Horizontal Directional Drilling Training Manual A Training Program Presented by Horizontal Drilling International Houston, Texas, USA & Paris, France for Sumitomo Metal Industries, Ltd. Osaka & Tokyo, Japan February 1999 -i © 1999 Horizontal Drilling International Houston, Texas, USA, & Paris, France All rights reserved. This publication, including all paper and electronic copies, is strictly confidential and the sole property of Horizontal Drilling International. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, recording, or otherwise, without the prior written permission of Horizontal Drilling International. Illustrations produced by ALBACORE, Paris, France. Technical editing, desktop publishing, and electronic publishing by The Write Enterprise, Houston, Texas, USA. Contents Chapter 1 Planning and Scheduling Chapter 2 Engineering Chapter 3 Steering Chapter 4 Reaming Chapter 5 Pullback Chapter 6 Mud Appendix A Units and Abbreviations Appendix B Glossary -iii Chapter 1: Planning and Scheduling Introduction ........................................................................................ 1-1 Horizontal directional drilling .............................................................................. 1-1 The importance of planning and scheduling ...................................................... 1-1 Case study ......................................................................................................... 1-1 Dimensions and characteristics of the crossing ...............................................................1-1 Soil investigation report ...................................................................................................1-2 Identifying tasks ................................................................................................. 1-2 Site Visit .............................................................................................. 1-3 Access................................................................................................................ 1-4 Rig side .............................................................................................................. 1-4 Water source...................................................................................................... 1-4 Pipe side ............................................................................................................ 1-4 Tru Tracker™ coils............................................................................................. 1-5 Obstacles and local constraints ......................................................................... 1-5 Communications ................................................................................................ 1-5 Accommodations and board .............................................................................. 1-6 Planning and Estimating Costs ........................................................ 1-6 Size of the drilling rig and support equipment .................................................... 1-6 Drilling method and tools.................................................................................... 1-7 Pilot hole ..........................................................................................................................1-7 Reaming ............................................................................................................................1-8 Pulling ..............................................................................................................................1-8 Anchorage of rig...............................................................................................................1-8 Subcontracts ...................................................................................................... 1-8 Work schedule ................................................................................................... 1-9 Quantities ........................................................................................................... 1-9 Crew .................................................................................................................................1-9 Drilling accessories........................................................................................................1-10 Drilling consumables......................................................................................................1-10 Rig consumables and spares ..........................................................................................1-11 Mobilization/demobilization...........................................................................................1-11 Other considerations ........................................................................................ 1-12 Customs duties and taxes................................................................................................1-12 Local taxes......................................................................................................................1-12 Insurance ........................................................................................................................1-12 Weather conditions .........................................................................................................1-12 Terms of payment ...........................................................................................................1-12 Bid bond..........................................................................................................................1-12 Performance guarantee ..................................................................................................1-12 Bank guarantee upon completion ...................................................................................1-12 Closing meeting ............................................................................................... 1-12 Preparing to Work.............................................................................1-13 Permits ............................................................................................................. 1-13 Equipment ........................................................................................................ 1-13 Rig and spare parts ........................................................................................................ 1-13 Drill pipes and downhole tools ...................................................................................... 1-13 Pumps and spare parts................................................................................................... 1-13 Recycling equipment and spare parts ............................................................................ 1-13 Pipe rollers and cradles ................................................................................................. 1-13 Transporting equipment ................................................................................................. 1-13 Clearing customs............................................................................................................ 1-13 Personnel ......................................................................................................... 1-13 Selecting the crew .......................................................................................................... 1-13 Briefing the superintendent and assistant ...................................................................... 1-14 Transporting the crew .................................................................................................... 1-14 Consumables.................................................................................................... 1-14 Bentonite ........................................................................................................................ 1-14 Water .............................................................................................................................. 1-14 Fuel ................................................................................................................................ 1-14 Electric wire ................................................................................................................... 1-14 Line of sight and coil installation....................................................................... 1-14 Subcontracts..................................................................................................... 1-14 Civil works ..................................................................................................................... 1-14 Sheet piling for rig anchorage ....................................................................................... 1-15 Mud return line .............................................................................................................. 1-15 Mud trucking .................................................................................................................. 1-15 Pipeline prefabrication .................................................................................................. 1-15 Buoyancy control system................................................................................................ 1-15 Mud removal .................................................................................................................. 1-15 Communications and coordination ................................................................... 1-16 HD-650 drill unit. ii List of Figures Fig. 1.1. Soil investigation report. ....................................................................................1-2 Fig. 1.2. Map view of job site...........................................................................................1-3 Fig. 1.3. Size of the drilling rig. .......................................................................................1-6 Fig. 1.4. Typical maxi-rig.................................................................................................1-7 Fig. 1.5. Typical marine installation...............................................................................1-16 List of Tables Table 1.1. Bentonite consumption estimates. .................................................................1-10 Pipeline pullback. iii Notes iv Chapter 1: Planning and Scheduling Introduction Horizontal directional drilling Horizontal directional drilling (HDD) is a technique that comes from the oil field, but it is applied to the crossing of rivers, railways, motorways, dikes, and other obstacles. The drilling assembly has a bent sub for steering purposes, and is equipped with an electronic probe to continuously report the position of the pilot hole to the driller. Interpreting this information allows the pilot hole to follow the designed path. Then the pilot string is removed and the hole enlarged by reaming according to the diameter of the pipeline or conduit to be installed. This is done with a reamer or hole opener, which is pulled and rotated into the pilot bore. The bentonite carries the cuttings out of the hole, and leaves a lining (the filter cake) on the wall of the bored pathway. Arriving at the final size required for the reamed hole may require one or more passes. The hole is lubricated and the cuttings removed by using drilling mud (generally bentonite-based mud). This process is repeated until the drill bit exits on the other side of the obstacle. The pipeline or conduit, which has been assembled in one continuous string, if possible, is placed on launching rollers or in a flotation ditch. It is then connected to the drill pipe by a swivel joint, preceded by a reamer and is pulled into the reamed hole. The importance of planning and scheduling This course is designed to assist the Sumitomo project manager in planning and scheduling an HDD project. This chapter reviews all questions that should be answered when a project is in planning, out for bid, or in the process of mobilization. By taking the time to answer these questions in the early stages of the project, the project manager will save his company time and money. Case study A case study designed to walk you through the various planning stages is presented throughout this chapter. Project specifics for the case study are set in green italicized type, as follows: This case study concerns a seaway crossing, the Ij Meer, near Amsterdam in the Netherlands. It was awarded to HDI in early May 1995 and construction took place in June 1995. Dimensions and characteristics of the crossing. Typically, by the time the project is assigned to the project manager, the pipeline route has already been established. This being the case, the HDD considerations concerning route selection will not be considered here. However, in those instances where the project manager has preliminary input to the pipeline route, following these guidelines whenever possible will minimize construction risk: • Keep the crossing as short as possible. Crossings less than 1000 ft (300 m) are considered short, crossings between 1000 and 2950 ft (300 and 900 m) are considered medium, crossings between 2950 and 4600 ft (900 m and 1400 m) are considered long, and crossings longer than 4600 ft (1400 m) are considered extremely long. • Keep the entry and site exit sides of the crossing as close to the same elevation as possible—try to avoid elevation differences of more than 50 ft (15 m). Horizontal Directional Drilling Training Program • Avoid routes where the pipeline cannot be constructed in one continuous string. • Maintain a minimum separation of 50 ft (15 m) from other existing pipelines. • Cross the river or obstacle in a straight line. • Avoid placing a crossing near large masses of steel, such as railroad bridges, steel piling, or docks where barges are moored. The client provided the following data for the project: Banks: No significant difference in elevation Construction period: Award in three weeks and construction within three months Other: Horizontal curve 8° at 2/3 of the crossing with 1640-ft (500-m) radius. Soil investigation report. The single most important consideration to the directional drilling contractor is the nature of the soils at the crossing location. The subsurface condition is the primary factor in determining the methods, price, and feasibility of a project. Clients should provide geological information with their tender document. Pipeline diameter: 16 in. (406.40 mm) Wall thickness: 0.75 in. (19.10 mm) Coating: 0.12 in. (3 mm) polyethylene (PE) Length of the crossing: 3821 ft (1165 m) Width of the watercourse: 3018 ft (920 m) Depth of the crossing: 100 ft (30 m) Vertical drilling radius: 1640 ft (500 m) In this project, the subsoil consists of alternating layers of clay, silty clay, peat, and sand (Fig. 1.1). The navigation channel overlies a deep sand deposit. Standard Penetration Test results range from 10 blows per foot (bpf) in the peat layer to 25 bpf in the clay layers, and average 35 bpf in the sand formations. No sieve analysis was provided. 1 Fig. 1.1. Soil investigation report. 1 Soil boring Identifying tasks The first task is to assess the feasibility of the crossing by HDD. The project manager will review and analyze the data provided 1-2 by the client and visit the site, preferably with a client representative. Planning and Scheduling: Site Visit The second task, once the feasibility of the project is confirmed, is to estimate the construction costs. For this purpose, the project manager will determine the necessary equipment and crew, assess the drilling, reaming and pulling methods (types of tools and sequences), prepare a tentative construction schedule, and estimate quantities of consumables. Then the selling price can be determined. When the offer is accepted by the client, the project manager must mobilize all the necessary equipment and consumables, finalize the necessary subcontracts, and brief the construction crew about the specifics of the project. The following pages will take you through the complete exercise, based on the specifics of the case study. Site Visit It is useful to visit the site with a client representative, because they will often communicate their concerns about local restrictions and regulations placed on them by governing bodies. During this site visit, take relevant photographs and write a report to document what has been seen and discussed; it is common that the actual construction takes place several months after the initial site visit. If the contract specifically states, “Grounds (or roads) will be returned to their original condition,” the photographs are especially useful to docu- ment that you have complied with contract specifications. For this project the client organized an onsite meeting with all the prequalified contractors, followed by a site visit. During the meeting they were very specific about the accuracy of the drilling profile: the permit allowed for a corridor of only 20 ft (6 m) wide, which would be checked by a gyroscopic survey performed after the project’s completion by a third party at the client’s expense (Fig. 1.2). 1 3 2 1 Fig. 1.2. Map view of job site. 1 Pipeline route 2 Initial crossing alignment 3 Revised crossing alignment 1-3 Horizontal Directional Drilling Training Program Access Because the drilling spread consists of wheel-mounted loads that average 25 tons each and measure approximately 40 ft long and 13 ft high (12 m long and 4 m high), make sure that it is possible to deliver all the equipment to the rig side of the crossing. For this reason, make note of low bridges, sharp turns in roadways, or anything else that may impede access. Usually the access to the crossing site is a temporary construction road (dragline skids, gravel) and the length of this temporary access road must be estimated during the site visit. The same is true for access to the pipe side. Access to the Ij Meer rig site is straightforward, via highway and paved road until 260 ft (80 m) from the entry point. The pipe side is accessible by barges or, for light equipment, by a narrow paved road. Rig side A crossing with the maxi-rig requires a drilling site of 200 x 200 ft (60 x 60 m), while a crossing with the midi-rig only requires a site of 70 x 100 ft (20 x 30 m). For a large crossing through rock or coarse granular materials, the workspace should be increased to 200 x 260 ft (60 by 80 m). The total available workspace is sufficient, but the entry point chosen by the client is too close to the embankment of the adjacent road. During the site visit with the client, it was agreed that the entry point be shifted by 10 ft (3 m), which is far enough from the embankment (Fig. 1.2, item 3). Any shift in the entry point must stay within the crossing corridor approved by the river authorities. Water source During the site visit, determine the freshwater source for mixing the mud: • City water: Can city water from a hydrant be used? What notice is required by the city water companies? Is a meter required? Where is that arranged? What is the cost? If the available water source is located some distance from the planned entry point, the drilling spread must have enough hose and pump capacity to move the required volumes the distance and elevation changes that you will encounter. River water: Can water from the river be used? Is it fresh water? There is no problem with pumping large quantities of river water in the Ij Meer, but the water salinity must be checked. A laboratory test confirms a salt content of less than 120 mg/l, which is acceptable for mixing the bentonite (see Mud, page 6-14). Ideally, the pipe side should have enough temporary workspace to lay the pipeline in a continuous string in the axis of the crossing. The pipeline should be prefabricated in this temporary workspace starting approximately 50 to 100 ft (15 to 30 m) beyond the exit point. This space should be 30 to 50 ft (10 to 15 m) wide, depending on the diameter of the pipe. Larger-diameter pipelines require larger pieces of equipment and therefore more working room. At the exit location, a temporary workspace of 50 ft wide by 100 ft long (15 by 30 m) is ideal for most intermediate crossings. For large crossings through rock or coarse granular materials, a temporary workspace 100 ft wide by 150 ft long (30 by 45 m) may be needed to accommodate the necessary equipment. • Pipe side 1-4 Planning and Scheduling: Site Visit In some cases (especially swampy areas), the roller track can be replaced by a flotation ditch. In this area, the pipeline cannot be built in line with the drilling alignment. However, by curving the right-of-way 45° about 160 ft (50 m) after the exit point, the 3821-ft (1165-m) pipeline can be welded in one section along a road that must stay open for traffic. A temporary bridge, made of rollers placed on top of containers, is installed to cross the road. At the exit point, no room is available for placing a mud pit. Because of the access, no vacuum trucks can reach the site. Therefore, a small desanding unit is needed to preclean the mud; then the mud is pumped across the Ij Meer back to the rig side through a temporary 6-in. (150-mm) highdensity polyethylene (HDPE) pipe attached to a 2-in. (50-mm) steel cable to sink it. Tru Tracker™ coils On both sides of the river, permission is needed to set up a wire Tru Tracker coil from the edge of the water to either the entry or exit points. Generally, these coils are set as wide as the crossing is deep at the particular location. Setting these coils disturbs very little of the surface vegetation. For a complete discussion of setting Tru Tracker coil, see Steering (page 3-30). A coil could not be installed on the pipe side because of housing and private properties. On the rig side, the coil could be installed, but very little room was left between the entry point and the riverbank. Obstacles and local constraints During the site visit, identify obstacles such as existing pipelines, cables, or sheet pilings. Massive steel structures such as pilings, pipelines, or high voltage lines will disturb the local magnetic field and create interference for the steering tools. In these cases, it is almost mandatory that the Tru Tracker locating system is used to drill accurately. Constraints such as neighboring housing, which limits the acceptable noise level, or special environmental considerations about the handling of mud, should also be identified at this stage. At the Ij Meer location, there was no such constraint. However, because of the narrow corridor allowed by the water authorities, wooden piles were installed to aid the laying of Tru Tracker coil at intervals along the crossing. Also, a very strict criterion was determined for accepting the pilot hole data: if a reading made in the coil is more than 7 ft (2.2 m) away from the centerline, it is rejected and the joint is redrilled (the corridor allows for 10 ft [3 m], so the reading must be accurate—2% of the depth— and a half-diameter of pipe). Communications During the site visit, locate the shortest routes to transport equipment and personnel from one side of the crossing to the other. On a large crossing that lacks a bridge, a barge and tug must be planned. The Ij Meer is very shallow outside the navigation channel and barges cannot be used. Therefore, only the narrow road can be used, which means limiting the number of trucks and allowing no vacuum truck to be used; hence the mud return line. Crew members can easily get from one side to the other by car. A boat is needed to install and operate the Tru Tracker coil. 1-5 Horizontal Directional Drilling Training Program Accommodations and board Several reputable hotel chains exist in Holland and it is never difficult to find suitable accommodations except during holidays. The Ij Meer crossing was not conducted near a holiday, so accommodations were easy to find. The quality of the living accommodations and board is very important for the morale of the crew, and a crew with good morale will often be more efficient. The site visit is a good opportunity to check the quality and prices of neighboring hotels or motels; prices are often negotiable for groups and extended periods of stay. Planning and Estimating Costs Size of the drilling rig and support equipment The choice of rig is an important decision. The chart in Fig. 1.3 indicates the pulling force the rig should have for various diameters and standard wall thicknesses of steel pipes relative to the length of the crossing. In the Engineering chapter (Chapter 2), a more precise calculation of the pull force is explained, which also takes into account an eventual buoyancy control system. F (KN) Ø (") 5000 40" 4500 4000 36" 3500 3000 32" 2500 28" 2000 24" 1500 20" 1000 16" 500 12" 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 L (m) Fig. 1.3. Size of the drilling rig. Available torque is another important item to consider when choosing a rig configuration for a particular job. Normally, higher torque is required when planning largediameter hole-opening operations in soft or hard ground and rock. Proper makeup and breakout torque is the minimum required torque. A rig should also have the power to turn at a specified rotary speed with specified torque, without impacting the pulling or rotation specifications. Hole opening in rock requires higher rotary speeds in smaller sizes and lower rotary speeds in larger sizes. If the correct rotary speed is 1-6 not maintained, lower penetration rates will result. A fast carriage travel speed is recommended when drilling in soft formations. It is rarely necessary otherwise, but does save time. For the above reasons, sometimes only two (out of four) translation motors are used on the maxi-rigs, thereby increasing the carriage travel speed on crossings where a moderate pull force is expected, and one (out of two) rotation motor is used with double rotation speed on reaming small diameters in rock or hard formations. Planning and Scheduling: Planning and Estimating Costs A midi-rig was too small so a maxi-rig was chosen, using only two translation motors and one rotation motor to increase efficiency. For this project, one pumping skid was used, delivering 140 cum/hr at 150 bars. Pumping rates would be as high as 100 cum/hr during casing and reaming. The project manager must now decide upon the mud system, comprising a mixing unit, mud pump(s), and recycling unit. In the chapters on Steering (Chapter 3), Reaming (Chapter 4), and Pullback (Chapter 5), indication of flow rates are given, as well as the theory behind them. A typical maxi-rig is shown in Fig. 1.4. A standard mud mixing unit was chosen for the rig side. In addition, mud was recycled, with one unit able to process 150 cum/hr of mud with 25% cuttings on the rig side. For the reaming operations, a desanding unit was placed at the pipe side for precleaning, and the mud with 4 to 7% cuttings was pumped back to the rig side with a pipeline service pump through the 6-in. (150-mm) mud return line. Fig. 1.4. Typical maxi-rig. Drilling method and tools At this stage, it is critical to understand the specifics of the project and define the methods. In particular, answer the following questions about the pilot hole, reaming, pulling, and anchorage of the rig: Pilot hole. • Should a jet or mud motor be used, and what type of bit is used? • Should a casing be used? • How many shifts per day will the crew work? In this project the decisions were to: • drill by jetting because of the soft, alluvial soils • use a 12-in. (300-mm) casing on the first 500 ft (150 m) to protect the entry curve because of the length of the crossing and soil conditions (more than 3300 ft [1000 m] in alluvial materials) • work the day shift until the casing is installed, and a double shift after that. 1-7 Horizontal Directional Drilling Training Program Reaming. Pulling. • Is it necessary to do pre-reaming? • Should a buoyancy system be used? • What will be the final diameter of the reaming? • Should a special reamer, such as a gravel reamer, be used? • Will reaming be done with a fly cutter or hole opener, and what types of cutters will be used? • How much space is needed between rollers and how many rollers will be used, or will a flotation ditch be used? • How many passes will it take to reach the final diameter? • How many and what kind of supports will be used for the catenary? • • Will reaming be done backward or forward? How many shifts per day will the crew work? • How many and what size mud pumps will be used? • Will a second rig or a winch be used to ream in rock? • How many shifts per day will the crew work? In this project the decisions were to: • use no buoyancy control system because of the small pipe diameter (less than 27.5 in. [700 mm]) • use a standard bullet nose or fly cutter for pulling, rather than a special tool (the final decision was left with the superintendent) • use 50 ft (15 m) between supports, thereby requiring 75 pipe rollers • fix the catenary to cross above the road, and place rollers on top of the containers • be on alert to pull with a double shift, and to start pulling shortly after the reaming is finished. In this project the decisions were to: • execute a pre-reaming because of the favorable soil conditions, moving directly to a 30-in. (760 mm) diameter with a standard fly cutter reamer • bring a double quantity of drill pipe to facilitate the pre-reaming • ream backward, pulling the reamer to the rig, because of the space restrictions on the pipe side; and because the length of the crossing did not allow the use of a side boom or dozer, but rather a winch with at least 50 tons of pulling capacity • work a double shift because of the length of the crossing and the alluvial soil materials. Anchorage of rig. Because of the expected push/pull forces, is extra anchorage obtained by using a single-frame or doubleframe sheet piling? A single-frame sheet piling was installed because of the pull force necessary to remove the casing and pull back the 3821-ft x 16-in. (1165-m x 400-mm) pipeline. Subcontracts Civil works (access, site preparation, reinstatement) and pipeline prefabrication (stringing, welding, coating, testing) can be handled by the client when they are a pipeline contractor or the pipeline division of your company. In this case, you have a contract for drilling services only. 1-8 Civil works can easily be integrated into the scope of work in a turnkey contract. In these cases, the non-drilling aspects of a job are often subcontracted to another company or to another division of your company. However, you can also decide to perform the access and site preparation on the rig side when no major earth moving is involved. Planning and Scheduling: Planning and Estimating Costs When choosing a subcontractor and negotiating the subcontract, keep in mind that the cheapest price might not always mean the best deal. It is important to make certain that work schedules are kept and that the access is finished when the rig arrives, or that the preliminary hydrotest and joint coating are finished by the time reaming is started. HDI was a subcontractor of A.Hak, and the contract only included drilling services. Therefore, the only concern about civil and pipeline works was the timing of the operations. Once A.Hak set the date when the pipeline would be ready for pulling, HDI worked backward to plan the mobilization and drilling operations, and informed A.Hak of the date when access and rig site would be ready for the rig’s arrival. Work schedule Based on the above decisions about drilling methods and tools, together with knowledge of usual progress rates for each drilling step and tool in similar soil conditions, it is now time make a tentative work schedule. In this project the following was anticipated: • 1/2 day (one shift) of slack time for potential problems (shorts, mechanical failure, etc.) • 1/2 day (one shift) for preparing the reaming (removing the spider subs, etc.) • 1/2 day (one shift) for removing the 12in. (300-mm) casing • 1 1/2 day (three shifts) for reaming the hole and preparing for pulling • two days for mobilizing all the equipment to the site • • three days (three shifts) for rigging up the rig and mud system one day (two shifts) for pulling the pipe, with the second shift starting the rig down • two days (two shifts) for rigging down and loading all the equipment • two days (two shifts) for drilling the first 1300 ft (400 m) • two days for demobilizing. • two days (two shifts) for installing 500 ft (150 m) of 12-in. (300-mm) casing • two days (four shifts) for drilling the remaining 2500 ft (765 m) The totals were: • four days of transportation • five days of rig up/rig down (five shifts) • 10 days of horizontal directional drilling (16 shifts). • one mechanic/pipe sider • one floorman—for a total of six crew members on small crossings. Quantities Crew. Once the basic decisions about the drilling program are made (type of rig, method, and tentative schedule), it is time to plan the crew. Typically, a crew working a single shift consists of: Midi-rig: Maxi-rig: • one superintendent • one superintendent • one driller • one driller • one surveyor/assistant superintendent • one surveyor • one mud technician • one mud engineer • one recycling technician 1-9 Horizontal Directional Drilling Training Program Drilling accessories. In view of the mobilization, you must carefully plan the quantities of drilling accessories, consisting mainly of drill pipes and rollers. • one mechanic • one pipe sider/welder • two floormen* • one operator (crane/excavator)—for a total of 10 crew members on large crossings. A large crew of 10 was planned for the day shift and a smaller crew of eight for the night shift (without a superintendent or mechanic). *For medium-sized crossings, the mud technician can also do the recycling and only one floorman is necessary, thus reducing the number of crew to eight. This job required 75 pipe rollers, and 2 x 1165/19.4 = 248 drill pipes with 5-in. diameters (plus a few spare pipes—typically 10%). Drilling consumables. An important part of the cost of an HDD project is the mud system. Tables compiled from experience help estimate the quantity of bentonite required for a job of a given size (length and equivalent diameter), in given soil conditions (alluvium or rock), and with or without recycling (Table 1.1). Table 1.1. Bentonite consumption estimates. Reaming in soft formations Reaming sequence Pipe Final Hole diameter Ream #1 Ream #2 Ream #3 Ream #4 reaming volume (mm) (mm) (l/m) (mm) (mm) (mm) (mm) 100 200 300 400 500 600 700 800 900 1000 1100 1200 400 500 600 700 800 900 1000 900 900 900 1000 1000 1100 1200 1400 1400 1400 400 500 600 700 800 900 1000 1100 1200 1400 1500 1600 1500 1600 126 196 283 385 503 636 785 950 1131 1539 1767 2011 Reaming in rock Reaming sequence Pipe Final Hole diameter Ream #1 Ream #2 Ream #3 Ream #4 reaming volume (mm) (mm) (l/m) (mm) (mm) (mm) (mm) 100 200 300 400 500 600 700 800 900 1-10 437.5 437.5 437.5 437.5 437.5 437.5 437.5 437.5 437.5 650 650 650 650 650 650 650 900 900 850 900 900 1000 1100 1200 437.5 437.5 650 650 900 900 1000 1100 1200 150 150 332 332 636 636 785 950 1131 Without recycling 50 kg b/ft With recycling 50 kg b/ft 0.36 0.56 0.81 1.10 1.44 1.82 2.24 2.72 3.23 4.40 5.05 5.74 0.14 0.22 0.32 0.48 0.57 0.73 0.90 1.09 1.29 1.76 2.02 2.30 Without recycling 50 kg b/ft With recycling 50 kg b/ft 1.72 1.72 3.79 3.79 7.27 7.27 8.98 10.86 12.93 0.57 0.57 1.26 1.26 2.42 2.42 2.99 3.62 4.31 Planning and Scheduling: Planning and Estimating Costs With a given quantity of bentonite, mix a volume of mud that, in cubic meters, is approximately 14 to 17 times the tonnage of the bentonite. Out of this volume anticipate that 2/3 will have to be treated or disposed of after the project. When there are a series of crossings in the same area, it is also possible to plan vacuum trucks and move the liquid mud from one job to the next if the costs of removal are high. In this case, the project manager should think globally about his mud consumption. In this case, Table 1.1 shows that with recycling, anticipate 0.48 x 50 kg x 116510.3048 = 91,730 kg of bentonite will be used, therefore mixing a total of 14 x 57.333 = 1280 cum of mud. Approximately 213 x 1280 = 852 cum of used mud will be left over at the end of the job. If fresh water cannot be pumped from the river, the total volume of water that must be purchased is calculated the same way. For practical reasons, locate a source of fresh water that can deliver as much as 60 cum/ hr; otherwise plan for storage water pits to be sure that there is enough flow when you need it (during casing and reaming). Rig consumables and spares. The drilling spread should always travel with sufficient spare parts to remediate mechanical breakdowns onsite and sufficient consumables (wire, grease for tool joints, hydraulic oil, etc.) for the job or series of jobs to be conducted. For estimating purposes use a day rate, which is a daily average of the amount spent over a year. Give special consideration to the quantity of fuel needed for the project—a midi-rig spread uses an average of 300 gal (1150 l) per 12-hr shift, while a maxi-rig spread with complete pumping and recycling capabilities uses as much as 520 gal (2000 l) per 12-hr shift. Mobilization/demobilization. When the type of rig, type and number of pumps, type of recycling unit, and number of drill pipes and rollers have been decided, the number of trucks necessary to mobilize the complete spread can be estimated. Of course, the equipment might not all come from the same place, and considerations other than the number of trucks are important when planning a mobilization. These other considerations will be reviewed later. For this job the following was needed: • three tractors for the rig, mud tank, and power unit • one tractor and a flat-bed trailer for the recycling unit • two tractors and a flat-bed trailer for the control, workshop, spares, and crew containers • three tractors and a flat-bed trailer for the 75 rollers • one tractor and a flat-bed trailer for the 500-ft x 12-in. (150-m x 300-mm) casing and the dead man • four tractors and a flat-bed trailer for the 260 5-in. drill pipes and monels. Another important consideration when planning a job is the time needed to mobilize the drilling spread. This obviously affects the price, since this time cannot be used to work elsewhere and therefore represents an opportunity cost. To reduce this cost, plan the jobs so that the crossings performed in one region are completed one after the other during the same period of the year. Of course, this is often a question of opportunities, but it is important to keep this aspect of the planning in mind. Furthermore, when planning and pricing a job, consider the crew mobilization and plan the relevant train or plane tickets and expenses. Again, if crossings in the same region can be grouped, it is possible to mobilize a single crew for several jobs. When bidding the Ij Meer crossing, a contract with another client was already signed for two 30-in. (760-mm) crossings in the Amsterdam region. So all three crossings were completed in the same time frame using the same rig and crew. 1-11 Horizontal Directional Drilling Training Program Other considerations The following considerations are listed for completeness, since each project has its own specifics (client, country of execution, financing). Customs duties and taxes. Consider not only the cost of these duties and taxes, but also the time spent at the customs office. Local taxes. Other taxes that may apply when pricing a job include local income taxes (which can sometimes take the form of a percentage of the turnover) or taxes on salaries. Insurance. In general, the drilling contractor must present its own third-party liability insurance. But quite often, a Construction All Risk (CAR) policy is offered by the client or main contractor, since they have greater bargaining power with the insurance company and can spread the risk on a wider range of activities. If a CAR policy is not offered by your client, you should think about the cost of obtaining one before starting the project. Weather conditions. Although the HDD method for river crossings is fairly independent of weather conditions, remember a few basic considerations when planning a job: • If heavy rains are expected, pay attention to preparing and maintaining the access roads and work areas during the project. • If freezing is expected, daily progress will be hampered by drainage proce- dures for all the water lines and mud lines at each end of day. Also, the power unit must be protected from excessive cold. One solution is to work double shifts systematically, and install a tent with heaters on the power unit for moderate cold (-10°C [14°F]). For very cold and windy conditions, plan a Sprung structure to protect the entire drilling spread and crew. Terms of payment. The terms of payment will influence the cash flow of the project and therefore will generate financial costs or gains. Bid bond. Some clients request a bid bond to be deposited in a bank of their choice before a drilling contractor can have his bid considered at the price opening meeting. This has a cost, although moderate. Performance guarantee. Some clients ask for a performance guarantee when awarding a job to a contractor; this also has a cost. Bank guarantee upon completion. It is common that the final payment (5 or 10%) is linked to the final acceptance of the project. This payment is typically made one year after the provisory acceptance, unless a bank guarantee of the same amount is arranged by the contractor for the benefit of the client, with the corresponding validity period; only then is the final payment made at the time of the provisory acceptance. These costs should also be considered. Closing meeting There should always be a closing meeting initiated by the project manager with his management. In this meeting, the project 1-12 and its context are presented, and the selling price and conditions are discussed and agreed upon. Planning and Scheduling: Preparing to Work Preparing to Work Assume that after this careful study and bidding, Sumitomo is awarded the construction of the project. The project manager should now review all the tasks described above and make sure that everything will be available and delivered on time to start the job. Meanwhile, he should also monitor the progress of the civil and pipeline works to make sure that no delays occur, or adjust the mobilization plan in case of deviations in the planning. The following section outlines all the tasks the project manager will need to complete. Permits Usually, permits are delivered by the client or main contractor, but the project manager should follow the progress of the permit- ting since the onsite work cannot start until all permits are delivered. Equipment Rig and spare parts. Determine which rig you will use, check its working condition, and replenish its spare parts stock. Drill pipes and downhole tools. Locate the necessary length of drill pipes and check their condition. Locate the drilling tools you will need (jet assembly or mud motor) and the drill bits. Check the available reamers (barrel reamer/fly cutters/hole openers) and their condition, and build new tools if the required sizes are not available. Pumps and spare parts. Check the availability of the pump(s) and replenish the spare parts stock if necessary. Plan sufficient hoses to install the pump(s) on the construction site. Recycling equipment and spare parts. Check the availability of the recycling unit(s) and replenish the spare parts stock if necessary. Plan sufficient hoses to install the recycling unit(s) on the construction site. Plan the feeding pumps accordingly. Pipe rollers and cradles. Check the availability of the rollers. Note that rollers are often requested to be delivered on the pipe side before beginning the project, because pipeline contractors might decide to install the rollers at the same time that the pipeline is being welded. Even if a flotation ditch is used for the complete string, placing a few rollers at the entry of the pipe in the hole could be useful. For the launching ramp, locate cradles of sufficient size for the pulling operation. Transporting equipment. Plan the schedule of the truck transports, equipment (cranes), and crew to load and offload the equipment. For convenience, plan to receive the rig and support equipment onsite the first day, and receive the drill pipes and supplies the second day when the rig is almost rigged up. Clearing customs. At each border crossing there is a procedure for clearing customs. In some cases, detailed lists of equipment and consumables must be prepared to expedite the clearance. If this is not prepared carefully and on time, it might result in a considerable loss of time at the border. Personnel Selecting the crew. Crew members are selected based on their specialties and sometimes upon other criteria, such as language skills, past relations with a given client, or specific experience (long cross- ings, large-diameter crossings, rock crossings). Use a mixed crew of specifically experienced people with less experienced people in order to train those with less experience. Experience in the 1-13 Horizontal Directional Drilling Training Program field is the best training ground for directional drilling. Briefing the superintendent and assistant. Before the work starts, brief the superintendent and possibly his assistant or the driller about the project—especially about the soil conditions. At this stage, the project manager must be open to suggestions, new ideas, or requests for specific equipment coming from the superintendent. Practical considerations of the superintendent often save time and avoid inconveniences onsite during construction. Transporting the crew. Prepare the final mobilization plan of the crew(s) and inform all personnel. Usually the drilling superintendent is mobilized earlier to supervise the preparatory activities at the site. Even if these activities are not in the scope of work but performed by the main contractor, the superintendent must be onsite to coordinate the effort. The superintendent also informs the project manager about the progress to correctly plan the equipment and crew mobilization. Consumables Bentonite. Place orders for the supply of bentonite. On large crossings with limited working space, you can plan a gradual delivery to the site following the progress of the job, but only if the supplier is reliable. Avoid being left on standby because the bentonite supply has been depleted. Water. Check whether you need a permit to pump in the river, and if you do need one, be sure that you have it. When loading the equipment on the trucks, check again that there is sufficient length of hoses to reach the source of fresh water for mixing the mud. If you have to buy the water, finalize the contract now. Fuel. Locate a local fuel supplier and finalize a contract, stressing the importance of regular deliveries. Again, avoid being on standby because there is no fuel left on the job. Electric wire. Check the meterage of wire for directional control. As explained in Steering (Chapter 3), always use new wire to try to eliminate the risk of electrical shorts when drilling the pilot hole. Line of sight and coil installation Before any onsite activity, make sure that the line of sight of the crossing and entry and exit points of the drilling are properly marked. Entry and exit points should be identified by the client and checked by the crew surveyor. The surveyor will then place the survey stakes, marking the line of sight of the crossing. This must be completed before preparing the platform and installing the sheet piling, to make sure that everything is properly placed. The crew surveyor installs the coil while the rest of the crew is rigging up. Subcontracts Civil works. Most of the time, civil works consists only of preparing the final access road for the rig (and pipe) site(s) and the drilling platform, mud pits, and water pit, when necessary. This must be ready before the drilling and support equipment arrives. The reinstatement will be done immediately after the tie in. As already mentioned, the access road must be strong enough for loads of 25 tons. 1-14 Very often, mud removal is part of another subcontract and is not performed by the civil works company. The subcontract for civil works must incorporate the client’s specifications for reinstatement. Also, since the HDD method is environmentally friendly, reinstatement should be done quickly and properly to leave a good impression of the river crossing method. Planning and Scheduling: Preparing to Work Sheet piling for rig anchorage. When a sheet piling is necessary, organize it a day or two before the drilling equipment arrives onsite. This work can be subcontracted. Mud return line. When a mud return line is necessary, make sure it is in place before the reaming operation begins. Try to install it before the rig arrives to make sure that reaming activities will not be delayed once the pilot hole is finished. This preparation can be subcontracted or executed by a few crew members mobilized early onsite. Mud trucking. When a mud return line cannot be installed, for small crossings or when forward reaming is used, you can locally hire a few vacuum trucks or farm tractors with tanks to move the drilling mud surfacing in the pipe side exit pit back to the recycling unit located on the rig site. Finalize the contract with a service company or local farmers, making sure it also states the working hours. Particularly, nighttime working hours should be scheduled to ensure that the night crew has the support they need to continue working. Pipeline prefabrication. Finalize the subcontract for pipeline prefabrication (if any) at this stage, although probably much (such as the choice of the subcontractor) has been decided during the tender and negotiation phases of the main contract. Remember that good pipeline works are essential for the success of the project. The client is interested not only in a finished product, but in a finished product that is in good working condition. This means that the pipeline must withstand the expected pressures, maintain its circular shape, and have a proper coating. The best way to achieve this is to make sure that the prefabricated pipeline fulfills these requirements before you start the pulling operation. Another important consideration when finalizing the subcontract is the respect of the work schedule. Avoid being on standby after the pilot hole because the pipeline is still not tested or because the field joint coating materials have not yet been delivered. In any case, clearly identify the limits of the subcontract and responsibilities. For example, use a formal procedure, with an acceptance sheet, for delivering the pipeline welded, tested, and coated to the drilling contractor; from this point the drilling contractor is responsible for the pipeline. Also, make it clear who supplies and welds the pulling head (the design being, of course, the responsibility of the drilling company, unless stated otherwise). The principle of a formal acceptance of the pipeline also applies when you are a subcontractor of a pipeline main contractor. Buoyancy control system. When a buoyancy control system is necessary, it always remains under the direct responsibility of the HDD contractor. Even if the supply and installation are subcontracted, its constituents and dimensions are engineered by the drilling contractor, and the construction should be supervised by one of its crew members. At this stage of the project, it is mandatory to pass orders for the supply of materials if they are not in stock, and plan the construction onsite. Even if the system can be put into place only after the pipeline has been successfully pretested, you can plan the materials delivery and some preparatory works (such as double-jointing of HDPE pipes, constructing the flanges) during the pipeline prefabrication period. Mud removal. Devise a good solution for mud removal at this stage of the project. If left until the end of the project, you may find yourself dealing with high prices and an unhappy client. Since the inception of mud recycling techniques on directionally drilled crossings that use new light and mobile recycling units, there is usually little liquid mud to be evacuated. In some cases, farmers may allow you to spray the mud on their fields. Dispose of the dry cuttings coming out of the hole (for a total equivalent to the volume of the reamed hole), which have been separated from the mud. Often these cuttings can be locally backfilled. In all circumstances, obtain from the bentonite supplier a composition certificate for 1-15 Horizontal Directional Drilling Training Program his product. You may wish to conduct laboratory tests on mud samples to confirm that it is harmless before locating a disposal area. As mentioned in the Drilling Consumables section (page 1-10), when there are several crossings in the same region, liquid mud can be moved from one site to the next with vacuum trucks or farm tractors with tanks, to create as little waste as possible. Communications and coordination It is very important to organize a good communication system between the job site and the outside world (phone, fax). This will enable the site to inform its base regularly about the progress of the project, confirm orders for new deliveries of consumables, request spare parts from the base, discuss technical problems with other specialized colleagues at the base, and make faster and better decisions. The progress of the subcontracts and delivery of consumables during this preparatory phase, as well as during construction, must be watched closely by the project manager. He is the central point of the project organization through whom all communication must flow to make efficient decisions and adjustments. For a successful operation, you must establish a good working collaboration between the project manager and the construction superintendent. Fig. 1.5. Typical marine installation. 1-16 Chapter 2: Engineering Generalities......................................................................................... 2-1 Presenting the engineering course .................................................................... 2-1 Strength of materials—Background ................................................................... 2-1 Basic strength of material ................................................................................................2-1 Stresses combination ........................................................................................................2-2 Beam strength of materials...............................................................................................2-2 Beam/pipeline formulas....................................................................................................2-2 Pipeline Codes.................................................................................... 2-3 Definitions .......................................................................................................... 2-3 Location classes................................................................................................. 2-3 Construction types ............................................................................................. 2-3 Pressures ........................................................................................................... 2-5 Design criteria .................................................................................................... 2-5 Stresses During Testing or Operations ........................................... 2-6 Hoop stress ........................................................................................................ 2-6 Bending stress ................................................................................................... 2-6 Temperature stress ............................................................................................ 2-6 Restrained pipeline stress.................................................................................. 2-6 Traction stress.................................................................................................... 2-6 Ground pressure ................................................................................................ 2-7 Pipeline specifications........................................................................................ 2-7 Pipeline Engineering.......................................................................... 2-7 Verifying wall thickness ...................................................................................... 2-7 Hoop stress .......................................................................................................................2-7 Ground pressure ...............................................................................................................2-8 Hydrostatic test .................................................................................................. 2-9 Operating pressure .......................................................................................... 2-10 Comments........................................................................................................ 2-10 Installation conditions....................................................................................... 2-10 Minimum radius................................................................................................ 2-10 Crossing Engineering ...................................................................... 2-11 Introduction ...................................................................................................... 2-11 The crossing’s path design .............................................................................. 2-11 River ...............................................................................................................................2-11 Exclusion area ................................................................................................................2-11 Entry angle .....................................................................................................................2-12 Exit angle........................................................................................................................2-12 Subsoil nature or obstacles ............................................................................................2-12 Design of the profile .......................................................................................................2-12 The crossing’s layout........................................................................................ 2-15 Entry side ....................................................................................................................... 2-15 Pipe side ......................................................................................................................... 2-16 Catenary......................................................................................................................... 2-18 Engineering Procedures ..................................................................2-19 Preliminary evaluation ...................................................................................... 2-19 Product line nature ........................................................................................................ 2-19 Pipe size ......................................................................................................................... 2-19 Pipe length ..................................................................................................................... 2-19 Pipe mechanical characteristics .................................................................................... 2-20 Pipeline coating and field joints .................................................................................... 2-20 Catenary ........................................................................................................... 2-21 Multiple pipeline installation. ii List of Figures Fig. 2.1. Stress-strain curve. .............................................................................................2-1 Fig. 2.2. Determining the exclusion area........................................................................2-12 Fig. 2.3. Designing the pilot hole profile........................................................................2-13 Fig. 2.4. Crossing’s profile: minimum depth. ................................................................2-14 Fig. 2.5. Crossing’s profile: minimum length. ...............................................................2-14 Fig. 2.6. Typical entry side layout. .................................................................................2-16 Fig. 2.7. Typical pipe side layout. ..................................................................................2-17 Fig. 2.8. Pipe side, South Louisiana, USA. ....................................................................2-17 Fig. 2.9. Catenary with and without an exit pit. .............................................................2-18 Fig. 2.10. Length/diameter feasibility range. .................................................................2-20 Fig. 2.11. Catenary. ........................................................................................................2-22 Fig. 2.12. Pipeline string and catenary. Norfolk, Virginia, USA. ..................................2-22 List of Tables Table 2.1. API pipeline specifications. .............................................................................2-3 Table 2.2. Classification of steel pipe construction (API Table 841.15A)........................2-4 Table 2.3. Values of design factor F (API Table 841.1A).................................................2-5 Table 2.4. Longitudinal joint factor E (API Table 841.1B). .............................................2-8 Table 2.5. Temperature derating factor T (API Table 841.1C). ........................................2-9 Maxi-rig, Southeast Texas, USA. iii Notes iv Chapter 2: Engineering Generalities Presenting the engineering course This chapter reviews the objectives of horizontal directional drilling (HDD) engineering and the course plan of the modules dealing with engineering. The engineering exercises are aimed toward issuing a recommendation on the feasibility of an HDD crossing with regard to technical, scheduling, and economical criteria, and defining the crossing’s acceptance criteria. It is assumed that the engineer has the following minimum information: • pipeline characteristics • pipeline route • obstacle profile • subsoil conditions. Strength of materials—Background Basic strength of material. The strength of a material depends on the relationship between external forces applied to elastic bodies and the resulting deformations and stresses. Forces on pipelines are produced by gravity, buoyancy (if any), pulling on the pipe, bending the pipe, soil reaction (friction), and internal hydrostatic pressure. Many mechanical properties of materials are determined by testing, which gives the relationship between stresses and strains, as is explained in the following section. Stress is the force per unit area and is expressed in lb/in.2 (Newton/m2 or Pascal [Pa]). The megapascal (Mpa) is often used as a convenient multiple of the Pascal. If the stress tends to stretch the material, it is called a tensile stress; if it compresses or shortens the material, it is a compressive stress. By convention, a tensile stress is negative. Unit strain (or strain) is the amount by which a dimension of a body changes when the body is submitted to a load, divided by the original value of the dimension. When the load varies, you plot a curve showing strain vs. stress. Usually, this curve is linear until a limit called the proportional limit is reached. Elastic limit is the maximum stress under which a test specimen may be subjected and still return to its original length when the load is released. If the stress exceeds this elastic limit, the material is said to be stressed in the plastic region where permanent deformation occurs, until the ultimate strength is reached, when the material breaks (Fig. 2.1) 1 Fig. 2.1. Stress-strain curve. 5 4 1 = Strain 3 2 = Stress 3 = Proportional limit 4 = Elastic limit 5 = Ultimate limit 2 Horizontal Directional Drilling Training Program The modulus of elasticity E, also called Young’s modulus, is the ratio of unit stress to unit strain, within the proportional limit. When a material is subjected to a longitudinal strain within the proportional limit, there is a lateral strain that is proportional to the longitudinal strain. The ratio is called Poisson’s ratio ν. It is important to understand that if a material is not allowed to strain in one direction, the strain in the other direction induces stresses in the material. For example, during pressure testing of a pipeline, if the pipeline section is restrained from shortening, you will observe a tensile stress in the pipeline equal to the tensile stress that results from pressure multiplied by Poisson’s ratio. The values of E and ν for steel are: Poisson’s ratio: νsteel = 0.3 Young’s modulus: Esteel = 2.1 105 Mpa or 2.1 107 T/m2 Stresses combination. Stresses cannot simply be added if they occur in different directions. For example, if a material is subjected to two perpendicular stresses, both compressive or both tensile, it will break or reach the plastic region long before the same material is subjected to the same stresses with one being compressive and the other tensile. When discussing Poisson’s ratio, it was stated that a material that was subjected to tensile stress would shrink in the other direction. If the material is subjected to a tensile stress in that direction, the action of this tensile stress is very destructive on the material that would otherwise shrink. Different formulas are used to combine stresses. The formulas will not be derived here, since that is beyond the scope of this course. They will only be mentioned when necessary. Beam strength of materials. When considering the strength of materials, a pipeline is equivalent to a beam, having a constant 2-2 section. For beam calculations, you must determine at any point x the moment of all forces applied to the beam, either at the right or left of that point x. These two values are equal in static equilibrium; therefore, use the one that is easiest to calculate. If a beam is subjected to a longitudinal (pulling) force, the stress caused by the Fx component of the force F is: F σ = -----x A If M(x) is the moment of a straight and horizontal beam, then the deformation of the beam can be calculated by resolving the following differential equation: M(x) d2y --------2 = ------------EI dx The stress due to moment M is tensile or compressive, depending on the orientation of the moment and the point in the beam material that is considered. The maximum stress is on the upper and lower fiber of the beam, and equal to: MxD σ = ------------2l Beam/pipeline formulas. With the notations: D = outside diameter in m d = inside diameter in m e = wall thickness in m E = modulus of elasticity l = length you have the following values: Section Area “A” = π (D2 - d2)/4 = π e(D - e) Section Inertia “I” = π (D4 - d4)/64 Engineering: Pipeline Codes Pipeline Codes Definitions The code applied to the pipeline construction indicates the various basic data that must be used to design the pipeline. A different code applies to gas or oil pipeline, and different codes apply to each country, according to national laws. However, most of the “national” codes refer to the American National Standards Institute (ANSI) B 31-4 for oil pipelines and ANSI B 31-8 for gas pipelines. The following terms are used in this section: Design pressure: The value of the pressure used for pipeline design. Operating pressure: The value of the pressure during pipeline operation. Test pressure: The value of the pressure used for pipeline testing. Class Location: The class of a pipeline section as per applicable code. Construction Type: The type of construction for a pipeline section. SMYS: Specified Minimum Yield Strength. This is the elastic limit of the pipe material as defined by the American Petroleum Institute (API) (Table 2.1). Table 2.1. API pipeline specifications. Grade Minimal yield strength A B X42 X46 X52 (psi) 30,000 35,000 42,000 46,000 52,000 (Mpa) 207 241 289 317 358 X56 56,000 386 X60 60,000 413 X65 65,000 448 X70 X80 70,000 80,000 482 551 Minimal ultimate tensile strength (psi) 48,000 60,000 60,000 63,000 66,000 72,000 71,000 75,000 75,000 78,000 77,000 80,000 82,000 90,000 (Mpa) 331 413 413 434 455 496 489 517 517 537 530 551 565 620 Location classes Class Location and Construction Type allow you to determine, for every section of the pipeline, the design factor F applicable to that section. The most significant factor contributing to the failure of a pipeline is damage to the line by human activity along the route of the pipeline. You can quantify this activity by determining population density indices and relating the design of the pipeline to the appropriate population density index. The code requires you to lower the stress level relative to increased activity. Four class locations are defined in the code, from Class 1 to Class 4. Construction types Class Location alone is not sufficient to assess the risk of damage to a pipeline, since various situations (such as road, river, or bridge crossings) may increase the risk regardless of the population density index. Four construction types are defined from Type A to D, according to the ANSI B 318-1982 Table 841.15A. (Table 2.2). 2-3 Horizontal Directional Drilling Training Program Table 2.2. Classification of steel pipe construction (API Table 841.15A). Characteristics Design Factor F Type A Construction 0.72 Type B Construction 0.60 Location where type A. On private of construction will be rights-of-way in used Class 1 locations B. Parallel encroachments on: 1) Privately owned roads in Class 1 locations 2) Unimproved roads in Class 1 locations A. On private rights-of-way in Class 2 locations B. Parallel encroachments on: 1) Privately owned roads in Class 2 locations 2) Unimproved roads in Class 2 locations 3) Hard-surfaced roads, highways, or public streets and railroads in Class 1 and 2 locations C. Crossings with- C. Crossings without casings on pri- out casings on: vately owned 1) Privately owned roads in Class 1 roads in Class locations 2 locations 2) Unimproved public roads in Class 1 and 2 locations 3) Hard-surfaced roads, highways or public streets and railroads in Class 1 locations D. Crossings with casings on unimproved roads, hard-surfaced roads, highways, or public streets and railroads in Class 1 locations D. Crossing with casings on hardsurfaced roads, highways, or public streets and railroads in Class 2 locations E. On bridges in Class 1 and 2 locations F. Fabricated assemblies pipelines in Class 1 and 2 locations 2-4 Type C Construction 0.5 Type D Construction 0.40 A. On private A. All in Class 4 rights-of-way in locations Class 3 locations B. Parallel encroachments on: 1) Privately owned roads in Class 3 locations 2) Unimproved roads in Class 3 locations 3) Hard-surfaced roads, highways, or public streets and railroads in Class 3 locations C. Crossings without casings on: 1) Privately owned roads in Class 3 locations 2) Unimproved public roads in Class 3 locations 3) Hard-surfaced roads, highways, or public streets and railroads in Class 2 and 3 locations D. Compressor station piping E. Offshore platform piping, including risers, and for a distance of 5 pipe diameters beyond the bottom elbow, bend or fitting. Transition pieces at the end of this pipe are not considered fittings. F. Near inhabited areas in Class 1 and 2 locations Engineering: Pipeline Codes Usually, Type A construction applies to Class 1 location, Type B to Class 2, and so on, but there are many exceptions stated in this table. Therefore, each section of the pipeline is given a type, which determines the factor F to be applied at the design stage, as follows (Table 2.3; ANSI B 31-41982 Table 841.1A): Table 2.3. Values of design factor F (API Table 841.1A). Construction Types (see 841.151) Design Factor F Type A Type B Type C Type D 0.72 0.60 0.50 0.40 Pressures Maximum operating pressure is the value of the maximum pressure in the pipeline during operation. It is the lowest value of the design pressure and the test pressure divided by: 1.1 for Class 1 1.25 for Class 2 1.4 for Class 3 1.4 for Class 4. Design pressure was previously defined as the value of the pressure, greater than operating pressure, that is used to design the pipeline. Test pressure varies with pipeline class, as follows: Class 1: (1.1*Maximum operating pressure) Class 2: (1.25*Maximum operating pressure) Class 3: (1.4*Maximum operating pressure) Class 4: (1.4*Maximum operating pressure). The test is carried out with water. The maximum operating pressure and design pressure have a single value for the entire pipeline. The test pressure, on the other hand, varies with pipeline class. Each section of the same class is tested separately, and a general test is carried out at the end of construction according to the abovementioned coefficients, using a test pressure that does not overstress the pipeline. Design criteria The engineer must first determine the construction type that is most applicable to the crossing. Based on horizontal drilling experience, an HDD crossing can be Type A with a design factor F equal to 0.72 if the land section on both sides of the crossing is also Type A. In fact, the river section is safer than the land section because there is no risk of human interference. Therefore, whenever the local regulations or laws allow it, try to use the same classification for the crossing as for the land line. This is important, because you must use the design factor F to verify that the pipe is not overstressed in different situations during construction and operation. Stresses may be caused by pressure inside the pipeline (during testing or operations), pressure outside the pipeline (including ground pressure), temperature variations, bending the pipeline in the hole (during testing or operations), or bending the pipeline out of the hole (during installation). 2-5 Horizontal Directional Drilling Training Program Stresses During Testing or Operations Hoop stress Hoop stress is the stress caused by internal pressure. Its value is given by the Barlow formula, where P is the differential pressure (the difference between internal and external pressure), D is the outside diameter, and t is the wall thickness. The following formula is valid if the ratio D/t is greater than 20. PD σ H = -------2t Bending stress The maximum bending stress is: ED σ b = ± -------2R where R is the bending radius. This stress is a compression on the “outside fiber” and a compression on the “inside fiber.” Temperature stress If the temperature of the fluid carried by the pipeline is different from the temperature during installation, you must consider the stresses caused by temperature in the restrained pipeline (there would be no stresses if the pipeline was free to expand or contract). This is the case when the pipeline is a gas pipe, where gas temperature may be much higher than ground/installation temperature, or for an oil line where the oil must be heated to be pumpable. Temperature stress caused by a ∆T variation of temperature is: σ t = Eα∆T where α is the linear expansion coefficient in m per unit length per degree Celsius (11.7 10-6 m/m/˚C for steel). Restrained pipeline stress Earlier in this chapter (Basic Strength of Material, page 2-1) it was mentioned that a stress in one direction would create a stress of the same sign in the perpendicular direction if the material was restrained from expanding or contracting in that direction (the restrained pipeline stress), and that the ratio between these two stresses was the Poisson coefficient ν. For example, hoop stress σH would generate a longitudinal stress equal to: σ L = νσ H Traction stress If the pipeline, having a section area A, is submitted to a pulling force PF, then there is a longitudinal stress (traction stress) equal to: 2-6 P σ a = ----FA PF σ a = --------------------πt ( D – t ) Engineering: Pipeline Engineering Ground pressure When the pipeline cover is important, and when the soil cohesion is low, you must consider the weight of the ground on top of the pipeline. The following formula, taken from Dreyfuss (Thin metallic conducts under roads and railways, Technip Edition), can be used to estimate ground pressure σg: D σ g = 0.4γh ---2t where When the D/t ratio is high, there is a risk of elastic instability. Elastic instability is when a body collapses even though the load applied to this body does not create stresses in excess of yield. This is because the stress formulas assume that the load is perfectly centered and that the pipe is perfectly round. The critical value for external pressure on a pipe is given by the formula: 2E 1 P tc = --------------2 --------------------------2 1 – ν DD ---- ---- – 1 tt γ = ground specific weight h = depth of top of pipe. where Ptc is the critical external pressure. Pipeline specifications API specifications 5L, 5LX and 5LS first stated the chemical requirements of steel used for seamless or welded pipeline. The minimum yield limit (SMYS), minimum ultimate tensile stress, and minimum percentage of elongation are also specified, as are tolerances on dimensions and weight. The API grades and corresponding SMYS are given in Table 2.1 (metric and US units). Some of the grades may not be used in certain areas, especially when very low temperatures are expected. Pipeline Engineering Verifying wall thickness The engineer must first check that the wall thickness of the pipeline is sufficient with respect to working pressure. t = nominal pipe wall thickness D = nominal pipe diameter F = design factor Hoop stress. Hoop stress was previously defined as the stress caused by internal pressure in the pipeline during testing or operations. The formula for that calculation is given in ANSI B 31-8: St P = 2 ----- × F × E × T D where P = design pressure S = SMYS E = longitudinal joint factor T = temperature derating factor. The values of factors F, E and T are given by ANSI B31.8-1982, in Tables 841.1A, 841.1B, and 841.1C, respectively (reproduced here as Table 2.3, Table 2.4, and Table 2.5, respectively). This is the Barlow formula used to determine the strength of materials (Bending Stress, page 2-6), where the hoop stress σH must not exceed SMYS x F x E x T. Please note that D is the nominal diameter of the pipeline. 2-7 Horizontal Directional Drilling Training Program Ground pressure. If pipeline cover is important, you must check that the pipeline will not collapse because of external pressure. The formula mentioned in Ground Pressure (page 2-7) should be used: D σ g = 0.4γh ---2t where γ = ground specific weight h = depth of top of pipe If the calculated stress exceeds 70% of SMYS, then proceed with a detailed analysis of collapse and out-of-roundness risks. The elastic instability should also be checked because a high D/t ratio increases this risk. The critical external pressure Ptc must be more than four times the external pressure. Table 2.4. Longitudinal joint factor E (API Table 841.1B). Spec Number ASTM A53 ASTM A106 ASTM A134 ASTM A135 ASTM A139 ASTM A211 ASTM A381 ASTM A671 ASTM A672 API 5 L API 5 LX API 5LS Pipe Class Seamless Electric Resistance Welded Furnace Welded Seamless Electric Fusion Arc Welded Electric Resistance Welded Electric Fusion Welded Spiral Welded Steel Pipe Double Submerged Arc Welded Electric Fusion Welded Electric Fusion Welded Seamless Electric Resistance Welded Electric Flash Welded Submerged Arc Welded Furnace Butt Welded Seamless Electric Resistance Welded Electric Flash Welded Submerged Arc Welded Electric Resistance Welded Submerged Arc Welded E Factor 1.00 1.00 0.60 1.00 0.80 1.00 0.80 0.80 1.00 1.00* 1.00* 1.00 1.00 1.00 1.00 0.60 1.00 1.00 1.00 1.00 1.00 1.00 *Includes Classes 12, 22, 32, 42, and 52 only (definitions for the various classes of welded pipe are given in 804.243). 2-8 Engineering: Pipeline Engineering Table 2.5. Temperature derating factor T (API Table 841.1C). Temperature °F Temperature Derating Factor T 250 or less 1.000 300 0.967 350 0.933 400 0.900 450 0.867 Note: The conversion between °F and °C is °C = 5/9 (°F + 32). Therefore, the above temperatures’ C equivalents are: °F °C 250 300 350 400 450 121.1 148.9 176.7 204.4 232.2 Hydrostatic test In Pressures (page 2-5) it was stated that the test pressure is equal to the maximum operating pressure multiplied by a coefficient that varies with pipeline class location: Class 1: (1.1*Maximum operating pressure) Class 2: (1.25*Maximum operating pressure) Class 3: (1.4*Maximum operating pressure) Restrained pipe: σr = -ν σH Longitudinal stress: σa = - |σ0| - ν |σH| Generally, the residual traction Pr is negligible and the residual stress σ0 can be considered zero, so essentially you have a combination of longitudinal and hoop stress. The Von Mises criteria is commonly used for these stress combinations. The combined stress is equal to: Class 4: (1.4*Maximum operating pressure). Maximum allowable operating pressure is also equal to the lowest of design pressure and test pressure divided by the above coefficients. However, the installed pipeline is also subjected to bending stress (page 2-6) due to curves in the reamed hole, whether intentional or not. A residual traction (page 2-6) may increase the longitudinal stress and the restrained pipeline stress (page 2-6). These stresses can be calculated as follows: Hoop stress: σH = PD/2t Residual traction: σ0 = Pr /(πt(D-t)) Bending stress: σb = ± ED/2R σ2 = (σH 2 + σL 2 - σH σL + 3σs) where σs is the shear stress. In this case the shear stress is negligible, and the above equation can be reduced to: σ2 = (σH 2 + σL 2 - σH σL) where σL = σa ± σb This equivalent stress σ must be less than or equal to 95% of SMYS. Since the bending stress varies with the bending radius, this formula will give a minimum bending radius due to hydrostatic test Rtest. 2-9 Horizontal Directional Drilling Training Program Operating pressure The ANSI B31.8 article 833.4 specifies that combined stress due to expansion, longitudinal pressure, and longitudinal flexion must not exceed SMYS, and that the sum of longitudinal pressure and longitudinal flexion must not exceed 75% of SMYS. For pipes installed by HDD, assuming that hole diameter is closed from the pipe’s outside diameter (OD), the combined expansion stress is negligible if the soil resists lateral movements of the pipe and if the pipe is not subjected to torsion during pulling. In that case, you only need to check that: |σa| + |σb| ≤ 0.75 x SMYS x F x T where σa = σ0 - ν Pi/2t σb = ± ED/2R Pi = Maximum operating pressure. The minimum radius due to operating conditions can be calculated and is equal to Roper. However, if the temperature of the fluid carried by the pipeline is high, ANSI B31.4 article 419.6.4 applies, with a longitudinal stress equal to: σa = Eα∆T - |σ0| - |σH| + |σb| where ∆T is the difference between the maximum operating temperature and the installation temperature. Comments The above calculations apply to pipeline installed with the HDD method only. The soil should be strong and stable; additional engineering is required for very soft or muddy soils, seismic areas, and zones sub- ject to ground slippage. This additional engineering is beyond the scope of this chapter because it is based on standard pipeline engineering. Installation conditions During installation, the pipeline is subject to traction forces, balance by ground friction into the hole or on the rollers, and by bending according to drilled path profile. You must estimate the pulling force to check that the pipe will not be overstressed. In addition, the pipe is generally laid horizontally on rollers or in a flotation ditch. Since the pilot hole exits at an angle, the pipe must be handled so that it enters the ground with an equivalent angle. This is what is called the catenary. The pulling force estimation and catenary calculation will be explained later, and for now assume than the pulling force PF is known. The longitudinal stress σa due to PF must be less than 95% of SMYS. Accordingly, calculate the minimum radius during pulling of the pipe Rpull: σa = PF /(πt(D-t)) ± ED/2R ≤ 0.95 SMYS Minimum radius You have determined the minimum radius for various conditions. The minimum radius of the crossing must be the greatest of: Minimum radius during testing: Rtest Minimum radius during operation: Roper 2-10 Minimum radius during installation: Rpull However, there may be other situations where you would use a higher radius than this. First, the pilot hole cannot be drilled perfectly. Use a coefficient to allow for unexpected variations in hole profile and to make sure that the radius cannot be less Engineering: Crossing Engineering than the minimum. Second, the radius is an important factor for pull force value. For a large pipeline, use a higher radius to reduce the anticipated pull force. The relationship between radius and pulling force will be described later. Crossing Engineering Introduction You now have the basic engineering information required to design a crossing. You know how to determine the minimum allowable radius and how to verify that the pipe wall thickness is acceptable for HDD. However, this is still not enough. The various parameters you must understand and use to design a crossing and determine whether it is feasible will now be reviewed. First, you will learn how to design the crossing’s profile based on the minimum radius and exclusion area. Then the layout on both sides of the river and the necessary resources you must have are described. The crossing’s path design River. The basic information you will need is a profile of the river. Particularly, you should obtain the current profile of the river—some rivers may change during a year’s time, so old profiles must be used and checked very carefully. high. There may also be an existing navigation channel or one planned for the future. If the river is dredged, you must leave an allowance for the dredge below the nominal dredging depth. It may sometimes be difficult to determine where the river bottom is, especially when the river is subject to scouring. The scouring level must be estimated according to the river’s hydrologic data. Exclusion area. At this stage, you should know the pipe and entry sides, the water source, the quality of the water, the river bottom’s location, and the location of its banks. These data are sufficient to start drafting a tentative profile of the crossing. You must also determine where the river banks are, because the river can shift from time to time, especially after a flood. In that case, the banks may be the limits of the flood area, or any other point within these limits where you can be sure that the river will not shift and expose the pipeline. There may be obstacles in the bed of the river, such as bridge piers, which may cause problems when the river flow is very On a drawing of the river’s profile, mark the dredging limit (if any), the scour level (if any), and the real banks of the river. The area delimited by the verticals from the banks and the lowest of river bottom, scour level and dredging area, plus minimum pipeline cover, is called the exclusion area. This defines a rectangular area (Fig. 2.2) where the pipeline must not be installed. 2-11 Horizontal Directional Drilling Training Program 1 2 Fig. 2.2. Determining the exclusion area. 1 Exclusion area 2 Bedrock If the river is very stable, the bottom line of the exclusion area may follow the river’s bottom (i.e., parallel at a distance equal to minimum pipeline cover). Minimum pipeline cover refers to the minimum soil height that must cover the pipe to make sure that it will not rise toward the surface when it is empty. Generally, about 15 ft (5 m) are sufficient. This can be reduced somewhat in rock or hard formation, but you also must remember that pilot hole drilling is not that accurate. You can add a drilling safety margin to the minimum cover, which should be 2 to 5 ft (1 to 2 m), according to the crossing’s length. 2-12 Entry angle. The entry angle is limited by rig design and by safety guidelines for the drilling crew working on the rig’s walkways. The inclination should not be more than 18˚, and a minimum entry angle of 8˚ is suggested. Exit angle. The maximum suggested exit angle is 10˚, which can be reduced to 4˚ for large-diameter pipelines. Generally, the exit angle must be as low as possible for large-diameter pipes. The basic data for a crossing’s design are the exclusion area parameters discussed above. However, there may be another restriction, which is the maximum ground cover that is allowed above the pipe. It was previously mentioned that ground pressure (page 2-7) could be a problem. In that case, the formula will give you a maximum cover on top of the pipe. Mark that limit on the profile’s drawing, which will be a horizontal line called bottom limit. Subsoil nature or obstacles. The best soils for river crossings using the HDD method are sand, silt or clay. Gravel is the most difficult to work with, and bedrock is also problematic (the problem with bedrock is the interface between the soft and hard ground). Therefore, whenever possible, avoid the gravel areas and remaining higher than the bedrock. If you have no other alternative than to drill through the bedrock, the angle between drill path and bedrock must be as high as possible. There may be another reason to have a bottom limit: there may be bedrock, a hard formation, or a gravel area that you want to avoid. At this stage of the engineering of the crossing, you may not know exactly where that limit is. You can design the crossing and adjust later, once the soil investigations are available. Design of the profile. You have now determined and mapped the exclusion area, and marked the bottom line and the problematic areas where you want to avoid drilling. You are now ready to design the pilot hole profile, which is a simple combination of arcs and lines. Usually, the path is split into: Engineering: Crossing Engineering One tangent: C0–C1 One radius: C3–C4 One tangent: C4–C5 One radius: C1–C2 The coordinates of these points are Xi and Zi (Fig. 2.3). One tangent: C2–C3 C5 C0 C4 C1 C2 C3 Fig. 2.3. Designing the pilot hole profile. C0 C1 C2 C3 C4 C5 Entry Point of curvature Point of tangency Point of curvature Point of tangency Exit Section C2–C3 does not need to be horizontal, although this is generally the case. If the river is deeper on one side, and if you want to avoid some gravel area on the other side, you can decide to make this section with an angle. First calculate the horizontal and vertical projections of the two circular sections. This is easy, since you know the radius R is the minimum allowable radius, and you know the entry and exit angles. With the basic formulas mentioned in Strength of Materials (page 2-1), you have: X2 - X1 = - R sin(aentry) Z2 - Z1 = - R (1 - cos(aentry)) If Z2 ≠ Z3, with amiddle being the inclination of the middle section, you have: X2 - X1 = R (-sin(aentry) + sin(amiddle)) Z2 - Z1 = R (cos(aentry) - cos(amiddle)) X4 - X3 = R (sin(aexit) + sin(amiddle)) Z4 - Z3 = R (cos(amiddle) - cos(aexit)) Note that the angles are trigonometric angles (i.e., horizontal is zero, a 10˚ entry angle [100˚ on the steering tool] is -10˚, and an 8˚ exit angle [82˚ for the steering tool] is +8˚). Thus the entry angle is negative, exit angle is positive, and middle section angle is either or null. For the straight sections, with L being the length of the section, you have: X1 - X0 = L cos(aentry) Z1 - Z0 = L sin(aentry) X4 - X3 = R sin(aexit) Z4 - Z3 = R (1 - cos(aexit)) X3 - X2 = L cos(amiddle) Z3 - Z2 = L sin(amiddle) 2-13 Horizontal Directional Drilling Training Program sible. You may prefer the crossing to remain as close to the surface as possible, especially if the soil conditions worsen with depth. X5 - X4 = L cos(aexit) Z5 - Z4 = L sin(aexit) or, if the elevation difference is given: If you are concerned about the soil changes that occur with depth, set the middle section as close as possible to the middle section of the exclusion area (Fig. 2.4) and start the circular section at the vertical section of the banks. X1 - X0 = (Z1 - Z0)/tan(aentry) X3 - X2 = (Z3 - Z2)/tan(amiddle) X5 - X4 = (Z5 - Z4)/tan(aexit) You must change the entry angle if the bottom limit of the crossing is too high compared to - R (1 - cos(aentry)). The same applies to the exit angle. Once you have modified these two angles, if required, you must decide whether you want the crossing to be as short as possible, or as low as pos- If you are not concerned about the depth and want a short crossing, reduce the length of the middle section as much as possible (even to zero), provided that the lowest point is still above the bottom limit (Fig. 2.5). 1 2 Fig. 2.4. Crossing’s profile: minimum depth. 1 Exclusion area 2 Bedrock 1 2 Fig. 2.5. Crossing’s profile: minimum length. 1 Exclusion area 2 Bedrock 2-14 Engineering: Crossing Engineering The crossing’s layout Entry side. First, define the entry and exit sides of your crossing. For the driller, the entry is where the drilling tool enters the ground. The other side is the pipe side or exit point. From time to time, the term entry pit is also used for the pipe side. The entry pit is the pit that is dug at the place where the pilot hole exits. The entry pit collects mud returns from the hole and, if required, reduces the height of the catenary. age tank is required. Usually, the water supply will not be able to meet the rig’s demand during pre-reaming or pullback, and in any case, you should not rely on a third party for water. Be sure that sufficient water, in quality and quantity, is available during all critical phases of the job, even if these phases last longer than scheduled. You cannot afford to run out of water during a difficult pre-reaming or pullback. Generally, the pipe side is selected first because its requirements are more restrictive. However, there are also some requirements for the entry side related to available space, water supply, and access roads for the equipment and crew. As explained in the drilling fluids section of this course (Mud, Chapter 6), water quality is also important. During the site visit, take water samples and proceed with the water analysis to make sure that bentonite will mix properly with the available water. The total weight for a 250-ton pull force rig and its ancillary equipment consumables is approximately 250 tons; several single loads weigh 30 to 35 tons. Normal transportation to the site is by truck. Access roads must be wide and strong enough to handle such loads safely. Overhead clearance must also be checked, as well as local transportation restrictions. An alternative to road transport is river transport. Obviously, the river must be free from ice, unless the ice is very thick. Water depth must be sufficient for barges and tugs to reach the site. In addition, an access ramp must exist or be built close to crossing’s site to unload equipment. Water is usually supplied from the river. If this is not the case, water supply must be provided on the entry side and a safety stor- Another potential problem related to the entry side is noise. Whenever possible, the entry side must be away from housing areas. The pipe side is generally not as noisy. A typical entry side layout is shown in Fig. 2.6. The area required is about 200 x 200 ft (60 x 60 m), depending on mud and water pit sizes. It does not need to be square, but it is good practice to have mud pits close to the entry point and good access to these pits for dump trucks. Also make sure that heavy equipment can move easily around the rig. Remember that in most cases, mobile cranes won’t be able to move in front of the entry point, especially after pre-reaming, because they may cause the hole to collapse. 2-15 Horizontal Directional Drilling Training Program 9 19 50 m 12 10 HDT 11 Mud Pit 15 x 15 m 500 m3 17 18 12 28 HDT 20 Mud Pit 20 x 10 m 500 m3 27 50 m 13 25 16 7 Access 25 Mud Return Line 4 6 22 14 24 1 5 15 21 Center Line 26 2 3 Fig. 2.6. Typical entry side layout. 1 Drilling rig 11 Workshop 21 Diesel storage 2 Power unit 12 Recycling unit 22 10 m3 waste 3 Control cabin 13 250 kva generator 4 5 6 7 8 9 10 14 15 16 17 18 19 20 23 10 m3 waste 24 75 kva generator 25 Dirty mud pump 26 Clean mud pump 27 Dirty mud storage 28 Clean mud storage 20-ton mobile crane Mud unit Drill pipes Bentonite storage Spare container Tools container Crew room Mud pump Mud pump Drill path Cuttings dump area Parking area Toilet container Site office Pipe side. The most important requirement for the pipe side is space for the pipe string (Fig. 2.7 and Fig. 2.8). Water supply may also be a problem if the pipe must be ballasted. In that case, refer to entry side comments about water (page 2-15). The pipeline should be welded and pretested in a single string in the alignment of 2-16 the proposed crossing. The risk of getting stuck during pullback is increased by standby in the pulling operation, whether it is because of a mechanical problem or a tie-in of two sections. A tie-in may last several hours because the pipe must be aligned properly, welded, and allowed to cool down before x-ray inspection; and the joint must be coated and allowed to dry (if necessary). Engineering: Crossing Engineering 7 8 9 6 3 1 2 4 5 Fig. 2.7. Typical pipe side layout. 1 2 3 4 Pipeline string Pipeline rollers Entry pit Mud pit 5 6 7 8 9 Mud pit (dirty mud) Pipeline handling cranes with cradles Water hose reel for ballasting (if required) Water pump for ballasting (if required) Hose from water source Fig. 2.8. Pipe side, South Louisiana, USA. Most of the pipe side area need not be wider than the regular right-of-way. There are two exceptions to this rule: 1. If mud returns must be trucked out to the entry side, there must be sufficient space for dump trucks to maneuver without any restrictions. 2. Close to the exit point, an entry pit must be dug and mud pits must be built. Moreover, the pipe must be han2-17 Horizontal Directional Drilling Training Program dled with heavy equipment to enter the entry pit with the correct inclination, which is the pilot hole exit inclination. Generally, catenary cranes or sidebooms will be on the left side of the pipe string, looking at the river. The truck road, along the pipe string, will be on the right side. If possible, mud pits must be ahead of the entry pit and on the right side. This is because dump trucks should be free to move between the mud pits and the exit of the pipe side. Also, any equipment required to handle tools or pipe should be free to reach the entry pit in case of emergency. Therefore, the right-of-way must be wider in the catenary area. Catenary. The pilot hole exits at an angle ranging from 4 to 10° and the pipe string is laid on the ground. Be sure to handle the pipe without buckling it—this is what is defined as the catenary. The catenary is the path that the pipe must follow to limit the stresses in the pipe and load on the cranes or sidebooms. This path is determined with a computer program, which will be explained later. It is important to remember that a small variation in the path because of incorrect positioning of even one crane can drastically increase the force on the crane(s) and stresses in the pipe. You can estimate the length of the catenary with a simple hand calculation, once you know the minimum installation radius (see Installation Conditions, page 2-10). If you approximate the catenary with a combination of circles, with a radius equal to the above-mentioned minimum radius, the length and height of the catenary are: L = R sin(a) + 2R sin(a/2) H = R(1 - cos(a)) where a is the pilot hole exit inclination. To reduce these two values, especially the height, dig an entry pit for the pipe string. This will also reduce the risk of mud breakouts on the pipe side (Fig. 2.9). This is very important for large-diameter pipes because the handling equipment for the catenary is very heavy (60- to 100-ton cranes) and the soil supporting these cranes must be reinforced. 1 2 Fig. 2.9. Catenary with and without an exit pit. 1 Catenary with exit pit 2 Catenary without exit pit; height and length increased 2-18 Engineering: Engineering Procedures Engineering Procedures Preliminary evaluation At this stage you may only have a rough idea of the pipeline route, pipeline characteristics, nature of obstacles, and subsoil conditions. Answer questions in these four areas: 1. The pipeline nature and characteristics: Can you pull that type and size of pipeline, or can you recommend a different type and size, or casing, so that you can do the job? 2. The length of the crossing: Can you drill that length, and can you pull it? Can you move the route elsewhere to shorten the length? Can you split the crossing into two shorter ones? 3. The necessary access and work areas: Can you lay the pipe in the alignment of the crossing, in one single section, or can you modify the alignment accordingly? Do you have access for the rig, and do you have water of acceptable quality and quantity? 4. The subsoil: Is it “good for HDD”; i.e., is it possible to avoid gravel layers and remain above the bedrock, if any? These simple questions should be easy to address. If, based on experience, the crossing is too long, the subsoil is too difficult to drill through, or other problems are evident, it is best to stop now and look for alternatives. Product line nature. The product line must be pulled in a pre-reamed hole, as mentioned earlier. Therefore, it is not possible to install a water pipeline with bolted connections, for example. The line must be a steel line, or a high-density polyethylene (HDPE) pipe with fused connections. Pipe size. The maximum size of pipeline that has been installed using the HDD method is 48 in. (1.2 m). An alternative is to lay two lines of smaller size across the river. However, this solution is not ideal, since the line maintenance may become difficult. Pipe length. Depending on soil conditions, the maximum length that has been drilled is between 5000 and 6000 ft (1500 and 1800 m). You may need to cross the river at a different place, or drill from an island in the middle of the river (if any). You can also run a casing during pilot hole drilling. To help you decide, refer to Fig. 2.10, which shows the feasible length/diameter range for HDD, based on a good alluvial soil or rock crossing. 2-19 Horizontal Directional Drilling Training Program L (m) 2000 3 1800 1600 2 1400 Fig. 2.10. Length/diameter feasibility range. 1200 1 = Feasible 1000 2 = Feasible with good alluvial soils 800 3 = Not feasible as per state-ofthe-art 1 600 400 200 0 10“ 20“ 24“ 30“ 36“ 48“ Pipe mechanical characteristics. If the crossing meets the nature, length, and size criteria, verify that its mechanical characteristics are sufficient or can be adapted to HDD requirements. Generally, various wall thicknesses are available for the pipeline construction. Go through the stress calculations in this chapter and verify that the available pipe is acceptable. If it is not, you must find out whether acceptable pipe can be purchased or fabricated in time for the project. Pipeline coating and field joints. Pipeline coating (and cathodic protection) will not directly influence the feasibility of a crossing. You only need to remember that certain types of coatings are not acceptable; use any of the following: 2-20 • three-layer polyethylene (PE) coating • sintered PE coating • Powercrete™ coating • epoxy coating. ∅ A fifth coating, called polypropylene, is being developed and appears to be better than three-layer PE. However, some problems are still being resolved for the joint coating. In all cases, use a thicker coating to allow for some surface damage without risking the cathodic protection. The field joints are the weakest part of the pipe coating, except for sintered PE, where the coating continuity is fully restored when it is done carefully. Shrink sleeves are an acceptable solution if they are specially designed for river crossing applications. For standard sleeves, the glue is soft so all gaps can be filled. For river crossings, it must be hard to resist shear stress. The pipe coating ends must be carefully beveled to allow proper shrinkage and adherence of the sleeve. The sleeve’s outer material must be reinforced with fiberglass, and the front end must be protected from shearing with a special band. Engineering: Engineering Procedures The last alternative is to use epoxy paint, although this solution is not recommended because these coatings are almost impossible to repair if they become damaged. For this reason, epoxy coating is not recommended if PE coating is available. Powercrete is a rock shield coating compatible with the fusion-bonded epoxy corrosion coating. Powercrete has a very low coefficient of friction and is applied over the fusion-bonded epoxy. This combination of coatings is the most effective for protecting the pipelines during installation. Under any conditions, tape coating of field joints is not recommended. The same restrictions apply to field repairs to the coating. Although it is quite long, a sintered PE pipe can be repaired using the same procedure as for field joints. For major repairs on a three-layer PE coating, shrink sleeves can be used. Patches are acceptable for small repairs. For epoxy coatings, epoxy repair paint is a possible solution. Catenary It was mentioned earlier that the pipeline string can be considered as a beam with constant inertia. This beam is subjected to its own weight, including the weight of the buoyancy control system, if any, and to reaction forces at each roller or cradle. It is also subjected to the weight of the pulling assembly (reamer or bullet nose, swivel, pull head) and to the pull force necessary to balance the friction on the rollers. The rollers are generally installed 40 ft (12 m) apart, which is the average distance between each field joint. There is no need to calculate the stresses for the whole string lying on its rollers since the hyperstatic problem takes much longer to solve when the number of supports increases. However, the rollers that are more than 330 ft (100 m) away from the cranes have no influence on the loads and stresses in the cranes area. Therefore, the catenary calculation will consider the two or three cranes and the first five to 10 rollers. The strength of materials problem is to determine the rollers’ reaction for a given position and determine the number of rollers/cranes. The length of pipe string that is not input into the calculation applies a friction force at the pipe end. The pulling assembly and pull force are equivalent to a given force at the other end of the pipe string, on the entry pit side. The direction of that force is known, since it is the inclination of the pilot hole exit. The horizontal projection of that force must be equal and opposite to the friction force. Therefore, you can calculate the vertical projection, and the only unknown values are those of the n reactions on the n rollers/cranes (Fig. 2.11 and Fig. 2.12). 2-21 Horizontal Directional Drilling Training Program 5 7 2 1 6 3 4 6 8 9 Fig. 2.11. Catenary. 1 2 3 4 5 6 7 8 9 Pipe end for catenary calculation Crane and cradle number 1 Crane and cradle number 2 Crane and cradle number 3 Pulling assembly (pull head, swivel, reamer or bullet nose) Pipeline rollers Force at pipe end (friction on remaining rollers) Pulling force Weight of pulling assembly Fig. 2.12. Pipeline string and catenary. Norfolk, Virginia, USA. 2-22 Chapter 3: Steering Guidance Principles........................................................................... 3-1 Basic principles .................................................................................................. 3-1 Instrumentation .................................................................................................. 3-1 Coordinate systems ........................................................................................... 3-2 Calculation systems and methods ..................................................................... 3-2 Mathematical review .......................................................................................... 3-3 A review of basic trigonometry.........................................................................................3-3 Tangential method ............................................................................................................3-4 Tangential calculations ....................................................................................................3-4 Average angle method ......................................................................................................3-6 Average angle calculations. .............................................................................................3-6 Radius of curvature method..............................................................................................3-7 Radius calculations ..........................................................................................................3-8 Magnetics............................................................................................ 3-8 Borehole direction and inclination ...................................................................... 3-8 Geographic location ........................................................................................... 3-9 Magnetic sensor spacing ................................................................................. 3-10 Z axis interference ..........................................................................................................3-10 Spacing ...........................................................................................................................3-11 Outside sources of interference ....................................................................... 3-11 In-ground sources...........................................................................................................3-11 Above-ground sources ....................................................................................................3-13 Magnetic interference....................................................................................... 3-14 Steering tool interference ...............................................................................................3-14 Using Tru Tracker ..........................................................................................................3-22 Accuracy ........................................................................................... 3-27 Accuracy vs. repeatability ................................................................................ 3-27 Instrumentation ................................................................................................ 3-27 Human error ..................................................................................................... 3-28 Magnetic variation ............................................................................................ 3-28 Course length variation .................................................................................... 3-29 Job Site Actions—Pilot Hole ........................................................... 3-29 Arrival ............................................................................................................... 3-29 Walk the line ...................................................................................................................3-29 Unload and check equipment .........................................................................................3-30 Tru Tracker layout ............................................................................................ 3-30 Width .............................................................................................................................. 3-30 Length............................................................................................................................. 3-30 Wire ................................................................................................................................ 3-30 Corners........................................................................................................................... 3-30 Elevations....................................................................................................................... 3-30 Line sags ........................................................................................................................ 3-31 Coil shapes ..................................................................................................................... 3-31 Offset coils...................................................................................................................... 3-31 Testing ............................................................................................................................ 3-31 Preparing Tru Tracker data........................................................................................... 3-31 Steering tool rig-up ........................................................................................... 3-31 Profile ............................................................................................................... 3-32 Physical measurements ................................................................................... 3-33 Rig measurements .......................................................................................................... 3-33 BHA measurements ........................................................................................................ 3-33 Drill pipe measurements ................................................................................................ 3-33 Line azimuth shoot ........................................................................................... 3-33 Pressure testing................................................................................................ 3-35 Spud................................................................................................................................ 3-35 Drilling ahead.................................................................................................... 3-36 Tool operation................................................................................................................ 3-36 Data quality.................................................................................................................... 3-36 Projections ..................................................................................................................... 3-36 Directional control decisions............................................................................. 3-37 Radius control ................................................................................................................ 3-37 Intermediate targets ....................................................................................................... 3-37 Radius calculations ........................................................................................................ 3-38 Radius averaging ........................................................................................................... 3-38 Directions to driller............................................................................................ 3-39 Angular targets .............................................................................................................. 3-39 Position targets .............................................................................................................. 3-39 Drilling problems............................................................................................... 3-39 Wireline shorts ............................................................................................................... 3-39 Wireline leaks................................................................................................................. 3-40 Wireline opens................................................................................................................ 3-40 Tripping pipe out............................................................................................................ 3-40 Tripping pipe in.............................................................................................................. 3-41 Punchout .......................................................................................................... 3-41 Construction of as-built..................................................................................... 3-41 ii List of Figures Fig. 3.1. Right triangle......................................................................................................3-3 Fig. 3.2. Charting a 500-ft (152-m) crossing..................................................................3-18 Fig. 3.3. Charting a 1700-ft (518.5-m) crossing.............................................................3-20 List of Tables Table 3.1. Survey tabulation sheet. ...................................................................................3-5 Table 3.2. Calculating linear azimuth correction factors................................................3-16 Table 3.3. Calculating straight line azimuth correction factors. .....................................3-16 Table 3.4. Scales for constructing a Mag/Dip Chart.......................................................3-18 Table 3.5. Magnetic mapping of the shoot area..............................................................3-32 Table 3.6. First test of line azimuth shoot data. ..............................................................3-34 Table 3.7. Second test of line azimuth shoot data. .........................................................3-35 Drilling the pilot hole. iii Notes iv Chapter 3: Steering Guidance Principles This chapter covers the basics of guidance services. These services may be provided by using surface locators, surface coil sys- tems, gyroscopic systems, and magnetic azimuth systems. Basic principles The principle of borehole guidance is to accurately determine the relative position of the bore from an entry point so that the bore can be directed to a predetermined exit point. Using a wireline steering tool, positions and steering criteria can be calculated from four basic measurements: Pipe length: The distance measured along the course of the borehole from the entry point. Inclination: The angle between the vertical and the axis of the borehole at a chosen distance from entry. Azimuth: The angle between the horizontal component of the borehole at a specified point measured clockwise from magnetic north. All azimuths are expressed in the 0 to 360° system. Tool face: A measurement of the position of the bias of a bottomhole assembly (BHA) perpendicular to the axis of the borehole. From the above measurements, standard trigonometry can be used to calculate from entry an elevation and left/right position of the bore at the instrument’s position. From tool face, a deflection tool can be oriented to maintain or change the direction or elevation of the bore. Instrumentation The inclination and azimuth readings are measured by electronic survey instruments within the borehole, and the distance away from the entry is measured by direct pipe measurement at the rig. A wireline steering tool consists of a sensor section and a wireline transmission section. The sensors contained are three accelerometers and three magnetometers mounted orthogonally. The gravity and magnetic data obtained from any attitude of the tool in space can resolve its inclination and azimuth. The transmission section receives the sensor data, converts it from analog to digital format, and transmits it along a single conductor wireline to the surface interface. The signal then moves from the interface to a laptop or desktop computer. After processing, the data are displayed on the computer screen and sent back to the interface, where it is provided through another wireline to a remote display located directly in front of the driller. The entire process occurs about once every second. The data are used by the software to calculate and store survey calculations of current and previous bore positions. Since the tool measures the earth’s magnetic field to resolve magnetic north, it is important to house the downhole probe in an area free of any extraneous magnetic interference. The bit, downhole motors, most subs, and the drill pipe are strong sources of magnetic fields. The high carbon content of the high-quality steel needed for the drilling process generates high residual fields. The probe is housed within a nonmagnetic collar separating the drill pipe and the drilling assembly. Therefore, magnetic sensors are spaced away from the interference fields of the assembly and the drill pipe. Horizontal Directional Drilling Training Program Coordinate systems Plans for drilling operations are represented on paper, but the work is done in three dimensions on the curved surface of the earth. It is not possible to represent a sphere precisely in two dimensions; however, since most jobs connect an entry and exit with a straight line, two dimensions are normally sufficient. In many cases, a pipeline’s length from its origin is used to measure or position the entry point. This is called a station, which has an origin point (0 + 00) at the beginning of the pipeline. Sometimes the profile is represented based on stations. In every case, you are dealing with distance away from the entry, however represented, and elevations. Actual planned profiles begin at the entry point and terminate at the exit point, or the local coordinate system, which is determined for a specific project. A client will accept data on a local system as long as the entry point is known. Elevations also may be expressed in a local system with the entry point considered to be zero. Often, mean sea level (MSL) or another local datum is required. Once the coordinate system is determined, a drilling profile is drawn. Calculation systems and methods Calculating survey data for plotting on a directional plan involves fundamental trigonometry. This section covers various calculation methods and some operational recommendations to use in the field. Read the following definitions before beginning the section to review important information. Measured distance: The total length of the drill pipe and that part of the BHA up to the probe’s sensor, measured from the entry point. Vertical depth: The vertical distance from the surface reference elevation datum to the probe’s sensor. Inclination: The angle of the borehole in degrees, measured from the vertical or horizontal plane. Entry point: The point of entry chosen as the beginning of the vertical and horizontal profiles. Normally, the point where the drill pipe enters the ground in front of the rig. Exit point: The target expressed in distance from entry, elevation, and a position left, right, or directly on a centerline. This may be a planned exit or an actual exit point. Horizontal plan: A projection in plan view of the left or right position of the bore against a planned centerline. 3-2 Profile: A projection of the vertical position of the bore against a planned vertical profile. Vertical section: A mathematical calculation to express 3-D positions in two dimensions. Radius: An expression defining the exact curvature of a line, expressed in feet or meters. Dogleg severity: The total 3-D change of angle between two given points. This is expressed by the calculation program in degrees per 100 ft (30.5 m) and may be directly converted to a radius between the two points. Raw data are used to determine the position of a point along a borehole. Instruments currently in use produce the raw data, which are then used in calculations to obtain the final values. Many new methods have improved the calculation of the curved path of the bore between two survey stations. Since the calculation’s accuracy depends on the frequency of survey stations and surveying takes time, much effort has been expended in mathematically modeling the theoretical bore path between stations. These models are the tangential method, average angle method, and radius of curvature method. These methods are discussed in detail in Steering: Guidance Principles the following sections, along with the calculations appropriate for each method. None of these methods take into account the fact that the driller can influence the calculation method. He sees his angular position at every foot drilled and makes corrections as needed. Normally, he is given an inclination target that he must hit at the end of the joint to be drilled. Usually, he hits this target within the first third of the joint and uses the balance of the joint to hold his target angle. In a 30-ft (9.2-m) joint, the first 10 ft (3 m) would then be a curve, while the following 20 ft (6 m) would be a straight line at the desired higher angle. Since the angles measured form the basis for the resulting calculated position, the driller can bias the calculations by changing when he reached the desired angular target during the joint. This bias must be accounted for. Mathematical review This section covers the fundamental mathematics required for the job. As a minimum, basic trigonometry is necessary, while a working knowledge of geometry is also beneficial. A review of basic trigonometry. A right triangle is composed of one angle equal to 90°, and two angles less than 90° (Fig. 3.1). The side opposite the 90° angle is called the hypotenuse, labeled c. All three angles must add up to 180°. lp ril (d a (vertical) c e) ip Fig. 3.1. Right triangle. A b (horizontal) If the length of any two sides of the right triangle are known, the length of the other side can be determined by Pythagorean’s Theorem: are listed below for the angle marked A in Fig. 3.1. a sin A = -c a2 + b2 = c2 For example, if c = 10 ft and b = 9 ft, then: a = 10 2 – 9 2 = 4.36ft Furthermore, if one side of the triangle and an angle (other than 90°) are known, all other sides and angles can be solved using trigonometric functions. These functions b cos A = --c tan A = --ab For directional drilling, the hypotenuse of the triangle c is the drill pipe, side b is the away or horizontal distance, and side a is the vertical drop, or build. 3-3 Horizontal Directional Drilling Training Program For example, if angle A = 12° and side c = 10 ft, then: a sin 12° = -----10 10 sin 12° = a 10 ( 0.208 ) = a 2.08 = a To solve for side b: b cos 12° = -----10 10 cos 12° = b 10 ( 0.978 ) = b 9.78 = b Tangential method. This method assumes that the bore maintains the same inclination angle and hole azimuth as measured at the end of a drilled joint. Advantages. • The method is easily calculated by hand. • The error tends to show a slight increase in elevation over distance, thereby better reflecting how most drillers drill a joint. Disadvantages. • No theoretical justification. • Automatically generates an elevation increase over distance. or walkover system positions. Use the best fit. Tangential calculations. As covered above, the tangential method of calculating position is quick and easy. Refer to the survey tabulation sheet (Table 3.1) for use in this example. A 10°-entry angle and 30-ft drill pipe stems will be used. Line A is the bit-to-sensor measurement. This is the physical measurement from the bit to the probe sensors in the non-magnetic collar. D = C - (A + B) With the initial course length, calculate the away station using the tangential method, distance left or right, and the elevation. Remember that the initial entry angle was 10°, but note that the probe reads 80°— this is the number used in the calculation. Suppose that the course length in Column D is 11.5 ft and that the angle is built to 80°. This angle at the bottom of the drilled joint is the angle to use with the tangential method. The azimuth is also used to calculate closures. If the line azimuth (Az) is 150° and, because of magnetic interference near the rig, it was necessary to plug the Az at 150°: Away = course length x sin (Inc) x cos (Az) Note that this Az in the calculation is the difference between line Az and drilled Az, which in this case would be 0. Therefore: Away = 11.5 x sin (80.6°) x cos (0°) Away = 11.5 x 0.9866 x 1 Away = 11.34 ft Recommendations. Always begin a job using this calculation method. Watch how the driller obtains his targets. If he aggressively chases the target early, stay with the tangential method. If he waits to obtain his desired angle at the bottom of the joint, change to another method of calculation. Compare both methods to direct elevation readings from Tru Tracker™ coil positions 3-4 This number is placed in Column H. Next, calculate the distance moved left or right of centerline: Right = course length x sin (Inc) x sin (Az) Table 3.1. Survey tabulation sheet. Client Location Country Job No. Engineer Probe No. Ground Elevation: Entry Date Remarks Jt. No. Time Sht Of Sht Azi. Mag Bit–Sensor Vice–Entry TF Offset BHA Length Crossing Length Coil File Sumitomo Directional Drilling Systems Dip Rig Azi. Surv.File A B C Exit Pipe Length CL MD D K E L High Side Inclination Raw Avg F Azimuth Raw Avg G Mag Dip Elevation Station Away Survey TT H I Survey Left Right Ja Tru Tracker Left Right Jb Steering: Guidance Principles 3-5 Horizontal Directional Drilling Training Program Again, this AZ is the difference between the line Az and drilled Az. Right = 11.5 x sin (80.6) x sin (0°) Right = 11.5 x 0.9866 x 0 Right = 0 ft Because the Az did not change, it did not deviate from centerline. This number is entered in either Column Ja or Jb, depending on whether it moved left or right of centerline. Now calculate the elevation drop or true vertical depth (TVD): TVD = Course length x cos (Inc) TVD = Course length x cos (80.6) The average angle method treats the bore as a straight line, but approximates the slope of the line by taking the average of the inclination angles at each end of the drilled section. This process is also carried out for the hole direction (azimuth) readings. These averages are used in a standard tangential calculation to determine elevations and left/right positions. This method becomes less accurate as the difference between either pair of angles increases or as the distance between survey stations becomes large. Within these limitations, however, the results obtained with this method differ little from those obtained from more sophisticated methods. Advantages. • Fairly accurate, and good repeatability with other more advanced methods. • Calculations are simple enough for field use with a non-programmable calculator. TVD + 11.5 x 0.1633 TVD = 1.878 ft By drilling 11.5 ft and moving from an entry angle of 80° to a drilled angle of 80.6°, TVD has dropped approximately 1.9 ft in elevation. This number goes in Column I. The next course length, Column K, will be added to the initial measured depth, Column E, to determine the new measured depth, Column L. Use Column K to do the next set of calculations. Note: 1. From now on, the difference in azimuth will be the difference between the previous azimuth and the present azimuth. 2. After calculating the away, elevation, and left/right, add these to the previous distances to maintain a running tally. Average angle method. This calculation method, also called the angle averaging method, assumes that the borehole is parallel to the simple average of both the inclination and hole azimuth angles between two survey stations (the beginning and end of a joint). 3-6 Disadvantages. • No theoretical justification. Recommendations. On many crossings, this method works well. Always compare the tangential method with the average angle method at various points during a crossing. The choice of methods should be based on driller bias and further comparison with surface location systems. Average angle calculations. Calculating with the average angle method will now be reviewed, using the same numbers that were used in the tangential method. Course length = 11.5 ft Inclination1 = 80° (entry angle) Inclination2 = 80.6° (drilled angle) Azimuth1 = 150° (line Az) Azimuth2 = 150° (plugged Az) Steering: Guidance Principles To calculate the away station using the average angle method: ( Inc 1 + Inc 2 ) ( Az 1 + Az 2 ) - × cos ----------------------------Away = Course length x sin ------------------------------2 2 ( 80° + 80.6° ) ( 150° + 150° ) Away = 11.5 x sin --------------------------------- × cos ---------------------------------2 2 Az 1 + Az 2 ------------------------- = Az 3 Note: 2 Just as in the tangential method, take the cosine of the difference between line Az and Az 3 to use in this formula. Away = 11.5 x 0.9857 x 1 Away = 11.33 ft This number will be placed in Column H. Next, calculate the distance moved left or right of centerline: ( Inc 1 + Inc 2 ) ( Az 1 + Az 2 ) - × sin ----------------------------Right = Course length x sin ------------------------------2 2 Az 1 + Az 2 Again, ------------------------ = Az 3 2 Take the cosine of the difference between line Az and Az3. Right = 11.5 x sin (80.3°) x sin (0°) Right = 11.5 x 0.9857 x 0 Right = 0 Finally, calculate the elevation change or TVD. ( Inc 1 + Inc 2 ) TVD = Course length x cos ------------------------------2 TVD = 11.5 x cos (80.3°) TVD = 11.5 x 0.1685 TVD + 1.9376 ft Radius of curvature method. In the radius of curvature method, the data from two survey stations are used to define the assumed circular arc trajectory of the borehole between these points. The borehole is assumed to be curved in either or both vertical and horizontal planes. Advantages. • Sound theoretical justification. Disadvantages. • Complex calculations require a programmable calculator or computer. 3-7 Horizontal Directional Drilling Training Program • Rarely different from average angle calculations. • Not easily explained to customers. If calculating the horizontal distance of the same curve using the same information, use the following formula: Horizontal distance = cos 78° x 1000 ft Radius calculations. With any horizontal crossing, the depth and the horizontal distance of a curve must be calculated. To make these calculations, some basic information is needed. If the drop in an entry curve is calculated, the expected entry angle and radius to be drilled must be known. In the following calculations, an entry angle of 78°, a radius of 1000 ft, and the end of the curve at 90° (horizontal) are used: Drop = R - (sin 78° x R) Drop = 21.85 ft Horizontal distance = 207.91 ft The horizontal distance and the amount of drop in the curve are now known. Situations may arise where you have a known entry angle and the horizontal distance to the location where the curve must end at 90°. If given an entry angle of 78° and a horizontal distance of 300 ft, you can calculate the radius you must drill to accommodate the known data. Do this by using the following formula: Radius = 300 ft/cos 78° Radius = 1442.92 Magnetics During the process of drilling a borehole, the steel components of the drill string become magnetized. Magnetic surveying devices placed within the drill string are affected by magnetized components of the drill string. Therefore, surveying devices are always placed in a non-magnetic section of drill string. These non-magnetic sections act as spacers, causing the magnetic poles to be “spaced” away from the sensors/compass. By spacing the sensor/ compass a proper distance from the magnetic poles, the interference on the sensor/ compass will be minimized. Magnetic field interference varies with the inverse square of the distance between the source and the sensor/compass. That is: PoleStrength InterferingForce = ---------------------------------Dis tan ce 2 Therefore, as the distance between the magnetic source and the sensor/compass increases, the force on the sensor/compass decreases exponentially. For example, if a force F is affecting a sensor/compass at a distance of 4 ft, then the interfering force (IF) will be reduced to 1/4 strength at 8 ft, or to 1/9 strength at 12 ft. Borehole direction and inclination A leveled magnetic sensing device, such as a compass or a magnetometer, actually relies only on that portion of the earth’s magnetic field that is in the horizontal plane. Therefore, only that portion of the IF (caused by magnetized steel) that is in the horizontal plane will affect the magnetic setting. As the inclination of the drill string becomes more horizontal, the greater will be the IF that exists in the horizontal plane. Therefore, at high inclinations (e.g., 90° borehole) the effect on the sensor is maxi3-8 mized. The horizontal component of the interfering force IFH is defined as: PoleStrength IF H = ---------------------------------× sin ( inclination ) Dis tan ce 2 The direction (azimuth) in which the drill string is positioned is also a factor in determining the effect of the IF on the magnetic sensor. If IFH is divided into north-south and east-west components, then angle a Steering: Magnetics represents the direction of the drill string. IFH can be divided into a north component (IFH north) and an east component (IFH east). At angle a the following vectors can be determined: Total north vector = H + IFH north Total east vector = IFH east The following formula mathematically expresses the vector addition of magnetic north and the IF (north and east) components: IFtotal = Total north vector + Total east vector = ( H + IF H north ) 2 + ( IF H east ) 2 The total IF will cause the sensor to read an erroneous magnetic north. The azimuth error is represented by angle Z and can be expressed as: IF H east sin Z = -----------------IF total or IF H east Z = Arc sin -----------------IF total The above formulas are included to make you aware that it is possible to calculate interference originating from the drill string. This is called Z axis interference, since the Z axis, magnetometer (the one in the pipe axis) is the one picking up most of the interference from the drill string. Remember that if Z axis interference is present while drilling, the resultant azimuth will be affected differently as inclination and direction changes. Geographic location Geographic location must also be considered when understanding the effects of magnetic interference caused by magnetized drill string components. As stated earlier, a leveled magnetic sensing device senses the horizontal component of the earth’s magnetic field. The amplitude of the horizontal component of the earth’s magnetic field varies with geographic location. The horizontal component of the earth’s magnetic field is at a maximum near the (magnetic) equator, and at a minimum near the north and south poles. Only the horizontal component of this magnetic field affects a leveled magnetic sensor used to indicate azimuth (such as a compass or sensor). As the latitude increases north or south from the equator, the angle of dip of the earth’s magnetic field increases. This increases the effects of the vertical component of the earth’s magnetic field and decreases the effects of the horizontal component. Thus, any magnetic sensor is required to act on a diminishing horizontal component as it is moved north or south from the equator, and it is more likely to be affected by interference from other horizontal field effects. Therefore, a magnetic sensor can sense magnetic north easier at the equator than near the poles because a stronger natural horizontal force will be exerted on the sensor. If an IF is present, it will have a more noticeable effect on directional readings taken near the poles than on readings taken near the equator. That is, the magnetic north vector (H) will be less pronounced at the poles, so the effect of an IFHeast or IFHwest will be even more influential. Understand that the increase or decrease in magnetic interference at different geographic locations is not caused by an increase or decrease in the IF of the magnetized drill string, but is caused by the increase or decrease of the horizontal component of the earth’s magnetic field. Any lessening of the earth’s natural field allows the drill string field to have more influence. Sensing devices measure the inclination and direction of the hole as well as the high side of the BHA. When magnetic interference is present, some of these sensors will be affected. Since the inclination and high side tool face are measured by accelerometers and are fairly independent of magnetic north, they are not affected. However, hole direction is referenced to magnetic north and any error in detecting magnetic north 3-9 Horizontal Directional Drilling Training Program will result in an erroneous hole direction or azimuth. At points on the earth’s surface where the horizontal component of the magnetic field is minimal, a dip needle will rest with its axis vertical. Such points are called dip poles. Principal poles of this kind are situated near the north and south geographical poles; they are called the magnetic north and magnetic south poles. (The dip pole near the geographic north pole is, in reality, a south magnetic pole, although it is referred to as magnetic north.) Magnetic sensor spacing As noted earlier, the BHA and drill pipe are strong sources of magnetic interference, commonly called Z axis interference, which must be minimized. The greatest responsibility during rig-up on location is to accurately establish the line azimuth. This cannot be done with confidence if Z axis interference is present. Z axis interference. Take the following steps to test for Z axis interference: 1. Locate a magnetically clean area by connecting a test lead to a steering tool probe and roughly aligning with the axis of the planned bore. Ensure the probe is rotated to probe high side and is not software-corrected. Note H-Total and dip on scratch paper. Move the probe 5 ft (1.5 m) right or left and note data. Move 5 ft (1.5 m) forward or back and note data. The three readings should be very close as long as tool high side has not been changed during movement. If the readings differ by more than 0.1° dip or more than 40 in the H-Total, move back to first locations and attempt to repeat initial readings. They should repeat. After repeating, move the probe in directions opposite from the first moves. Again, look for differences. If different, continue moving forward until a location is found that repeats the dip and H-Total within specs. Once a clean location is found, orient the probe to centerline. Note dip, H-Total, and azimuth on paper. 2. Lay the BHA on the ground at least 15 ft (4.6 m) from the probe. Lay down the jet or motor 12 in. (30.5 cm) from the front of the probe, and look at the data. If different from what was noted 3-10 on paper, continue moving the motor or jet forward, further from the probe until the original readings are obtained. At this point, move the assembly an additional 24 in. (61 cm). Leave the assembly in position on the ground. 3. Pick up the crossover sub and lay it in its normal connected position on the ground. Check that the data are not affected. If so, move sub and motor or jet further from the probe. 4. Pick up the non-magnetic collar and lay it alongside the probe, being careful not to touch or move the probe. Note the data on paper. 5. Pick up a joint of drill pipe with its crossover installed and lay it in its normal running location behind the nonmagnetic collar. Check data. If affected, begin moving it further behind the assembly until the original readings are obtained. At this point, move the drill pipe an additional 24 in. (61 cm) and measure the distance from the shoulder of the crossover sub on the end of the drill pipe to the shoulder of the non-magnetic drill collar. This is the length of additional non-magnetic collar that you need. 6. Measure the distance from the shoulder of the bottom of the probe to the probe connection shoulder in the orienting sub. This is the distance to space the probe away from the drilling assembly. 7. You now have a clean BHA that is not producing Z axis interference. 8. In some cases, non-magnetic collars will become slightly magnetized. This would have been noted in step 4. Nor- Steering: Magnetics mally, it is OK to drill with some interference. If you locate a magnetically clean area, pull the probe through the non-magnetic collar and print screen at each foot of length. The resulting magnetic picture should be the same throughout. If it is not, identify exactly where the “hot spots” are and ensure that you space away from these spots. Spacing. Once all measurements of the BHA have been made, check the following three points, taking into account spacing away from Z axis interference: 1. Distance from bit to probe sensors: This is the physical measurement from the end of the bit to a point between the magnetometers and the accelerometers. Record this measurement on the field sheet in the space allotted. 2. Entire BHA: The physical measurement from the face of the bit to the shoulder of the crossover sub above the non-magnetic collars, including the sub. Record the measurement on the field sheet in the space allotted. 3. Make up BHA: Once the assembly is made up before spud, ensure the previous measurements are reasonable. This can take the form of a second measurement, stepping off the length or, in some cases, estimating the length. Once you’ve done this, refer back to your initial measurements and compare them. If they are correct, proceed to spud. If you do determine a BHA measurement difference, note it on the field sheet and attempt to quantify the error before spud. Note the same in your daily report. Outside sources of interference Z axis interference relative to the drill string was previously discussed. In addition, you may also see Z axis interference when approaching an outside magnetic field. If so, usually you will not be able to quantify it as Z axis, unless you are horizontal and not changing direction. By watching the sensor readings and seeing no changes in your X and Y magnetics, but some change in Z, you may identify an isolated occurrence of Z axis interference. Usually, you will not have time to watch sensor readings in isolation, but will be watching H-Total and dip for interference warning purposes. Normally, in utility and pipeline drilling, there are many sources of interference to look for. Immediately on arrival in a new location, make time to walk the line. Keep your eyes open for any potential magnetic problems. Look at the topography and the surrounding landscape, and make notes for later reference. In-ground sources. There are many sources of underground interference. Look at the field drawings. Pipelines and services will be shown—most of the time. Abandoned services, however, usually will not. Pipelines. Buried pipelines are common, and they may cross perpendicularly or obliquely anywhere. If trenched, they will normally be 3 to 5 ft (0.9 to 1.5 m) below the surface. If drilled, they may be anywhere. It is important to locate pipelines relative to the bore path being drilled. This should take the form of physically measuring its location and transferring the measurements to the drilling plan, if it could pose a hazard to progress. Magnetically, it is important to understand exactly where the line is. Pipelines normally have a cathodic protection current running through the line. This is a direct current (DC) source; normally low-current, powering cathodes. These are used to slow the oxidation process of a pipeline by sacrificing a faster oxidizing metal. If Tru Tracker coils are associated with cathodic protection, the readings will be affected. Normally, unless the bore path is very close (5 in. [12.7 cm] or less), cathodic protection will not affect azimuth. The steel of the pipeline will, however. If the bore path is within 30 ft (9 m) of a 12in. (30-cm) line or larger, some interference can be expected. Measure the distance both 3-11 Horizontal Directional Drilling Training Program horizontally and vertically. Beyond 30 ft, you should be aware of the line. Entry and exit points are critical. With permission, expose any line you are approaching in azimuth or elevation. Do not fall back on the client’s “as laid” drawings. Alert the client to the possible problem and ask to expose the line while you drill at the sensitive point. Underground tunnels. Expect that tunnels will have significant associated steel within their construction. Their size will determine their affect on azimuth. Fiber optic cables. All the above comments relative to safety pertain to fiber optic telephone cables. These cables normally have a steel outer shield. The effect on azimuth normally is minimal, depending on your distance from it. Underground trash. Old building foundations, bridge abutments, landfill areas, and many other items may cause guidance problems. Normally, by walking the bore path, you will locate many potential problems. Make notes and physically measure those that could have the most impact on a job. Draw them on the drilling plan to scale. Power cables. All comments relative to safety pertain to power cables. These cables vary from very low alternating current (AC) to steel-coated, oil-filled megawatt transmission lines. They will affect azimuth and Tru Tracker readings. Telephone cables. All comments relative to safety pertain to copper telephone cables. In many areas high- and low-volume copper cable is still in use, rather than fiber optic cable. Since telephone lines use DC current, they are a major source of azimuth and Tru Tracker interference. All other cables. Most underground cables will generate interference. It is best to stay as far away as possible from them and note on the drilling plan exactly where they are. Plastic pipelines. Plastic pipelines will not generate interference. It is still best not to plan a bore near them, although normally it is not possible to choose the best path every time. Sheet piling. Normally, sheet piles are associated with river banks, although they may be found in any area for ground consolidation. They are usually steel and will significantly affect magnetic azimuth when drilling under or parallel them. Tru Tracker will be affected if the coil wire is placed such that the pile is located between the probe and the coil wire. It will also be affected when attempting to enter sheet3-12 piled exit pits. Expect major interference within 30 to 60 ft (9 to 18 m) of sheet piling. Bridges. Pipeline crossings often are planned near bridges since the right-of-way permissions are easier to obtain. Bridges pose real guidance problems if close enough to impact magnetic azimuth. There are two problems to overcome with bridges. First is the mass of the bridge itself. Regardless of the type of construction, steel or concrete, there is a very significant mass of iron to be concerned about. The actual bridge may rise in elevation toward the center of the span, causing different magnetics on every joint. Second, the bore path may not be parallel to the bridge, also causing different magnetics on every joint. The footings of the bridge will be supported either by bedrock or deep construction pilings. As drilling progresses near bridge footings, the magnetic intensity of the interference increases and decreases as the footings are passed. Expect magnetic problems from the span about the same horizontal distance as the height of the span. Depending on the type and depth of the footings, expect problems closer than 100 ft to the footings. The magnetics will be different on the entry and exit sides of the river. Measure and plot on the drilling plan the orientation of the span relative to the bore path. Also, measure and plot the footings against distance on the bore plan. Steering: Magnetics Above-ground sources. transmitting frequencies and length of transmissions. Bridges. Note above comments on bridges. Buildings. The amount of interference differs with the size and type of building construction, as well as how far away the bore path is planned. Expect minimal problems with housing construction and significant problems with office towers. All transmitting antennas and repeater stations are grounded to the earth. During transmissions an in-ground field will be established, causing potential Tru Tracker interference. This has been noticed up to 200 ft (61 m) away, although it was difficult to determine if the transmission or the antenna ground was the cause. Tanks and tank farms. A single tank (or metal object with mass) has significant magnetic properties associated with it. These are generally local in nature and may be bypassed relatively quickly. Once 30 ft (9 m) or more away, the interference diminishes. Railroads. There are three problems with railroad crossings. First is the steel rails themselves, which cause a local field as you pass under them. Tru Tracker will not be affected by the rails alone. A storage tank farm, on the other hand, generates a significant local anomaly in the earth’s magnetic field strength and dip. If drilling within the tanks, the magnitude of interference will render azimuth readings worthless. If Tru Tracker coils are laid improperly, these data will also be affected. Always refer to office personnel for assistance in determining correct coil layouts when drilling within a tank farm. Second are the various services that may be present. Rail rights-of-way are used by many utility companies for in-ground services. The railroad itself will use the rightof-way for signal cables, switching cables, and communication cables. Tru Tracker will be affected significantly by signal and switching cables. The effect will be an offset position when the signal or switching current is on. Since you do not know when this happens, you are faced with secondguessing the data. In planned crossings that drill toward, away from, or parallel to tank farms, expect changing magnetics in varying degrees up to 1000 ft (305 m) away from the nearest tank. Azimuth differences will occur between entry and exit readings. Benchmark an entry and exit shoot to account for these differences. Grain elevators. Normally, consider these as buildings with local problems only. Cranes and other heavy equipment. These create local problems only, which will diminish quickly when passed. Communication station antennas. Shortwave (SW), very high frequency (VHF), ultra-high frequency (UHF), and microwave antennas generate electromagnetic fields. The high frequency of the emissions normally will not affect magnetic azimuth a great deal. Long-wave (LW) and very low frequency (VLF) will affect azimuth within a mile (1.6 km) or so of the transmitting station. The magnitude of interference will not be quantifiable because of different Third, in most areas of the world, you will find electric trains powered by an overhead system consisting of traction current. This DC current is applied to the overhead from a cable underground at various points along the length of the rail line. As the train moves between sectors, it will draw its power requirements from the nearest source. As a train approaches, the current nearest the probe will increase, reaching the maximum current draw when the train is at its nearest point to the probe. Since the magnetic field’s magnitude follows the current curve, both azimuth and Tru Tracker will be affected somewhat as soon as the train begins drawing its power from the local power sector. The azimuth error magnitude will increase smoothly with the train’s approach and decrease as the train moves away. A Tru Tracker reading will show increasing offsets as the train approaches, and decreasing offsets as it moves away. Interference has 3-13 Horizontal Directional Drilling Training Program been noticed up to 200 ft (61 m) away from the tracks. These problems normally may be overcome by simply waiting for trains to pass, although in highly traveled areas in large cities, it remains a major problem. The client must be kept advised of the problems and an attempt to determine or quantify degradation of accuracy should be made. Overhead cables. Generally, overhead cables cause few problems since you pass under and move away from them. Usually they will not affect readings within 100 ft (30.5 m), although with megawatt lines parallel to bore path the influence can exceed 100 ft. The magnetic field generated from the overheads will vary with time, causing azimuth and Tru Tracker readings to offset. The magnitude of the offset sometimes may be quantifiable, allowing operations to continue safely. Magnetic interference First determine the accuracy of the azimuth or Tru Tracker reading. Identify the interference and attempt to quantify it. If done in an organized manner, the punchout accuracy will improve. This section covers both azimuth and Tru Tracker interference. Steering tool interference. As noted previously, the earth produces a magnetic field that can be measured with magnetometers. If three magnetics are used orthogonally, the measurements will resolve the earth’s field strength, dip angle, and azimuth relative to the instrument. If the instrument is moved physically in a straight line and the magnetic field does not change, the azimuth produced will be the same at all points on the line. If the dip or field strength changes because of a local magnetic anomaly, the azimuth reading will change even though the instrument continues to move in a straight line. This effect forms the basis of most interference troubleshooting. The field data sheet (Table 3.1) has columns for azimuth, mag, and dip to be recorded. They should be noted at every survey station during the pilot hole. In some cases where strong local fields are encountered, it may be necessary to stop the drilling operation every few feet to check the change in mag and/or dip. while the best case is a north/south orientation. Unlike Z axis interference, which is predictable in terms of the direction of the error, interference from surface or subsurface sources affects all three sensors, with the X and Y sensors being most affected. This is much more difficult to predict since in many cases you will not be able to identify the source. If the source is identifiable, the problem becomes much easier to handle. It is not possible to quantify from the data the amount of error you see in a given survey. It is possible to judge whether the interference causes an increase or decrease in the azimuth reading when the only interference source is located to the right or left of the bore path and is a surface source (such as buildings, towers, or bridges) An underground source whose elevation is lower than the bore path should produce an opposite effect of a source located higher than the bore path. The polarity of a magnetic field will produce opposite effects when reversed. Azimuth effect if known source of interference is right of the bore path. When drilling north: Interference to the azimuth occurs when the intensity or dip angle changes. The worst case (largest magnitude) of interference occurs in an east/west orientation, 3-14 • If dip goes up, azimuth goes down. • If dip goes down, azimuth goes up. Steering: Magnetics When drilling east: • If dip goes up, azimuth goes down. • If dip goes down, azimuth goes up. When drilling south: • If dip goes up, azimuth goes up. • If dip goes down, azimuth goes down. When drilling west: • If dip goes up, azimuth goes up. • If dip goes down, azimuth goes down. Azimuth effect if known source of interference is left of the bore path. When drilling north: • If dip goes up, azimuth goes up. • If dip goes down, azimuth goes down. When drilling east: • If dip goes up, azimuth goes up. • If dip goes down, azimuth goes down. When drilling south: • If dip goes up, azimuth goes down. • If dip goes down, azimuth goes up. When drilling west: • If dip goes up, azimuth goes down. • If dip goes down, azimuth goes up. Magnitude of error quantification. Any attempt to quantify the amount of azimuth error must be based on a significant amount of data and its logical presentation. A Mag/ Dip Chart will assist in graphically keeping track of the data in a logical format. The questionable areas of interference will be immediately apparent and azimuth decisions can be made on a structured basis. The chart should be used on every occasion where interference is experienced, where Tru Tracker is not used, and where exit limits are tight. Benchmarking a magnetic azimuth may be undertaken directly from the chart. Methods of constructing the Mag/Dip Chart follows this section (page 3-17). Given a clean Z axis situation and a clean probe orientation where mag, dip, and azimuth have been noted before spudding the bore, the mag and dip will be constant for the entire length of the bore. If the mag or dip changes, the resultant azimuth will be affected, as stated earlier. Magnetic intensity also produces proportional changes, but they are more difficult to quantify. Roughly, its effect on azimuth follows dip somewhat, but since it is an expression of force, it is much more difficult to predict. For the purpose of quantifying errors, the methods will be limited to dip angles. Since the magnetic field size causing the problem is not known, the magnitude of the error cannot be accurately predicted; however, some rules of thumb may be applied: 1. When drilling north or south and the interference source on either side of the bore path is not known, large dip changes produce small azimuth errors. 2. When drilling east or west and the interference source is on the right of the bore path, small dip changes produce small azimuth errors, and large dip changes produce large azimuth errors. 3. When drilling east or west and the interference source is on the left of the bore path, small dip changes produce large azimuth errors, and large dip changes produce even larger azimuth errors. The worst case of interference will be a source to the right of the bore path when the line azimuth is east or west. Consider this when planning jobs and while drilling. Apply the above principles when attempting to quantify the amount of error in azimuth. In addition, closely study the topography and relate it to the error problems that are occurring. Plot known sources or expected sources of interference 3-15 Horizontal Directional Drilling Training Program on the Mag/Dip chart within a judged scale. Calculating linear azimuth correction factors. While drilling, if you encounter a 2° increase in dip combined with a 5° increase in azimuth, and a building is located 30 ft (9 m) to the left of the bore path, which is east, a very large error in azimuth will occur. If at the end of the next joint drilled, the dip returned to normal and azimuth decreased by 5°, you would now have a real quantification of dip-to-azimuth correction (+2° of dip = +5° of azimuth). Note this situation only applies if azimuth is identical on both sides of the interference; in other words, you have drilled straight ahead with no hor- izontal turn. Apply this determination in a linear methodology (if 2 = 5 then 1 = 2.5, etc.) throughout the balance of the crossing as long as the additional problems encountered have a similar mass and are a similar distance from the bore path—in this case on the left. This will occur when drilling near bridges or along overhead cable rights-of-way, where the bridge pillars or footings and the overhead cable pylons are evenly spaced away from the bore path. For the calculations, change the azimuth of the joint where the error occurred to more reasonably reflect the bore path movement from the previous reading to the next reading (Table 3.2). Table 3.2. Calculating linear azimuth correction factors. Horizontal distance ft (m) Dip (%) Raw azimuth (%) Azimuth correction (%) Corrected azimuth (%) 650 (198) 680 (207) 710 (217) 740 (226) 770 (235) 800 (244) 830 (253) 51.5 51.5 52.0 53.5 52.5 51.5 51.5 91.5 91.6 92.2 96.5 94.0 91.5 91.5 0.0 0.0 1.2 5.0 2.5 0.0 0.0 0.0 0.0 91.5 91.5 91.5 0.0 0.0 Calculating straight line azimuth correction factors. More normally when drilling with interference, the bore will turn according to formation tendencies and/or driller bias. The following readings would be corrected more subjectively (Table 3.3). Table 3.3. Calculating straight line azimuth correction factors. 3-16 Horizontal distance ft (m) Dip (%) Raw azimuth (%) Azimuth correction (%) Corrected azimuth (%) 650 (198) 680 (207) 710 (217) 740 (226) 770 (235) 800 (244) 830 (253) 860 (262) 890 (271) 920 (281) 51.5 51.5 52.0 53.5 53.5 52.5 52.5 52.0 51.5 51.5 91.5 91.5 92.2 96.5 96.5 94.0 93.5 91.7 89.7 89.5 0.0 0.0 0.2 0.5 0.8 1.0 1.3 1.5 0.0 0.0 91.5 91.5 91.3 91.0 90.7 90.5 90.2 90.0 89.7 89.5 Steering: Magnetics In this case, you were drilling east, attempting to drill as straight as possible. You entered the interference at 710 ft (217 m) out and drilled ahead to 920 ft (281 m) out. The dip evened out at 890 ft (271 m) while azimuth continued to drop. The bore began to turn at some point. While watching the driller’s orientations during the period of interference, you would have noted a slight bias to the left, causing the bore to turn. Without the bias, the formation may have pushed the bore off line. Correct the survey position by applying a correction to those azimuths experiencing interference. Do this on a best-guess basis, applying a straight line correction factor between good shots. The bore moved 1.8° over seven stations. Divide 1.8 by 7 to determine the correction factor to apply on a cumulative basis (see Table 3.3 above). Recalculate the survey to determine an updated position. Inform the driller or client that the bore is 1.8° off line. Either pull back and sidetrack to bring it back to line or turn the bore right and approach the line. The averaging nature of this method assumes that the bore will start turning immediately when interference is noticed. If the driller bias was noticed only after 770 or 800 ft (235 to 244 m) out, you could reasonably assume that the bore before the bias was straight and the turn occurred only after 800 ft (244 m) out. You would then straight line a 1.8° correction over only two or three stations, yielding a higher rate of turn. Note that stations at 890 and 920 ft (271 and 281 m) showed a rate of turn of only 0.2°. In this case, the bore probably began to turn at a very low rate. To achieve 1.8°, it probably took five or six joints. When a high rate of turn is present, the same or greater rate will normally be present on the next station unless the turn is broken by applying opposite bias. If the rate of turn at 920 ft (281 m) corresponds to the straight line method, it is possible to derive a correction factor for dip similar to that used in the first example. Note the correlation between the two methods. Almost all azimuth corrections will be made using one of these two methods or a combination of the two. The key is determining when you do and do not have interference. To make this determination, be comfortable with the initially established line azimuth and the clean mag and dip readings. Constructing a Mag/Dip Chart. On a length of graph paper, lay out a convenient scale along the bottom of the horizontal distance of the crossing. A scale of 1 in. = 50 ft (2.54 cm = 15 m) works well for rigs using 10- or 15-ft (3- to 4.6-m) joints, while a scale of 1 in. = 100 ft (2.54 cm = 30.5 m) works well for rigs with 30-ft (9-m) joints. From the bottom, move up about 2 in. (5 cm) and draw a horizontal line along the entire length of the page. Draw a vertical line about 1 in. (2.54 cm) from the left side of the paper. Near the center of the paper, draw another horizontal line from 0 ft to the end of the crossing. About 2 in. (5 cm) down from the top of the page, draw another horizontal line from 0 ft to the end of the crossing. Label the scale of horizontal distance every inch (2.54 cm) from 0 ft to the end of the crossing. From the land survey notes, draw in the relative locations of all possible sources of magnetic interference that were noted against distance and left/right of the line. It may be necessary to adjust the scale to ensure space. Now the plotting axis for azimuth on the bottom, dip in the center, and dip at the top is established. Refer to your field sheets to obtain the readings you established as your initial line azimuth, clean mag, and dip. Note these readings to the left of the vertical line on the left of the paper. You must now choose a plotting scale for all three. It is important to always orient yourself and the readings to the physical line on the ground. If your line azimuth is 190°, left of the line would be a smaller azimuth and right of the line would be a larger azimuth. Therefore, all numbers on the chart should 3-17 Horizontal Directional Drilling Training Program increase from top to bottom. Good workable scales would be as follows (Table 3.4): needs to be completed throughout, especially when Tru Tracker is not used. Table 3.4. Scales for constructing a Mag/Dip Chart. While drilling, make notes of anomalies as they occur against distance. When the azimuth changes, question whether it is a real turn or interference. Refer to previous positions where dip and azimuth changed and attempt to quantify the amount of error. Become familiar with the presentation of the data in graphical form and use the valuable information derived. 1 in. = 50 ft (2.54 cm = 15 m) or 1 in. = 100 ft (2.54 cm = 30.5 m) Azimuth 1 in. (2.54 cm) = 2 or 2.5 or 4° Dip angle 1 in. (2.54 cm) = 2° Mag intensity 1 in. (2.54 cm) = 1000 gammas Distance On the field tabulation sheet, write down all the information as it is obtained. Update the chart by plotting the measured points as necessary. In the midst of major interference, it is necessary to plot the chart as the data are gathered. Decisions must be made regarding the data immediately, and the trends must be identified and acted upon. Dip angle Mag. field If you are in a relatively clean area, you may drill a few joints before catching up with the plotting. In any case, the chart Using the Mag/Dip Chart. Two charts are presented as examples. The first (Fig. 3.2) discusses a 500-ft (152-m) crossing. The following shoot information is provided: • Line azimuth = 189.5° • Dip = 68.6° • Mag = 55,600 gammas • Shoot location = 65 ft (20 m) in front of rig. 52,500 53,500 54,500 55,500 56,500 57,500 58,500 66 68 70 72 74 76 180 182 Azimuth 184 186 188 190 192 194 196 198 0 50 100 150 200 250 300 350 400 450 500 550 Away Fig. 3.2. Charting a 500-ft (152-m) crossing. Observe the following: 1. Major interference from 0 to 200 ft (0 to 61 m). This is relatively common since the area near the rig (within 100 ft [30.5 m] on large rigs and 60 ft [18.3 m] on smaller rigs) will be 3-18 affected by the rig mass. Also, ground consolidation construction is common around rivers. In this case, steel piling was used to construct a wall at the river’s edge. 2. Note the sine wave signature of mag, dip and azimuth. This will occur when- Steering: Magnetics ever passing directly under a magnetic source. You must look for it, since the center of the sine wave will identify roughly the distance away from the entry point of the steel piling. This is very important on the exit side on occasions where you are unsure of total distances. 3. Dip readings correlate exactly with the shoot readings, while the magnetic intensity is off by about 500 gammas. This indicates slight interference in the shoot location 65 ft (20 m) in front of the rig. Since the bore direction is southerly, the impact on azimuth would be minimal, if any. 4. Observe the azimuth and dip at about 70 ft (21 m) out and then again at about 260 ft (79 m). There is a significant offset in areas where both mag and dip are well within the expected areas. Remember the azimuth correction methods described in Calculating Linear Azimuth Correction Factors (page 3-16). Since there is an offset, review Calculating Straight Line Azimuth Correction Factors (page 3-16). Place a straight edge between the azimuths at 220 and 300 ft (67 and 91.5 m) out. The rate of turn in that 80 ft (24 m) projected back to the previous good azimuth at 70 ft (21 m) indicates a constant driller bias to the right. Every azimuth between 70 and 220 ft (21 and 67 m) could have been corrected using the straight line method. In addition, an assumption could have been made regarding the distance from 0 to 70 ft (0 to 21 m) out. Since the reading at 70 ft was good and matched the shoot azimuth, it would have been a reasonable assumption that all azimuths between 0 and 70 ft were similar. Those azimuths could also have been corrected with the straight line method. 5. During this job, the surveyor assumed there was too much interference to pre- dict an accurate line azimuth. He attempted to drill as straight as possible and wait for the mag and dip to remain constant. This happened between 220 and 250 ft (67 and 76 m) out where the azimuth was 192°. He assumed he had drilled straight ahead, chose 192° as a correct azimuth, discounted his original shoot azimuth (even though the mag and dip were almost identical), and drilled ahead to his target. The ground exit was 17 ft (5.2 m) right, which was unacceptable. The pipe was pulled back, sidetracked, and redrilled from 350 ft (107 m) out, causing an additional day of pilot hole operations. 6. The surveyor failed in three areas. First, when he originally arrived on location and observed the topography, he realized the entry side had magnetic problems. Wall, sheet piles, and rig location indicated that he would have magnetic interference problems. The exit side had no sheet piles and no other visible magnetic sources. He failed to make an exit side confirmation shoot to attempt to match the entry side shoot. Had he done so, he would have accurately established his original line azimuth, and determined at 220 ft (67 m) out that he was off line. Second, he failed to recognize good, clean azimuth at 70 and 220 ft (21 and 67 m) out. He allowed the magnitude of the interference to affect his reasoning. Finally, he assumed the driller could drill 200 + ft (61+ m) straight ahead, without moving off line, and based the entire job on that assumption. In some cases, this is the only way to proceed. Normally, a pullback and redrill will occur when this assumption is made. Therefore, it should be a last resort assumption. In this case, the assumption was made to avoid spending the time and effort of doing an exit side shoot. 3-19 Horizontal Directional Drilling Training Program In Fig. 3.3, a 1700-ft (518.5-m) crossing is presented, using a combination of magnetic and Tru Tracker problems in a single job. It was designed to focus your attention on usable techniques and corrective measures when confronted with similar problems. The shoot information is as follows: • Line azimuth = 137.8° • Dip = 65.3° • Mag = 53,000 gammas • Shoot location = 90 ft (27 m) in front of rig. Azimuth Dip angle Magnetic field 65,000 60,000 55,000 50,000 45,000 40,000 35,000 80 75 70 65 60 55 50 45 110 120 130 140 150 160 Bridge supports 170 0 100 200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 Away Fig. 3.3. Charting a 1700-ft (518.5-m) crossing. Observe the following: 1. This crossing was planned to be drilled 30 ft (9 m) left of a double-span highway bridge starting about 325 ft (99 m) away from the entry point. The shoot was performed at 90 ft (27 m) in front of the rig and an exit side shoot was not done. The exit side was clean magnetically, while the entry side was located 30 ft left of a major highway approach to the bridges and inside a heavily used recreational parking area. The exit side, also 30 ft left of the highway, was next to dense woods. The two highway spans were 50 ft (15 m) wide separated by a gap of 20 ft (6 m). An offset Tru Tracker coil was laid on the nearest bridge span, outside of the bridge on each side. The elevation of the bore was 30 ft (9 m) below the river bottom. Water depth averaged 18 ft (5.5 m). The bridges were about 12 ft (4 m) above the water. Tru Tracker coils were laid between 400 3-20 and 750 ft (122 and 229 m) away from exit on the closest bridge, yielding a coil width of 50 ft (15 m). Before the job was started, the surveyor failed in a number of areas. First, the line azimuth was not accurately established. He did not establish a clean shoot area between the rig and the river. Clean magnetics existed between 120 and 300 ft (37 and 91.5 m) away. He did not elect to do an exit side shoot where the magnetics were obviously better. As was stated in Magnitude of Error Quantification (page 3-15), he did not realize that he was in a magnetically worst-case situation and did not make stronger efforts to set up the job properly. Tru Tracker was available throughout the length of the crossing, but he failed to use proper coil-building techniques in specifying the coil shape. He was Steering: Magnetics drilling 30 ft (9 m) to the left of the coil that was only 50 ft (15 m) wide. In addition, he was drilling 60 ft (18 m) below the Tru Tracker elevation. Using the precept that the coil width should be at least 5% wider than the depth, he should have expected his intensities from the coil to be very low. Also, since the search area outside of an offset coil is roughly half the width of the coil, drilling at 30 ft left was 5 ft (1.5 m) outside the search area. 2. While drilling at 120 ft (37 m) away, the azimuth moved from the shoot azimuth to 139.5°, and this continued to 300 ft (91.5 m) away. Tru Tracker readings throughout the entry coil indicated a straight course. The surveyor did not recognize this as the real azimuth and continued using the shoot azimuth. With Tru Tracker confirmation, this was incorrect. At 300 ft (91.5 m) away, the first interference problems began with an increasing dip and azimuth. The dip, mag, and azimuth began moving up and down at roughly the same rate and quantity. Drilling continued “blind” to about 430 ft (131 m), where the first bridge Tru Tracker coil was set. The coil indicated a small movement to the right but the intensities were so low that the information was disregarded. Drilling continued through the coil to about 700 ft (213.5 m). Tru Tracker readings began showing a stronger right movement but were still disregarded, since the intensities and mismatch readings were out of scale. yielding very low intensities, was also reading a right-hand movement. This was correct but rejected. 3. Drilling continued with the azimuth spikes increasing in magnitude to about 1000 ft (305 m) away. The azimuth spikes’ magnitude built to approximately 17°. At this point, the spikes reversed and began spiking in the opposite direction. At 1050 ft (320 m), a spike of 30° was noted. 4. At 1100 ft (335.5 m) the mag and dip returned to near normal until 1150 ft (351 m). 5. Between 1150 and 1300 ft (351 and 396.5 m) the same scenario occurred as was noted between 350 and 600 ft (107 and 183 m). 6. At 1320 ft (403 m) a very large spike of 34° occurred. This was similar to the spike at 1050 ft (320 m). 7. Between 1350 and 1480 ft (412 and 451 m), the spikes again reversed. 8. Good mag and dip readings began at 1500 ft (457.5 m) and continued throughout the balance of the drilling. The surveyor failed to recognize that with an increasing magnitude of spike, the bore must have been approaching the bridge (see 2, 3, and 5 above). He also failed to recognize that a very large spike could only occur when close to a major source of magnetic interference. At this point, he passed under a bridge footing (see 3 and 6 above). The surveyor failed to measure and plot the locations of each of the bridge footings relative to centerline and distance away. The observed spikes occurred only when the probe was located the same distance away from the bridge footings. The surveyor failed to recognize that a reversal of the spikes indicated he was drilling on the opposite side of the interference (see 3 and 7 above). He also failed to recognize that good mag and dip readings indicate good azimuth readings (see 4 and 8 above). The azimuth throughout continued moving up and down with an increasing magnitude and was averaging a right-hand movement. This was correct but disregarded. The Tru Tracker coil, even though improperly set up and The overall effect of all the guidance failures in this case would be a bore passing under both bridges; if it had been punched out, it would have been more than 200 ft (61 m) to the right of the target. In addition, the bore would have passed directly under 3-21 Horizontal Directional Drilling Training Program at least two bridge footings. The dotted line of the drawing indicates a fair representation of the actual azimuth movement using the correction methods introduced above. Lost time and redrills would have resulted. This job could have been completed with few problems if the proper setup techniques and magnetics correction methods had been used. Using Tru Tracker. Since the Tru Tracker system is a secondary means of determining a bore position, it is important to understand not only its method of operation, but also how to judge the relative accuracy of the output. Operating guidelines and techniques. The Tru Tracker coil, when accurately installed on the ground and in the correct position, generates a magnetic field that can be accurately predicted through mathematical modeling. The field shape and relative strength at every position within and some distance outside of the coil is magnetically unique. The magnetometers in a steering tool measure those parameters both in a positive and negative polarity, compare the data to the model, determine the closest match to the field’s unique parameters, and print out the result. The input data are the amount of amperage input to the coil and the horizontal distance of the probe as calculated by the survey program in the computer. Setup. A Tru Tracker coil is only as good as the input data the surveyor enters into the computer. A proper setup is imperative for an accurate shot. The most important aspect of Tru Tracking is determining where to place corners. By walking the coil area on both the entry and exit sides, a surveyor can determine where coil corners are necessary. Corners need to be placed anywhere there is an anomaly in the coil path, both in elevation and/or distance left and right of centerline. Once you have established the location of the corners, sturdy stakes must be placed at these points. 3-22 The surveyor now needs to measure the horizontal distance from the entry point to each corner along the centerline and the perpendicular distance to each corner from centerline. This is very important. A leftright error in a distance of 2 ft (0.6 m) will mean a 2-ft error in tool positioning. The transit must be set up to get an accurate elevation of each corner relative to entry elevation. As the Tru Tracker accuracy is 1 to 2% of total probe depth, it is critical that you obtain accurate elevations on your corners. Coils should be as wide as the anticipated depth of the probe. For example, if the probe is expected to be 50 ft (15 m) deep, then the effective search area of a coil W wide would be 3W at a depth of W. The coil wire must be stretched straight and tight from one corner to the next. If you cannot go in a straight line from one corner to the next, then you will need to place another corner between these two points. Always number the coil corners in a clockwise direction. Corner measurements must be in the same length units as the directional survey and must use the same reference tie-in (i.e., from the entry point). If entry is listed as 0 away and 0 elevation, then the corners must be measured relative to this point. A corner left of centerline looking toward the exit point must be entered with a negative sign for the right coordinate. If you are using actual survey station numbers for the tie-in and you are drilling backward relative to the stations, all corners must have a negative sign for the away distance. For example, if your entry station is 2000 and your exit point is 1000, and you are drilling backward relative to these stations, then each corner must be entered with a negative value. After loading your coil into the computer, it is always a good idea to select Load and Print a Coil to double-check for accuracy. Taking measurements. Once a joint has been drilled down, it is time to take a sur- Steering: Magnetics vey. Go to Take A Survey on the menu. The computer will prompt: Enter course length: Plug the azimuth (Y/N) Use Tru Tracker? (Y/N) You will next be prompted to enter forward current. If the current is negative, it must have a minus sign in front of it. Ask the coil operator for forward current. There are two important criteria at this stage. The first is that the coil operator must ensure that the current has stabilized before giving this information to the surveyor. The second is that the operator cannot break the connections loose until the surveyor is prompted to do so by the computer. Breaking loose too soon will result in measurement errors and inaccurate data. The operator should also be aware that keying the mike near the Tru Tracker box will cause the readings to fluctuate. The current should be read before transmitting the data. Once the surveyor has been prompted for reverse current, the operator can reverse the leads. When current stabilizes and the reading has been put into the computer, the computer will begin its search. Do not break the leads loose until the computer has completed its search and locked onto the tool. Determining the accuracy of a Tru Tracker shot will be covered in Determining Shot Validity (page 3-25). Power source problems. A solid direct current (DC) power source is required to use Tru Tracker properly. Insufficient or fluctuating power can cause erroneous readings and inaccurate surveys. A good DC welder is normally used to power a Tru Tracker coil. Ensure that there are no nicks in the welder leads that can ground to earth. Cable problems. Nicks in the coil wire or insufficient wire size for the length of the coil are two areas where cable problems can occur. Check the wire thoroughly after laying out the coil to ensure there are no areas where the current can go to ground, especially at splices. If the coil is 1000+ ft (305+ m) long then American Wire Gauge (AWG) 6 wire is recommended. If it is less than 1000 ft, then AWG 8 wire should be sufficient. On 200- to 300-ft (61- to 91.5-m) coils where you do not anticipate going very deep, then you may be able to use 10-gauge wire, although paralleling two lengths of AWG 10 wire is recommended to ensure that you are getting sufficient current and the wire does not overheat. Testing amperage. After a coil has been loaded into the computer, go to the selection titled Predict Field at a Known Point. This selection will allow you to enter theoretical closures (away, right, elevation) and the total current anticipated. The computer calculates the radial angle, radial intensity, and axial intensity. This option will help you determine the current necessary to provide a 2000- to 5000-gamma radial intensity. Best-case layouts. A coil with as few corners as possible, thereby introducing less human error into the equation, is the best scenario. If possible, use an away station of zero and an entry elevation of zero for your entry point. This will give you a simple benchmark for setting up your corner data. For example, suppose you anticipate being 50 ft (15 m) deep toward the end of your coil. As stated before, the coil must be as wide as the anticipated depth, but to do this you would need to put two additional corners in the coil to maneuver around an obstacle. To keep the coil as basic and simple as possible, it would be better to make the coil 55 ft (17 m) wide at this point. This will provide a straight line to the corners without having to add the additional corners necessary to go around the obstacle. The best-case scenario is to use as few corners as possible, but to still place corners at anomalies. If you can put fewer corners and still not upset the depth-of-probe to width-of-coil ratio substantially, then do so. A depth of 50 ft (15 m) with a coil width of 40 to 60 ft (12 to 18 m) will not cause you to lose accuracy on your Tru Tracker shots. In another example, assume you have a 5-ft (1.5-m) error in elevation over a 30 ft (9 m) horizontal distance. If you can get your 3-23 Horizontal Directional Drilling Training Program wire tight enough to go from point A to point B without placing a corner at point C, and ensure that there is no sag in the wire, then do so. There is less chance for error without compromising accuracy. Keep the number of corners to a minimum while still maintaining coil integrity. By placing as few corners as possible, and taking into consideration elevation and left/ right anomalies, there are fewer chances for error. Worst-case layouts. The worst-case scenario for your Tru Tracker coil is where there are numerous corners because of extreme elevation changes or many obstacles in the path of your coil. A coil may have up to 256 corners, but one coil of this size will be very susceptible to inaccuracies. Try to keep the number of corners to a minimum, or make several coils to allow for these anomalies. This will enhance the overall accuracy of your coils by minimizing the human errors. Extreme elevation changes will cause the most inaccuracy in coil configurations. It is imperative that the surveyor obtains an exact elevation on the corners for these coils. Errors in elevation cause errors in depth during Tru Tracking. The transit may have to be moved several times to ensure accuracy, but this is very important. It is also imperative that correct horizontal distances are input for coils in which you encounter extreme elevation changes. Do not use the distance from stake to stake when measuring the corners, but rather use the horizontal distance. This mistake can cause extreme errors in the accuracy of the measurements from your coils. 3-24 bottom is the most accurate way to determine the elevations of your corners when laying water coils. If sounding is not possible, then using the elevation of the centerline can help keep the surveyor on course. The most effective way to lay coils in the water is to weigh them down with lead weights to help ensure that currents or tides do not move the coil during the course of your drilling operation. Establish benchmarks on the entry and exit side of the river to help guide you in a straight path. If it is necessary to have splices in the line you are laying across the water, you must make sure that efficient, watertight connections are made. If you do not have a good heat shrink available, then it is recommended that you use vulcanized tape followed by electrical tape to prevent seepage into your splices. Any leakage can cause erroneous readings. Coils terminating in the water are more difficult to lay, but are a very effective way to help ensure course accuracy. The most effective way to lay a coil that terminates in the water is by using divers. Professional divers can establish a credible centerline on the water bottom, and through the surveyor’s guidance, create a viable Tru Tracker coil. The surveyor must work closely with the divers to make them fully aware of his needs with respect to distances left/right of centerline to maintain course integrity. Suspended coils. Suspended coils are somewhat more difficult to establish. The main priority when constructing a suspended coil is to keep as much sag out of the wire as possible. Any sags will create errors in your Tru Tracker depths. Extreme deviations left and right can also cause errors in measurement. Remember that a tool W in depth with the coil W wide has 3W search area. Coils too wide or too narrow can give erroneous readings. In such cases, you may need to lay offset coils to enhance the accuracy of the information received. Try to keep the wire out of the water, as this can also cause errors. The current from the water can cause the wire to sway, preventing you from obtaining an accurate shot. Usually the computer will tell you that it cannot lock on the tool and no shot will be available. Water coils. Water coils can be very useful tools when drilling across areas of extreme magnetic interference. Sounding the river If there is a sag in the wire, then you must establish a corner at the sag point. This can be done by setting up the transit on the Steering: Magnetics bank and transporting the range rod to the lowest point in the sag. By holding the rod at water level, an elevation can be established. You can also shoot stadia to establish an away station at this point. Determining shot validity. A Tru Tracker shot should be evaluated and monitored to ensure that the data obtained is accurate and reliable. The following indicators are used to determine the accuracy of a Tru Tracker shot: H-Total, G-Total, Radial Intensity, Radial Angle, Radial Angle Mismatch, Radial Intensity Mismatch, and Axial Intensity Mismatch. The values are printed as the shot is taken and should be reviewed at each shot. H-Total. The data from the magnetometers are used by the software to locate the probe. Since the H-Total is also monitored to detect possible magnetic interference, a static or natural H-Total should be recorded at the probe shoot and maintained on a survey tabulation sheet to serve as a reference. As was previously discussed, the H-Total or magnitude of the earth’s magnetic field is region-specific and can be determined before the start of a bore. If the probe is located somewhere within the confines of the coil, the following results can be expected: 1. A forward current will result in an HTotal somewhat higher (ideally between 1000 and 5000 gammas) than the natural or background H-Total recorded at the shoot. 2. A reverse current will yield a lower HTotal of similar magnitude. You can determine a current strength requirement by applying forward current while the tool is idle and monitoring the H-Total displayed on the screen. If an increase of 1000 gammas or more is noted, then the setting on the DC power source is acceptable. If the H-Total falls below the background value, then one of two situations exists: either the polarity of the input current is reversed, or the probe is outside of the confines of the coil. Determine which it is and proceed. G-Total. The G-Total is the result from the accelerometers, which are gravity-sensing devices. The G-Total is primarily used by the software to ensure that the tool remained stationary while the forward and reverse currents were being recorded. The software will alert the operator if it detects a discrepancy in an accelerometer sample between the forward and reverse current applications. A warning will appear on the screen that the tool moved and the shot is invalid. Radial intensity. The value of the radial intensity is a quick indicator of the current strength that the magnetometers are sensing. This value should be between 1000 and 5000. While a reading of below 1000 should not be discounted totally, the absolute accuracy of the shot should be scrutinized. If this value is above 5000, too much current is being applied to the coil. Damage to the magnetometers can occur if an extremely high current is allowed to persist. Radial angle. The radial angle value should read between 180° and 360° (the proper operating range), or 270° if the direction of the magnetic field vector is closely aligned with the probe. The radial angle can indicate improper coil connections to the Tru Tracker control box if it is out of the specified parameters or if the probe is beyond the effective search area of the coil. The coil wire leaving the operator’s left hand should be connected to the positive terminal of the control box. Radial angle and radial intensity mismatch. Mismatch percentages are the differences between actual and theoretical results. Axial intensity mismatch. The axial intensity mismatch will fluctuate more than the radial angle and radial intensity mismatches. Ideally, it should remain less than 15%. Factors that will cause this mismatch to be more than 15% are proximity of the beginning or end of a coil, or entering of an erroneous away distance value. Doublecheck the pipe count. A good rule of thumb is that the probe is inside the coil by at least one-half the width of the coil when a shot is considered good. 3-25 Horizontal Directional Drilling Training Program Tru Tracker interference.Tru Tracker is not a panacea—it cannot be run in a magnetically corrupt environment (such as when the H-Total is near 70,000). Constant lowlevel noise or interference, intermittent surge noise, or spike-type interference can be recognized, and an operator can make allowances or modify the procedures to compensate for such anomalies. Positive vs. negative readings. It is good practice to apply the following procedure periodically throughout any bore, at least to test that no unknown DC sources or hidden ferrous masses are distorting Tru Tracker results. Once comfortably inside a coil, you may make a shot using the following method: When the computer prompts for Forward Current, apply forward current as usual. When the request is made for Reverse Current, do not apply any current to the coil and simply enter H as a reverse current value. Wait for the results, and when the prompt for Take A Repeat appears, answer Yes. Repeat the process. Apply no forward current and enter for this value. Apply the normal reverse current and enter it accordingly. If there is a source of interference on one side, the axial intensity will reflect that source. If the normal forward current and H reverse current results show an almost 0% axial intensity mismatch, the H forward current and normal reverse current results show a 3 to 4% axial intensity mismatch, and movement of 3 to 5 ft (0.9 to 1.5 m) to the right is noted, then there is a source of interference paralleling the bore to the right of the bore path. The operator may choose to continue using an H reverse current method if the DC source is large enough to supply ample current to the coil, or he may elect to reset the entire coil to a configuration that locates the source of interference outside of the coil. Corridor benchmarking. The above procedure is effective for sources of interferences that remain stable or constant. Some sources of interference are variable and interfere at a regular frequency. The 3-26 suggested method of detection and control is described here: To determine if Tru Tracker results are being corrupted by a variable-strength source, take four shots at the same location, not moving the probe, and apply current at a consistent level. If variable interference is affecting the shots, the results may wander 5 ft (1.5 m) or more to the left or right. Plot all of these points. Drill another joint and repeat this procedure. Plot all of the points. As the bore proceeds, a corridor of some constant width or spread will develop. The operator should steer the bore until the corridor straddles the desired centerline, and continue the bore in this fashion until exit or the corridor narrows to a negligible width. Determining azimuth from Tru Tracker data. An operator is often forced to begin a bore without a true, undistorted heading because of the expanse of the obstacle to be crossed, which is usually a body of water and nearby magnetic interference. Using Tru Tracker, it is possible to resolve a true heading or confirm the heading chosen. If this method is used, extremely accurate measurements must be taken when laying out the coil. When in highly congested areas where there is no opportunity to shoot offsets to escape corruption, the operator may resort to this method to help establish a line azimuth or determine that the chosen azimuth is valid. As mentioned before, if this method is used, all measurements must be exact and the coil must be constructed so that every side is a precise, straight line between corners: 1. Shoot the rig in on line and monitor the entry of the first joint with the survey instrument, if possible. This will ensure as straight an entry as possible. 2. Instruct the driller to drill only straight up and straight down, taking time to stop, reorient, and then continue his push. This will eliminate some of the wander caused by right-hand rotation, and is good practice at the start of any bore. Steering: Accuracy 3. Proceed with the bore. When reliable Tru Tracker shots are recorded, three shots at the same away distance agree with each other, and the azimuth indicators of the steering settle to a reliable repeating constant (dip and H-Total are constant). 4. Steer to maintain on centerline according to Tru Tracker. Take standalone shots at five intervals to provide a database for determining a trend. 5. Plot the Tru Tracker vs. the calculated course on a 10 to 1 (or more) scale. Continue this procedure until there is no more coil. 6. Adjust the line azimuth using the tangential method until the calculated values fall in line with the Tru Tracker values. This will be your final line azimuth and should require few further adjustments. Accuracy Within this industry, there is much discourse concerning accuracy. Is accuracy defined as exit point accuracy or instrument accuracy? Within most drilling contractors’ contracts, there will be a clause specifying accuracy. In some, the limits of job accuracy will be specified in terms of the exit point. Some will specify exit point limits, cover limits and, in some cases, corridor limits. Some will specifically note instrument accuracies. Finally, some will mention all of the above. As a guidance company, you should be aware of accuracy in all its various forms and be able to correctly transmit this information to your clients. Accuracy vs. repeatability Accuracy is the quality or state of being exact or precise. Repeatability is the ability to produce the same result again and again. In terms of instrumentation, accuracy can be defined as comparing survey results from one device to survey results from another device to confirm that similar data have been generated from both types of survey instrumentation. Repeatability is a procedure that is used to confirm a survey tool’s accuracy and ensure that the downhole environment has not affected the accuracy of the instrument. Switch-on to switch-on repeatability is necessary. Measuring instruments are calibrated to a particular accuracy, which is determined by the application. Beam accelerometers nor- mally measure gravity, resolve inclination, and tool face or roll. Magnetometers measure the earth’s magnetic field and resolve tool azimuth relative to magnetic north. All sensors are calibrated to resolve tool accuracy to 0.1° in inclination and 0.1° in azimuth. Tool face or roll will also resolve to 0.1°. In addition, a tool will repeat itself to the specified accuracy if it is within calibration specifications. Switch-on to switch-on should repeat itself as long as the tool is not moved or the earth’s field has not changed. As long as a tool will repeat itself within specs, its overall calibration in terms of magnetic north has nothing to do with the accuracy of the ground exit. Its calibration in reference to gravity, however, has everything to do with elevation accuracy. Instrumentation There will always be some error in any survey instrument’s compass. The errors in the instrument itself are less than the opera- tional errors that may result from outside influences. 3-27 Horizontal Directional Drilling Training Program The accuracy of punchout is dependent upon many conditions, some of which may produce compensating errors and others cumulative errors. Since these conditions or a combination of conditions are important factors in punchout accuracy, it is difficult to isolate the exact cause other than interference, which is relative easy to identify. Therefore, interference becomes a catch-all answer to punchout accuracy. Recognize that two surveys might err within reasonable limits in the same direction, while they also might err in opposite directions, producing large differences. A steering tool is within specification if it achieves a repeatable horizontal survey accuracy of 1.7 ft per 1000 ft (sin 0.1° x 1000 ft). In other words, at a distance of 1000 ft (305 m) away from the drilling rig, the tool could be 1.7 ft (0.5 m) left or right of the planned centerline and 1.7 ft higher or lower than the planned elevation. Most tool error is not cumulative; therefore, the actual position should be much better than a radius of 1.7 ft. Tool face accuracy has little to do with job accuracy. Keep in mind: tool accuracy is only that! The tool must be placed in a protective housing, and then placed into a drilling assembly that is bent relative to the hole axis. The bend, if not properly accounted for, can cause elevation errors. The drilling assembly may exert magnetic influence on the azimuth. The formation will exert side forces on the assembly, which can prohibit its proper steerability with any type of guidance instrument. Finally, human error will cause major job accuracy problems. None of these are tool problems. The tool transmits a measurement, and it is up to the surveyor to interpret the data and determine a position reference. Human error In today’s computer age, we are familiar with the phrase “garbage in, garbage out,” meaning that bad solutions will result from bad data. The surveyor has total control over the quality of the data, within reasonable limits. When the surveyor is presented with magnetic problems, if he has spent the time to set up properly on the first day, if he uses his training and experience, and if he uses a structured problem-solving methodology, he will normally be able to overcome problems and provide generally acceptable results. However, there will be many occasions where the magnetics are sufficiently confused to cause major error in position and human uncertainty. When this happens, punchout accuracy will be seriously affected. All surveyors must communicate to the client’s supervisory personnel the factors affecting job accuracy as they occur. Magnetic variation A survey instrument, even though operated in non-magnetic drill collars, will be deflected from its normal heading in the earth’s magnetic field by the magnetized drill string, unless the length of the nonmagnetic drill collar removes the compass completely from the horizontal component of the drill string’s magnetic field (Z axis interference). It is probable that many jobs have been completed with this interference and were slightly in error from the beginning. These errors can range from a minimum while drilling north/south to a maximum while drilling east/west. Errors of this nature will always cause the azimuth to read further to the north than is really the 3-28 case. Therefore, an easterly crossing would normally exit further to the right of target, while a westerly crossing would normally exit further to the left of target. The amount of compass deflection caused by a magnetized drill string is directly proportional to the magnetic pole strengths, and inversely proportional to the square of the distance from the instrument to the pole. Since drill string components are often changed during the course of a bore, and since even the magnetism of any particular drill string component might vary somewhat from day to day, it would seem highly probable that a particular BHA, Steering: Job Site Actions—Pilot Hole being different magnetically from the previous assembly, will produce a different azimuth once back on bottom. magnetic elements to compensate for the known effects of drill string magnetism, which also provides insurance against unknown effects. The solution to this type of problem consists of using an adequate length of non- Course length variation Unlike land surveys where backsight and foresight are visible from every point, a borehole survey position is made up of a series of tangents to the curves of the borehole. Therefore, the shorter the course lengths, the more accurate the surveyed position. It also follows that unless the survey points of different surveys of the same borehole are identical, the coordinates of the survey will probably differ. 30-ft course length survey would produce a left/right position of 30 ft, while the 15-ft course length calculation would produce a left/right position of 15 ft. The following hypothetical case will illustrate this point. Suppose two surveys, one using 30-ft (9-m) course lengths and one using 15-ft (4.6-m) course lengths are made over 500 ft (152.5 m) of hole where a uniform turn of a 500-ft radius exists. Using a standard tangential calculation, the There is a strong case for using shorter course lengths in the turn sections of a bore, and longer course lengths in the tangent or straight sections of a bore. The extra time required must be evaluated against benefit, and normally this time is spent only when exit tolerance is tight. Errors caused by excessively long course lengths and to the location of survey points with respect to hole curvature may be either random or cumulative, depending upon the configuration of the bore. Job Site Actions—Pilot Hole The single most important function during the job setup is establishing the initial line azimuth. Failure to spend the time to do this accurately will result in, at the very least, pullback on the exit side, resulting in lost time. It will definitely result in a course change within the Tru Tracker coil on the exit side, causing excess friction during pullback of the pipeline. The surveyor responsible for guidance must have good, logical observation skills and must apply practical methodologies. This section covers the basic actions required of the surveyor to successfully complete a pilot hole. Upon your arrival and after the initial introductions are made, look at the job in overview. This is normally the last time you will have the opportunity to do this. Once the job begins, you will be concentrating on solving problems of detail, with no time to sit back and consider the overall project. 1. Be observant as you walk. Make notes of potential magnetic problems and their locations. Arrival Walk the line. Take the following steps when walking both sides of the line: 2. Determine where you will do a probe shoot based upon observation. 3. Plan your setup of Tru Tracker coils as you walk. Determine if this is a straightforward setup or if you will need any special equipment. 3-29 Horizontal Directional Drilling Training Program 4. Study the topography, keeping in mind how you will shoot centerlines and lay out Tru Tracker. 5. Finally, determine from the client how much time you have to get rigged up and ready to spud. Fully discuss with him any problems you have observed and advise him of how much time you will need. Ask for assistance where required. Unload and check equipment. After walking the line and before you do anything else, unload your equipment. Set the interface, readout, computer, printer, power supplies, cables, etc., in their locations. Make up the probe in its housing and set aside. Check your equipment now to make sure you have everything you need for the job. Tru Tracker layout Having walked the line and studied the plans, you will have a clear idea of how to proceed with the Tru Tracker layout. The following issues should be addressed whenever possible conflicts or clarity problems arise. Corners. Lay wire ready for spud on the entry side. If possible, set corner stakes on the exit side ready for wire. 2. Ensure that any deviation in wire direction or elevation begins and ends at a peg or stake. Do not allow the wire to curve. Make the segments straight. Width. From the drilling plan, locate the total elevation change between the entry point elevation and proposed depth at the end of the entry coil. The width of the coil at the deepest point of the bore should be about 5% wider than the depth. The extra width will compensate if you lose angle while drilling the entry curve and end up deeper at the end of the coil. In addition, after the coils have been laid, and during the job, the client might wish to replan to a deeper point. 3. Shoot a centerline from entry to exit and place centerline stakes perpendicular to each corner. Use a right-angle surveyor’s prism. Finally, if drilling deeper than the coil width, it is common for radial intensities to decrease rapidly and the field to flip. Always make the coil 5% or more wider than the planned depth. 5. From the entry point, measure the horizontal distance to each centerline stake and note the distances. Against each centerline distance, measure the left/ right distance to its representative coil stake. Length. Make the coil’s length as long as required within the limits of strong measured fields. A coil of 1000 ft (305 m) at 60 ft (18 m) of depth will work, whereas an elevation of 80 ft (24 m) might not yield a strong enough radial intensity. Wire. Use insulated AWG 8 (or 10) squared stranded wire. Make strong splices that will not pull apart. Insulate with rubber bonding tape and cover with electrical vinyl tape. 3-30 1. Number the corners in a clockwise direction, starting from the corner where you set the power source (welding machine). 4. Place centerline stakes perpendicular to any obstructions you noted when you walked the line. Measure their distance from entry and note the measurements on the coil data sheet. Measure the distance from centerline left or right to the obstruction. 6. Measure the topographic elevations. 7. Check on the progress of the rig crew as they prepare to spud. Discuss your progress with the client. Elevations. Measure and record your elevations accurately, because corner elevation inaccuracies will affect Tru Tracker readings significantly. Steering: Job Site Actions—Pilot Hole Line sags. If you are building an unsupported coil segment across a river or canal, you will need to consider line sag. You must ensure that any splices in the segment can survive the pulling forces required to tighten the wire and support its own weight. If the ground elevation on each side is the same, the process of developing measurements is relatively easy. The lowest point of the sag will occur exactly in the middle of the segment. If you have constructed both the left and right sides parallel, the away distance can be derived once and used for both sides. If they are not parallel, you will need to plot the centerline and both sides to scale on graph paper. Using a right-angle triangle, scale the center of each side against the centerline and use this for its away distance. Then scale the left or right distance of the lowest point of the sag to the centerline. Finally, determine the amount of the sag. If a boat is available, use it to physically measure the lowest point. Again, if both sides are the same elevation, this is easy. Measure the distance of the wire from the water and relate this to the distance of each side to the water. Subtracting one from the other yields the line sag elevation. If the elevations are different on each side, you must again use graph paper and draw the stake elevations on each side to scale. Measure the elevation of the water and plot it against the sides. Finally, measure the lowest point of the line sag in the water and plot it. This will be the elevation of the line sag. Measure both the left and right side every time. Ensure that this phantom corner is accurately noted in the proper sequence on the Tru Tracker coil data sheet. Coil shapes. A Tru Tracker coil should be longer than it is wide. The most accurate coils are rectangles, so try to attain a rectangle where possible. On the entry and exit, you may taper the beginning and end back to the entry and exit points, always ensuring that it remains wider than it is deep. Generally, a coil can attain any shape as long as it roughly approximates a rectangle. Zigzags in the sides over a short distance should be avoided at all times. If the surface topography requires this, consider setting out two coils. Otherwise, do not trust your readings within 50 ft (15 m) of the zigzag. The zigzag produces erroneous axial readings where the probe is not expecting them, causing errors. Offset coils. It is possible to offset the coils. Ensure that measurements are very accurate and the widths are adequate to produce a strong field that is readable by the probe. Testing. Once the entry side is ready, hook up the power source and make tests. Vary the current and note amperages. Refer to the Tru Tracker program to project these amp readings against depth to ensure your coil will produce high enough radial intensities. Preparing Tru Tracker data. Complete the Tru Tracker data sheet now, while the measurements are fresh in your mind. Do not leave this step to later, because you may forget a measurement. Steering tool rig-up Check on progress of the rig crew as they prepare to spud. Discuss your progress with the client and how long you will need to get ready. box. Lay out a shoot test lead to the shoot location. Tighten the probe connections and move it to the shoot location. Connect the test lead and power the probe. Rig up your surface equipment and power up. Input your coil data files and make up a survey tabulation sheet. Note the coil data file names on the sheet in the appropriate Turn the probe to its high side and point it generally toward the exit point. Print screen and move the probe 10 ft (3 m) right, still pointed toward the exit. Print screen. Note 3-31 Horizontal Directional Drilling Training Program the position of the probe relative to the first check in writing on the printout. Move the probe 10 ft toward the exit point back on centerline. Print screen. Move the probe 10 ft left of the first check and print screen. Finally, move the probe 10 ft closer to the rig on centerline. Print screen. You have magnetically mapped the shoot area. Create a table as follows (Table 3.5): Table 3.5. Magnetic mapping of the shoot area. Distance ft (m) Position H-Total (gammas) Dip (degrees) 90 (27 m) 100 (30.5 m) 100 (30.5 m) 100 (30.5 m) 110 (33.6 m) CL -10 CL +10 CL 48557 48530 48558 48560 48555 60.3 60.2 60.3 60.2 60.3 By the H-Total, you can see that the centerline shots are consistent. The only anomaly seems to be the left position. Walk around and look at the area for the cause of the different magnetics. Recheck the position with the probe. Move it to a position 20 ft (6 m) left and see if the H-Total continues to drop. In the above example, the magnetics are clean and ready for the shoot. If they are not, in practice, continue testing until you locate a clean position. At this point, you have a lot of data generated from the Tru Tracker coil layout. You must relate this to the profile provided by the client or to the data provided. If you will be drawing the profile, now is the best time. You may wait until after the probe shoot, but you take the chance of needing to change the profile if the client’s data are wrong (remember, it is wrong in some way 95% of the time). the client if the radius is too small for the line with a four times safety factor. If the client proposes to proceed without the safety factor, advise the office by phone as soon as possible, and fax the information in your evening report. Ensure proper probe operation. Remove the test lead and connect it to your spare probe. If you have time, leave a probe connected and rig up your spare interface and spare driller’s readout. Test them to ensure proper operation. If you do not have time now, you should make time to do it later. Profile On the vertical profile, draw in the surface topography and all in-ground or surface obstructions you noted when you walked the line. Remember, you measured distances to each obstruction when you set up Tru Tracker. On the horizontal plan, draw in the obstructions to scale if possible. Ensure that the proposed radius will work for the pipeline to be pulled. Discuss it with 3-32 Make sure the profile fits the topography, length, and cover limits, and circumvents all in-ground obstructions. If you must approach a cable or in-ground line, make sure their positions are accurately known. If you have concerns, express them to the client and always have a firm recommendation ready. You may advise the exposure of in-ground services before spud if you must converge or pass close to any live line. Once the profile is checked and ready, set it aside. Steering: Job Site Actions—Pilot Hole Physical measurements A number of measurements must be made on the surface and downhole equipment. Make these measurements before the probe shoot and note them on paper. Rig measurements. Note measurements on paper: the following • A—Horizontal distance from the center of the vises on the rig to the planned entry point. • B—Height of the center of the vises from ground level and then to the same elevation as the entry point. • C—Distance from the center of the vises to the entry point. You have now measured a right triangle. From the vise elevation and the rig angle, calculate the projected horizontal distance to the entry point: (vise elevation/tan of entry angle) = horizontal distance from vises to entry Compare the calculations to your physical measurements—they should be the same. If not, find out why and discuss this with the client. Note the difference on paper. It will produce a new physical entry point relative to the plan. Be careful when measuring the center of the vises, because some rigs have movable front vises. You may need to establish the point of pipe breakoff during drilling oper- ations and use this instead of the center of the vises. You should always check the rig angle yourself before spud. If a mistake was made, you need to know now, not during the confusion that always occurs while drilling the first few joints. Discuss your findings with the client and how the inaccurate rig angle will affect the job. BHA measurements. Now is the time to measure all drill string components of the BHA. Make a list of each component and note the measurements of each, shoulder to shoulder, starting with the bit or nose of the jet: • Bit = 1.2 ft (0.4 m) • Bit sub = 8 ft (2.4 m) • Motor = 20.7 ft (6.3 m) • Orientation sub = 2.3 ft (0.7 m) • Non-mag drill collar = 27.5 ft (8.4 m) • Non-mag drill collar = 15.0 ft (4.6 m) • Drill pipe crossover = 1.8 ft (0.6 m) • Total BHA = 69.3 ft (21.1 m). Drill pipe measurements. Tell your client that you need to know the measurements of each joint of drill pipe. Ask him to have them measured row by row as they are being used and provide the measurements to you. Find out exactly how many joints of drill pipe are on location and make a note of it. Count them yourself to double-check. Line azimuth shoot The following procedure assumes that the non-magnetic collars were magnetically tested back at the shop and found clean: 1. Power up the probe to be used. Place the probe in its protective case on V blocks or non-magnetic orientation stands. Using one of the centerline Tru Tracker stakes about 30 to 50 ft (9 to 15 m) from the probe position, set up the theodolite, and confirm its centerline position by sighting the entry and exit point. Using a plumb bob or the instrument’s optic plumb, center the instruments over the stake and level accurately. Shoot the exit point and flip to backsight. Shoot the entry point. If misaligned, move the instrument and relevel. Continue doing this until foresight and backsight intersect the exit and entry point, respectively. Make sure the instrument is leveled. 3-33 Horizontal Directional Drilling Training Program 2. Using the backsight, shoot the power sub on the carriage. Estimate how much the rig is misaligned and in what direction. Note this on paper. Flip to foresight. 3. Sight the front and rear of the probe using the vertical crosshair in the scope. Lay the crosshair alongside the probe case and continue adjusting the probe until it is exactly parallel to the crosshair. Turn the probe to its high side. 4. Recheck the centerline position by again sighting the exit and entry points using backsight and foresight. Check that the instrument is level. Again, check that the probe is parallel to the vertical crosshair. 5. Print screen; turn to a tool high side of 90°. Print screen; turn to 180°. Print screen; turn to 270°. Print screen; turn back to high side at 0°. Print screen. Construct the following table (Table 3.6) and set it aside for later. Table 3.6. First test of line azimuth shoot data. Orientation H-Total (degrees) (gammas) 0 90 180 270 0 48560 48555 48572 48520 48555 6. On the theodolite, recheck the line using foresight and backsight and then recheck the probe orientation. It sometimes moves during the probe roll, which would necessitate another roll set of readings. If all is OK, continue. 7. Instruct the crew to bring the motor, bit, and orientation sub to a position about 5 ft (1.5 m) from the exit side of the probe. Lay the assembly on line. 8. Check the H-Total, dip, and azimuth on the screen. If different than during the probe roll, move the motor farther away by 3 ft (1 m). Check again. Continue moving the motor away from the probe until the exact azimuth measurement noted during the probe roll is obtained. Measure the distance from the shoulder of the orientation sub to the T slot on the probe. This is the spacing required from the top of the orientation sub to the probe to obtain clean magnetics during the job. 9. Total the lengths of the two sections of non-magnetic collars. In the example 3-34 Dip (degrees) Azimuth (degrees) 60.3 60.2 60.3 60.1 60.3 27.3 27.2 27.4 27.0 27.3 above, they total 42.5 ft (13 m). Measure this distance from the shoulder of the orientation sub toward the rig and place a marker. Instruct the rig crew to bring one joint of drill pipe, including the crossover sub, to this position and lay them on line. You may need to move the theodolite. 10. Print screen and note the readings on the paper. The H-Total, dip, and azimuth should be the same as during the roll test. If not, add another non-magnetic collar until the readings match. If this is not possible, do the following: • Move the motor assembly out of the way completely. Move the drill pipe toward the rig until the magnetic readings match the shoot readings. Then begin approaching the probe with the motor online, until you reach the non-magnetic collar measurements. Again, in the example above, the length of the two non-mags was 42.5 ft (13 m). • Print screen and note the measurements on paper. Now, repeat the Steering: Job Site Actions—Pilot Hole probe roll and construct another table (Table 3.7). Table 3.7. Second test of line azimuth shoot data. Orientation H-Total (degrees) (gammas) 0 90 180 270 0 48460 48455 48472 48420 48455 Remember, if you must drill with Z axis interference, it is best to have the interference in front of the probe and not behind it. The drill pipe has a stronger magnetic influence than the motor and can change often downhole through rotation. Dip (degrees) Azimuth (degrees) 60.6 60.6 60.7 60.4 60.6 27.8 27.8 27.7 27.3 27.8 With the theodolite, recheck the line and the probe orientation. Do not neglect this step—always recheck that the probe has not moved once you have established a line azimuth for the job. Pressure testing Before spudding, it is necessary to pressure test the system. Push the motor or jet assembly to the ground and engage the pumps at a low rate. Establish mud flow through the jet or motor. Note on paper the pressure on the gauge at the point the bit begins turning. Turn off the pump and reengage. Note again the point where the bit begins to turn. Do this until you have a repeatable projected pressure to begin motor operation. Once this step has been completed, increase the flow and watch the pressure. Continue increasing until you reach recommended drilling pressure for the type of motor you are running. When you reach the recommended pressure, stop immediately. In the case of the jet, establish stroke count at your projected drilling pressure. Ensure that the bit will enter the ground at the entry point without a sag in the pipe. Attempt to prop up the string until it is obvious that the rig will have a straight push—not left/right, sagging, or too high. Work with the crew to ensure that the push is straight. Push ahead into the ground about 5 ft (1.5 m), and then stop. Observe the entry closely to again check alignment. Physically measure the exact entry point relative to the planned entry and note the actual numbers on paper. Go inside and observe the inclination reading on the probe. At this point, you will be reading only the actual rig inclination, not the inclination on the drilling assembly in the ground. This is the reason for the extra care in spudding for a straight push. Throughout the test, observe the probe operation, watching for shorts or any improper operation. Also, observe the rig systems to ensure proper operation. You will be able to easily observe if the motor or jet is building angle too fast. If so, pull back until the bit is just below ground and begin rotation. Rotate ahead for the same 5 ft (1.5 m) and check that you have dropped angle. Continue to adjust until you have the alignment you need. Spud. You have now completed all preparations and are ready to spud. Leave the tool operating and advise the driller to begin pushing the bit into the ground, staying on the high side and using your hand signals. Go outside near the entry point where the driller can see you. Again, push ahead on the high side another 5 ft (1.5 m). If you are building too much angle, withdraw to your previous position and again begin rotation. Rotate ahead 10 ft (3 m) and stop. Check that you have a straight push and continue working the motor or jet into the ground very carefully. 3-35 Horizontal Directional Drilling Training Program Always be high when you spud and work yourself down to the correct position. Remember, it is easy to drop angle in surface soil, but it is impossible to build angle once you’ve already dropped. Continue working the motor into the ground until the non-mag collar is in the vises. Print screen, and note the position on the printout. Add the final length of the BHA. Push this to the vises using a combination of high side and rotation. At this point, reenter the Set Up Survey File and correct the tie-in information if the actual entry point is different from the planned entry point that was previously input. Take the first survey, using the first course length you calculated earlier. Note all data on the tabulation sheet. Carefully study the data as a reasonable test. Does the calculated position look correct relative to what you observed? If not, look for your mistake and correct it before continuing to drill. Make sure now that everything is correct and ready to drill. If so, you have just completed a successful straight spud. Drilling ahead You will serve many functions during drilling operations. Not only will you be ensuring proper tool operations, but you will also be concerned with the position of the bore. you make relative to the data quality. Take these steps to ensure high-quality data: Tool operation. Throughout the job, you are responsible for the proper tool operation. You not only need to watch constantly for problems, but also ensure good data quality. With this in mind, keep all required records up-to-date. Fill out the tabulation sheet and your daily reports completely as the job progresses. Observe the tool operation constantly, looking for shorts in the wireline. 2. Ensure that switch-off and switch-on readings are the same. If not, find out why. Be available to the driller to answer his questions regarding magnetics and what is or is not possible. Focus on the job of ensuring good equipment operation. Be the first to spot something wrong, either with your equipment or theirs. Make the driller aware of your concerns and have him shut down until equipment problems can be explained and rectified. Also, assist the driller in looking out for the safety of the rig crew. Data quality. In addition to proper tool operation, you are responsible for the accuracy of the bore path, with or without interference! Since your performance is measured by where the bore exits relative to the target and the distance you may be off centerline during drilling, the data quality is critical to that performance. You must have justifiable reasons for any decision 3-36 1. Construct a Mag/Dip Chart (page 3-17) when you have interference. 3. In some cases, take a survey before the probe has settled to a final number. Switch off after the survey and tell the driller to make a connection. After the connection, if you switch on and find the inclination is now half a degree lower, immediately delete the survey you took and retake it—all while still at the top of the next joint. Then correct your paperwork and begin drilling. 4. While drilling with a motor, the readings will bounce around as the GTotals decrease. Be available to assist the driller in determining the correct number. Projections. Always be ready to project ahead mathematically from your current position. Base this projection on the response from your drilling assembly during the build sections of the bore. For example, if you are not achieving your expected radius, you must calculate exactly how much deeper than plan you expect to be. This must be brought to the client’s attention for his approval. Steering: Job Site Actions—Pilot Hole In this example, you will not only be lower than plan, but you will need to replan the exit curve, taking into account the larger radius you are achieving. This will change the entire profile, in some cases making it an impossible situation. The earlier you know this, the sooner you can correct the situation with a trip to change assemblies. The earlier you involve the client with problems, the easier it will be to gain his approval for your recommended actions. Always project ahead to satisfy yourself that everything is being done to meet your objectives. Directional control decisions Always know where you are relative to the plan, the surrounding topography, and subsurface obstructions. Radius control. You should know where your course is relative to the planned radius. To do this you must plot radius targets on the vertical profile. The fastest and easiest procedure is as follows: sin 1° x planned radius = measured distance along curve Take the resulting distance and with an engineer’s scale, begin scaling the distance from the beginning of the curve. Place a tic mark at each scaled distance. For example, if the planned radius is 2000 ft (610 m) and the entry angle is 12°, then: than planned, if you respect the radius limit. At this point you will need to discuss radius limits with the client, pointing out your position on the plot and what you will need to do to bring the curve back on line. Do not make this decision yourself. If your inclination is higher than plan at any point, you will reach the bottom of the plan higher than planned. You may relax the radius slightly. Do not do this over two or three joints. Project ahead a smaller radius to reach 90° at the same point as the original plan. Always compare the plotted position’s inclination to the planned inclination at the same away distance. This is the only way you will get an early warning of future location problems. sin 1° x 2000 = 34.9 ft (10.6 m) Measuring this distance from the beginning of the curve, place a tic mark 34.9 ft (10.6 m) along the curve. From that point, place another tic mark 34.9 ft further along the curve. Continue placing the tic marks and scaling until you reach the end of the curve. This should measure exactly that point where the planned curve reaches 90°. If it does not, check for errors. Once the tic marks are plotted, write the planned inclination at about an inch (2.54 cm) above the marks. Again, if you started at 12° (78° from vertical), you will have ascending numbers: 78, 79, 80, 81…90. Your plan is now in place. While drilling the curve, plot your position as normal. Look at the inclination and compare it to the planned inclination at that point. If your actual inclination is lower than plan, you will reach the bottom of the curve lower Intermediate targets. Every joint you drill should be toward an intermediate target. Setting targets is a function of present inclination and azimuth, planned inclination, and azimuth vs. present and planned positions. You will know if you are ahead or behind the curve from the radius tics. If you are on the curve and do not need to break or relax the radius, the projected inclination target is easy: next joint length/(sin 1° x radius) = expected degrees per joint Add the quantity derived to the previous inclination to generate the next intermediate target. If the centerline is straight, the target azimuth should be the same. If you are right or left of the line, you should normally attempt to close the line slightly by giving 3-37 Horizontal Directional Drilling Training Program the driller a target pointing toward the line. Normally, a 5° left or right tool face setting on one joint, on both the high and low side, will achieve an azimuth movement of between 0.1 and 0.3°. A 10° tool face setting will achieve 0.2 to 0.5° of azimuth. Example 2: 2000-ft radius planned = 0.86° per 30-ft joint Previous inclination = 80.5° Previous azimuth = 271° Present inclination = 81.3° Radius calculations. Never turn the bore without considering radius. In the example above of a 2000-ft (610-m) radius, if you achieve the exact planned radius on inclination and 1/2° of turn in a joint, you will have exceeded or broken the radius by a factor of approximately 10%. Use the following rule of thumb to calculate a combined radius: if you add the change in inclination and the change in azimuth in degrees, and take 70% of the result, you will roughly approximate the angle on a combined basis. Then determine the radius of the change in combined angle: Present azimuth = 271.5° 81.4° – 80.5° = 0.8° 271.5° – 271° = 0.5° (0.8 + 0.5)(0.7) = 0.91° 30 ft/(sin 1 x 0.91°) = 1889-ft radius Example 3: 2000-ft radius planned = 0.86° per 30-ft joint Previous inclination = 80.5° Previous azimuth = 271° Present inclination = 81.0° Present azimuth = 271.5° 30-ft joint/(sin 1 x angle) = resulting radius 81.0° – 80.5° = 0.5° 271.5° – 271° = 0.5° Example 1: 0.5 + 0.5 x 70% = 0.70° 30 ft/(sin 1 x 0.70°) = 2455-ft radius 2000-ft radius planned = 0.86° per 30-ft joint Previous inclination = 80.5° Previous azimuth = 271° Present inclination = 81.5° Present azimuth = 271.5° 81.5° – 80.5° = 1° 271.5° – 271° = 0.5° (1.0 + 0.5)(0.7) = 1.05° 30 ft/(sin 1 x 1.05°) = 1637-ft radius 3-38 You can see from these examples how sensitive the radius actually is to combined changes. In determining an intermediate target, you must ensure that you respect the radius on a vertical and combined basis. If you exceed the radius, you must have the client’s permission to do so. The survey printout at the end of the job will form the basis of proof. Radius averaging. It is not realistic to attempt to drill a perfect radius. The formation will push you up, down, left, and right as you drill, making the attempt of a perfect bore nearly impossible to achieve. You must control the radius rather than letting it control you. This means making early decisions, ensuring good communications with the client, and averaging. Steering: Job Site Actions—Pilot Hole The expression of dogleg on the screen is an angular expression of radius. Using the formula above: 30-ft joint/(sin 1 x dogleg angle degrees) = radius After surveying a joint, look at the dogleg angle. Change it to radius by using the above formula. If the result is acceptable, note it on your tabulation sheet. Continue making notes on every joint. Since dogleg is an expression of a combined radius as an angle, and it is projected out over 100 ft (30.5 m), it is correct to average three 30-ft (9-m) joints to better approximate the real radius. A point 30 ft from the previous one that results in a 1600-ft (488-m) radius when the target radius is 2000 ft (610 m) may be accepted if the following two joints average 2200 ft (671 m). The sum of the three joints will total 6000 ft (1830 m) which, when averaged, will be an average radius of 2000 ft. Use a running average throughout the curve. Remember when using dogleg that this is a combined curve angle. The probe resolves azimuth from the earth’s magnetic field. Therefore, if there is magnetic interference, the dogleg angle will be incorrect. You must correct the azimuth first, by plugging the azimuth when you take a survey, or by editing the survey file and recalculating, before you can use the dogleg in radius terms. Directions to driller There are two types of drillers—those who want you to give them angular targets, and those who want you to give them position targets. tion to a particular number, such as 86.5°, azimuth of 217.5°. You will have already calculated these numbers and have them available when required. Angular targets. This target is one where you ask the driller to build or hold inclina- Position targets. This target is subjective— build 2° and go straight ahead, for instance. Drilling problems Wireline shorts. With any wireline, you will experience electrical shorts. You need to understand how to troubleshoot shorts to determine their location. A short is exemplified when the amp needle on the front of the interface moves to maximum or the power fuse blows. Use the following procedure to locate a short: 1. The most likely place for a short is downhole at a wireline connection or at the centralizer blades on top of the probe. You should begin looking downhole. Rig a test lead from the positive terminal of the interface box long enough to reach the wireline from the pipe in the rig vises. Remove the existing power lead from the interface and connect the test lead. 2. Switch on the probe and determine proper operation. 3. If the test indicates a short is present, the short is downhole. Trip pipe back until the short is located. 4. If the probe works normally, the short is somewhere between the interface box and the wire connection on the rig carriage. 5. Continue isolating discrete strings of wire and testing either with the probe or with a continuity tester until you locate the short. 6. In some cases, the short will be intermittent. These are the most difficult to locate. You must continue moving the wire uphole or downhole until the location is found. 3-39 Horizontal Directional Drilling Training Program 7. Many times a quick test with a voltage output meter (VOM) of the probe will tell you if the short is downhole: • First, disconnect the test lead from the wireline of the joint in the vises. Using a VOM, set the resistance scale to at least 300 ohms, and connect the leads between the power wire and ground. Use the joint for ground. • You should read a resistance of between 20,000 and 40,000 ohms. If you read more than 40,000, a wireline leak exists between the test lead and the probe. Pull on the wireline at times during the test to attempt to make the readings vary, which would indicate a leak. • Reverse the test leads. Watching the meter, you should see a capacitance kick. The needle should kick to about 300 ohms and gently bleed back near zero. Wireline leaks. A leak is still defined as a short, but probe operation continues. A leak is not yet large enough (200 ma) to stop probe operation. Leaks will generally turn into shorts with time. In some cases, they will cause a trip within a couple of joints, and in other cases, you may drill the entire crossing with the leak. A leak is usually caused by wire insulation damage. The wireline may be skinned, exposing the wire to the mud. Power will be lost to the mud in varying amounts until the leak becomes too great and the fuse blows. A leak may “heal” itself on occasion. The electrolysis effect of copper and the mud can cause oxidation of the copper wire, effectively building a non-conductive coating around the wire. This then seals the mud away from the current, reducing the quantity of amperage being lost. This will happen only with very small leaks where the insulation has only a slight cut. This insulation effect will be lost completely if you ever elect to change the mud system from mud to water. The water will wash the coating away, again leaving the copper exposed to the fluid. 3-40 Downhole leaks should be treated as shorts, identified, and a course of action determined. It is normally wise to trip to locate and repair the leak early, rather than tolerate it for a whole job. On the other hand, if you are 2 to 300 ft (0.6 to 91.5 m) from punchout, the client may wish to complete the distance. This should always be his decision, but he is depending on you to make a judgment of success. Wireline opens. A wireline open is defined as zero continuity between the interface and the probe. The amp needle on the interface will not move, indicating a wireline break somewhere in the system. The positive or negative wire may be broken. If the wire breaks downhole, normally you will see some amperage on the needle. Begin looking for an open on the surface between the interface and the rig connections. Tripping pipe out. You must keep track of exactly how many joints of pipe are below the vises at all times. All your measurements are made from this reference point, which makes it very important. When drilling problems force a decision to trip out, either a few joints or all of them, you must keep track. Since you normally start drilling a new joint that has not been surveyed, you should lay down that first joint and note its unsurveyed depth and number on the field tabulation sheet. For each additional joint you lay down on the rack, indicate on the left side of the tabulation sheet an arrow pointing up, next to the joint number. Continue removing joints and noting the arrows until you reach the planned number. Once you have removed the required number, go outside and count the joints you have removed. Compare the number to your noted numbers for agreement. If they do not agree, count all joints on location, add the downhole joints, and compare the total joints to the total joints on location that you counted at the beginning of the job. Be precise and make sure you can account for every joint. Steering: Job Site Actions—Pilot Hole Tripping pipe in. On your return into the hole, place an arrow pointing down against each arrow you previously noted coming out, once each joint is down. Using a test lead, power up the probe about every five joints and take a print screen. Note the inclination and azimuth on the tabulation sheet against the representative data. Compare constantly—the readings should be similar. Punchout Well before punchout, you determined your margin for error in elevation. Given good Tru Tracker readings, you will know where you are in elevation within a small tolerance. If you are on a long job, the elevation accuracy may degrade because of a number of factors, such as driller bias, distance errors, formation tendencies, short Tru Tracker coils, no Tru Tracker coils, and survey calculation methods. You should recalculate your complete survey against both average angle and tangential methods several times during the job to compare the methods. Normally, one method will match Tru Tracker better than the other. In most cases, the methods will produce a bracket of elevation numbers. Tangential calculations may indicate you are at -22.5 ft (-7 m), while average angle calculations indicate -26.0 ft (-8 m). At the same point, Tru Tracker will often be between the two, such as at -23.5 ft (-7 m). This will normally indicate the actual elevation to be between the tangential and Tru Tracker readings. Plot each elevation as points throughout the last 200 ft (61 m). Discuss the different calculation methods and error possibilities with the client and determine his wishes as to crossing length. He may prefer you to be short rather than long. He may indicate that he only has the required length of pipeline as planned, meaning that you cannot be long. The best case, naturally, is that all methods are close—but don’t count on it! Play the percentages and plan ahead. Remember, when you punch out long, failing a major pullback and sidetrack, you will not be able to redrill to a shorter location. Punching out short gives you the option of pulling back a couple of joints and lengthening the distance considerably. Construction of as-built As soon as feasible, you should construct your as-built print out. Physically measure the punchout position and note it on your tabulation sheet and daily report. the closure angle between the two positions as follows: • Divide the difference between the actual and calculated left/right positions by the horizontal length of the crossing. Take the arc sin of the result. This is the overall angular difference from the beginning of the crossing which, when applied to the line azimuth, will overlay the actual exit point and the calculated exit point. • If you have plugged azimuths based on justifiable analysis, compare the course with Tru Tracker positions to find the best fit. You may find that the best fit causes you to change the values of the previously plugged azimuths. Take an initial print of the survey using the Survey Processing and Print Screen in the program. Compare the final position on paper to the actual punchout position. Use the calculation method that best approximates the actual punchout elevation. Determine the calculated left/right position and compare it to the actual punchout location. If you have been steering to punchout using Tru Tracker readings and not azimuth, there will be a difference. Determine 3-41 Horizontal Directional Drilling Training Program Notes 3-42 Chapter 4: Reaming General ................................................................................................ 4-1 Purpose of reaming............................................................................................ 4-1 Enlarging the drilled pathway..........................................................................................4-1 Removing cuttings from the hole ......................................................................................4-1 Reaming alternatives ......................................................................................... 4-1 Selecting tools.................................................................................................... 4-1 Troubleshooting ................................................................................................. 4-1 Determining the number of passes .................................................................... 4-1 Definitions........................................................................................... 4-2 Types of Reaming .............................................................................. 4-6 General .............................................................................................................. 4-6 Silt and sand .....................................................................................................................4-6 Clay...................................................................................................................................4-6 Rock ..................................................................................................................................4-6 Teeth sizing: Bottom’s up .................................................................................................4-7 Number of passes..............................................................................................................4-7 Pre-reaming ....................................................................................................... 4-8 Reaming and pulling .......................................................................................... 4-8 Back reaming ..................................................................................................... 4-8 Forward reaming .............................................................................................. 4-10 Tool Selection................................................................................... 4-11 General ............................................................................................................ 4-11 Fly cutter reamers ............................................................................................ 4-11 Fly cutter with stabilization ring ....................................................................................4-11 Fly cutter with stabilization ring and reversing skirt .....................................................4-11 Fly cutter without stabilization ring ...............................................................................4-11 Barrel reamers ................................................................................................. 4-12 Barrel reamers with buoyancy control...........................................................................4-12 Barrel reamers without buoyancy control......................................................................4-12 Bullet-nose reamers ......................................................................................... 4-12 Centralizers/stabilizers ..................................................................................... 4-13 Centralizers ....................................................................................................................4-13 Stabilizers .......................................................................................................................4-13 Hole openers.................................................................................................... 4-13 Hydraulics..........................................................................................4-14 Annular velocities and flow rates ...................................................................... 4-14 Weight and rotary speed .................................................................................. 4-14 Size of completed reamed pathway ................................................................. 4-15 Penetration rates .............................................................................................. 4-15 Pumping ........................................................................................................... 4-16 Velocity/annular velocity ................................................................................... 4-17 Viscosity ........................................................................................................... 4-19 Acceptable yield point....................................................................................... 4-19 Acceptable plastic viscosity .............................................................................. 4-19 Sand content .................................................................................................... 4-19 Troubleshooting................................................................................4-20 General............................................................................................................. 4-20 Increasing torque.............................................................................................. 4-20 Increasing torque—a few seconds ................................................................................. 4-20 Increasing torque—several minutes............................................................................... 4-20 Increasing torque—sudden lockup................................................................................. 4-20 Twistoff of drill pipe........................................................................................... 4-20 Fishing .............................................................................................................. 4-21 Recovery .......................................................................................................... 4-21 Salvaging hole................................................................................................................ 4-21 Severing drill pipe .......................................................................................................... 4-22 Lost or decreased circulation............................................................................ 4-23 Stuck reaming assembly .................................................................................. 4-23 Mud pressure increase ..................................................................................... 4-23 Mud pressure decrease.................................................................................... 4-23 Inadvertent returns ........................................................................................... 4-24 Reduced penetration rate ................................................................................. 4-24 ii List of Figures Fig. 4.1. Fly cutter. ...........................................................................................................4-2 Fig. 4.2. Barrel reamer......................................................................................................4-2 Fig. 4.3. Bullet-nose reamer. ............................................................................................4-3 Fig. 4.4. Bullet-nose reamer completing a pullback. Mobile Bay, Alabama, USA. .......4-3 Fig. 4.5. Conventional hole opener. .................................................................................4-3 Fig. 4.6. Centralizer/stabilizer. .........................................................................................4-5 Fig. 4.7. Back reaming. ....................................................................................................4-9 Fig. 4.8. Forward reaming. .............................................................................................4-10 Fig. 4.9. Mud pumps.......................................................................................................4-17 Fig. 4.10. A fishing tool completing a pullback. ............................................................4-21 List of Tables Table 4.1. Bottom’s up chart.............................................................................................4-4 Table 4.2. Minimum annular velocities and flow rates for cleaning large-diameter holes (metric and US units)......................................................................................4-14 Table 4.3. Weight and rotary speed recommendations for hole openers (metric and US units)............................................................................................................4-14 Table 4.4. Penetration rates chart....................................................................................4-16 Table 4.5. Velocity chart. ................................................................................................4-18 iii Notes iv Chapter 4: Reaming General This chapter outlines the different topics that pertain to reaming. Reaming means to enlarge a hole from one size to another size of greater diameter. Purpose of reaming Enlarging the drilled pathway. To determine the size of the reamed hole, you must know the size of the pipe to be installed. Normally, the reamed hole is 1.5 times the diameter of the pipe to be installed. On crossings that are greater than 4000 ft (1500 m) with a diameter greater than 30 in. (762 mm), or where you may encounter gravel, you may choose to increase this factor. Removing cuttings from the hole. To install a pipe in a pre-reamed pathway, it is important to remove the native materials (cuttings) from the pathway. Reaming alternatives There are many considerations when planning a reaming exercise: • use one or two rigs to facilitate the reaming. • pull the pipeline and ream at the same time The following sections will cover all of the ways you can ream a hole. • ream forward or backward Selecting tools Proper tool selection is one of the most important decisions you will make in a reaming strategy. Your decision will make a tremendous difference in your progress, your risk, and your success rate. Troubleshooting Your success will largely be determined by your ability to identify problems and cor- rect them. As problems occur, record them and their solution for future reference. Determining the number of passes When reaming for large-diameter pipe installations, it is sometimes necessary to ream the pathway in stages. The main consideration in determining the number of reaming passes you must make is the types of soils that will be encountered. In softer formations, the determining factor is generally the volume of cuttings that must be removed with each pass, while in harder formations, the torsional requirements and volume of cuttings must both be considered. Horizontal Directional Drilling Training Program Definitions Fly cutter: A fly cutter is a reaming device that has a center shaft with three or four spokes (Fig. 4.1). When facing the tool, the spokes are at the 10, 2, and 6 position on a clock face. A fly cutter can be fabricated with or without a circumventing ring. This tool is used as the primary cutter when enlarging a hole through alluvial formations. Fig. 4.1. Fly cutter. Barrel reamer: A barrel reamer is a center shaft mounted concentrically in a cylinder of pipe that may have a wide range of diameters and lengths (Fig. 4.2). Both ends of the reamer are tapered at approximately 40° off the center shaft. The barrel reamer can be baffled at either end (or neither end) for buoyancy control. Fig. 4.2. Barrel reamer. 4-2 Reaming: Definitions Bullet-nose reamer: A bullet-nose reamer (Fig. 4.3 and Fig. 4.4) is the same as a barrel reamer, with one exception. The ends, instead of being tapered, are made from weld caps. They are used more for pulling in front of the pipeline during pullback or as a centralizer. They are not used for reaming, but for cleaning cuttings from the hole. Fig. 4.3. Bullet-nose reamer. Fig. 4.4. Bullet-nose reamer completing a pullback. Mobile Bay, Alabama, USA. Conventional hole openers: Conventional hole openers (Fig. 4.5) are designed for use in rock, from the softest to the hardest formations. A conventional hole opener is cast, and has a center shaft with three to six arms onto which are mounted roller cones. The cones come with or without sealed bearings. The cones range from mill teeth for the softer formations, to tungsten carbide inserts for the harder formations. Fig. 4.5. Conventional hole opener. 4-3 Horizontal Directional Drilling Training Program Kennemetal teeth: Kennemetal™ is a brand name for cutting teeth that are used, almost exclusively, on cutters and reamers in this industry. They can be inserted into holders that are welded on the cutters or reamers, or welded directly on the cutters and reamers without the holders. Gauge: Gauge is the scale of measurement of a bit, reamer, or hole opener. It is the absolute outside diameter of a given bit size or reamer. Chisel teeth: Chisel teeth can be fabricated by most machine shops and are used when you expect to encounter cobbles or boulders embedded in normal soils. The approximate dimensions are 1.5 in. (38 mm) in diameter and 2 to 4 in. (50 to Bottom’s up: Bottom’s up is a reference of time and volume pertaining to a cylinder or hole. Bottom’s up time is the time required to displace a known quantity of fluid from the bottom of a hole to the surface. Bottom’s up volume is the amount of fluid that must be displaced in a hole (see Table 4.1). 100 mm) long. The cutting edge is chiselshaped and made of tungsten. Table 4.1. Bottom’s up chart. Hole diameter (in.) Enter Distance from rig (ft) bbl/ 3 min ft /min 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 4-4 5.61 11.23 16.84 22.46 28.07 33.69 39.30 44.92 50.53 56.15 61.76 67.38 72.99 78.61 84.22 89.84 95.45 101.07 106.68 112.30 117.91 123.53 129.14 134.76 140.37 400 800 1200 1600 Hole radius (ft) 31.75 1.32 2000 2400 Volume of 1 ft of hole (ft3) 5.4981408 2800 3200 3600 4000 4400 Result in minutes 391.68 195.84 130.56 97.92 78.34 65.28 55.95 48.96 43.52 39.17 35.61 32.64 30.13 27.98 26.11 24.48 23.04 21.76 20.61 19.58 18.65 17.80 17.03 16.32 15.67 783.35 1175.03 1566.71 391.68 587.52 783.35 261.12 391.68 522.24 195.84 293.76 391.68 156.67 235.01 313.34 130.56 195.84 261.12 111.91 167.86 223.82 97.92 146.88 195.84 87.04 130.56 174.08 78.34 117.50 156.67 71.21 106.82 142.43 65.28 97.92 130.56 60.26 90.39 120.52 55.95 83.93 111.91 52.22 78.34 104.45 48.96 73.44 97.92 46.08 69.12 92.16 43.52 65.28 87.04 41.23 61.84 82.46 39.17 58.75 78.34 37.30 55.95 74.61 35.61 53.41 71.21 34.06 51.09 68.12 32.64 48.96 65.28 31.33 47.00 62.67 1958.39 979.19 652.80 489.60 391.68 326.40 279.77 244.80 217.60 195.84 178.04 163.20 150.65 139.88 130.56 122.40 115.20 108.80 103.07 97.92 93.26 89.02 85.15 81.60 78.34 2350.06 1175.03 783.35 587.52 470.01 391.68 335.72 293.76 261.12 235.01 213.64 195.84 180.77 167.86 156.67 146.88 138.24 130.56 123.69 117.50 111.91 106.82 102.18 97.92 94.00 2741.74 1370.87 913.91 685.43 548.35 456.96 391.68 342.72 304.64 274.17 249.25 228.48 210.90 195.84 182.78 171.36 161.28 152.32 144.30 137.09 130.56 124.62 119.21 114.24 109.67 3133.42 1566.71 1044.47 783.35 626.68 522.24 447.63 391.68 348.16 313.34 284.86 261.12 241.03 223.82 208.89 195.84 184.32 174.08 164.92 156.67 149.21 142.43 136.24 130.56 125.34 3525.09 3916.77 4308.45 1762.55 1958.39 2154.22 1175.03 1305.59 1436.15 881.27 979.19 1077.11 705.02 783.35 861.69 587.52 652.80 718.07 503.58 559.54 615.49 440.64 489.60 538.56 391.68 435.20 478.72 352.51 391.68 430.84 320.46 356.07 391.68 293.76 326.40 359.04 271.16 301.29 331.42 251.79 279.77 307.75 235.01 261.12 287.23 220.32 244.80 269.28 207.36 230.40 253.44 195.84 217.60 239.36 185.53 206.15 226.76 176.25 195.84 215.42 167.86 186.51 205.16 160.23 178.04 195.84 153.26 170.29 187.32 146.88 163.20 179.52 141.00 156.67 172.34 Reaming: Definitions Tripping out: Tripping out means to remove the drill pipe from the borehole. Cuttings: Cuttings are the formation materials removed from the hole and suspended in the drilling fluid. Centralizer/stabilizer: These two items are discussed together because the same tool is used as both a centralizer and a stabilizer. The difference is in their placement in the hole. A centralizer/stabilizer can be a barrel or bullet-nose reamer, or other tools of different shapes and sizes (Fig. 4.6). A centralizer is run in front of the primary cutter, and is used to hold the cutting assembly up in the center of the hole, guarding against the cutter’s normal tendency to drop to the bottom and cut the hole in a tear-drop shape. A stabilizer is run behind the primary cutter for stabilization and to keep the primary cutter from bouncing and tilting. Fig. 4.6. Centralizer/stabilizer. Cutter sets: Hole openers can be fitted with different types of teeth, depending on the formation material. Each type of teeth comes in a numbered cutter set. Tungsten carbide inserts: On the hole opener, tungsten carbide inserts (TCIs) are the cutting teeth on the roller cones that do the actual cutting or breaking of the rock. TCIs are used in medium and hard rock formations. Mill tooth cutters: Mill teeth are teeth that look more like blades than inserts and are used in soft rock formations. PDC teeth: Polycrystalline diamond compact (PDC) teeth are made of manmade diamonds and are used mainly in shales. 4-5 Horizontal Directional Drilling Training Program Types of Reaming General This section covers reaming in different types of soils, determining the number of passes, and removing cuttings from the drill path. For discussion purposes, the soil types are divided into silt, sand, clay, and rock. The formation will usually consist of combinations of these soil types—silty sands, sandy clays, sand with gravel, etc. Silt and sand. Silty and sandy soil densities can vary from loose and unconsolidated to very dense and compact. In dense silts and sands, your rate of penetration will depend on the pull and torque required to physically cut through the formation. With these limitations, the major concern in reaming will be pumping enough fluid to completely remove the cuttings from the pathway. In unconsolidated silts or sands, the torque required to rotate the reamer will be low and you will be tempted to ream too fast. When tempted to ream at a faster rate, remember what you are trying to accomplish. The silt and sand must be removed from the pathway, and what is not removed should be encapsulated with bentonite so it cannot compact. This can only be accomplished by reaming at the proper penetration rates. If you ream too fast, the sand that is cut in the pathway will settle out of the drilling fluid shortly after passing through the reamer. The result will be an insufficiently cleaned pathway or improperly encapsulated sand left in the pathway. You may be able to complete smaller-diameter, shorter-length crossings that have been reamed too fast. Generally, on these types of crossings, you can make mistakes and still be successful. However, as the lengths and diameters of crossings increase, the chances for failure will also increase unless you use proven, time-tested methods. 4-6 Clay. Similar to silts and sands, the clayey soils range from soft to very stiff. The stiffer the clay, the more difficult it is to ream fast; the softer the clay, the easier it is to overpenetrate. When you penetrate soft clay too fast, you tend to remove the clay in slabs that will pile up behind the reamer and eventually plug the hole, causing mud returns to stop. In most cases, the only way to remove the slabs is to rotate back through the reamed hole and recut the slabs. There will be times that you will need to pull the cutter all the way back to the surface to remove the slabs and regain drilling fluid returns. If you examine the slabs that come to the surface, upon breaking them open you will see that they are dry on the inside, exactly as they were in situ. If you allow these slabs to accumulate behind the reamer, your chances of completing the pipe installation will be reduced. Remember, one of the main functions of the reaming process is to remove enough material from the pathway to allow the pipe installation. Generally, when the pipe is being pulled into place, a bulletnose reamer is used in front of the pipe. This reamer is designed to force the slurry and remaining solids outside of the hole. Clay slabs resulting from a too-fast ream will litter the pre-reamed pathway and be pushed ahead of the bullet-nose reamer, eventually clogging the entire pathway. If enough of these slabs are forced outside of the bullet-nose reamer and accumulate around the pipe, they can cause the pipe to become lodged. When clay is reamed properly, the pipe can be pulled through the pathway with a minimum of force and as fast as the rig carriage will travel. Clay should be the most conducive soil for directional drilling if approached properly. Rock. Reaming in rock is performed with special downhole reamers known as hole openers. Hole openers can be configured in a variety of ways, depending on the type of rock encountered. Typically, the driller has a good idea of the type of rock by the time Reaming: Types of Reaming reaming is necessary, both from geotechnical studies and from drilling the pilot hole. Reaming in rock requires the widest range of reamer and cutter types. A tooth that will cut 2000-psi (14-Mpa) rock will not last half a day in 10,000-psi (70-Mpa) rock. A tooth that will cut 10,000-psi rock is so short that you will make little progress in 2000-psi rock. Normally, one to three types of teeth should be tried for a specific project. You must learn to determine which tooth is most effective. Drilling the pilot hole will give you a good idea of which type of tooth cutter to use, but the only way to know for certain is to run different types of teeth in the hole. Teeth sizing: Bottom’s up. Since the size of the tooth determines the size of the cuttings, and the amount of cuttings returned out of the hole depend on the drilling procedures and mud program, choose the most aggressive tooth you have. When you start reaming, look at the cuttings coming across the primary shaker: if you see only cuttings smaller than the size you are cutting, either change your mud program or put a less aggressive tooth in the hole. An additional cleaning practice is to pump bottom’s up periodically so that any cuttings that drop out can be picked up and circulated out of the hole. This is also a good practice if you plan to stop reaming for a specified time, such as when you are working a single shift. By pumping bottom’s up, you purge all of the fluid that is laden with cuttings from the reamer to the surface. Simply stop reaming (occasionally rotate the pipe and reamer to stir the hole) and pump your known volume for a specified time. If the drilling fluid in the hole is heavy with cuttings and your new fluid is much lighter, the new fluid will channel along the top of the hole. You can easily determine this if your clean fluid returns to the surface much faster than calculated. Number of passes. To determine the number of passes to make, you must first know the type of material you will be reaming. As stated earlier, if you are reaming in rock, some of your decisions have already been made. The pilot hole diameter will probably be 9 7/8 in. (251 mm) and there are only a few openers that will cut from this hole size. The 17 1/2-in. (445-mm) opener is the largest conventional opener that will cut from a 9 7/8-in. (251-mm) diameter. Assuming you need to open a hole in mediumstrength rock to 42 in. (1067 mm), the recommended number of passes is typically: • a 17 1/2-in. (445-mm) pass • a 26-in. (660-mm) pass • a 36-in. (914-mm) pass • a 42-in. (1067-mm) pass. To establish the exact number of passes, you must determine the volume of material you are attempting to remove. The four passes listed above, plus the pilot hole, contain the following volume in US units: 17 1/2 in. - 9 7/8 in. = 1.14 ft3 of material per linear foot of hole 26 in. - 17 1/2 in. = 2.01 ft3 of material per linear foot of hole 36 in. - 26 in. = 3.39 ft3 of material per linear foot of hole 42 in. - 36 in. = 2.55 ft3 of material per linear foot of hole or in metric units: 445 mm - 251 mm = 0.032 m3 of material per linear meter of hole 660 mm - 445 mm = 0.057 m3 of material per linear meter of hole 914 mm - 660 mm = 0.096 m3 of material per linear meter of hole 1067 mm - 914 mm = 0.072 m3 of material per linear meter of hole. You can see that the third pass is the largest cut. You might decide, depending on your first two passes, to add a 30-in. (762-mm) pass. You would determine this when you have all the pertinent information. Another consideration when planning and executing rock reaming is the size of the 4-7 Horizontal Directional Drilling Training Program pilot hole, or the preceding hole-opening pass and the size of the next cutters’ core buster. The core buster is the set of blades in front of the hole opener designed to keep rock pieces from accumulating in the inner circle of the hole opener, and to help centralize the hole opener for concentric holeopening passes. Always double-check the sequence of planned hole-opening passes to ensure that the hole-opener sizes on the job site are correct, and that there is no part of the formation that will be missed by one of the hole openers. Always measure every hole opener as it arrives onsite and make a sketch in your field notes. By doing this, you know what you have on hand and whether you need to order additional equipment. It is much better to solve problems in advance of the need. Pre-reaming Pre-reaming means that you enlarge the hole before pulling the pipeline. It is not always done, but it always reduces your risk. Reaming and pulling Reaming and pulling means that the hole is reamed simultaneously as the pipe is pulled. Hundreds of lines have been installed in this manner, but they were not long, large-diameter crossings. Generally, the time saved by reaming and pulling is not worth the risk of sticking the pipe. Back reaming Back reaming is a term used when the hole is enlarged from the exit side of the crossing (Fig. 4.7). The main advantage is that the rig has complete control of the drill pipe and the reamer. The rig operator can more easily control the torque and pull than when forward reaming. The main disadvantage is that the return fluid is returned to the exit side of the crossing and all of the cleaning equipment is at the entry side of the crossing. This requires one or more of the following: 4-8 • setting up a cleaning system and pump at the exit side • setting up a cleaning system at the exit side, and hauling or pumping the fluid back to the entry side • holding the fluid in pits or tanks and later sending to a disposal site. When the pilot hole is completed, the jetting assembly (or motor) and non-magnetic collar are removed and a reamer is installed onto the drill pipe. The pipe is then rotated by the rig and pulled toward the rig to enlarge the hole to a predetermined diameter. For hole sizes up to 30 in. (762 mm), this is usually accomplished in one pass (except for rock or very dense or stiff alluvial deposits). For larger hole sizes, two or more passes are usually required. As the reamer is rotated and pulled, a predetermined volume of fluid is pumped through the drill pipe and exits the reamer through jet nozzles. The fluid is then mixed with the soils being cut away by the reamer, and the fluid becomes the medium through which the soils are removed from the hole. The primary objective is for all the slurry to pass back through the enlarged hole to a pit at the exit point of the borehole. Reaming: Types of Reaming 1 2 3 4 Fig. 4.7. Back reaming. 1 2 3 4 Rig Drill pipe Fly cutter reamer Drill pipe For the first 15 years in the horizontal directional drilling (HDD) industry, reaming was first done by means of a bit on the end of the pipeline, and later by back reaming. The main reason for this was that mud disposal was not a problem, as the mud was allowed to flow directly into the river. At the time, neither mud nor mud disposal was of great concern, and 95% of the crossings were short to medium length, small to medium diameter, and never through rock. As the industry grew and longer crossings with larger-diameter pipe were being attempted, the mud volume and viscosity changed to accommodate the hole sizes and lengths. Also, the industry expanded into rock crossings, and the volumes needed to power the mud motors increased rapidly. Up until the mid to late 1980s, it was unusual to have a pump on location that would pump more than 4 to 5 bbl/min or 160 to 200 gal/min (636 to 794 l/min). Then, as the requirements changed, so did the pumps. Soon mud motors that required up to 30 bbl/min or 1200 gal/min (4770 l/ min) were being used. Naturally, the bentonite usage increased with these increased volumes. If you assume a pumping rate of 4 bbl/min (636 l/min) with an average of 20 lb of bentonite per barrel (57 kg per m3), the hourly consumption of bentonite would be about 4800 lb (2180 kg) or 44 50-kg sacks. If you then increase this pumping rate to 30 bbl/ min (4770 l/min) with the same bentonite proportion, you are using 36,000 lb (16,344 kg) each hour, or 326 50-kg sacks. Not only is this cost-prohibitive, it requires physically adding a 100-lb sack every 10 seconds through the hopper; neither the personnel nor the mixing units can keep up with this requirement. Adding to the problem was disposing of these tremendous quantities of fluid. With today’s concern for the environment, large quantities of drilling fluid cannot be allowed to directly enter a waterway. 4-9 Horizontal Directional Drilling Training Program Forward reaming Forward reaming is enlarging a hole from the entry side (Fig. 4.8). To forward ream, you need some source of pulling power at the exit side. HDI has used a second rig, a dozer, a track hoe, and/or a pulling unit. Using a second rig is the preferred choice, but it is the most expensive. In addition to the extra mobilization of the rig and components, you have to employ additional personnel to man the rig. In most cases, HDI uses a track hoe or dozer. The disadvantage is that you try to pull as many joints as possible before disconnecting so that less time is wasted. However, since the rig must not only turn the pipe in the hole, but also the pipe on the ground at the exit side, you are limited in how far you can go before breaking the drill string. 3 2 1 Fig. 4.8. Forward reaming. 1 Pulling machine 2 Swivel 3 Recycling unit While communication is important when you are back reaming, it is critical when forward reaming. The operator at the entry side must continuously instruct the opera- 4-10 tor at the exit side to pull more, pull less, stop pulling, start pulling, etc., throughout the procedure. Reaming: Tool Selection Tool Selection General In this business, planning is just as important as executing a job. With short crossings, you can devise a plan quickly, and then totally disregard the plan once drilling commences and still be successful. This is never the case for longer crossings, where there is little room for error. Jobs must be planned well and the plan must be followed precisely to expect success. On large crossings, there will be hundreds of steps to follow. There will be a multiplestep mud program that must be adhered to, and omitting one step can be disastrous. The pilot hole must be planned so that nothing is overlooked, and planned reaming rates must be followed. Tool selections must be adhered to unless field conditions prove the plan wrong. Fly cutter reamers The fly cutter (Fig. 4.1) was the first reaming tool used in HDD and is one of the most commonly used reamers today. It is used in clay, silt, sand, combinations of sand and gravel, silt and sand, and even soft rock. The first and most basic fly cutter was a center shaft with three spokes. If you face the fly cutter, you will see a spoke at the ten o’clock, two o’clock, and six o’clock positions. Fly cutter with stabilization ring. This is a basic fly cutter with a ring encircling the spokes. The ring is normally about 6 in. wide and 1/2 in. thick. Purpose and application. The ring is used to stabilize the fly cutter while reaming in sand, and to help eliminate the tendency of the fly cutter to walk over logs that are buried beneath rivers and streams. Normally, the rings are only used on sandy crossings. Nozzle sizing and configuration. On sandy crossings, the nozzle size may vary from 16/32 in. (12.7 mm) to no nozzle at all. Sometimes, if you do not have the proper size jets for sand, you should remove the nozzle altogether. You need to be able to pump high volumes with minimum pressures, to minimize disturbing the sand outside the diameter of the ring. The number of jets on a fly cutter depends on its size relative to arm length. You should open all jets on the cutting side of the fly cutter that will be against the face. Open three to four on the backside of the fly cutter for cleaning, and in case you need to pull the fly cutter out of the hole. Fly cutter with stabilization ring and reversing skirt. This is the same as described above, except that on the back side of the ring there is a skirt slanted toward the center to assist when pulling the fly cutter backward out of the hole. Purpose and application. The original fly cutter and ring had no skirt, and when it was pulled backward it had a tendency to cut down in the hole, preventing a rapid retraction. The skirt helps keep it in the original hole for easy retraction. Nozzle sizing and configuration. The same as for a fly cutter with stabilization ring. Fly cutter without stabilization ring. Usually the ring is removed when reaming in clay. With the ring, the fly cutter tends to ball up more easily. The clay packs the openings between the spokes, and when they are completely closed, the fluid cannot flow back through the openings. When this happens, the fluid under pressure will fracture to the surface, causing a loss of returns. Purpose and application. A fly cutter without a stabilization ring is used to lessen the probability of balling. Removing the ring allows the fly cutter to clean itself more easily. Nozzle sizing and configuration. Using nozzles from 8/32 to 12/32 in. (6.4 to 9.5 mm) increases the pressure to help cut the clay. You will find the proper penetration rate by your torque. The nozzles 4-11 Horizontal Directional Drilling Training Program should cut just ahead of the cutting tips so that your torque is reduced. If you are reaming from pilot hole diameter to 30 in. (762 mm), open all the jets on the cutting side of the fly cutter. If you are reaming from 30 to 42 in. (762 to 1067 mm), close the inside circle of jets so that you can get more hydraulic cutting power to the outside where you need it. As always, leave three or four jets open to the back of the fly cutter in case the cutter needs to be retracted from the hole. Barrel reamers A barrel reamer (Fig. 4.2) is a center shaft mounted concentrically inside a section of pipe 2 to 8 ft (0.6 to 2.4 m) long with varying diameters. The ends are conicalshaped, with a 30 to 40° taper off the center shaft. They are used in front of or behind primary cutters. If you try to ream with a barrel reamer, the fluid and cuttings cannot flow around it because the cutting diameter is the same as the diameter of the barrel. The fluids will be forced to fracture and hole cleaning will not be adequate. Barrel reamers with buoyancy control. A barrel reamer with buoyancy control has sealed chambers that allow the fluid to reach the nozzles, but restrict the fluid from entering the center chamber. Purpose and application. These are typically used in the larger-sized barrel reamers to reduce weight in the hole and, consequently, the torque requirements. Nozzle sizing and configuration. Since the barrel reamers are not used as primary cutters, the nozzle sizing and configuration are not important. You simply want to open enough nozzles to keep the reamer face clean and get additional volume in the hole. Barrel reamers without buoyancy control. These are built the same as those with buoyancy control, except that the fluid completely floods the inside of the reamer, making the reamer heavier. The reamers without buoyancy control cost much less to build. Bullet-nose reamers The basic design of a bullet-nose reamer is a center shaft mounted concentrically inside a pipe of varying diameters (Fig. 4.3). Instead of having conical-shaped ends, a bullet-nose uses weld caps on which are mounted a minimum number of teeth. Purpose and application. The bullet-nose has been in use for only six to eight years. As the holes were better cleaned, the speed of the pullback drastically increased. Something was needed that required almost no torque and had no tendency to recut the hole. The bullet-nose was the answer, since it is approximately 6 in. (152 mm) smaller than the hole diameter and approximately 6 in. larger than the diameter of the pipeline. These reamers are primarily pulled in front of the pipeline during pullback. Nozzle sizing and configuration. Nozzles range from 16/32 to 1 in. (12.7 to 4-12 25.4 mm). Larger nozzles are necessary so that you can get the fluid to the hole without plugging the jets. When deciding what size nozzles to use, always know what your filtering system is capable of and be confident that it will work properly. If you are taking water from a river, you should have filters on the water supply. You should always have a filter between the mixing tank and the pressure pumps. Operators walking on top of the tank will loosen small rocks or pebbles that were picked up while on the ground. These pebbles will fall into the tank and be pumped downhole if there is no inline filter. If the pebbles are larger than the nozzles they will block them, causing the reaming to stop and a trip out of the hole for cleaning. Reaming: Tool Selection Centralizers/stabilizers A centralizer is used in front of the primary cutter to centralize the cutter, and a stabilizer is used behind the primary cutter to stabilize the cutter (Fig. 4.6). Centralizers. Centralizers can be specially fabricated for a particular project and may have rollers mounted to ease the torque. More often than not, the centralization is by means of a barrel reamer or bullet-nose reamer. Purpose and application. A constant problem in horizontal drilling is the tear-drop effect you get when reaming a hole, especially when several passes are required. The normal tendency, without centralization, is for the drill pipe in front of the cutter to drop to the bottom of the hole, which prevents the cutter from cutting a concentric hole. Centralizers are used to hold the center of the primary cutter up in the center of the previously reamed hole. Stabilizers. Stabilizers, like centralizers, can be specifically fabricated for a project, but often barrel reamers or bullet-nose reamers are used to stabilize the primary cutter. Purpose and application. If you are reaming a large hole (30 in. [762 mm] or more) without stabilization, the center of the drill pipe is a minimum of 15 in. (380 mm) above the bottom of the hole. The weight of the drill pipe during rotation causes the fly cutter or hole opener to tilt backward, reducing its cutting efficiency. By adding a stabilizer behind the fly cutter, the tilt of the fly cutter is eliminated. You will notice when you remove the stabilizer that there is more wear on the end away from the fly cutter. This is because the stabilizer is being weighed down by the trailing drill pipe. Hole openers When the HDD industry first experimented with rock crossings in 1980, the existing tools, which were built for vertical use, could not endure the side loading inherent in horizontal drilling. Due to the cost, time required, and lack of interest on the part of the tool companies to modify their tools, it was almost seven years before another rock crossing was attempted. During this seven-year period, no change was made to the tools required to enlarge the holes or to the bits used for drilling the pilot holes. Eventually, as more and more river crossings were attempted in rock, modifications were made to the hole openers to improve their performance and longevity. Hole openers are reaming devices used to enlarge holes in rock formations. A hole opener consists of roller cones mounted on shafts or pins. The number of cones ranges from three on the smaller hole openers to six on the larger hole openers. The cones revolve around the center shaft as the hole opener is rotated. As weight and rotation are applied, the cones rotate in the opposite direction of the drill pipe. The rock is fractured under the weight and movement of the cones and the teeth. Purpose and application. The purpose of the hole opener is to enlarge a hole from any given size to a size of greater diameter when the formation consists of rock of varying strengths. Nozzle sizing and configuration. Jet nozzles on a hole opener clean the cutters by creating turbulent fluid action at the face of the rock being cut, forcing the cuttings away from the face. In some cases, the jet nozzles also aid in the cutting action. For nozzle sizing, you must determine the volumes that you will be pumping, calculate the pressure drop at the nozzle (assume a size), and the line loss in your drill pipe. If the result is a pressure that you can accommodate, you need not change the nozzle size. If the pressure you calculated cannot be accommodated, increase the size of the jets and recalculate. 4-13 Horizontal Directional Drilling Training Program Hydraulics Annular velocities and flow rates Nozzle selection is based on proper hole opener hydraulics calculations. Some generally accepted rules of thumb are used to help with the calculations. For example, basic guidelines for minimum annular velocities and flow rates for efficient cleaning of large-diameter holes are shown in Table 4.2. These values should be considered only guidelines, since operators and contractors have developed their own minimum flow rates and annular velocities based on their experience. When viewing the chart, you will see that these numbers will be very difficult to attain. Table 4.2. Minimum annular velocities and flow rates for cleaning large-diameter holes (metric and US units). Hole size (mm) Annular velocity (m/min) Flow rate (m3/min) 445 660 914 1067 18–21 14–17 8–11 6–8 2.650 4.540 4.920 5.390 Hole size (in.) Annular velocity (ft/min) Flow rate (gal/min) 17 1/2 26 36 42 60–70 45–55 25–35 20–25 700 1200 1300 1425 Weight and rotary speed The weight and rotary speed recommendations for hole openers are found in Table 4.3. Again, you will probably deviate from these numbers in actual reaming. When using Table 4.3, keep in mind that these numbers are for vertical drilling where they can put an exact weight on the bit. Since you will be drilling in a horizontal position, your calculations will be different. Table 4.3. Weight and rotary speed recommendations for hole openers (metric and US units). Size Soft shale Rotary Weight speed Metric units (weight x 1000 kg) 445 4.5/6.8 50/90 660 6.8/11.4 45/80 711–762 9.0/15.9 50/70 813–914 9.0/15.9 40/60 965–1067 9.0/15.9 30/50 Size Soft shale Rotary Weight speed US units (weight x 1000 lb) 17 1/2 10/15 26 15/25 28–30 20/35 32–36 20/35 38–42 20/35 4-14 50/90 45/80 50/70 40/60 30/50 Medium shale Rotary Weight speed Hard limestone Rotary Weight speed 6.8/11.4 11.4/15.9 13.6/50 13.6/50 13.6/50 9/13.6 13.6/5 15.9/60 15.9/60 15.9/60 40/70 35/55 35/50 30/45 30/40 Medium shale Rotary Weight speed 15/25 25/35 30/50 30/50 30/50 40/70 35/55 35/50 30/45 30/40 25/45 25/40 15/30 15/30 10/25 Hard limestone Rotary Weight speed 20/30 30/5 35/60 35/60 35/60 25/45 25/40 15/30 15/30 10/25 Reaming: Hydraulics Size of completed reamed pathway The rule of thumb in determining what size hole to ream is 1.5 times the diameter of the pipe. However, because of the pipe sizes, you will not always have a reamer that is exactly 1.5 times the pipe diameter. You may have a reamer that is 1.3 times larger and one that is 1.7 times larger. In normal conditions, use the one that is more than 1.5 times larger. If you have reamed through material such as gravel, consider making one pass larger than the rule to give the pipe a little more freedom in the hole. Penetration rates Penetration rates are largely determined by the pumping capacity you have onsite. There is a direct relationship between pumping and the rate at which you can penetrate. The relationship between reaming and pumping is one of the most important relationships in drilling. If you pump too little, in most cases you will stick your pipe. If you pump too much, you can fracture the formation, cause a washout in the hole, or simply waste your time and effort by mixing and pumping more than is required. Stated another way, penetration rates are directly related to the amount of material you are trying to remove from the pathway. The amount of material that can be removed from the pathway depends on the quality and volume of the drilling fluid. The quality of the drilling fluid is discussed later in this chapter (page 4-17). Assuming that the quality of the drilling fluid is adequate, the optimum percentage of cuttings that can be removed by the fluid is approximately 20%. This means the only way to safely increase penetration rates is to increase the quantity of fluid that is pumped during the reaming process. This figure of 20% has become the basis for establishing reaming rates. After determining the amount of solids to be removed and the pumping capacity, your penetration rates can be calculated. For example, if you plan to ream a 762-mm (30-in.) hole, calculate the volume of one linear foot of hole: 0.762 2 × π ⁄ 4 = 456 liters of solids per linear meter of hole (4.91 ft3 per linear foot) If your maximum pumping capacity is 954 l/min (6 bbl/min), you must calculate the ratio of solids/pumping capacity: 456/954 = 47.8% Remember it was stated that you can penetrate at a rate where the solids do not exceed 20%. 20/47.8 = 0.42 m/min (1.37 ft/min) These calculations tell you that if you are going to ream a 762-mm (30-in.) hole and your maximum pumping capacity is 954 l/ min (6 bbl/min), you should not penetrate at a rate faster than 0.42 m/min (1.37 ft/ min). Table 4.4 will help you determine your allowed penetration rates. First, look under Hole Diameter for the size you want to ream. Then, go down the left side of the chart until you find your maximum pumping capacity. Draw your finger across the chart until you find a number that is 20% or just below 20%. Now go up the column to find your Rate of Penetration. For the example above, you will see that 1.5 ft/min is too fast and 1 ft/min is not fast enough. The charts make it easier to quickly determine the penetration rates. 4-15 Horizontal Directional Drilling Training Program Table 4.4. Penetration rates chart. Hole Hole diameter radius (in.) (ft) Rates of penetration (ft/min) ft3 of material bbl/ bbl in min ft3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 5.61 11.23 16.84 22.46 28.07 33.69 39.30 44.92 50.53 56.15 61.76 67.38 72.99 78.61 84.22 89.84 95.45 101.07 106.68 112.30 117.91 123.53 129.14 134.76 140.37 Enter 30 1.25 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 2.45 4.91 7.36 9.82 12.27 14.73 17.18 19.64 22.09 24.54 27.00 393% 197% 131% 98% 79% 66% 56% 49% 44% 39% 36% 33% 30% 28% 26% 25% 23% 22% 21% 20% 19% 18% 17% 16% 16% 437% 219% 146% 109% 87% 73% 62% 55% 49% 44% 40% 36% 34% 31% 29% 27% 26% 24% 23% 22% 21% 20% 19% 18% 17% 481% 240% 160% 120% 96% 80% 69% 60% 53% 48% 44% 40% 37% 34% 32% 30% 28% 27% 25% 24% 23% 22% 21% 20% 19% Percentage of cuttings removal 44% 22% 15% 11% 9% 7% 6% 5% 5% 4% 4% 4% 3% 3% 3% 3% 3% 2% 2% 2% 2% 2% 2% 2% 2% 87% 44% 29% 22% 17% 15% 12% 11% 10% 9% 8% 7% 7% 6% 6% 5% 5% 5% 5% 4% 4% 4% 4% 4% 3% 131% 66% 44% 33% 26% 22% 19% 16% 15% 13% 12% 11% 10% 9% 9% 8% 8% 7% 7% 7% 6% 6% 6% 5% 5% 175% 87% 58% 44% 35% 29% 25% 22% 19% 17% 16% 15% 13% 12% 12% 11% 10% 10% 9% 9% 8% 8% 8% 7% 7% 219% 109% 73% 55% 44% 36% 31% 27% 24% 22% 20% 18% 17% 16% 15% 14% 13% 12% 12% 11% 10% 10% 10% 9% 9% 262% 131% 87% 66% 52% 44% 37% 33% 29% 26% 24% 22% 20% 19% 17% 16% 15% 15% 14% 13% 12% 12% 11% 11% 10% 306% 153% 102% 76% 61% 51% 44% 38% 34% 31% 28% 25% 24% 22% 20% 19% 18% 17% 16% 15% 15% 14% 13% 13% 12% 350% 175% 117% 87% 70% 58% 50% 44% 39% 35% 32% 29% 27% 25% 23% 22% 21% 19% 18% 17% 17% 16% 15% 15% 14% Pumping The relationship between penetration rates and pumping is the most important in this business. Learn to constantly monitor what you are pumping and you will be able to head off potential problems with your hole. Make everyone on the site aware of what is 4-16 going on and train them to notify someone when there is a deviation from the normal. Fig. 4.9 shows typical mud pumps in operation. Reaming: Hydraulics Fig. 4.9. Mud pumps. Velocity/annular velocity This topic is divided to demonstrate the benefit of velocity when a pipe is inserted into the hole. By doing this, the differences between vertical drilling and horizontal drilling and the role velocities play will be demonstrated. The original cleaning systems adopted from the vertical drilling industry were not designed to cope with the high-viscosity fluids that are common to horizontal drilling. The main reason is that in vertical drilling, velocity plays a much bigger part in cleaning the hole than viscosity does. The cuttings that might fall during a connection will only fall a few centimeters or meters, and are immediately picked up when the pumps are started after the connection is made. In horizontal drilling, viscosity is kept higher to prevent the cuttings from settling to the low side of the hole, which is only a few centimeters away. The cuttings must be kept in suspension so that they can be circulated out of the hole at a much lower velocity. In addition, most horizontal drilling projects are based on 12hour single-shift work, and the drilling fluid must be capable of holding the cuttings in suspension during the work stoppages. Refer to the velocity chart (Table 4.5) to understand the relationship between hole sizes and velocities. In the chart, you can see the tremendous differences in vertical cleaning and horizontal cleaning. To illustrate these differences, assume an average velocity in vertical drilling of 18 m/min (60 ft/min). You will quickly see from the charts how difficult it is to achieve these numbers in horizontal drilling. Refer to Table 4.5 for a 762-mm (30-in.) diameter hole. At the bottom of the page, you see that at 6.4 m3/min (40 bbl/min), the velocity is only 13.9 m/min (45.75 ft/min). You need to pump more than 7.9 m3/min (50 bbl/min) to reach a velocity of 18 m/ min (60 ft/min). Assuming that you install a 508-mm (20-in.) pipe in this hole, you still need to pump more than 4.7 m3/min (30 bbl/min) to achieve a velocity of 18 m/ min (60 ft/min). Even though it is possible to pump this amount, it is not economically feasible to have that much pumping capacity onsite. Lost circulation and its effects on velocity must also be addressed. It is rare to complete a crossing without having lost circulation at some point in the crossing. When this happens, there is a section of the hole where velocity is zero. To reiterate, the drilling fluid must be capable of holding these cuttings in suspension until the subsequent pass when they can be circulated out of the hole. 4-17 Horizontal Directional Drilling Training Program Table 4.5. Velocity chart. Hole diameter (in.) Hole radius (ft) Volume of 1 ft of hole 30 1.25 4.91 (bbl/min) (ft3) (ft/min) (ft/sec) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 5.61 11.23 16.84 22.46 28.07 33.69 39.30 44.92 50.53 56.15 61.76 67.38 72.99 78.61 84.22 89.84 95.45 101.07 106.68 112.30 117.91 123.53 129.14 134.76 140.37 145.99 151.60 157.22 162.83 168.45 174.06 179.68 185.29 190.91 196.52 202.14 207.75 213.37 218.98 224.60 1.14 2.29 3.43 4.58 5.72 6.86 8.01 9.15 10.29 11.44 12.58 13.73 14.87 16.01 17.16 18.30 19.45 20.59 21.73 22.88 24.02 25.17 26.31 27.45 28.60 29.74 30.88 32.03 33.17 34.32 35.46 36.60 37.75 38.89 40.04 41.18 42.32 43.47 44.61 45.75 0.02 0.04 0.06 0.08 0.10 0.11 0.13 0.15 0.17 0.19 0.21 0.23 0.25 0.27 0.29 0.31 0.32 0.34 0.36 0.38 0.40 0.42 0.44 0.46 0.48 0.50 0.51 0.53 0.55 0.57 0.59 0.61 0.63 0.65 0.67 0.69 0.71 0.72 0.74 0.76 Enter 4-18 Reaming: Hydraulics Viscosity Viscosity plays an important role in horizontal drilling. Learn to perform the proper tests and be on top of the fluid situation at all times. Train your personnel to keep the viscosity at whatever level you prescribe. The technicians on the tanks should take readings about every 15 min (with a Marsh Funnel) and report to you every hour. By recording these readings and your pumping data, you will quickly learn the ratios of bentonite to water for your different applications. Acceptable yield point Yield point (YP) can range from singledigit numbers up to perhaps 60 cp. Look for a number that is two to three times the number for plastic viscosity (PV). For instance, if you are recycling on a large project, you might start with readings of 45 for YP and 12 for PV. These are very good readings that show a high capacity for carrying the solids out of the hole. However, if you do not add bentonite, you will see over the next few days that the readings may change to 30 YP and 30 PV. At this point, you should consider dumping and replacing and, at the very least, adding considerable bentonite to raise the YP. The YP and PV are determined by a rheometer. You should require your technicians to perform rheometer tests on the fluid at least twice per shift. By performing these tests on a regular basis, you can correct any deficiencies in the drilling fluid before the problem gets out of control. Acceptable plastic viscosity PV is an indicator number that tells you the ratio of fine solids in your fluid relative to the amount it can carry. These numbers are derived from rheometer tests. Sand content Know the sand content of your fluid at all times. Sand can enter the system either through the water source or from the cuttings in the fluid. Your technician can give you these numbers by using a sand content testing unit. The test takes about 2 min and should be performed and logged at least once per hour. Your recycling equipment should keep your sand content below 0.5%. You should not attempt to pump the fluid through your pumps if the sand content is above 1%, because you will damage your pumps. 4-19 Horizontal Directional Drilling Training Program Troubleshooting General There are many problems you can encounter while drilling, and the following sections cover a few of them. For general troubleshooting: 1. If fluid is not passing through the cones, replace or adjust where applicable. 2. If you get a low pressure reading, check in the following order: tank level, suction plugging, and pump. If everything checks to the pump, first check the packing and, finally, the impeller for wear. Increasing torque The most common reasons for increased torque are listed below. 3. Ask them to make sure the pipe outside the hole is not restricted from turning. Increasing torque—a few seconds. If you experience rapid increase in torque, contact the opposite side immediately to determine if any of the following might be the cause: 4. Check the fluid viscosity. 1. Check to make sure a pump has not gone offline (the mud gauge should be constantly monitored). Increasing torque—sudden lockup. STOP EVERYTHING! Contact the opposite side to determine if everything is normal (someone can inadvertently close the vice or tongs). 2. Check the pilot hole data to make certain there is no unusual bend at this section of the hole. This should have already been checked and marked on the reaming sheet as a section in which to expect possible increased torque. 3. Check the pilot hole data to see if this area was marked hard or difficult (if so, it should have been flagged on the reaming sheet). Increasing torque—several minutes. If the torque increases over several minutes: 1. First, contact the opposite side to determine if they are doing anything differently. 2. Ask them to check the swivel. 5. Switch to a crossover filter and check the used filter. 1. Alluvial materials: STOP AND MAKE CONTACT! Lockup is much less likely to happen in alluvial soils and, for this reason, is usually more serious. If the cause is not above-ground, you have probably hit something in the pathway. 2. Rock: This is a common occurrence in rock reaming, but you should never overlook or expect it. Continue to contact the opposite side every time lockup happens. Normally, you can pull or push while trying to turn and it will free itself. However, there are times that the opposite side will need to pull you back to free the reamer. Twistoff of drill pipe When a twistoff occurs, STOP IMMEDIATELY. Assemble all the decision-makers in the control cab and discuss all the options. If you attempt to go fishing, log all pertinent information, mark a reference 4-20 point on the rig, and measure all the pipe that comes out of the hole. You will want to know, to the centimeter, exactly where your fish is when you go back in the hole. Reaming: Troubleshooting Fishing Fishing is very difficult, at best, in HDD. When the break occurs, the fish falls to the bottom of the hole or to the side of the hole. If the soils are soft and you plan to use an overshot, you will have great difficulty just getting the tool to the fish, much less getting it over the fish. The same is true for a taper tap—just getting it to the fish is a major hurdle. Generally, you have less than a 50% chance of getting the tool to the fish, and if you do, you have less than a 50% chance of getting on the fish and reestablishing contact between the two sides. If the separation occurred during the pilot hole, it is extremely difficult to salvage. A fishing operation is shown in Fig. 4.10. Fig. 4.10. A fishing tool completing a pullback. Recovery This section concerns reaming, where you will have pipe sticking out both sides of the crossing. This gives you many options, a few of which are covered below. Salvaging hole. The first order of business after a twistoff is to stop all work and discuss all the options. The options available will depend on where the pipe has separated. Usually the separation will occur between the reamer and the drilling rig providing the rotation, but it can also occur on the other side of the reamer. The following is a discussion of the different types of separations and possible remedies. One remedy is to use one rig pulling the reamer toward the rig from the pipe side. If the separation occurs between the reamer and the rig, you will know it by the lack of torque required to turn the drill string, the carriage surging back, and the mud pressure dropping. First, cease all operations. Try to determine what events happened just before the separation. If the drill pipe on the pipe side was spinning and stopping erratically, it is possible that the pipe in front of the reamer just unscrewed. Attempt to move the pipe slowly forward away from the rig while rotating. If the pipe has become unscrewed, you may be able to screw back into the pipe. If these efforts are not successful and the separation is close to the pipe side, you may be able to retract the reamer with conventional equipment without rotating, and reestablish your hole by pushing the pipe from the drilling rig while pulling the reamer. As a last resort when salvaging the hole, consider moving the drilling rig to the pipe side of the river and retracting the reamer using the drilling rig. If you choose to exercise this option, retract the pipe on the rig side and determine where the break 4-21 Horizontal Directional Drilling Training Program occurred. After you have removed the drill pipe and reamer, you will have to move the drilling rig back to the rig side and reestablish the hole by pushing a floater back through the pathway. Once this is accomplished, you can continue reaming. A floater is a blunt-nosed assembly on the end of the drill string. This assembly has a large blunt nose with holes cut in it through which you will pump small amounts of drilling fluid. Because it is somewhat rounded on the end, it is possible to push the assembly through a pre-reamed pathway without sidetracking. This assembly works about 70% of the time, and works best in more consolidated materials. ing fluid from the opposite side of the river as the equipment is configured. Consequently, you will not be able to remove the reamer. In this event, salvage as much of the pipe between the surface and the reamer as possible. If, while reaming and pulling to the drilling rig, you separate behind the reamer, stop all operations and try to determine what caused the separation. This type of separation will only be noticed on the pipe side. The pipe will stop rotating and pulling into the pathway. On the rig side, it may be that nothing will appear to have changed. The chances of pushing the reaming assembly and the pipe back into a joint that has become unthreaded are minimal. However, it is still worth trying. More than likely your best option will be to continue the ream until the reamer has exited on the rig side. The drill pipe on the pipe side of the reamer can be removed using conventional equipment. Once the ream is completed, try to reestablish the hole, again using the floater assembly. If you have two drilling rigs available during the reaming process, a lot of time can be saved in the event of a pipe separation. If the break is in front of the reamer, the rig at the exit side can rotate the reamer and withdraw the pipe to the exit side. At the same time, the rig at the entry side can add joints and follow the reamer out to the exit. If the break is behind the reamer and plug, the rig at the entry side can withdraw the pipe while the rig at the exit side is adding joints and following with the pipe out of the hole. If the break is between the reamer and the plug, the reamer must be pushed out by the rig at the entry point, while the rig at the exit point withdraws only fast enough to stay just ahead of the reamer. Constant communication must be maintained between the two rigs. If you are unable to follow the reamer out in either of the above situations, you can still use the floater assembly to reestablish the pathway. If the separation occurs while you are reaming away from the drilling rig, but between the drilling rig and the reamer, you should stop all operations. This type of failure will be noticed on the drilling rig side by loss of torque and loss of mud pressure. On the pipe side, the crew should notice that the pipe has stopped rotating. Gather all the information just prior to the mishap and try to find out how the separation occurred. If you assume that the pipe became unscrewed you can attempt to screw back into it, but you will have little chance of success. You can attempt to secure and use fishing tools, but again, because of the size of the hole, your chances will not be very good. Because of the pipe plug in front of the reamer, you will not be able to pump drill4-22 If, while reaming away from the rig, the pipe separates in front of the reamer, stop all operations and analyze the situation. In all probability, you will have to retract the reamer to the rig side and pull the remaining drill pipe out on the pipe side. At this point you can either take the rig to the pipe side or resign yourself to redrilling the pilot hole. If the attempt to reestablish the hole in any of the above situations is unsuccessful, you will be forced to move the rig and redrill the pilot hole, starting from scratch. Severing drill pipe. If you decide to redrill, you want to recover all that is salvageable. If the reamer itself is stuck, you must try to recover everything up to the reamer, on both sides. Many companies prefer to twist the pipe off and recover whatever they can, as opposed to placing a shaped charge and severing the pipe at a predetermined point. However, if you happen to be stuck 3000 ft Reaming: Troubleshooting from the rig and you twist off just below the ground, you have made a bad decision. Base your decision on economics. Lost or decreased circulation Most project managers tend to neglect decreased or lost circulation with the mindset that there is not a lot they can do, or that to try to rectify the situation is only a waste of time. This thinking is in error and irresponsible. Your risks are greatly reduced when you are successful in maintaining circulation. It is true that you can be successful even when you lose circulation, but your chances are greatly increased if you maintain returns. Train your personnel to watch the return pit so that they can immediately notify super- visors of any decrease in returned drilling fluid. If you are using a recycling system, you will quickly notice that you are getting less back than you are pumping. The level in the recycling tank will drop and it should be noticed in time to prevent total loss. When a reduction in returns is noticed, make every effort to regain the lost fluid, even if it means tripping all the way out of the hole. It is understood that you want to progress and do not like to pull back, but regaining circulation will help you later on. Stuck reaming assembly If the reaming assembly becomes stuck and you are in a rocky formation, you should be able to free it up with enough time and effort. If the reaming assembly becomes stuck in gravel or as a result of a gravel collapse, you probably will not be able to free it. If you become stuck in sandy soils, you must free it quickly or you might be unable to free it. If you are using a rig on each side of the river and the reamer becomes stuck in rock, you have the advantage of turning the reamer in both directions, first from one side and then the other. Also, you can pull from either side while the opposite rig applies the torque. While doing this, pump high-viscosity sweeps, which can sometimes aid in extricating the reamer or pipe. Mud pressure increase If there is a mud pressure increase, the probable causes are: • the pump(s) have been throttled up • the viscosity has increased • the reamer nozzles are restricted • the borehole has packed off and you are about to fracture the formation. If the increase is caused by the pumps or viscosity, the problem is easily solved. If the problem is caused by either the jet nozzle(s) or the borehole packing off, you will be able to distinguish between the two. When the borehole packs off, the pressure increase will be less than 20 psi (140 Kp). When a jet nozzle is restricted, the increase will likely be 50 to 200 psi (350 to 1350 Kp). Check to make sure the filter does not have a rupture or tear that is allowing pebbles to pass unobstructed down the hole. Mud pressure decrease If there is a mud pressure decrease, the probable causes are: • the pump is not being fed properly by the mix tank • the pump drive has been throttled down, or there is a problem with the pump internally (if this is the case you will usually hear the banging) 4-23 Horizontal Directional Drilling Training Program • the mud filter between the mix tank and the pump is plugged • there is a washout downhole, usually at the reamer. Again, you should be aware of what is going on around you and should be able to say, within a few minutes, that the problem is downhole. You must determine whether or not to make a trip, depending on where you are in the hole. Inadvertent returns Normally, inadvertent returns are caused by either overpenetrating or overpumping. You can cause this by not letting the clues tip you off to the potential problems. For instance, you may gradually increase your viscosity until you are over 250 sec, and then notice that when disconnecting from a joint, the pressure is escaping through the open end of the drill pipe. At the same time, while removing a joint from the rig, you notice that the fluid cannot even run out of the pipe because it is so thick. If you are not using polymers, you are exerting a tremendous pressure on the formation and it may not be able to withstand the pressure. Another cause of inadvertent returns is the following: You dig a mud pit in front of the rig and call it an entry pit. When you spud in the bottom of the pit, the return fluid comes back through the hole at a certain velocity and enters the pit, and the velocity drops immediately to zero. The cuttings drop out in the bottom of the pit and, over time, will plug the entry hole. It can and will build up to the point that the fluid can no longer push through it, and will instead surface at some other point where the ground is weaker. This happens many times. If you have the space, it is better to dig your pit to the side of centerline so that the fluid can continue to move until it is away from the entry hole. Reduced penetration rate Reduced penetration rates are caused by many things: 1. The most common cause is that the formation has changed to a harder formation. The notes from the pilot hole should mention if this is the case. If increasing the force on the cutter creates too much torque, you will probably have to accept the slower penetration rates. 2. If the Kennemetal teeth, cutter blades, or inserts on hole openers or reamers become worn, the penetration rate will naturally decrease. Depending on the amount of reaming left, you must decide whether to trip out the assembly and replace or repair it before continuing with the reaming. 3. If you are not applying enough force against the face of the formation, penetration rates will decrease. To correct this, you must apply more force. 4-24 4. If your rotary speed is too slow, the penetration rate will probably be reduced. If possible, increase the rotary speed to remedy this situation. 5. When reaming in rock formations and in some alluvial formations with very abrasive soils, sometimes the gauge of the reamer is worn down to the extent that the outside wall of the reamer begins to be pinched by the side of the reamed pathway. This can increase torque and consequently reduce your penetration rate. Depending on how much reaming remains, you may opt to trip the assembly out of the hole and repair or replace the reamer or cutters. 6. If the pumping volume/pressure relationship changes, the penetration rate may be reduced. 7. The pressure loss may be the result of less fluid being pumped or the jet nozzles on the reamer being washed out. If it is the jet nozzles, decide whether to proceed at a slower rate or trip the Reaming: Troubleshooting assembly and repair or replace the jet nozzles. 8. In clay, the reamer or hole openers will sometimes ball up. This results from the adhesive material filling all the areas between the teeth or cutter blades. This material can become so tightly packed that the protruding teeth, blades, or inserts cannot make sufficient contact with the face of the pathway you are cutting. Progress will gradually come to a halt, once the clay material is simply rubbing against the wall of the pathway. There are some additives that can be injected into the mud to prevent balling, but not many of them work after the fact. The best solution is to trip the reamer or cutter and clean it on the surface. Then use the additives when proceeding with the reaming to prevent balling. 4-25 Horizontal Directional Drilling Training Program Notes 4-26 Chapter 5: Pullback Pipeline................................................................................................ 5-1 General .............................................................................................................. 5-1 Steel pipeline...................................................................................................... 5-1 Pipe diameter....................................................................................................................5-1 Pipe wall thickness ...........................................................................................................5-1 Buoyancy control..............................................................................................................5-1 Coatings............................................................................................................................5-3 HDPE pipe ......................................................................................................... 5-3 Standard Dimension Ratio ...............................................................................................5-3 Buoyancy control..............................................................................................................5-4 Soils..................................................................................................... 5-4 Clay .................................................................................................................... 5-4 Sand................................................................................................................... 5-4 Rock ................................................................................................................... 5-4 Mud Program ...................................................................................... 5-5 Drilling fluids....................................................................................................... 5-5 Volumes ............................................................................................................. 5-5 Fluid control........................................................................................................ 5-5 Disposal ............................................................................................................. 5-5 Pulling Assistance ............................................................................. 5-6 Support equipment............................................................................................. 5-6 Breakover or overbend....................................................................................... 5-6 Pulling support ................................................................................................... 5-8 Pulling Program.................................................................................. 5-8 BHA.................................................................................................................... 5-8 Pulling speed...................................................................................................... 5-8 Pulling loads....................................................................................................... 5-8 Pulling across the bottom of the profile and the pull increases with every joint .............5-9 Pulling across the bottom of the profile and the pull suddenly increases........................5-9 Pulling through the exit side vertical curve and the pull increases with every joint .......5-9 Pulling through the exit side vertical curve and the pull suddenly increases ..................5-9 Pulling and the pull suddenly decreases ..........................................................................5-9 Salvaging Stuck Pipe ......................................................................... 5-9 List of Figures Fig. 5.1. Buoyancy control with styrofoam cylinder. ...................................................... 5-2 Fig. 5.2. Buoyancy control with HDPE pipe. .................................................................. 5-2 Fig. 5.3. Pipeline with Powercrete coating. Providence, Rhode Island, USA. ................ 5-3 Fig. 5.4. Breakover or overbend. ..................................................................................... 5-7 Fig. 5.5. Gravel shield reamer. .................................................................................. 5-8 Notes ii Chapter 5: Pullback Pipeline General The final objective when planning, designing or executing a horizontal directional drilling (HDD) project is the installation or pullback of the pipeline or pipelines (bundle). To properly plan a directionally drilled crossing, you must know the diameter, wall thickness, and type of pipe material to be installed, and the types of soils that will be encountered. This chapter discusses the factors you should consider when installing steel pipeline, concretecoated pipe, and high-density polyethylene pipe (HDPE). Steel pipeline Steel pipelines are manufactured in various diameters, wall thicknesses, and grades of steel. Each of these components should be considered when planning a directionally drilled crossing. The difficulty of directionally drilled crossings increases geometrically with increasing diameters and installation lengths. Pipe diameter. The pipe diameter is crucial when designing a directionally drilled crossing. The larger the pipe diameter, the larger the radius required to facilitate the installation and limit the amount of stress on the outer fiber of the pipe. The minimum radius should be 100 ft (30.5 m) for each diameter inch (25.4 mm). Therefore, a pipeline with a diameter of 30 in. (762 mm) would warrant a minimum radius of curvature of 3000 ft (91.5 m). This design will limit the amount of stress on the pipe once the installation is complete. This is discussed in greater detail in Engineering (Chapter 2). Pipe wall thickness. The pipelines proposed for directional drilling should have a diameter-over-thickness ratio of 50 or less. The reason for specifying a minimum diameter-over-thickness ratio is to prevent pipe collapse during the installation. Largediameter pipelines with thinner walls can collapse under the pulling stresses, as well as the external pressure of the hydrostatic head of the drilling fluid around the pipe. Buoyancy control. In any directionally drilled crossing, one of the main considerations of the pullback is the weight of the pipe in the pathway and the associated force necessary to overcome this resistance. Obviously, the heavier the pipeline, the more difficult the operation. When installing large-diameter pipelines, the buoyancy of the pipe in the fluid creates more resistance than the gravitational weight of the pipe. To successfully install large-diameter pipelines, you must consider the weight and buoyancy of the pipe. If the pipe is too buoyant, consider adding weight to the pipe. The preferred method for combating buoyancy is to add water into large-diameter pipelines during the pullback operation. The simplest method is to pump water directly into the pipe through a filler line or pipe. This water is pumped into the pipeline as it goes below the ground surface without adding weight to the pipe on the surface. The problem with this method is that you have no control over the distribution of the water, and you may end up with too much water at one point and not enough at the higher elevations. There are several different means of controlling the water distribution. One method is shown in Fig. 5.1. Styrofoam cylinders are placed inside the pipe at specified intervals, with a filler pipe running through the center and water filling the space between the styrofoam and the pipe. Another method is shown in Fig. 5.2. Smaller-diameter HDPE pipelines can be placed inside Horizontal Directional Drilling Training Program the large-diameter carrier pipe and filled with water as the pipeline is installed. The latter of these two methods has been the most successful. With a little planning, you can essentially cause the large-diameter Buoyancy force pipelines to have a neutral weight in the pre-reamed pathway, thereby significantly reducing the amount of pull force that will be required to install crossings. 1 Fig. 5.1. Buoyancy control with styrofoam cylinder. 3 1 = Styrofoam cylinder 2 2 = Drill pipe 3 = Filler pipe 4 = Water 4 Weight Concrete coating, although an excellent means of achieving the additional weight needed, can cause problems for the HDD contractor. It increases the diameter of the pipeline, which is generally large to begin with. It may crack and break off during the installation, possibly into the reamed pathway. In addition, its coarse exterior surface will add resistance to the pullback effort, 1 and it is difficult to handle on the surface because of its weight. In the future, these disadvantages will be solved and concrete coating will be the preferred choice for decreasing the buoyant effect of largediameter pipelines. Until then, adding water to large-diameter pipes to control the effects of buoyancy is the easiest and most effective method. Buoyancy force Fig. 5.2. Buoyancy control with HDPE pipe. 1 = Carrier pipe 3 2 = HDPE pipeline 3 = Water 2 Weight 5-2 Pullback: Pipeline Coatings. The main purpose of pipe coatings is to protect the pipe in place against corrosion. The coatings should have a low coefficient of friction so that they do not adversely affect the installation. In most instances in alluvial soils, the fusionbonded epoxy coating applied at a thickness of 0.8 to 0.9 in. (20 to 24 mm) is sufficient for protection. However, in areas with large concentrations of angular gravel or in rock installations, additional protection is recommended. A rock shield coating known as Powercrete® is compatible with the fusion-bonded epoxy corrosion coating (Fig. 5.3). Powercrete has a very low coefficient of friction and is applied over the fusion-bonded epoxy. This combination of coatings is the most effective for protecting the pipelines during rock installations. In Europe, polyethylene coatings (three-layer or sintered) are also commonly used. A more thorough discussion of coatings can be found in the Engineering chapter (page 2-20). Fig. 5.3. Pipeline with Powercrete coating. Providence, Rhode Island, USA. HDPE pipe The use of HDPE pipe is increasing, especially for conduits, water lines, buoyancy control, and environmental work. HDPE allows you to drill much tighter radius holes, and it will bend around buildings and other surface structures. The forces that are incorporated into steel pipeline pullbacks will not apply when using HDPE. Standard Dimension Ratio. Standard Dimension Ratio (SDR) is the ratio of the pipe outside diameter (OD) to the minimum thickness of the pipe wall. Phillips Driscopipe, a manufacturer of HDPE pipe, subscribes to the SDR method of rating pressure pipe. It can be expressed mathematically as: SDR = D/T where: D = Pipe OD in millimeters or inches T = Pipe minimum wall thickness in the same unit as D. For a given SDR, the ratio of the OD to the minimum wall thickness remains constant. An SDR 11 means the OD of the pipe is 11 times the thickness of the wall. This remains true regardless of diameter. For example, a 14-in. (355.6-mm) diameter pipe with a wall thickness of 1.273 in. (32.3 mm) is an SDR 11 pipe. An 18-in. (457.2-mm) diameter pipe with a wall thickness of 1.637 in. (41.6 mm) is also an SDR 11 pipe. Standard SDR ratios are 9.3, 11, 13.5, 15.5, 17, 19, 21, 26, and 32.5. For 5-3 Horizontal Directional Drilling Training Program high SDR ratios, the pipe wall is thin compared to the pipe OD. For low SDR ratios, the wall is thick compared to the pipe OD. Thus, high SDRs correspond to low pressure ratings and low SDRs correspond to high pressure ratings because of the relative wall thickness. Buoyancy control. When installing an HDPE pipe, fill the pipe with water during the installation. This should be done with pipe diameters greater than 10 in. (254 mm) to prevent collapse from external pressure. During the installation, make sure that the hole is clean and open to prevent pulling the pipe apart because of the friction load along the pipe’s exterior and the relatively low tensile strength of the material. When drilling in gravelly sands, ream the hole oversized to allow more open space in the hole. Soils A few of the soil types you will encounter and the effects they have on the pipe are discussed in this section. Additional infor- mation on soils can be found in the Reaming chapter (page 4-6). Clay is the easiest of the soils to drill through, being very predictable and easy to manipulate. By the time you reach the pullback phase, you will be aware of the characteristics of the clay through which you have drilled and reamed. At this stage you should be confident that you have reamed the hole to the required diameter, cleaned the hole by running a wiper or swab pass, and planned your pullback, complete with contingency plans for anything unexpected. Sand is less predictable than clay, but can be controlled by using proven reaming and pullback methods. The biggest problem with sand is that you do not have the freedom to shut down for extended periods of time. This is because the longer the pullback is delayed, the greater the probability that sand will settle out of the drilling fluid around the pipe. In rock, pullback will proceed much the same as in clay if you have prepared for it through your drilling and reaming practices. If the hole is reamed to the proper size and is clean, your success should be guaranteed. An exception is when drilling through a weathered rock formation, which may crumble and fall into the hole. If this happens, your actions will depend on whether the rock fragments fall in front of the bullet nose or in front of the pipe. If you are experiencing torque from the rock, continue and try to break it up. If they fall in front of the pipe and cause your pull to increase, it is better to pull the pipe back to get the piece of rock in front of the bullet nose. Clay Sand Rock 5-4 Pullback: Mud Program Mud Program Drilling fluids The drilling fluids chosen for the pilot hole and reaming will also work for the pullback, except that you may want to add extra lubrication. This can be applied directly to the pipe or mixed with the fluids you are pumping. Volumes The volume of drilling fluid you pump will depend on how much hole cleaning is necessary. If you are reaming and pulling at the same time, use the bottom’s up chart that is used for reaming (page 4-4). For large-diameter crossings, you can significantly reduce the volume pumped because of the amount of fluid being displaced by the pipe. This is especially true for clay or rock crossings where the holes are normally very clean for pullback, and less true for sand and sandy gravel crossings. For example, when pulling a 36-in. (914-mm) pipe at the rate of 31 ft/min (9.4 m/min), almost 40 bbl/min (6.4 m3/ min) of fluid is being displaced and exiting the hole at one end or the other. In this case, you are moving enough fluid through the hole that very little is required to be pumped through the bullet nose. Fluid control When executing an HDD crossing, it is essential to maintain control over the drilling fluids being used. While you want to have enough drilling fluids mixed so as to avoid a shutdown, you do not want such an excess of drilling fluids onsite that you have to cease operations to control the fluids. Closely monitor the mixing of your drilling fluids in a closed-loop system. You will have to continually mix fluids while drilling forward and with each reaming pass to account for the increase in the size of your pathway—but guard against mixing too much. Mixing too much fluid will be an unnecessary expense during the installation and can also cause additional cleanup costs. At each location, especially the largerdiameter and longer crossings, you will need a certain holding capacity for excess fluids. This holding capacity can be in the form of mud pits or steel holding tanks. Disposal Although the drilling fluid used in the HDD industry is not harmful to the environment, it can create a mess around the drilling location and surrounding area if not controlled. You will also have the problem of disposing of the excess drilling fluid. 2000 ft (600 m) long by 30-in. (762-mm) pipe. Onsite you have a return pit to collect the return fluid, a 6-in. (150-mm) transfer pump to transfer the fluid to the recycling unit, two pumps to transfer the fluid through the tank, and a pump to transfer the fluid to the mix tank. The following is a quick comparison of practices and their resultant costs for a sample project. This comparison is based on one of the most common reasons you might inadvertently build excess volume. Assume you have a beach approach of If any of these pumps are taken offline for repair, the circulation through the loop stops or the drilling or reaming must stop, and you do not want to shut down the rig for any reason. However, if the problem is with the pump at the entry pit, you will 5-5 Horizontal Directional Drilling Training Program usually have to shut down. The error here was that there was no spare pump that could be put online in a matter of minutes. If the problem is with one of the pumps on the recycling unit, the fluid is normally diverted to holding tanks, water and bentonite are continuously added to the mixing tank, and the rig continues to work. The result is that you are building volume that you must eventually use or dispose of. This scenario is acceptable if there is sufficient reaming remaining to use the volume to fill the hole. Unfortunately, the volume in the holding tanks is usually forgotten and even added to. At the pullback phase, the 42-in. (1067-mm) hole is full of fluid, the entry pit is full, the mixing tank is full, the recycling tank is full, and you do not know when the fluid will start coming to the entry side during pullback. What do you do with the 30 bbl/min (4800 l/min) of fluid that will be displaced by the pipe as it is pulled in the hole at rates of 30 ft/min (9.1 m/min), as well as the 5 to 8 bbl/min (790 to 1270 l/min) that you will be pumping? The result is excess drilling fluid at the entry, which will cost time and money to clean up. These costs can be reduced or eliminated through proper planning. By keeping the excess volumes as low as possible, your disposal costs will be minimized. Pulling Assistance Support equipment As a drilling contractor, you must be knowledgeable about the equipment requirements on the pipe side of the crossing. Preferably, you will have experienced pipe-handling personnel on the pipe side who will prepare the carrier pipe for instal- lation. Adequate equipment and personnel to handle the pipe during the installation process are essential to the successful installation of a directionally drilled crossing. Breakover or overbend Breakover or overbend is the bend through which the pipe must pass from its horizontal position on the rollers to its alignment with the hole (Fig. 5.4). This angle should 5-6 be as low as possible so that the pipe does not require undesirable heights above the ground to conform to the bend. Pullback: Pulling Assistance Fig. 5.4. Breakover or overbend. For example, assume that you have a 30-in. (762-mm) pipe to pull, the exit angle is 8˚, and the minimum allowable radius is 1800 ft (550 m). The top of the overbend, or the point at which the pipe is the highest above-ground (assuming the ground is level) is 17.5 ft (5.33 m); this point is 250 ft (76.2 m) from the exit point. If the lifting equipment is spaced 60 ft (18.3 m) apart, four pieces of equipment will be required to handle this section. Also remember that the pipe behind the overbend must curve back toward the ground, in a reverse curve, until it rests on the rollers or in the flotation ditch. This will require a minimum of three pieces of equipment. To minimize the equipment requirement, either lower the exit angle, shorten the radius, or place most of the overbend below-ground. Assume you have the same 30-in. (762-mm) pipe with the same exit angle and are restricted to the same minimum allowable radius. However, instead of placing the overbend from ground level to a point 17.5 ft (5.33 m) above-ground, place the overbend from a point 14 ft (4.3 m) below the exit elevation to a point 3.5 ft (1 m) above the ground elevation. The pro- cedure is as follows, starting at pilot hole completion: When the pilot bottomhole assembly (BHA) has exited, remove the BHA so that nothing but steel drill pipe remains in the hole. Strip back along the pipe to the correct elevation point that places the top of the pipe overbend at a level equal to the top of your rollers. If you plan to place sheet piling on both sides of the pipe to prevent cave-ins, do this now. Reference the point to which you have dug with a survey so that you can return. You can now begin and complete all phases of reaming. When you are ready to place the pipe for pullback connection, place your rollers so that they are at the proper elevations. When the pipe is placed on these rollers, you will have an overbend that begins 250 ft (76.2 m) from the point at which you are 14 ft (4.3 m) deeper than the exit elevation, and it breaks over to lay on the rollers in a perfect curve. The last roller will be placed 60 to 70 ft (18.3 to 21.3 m) from the point you originally surveyed that is 14 ft (4.3 m) below the exit 5-7 Horizontal Directional Drilling Training Program point. This results in the same configuration, the only difference being that it is mostly below-ground and requires no equipment to keep it in position. Pulling support As the lengths and diameters of crossings increase, so will the need for assistance to install the pipe. The assistance can be in the form of dozers with winches or pulling units that are anchored to allow maximum pulling assistance from the opposite side. Many of our crossings would not have been successful without this assistance. In other cases, failed crossings would have been successful had assistance been obtained. Pulling Program BHA For pullbacks, the conventional BHA consists of a bullet-nose reamer and an exposed swivel connected to the pipeline with shackles. An unconventional BHA, called a gravel shield reamer (Fig. 5.5), was introduced for rock and gravel crossings. The basic difference in the gravel shield reamer and the conventional pulling BHA is that every part of the BHA is enclosed except the reamer. The reamer can be a bullet-nose, fly cutter, barrel reamer, or hole opener. The main purpose is to prevent any large material from building up in front of the pull head, which could hinder the pipe pulling. Fig. 5.5. Gravel shield reamer. Pulling speed If you have properly reamed and cleaned the hole, you should be able to pull the pipe as fast as your rig will travel. This is usually true even if you have a sandy or gravelly soil to pull through. Begin the first 100 or 200 ft (30 or 60 m) of your pullback by pulling at reasonable speeds, allowing the pipe to find its proper position, which you will know by the torque readings. If you are getting torque in the first part of the hole where none was expected, it is usually due to angle misalignment. This can be corrected by adding water, removing water, slowing your pull, or adjusting your breakover. When you are certain that the pipe is properly aligned and your torque has disappeared, pull the pipe as fast as practicable. Pulling loads You will have some indication of what pulling loads to expect prior to pullback, but you will only know for certain once you begin pulling. There are too many 5-8 unknowns to predict exactly what the loads will be. Some of the nuances of pulling are covered below, which should aid you in diagnosing different situations. Pullback: Salvaging Stuck Pipe Pulling across the bottom of the profile and the pull increases with every joint. This situation is the most difficult because you may have several hundreds of feet yet to pull and you don’t know whether to stop or continue. You must make that decision based on how much you have pulled and how much you have yet to pull. You can determine what the pull might reach if you project from the information you have. For example, if the pull was increasing for the past 15 joints at about 100 psi (689 Kpa) per joint, observe the current gauge reading. If the pull gauge was reading 1000 psi (6.9 Mpa) before the last 15 joints, and is now reading 2500 psi (17 Mpa), determine whether your pull will maximize if you continue. If you have only 15 joints remaining, you should continue. If you have 30 joints remaining, you should probably stop. There is no clear-cut answer and it is something that you must determine onsite. Pulling across the bottom of the profile and the pull suddenly increases. It is possible you have experienced a sudden hole collapse but, more than likely, something has happened above-ground on the opposite side. You should immediately stop pulling and contact the supervisor on the exit side to ask if anything unusual has happened. The person at the return pit should have reported by this time if circulation has been lost. If circulation suddenly stopped, you have probably experienced a hole collapse and only additional pulling will tell you if you should continue. If you are in rock, it is possible that a piece of rock has jammed between the pipe and the outside of the hole. If this is the case, you will continue to have circulation. You should pull back a short distance to try to release the rock that has caused the jam and move it in front of the reamer. If it is in front of the reamer, you can try to keep skipping it forward until it finds a place to fall out; however, it may pass by the reamer and jam the operation again. You must make this determination on the job. Pulling through the exit side vertical curve and the pull increases with every joint. Usually, the pull will drop once you are around the curve and into straight hole. Pulling through the exit side vertical curve and the pull suddenly increases. If you have accepted a bend in one joint that is greater than allowed, it should have been marked as a place to slow the pull. If it was not, check your data sheet. When it is a bend, the torque will also increase. Pulling and the pull suddenly decreases. Stop and contact the exit side to see if they have made any adjustment and if the pipe was still moving when you stopped. These are just a few of the possibilities that can occur. Accumulate the facts and base your decision on those facts, although there will never be a standard response to every conceivable problem. You must learn from every situation and record the experience for future reference. Salvaging Stuck Pipe In the case of stuck pipe, the first thing you must do is gather all the facts. Have an open discussion with everyone involved and come to an agreement as to the best course. Make a list of what you need to do; determine what, if anything, you need to mobilize; and proceed in an orderly fashion. Prepare a report for your client that includes what happened, and what your plan is for the short term and the long term. Provide the client with a schedule of events to demonstrate that you have the situation under control. Be sincere in your dealings with your employees, your subcontractor or prime contractor, and your client. Meet with your supervisors and begin discussing what the course of action will be if you are unsuccessful in retrieving the pipe. If additional right-of-way will be required, now is the time to begin working on it. 5-9 Horizontal Directional Drilling Training Program Notes 5-10 Chapter 6: Mud Functions of a Drilling Fluid.............................................................. 6-1 Cooling and lubricating the drill string ................................................................ 6-1 Removing cuttings.............................................................................................. 6-1 Suspending and releasing cuttings .................................................................... 6-1 Forming a filter cake........................................................................................... 6-1 Providing geological information ........................................................................ 6-2 Protecting the formation ..................................................................................... 6-2 Transmitting hydraulic horsepower .................................................................... 6-2 Supporting the drill pipe weight .......................................................................... 6-2 Drilling Fluid Tests ............................................................................. 6-3 Mud weight......................................................................................................... 6-3 Viscosity: Marsh Funnel ..................................................................................... 6-4 Viscosity: Rotational Viscom .............................................................................. 6-5 Measuring YP and PV ......................................................................................................6-5 Gel strength ......................................................................................................................6-6 Filtration (low-temperature test) ......................................................................... 6-7 Sand content ...................................................................................................... 6-8 pH....................................................................................................................... 6-9 Chemical analysis ............................................................................................ 6-10 Clay Chemistry ................................................................................. 6-11 Basic chemistry ................................................................................................ 6-11 Atomic and molecular weights ......................................................................... 6-11 Valence and chemical bonds ........................................................................... 6-12 Dissociation and equivalent weights ................................................................ 6-12 Clay chemistry.................................................................................................. 6-12 Montmorillonite................................................................................................. 6-12 Na-montmorillonite ........................................................................................................6-12 Ca-montmorillonite ........................................................................................................6-12 The structure of clays....................................................................................... 6-13 Montmorillonite ..............................................................................................................6-13 Attapulgite ......................................................................................................................6-14 Sepiolite ..........................................................................................................................6-14 Effects of adding positive ions.......................................................................... 6-14 Salt clay ..........................................................................................................................6-14 Yield ................................................................................................................................6-15 Rheology............................................................................................6-16 Introduction....................................................................................................... 6-16 Non-Newtonian fluids ....................................................................................... 6-17 Bingham plastic model ..................................................................................... 6-18 PV................................................................................................................................... 6-19 YP ................................................................................................................................... 6-19 Gel strength.................................................................................................................... 6-19 Power Law model ............................................................................................. 6-20 Power Law ..................................................................................................................... 6-20 n index ............................................................................................................................ 6-21 K index ........................................................................................................................... 6-22 Modified Power Law model .............................................................................. 6-22 Slip velocity .................................................................................................................... 6-22 Critical velocity.............................................................................................................. 6-23 Reynolds number ............................................................................................. 6-24 Filtration.............................................................................................6-24 Conditions affecting filtration ............................................................................ 6-24 Time.................................................................................................................. 6-25 Control of filter cake permeability ..................................................................... 6-25 Filtration control additives................................................................................. 6-25 Clays............................................................................................................................... 6-25 Starch ............................................................................................................................. 6-25 Dispersants..................................................................................................................... 6-26 CMC ............................................................................................................................... 6-26 Solids Control ...................................................................................6-26 Introduction....................................................................................................... 6-26 Monitoring solids content.................................................................................. 6-27 The solids removal system ............................................................................... 6-28 Shale shakers................................................................................................... 6-29 Screen arrangement ....................................................................................................... 6-29 Position of vibrator ........................................................................................................ 6-29 Screen type ..................................................................................................................... 6-29 Sand traps ........................................................................................................ 6-30 Desander .......................................................................................................... 6-30 Desilter ............................................................................................................. 6-32 Mud cleaner...................................................................................................... 6-33 Centrifuges ....................................................................................................... 6-33 ii List of Figures Fig. 6.1. Mud balance. ......................................................................................................6-3 Fig. 6.2. Marsh Funnel. ....................................................................................................6-4 Fig. 6.3. Fann viscometer. ................................................................................................6-5 Fig. 6.4. Dial reading vs. rotary speed..............................................................................6-6 Fig. 6.5. Standard filter press............................................................................................6-7 Fig. 6.6. Sand content kit..................................................................................................6-9 Fig. 6.7. pH meter...........................................................................................................6-10 Fig. 6.8. Water hydration of montmorillonite. ...............................................................6-13 Fig. 6.9. Yield curves for four different clays (A through D). .......................................6-15 Fig. 6.10. Shear stress vs. shear rate for a Newtonian fluid. ..........................................6-16 Fig. 6.11. Shear stress vs. shear rate for a typical mud. .................................................6-17 Fig. 6.12. Viscosity vs. shear rate for a typical mud. .....................................................6-17 Fig. 6.13. Newtonian and non-Newtonian fluids. ..........................................................6-18 Fig. 6.14. Comparison of Bingham and Power Law models..........................................6-20 Fig. 6.15. Velocity profile of fluids with different n indices..........................................6-21 Fig. 6.16. Power Law on log-log paper. .........................................................................6-22 Fig. 6.17. Solids content of low-weight muds................................................................6-27 Fig. 6.18. Mud weight vs. solids content........................................................................6-28 Fig. 6.19. Particle size distribution. ................................................................................6-28 Fig. 6.20. Desander.........................................................................................................6-31 Fig. 6.21. Centrifuge.......................................................................................................6-34 List of Tables Table 6.1. Approximate n values of standard field muds................................................6-21 Table 6.2. Cuttings classification and recommended removal equipment......................6-29 Table 6.3. Mesh size and equivalent US screen grade....................................................6-30 Mud at the exit pit. iii Notes iv Chapter 6: Mud Functions of a Drilling Fluid The main functions of a drilling fluid are to: • • • cool and lubricate the drill bit and string remove cuttings and transport them to the surface hold cuttings in suspension when circulation is stopped • line the hole with a thin, impermeable filter cake to minimize fluid losses • provide geological information about the formation • protect the formation from damage or contamination • transmit hydraulic power • partially support the weight of drill pipes or pipeline. Cooling and lubricating the drill string Considerable heat is generated by the cutting action of the bit and the drill pipe rubbing on the sides of the wellbore. The circulating drilling fluid effectively cools, lubricates, and prolongs the working life of the bit, while a slick filter cake reduces the frictional load when the pipe is pulled. Removing cuttings Efficiently removing cuttings from the bottom of the hole is essential to maximize drilling rates. As the mud ascends the annulus, the natural tendency is for entrained cuttings to settle out and sink to the bottom of the hole. It is vital to maintain an adequate annular mud velocity that exceeds the settling rate of the suspended solids, such that the resultant motion of the parti- cles is up toward the surface where they can be removed. The units for measuring velocity and volume are: • pump output (l/min) • annular velocity (m/min) • annular volume (l/m) Suspending and releasing cuttings A drilling fluid should be thixotropic. This means that when mud circulation is stopped, the mud should have sufficient gel strength to hold the cuttings in suspension until they are transported to the surface. When circulation resumes, the mud should revert to its lower viscosity so the cuttings may be carried to the surface. You should check the sand content of the mud from the flow line and after being processed by all the solids control equipment to verify that the sand is being released and not being recirculated down the hole. Any sand carried forward will cause serious abrasion to pumps and equipment. Whenever possible, do not allow the sand content to exceed 1%. Forming a filter cake When porous formations are encountered, the drilling fluid will deposit a thin, impermeable filter cake that minimizes fluid loss and consolidates the formation. This wall- building property of mud is enhanced by the addition of bentonite, whose colloidal nature and platelet structure effectively seal the formation. Horizontal Directional Drilling Training Program Providing geological information Inspecting the cuttings removed by the shale shaker will provide geological infor- mation about the formation you are penetrating. Protecting the formation A drilling fluid must be carefully selected to minimize formation damage. Whenever possible, never use a fluid that will react with the formation. Transmitting hydraulic horsepower The role of the drilling fluid in transmitting hydraulic horsepower is becoming more important due to the increasing use of downhole motors, turbines, and hydraulically operated downhole equipment. The bit hydraulics and pressure drop required by any downhole equipment must be carefully considered when planning a mud program. Optimum hydraulic horsepower should be available to assist in cuttings removal while drilling hard formations. However, if the formation is very soft, the size of jet nozzles should be increased. Although this will reduce the hydraulic horsepower at the bit, the lower jet velocities will allow you to use a higher pump rate, resulting in increased hole cleaning. The lower velocities will also help avoid hole washouts and irregular trajectories, especially when drilling a deviated hole. The flow properties and mud weight greatly affect the hydraulics program and should be carefully controlled to ensure that the hydraulics of the system are within the required limits. Supporting the drill pipe weight The mud in the hole partly supports the weight of the casing and drill pipe because of the buoyancy effect. Savings in wear and 6-2 tear on rig equipment and electrical power consumed are additional factors attributable to mud buoyancy. Mud: Drilling Fluid Tests Drilling Fluid Tests Mud weight Use the following procedure to measure mud weight using a mud balance (Fig. 6.1): 5. Read the mud density off the appropriate scale and immediately clean the balance. 1. Place the base (pivot) of the mud balance on a level surface. 6. Use the following mathematical relationships: 2. Fill the cup (which should be clean and dry) with the mud to be tested. Tap the cup gently to remove trapped air. 3. Place the cap on the cup and rotate it until it is firmly in contact with the top of the cup. 4. Place the arm in position on the base, and move the balance weight until the arm is balanced horizontally. • specific gravity = lb per ft3/62.3 • mud gradient = lb per ft3/144 • mud gradient = lb per gal/19.24 • mud gradient = specific gravity/ 2.31 7. Calibrate the mud balance as necessary. When calibrated correctly, fresh water at 21˚C should give a reading of 1.0 (8.33 lb/gal). Fig. 6.1. Mud balance. 6-3 Horizontal Directional Drilling Training Program Viscosity: Marsh Funnel The Marsh Funnel (Fig. 6.2) is used to measure the funnel viscosity, which is the number of seconds required for the outflow of 946 cm3 (1 qt) from a standard Marsh Funnel containing 1500 cm3 (1.6 qt) of fluid. Use the following procedure: 3. With the Marsh Funnel held vertically, simultaneously remove your finger and start a stopwatch. Allow the mud to run into a clean, dry viscosity cup. 1. Check the orifice of the Marsh Funnel to ensure that it is free from any obstruction. 4. Stop the stopwatch when the level of the mud reaches the mark on the viscosity cup (946 cm3). Record this time, to the nearest second, as the funnel viscosity. Also record the temperature of the sample. 2. Cover the orifice with a finger and pour a fresh mud sample through the top screen until the fluid level reaches the bottom of the screen. 5. The Marsh Funnel viscosity of fresh water at 21˚C should be 26 ± 1/2 sec. If it is not, then replace the funnel, because it cannot be recalibrated. Fig. 6.2. Marsh Funnel. 6-4 Mud: Drilling Fluid Tests Viscosity: Rotational Viscom The Rotational Viscom (also called Fann Viscom) is also used to measure viscosity. There are several types of viscoms avail- able, but horizontal directional drilling (HDD) rigs are usually equipped with the Fann VGM six-speed viscom (Fig. 6.3). Fig. 6.3. Fann viscometer. All viscoms operate on the same principle. Mud is placed in the annular space between two cylinders. The outer cylinder (the sleeve) is rotated at constant preset speed. The effect of this rotation on the mud sets up a torque on the inner cylinder (the bob), which itself rotates until the torque in the restraining spring attached to the bob is equal and opposite to the torque applied by the mud movement. A numerical value is given to this torque by reading a dial attached to the torsion spring. The instrument is designed and built so that the plastic viscosity (PV) and yield point (YP) values can be calculated by using the dial readings obtained when the outer cylinder is rotated at 600 and 300 rotary speed. Notes on use of the viscom: • Change the gears only when the motor is running. • Clean the viscom thoroughly after use. To do this properly, remove the outer sleeve by rotating it slightly to release the lock and then pull the sleeve downward. Measuring YP and PV. To measure YP and PV: 1. Pour a fresh mud sample into the metal container provided with the viscom, up to the line marked in the container. 2. Position the container properly on the base of the viscom, and lift the base into a position such that the cylinder sleeve is immersed in the mud up to the mark on the sleeve. 3. With the gearing in the 600/300-rotary speed position, start the motor by putting the switch into the “High” (600 rotary speed) position. Allow the dial reading to reach a steady value, which you will record as the 600-rotary speed reading. 6-5 Horizontal Directional Drilling Training Program 4. Move the switch to the “Low” position and allow the dial reading to reach a steady value, which you will record as the 300-rotary speed reading. 5. Obtain the PV (in cp) by subtracting the 300-rotary speed reading from the 600-rotary speed reading. 6. Obtain the YP (in lb/100 ft2) by subtracting the PV from the 300-rotary speed reading (Fig. 6.4). 7. Obtain the apparent viscosity (AV) by dividing the 600-rotary speed reading by 2. Thus: 600-rotary speed readings. PV is the slope of the line joining the 300 and 600 rotary speed values (projected on the y axis) and the intercept of the extrapolated line is YP. Gel strength. To obtain a gel strength measurement: 1. Stir the same mud sample (by rotating the outer cylinder at 600 rotary speed) for 10 sec, change the gearing to the 300/600-rotary speed position, and turn off the motor after 10 sec. AV = θ600/2 2. Move the switch into the “Low” position, note the maximum reading on the dial, and turn off the motor. This value is the 10-sec initial gel in lb/100 ft2. where θ600 is the dial reading at 600 rotary speed and θ300 is the dial reading at 300 rotary speed. A flow diagram of dial reading vs. rotary speed can be drawn using the 300- and 3. Allow 10 min to elapse and then turn the motor on by moving the switch to the “Low” position. Note the maximum reading. This value is the 10-min gel in lb/100 ft2. PV = θ600 - θ300 YP = θ300 - PV θ 600 θ 300 } } 1 Fig. 6.4. Dial reading vs. rotary speed. 1 1 = Plastic viscosity 2 =Yield point 2 300 6-6 600 Rotary speed Mud: Drilling Fluid Tests Filtration (low-temperature test) The static filter-cake building and fluid loss control characteristics are measured using a filter press (Fig. 6.5). The low-temperature test is the only test used for HDD, and is carried out at room temperature and 100 psi differential pressure. 6 1 2 7 3 8 4 9 10 5 11 12 13 Fig. 6.5. Standard filter press. 1 2 3 4 T bar Pressure inlet Mud container Stand 5 6 7 8 Graduated cylinder Top cap Rubber gasket Cell body The American Petroleum Institute (API) fluid loss is reported as that volume (in cm3) of filtrate lost from the filter press in 30 min. Use the following procedure: 1. Before assembly, check the drain tube for any obstruction. Also, check the rubber gaskets. 9 10 11 12 13 Rubber gasket Filter paper Wire mesh screen Rubber gasket Bottom cap with drain tube 2. Carry out the assembly in the following order: base cap, rubber gasket, wire screen, one sheet of filter paper (Whatman n˚50), and rubber gasket. Then lock the cell body into the base cap by turning clockwise until tight. 3. Fill the cell with a new sample of mud to within 1/4 in. (7 mm) of the top. Then put on the top cap (with rubber 6-7 Horizontal Directional Drilling Training Program gasket) and fit the complete unit into the filter press frame. Hold in place by turning the “T” bar on top of the stand until it is tight. 4. Insert a new CO2 cartridge below the regulator. 5. With the measuring cylinder in place below the drain tube, turn the pressure regulator handle clockwise until the pressure gauge shows 100 psi (689 Kp) and start the stopwatch as soon as the pressure is applied. 6. After 30 min have elapsed, note the volume of filtrate in the measuring cylinder to the nearest 0.1 cm3. This volume is the API fluid loss. If you note a fluid loss greater than 60, it should be reported as “No Control.” 7. Before disassembly, turn the regulator handle counter-clockwise to isolate the CO2 cartridge, and bleed the pressure off the cell by lifting the plastic pressure release valve. 8. Remove the cell from the frame and disassemble, taking care not to disturb the layer of filter cake on top of the filter paper. 9. Measure the thickness of the filter cake to the nearest 1/32 in. (mm). 10. Save the filtrate for the chemical analysis described later. 11. Clean and dry the equipment. Sand content Any sand not removed from the mud will have a detrimental effect on the life of the mud pumps and centrifugal pump parts. Thus, you should monitor the sand content of the mud closely. The following method determines the percentage of sand and other coarse material (having a particle size greater than 74 µ or 200 mesh) contained in the mud: 1. The equipment is composed of a plastic cylinder containing a 200-mesh screen, a funnel that fits onto the cylinder, and a graduated glass tube (Fig. 6.6). 2. Pour the mud into the graduated glass tube until it reaches the “Mud to Here” mark. 3. Add water to the graduated tube until it reaches the “Water to Here” mark. 4. Block the mouth of the tube and shake it vigorously. 6-8 5. Pour the mixture onto the clean 200-mesh screen. Add more water to the tube, agitate, and empty the contents onto the screen. 6. Repeat this operation until the tube is clean. 7. Wash any remaining mud off the sand retained by the screen. 8. Fit the funnel upside down over the screen, and invert the assembly and place it so that the funnel outlet is inserted into the mouth of the graduated tube. 9. Wash the sand off the screen with a spray of water into the tube. 10. Allow the sand to settle. Read the volume of sand directly from the graduated marks and record it as the volume percent of sand in the mud. Mud: Drilling Fluid Tests Fig. 6.6. Sand content kit. pH pH is a measure of the hydrogen ion concentration of a fluid, reported on a logarithmic scale ranging from just less than 1 to 14. Distilled water is neutral and has a pH of 7, while a fluid with a pH of less than 7 is considered acidic. A fluid with a pH greater than 7 is considered alkaline. pH is usually measured with pH paper or a pH meter (Fig. 6.7). pH is important because: • certain chemical additives perform better at certain pH levels • pH change may be an early indication of contamination • certain formations are pH sensitive and an 8.0 to 9.0 is required to reduce formation damage • drilling fluids are generally alkaline, with pH in the range of 8.0 to 12.0, with 9.0 to 10.5 being most common. 6-9 Horizontal Directional Drilling Training Program Fig. 6.7. pH meter. Chemical analysis 6-10 The following chemical analyses can be performed on drilling fluids: • cation exchange capacity (methylene blue test) • filtrate alkalinity • potassium content. • whole mud alkalinity • lime content • chloride content • total hardness (calcium and magnesium) • calcium content • calcium sulfate (excess gypsum) content It is beyond the scope of this chapter to derive or demonstrate all these measurements, which require a mud engineering background. If mud problems cannot be solved by the HDD engineer, you should have a drilling mud engineer from the oil industry come to the site and conduct all the necessary tests. However, the basics of clay chemistry are reviewed below, since HDD mud is usually simple bentonite mud. Mud: Clay Chemistry Clay Chemistry The most commonly used drilling fluid is mud made up with water as the continuous liquid phase (a water-based mud). Various solids are present as a result of drilling, and others may be added to alter the characteristics of the mud to meet operational requirements. Moreover, for HDD, environmental considerations further limit the materials that can be added to water to fabricate the mud, since it is almost impossible to control or confine mud returns. To fully understand the effects of various additives on water-based mud, you must first understand the basics of elementary chemistry. Basic chemistry Pure substances are composed of a single element or compound. An element is a material made up of only a single atom. When two or more different kinds of atoms react to form a new material, the resultant material is called a compound. Thus, sodium (Na) and chlorine (Cl) are elements, although Cl normally appears as a Cl molecule resulting from the combination of two Cl atoms. When Na and Cl react, a new material, sodium chloride (NaCl), is formed. This new material is a compound composed of two different kinds of atoms. When elements or compounds are mixed without a chemical reaction taking place so that the original materials retain their identity, the result is simply a mixture. An atom is the smallest particle of an element, exhibiting all the chemical properties of that element. Its structure determines the chemical and physical properties of the ele- ment and different structures produce different elements. An atom is made up of a nucleus surrounded by orbiting electrons of varying numbers and different orbits or shells. The nucleus contributes most to the mass of the atom and consists of protons and neutrons. The proton is a fundamental particle of high mass with a positive electrical charge. Neutrons do not have an electrical charge. The mass of a proton is almost identical to that of a neutron and far greater than the mass of an electron. In all atomic nuclei there is a surplus of protons, so that the nucleus always carries a positive electrical charge that is counterbalanced by an equal number of negatively charged electrons, making the whole atom electrically neutral. It is the configuration of the outer shell of orbiting electrons that gives the atom most of its individual chemical properties. Atomic and molecular weights The atomic weight of an element is determined by the number of protons and neutrons contained in its nucleus and, to a lesser extent, the number of electrons. For example, originally the oxygen (O) atom was used as the standard by which to compare all other elements. (Today, atomic weights are more accurately based on the carbon isotope C12). The O nucleus contains eight protons and eight neutrons and has an atomic weight of 16. Some typical atomic weights (based on C12) of common elements are: • hydrogen (H): 1.00797 • carbon (C): 12.01115 • oxygen (O): 15.9994 • sulfur (S): 32.064 • chlorine (Cl): 35.453 It follows that since compounds consist of groups of atoms called molecules, then the molecular weights of compounds can be calculated by simple addition. The approximate molecular weights of some common substances are as follows: 6-11 Horizontal Directional Drilling Training Program • water (H2O) = (2 x 1) + 16 = 18 • carbon monoxide (CO) = 12 + 16 = 28 • sulfuric acid (H2SO4) = (2 x 1) + 32 + (16 x 4) = 98 Valence and chemical bonds The valence of an atom can be described as the number of H atoms it can combine with, and is determined by the number of electrons in the outer shell. Some elements with few electrons orbiting in the outer shell have a tendency to lend or borrow electrons from adjoining atoms. These elements are termed reactive and would include H and Cl. Atoms having given up or gained an electron are no longer at zero potential and are called ions. Those atoms acquiring a positive charge (i.e., losing electrons) become cations, while those atoms acquiring a negative charge (i.e., gaining electrons) become anions. Dissociation and equivalent weights In certain circumstances, it is possible to separate a molecule into ions by dissolving the material in a solvent. This process is known as dissociation, which enables the ions to become unattached charged particles. The equivalent weight of an atom is its atomic weight divided by the charge of the ion it forms (i.e., its valence). Clay chemistry The earliest type of drilling mud was “muddy water,” which provided the early rotary drillers with considerable improvements in hole cleaning when compared to plain water. Their initial experiments in dissolving soils and clays in the mud to increase viscosity were gradually refined until one type of clay was found to be ideal. This clay was Wyoming bentonite. It produced the maximum viscosity for the minimum amount of materials added. Wyoming bentonite is known chemically as sodium montmorillonite (Na-montmorillonite) and possesses properties that enable it to expand and absorb large quantities of water. It is these two characteristics, and its makeup of very small particles that have a huge total surface area, that govern its chemical and physical reaction in drilling muds. Montmorillonite 6-12 Montmorillonite was originally discovered in Montmorillon, France, and it appears in two forms, Na-montmorillonite and calcium montmorillonite (Ca-montmorillonite). Ca-montmorillonite. Ca-montmorillonite (commonly known as sub-bentonite) will only swell to less than half the volume of bentonite, and also produces slightly larger and thicker particles, thus limiting its suitability for producing a thin, impervious filter cake. Na-montmorillonite. Na-montmorillonite (bentonite) is an extremely high-quality clay used for drilling. It has the ability to swell when mixed with water to at least 10 times its original volume, giving good fluid loss control and filter cake properties. The primary use of Ca-montmorillonite is to improve particle size distribution, especially in areas where the mud system is not incorporating solids from mud-making shales, or in making sea water muds where improved particle size enhances the effectiveness of fluid loss control agents. Mud: Clay Chemistry The structure of clays Clay structure consists of fine-grained materials which, when dispersed in water, form particles of around 2 µ or less. These particles remain in suspension in the water, forming colloids. Montmorillonite. The structure of montmorillonite is unique when compared with + - + + + - + + + + other clays (Fig. 6.8). The crystal lattice structure consists of sheets of atoms that are much thinner and are more readily separable in water than those of other clays. Thus, montmorillonite clays exhibit a much larger surface area when added to water than do other clays. This is especially true for Na-montmorillonite. Cations Calcium montmorillonite + - + Silica Aluminum + - Silica + + + + + + + + + Cations Hydration water Montmorillonite Silica Aluminum Silica + Water Silica Aluminum Silica Silica Aluminum Silica Silica Aluminum Silica Sodium or Calcium montmorillonite Sodium montmorillonite Fig. 6.8. Water hydration of montmorillonite. Montmorillonite is made up of a great number of nearly flat, thin sheets, very similar to mica. These thin, sheet-like particles are themselves made up of three plateletlike layers (i.e., two outside, tetrahedrally shaped silica (Si) plates surrounding an octahedrally shaped aluminum (Al) plate [Fig. 6.8]). The clay platelet is negatively charged and has a cloud of Na or Ca cations associated with it. The monovalent Na cation will attract the negative platelet; however, the more positively charged, divalent Ca cation will exert an even stronger attraction on the negative platelets, as shown in Fig. 6.8. When the clay is hydrated, the bulk of the water absorbed is attracted around the platelets. A greater volume of water can be 6-13 Horizontal Directional Drilling Training Program absorbed by Na-montmorillonite than Camontmorillonite. Attapulgite. Attapulgite is a chain-structure clay of hydrous magnesium aluminum silicate. Attapulgite clays have been widely used to improve the viscosity of drilling fluids made up with salt or brackish water. One of the main attributes of attapulgite is that when properly dispersed and sheared, it produces as much viscosity in salt water as it does in fresh water. One drawback, however, is that it does not give any significant filtration control and additional chemicals must be used. Sepiolite. Sepiolite is a rod-structure clay similar to attapulgite, but is much more stable at high temperatures. Effects of adding positive ions Clay particles can associate in three ways: face-to-face, edge-to-edge, or edge-to-face, depending on the chemical balance. The linking of particles in these ways may proceed simultaneously, or one type may predominate. Face-to-face association, or aggregation, merely leads to the formation of thicker plates or packets. This decreases the number of individual particles and decreases the viscosity. Divalent exchange cations can cause aggregation. This is observed when gypsum is added to a hydrated bentonite suspension. After an initial increase in the viscosity (due to flocculation), the suspension will thin to some value of viscosity that is lower than the original viscosity of the suspension. Dispersion, the reverse of aggregation, leads to a greater number of particles and higher viscosity. Clay platelets are normally aggregated before they are hydrated and, as they hydrate, some dispersion takes place. The degree of dispersion depends on the electrolyte content of the water, time, temperature, the exchangeable cations on the clay, and the clay concentration. Edge-to-edge or edge-to-face association is a flocculation process that forms a “house of cards” structure. This also increases the viscosity. Particle linking is governed by the forces acting on them and the availability of particles to be linked. Anything that reduces the repelling forces between particles, or shrinks the absorbed water layer (such as adding a limited quantity of divalent cations, or high temperatures) will promote flocculation. Note that divalent cations (such as Ca when gypsum is added) will cause the clays to aggregate. Certain chemicals added to mud 6-14 neutralize the charges on the platelets, with the result that particles no longer associate edge-to-edge-to-face; the mud has been deflocculated. An example of a deflocculating chemical is lignosulphonate. Only a small concentration of this chemical is needed to fully deflocculate a low solids content mud, since there is a relatively small area on the edge of the plates where lignosulphonates are absorbed. Chrome lignites are used to deflocculate muds in high-temperature situations where lignosulphonates are ineffective. Salt clay. The effect of positively charged ions, such as Ca, is to flocculate bentonite muds by disturbing the balance of charges in the bentonite suspension. The presence of negatively charged ions, such as chlorides, will also reduce the efficiency of these types of drilling fluids by a similar mechanism. If the mud is to be mixed in salt water, bentonite will not economically provide adequate viscosity. Also, if large salt sections will be drilled, bentonite will be flocculated by the salt, giving poor rheology. However, salt clay, or attapulgite, can be mixed and will provide viscosity in the presence of strong electrolytes such as salt. The structure of attapulgite consists of needle-shaped particles of hydrous magnesium aluminum silicate. The structure requires shearing to provide viscosity, although it will not provide control of filtration or water loss. If attapulgite muds are used, some additional fluid loss control agent will be required. The most cost-effective materials are starches or carboxyl methylcellulose (CMC). Mud: Clay Chemistry Yield. The yield of a clay is defined as the number of barrels of 15-cp mud that can be produced from 1 ton of dry clay by adding fresh water. Fig. 6.9 shows the yield vs. viscosity curves for a range of muds. In general, there is little change in the viscosity for large additions of clays until a viscosity of 15 cp is reached, after which there is a large increase in viscosity for small increases in solids content. Pounds Per Cubic Foot 67.5 63.7 8.5 71.2 Pounds Per Gallon 9.5 10.0 9.0 B A 60 75.0 78.7 82.5 10.5 86.2 11.0 11.5 90.0 12.0 D C Viscosity in Centipoise 50 40 30 20 10 0 0 5 10 200 100 75 2 10 50 4 20 30 40 15 20 25 30 35 Percentage Solids by Weight 40 40 30 25 20 18 16 14 12 Yield (15 Centipoise Mud) in Barrels Per Ton 6 50 10 12 14 16 18 20 Percentage Solids by Volume 75 100 150 Solids in Pounds Per Barrel of Mud 45 50 Specific Gravity of Solids = 2.4 10 25 8 200 9 8 30 250 Fig. 6.9. Yield curves for four different clays (A through D). Clays have an essential role to play in the formulation of drilling fluids. Where there is no excessive formation pressure to counterbalance, a low-solids, high-viscosity mud with good fluid loss control can be achieved by adding high-yielding bentonite to fresh water. A yield in excess of 90 bbl/ ton can be anticipated. However, if the makeup water contains salts or certain ions, there is a marked reduction in the yield. This is caused by the cations in the makeup water that neutralize the negatively charged platelets and thus restrain them from separating and absorbing water. One way of partially overcoming this problem is to pre- hydrate the clay with fresh water and then add salty water to the slurry. The overall yield will be less than if just fresh water had been used, but an improved yield will be achieved over that obtained by hydrating with only salty water. Due to its plate-like structure, bentonite is a perfect medium for deposition on the borehole wall surface, where it forms a thin, compressible filter cake, minimizing fluid loss into the formation. Attapulgite is much better suited for mixing with salt water and gives a similar 6-15 Horizontal Directional Drilling Training Program viscosity to bentonite for the same concentration. A yield in excess of 100 bbl/ton can be expected. Rheology Introduction It is vital that you understand the quality of a drilling fluid under a wide range of operating conditions, and that you can control the various parameters of the fluid to ensure that it performs effectively. The drilling fluid viscosity is one such parameter. The science of flow and deformation of fluids is known as rheology. As a fluid flows through a pipe, there is a layer of fluid adjacent to the pipe wall that is stationary. As the point of reference moves from the pipe wall, the velocity increases and attains a maximum at the centerline of the pipe. The force required to move a unit area of a layer of liquid with respect to an adjacent layer is known as the shear stress. The rate at which one layer moves relative to an adjoining layer is known as the shear rate. For a simple fluid like water or glycerine, shear stress is proportional to shear rate, as illustrated in Fig. 6.10. Such liquids are classified as Newtonian. The slope of the graph is a constant K, and since shear stress is proportional to shear rate, it can be written: shear stress = K x shear rate ss K = ----- = vis cos ity sr Ss Fig. 6.10. Shear stress vs. shear rate for a Newtonian fluid. Ss = Shear stress Sr = Shear rate K Sr 6-16 Mud: Rheology Non-Newtonian fluids Unfortunately, drilling fluids are more complex than water and do not display constant viscosity over a range of shear stress/ shear rate ratios. They are classified as nonNewtonian fluids. The graph for a typical drilling fluid would be similar to the one shown in Fig. 6.11. As can be seen from the graph, no longer is the relationship of shear stress/shear rate a straight line, it is now a curve. In addition, the curve does not start at zero but at some positive value of shear stress, which indicates an initial resistance to movement. The slope of the curve K is continually changing, and since K = viscosity, the value of viscosity at any given shear rate is known as the apparent viscosity. Ss Fig. 6.11. Shear stress vs. shear rate for a typical mud. Ss = Shear stress Sr = Shear rate Sr Therefore, it is possible to plot a graph of apparent viscosity vs. shear rate for any given fluid, as shown in Fig. 6.12. Shear stress is normally expressed in lb/100 ft2, and shear rate is normally expressed in reciprocal seconds, or sec –1. Ss Fig. 6.12. Viscosity vs. shear rate for a typical mud. Ss = Shear stress Sr = Shear rate Sr In the field, a simple test to determine viscosity is to pour a mud sample into a Marsh Funnel and note the number of seconds it takes for a quart of mud to pass through it. The resultant measurement is known as funnel viscosity and is a quick test performed routinely by drilling crews (see page 6-4). 6-17 Horizontal Directional Drilling Training Program A more accurate instrument for measuring a range of apparent viscosity is the Fann VGM, which is also described on page 6-4. You can determine apparent viscosity in centipoise units by applying a simple formula to the observed readings. Because of the complexity of drilling fluids and the range of apparent viscosity that can be determined for various shear rates, a mathematical model became necessary to more accurately forecast the viscosity profile over a range of shear rates, given a minimum of basic data. Bingham plastic model Bingham developed his mathematical model to express plastic flow, and from it you can plot PV and YP. This is achieved by adding a sample of mud to a Fann VGM, noting the Fann dial readings at 300 and 600 rotary speed, and plotting a graph (Fig. 6.4). PV (in cp) = Fann reading (600 rotary speed) Fann reading (300 rotary speed) YP = Fann reading (in lb/100 ft2) PV (300 rotary speed) The Fann VGM is scaled so that the dial readings give the PV in cp units and the YP in lb/100 ft2. The formula can now be simplified as: Dial reading = YP + PV x (Fann rotary speed)/300 Fig. 6.13 shows the ideal curve produced for a non-Newtonian fluid. It is important to note in Fig. 6.13 that initially no movement takes place as the shear stress is increased from zero. This is because the gel strength of the fluid resists the shearing action. A transitional period follows as the fluid starts to flow, with increasing shear rate until a linear relationship is established between shear rate and shear stress. The linear phase is known as viscous flow and the slope of the line gives PV at 300 rotary speed. Extrapolating the straight-line part of the graph intersecting the shear stress axis gives the YP. Ss Fig. 6.13. Newtonian and non-Newtonian fluids. A 1 = Bingham YP 2 = Transition from plastic to viscous flow 1 3 = Plug flow 2 4 = True yield 3 A = Plastic 4 B = Newtonian B Sr 6-18 Mud: Rheology PV. PV is a measure of the viscosity produced by mechanical friction of the solids and particles present in the mud once the mud is flowing, plus the shearing effect of the liquid phase. As solids are ground down in size, their surface area increases and adds to the viscosity of the mixture. To maintain an ideal viscosity, drilled solids should be removed at the surface by settling or mechanical solids control. This subject is discussed in detail later in this chapter (page 6-26). The mud viscosity should be maintained at a sufficient level to carry cuttings to the surface and hold weighting agents in suspension. YP. YP is a measure of the electrochemical resistance to flow as a result of the electrical interaction between the surface of adjacent particles. The YP value is a function of several different considerations: • the surface charges present on the solids • the concentration of solids • the concentration and types of ions present in the liquid phase of the mud. High YPs (which, in general, should be avoided) can be caused in the following ways: • Salt, cement, or anhydrite contamination of the drilling fluid causes flocculation by neutralizing the negative charges on the clay particles. • Highly reactive shales disperse in the mud, resulting in an increased surface area exposed to attractive forces and leading to flocculation of the particles. Adding suitable chemicals, such as lignins and lignosulphonates, neutralizes the attractive forces and promotes deflocculation. Ca or magnesium (Mg) ion contamination should be precipitated out with soda ash, thus lowering the YP. In some cases, where the contaminant cannot easily be removed by precipitation (such as with Cl contamination) water can be added to reduce its concentration, but this action will also lower mud weight, so great care should be exercised. Gel strength. Gel strength is a measure of the electrochemical attractive forces present in a static liquid. A typical drilling fluid has a tendency to gel when allowed to stand for a while. This feature is very important as it allows cuttings to be held in suspension when circulation is stopped. However, excessive gel strength can cause problems, such as: • excessive pressure generated when resuming circulation • difficulty in separating drilled cuttings from the mud on the surface • excessive swabbing and surging during trips. Thixotropy, as previously defined (page 61), is the ability of a mud to change from a gelled state to a pumpable viscous fluid as a result of an applied shearing action, and to gel again when circulation has stopped. All good drilling fluids should be thixotropic. To determine the thixotropic value of a mud, tests are carried out with a Fann VGM. Readings are taken and noted after the mud has been allowed to gel for 10 sec, and again 10 min later. If a large difference in readings is apparent, the mud has a progressive gel. This implies that the gelling effect noted after 10 min would continue to increase with time until an unacceptably high gel strength was reached, necessitating a high pump pressure to break circulation. A small difference in readings between the 10-sec and 10-min gel strengths indicates a fragile gel, which is the desired condition. 6-19 Horizontal Directional Drilling Training Program Power Law model Power Law. While the Bingham plastic model gives satisfactory results at higher shear rates equivalent to a Fann VGM reading of 300 to 600 rotary speed, it is not as accurate at shear rates below 225 sec-1 (equivalent to a Fann VGM reading of 130 rotary speed). Since these lower shear rates are encountered in the annulus, a model was developed to cover these shear rates. A more accurate shear stress/shear rate profile over the whole range of shear rates from zero upward can be calculated from the Power Law formula: Ss = KSrn K = Consistency Index, dynes secn/cm2 Note: 1. 1.067 is a constant for the Fann viscom (converts dial readings of θ to lb/100 ft2) 2. 1 lb/100 ft2 = 4.788 dynes/cm2 3. Shear stress, dynes/cm2 = θ x 1.067 x 4.788 = 5.11 x θ The Consistency Index is calculated as lb - secn/100 ft2: K = 1.067 x θ300/511n Equation 1 Equation 4 which is often written: Sr = Shear rate, sec -1 K = θ300/511n Ss = Shear stress, dynes/cm2 = θ x 5.11 n = 3.32 log10 x θ600/θ300 Equation 2 n = Power Law Index (no units) K = 5.11 x θ300/511n Equation 3 Shear rate (sec-1) = rotary speed reading of viscom x 1.703 Equation 5 Fig. 6.14 shows a comparison between the Bingham plastic model, Power Law model, and actual curves for shear stress/shear rate. All three curves closely follow each other until the lower shear rates (i.e., annular shear rates) are encountered. Ss 30 1 20 Fig. 6.14. Comparison of Bingham and Power Law models. 3 1 = Bingham plastic model 2 2 = Actual mud 3 = Power Law model 10 Sr 50 6-20 100 150 Mud: Rheology n index. In the Power Law formula, n is a measure of the non-Newtonian behavior that a fluid shows over a range of shear rates. In the case of a Newtonian liquid such as water, oil, or glycerine, the n value = 1. Such liquids have a velocity profile 1 across a pipe, as indicated in Fig. 6.15. A fluid with a parabolic velocity graph (where n = 1 in Fig. 6.15) has very poor hole-cleaning characteristics, since cuttings tend to move and collect in areas of low velocity. A B 200 160 120 n = 1.0 n = 0.667 n = 0.5 n = 0.25 n = 0.125 n Ss = KSr 80 40 0 2 3 4 5 6 Fig. 6.15. Velocity profile of fluids with different n indices. 1 Liquid velocity (ft/min) 2 Radius (in.) The flatter characteristic produced by liquids with n values less than 1 have excellent hole-cleaning characteristics (low shear rates in the annulus give high annular viscosity, enabling cuttings to be carried to the surface). n is generally reduced by adding a viscosifier such as XC Polymer™. Reducing the n value produces a more pseudoplastic liquid that makes it more shear thinning. This characteristic leads to a lower viscosity at the bit (an area of high shear), which promotes increased penetration rates. Conversely, in areas of low shear, such as in the annulus, the viscosity will increase, thereby improving the carrying capacity of the mud. See Table 6.1 for approximate n values of various muds. A Drill pipe B Hole wall Table 6.1. Approximate n values of standard field muds. n value Approximate Mud type PV/YP 1 0/0 0.7–0.8 30/15 0.6–0.7 25/20 0.5–0.6 20/20 0.4–0.5 10/20 0.2–0.3 5/20 Water Weighed, dispersed bentonite mud containing a high proportion of drilled solids Low-weight, dispersed bentonite mud containing few drilled solids Non-dispersed bentonite/polymer mud Non-dispersed polymer mud Water/xanthum gum 6-21 Horizontal Directional Drilling Training Program K index. K, the Consistency Index, is a function of the quantity and type of solids present in the mud (control of K is similar to the control of PV). K is expressed as the viscosity of the drilling fluid at a shear rate of 1 sec-1. It is found graphically by extrapolating the tangent of the rheological curve until it intercepts the shear stress axis of the graph. If the graph Ss vs. KSrn is prepared on logarithmic paper, it will be a straight line with the slope of the line being n and the intercept on the Ss axis (with Sr = 1) being K (Fig. 6.16). The higher the K factor, the higher the shear stress will be. Consequently, the higher the viscosity will be, thereby exerting a greater retarding force in the annulus on the particles attempting to settle through the liquid. Circulating pressure losses, viscosity at the bit, and hole-cleaning ability are all affected by the K value of the mud. To minimize the viscosity at the bit and the equivalent circulating density, K should be maintained as low as possible (as long as hole cleaning is not adversely affected). With regard to PV, an increase in inert solids content will raise the K value (with little or no effect on n). In addition, K may be reduced by diluting with new mud or by using the solids control equipment effectively to remove solids. Adding XC Polymer will increase K while (at most concentrations) reducing n. Ss 1 Fig. 6.16. Power Law on loglog paper. n K Log Sr 300 600 Modified Power Law model One shortcoming of the standard Power Law model is that it does not allow for yield stress; i.e., the initial resistance encountered in a fluid before flow is established. In the Modified Power Law, yield stress is included and is expressed as follows: Ss = Ys + KSrn Equation 6 where Ys is yield stress. The yield stress is calculated from the readings of a Fann VGM rotating at 300 rotary speed; i.e., the 10-sec gel reading. 6-22 Of the three models discussed, the Modified Power Law most closely represents the characteristics of the majority of drilling muds over the whole range of shear rates. Slip velocity. Slip velocity is the rate at which cuttings settle in a stationary fluid. It follows that as cuttings are being transported up the annulus, the mean velocity of the particles or cuttings will be the difference between the mud annular velocity and the slip velocity, expressed as: Vp = Va - Vs Equation 7 Mud: Rheology The slip velocity can be estimated using the following equation: Vs = 113.4 x (PD(pp - p)/Kfp)1/2 Equation 8 For a particle Reynolds number above 2000, Kf is a constant at 1.5. For particle Reynolds numbers below 2000 (i.e., for most routine solutions): Vs = 175 PD(pp - p)0.667/(pµ)0.333 Equation 9 Equation 11 The average velocity of mud inside the drill pipe is given by: V = 24.5Q/(ID)2 The pressure loss in the drill pipe with mud in turbulent flow is: Pp = 7.7 105 p0.8 Q1.8 (PV)0.2 L/(ID)4.8 Equation 11b Annular flow. where µ = ((2.4Va/(Dh - Dp)) x ((2n + 1)/3n))n x 200K(Dh - Dp)/Va Equation 10 In the Power Law equation where n = 1, the velocity profile across the annulus is a parabolic curve, as shown in Fig. 6.15, clearly illustrating that the velocity varies with the distance from the side of the hole and from the outside of the drill pipe. It follows that there will be points where the annular velocity is greater than, equal to, or less than the slip velocity. The result is that some cuttings are not efficiently transported to the surface, and in extreme cases are recycled in the annulus. The lower the n value, the flatter the velocity profile becomes, and the more efficient the transportation of cuttings. The flat part of the velocity profile is known as plug flow and only occurs with non-Newtonian fluids. Critical velocity. The critical velocity (Vc) of a fluid is that velocity at which there is a transition from one flow pattern to another. If V < Vc, then the fluid is in laminar flow If V > Vc, then the fluid is in turbulent flow. Flow inside the drill pipes. Vc ((3n + 1)/4n))(n/(2-n)) = (5.82104 K/P)(1/(2-n)) x ((1.6/ID) x Vc=(3.878 104 K/p)1/(2-n) x ((2.4/(Dh - Dp))x(2n + 1)/3n)n/(2-n) Equation 12 The above equation assumes the flow pattern changes from laminar to turbulent at a Reynolds number of 3000. The average velocity of mud in the annulus is given by v, where: V = 24.5 Q/(Dh2 - Dp2) Equation 13 The pressure losses in the annulus due to mud in laminar flow are: Power Law: PA = (2.4V/(Dh - Dp) x (2n + 1)/3n)n x KL/(300(Dh - Dp)) Equation 13b Bingham: PA = (PV)VL/(60000(Dh - Dp)2) + (YP)L/(200(Dh - Dp)) Equation 13c The pressure loss in the annulus due to mud in turbulent flow (assuming Bingham model) is given by: PA = 7.5 105 p0.8Q1.8(PV)0.2/ ((Dh - Dp)3(Dh + Dp)1.8) Equation 14 6-23 Horizontal Directional Drilling Training Program Reynolds number The normally accepted flow patterns for various Reynolds numbers are as follows: Nr < 2000—laminar flow 2000 < Nr < 3000—transition from laminar to turbulent flow The pressure losses in turbulent flow are directly proportional to the Fanning friction factor, f, (a dimensionless number), which is in turn related to the Reynolds number (also dimensionless) given by the following equation. Nr > 3000—turbulent flow. It should be noted that Equations 11, 11b, 12, and 14 were developed assuming that the mud flow pattern changes from laminar to turbulent at a Reynolds number of 3000. If this assumption is not correct, a new set of equations needs to be developed for pressure losses in turbulent flow for both the annulus and inside the drill pipe (the pressure loss equations for laminar flow are unchanged). (Annulus) NR = 15.47(Dh - Dp)pVa/µ Equation 15 where µ is given by Equation 10. f is then found (usually graphically) and the annular pressure losses are calculated using the following formula: PA = pVa2Lf/(93000 (Dh-Dp)) Equation 16 Filtration Normally, the hydrostatic pressure exerted by the mud in the borehole is maintained above that of the formation pressure to prevent the formation fluids from passing into the borehole. This positive differential pressure from the borehole to the formation will, in a newly exposed section of borehole, cause an initial spurt of mud into the formation if it is porous and permeable. into the formation is called filtrate, and the loss of filtrate from the mud is called fluid loss or filtration. Assuming that the distribution of particle sizes in the drilling fluid is such that the pores in the formation can be bridged by suitably sized particles, the bridge will then build up by additional particles, forming the porous layer of filter cake. (If the formation is impermeable to the passage of drilling fluid, then no filter cake can form.) The fluid that passes through the filter cake • unnecessarily thick filter cake, leading to potential stuck pipe and swab and surge problems during trips • loss of fluid and expensive chemicals into the formation • unstable wellbore with the possibility of cave-ins. Controlling fluid loss and building a tough, thin filter cake are vital when drilling a well. Some problems that can occur as a result of excessive fluid losses are: Conditions affecting filtration There are two types of filtration encountered when drilling a well: static filtration and dynamic filtration. Static filtration is the filtration that occurs when the mud is not moving. This type of filtration normally results in an increased rate of filter cake deposition. 6-24 Dynamic filtration is the filtration that occurs when the mud is flowing. Due to the erosive effect of the moving mud, less filter cake is deposited under dynamic conditions than during static conditions. A state of balance is reached when the rate of filter cake deposition and the effects of erosion are Mud: Filtration equal, resulting in a uniform cake thickness and a steady fluid loss. Other parameters that affect the rate of filter cake deposition are time and the mud composition (pressure and temperature are also factors, but not applicable to HDD). After the initial spurt of mud has filtered into the formation, the volume of filtrate Q passing through the filter cake is directly proportional to the square root of the time t in seconds. By using the following formula on observed laboratory tests, you can predict fluid losses: t1 = time interval for fluid loss Q1 in min Time t Q 2 = Q 1 ---2 t1 where: Q1 = measured fluid loss over time t1 in cm3 Q2 = calculated fluid loss over time t2 in cm3 t2 = time interval for fluid loss Q2 in min For example, if the fluid loss is 4 cm3 after 7.5 min, the calculated fluid loss Q2 after 30 min will be: 30 Q 2 = 4 ------7.5 Q2 = 4 x 2 = 8 cm3 In an ideal situation, the laboratory test could be carried out over a 7.5-min period and the result multiplied by 2 to give the approximate fluid loss (Q2) over a 30-min period. This is not an accurate approximation with some muds, and it should be noted that the standard API test requires fluid losses to be measured over a 30-min period. Control of filter cake permeability Permeability of the filter cake is largely a function of the size, shape, and distribution of solid particles. Larger spherical particles tend to compact and create incompressible filter cakes. Colloidal particles below 2 µ give a better control of permeability. The best results are obtained with bentonite because of its colloidal, platelet-like struc- ture. Under compression, these platelets are progressively spread within the filter cake, thereby reducing its permeability. If a mud is flocculated, it will be necessary to adequately disperse it to achieve a thin, compressible filter cake. Filtrate can easily pass around flocculated groups of particles. Filtration control additives Clays. The fundamental fluid loss control agent for most water-based drilling fluids is bentonite with a wide distribution of particle sizes down to less than 1 µ. The colloidal, platelet-like structure is perfectly adapted to the production of a compressible filter cake, and is further assisted by the water of hydration surrounding each molecule. Regular bentonite treatments are necessary when solids control equipment is being used, because some smaller particle sizes are removed with the larger drilled solids. Starch. Starch is a very popular mud additive that reduces fluid loss. In warm water, the starch expands and absorbs some of the water, forming small, amorphous masses that plug the passages in the filter cake. 6-25 Horizontal Directional Drilling Training Program Dispersants. Adding dispersants to the mud helps form a resilient, thin, compressible filter cake by preventing flocculated particles from aggregating, and promoting an even distribution of particle sizes. Adequate mud dispersion allows more bentonite than normal to be used while still maintaining a low viscosity. Some dispersants with a colloidal nature, such as lignosulphonates and lignites, assist fluid loss control by bridging formation pores. CMC. CMC is a long-chain polymer that can reduce fluid loss, depending on the application. Different types of CMC are available, depending on whether the mud is plain bentonite, or bentonite with salt water. Measuring fluid loss by the various tests available is not a precise criterion by which to judge what is happening downhole—it is only an indication. Factors such as depth, formation, pressure, and temperature can significantly alter the acceptable fluid loss values. It is the responsibility of the mud engineer to establish what is an acceptable fluid loss figure for the job, and to make any necessary adjustments with the most suitable fluid loss control agents. Solids Control Introduction Controlling and removing drilled cuttings from the circulating mud is very important in all drilling operations. A correctly designed system must be able to process the full flow of mud from the hole at all times. Since the particles sizes can vary from colloidal clays of less than 2 µ up to rocks weighing a few pounds, a range of specialized equipment is necessary to meet this requirement. The primary objective of any solids control program is to remove all the cuttings on the first circulation. If this is not achieved and cuttings are recycled, they will be ground by the drill bit into progressively smaller particles until they cannot be effectively removed by the solids control equipment. When these fine solids below 2 µ accumulate in the mud, they give rise to high viscosity, poor filtration, and increased chemical treatment and dilution costs. The condition is particularly exacerbated when 6-26 drilling reactive shales containing Namontmorillonite, because as the particles hydrate, disperse, and then flocculate, there is a significant increase in viscosity. Some mud systems display a better tolerance to solids content than others, as illustrated in Fig. 6.9. Mud A has a constant viscosity with an increasing solids content until the critical point is reached, after which, for a small increase in solids content, there is a disproportionately large increase in viscosity. Mud D displays similar characteristics, but because it has a greater solids tolerance, the increase in viscosity due to increased solids content is delayed relative to Mud A. All muds will follow this characteristic curve, and unless the solids content is reduced by removal or dilution, they will reach their own critical point and become unpumpable. Mud: Solids Control Monitoring solids content solids content, and suitable for use on a weighted mud, is by solids retort. This method produces results that are approximate at best, since this instrument was designed to measure oil and not solids. The solids measured in this way include soluble salts, barite, commercial chemicals, and the drilled solids. The first indication of a solids problem will often be an increase in flow line viscosity. There are two methods of estimating the solids content of a mud. The first is with a nomograph, as shown in Fig. 6.17. However, remember that this nomograph is not suitable when the mud is weighted with barite. The second method of measuring 25 000 50 000 75 000 100 000 125 000 220 200 180 160 140 120 100 80 60 40 20 0 24 22 20 18 16 14 12 10 8 6 4 2 0 (Volume %) 120 (lb/bbl) 0 150 000 175 000 115 110 105 100 95 90 85 te ud M sc lid So w on t( en co Ch lo rid e e (lb ig /g ht al ) nt ) pp de In nt il O (v 80 m x c ol on um te e nt % ) 200 000 Fig. 6.17. Solids content of low-weight muds. It is standard practice for mud engineers to record total solids unless the operator specifically requests otherwise. You can calculate the amount of drilled solids present, but remember that the large potential error present when using the retort appears proportionally larger in the final drilled solids calculation. A more realistic interpretation of the potential solids problem can be obtained by the PV and Methylene Blue Test (MBT) results. PV should be maintained as low as possible, as it does not contribute to good, stable mud properties. Any increase in the drilled solids retained in the mud will be shown by an increased PV. The MBT will show an increase only if the solids contain reactive clays. Viewed together, the PV and MBT results provide a more meaningful and accurate presentation of drilled solids content than a solids retort result on its own. 6-27 Horizontal Directional Drilling Training Program Fig. 6.18 shows mud weight vs. percent solids content and indicates the range of percent solids content that can be present for a given mud weight. For example, with a mud weight of 12 lb/gal, the solids content can vary from 13 to 27.5%. The ideal operating zone is in the shaded area. 60 Percent solids 50 40 Fig. 6.18. Mud weight vs. solids content. 30 20 10 0 9 10 11 12 13 14 15 16 17 18 19 Mud weight (ppg) The solids removal system Fig. 6.19 shows a possible solids size distribution in a mud prior to being processed by solids control equipment. The effective operating range of each of the commonly available separating devices is shown. The solids removal system can be compared to a chain composed of numerous links. Since any chain is as strong as its weakest link, it is essential that each separating device operate efficiently at full flow conditions. Failure to meet this requirement will result in increased mud costs because of the additional dilution required to maintain mud properties. 5 100 4 80 Fig. 6.19. Particle size distribution. Percent solids 3 60 1 = Desilter 2 = Centrifuge 40 3 = Desander 2 0 6-28 4 = Screens 1 20 5 = Screens 0 2 20 50 100 200 500 Particle size (µ) 1000 Mud: Solids Control Table 6.2 illustrates the range of cuttings that are typically encountered, their classi- fication, and the equipment best suited for their removal. Table 6.2. Cuttings classification and recommended removal equipment. Solids size range Greater than 2000 µ 2000–250 µ 250–74 µ 44–74 µ 2–44 µ Less than 2 µ Solids classification Large cuttings, cavings Medium cuttings API sand Silt Barite Colloids to clay The standard used for measuring particle size is the micron, which is a thousandth of a millimeter or 1/25,400 of an inch. The level of mechanical separation equipment Removed by 10-mesh screens 10–80-mesh screens Desander, desilter, mud cleaner Desilter, settling tank Clay ejector, centrifuge Centrifuge required on a typical onshore or offshore drilling rig is covered in the following sections. Shale shakers This is the first and most important solids control device that the return mud encounters. Normally, you will have two or three shale shakers onsite and they should be capable of handling at least 1300 gal/min of weighted drilling mud through 20- or 30-mesh screens. Shakers are classified by screen arrangement, location of vibrator, capacity, and screen type. Screen arrangement. For most soft-rock drilling, the multiple deck arrangement of parallel screens is preferred. This allows you to use very coarse 12-, 20-, or 30-mesh screens on top to remove the larger cuttings, cavings or mud balls. This reduces the load on the fine screens below, which improves separation efficiency and increases screen life. In more hostile offshore environments, older styles of shakers installed on floating rigs have proved to be very inefficient, and large volumes of mud have been lost because of the rig pitching during bad weather. The screens of these older-design shakers were prone to binding with larger cuttings and mud balls, thus impeding sep- aration, reducing screen life, and increasing mud losses. Position of vibrator. The vibrator on multiple deck shakers is generally balanced at the center of gravity, thus imparting a circular vibratory motion. This greatly improves cuttings transport down the screen. In the case of a vibrator located above the screen, the motion is less regular and this aggravates the buildup of cuttings on the discharge end of the screen. Screen type. The type of screen support is another important feature to consider when selecting shale shakers. The bottom-supported system used on most rig shakers is stronger than the top-supported system. If you use fine mesh screens, you will also need a backup screen of coarse plastic or stainless steel mesh. The shaker screens made to API specifications have square openings, although rectangular-shaped openings permit the use of heavier gauge wire with resulting improvements in screen life. A slight decrease in separation efficiency will be experienced with rectangular screens, but this is offset by the increased fluid capacity of these screens. 6-29 Horizontal Directional Drilling Training Program Screen selection is largely a matter of experience. A good guideline is to use the finest-mesh screen that will give minimum mud losses. See Table 6.3 for commonly available mesh sizes. Table 6.3. Mesh size and equivalent US screen grade. Mesh size (µ) US screen grade 762 541 381 234 177 104 74 44 20 30 40 60 80 150 200 325 Sand traps Sand traps or settling pits are included in this section because of their vital importance in the chain of solids control equipment. Anyone who has struggled to dump several feet of accumulated silt and sand from these traps will appreciate their importance. Sand traps should have as large an area as possible and should not be used as suction compartments, as this disturbs the settling action of the solids. The base of the tanks should be angled at about 45˚ toward a large dump valve. These tanks should not be dumped during connections unless it is unavoidable, as difficulties can occur when trying to close the dump valve with an accumulation of sand on the seat. Drilling is not paused when the mud engineer clears this blockage and, consequently, large quantities of clean mud can be lost when circulation is prematurely resumed. Ideally, you should clean out these tanks during a round trip when more time is available. During periods of high penetration, check the tanks more frequently and dump as required to avoid solids contamination of the mud. In this case, you should stop all drilling and circulation and do not resume until the dump gates are properly sealed. Desander Removing solids by gravity settling has long been an accepted practice in the industry. The methods vary from normal gravity settling pits or ponds, to cone-type mechanical equipment where higher gravitational forces are developed to improve settling (Fig. 6.20). Whatever method is 6-30 used, the principle remains the same and is governed by Stoke’s Law, which states that the settling rate of a solid above clay size is a function of the acceleration due to gravity, particle size, specific gravity of the particle, specific gravity of the liquid phase, and viscosity of the liquid phase. Mud: Solids Control 4 3 2 5 1 6 7 8 9 10 11 Fig. 6.20. Desander. mud mixture enters 1 Pressurized tangentially here 2 Feed in 3 Feed chamber 4 Liquid discharge 5 Vortex finder moves inward and upward 6 Liquid as a spiraling vortex rotation develops centrifugal forces in 7 Slurry cyclone are driven to the wall and moved 8 Solids downward in an accelerating spiral 9 Trinut for adjusting apex size 10 Apex 11 Solids discharge 6-31 Horizontal Directional Drilling Training Program For any given mud, one of the parameters that can be changed to increase the settling rate is the acceleration due to gravity in mechanical cone-type equipment: Vs = 2GD2(Pc - Pm)/92.6µ where: Vs = settling velocity (ft/sec) G = acceleration due to gravity (ft/sec2) D = largest cutting diameter (in.) Pc = density of cuttings (lb/ft3) Pm = density of mud (lb/ft3) µ = viscosity of mud (0.000673 x viscosity cp). G is increased by injecting the mud tangentially and at high pressure into the top of the cone (Fig. 6.20). The resulting circular motion produces a centrifugal force and a consequent separation of solids and liquids. The speed at which the mud swirls at a constant pump pressure is a function of cone size. The smaller the cone, the faster the mud swirls. For this reason, desanders, which remove large particles, generally have 6- or 8-in. diameter cones. Desilters, which remove smaller particles down to colloidal size, have 4-in. cones; 2or 3-in. diameter cones can be used to either discard colloidal material or recover barite. The whirling stream of mud entering near the top of the cone is directed downward toward the apex of the cone (and underflow) by a vortex finder extending into the cone body from the top. The larger and heavier particles settle to the outside by centrifugal force and migrate down the cone to the underflow, where they are discarded. The smaller, lighter particles and the liquid fraction reverse their direction, moving up the vortex finder pipe and back into the mud system. For the solids removal equipment to match a circulating rate, usually more than one cone must be used. A number of cones are manifolded together in parallel to increase their capacity. Desanding cones have the advantage of being able to handle large volumes of mud (up to 1000 gal/min), but have the disadvantage of making coarser particle size cuts (from about 80 µ upward), and therefore do not discharge the finer particle size solids. To obtain the best results from a desander, you should install it with its own centrifugal pump that feeds it at a steady pressure. Direct the overflow into another pit or compartment that is downstream from the desander pump suction. You can check whether the hydrocyclone is operating properly by placing a finger in the bottom discharge of the cone. When operating correctly, the solids will be discharged as a fine spray and you will feel a slight suction in the orifice. Desilter Generally, a 4-in. cone is used for desilting. It is important to link the cones in parallel so that their capacity can match the volume of mud being circulated. In a well-designed 4-in. cone, the median cut is about 40 µ. It is very important in desilting not to get a cut low enough to remove the finer clays, which contribute to good wall-building characteristics in the mud. Some important advantages to the proper desilting of drilling fluids are: 6-32 • thinner filter cake in water-based drilling fluids, minimizing the possibility of differential wall sticking • reduced drill pipe torque due to better filter cake characteristics • reduced amount of water dilution required for solids control, minimizing the amount of chemical additions, especially where low weights and fluid loss control are important • minimum mud weights with less liquid loss than is possible by discarding whole mud Mud: Solids Control • longer bit life obtained by removing abrasive drilled solids and sand • increased penetration rates • increased parts life on mud pumps and related equipment. Mud cleaner Mud cleaners are of particular value when drilling large-diameter holes with weighted drilling muds. The desilter will perform an efficient job in removing the sand- and siltsized particles that pass through the primary shale shaker. However, the desilter may discharge large amounts of the coarsely ground fraction of barite and liquid mud, so using it may get expensive. The mud cleaner passes the underflow from the cones through a vibrating screen. All of the liquid is returned to the active mud system, while the drilled solids are discharged. The median particle size cut is determined by the grade of screen mesh used. If screen life is acceptable, the 200-mesh screen is preferred. The mud cleaners are an excellent solids control tool and will result in considerable savings if you give careful attention to their installation and continued operation. A capacity of 800 to 900 gal/min is required of any mud cleaner to be effective. However, like all other hydrocyclone equipment, they are susceptible to alternations in the feed pressure to the cones. If the shakers are bypassed for any reason, the accumulation of large cuttings will rapidly plug the cones and render them inoperative. This must be avoided. You should pay particular attention to ensure that the shakers are not bypassed. Centrifuges The decanting centrifuge also works on the same principle as the hydrocyclone, except that the cone is installed in the horizontal plane and rotates at high speed (Fig. 6.21). Inside the cone, a screw conveyor mounted on a hollow spindle is installed. The conveyor rotates in the same direction as the outer cone but at a slightly lower speed. Mud is injected through the hollow spindle of the conveyor, where it is thrown outward into the annular ring of mud called the pond. The level of the pond is determined by the height of the discharge ports at the larger flanged end of the cone. As solids settle against the inner wall of the cone because of centrifugal force, the action of the screw conveyor pushes them along the cone toward the smaller end. They are discharged at the small end as dried particles, while the liquid is discharged at the larger flanged end through the discharge port. It is important when operating the centrifuge to dilute the mud with water at a predetermined rate to reduce the viscosity and maintain the separation efficiency of the machine. You should use a centrifuge on a weighted mud system when you observe increases in viscosity and gel strength. However, if the fine particles are removed by the centrifuge, you will have problems with fluid loss control and will need to add fresh chemicals. In certain mud systems, you need to compensate for this loss to maintain mud parameters, and add bentonite to restore the wall-building quality of the mud. The dilution water added at the centrifuge is discharged with the rest of the effluent, but treatment will be required to maintain the original balance of the system. The operation of the centrifuge can be changed such that in the case of an unweighted mud, or an inhibitive or oilbased mud where the liquid phase is very expensive, the liquid discharge can be saved and the underflow discarded. In this case, the only liquid loss is that adhered to the underflow solids. 6-33 Horizontal Directional Drilling Training Program 2 3 @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, ,,,,,,,,,,,, @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, ,,,,,,,,,,,, @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ @@@@@@@@@@@@ ÀÀÀÀÀÀÀÀÀÀÀÀ ,,,,,,,,,,,, 1 5 4 Fig. 6.21. Centrifuge. 1 Feed in 2 Bowl rotates, creating high centrifugal force rotates same direction as bowl, but at slightly 3 Conveyor lower speed to convey coarse solids 4 Coarse solids discharge (underflow) 5 Clay liquid discharge (effluent) A secondary application of the decanting centrifuge is in processing the underflow from the desilting hydrocyclones. As the hydrocyclones are designed to process the full flow of a mud system, the centrifuge can successfully handle the partial flow of the underflow, drying out the solids dis- 6-34 charged by the desilter. This type of operation is particularly advantageous when the liquid phase of the mud is very expensive. A further justification for this operation is where environmental controls dictate complete recovery of the liquid phase. Appendix A: Units and Abbreviations 2-D 3-D AC Al ANSI API AWG Az b, bbl BHA bpf C Ca Cl cm CMC cp cum °C °F DC Dh two-dimensional three-dimensional alternating current aluminum American National Standards Institute American Petroleum Institute American Wire Gauge azimuth barrel bottomhole assembly blows per foot carbon calcium chlorine centimeter carboxyl methylcellulose centipoise cumulative degrees Centigrade degrees Fahrenheit direct current hole diameter (in.) F ft gal H HDD HDPE HPb outside diameter of drill pipe (in.) Young’s modulus; modulus of elasticity Fanning friction factor (dimensionless) force feet gallon hydrogen horizontal directional drilling high-density polyethylene pipe hydraulic horsepower at the bit hr ID IF IFb hour inside diameter of drill pipe (in.) interfering force impact force at the bit (lb) in. K inch consistency index, Power Law model frictional drag coefficient Dp E f Kf kg km Kpa l L lb LW µ m ma MBT mg Mg min mm Mpa MSL n Na Nr Pa Pa kilogram kilometer kiloPascal liter length of annulus (ft) pound long wave mud viscosity (cp) meter milliangstrom Methylene Blue Test milligram magnesium minute millimeter megaPascal mean sea level exponent in Power Law Model sodium Reynolds number (dimensionless) oxygen outside diameter of drill pipe (in.) pressure loss for any section of length L (psi) Pascal annular pressure drop (psi) Pb pressure loss through the bit (psi) Pc sum of circulating pressure losses, excluding losses at the bit (psi) polycrystalline diamond compact particle diameter (in.) O OD P PDC Pd Pg Pp surface pressure required break gel (psi) drill pipe pressure drop (psi) ppg ppm Ps parts per gallon parts per million surge pressure (psi) Psp stand pipe pressure (psi) PV Q plastic viscosity (cp) circulation rate (gal/min) to Horizontal Directional Drilling Training Program R S SDR sec Si SMYS Sr Ss SW θ t T TCI TVD UHF A-2 radius of a drill pipe (in.) sulfur standard dimension ratio second silica Specified Minimum Yield Strength shear rate shear stress short wave Viscom readings (lb/100 ft2) thickness tension tungsten carbide insert true vertical depth ultra-high frequency v V Va Poisson’s ratio average fluid velocity (ft/min) average annular mud velocity (ft/min) Va(max) maximum annular fluid velocity (ft/min) critical velocity of mud (ft/min) Vc VHF VLF Vn very high frequency very low frequency velocity through nozzles (ft/sec) VOM Vp Vs voltage output meter average velocity of particles (ft/min) slip velocity of particles (ft/min) YP yield point (lb/100 ft2) Appendix B: Glossary A accuracy aggregation angular target anion annular velocity apparent viscosity as-built atom atomic weight attapulgite azimuth quality or state of being exact or precise process of clay particle association by face-to-face arrangement building or holding inclination to a particular number atom that has acquired a negative charge by gaining an electron fluid velocity in the borehole annulus value of viscosity at any given shear rate drawing depicting the final location of an installed pipeline smallest particle of an element, exhibiting all the chemical properties of that element measure of the number of protons and neutrons contained in an element’s nucleus and, to a lesser extent, the number of electrons chain-structure clay of hydrous magnesium aluminum silicate angle between the horizontal component of the borehole at a specified point measured clockwise from magnetic north B back reaming ball up Barlow formula barrel reamer beam bentonite Bingham plastic model bottom limit bottom’s up breakover bullet-nose reamer enlarging the hole from the exit side of the crossing clay material filling all the areas between the reamer teeth or cutter blades, so that the inserts make no contact with the formation formula used for calculating hoop stress reamer with a center shaft mounted concentrically in a cylinder of pipe with a wide range of diameters and lengths solid with a length at least five times its height sodium montmorillonite; expandable clay material that can absorb large quantities of water mathematical model to express plastic flow horizontal line denoting the base of the maximum allowable ground cover above a pipeline measure of the time required to displace a known quantity of fluid from the bottom of a hole to the surface bend through which the pipe must pass from its horizontal position on the rollers to its alignment with the hole (also: overbend) same as a barrel reamer, only with weld cap ends Horizontal Directional Drilling Training Program C catenary cation centralizer chisel teeth Class Location colloid compound compressive stress Construction Type conventional hole opener core buster cradle critical velocity cutter sets cuttings path that the pipe must follow to limit the stresses in the pipe and load on the cranes or sidebooms atom that has acquired a positive charge by losing an electron tool run in front of the primary cutter to hold the cutting assembly up in the center of the hole used when encountering cobbles or boulders embedded in normal soils class of a pipeline section as per applicable code particle 2 m or less in size material made up of two or more different kinds of atoms measure of the maximum compression of a material before it experiences failure type of construction for a pipeline section cast hole opener designed for use in rock; has a center shaft with three to six arms onto which are mounted roller cones set of blades in front of the hole opener designed to keep rock pieces from accumulating in the hole opener, and to centralize the hole opener pipeline roller attached to lifting equipment velocity of a fluid at which there is a transition from one flow pattern to another numbered teeth sets that are fitted onto hole openers formation materials removed from the hole and suspended in the drilling fluid D dead man decanting centrifuge deflocculation desander design pressure desilter dip poles direction dispersion dissociation dogleg severity dynamic filtration B-2 anchorage for the rig to oppose pull/thrust forces solids control device used with weighted mud systems process of breaking up clay particles by neutralizing the charges on the platelets via a chemical catalyst solids control device that removes sand-sized particles from a fluid value of the pressure used for pipeline design. solids control device that removes silt- to colloidal-sized particles from a fluid magnetic north and magnetic south poles borehole direction referenced to magnetic north process of breaking up clay particles; opposite of aggregation process of separating a molecule into ions by dissolving the material in a solvent total 3-D change of angle between two given points filtration that occurs when the mud is flowing Glossary E elastic instability elastic limit electron element entry angle entry point entry side equivalent weight exclusion area exit angle exit point collapse of a body even though the load applied to the body does not create stresses in excess of yield maximum stress under which a specimen may be subjected and return to its original length upon load release part of an atom with a negative electrical charge material made up of a single atom, or atoms of only one kind angle of entry of drilling tool into the ground; maximum of 18° and minimum of 6° point where the drill pipe enters the ground in front of the rig side where drilling tool enters the ground an atom’s atomic weight divided by the charge of the ion it forms during dissociation area delimited by vertical lines from the banks and the lowest of river bottom, scour level and dredging area, plus minimum pipeline cover angle of pipeline exit from the ground; maximum of 12° and minimum of 4° target expressed in distance from entry, elevation, and a position left or right or directly on a centerline F Fann Viscom filter cake filtrate filtration fishing floater flocculation fly cutter forward reaming fragile gel device used to measure fluid viscosity (also: Fann VGM) lining on the wall of the bored pathway fluid that passes through the filter cake into the formation loss of filtrate from the mud (also: fluid loss) retrieving tools from the hole following a tool failure blunt-nosed assembly on the end of the drill string; used to push the assembly through a pre-reamed pathway without sidetracking process of clay particle association, arranged either edgeto-edge or edge-to-face reaming device that has a center shaft with three or four spokes enlarging a hole from the entry side gel with a small difference in readings between the 10sec and 10-min gel strengths; desirable gel condition G gauge gel strength scale of measurement of a bit, reamer, hole opener, or wire measure of the electrochemical attractive forces present in a static liquid B-3 Horizontal Directional Drilling Training Program gravel shield reamer ground pressure G-Total unconventional bottomhole assembly used for rock and gravel crossings weight of the ground on top of the pipeline accelerometer reading that detects movement of the probe during forward and reverse current applications H hoop stress horizontal plan H-Total stress caused by internal pressure in the pipeline during testing or operations projection in plan view of the left or right position of the bore against a planned centerline magnitude of the earth’s magnetic field I inclination inside diameter ion angle between the vertical and the axis of the borehole at a chosen distance from entry internal diameter of a pipe atom having given up or gained an electron that is no longer at zero potential K Kennemetal teeth cutting teeth used on cutters and reamers L lost circulation failure of pumped drilling fluid to recirculate to the mud return pit M Marsh Funnel maximum bending stress maximum operating pressure maximum pipeline length maximum pipeline size measured distance mill tooth cutters minimum pipeline cover mixture molecules monel B-4 device used to measure fluid viscosity measure of the compression on the “outside fiber” and “inside fiber” of a pipe value of the maximum pressure in the pipeline during operation between 5000 and 6000 ft (1500 and 1800 m) 48 in. (1.2 m) total length of the drill pipe and that part of the BHA up to the probe’s sensor, measured from the entry point bladed teeth used in soft rock formations minimum soil height above the pipe to ensure that it does not rise toward the surface when empty combination of two or more components in varying proportions that retain their own properties compounds consisting of groups of atoms non-magnetic drill string Glossary montmorillonite mud cleaner sheet-like clay that can absorb water; key component of bentonite solids control device, used in conjunction with desanders and desilters N neutron Newtonian fluids nominal diameter non-Newtonian fluids north, geographic north, magnetic north, map nucleus part of an atom with a mass nearly equal to that of a proton and having no electrical charge fluids in which shear stress is proportional to shear rate inside diameter of standard wall thickness pipe, up to 12 in. fluids that lack constant viscosity over a range of shear stress/shear rate ratios direction from any point on the Earth’s surface toward the geographic north pole (also: true north) uncorrected compass north; differs from geographic north by the amount of magnetic declination at any given point Lambert north part of an atom that contains most of the mass and consists of protons and neutrons O operating pressure outside diameter overbend value of the pressure during pipeline operation external diameter of a pipe see breakover P PDC teeth pH pipe length pipe side plastic limit plastic region Poisson’s ratio position target pre-reaming profile progressive gel manmade polycrystalline diamond compact teeth; used in shales measure of the hydrogen ion concentration of a fluid, reported on a logarithmic scale from 1 to 14 distance measured along the course of the borehole from the entry point exit point; side where the pipeline exits the ground ratio of fine solids in the drilling fluid relative to the amount it can carry (also: plastic viscosity) region where a material is strained beyond the elastic limit, causing permanent deformation ratio of lateral strain to longitudinal strain subjective target (e.g., “straight ahead”) enlarging the hole before pulling the pipeline projection of the vertical position of the bore against a planned vertical profile gel with a large difference in readings between the 10-sec and 10-min gel strengths; undesirable gel condition B-5 Horizontal Directional Drilling Training Program proportional limit proton pullback punchout on a strain vs. stress curve, the point at which the plot is no longer linear part of an atom with high mass and a positive electrical charge pipeline installation point at which the drill string exits the ground R radial angle mismatch radial angle radial intensity mismatch radial intensity radius reaming reaming and pulling repeatability restrained pipeline stress Reynold s number rheology difference between actual and theoretical measurements indicator of improper coil connections to the Tru Tracker control box difference between actual and theoretical measurements indicator of the current strength measured by magnetometers expression defining the exact curvature of a line, expressed in feet or meters enlarging a hole from one size to another size of greater diameter reaming the hole simultaneously as the pipe is pulled ability to produce the same result again and again stress in one direction that creates a stress of the same sign in the perpendicular direction if the material is restrained from expanding or contracting in that direction numerical quantity used to characterize the type of flow in a hydraulic structure in which the resistance to flow depends on the viscosity of the liquid and inertia science of flow and deformation of fluids S sand trap sepiolite shale shaker shear rate shear stress shear thinning slip velocity solids retort stabilizer standard dimension ratio B-6 solids control device that collects sand-sized particles from the drilling fluid rod-structure clay similar to attapulgite solids control device that filters large cuttings from the drilling fluid rate at which one layer moves relative to an adjoining layer force required to move a unit area of a layer of liquid with respect to an adjacent layer pseudoplastic characteristic of a fluid that leads to lower viscosity at the bit rate at which cuttings settle in a stationary fluid method of measuring solids content of a fluid tool run behind the primary cutter for stabilization and to keep the primary cutter from bouncing and tilting ratio of the pipe outside diameter to the minimum pipe wall thickness Glossary static equilibrium static filtration Stoke’s Law strain stress when, at any point x, the moment of all forces applied to a beam, either at the right or left of that point x, values are equal filtration that occurs when the mud is not flowing states that the settling rate of a solid above clay size is a function of the acceleration due to gravity, particle size, specific gravity of the solids particle, specific gravity of the liquid phase, and viscosity of the liquid phase amount by which a dimension of a body changes when the body is submitted to a load, divided by the original value of the dimension force per unit area T temperature stress tensile stress test pressure thixotropy tool face traction stress tripping in tripping out tungsten carbide inserts stress caused by a temperature change measure of the maximum stretch of a material before it experiences failure value of the pressure used for pipeline testing property of a mud that allows it to change from a gel to a liquid when shaken, but to increase in strength upon standing; helps manage cuttings in suspension measurement of the position of the bias of a bottomhole assembly perpendicular to the axis of the borehole longitudinal stress entering the borehole with the drill pipe removing the drill pipe from the borehole cutting teeth on the roller cones of hole openers that cut or break the rock U ultimate strength point at which a material is strained beyond the plastic region, causing material failure V valence vertical depth vertical section viscosity viscous flow the number of hydrogen atoms with which an atom can combine vertical distance from the surface reference elevation datum to the probe’s sensor mathematical calculation to express 3-D positions in two dimensions measure of a fluid’s resistance to flow occurs when a linear relationship is established between shear rate and shear stress B-7 Horizontal Directional Drilling Training Program W water-based mud wireline leak wireline open wireline short mud made up with water as the continuous liquid phase electrical drain not yet large enough to stop probe operation zero continuity between the interface and the probe electrical spike causing the amp needle to move to maximum or blow the power fuse Y yield yield point yield stress Young’s modulus (of a clay): the number of barrels of 15-cp mud that can be produced from 1 ton of dry clay by adding fresh water measure of the electrochemical resistance to flow as a result of the electrical interaction between the surface of adjacent particles initial resistance encountered in a fluid before flow is established modulus of elasticity; ratio of unit stress to unit strain within the proportional limit Z Z axis interference B-8 magnetic interference