|
A Directional Drilled Crossing of the Saskatchewan River
Rod Karius, P.Eng., Associated Engineering
Edmonton, Alberta
Contact: kariusr@ae.ca
ABSTRACT
From a global perspective, directional drilling is not a
new construction technique. It was adapted in the early
1970s from oil well drilling technology. Initially, its
use was limited to steel pipeline construction in the petroleum
industry for crossing under natural and manmade obstacles
such as rivers and highways. In the 1980's, the technology
was applied to water transmission lines and sewage forcemains.
Today, directional drilling is used not only for the installation
of pipelines but also electrical and communication cables.
Installations have been as large as 1200 mm
in diameter with distances exceeding several thousand metres.
In contrast to the apparent broad usage of directional drilling,
the application of this technology to water and wastewater
pipeline installations in western Canada is still relatively
rare. In researching the use of horizontal directional drilling
for the installation of a polyethylene sewage forcemain
across the Saskatchewan River at Nipawin, Saskatchewan,
no other installations of similar pipe material or diameter
were found in western Canada.
This paper has been prepared to document the
case history of the directional drilled river crossing at
Nipawin. The project is noteworthy in terms of the size
of pipe installed (large for polyethylene), length of the
crossing, depth of the river valley and variability of the
soils encountered. The paper provides a comparison of the
costs and environmental impacts for both conventional open
cut and directional drilled crossings. Also presented, is
a review of the technical considerations that apply to the
design of a directional drilled crossing as well as the
contractor's proposed and actual methods of dealing with
the technical challenges presented by this particular crossing.
THE
PROJECT
As a result of changes in provincial regulations
governing sewage treatment, the Town of Nipawin was required
to upgrade it's sewage treatment facility. Also affected
were a number of smaller nearby communities, cottage subdivisions
and a canola processing plant. This lead to the development
of a new regional sewage treatment facility. Click
here to view Figure 1 in a new window.
Construction of the new facility was carried
out under a number of contracts, one of which covered the
installation of sewage forcemains. The largest component
of the forcemains contract was the 400 mm diameter, 3060
m pipeline connecting a new sewage pumping station at the
Town of Nipawin to the new treatment facility; consisting
of a four cell, 60 ha facultative lagoon. Click
here to view Figure 2 in a new window.
THE
SASKATCHEWAN RIVER CROSSING
It was recognized early in the design process that the Saskatchewan
River would be a major obstacle in the construction of the
forcemain. The river valley is 40 m deep and 500 m wide
with steep side slopes containing loose deltaic sands overlaying
highly variable glacial till deposits. Click
here to view Figure 3 in a new window. Water levels
fluctuate between two and six metres in depth because of
hydroelectric generating stations operating upstream and
downstream of the crossing location. Finally, and perhaps
most importantly to the Town, the River is a major recreation
facility and significant generator of tourism revenue.
Directional drilling was the first construction
method to be examined as it had the apparent advantage over
conventional open-cut construction of avoiding the problems
associated with working in the river valley. However, the
initial findings were disappointing. Because of the depth
of the river valley and limitations on the entry and exit
angles, the total drilling distance was going to be twice
the width of the river valley. This would place the entry
and exist points too far away from the pipelines proposed
right-of-way. In addition, the cost appeared to be about
twice that of an open-cut crossing.
Engineering work proceeded into the detailed
design stage on the basis of a conventional open-cut crossing.
Polyethylene was selected for the pipe material. Details
were developed to deal with river bank erosion and concrete
ballast was sized for the submerged section of the pipeline.
Protection of the submerged pipeline during
flood events proved to be an obstacle that would in the
end raise the cost for open-cut construction and bring it
into the same order of magnitude as directional drilling.
The flood frequency selected for design was a 1:100 year
return period. This yielded a flow of 6400 m3/s
and a velocity of 2.2 m/s. Scour at this velocity would
extend through the sandy river alluvium to the till formation
below, requiring the pipe to be placed on the surface of
the till layer and covered with a scour protection apron,
or to be placed into the till layer with a minimum cover
depth of one metre. The latter option was carried through
into final design.
The necessity to excavate into the till layer
was likely going to require unconventional methods and/or
heavy marine excavating equipment. Recognizing this and
its cost implications, it was decided to revisit the directional
drilling alternative. However there was insufficient time
remaining in the schedule to complete a detailed design
for this approach. The project went to tender on the basis
of a conventional open-cut river crossing with provision
for directional drilling to be submitted as an alternative
bid item.
Five bids were received; three were based
on an open-cut crossing while two of the bidders provided
prices for the directional drilling alternative. A comparison
of the pricing for the bid items pertaining to the two crossing
methods is provided in Table 1.
TABLE 1
|
BID COMPARISON OF CROSSING ALTERNATIVES
|
|
Bid Items
|
Quantity
|
Bid #1
(Open-cut)
|
Bid #2
(Drilled)
|
Bid #3
(Drilled)
|
Bid #4
(Open-cut)
|
Bid #5
(Open-cut)
|
| Trenching |
205 m |
$28,120 |
- |
- |
$66,500 |
$47,500 |
| Trench Dams |
10 |
18,000 |
- |
- |
40,000 |
20,000 |
| Sodding |
5,680 m2 |
11,360 |
- |
- |
18,460 |
56,800 |
| Marine Excavation |
375 m |
621,375 |
- |
- |
469,125 |
1,639,875 |
| Concrete Ballast |
255 |
35,700 |
- |
- |
140,250 |
63,750 |
| Directional Drilling |
580 m |
- |
776,250 |
750,000 |
- |
- |
| Pipe: 450 mm DR11 |
580 m |
70,128 |
84,680 |
258,100 |
132,775 |
171,500 |
| TOTAL PRICE |
|
$784,683 |
$860,930 |
$1,008,100 |
$867,110 |
$1,999,425 |
The lowest directional drilling bid came in
at a relatively small premium of only 10% over the lowest
open-cut bid. This was considered to be a reasonable price
to pay for the environmental benefits gained in not having
to disrupt aquatic and recreational activities on the River.
It also eliminated disturbance of the River valley's steep
side slopes. Based on these benefits, the project was awarded
to Bidder #2 for construction of the river crossing by directional
drilling.
DIRECTIONAL DRILLING: TECHNICAL CONSIDERATIONS
If time would have permitted detailed design of the directional
drilling alternate to be carried out, a series of technical
considerations would have been addressed to establish performance
specifications for the pipe and its installation. However
the situation was now reversed. The pipe was already specified
and the contractor was in control of the construction details.
In order to deal with this situation, the contract award
was made conditional on certain technical considerations
being satisfactorily addressed by the contractor.
The contractor was requested to provide information
on the entire directional drilling concept and to specifically
address the following seven components:
- Drilling and pipe installation process
- Right-of-way requirements
- Geotechnical considerations
- Impact on specified product pipe
- Pulling head design
- Testing and commissioning procedure
- Contractual issues.
Excerpts from the contractor's submissions
are outlined below to highlight the unique aspects of this
project and to contrast with some of the actual events and
difficulties that occurred during construction.
Drilling and Pipe Installation Process
(Contractor's Plan)
The contractor proposed to set up the drilling rig on the
east bank of the River and increase the 12_ optimum entry
angle into the 17_ to 20_ range. The rig could then be placed
as close as possible to the River to minimize the drilling
distance. However, this steep angle would be at the rig's
upper limit, increasing the risk of mechanical and safety
problems. The borehole would then follow the contour of
the river bottom with a minimum cover of 6 m at its shallowest
point and exit at an 8_ angle onto the west bank resulting
in a total crossing distance of 568 m.
The drilling operation would take place in
several stages (Click
here to view Figure 4 in a new window), the first being
the pilot hole. The contractor proposed to drill the pilot
hole with a 250 mm diameter bit attached to a 165 mm mud
motor. The pilot drilling would be followed by two reaming
operations at diameters of 450 mm and 600 mm. The reaming
tools would be the tri-cone type in order to cut through
any rocks and boulders that might be encountered. Concurrent
with the drilling operation, the poly pipe would be assembled
on the west side of the River. The entire length of the
crossing pipe had to be fused into a continuous section
and tested. Immediately following the final reaming operation,
the entire length of the polyethylene pipe for the crossing
would be pulled into the borehole on the west bank and under
the river, exiting at the drilling rig on the east bank.
The total directional drilling operation from
mobilization through to installation of the pipe was to
take no more than four weeks during the period between mid
April and mid May, 1995. The duration of specific activities
was anticipated to be as follows:
- pilot borehole: 4 to 5 days
- first reaming operation: 3 to 4 days
- second reaming operation: 3 to 4 days
- pipe pull operation: 8 to 20 hours
Right-of-Way Requirements
On the east side of the River, the contractor identified
the need for a 20 m x 40 m working area for the drilling
rig and support equipment. The working area had to accommodate
a large drilling fluid tank, skid mounted power plant, control
cab, two flatbed trailers containing the drilling pipes
plus laydown areas for bagged bentonite, drilling head assemblies
and other accessories. The drilling rig also needed access
to a continuous supply of water.
At the exist end on the west bank, a smaller
working area was needed immediately adjacent to the borehole
for a backhoe and loader to assist in the movement of the
pipe during installation. Of more significance was the area
needed to string, fuse and test the pipe. Ideally, in order
to minimize drag forces, the alignment for this area should
be a straight line continuation of the borehole. In addition,
the ground should be vegetated or if stripped, the soil
should be free of stones.
Geotechnical Considerations
The contractor's knowledge of the subsurface soil conditions
and the tools employed to deal with these conditions are
the most important factors in how successful the directional
drilling operation will be. Ideally, test holes should be
drilled along the crossing alignment to establish a profile
of the soils and their properties.
On this project, the contractor elected to
make use of existing geotechnical information without doing
any exploratory testing of his own. The information made
available to the contractor was compiled previously during
studies of proposed locations for a hydroelectric generating
station that was eventually constructed approximately 4
kms upstream of the crossing location. The information was
in the form of drill hole logs and interpretive geologic
profiles. However, none of this information was specific
to the crossing site and it gave no indication of the extent
to which rocks and boulders could be encountered in the
till formations.
Impact on Specified Product Pipe
Under normal circumstances, the specifications for pipe
material to be installed by directional drilling would be
determined through an analysis of the following operational
and installation conditions:
- internal operating pressure;
- external pressure;
- differential pressure during installation;
- buoyancy pressure;
- axial binding stresses;
- thermal stresses and strains;
- dynamic stresses;
- tension stresses.
In this case, however, the pipe diameter and wall thickness
had already been set during design of the open cut installation.
Fortunately, the original design had called for the wall
thickness of the river crossing section of the pipeline
to be increased from DR21 to DR11 in order to accommodate
the higher operating pressure at the low elevation in the
river channel and in consideration of the rough handling
the pipe was expected to receive during the open cut installation
process.
Theoretical analysis of the anticipated pressures
and stresses, as well as input from the pipe manufacturer,
resolved all concerns except two: differential pressure
during installation and tension stresses. Differential pressure
posed a problem because of the 500 to 550 kPa hydrostatic
pressure that would be exerted externally by the drilling
fluid and the absence of any compensating internal pressure
based on the contractor's proposed "dry" installation. The
calculated differential pressure exceeded the pipes critical
external collapse pressure based on the estimated 8 to 20
hours it would take to complete the pull, open the head
end and pump water into the pipe to equalize the pressure.
The other concern, tension stresses, resulted from the 75,000
kg pulling capacity of the drilling rig as compared to the
40,000 kg maximum permissable pulling force on the DR11
pipe. The potential existed for the rig operator to tear
the pipe apart during the pulling operation.
Of the two outstanding concerns, the pipe
collapse possibility was the most serious and difficult
to deal with. The pipe separation issue could easily be
addressed through close observation of the rig's pulling
forces by monitoring instrumentation located on the rig
operator's control console. The pipe collapse issue required
a major change in the contractor's installation procedure.
The pipe pulling process would have to change from a "dry"
to a "wet" installation.
Three "wet" installation options were considered.
The first was to have the pipe filled with water prior to
the pulling operation. This was rejected on the basis of
the additional weight the rig would have to pull which would
increase the risk of the pipe being pulled apart.
The second option was to add water during
the pulling operation only in sufficient quantity to fill
the section of pipe at the low elevation in the river channel.
This option had a complication however. A vacuum condition
in the head end of the pipe would occur when the pipe started
its climb up the east bank. This could have been overcome
by stringing a small diameter, thick walled pipe through
the entire length of the product line to allow air to enter
the head end of the forcemain. The contractor rejected this
approach on the basis of cost and complexity.
The third option was to use a perforated pulling
head that would permit drilling fluid to enter the product
pipe as it was being pulled through the borehole. This option
was the simplest and least costly but it did have a margin
of risk in that the perforations could become plugged with
borehole cuttings. However, the contractor assessed this
option as having the least risk and selected the perforated
pulling head as the preferred means to facilitate a "wet"
installation.
Pulling Head Design
The pulling head is the tail end piece of a connection that
couples the drill stem to the product pipe. Other components
in this assembly include a barrel reamer, swivel and shackles.
The pulling head is generally custom built
for each crossing to suit the diameter and DR of the product
pipe as well as the anticipated pulling stresses. The pulling
head is fabricated out of steel and is cylindrical in shape
for insertion into the product pipe. Bolts connect the pulling
head to the pipe.
The number of bolts and their spacing is critical.
An insufficient number of bolts will result in shear failure
under the load imposed during the pipe pull. Too many bolts
or too close of a spacing and the product pipe will tear
apart under load.
A further consideration was introduced with
the need to have openings in the pulling head for the "wet"
installation. This would require reinforcing to be added
between the openings to strengthen the pulling head.
Testing and Commissioning Procedure
Before the drilling rig would be permitted to leave the
site, the contractor would have to demonstrate through testing
that the pipe had been installed satisfactorily. Three tests
were agreed to. The first being a leakage test of the fused
pipeline prior to installation. The second being a leakage
test after installation, and the third being a flow test
to confirm that collapse of the pipe had not occurred. In
addition, the forcemain would have to be pigged to remove
the drilling fluid and borehole cuttings that would enter
the pipeline as a result of the "wet" installation.
Contractual Issues
A significant concern to the Town of Nipawin was the level
of contractual risk they were taking in awarding the contract
on the basis of what was little more than a "proposal" for
the river crossing component of the project. This was addressed
in a number of ways. Firstly, all of the technical issues
had to be dealt with. Secondly, the contractor had to provide
confirmation that the directional drilling sub-contractor's
work was covered under his Performance Bond and his Labour
and Material Payment Bond. Last of all, the contractor had
to agree to lock in the quoted drilling price as a lump
sum rather than a unit price to eliminate any possibility
of the cost increasing due to a longer than anticipated
borehole distance.
CONSTRUCTION
Site Preparation and Setup
The drilling subcontractor mobilized to the site in mid
April, about two weeks later than initially proposed because
of the late spring thaw. Equipment setup and stockpiling
of materials took place between April 16 and 25.
Site preparation work on the rig (east) side
of the crossing included stringing fire hose overland to
the closest hydrant, excavation and concrete placement for
an 11 m3 anchor to hold the rig in place and
erection of temporary fencing to secure the working area.
On the pipe assembly (west) side of the crossing, the working
right-of-way limits were established for stringing and fusing
the pipeline.
During the process of establishing the west
side right-of-way, the contractor requested a change in
the location of the exit point for the borehole. The contractor
preferred to exit on higher ground to eliminate difficult
trenching conditions up a ravine. However, this would lengthen
the river crossing. The change was agreed to on the basis
that the drilling component of the river crossing would
be done for the same total price tendered for the original
crossing location. In other words, payment for the drilling
component became a lump sum price.
The entry and exit points were established
on the ground. A ground profile was surveyed between these
two points and the water's edge on each bank. Sensing cable
for the guidance system was then strung along the ground,
offset on both sides of the profile alignment, between the
exit/entry points and the river bank.
The surveyed ground profile was entered into
a computer program employed by a specialist firm the drilling
contractor retained to provide steering and tracking for
the drilling of the borehole. The software generated a profile
of both the ground/river bed surface and the proposed borehole
path. The resulting crossing distance of approximately 680
m was, as anticipated, significantly longer than the 568
m estimated earlier by the contractor. This necessitated
an increase in the quantity of DR11 pipe and a corresponding
marginal increase in the project's cost. Fortunately, the
drilling cost did not increase as the contractor had already
agreed to a lump sum price.
The borehole trajectory was fine tuned to
meet minimum clearance requirements between the pipe and
the river bed. The entry and exit angles were set at 17_
and 13_ respectively.
On April 26 the drilling head components were
assembled and placed into position on the rig. The assembly
included a 250 mm diameter drill bit, mud motor, the steering
section known as a bent housing, and a downhole probe that
relays inclination, drill head orientation and positioning
data back to the guidance computer.
The subsequent sequence of events involved
in the drilling of the borehole and installation of the
pipe are depicted in a series of diagrams on Figures 5
and 6
followed by a chronologic summary on Figure
7. These events are elaborated on in the text that follows.
Borehole
Drilling commenced early on April 27. By the end of the
first day a distance of 150 m had been covered. Drilling
commenced the next morning and had progressed for several
hours when the guidance system started to indicate the borehole
was moving off the design trajectory. The entire drill stem
(20 pipe lengths) was pulled out and the borehole restarted.
The second attempt was more successful as
the borehole maintained the desired trajectory down the
east bank and across the river bottom. By late in the day
on April 29, the borehole was well on its way up the west
bank when the rate of progress started to decrease rapidly
to the point of no forward progress at all. Furthermore,
reversing the progress made to this point was found to be
impossible as the drill stem could not be pulled back out
of the borehole despite maximum pulling forces being applied
by the rig. This served only to dislodge the 11 m3
concrete block anchoring the rig. The drill bit and stem
were stuck!
The problem was attributed to rounded rocks
and boulders in the till that the drill bit was not cutting
into. Instead, the bit was being deflected sideways in various
directions as it travelled through the till causing the
drill stem to bend and bind on the rocks. The friction pressure
generated exceeded the safe torque capacity of the drill
rig.
A number of options were considered by the
drilling contractor to get "unstuck". Explosive charges
could be sent down the hole, inside the drill stem to perforate
the pipe, allowing drilling fluid to lubricate the pipe
behind the drill bid assembly. Or, a smaller rig could be
brought in and set up on the west bank to drill along the
exit trajectory down to the bit and along side some length
of the drill stem.
Both of the above options were fairly risky
in comparison to the preferred choice of excavating down
to the drill bit. This option was favoured because the drill
bit was thought to be relatively close to the exit point.
The computerized guidance system placed the drill bit approximately
50 m from the exit point and only 11 m below ground.
On May 1 the general contractor's largest
backhoe on the project was moved to the calculated location
of the drill bit. The operation was successful in exposing
the drill bit at the 11 m depth but it did not help the
efforts to free the drill stem. It was therefore decided
to enlarge the excavation and slope it back to the exit
point so that the drill stem could be pulled from the exit
end at the same time that the rig was applying force to
move it forward. It was hoped that the added pulling power
would be sufficient to overcome the friction pressure.
Over the next several days the excavation
was enlarged, the drill bit removed and replaced with a
pulling head and a large crawler tractor and heavy cable
brought in. On May 5 the drill stem was successfully dislodged
and moved forward in the open excavation to ground surface
at the exit point.
Reaming Operation
With the pilot hole now completed, the drilling contractor
retooled for the reaming operation. Because of the problems
encountered in the drilling of the pilot hole, the initial
reaming would be carried out with a smaller, 250 mm diameter
cutting head instead of the 450 mm size proposed in the
contractor's original construction plan. Between May 8 and
17, three reaming operations were successfully completed
at progressively larger diameters of 250 mm, 450 mm and
550 mm. On May 19 the final reaming, at 650 mm diameter,
commenced but ran into problems only 60 m into the borehole
when the centering tool came loose from the drill stem.
Attempts to move it to the surface with the drill stem were
unsuccessful so the contractor elected to send the 550 mm
reaming tool back into the borehole to either bring it out
or push it into the surrounding till formation. The latter
was assumed to have taken place as the centering tool did
not emerge with the cutting head. The final reaming was
then able to proceed and was completed without further incident
on May 26.
During the reaming operations, the general
contractor was busy on the west side of the river fusing
the poly pipe and carrying out a leakage test. In addition,
the pulling head was modified to incorporate the openings
needed to allow drilling fluid to enter the pipe for the
"wet" installation that would counteract high differential
pressures in the bottom of the river channel.
Pipe Pull
With the pipe successfully tested and the pulling head assembly
in place, the pipe pull commenced at 7:00 a.m. on May 27.
A backhoe was positioned near the exit point to move the
poly pipe into line with the borehole as the pipe was strung
out along a right-of-way that was at right angles to the
crossing. A crawler loader was also employed to keep the
far end of the pipe elevated which helped to reduce tension
stress in the pipe.
On the east side, at the control console,
the drill rig's carriage force was being carefully monitored
to ensure it was kept below the 40,000 Kg maximum set by
the pipe manufacturer. The pipe made good progress down
the west side of the crossing, moving at an average rate
of about 1.8 m/min. This continued until the pipe passed
the half way point at about 10:30 am. This is when friction
between the pipe and the borehole wall plus the accumulation
of borehole cuttings in front of the pulling head started
to increase the load on the rig. Progress on the next 100
m slowed to less than one metre per minute and further declined
to half a meter per minute as the pipe began its ascent
up the east bank. Progress halted entirely at the 520 m
mark when a roller broke on the rig's carriage platform.
The replacement part had to be flown in, necessitating a
shutdown until the following day.
Any shutdown during the pipe installation
operation has to be considered as a significant potential
problem. Consolidation of borehole cuttings and/or collapse
of the borehole wall could result in such high drag forces
that the pipe might not be able to be moved again. Compounding
this was the apparent build up of sand in front of the pulling
head as evidenced by the large sink holes developing at
the top of the escarpment on the east bank. Furthermore
there was concern about how successful the open pulling
head had been in allowing drilling fluid to enter the pipe.
If not successful, the pipe could be flattened before the
pull is restarted and completed.
The new roller arrived early the next morning,
was installed and the drilling rig put back into operation.
With some considerable effort the pipe moved forward slowly
and progressed 15 m when a second mechanical failure halted
the pull. The swivel joint in the pulling head assembly
had broken.
The broken swivel was a serious problem in
that the drill stem had separated from the pipeline. The
pulling head wasn't close enough to the surface to excavate
a hole to access it as had been done to solve the earlier
problem on the west side. The only recourse was to pull
the pipe, approximately 530 m, back out of the borehole!
On May 29 heavy equipment was moved to the
west side of the river. Slings were employed as the only
practical means to grip the pipe. However, this produced
major deformations in the pipe which resulted in pieces
having to be cut out and replaced. Removal of the pipe took
two days with another two days needed for inspection of
the pipe by its supplier and replacement of the deformed
sections. During the pipe inspection, no evidence was found
of deformation due to excessive external pressure in the
borehole.
During this period, the 650 mm reaming tool
was sent through the hole to remove sand that had slumped
into the borehole on the east bank. Upon completion of the
reaming operation, a new swivel joint, along with the remainder
of the pulling head assembly, was placed into position at
the end of the drill stem for another attempt at the pipe
pull. The tools in the pulling head assembly were supplemented
by the addition of the 650 mm reamer at the front end. This
would assist in dealing with the sand problem on the east
side incline.
At 7:00 am on Monday, June 2, 1995 the second
attempt to pull the pipe across the Saskatchewan River commenced.
The pipe pull progressed much quicker than the first time
and reached the incline on the east side by 10:00 am. Once
again, the rate of forward progress declined rapidly as
the pulling head moved through the toughest part of the
pull. Sink holes on the east side between the edge of the
escarpment and the rig were becoming quite deep, presenting
a hazard to personnel and other utilities in the area including
Nipawin's main trunk sewer.
Forward movement of the pipeline continued
and increased in speed as it approached the surface. At
1:35 pm the pulling head emerged, caked in heavy mud. The
contractor was immediately instructed to clear the mud away
from the perforations on the pulling head to allow air to
enter the pipe. As the openings in the pulling head were
exposed, there was an immediate rush of air into the pipe
confirming that the pipe was under a vacuum condition but
more importantly, confirming that at least some amount of
fluid had entered the pipe.
Commissioning
The suction head observed at the end of the pipe pull was
one of a number of concerns that could only be answered
through the process of commissioning the forcemain. Other
concerns included evacuation of the drilling fluid from
the pipeline and most importantly, whether or not the "wet"
installation was successful in keeping external hydrostatic
pressure from collapsing the pipe under the River.
Following connection of the west end of the
river crossing forcemain with the balance of the pipeline
that was already in place, a pig was introduced on the east
side. It was moved through the pipeline under pressure from
a 50 mm water service connection since the new pumping station
was not yet operational. This proved to be futile as there
was insufficient flow to move the relatively heavy mass
of bentonite and borehole cuttings up the west incline of
the River crossing. In fact, this complicated the cleaning
operation by effectively creating a mass blockage in the
pipe at the base of the west side incline.
Rather than bringing in a large volume portable
pump, the contractor elected to use jetting equipment, introduced
at an air release structure on the west side, to breakup
the mass of bentonite and borehole cuttings. This proved
to be unsuccessful and was eventually abandoned in favour
of using the pumps in the new sewage pumping station. This
resulted in a temporary shutdown of the commissioning operation
while work on the pumping station was completed.
When the new pumps were finally brought on
line they had little difficulty in opening the pipeline.
Subsequent leakage testing of the poly pipe was successful
and measured flow from the pumping station, at 108 l/s,
exceeded the design output of 98 l/s. With evidence of better
than anticipated flow through the pipeline, the directional
drilled crossing of the Saskatchewan River could finally
be declared finished and operational.
CONCLUSION
The selection of directional drilling over conventional
open-cut methods to cross the Saskatchewan River was made
primarily on the basis of environmental considerations.
A secondary benefit was the added protection of the pipe
from river scour damage by virtue of the deeper burial depth.
These benefits were obtained at a relatively small (10%)
cost premium.
The physical characteristics of the Saskatchewan
River valley at Nipawin coupled with the size and type of
pipe installed, tested the abilities of an experienced contractor
and highlighted the risks associated with directional drilling.
These risks can be minimized, but not entirely eliminated,
by thoroughly addressing all of the pertinent technical
considerations.
Most important of the technical considerations
is the pipe material and its wall thickness. This entails
a rigorous stress analysis to ensure the pipeline withstands
all of the forces exerted on it during installation.
From a cost stand point, the most important
technical consideration is the subsurface soil conditions.
The type of soils and the thoroughness of site specific
geotechnical information are the biggest factors in the
contractor's assessment of risk which in turn impacts the
project's schedule and cost.
Despite the risks involved and the problems
encountered, the Nipawin project has demonstrated that directional
drilling can be successfully employed to cross a major waterway
at reasonable cost and without any negative environmental
impacts.
ACKNOWLEDGEMENTS
The author gratefully acknowledges the contribution of technical
literature by Kamloops Augering Ltd. and Perma Engineered
Sales (1983) Ltd., with a special thanks to the Town of
Nipawin for their foresight and cooperation.
REFERENCES
Associated Engineering (Sask.) Ltd. (1994), Nipawin Regional
Sewage Treatment Facility Predesign Report, Regina, Saskatchewan.
Associated Engineering (Sask) Ltd. (1995),
Nipawin Regional Sewage Treatment Facility General Operating
Manual, Regina, Saskatchewan.
Ensor, W.D., Fortin and Skipper (1993), Drilling
with direction, Civil Engineering J., September, pp. 48-51.
Iseley, Dr. T and R. Tanwani (1990), Trenchless
Technology - A paper outlining the methodology of directional
drilling, Louisiana Tech Engineer J., Vol. 45, No. 1.
Kamloops Augering Ltd. and D.L. Fisher (undated),
Trenchless Technology - A paper outlining directional drilling
design parameters, Kamploops, British Columbia.
KWH Pipe (Canada) Ltd. (1993), Sclairpipe
High Density Polyethylene Pipe Systems Design Manual, Table
4, pp 11.
Phillips Driscopipe, Inc. (undated), Technical
Note #20 - Pulling Head Designs
Phillips Driscopipe, Inc. (1993), Technical
Note #41 - "Technical Expertise" Application of Driscopipe
pipe in directional drilling and river crossings.
Sharewell Directional Guidance Sytems, Inc.
(undated), Steering System for Directional Bores, Stafford,
Texas.
Svetlik, H.E. (1995), Design considerations
for HDPE pipe used in directional drilling, Proceedings
of No-Dig Engineering Conference.
|