DESIGN CALCULATIONS SHEET - 12"

CLIENT- INDIAN OIL CORPORATION LTD

PMC- TRECTABEL ENGINEERING PVT.LTD
TPIA-VISION INDIA SERVICES PVT.LTD
CONTRACTOR- ARIO INFRASTRUCTURE PVT.LTD
MATERIAL & GRADE OF PIPE Steel pipe,
Sl .No. Parameter Symbol Value Unit
1 Pipe O.D. D 0.324 m Given
2 Wall thickness t 0.0064 m Given
3 Pipe I.D. d 0.30962 m Calculated
Pipe Grade Pgr API 5L GR.X Given
4
52
5
Specified Min. Yield Strength (SMYS) SMYS 360 Mpa(N/mm2) FOR X-52 GR
PIPE
6 Hydrostatic test pressure - pre Hydtpr-pre 73.5 Kg/cm2 Given

7
Hydrostatic test pressure - post Hydtpr 73.5 Kg/cm2 Given

8 Modulus of Elasticity E 200000 Mpa Standard

9 Weight of empty pipe in air Wt 45.00 Kg/m Given
10 Coefficient of friction downhole µ 0.4 Standard

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

12 Proposed min. radius of curvature R 350 m Calculated
13 Angle of entry α 12 Degree Std. practice
14 Angle of exit β 10 Degree Std. practice
Length of crossing L 300 m Calculated
15

16 Max. allowable stress (% of SMYS) % 90 % Given

17 Design pressure Dpr 4.9 N/mm2 Given
18 Poisson’s ratio/ Coefficient n 0.3 Standard for

19
Linear coefficient of thermal expansion α’ 0.0000117 /0C Standard for
Steel
Design temperature TD 65 0 Given
C
20

Ambient temperature TA 35 0 Taken/

21 C
Temperature Difference ΔT 30 0 Assumed
Calculated
22 C

23
Mud density/ Density of drilling fluid dm 1200 Kg/m3 Standard/
Assumed
24 Minimum Cover hlbl 1.50 m Given
25 Coefficient of Friction on Rollers µR 0.2 Assumed
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 5.73 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
31 Soil Density - dry ds 1470 Kg/m3 Standard
32 Water Density dw 1000 Kg/m3 Standard
25 0 Standard
33 Installation Tempertaure C
-20 0 Standard
34 Operating Tempertaure 1 C
35 Operating Tempertaure 2 60 0
C Standard
I
1- Crossing Design
CONTRACT INFORMATION
CLIENT/CONSULT
Contractor AIPL TPIA VISPL IOCL/TEPL
ANT

PIPE CHARACTERISTICS
Pipe Carbon Steel Grade API 5L Gr X-52 Diameter(") 12.75
Specific gravity
Diameter(mm) 324 Thickness (mm) 6.4 7.85
(g/cm3)
External coating 3LPE Internal coating None
3
Thickness(mm) 3.20 Spec. Gravity 960 Kg/m
WEIGHT CALCULATION(Kg/m)
Bare pipe 45.00 Kg/m
External Coating

Thickness of coating= 3x1mm = 0.0032 m

External diameter of coating = Pipe OD+ (Coating Thickness x 2) = 0.3304 m

Internal Diameter of Coating = 0.324 m

2 2
Area of Coating = π/4 (OD - ID )
= 0.003287706 m2
Weight of Coating = Density x Volume
= 3.156197376 Kg/m = 3.2 Kg/m
Total weight of Pipe = Bare weight + Weight of Coating
= 48.2 Kg/m

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

2
Buoyancy in drilling fluid = B = π D dm/4
= 98.887392 Kg/m
Net Weight of Pipe Downhole = NWt= Weight of empty pipe in air - B
= -50.69 Kg/m
Maximum Bending Moment
Bmax = (Modulus of Elasticity x Moment of Inertia)/ Radius of Curvature = E I/R
4 4
Where, I = π/64 (D -d )
4
= 0.00008978 m
Bmax = 51302.86 Nm
Maximum Allowable Stress
Maximum allowable stress, Asmax = 90% of SMYS
2
Asmax = 324.00 N/mm
2-Pull Force
CONTRACT INFORMATION
CLIENT/CONSULT
Contractor AIPL TPIA VISPL IOCL/TEPL
ANT

PIPELINE WEIGHT DOWNHOLE- BUOYANCY SYSTEM

PIPE WEIGHT DOWNHOLE (Kg/m, negative when floating)
Mud density 1200 Buoyancy in drilling mud 98.887392 Net weight of empty pipe downhole -50.69

OTHER PULLING PARAMETERS

FRICTION COEFFICIENT-MUD-COHESION-GRAVITY- (STANDARD VALUES)
Friction coefficient downhole 0.4 Gravity 9.81
2
Friction coefficient on rollers 0.20 Mud cohesion (N/m ) 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 = 59,669.21 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 = 1222.20 N

FORCE TO COUNTER COHESION

δ = Coefficient of drag

D = External diameter of pipe including external coating F3 = δ.π.D.L

L = Length of pipe F3 = 72944.71 N

F3 = Force to counter cohesion

FORCE ON ROLLER

µ = Coefficient of friction of roller F4= µ. Wt.

Wt = Total weight of Pipe (Bare weight + Weight of Coating) F4= 9.64

TOTAL PULLING FORCE REQUIRED

TF = Total pulling force (Kg) TF = F1+F2+F3+F4 133845.76 N

TF = 13643.81 Kg
Min. capacity of drill rig required (taking safety factor) = T.F. x S.F. = 17.05 17.10 Ton

The Total Force Required to pull the product Pipe string 17.1TON

70 Ton Rig will be deployed for executing the work , Drill Rig pulling capacity is more than the calculated total pull force
required for 12" pipe Pulling, hence design is safe.
3- Stress Analysis

CONTRACT INFORMATION
CLIENT/CONSULT
Contract AIPL TPIA VISPL IOCL/TEPL
ANT
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) 4.9
D Pipe dimeter 324 mm SMYS Specified min. yield strength (Mpa) 360.00
2 2 2
t Pipe wall thickness 6.4 mm AS Cross sectional area mm = π/4 ( D -d )
R Min. radius of curvature 350 m = 7152.49
/0
α Coeff. of thermal expansion 0.0000117 C Asmax Max. allowable stress (N/mm2) 324.00
Sf Safety factor 1.25 n Poisson coefficient 0.30

EQUIVALENT STRESS DURING PULLING

TF = 133845.76 N
2
St = TF/As = 18.71 N/mm
2
Sz = ED/2R = 92.57 N/mm Se < ASmax
2
Sx = St+Sz+nSy = 111.28 N/mm
2 2 2
Se = √Sx +Sy -Sx.Sy = 111.28 N/mm

EQUIVALENT STRESS DURING OPERATION

2
Sy = DPR x D/2t = 124.03 N/mm
2
Sz = ED/2R = 92.57 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 59.58 N/mm or -125.56 N/mm
2 2 2
Se = √Sx +Sy -Sx.Sy = 107.44 or 216.16 N/mm
2
Taking Larger Value, Se = 216.16 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 = 123.49 Kg/m
2
BM = Max. bending moment (Nm) = Wt . LR / 10 69778.76544 69,778.77
3
Z = Section modulus (mm ) = 2.I/D = 554197.5309
2
Sz = Stress due to roller spacing = BM /Z = 125.91 N/mm
2
Sy = HYDTPR-pre.D/2t = 182.51 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 180.66 N/mm or -71.16 N/mm
2 2 2 2
Se = √Sx +Sy -Sx.Sy = 181.59 N/mm or 226.63 N/mm
2
Taking Larger Value, Se = 226.63 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 = 182.51 N/mm
2
Sz = ED/2R = 92.57 N/mm Se < ASmax
2 2
Sx = nSy-EαδT±Sz = 147.33 N/mm or -37.82 N/mm
2 2 2
Se = √Sx +Sy -Sx.Sy = 167.71 N/mm or 204.07
2
Taking Larger Value, Se = 204.07 N/mm
 EQUIVALENT STRESS DURING PULLING ON ROLLERS
LR = Roller spacing (m) = 24 Pipe Weight on rollers = 48.2 Kg/m
2
BM = Max. bending moment (Nm) = Wt . LR / 10 27235.6992 27235.7
3
Z = Section modulus (mm ) = 2.I/D = 554197.5309
2
Sz = Stress due to roller spacing = BM /Z = 49.14439073 N/mm
2
St = µroller. L.Wt/As = 3.97 N/mm Se < ASmax
2
Sx = St+Sz+nSy = 53.11 N/mm Here, Sy =0
2 2 2
Se = √Sx +Sy -Sx.Sy = 53.11 N/mm
MIN. RADIUS OF CURVATURE
Rmin = Min. radius of curvature (m) = E.(D/2) / 90% of SMYS = 100.00

Taking multipication factor of 1.85, Minimum elastic bend radius = 1.85 x R min.

= 185 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) = 139.21

Our proposed Min. Radius of Curvature is 350 Mtr is more than the calculated Min. Radius of Curvature .

.
Collapse Pressure, Pc' (determined from theoretical elastic curve equation)
2 2
Pc' = 2E / [(1-n )(D/t)(D/t-1) ]
Here, Pipe Dimension Ratio, D/t = 50.63
2
Pc' = 3.53 N/mm
2
Maximum allowable overburden pressure, Pc = 0.75 of Pc' = 2.64 N/mm

Maximum possible overburden pressure, Po

Po = (hrig*dm + hs*ds + hw*dw)g
2
Po = 0.07 N/mm

Po/Pc = 2.55%
Since overburden is only 2.55% 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)
2
Wv = K * B * 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 = 0.51 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= 2.50
3
Dsw = Sat. soil density = g * dsw 24.23 kN/m

Thus, Wv = 15.63 kN/m

Check for Buckling -

Horizontal % deflection in the pipe because of vertical load - Wv =
3
% deflection = (0.162 * DL * Wv)/(E * (t/D) + 0.0915 X M)
Here, DL = Deflection lag factor = 1
M= Modulus of soil reaction = 3.50 Mpa
% deflection = 0.001 m
= 0.42% of pipe dia Since deflection is less than 3%, buckling will not occur.

Check for Flexural Stress -

2
Flexural Hoop Stress, SF = C * K * (D/B) * Dsw * D * DL
2 3
Here, C = Pipe Stiffness factor = (0.5 * E * (t/D) + 0.0053 * (D/t) * M)/(E * (t/D) + 0.0915 * M)
C= 1,086.55
SF = 8.67 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 = 50.69 kg/m
Angle of friction, ɸ = 29.5 degree
N= NWt/(ɸ/360*pi() D)
2
N= 607.69 kg/m
2
Therefore, Sx = 518.33 kg/m

Since longitudinal soil stress is only 2.07% of PE coating adhesive force, coating is safe.
Sx/PE coating adhesive force= 2.073322826

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