DESIGN AND CONSTRUCTION OF EWPL CROSSINGS

Presentation by:

S Jayachandran, J ch ndr n Reliance Gas Transportation Infrastructure Ltd.

Contents
EWPL Project and its Challenges Special Crossings Crossing Methodologies Microtunnel HDD Float and Sink Cofferdam

EWPL Project and its Challenges

East West Gas Pipeline (EWPL) comprise of 1375 km long 48 dia trunk line from Kakinada, Andhra Pradesh to Bhadbhut, Gujarat; 82 km long spur lines of various diameters from 24 to 30, 11 Compressor Stations, 6 M&R Stations, 37 MLVs, 4 TOPs, 2 P l P Pipeline Operations Centers and other associated facilities. EWPL is one of the major pipeline projects executed in the world during the four years period since 2005. EWPL Project achieved significant distinctions during the execution j g g including establishing World Record in HDD and Microtunneling.

EWPL Project and its Challenges j g

Largest single pipeline project ever undertaken in India All types of harsh and challenging terrains:
Over 800 km of trenching in rock by blasting Over 150 km of marshy and slushy coastal land Undulating stretches of around 50 km Over 100 major perennial and tidal water body crossings requiring special construction methods.

Construction methods viz. Micro tunnelling, HDD, Float and Sink, Cofferdam and other construction adopted World record crossing of over 2 400 m long Gauthami Godavari 2,400 river executed by using Microtunneling World record HDD crossings of 48 diameter pipeline; 1,724 m long Vashista Godavari river and 1 500 m long Narmada river 1,500

EWPL Project and its Challenges j g

First time use of Cable Crane System for laying of pipeline on steep Bhivpuri Ghat; over 1,400 m long stretch with an elevation rise of over 500 m Record mainline welding of X-70 grade line pipes in excess of 55,45,000 inch-dia & combined welding of mainline, spur line, compressor station piping and M&R station piping in excess of 61,26,000 inch dia. 61 26 000 inch-dia Completed in 3 years with Project kick off in Dec., 05, Construction start in Oct 06, Pre-commissioning in May , 08 and Commercial operation from west coast in Dec 08 Dec.,

Trunkline Crossings

Record number of Crossings viz. Road (NH, SH, MDR, Others), Railway, Canal, River, Streams, 3rd Party Pipelines, etc. encountered by Trunkline. In all 1770 crossings were encountered, which is approx. 1.3 Crossings per km of pipeline length Total HDD Crossings in EWPL is over 8,200 m

EWPL Crossings Location

River Crossings
Crossings are the most difficult part of pipeline project execution. It involves extensive surveys investigation design evaluation of surveys, investigation, design, construction methodology including identification of technology limitations, careful planning and establishment of additional infrastructure. Resource mobilization of specialized equipment and manpower is a challenging task as additional specialized equipment to tackle contingency measures also to be mobilised. g y Crossing location normally selected during overall pipeline route selection Selection is done such that the crossing length is minimum, river does not meander, meander riverbed with minimum rock gentle banks on both sides rock, sides, adequate space available beyond the banks for construction infrastructure .

River Crossings Design

Design D i complies ASME B31 8 f gas li li B31.8 for lines and B31 4 f li id li d B31.4 for liquid lines and d other statutory requirements Score potential of the river bed established based on sub-soil and hydrological h d l i l survey i l di including fl di flooding and th pipeline l d the i li located 2 5 m t d 2.5 below the scour profile. Pipeline wall thickness and radius of curvature is established based on installation d i st ll ti and operational conditions. ti l diti s Anti-buoyancy measures required in case of open cut crossings as a permanent measure. Temporary anti - buoyancy measures also required in case of float & sink or bottom-pull methods to minimise the pulling loads.

Presentation Coverage
This presentation covers : World Record Microtunnel Crossing across Gauthami Godavari World Record HDD Crossing across Vashista Godavari Tapi River Crossing adopting Float & Sink Technique Terna River Crossing adopting Cofferdam Technique

Gauthami Godavari - World Record Microtunnel Crossing

Crossing Location

HDD

Gautami Godavari Microtunnel Crossing

Crossing located at KP 60.2, Andhra Pradesh State Length of the crossing more than 2400 m. HDD option ruled out due to technological limitations at the time of planning th job. l i the j b Other options considered include a pipe bridge and a micro-tunnel. Due to prolonged construction time and safety hazards involved with above-ground structures with high pressure pipeline, decision for microtunnelling made.

Gautami Godavari Microtunnel Crossing

Microtunnelling is a trenchless construction method that pushes the tunnel pipe into place behind a remote controlled TBM. Generally st i ht alignment adopted. C G ll straight li m t d t d Curved alignment simil t HDD d li m t similar to possible with suitable navigation guidance system and special tunnel pipe design g Curved alignment (both vertical and horizontal) allows longer drives with fewer shafts and shallower shafts Gautami Godavari profile incorporates combination of curved and straight alignment

Infrastructure Established
Access Roads to Shaft locations Temporary Pipe Bridge across an irrigation canal on East side Hard Stand provided around Shaft Temporary pipe factory for shaft segments and jacking pipes p ypp y g j gpp

East Shaft approach road, 2km

Center Shaft Approach Road, 1 km Pipe Factory

Jacking Pipes Production at Pipe Factory

Pipe F t Pi Factory

Jacking Pipe Cage Reinforcement in Progress

Cage Mould being Installed

Jacking Pipe, 2.4 m ID, 0.23 m thk, 4 m Long,

Jacking Pipe Ready for k P d f Installation

Shaft Locations
West Shaft

Center Shaft

East Shaft

Shallow Sh ll Shaft

1304 m

1135 m

80 m

East Shaft West Shaft Central shaft Shallow shaft

- 11.1 m dia, 8.5 m deep (Launch) 11.1 m dia, 9 m deep (Launch) 8.8 m dia, 26.7 m deep (Receipt) 8.8 m dia, 7 m deep (Receipt)

Shaft with Pre-cast Concrete Segments

Shaft Rings

Soft Eye

Soft Eye

Base Slab

Grout

Shaft Installation

Site Preparation

Ring Segment Placement

Shaft Sinking

Shaft Sinking

Base Slab Concreting

Problems faced during Shaft Sinking

West Shaft : High water table during sinking Dewatering system provided to lower the ground water level Invert level raised by 3 m to avoid heavy seepage East Shaft : Invert level raised from 11.0m to 8 m to minimise excavation. Shallow Shaft : Originally not planned. Provided to minimise excavation. Central Shaft : Due to stiff clay layer encountered in the river bed, shaft could not be lowered t th required d pth and in n tb l d to the qui d depth nd invert l t level raised b 3 m l is d by

Tunneling Operations g p
Tunnelling operations planned from both east and west banks simultaneously, so that the activity completed before onset of monsoon. Two TBMs mobilised to site. Tunnel driven through silty fine sand, clayey sand, clayey silt and fine to medium sand with traces/pockets of clay or gravel m um n w /p f y g Dual mode TBM (EPB 2400 AH) mobilised, which operated on EPB (Earth Pressure Balance) for clayey silt and Slurry mode for sand and g gravel TBM cutting head turns during tunnel pipe jacking operation and the cutting tools at the face cut the soil. Soil is pressed through the opening in the cutter head into excavation chamber. p g In EPB mode, soil is transported via screw conveyor out of the excavation chamber to a belt conveyor and into a muck car. Muck car p pulled over the rails installed within the tunnel pipes by a hydraulic pp winch.

Tunneling Operations g p
In Slurry mode, the material is transported via screw conveyor out of the excavation chamber to a slurry box. Soil is mixed with water and then pumped through a slurry line to surface via pumps. Pump transfers the material to a desander where the water from material is separated. Jacking is done with the help of 4 no. hydraulic cylinders, 4 m stroke length, located within the launching shaft. Jacking arrangement connected with hydraulic hose to the control container located y above ground near the shaft Lubrication system comprising of mixture of water and bentonite is used to reduce skin friction between tunnel pipe and surrounding soil

Tunneling Operations u g p
Intermediate jacking station (IJS) is used to give additional thrust to push the pipes. Control of pipeline alignment is monitored through UNS, capable pp g g , p of detecting deviations from planned alignment and level occurring during jacking operation. Once deviations are detected, the same is corrected through the steering cylinders at the head of TBM. Rubber sealant is used between tunnel segments for water g tightness

Jacking Pipe
Anchor Steel Collar Rubber Seal

Hydrophilic Seal

Sealing

Animation Courtesy Zublin

TUNNELLING OPERATIONS

TBM Under positioning in Shaft

Commencement of Tunnelling

Pipe Jacking Setup with Gantry East Shaft

Jacking Pipe with Rails and other Piping for Construction

Jacking Pipe Lowering, Aligning & Jacking

Gantry Set-up

Jacking Pipe Handling g p g

Jacks in Operation
Jacking Pipe Aligning

Jacking Pipe Lowering

Tunneling Operation u g p
West Shaft

Center Shaft

East Shaft

Shallow Sh ll Shaft

1304 m

1135 m

80 m

 Intermediate Jacking Station

IJS No.1

IJS No.2

Main Jacks

(Animation Courtesy Zublin)

Lubrication System
Lubrication Compr. Air

Bentonite Lubrication

Bentonite Valve Station

(Animation Courtesy Zublin)

PRODUCT PIPE PUSHING OPERATIONS

Original plan was to fabricate the pipe string and push the pipes from both sides of the river and make a tie-in within the central shaft Due to time schedule and RoU issues, the plan revised to pushing from one side of the river i.e. east bank. This eliminated the need for tie-in within the shaft 3 no pipe string fabricated instead of one continuous string due to limited no. space availability on east bank. Strings placed on 20 T/ 80 T custom fabricated rollers to minimise pulling efforts Pipe Thruster from Herrenknecht, Germany mobilised and placed at entry of shaft for undertaking pushing operations. winch thus eliminated Pipe thruster with 2 no. hydraulic cylinders capable of providing a max thrust of 500 t 5 m/min speed with a provision to accommodate 5 to 15 deg t, angle manufactured for the first time in the world deployed at EWPL site. Need of pulling cables and drum

PRODUCT PIPE PUSHING OPERATIONS

Original plan was to push the product pipe into the tunnel using rail-car system g p p p pp g y This method required precise alignment rail and pipe string. Due to mis-alignment of rail segments installed within the tunnel, flexibility of trolley car wheels and stiffness of fabricated pipe string the trolley cars were string, getting derailed and pushing could not be continued. Finally this method abandoned Limited time available before onset of monsoon, improvised method involving placement of 20 T rollers within the entire length of tunnel considered, which y g g pp g would not only take higher degree of rail/pipe mis-alignment, but would not result in pipe falling off the rollers. pushing efforts. This method also would minimise the

PRODUCT PIPE PUSHING OPERATIONS

Spare availability of rollers helped in implementing this methodology Pipe string provided with a cone pull-head helped in tackling the misalighment of tunnel pipe and still pipe string. Pushing of 1st string with Thruster went off smoothly. 2nd string rolled over, brought in alignment, welded with 1st string and pushing continued. Similar procedure adopted for 3rd string. Total length of th pipe string pushed i t th t T t ll th f the i t i h d into the tunnel was 2438 m. l Post hydrotest completed after Installation of Pipe inside the tunnel Riser with 6 D bends installed within West Shaft, to bring the product pipe to the ground level.

Initial Pipe Pushing Operations

Pipe string on rollers

Shallow Shaft Entry Profile

Pipe Thruster in Action

Pipe Pushing in Progress

Tunnel View Prior to Pipe Entry

Pipe Pushing Rail Car System

Rail Car being Placed

Pipe Lift-off

Rail/wheel Misalignment

Rail Misalignment

Annular Space Grouting Operations

CP system and OFC ducts are laid inside the tunnel prior to product Pipe installation ll To prevent upheaval buckling and for effective Cathodic Protection, annular space between product pipe and tunnel pipe grouted grouted. 8 HDPE pipe is laid inside the tunnel for grouting activities Approx. 52 grout samples prepared with different proportions of Cement, Bentonite, Flyash and Water mix Grout mix finally adopted consisted of 150kgs Cement + 400kgs Fly ash + 30k s B t it + 850 lts water sh 30kgs Bentonite t Set up for Grout mix plant consisted of 4nos Steel mixing tanks, 10 p ( g g ) g , Pumps (Mixing+Charge+Transfer) , Agitators, and manual labour

Project Milestones
Infrastructure works commenced in May, 2006 Site development and pipe factory works commenced in June, 06 Shaft construction started in Nov 06 and completed in April 07 East, West, East West Central and Shallow Shafts took 26 23 72 and 14 days 26, 23, respectively to complete Tunneling commenced in January 07 and completed in May 07 Tunnel from East to Central Shaft (280 pipes), West to Central Shaft (324 pipes) and East to Shallow Shaft (12 pipes) took 84, 83, and 16 days respectively i l Fabrication of 2400 m long product pipe took 4 months between Feb and May 07 Product pipe pushing took 6 days to complete in July 07

Project Statistics
Approx. 20,000 m3 of soil removed during tunneling Tunnelling activity took days to complete Total concrete used is 5,700 m3 and steel used 820 t. Number of RCC Tunnel pipes used is 616. Annular space filled with grout (mix of fly ash, cement and bentonite); 3,500 t of fly ash, 1,000t of cement and 400 t of ) y bentonite; Total grout used 8,600 m3. Grout filling done from East to Central Shaft and Shallow to Central Shaft in C t l Sh ft i 12 d s and 22 d s respectively days d days s ti l

Vashista Godavari - World Record HDD Crossing

Background
Past history in executing large dia HDD were limited at the project development stage. 48 48 Size & over 1700 m length made this crossing biggest HDD attempted ever before. Any failure would seriously affect the project completion schedule, thus a fail-safe methodology was required required. HDD Contractors willing to stretch the limit of technology, but were unwilling to take high risks involved. Despite approaching renowned HDD Contractors worldwide, firm proposals could not be secured. g p p p To encourage HDD Contractors participation, innovative concepts of Cost Plus and Risk Sharing were required. Infrastructure related works got done separately Renowned HDD specialists engaged to finalise methodology and equipment selection.

Constraints
River flood-prone during monsoon (July October) and HDD works were to be performed between November and June. High embankment (> 5m) on either banks (Flood Bunds) restricted the working space availability. Entry/exit points were to be located within the river, so that drilled length is minimum and the construction methodology feasible feasible. Any delay in construction, may result in work abandonment due to river flooding Space available between exit point and the flood bund not enough for accommodating the product pipe string p p q g g Flood Bunds were not permitted to be cut open, hence requiring huge temporary ramps to be constructed on either sides Pulling the pipe over the ramp required additional equipment provision

Crossing Location
Crossing located at KP 64.7 on EWPL Trunkline in Andhra Pradesh State Length of the crossing more than 1700 m m. Product pipe : 48 dia, 25.4 mm thk, X-70, & FOC 8 dia

Flood Bund

Flood Bund

Pipe Side

Rig Side

Design
Site investigation done, soil analysis and scour potential estimated, pipe profile worked out to be below the scour profile. M i Maximum cover of 36 m b l f below th river b d the i bed Due to stiffness of 48, 25.4 mm thk pipe, profile with a radius of 2000 m for both entry and exit curves required. Pipe profile passed through successive layers of 200 m of silty sand at entry curve, a second section of 1100 m of clay layer on the central horizontal section, and in a final section of 424 m of silty sand at the exit curve Entry & Exit angle - 6 Deg silty Soil conditions favorable for HDD, but the interface between the siltysand and clay layers were critical

Methodology
Methodology developed duly taking into account the field constraints and the risks involved Two rigs envisaged to provide assistance when needed envisaged, Para Track system considered of tracking the pilot hole Floatation trench considered to reduce the pipe weight and to reduce the pull-back forces pull back Ramps on either sides of flood bund on pipeside considered to enable pipe cross-over during pull-back operation Buoyancy system considered to reduce downhole pipe weight, and also y y y pp g not to exert loading during pull-back on ramp Multiple contingency arrangements viz. RCC Anchors, Air Hammer and winches provided for Round the clock working considered due to the type of soil present HDD Specialists mobilised to provide round the clock support and technical assistance

Pipeline P fil Pi li Profile

Pipe Profile p

Scour Profile

Infrastructural Works
Approach roads from nearest main road to Rig Side and Pipe Side
Anchor foundation for 400T/250T Rig Lagoons for mud preparation & water storage Hard stand around Rig site & Pipe site area Ramp on Flood bunds for Vehicular movement and string preparation/Pulling Floatation Trench for Pipe string Anchors for contingency

Equipment Deployment
Drilling Spread comprising of 2 no. rigs viz. 400 T with a torque capacity of 120 kNm on the rig side, and a 250 T rig with a torque capacity of 90 kNm on the pipe side. Downhole tools consisting of 2000 m 5 drill pipes Gr S 135 and 2000 m 5 Gr S 135 drill pipes; 10 no. fly cutters and 9 no. barrel reamers of various sizes Mud equipment included 2 no. mud mixing tank, 2 no. recycling unit, 3 no. high pressure pumps (for 2.5 m3/minute), 13 no. transfer pumps and 2 no. mud return pumps (150 m3/minute) for running the mud system in between mixing, recycling and pumping equipment. Air Hammer Taurus combined with 2 no. 30 t winches to provide assistance to 400 T rig at the tail of the product pipe during pull back operation 600 T THR Bentonite and 50 t additives mobilised with mud engineers Side boom 90 t 5 no 70 t 2 no no., no.

HDD O Operations i
Mobilization started in September 2006, and the first drilling spread (250 tons) reached the site two months later for starting the first pilot hole Drilling spreads, including one 400 T and 250 T rigs, set up at entry and exit points, located inside the floodable zone of the river Product pipe string, 1724 m long, positioned at the exit side, over 5 m high flood bund by building two ramps . To reduce the pulling loads, entire pipe string beyond flood bund made to float within a trench filled with water. Custom built heavy duty rollers (80 T) used for accommodating the pipe string between the trench and exit point, thru the ramp.

Exit Side Layout

Floatation Trench & Ramp Over Flood Bund

Rollers over Ramp

48 String in Floatation Trench

HDD Operations
Work performed on 24 hrs basis due to the nature of soil present 1st Pilot hole completed in 23 days including pull back of casing pipe. 2nd Pilot hole completed in 16 days Both the pilot holes with 250 t rig and days. 5 drill pipe. For both pilot holes, entry casings 200 meter, 12 diameter, inserted in the first sand layer at entry side in order to maintain the drill string in position while pushing on the long drill string. Hole opening completed in 52 days with both 400 t and 250 t rig working in tandem and using 5 drill pipe pipe. Hole opening operation done in five successive reaming passes with buoyant fly cutters upto a final size of 68.
32 Fly 44 Fly 54 Fly 60 Fly 66 Fly + + + + + 28 Barrel 40 Barrel 50 Barrel 56 Barrel 62 Barrel 1st stage 2nd stage 3rd stage 4th stage 5th stage

HDD Operations
During 1st pull back operations, a twist off of the pulling assembly occurred between swivel joint and pull head, while pulling thru gravel interface at exit curve. 48 pipe already pulled approx. 500 m inside the reamed hole was removed with assistance of Taurus Air Hammer and side booms After reconditioning the product pipe and the reamed hole 2nd pull pipe, hole, back attempt performed two weeks later successfully in 72 hrs, and experiencing a maximum pull force of 320 t. HDPE Pipes inserted taken out with difficulty due to damage caused difficulty, by air-hammer oprations.

Contingency Arrangement g y g

Buoyancy System Insertion and Retrieval

HDPE Pipes insertion

HDPE Pipes Retrieval

HDD Crossings in EWPL

LIST OF HDD CROSSINGS
Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 Name of the Crossing CORANGI RIVER 1 & 2 CORANGI CANAL MANDAPETA CANAL MADKI CANAL+NH5 GODAVARI MAIN CANAL VASISTA GODAVARI RIVER ENUMUDURU DRAIN+ CANAL ELURU CANAL+NH5 ELURU CANAL+NH5 PURNA RIVER KIM RIVER NARMADA RIVER Chainage ( ) (km) 9.20 19.38 49.46 57.54 57 54 62.75 64.78 76.68 99.96 125.55 1287.49 1342.58 1342 58 1368.23 Total Length, m LENGTH 945.0 328.0 359.0 440.0 440 0 535.0 1724.0 515.0 355.0 331.0 670.0 710.0 710 0 1324.0 8236.0

World Record
Notwithstanding several setback faced during construction including delayed arrival of rigs, bentonite blow-out, failure during 1st pull back attempt, damage to HDPE Pipes during pull back, the entire operation could be completed and World Record thus made due to determination of Team EWPL Critical and timely decisions helped in accelerating the work execution and creating History.

TAPI RIVER CROSSING

FLOAT & SINK TECHNIQUE

Tapi River Crossing Location

Surat

LOCATION
Located at KP 1322 on Trunkline Route, south of Surat City in Gujarat Location isolated from tidal influence due to barrage present

downstream Perennial River with average water level of 3 5 m; 3.5 Bed width : 532 m; Bank width : 585 m ; North Bank 19m; South B k +18 m; Ri N h B k + 19 h Bank 18 River B d -3.1 m; HFL +19.85 m; Bed 3 1 19 85 Max Vel : 4.3 m/sec Soil investigation (d l (deep b bore h l ) and h d l holes) d hydrological d l data collected ll d Soil found to be suitable for HDD

EXECUTION
HDD work awarded, equipment mobilised and installation procedure finalised in time to commence the work. RoU issues arose at the work site, thus necessitating re-routing resulting in change in crossing location. Soil investigation redone and presence of gravel and boulders detected. HDD option ruled out due to this soil strata and alternate installation strata, methodologies became necessary g Micro-tunnelling not found feasible within the time available for implementation Trench excavation by open-cut the trench and pipeline installation by float & sink technique was only feasible option.
4

EXECUTION
Trenching in underwater with water based equipment, excavation in steep banks and State Highway crossing near the north bank posed difficulties in working out an installation methodology Also no Contractor was willing to undertake the works with a single point responsibility. Specialists engaged separately to detail the installation methodology , identify and select the equipments, and make a plan for implementation. Separate Agencies engaged for underwater trenching/backfilling & excavation on bank pipeline installation

Equipment q p
Crossing location being far from coastal area, equipment to work within the waterbody were not readily available. Pontoons were identified and mobilised to site by road trailors, so that a floating working platform could be established, over which land based dredger/excavators or dredging equipment could mounted for carrying out trench excavation works works. Custom designed, Pi-Derrick supporting structure fabricated at site, to assist in holding the swan neck during pulling operation. g gp g p

Design g
Pipeline designed in compliance with ASME B31.8 and applicable statutory p g mp E . pp y regulations. Pipe wall thickness selected for design and checked for installation conditions involving pulling of pipeline Anti-buoyancy measures viz. continuous concrete coating of 130 mm provided on the pipe Elastic bending radius of 2000 m adopted Pipeline designed t h Pi li d i d to have a minimum cover of 2 5 m f i i f 2.5 from th riverbed. the i b d

Installation Methodology Development

Uneven riverbed profile with varying soil strata and varying water depth during the installation duration offered difficulty in selecting the method ll l l of trenching within the river. Cutter suction dredger (combination of rotary cutter suction pipes & mud cutter, pumps) , track mounted excavator with long boom mounted over floating pontoons equipped with spud poles, mooring provision & anchoring, sand boat dredgers were considered for trenching/backfilling works within the river Depth of the river and the consequent depth to which the pipeline to be laid near the north bank, space limitation on north bank, profile and limited land available for temporary use in south bank were the main constraints in developing methodology for string fabrication for pulling

Installation Methodology Development

Pipe string with swan neck bends on either sides of the straight section considered, to avoid coffer-dam for tie-in with adjoining section. PI-Derrick PI Derrick considered to hold and stabilise swan neck bends during pulling operations in water HDD Drill Rig considered for pipe pulling instead of conventional drum g pp p g winch, as it could be erected within the RoU, could be mobilised easily, to provide pull force in a controlled manner To enable the concrete coated pipe to float during pulling, custom designed floatation tanks considered Partial pulling followed by mounting of floatation tanks considered due to interfering State Highway on the north bank

Installation Methodology Development

Special mechanism considered for floatation tank release, for better control in release and recovery after installation l l ll Hold-back with side-booms and dozers considered to prevent string slip-off slip off during pulling operations To reduce the pipe pulling loads, concrete coated pipe string fabricated over custom-made heavy duty rollers. (26 T each pipe wt.) y y ( pp ) Shoring with sheet piles considered to prevent trench collapse Combined dead-man anchor and sheet-pile wall considered to take care of the HDD Rig loads during pulling Trench profile monitoring with echo-sounder and GPS considered

String Fabrication and Pulling

Trench prepared on both banks to suit the profile of the pipeline. (Max depth > 20 m and width approx. 25 m) Pipe string of 41 pipes of 492 m l P f f length prefabricated on pipe rollers. h f b d ll Floats mounted on pipes and connected to the steel band tied over the pipe thru a easily detachable pin; also connected to a cable laid along the pipe to facilitate easy pull-out , p , After trench clearance, Pi-Derrick mounted on potoons launched, and the swan neck bend held in position with a chain-pulley block. HDD Drill pipe with a swivel attached to the pull-head provided at the bottom of swan neck bend. Pulling of the string carried out with HDD Rig (400 T); 90 T sidebooms also pushed the pipe d l h d h during pulling operation, to reduce the pulling ll d h ll efforts Drill Rig
11

Sinking
During the pulling operation water was filled into the pipe string at two stages i.e. at 40% and 60% of pulling to partly submerge the pulled string to ensure stability against river currents and wind Once the swan neck bend reached the south bank, swan neck for the north bank welded to the end of the string and pulling continued till the time the bends reached the designated location location. Once the location reached, pulling mechanism released the floatation tanks, facilitating sinking of the pulled string to the bottom of the river bed

12

Trenching Operations

Excavation near North Bank

Excavation in River

Excavation near South Bank

Pulling Operations

Pi-Derrick with Swan Neck

Pulling North Bank

String Floatation

Sidebooms Assisting Pull

Pulling Near Completion

Swan Neck Welding prior to Final Pull

Back filling
Sand and spoil dredged earlier were again dredged and pumped back in to the trench over the pipe for cover, using pontoon mounted excavator and sand boat dredgers. Wherever the cover found to be less, grout bags with sand and cement in 1:10 ratio placed over the backfill; transportation by barge and placement by excavator excavator. Positioning done with GPS and monitoring done with bathymetric y survey. In addition, smaller grout bags with sand cement mix were also spread over the large grout bags in post-monsoon season.
15

Summary
Despite the set-back in the intiial plan, alternative installation methodology worked out, specialist agencies engaged, equipment mobilised to undertake and complete the pipeline installation in a short time span available before onset of monsoon monsoon. Trenching took over 4 months and fabrication of strings and other paraphernal a paraphernalia took over 2 months, where as the actual pulling o er pull ng completed in 3 days time. Entire activities including bank stabilisation done prior to onset of monsoon and in time for pre-commissioning of adjoining pipeline sections

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TERNA RIVER (MAKNI SUBMERGENCE) CROSSING

COFFER DAM METHOD

TERNA CROSSING DETAILS

Located at KP 687 Trunkline Route near vicinity of Osmanabad in Route, Maharashtra Crossing was initially a 50 m long crossing with less than 1 m water crossing, depth. No special construction methodology envisaged Due to unprecedented rainfall in the year 2007, the extent of submergence increased to 2220 m and the water depth at the crossing location found to be varying between 6 - 9 m encountered. Soil investigation revealed hard gravelled strata at the river bed level level.
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TERNA CROSSING DETAILS

Extent of submergence, soil strata and accessibility to site posed f g , y p constraints in carrying out HDD. Inaccessibility of crossing location, necessitated developing an nacc ss ty cross ng ocat on, n c ss tat op ng installation methodology adopting conventional technique. Due to difficulties in trenching/backfilling in varying water depth of 6 9 m, bottom pull option ruled out. Cofferdam methodology, even though quite voluminous, was found feasible. Hence adopted for implementation

19

PROJECT PLANNING
Soil required for cofferdam construction was approx. 350,000 cu m (Approx. 40,000 dumper truckloads) Dewatering the cofferdam required approx. 10,000 cu m / hr pumping capacity To ensure stability, cofferdam size minimized and 4 no. of cofferdam constructed which eased the pipeline construction In order to avoid increase in water level during monsoon and consequent difficulty in constructing cofferdam, works were planned to be completed within 16 weeks time.
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PROJECT PLANNING
Resources identified and mobilised to complete the works within 16 weeks. k Major resources required were dumpers, dewatering pumps, excavators and rock b d k breakers. k To minimise the time for transportation of soil, land in the vicinity of crossing l i leased and soil excavated f construction of cofferdam. Thi d d il d for i f ff d This methodology substantially saved the efforts and in turn time. Two d ff different agencies engaged viz. d
Cofferdam construction and dismantling Dewatering, t D t i trenching, stringing, pipeline i t ll ti and b kfilli hi t i i i li installation d backfilling
21

COFFERDAM CONSTRUCTION
Width of Cofferdam at the base kept considering the eventuality of encountering water level increasing upto 9 m. Layered polythene sheets used to minimize seepage of water through cofferdam Dewatering pumps to maintain discharge capacity of 10,000 m3/hr deployed. Once dewatered, equipment mobilised to cofferdam for trenching and rockbreaking. Dewatering pumps kept in operation continuously to take out seepage water Pre-tested pipes strung and welded in trench and equipment movement within cofferdam minimised. Due to difficulty in handling heavy concrete coated pipes, option of geotextiles bag filled with crushed stone (2.2 T/m) adopted for anti-buoyancy measure.

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Cofferdam Construction Sequence

Pipeline Installation Coffer Dam #2

Coffer Dam #3

S u b m e r g e n c e

Coffer Dam #1 Coffer Dam #4

Dewater
Pipeline Buried

Terna River

S u b m e r g e n c e

Difficulties Encountered
Difficulties faced including partial collapse of cofferdam, water seepage, increased water level due to early onset of monsoon, etc. Despite all the difficulties, the work could be carried out and completed within the targeted time schedule of 4 months from December 07 to April 08.

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Acknowledgement
Thanks to Reliance Management for this Presentation and h k l f h P d Reliance Construction Groups for providing valuable inputs in preparing pr p rin this pr s nt ti n presentation

Q Question and Answer

Thank You