IBP576_03

HORIZONTAL DIRECTIONAL DRILLING (HDD)

FOR SHORE APPROACH APPLICATIONS
Neil Smith1

Copyright 2003, Instituto Brasileiro de Petróleo e Gás - IBP

Este Trabalho Técnico foi preparado para apresentação na Rio Pipeline Conference & Exposition 2003, realizado no período de 22 a 24 de
Outubro de 2003, no Rio de Janeiro. Este Trabalho Técnico foi selecionado para apresentação pela Comissão Técnica do Evento, seguindo as
informações contidas na sinopse submetida pelo(s) autor(es). O conteúdo do Trabalho Técnico, como apresentado, não foi revisado pelo IBP. Os
organizadores não irão traduzir ou corrigir os textos recebidos. O material conforme, apresentado, não necessariamente reflete as opiniões do
Instituto Brasileiro de Petróleo e Gás, Sócios e Representantes. É de conhecimento e aprovação do(s) autor(es) que este Trabalho Técnico seja
publicado nos Anais da Rio Pipeline Conference & Exposition 2003.

Abstract

Horizontal directional drilling (HDD) has become a commonly used construction method for
pipeline shore approaches. HDD can mitigate environmental impact, provide greater burial
depths and minimize construction schedules. The risks that are associated with HDD river
crossings, which are generally well recognized, also apply to HDD shore approaches where they
are combined with specific risks occurring from working in the marine environment. The shore
approach projects of The Bronx and Hunts Point provide good practical examples of the benefits
of this technology in spite of the various challenges encountered.

Introduction

The paper provides a general description of horizontal directional drilling (HDD) used as a
trenchless method of pipeline installation. Emphasis is given to HDD for pipeline shore
approach construction. Site investigation and design is discussed followed by a description of
the construction method. The paper concludes with a case study of a recent project that involved
the construction of two (2) 610mm diameter steel pipeline shore approaches of 1,375m and
1,070m in length.

1-A brief history of HDD

The directional drilling method for performing pipeline crossings of a wide variety of surface
obstructions was developed in the 1970’s. Since that time, the advantages of the HDD technique
have been embraced by the pipeline industry. The technology has been applied as the most
environmentally responsible and economical method of installing river crossings on many
projects worldwide.

The HDD industry has undergone many improvements since its early days. Engineering and
technological developments have enabled larger, more accurate, and more complex pipeline
installations by HDD. As the technology became more widely accepted, more companies
entered the market driving further technological advances which were necessary to reach higher
levels of efficiency and provide competitive advantages.
1
CEng BSc(Hons) MICE – Mears HDD, LLC - MGI do Brasil Ltda.
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The advantages that HDD could bring to pipeline shore approaches, compared with the
conventional bottom-pull, open-cut methods, were quickly accepted. In the 1980’s several
pipeline shore approaches were installed although the conventional methods were still more
common. The general acceptance of HDD as a method for the installation of pipeline shore
approaches continued in much the same way as it had for onshore crossings. In several areas it
has become the normal method of construction for pipelines’ and cable conduits shore landings.

2-Advantages__________________________________________________________________

The advantages of the directional drilling installation method over alternative construction
methods are numerous. Environmental issues are minimized as operations are limited to
relatively small areas at each end of, as opposed to, the complete length of, the installation.

Optimum depth of cover in the design of a crossing yields maximum protection for the pipeline
from anchors and future dredging and reduces long-term maintenance costs. Beach erosion risks
are minimized and construction activities in surf zones can be avoided. In many cases HDD is
less expensive than other methods.

3-Site Investigation and Design___________________________________________________

Time and money is well invested in the site investigation phase of an HDD project. Topographic
and bathymetric surveys are required. These surveys in conjunction with a comprehensive
geotechnical investigation will enable a suitable design for the HDD profile.

The number of exploration holes (“bore holes”) taken in the geotechnical investigation is a
function of the proposed crossing length and the complexity of the strata. For short shore
approaches a bore hole made at the proposed drill “entry point” (at the landward end of the HDD
crossing) and a bore hole on the beach may suffice. However, if the findings from the bore holes
indicate anomalies, discontinuity in the strata, the presence of rock or large concentrations of
gravel it is advisable to make additional borings to better define the strata. Longer shore
approaches require more bore holes to provide reasonable conclusions regarding the likely
subsurface conditions that will be encountered in the HDD process. Geophysical surveys can be
useful when used in conjunction with exploration bore holes to provide additional information
about subsurface strata.

A shore approach HDD profile is designed while considering the site investigation data and
other project specific requirements and restrictions such as land availability, site constraints, and
the required water depth for the shore approach termination. An entry angle between 8° and 16°
can be used for most shore approaches. It is preferable that straight tangent sections are drilled
before the introduction of a long curvature radius. A general “rule-of-thumb” for the radius of
curvature is 1200 times the pipeline diameter for steel line pipe. The curve usually brings the
profile to the elevation providing the design cover of the pipeline under the beach and the
seabed. Long horizontal runs can be made at this elevation before curving up towards the “exit
point”. Generally, the exit angle is kept between 3° and 6° to facilitate the transition of the
product pipeline from the HDD shore approach to the conventionally laid offshore section.

In finalizing the design, the pipeline stresses imposed during construction and in-service must be
calculated and checked to be within allowable limits. The stresses at each stage must be
considered acting individually and in combination. Stresses result due to the hydrostatic testing
pressures, pulling forces during installation, radius of curvature as the pipe enters the ground, the
drilling profile curvature, external pressures in the drilled hole, and the working pressure.
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4-Technique___________________________________________________________________

The process generally includes three distinct phases beginning with the drilling of the “pilot
hole” from the land, along a designed profile to exit at a predetermined target offshore. The
second phase entails the reaming of the pilot hole to a diameter sufficiently large enough to
accept the pipeline or conduit. Finally, the pipeline is pulled into place within the enlarged hole.
A slant drill unit is set up on the land site. A pilot hole is drilled along a pre-designed profile
consisting of straight tangents and long radius arcs.

The directional control during the drilling of the pilot hole is accomplished by a small bend in
the drill string just behind the cutting head. For shore approaches, magnetic steering tools are
generally used to monitor the drilled path. The magnetic steering tool allows the drill crew to
calculate the position of the drill at any time during the drilling. Drilling corrections are made so
the pilot hole complies with the crossing specifications. The magnetic steering tool uses a tri-
axis magnetometer to determine the tool position relative to the earth’s local magnetic field. A
tri-axis accelerometer package is used to determine the tool position relative to the earth’s axis.
Together, the data output from the instruments are mathematically transformed to yield the tool
attitude. The attitude includes the inclination of the steering tool and the tool face, and reference
of the tool body position relative to the drill path. Each successive set of measurements is used
to calculate the incremental position of the drill along its designed path. The incremental
position calculations are added at each point and the actual drill path can be plotted.

Magnetic steering tools are often used in conjunction with the Tru-Tracker system. The Tru-
Tracker system consists of an electric cable positioned on the surface over the drill path in a grid
or “coil”. The cable position is surveyed and selectively energized, producing a local magnetic
field of known intensity and location. The magnetic steering tool is sensitive to this induced
magnetic field and proprietary software is used to refine the steering tool and pilot hole position
during the drilling. Tru-Tracker is usually used for the onshore section and can also be used
offshore by laying the cable on the seabed.

Once the pilot hole is complete, the hole must be enlarged to a suitable diameter for the
installation of the product pipeline. For instance, if the pipeline to be installed is 36 in. diameter,
the hole may be enlarged to 48 in. diameter or larger. This is accomplished by “pre-reaming”
the hole to successively larger diameters. Generally, a cutter is attached to the drill string on a
support barge at the offshore end of the shore approach (the exit point) and pulled back into the
pilot hole. Joints of drill pipe are added on the support barge as the cutter makes its way back to
the drilling rig. Large quantities of slurry are pumped into the hole to maintain the integrity of
the hole and to flush out cuttings. It has been advantageous on several projects to pre-ream the
drilled pilot hole by running the cutters through the hole in the opposite direction i.e. from shore
to offshore – this technique is known as “forward reaming”.

Irrespective of the selected pre-reaming technique, staging vessels are required at the exit point.
The selection of the vessels is dependent on the sea conditions and the availability of vessels in
the area. Relatively small inshore barges (generally on spuds) have been used in shallow,
sheltered waters. In deeper, open water the tendency has been to use either jack-ups (lift boats)
which provide a stable platform, or, if already a part of the project spread, it can be economically
feasible to use ocean going barges, even lay- or derrick- barges, on anchors.

If forward reaming is the chosen method, a second drilling rig at the exit point can be used to
exert tension on the drill pipe. The slant drilling rigs used for HDD crossings have only limited
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capacity to withstand the yaw, pitch and roll movements of a barge. Only small motion of the
staging vessel can potentially over stress the drill pipe and the rig's mechanical components. In
the selection of a vessel to stage a drilling rig offshore, the method of anchorage is of paramount
importance. Ideally, anchorage should be provided that will enable the drilling rig to exert its
maximum capacity push / pull loads in the most extreme sea conditions anticipated (considering
the worst case environmental loadings from wind, current and wave actions). As mentioned
above, jack-up platforms can provide stable drilling platforms; however, in order to use one of
these vessels, comprehensive analyses must be undertaken to determine the forces that will result
from the design loadings. The loadings, and particularly the horizontal components of the forces
imposed on a jack-up, will cause overturning moments and sliding forces which must be resisted
by the vessel, and bending moments and shear stresses in the vessel's legs that must be limited to
prevent failure or collapse.

Sea states must also be considered in the planning for pipe fabrication and handling procedures.
Tidal currents can jeopardize a poorly stabilized or inadequately protected pipestring. For large
diameter pipelines, the inherent buoyancy of the pipe requires that special attention be applied to
provide stability prior to installation and secure handling during the pullback operation.
Conversely, for small diameter pipelines, negative buoyancy may need to be countered by the
addition of floatation aids in order to reduce, or prevent, siltation of the pipestring on the seabed
prior to its installation.

Once the drilled hole is enlarged, the product pipeline can be pulled through it. The pipeline is
prefabricated and laid on the seabed extending offshore away from the exit point. A reamer is
attached to the drill string, and then connected to the pipeline pullhead via a swivel. The swivel
prevents any translation of the reamer’s rotation into the pipeline string allowing for a smooth
pull into the drilled hole. The drilling rig then begins the pullback operation, rotating and
pulling on the drill string and once again circulating high volumes of drilling slurry. The
pullback continues until the reamer and pipeline break ground at the drilling rig.

The logistical challenges associated with working in remote HDD locations are similar to those
encountered on shore approaches. The often overlooked ease of receiving deliveries of supplies,
be they fuel or drilling fluids, and the transportation of crews can take on a new light when
operating several hours by sea from the nearest dock. Planning of the work and maintaining
contingencies become ever more important processes.

A mechanical failure or delay during the pullback operation can be catastrophic. For shore
approaches remedial measures are generally more limited than those available on land. As is
always the case, the possibility of recovering from a "stuck pipe" situation greatly diminishes
with time. In a marine environment where currents or tidal movement may be acting at the exit
point, the time factor adds even greater importance since silting action is an added risk.

5-Drilling fluids________________________________________________________________

The HDD operation uses drilling fluid to facilitate the drilling and installation of the product
pipe. The fluid also serves to stabilize the surrounding formations and provide a seal that
reduces the risk of the fluid migrating into the formation. The fluid is composed of bentonite
(naturally occurring clay) and water. The clay is insoluble and made up of small particles that
function as both a lubricant for the drill head and pipe and a sealant that fills the pore spaces
surrounding the drill hole. Various benign, non-toxic additives (polymers) may be added to the
drilling fluid to optimize its properties.

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The drilling of the pilot hole includes the use of drilling fluid to run the drill motor or jet bit to
cut through the earth material, to seal off fractures in the formation, to lubricate the drill pipe
during installation, and to remove the drilled soil or cuttings from the pilot hole. The drilling
fluid is pumped down the inside of the drill pipe and exits through the drill bit. Then the fluid
can return to the surface at the rig site through the annular space between the outside of the drill
pipe and the drilled hole. The fluid returning to the drill site is called “returns”. At the
beginning of the pilot hole, a large percentage of the drilling fluid returns to the rig site. As the
drill progresses, more of the returns are absorbed by the earth and are not returned to the rig site.
At some point, gravity and friction overtake the ability of the fluid to return to the drill site. It is
not uncommon to not have any of the fluid return to the drill site during the majority of the
drilling operations, without any release of the fluid to the surface. The drilling fluid is usually
absorbed by the formation or is drawn down into fractures. A loss of returns, even a complete
loss of returns, is a fairly normal occurrence during HDD that does not necessarily mean that
drilling fluid is coming to the surface or impacting the marine environment.

When the pilot hole is completed, the drill bit “punches out” of the seabed and a relatively small
quantity of drilling fluid is released at the exit point. During pre-reaming and pipe pullback a
considerable percentage of the drilling fluid used will exit the drilled hole and be returned to
either the entry point or the exit point. The returns emitted at the entry point can be cleaned and
recycled. The “forward reaming” technique produces a larger proportion of the returns flowing
to the entry point where they can be easily recycled. If the reaming process is undertaken from
the offshore exit point towards the shore (in the fashion of a conventional “back-ream”) the vast
majority of the returns will be emitted at the offshore end of the drilled hole (at the exit point).
During reaming and pipe pulling, drilling fluid may be lost into the surrounding formation in
much the same manner as during the drilling of the pilot hole. The only significant difference is
that the volumes of fluid that are used are larger. Although containment of returns offshore is
usually not necessary, there can be an economic advantage to maximizing drilling fluids’
recycling by using the forward reaming method.

During drilling of the pilot hole, reaming or pipe pulling, a complete and sudden loss of returns
could be an indication that a significant ground fracture has been encountered. In most cases,
the drilling fluids are drawn down by gravity or seal off the fracture. A complete and sudden
loss of returns is a signal to the HDD crew to watch closely for a possible surface release. Such
surface releases are termed “inadvertent returns”. A key to containing and controlling an
inadvertent return is early detection and quick response by the HDD crew. A good prevention
and control plan will identify the activities to be monitored and appropriate response actions to
be taken to ensure that any release of drilling fluid is minimized. Such a plan outlines a process
of monitoring the drilling fluid in order to identify a loss-of-returns situation and of determining
if there is a release to the surface. Specific measures to be taken to reduce the amount and
likelihood of surfacing drilling fluid, and other actions to be taken, are included in the plan. In
the event of an inadvertent return, lost circulation materials (LCM) may be added to the drilling
fluid. LCM’s typically include cotton dust, cottonseed hulls, wood fiber, mica and cedar fiber.

6-Case Study__________________________________________________________________

Mears/HDD completed two major shore approaches in New York using HDD through extreme
subsoil conditions during the 2002 / 2003 winter season. The HDD shore approaches were
performed under subcontract to Horizon Offshore Contractors, Inc. on Iroquois Pipeline’s
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Eastchester Extension Project. The HDD installations are at each end of the 610mm diameter
marine pipeline that passes through Long Island Sound to New York. By using HDD, the
shorelines’ integrity was protected, ecological disturbance was minimized and the pipeline’s
security was enhanced.

The 1,375 meter long Hunts Point shore approach in New York’s Bronx was constructed using
Mears’ 400 tonne capacity HDD rig. The HDD passed through alternating hard rock (gneiss and
schist) and soft sediments near shore before continuing through very soft sediments. This
installation also incorporated a horizontal curve providing a 30 degree change of direction and
exited within a 6 meter wide pre-excavated open ended sheet piled cofferdam in 16 meter water
depth.

The HDD shore approach onto Long Island was 1,070 meters long. With an HDD rig (227 tonne
push / pull capacity) set up onshore, the drilling, which passed through glacial deposits including
sand and gravel, exited in another similarly restricted (6 meter wide) cofferdam in 12 meter
water depth.

At each shore approach, the drilled holes were opened to a diameter of approximately 1 meter to
accommodate the 610mm diameter steel pipeline which had a 30mm thick concrete coating.
Horizon’s laybarge “Gulf Horizon” pre-laid, and pre-tested, the pipeline strings on the seabed.
With the onshore HDD rigs pulling the pipelines into the drilled holes, Mears completed the
installations at Northport and Hunts Point at the end of November 2002 and in mid February
2003, respectively.

The project presented several technical challenges which included the combination of large
HDD crossings (1375 and 1070 meters long and 610mm diameter steel pipe with 30mm concrete
coating), in difficult geotechnical conditions, and the requirement for very high steering
accuracy while exiting in open, tidal sea conditions.