PROCEDURE FOR TRENCHLESS INSTALLATION METHOD

Doc. No. ID-PRC-09 Rev. No. 1

Date: 13-01-2022 Page : 1 of 15

ID-PRC-09

PROCEDURE FOR
TRENCHLESS INSTALLATION METHOD
(JALAN HAJI ABDUL MANAN: CH0.0C-CH96.0C)
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TABLE OF CONTENTS

SECTION PAGE

 Cover Page 1

 Table of Contents 2

1.0 Introduction 3

1.1 Scope
1.2 Definitions

2.0 General 3

3.0 Personnel 4

4.0 Plant and Equipment 4

5.0 Method of Installation 4

5.1 Preparation Works for Road Closure
5.2 Boring or Jacking
5.3 Horizontal Directional Drilling (HDD)
5.4 Emergency Procedure

6.0 Inspection Test Plan 13

7.0 Health and Safety 13

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TRENCHLESS METHOD PROCEDURE

1.0 INTRODUCTION

1.1 Scope

This procedure covers the minimum requirements of the pipeline construction

which related to trenchless method for the road crossing, water way crossing,
and underground crossing for Natural Gas Distribution System Project.

1.2 Definitions

CLIENT means GAS MALAYSIA DISTRIBUTION SDN

BHD (GMD) or its designated representative

CONTRACTOR means I Drill Pipelines Constructions Sdn Bhd

(IDRILL) or its designated representatives

SUB-CONTRACTOR means SUB-CONTRACTORS retained by

IDRILL to perform work

2.0 GENERAL

Pipeline construction which related to road crossings, water way crossing and
underground crossing shall be installed in accordance with drawings or proposed
HDD procedure which have been approved by CLIENT and in manner, which
satisfies all requirements of the authorities having jurisdiction over the crossing.
Impact on users of the roads shall be minimised and the safety of the roads shall not
be adversely affected.

CONTRACTOR shall obtain all permits necessary for all crossings when requuired.
Prior to commencement of work, a joint survey will be carried out together with the
client to finalise and confirm the crossing alignment.

CONTRACTOR shall determine the precise location of all-subsurface utilities or

structures in close proximity to the pipeline or which the pipeline will cross.
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3.0 PERSONNEL

CONTRACTOR shall employ only qualified personnel to perform the works under
safe conditions.

4.0 PLANT AND EQUIPMENT

CONTRACTOR shall use only appropriate plant and equipment. All such plant shall
be in good condition.

5.0 METHOD OF INSTALLATION

Subject to the approval of CLIENT and the relevant authority, CONTRACTOR may
use one of the following methods of installation.

 Boring or Jacking
 Horizontal Directional Drilling ( HDD )

5.1 Preparation Works for Road Closure

CONTRACTOR shall ensure the following documents/works are ready prior

to the subsequent work:

i. Traffic Management Plan & Road Diversion Plan

ii. Public Announcement
iii. All machinery and tools shall be pre-test and maintain in good
condition before the work, to ensure the work is not affected and
hindered by machinery breakdown.

For trenchless installation work which involved total road closure,

CONTRACTOR shall ensure the work can be completed within the duration
agreeable by CLIENT & Related Authority, otherwise emergency procedure
shall be carried out.

5.2 Boring or Jacking Pilot Casing

5.2.1 Working Pits

CONTRACTOR shall dig working pits to conform to safety

requirements on either side of the road to permit the operation of the
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boring of jacking equipment and the subsequent installation of the

pipeline to the specified profile.

No excavation shall be performed within 2 metres of a paved surface

or toe of fill. Drainage shall be maintained.

5.2.2 Boring or Jacking of Uncased Pipeline

This method of pipe installation shall be adopted as a substitute to

Horizontal Directional Drilling (HDD ) if the local authority and client
permits the contractor to perform such activities. For the purposes of
this project, Boring and Jacking method would only be used as a
substitute to HDD prior to client’s and local authority’s approval.

5.2.2.1 Pilot Casing

Boring or jacking shall be performed using pilot casing of a

diameter larger than the carrier pipe. The collar size of the first
casing pipe will be of a thickness to allow maximum control
over the direction and alignment of the casing during jacking
operations. Soil shall be removed through the pilot casing.

To remove the bored materials, mechanised tools (such a

auger) will be used. In the jacking method, the soil inside the
pilot casing will be removed manually. The contents of soil will
be logged to give advance warning of possible obstructions,
which may deviate the casing pipe from the approved
alignment. Boring and jacking shall conform to the line and
level specified on the approved drawings.
Simultaneously, or before the boring and jacking operation,
pipeline sections will be fusion joint and joint integrity visually
inspected in accordance with relevant approved working
procedure.

5.2.2.2 Carrier Pipe Installation

When the pilot casing has emerged at the opposite end of the
bore, the boring or jacking equipment shall be removed and
the carrier pipe temporarily held to the pilot casing. The pipe
shall then be advanced through the bore until the carrier pipe
is in the desired position, allowing adequate free pipe
(minimum 3 metres) for tie-ins and for inspection of pipe
surface. The pilot casing shall then be removed for re-use on
subsequent crossings.
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Alternatively, when the pilot casing has emerged at the

opposite end of the bore, the carrier pipe will be temporarily
welded to the pilot casing at the other end. The pilot casing
shall then be withdrawn pulling the carrier pipe in its location.

Pipe surface shall be inspected for damage and if, in the

opinion of CLIENT, the damage is unacceptable, the carrier
pipe shall be removed, coating repaired, cause of damage
rectified and the pipe reinstalled

5.2.2.3 Backfilling

Once the carrier pipe has been installed to the client

satisfaction, tie in shall commence immediately and the pipe
end raised to the level of the adjacent of feeder line. The
working pit shall be backfilled for safety reasons. Pipe end
locations will be pegged to allow easy reopening for tie-in
purpose.

Where the adjacent pipe is to be tied in within one week and

leaving the working pit open will not present an unusual safety
hazard; CLIENT may waive this requirement.

5.3 Horizontal Directional Drilling

5.3.1 Site Survey, Planning And Bore Design

 Site survey shall be carry out to identify the changes in elevation of

ground, obstacles (such as railway, waterway, or road/highway
crossings), utilities, traffic accessibility, soil type and ground condition.
Accessibility and geographical aspects of the jobsite, entry and exit points
will also be identified.

 Extensive investigation using radio detection shall be conducted to

finalize the position of the entry and exit pit. Trial hole will be excavated to
verify the location of any underground utilities.

 The horizontal distance and cross section profile determination of the

proposed bore shall be measured by using a measuring tape and auto
level survey equipment.
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 The drill profile shall be designed with a minimum depth of 2.0 meters
from the existing ground level. The depth will also be depending on
authorities requirements.

 Additional details of underground utilities shall be marked clearly on

the plan (if any) and reviewed at site. If necessary, final adjustment will be
made at site.
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5.3.2 Drilling Fluid

 Highly viscous (HI-VIS) drilling fluid shall be used to ensure hole

stability and reduce fluid loss.

 Drilling fluid of adequate funnel viscosity will give a good performance

for hole stabilization and will suspend and transport the spoils out from the
tunnel.

 The drilling fluid will be consistently monitored and maintained at

designed funnel viscosity with the Marsh Funnel equipment.

 Water with pH level 8 - 9 is ideal for mixing with bentonite.

 Additive such as Polymer is required to enhance the characteristic of

bentonite by building up a filter cake on the hole wall as well as enhance
the lubrication and cooling of the hole.

 pH strips will be used to test the pH level of water. If the pH strips

show a value below 7, soda ash will be added into the water to neutralize
the water acidity.

 Two mixing tanks will be used for bentonite mixing. One will act as
standby tank while the other one is being discharge.

 Properties of the bentonite are measured for every bentonite mixing to

ensure the consumption of bentonite is at the required properties.

 When the drilling fluid at the 1st tank is nearly empty, the discharge
valve of the 1st tank will be closed. At the same time, the discharge valve
for the 2nd tank will be opened. Through this practice, continuous
consumption of the bentonite can be achieved.

 Before re-mixing of bentonite into the empty tank, the tank will be
cleaned by flushing with water.
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5.3.3 Drilling Operation

i. SITE PREPARATION

 The drill path will be marked on the ground surface according

to the design path.

 A small pit measured approximately 2.0m in length x 1.0m

width x 2.0m depth, shall be dug at the entry and exit point to cater for the
cut material and also bentonite fluid. This pit will also serve to verify that
the vicinity is hazard free from third party utilities.

ii. SETTING UP AND CALIBRATION

 The HDD tracking equipment, receiver and transmitter are

calibrated before the start of the drilling.

 The transmitter will then be installed inside the drill head

housing and jointed to the 1st length of 4.57 meters drilling rod, which is
already onto the rig machine (rod length may vary, subject to HDD
machine manufacturer and size).

 The jacks of the rig machine will be adjusted accordingly until

the receiver shows the reading that the rig is set at the designed entry
angle.

iii. PILOT DRILL

 The 1st length of the drill rod guided by the drill head will be
rotated and jacked into the ground without any bending. Bending will be
started during the 2nd rod of drilling.

 When the end of the 1st drill rod reach the jaw of the rig, one
rod is considered drilled into the ground and the 2nd rod is then attached to
the end tail of the 1st rod. Bending will made at the 2nd rod drilling.
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 Through out the forward run phase, the location and direction
of the drill is monitored at every 4.57 meters interval (length of 1 drill rod).

 When the particular drill rod has achieved the zero bending
state, the location shall be marked as the exit point for the HDD pipes
during pulling stage. The entry point for HDD pipes shall be marked
whereby the drill rod is still subjected to zero bending (0 degree pitch).

 If the drill head strays off the course, the locator technician
shall inform the drilling operator via two ways radio communication. The
operator will make the required adjustment until the drill head gets back to
the original course.

 Upon completion of the pilot drill, ground level along the actual
pilot drill alignment will be taken at an interval of each drill rod. All the
readings of this ground level shall be incorporated in the HDD profile
drawings and will be converted and referred from the datum levels as per
the survey drawing.

Fig 4: Pilot drill cross section diagram

iv. BACK REAMING

 Once the drill head reaches the exit point, it is removed and a
fluid jet reamer is attached and the back reaming operation is reversed
from the exit pit towards the entry pit.
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 A swivel is installed at the back of the reamer to allow the drill

rods (which will then be connected at the back of the reamer during back
reaming) remain at a free from rotation condition while the rig machine is
rotating the drill string at the front of the reamer.

 During the back reaming activity, drill rods are extracted from
the entry point (at rig machine). In order to maintain a string inside the
tunnel during the hole enlargement, drill rods are jointed up at the exit pit
until the reamer reaches the entry pit.

 During the retraction of the reamer, the borehole will be

enlarge. Also the bentonite fluid will stabilize the tunnel and transport the
cutting materials out of the created tunnel.

 Once the back ream completed, then we are ready to pullback

the product pipe.

Fig 5: Back reaming cross section diagram

v. PULLBACK INSTALLATION (STRINGING OF PIPES)

 Upon completion of the back reaming process, the product

pipes, which are attached to the swivel beacon and guided with a swab
reamer, will then be pulled into the enlarged tunnel. The HDD operator
shall then obtain depth reading emitted from the swivel beacon upon
complete pulling of each rod.
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 The swab reamer used during pipe installation is to ensure that

the hole is properly enlarged and conditioned in order to reduce the
friction and drag resistance.

 A towing head will be used and welded at the end of the

Client’s steel pipe (the end which first enters the bore hole). With proper D
shape shackle, the towing head is connected with swivel beacon. The
reamer is installed at the front of the swivel beacon.

 The string of the product pipes is placed on the excavated

trench for the HDD pipes of depth of 2 meters. The trench shall start from
the proposed entry point during pulling stage as marked during piloting
stage. This is to avoid the pipes from being subjected to any bending
during the pulling stage at the entry point before and during pullback.

 During the pullback activity, pulling pressure will be read from

the pressure gauge installed to the rig machine and recorded into the
record sheet to ensure that the product pipes are not over stressed.

Fig 6: Pipe pulling cross section diagram

 Once the reamer and towing head reach to the exit pit, the
reamer and swivel beacon will be dismantled. The towing head will be cut
out and the pipes will then be properly sealed.

vi. SITE CLEANING

 Upon the completion of all installation works, the drilling

equipments will be properly packed and prepared for demobilization.
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 Site area will then be cleaned from any dumped and unused
material.
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5.4 Emergency Procedure

The work shall be completed and affected road shall be reopen to the public
within the time frame agreeable by CLIENT and Related Authority. If the work
cannot be completed due to certain circumstances, CONTRACTOR shall cut
the pipe and the affected road shall be clean up and reopen to the public
within the time frame.

6.0 INSPECTION & TEST PLAN

i. Calculation for combined stress for HDD stress analysis shall not
exceed 40% of SMYS.

ii. Reaming work shall only commence after actual drawing and stress
analysis has been approved by SEC representative.

iii. Pipe pulling shall not proceed unless swivel beacon is attached
utilized.

iv. Entry and exit pit shall be trial pit to minimum depth of 2m

v. HDD profile curvature shall be a minimum of 1000 x O.D of pipe.

vi. Non-destructive test (NDT) shall be endorsed by approved third party

prior to pipe pulling.

7.0 HEALTH AND SAFETY

A. HEALTH AND SAFETY

The supervisor shall be responsible for the site safety. He shall be reporting
to the main contractor’s site representative in the event of an
accident/incident happens. Safety measures to be implemented are as
follows: -

i. Prior to any site excavation, a survey of the site shall be carried out to
determine the presence (if any) of buried third party cables or services.
ii. Warning signs and colored bunting shall be erected at the location of
overhead power cables.
iii. Warning signs (DANGER KEEP AWAY), shall be erected at all site of
excavation.
iv. Workers will be equipped with PPE.
v. Fire extinguisher will be provided at job site.
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vi. Traffic cones and wall barrier (if necessary) to be provided where
working at busy public traffic area.