DCA NEWSLETTERNo.17 December 2004English Version

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Bulletin of the Drilling Contractors Association (DCA-Europe)Verband Güteschutz Horizontalbohrungen e.V.

Association des Entrepreneurs de Forage Dirigé

Charlottenburger Allee 39 • 52068 Aachen • Germany • Phone ++49/241/9019290 • Fax ++49/241/9019299

Foreword by our PresidentGerard P Hoogveld

Dear Members and colleagues in HorizontalDirectional Drilling,

our annual symposium Antwerp 2004 is behind usnow. The Radisson SAS hotel proofed to beexcellent for our purpose. Stories heard are: “I neverlost my attention”, “good lectures”, “perfect climate inthe conference room”, “nice bar”, “activeparticipation and engagement in workshops”, and“we have spoken with...”Dinner at the Horta, which in my memory was stillstanding in Brussels, was special. Mr Pelicaen fromHSS moved it for us to the centre of Antwerp. Welldone Mr Pelicaen! The Jewish area of our hotel,made me believe that we were in the safest area ofEurope in the present terrorist times.

Curtis Allen of Baroid and the president of DCCA inthe United States, was there this time. We arewaiting to hear from DCCA, how they change orhave changed into a subdivision of DCA, DistributionContractors Association. This is expected to happenany moment now, however it has not beenconfirmed as yet.

Hans Ringers and Denis Pellerin had a fantasticstory on the progress of HDD technique over the last10 years. They told us what all has changed over thepast years in HDD. Other matters have changed too.Not in the last instant, the numbers of DCAmembers. From an initial commencement with sixfounding members, to a maximum number of overseventy in the year 2002. At this moment, numbersagain drop a little.

In the last annual members meeting it was promisedto rethink the structure and rates of DCA. A new planwill be tabled for this at the next meeting. Voting foracceptance is expected to happen in order to try andgive a hand to parties where this would be possible.

Meanwhile two active workgroups try to make someprogress. The Dutch-German group for Education,have met once and have set a second meeting soonin Veendam, half way between the middle of Hollandand Oldenburg. Soil and Conditions group, tries tocome to a conclusion in January.

Other matters will be tackled, when you as memberslet us know and develop initiative for it. We needyour active help, time and input. We all work for whatwe believe in, however it is mostly based voluntarywork and sharing your experience and free time andengineering. Please let us know if you can help!

We trust that we soon hear from you and we lookforward to meet you all at our annual membersmeeting on February, 9th 2005 in Oldenburg.

I wish to all of you and your families a merrychristmas and a happy and successfull year 2005

Gerard P Hoogveld, your president

Drilling Contractors Association (DCA-Europe)Charlottenburger Allee 39D-52068 Aachen

Executive secretary:Dipl.-Geol. D. QuanteTelefon +49(0) 241-9019290Mobil +49(0)175-526-7801E-Mail: dietmar.quante@dca-europe.de

Office:Wenke Steenhagen-BlaßTelefon +49(0) 241-9019290Telefax +49(0) 241-9019299E-Mail: dca@dca-europe.deInternet: www.dca-europe.de

DCA NEWSLETTERNo.17 December 2004English Version

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10 years of Experience, Know How and Quality

DCA draws a positive balance

Arthur Graf zu Eulenburg, Chief Editor of bi-UmweltBau, reports from Antwerp:DCA – 10 years of experience, know-how andquality – this was the motto the DCA announcedto invite its members and guests to Antwerp, andthe response was unbroken. 120 participantssurely had no reason to regret their decision tofollow the invitation, for the scientific level of theevent was praised and recognised again andagain from various sides. In his welcomingspeech, executive secretary Dietmar Quantecalled the past ten years of DCA history to mind,beginning with the association’s foundation onDecember 1, 1994. Starting with seven foundingmembers, the DCA developed into an importantfigure in Europe in the meantime.

In this context, Quante referred to the mostsubstantial successes that the associationachieved for its field of business. The formulationand Europe-wide spreading of the technicalguidelines in three languages, the successfulintroduction of training courses for the crew atthe sites and those working on the devices, andthe support of science and research in the field ofthe horizontal drilling technique were exemplaryto Quante. Now it was important that the DCAdefined new and future oriented goals and tasks.This course had been discussed intensivelyalready during the past year in task groups, andnumerous suggestions and measures wereworked out that called for a translation into actionnow. That a lot is still left to do was alsoemphasized by DCA’s president Gerard P.

Hoogveld. Although the technique of horizontaldrilling had reached an excellent level in technicalrespects, and although it offered the cleanestsolution to lay pipelines in many cases, thismethod was too seldom applied in practice –often because of ignorance. Hoogveld invited allthose that were interested not only to getthemselves informed about the HDD technology,but also to start discussions with this field ofindustry and the DCA. This was also and explicitlydirected to the companies of the gas, oil, water,and cable industry and to the operating authoritiesof distribution networks. The annual DCAcongress offered an excellent platform.

“Look to the future but do not forget the past“– that was the issue of the lecture by two foundingmembers of the DCA. In their looking back on tenyears, Denis Pellerin of HDI and Hans Ringersof Visser und Smit Hanab examined the technicaldevelopment that could be achieved in thisperiod. The progress made in the areas of controltechnique, drilling fluids, drilling equipment,pipeline coatings, and the further development ofthe drilling devices from mini rig to the big drillingsites of more than 400 t pulling force, or the betterchances and requirements for qualifications werejust some of the aspects used by Ringers andPellerin to draw their picture illuminating the basissupporting today’s performances of horizontaldrilling. Drilling in permafrost, spectacular rockdrillings, or drillings including curves of 90° wereonly some outstanding results of this progress.

Stefan Roßbach of the Technical University inClausthal-Zellerfeld made clear that progressdoes not stand still. He was the recipient ofDCA’s Sponsorship Award of 2004 for hisdissertation about optimizing the process ofpulling in pipelines by the HDD method.Supported by Professor Dr. Tudeshki, Roßbachinvestigated whether and how vibrations had apositive effect when pipelines were pulled in andpresented his findings to an interested audiencein Antwerp.

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f.l.t.r.: H. Lübbers, S. Roßbach, Prof. Dr. Tudeshki

The vivid discussion after Roßbach’s explanationsshowed how interesting his approach was, but italso became obvious that many questions wereleft to answer before this technique can beapplied on sites. The DCA could win Klaus Küselas guest lecturer, the president of RBV. In frontof the DCA members, Küsel urgently appealed tothe supply industry to well observe theirresponsibilities to maintain the networks for thebenefit of the economically important supply

security and to maintain the extremely importantarea of competence of pipeline constructors.

“A secured supply and disposal claiming ahigh quality of machinery and trainedpersonnel is only possible, if a sufficientinvestment to maintain the networksguarantees a long-term supply,” said Küsel.An alignment of the European pipelinenetworks on the lowest level could not be thestrived for benchmark of a Europeanagreement, the RBV president criticized.

RBV President Klaus Küsel on the DCA Kongress

Technical Guidelines

DCA TECHNICAL GUIDELINESInformation and Recommendations for the Planning, Construction and Documentation of HDD-

Projects

DIRECTIVES TECHNIQUES DU DCA

Informations et recommandations pour les études, la réalisation et la documentation technique deprojects de forage horizontal dirigé

TECHNISCHE RICHTLINIEN DES DCA

Informationen und Empfehlungen für Planung, Bau und Dokumentation von HDD-Projekten

DCA NEWSLETTERNo.17 December 2004English Version

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Ladies on Tour

This year’s ladies’ tour on the occasion of the 10thannual congress of the Drilling Contractors AssociationDCA led to the old Hanse town Bruges, Europe’sCultural Capitol of 2002. Having been a centre formarkets and fairs already in the 10th century, HanseaticBruges became the most important commercial centreof Europe in the 13th and 14th century because of thetrade in cloth, furs, spices, and gold, as well as themoney trade of Italian bankers. With the fall of theHanse this blossoming period of the “Venice of theNorth” had an end. But since the time of industrializationleft the medieval town nearly untouched, many buildingsof architectural value could be preserved. The townBruges now belongs to UNESCO’s Cultural Heritageand is able to present 300 buildings that are classifiedas historical monuments.

On its way to the centre, the proficiently guided tour ofthe city passed the idyllic Beguine’s House that wasfounded in 1245 by the sisters of the Benedictine order.This way of women living together in a conventoriginates from the times of the crusades. TheBenedictines, however, always offered social servicesto their neighbours. Former poorhouses show thedecline of the blooming trading city Bruges at the end ofthe Hanse Passing picturesque city canals, wheretourist boats were cruising, the guide took the groupthrough small lanes into the centre of Bruges, themarketplace. Here the City Hall (Stadhuis) in aflamboyant gothic style, the former state chancellery(Civiele Griffie), a Renaissance masterpiece, and theromanic-gothic Basilica of the Holy Blood displaying anampoule of a blood drop of Christ that is adored as arelic can be admired. The Belfry is a tower of 80 m andcrowns the market place with its carillon from the 15th

century. Another highlight of the city tour was the visit toBruges’ Church of Our Lady.

Underlain by the sound of clattering horseshoes fromthe barouches and the babble of voices in the smalllanes, the group scouted the shops offering famousBrussels lace produced by the popular bobbin craft,as well as the shop windows of the chocolatiers whoinvite everyone to buy some of their treats. After adelicious lunch in the winter garden of a Brugesteahouse, the group returned to Antwerp.On Friday the diamond museum of Antwerp situatednear the station was planned. Apart from thegeological development of diamonds and theirmining, the ladies learned a lot about Antwerp’simportant diamond trade. During the tour cuttingtechniques were shown, as well as the quality criteriaof cut diamonds. Of course it was possible to admiremagnificent jewellery studded with diamonds fromhistory and present. This year’s ladies programmeended very pleasantly in an Antwerp café.

Golftournament

After the annual congress on friday afternoon agolftournament with 14 players where held at theTernesse Golf and Country Club. Very nice weathermade the afternoon, and the drinks on the very niceand correct Ternesse Golf Club have been verypleasant. On the day before around the dinner in theCity of Antwerp our president Gerard Hoogveldcongratulated the last years champion Mrs MargaNoorman with a big cup.

“Highest scorer” on friday this year was Mr Pelicaenof HSS. The DCA participants the following peopleended in the top Rankin:

Ray Clayton, Derrick, Handicap 8, 36 pts,Hans Ringers, VSH, Handicap 32, 34 ptMrs Marga Noorman, Handicap 22, 33 pts

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HDD-Workshops

The workshops, carried through for the first time on the occasion of

DCA’s annual congress last year, again met with a sound response and

approval.

The following issues were dealt with:

Workshop 1: Stains on Coatings in HDDChairmen: Gerhard Hermann

Hermann Lübbers, NACAPDr. von Ameln, E.ON Ruhrgas AG

The workshop first presented and discussed the requirements and specifications for steel line coatings. The

requirements and specifications were then considered in connection with the loads during horizontal drilling. It

became obvious that significant loads may occur in particular during storage of the line pipe on wooden supports

(storage at line pipe yard as well as storage during transportation and on site). These loads can be well above the

values specified. Also discussed were the loads acting on the coating material when supported by rollers as used

during draw-in operations. In this case too, significant loads may occur. However, they tend to be less severe than

the loads during storage on wooden supports.

Workshop 2: Contractual IssuesChairmen: Freek Noorman, Visser and Smit Hanab bv

Norbert Landesberger, TAU Ingenieurgesellschaft

Workshop 2 about “Contractual Issues” primarily discussed the approach to reconcile two contractual parties by

means of mediation that had been introduced in the morning by Prof. Robert Jackson of the Salford University in

Great Britain. Mediation principally is a method to solve a conflict between two contract parties out of court, where

all those involved, supported by an external and neutral third party, the mediator, are working out voluntarily and

autonomously and together a solution to their conflict that is directly related to the acute problem. The

fundamental prerequisite to mediation is that all contract partners act voluntarily, accepting, open-mindedly, and

confidential. Mediation offers the possibility to abstain from time- and cost-consuming court proceedings. The

workshop used a typical conflict between a client and a constructor for a role play. With the help of a mediator,

various groups tried to persuade the two contract partners to find an agreement. The result was that most groups

achieved a solution that was acceptable to both parties. Prof. Jackson explained in the ensuing discussion that

this example was a real one that was not settled by means of mediation, but only in court with immense costs

included. And in that case only one group was satisfied with the outcome, namely the respective highly-paid

lawyers of the two parties involved. In the second part of the workshop the participants intensively discussed the

issue “Soil Risks” and the related liabilities without finding a concluding result, however.

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Workshop 3: Recycling of Drilling FluidsChairmen: Hans van Putten, Cebo

Andreas Schulze, MI HDDArnold Wachtendorf, MI SWACO

The participants in workshop 3, which was headed by Hans van Putten of Cebo and Andreas Schulze of MI HDD,

discussed the issue “Recycling of Drilling Fluids”. The workshop was split into the topics “Environmental Issues”

and “Technical Realizations”. Main focus concerning the environmental aspect was directed onto the disposal of

bentonite and the related varying procedures on local levels and in the individual European countries. According

to some participants, it is one of DCA’s future tasks to achieve a standardized procedure of disposal on a

European level. During the second part of the meeting the participants discussed various technical possibilities of

disposal, the question of costs being to the fore as expected.

Workshop 4: Quality and Education

Chairmen: Gerard P. Hoogveld, LMR DrillingClaus Gaile, Hans Brochier

Workshop 4, which dealt with the subject “Quality and Education”, first discussed various quality systems. In this

context, Hoogveld introduced an excerpt from a publication by NSTT, where the quality standard of a construction

performance was defined as a product from several partial works of high quality. The failure at a decisive points,

like for example during the preparation of the work or the provisional soil inspection, would quickly multiply

because of the close interconnection of these partial works and lead to considerable problems in the further

course. During the following discussion about an improvement of quality standards in HDD drillings, the

participants talked about compiling a checklist for HDD drillings based on DCA’s guidelines. The demands on

HDD drillings were so complex and divergent that the participants saw an urgent need for action.

During the second part of the workshop the group discussed the issue training in the field of HDD on a European

level. Extensive experiences could be made in Germany already. Now it was important to transfer these

experiences to other European countries. The first meeting about an agreement in relation to training in the

Netherlands, which had been fixed during this workshop, was held already (see also page 8)

Outlook

On balance the result of the workshops is the really positive impression it left on the participants and heads.

Contrary to mere lectures, surely adding a lot to a broader knowledge of the matter, workshops encourage its

participants to actively and productively cooperate. This was impressively confirmed in Antwerp. The course taken

proves right and will be followed by the DCA in future.

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Further Information

Workshop „SOIL, CONTRACT & QUALITY”Chairmen: Gerald Hoogveld, Freek Noorman und Norbert Landesberger

“GUIDELINES FOR DESIGN, CONTRACTING AND EXECUTION OF HORIZONTALDIRECTIONAL DRILLING PROJECTS”

The guidelines will be finished in January 2005

The Work group „SOIL, CONTRACT & QUALITY” has been founded, due to the desire to emphasisethe understanding that “Soil” is the major element in a HDD project especially when a Lump Sumcontract solution is asked for.

The following items will be discussed in the paper

• QUALITY FORMULA• PROJECT PHASES, PROCEDURES AND MILESTONES• FLOW SHEETS FOR QUALITY ASSURANCE• CHECK LISTS FOR QUALITY ASSURANCE• GRAFICS ON DIFFERENT TYPE OF UNDERGROUND CONDITIONS• REFERENCES

The additional guidelines and checklists are made in here in order to assist and get the properattention of all parties engaged in an HDD project.

QUALITY ASSURANCE OF HDD VERSUS SUBSOIL AND UNDERGROUND RISK

Working on- and understanding SOIL is the unknown of a Lump Sum Project and thus the key toquality assurance or subsoil and underground risk. In most European countries the subsoil andunderground risk is a common term in the field of engineering and construction works. In view of thefact that the client is specifying what he needs and defines the choice of the location of the crossing,the subsoil / underground risk in the field of HDD can be defined as follows:

Subsoil / Underground RiskThe subsoil risk is an unavoidable remaining risk which can lead to unpredictable effects anddifficulties during the use of the subsoil respectively any related additional measures or delays of theconstruction works or any related damages of the construction, although - the person who providesthe subsoil / underground conditions, has done everything for the complete investigation andcharacterisation of the subsoil, groundwater and underground conditions with respect to the current,updated standards and laws, and although - the contractor had fulfilled the demand of his examinationand notice duty

(Englert 1995, Katzenbach 1995, modifed)

The definition includes also the companies or persons engaged in assisting the client for the technicaland geotechnical investigations, drilling design, tender and/or supervision, which are usually namedthe engineers or consultants.”

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HDD training in the Netherlands – The first meeting took place in Oldenburg

On November 8, 2004, the first meeting on the issue HDD training in the Netherlands was held inOldenburg at Zentrum für Weiterbildung (ZfW).

Participants:Mr Oetken, ZFWDr. Picksak, Bohrmeisterschule CelleMr Lübbers, DCAMr van der Werff, Visser and Smit HanabMr van der Meijs, Gebr. van Leeuwen Boringen B.V.Mr van Leeuwen, Gebr. van Leeuwen Boringen B.V.

The following can be stated as result from the discussion

1. All participants agree that the quality of work in the field of HDD can only be improved by meansof training measures of the people involved.

2. An adequate training, as it is performed in Germany now under the supervision of the DCA incooperation with DVGW (Deutsche Vereinigung des Gas- und Wasserfaches) and rbv / brbv(Rohrleitungsbauverband / Berufsförderungswerk des rbv) according to worksheet GW 329 doesnot exist in the Netherlands at the moment, but seems to be desirable and necessary.

3. The certification system customary in Germany as it was initiated by the DVGW for the whole gasand water industry does not exist in this form in the Netherlands.

4. All participants think it necessary, however, under the consideration of national conditions (laws,regulations) to install adequate training courses also in the Netherlands (later also in otherEuropean countries). The focus of the attention should have courses for machine operators andsite mangers.

5. In the view of all participants the following steps necessarily have to be taken:

5.1 Check and comparison of the customary regional typical job titles (Geräteführer = Driller,etc.)

5.2 Check and comparison of the job training regulations that are valid as prerequisiteaccording to GW 329 (skilled worker = LBO?, master = MBO?)

5.3 Reworking / translation of the courses’ content and adaptation to the national law5.4 Laying-down of the concept of training courses (teaching by topics in blocks, developing

modules within the courses, training outside the centre, admittance to examinationswithout having participated in courses, as well?)

5.5 Eventually looking for support by certificatories/insurances5.6 Eventually looking for suitable training centres

The date for the next meeting where this discussion should be continued wasfixed for December 20, 2004 at 10:00 a.m. at Visser & Smit Hanab in Veendam.

Information around the DCA-Office

The secretary of the DCA Mrs Claudia Katzenberger will get a baby in the beginning of january 2005.She will stop working for one year. Mrs Wenke Steenhagen-Blaß will be her substitute in the nexttwelve months. DCA wants to say thank you very much to Mrs Katzenberger for all the input for theorganisation in the last four years. We wish her and her husband a pleasant time with the baby and allthe best for the future.

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Company presentation: Atlas Copco – BHMT

We are happy to be able to welcome Atlas Copco – BHMT as a new DCA member

Atlas Copco BHMT1600 S. Great Southwest ParkwayGrand Prairie, Texas 75053-1226

USA

Atlas Copco recently acquired Baker Hughes Mining Tools from the Baker Hughes / Hughes Christensenorganization. The resulting company, Atlas Copco BHMT, will continue to be dedicated to the mining andconstruction industries and will be a part of the Atlas Copco Secoroc division. Atlas Copco BHMT has a longhistory in the Mining and Construction industry and we have been active in the HDD market for many years. Allof our products are manufactured in Grand Prairie, Texas under stringent quality standards (ISO 9001 and APIcertified).

We have Random Rock Split Bit Hole Openers in sizes ranging in diameters from 8” and up. These HoleOpeners utilize custom designed and manufactured “Random Cutting Structure” bit thirds. Each hole opener isdesigned, manufactured and assembled to the same strict standards as our rotary rock bits. In fact, Atlas CopcoBHMT is the first Rock Bit manufacturer to actually supply a finished split bit reamer to the HDD industry. We havea full range of Premium Quality HDD Rotary Pilot Bits – 4 3/4” Diameter and above (up to 17 1/2”). Many of theseproducts have been designed specifically for Horizontal Drilling and have many features that enable them to drillfaster and stay in the hole longer.

Also, we support a full line of conventional, large diameter hole openers ranging in sizes from 17 ½” to 60” indiameter. These hole openers utilize either Trojan B cutters (17 ½”) or Trojan H (> 17 ½”) which are fullyreplaceable/field changeable on either saddles or half-saddles. These cutters were formerly referred to as Mini Qand Q cutters but have recently been re-engineered to greatly enhance performance levels.

As with any products supplied by Atlas Copco, we provide our customers with the complete “package”, includingengineering and product support. Our customers can be assured that we will react quickly to meet and exceedtheir requirements.

If you have questions or require any additional information, please contact Atlas Copco BHMT at the numbers oremail address listed below.

Best Regards,

Dale RottoProduct Specialist – HDDAtlas Copco BHMTOffice: 972 337 9723Cell: 817 229 4218dale.rotto@us.atlascopco.com

Atlas Copco BHMT A Company within the Atlas Copco Group

1600 S. Great Southwest Pkwy. Phone: 800-527-1632P. O. Box 531226 972-337-9700Grand Prairie, Texas 75053-1226 Fax: 972-602-3135

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Information about Hütte & Co. Bohrtechnik GmbH

At the beginning of October 2004, the Casagrande Group decided to transfer the production of its works fordrilling devices “Hütte” to Italy. The sales of drilling devices, spare parts, and accessories, as well as theservice department will stay at the known location in Olpe, however. The products will be manufactured underthe known name “Hütte” at the works of Casagrande SpA in Italy. The company is one of the world’s leadingproducers of pile and anchor drilling devices, as well as all the necessary equipment for special earthmovingconstructions, with an annual output of more than 250 drilling devices. Its modern production centre, inaccordance with the strict European standards and of course working according to ISO 9001 for ten years nowalready, followed by Vision 2000 in the year 2002, is able to certify and offers all the advantages of a bigcompany with a distribution system into the whole world. Hütte states that the structural changes allow an evenbetter chance to answer the steadily growing demands of the international clients if an extensive machinery,standardized documentation, or short terms of delivery are concerned. The types HBR 609, HBR 605, HBR504, HBR 503, HBR 203 of drilling devices, and various drill stems and excavator-mounted carriages willfurther be standardized and produced. Still it will be possible in future, Hütte says, to offer drilling devices forspecial requirements.

Source: info, Siegbert Ottersbach

Vivento Technical Services GmbH & Co. KG wurde am 01.07.2004 gegründet„Mitgliedschaft im DCA war und ist eine logische Konsequenz“

Die Vivento Technical Services GmbH & Co. KG (VTS) wurde am 01.07.2004 gegründet und ist eine100%ige Tochter der Deutschen Telekom AG. Der Bereich „Düker- und Leitungstunnelbau“ wurdedieser neu gegründeten Gesellschaft zugeordnet, existiert bereits seit 1988 und ist als Bestandteil der

„Deutsche Fernkabel-Gesellschaft“,„DeTeLine Kommunikationsnetze“ und„Network Projects“

seit vielen Jahren eine feste Größe auf dem Markt der Planung und Realisierung vonDükerbauwerken in Deutschland. Es war - und ist für uns auch heute noch - unerheblich, in welcherBauweise und unter welchem Hindernis die Düker hergestellt werden. Die Auswahl der zu Einsatzkommenden Technologie erfolgt nach technischen und ökonomischen Rahmenbedingungen, wobeider Schwerpunkt in den letzten Jahren immer mehr auf der Horizontalbohrtechnik liegt. Deshalb warund ist die Mitgliedschaft im DCA eine logische Konsequenz, die wir auch in unsere neueFirma, gerne mit übernommen haben. Mit der Verbesserung der Bautechnologien haben sich nichtnur die Dimensionen und Längen unserer Düker vergrößert, sondern auch wir uns weiterentwickelt.Wir erfüllen nicht nur Planungsaufgaben, sondern übernehmen das gesamte Projektmanagment fürden Bau eines Dükers und den gesamten Service rund um das Bauwerk. Bereits vorher gab esinnerhalb der Firma Spezialisten, die sich mit diesem Thema befassten. Angefangen haben wir mitder Planung von Düker- und Leitungstunneln für die Deutsche Post. Das waren meistenteilsKabelrohranlagen kleinerer bis mittlerer Dimension, aber auch riesige Rohrpakete. So war es nur einkleiner Schritt über die Mitverlegung von Kabelschutzrohren für einen Stromanbieter zur komplexenVerlegung aller Medien in einem Düker. In den letzen 14 Jahren haben unsere Mitarbeiter für mehrals 400 Düker Ingenieurleistungen erbracht. Dazu kommen jährlich noch ca. 70 Tiefenlagemessungenfür Horizontalbohrungen und diverse Lage- und Tiefenermittlungen zur Bestandsdokumentation alterKabel und Rohre.Mit der Einführung der GW 329 hatte für uns als Ingenieurbüro natürlich die Qualifizierung unsererMitarbeiter als „Fachaufsicht für steuerbare, horizontale Spülbohrverfahren“ aller erste Priorität. Somitsind wir jetzt auch in der Lage, diese für kleine und große Bohranlagen anzubieten.

Source: info, Dipl.-Ing. Klaus-Dieter Hartung

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Herrenknecht HDD in operation worldwide.

China: HK150T is working on the East-West Gas PipelineAzerbaijan:: HK250F is drilling for the BTC PipelineSpain: HK400M drilled the Sea Outfall Pipeline through hard rock

Wherever pipelines have to be installed under obstacles, trenchless Horizontal Directional Drillingtechnology (HDD) is used. Herrenknecht Maxi and Mega Rigs have made a name for themselves inthe international business and proved their worth in numerous projects. With pull forces from 600kN to6,000kN, the Herrenknecht HDD range covers Modular, Trailer, Crawler and Frame Rigs. The specificproject requirements form the basis for the design of each individual rig. To ensure the successfulrealization of the projects, our customers receive comprehensive training and competent support byHerrenknecht specialists, whether the equipment has been purchased or rented.

Source: info, Herrenknecht AG Schwanau

The DCA Members Nacap Europe and LMR Drilling GmbH presented interesting HDDprojects at the 22nd International NO DIG Conference and Exhibition in Hamburg2004

At the end 2003 the DCA was invited to present two HDD projects at the 22nd International NO DIGConference and Exhibition in Hamburg in November 2004.

The following projects were presented (pictures of project 2, LMR Drilling GmbH)

Project 1: „The installation of a 1440m long pressure sewer DN 150 under the natural reserve areaReith and a side arm of the river Elbe in Hamburg Ochsenwerder“, by Nacap (Speech: HermannLübbers)

Project 2: Large Horizontal Directional Drilled crossings. Project mentioned and presented: SinusSetubal project in Portugal, by LMR-Drilling GmbH (Speech Gerard P. Hoogveld)

The 23rd International NO-DIG Conference and Exhibition will be hold in 2005 in Rotterdam. The DCAwill hold like in the year 2004 interesting lectures about current HDD projects.

source: www.no-dig2005.com

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Members inform Members

Current HDD Projects

Auflagenreiche Kreuzung des Oder-Havel-Kanalsvon Oliver Knopf, Moll prd

Die Kreuzung des über Geländeniveau liegenden Oder-Havel-Kanals mit 4 im gesteuertenHorizontalbohrverfahren zu verlegenden Leitungen war mit einer Reihe von ungewöhnlichen Auflagenverbunden. Die Moll-prd erhielt für dieses Projekt den Auftrag zur Planung und Ausschreibung des LosesHorizontalbohrungen und war während der gesamten Bauausführung im Rahmen der von denGenehmigungsbehörden geforderten Fachaufsicht B nach DVGW-Arbeitsblatt GW 329 als örtlicheBauüberwachung für die Bauherren tätig.

Das Projekt

Der geplante Ausbau der Havel-Oder-Wasserstraße (HOW) machte eine Neuverlegung der derzeitvorhandenen Mineralöl- und Kraftstoffleitungen der beiden Betreiber PCK Raffinerie GmbH und MVLerforderlich.

Zwei Leitungen, DN 700 und DN 500, sind Rohölpipelines und dienen der Versorgung der Total RaffinerieMitteldeutschland GmbH. Eine Stahlleitung DN 300 transportiert Mineralölprodukte in das nahe gelegeneTanklager Seefeld. Der vierte Düker ist ein HDPE-Rohr DA 450 und dient beiden Betreibern alsVersorgungsdüker. Der seitliche Abstand der parallel zu verlegenden Leitungen lag zwischen 8 und 14 m, dieLänge der Bohrungen zwischen 250 und 285 m.

Das Problem

Was die Länge und den Durchmesser der zu verlegenden Rohrleitungen betrifft, eigentlich kein Projekt mitherausragendem Schwierigkeitsgrad, aber ein Problem gab es doch: Der Oder-Havel-Kanal liegt höher als dasumgebende Gelände! Das allein eigentlich schon Anlass genug, mit besonderer Vorsicht an dieHorizontalbohrungen heranzugehen, leider kam hier noch hinzu, dass das Wasser von offiziell alsstandsicherheitsgefährdet eingestuften Dämmen und vermutlich nicht mehr überall intakter Kanaldichtung inseiner derzeitigen Position gehalten wird.

Zielseite (Nord)

+37,22

+28,56

+37,47

+32,00

+31,20

Startseite

Hmin. Überdeckung

R

maßgebendes GW-Potential

Abb. 1 Systemskizze Kanal und Geländeprofil

Auf jeden Fall war es eine nicht zu unterschätzende Gefahr, die eine Reihe von Maßnahmen zur Verhinderungeines Kontaktes zwischen Bohrungen und Kanal und zur ggf. notwendigen Havariebekämpfung zur Folge hatte.

DCA NEWSLETTERNr.17 – Dezember 2004Deutsche Version

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Die Auflagen

• Anhebung des Geländes an den Startpunkten der Bohrungen um bis zu 3m

• Um die Standsicherheit des Bohrlochs zu sichern und Zuströmtendenzen in Richtung des Bohrkanals vonvornherein auszuschließen, musste der Spülungspegel bei einem spezifischen Spülungsgewicht von min.1,25 in den Startgruben permanent auf dem errechneten Niveau der Anschüttung gehalten werden

• Permanente Anwesenheit einer Fachaufsicht (B) für steuerbare, horizontale Spülbohrverfahren nach DVGWArbeitsblatt GW 329

• Begleitung der Bohrarbeiten durch einen erfahrenen Spülungstechniker

• Die Überdeckung der Rohrleitungen unterhalb der zukünftigen Ausbausohle des Kanals durfte in keinem Fall8 m unterschreiten

• 3-fache Sicherheit gegenüber den rechnerisch ermittelten Einzugkräften bei der Auswahl der Bohranlagen

• Der Kanal und beide Dämme mussten vor Beginn der Arbeiten und nach jedem Arbeitsschritt der einzelnenBohrungen auf den Bohrungsachsen und jeweils 5 m links und rechts im Abstand von 2 m aufHöhenveränderungen vermessen bzw. gepeilt werden

• Etwa 13 Grundwassermessstellen im Umfeld der Kreuzungsstelle, darunter 3 eigens für die Baumaßnahmeangelegte, mussten täglich - zum Teil auch mehrmals - auf Veränderungen kontrolliert werden

• Erstellung eines Havarieplanes für fast alle denkbaren Zwischenfälle

• Vorhaltung von Abdichtmaterialien für Bohrloch und Kanalsohle + Material für Auflastdrän zurDammsicherung

Der Baugrund

Der Baugrund sollte bis ca. 6-8 m Tiefe vorwiegend aus Fein- und Mittelsand bestehen, unterlagert vonsandigen Schluff- und Mergelhorizonten. Findlinge sowie Stein- und Kiesnester waren jedoch nichtauszuschließen, was bei den Bohrarbeiten später deutlich zu 'hören' war und durch die 'Beifänge' und teilweiseden Zustand der Räumwerkzeuge auch optische Bestätigung fand.

Abb. 2 Stein im Fly-Cutter 26" Abb. 3 Kies am Hole Opener 38"

Entsprechend der Schichtenverzeichnisse waren der Schluff und der Mergel überwiegend leicht bis mittelschwerlösbar, vereinzelt jedoch auch schwer. Der Tonanteil im Mergel sollte eher gering sein.

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Die Bauausführung

Für die einzelnen Bohrungen wurden von den genannten Firmen Bohrgeräte mit folgenden Zugkräfteneingesetzt:

DA 450 HDPE 75 t Fa. MüsingDN 300 Stahl 75 t Fa. MüsingDN 500 Stahl 100 t Fa. Bohlen & DoyenDN 700 Stahl 150 t Fa. LMR Drilling

Messtechnik

Die Ortung und Vermessung der Bohrungen erfolgte komplett mit Hilfe der ParaTrack 2 Messtechnik (Fa. PrimeHorizontal). Nach Herstellung der Bohrung für das HDPE Rohr DA 450 mit konventionell entlang der Bohrachseausgelegtem Kabel wurden die folgenden 3 Bohrungen auf Basis eines in diesem Rohr verlegtenReferenzkabels aufgefahren. Um die Lage dieses Kabels möglichst exakt zu kennen, wurde die Lage des 450erRohres zuvor mit Hilfe eines Kreiselkompasses dreidimensional eingemessen.

Abb. 4 Systemdarstellung ParaTrack – Messtechnik am Oder-Havel-Kanal

Ein Grund für die Auswahl dieser Messtechnik im Vorfeld war, dass wegen der eingeschränktenPlatzverhältnisse die Krümmungen der geplanten Bohrlinien DN 700 und DN 500 sehr nah an die zulässigenelastischen Biegeradien dieser Rohre gelegt werden mussten und deshalb durch ungenaue Ortung entstehendeLageabweichungen von vornherein ausgeschlossen werden sollten.

Ausbläser

Das Auftreten von Ausbläsern im Kanalbereich und damit ggf. das Erzeugen einer hydraulischen Verbindungzwischen Bohr- und Schifffahrtskanal war neben der Angst vor Dammsetzungen von Anfang an Thema Nr.1.

Nur eine von vier Pilotbohrungen – die letzte – konnte ohne Ausbläser und mit vollständigem Spülungsrücklaufwährend der gesamten Zeit fertig gestellt werden.

Nachdem insbesondere bei der zweiten Bohrung zum Teil erhebliche Spülungsaustritte gerade noch außerhalbdes Kanalbereichs auftraten und kein Spülungsrücklauf mehr aufrechterhalten werden konnte, vergrößerte sichdie Skepsis der zuständigen Genehmigungsbehörden gegenüber dem HDD-Verfahren weiter und es wurdenVorschläge und Maßnahmen zur zukünftigen Vermeidung dieser 'Begleitumstände' gefordert. Diese wurdenauch erarbeitet, konnten aber erst bei der letzten Bohrung umgesetzt werden.

Insbesondere der große Durchmesser der Pilotbohrung und der Einsatz eines Drucksensors zur Überwachungdes effektiven Ringraumdruckes waren die Hauptursachen dafür, dass bei der vierten Bohrung weder Ausbläsernoch Verlust des Spülungsumlaufes oder Schwankungen an einem der Grundwasserpegel ein Thema waren.

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Bohrtechnik

Das Herstellen der Pilotbohrung und das Aufweiten des Bohrkanals wurden teilweise recht unterschiedlichgehandhabt. Drei der vier Pilotbohrungen wurden mit 8½" bzw. 8" Jetbit hergestellt, wobei in derBohrgeschwindigkeit gegenüber dem 12¼" Düsenrollenmeißel kein Unterschied festzustellen war, abgesehenvielleicht davon, dass bei letzterem bei gleicher Geschwindigkeit ca. das 4 bis 5-fache Bodenvolumen abgebautund ausgetragen wurde. Auf Grund eines nicht umfahrbaren Hindernisses musste bei der letzten Bohrung ein6¾" Bohrmotor eingesetzt werden, der in Verbindung mit einem 3° Bent Housing und dem 12¼" Meißel für einPilotbohrloch von ca. 17,5" sorgte.

Gerade bei der Art des hier angetroffenen sehr festen, beim hydraulischen Lösen jedoch durch den hohenSchluffanteil zum größten Teil in der Spülung dispergierenden Mergels wurde beim Vergleich derBohrgeschwindigkeit auch die Bedeutung von Anordnung, Anzahl und Größe der Düsen in den Bohr- undAufweitwerkzeugen deutlich. Düsenstrahlgeschwindigkeit und die von den Düsen erzeugte Aufprallkraft desDüsenstrahls hatten einen nicht unerheblichen Einfluss auf die Effektivität des Bodenabbaus und desBodenaustrags.

Wie der Zustand der Rohre nach dem Einziehen zeigte, war die planmäßig vorgesehene Schutzumhüllung mitGFK auf Grund der zu durchfahrenden Kies- und Steinbereiche eine äußerst sinnvolle Maßnahme.

Bohrspülung + Ringraumverdämmung

Die eingesetzten Spülungssysteme konnten den an sie gestellten Anforderungen gerecht werden. Vorteilhaftwar vor allem, dass durch die permanente Anwesenheit eines mit dem jeweiligen Produkt vertrautenSpülungstechnikers (Fa. Phrikolat bzw. Fa. GelTeq) eine optimale Kontrolle und Überwachung derSpülungsparameter möglich war.

Alle Bohrungen wurden beim Einzug über den Räumer mit einer selbst aushärtenden Suspension verdämmt.Das Produkt hierzu war vorgeschrieben (Drill-Mix 330, Fa. AZ-BUT) und in seiner Konsistenz und Rheologiebekannt. Interessant und für den erfolgreichen Ablauf des Einziehvorganges nicht ganz unbedeutend, war dasReaktionsverhalten dieses Produktes beim Zusammentreffen und der Vermischung mit der Bohrspülung imBohrkanal. Hierzu wurden im Vorfeld von der Moll-prd in Zusammenarbeit mit den jeweiligenSpülungstechnikern umfangreiche Versuche gefahren, bei denen deutliche Unterschiede in der Konsistenz des'Mischproduktes' festgestellt wurden, von unverändert flüssig bis nicht mehr pumpbar. Dabei hatten sowohl dasverwendete Spülungsprodukt als auch der Feststoffgehalt (Dichte) der Bohrspülung erhebliche Auswirkungen.

Fazit

Trotz relativ unterschiedlicher Herangehensweise konnten alle 4 Bohrungen ohne die befürchtetenAuswirkungen auf die Standsicherheit des Oder-Havel-Kanals erfolgreich beendet werden. Das Wasser desOder-Havel-Kanals fließt noch dort, wo es schon 1917 – als der Kanal von Kaiser Wilhelm II alsHohenzollernkanal der Öffentlichkeit übergeben wurde - floss, und die vier neuen Düker liegen dort, wo sieliegen sollen.

Der direkte Vergleich von vier nahezu unter identischen Bedingungen ausgeführten Horizontalbohrungen ergabeinige interessante Erkenntnisse, insbesondere hinsichtlich Vermeidung von Ausbläsern, Bohrspülung,Ringraumverdämmung, Werkzeugauswahl und Bohr– und Räumgeschwindigkeit. Nichts grundsätzlich neues,auch keine perfekte Technologie für die Zukunft, aber mit Sicherheit einige Punkte, die bei zukünftigenProjekten mit ähnlichen Randbedingungen einer Überlegung wert sind.

Einen etwas ausführlichen Bericht über dieses Bauvorhaben finden Sie in der Dezemberausgabe derZeitschrift bi-Umweltbau.

Oliver Knopf

Moll-prdPlanungsgesellschaft

für Rohrvortrieb und Dükerbau

DCA NEWSLETTERNr.17 – Dezember 2004Deutsche Version

No.17 - Page- 16

HDD-Training Courses

will take place at January/February 2005 in Celle

Topics Length Dates Places

2.1.16 Fachaufsicht (A/B) für horizontales Spülbohrverfahren nach DVGW-Arbeitsblatt GW 329

Topografie und Geologie,Bohrspülungen, Bohrstrang, Werkzeuge,Ortungsverfahren, Rohwerkstoffe,Vorschriften, Arbeitssicherheit

A: 5 TageB: 7,5 Tage

A: 10.-14.01.2005B: 10.-19.01.2005

Celle

2.1.17 Bauleiter (A/B) für horizontales Spülbohrverfahren nach DVGW-Arbeitsblatt GW 329

Grundlagenwissen, Topografie,vorhandene Anlagen, Bodenkennwerte,Bohrspülungen und Bohrlochhydraulik,Bohrstangen, Bohrwerkzeuge,Rohrumhüllungen, Rohrwerkstoffe

A: 10 TageB: 15 Tage

A: 17.-28.01.2005B: 17.1-04.02.2005

Celle

2.1.18 Geräteführer (A/B) für horizontales Spülbohrverfahren nach DVGW-Arbeitsblatt GW 329

Mathematik, Physik, Aufbau und Wirkungvon Horizontalspülbohranlagen,Projektgrund- lagen, Projektdurchführung,Bohrspülung, Spülungskreislauf,Spülungspumpen

A: 12 TageB: 17 Tage

A: 17.01.-01.02.2005B: 17.01.-08.02.2005

Celle

Info: DCA Members will pay a reduced fee!

For further information or register:Walburga FinzelBerufsförderungswerk des Rohrleitungsbauverbandes GmbHMarienburger Str. 15, 50968 KölnTelefon 0221/37 658-25, Telefax 0221/37 658-60E-Mail: finzel@brbv.dehttp://www.brbv.de

DCA NEWSLETTERNr.17 – Dezember 2004Deutsche Version

Nr.17 - Seite- 17

DCA Sponsorship Award 2005

The DCA-Europe has established the DCA Sponsorship Award 2000 to support the new generation of

academics in the field of Horizontal Directional Drilling (HDD).

The Sponsorship Award aims to support examinees writing their dissertation specifically in the field of

the technique of Horizontal Directional Drilling (HDD) and is addressed to those colleges and technical

universities in countries represented by DCA which are specialized in a comprehensive education in the

field of Horizontal Directional Drilling (HDD) and related disciplines. The Sponsorship Award will

comprise

5.000,00 Euro

and will be awarded every year.

Requirements for eligibilityApplications in written form are sent to the DCA offices in Aachen by the institute of education. The

application (threefold) has to consist of the following information:

Institute of EducationCoordinator of the institute’s program

Introduction of the ApplicantSubject and introduction of the Dissertation

Schedule

The Sponsorship Award will be given to one of the applying scientific institutions, after the incoming

application documents were examined by a DCA committee. In case of a justified exception the

Sponsorship Award can be given to two institutes (EURO 2.500.- each).

Deadline to apply for the Sponsorship Award is

March 31st, 2005.

After evaluation of the incoming documents, and after the DCA committee reached a resolution, a

contract with the program coordinator of the college or university will be completed to verify the

formalities to sponsor the respective examinee. If the dissertation sponsored by the DCA is completed,

the candidate has the chance to present his or her scientific work at DCA`s Annual Congress. For

further questions please do not hesitate to contact our Aachen office any time.

DCA NEWSLETTERNr.17 – Dezember 2004Deutsche Version

Nr.17 - Seite- 18

Upcoming events

January - February 2005

DCA - MEMBERS MEETING 2005

Wednesday, 9. February 2005, Start 15.00h

Place: Hotel Wöbken, Oldenburg

We invite you to participate in the 2005 DCA Members meeting which will be held like last year one day

before the Oldenburger Rohrleitungsforum. The Members Meeting will take place at the Hotel Wöbken,

Oldenburg, Germany. DCA has made accomodation reservations in the Hotel Wöbken. Those have to

be confirmed direct at the Hotel until January, 15 2005.

For further Information please contact our Aachen office any time.

Hotel Wöbken:Hundsmühler Straße 25526131 OldenburgTel.:+49(0)441-95577-0 ; Fax:+49(0)441-502324e-mail: info@HotelWoebken.de ; internet: www.HotelWoebken.de

Oldenburger Rohrleitungsforum 2005

10.-11. Februar 2005 in OldenburgTopic: "Rohrleitungen – verbinden Europa"

Ort: Fachhochschule Oldenburg

Speeches : Horizontal Directional Drilling

Part 1: Thursday 10.02.2005: 11.15 Uhr – 12.45 Uhr

Moderator: Gerard P. Hoogveld M. Sc. (Delft), LMR DrillingPresident Verband Güteschutz Horizontalbohrungen e.V., Aachen

Speech 1: Offshore HDD for the salvage of the vessel TricoloreSpeaker: ir. Luc Vandenbulcke, Hydro Soil Services

Speech 2: HDD-Technologie in neuen AnwendungsherausforderungenSpeaker: Dr. H.-J. Bayer, Tracto-Technik Spezialmaschinen GmbH

DCA NEWSLETTERNr.17 – Dezember 2004Deutsche Version

Nr.17 - Seite- 19

Speech 3: Rock drilling an outfall in Holyhead: a 300-m drill plus 1000-m trenched outfall.Referent: Jez Seamans, geologist, LMR Drilling UK

Part 2: Thursday 10.02.2005: 13.30 Uhr – 15.00 Uhr

Moderator: Dipl.-Ing. Hermann Lübbers, Nacap Europe B.V.Board Verband Güteschutz Horizontalbohrungen e.V., Aachen

Speech 1: Korrosionsschutz an Stahlrohren bei Horizontalbohrungen –Neue Verfahren der GFK-BeschichtungSpeaker: Dipl.-Betriebswirt Frank Hellmann, Franken Plastik GmbH

Speech 2: Zwei 1000 m lange parallele Rohrbündel mit engen Lagetoleranzen unter starkerBeeinflussung der Messungen auf nicht zugänglicher Trasse in schwierigenBodenverhältnissen unter strengen Sicherheits- und Umweltauflagen mittelsHorizontalbohrung verlegt.Speaker: Jens Groninger, LMR Drilling GmbH

Speech 3: HDD-Bohrspülungen unter extremen Bedingungen –Anforderungen und Problemlösungen anhand einiger FallbeispieleSpeaker: Dipl.-Ing. Markus Trimpin, Süd-Chemie AG

For more information please contact our office in Aachen any time or look unter www.dca-europe.de.

We wish you a Merry Christmas and a Happy and SuccessfulNew Year 2005!