HDD

Client : M/s.
Indian Oil Corporation Limited

Project : LAYING OF 30" OD PIPELINE ACROSS MAJOR CROSSINGS OF 30" HBPL
PIPELINE FROM HALDIA TO BARAUNI BY HORIZONTAL DIRECTIONAL DRILLING
(HDD) TECHNIQUE AND ASSOCIATED WORKS, GROUP A- WEST BENGAL(PART-I),
GROUP B - WEST BENGAL (PART-II), GROUP C - JHARKHAND AND BIHAR STATE.
Contractor : M/s. NRP Projects Private Limited.
Rev & Dt : 00, 16.10.2019
2.0 COMBINED STRESS CALCULATION USING VON-MISES FORMULA – AJAY
2.1 Combined stress = [(S12 + S22) – (S1 x S2)] 0.5
Where S1 = Axial stress and S2 = Tangential stress under particular condition as under
2.1.1 On Conveyors (during pre-hydrotest)
PD
Pipeline stress due to test pressure 137 kg/cm2 =
2t
= 13.42 x 762/(2x 12.70)
Stress due to Hydrotest = 402.6 N/mm2
Spacing of pipe supports = 10 m

Total weight of pipe with water = 10 x 402.6 + x (0.762)2 x 10 x 1000
4
= 4026 + 4560
= 8586 Kg
This load acting on c/s area of pipe for bending
Bending Stress = 8586 / 0.030 m2
= 286200 Kg/m2
= 2.92 N/mm2
Combined Stress
= [[(402.6)2 + (2.92)2] - [(402.6 x 2.92)]] 0.5
= [162087 + 8.52 – 1175]0.5
= (160920)0.5 = 401 N/mm2
Page 4 of 16
Client : M/s. Indian Oil Corporation Limited
Rev & Dt : 00, 16.10.2019
2.1.2 On Conveyors (Empty)
When the pipe is empty it is only the self load of pipe.
Weight of pipe = 1220 Kg.
Bending Stress = 95300 Kg/m2
= 0.95 N/mm2
Since there is no axial stress, Combined Stress = 0.95 N/mm2
2.1.3 During Pull back (Empty)
Total pulling force = 1826803.38 N
Longitudinal Stress = 61.11 N/mm2 (Refer page No. 2 of 16)
Axial Stress = Bending Stress
= 95.30 N/mm2 (Refer page No. 2 of 16)
Combined Stress = (95.302 + 61.112 - (95.30 x 61.11) )0.5
= (9082 + 3734 – 5824) 0.5
= 84.00 N/mm2
2.1.4 Post Installation hydrotest
Hydrotest Pressure = 9.40 N/mm2
Stress due to hydrotest= 9.40 x 762/ 2x12.7 = 282 N/mm2
Radius of bending = 800 M
Er
Bending Stress = R
= 2x10^5x0.381 / 800
= 95.25 N/mm2
Combined Stress = [[(282)2 + (95.25)2] - [(282 x 95.25)]]0.5
= 248.46 N/mm2
Page 5 of 16
Rev & Dt : 00, 16.10.2019
Conclusion: From the above, the combined stress is less than the allowable stress (425.65 N/mm2)
3.0 PERMISSIBLE OVERBURDEN PRESSURE FOR 30” PRODUCT PIPELINE
Collapse Pressure (Cp) - 2E

(1-  2) (D/t) [D/t)-1]2
2 x 2.00 x 105
- (1-0.32) (762/12.7) [(762/12.7) – 1]2
- 2.104 N/mm2
- 2104 KPa
Where µ - Poissons ratio for Steel
Applied safety factor of 0.75 on collapse pressure, the maximum allowable overburden pressure is
1578 KPa.
Maximum theoretical overburden pressure = [h1(Ds) + h1 (Dm) + h2 (Dd)] x g

Where
Column height from water level to t.o.p (h1) max = 23.50 m (Ref. Dwg.)
Column height from GL to water level (h2) = 5.50 m (Ref. Dwg.)
Saturated Density (Ds) (as per Soil Report) = 1982 Kg/m3
Mud Density (Dm) = 1200 Kg/m3
Dry density (Dd) = 1772 Kg/m3
Maximum theoretical overburden pressure = [23.50(1982) + 23.50(1200) + 5.50

(1772)]x 9.81
= 829 KPa
Since the maximum theoretical overburden pressure (829 KPa) is less than the maximum
allowable overburden pressure (1578 KPa). Hence the empty pipe is safe from collapse.
Page 6 of 16
Rev & Dt : 00, 16.10.2019
4.0 FLEXURAL HOOP STRESS FOR 30” PRODUCT PIPELINE
For an elliptical collapse, the load factor is :
k = Pi[1+a-(D/d)2] / (4xb)
= 3.14 [ 1+0.037-(0.762/1.168)2] / (4 x 0.15)
= 3.20
(Where a & b are constants
& d = 28” Hole dia = 1.168 m)
Soil density y = Ds x g
= 1000 x 9.81
= 9810 N/m3
Vertical soil load per unit length of pipe q = y x d2 x k

= 9810 x 1.168 2 x 3.20
= 42825 N/m3
T.D. Rourke Suggest that modulus of soil reaction M is 3500 KPa (3.5 x 106 N/m2)
Flexural hoop stress S = C x k x (D/d)2 x Y X D X L
Where C is the pipe stiffness parameter
C = (0.5 x E x (t/D) + 0.0053 x (D/t)2 x M) / (E x( t/D)3 x 0.0915 x M)

= (0.5 x 200 x 106 x (0.0127 / 0.762) + 0.0053 x (0.762/0.0127)2 x 3500
(200 x 106 x (0.0127/0.762)3 + 0.0915 x 3500)
= 1743.60
Flexural hoop Stress S = 1743.60 x 3.20 x (0.762/1.168)2 x 9.81 x0.762x 1.0

= 17752
= 17.752 x 103 Kpa
The Flexural hoop stress S is less than allowable stress (427620 KPa)
Page 7 of 16
Rev & Dt : 00, 16.10.2019
5.0 COATING STRESS

5.1 Analysis and Results
Buoyancy of Empty pipe = (Vol. displaced x Bentonite fluid density) – Pipe Weight
= -312.29 Kg/m (Refer Page No. 1 of 16)
= -3063.56 N/m
Submerged Drill Pipe weight
OD = 168.30mm
OD = 0.17m
Wall Thickness = 0.011m
Pipe Weight = (420 / 9.5M) = 44.21 kg/m
(Physical Weight of 9.5M Long Drill Pipe = 420 Kgs)
Mud gravity = 1200 kg/m3
Mud Displacement = pi( )*[OD2 – (OD-2 x WT)2]/4 x dm

= 5.10 Kg/m
Drill pipe weight = Pipe weight – Mud Displacement

= 44.21 – 5.10
= 39.11 Kg/m
= 383.66 N/m
The pipeline will be empty at the start of the pullback till 01 joint enters into the hole and further as the
pipe is pulled into the hole required amount of water will be added according to the calculations done
to counter buoyancy. The pipeline will be pulled from the one end to the other, displacing some of the
drilling mud. The maximum shear stress in the pipeline external coating after installation depends upon
relative movements of the pipeline and surroundings soil (caked drilling mud), resulting from the
pipeline expansion and contraction or soil consolidation. Using bentonite mud, the low friction soil-
coating interface will be at minimum. For liquid transportation, the effect of the temperature
changes will be at a minimum.
The polyethylene pipe coating strength will be much greater than the adhesion developed by the mud.
Typically, good PE coating should resist more than 10 to 15 psi longitudinal soil stresses while mud
with high moisture contents develop less than 1 psi. Bentonite prevents sandy soils from transferring
shear stresses to the pipeline coating.
Page 8 of 16
Rev & Dt : 00, 16.10.2019
5.2 Coating Shear Stress:

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.
The maximum stress per linear meter of pipe

S = (Coefficient of friction in down hole x Buoyancy) / Coating width
= (0.36 x (-312.29) / 0.085
= -1323 KPa = -1.32 MPa
(Assuming the coating width is 1/10 of the pipe circumference)
The sleeves wrapped around the coated pipe and weld joint will withstand the higher friction forces
during pulling in the range of 3MPa or more which is more than the anticipated shear stress
calculated. After installation, even if the movement of the pipeline takes place, the coating will not
be damaged as the cake bentonite surrounding the pipe will minimize the friction force at the
interface of soil and coating. Also the underground pipe will have negligible expansion.
Page 9 of 16
Rev & Dt : 00, 16.10.2019
6.0 BEND RADIUS FOR 30” PRODUCT PIPELINE
6.1 Pipeline maximum longitudinal stress during Installation:
Total maximum longitudinal stress in the pipeline due to tension and bending at any location shall not
exceed 95% of the SMYS of the pipe material
The allowable Stress = 427620 KPa - Refer Page No. 3 of 16
6.1.1 When Pipe on Rollers

Static friction coefficient of rollers = 0.20
Pipe length = 1204.03 m
Pipe weight/m = 234.67 Kg/m or 2302 N/m
Area of steel = 0.03 m2
SPULL = (static friction coefficient x length x weight)/area of steel

= 18478 KPa
This is less than allowable stress (427620 Kpa)
6.1.2 When Pipe Experience first point on curvature at 97.02 M
First Point of curvature (Lcur) = 97.02 M (Refer HDD Profile drawing)
Combined longitudinal stress = Bending Stress + Tensile stress
Bending Stress Sb = (E x D) / 2R
= 95.3 N/mm2 = 95300 KPa - Refer Page No. 3 of 16
Tensile Stress = (0.5 x Buoyance Force (Cp) x Lcur) + (0.15 x Wt x 9.81 x L)

As
= (0.5 x 2104 x 97.02) + (0.15 x234.68 x 9.81 x 1107.1)
0.03
= 12778 KPa
Combined Longitudinal Stress = 95300 + 12778

= 108078 KPa
The combined stress is less than allowable stress (427620 Kpa)
Page 10 of 16
Rev & Dt : 00, 16.10.2019
6.1.3 When pipe fully down hole
Bending Stress Sb = (E x D) / 2R
= 95.3 N/mm2 = 95300 KPa - Refer Page No. 3 of 16
Tensile stress = (0.36 x L x Wt) / As

= (0.36 x 1204.03 x 234.68 x 9.81) / 0.03
= 33263 Kpa
Combined Longitudinal Stress = 95300 + 33263

= 128563 KPa
This value is less than the allowable stress (427620 Kpa)
6.2 Pipeline maximum equivalent stress during final hydrotest
Hydrotest Stress = PD / 2t
Hydrotest Pressure (P) = 9.40 N/mm2 = 9400 KPa
Diameter of Pipe = 0.762 m
Wall Thickness = 0.0127 m
Hydrotest Stress = (9400 x 0.762) / (2 x 0.0127)

= 282000 KPa
Bending Stress = Allowable stress – hydrotest stress

= 427620 –282000
= 145620 KPa = 145.62 N/mm2
The minimum radius from Euler’s formula is

R = E x r / Sb
= (2.00 x 105 x 381) / 145.62
R = 523.27 M
The down hole Radius 800m is within the limits of the minimum radius. Hence the design profile is
safe.
Page 11 of 16
Rev & Dt : 00, 16.10.2019
7.0 STRESS CALCULATIONS FOR RESTRAINED AND UNRESTRAINED CONDITIONS FOR

30” PRODUCT PIPELINE
7.1 During Installation
Internal Pressure = 0
External Pressure as per over burden stress = 829 KPa
Analysis carried out only for unstrained condition
Unrestrained Conditions:
SL = 0.5 SH + SB + (P/A)
Where
P = Pull force = 1826.80 KN (Total Pulling force) - Refer Page No. 2 of 16
A = Pipe area = 0.03 m2
SH = PD / 2t
Where
t = 0.0127 m
P = Hydrostatic Pressure = 829 kPa
D = 0.762 m
SH = 24870 KPa
CASE - I
SL = 0.5 SH + SB + (P/A)
= 0.5 x 24870 + 95300 + (829/0.03)
= 135368 ~ 0.30 SMYS
SH - SL = 24870 –135368= -110498~ 0.24 SMYS
CASE - II
SL = 0.5 SH - SB + (P/A)
= 0.5 x 24870 - 95300 + (829/0.03)
= -55232~ 0.12 SMYS
SH - SL = 24870 – (-55232) = 80102 ~ 0.17 SMYS
From the above case SL<0.95 SMYS and (SH - SL) <0.95 SMYS, hence it is safe.
Page 12 of 16
Rev & Dt : 00, 16.10.2019
7.2 Post Installation Hydrotest
Internal Pressure (P) = 96 Kg/cm2

Differential Temperature (T) = 10 Deg. C
Analysis carried out only for restrained condition
Restrained Conditions
SL = v SH - E ά ∆T ± SB
Where E = Modulus of elasticity = 200 x 106

ά = Coff. Of thermal expansion = 11.7 x 10-6
v = 0.3
SH = PD / 2t
Where
t = 0.0127 m
P = Hydrostatic Pressure = 9400 kPa (Post-Test Pressure)
D = 0.762 m
E = 200 x 106 KPa
SH = 282000 KPa
CASE - I
SL = v SH - E ά ∆T + SB
= 0.3 x 282000 – (200 x 106 x 11.7 x 10-6 x 10) + 95300
= 80360 KPa ~ 0.17 SMYS
SH - SL = 282000–80360 = 201640~ 0.44 SMYS
CASE - II
SL = v SH - E ά ∆T - SB
= 0.3 x 28200 – (200 x 106 x 11.7 x 10-6 x 10) - 95300
= -110240 KPa ~ 0.24 SMYS
SH - SL = 282000 – (110240) = 392240~ 0.87 SMYS
Page 13 of 16
Rev & Dt : 00, 16.10.2019
7.3 During Service
Restrained Conditions:
Differential Temperature = 25 Deg. C
(Design Temp 45 Deg. C & Installation Temp 20 Deg.C)
Where E = Modulus of elasticity = 200 x 106

ά = Coff. Of thermal expansion = 11.7 x 10-6
v = 0.5
SH = PD / 2t
Where
T = 0.0127 m
P = Hydrostatic Pressure = 13420 kPa (Design Pressure)
D = 0.762 m
E = 200 x 106 KPa
SH = 402600 KPa
CASE - I
= 0.5 x 402600 – (200 x 106 x 11.7 x 10-6 x 25) + 95300
= 238100 KPa ~ 0.52 SMYS
SH - SL = 402600 – 238100 = 164500 ~ 0.36 SMYS
CASE - II
SL = v SH - E ά ∆T - SB
= 0.5 x 402600 – (200 x 106 x 11.7 x 10-6 x 25) - 95300
= 47500KPa ~ 0.11 SMYS
SH - SL = 423446 – (47500) = 375946 ~ 0.83 SMYS
Page 14 of 16
Rev & Dt : 00, 16.10.2019
8.0 MXIMUM SPACING FOR ROLLERS
Bending Stress on Rollers = Allowable Stress – Tensile Stress (Spull)

= 427620 – 18478
= 409142
The bending moment M is calculated as follows:
M = Sb Z
= 409142 x 0.000551
= 225 KN-m
Weight of pipe; W = 234.68 Kg/m = 2302 N/m
The permissible cantilever length is calculated as follows:
L = (2M / W) 0.5
= ((2 x 225 x 1000) /2302) 0.5
= 13.98 m
As placing of rollers is 10 m apart; so effect of cantilever is negligible.
Page 15 of 16
Rev & Dt : 00, 16.10.2019
9.0 RIG PULLING FORCE CAPACITY
9.1 Pull Force Calculations considering the Anti-Buoyancy measures :

The maximum tension required on the pull head of the rig will occur to initiate movement of the
pipeline on the rollers.
Pull Force on Pull head = (Static friction coefficient on rollers x Length x Pipe
Weight of 30” Pipe) +(Static friction factor in
bentonite hole x Length x submerged drill pipe
weight)
= (0.2 x 1204.03 x 234.68) + (0.36 x 1204.03 x 44.21)
= 56448 + 19141
= 75675 Kgs = 75.67 Tons
= 742 KN
We are using DL4500 Rig with 10,00,000 Lbs pulling capacity. Hence, it is safe.
10.0 REFERENCES
1. ASME B 31.8
2. OISD 141
3. DCA technical Guidelines (2nd Edition)
4. Pipe Hand book by Sabin Crocker
5. T. D. Rourke
6. J.D. Hair & Louis J. Cappozzoli – Installation of Pipeline by Horizontal Directional Drilling.
7. IOCL Specification No. No. IOCL-HDD-INST-SPEC).
Page 16 of 16

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2.0 COMBINED STRESS CALCULATION USING VON-MISES FORMULA – AJAY

2.1 Combined stress = [(S12 + S22) – (S1 x S2)] 0.5

2.1.1 On Conveyors (during pre-hydrotest)

= 13.42 x 762/(2x 12.70)

Stress due to Hydrotest = 402.6 N/mm2

Spacing of pipe supports = 10 m

This load acting on c/s area of pipe for bending

Bending Stress = 8586 / 0.030 m2

= [[(402.6)2 + (2.92)2] - [(402.6 x 2.92)]] 0.5

= [162087 + 8.52 – 1175]0.5

= (160920)0.5 = 401 N/mm2

2.1.2 On Conveyors (Empty)

When the pipe is empty it is only the self load of pipe.

Weight of pipe = 1220 Kg.

Bending Stress = 95300 Kg/m2

Since there is no axial stress, Combined Stress = 0.95 N/mm2

2.1.3 During Pull back (Empty)

Total pulling force = 1826803.38 N

Longitudinal Stress = 61.11 N/mm2 (Refer page No. 2 of 16)

Axial Stress = Bending Stress

= 95.30 N/mm2 (Refer page No. 2 of 16)

Combined Stress = (95.302 + 61.112 - (95.30 x 61.11) )0.5

= (9082 + 3734 – 5824) 0.5

2.1.4 Post Installation hydrotest

Hydrotest Pressure = 9.40 N/mm2

Stress due to hydrotest= 9.40 x 762/ 2x12.7 = 282 N/mm2

Radius of bending = 800 M

Combined Stress = [[(282)2 + (95.25)2] - [(282 x 95.25)]]0.5

3.0 PERMISSIBLE OVERBURDEN PRESSURE FOR 30” PRODUCT PIPELINE

Collapse Pressure (Cp) - 2E

Where µ - Poissons ratio for Steel

Maximum theoretical overburden pressure = [h1(Ds) + h1 (Dm) + h2 (Dd)] x g

Maximum theoretical overburden pressure = [23.50(1982) + 23.50(1200) + 5.50

4.0 FLEXURAL HOOP STRESS FOR 30” PRODUCT PIPELINE

For an elliptical collapse, the load factor is :

Vertical soil load per unit length of pipe q = y x d2 x k

Flexural hoop stress S = C x k x (D/d)2 x Y X D X L

Where C is the pipe stiffness parameter

C = (0.5 x E x (t/D) + 0.0053 x (D/t)2 x M) / (E x( t/D)3 x 0.0915 x M)

Flexural hoop Stress S = 1743.60 x 3.20 x (0.762/1.168)2 x 9.81 x0.762x 1.0

5.0 COATING STRESS

Mud Displacement = pi( )*[OD2 – (OD-2 x WT)2]/4 x dm

Drill pipe weight = Pipe weight – Mud Displacement

5.2 Coating Shear Stress:

The maximum stress per linear meter of pipe

(Assuming the coating width is 1/10 of the pipe circumference)

6.0 BEND RADIUS FOR 30” PRODUCT PIPELINE

6.1 Pipeline maximum longitudinal stress during Installation:

The allowable Stress = 427620 KPa - Refer Page No. 3 of 16

6.1.1 When Pipe on Rollers

SPULL = (static friction coefficient x length x weight)/area of steel

This is less than allowable stress (427620 Kpa)

6.1.2 When Pipe Experience first point on curvature at 97.02 M

First Point of curvature (Lcur) = 97.02 M (Refer HDD Profile drawing)

Combined longitudinal stress = Bending Stress + Tensile stress

= 95.3 N/mm2 = 95300 KPa - Refer Page No. 3 of 16

Tensile Stress = (0.5 x Buoyance Force (Cp) x Lcur) + (0.15 x Wt x 9.81 x L)

Combined Longitudinal Stress = 95300 + 12778

The combined stress is less than allowable stress (427620 Kpa)

= 95.3 N/mm2 = 95300 KPa - Refer Page No. 3 of 16

Tensile stress = (0.36 x L x Wt) / As