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0 Horizontal Directional Drilling

Horizontal Directional Drilling is a guided horizontal boring system capable of
installing utilities such as steel pipes and cables. Its primary application is in developed
areas where surface disruption is a consideration, not only because of cost but also
because of traffic flow, customer satisfaction and environmental friendly. The technology
is totally safe and tremor free. It will not result in disturbances to surrounding
environments and soil composition. It is unobtrusive to community in terms of noise level
and traffic disruptions. When use in congested and high traffic area, this method causes
the least disturbance. This technique can be applied to drill through the river, road,
housing area, railway track and airport runway.

2.2.1 The Equipment

The equipment can produce tunnels ranging in size from 50 mm to 500 mm with
typical run lengths of between 120 m to 360 m depending on soil conditions, equipment
used and drilling depth. This system uses high-pressure fluid jets for cutting. These jets
are sometimes augmented with carbide cutting blades to help penetrate the more
consolidated sediments and permit operation in chalk, some shale, and occasional
encounters with rubble and gravel up to 30 % in volume.

The drilling fluid is a mixture of water and bentonite. Fluid jet cutting with
bentonite provides a means of excavating sediment while at the same time leaving a
lubricated tunnel for installing the utility. The bentonite solution is a viscous fluid that
suspends the sediment particles and transports them back to the surface. The fluid jets
themselves will cut the sediment but will not cut into adjacent utilities whether they be
concrete, metal or plastic. Operating pressure for the fluid jets are typically up to 250 bar
and jet diameters are typically 1 mm or less. With the cutting head and back-reamer
arrangement used, the maximum fluid consumption is 30 liters per minute when
producing tunnels up to 175 mm. The fluid jets at 250 bar penetrate about 1 cm into clay-
type sediments. This means that high pressure fluid jet cutting is substantially different
from water boring techniques, which use much larger quantities of fluids that can cause
substantial voids and result in surface subsidence. From our operating experience, no
surface subsidence has been observed.

The system uses the orientation of the jets and head shape to control the path of
the boring or drilling tool. A separate piece of equipment above the ground, in
combination with a transmitter located in the boring or drilling head, determines the
position of the tool to within 2.5 cm at typical placement depths of about 1.5 m. The
tunnel placement accuracy can be held to 15 cm depending on the requirements of the job
and the sediment type. A contoured path requiring a tool steering radius of 9 m or more
can be maintained with equipment.

With the placement accuracy capability, our companys guided boring system can
be used in the vicinity of other utilities after first locating the existing utilities in the
ground either electronically of by means of small excavation pits. Once the utilities are
exposed, a course can then be carefully laid out to avoid running into existing utilities.
Since no trenching is involved, the course can be above, under or to the side of the
existing utilities, allowing much more flexibility in placement of the new utility. Unlike
trenching, there is generally no difficulty in going deeper to get under a sewer, water pipe
or other utilities. The depth of the tool can be accurately measured down to 25 m with the
electronic locating equipment. Because of the accurate placement capability, many utility
companies will allow drilling next to active primary electric cables, while contractors
using conventional techniques have to de-energize the cables, which contributes to
further customer disruption.

2.2.2 The Process

The entire drilling process is controlled by an operator from the central control
panel of the mobile power supply unit together with one other operator at the site, who
remotely directs the drill head with the help of a specialized receiver. The mobile supply
unit as well as hydraulic power produces all power necessary for the drilling process. A
radio-detection unit is used to investigate and locate any hidden obstacles such as
undetected pipes or other cables along the proposed drill path. The field power unit
provides the high-pressure cutting fluid, hydraulic, pneumatic and electric connection.
Once these pits have been dug, the drill unit is brought to the site. The unit is set up 4m to
5 m behind the first access pit. The tool and the first 3 m section of drill pipe are put on
the drill frame, which is angled at about 15 degrees to the ground. The directional drilling
or guided boring process begins by drilling into undisturbed surface at this 15 degrees
angle. As the tool penetrates the ground, the second drill pipe is added. The process
continues with the steering controlled so that the drilling tool will enter the first pit level
at the proper depth.

The success of horizontal directional drilling lies on the construction of the drill
head and reamers. The drilling process can be divided into two main working procedures.

Stage 1: Firstly, a small entrance called the start pit is dug at the convenient
location. Then the drilling tool is attached to the drill rods and advanced through the
ground to reach a target pit where the utilities cable or pipes are to be pulled.

Bentonite is emitted from jets into the drill tool and forced through the ground
forming a pilot hole. The diameter of mud pressure and mudflow transports the removed
soil back along the pilot hole to the start pit. A transmitter is located in the drill head
allowing the operator to locate the drill head to a tolerance of 2 cm. With a two ways
radio, the operator is able to issue command in steering the drill head along the desired
drill run, thus giving total control.

The drill head can be steered in a straight line or in any other selected direction to
the left, right, up or down. The drilling machine can drill up to length of 1800 m
depending on soil conditions.

Stage 2: Involves back-reaming and product pipes installation which in other
words, the return journey. Upon reaching the target pit, the drill head is then removed
from the drill rods in the target pit. A back-reamer relevant to the size of the utility cable
to be installed is then attached directly behind the reamer.

The back-reamer has a series of jets, which produce sufficient mudflow and
pressure to cut away and remove soil, widening the pilot hole to the desired diameter.
Cable or duct diameter may range from 50 mm to 500 mm. The drill rods will continue to
rotate and retract, pulled along the utility cable, attached and the product is
simultaneously installed, stress free.

2.2.3 The Techniques

The directional drilling or guided boring system techniques is generally divided
into three phases.
Phase 1: The key to success is the accuracy of the initial pilot tunnel, the steering
tool is guided along the pilot tunnel enabling the crossing to be carried out exactly as
planned. The steering tool appears in the correct position required on the other side of the
river or target pit ( refer to Figure 2-1)


Figure 2-1: Pilot Drilling In Progress

Phase 2: A wash-pipe is then fitted over the pilot string and advanced whilst
rotating.When a wash appears on the opposite side of the river or target pit, the pilot
string is retracted. The wash-pipe is then fitted with a reamer and pulled back to the
starting point on the other side of the river. This process widens the initial pilot tunnel, if
further widening is required this process is repeated.( refer to Figure 2-2)

Figure 2-2: Reaming In Progress
Phase 3: The product pipes to be installed is in position ready to be attached to a
swivel, which is then attached to the reamer. The reamer is then retracted with rotation
and mud, and the customers product is installed rotation free on this final crossing. The
drilling mud protects the product and lubricates the installation process. (refer to Figure
2-3)

Figure 2-3: Pulling Of Pipeline.

2.2.4 The Safety

During the entire drilling and back-reaming operation, the safety equipment and
procedures will protect the operators from any possible injury caused by inadvertent
contact with the energized electric cables underground. Although this rarely occurs, the
safety equipment and procedures ensure that operators are protected from electrical
hazards. Because of the safety equipment and procedures, most utility companies will
allow drilling operations next to their live cables, while other contractors using surface
trenching and unguided boring techniques are required to disconnect power in the vicinity
of the installation. This means that new electric cable can be installed adjacent to the
failing electric cables through out an entire city section with only a brief disruption to
customers when switching over from the old cable system to the new cable system.
Similar benefits can also be experienced with the installation of telecommunication
cables and gas pipes in common trenches with electric utilities.