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Installation Stress Analysis, 54; Operating Loads and Stresses, 56; Combined
Stressesand Limitations, 57; Example Operating Stress Analysis, 58;
Spreadsheet - Load and
Stress Analysis, 59.
6.Construction Impact
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.................................
61
Workspace, 61; Horizontal Drilling Rig, 61; Pull Section Fabrication, 63;
DrillingFluids, 65; Functions, 66; Composition, 66; Quantity
Estimating Calculations, 67;
Recommended Disposal Methods, 70; Environmental Impact, 73.
7.Contractual Considerations
................................................................
.......................
77
Lump Sum Contracts, 77; Pricing, 77; Unknown Subsurface Condition
Risk, 78;Technical Specification, 78; Plan & Profile Drawing, 78; Daywork
Contract, 83;
Uniform Daywork Bid Sheet, 83; Equipment Failure Risk, 83.
8.Construction Monitoring
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
87
Drilled Path, 87; Construction Staking, 87; Pilot Hole, 87; Directional
DrillingPerformance, 92; Downhole Survey Calculations, 92; Radius of
CurvatureCalculations, 94; TruTracker Surface Monitoring System, 95; Asbuilt
Error
Distribution, 96; Pipe Installation, 96; Pull Section Handling, 96; Buoyancy
Control,96; Coating Integrity, 96; Drilling Fluid Flow, 96.
BibliographyMetric SI Unit Conversion TableGlossary
EXECUTIVE SUMMARY
This engineering design guide is the principal product of PRC project PR-2279424.
Its purpose
is to serve as a step by step guide for engineers engaged in the evaluation,
design, and
management of natural gas pipeline construction by Horizontal Directional
Drilling (HDD).
2
SECTION 1 - THE HORIZONTALDIRECTIONALDRILLING PROCESS
STAGE 1, PILOT HOLE DIRECTIONAL DRILLING
HORIZONTALDRILLING RIGDRILLING FLUID RETURNSTHEORETICAL
ANNULUSEXITPOINTDESIGNED DRILLED
P ATH
GENERALDIRECTION OF PROGRESSPILOTHOLE DRILLING
STAGE 2, REAMING & PULLING BACK
THEORETICAL ANNULUS
PREREAMING
GENERALDIRECTION OF PROGRESSGENERALDIRECTION OF PROGRESSPULLING
BACK
Figure l-l
The HDD Process
Downhole Motors
Downhole mechanical cutting action required for harder soils is provided by downhole
hydraulic motors.
Downhole hydraulic motors, commonly referred to as mud motors,
convert hydraulic energy from drilling mud pumped from the surface to
mechanical energy atthe bit. This allows for bit rotation without drill string
rotation.There are two basic types of mud motors; positive displacement and
turbine.Positive displacement motors are typicallyused in HDD applications.
Basically, a positive displacement mud motor consists of a spiralshaped stator containing a sinusoidal shaped rotor.Mud flow through
the stator imparts
rotation to the rotor which is in turn connected through a linkage to the bit.
Wash Pipe
In some cases, a larger diameter wash pipe may be rotated concentrically over
the nonrotating steerable drill string.
This serves to prevent sticking of the steerable string andallows its tool face to be freely
oriented.It also maintains the pilot hole if it becomes
necessary to withdraw the steerable string.
Downhole Surveying
The actual path of the pilot hole is monitored during drilling by taking
periodic readings of the inclination and azimuth of the leading
edge.Readings are taken with an instrument, commonly referred to as a
probe, inserted in a drill collar as close as possible to the drill bit.
Transmission of downhole probe survey readings to the surface is
generally accomplished
t h r o u g h a w i r e r u n n i n g i n s i d e t h e dr i l l s t r i n g . T h e s e r e a d i n g s , i n
conjunction with
measurements of the distance drilled since the last survey, are used to calculate
the horizontaland vertical coordinates along the pilot hole relative to the initial
entry point on the surface.Survey calculation methods are discussed in detail
inSection 8.
Azimuth readings are taken from the earths magnetic field and are
subject to interference
from downhole tools, drill pipe, and magnetic fields created by adjacent
structures.
Therefore, the probe must be inserted in a non magnetic collar and positioned in
the string sothat it is adequately isolated from downhole tools and drill
pipe.The combination of bit, mud
motor (if used), subs, survey probe, and non magnetic collars is
referred to as the Bottom
System. This
system uses a surface coil of known location to induce a magnetic
field.The probe senses its
location relative to this induced magnetic field and communicates this
information to the
surface. This is shown schematically in Figure l-3.
KNOWN CORNER LOCATIONS
SURFACE COIL
Figure l-3
TruTracker Surface Monitoring System
(TruTracker is a Trademark of Sharewell, Inc.)
Reaming & PulIing Back
Enlarging the pilot hole is accomplished using either prereaming passes prior to
pipe
installation or simultaneously during pipe installation. Reaming tools
typically consist of a
circular array of cutters and drilling fluid jets and are often custom made by
contractors for aparticular hole size or type of soil.
Figures l-4, l-5,
1-6.
Examples of different types of reaming tools are shown in
Prereaming
Most contractors will opt to preream a pilot hole before attempting to
install pipe.
For a
prereaming pass, reamers attached to the drill string at the exit point are rotated
and drawn to
the drilling rig thus enlarging the pilot hole. Drill pipe is added behind
the reamers as theyprogress toward the drill rig.This insures that a
string of pipe is always maintained in thedrilled hole. It is also
possible to ream away from the drill rig. In this case, reamers fitted
into the drill string at the rig are rotated and thrust away from it.
Pulling Back
Pipe installation is accomplished by attaching the prefabricated pipeline pull
section behind areaming assembly at the exit point and pulling the reaming
assembly and pull section back tothe drilling rig.
This is undertaken after completion of prereaming or, for smaller
diameterlines in soft soils, directly after completion of the pilot hole.A
swivel is utilized to connectthe pull section to the leading reaming
assembly to minimize torsion transmitted to the pipe(refer to Figure 1-5).
The pull section is supported using some combination of roller stands,
pipe handling equipment, or a flotation ditch to minimize tension and
prevent damage to the pipe.
SECTION 2
FEASIBILITY CONSIDERATIONS
Three standards may be used to assess the feasibility of HDD for a given
crossing.These are technical, contractual, and economic. First, a crossing is
technically feasible if it can be installed using existing tools and
techniques regardless of uncertainties surrounding the cost of
installation. Second, a crossing is contractually feasible if the cost of
installation can be accurately estimated in advance allowing contractors to
submit lump sum bids. Third, a crossing is economically feasible if its
installation cost is less than the cost of an equivalent construction
method.
Technical Feasibility
For a pipeline to be installed by HDD, one of two conditions must be
achieved downhole .Either and open hole must be cut into the subsurface
material to such an extent that installation of a pipeline by the pull back
method is possible, or the soil properties must be modified sothat it
behaves in fluid manner allowing a pipeline to be pulled through it. The
possibility of achieving either of these conditions downhole is dependent
primarily on subsurface soil conditions.
The open hole condition is similar to that achieved in a typical oil well.A
cylindrical hole is cut in the subsurface. Drilling fluid flows to the
surface in the annulus between the pipe and the hole wall. Drilled spoil is
transported in the drilling fluid to the surface. This is generally applicable to
rock and cohesive soils.It may also apply to some sandy or silty soils
5,850 ft.
(1,783 m)
10 in.
(DN 250)
48 in.
(DN 1200)
Alluvial
Alluvial
1994
Gravel %
by Weight
Very soft to
Plugging of the annulus
hardstrength,
stem during pilot
possiblyslickensided,
produce inadvertent
clay
HDD Feasibility
N/A
Good To Excellent.
surrounding the drill
hole drilling may
Economic Feasibility
Determining the economic feasibility of a prospective HDD installation is a
fairlystraightforward exercise involving comparison of the estimated cost of
HDD with theestimated cost of an alternate installation method.If the HDD
estimate is less, it is economically feasible. When making this
comparison, it is important to estimate the cost of equivalent designs and
to include all costs associated with each method. For example, itwould not be
valid to compare the cost of a pipeline river crossing installed by open
excavation with 3 feet of cover against the cost of a drilled installation
providing 25 feet of cover without including some adjustment in the
excavated estimate to account for possiblefuture remedial work
brought on by the relatively shallow 3 foot cover.Restoration costs
and the costs associated with environmental impact for each method considered
must also be i n c l u d e d .
The environmental impact associated with HDD construction operations
isdiscussed inSection 6.A procedure estimating the cost of specialized HDD
services is presented in the following paragraphs.