DESIGN CRITERIA TO ACCEPTABILITY OF 300 M RAIDUS OF CURVATURE INSTALLATION OF API 5L.

GRADE 42 PIPELINE USING HDD TECHNIQUE DISANG RIVER CROSSING, 4'' PIPELINE
PROJECT :-BCPL

Consultant :- EIL Contractor :- Gammon India Ltd. Job Contractor :- MANSI GANGA BUILDERS & ENGINEERS P.LTD Outside Diameter Inside Diameter Wall Thickness Moment of Inertia Weight of Pipe in Air Cross Section of Pipe Section Modulus Modulus of Elasticity Radius of Curvature Co-efficient of Drag Poisson's ratio Mud Density Soil Density Proposed Length Entry Angle Exit Angle Hydrotest Pressure Design Pressure Wt of Drill Pipe (3 M Length) Do Di T I Wt As Z E R d v dm ds L 114.3 mm 100.1 mm 7.1 mm 3.4513E+06 18.80 Kg / m 0.0024 m2 60334.68 mm3 2 x105 300.0 M 172 N/m2 0.3 1250 Kg/m3 2660 Kg/m3 228.0 m 10.0 Deg 9.0 Deg 6.72 N/mm2 4.80 N/mm2 50.00 Kg

mm4

3.4513E-06 m4

N/mm2

(Assumed)

P p -

1. MAXIMUM LONGITUDIONAL STRESS DURING INSTALLATION Buoyancy of Steel Pipe in Down Hole :
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= = Wb = = = =

/4 x Do2 x Density of Drilling Fluid 0.79 12.82 /4 x Di2 x Density of water 0.79 7.87 x Kg/m 0.1 x 1000.00 x Kg/m 0.11 x 1250

Weight of water in pipe in downhole :

Per unit length Weight of Steel Pipe in Down Hole : = = = (Wt. of Pipe) + (Wt. of water) - (Buoyancy of Pipe in Down Hole) 18.80 13.85 Kg/m 12.82 + 7.87

Buoyancy Force on total length :xN = F = ( Buoyancy Factor x Proposed Length ) x N = = 0.5 15486.26 x( N 13.85 x 228 ) x 9.806

Bending Moment := = = EI/R 2 x 1011 2.3008E+03 Nm Pulling Force Calculation Due to Buoyancy Force :F1 = F x N = = x 3451264.6614 x E-12 x 300

( Buoyancy Factor x Proposed Length ) x N

= Due to Curvature :F2 = = = Due to Cohesion :F3 = = = Pulling Force := = =

15486.26 4 x Bending Moment F 1/2 x 2 /360 (Q entry R + Q Exit R) 4 0.5 x 2 x 3.14 / 360 x (( 66.64 d x /2 x Do x L 172 7054.13 F1 + F2 + F3 15486.26 22607.03 N + x N x

0.36 10.0

x 2.30E+003 x 300.0 )+(

9.0 x

300.00

))

1.57 x N

0.114

228

66.64 +

7054.13

Considering Safety Factor & Drill pipes & Reamer Wt. = 1.5 times x Pulling force + Drill Pipe + Reamer Wt. = 3458.14 + 1900 + 150 = 5.51 Tons 12117.91 lbs 1 kg We are using HDD machine with 61000 Lbs pulling capacity, hence safe. STRESS CALCULATIONS Allowable Stress :S = = = = Bending Stress := = ED / 2R 200000 x 114.3 / 2 x 300000 90% of SMYS 90% x 37800 260.56 42000 PSI PSI N/mm2

2.20 pound

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= Hoop Stress:= = = Tensile Stress := = = Allowable Stress > > 260.56 > = Pdi/2t

38.10

N/mm2

6.72

100.1 /

2x

7.10

47.37 N/mm2

Pulling Force (N) Cross Section Area (m2) 22607.03 9.45 / N/mm2 0.002

Longitudional Stress during Installation :Tensile Stress + Bending Stress 9.45 + 38.10 47.55 N/mm2 which is very much lower than allowable stress, thus safe.

2. MAXIMUM EQUIVALENT STRESS DURING FINAL HYDROSTATIC TEST Hydrotest Stress := = = Bending Stress = PDo / 2t 6.72 x 114.3 / 2 x 7.1 54.09 N/mm2 38.10 N/mm2 Bending Stress + Hydrotest Stress 38.10 + 54.09
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Post Installation :Allowable Stress > >

260.56 > =

N/mm2 92.19 which is very much lower than allowable stress, thus safe.

3. MAXIMUM EQUIVALENT STRESS DURING SERVICE Minimum Allowable Radius of Curvature of Pipeline (as per ANSI B31.8) = = = = = = 60.51 m 60.51 x 1.85 times Which is lower than assumed Radius of Curvature, hence safe. = 111.94 M E x Do/2 (0.75 x 90% of SMYS ) - (( x Do2 x p) / 4 x As) 2 x 105 x 114.3 42000 ) - (( 3.14 (0.75 x 90% of 11430000 188.9 / 2 x 114.3
2

4.80 ) / (4 x

0.0024

4. SPANNING STRESS:-

Max Bending Moment (BM)

= = = = =

90% of SMYS 90% x 37800 260.56 26.588

42000 PSI PSI N/mm2 kg/mm2

Longitudinal stress = = =

N/mm2 kg/mm2
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We have Pdo/4t where +

Ww x l2 /8Z Ww x l2 /8Z l2
l l

<= = = = =

BM 23.83 1460898870.39 38221.71 38.22

mm2 mm
m

So, the rollers can be placed at maximum distance of 31.13 m They are safely placed at 20 m apart Spanning, on the last support is :-

Max Bending Moment (BM)

= = = = =

90% of SMYS 90% x 37800 260.56 26.588

42000 PSI PSI N/mm2 kg/mm2

Longitudinal stress = = = We have Pdo/4t +

N/mm2 kg/mm2

Ww x l2 /2Z

<=

BM Page 6 of 9

where

Ww x l2 /2Z l2
l l

= = = =

23.83 365224717.6 19110.85 19.11

N/mm2 mm2 mm
m

So, the maximum overhang of the pipe at the last support can be 18.49 m The last overhang is planned at 10 metres, hence safe.

Calculation of Spanning Stress: Axial spanning stress, when the pipe is empty, is given by
= = =

Wt x l2 /8Z
14.23 kg/mm2 139.41 N/mm2

Axial spanning stress, when the pipe is filled with water, is given by
= = =

Ww x l2 /8Z
5.96 kg/mm2 58.38 N/mm2

5. COATING STRESSES:The maximum shear stress in the pipeline coating during installation depends upon the relative
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movement of the pipeline and the surrounding soil. Using bentonite mud, the low-friction soil-coating interface will be at a minumum.
Coating failure check:

PE coating resistance = 2.5 kg/cm2 Longitudinal soil stress, = where, N is the force normal to the pipeline due to buoyancy = 0.92 kg/cm Friction Angle() = N = = 2- sin30 = = =

N(2-sin)tan

30 degree, (approximated as per soil inverstigation report) N/(30/360*3.14*Do) 0.07724 kg/cm2 1.5 (N x 1.5 x tan30) 0.067 kg/cm2 which is negligible as compared tothe adhesive forve of 2.5 kg/cm2 i.e. Only 2.68%, hence the coating is safe

6. COLLAPSE PRESSURE From theoritical elastic curve equation, Pc = 2E/[(1-v2)(Do/t)(Do/t 1)2] N/mm2 where Do/t (Do/t-1)2
11.977

and Pc =

= = N/mm2

16.1 227.97

7. MAXIMUM OVERBURDEN PRESSURE, Po = (h*Db + hs*Ds + hw*Dw) Po

h = maximum profile depth hs = column height from bed to t.o.p. hw = column height from water level to t.o.p. Dw = Density of water
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Db = Density of Bentonite/mud Ds = Soil Saturated Density

=
=

1.47 12.27%

N/mm2

Po/Pc

Since the overburden is calculated to be only

12.27% of collapse pressure, the pipe is safe.

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