Trenchless Engineering

TABLE OF CONTENTS
DESIGN & ENGINEERING CALCULATIONS - IVONDRO RIVER

S.No.
A
B
C
D
E

Description
Purpose
Project Description
Reference Specification
Specifications details
Design & Engineering-IVONDRO River

Introduction

Pipe Weights

Stress Analysis/Other calculations

Coating Stress

Pulling Capacity

Proposed Profile,

INTRODUCTION
A.

Purpose
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The purpose of this document is to provide and implement the calculations and results
pertaining to certain clauses contained in SNCL Specifications Laying of Pipeline
through Horizontal Directional Drilling across Ivondro River for Ambatovy
Nickel Slurry Pipeline Project

B.

Project Description
Laying of pipeline through Horizontal Directional Drilling across Ivondro River is a
project consisting of the installation of a 609.6 mm O.D. pipeline beneath Ivondro
River Crossing using the horizontal directional drilling method. The 6 O.D Steel
conduit shall be pulled in the separate hole and 2 x 50 mm OD HDPE shall be
interducted in steel pipe for OFC after pulling .The pipeline shall be Steel Pipe of API
5L X 70, with a wall thickness of 11.913 mm. The external corrosion coating on the
pipeline will be three layers Polyethylene.

C.

Reference Specification
1. ASME B 31.4

DESIGN & ENGINEERING CALCULATIONS -IVONDRO RIVER

24 Product Pipe in hole of 36 dia., Length = 916 m

D.

Specifications Details
Pipeline Size

= 609.6 mm (24) O.D. with 11.913 mm W.T.

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Conduit

=168 MM C.S.ERW PIPE IS: 3589-2001 GR330/410.

6.4 MM W.T.

HDPE Conduit

Pipeline Material

Anti Corrosion Coating

= 3 Layer Polyethylene Coating for 24 pipe.

Joint Coating

= DIRAX Sleeves of M/s Raychem

= 2 Nos. 50mm O.D X 4.0 mm

=API 5L Grade X 70

E. Design and Engineering-IVONDRO

Length of Crossing

= 916 Meters

Maximum Depth of Profile

= 25 Meters

1.0

INTRODUCTION

The following calculations examine the stress imposed on a pipeline during the installation of
a horizontal directionally drilled crossing prior to pullback during pullback and post
installation to confirm that the pipeline will not fail.
The calculations are based on the following:
Pipe empty on conveyors
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Pipe full of water on conveyors
Pipe Pull back- empty

The following stresses are considered

Spanning Stress
Curvature Stress
Pulling Forces
External Pressure
The pipe will be pulled empty.

2.0

PIPE & PROFILE DATA BASIS

24 Steel Pipe
Item
Outside diameter
Outside radius
Inside radius
Internal diameter
Wall thickness
Coating thickness

Symbol
OD
OR
IR
ID
Wt
Ctt
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Value
609.6
304.8
292.89
585.77
11.913
3.20

Unit
mm
mm
mm
mm
mm
Mm

Source
Specification
Specification
Specification
Specification
Specification
Specification

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Concrete thickness ( outside )
Section modulus
Young modulus
SMYS (Specific Minimum Yield Strength)
Pipe wall area
Coating Wall Area
Concrete Wall Area
Density of pipe
Density of Coating
Density of concrete
Density of Bentonite
Density of Fluid (Water)
Pipeline length
Radius of curvature downhole
Radius of curvature on overbend
Maximum depth of profile
Conveyor spacing (Roller Spacing)
Skid spacing
Friction factor (on conveyor)
Friction factor (downhole)
Friction Drill Fluid- Pipe Body
Poison' ratio
Pre Installation Test Pressure
Post Installation Test Pressure

3.0

Cct
Z
E
Qmax
Ap
Act
Acc
Dp
Dct
Dcc
Db
Dd
L
Rd
Ro
D
S
Ss
Fc
Fd
Fdd
v
Ppre
Ppost

0.00
3278385
210000.00
482.3
22368.9
6160.54
0.00
7850.00
920.00
2400.00
1200.00
1000.00
916.00
1000.00
1000.00
25.00
12.0
12.0
0.20
0.40
0.000239
0.30
153
113

Mm
Mm
N/mm
N/mm
Mm
Mm
Mm
kg/m
kg/m
kg/m
kg/m
kg/m
M
M
M
M
M
M

N/mm
Bar
Bar

Specification
Specification
Specification
Specification
Specification
Specification
Specification
Specification
Specification
Specification
Specification
Specification
Profile
Profile
Profile
Profile
Specification
Specification
Specification
Specification
Specification
Specification
Specification
Specification

PIPE WEIGHTS

Pipe above Ground Empty = A pipe x Density of Steel

Pipe above Ground Full of test Water = Pipe above Ground Empty + ID2 x Density of Water
----4
Pipe below Ground Empty = Pipe above Ground Empty - OD2 x Density of Bentonite
----4
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Weights are calculated taking 3.2mm PE Coating into consideration

Weight of Coating

5.4 Kg/m

Pipe on conveyors Empty

pipe

181.00 Kg/m

Pipe on conveyors, filled with Water

pipew

450.64 Kg/m

Pipe down hole Empty

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pipeb

-176.49 Kg/m

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4.1

Spanning Stress

Spanning will only occur on Skids/Conveyors; therefore the free spanning length is the
distance between the rollers.
Pipe Empty
We x S2
Spanning Stress (Sse) = ----------------8xZ

Spanning Stress = 9.76 N/mm2

Pipe Full filled with water
Spanning Stress (Ssf) =

W f x Ss 2
----------------8xZ
Spanning Stress = 24.27 N/mm

4.2

Curvature Stress

Curvatures stresses are calculated as shown below:

On Conveyers
Curvature Stress= E x OR / Ro
Curvature Stress (Scc) = 64.01 N/mm
Pipe down hole Empty
Curvature Stress (Scd) = E x OR / Rd
Curvature Stress (Scd) = 64.01 N/mm

4.3

Tensile Stress

Tensile stress occur on conveyor and down hole

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For calculating the stresses it is necessary to calculate the Pull Force.

Pull Force (Tce)

= W e x L x Fc

Tensile Stress (Stce)

Stresses

= Pull Force/ Ap

Tensile Stress - Conveyors

Pull Force (Tce) = W e x L x Fc

Pull Force

= 33.18 Tones

Tensile Stress (Stce) = Pull Force/ Ap

Tensile Stress

= 14.553 N/mm

Tensile Stress -Downhole Empty

Pull Force (Tde)

= W de x L x Fd + { x (OD+2. ctt) x Fdd x L}

Pull Force

= 64.67 MT

Tensile Stress (Stde)

= Pull Force/ Ap

Tensile Stress

= 28.4 N/mm2

4.4

Hoop Stress

External Pressure Based On experimental measurements for Bentonite

External Pressure (Pext ) = 1.5 x Depth of Profile (D) x Bentonite Density (D b)
= 45000.00 kg/m
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Hoop Stress External (She) = Pext x OR / W t

= - 11.29 N/mm
Longitudinal Stress(Sle)

= v x Hoop Stress
= -3.39 N/mm

Hoop Stress Pre Hydro Test

Hoop Stress(Sht) = Ppre x OR / W t
=391.46 N/mm
Longitudinal Stress (Slt) =0.5 x (Sht)
= 195.73 N/mm
Hoop Stress Post Hydro Test
Hoop Stress(Shp)

= Ppost x OR / W t
= 289.12 N/mm

Longitudinal Stress (Slp) = 0.5 x (Shp)

= 144.56 N/mm

SUMMARY
ON SKIDS

ON CONVEYERS /
OVERBEND

Pre Test
Axial

Spanning
Curvature

24.3
-24.3

Tangential

DURING PULL BACK

Empty
Axial

Tangential

9.8
-9.8
64.01

Empty
Axial

64.01

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Tangential

DOWNHOLE/
INSTALLED
Post Test
Tangentia
Axial
l

64.01

Trenchless Engineering
-64.01
14.6

Tensile
Hoop Ext.
Hoop

195.7

Pre Test
Hoop
Post Test
Total
(Positive)
Total
(Negative)
Combined
stress

-64.01
28.4
-3.39

-64.01
-11.3

-3.39

-11.3

144.6

289.1

391.5

220.0

391.5

88.3

0.00

92.4

0.00

208.6

289.1

-24.3

0.00

-73.8

0.00

-67.4

-11.3

-67.4

-11.3

404

88

Von Mises
(Greater
of above )
As
S.M.Y.S. %

100

328

404

88

100

216

83.8%

18.3%

20.4%

68.0 %

Combined stress =
5

COATING STRESS

5.1

Introduction

((S12 +S22) - (S1 x S2 ))

(Von Mises Equation)

This section provides the analysis and results in regard to requirement of coating
stresses, which requires the determination of certain parameters and the resultant
anticipated maximum shear stress, which may be exerted upon the pipeline corrosion
coating.
For proposed Crossings the following parameters apply:
Pipe Outside Diameter

= 609.6 mm

Pipe Weight

= 181 Kg/m

Volume Displaced by Pipe

= 0.0285 m3/m

Back-reamed hole diameter

= 0.914 m

Bentonite fluid density

= 1200 Kg/m3
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Pipeline submerged weight in Bentonite fluid:

Buoyancy of Empty pipe = (Vol. displaced x Fluid weight) - Pipe weight)
= 146.77kg/m = 1439.8 N/m
Coating shear stress
The maximum shear stress in the pipeline external coating after installation depends
upon relative movements of the pipeline and the 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 a minimum.
The 3.2 mm extruded polypropylene pipe coating strength will be much greater than
the adhesion developed by the mud. Typically, good PE coating should resist 10 to 15
psi longitudinal soil stresses while mud with high moisture contents and bentonite
develops less than 1 psi.
Use of drilling mud prevents sandy soils from transferring shear stresses to the
pipeline coating. As = tan and as , the effective friction angle approaches zero,
, the longitudinal soil stress approaches zero.
Check for the Coating shear .:The maximum stress per linear meter of pipe S = f1x B/s
f1 = Friction coefficient in hole
B = Buoyancy
s = coating width
Assuming the coating width is 1/10 of the pipe circumference
S =3.00735 KPa
where
f1 = 0.4
B = 146.77 Kg/m
D = 609.6 mm

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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, the relative movement of the pipeline and the
surrounding caked bentonite can not damage the coating since, the pipe is surrounded by
the caked bentonite which minimize the friction force at the interface of soil and coating. Also
the underground pipe will have negligible expansion.

7.0 Checking of Radius of Curvature

Maximum Tensile stress occurs during Post Hydrostatic testing can calculated using Barlows
formula:
S =

(P)(D)/2(t)

S =

Where

P =

Test Pressure

= 11300 KPa

D =

Pipe Diameter

= 0.6096 m

t =

Pipe Wall thickness = .011913 m

289116 KPa

Maximum Allowable stress =90% of SMYS of Pipe Material = 482300 x .090 =434070 KPa
Thus available stress for Bending
434070 KPa - 289116KPa = 144954 KPa
The minimum radius according to Eulers formula should be
R=Exr
Sb

Where E = 210.00 x 106 KPa

r = 0.3048 m (Outer Radius)
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Sb = 144954 KPa
R = 441.6 m

The above calculations shows that the considered down hole Radius 1000 m is within the
limits of the minimum radius, hence the design profile are safe under all conditions.

8.0 PULLING CAPACITY

8.1

Introduction
This section provides the analysis and results in regard to SNCL Specification, which
requires calculation of the maximum tension required on the pull head of the rig.

8.2 Analysis and Results

The maximum tension required on the pull head of the rig would occur to initiate
movement of the pipeline on the onshore rollers. This value is calculated as n the
case of pull force on conveyors when pulled empty.
Pull Force on conveyors (Empty)

= 33.18 MT

Also, the maximum pull forces in different circumstances as calculated

Pull Force down hole (Empty)

= 64.67 MT

As the pipeline moves into the mud-filled hole the required tension will continually
decrease since the effective weight becomes the Buoyant Force.
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