Challenges of Large Diameter Horizontal Directional Drills

In the past two decades, the Hillsborough County Water Resource Service Department (HCWRS) has been actively expanding its reclaimed water system in the south-central service area, both as an effluent disposal method and as a potable water saving mechanism. Currently the HCWRS reclaimed water customer base is comprised of golf course users, industrial users, commercial and residential customers. To meet increasing demands in the south-central service area and pressure requirements during the peak hours, HCWRS has identified the need for additional Reclaimed Water Transmission Main (RWTM) capacity along Lithia Pinecrest Road and Bloomingdale Avenue. To serve high demands of the fast growing communities in Hillsborough County, Florida, HCWRS is challenged with designing new transmission mains within highly congested and restricted right-of-way. For each project the Water Department designers must be conscious of the impact of surface disruption and the associated socio-economic costs to the general public, as well as the projects' overall cost. The design for the 24 in. (610mm) transmission main in Lithia-Pinecrest Road, a two-lane thoroughfare, was no different. This project was complicated by the volume of traffic in combination with portions of the alignment transitioning through a very congested right of way. The line begins at the intersection of Lithia Pinecrest Road and Bloomingdale Avenue, an east-west arterial highway and proceeds in a southeasterly direction for approximately 12,500 ft. (3.6 km) on an alignment that takes it past schools, businesses, and residential areas, and terminates at the entrance to River Hills Country Club. After a thorough analysis of the route studies and cost of open-cut construction versus horizontal directional drilling (HDD) methods, HCWRS project management chose to install the line using both open-cut and HDD construction methods. The 6,000 ft. (1.8 km) of water line installed by HDD construction would be a series of seven separate pulls using 24 in. (610 mm) flexible restrained joint ductile iron pipe manufactured by American Ductile Iron Pipe in 20 ft. (6.1 m) joint lengths. This paper will discuss in detail the comparison of the costs of the different routes and the two (2) methods of construction. It will then detail that portion of the line installed using HDD technology and address the flexible restrained joint ductile iron pipe and how using the cartridge method minimized disruption to the general public.

Design and feasibility analysis of a fluidic jet oscillator with application to horizontal directional well drilling

Horizontal directional drilling (HDD) was used to complete two very difficult portions of pipeline construction and installation for the Port of Portland (Port) Portland International Airport (PDX) Deicing Collection and Treatment System Enhancement Project in Portland, Oregon. The PDX Deicing Project added surface runoff treatment to the existing deicing system at the Portland Airport. The project consisted of more than 8 miles of piping on Port-governed property. HDD was selected for two of the most difficult areas of pipeline construction which included a new outfall into the Columbia River and a significant active airfield crossing. The Columbia River outfall HDD installation presented several unique challenges. The installation included 1,100 feet of 30 inch polyethylene pipe. The HDD rig and boring operation was land-based while the pipe was installed using water-based floatation and insertion. Other challenges included tight in-water environmental constraints on construction techniques, activity on protected water with endangered species, crossing of an Army Corps of Engineers levee, and the need for underwater construction. The active airfield HDD installation crossed active runways, taxiways, and ramp areas, and presented several unique challenges. The installation included a 24 inch and 6 inch fusible polyvinylchloride pipe dual insertion, installed in a single 3,800 foot bore. This installation also had tight environmental challenges regarding fusion and layout areas, a significant depth of bore required under working runway and taxiway crossings, and consideration of Transportation Security Administration airfield security requirements. This paper will detail the design and construction efforts associated with both of these HDD installations and the lessons learned from both of these very challenging yet different uses of HDD methodology.

From October 2002 to April 2004, data were collected from Dallas/Fort Worth (DFW) International Airport (TX, USA) outfalls and receiving waters (Trigg Lake and Big Bear Creek) to document the magnitude and potential effects of aircraft deicer and anti-icer fluid (ADAF) runoff on water quality. Glycol concentrations at outfalls ranged from less than 18 to 23,800 mg/L, whereas concentrations in Big Bear Creek were less because of dilution, dispersion, and degradation, ranging from less than 18 to 230 mg/L. Annual loading results indicate that 10 and 35% of what was applied to aircraft was discharged to Big Bear Creek in 2003 and 2004, respectively. Glycol that entered Trigg Lake was diluted and degraded before reaching the lake outlet. Dissolved oxygen (DO) concentrations at airport outfalls sometimes were low (<2.0 mg/L) but typical of what was measured in an urban reference stream. In comparison, the DO concentration at Trigg Lake monitoring sites was consistently greater than 5.5 mg/L during the monitoring period, probably because of the installation of aerators in the lake by DFW personnel. The DO concentration in Big Bear Creek was very similar at sites upstream and downstream of airport influence (>5.0 mg/L).

The Runway Incursion Prevention System (RIPS) program is an ongoing National Aeronautics and Space Administration (NASA) research effort intended to reduce the number of runway incursions at airports throughout the National Airspace System (NAS). The RIPS program flight tests and demonstration of technologies activities at the Dallas/Fort Worth (DFW) International Airport were completed in October 2000. The demonstration involved the application of both airborne and ground based technologies, as well as the integration of these technologies to form a complete runway incursion prevention system. This paper presents information on the research activities conducted at DFW related to the Ohio University Avionics Engineering Center (AEC) installed Global Positioning System (GPS) Local Area Augmentation System (LAAS) ground facility (LGF), it's use, the preliminary results obtained, and observations or conclusions when appropriate. A description of the RTCA DO-247 Surveillance and Guidance Sensor requirements is provided. Details of the DFW LAAS upgrade for NASA RIPS testing, AEC GPS LAAS test van equipage, and the Rockwell Collins Multimode LAAS receiver integration activities are presented. Data analysis activities have just been initiated.

This paper presents the design and execution of a complex river crossing project involving the microtunnelling installation of three hydrocarbon pipelines—16" NB, 14" NB, and 8" NB—beneath the Raidak-II River in the geologically intricate Dooars region of Eastern India. These hydrocarbon transportation pipelines own and operated by two National Oil companies viz. Oil India Limited and Indian Oil Corporation limited are critical to energy transportation in the region, with two of them operational for over seven decades. The project was initiated by Oil India Limited as part of a phased conversion of overground pipelines—previously suspended from railway bridges—to underground installations for enhanced safety and reliability. The project involved 5 no. of Microtunnelling in total at different river locations. The Dooars region, located at the foothills of the Eastern Himalayas and characterized by rolling plains, dense forests, and dynamic river systems, posed significant engineering and environmental challenges. While Horizontal Directional Drilling (HDD) and open- cut methods were employed in most locations for pipeline crossing along the route, geotechnical investigations revealed that HDD was unsuitable at certain sites due to subsurface conditions dominated by boulders, cobbles, and pebbles. Consequently, microtunnelling was adopted as an alternative solution. The project demanded meticulous planning, advanced hydrological and geotechnical assessments, and the use of innovative engineering techniques. Structural modelling using STAAD.Pro and ANSYS played a pivotal role in optimizing the tunnel and support system design, ensuring structural integrity and minimizing risk. A unique aspect of the project was the simultaneous installation of three pipelines within a single RCC casing, offering a cost-effective and space-efficient solution for bunched pipeline crossings beneath major water bodies. This paper details the design methodology, execution strategy, and site-specific engineering solutions adopted to overcome challenges such as pipeline alignment, shaft sinking in boulder-rich soils, spatial constraints for welding, and environmental disruptions. The successful completion of this microtunnelling operation underscores the viability of bundled pipeline installations in complex terrains and contributes valuable insights for future infrastructure projects in similar geographies.

Currently, the constant growth in the volume of the horizontal directional drilling procedure dictates the improvement of the drilling technology and the technical requirements. One of the important technical requirements for the horizontal directional drilling device is the transmission of information about drilling parameters to the operator (depth, rotation angle, inclination angle). The solution to this problem is possible with the help of measuring systems installed inside the drilling head. Traditionally, in real drilling conditions, three communication channels are distinguished: electrically conductive, hydraulic and electromagnetic, each of which has some advantages and disadvantages. The use of acoustic waves excited in the internal space of the drilling head and propagating in the material of the drilling column to the receiver allows to eliminate the disadvantages of the listed communication channels and ensure the highest quality horizontal directional drilling procedure. The paper investigates the acoustic method of information transmission in a horizontal directional drilling device. An acoustic system for positioning a drilling tool has been developed, which provides the transmission of information about the coordinates of the drilling head. The acoustic channel of information transmission has been studied in terms of constructing its structural components: the design of the probe-transmitter (electromechanical transducer) has been developed, as well as the hardware of the system. In order to determine the requirements for the modulator-demodulator of signals of an acoustic information transmission channel, the propagation of an information package was simulated taking into account the resonant properties of the converter using the Multisim circuit simulation program. Thus, the use of an acoustic system for monitoring and transmitting information about the positioning of the drilling head makes it possible to abandon expensive contact methods for determining the position of the drilling head, which give point information and require a lot of time. The proposed acoustic information transmission channel allows for tight acoustic contact between the protective container and the drilling column to eliminate power losses, increases the efficiency of the device and reduces the loss of a useful signal during its propagation and also simplifies the operation of the device. As a result, the developed acoustic system provides an opportunity to perform the highest-quality horizontal directional drilling procedure with the necessary requirements for the volume of transmitted information and stability of operation in complex noise-signal conditions, which eliminates the disadvantages of previously used methods.

Directional boring commonly known as Horizontal Directional Drilling (HDD) is a technique widely employed in landfall areas. HDD provides advantages of crossing considerable lengths with local soil disturbance and low environmental impact, which has contributed to turn it into one of the preferred techniques between various authorities. In despite of these advantages, the corrosion protection of the HDD is complex due to the unfeasibility of installation of sacrificial anodes distributed uniformly along the HDD, which would require a remote protection engineering solution as an alternative. The remote solution adopted, the level of coating damage on the pipeline after the installation, the corrosiveness and resistivity of the surrounding environment, in particular when very different environments encounter, i.e. sea-sand-rock, are major uncertainties that must be considered on the design. In addition, the lack of recommendation on international standards and the difficulties involved with the direct inspection of the pipeline section inside the HDD increases the robustness required for the design and its verification. This paper presents the corrosion protection system of a gas line section inside a HDD in a landfall area, describing the combination of pipeline coating and cathodic protection systems both specified to resist the service life of the pipeline. After a brief review of published works related to this subject, this paper will focus on the coating and cathodic protection design presenting not only the premises, design data and methodology adopted, but also associated results and installation issues. Computing modeling and recommended practices are used to identify the best and the most feasible solution. Finally, conclusions and recommendations will be presented in order to support future projects with similar challenges.

The Miami International Airport (MIA) sanitary system discharges into the Miami-Dade Water and Sewer system, via an existing 20 C.I. Force Main located on NW 21st Street, which was built in 1964. On January 25th, 2010, this main trunk line failed and sewage started to surface on the MIA access ramps. In an emergency meeting between the MIA and M-D WASD, it was agreed to replace the existing force main with a new 20 HDPE Pipe that would be installed as an emergency via Horizontal Directional Drilling (HDD) to avoid complications and possible MIA down time. Challenges faced by this project include calculating the proper alignment, radius of curvature, and entrance and exit angles of the new pipeline to provide sufficient vertical and horizontal clearances from high mast light poles, overhead electric poles, drainage structures and existing utilities, in addition to facilitating a clear path for directional drilling below the foundations of Ramps K, I, and L servicing the Miami Intermodal Center. The well executed design in close coordination with the Contractor of the emergency operation allowed construction to take place within a week's time, with no major setbacks. The scope of this project was the design and construction of a 20-in force main (800 LF) using High Density Polyethylene Pipe (HDEP) that was installed by Horizontal Directional Drilling (HDD) to replace a failed section of an existing 20-inch diameter force main that serves the Miami International Airport (MIA). The HDD process begins with boring a small, horizontal hole (pilot hole) under the crossing obstacle (i.e. a highway) with a continuous string of steel drill rod. When the bore head and rod emerge on the opposite side of the crossing, a special cutter, called a back reamer, is attached and pulled back through the pilot hole. The reamer bores out the pilot hole so that the pipe can be pulled through. The pipe is usually pulled through from the side of the crossing opposite the drill rig. Proper selection of pipe involves consideration not only of installation design factors such as pull-back force limits and collapse resistance, but also of the long-term performance of the pipe once installed in the bore-hole.

One of the most commonly used piping materials for transport of water and wastewater in the United States is ductile iron pipe (DIP). Although this piping normally is installed using open trench cuts, a trenchless installation method that is finding increased popularity for DIP is horizontal directional drilling (HDD). Many HDD installations utilize specialized drilling fluids, commonly called “drilling muds,” which may be composed of bentonite clay, various organic and inorganic additives, polymers, lubricants, wetting agents, or polymers mixed with water (or any combination thereof). To evaluate the corrosion characteristics of these fluids in contact with DIP, a 1-year corrosion study involving more than 200 ductile iron pipe specimens was conducted comparing five commercially available directional drilling fluids. Corrosion tests were conducted using electrochemical test methods described in ASTM G59, Standard Test Method for Conducting Potentiodynamic Polarization Resistance Measurements, ASTM G102, Standard Practice for Calculation of Corrosion Rates and Related Information from Electrochemical Measurements, and ASTM G106, Standard Practice for Verification of Algorithm and Equipment for Electrochemical Impedance Measurements, and these results were compared to 1-year weight loss test results obtained using ASTM G162, Standard Practice for Conducting and Evaluating Laboratory Corrosions Tests in Soils. This paper discusses which electrochemical test method and method of analysis gave results closest to those obtained with ASTM G162 weight loss evaluation.

Portable X-ray fluorescence (pXRF) spectrometer allows fast in-situ elemental determination without wet digestion for soils or geological materials, but the use of XRF on wet materials is not well documented. Our objective was to develop a rapid field method using pXRF to measure metals in the residues from horizontal directional drilling (HDD) operations so that proper disposal decisions can be made in-situ. To establish the procedure, we spiked soil samples with 4 concentrations of Cr, Ni, Cu, Zn, As, Cd, and Pb up to 1000 mg kg−1, and then the metal concentrations were determined by wet chemical method after drying and acid digestion (standard method), and by pXRF, also at laboratory conditions, after drying and at two different moisture conditions. The measurements by pXRF and standard method after drying and after removal of excess water (AREW) were highly correlated with slopes ranging from 0.83 ± 0.01 to 1.08 ± 0.01 (P < 0.001) for all metals. The relationship was better AREW than the saturated paste without removal of excess water and the moisture content affected only the accuracy of As, Cd, and Pb. The procedure established was successfully used for HDD residues collected from 26 states of US with moisture content ranging from 14 to 83% AREW. The pXRF was proven to be a reliable tool for fast detection of common metals in dried soils and HDD residues, and samples containing < 30% moisture content without needing to correct for moisture. If the moisture is > 30%, excess water in samples need to be removed with a commercially available filter press to achieve high accuracy. The developed procedures reduce time of metal detection from days to about an hour which allows drilling operators to make quick decisions on soil or HDD disposal.

In 2009, China surpassed the United States to become the largest global energy consumer. By 2013, coal, crude oil, and natural gas combined represented more than 90% of this consumption, and it is estimated that China's energy consumption needs will more than double by the year 2040. This projection highlights China's growing challenge to safely and efficiently supply energy resources across the country. This effort will include new supplies to areas with developing rural populations and increased supplies to rapidly growing urban areas. Buried pipeline has become the selected method of transmission, as pipelines are more cost effective, more sustainable, and more efficient than the construction and operation of aboveground railway or long-haul trucking. To meet the demand, the Chinese government has implemented massive buried pipeline construction initiatives, allowing China to become the fastest growing country in trenchless technology construction methods. Horizontal directional drilling (HDD) has played a particularly critical role in executing large-scale pipeline construction by providing an economical, timely, and environmentally responsible method to bypass challenges along the path of the pipelines. Thus, Chinese HDD contractors have played a critical role in the overall development of China's buried energy infrastructure. Understanding this role would be of great value to the global trenchless technology community. Developing countries would benefit from the Chinese advancements for large-scale HDD installation. In developed areas, such as North America, studying Chinese execution may allow for new ideas to help to improve long-established HDD best practices.

People living in cities and rural areas within one hundred mile radius from large international airports such as Dallas/Fort Worth International Airport (DFW), O'Hare International Airport (ORD), and Houston Intercontinental Airport (IAH) rely on their personal car, a taxi or shuttle bus to get to access those airports for travel to long-haul domestic or international destinations. Recently airlines have cut down on the frequency of operations or reduced their flights from regional airports. In some cases they have totally eliminated unprofitable flights to major hubs. Due to these changes in air service, residents up to 250 miles away from the major hub airports may no longer have a viable air link to the hub airports and may need to rely on ground service. This research details, whether a convenient, affordable and comfortable air service is viable for a specialized short-haul air service connecting the regional airports with a major hub airport. The analysis presents population forecasts for the counties and cities and air travel demand forecasts for the airports. Historical air carrier operations, number of arrival and departure seats, past air fare data for each of the regional airports is obtained from the FAA data base and Bureau of Transportation Statistics (BTS). In addition, fuel price, parking rates, landing fees are included in the analysis. The selected regional airports are; Abilene Regional Airport (ABI), East Texas Regional Airport (GGG), San Angelo Regional Airport (SJT), Tyler Pounds Regional Airport (TYR), Waco Regional Airport (ACT) and Wichita Falls Municipal Airport (SPS). The proposed short-haul scheduled flights from these airports to DFW are enumerated for cost evaluation and sustainability. Eight different turboprop aircraft with 6 to 80 seats are considered in this study and the results prove that this short-haul air service is feasible and a profitable venture to operate as a no frills, Low Cost Air Carrier Service (LCAC).

As part of the Devil Creek Development Project, Apache successfully used horizontal directional drilling (HDD) with a delayed break out as the installation method for the shoreline crossing of a new gas pipeline at Gnoorea Point, 45 km southwest of Dampier, Western Australia to achieve excellent environmental and social outcomes. Technical, environmental and community engagement challenges included an HDD reach distance of 1.85 km, a delayed break out technique, hard complex and variable geological strata, the HDD exit point in shallow water (6 m) and surrounded by benthic habitats consisting of corals, seagrass and macroalgae within a Marine Conservation Reserve, stringent regulatory requirements and the onshore drilling location directly adjacent to a heavily used camping area and a public boat ramp with adjacent beach.

a hydraulic hammer with fluidic actuator was manufactured and applied to directional drilling due to the low penetration rate, long construction period and high drilling cost occurred during the operation of horizontal directional drilling in complicated formations, such as hard, fractured and cavy stratum. On the basis of hydraulic percussion rotary drilling technology, the hydraulic hammer has been innovatively designed and applied to trenchless drilling with horizontal directional wells, which is actuated and controlled by a fluidic amplifier. In addition, the actuator was tested in field by various pumped mud with different flow rates. Test results have implied that structure design of the whole drilling tools is qualified, and the pressure loss of fluidic actuator is permissible, which is suitable for the horizontal directional drilling of trenchless engineering project. Therefore, the original design of hydraulic hammer with fluidic actuator has solved the technical problem on horizontal directional drilling in complicated stratum, which has an excellent application value and promoted potential.