830754.9792
Sz = Stress due to roller spacing = BM /Z = 18.98 N/mm2
2
Sy = HYDTPR-pre.D/2t = 283.66 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 104.08 N/mm or 66.12 N/mm
Se = √Sx2+Sy2-Sx.Sy = 248.54 N/mm
2
or 257.06 N/mm
2

2
Taking Larger Value, Se = 257.06 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 = 161.69 N/mm
2
Sz = ED/2R = 89.96 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 138.46 N/mm or -41.45 N/mm
Se = √Sx2+Sy2-Sx.Sy = 151.42 N/mm
2
or 185.91
2
Taking Larger Value, Se = 185.91 N/mm

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

 EQUIVALENT STRESS DURING PULLING ON ROLLERS
LR = Roller spacing (m) = 10 Pipe Weight on rollers = 89.35668132 Kg/m
BM = Max. bending moment (Nm) = Wt . LR2 / 10 8765.890437 8765.89

Z = Section modulus (mm3) = 2.I/D = 830754.9792

Sz = Stress due to roller spacing = BM /Z = 10.55171527 N/mm2
2
St = µroller. L.Wt/As = 2.51 N/mm Se < ASmax
Sx = St+Sz+nSy = 13.06 N/mm2 Here, Sy =0
Se = √Sx2+Sy2-Sx.Sy = 13.06 N/mm2
MIN. RADIUS OF CURVATURE
Rmin = Min. radius of curvature (m) = E.(D/2) / 90% of SMYS = 113.46
Taking multipication factor of 1.85, Minimum elastic bend radius = 1.85 x Rmin.
= 209.8927559 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) = 158.28

Our proposed Min. Radius of Curvature is 360 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 = 28.92
2
Pc' = 19.51 N/mm
2
Maximum allowable overburden pressure, Pc = 0.75 of Pc' = 14.63 N/mm

Maximum possible overburden pressure, P o

Po = (hrig*dm + hs*ds + hw*dw)g
2
Po = 0.08 N/mm

Po/Pc = 0.57% Since overburden is only 0.57% 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 = 0.61 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= 2.74
3
Dsw = Sat. soil density = g * dsw 24.23 kN/m

Thus, Wv = 24.71 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 = 0.000 m
= 0.14% 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= 404.27
SF = 2.46 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 = 13.13 kg/m
Angle of friction, ɸ = 29.5 degree
N= NWt/(ɸ/360*pi() D)
N= 157.54 kg/m2
Therefore, Sx = 134.37 kg/m2

Since longitudinal soil stress is only 0.54% 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