North American Special - Trenchless International

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HDD is the key to the Keystone Pipeline by Lyndsie Mewett TransCanada is undertaking an innovative, cost-competitive way to accommodate the expected growth in Canadian crude oil production over the next decade. The Keystone Pipeline project is unique compared with other projects in that it combines both the construction of a new 2,219 km pipeline in the US and the conversion of an existing 864 km existing pipeline from natural gas to oil service. HDD is essential to preserve the stunning landscape and achieve the necessary river crossings. “The challenge for the Pembina River HDD is ensuring we protect the special features and the natural beauty of the area while getting the pipe in place to deliver oil.” north america April 2009 - Trenchless International The 3,456 km Keystone Pipeline is also set to serve the interests of the United States by providing a secure and reliable supply of Canadian crude oil to meet the growing demand by US refineries and markets. TransCanada spokesperson Cecily Dobson says that the project is seen as an innovative and economic way to accommodate the expected growth in Canadian crude oil production during the next decade. Canada is the largest importer of crude oil to America, supplying 2.2 MMbbl/d. TransCanada has secured commitments for 910,000 bbl/d over an average term of 18 years for the Keystone Pipeline. Ms Dobson says that this represents 83 per cent of the system’s commercial design. Approximately 2,219 km of new pipeline is to be constructed in the United States. The Canadian portion of the project includes the construction of approximately 373 km of new pipeline and the conversion of approximately 864 km of existing TransCanada pipeline from natural gas to crude oil transmission. HDD: protecting the environment The project crosses several large rivers, including the Mississippi, Missouri, South Saskatchewan and Red Deer rivers, using horizontal drilling technology. TransCanada spokesperson Terry Cunha outlined the details of one HDD The pipeline The pipeline is set to be 76 cm in diameter to Illinois and 91 cm from the Nebraska/Kansas border to Cushing, Oklahoma. The pipeline will be buried with a minimum depth of cover of 1.2 m, depending on land use. The estimated operating pressure of new pipeline sections will be 9,930 kPa. The existing pipeline proposed for conversion to crude oil transportation will be operated at its current approved allowable operating pressure of 6,067 kPa. drive, the Pembina River crossing, west of Walhalla. The North Dakota State Forest Service acquired 432 acres of Pembina Gorge land in 1970 that now is Tetrault Woods State Forest. In May 2006, the Forest Service started to negotiate with representatives of Keystone Pipeline. The commission said TransCanada had to use HDD to bury the pipe in some locations, including parts of Pembina and Sargent counties. The technique will avoid the need to cut down trees in the Tetrault Woods state forest, and a Sheyenne River Valley scenic area in North Dakota's southeastern corner. In Pembina County, the crossing involved setting up a drill rig on the south side of the Pembina River. A 4 to 6 inch diameter pilot hole was drilled at an inclined angle, 7 to 9 metres below the surface of the ground and river. Sections of pipe were then hooked to the drill head and pulled on rollers through the hole, under the river, to the other side a distance of 1,051 metres. Bentonite clay was used to fill the hole around the pipeline. The drive involved approximately 15 workers in making the hole to feed the pipe under the Pembina Gorge. Mr Cunha said that similar to other HDD drives on the project, “the challenge for the Pembina River HDD is ensuring we protect the special features and the natural beauty of the area while getting the pipe in place to deliver oil.” Stakeholder involvement at length Not only is the Keystone Pipeline project unique in the fact that it involves the conversion of an existing pipeline, but the project's length means that it is being overseen by various provincial, state and federal regulators in both Canada and the United States. Ms Dobson says that a comprehensive stakeholder engagement program, developed and adapted to specific stakeholder needs according to the nature, location and potential effects, has been implemented. Stakeholders include landowners and residents; community leaders; federal, provincial and local elected representatives; aboriginal and Native American stakeholders; regulatory agencies; emergency services organisations; special interest groups; and, co-located right of way owners. “We recognise the importance of incorporating public input into our project plans,” says Ms Dobson. “We believe that through consultation we can address questions and concerns, and integrate important public input into our activities. “We share project information and gather input throughout the planning phase and incorporate feedback into our project design and implementation as appropriate,” she says. Converting to oil Converting the existing facilities and constructing new facilities in Canada, North Dakota and northern South Dakota began in 2008, while construction of new facilities in South Dakota, Nebraska, Kansas, Missouri and Illinois will begin this year. “It is estimated that more than 5,000 individuals will have worked on the design and construction of the Keystone project by the time it’s been completed,” says Ms Dobson. Ms Dobson says that the first task of the converting of the natural gas pipeline to oil service was to isolate the natural gas pipeline from the other pipeline to which it was interconnected. Existing natural gas in the pipeline was transferred to other natural gas pipelines using a portable transfer compressor. According to Ms Dobson, the greatest challenge of the conversion was to separate the converted pipeline from the other gas pipelines in a safe manner while ensuring there was no impact to existing shippers. Once the pipeline has been purged of natural gas, it will be ready for the removal of drip tanks and tie-over assemblies. Following the isolation of the pipeline, an in-line inspection using a pigging tool will be completed to ensure the integrity Timeline of the pipeline and that it is ready for oil service. Overcoming challenges In addition to the challenge of the HDD crossing, Ms Dobson said the weather was also a factor to be overcome. The Keystone project experienced some extremely wet conditions during the 2008 construction season. In North Dakota, it was one of the wettest years recorded in history. Ms Dobson said that TransCanada was forced to extend the construction season later into the year and postpone clean up until 2009. Keystone Wood River Pakota – expected to be in service in 2009 Keystone Cushing – expected to be in service in 2010 Keystone Gulf Coast – expected in be in service in 2011 Keystone Steele City – expected to be in service 2012 north america April 2009 - Trenchless International 66 67
Undersea HDD rescue in Saudi Arabia About ISTT/Membership The ISTT is the umbrella organisation for trenchless technologists in over 40 countries of the world. In 22 countries groups of trenchless technologists have their own national groups which are affiliated while the remainder are registered directly with the ISTT. In 2007-08 a pioneering HDD project was started using Trenchless Technology on the Berri Causeway and Abu Ali Island on the Persian Gulf coast of Saudi Arabia. Two parallel 3,050 metre long steel pipelines were to be installed under the bay. Trenchless technology covers the repair, maintenance, upgrade and new installation of underground utility services using equipment and techniques which avoid or considerably reduce the need for excavation. The ISTT promotes research, training and the more extensive use of trenchless technology through publications, co-operation with other NGOs, an annual international conference and an interactive website. oil and gas April 2009 - Trenchless International The smaller 24 inch pipe was to be used as an oil trunk line and the larger 30 inch, with a total steel pipe weight of more than 1,500 tonnes, to serve as a water injection line. The project was reported to be the world’s longest undersea HDD crossing. In November 2008, Middle East specialist HDD contractor Digital Connection Co Ltd of Al-Khobar, Kingdom of Saudi Arabia sought technical advice and assistance in the recovery of a 42 inch hole-opener that had become stuck along with the 3 km drill string beneath the seabed during a pre-ream pass on the second of two subsea pipeline crossings. The Berri Causeway pipeline project in the Middle East was always seen as a big challenge. Both the length of the crossings and the dimensions of the pipeline, which would weigh more than 1,525 tonnes, were testing the boundaries. While the first 24 inch oil pipeline had previously been successfully installed, unforeseen delays between the drilling process over a twelve week, non-working period had caused the drill string and the 42 inch hole-opener to become stuck on the second, 30 inch pipeline crossing and installation. They had little time to provide a solution to releasing the 3 km stuck drill string and 42 inch hole-opener. However, emergency discussions between TT-UK, the main contractor, and the local drilling contractor quickly led to a response. The company recommended using the Grundoram Taurus impacting hammer combined with steel pipe adaptations. The adaptations were designed and formulated to transfer dynamic impact performance energies through special steel fabrications adapted to the drill string via the Grundoram dynamic impacting hammer. Sharing the project information with other TT Group offices in the USA and For further information please contact TT UK LTD (+44) 1234 342566 fax: (+44) 1234 352184 email: info@tt-uk.com website: www.tt-uk.com Germany, TT-UK drew up a strategic plan together with a technical proposal on how they believed the drill string could be freed up using dynamic impact vibration energy. While similar successful undertakings had previously been carried out worldwide, few have been attempted for releasing stuck drill rods over such an exceptionally long distance, with each drill rod weighing 480 kg. Dynamic impact vibration energies have normally been placed on the end of product pipes for assistance in completing HDD (ram assist), or using HDD techniques for product pipe retrieval where the product pipe has become stuck. Few undertakings had previously attempted with stuck drill rods due to the enormous impact power that has to be contained onto a relatively small size drill rod (6/58th) from a large impacting hammer in a usable and controllable process. The Project owner is Saudi Aramco. The main pipeline contractor is Al Robaya and the HDD subcontractors are DCL and TATCO. The combined efforts from all companies and the personal attendance on site of Roger Atherton of TT-UK proved invaluable to the success and final retrieval of this problematic drill bore taking TT’s Grundoram and pipe ramming technologies to a new level of HDD ram assist, pipe/drill stem rescue method. Following bore-hole salvage the 3 km, 30 inch water injection pipe-line was finally and successfully installed on 13 January 2009. This rescue prevented significant financial implications such as the total cost of a lost drilled bore, any contractual penalties and ongoing cost delays in commissioning the final pipelines. Associated costs involved in planning a new bore and the actual costs of duplicating all the undertakings of a new bore/ installation. ISTT Membership/Directory Please complete the following form. Please note: Entry in the ISTT Directory is free to Corporate Members but only if the Industry Sector is completed. Alternatively, you can fill in this form online at www.istt.com. MEMBERSHIP TYPE Corporate Membership COMPANY DETAILS Company/Organisation Name: Name of Affiliate: Please write ISTT if there is not an ISTT Affiliate in your country. CONTACT DETAILS Title: First Name: Position: Department: Address: City: State/County: Zip/Postal Code: Country: Telephone: Email: Website: Trenchless technology is recognised as an Environmentally Sustainable Technology and is particularly suited to use in densely populated urban areas by reducing disruption to peoples daily lives, social costs (traffic congestion, damage to road surfaces and buildings, air quality), noise and dust. Trenchless technologies also have a considerably reduced carbon footprint compared to trenching in most situations. Ordinary Membership Last Name: Fax: INDUSTRY SECTOR Please select the industry sector that best describes your company, multiple selections can be made. Please check all relevant boxes. Agent Consultant Contractor Site Survey / Inspection / Leakage Detection Off Line Installation / Replacement Moling / Ramming Boring / Directional Drilling Pipe jacking / Microtunnelling On Line Replacement - Pipe Bursting / Splitting / Eating Repairs Internal Sleeves / Seals Resin Injection Robotic Repairs Renovation Cured in Place Sliplining (incl. spiral wound) Close Fit Lining Spray Lining Large diameter Systems (incl. segment lining, in situ lining and manholes) Equipment / Materials Supplier / Manufacturer Equipment Rental Public Sector / Utility Water / Sewerage Gas Electricity Telecoms Other Education / Research / Test Laboratory the international society for trenchless technology April 2009 - Trenchless International 68 69
Page 1 and 2: In this issue | Canada | USA | Japa
Page 3 and 4: Dec Downey Istt Chairman Trenchless
Page 5 and 6: EXECUTIVE DIRECTOR'S REPORT John He
Page 7 and 8: Pipes & People Prime Horizontal pip
Page 9 and 10: Trenchless in Toronto The 2009 Inte
Page 11 and 12: Events ISTT International No Dig 20
Page 13 and 14: projects April 2009 - Trenchless In
Page 15 and 16: Insertion of the liner takes about
Page 17 and 18: Alleviating flooding in Ashbourne S
Page 19 and 20: obotics April 2009 - Trenchless Int
Page 21 and 22: Risky business by Roderick Lovely a
Page 23 and 24: Deterioration Factors Distress Indi
Page 25 and 26: environment Supplying the community
Page 27 and 28: Record SWP down under Interflow, an
Page 29 and 30: north america April 2009 - Trenchle
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Page 33 and 34: disc cutter heads to work through t
Page 35: “We had a very tight window to ge
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