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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
Coating Stress
Pulling Capacity
Proposed Profile,
INTRODUCTION
A.
Purpose
PAGE 1
Trenchless Engineering
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
D.
Specifications Details
Pipeline Size
Trenchless Engineering
Conduit
HDPE Conduit
Pipeline Material
Joint Coating
=API 5L Grade X 70
Length of Crossing
= 916 Meters
= 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
PAGE 3
Trenchless Engineering
Pipe full of water on conveyors
Pipe Pull back- empty
2.0
24 Steel Pipe
Item
Outside diameter
Outside radius
Inside radius
Internal diameter
Wall thickness
Coating thickness
Symbol
OD
OR
IR
ID
Wt
Ctt
PAGE 4
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
Trenchless Engineering
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
Trenchless Engineering
5.4 Kg/m
pipe
181.00 Kg/m
pipew
450.64 Kg/m
PAGE 6
pipeb
-176.49 Kg/m
Trenchless Engineering
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
W f x Ss 2
----------------8xZ
Spanning Stress = 24.27 N/mm
4.2
Curvature Stress
4.3
Tensile Stress
Trenchless Engineering
= W e x L x Fc
= Pull Force/ Ap
Pull Force
= 33.18 Tones
= 14.553 N/mm
Pull Force
= 64.67 MT
= Pull Force/ Ap
Tensile Stress
= 28.4 N/mm2
4.4
Hoop Stress
Trenchless Engineering
= v x Hoop Stress
= -3.39 N/mm
= Ppost x OR / W t
= 289.12 N/mm
SUMMARY
ON SKIDS
ON CONVEYERS /
OVERBEND
Pre Test
Axial
Spanning
Curvature
24.3
-24.3
Tangential
Empty
Axial
Tangential
9.8
-9.8
64.01
Empty
Axial
64.01
PAGE 9
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
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
= 0.0285 m3/m
= 0.914 m
= 1200 Kg/m3
PAGE 10
Trenchless Engineering
PAGE 11
Trenchless Engineering
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.
(P)(D)/2(t)
S =
Where
P =
Test Pressure
= 11300 KPa
D =
Pipe Diameter
= 0.6096 m
t =
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
Trenchless Engineering
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.
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.
= 33.18 MT
= 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.
PAGE 13
Trenchless Engineering
PAGE 14