Challenges faced in HDD Technology

Ayon Roy*and Chinnari Raghu Vamsi

*Deputy Maintenance Manager (Mainline) at IOCL’s HMRB Pipelines, Mourigram HQ

Operations and Maintenance Engineer at IOCL’s HMRB Pipelines, Mourigram HQ

ABSTRACT

Horizontal Directional Drilling (HDD) is a steerable trenchless technology process for the installation
of an undeground pipeline which is accomplished in three stages namely – Pilot Hole, Pre-reaming
and Pull back. Today’s oil companies have the ability to drill horizontal bores to cross obstacles such
as rivers, mountains, roads and residential areas, as well as difficult terrain and nature protection
zones underground. HDD is increasingly becoming an economic, safe and time saving solution among
pipeline operators. Though HDD was evolved from the directional drilling method once adopted in oil
fields but the technique is increasingly becoming popular in sewage disposal, potable water supply
network, telecom operators, electricity / city gas networks and a wide range of other services.

Based on experience and observations, this paper discusses the challenges related to site accessibility,
difficulty in achieving bore profile, pipe installation, etc. which are generally faced during HDD.

1. INTRODUCTION

HDD is a high end technology transferred from practical problems crop up during the HDD
oil exploration industry to nowadays micro- execution. These challenges are listed in the
tunnelling for installation of utilities such as below table and can be divided into three
power cables, telecom conduits, water mains and categories:
gas mains, etc. This specialised technique is
featured with a drilling rig on surface and a mud Geo-technical During Bore During pipe
aspects preparation installation
motor to drive the cutting tools such as tri-cone
Space Loss of Damage to
bit and reamers. It is almost certain that problems constraints for circulation of carrier pipe
will occur in very carefully planned HDD string drilling fluid
operations. Understanding and anticipating preparation Obstructions
drilling problems, understanding their causes and along drill
planning solutions are necessary for overall- path
construction-cost control and for successfully Line and
reaching the target zone by achieving the desired grade
problem
pipeline profile and alignment. Before applying
Bore-hole
this technique, careful planning, design collapse
procedures, thorough site investigation (soil / Rocky area Surface Hydro-lock
water / topographic) and precise preparation is heave or
required to ensure a practical solution before humping
tendering, and more importantly, to ensure Dogleg
inclusion of all technical requirements and severity
Lost probe
concerns for the HDD works under the Contract
connection
for the Contractor to implement during the
Magnetic
construction stage. A dedicated pre-qualification interference
process can be helpful to assure properly Jam in drill
qualified HDD Contractors and materials for the bit nozzle
process. In spite of all the preparedness, some Table: 1
2. DISCUSSIONS:
2.1 Challenges of Geo-technical aspects:
2.1.1 Space constraint for string
preparation: As a convention, pull back
through HDD bore is done with a single
pipeline string. However, due to
geographical constraints wherever space
for preparation of a single string and
placement of same on rollers during pull
back is not possible, pipeline operators
tend to pull the HDD string in sections by
joining the sections with golden joints
(joints which aren’t subjected to
hydrostatic test). Since the weld joint will
not be pressure tested, NDE is performed
in lieu of pressure test. The best welders
are to be deployed to weld these joints
because defects in such joints may cause
further delay in pipe pulling. Going for
Golden joints is also critical time has to
be given for completion of activities like
welding, radiography and joint coating of
golden joint during pipe pulling.
Probability of bore collapse in soft coarse
soil with low quality mud during this halt
period is also an additional challenge. In
order to avoid such circumstance, bore
hole has to be filled with good quality
drilling fluid / mud during clean pass. It
is better to make the golden joint away
from the exit point so that pipe string can
be pulled after the completion of each
activity which reduces the chance of bore
collapse.
2.1.2 Drilling in rocky areas: Execution of
HDD successfully in hard, rocky areas
has always been a challenge. The added
time and tool wear seem to be the biggest
concern amongst drillers operating in
these conditions. Drill bit with multiple
nozzles must be used to avoid jam
because of rock particles. Proper drill bit
with qualitative drilling fluid must be
used for achieving the required bore
profile.
2.1.3 Mitigation of Geo-technical challenges:
Pre-construction surveys during the
design phase must be carried out which
may typically involve surface survey
(Ground features like roadways, utility
poles, overhead power cables, culverts,
etc., Structures like buildings, tanks,
bridges, hazardous material storage, etc.,
Flora spread like mature trees, crops and
manmade slopes or retaining walls, etc.)
and sub-surface survey (soil investigation
and underground utilities)
2.1.4 Case study:
2.2 Challenges during Bore preparation:
Failure to complete the bore is often the
main concern globally for the executors
of HDD. The following are some of the
challenges / problems that are faced
during bore-hole preparation:
2.2.1 Loss of circulation of drilling fluid:
During the HDD, loss in circulation of
drilling fluid (bentonite solution) may
occur by drilling through voids, highly
fractured rock etc. An effective drilling
fluid at a suitable pumping rate and
viscosity must be pumped for achieving
the bore as per the subsurface conditions.
These are critical factors for maintaining
circulation and bore-hole stability.
Circulation can be lost very quickly if
voids are encountered and cannot be
resumed until the void is filled or the
path to the void is sealed. In general,
viscosity of the drilling fluid shall be
increased to seal the void / low resistant
path.
2.2.2 Obstructions along drill path:
Obstructions can cause a failed bore if
the drill bit, reamer, or product pipe
cannot be advanced past the object. If
identified during planning, the best
approach is to avoid the obstacle. Typical
obstructions faced during HDD
construction are cobbles and boulders,
gravel beds, wood, bedrock, and
construction debris or foundations. There
 might be chances of worn out drill bit if it
encounters hard rock along the drill path
which would effect in even cutting soft
soil further.
2.2.3 Line and grade problems: These occur
due to faulty tracking and steering or
subsurface conditions that prevent or
hamper the proper steering. Improper
matching of the down-hole tools to the
subsurface conditions can also cause line
and grade problems.
2.2.4 Bore-hole collapse: Bore hole collapse
severely impacts the chances of success
on any HDD project. Soft or loose soils
present a high risk of collapse during
HDD operations. When a bore hole
collapses, there is an immediate increase
in rotary torque and pressure and a
decrease or loss of circulation. Increasing
the viscosity of drilling fluid might help
in reducing the chances of bore collapse.
2.2.5 Surface heave or humping / Frac-out:
This is a condition that is usually a result
of excess pumping of drilling fluids after
a loss of circulation. This condition can
quickly pressurize the formation and
cause a heave at the surface. Heaving can
also arise from reaming with a barrel
reamer without enough depth, which can
result in a displacement of soil towards
the surface. Heaving or humping the
surface is a far more common
occurrence. Several factors contribute to
the development of surface heave
including back ream rate, borehole
pressure, down-hole tooling, depth of
cover, annular space size, geotechnical
properties, etc.
Figure: 1
2.2.6 Surface Collapse: This is typically a
result of a significant over excavation
above the bore hole, which can be caused
by large volumes of thin drilling fluid
used at high velocities, incomplete filling
of the annulus with drilling fluids for a
large-diameter bore near the surface, or
leaks in high- pressure pipes after
installation, which erode the soil above
the bore hole.
2.2.7 Dog Leg Severity (DLS): Dogleg
Severity is a measure of the amount of
change in the inclination, and/or azimuth
of a borehole, usually expressed in
degrees per 100 feet. Since in a
directional well, we continuously have
changes in inclination and/or azimuth,
thus the presence of DLS is always there.
The dogleg severity is low if the changes
in inclination and/or azimuth are small or
occur over a long interval of course
length. The dogleg severity is high when
the inclination and/or azimuth changes
quickly or occur over a short interval of
course length. At low inclinations a
change in azimuth will have a small
dogleg severity. As the inclination
increases, the dogleg severity will also
increase for the same change in azimuth.
Methods to reduce DLS: Once a severe
dogleg comes into play, its effect can be
reduced by using lubricants in mud
system. The lubricant reduces the
coefficient of friction between the drill
string and the bore wall thereby reducing
the tension in the drill string.
Problems associated with dogleg: As
drilling continues, the drill string tension
in the dogleg increases which increases
the lateral force. The lateral force causes
the drill string to cut into the bore wall at
the dogleg (refer figure below). Repeated
abrasion by the drill string in a particular
location of the dogleg results in a
worn spot called a key seat, in which
the BHA (Bottom Hole
Assembly) components may
 become stuck as they are pulled through
the section. Severe doglegs results in
worn of casing which can lead to collapse
of hole in the casing. Casing string may
no longer easily fit through the curved
section and casing may wear unusually
quickly due to higher contact forces
between the drill string and the inner
diameter (ID) of
Figure: 2
of the casing through the dogleg.
Excessive doglegs increase the overall
friction to the drill string, increasing the
likelihood of getting stuck or not
reaching the planned total depth. Usually
these problems are manageable. If the
dogleg impairs the well, remedial action
can be taken, such as reaming or under
reaming through the dogleg or even
sidetracking in extreme situations.
Dog leg formation rarely occurs and can
be controlled by carefully steering the
tool.
2.2.8 Lost connection from probe
(Accelerometer + Magnetometer): This
problem arises when the welder makes a
poor wire line joint. When there is a
change in inclination of a particular drill
rod, it exerts a compressive force on the
wire which cause rupture in the weakest
joint. This makes the wire to short as it
gets contacted with the drilling fluid. In
HDD terms, it is called as tripping. Wire
once tripped, connection from the probe
is lost and there will be no further data
feedback (Inclination and Azimuth) from
the probe. This makes the operator to
retrieve the drill pipe until he finds the
damaged joint. Hence, wire of good
make& quality, experienced welder along
with a robust solenoid machine to be
deployed for soldering the wire line
joints.
Figure: 3
2.1.9 Jam in drill bit nozzle: This can occur
because of various reasons. Jam in the
drill bit nozzle may occur when foreign
materials like pieces of gasket get
pumped along with drilling fluid through
the drill rods. Also in soft soil, where
mud pressure is kept low to avoid frac-
out and sag of drill string, material
outside the string might enter into the
drill bit’s nozzle and gets jammed. Even
there is a chance of wire line to break
from spider and jams the nozzle.
However, jam in a single nozzle of drill
bit might not create a problem but the
jam in all nozzles shall stop the fluid
pumping and further cutting action. Even
in this case also all the drill pipes need to
be retrieved and drilled again freshly.
2.1.10 Magnetic interference: This is due to
lying of foreign magnetic material or old
/ stuck drill pipe near to the drill path.
This creates a magnetic interference
which shall produce error in readings
obtained from Magnetometer. Hence,
separate coiling (in the shape of square
box) with induced current need to be
done at those areas for creating an
induced magnetic field. Once these
details (GPS coordinates of corners,
 forward & reverse current readings) tandem to get the carrier pipe free. The
entered in the Tensor / Para-track percussive action of a pipe rammer in this
software, exact position of drill bit can be situation is used to free the jammed pipe.
determined in spite of having interference Pipe rammer (say Grundoram make) is
from external source. attached to the carrier pipe string at the
end so that it rams the pipe inside the
2.3 Challenges during pipe installation: ground. In many cases, the percussive
power of the pipe rammer is enough to
2.3.1 Damage to carrier pipe: A failure or free the jammed product pipe.
damage to the product pipe during HDD
installation can occur due to an improper 3. CONCLUSION:
ream bore-hole, poor workmanship and
improper HDD design. The best Potential risks need to be identified
approach to avoid carrier pipe failures is during the planning and design phase so
to establish conservative design criteria that they may be eliminated or reduced.
and follow the pipe manufacturer’s A risk contingency plan with proper
guidelines. Another key factor in procedure needs to be developed for
maintaining suitable carrier pipe is to resolving them. Concerted effort with
ensure that all pipe joints are properly coordination among all is to be
welded and tested. maintained during HDD execution for
2.3.2 Hydro-lock: It is a condition that may proactively attending the areas which can
occur when circulation from the bore dilute the influence of any expected
hole is lost and the subsurface formation problem during work.
is resistant to fracturing, resulting in a
hydraulic cylinder in the bore hole. This
problem is common in fine-grained rock,
frozen ground and any formation that is
resistant to hydraulic fracturing. Hydro-
lock occurs mostly when drilling
underwater. This also happens when the
external pressure being put on the
product pipe from ground water pressure,
drilling fluid pressure and soil pressure
exceeds the drill rig’s pullback capacity.
This is possible when there is a collapse
in bore hole. When hydro-lock occurs,
there is an immediate increase in rotary
torque and pressure. Operator tries to
increase the puling load until the pipe
string gets free. This increase in load
might cause higher tensile stress in pipe.
Hence, using a higher wall thickness pipe
is desirable for absorbing more tensile
stress.
To overcome this, a pullback assist
technique need to be used that
incorporates the use of both a pipe
rammer and an HDD rig working in