Update on the Direct Pipe Method in NA

Maureen Carlin and Jonathan Barrie

Agenda
Maureen Carlin & Jonathan Barrie

• Safety Moment
• Overview of DSPT
• Projects to Date
• Methodology Comparison
• TMEP Sumas Case Study
• TMEP Challenges and Outcomes
• Discussion

2
Safety Moment
Working in Extreme Temperatures

Bothar employees have worked in -67F (-55ºC) with windchill

in and up temperatures of 115F (+46ºC) with high humidity.
In both cases the important thing is to maintain hydration.

Why is hydration important in very cold weather?

Staying hydrated through winter can boost immune system
and give your body the support it needs to fight off
infections. But just as important, your body uses water to
maintain a temperature balance and when you aren’t
adequately hydrated your body can become cold.

3
Winterization of Equipment
Safety, training, enduring the elements & overcoming risks

Tunnelling all year long

• Extensive experience in winter operations with temperatures as low as -67F (-55ºC)
• Enduring natural weather elements and soil conditions

4
What We Do
Superior tunnelling solutions

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Microtunnelling
Equipment Fleet

MTBMs ID (in) # MTBMs ID (in) #

AVN 3000AB 120.00 1 AVN 1200XC 48.00 2
AVN 2500AB 100.00 1 AVN 1000XC 40.00 3
AVN 2400AB 96.00 1 AVN 1000XC 40.00 2
AVN 2000 80.00 1 AVN 800XC 32.00 4
AVN 2000TB 80.00 1 AVN 800 32.00 6
AVN 2000AB 80.00 1 AVN 700 28.00 1
AVN 1800TB 72.00 1 AVN 600XC 24.00 2
AVN 1600 64.00 1 AVN 600 24.00 1
AVN 1500 60.00 2 AVN 500 20.00 1
AVN 1500TB 60.00 2 AVN 400XC 16.00 3
AVN 1200 48.00 5 AVN 400 16.00 1
AVN 1200TC 48.00 1 TOTAL 44

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Industries We Serve
Building the world beneath you

Energy:
• Oil and gas pipeline

Civil / Infrastructure:
• Sewer / sanitary installations (lined/unlined)
• Storm water networks (lined/unlined)
• Watermain / telemetry – insertion required
• Marine intake and out take
• Electrical installations
• Fuel pipelines
• Offshore Applications

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Trenchless Technology Overview
Rehabilitation, New Installation and Assessment

Crossing Applications
• Environmentally Sensitive
Trenchless Technologies
Areas
• Railroads, Highways and Rehabilitation Installation Assessment
Roadways
• Rivers, Streams, Bogs, Bayous,
Lakes Pipe CIPP Close-Fit Pipe
Slip Lining Shotcrete
Bursting Lining Lining Eating
• Mountainous Areas
• Urban Areas
• USACE Regulated Zones: SSET CCTV NDT Man Entry
Rivers, Ship Channels,
Canals, Dams, Levees
• Water to Land Crossings: Sea Impact Micro- Water Pipe Pipe Auger
Outfalls , Lake Intakes, Shore Moling Tunneling Jetting Jacking Ramming
HDD
Boring
Approaches
• Areas of Contaminated Soils
Direct Steerable Pipe Thrusting

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Direct Pipe® Installation
What we do

Herrenknecht | The Direct Pipe Method ® (DPI) combines the advantages of microtunnelling and HDD
technology. In one step only, a prefabricated pipeline can be installed and the required borehole excavated
at the same time. This allows speedy and highly economic installation of pipelines with lengths of more
than 1,500 meters.

Process Patent: Slurry-supported Herrenknecht Microtunnelling Machine (AVN) + Herrenknecht Pipe

Thruster

American Society of Civil Engineers | Direct Steerable Pipe Thrusting (DSTP) is the common name for the
installation of a steel pipeline that is installed into a bore using a pipe thruster, steerable and typically
installed between shallow launch and reception portals along a designed bore path that includes curves.

VS.

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Direct Pipe® Installation
Methodology

• Developed in 2007 by Herrenknecht

• Adapted Micro-tunnelling technology to near surface launch of steel pipe
• Developed a new thrusting system to grip and thrust the installation pipe
• Adapted internal components to be installed in one concurrent extended length
• Multiple strings can be prepared for longer crossings with limited working room
• Size range from 0.8 m (30”) to 1.5 m (60”), varying lengths based on soil conditions and pipe size
• Annular lubrication is performed at the MTBM and at the tail can reducer behind the MTBM
• No Intermediate Jacking Systems (IJS), ability to add a jacking station behind the MTBM
• Ability to retract the entire string if required
• There have been 186 Direct Pipe Installations worldwide
• Bothar has completed 21 DPI crossings in Canada

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Direct Pipe® Installation
What we do

Pipe Thruster

Invented as Aid
Tool for HDD assist

One-pass pipeline
installation method
combining
Microtunnelling and
HDD techniques

30” (800mm) to 60”

(1,500mm) pipe
installations up to
7,000’ (2,100m)

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Direct Pipe® Installation
Site layout

• Large fully serviced and

operational fleet available

• Proven and updated in various

soil conditions around the world

• Efficient mobilizing of expert

personnel and equipment across
the globe

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Direct Pipe® Installation
Site layout

13
Direct Pipe® Installation By Year
Methodology

17
Direct Pipe® Installation By Year
Methodology

18
Direct Pipe® Installation By Footage
Methodology

19
Direct Pipe® Installation
Methodology

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Direct Pipe® Installation Length | Diameter
Methodology

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HDD vs. MT. vs. DPI
What is historically considered..

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HDD, Direct Pipe®, Microtunnel Comparison
CRITERIA HDD DIRECT PIPE MICROTUNNELING

Design Length Longer and Deeper Short and Shallow Short and Shallow

Maximum Length >17,000 feet (5,200m) >7,000 feet (2,100m) >7,000 feet (2,100m)

Depth of Cover Generally Greater Than 25 feet Can Be as Low as 3X Pipe Diameter Can Be as Low as 3X Pipe Diameter

Entry 8 to 14 Degrees Launch 0 to 8 Degrees

Design Angles Generally 0 Degrees
Exit 10 to 16 Degrees Reception 2 to 10 Degrees

Entry/Launch
Surface Entry Near Surface Launch Shaft Launch
Approach
Governed By Installation and Governed By Installation and
Min. Install Radii Generally Flat or Sloped
Operating Stresses Operating Stresses

Engineered Shoring for Shallow

Engineered Shoring for Launch and
Pit/Shaft Design Shallow Pit, Non-Engineered Launch Pit; Shallow, Non-Engineered
Reception Shaft
Reception Pit

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HDD, Direct Pipe®, Microtunnel Continued
CRITERIA HDD DIRECT PIPE MICROTUNNELING

Engineered For Site Conditions Engineered For Site Conditions

Foundation Traditional Deadman
& Anticipated Loads & Anticipated Loads

Pipe Segment Storage on Launch

Pipe Stringing Typically Exit Side Launch Side
Side

Compression, Bending and

Installation Stresses Tension, Bending and Combined Compression and Buckling
Combined; Column Buckling

Hydrostatic Drilling Fluid Pressure Hydrostatic Lubricating Pressure and Hydrostatic Lubricating Pressure and
Annular Pressures
and Cutting Transport Pressure Slurry Over Pressure Slurry Over Pressure

Gravel, Cobbles and Can Negotiate Up To 1/3 Size Of The Can Negotiate Up To 1/3 Size Of The
High Risk Of Failure
Boulders Cutterhead Cutterhead

Clay Soils High Risk of Hydraulic Fracture Low Risk of Hydraulic Fracture Low Risk of Hydraulic Fracture

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Annular Pressure Comparison
Direct Pipe vs. HDD

180 100

160
LEVEE
0
Annular Pressure, Psi

140

ELEVATION, FT
120 -100

100 LEVEE -200

80 MONITORING
60 ZONE -300

40
-400
20

0 -500
0+00 5+00 10+00 15+00 20+00 25+00 30+00 35+00 40+00 45+00 50+00

Limit Pressures with FOS=2 Estimated Annular Pressure - HDD Estimated Annular Pressure - DP
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Method of Construction Favorability
What we do

& Cobbles

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Method of Construction Favorability
What we do

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TransMountain Pipeline – Sumas River Crossing
Field operations, Direct Pipe Installation - DPI®
TransMountain
Client introduction

• Trans Mountain operates 1,150 km (715 mi) 24” pipeline through Alberta and British Columbia, supplying 300,000
barrels of oil per day.

• Currently constructing an expansion, which is 980 km (610 mi) of 36” product line along the existing Right of Way.

• Sumas River replacement of 415 meters of NPS 24 on Line 1, near Abbotsford, BC

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Project Information
Overview

Owner: Trans Mountain Pipeline

Product: 24" steel pipeline installed by conventional open cut method in late 1950's
Length: 310 metres (1020’)
Location: Sumas River (controlled irrigation dike) near Abbotsford, BC

Concern: Corrosion issues under Sumas river

The original plan was to complete the replacement when the new expansion 36" line was to be installed, delays in the
construction of the 36" required the client to find an alternate solution

Options:
• HDD
• Micro Tunnel
• Direct Pipe

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Project Information
Overview

Crew Size:
• Our typical DPI crew consists of 11 field personnel and 4-5 onsite management during internal installation
• We ramp up to 26-28 during tunnelling, we split the same crew into night shift for tunnelling 10 and 10 per shift, plus
onsite management

Duration:
• Started tunnelling the 42” June 29th and Finished July 04
• Started Pulling the 42” back July 14, Finished July 15th (27 hours)

Thrust Loads:
• Theoretical thrust load was 105T, final thrust was 75T
• Pullback of the 42” started at 130T and steadily dropped, after only a couple metres we were at 85T

37
Project Information
Continued

Solution: Install 310 m (1020') new 24"

Problems:
• DPI not designed for that small of a pipe, over that length
• No additional Right Of Way (ROW), due to new NPS 36 pipeline construction, existing pipelines, valuable farmland
• Homeowner property on edge of ROW, house within 25', active 24" pipeline within 25'
• Culturally Sensitive Area
• Environmental/Wildlife Concerns
Solutions:
• Install 42" casing pipe first, insert 24", remove casing (corrosion concerns)
• Install new 24" on the 36" ROW, decommission old 24", then install new 36" under old decommissioned 24"
• Installation of vibration monitoring equipment
• Work with Indigenous Groups to understand and address their concerns
• Relocate endangered species (Oregon Forrest Snail), monitor and time crossing for Red Tailed Hawk nesting

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Site Layout

39
Technical Challenges
1: Pipe size

• NPS 42 x 3/4 WT, leaves 40.5" internally, once

internal rails and components are installed there is
very little working room.

• Electric DC powered carts are installed in between

slurry pumps to allow for travel throughout the pipe.
Inclination of the pipe can range from 0-15°

40
Technical Challenges
2: Construction of all internals prior to use

• As the pipe is inserted in one continuous

length, all electrical, communication, slurry,
lubrication, HWL must be connected and tested.
Any errors during the installation creates a
laborious process of troubleshooting and
repair, therefore ensuring well maintained
components along with a strict installation
procedure are required to reduce the number
of corrective actions once the internal are
installed in the pipe. With MT, you are
connecting components in shorter lengths
which are easier to identify and access if any
issues are noticed.

41
Technical Challenges
3: Construction of all externals prior to use

• The DPI method requires the mud system to be located

as close to the middle of the pipe string, this allows the
external utilities to reach the back of the pipe and have
enough travel for the pipe to reach the entry pit.

42
Technical Challenges
4: Foundation/Anchoring Design

• Typical MT/Pipe Jacking is subject to mainly horizontal loads due to the

relatively flat inclination, whereas DPI forces generate uplift, horizontal
loads, and downwards forces that need to be counteracted against.

• Sumas River crossing was situated on the old Sumas Prairie Lake bed
and had no significant soil strength from surface to 80 metres (262
feet) of depths. Blow counts from 0-18 per 300mm (12 inches) were
encountered at the entry pit where the foundation and Thruster unit
were setup. This caused the need to combine 36" x 18 metre helical
piles and driven sheet piles in order to generate the resistance needed
to hold the thruster in place.

• Combined thruster and clamp weight over 63,800 kgs (142,000 lbs) o
pump off.

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Technical Challenges
5: Insertion of 24" product pipe into 42"
casing

• Elected to pull the 24" pipe in utilizing an

HDD rig from the exit side.

• The 24" pipe required pipe spacers, several

3" HDPE tremie lines, 4 x 1/2" stainless
steel conduit for fibre optic cable for a leak
detection monitoring system.

44
Technical Challenges
6: Removal of the 42" casing

• In order to remove the 42" casing, we needed to fill the void between the
outside of the 24" line and the inside of the 42" casing, as well as allow for the
volume that the 42" casing wall thickness once the casing was removed to
maintain the integrity of the dikes on each side of the river.

• The DPI finish, to the casing pull had 10 days between the two, we advanced the
casing twice during this 10 day period to determine how the annular fluid was
holding up and to note the increase in forces required to move the 42" casing
compared to the final thrust forces of the tunnelling phase.

• Anchoring the 24" pipe. Due to the introduction of the slurry based void filling
material the forces imposed between the 24" pipe and the 42" casing were
higher than when inserting the 24" pipe dry. Drag of the 24" when dry, and
buoyant uplift forces when filled.

• A cleaning pig was attached to the back of the 24" product pipe in order to
ensure all of the void filling material was forced out of the open end thereby
filling the void as we removed the 42" casing.
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Technical Challenges
7: Extreme Heat

• During the installation process for the 42"

casing, the area experienced record
temperatures of 48°C or 118°F

• This caused the heat inside of the 42" to

climb well over 50°C, requiring the need to
wait until evening to enter the pipe for
maintenance. It also caused the mud
temperature to climb higher than normal
which reduced the effectiveness of the
hydraulic cooling slurry pipes behind the
MTBM.

46
Direct Pipe® Outlook

• Direct Pipe Installations are becoming more accepted by clients in Canada, and worldwide.
• Educating clients of the benefits of this trenchless installation method will help expand it into new markets.

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Go néirí an bóthar leat.
Good luck on your journey.
Research in Underground Risk
Source: Canadian Journal of Civil Engineering

Ariaratnam (2007) | Arizona State

• Studied the risks involved in the Horizontal Directional Drilling (HDD) and the
Open Cut (OC) excavation.
• Utilized the Total Risk Index Model (TRI) to calculate the risk value for
underground urban utility projects,
Ma et al. (2010) | China University of Geosciences
• Developed a model to quantify the risk of Maxi HDD projects
• Comprehensive Evaluation Method (FCEM) and Analytical Hierarchy
Process (AHP).
Gierczak (2014) | Clemson
• Focused on developing a model used for evaluating the safety risk of Mini,
Mid, Maxi HDD projects
• Fuzzy Fault Tree Analysis (FFTA) for risk assessment methodology mode.
Moganti (2016) | Clemson
• Developed a hierarchical safety risk assessment framework for
investigating the safety risks of HDD projects.

49
Risk and Design Considerations
Source: Ariaratnam (2007)

• Safety
• Soil Conditions
• Obstructions
• Site Access
• Project Details
• Client Specifications
• Existing Utilities
• Environmental Impact
• Restoration
• Project Specifications
• Costs
• Weather
• Traffic

50
Risk and Design Considerations
Top 5 Risks on Critical Crossings

Safety Concerns Insufficient Engineering

• Any issue regarding injury or illness as a result of field
• Insufficient geotechnical investigation
operations. • Improper planning, shortage of understanding site
Borehole Failure (HDD) specific constraints
• Collapse of borehole, damage to product pipe, ground • Lack of skilled engineering design
surface settlement • Incorrectly specified equipment
Hydraulic Fracture / Inadvertent Returns
• Negative environmental impact particularly in water
bodies.
• Stoppage of drilling / tunneling operations during
cleaning operations.
• Large Fines, Legal Fees and public opinion.
Damage to Adjacent Utilities
• Potential for explosion / fire
• Public Disruption
• Damage to utilities / structures

51
Risk and Design Considerations
Additional Parameters to Consider
• Safety
• Ground Settlement
• Differing Soil Conditions
• Gravels, Cobbles And Boulders
• Hydraulic Fracturing
• Inadvertent Returns
• Waterway Contamination
• Site Access
• Site Constraints
• Elevation Change
• Underground Utilities
• Site Considerations
• Crossing Distance
• Corrosivity
• Abrasively
• Contamination
• Groundwater Levels
• Artesian Pressures
• Dewatering Requirements
• Pipe Diameter
• Pipe Thickness
• Pipe Type
• Availability Of Water
• Injuries
• Fatigue
• Mental Health
• Equipment Breakdown
• Mislead Of Lasers
• Insufficient Torque
• Material Price Escalation
• Supply Chain Disruptions
• Skilled Labor Availability
• Increased Lead Times
• Increased Freight Costs
• Unpredictability Of Imported
Equipment And Material
• Acts Of God
• Extreme Cold Conditions
• Extreme Heat Conditions
• Protests
• Alluvial Soils With Very Low Blow-
counts
• Hard Rock With Hihg Unconfined
Compressive Strength
• Millennial Boulders
• Obstacles
• Corrosivity
• Abrasively
• Accuracy Limits / Line Of Grade
52
Direct, Indirect, and Social Costs of Underground Construction
Source: Ariaratnam (2007)

53
Method of Construction Selection
What we do

• Soil conditions
• Pipe material
• Pipe diameter
• Length
• Depth of cover
• Accuracy
• Marine requirements
• Fluid requirements
• Number of crossings
• Site constraints

So what is the most valuable solution ?

54
Trenchless Installation Methodology Risk Assessment
How do we decide which is the most appropriate methodology?

Objective is to understand and quantify the risk levels of

trenchless crossings project to facilitate, enhance and model
risk assessment.
• Analyze and identify the qualitative
risk level factor.
• Determine the significant factors
that contribute to the risk level prediction.
• Rank these factors using an
Analytic Hierarchy Process.
• Build an assessment based
on these factors.

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Trenchless Installation Methodology Risk Assessment

56
Trenchless Installation Methodology Risk Comparison

57
Trenchless Installation Methodology Cost Comparison
Risk vs. Reward

58
Trenchless Installation Methodology Cost Comparison
Risk vs. Reward

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