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COMMENT
CONTENTS
FRONT COVER
December 2008
Editor
george.demetri@aspermontuk.com
BA (Arch) BA(Hons), DipBldgCons (RICS)
Production editor
tim.peters@aspermontuk.com
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karen.leverington@aspermontuk
aspermontuk aspermontuk
.com
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Advertising production Advertising production
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+44 (0)20 7216 6053
Trenchless World (ISSN 1756-4093) USPS No: 023-
551 is published monthly (except January and July)
by Mining Communications Ltd, Albert House,
1 Singer Street London EC2A 4BQ England.
The 2008 US annual subscription price is US$170.
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contacts
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Regulars
1 Comment
2-4 Global news
A round-up of the latest news and technology
2m-diameter Hobas CC-GRP pipes were
inserted into steel host pipes as part of the
extension and reconstruction of the wastewater
system in Bratislava, Slovakia
Features
6-8 Project: India
Prime Horizontals record 2,008m HDD crossing of the Mahi River, Gujarat
9 Project: The Netherlands
Upgrading the gravity sewers in Groningen to handle higher flow during rain
10-11 Project: Poland
Crossing the River Sleza
12-14 Project: Indian HDD
Professor Niranjan Swarup describes the current state of play
15-18 Project: Texas, US
How Miller Pipeline and Earth Tool Co met a pipebursting challenge in Plano
19 Technology: locating equipment
20 Technology: HDD reaming
A recent HDD project in Egypt through unstable soil required a special reamer
22-23 Preview: UCT 2009
12
advertisers
American Augers
www.americanaugers.com Cov III
Baker Hughes
www.bakerhughesdirect.com 16
Barbco
www.barbco.com Cov II
Channeline International
www.channelineinternational.com 17
Colli Drill
www.collidrill.it 5
Connectra
www.ConnectraFusion.com 22
HDD Broker
www.hddbroker.com 14
Hermes Technologie
www.hermes-technologie.com 4
IDS
www.idscompany.it/georadar 11
Mal Geoscience, USA
www.malags.com 8
Mud Technology International
www.mud-tech.com 10
Prime Horizontal
www.primehorizontal.com 7
Radius
www.radiusHDD.com 18
Straightline
www.straightlinehdd.com 21
Tracto-Technik
www.tracto-technik.de 13
Vermeer
www.vermeer.com 3
The helpful, peak performer
T
ODAYS municipalities and utility owners
face enormous pressure to do more with less.
The recent battering of world economies will
do little to aid embattled operating and capital
infrastructure budgets. Added to this is the increasing
public pressure to be more environmentally
responsible. While certainly not the solution to
every problem, there is one peak performer that
can help: trenchless technology.
The technology is not exactly new, but increased
recognition and usage of these low-impact techniques
has fuelled both the science and the
growth of the trenchless industry.
The bonus is that, generally, the
installation or rehabilitation costs
are less than for traditional methods.
For owners, this has translated
into more trenchless options, along
with healthy bidder competition,
while satisfying social considerations.
For contractors and suppliers,
the expanding market has meant
quality equipment investments,
improved field practices and the
knowledge that they can successfully
bring the right solutions to urban problems while
reducing their risks.
Trenchless technology presents an ever increasing
menu of cost-effective and environmentally-friendly
approaches. The engineering world can now happily
spout a whole host of new acronyms, such as
CCTV, CIPP, HDD, HDPE, TBM and so on. The advance
of robotics for trenchless installations has given
the industry that 21st Century sense of
cutting-edge a far cry from the days of pick
and shovel indeed.
The adaptation of new approaches to
infrastructure problems should not only
be out of necessity to reduce costs and social
impact, but also as an opportunity to address
environmental and economic concerns
without sacrificing one for the other.
Michael J Willmets
Executive Director
North American Society for
Trenchless Technology
WEB ADDRESS www.trenchless-world.com
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December 2008
2
NEWS
US
IPR acquires
Underground
IPR acquires IPR acquires
Technologies
Underground Underground
US-BASED pipe-rehab company
Inland Pipe Rehabilitation (IPR)
has announced its acquisition of
Underground Technologies,
based in Knoxville, Tennessee.
The latter is an established,
privately-owned contractor
that specialises in pipebursting
and sliplining.
Described by IPR president
Joseph Cutillo as a result of his
companys continued, national
expansion efforts, the
acquisition is in line with the
companys growth plan,
particularly given the rapidly
evolving US infrastructure scene.
UCT San Antonio looking
to surpass Atlanta
US
WITH less than a month left to go
to UCT 2009 in San Antonio, Texas,
on January 20-22, the annual
underground construction event is
looking every bit more successful
than the Atlanta 2008 show.
Showing every sign of bettering
Atlanta, the organisers have
announced that there will be more
than 400 stands in the exhibition
hall and they expect around 3,000
visitors, who, if they turn up, will
ensure it becomes one of the best
trenchless events ever.
UCT (Underground Construction
Technology) is the US-staged, annual
event that highlights developments
in the underground construction
sector, particularly the no-dig
side. Visitors will have access
to the latest developments in
equipment, products and
services aimed at sewer, water,
gas distribution, telecom,
power/energy pipelines and
other engineering challenges.
A major component of
UCT is the conference
sponsored this year by 33
trade associations and universities
which is put together to provide
ample learning opportunities for
delegates. Also a part of the event
will be the third annual WaterWorks
conference (January 20-21) that
will highlight the key issues,
problems and
challenges in the
water infrastruc-
ture sector.
Online
registration is
possible, but
should be done
by January 2 to
allow time for
badges to be posted.
Exhibitor, programme or registration
information can be found at
www.uctonline.com or by emailing
convention manager Karen Francis
at kfrancis@oildom.com
See preview on pp22-23
ACCORDING to its annual
outlook survey, the US-based
Association of Equipment
Manufacturers (AEM) has forecast
that sales of trenchless equipment
for 2009 could rise, despite
not being that optimistic about
construction-machinery sales
in general.
The figures relate to predicted,
average sales of machinery used in
construction and infrastructure
works in the US, Canada and
worldwide.
The survey is based on AEMs
construction-equipment manu-
facturer members expected sales
and there are seven different
categories.
However, it is difficult to apply
the figures directly to trenchless
equipment as it is grouped with
other construction equipment in
the miscellaneous category,
which also includes machines such
as: heavy-duty and light-to-medium
trucks; earth drills (augers);
landfill/refuse compactors; side
dump, live bottom and flatbed
trailers; sewer vacs; environmental
grinders; equipment washers
and sweepers.
Nevertheless, the survey
forecast that sales of miscellaneous
equipment in 2009 are expected
to rise by 9.5% in the US, by
11.1% in Canada and 9.3%
worldwide.
But, this is far better than the
general scene, for which AEM has
predicted flat growth of 0.04% for
the US in 2009. Canada will fare
slightly better in 2009 with 2.2%
growth, while sales to worldwide
markets will rise by 5.4% in 2009.
AEM president Dennis Slater
said: We need to get dollars in
the construction pipeline. An
immediate increase in public
works funding will help jumpstart
the US economy.
Construction projects are being
deferred and our customers are
looking for work. It is estimated
that there are currently 3,000
projects that could begin work
within 30-90 days of a government
funding commitment.
He continued: Our ageing
roads, bridges and highways need
repair and upgrades. Committing
funds to infrastructure renewal
not only provides manufacturing
and construction jobs, but
also helps to ensure we have safe
and efficient movement of goods
and people.
An adequate transportation
network is essential to commerce
and maintaining US competitive-
ness in global markets.
US
AEM cautiously optimistic on construction machinery sales
Overall average % changes predicted for unit sales
US (%) Canada (% ) Other (%)
Equipment Type 2007/08 2008/09 2007/08 2008/09 2007/08 2008/09
Earthmoving -15.8 -3.3 -6.8 -0.6 6.0 4.8
Lifting -7.4 2.4 0.9 5.6 4.2 8.2
Bituminous -8.8 -3.3 -2.8 -0.6 16.4 7.8
Concrete/Aggregate -8.6 4.6 -5.3 2.0 20.4 3.9
Light -10.7 -1.9 1.1 3.0 5.0 3.1
Attach/Components 3.3 3.4 2.6 2.6 6.9 5.4
Miscellaneous -11.2 9.5 -1.6 11.1 16.5 9.3
Industry Wide Totals -8.6 0.04 -1.7 2.2 8.5 5.4
2008 copyright Association of Equipment Manufacturers
AEM outlook survey results
02,04trench0812.indd 2 15/12/08 16:41:10
UNEVEN TERRAIN, TOUGH SOIL
CONDITIONS, TIGHT SPACES.
We know you need reliable and productive equipment to stay on schedule and on budget.
Vermeer has the planning tools and trenchless equipment to help complete your
utility installation projects without shutting down a major street.
When it comes to underground installations, look to the industry
leader Vermeer. Call +1-641-628-3141 or visit Vermeer.com.
VERMEER and the VERMEER LOGO are trademarks of Vermeer Manufacturing Company in the United States and / or other countries.
2008 Vermeer Corporation. All Rights Reserved.
WE JUST DESCRIBED OUR IDEAL WORKING ENVIRONMENT.
Vermeer.indd 1 11/12/08 10:53:22
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December 2008
4
NEWS
UK
UK provider Yorkshire Water is
the first water company to trial
a new pipe-sealing technology
that seals leaks from inside the
pipe in a similar way to how
blood platelets seal cuts in the
human body. Currently being
trialled by the firm, the new
technology could revolutionise
pipe repair and minimise
disruption to customers.
When a leak is detected,
platelets are released into the
water-supply pipe and travel
under pressure to the trouble
spot where they seal the leak.
Launched earlier this year,
the technology was originally
developed for use in the oil and
gas industry by Aberdeen-based
Brinker, with whom Yorkshire
Water has worked.
The technology has already
been used by Yorkshire Water
on a burst cast-iron main in
Bradford, Yorkshire. Specially-
developed silicon cubes were
inserted into the pipe via a
hydrant and, within minutes,
they located the problem and
sealed the leak from the inside.
There was no need to dig up the
road and no need to fell a
nearby tree, which would have
had to come down to allow
engineers to work safety.
Yorkshire Water implement-
ation manager Stephen
Herndlhofer said: The repair
on Yew Tree Avenue is a great
example of how the new tech-
nology has the potential for us
to fix leaks in difficult locations.
Normally, we would have had
to dig a hole, remove the tree,
fix the pipe and fill the hole.
The technology developed
by Brinker of Aberdeen in
partnership with Yorkshire
Water allowed us to avoid the
need for roadworks and saved
the tree its a quicker, cheaper
and far more environmentally-
friendly way to repair bursts.
INSITUFORM Technologies has
won a US$4.4 million contract for
a water-pipe renewal project in
Victoria, British Columbia, Canada.
The project will involve the
rehabilitation of 4,496m of
high-pressure steel pipes, ranging
from 200-600mm in diameter,
located mostly in residential areas.
The firm will use its PuraGuard
technology a close-fit polyethylene
solution for water-pipe renewal.
Ken Foster, vice-president of
Insituform Canada, said: Insituform
has rehabilitated sewer lines for the
city of Victoria in the past and we
look forward to continuing our
productive partnership in the future.
We are confident our customer
service and superior watermain
rehabilitation methods will meet the
high standards the city has set for us.
PuraGuard is part of Insituforms
Blue line of tools for the trenchless
rehabilitation of potable water lines.
Insituform will complete the
work in Victoria in 26 installations,
rehabilitating 4,237m of 500mm,
152m of 600mm and 91m of
200mm water lines. Work began in
late November and is expected to
be completed in August 2009.
In another development, in
November, Insituform was awarded
a US$10.3m CIPP project in
Connecticut, which involves the
rehabilitation of about 83,000 linear
metres of sewer line using its
jointless, pipe-within-pipe system
that is designed to extend the life of
existing infrastructure by 100 years.
Work on the project, involving
line diameters of 150-750mm,
began in December and is expected
to last for about a year. Insituform
was awarded the contract by the
Metropolitan Development
Commission (MDC), which
provides sewer and drinking water
services to the Connecticut
municipalities of Bloomfield, East
Hartford, Hartford, Newington,
Rocky Hill, West Hartford, Windsor
and Wethersfield, as well as parts
of other towns in the region.
David Goldwater, business dev-
elopment manager for Insituforms
Atlantic Region, said: We are
excited to again have the opportu-
nity to work with MDC. We had a
very positive experience working
with MDC in 2007 and hope to
continue this relationship well into
the future. We also look forward to
developing additional projects and
relationships in this region.
HAMMERHEAD Trenchless Equip-
ment, North Americas largest
manufacturer of piercing tools,
pipebursting and pipe-ramming
systems, has launched a revamped,
state-of-the-art website.
Designed as a communication
channel for customers worldwide,
hammerheadtrenchless.com offers
comprehensive,
real-time,
interactive
media to
engineers,
contractors,
municipalities and the public.
HammerHead president and
CEO Brian Metcalf said: Hammer-
Head has led the industry in bring-
ing innovative, trenchless solutions
to customers in North America
and around the world. The new
website is a step to direct dialogue
with customers wherever they
may be, as well as a means of
communicating with them on the
latest news and technology in the
trenchless construction sector.
Insituform wins contracts in British
Columbia and Connecticut
Canada
US
Hammerhead rolls
out new website
Yorkshire Water
is first to trial
in-pipe sealant
HERMES
Products and Techniques
M-Coating
wet spraying
reguIating manhoIe frames
coating by hand
- over 20 years service to the
ProfessionaI ProfessionaI
renovating IateraI connections
HERMES
TECHNOLOGE
Ltd.
Phone
e-Mail: office@hermes-technologie.com www.hermes-technoIogie.com
.
Hastings, East Sussex Stafford, Staffordshire, UK
+44 (0)77 53 98 69 66 or +44 (0)77 21 76 40 63
+49 (0)23 04 97 123 0 (D) Head Office
.
wastewater
02,04trench0812.indd 4 15/12/08 16:42:02
20th
ANNIVERSARY
Colli Drill.indd 1 11/11/08 12:04:18
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December 2008
6
O
N AUGUST 18, 2006, the Gujarat
Global News Network, Ahmedabad,
India, filed the following report: State
government has started massive evacuation
operation to shift about 100,000 people from 26
villages of the Anand district as the Mahisagar
River is flowing through central Gujarat in its
worst fury. By 10am, 30,000 people have been
shifted to safer places while efforts are ongoing
to shift the rest of people.
The impact of this massive flood continues as
the damage to the infrastructure in the vicinity
of the flood is undergoing repair and reconstruc-
tion. In particular, a 300mm natural gas pipeline
across the Mahisagar River between Pavda and
Ganja near Vadodara was damaged and
unearthed by the flood. The pipeline is used to
supply gas to the Gujarat Electricity Board
power plant for electricity generation by the
Vadodara division of GAIL, one of Indias
state-owned gas distribution and marketing
companies.
At this location the river is 1,130m wide, and
the exit side bank of the river is very unstable,
leaving very little tolerance on each bank to
account for future erosion. In retrospect, the
original pipeline was simply installed with
insufficient cover above the product pipe.
The Mahisagar River is a tidal river, with a
daily tide that continually erodes the banks,
especially the exit side bank (Dabka side).
During the August 2006 flood, 300m of the
Dabka side bank were eroded away, exposing
and damaging the existing pipeline.
GAIL appointed Mecon of New Delhi as its
project management consultant to plan and
manage the installation of a replacement pipeline
with a design lifetime of 30 to 40 years. Mecon
proposed a 2,000m HDD pipeline crossing under
the river, and NR Patel & Co of Chennai was
awarded the HDD crossing contract.
NR Patel & Co appointed Prime Horizontal of
Amsterdam, Holland, a well-known HDD
guidance and consulting company, to provide
magnetic guidance services with Tensor and
later ParaTrack-II systems. The rig and drilling
equipment were mobilised to the site on
February 23, 2008 and pilot hole drilling started
on March 5, 2008. The project was completed
in July 2008 at 2,008m, the longest HDD
project in India to date.
PILOT HOLE DRILLING
The pilot bore used an 8in (215mm) bit on a
2 non-magnetic bent sub with a 5in (140mm)
IF drill string. Practically speaking, the project
had two phases: one was the drilling of a pilot
hole of 1,758m, guided with a Tensor system,
and the other was the drilling of a second pilot
hole, guided with the ParaTrack-II magnetic
guidance system and with ream and pull of
2,008.4m length.
The first pilot hole failed due to the presence
of a gravel layer that caused excessive drag force
near the exit side end. The decision was made to
deploy a second rig on the exit side to drill an
underground intersect with the longer existing
Crossing the Mahi River
Thomas L Teer and
Abhishek Khare of Prime
Horizontal discuss the
record 2,008m HDD
crossing of the Mahi
River in Gujarat, India
PROJECT: India
Herrenknecht 250T Model H016 Drilling Rig
06,08trench0812.indd 6 15/12/08 16:48:07
Prime Horizontal Companies
In Holland: +31 (0)251 271 790
In USA: 1-570-675-0901
visit our website: www.primehorizontal.com
HDD Guidance services for
Intersects and Drilled Crossings
using ParaTrack
Call us today for a consultation
Always Hiring Well Qualied Field Engineers
Prime Horizontal
Unexcelled Accuracy
Prime Horiz.indd 1 31/3/08 16:07:32
8
hole, but down-hole circulation was lost while
struggling with the gravels and this intersect was
abandoned on June 12. However, significant
information about the ground conditions from
the exit side was collected.
Armed with knowledge about the depth of
the gravel layer on the exit side, and with the
information available from a vertical borehole at
1,750m range and 8m to the right of the
abandoned hole, a new drilling profile was
developed. In this profile, the hole would start
building early, keeping the angle less than 2 to
ensure that the borehole was at least 12m below
ground at a range of 1,600-1,700m, where the
borehole would start to build to the exit point.
The new pilot hole was started 2m to the right of
the abandoned hole and about 3m higher on
June 20, and punched out on July 8.
REAMING AND PIPE PULL
Product pipes were provided by GAIL India.
Steel pipe was used with specification of 12in
(300mm) OD x 7.9mm wall API 5L Grade X 60.
Normal manual arc welding (in coils) was used
for preparing the pipe string.
There were no problems in reaming and pipe
pull after the pilot hole was completed.
Wiper sub run to reduce drill string torque
was started on July 8 and finished on July 12.
A fly cutter of 455mm started on July 13 and
finished on July 18, including the removal of
casing that measured 10in (250mm) OD x
300m.
A 455mm barrel reamer was used first as an
initial reaming and then as clean pass. This
started on July 19 and finished on July 2.
Product pipe 12in (300mm) OD pull back
finished on July 23.
SUMMARY
Given the size and the complexity of the
project, the longest HDD project ever
completed in India was very successful.
Prime acknowledges the vision and
unwavering support of GAIL and Mecon for this
project. Special acknowledgment is extended to
NR Patel & Co for its provision of untiring
operational support of the project. And thanks
are extended to Prime Horizontals field
engineer, Abhishek Khare, for his unflagging
efforts to make sure that this project was
successfully completed.
Once again, the boundaries of horizontal
directional drilling projects have been pushed a
little bit farther.
Equipment
Rig Herrenknecht 250T Model H016
High pressure mud pump Herrenknecht 550 GPM Model H 019
Gardner Denver 700 GPM PZ 8
Downhole tools Tensor Kits (Tensor Inc, USA)
ParaTrack2 Kit (Vector Magnetics)
Mixing tank 40ft (12.2m) two each (company owned)
Buffer tank 20ft (6.1m) one each (company owned)
Recycle unit Kemptron Double Deck Type Model Tango 1000S
Pumps Sykes Pump (Primax) for slurry
Backhoe L&T Komatsu PC 200, four each
Tata Hitachi EX 70, one each
Tata Hitachi EX 210, one each
Samsung SE 210LC, one each
(all company owned)
Crane Cap 25 T and 12 T, two each (hired)
Pipe layer BEML BP 41, one each (company owned)
PROJECT: India
December 2008
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Successful punch-out on the exit side
06,08trench0812.indd 8 15/12/08 16:48:22
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December 2008
9
G
RAVITY sewers in Groningen, the largest
city in northern Netherlands, could not
cope with high flow rates that occurred
during periods of heavy rain.
This was why the local authority decided to
extend the DN 1000- and DN 1200-sized sewer
main, but also to convert it into a closed-
pressure system to avoid sewage overflows and
the associated environ mental pollution.
Achieving 3,000m
3
/h flows and system
extension required 2.4km of Hobas CC-GRP
pipe not only to cater for future needs, but also
to allow another village to be linked to the
system in future.
Early on at the design stage, the engineers
decided to install the proposed pressure pipes
using pipejacking, as the line crosses a busy
part of the town and the client wanted minimal
dis ruption to the citys daily life.
The cost for the pipe alone on the entire
project was US$1.5 million. This included five
jacking sections using Hobas CC-GRP jacking
pipes (DN 1000-1500), as well as PN 6 Pressure
Pipes (DN 1000) and 1,600m of DN 1200.
Also included in the contract were flanges,
elbows, reducers and tees with stainless-steel
locked joints.
However, not all the project was pipejacked.
Various roads and channels presented obstacles
that necessitated the use of microtunnelling
in parts. The road authority stipulated that
two sections running below the highway would
have to be realised with cover pipes from
HOBAS Benelux, and HOBAS CC-GRP Pressure
Pipes were inserted. The largest with an
outer diameter of 1,500mm was used below
highway A7.
Three other microtunnelled sections were
carried out using PN6 CC-GRP pressure-jacking
pipes and flush FWC couplings. These ran
beneath a gas pipeline, a main road, several
streets and a navigable channel where the
installation took place 12m deep. A 275m-long
section with CC-GRP pressure-jacking pipes of
1,280mm outer diameter was jacked in a curve
of 1,300m radius.
In accordance with safety standards, the
contractor installed an intermediate station
which was required if jacking forces were to
exceed 4,000kN.
However, on this project, the smooth and
non-absorbing outer surface of the pipes, and
their light weight and constant outer diameter,
meant that the maximum jacking force did not
exceed 1,800kN.
The intermediate station was, therefore, never
really used.
Five different contractors were involved on
the project and a sixth will rehabilitate the
pumping station in two years.
Year of construction 2006-07
Length of pipe 2,400m
Pressure class PN 1, 6
Diameter DN 1000, DN 1200, DN 1500
OD 1099, OD 1280
Stiffness class SN 5000, SN 320000
Application SewerLine
Client Community of Groningen
Contractor 5 different contractors
Advantages Corrosion-resistant, low
weight, fast installation, whole
system by one supplier, long
lifetime, low maintenance costs
Gronigen project facts
Pressure was on to upgrade
gravity sewer in Groningen
PROJECT: The Netherlands
The HOBAS ush couplings used for jacking
are designed to be absolutely leak-tight
and facilitate assembly
Below: Several obstacles along the pipe
route, such as roads and a channel, were
overcome by microtunnelling
09-11trench0812.indd 9 15/12/08 16:35:24
10
We manufacture our own line of shakers,
desilters, desanders and mud pumps.
Our tank & Mixing Systems are designed
for maximum flexibility.
Technology Today
Shaping The Future
www.mud-tech.com
P.O.Box 509, Athens,Texas 75751
USA
PROJECT: Poland
S
ABEL is a specialist trenchless pipe con-
tractor and cable laying contractor that
employs 70 workers. It is one of the main
contractors working for Polish Railways and is
involved in rebuilding the railroad connecting
Wroclaw and Dresden. When completed, this
will cut the journey time between the two cities
by around a half.
Associated with the works was the construc-
tion of new electric cable networks, which
involved the installation of two 125mm HDPE
sleeves running 84m under the 79km-long river
Sleza, which is located in southern Poland and
is close to the city of Wroclaw.
HDD MACHINE TECHNOLOGY
To undertake the work, Sabel chose the TJ (Terra-
Jet) 2608 E machine. An interesting characteris-
tic of the machine is that the thrust and rotation
are driven by two separate hydraulic circuits,
which allows both circuits to be operated
simultaneously and at maximum power. For the
TJ 2608 machine, this allows a torque of
2,600Nm and a thrust and backreaming force of
80kN (8t) simultaneously, which is unique for
this size of HDD machine.
Having a rock-drilling capability for hard,
stony and rocky ground, the TJ 2608 E is
equipped with a Terra-Rock air percussion head.
Other features include quick gear for fast drill-
rod changing and an Automatic Drilling and
Backreaming System that adjusts the operating
speed of the machine according to the ground
conditions encountered on the bore.
The machine can be pit or surfaced launched.
For pit launch, hydraulic cylinders allow the
HDD machine to be easily set up and adjusted
to the required inclination in the starting pit. The
company claims specialised drilling tools used
in combination with a precise electronic
locating system guarantee the highest accuracy
for drilling lengths up to 150m.
Designed on a modular basis with separate
power packs and mixing systems, the machine is
compact and can be easily transported on a
small truck. The unit has a drilling fluid volume
of 100 litre/min and its mixing and pumping
station enables 2,000 litres of high-quality
drilling fluid to be mixed in only five minutes.
Maximum drilling fluid pressure is 70 bars.
PILOT BORE
The river is 2m deep and the installation was
required to be 3m beneath the river bed. The TJ
2608 E was installed in a 3m-long by 1.5m-wide
launch pit. To undertake the pilot bore in the
HDD crossing of
the River Sleza
HDD crossing of HDD crossing of
The 215mm backreamer reaches the HDD
drilling machine
09-11trench0812.indd 10 15/12/08 16:35:26
11
We manufacture our own line of shakers,
desilters, desanders and mud pumps.
Our tank & Mixing Systems are designed
for maximum flexibility.
Technology Today
Shaping The Future
www.mud-tech.com
P.O.Box 509, Athens,Texas 75751
USA
PROJECT: Poland
clay and gravel ground, a universal type C head
was used. Location by means of the i-Track
system from both sides of the river allowed
precise tracking of the pilot bore without the
need to have men in a boat above the drill line
in order to locate the drill head. After only six
working hours, the 100mm pilot bore was
completed, with the drill head reaching the
starting pit right on target.
BACKREAMING AND PIPE PULLING
Once the drill head was disassembled, the
borehole was enlarged using a 215mm-diameter
backreamer. Thereafter, a 300mm-diameter
backreamer and the pipe bundle of two lots of
HDPE pipe 125mm OD were pulled through
effortlessly in a single operation.
Facilitating the operation was the use of a
specialised Bentonite drilling fluid that fulfilled a
number of important functions. It suspends the
borehole spoil in the drilling fluid mix and
transports it back to the starting and launch pits;
it stabilises the borehole preventing collapse
during the drilling works, owing to its
thixotropic qualities; and it lubricates the
HDPE pipe during pipe pull-in, thereby
reducing friction.
Thanks to the good ground that was
encountered beneath the Sleza River, the works
were completed using only 30m
3
of drilling fluid;
the entire HDD component and HDPE sleeve
installation was completed in only two days.
The engineer responsible for the works
commented: This small HDD machine has
more power than I had ever seen before in such
a compact drilling system. Terra-jet 2608 E pit-launched HDD machine
215mm backreamer ready for intermediate backreaming
09-11trench0812.indd 11 15/12/08 16:35:31
12
T
RENCHLESS Technology applications in
India are increasing as a result of several
government initiatives and infrastructure
development activities. Also, increasingly dif-
ficult projects are being tackled. The successful
execution of such projects whether for cross-
country or city grids, for gas distribution or
telecom networks or other sub-surface sectors
will require substantial drilling capacities, both
in terms of HDD rigs and technical expertise.
This article discusses the HDD business in
India while talking about some of the recent
major projects, and invites international HDD
stakeholders to join the Indian trenchless
industry as a service provider.
INDIAN HDD MARKET
Similar to global markets, the Indian require-
ments for HDD crossings are for pipelines of:
Power and telecom networks;
Oil and gas transmission and distribution
networks;
Pressurised water supply networks and sewer
lines allowing partial line and grade
tolerances, especially in the Jawaharlal Nehru
Urban Renewal Mission (JnNURM) cities;
Pollution control (drainage) lines.
MARKET VALUATION
Recently, the Indian Society for Trenchless
Technology (IndSTT) conducted a study to
identify the HDD manufacturing business in
India for one stakeholder who intends to start an
HDD rig manufacturing unit in India. One of the
objectives of the study was market valuation,
which is applicable to both manufacturing and
contracting. Detailed hereafter are the market
values of the sectors indicated above.
To date, in the telecom sector, 670,000km of
optic fibre cable has already been laid and the
sector has grown by 21%. And with the
tremendous demand for broadband, DTH and
urban connectivity lines, there is tremendous
scope for laying telecom lines using HDD. This
sector is the major market for smaller rigs and
associated products which are currently being
imported from different manufacturing nations
such as China, the US and Germany.
For power transmission, the plan is to install
26,553 circuit kilometres in the current national
plan period. The urban portion of this network
will also call for installing the substantial
TRE CHLESS
U
December 2008
PROJECT: India
Indian HDD on the rise
Professor Niranjan Swarup, executive director,
Indian Society for Trenchless Technology,
describes the current state of play of Indian HDD
The 1.13km Mahi River has tidal ows
12-14trench0812.indd 12 15/12/08 16:40:26
13
Reaming 455mm fly cutter;
Clean Pass 455mm barrel reamer;
Pull product pipe of 300mm OD;
Length of crossing 2,008m.
Ground investigation works: Geotechnical
sub-soil investigation and topographical
survey was undertaken prior to the rig
mobilisation on site and was carried out by the
clients approved vendor, MK Soil Testing
Laboratory. Based on its reports, the project,
including the drilling profile, was designed by
NR Patel & Co. Steel product pipes of 300mm
OD API 5L Grade X 60 were provided by the
client (GAIL). Normal manual arc welding (in
coils) was used to prepare the pipe string.
Project timings: The project was awarded on
December 10, 2007. Rig spread mobilisation
was complete by February 23, 2008. The first
pilot was started using tensor kits on March 5.
Contractors were able to reach up to 1,758m
from one side. Upon facing the difficulty in
progressing ahead, they tried to intersect the
pilot from the pipe side using a second rig of the
same capacity with a tensor steering tool but
could not succeed and therefore abandoned the
hole on June 12.
A second pilot parallel to the first hole was
begun on June 21 and completed in July.
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industrial fluids.qxp 3/29/2007 3:38 PM Page 1
Untitled-1 1 31/8/07 09:20:57
17
PROJECT: Texas
New Slip line range New Slip line range
Joint & jack gaskets Joint & jack gaskets
Centralizing skids Centralizing skids
Low jacking loads Low jacking loads
Non man entry installation Non man entry installation
Any size, any shape Any size, any shape
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P.O. Box 8091, Dubai, United Arab Emirates
Tel.: +9714 3372877, E-mail: sales@apsdubai.com
Earth Tool Company, Mr Randa was familiar with
Mr Hallett and his team. But, neither he nor
Mike Walk, the ram-and-burst specialist from
Earth Tool Company who later became involved
with the project, had performed an upsize of this
magnitude. They echo Mr Hallett, who says:
This is not the biggest job weve ever done in
terms of length, but certainly the biggest that
weve undertaken in terms of complexity.
On the complexity front, the upsize was
just one of many challenges the team faced.
Added to this list are difficult proximity to
above-ground obstacles, incredible bypass
requirements, a right-of-way crowded with
existing utilities, tough ground conditions and
brutal weather. Rain set the project back by a
month when the time allowed for the job was
130 days. Originally, the target finish date was
August 31, but it was moved back to September
31, because in June alone, Texas was hammered
with more rainfall than it had received during
the whole of 2006.
THE BURSTING SYSTEM
ETC was primarily involved in just under 305m
of the job, carried out in four bursts 70m,
39m, 83m and 57m all of which involved
upsizing from 610mm to 813mm o.d. HDPE.
Previously, Mr Randa and Mr Walks largest
upsize went to 762mm, so equipment brought
to the site was truly custom:
Crews used a 914mm bursting head
The head featured a long pilot on the front to
keep the tool on line, and to keep material
from collapsing in front of the pipe and
impeding progress
It also featured a cutting blade, designed to go
through the old pipes concrete and wire mesh.
Traditional equipment included:
A 508mm pneumatic tool, mounted on the
tail of the pipe designed for a burst-assist
Three compressors: two 900 cfm units to run
the bursting head and a 1,300 cfm unit for
the burst-assist
A 20t winch to pull the bursting head through.
Most of the custom concepts
had been used before, but on
a much smaller scale. For
example, Mr Randa has
added pilots to bursting heads
before, but not for an upsize
like this. We basically
stepped up what had already
been proven technology,
he says.
The 508mm tool used for
burst-assist was an interesting
component. Its an application that has been
used many times before, but usually to save a
bore on an HDD project. We just turned the
hammer on running very slowly to relieve the
pipe drag and keep forward progress, says
Mr Randa. We wanted to have as much energy
downhole as possible to complete the job.
The 508mm tool was also on hand to back
up Millers static-bursting unit in case the
progress of the burst slowed or stalled. To save
the burst, the rod could be shuttled out of the
burst head through the back end of the pipe.
The hammer could be attached, pulled into
place and locked into the burst head. The burst
could then be resumed using a combination of
static and pneumatic forces. Although we
didnt use it, its good to have a contingency