HDD DESIGN CALCULATION

HDD DESIGN CALCULATION FOR CITY GAS DISTRIBUTION, TRIVANDRUM (CH:1414 - CH:1510) (TIE TO TIE LENGTH 96m)
PROJET: LAYING & CONSTRUCTION OF 8" U/G STEEL PIPELINE NETWORK & ASSOCIATED WORKS AT AKT GA.

CLIENT: M/s AG&P CITY GAS PVT LTD

TPIA: M/S TUV INDIA PVT LTD
CONTRACTOR: M/s ADITI SOLAR PVT LTD
HDD CONTRACTOR: M/S JPF & COMPANY
DOCUMENT NO:ASPL/HDD/DC-01 Rev - 00

Calculations required in accordance with ANSI code B31.8 for Gas Transmissions across Pipelines for the installation of
pipes by HDD are as follows:

A. INPUT VALUES AND PARAMETERS:

1 Pipe Dia D 21.91 cm Given
2 Wall Thickness t 0.64 cm Given
3 Internal Dia 20.63 cm Calculated
4 Pipe Grade X52 Grade Given
5 Specified Min. Yield Strength S 3655.96 Kg/cm2 Given
6 Cross Sectional Area As 42.74 cm2 Calculated
7 Moment of Inertia I 2,419.441 cm4 Calculated
8 Section Modulus of Pipe Z 220.85 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 49.0kg/cm2 Given
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 49.00 kg/cm2 Given
17 Length of Crossing L 14439 cm Calculated
18 Entry Angle 9 Degrees Designed
19 Exit Angle 9 Degrees Designed
20 Poisson's ratio m 0.3 Standard
21 Fluid drag coeff (betn slurry and pipe) f 0.00352 Standard
kg/cm2
22Coeff of friction between pipe and soil f' 0.3 Standard
23Buoyant weight of pipe w 0.09336 kg/cm calculated
24Density of mud used Db 0.00115 Kg/cm3 Standard
25Max depth of crossing h 300 cm Given
26ColumnheightfromwaterleveltoBedLevel Hw 0 cm Given
27Maximum ht. of soil above pipe Hs 300 cm Given
28Soil Density Ds 0.00185 Kg/cm3 Geotech
29WaterDensity Dw 0.001 Kg/cm3 Standard
30Coeff of Linear Expansion a 0.0000117 /oC/oC Standard
31Difference in Temperature during operation D 10 Assumed
32ProposedROC R 30000 cm Calculated
33Hoop Stress Limitation 0.9 of SMYS Given
34Bending Stress limitation 0.9 of SMYS Given
35Surface Area of Pipe 963163.6 cm2 Calculated
36Rig Pulling Capacity 32 Tons To be Used
37 OFCOD 0.00 cm Given
38OFCw.t. 0.00 cm Given
39OFCweight 0.00 Kg/cm Given
40OFC net Buoyancy 0.00000 Kg/cm Calculated
41RollerSpacing 1200 cm
Notes & Calculations

A. GIVEN:
To Install 21.91 cmx0.64 cm W.T. API5L Gr.X52 steel pipelines by Horizontal Directional Drilling technique as
per ASMEB31.8

B. PURPOSE:
Pipelines to be used for gas transmission. P = 49.00 kg/cm2

C. REFERENCE:
i) Specifications, ASME B31.8 for Gas Transmissions in Pipelines
ii) Angle of Soil Shearing resistance ASTM D-3080 methods (30degrees)
iii) Average coeff of friction between pipe & soil; recommended values between 0.21 to 0.30 (Maidla)
Maidla, EE : “Bore hole friction assessment and application to oil field casing design in directional.
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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

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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 = 300 x 0.00115 300 x 0.00185 + 0x 0.001
= 0.9
+
kg/cm2
Po/Pc = 0.76%
Since Overburden is only 0.76% 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 COATINGSTRESSES
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. Longitudinal Soil = t = N(2-sin d)tan d= 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)Friction An= 30(as per soil investigation report)
N = N/(30/360*3.14*D)
= 0.0171 kg/sq.cm.
2-sin 30o2-sin = 1.5
t = (N x 1.5 xtan(30)
= 0.0148kg/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 xAs
= 140630.16 kg

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 Check for Tensile Stress
Max long stress that can be applied by Rig = 32 Tons
= 33000 / As
= 772.11 kg/sq.cm.
Percentage of SMYS = 26.12% of SMYS
Since Max Tensile Stress is within limits and thus
SAFE Check for Bending Stress
For Long Bending Stress During installation at ROC = 30000cm
= Ec/r E = modulus ofelasticity
= 744.45kg/cm2 c = distance of natural axis from edge ofsection
Percentage of Total SMYS = 25.19% 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 StressS = Ec/r
Or R =
8396 cm
=
83.96 meters
B. During Installation

Max Pulling Load = 32Tons

P=F/As 771.734 kg/sqcm
30000 cm
=
Bending Stress Radius
= 744.45kg/sqcm
Hydrotest Stress = 0.00 kg/sqcm
TOTAL Stress = 1516.18 kg/sqcm
Total Percent of SMYS = 51.30%

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

Bending Stress at ROC = Ec/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 of0.72
= 22336171.41/ [ 1596 - 629.06 ]
= 23099.90 cm
= 231meters
Taking 10% higher ROC = 254meters
Permanent Radius Calc Check:
Bending Stress at ROC = Ec/R
= 744.45 kg/sqcm

Longitudinal Stress at Test Pressure = pd/4t

= 628.98kg/sqcm

Total Stresses = 1373.43 kg/sqcm

Stresses as Percent of SMYS = 46.47%

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6. Combined Equivalent Stresses
A: Before Installation

Hoop Stress Sh = pd/2t

Test Pressure Pt = 73.50 kg/sqcm
= 1257.97 kg/sqcm
= 42.56% ofSMYS

Bending Moment for Pipe at 1200 cm Supports

= Ww.L2/12
= 80,388.00 kg-cm
Bending Stress Sb = BM/Polar MI
= 363.891 kg/sqcm

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

= 377.39 + 363.89 = 377.39 - 363.89
= 741.28 kg/cm2 = 13.50 kg/cm2

Resultant Eq. Stress

Resultant1 = Sqrt(Sl12-Sl1xSh+Sh2) Or Sqrt (Sl12-Sl1xSh+Sh2)
= 1095.21 kg/cm2 1251.27 kg/cm2
= 37.06% of SMYS 42.34% of SMYS
B: After Installation
Pressure at Final Hydrotest = 73.50 kg/cm2
Hoop Stress Sh = 1257.97 kg/cm2
Bending stress at give radius Sb = Ec/r
= 744.54 kg/cm2
Combined LongStressSl1 = m x Sh - Ea.dT +Sb
= 377.39- 0.00 + 744.45
= 1121.85 kg/cm2

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

= 377.39 - 0.00 - 744.45
= -367.06 kg/cm2
Resultant Eq. Stress
Resultant1 = Sqrt(Sl12-Sl1xSh+Sh2) VON MISES'EQUATION
= 1195.87kg/cm2
= 40.46% ofSMYS
Resultant 2 = Sqrt (Sl22- Sl2xSh+Sh2)
= 1476.30 kg/cm2
= 49.94% of SMYS

C: During Operation
Operating Pressure = 49.00 kg/cm2
Hoop Stress Sh = pd/2t
= 838.74
Bending stress at give radius Sb = Ec/r
= 744.45 kg/cm2
Combined Long Stress Sl1 = m x Sh - Ea.dT + Sb
= 251.62 - 238.55 + 744.45
= 757.52 kg/cm2

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

= 455.14 - 238.55 - 744.45
= -527.87 kg/cm2
Resultant Eq. Stress
Resultant 1 = Sqrt (Sl12- Sl1xSh+Sh2)
= 801.26 kg/cm2
= 27.11% of SMYS
Resultant 2 = Sqrt (Sl22- Sl2xSh+Sh2)
= 1193.75 kg/cm2
= 40.39% ofSMYS

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7 ROLLER SPACING DURING PULL
Allowable Bending Moment for Roller Spacing = 90% SMYS
= 2659.99 kg/cm2
Max Tensile force that can be applied = 32tons
P=F/As = 771.73 kg/cm2

Available Stress for Bending Fb = 1888.26kg/cm2

Bending Moment = Z*Fb

417138.85 kg-cm
This bending moment will determine the roller spacing

For Simple spans (In between Rollers) BM =

wL2/12 Where w is the
weight of pipe in air
417138.85 x 12/ 0.336 )
Max spacing between rollers=L = sqrt(
3861.65
=
cm
= 38.62meters max

For Cantilever (On last Roller) BM =

wL2/2 Where w is the
weight of pipe in air
417138.85 x 2/ 0.336 )
Max spacing between rollers=L = sqrt(
1576.51
=
cm
= 15.77meters max

8 PULLING REQUIREMENTS
Pulling loads is divided into 3 main forces. Viz:
= Fluid Drag Resistance + Soil Drag Resistance + Fluid Weight on PullHead
= pDLf + f'wL + DbhA
= 2760.7 + 319.29 + 130
= 3210 kg
= 3.2Tons

Total Pulling Force Required 3.52Tons considering safety factor1.1

11%
=
% of Force Required to Rig Capacity =

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