“Leidinginstallatie met Direct Pipe”

Software days June 16, Colloquium Deltares

Outline

• A-Hak/Drillcon • Direct Pipe principle and total package • Tunnel Boring Machine • Industry perceptions early on and now • Measurement & control • Jobsite setup • Engineering • References & Milestones • Advantages • Video • Conclusion

A.Hak Drillcon part of A.Hak Group Contractor focused on Trenchless installations Services Main or Sub-contractor Project engineering, consultancy, execution

Equipment & tooling HDD technology 16 rigs in total, 8 Maxi rigs Pulling force up to 500 tons

Direct pipe 500 ton unit

Micro tunneling 6 units Up to 3m in diameter

A.Hak Drillcon

Direct pipe principle

Compared to standard HDD & MT Make a pilot bore with a hole size large enough

to accommodate the final product using the product as the drill string.

Microtunneling drillhead technology Inventor Mr Rudi Koegler

Consultant for Drillcon

Total package

Pipe thruster

Powerpack

Steering/control cabin

Tunnel Boring Machine

Pipe Thruster

Pipe clamp Segmented with large contact

surface per segment Hydraulically engaged Vulcanized inserts to increase grip

and protect pipe coating Guide rollers to centralize product

pipe

Thrust/pull frame Anchored to the ground Connected to the pipe clamp frame

with two hydraulic cylinders Angle setting hydraulically

Capacity Pipe OD up to 60”/1524mm Thrust/Pull velocity up to 3m/min Setup angle 0 – 15 degrees

Tunnel Boring Machine

Modified Micro tunnel (TBM) based machine in front of the product pipe Dimensions

Length 19m Machine diameter 1295mm Cutter head diameter 1325mm

Power Pack for main drive

Telescopic Station

Power Pack for Telescopic Station

Conical Interface Ring

Cutting Head Pipeline

Cutting head – adapted to geology

Power pack

Steering cylinder of the active steering joint

Feed line

Slurry line AVN - Machine

AVN1000XB Direct Pipe

Tunnel Boring Machine

19m

Cutting head options

Cobbles

Coarse gravel

Medium gravel

Fine gravel

Coarse sand

Medium sand

Fine sand

Sandy, Silty clay

Silt

Clay

Rock

Cutting Head for Soft Soil

Cutting Head for

Mixed Soil

Rock Cutting Head

Tunnel Boring Machine

10

Mode of operation of the cutting tools and the cone crusher.

Handling of obstacles

Tunnel Boring Machine

Tunnel Boring Machine

• Steering control

• Radius < 600 m

Steering cylinders

Supply lines

FEED AND SLURRY LINE

ATTACHMENT OF CABLES, LUBRICATION AND WATER LEVEL

LINES AND AIR HOSES ON HOOKS.

RUBBER ROLLERS FOR THE EASY ASSEMBLY AND DISASSEMBLY

Industry perceptions

Presumed challenges Risk for pipe coating “shear/peel off” since

the thrust and or pullback forces are transferred through the coating

Technology similar with micro tunneling thus high expected installation forces limiting the length capabilities

Coating possibilities

Coatings successfully tested – Polyethylene (PE)

– Polypropylene (PP)

– Glass reinforced plastic GRP

– Fusion bounded epoxy (FBE)

– Concrete *With and without slippage

Friction & hole stability Stabilized hole

Hole is kept open mechanically Soil properties

Cohesive, non-cohesive Depth diameter ratio (arching effect)

Fluid properties in the annulus Filtercake and fluid pressure

Friction Collapsed/partly collapsed annulus

SKIN FRICTION Contact surface times skin friction coefficient

Stabilized/open annulus FRICTION

Down hole weight times friction coefficient

Control with friction reducing additives

Experience on various projects has proven that the expected installation forces are closer to HDD than to traditional micro

tunneling

(1-3Kpa/m² versus 7.5-10Kpa/m²)

Product

FiltercakeSoil/rock

Return fluidProduct

FiltercakeSoil/rock

Cuttings

Friction reduction

Bentonite lubrication in the annular

1. Lubrication nozzles in the

first machine cans

2. Lubrication ring at the end of the machine

3. Bentonite tank connected with the launch seal / overcut

overcut

Leak prevention

Launch seal Seals up to 1bar pressure

Measurement systems

Measuring wheel

Horizontal orientation: (cm)

via continuous gyro compass

Altitude reference device

Vertical orientation : (mm – cm)

via hydrostatic water leveling system

Water level hose

Altitude sensor I + II

Manual recorded parameters

Monitored parameters

Monitored parameters

Jobsite setup

Equipment spread at launching area

Single pipeline or multiple pipe sections Pipe rollers and overbend construction

Launch Area

Field preparation

Pipe pusher

Launch seal

Pipe string

Pipe support Rollers

Position On surface Overbend Ramp

Pipeline in sections

Insufficient space to lay of the pipeline in one single piece.

Saving of cables, supply lines & pumps.

Target side

Recovery of the direct pipe drilling head – Above ground – Below ground

Engineering • Total or detail and post

engineering – Profile

• Customer requirements • Underground type and

stratigraphy • Product properties

– Construction • Anchoring • Pipe string setup • Seepage avoidance (kwelweg)

– Equipment and tooling selection • Soil investigation • Mud pressure calculations • Thrust force calculation

– Pipe stresses assessment • Pre- and post installation

– Drill technical – As build

• Front pressures • Thrust force • Location

Profile Underground

Construction anchoring

Construction pipe strings

Construction seepage avoidance

Analysis following NEN method

Use of seal and clay box (similar with HDD)

Equipment & tooling Shield pressure calculation

Equipment & tooling Thrust force modeling

Equipment & tooling Thrust force modeling

1. Friction of the pipeline behind the thruster on the rollers.

2. Friction between pipeline and lubricant fluid.

3. Front force at the cutting head of the microtunneling machine

4. Friction between pipeline and the borehole wall.

5. Friction due to buckling of the pipe.

Pipe Stresses

• HDD – Tensile stress

• Pulling > Tension

– Bending stress • Proportional with radius

– Hoop stress • Higher external pressure

due to flow – Hole erosion

• Can be compensated by balancing

• Direct Pipe – Tensile stress

• Pushing > Compression

– Bending stress • Proportional with radius

– Hoop stress • Low external pressure

• No means for full fledge balancing

– Rotational stress • Less than one percent of

total stress

The product stresses considered for Direct Pipe are similar with the ones considered for HDD

Drill technical

TBM

• Cutting wheel selection – Driven by soil

type/conditions

• Shield pressure – Driven by depth, ground

and groundwater pressure

• Thrust force – Soil properties, cutting

wheel velocity and radius

As build shield pressure

As build Thrust force

System measurements

As build profile

– Part of the installation report:

Profile verification by means of gyroscope.

Executed by third party

References Direct Pipe

Direct Pipe®- Projects

No. Project Country Pipe -

Ø

Drilling

Length

(m)

Geologie Coating Construc. Company Cliënt Year

1. Rhine crossing in Worms Germany 48’’ 484 Sand, gravel, clay None Sonntag EWR 2007

2. Brine Outlet in Rysum Germany 48’’ 283 Sand, clay, stones,

wood PE Meyer & John EWR 2009

3. Pipeline Angerlo-Beuningen Netherlands 48’’ 382 Sand, gravel PP A.Hak Drillcon Gasunie 2010

4. Pipeline Angerlo-Beuningen Netherlands 48’’ 435 Sand, gravel, wood PP A.Hak Drillcon Gasunie 2010

5. Expans project Phase VII in Arcada Florida USA 30’’ 224 Sand, clay, coral, shell FBE REM Directional inc. Florida Gas

Transmission 2010

6. Hartelkanaal Crossing in the harbour of

Rotterdam Netherlands 48’’ 545 Sand, clay, wood PP A.Hak Drillcon Gasunie 2010

7. Pipeline Ommen-Angerlo. Crossing of

railline Netherlands 48’’ 518 Sand, gravel, loam PP A.Hak Drillcon Gasunie 2010

8. Pipeline Ommen-Angerlo. Crossing of

railline Netherlands 48’’ 540 Sand, gravel, loam PP A.Hak Drillcon Gasunie 2010/2011

9. Highway 39 keysville Road in Paint City USA 38’’ 119 Sand, clay, coral, Shell FBE REM Directional inc. Florida Gas

Transmission 2011

10. Collier Parkway Crossing in Land O lakes USA 38’’ 228 Sand, clay FBE REM Directional inc. Florida Gas

Transmission 2011

11. Pipeline Ommen- Esveld. Crossing in

Lochem Netherlands 48’’ 1.400 Sand, gravel, loam PP A.Hak Drillcon Gasunie 2011

12. Pipeline Poggio Renatica, Scolo Riolo

Crossing Italy 48’’ 394 Clay, sand PE ICOP spa. SNAM 2011

13. Pipeline Poggio Renatica, Desala Crossing Italy 48’’ 800 Clay PE ICOP spa. SNAM 2011

14. Pipeline Paggio Renatica, Desalo Crossing Italy 48’’ 372 Clay PE ICOP spa. SNAM 2011

15. Tiaga Conutry Extension, state highway

392, Crossing in Carning, New York USA 42’’ 130 Gravel, cobbles None Michael’s Directional inc. Empire pipeline 2011

16. Crossing the River “de Maas” Netherlands 48’’ 1.026 Gravel, clay, sand PP A.Hak Drillcon Gasunie 2012

17. La Somme France 48’’ 1.072 Chalk, Marl, Clay PP A.Hak Drillcon GRT Gaz 2013

References A.Hak Drillcon

Year Client Project Crossed object Length Pipeline material Ground condition

2010 Gasunie Angerlo – Beuningen Road 402m1 Steel 48” w.t.22,7mm Sand / gravel

2010 Gasunie Angerlo – Beuningen Existing gas pipelines 462m1 Steel 48” w.t. 18,7mm Sand / gravel

2010 Gasunie Gasrotonde Europoort Hartelkanaal 536m1 Steel 48” w.t.22,7mm Sand / clay

2010 Gasunie Ommen – Esveld Railroad Zwolle – Almelo Main road N35

546m1 Steel 48” w.t.22,7mm Sand / clay

2010 Gasunie Ommen – Esveld Railroad Deventer - Almelo 570m1 Steel 48” w.t.22,7mm Sand / gravel

2011 Gasunie Ommen – Esveld Agricultural land, roads and existing pipelines

1.400m1 Steel 48” w.t.15,9mm

Sand

2012 Gasunie Odiliapeel – Melick De Maas Railroad Venlo – Roermond Main road N271

1.026m1 Steel 48” w.t.22,7mm

Sand / clay / gravel

2013 GRT Gaz Hauts de France II Agricultural land, road and La Somme

1.072m1 Steel 48” w.t.28,2mm

Gravel / clay / marl

2014 Gasunie Beverwijk - Wijngaarden Main road N201 Parking place Suspicious area of explosives

582m1 Steel 48” w.t.22,7mm

Sand / clay / salty groundwater

Milestones

World record

45

Length: 1.400 m in total

Pipe sections: 3 x 500 m

Construction Company: A.Hak Drillcon.

Client: N.V. Nederlandse Gasunie

(Dutch Gas supplier).

Geology: sand, small gravel and loam.

Gas Pipeline - Ø 48“ (1.220 mm).

Coating: Polypropylene PP.

Double pipe pusher setup

Maximum advance rate:

120 m in single shift of 12 hours

= 10 m/h.

230 m in one day (19.03.2011)

Setup of the second Pipe thruster

Advantages of the Direct Pipe method

• Hole is cased during drilling • Usable for any geological condition (e.g. : gravel)

Pullback option of the whole pipeline & machine Single-phase mode of operation Access from only one side → ideal for outfalls Start and exit point on or below surface No coupling time necessary (drill rods), continuous

process Smaller borehole diameter comparatively to HDD Low bentonite usage & pressures Static pressure in the annulus High velocity fluid isolated from the formation

Awards

Winner of the ISTT NO DIG AWARD 2008 at the NO DIG 2008 in Moscow

Top 5 nominee for the HERMES AWARD 2008 at Hanover Fair.

Winner of the technology award at the 2009 Iploca convention in San Francisco, USA

Winner of the NSTT NO DIG AWARD 2010 in the Netherlands.

Video

Conclusion

• Direct Pipe is globally recognized as the preferred trenchless installation method for:

– Bores in unstable/sensitive (e.g. coarse) formations

– Projects with limited exit space.

• Direct pipe combines the advantages of micro tunneling and HDD with low expected thrust forces

• Products up to 60”/1500mm can be installed over distances up to 1500m

The information contained in the presentation is based on widely accepted theories; calculations and practices, conditions may vary and information in the

presentation is to be used as a guideline only, no liability is assumed through the use of the theories; calculations and practices.