HDD Risk Identification
Last Updated on Thu, 15 Oct 2015 | Horizontal Directional
Potential risks that are a part of all HDD projects include a failure to complete the bore, safety
of the public and workers, environmental issues, damage to surface structures, and striking
other underground structures. Risk reduction is the attempt to identify potential risks during
the planning and design phase so that they may be eliminated or reduced. A risk contingency
plan is often used by the engineer and/or contractor to help identify the major risks and
develop general plans and procedures for resolving them. Unexpected risks often occur. Risk
contingency plans are a starting point for determining the best course of action to overcome
the problem. The use of experienced contractors is also a benefit when encountering
unexpected problems. Their resourcefulness and experience at solving HDD problems will
often reduce delays and find alternative methods in order to successfully complete the HDD
project.
Failure to complete the bore is often the main concern, as the project would not be attempted
if the product pipe could not be installed. The following are some of the frequent problems
that can result in a failed bore attempt:
1. The HDD can lose circulation by drilling through voids, highly fractured rock, a
collapse of the bore hole fast, improper drilling fluids, or a migration of water. An
effective drilling-fluids plan and a suitable drilling rate for the subsurface conditions
around the bore are required. These are critical factors for maintaining circulation and
bore-hole stability. Circulation can be lost very quickly if voids are encountered and
cannot be resumed until the void is filled or the path to the void is sealed.
2. Obstructions can cause a failed bore if the drill bit, reamer, or product pipe cannot be
advanced past the object. If identified during planning, the best approach is to avoid
the obstacle. If the bore cannot be changed, an appropriate response can be developed
before installation begins. Typical obstructions faced during HDD construction are
cobbles and boulders, gravel beds, wood, bedrock, and construction debris or
foundations.
3. Hydrolock is a condition that may occur when the circulation from the bore hole is lost
and the subsurface formation is resistant to fracturing, resulting in a hydraulic cylinder
in the bore hole. This problem is common in fine-grained rock, frozen ground, and any
formation that is resistant to hydraulic fracturing.
4. Line and grade problems occur due to faulty tracking and steering or subsurface
conditions that prevent or hamper the proper steering. The improper matching of the
downhole tools to the subsurface conditions can also cause line and grade problems.
5. Bore hole collapse severely impacts the chances of success on any HDD project. Soft
or loose soils present a high risk of collapse during HDD operations. When a bore hole
collapses, there is an immediate increase in rotary torque and pressure and a decrease
or loss of circulation.
6. A failure or damage to the product pipe during HDD installation can occur due to an
improper ream bore hole, poor workmanship, and improper HDD design. The best
approach to avoid product-pipe failures is to establish conservative design criteria and
follow the pipe manufacturer's guidelines. It is also important to make sure that the
products specified in the design are actually the products delivered to the work site.
Another key factor in maintaining suitable product pipe is to ensure that all weld or
fusion connections are properly performed and tested.
7. Surface heave or humping is a condition that is usually a result of excess pumping of
drilling fluids after a loss of circulation. This condition can quickly pressurize the
formation and cause a heave at the surface. Heaving can also arise from reaming with
a barrel reamer without enough depth, which can result in a displacement of soil
towards the surface. Pulling the reamer or product pipe through the bore hole too
rapidly can also result in a surface heave.
8. Fortunately large surface collapses are rare. Heaving or humping the surface is a far
more common occurrence. Surface collapse is typically a result of a significant
overexcavation above the bore hole, which can be caused by large volumes of thin
drilling fluid used at high velocities, incomplete filling of the annulus with drilling
fluids for a large-diameter bore near the surface, or leaks in high- pressure pipes after
installation, which erode the soil above the bore hole.
Experienced and knowledgeable personnel are valuable assets in the successful completion of
HDD projects. While unforeseen problems do arise, most problems encountered during HDD
installation result from the decisions made during the planning and design phase or from the
lack of contractor qualifications for the proposed crossing. Largely due to the rapid increase in
HDD construction, the skill and experience of many HDD contractors are questionable. Many
contractors are new to the HDD field and have limited experience. This makes it all the more
important that owners and engineers make an effort to ensure that the contractors are qualified
for the specific HDD project. In most cases a HDD contractor who has experience installing
small-diameter pipe or communications cable is not qualified for a large-diameter pipeline
crossing. The contract documents and technical specifications are an important part of most
HDD projects. A key part of the HDD project's success is the contractor's full understanding
of the project requirements. With proper planning and design and the contractor's full
understanding of the project, the chances of a successful HDD project are greatly increased.