CONSTRUCTION SPECIFICATION FOR PIPELINE AND UTILITY INSTALLATION IN SOIL AND ROCK BY HORIZONTAL DIRECTIONAL DRILLING (HDD)

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1 ONTARIO METRIC PROVINCIAL OPSS 450 STANDARD October 2009 SPECIFICATION (Draft v1.0) CONSTRUCTION SPECIFICATION FOR PIPELINE AND UTILITY INSTALLATION IN SOIL AND ROCK BY HORIZONTAL DIRECTIONAL DRILLING (HDD) TABLE OF CONTENTS SCOPE REFERENCES DEFINITIONS DESIGN AND SUBMISSION REQUIREMENTS MATERIALS EQUIPMENT CONSTRUCTION QUALITY ASSURANCE - Not Used MEASUREMENT FOR PAYMENT BASIS OF PAYMENT APPENDICES 450-A Commentary Draft Page 1 of 12

2 SCOPE This specification covers requirements for installation of underground pipelines (pressure pipe and gravity pipe), conduits, cable, or ducts using the trenchless technology known as horizontal directional drilling (HDD) Specification Significance and Use This specification has been developed for use in provincial - and municipal-oriented Contracts. The administration, testing, and payment policies, procedures, and practices reflected in this specification correspond to those used by many municipalities and the Ontario Ministry of Transportation. Use of this specification or any other specification shall be according to the Contract Documents Appendices Significance and Use Appendices are developed for the Owner s use in the contract documents. The decision to use any appendix is determined by an Owner after considering their contract requirements and their administrative, payment, and testing procedures, policies, and practices. Depending on these considerations, an Owner may not wish to invoke some or any of the available appendices. Appendices are not a mandatory part of this specification and only become part of the Contract Documents as the Owner invokes them in the contract documents. Invoking a particular appendix does not obligate an Owner to use all available appendices REFERENCES When the Contract Documents indicate that provincial-oriented specifications are to be used and there is a provincial-oriented specification of the same number as those listed below, references within this specification to an OPSS shall be deemed to mean OPSS.PROV, unless use of a municipal-oriented specification is specified in the Contract Documents. When there is not a corresponding provincialoriented specification, the references below shall be considered to be to the OPSS listed, unless use of a municipal-oriented specification is specified in the Contract Documents. When the Contract Documents indicate that municipal-oriented specifications are to be used and there is a municipal-oriented specification of the same number as those listed below, references within this specification to an OPSS shall be deemed to mean OPSS.MUNI, unless use of a provincial-oriented specification is specified in the Contract Documents. When there is not a corresponding municipaloriented specification, the references below shall be considered to be the OPSS listed, unless use of a provincial-oriented specification is specified in the Contract Documents. This specification refers to the following standards, specifications, or publications: Ontario Provincial Standard Specifications, Construction OPSS 180 General Specification for the Management of Excess Material OPSS 409 Closed-Circuit Television Inspection of Pipelines OPSS 504 Preservation, Protection, and Reconstruction of Existing Facilities OPSS 507 Site Restoration Following Installation of Pipelines, Utilities and Associated Structures OPSS 514 Trenching, Backfilling, and Compacting OPSS 517 Dewatering of Pipeline, Utility, and Associated Structure Excavation OPSS 538 Support Systems OPSS 539 Temporary Protection Systems Other Draft Page 2 of 12

3 ASTM F1962 Standard Guide for Use of Maxi-Horizontal Directional Drilling for Placement of Polyethylene Pipe or Conduit Under Obstacles, Including River Crossings ASTM F1804 Standard Practice for Determining Allowable Tensile Load for Polyethylene (PE) Gas Pipe During Pull-In Installation ASCE Standard Guideline for the Collection and Depiction of Existing Subsurface Utility Data Horizontal Directional Drilling Good Practices Guidelines (HDD Consortium) DEFINITIONS For the purpose of this specification, the following definitions apply: Active Interference means electrical interenence created by magnetic fields and radio frequencies such as power lines. Bore Path means a drilled path according to the grade and alignment tolerances specified in the Contract Documents. Drilling Fluid Fracture or Frac Out means a condition where the drilling fluid s pressure in the bore is sufficient to overcome the in-situ vertical confining stress, thereby fracturing the soil and allowing the drilling fluids to migrate to the surface at an unplanned location. Drill Fluid Control Points means locations along the bore path where control points are constructed to manage drill fluids. Drilling Fluids means a mixture of water and additives, such as bentonite, polymers, and surfactants designed to block the pore space on a bore wall, reduce friction in the bore, and to suspend and carry cuttings to the surface. Entry Point means the location or excavation from which the bore is initiated for the installation of product. Exit Point means the location or excavation to which the bore is directed for the installation of product. Guidance System means an electronic system capable of indicating the position, depth, and orientation of the drill head during the drilling process. Horizontal Directional Drilling (HDD) means directional boring or guided horizontal boring. Inadvertent Returns means the flow of unexpected fluids towards the drilling rig during the drilling process. Loss of Circulation means the discontinuation of the flow of slurry in the bore back to the entry or exit point or at drill fluid control points. Multi Product Installation means two or more products installed in the same bore path. The products may or may not have the same diameters. Passive Interference means electrical interence created by adjacent structures, buried metal, salt water, and minerals in the soil. Pilot Bore means the initial bore to set horizontal and vertical alignment between the connecting points. Product means pipelines, conduits, cable, or ducts. Draft Page 3 of 12

4 Pullback means that part of the HDD method in which the drill string is pulled back through the bore path to the entry point, usually installing the product at the same time. Reamer means a cutting tool specific designed for insitu ground conditions. The reamer is attached to the leading end of a drill string to enlarge the pilot bore prior to or during a pullback operation to enable installation of the product. The reamer must also deliver drill fluids into the bore and mix bore cuttings to form flowable slurry. Reaming means a process for pulling or pushing a tool attached to the end of the drill string through the bore path to enlarge the bore and mix the cuttings with the drilling fluid. This could include multiple passes prior to pullback. Rock means natural aggregate of minerals that are connected by strong bonding or attractive forces and considered consolidated material. Rock can not be sampled with a geotechnical investigation Split Spoon sampler. Single Product Installation means a single product installed into a bore path. The product may or may not have a tracer wire attached to it. Slurry means a mixture of soil cuttings and drilling fluid. Soil means natural unconsolidated sediments and deposits of solid particles that have resulted from the disintegration of rock or the accumulation of partially decayed vegetation matter. Solid particles can consist of clay, silt, sand, gravel, cobble and boulder size particles as defined in accordance with the Unified Soil Classification System and organic matter such as peat. Soils can be sampled with a geotechnical investigation Split Spoon or Shelby Tube soil sampler. Staging Area means an area set aside for the Contractor s drilling and pipe assembly operations and any other space requirements required by the Contractor. Strike Alert means a system that is intended to alert and protect the operator in the case of inadvertent drilling into an electrical utility cable. The strike alert system consists of a sensor and an alarm connected to the drill rig and a grounding stake. The alarm may be audio or visual or both. Subsurface Utility Engineering (SUE) means a branch of engineering practice that involves managing certain risks associated with utility mapping at appropriate quality levels, utility coordination, utility relocation design and coordination, utility condition assessment, communication of utility data to concerned parties, utility relocation cost estimates, implementation of utility accommodation policies, and utility design. Unified Soil Classification System (USCS ) means a soil classification system used in engineering and geology disciplines to describe the texture and grain size of a soil. The classification system can be applied to most unconsolidated materials, and is represented by a two-letter symbol. American Society for Testing and Materials, (ASTM) D 2487, Classification of Soils for Engineering Purposes details the USCS system DESIGN AND SUBMISSION REQUIREMENTS Submission Requirements Prior to bidding, the Owner should supply the geotechnical data necessary for the Contractor to be able to determine equipment, drilling fluids, and construction methods. Draft Page 4 of 12

5 The following site specific information shall be submitted to the Contract Administrator for approval prior to construction: a) A general work plan delineating the areas of the proposed construction methods and schedule to be used to complete the work. b) A list of personnel, including backup personnel, and their qualifications and experience. c) A traffic control plan. d) A drilling fluid management plan including source of fresh water and necessary permits or approvals; type of drilling fluids and potential additives and their Material Safety Data Sheets (MSDS); method of drilling fluid containment; method of recycling drilling fluid (as applicable); method transporting drilling fluids off site; disposal of excess drill fluids as per OPSS 180; and method to continually monitor fluid properties and pressure throughout the course of drilling and pullback operations to anticipate drilling fluid related problems before they occur. e) A health and safety plan including the company safety manual, emergency procedures, list of emergency personnel contact information f) A drilling plan indicating proposed type and size of directional drilling equipment, location and dimensions of staging areas; diameter of pilot hole and number and size of back reamers; guidance system; field determined elevations of the surface topography along the bore path; field determined elevations and locations of all existing utilities within 1.5m of the bore path; rod-by-rod profile data along the bore path; location of drill fluid control points; identification of active and passive interference along with appropriate compensation measures; method to continuously monitor and record tensile installation forces and down-hole fluid pressures (measurements should be taken between the reamer and the product pipe); pipe protection procedures; pipe gripping procedures; and temporary protection systems. g) A contingency plan in conformance with the Contract Documents including identifying potential environmental impacts and emergency containment and clean-up procedures. h) Work permits required under the authorities having jurisdiction necessary to complete the work MATERIALS Drilling Fluids The drilling fluids should be selected and mixed appropriately for the anticipated soil conditions. Only bentonite, polymers and industry accepted drill fluid additives should be permitted for use as drilling fluids. No petroleum-based additives shall be permitted. Continually monitor fluid properties throughout the course of drilling and pullback operations to ensure that the drill fluid properties align with the in-situ soils conditions Pipe Materials Pipe and fitting type, class, and size shall be as specified in the Contract Documents and shall be suitable for HDD installation and insitu soil conditions. Appropriate type and number of tracer wires shall be used as specified in the Contract Documents EQUIPMENT Directional Drilling Equipment General Draft Page 5 of 12

6 The directional drilling equipment shall consist of a directional drill rig and a fluid mixing and delivery system with sufficient capacity to complete the product installation. The drill rig and all associated equipment shall be in good mechanical working order. All drill operations and equipment shall be controlled by competent, experienced and trained personal Drilling Rig The directional drill rig shall: a) consist of a hydraulically powered boring system to rotate, push, and pull drill rod into the ground at a variable angle while delivering a pressurized fluid mixture to a guidable drill head. b) have drill rod which is suitable for both the drill and the product pipe installation. c) contain a drill head which is steerable, equipped with the necessary cutting surfaces and fluid jets, and be suitable for the anticipated ground conditions. d) have adequate reamers and down-hole tooling equipped with the necessary cutting surfaces and fluid jets to facilitate product installation and be suitable for the anticipated ground conditions. e) support a guidance system to accurately guide boring operations. f) be anchored to withstand the pushing, and pulling forces required to complete the product installation. g) contain an active strike alert system and be properly grounded during all operations Guidance System The guidance system shall be setup, installed, and operated by trained and experienced personnel. The operator shall be aware of any active and passive interference which may interfere with the guidance of the system. The type of guidance system shall be suitable for the design bore path and project specifications. The Contractor shall verify calibration of the guidance system prior to each daily use Drill Fluid Mixing and Delivery System The drill fluid mixing system shall be of sufficient size to thoroughly and uniformly mix the required drilling fluid. The delivery system and reamers shall have sufficient flow and capacity to ensure that all slurry volumes are adequate for the length and diameter of the final bore and the insitu soil conditions CONSTRUCTION General The Contract Administrator should be notified at least 48 hours in advance of starting the drilling operations. Operations shall not begin until proper preparations have been made. The Contractor should notify the owners of all above and below grade utilities in the vicinity of the drill path. It is noted that the utilities shown on the drawings are not necessarily complete or accurate. The location of all utilities in the work area shall be identified and located prior to drilling operations. If, prior to commencing drilling operations, a utility is found to exist that would conflict with the installation of the pipe, the Contractor is to notify the Contract Administration immediately. Draft Page 6 of 12

7 Site Preparation The area and grade of the access and work site shall be made adequate to allow for drill operations. All required activities for proper drilling operations shall be confined to designated work areas Preservation and Protection of Existing Facilities Preservation and protection of existing facilities shall be according to OPSS 504. Minimum horizontal and vertical clearances to existing facilities as specified in the Contract Documents shall be maintained. Clearances shall be measured from the nearest edge of the largest backreamer required to the nearest edge of the facility being paralleled or crossed. All known utilities in close proximity to the bore path shall be verified by the Contractor. As required by facility owner, Contractor or as specified in Contract Documents, the exposed utilities are to be left open during drilling operations. Should it become necessary for the Contractor to excavate and/or disturb existing utilities to retrieve lost boring equipment, the Contractor shall be responsible for obtaining all relevant approvals Transporting, Unloading, Storing, and Handling Materials Manufacturer's recommendations for transporting, unloading, storing, and handling of materials shall be followed Trenching, Backfilling, and Compacting Trenching, backfilling, and compacting for entry and exit points or other locations along the bore shall be in accordance with OPSS 514 or as specified in the Contract Documents Support Systems Support systems shall be in accordance with OPSS 538 or as specified in the Contract Documents Dewatering Dewatering shall be in accordance with OPSS 517 or as specified in the Contract Documents Temporary Protection Systems The construction of all temporary protection systems shall be in accordance with OPSS 539 or as specified in the Contract Documents. Where the stability, safety, or function of an existing roadway, railway, watercourse, other works, or proposed works may be impaired due to the method of operation, protection shall be provided. Protection may include sheathing, shoring, and piles where necessary to prevent damage to such works or proposed works Drilling Fluid Management The Contractor shall employ a containment, collection, and disposal method satisfactory to manage drilling fluids and mitigate the development of inadvertent returns. The Contractor shall manage the cleanup and dispose of drilling fluids as per the drilling fluid management plan or as specified in the Contract Documents. The fluids shall be disposed of in a proper manor Pilot Bore Draft Page 7 of 12

8 The pilot bore shall be drilled along the bore path in accordance with the grade, alignment, and tolerances specified in the Contract Documents. Drill rod and product bend radius shall be taken into consideration when completing the pilot bore. In the event the pilot bore does deviates beyond specified tolerances, the Contract Administrator shall be notified immediately. The Contractor shall accommodate any variations in the location of the pilot bore when making connections at each end of the HDD section. If a pilot bore is abandoned, it shall be decommissioned in an acceptable manor Reaming The bore shall be reamed to the appropriate size with tooling that is adequate for the insitu soil conditions and proposed product to be installed. The final staged ream should not exceed 1.5 times of product pipe largest outside diameter Product Installation General The product shall be jointed and installed according to manufacturer s recommendations and shall be protected from damage in the staging area and during pullback. The minimum allowable bending radius for the product shall not be exceeded during installation (i.e. movement to entry point, entrance into the staging or bore, or at any location along the bore path). Product shall be allowed to recover before the connection to new or existing facility is made. Product recovery time shall be in accordance with manufacturer's recommendations Pullback After completion of the pilot bore or reaming the bore to the required diameter, the product should be pulled into the bore path as soon as possible. The pullback operation should be a continuous operation, if possible, until the product pipe is installed. A proper gripping method must be seelected to allow the full tensile rating of the product to be developed. A swivel of sufficient capacity shall be used between the reamer and the product being installed to prevent rotational forces from the reamer being transferred to the product. A pipe load measuring device may be used to ensure that the manufacturer s recommended pullback force is not exceeded. (i.e. gauges, down-hole devices, weak links). The product shall be inspected for damage where visible at excavation pits and where it exits the bore. All damage should be reported to the Contract Administrator Product Testing Where required, product testing shall be as specified in the Contract Documents and in accordance with manufactures specifications. Draft Page 8 of 12

9 Record Keeping The Contractor shall keep record of the actual location of the product being installed (rod by rod data) and if required provide records to the Contract Administrator. Where required, the Contract Documents shall specify the verification requirements and as-built drawings of the installed pipe alignment and depth Closed-Circuit Television (CCTV) Inspection Where required, CCTV inspection shall be in accordance with OPSS 409 or as specified in the Contract Documents Site Restoration Where required, site restoration shall be in accordance with OPSS 507 and as specified in the Contract Documents Management of Excess Material Management of excess material shall be in accordance with OPSS 180 or as specified in the Contract Documents MEASUREMENT FOR PAYMENT Actual Measurement Single and Multi Product Installation Measurement for a product installation shall be in metres along the centreline of the useable product between final connection points or work completed. No additional payment will be considered for end pieces to achieve design elevation Plan Quantity Measurement When measurement is by Plan Quantity, such measurement shall be based on the units shown in the clauses under Actual Measurement BASIS OF PAYMENT Single and Multi Product Installation by HDD, "diameter of product, product material, use of product," - Item Payment at the Contract price for tender items shall be full compensation for all labour, equipment, and materials to do the work. Progress payments, when specified in the Contract Documents, should be made using the following guidelines: 20 percent of contract unit value for submittals and pilot bore completion 20 percent of contract unit value for delivery of product on site 60 percent of contract unit value for reaming and product pullback Draft Page 9 of 12

10 Appendix 450-A, August 2009 FOR USE WHILE DESIGNING MUNICIPAL CONTRACTS Note: This is a non-mandatory Commentary Appendix intended to provide information to a designer, during the design stage of a contract, on the use of the OPS specification in a municipal contract. This appendix does not form part of the standard specification. Actions and considerations discussed in this appendix are for information purposes only and do not supersede an Owner s design decisions and methodology. Designer Action/Considerations General The specification was written to encompass the majority of HDD drilling operations for small and medium sized projects with diameters generally up to 914 mm and drill lengths of less than 1,000 m. The basic design considerations should always include: minimum cover to prevent frac-out; geology of the area, including future river "scour" or meander projections; site logistics; connection requirements; and sitespecific issues (e.g., river crossings, wetlands, and archaeological sites). It should also include consideration that the design bore path could potentially fail during construction due to unforeseen ground or site conditions and/or equipment failure. Thus, design bore path should consider the risk for a failed bore path and the need to excavate to retrieve in ground tooling, equipment and/or materials. The designer should ensure the contract includes provision of all required government permits and landowner clearances that are required to complete the project. ( ). The principal safety concern in HDD is ensuring that the drilling equipment does not accidentally contact existing underground infrastructure. The risk of contacting other utilities can be mitigated by knowing the precise locations of all underground utilities in close proximity to the HDD bore path. Detailed knowledge of all subsurface utility locations is a critical component of a directional drilling project and this information should be included in the Tender Documents to facilitate the Contractor's bid. In congested areas Subsurface Utility Engineering (SUE) practices should be performed in accordance with ASCE Standard Guideline for the Collection and Depiction of Existing Subsurface Utility Data. The designer should specify the following elements in the Contract Documents: the minimum horizontal and vertical clearances to existing facilities; and the number of exposures required to monitor the work progress. ( ) Geotechnical and site condition information are required to for a successful project design, and to ensure that the contractor has the proper equipment and materials on the project (i.e., drilling fluid mixtures, methods, or equipment), for drill and product pipe set-up, and pipe design. Geotechnical technical information should be provided as part of the contract documents in the form of boreholes records, geotechnical report, or geotechnical baseline report. Geotechnical borings shall be completed in accordance with ASTM F1962 which states that they are put down at least 1m off the proposed design bore path. Geotechnical borings should be sufficient to quality site conditions, along the proposed bore path, and to verify that drilling show stoppers are unlikely to exist. Subject to the scope of operations, the designer may wish to specify in the Contract Documents a more detailed work plan prior to the commencement of work, particularly for multiple pipe installations, multiple day projects, congested work areas, or environmentally sensitive sites. For complex projects or for projects where the designer does not have training or experience in completing HDD project designs, the designer should consider a design-build contract submission (450.04). For a design-build contract, the designer shall specify all critical project contract performance criteria (i.e. pipe operation pressure, connection locations, internal or external diameters, minimum grades, contractor submission requirements, etc). Draft Page 10 of 12

11 The designer should provide the necessary grade, alignment, and tolerances for the product installation in the Contract Documents. The designer should consider the maximum deflection and entry angle of the pilot bore based on either limitations on drill rod deflection or maximum allowable bending radius of installed product. ( ) The tender item description for product installation by HDD must include reference to one or more of the attributes shown (i.e., diameter of product, product material, use of product, to be complete). ( ) The designer should ensure that the General Conditions of Contract and the 100 Series General Specifications are included in the Contract Documents. The designer should give careful consideration, in consultation with the pipe manufacturer, to ensure the installed pipe is suitable to resist all installation and long-term in-service loads. The design shall specify the pipe type, class, size, maximum bend radius and safe tensile load. ( ) The designer may consider a lower reaming diameter than that specified if the soil conditions are suitable. The designer should also understand that multiple passes of the reaming operation can be expected and is included in the unit cost for the product installation. ( ) The designer may consider special provisions for backfilling and compacting, including the consideration of unshrinkable backfill to ensure proper compaction in critical locations. ( ) The designer should review product-jointing standards as provided by manufacturers. Experienced personnel with jointing accreditation may be added as a requirement of the Contract Documents depending on the type of installation. For fusible pipe products, the pipe should be completely jointed prior to the pull back operation to avoid delays during installation. ( ). All pipe jointing shall be to manufacturer specifications. Quality Assurance and Quality Control Throughout the commentary, the designer is provided with guidance in the consideration of certain Quality Assurance and Quality Control (QA/QC) techniques. However, it should be noted that evolving technology and techniques for improved QA/QC are currently in development and the designer should refer to trade publications to identify the latest available methods. In all cases, the designer should specify the quality assurance acceptance criteria to be used for each specific project. For certain product installations, the designer may wish to consider the requirement of a weak link or breakaway connector to prevent excess pulling force from damaging the product. Buoyancy control should also be considered by the designer during conditions where pullback operations are required to be completed under water crossings, or where the ground water elevation is above the invert of the pulled pipe. The designer should also consider specifying a product recovery time period, in accordance with the manufacturer s recommendations, restricting any work from being completed on the pulled back product until the product returns to its original shape and length. ( ) The designer may consider specifying physical product testing through the use of product coupons from the exit pit. In addition, in situ pressure or vacuum tests can be used to ensure the integrity of the product installation. ( ) The designer should specify the method of verifying the product installation location. The designer may consider the use of the reporting information available from the drill rig, daylighting, installation of tracer wire with the product, or the use of acoustic/magnetic locating equipment. The designer should consider specifying the required maintenance and submission of a Daily Drill Log to record daily drilling progress, drilling fluid pressures, record any problems encountered, confirm alignment and depth of bore (see attached tables). ( ) Payment Draft Page 11 of 12

12 The designer s careful preparation of the project should greatly assist in the success of the installation. However, there may always be a risk of encountering unexpected problems that may require a fair resolution for payment. It is recommended that a process regarding payment for failed attempts be considered for inclusion in the Contract Documents. The designer s inclusion of both a site specific Geotechnical Baseline Report and a Sub-surface Utility Report will establish the baseline standard from which a fair resolution for payment should be assessed. (450.10) Where specified in the Contract Documents, the Contractor shall adequately monitor fluid properties throughout the course of drilling and pullback operations. Contract documents should specify drill fluid monitoring requirements, such as the use of real-time monitoring, to anticipate drilling fluid related problems before they occur. Where specified in the Contract Documents, the Contractor shall monitor and record the tensile installation forces and down-hole fluid pressures. Where specified in the Contract Documents, the Contractor shall measure the ovality of the product pipe. The designer must include the measurement methods, calculation procedures and tolerances. Contract Documents must specify if the Contractor is required to retain a Quality Verification Engineer. Requirements of the Quality Verification Engineer shall be specified. Draft Page 12 of 12

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