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PROjeCts October 2010 - Trenchless International 38 Borouge pipes up to help China’s eco city Borouge’s new high stress crack-resistant BorSafe PE100 material is specifically developed for installation in difficult conditions. It was put to the test in China’s new eco city in Tianjin, where a much needed new water supply pipeline had to pass under a canal. bOrOuGe IS a market leader in pipe solutions for drinking water and sanitation, gas distribution and industrial applications and domestic heating and cooling systems. A leading provider of innovative and value-creating plastics solutions, Borouge is providing advanced materials for pipe systems that require easy installation and superior durability. Borouge Vice President for Business Pipe Unit Hu Wei said “By using pipe produced from our new high stress crack resistant PE100 grade, the local water company was confident to install the pipe under the canal using directional drilling, knowing that any surface damage would not reduce the life of the pipe. “Our commitment to working with partners throughout the value chain ensured the ideal materials were being used for the different sections of the pipelines.” the project was to supply water to a city which is taking shape in China’s tianjin Binhai New Area, situated 45 km from tianjin and 150 km from Beijing. It is the tianjin eco city which is being jointly developed by the Chinese and singaporean governments. the total area is over 30 sq km and the city expects to have 350,000 residents by 2020. One major challenge for the developers was that the existing water supply did not match the current demand, let alone the future requirements of the city. A new water supply line was commissioned with a total length of 4.5 km, starting at a point 80 m to the west of Jingshan railway and then following the left bank of the Yongding New River, passing under the Ji Canal, and then to the pumping station which will provide the water to the eco city. since the pipeline needed to be installed as quickly as possible to prevent the construction work being constrained, the tianjin tEDA water company was keen to use polyethylene (PE) pipe to increase the speed of installation. However they were very concerned that the section under the Ji Canal, to be installed by directional drilling, could Learn more about Borouge at www.borouge.com Borealis at www.borealisgroup.com sustain considerable surface damage from stones or other hard materials in the soil under the canal bed as the pipe was drawn into position behind the drill head. to allay their concerns, pipe manufacturer Cangzhou Mingzhu Plastics, supported by Borouge, was able to offer pipe manufactured from the new PE100 high stress crack-resistant material. Borsafe HE3490-Ls-H was specified for this section of pipeline as it is extremely tough and will resist the development of cracks and damage that may be caused during the directional drilling operation. the remainder of the pipeline was manufactured from the standard Borsafe HE3490-Ls Black PE100 compound. All the pipes were manufactured by the well known local pipe producer Cangzhou Mingzhu Plastic Co. Ltd that is part of the Hebei Cangzhou Dongsu Group and the project was successfully completed on schedule. C M Y CM MY CY CMY K Fantastic networking and social events Convention and Exhibition Centre NO-DIG 3–6 OCTOBER TRENCHLESS SAVE THE DATE International keynotes Southbank TRENCHLESS TECHNOLOGY bigger and better www.nodigdownunder.com.au
October 2010 - Trenchless International PROjeCts Piloting to success in jacksonville by Stephen Tait Mears Group, Inc. recently completed a 7,400 foot horizontal directional drilling (HDD) bore in Jacksonville, Florida, US, a design-build project that allows a regional energy producer to expand its natural gas pipeline to serve new facilities. TO cOMPLeTe The project, Mears drilled a 7,400 foot pilot hole beneath the st Johns River at a depth of 130 feet below river bottom to install the 16 inch steel pipe. It is an essential link in a 50 mile pipeline that ends at the Jacksonville Electric Authority (JEA) Greenland Energy Center. though just 1.4 miles of the 50 mile pipeline, which is owned by tECO Peoples Gas, the section under the st. John’s River proved the most daunting in planning stages. Director of Engineering for tECO Peoples Gas Mark Haney said “this was the biggest obstacle to go from one side to the other.” HDD was virtually the only option to install the pipeline through that area. Mr Haney said “Other than HDD, there were no other good options.” But project officials said the timing of the project was also a major issue. Mr Haney said that the pipeline providing service to the power plant will be operational by 1 January 2011. that means JEA was dependent on the pipeline being in place in time to move forward on the operation of the power plant. to help ensure a timely project, The Mears rig in action. tECO hired Mears to complete a designbuild project. Project Manager for J.R. Giese Operations–Mears’ sub-consultant–John Fluharty said “If it is not built on time you literally have a billion dollar power plant there with no fuel.” Mr Fluharty said design-build allowed Mears to drill a pilot hole months in advance to pulling product pipe to ensure the project was feasible. “tECO wanted to know that early enough in the process so they would know if they needed to go in another direction, and wanted a true partnership put together so they could work out all the issues related to this special feasibility hole we did in advance,” Mr Fluharty said. Design-build is relatively new to the HDD industry, Mr Fluharty said. Design-build offers a subtle but important difference from the typical procedure for HDD projects. In the typical process, a company such as tECO would hire an engineer to develop plans, procure a construction company to implement those plans and then construct the project – often called design-bid-build. Designbid-build requires multiple contracts. With design-build, however, a single company is hired to engineer and to build the project, all under a single contract. susan Hines of the Design-Build Institute of America says utilising designbid-build can create contention between the engineer or designer of a project and the company that constructs the project. she said it creates a disconnect between the two parties that can often turn contentious because of concerns of liability and litigation. For instance, Ms Hines said when the construction company finds changes need to be made to designs during “Other than HDD, there were no other good options.” construction, it takes paper work and dialogue for the changes to be approved and implemented. “It slows things down a lot,” Ms Hines said. In the end, design-build projects help to improve two important aspects of any project – money and time. Design-build projects cost at least 6 per cent less than design-bid-build projects and are constructed 12 per cent faster, according to the Design-Build Institute of America. At the same time, the institute reports that design-build projects earned the highest owner satisfaction than other project concepts. “One of the main advantages of designbuild is the fact that everyone on the design and construction job is on the same side,” Ms Hines said. “they are all sharing in the risks and the rewards of a job well done.” she added, “Owners save money, they save time.” Mears drilled the feasibility pilot hole for the project in November 2009 and product pipe was pulled in April 2010. Mears Project superintendent Mike Maxwell said the crew drilled from both sides of the st Johns River and intersected the two holes under the river – a waterway lined with stately homes and used mostly for recreational purposes. A 330,000 pound rig was used for the pilot hole on one side of the river and a 140,000 pound rig was used to drill from the opposite side. Mears utilised its 500,000 pound rig to perform the reaming and to pull the product pipe through the hole, Mr Maxwell said. Additionally, Mr Maxwell said, the crews reamed the bore to 24 inch diameter and then swabbed the hole before pulling the product pipe. the crew drilled through sandy silt before making it to clay for the drill’s running depth. “It was fairly easy going; we were able to use a jetting bit all the way through,” Mr Maxwell said. Mr Maxwell said the length of the drill combined with the unique aspects of the job, made it a satisfying accomplishment. 40 41 PROjeCts October 2010 - Trenchless International
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