Pro Pipe Services (PPS), Energy Contract Services and Mears Group, Inc. set a high standard in safety, design and planning on the HDD project.

Contracted by PPS, Mears installed a 10 inch diameter steel pipeline. The 1,635 foot line replaced the existing product line to make way for a road expansion project at Airport Road. This product line connects to a major oil refinery located in Billings. The project was planned by Energy Contract Services’ Project Manager Derek Pfeifer.

PPS representative Ron Marsh said “Safety came first and foremost in the design and was visible throughout the course of this project. Energy Contract Services worked together with the owner to bring a unique blend of expertise and construction savvy to the table as this project came into fruition.

“Without their due diligence and commitment to the high expectations set by management, this project would have not been such a smooth and enjoyable project to be a part of. Upfront planning of a project before the bid process is key to the success of any project.” Setting safety standards for HDD

The project commenced on 9 January 2009 when Mears set up its new million pound rig in a constricted area along Airport Road overlooking the industrial area of Billings. Installation of the new product line required careful consideration of the proximity of the existing line.

“By bringing Mears Group on as a part of the construction team, it was evident that the direct and professional approach that PPS and Mears employees displayed would result in success. Working together with the owner’s project management and field representatives, meeting those high expectations of safety and performance would not be a problem,” said Mr Marsh.

During pilot hole operations, Mears drilled along the designed alignment within 2 feet of the existing line and then navigated a tortuous 37 degree curve toward the exit on the north side of Airport Road.

Transferring drill pipe can be extremely hazardous without the right procedures and equipment in place. Using a Deckhand to manoeuvre drill pipe on and off the rig, Mears’ staff moved the drill pipe with precision. The Deckhand allows the operator to place and remove drill pipe on and off the drilling rig with 360 degrees rotation, rotational control of the pipe and lateral movement. It also allows the drill pipe to be loaded at varying angles depending on the rig setup and configuration.

Project Manager for Mears Ron Halderman said “Having the right people and right equipment are key components to any construction project, and this crossing was no exception.”

The new rig that Mears commissioned for this project has many safety features that are integral to its design, such as handrails and ladders strategically placed to safely assist the crew during drilling operations.

The right rig

The Mears’ million pound rig was built by Prime Drilling in Germany and custom designed for Mears – it is the only one of its kind in North America.

The rig features a non-restricted mud course inlet and includes a unique sliding mandrel option. The drill frame has a tubular construction rather than the more typical I-beam configuration, making the drill frame stronger and more structurally sound. The carriage is equipped with a sophisticated bearing system with precise tolerances between the drill frame and carriage. Factoring safety into its fleet, Mears specifically required a pipe loader to be incorporated in the design of this new rig.

Pipe loader

The pipe loader eliminates the need for any manual assistance on the drilling rig and the associated possibility for errors during drill pipe loading and unloading operations. It allows the drill operator to maintain full control of the drill pipe while it is being loaded in to the rig. This produces safer work stations for the wire splicers during pilot hole operation while they connect the steering wire through the drill pipe. Equipped with a smart system, which is able to prevent any incorrect movement of the carriage during pipe loading operations, the pipe loader eliminates such hazardous situations or fatal errors. Keeping employees out of harms way, the pipe loader keeps the operation of the rig running safely and smoothly.

The power plant that accompanies Mears’ new rig spread contains features that make the rig unique to the industry. Weighing in at 78,000 pounds – which includes all components: tractor, trailer and power plant – the overall sound level of the entire setup is half that of a similar rig of this size. The unique sound suppressed system keeps sound levels to a minimum during drilling operations.

Mears Group Asset Manager Karl Quackenbush said “Acquiring a larger rig with the strength, precision and safety elements to keep complex and large projects on schedule was a key factor in the configuration of the design. When we acquired the rig, along with its pipe loader, we strategically selected the equipment components to optimise safety and to be the best suited for projects that are complicated and large.” Vibratory foundation driver

In setting up the rig in preparation for drilling operations, Mears used its new vibratory foundation driver that drove steel piles in front of the rig to provide solid anchorage during its drilling operations. On this crossing, this state-of-the-art system installed the sheet piling in only 15 minutes. All the drilling operations, and in particular the pullback operations, benefited from this set up that gave outstanding stability and holding capacity. Mears said the vibratory system for installing and removing the drilling rig’s anchors is not only more efficient than other more typical methods, but is infinitely safer and more controlled.

The product pipeline string was fabricated in 800 feet lengths due to the limited space, and then it was welded together halfway through the pullback operation. “Pullback went extremely smooth. We had a perfectly clean bore that made it very easy,” said superintendent of the Mears Group Gale Sarkozi.

The project was completed on schedule, ending 31 January

“It’s really good to see this level of safety commitment and professionalism exhibited by everyone who participated,” said Mr Pfeifer.