NGWSP_Blk_4a-4b_-_Revised_spec_sections_14NOV_2022_0003.pdf

Navajo-Gallup Water Supply Project San Juan Lateral – Block 4A/4B

140R4022B0001 Amendment 003

Horizontal Directional Drilling (HDD) 33 05 22 - 1

SECTION 33 05 22

HORIZONTAL DIRECTIONAL DRILLING (HDD)

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Horizontal Directional Drilling (HDD):

1. Measurement: Horizontal length along pipe centerline, without allowance for slope, between ends of pipe in place.

2. Payment: Linear foot price offered in the Price Schedule. Includes:

a. Preparation of drilling site, entry/exit points, and pullback areas, topsoil stripping, backfill, final grading, inspection, clean-up, and restoration.

b. Mobilization and demobilization of drilling and support equipment.

c. Pilot bore drilling, hole reaming and cleaning, and completing drilled hole to dimensions on drawings.

d. Hauling and disposal of drilling fluid, byproducts, and cuttings.

e. Furnishing specified HDD Pipe and connections required at both ends.

f. Two reinforced concrete anchor blocks to restrain the miter bend and pipe connection at each end of HDD. Includes forming, furnishing, and placing concrete, reinforcement, and finishing.

g. Pre- and post-pullback testing of the pipe.

h. Costs for providing and disposing of:

1) Sacrificial length of HDD Pipe at each end which extends beyond the miter bend connection locations to a point at least 3-feet above ground surface.

2) Sacrificial length shall be long enough to prevent settlement and strain recovery effects of the HDD Pipe from retracting the pipe ends below the ground surface.

3) Design and fabrication of pulling head.

4) Two temporary end caps or blind flanges, one at each end of HDD

Pipe, to prevent contamination or other debris from entering HDD Pipe before connection to Line Pipe.

5) Two pipe connections from Line Pipe to HDD Pipe, one at each end of the HDD installation:

6) Pipe connections shall be constructed as restrained pipe lengths between Line Pipe and HDD Pipe.

San Juan Lateral – Block 4A/4B Amendment 003

Horizontal Directional Drilling (HDD) 33 05 22 - 2

a) Different pipe materials may exist between Line Pipe and HDD Pipe. Connections shall accommodate different pipe materials.

7) Two miter bends, one at each end of the HDD Pipe, to transition from HDD Pipe slope to Line Pipe slope as constructed.

8) Abandoning an unsuccessful drill hole, drilling a new hole, and providing replacement pipe, fusing, and testing of additional pipe.

9) Pipe damaged beyond repair during installation as determined by OGR, or not retrieved from an unsuccessful pullback installation, shall be at expense of Contractor.

i. Additional trench excavation or backfill as necessary to make connections between HDD Pipe and Line Pipe.

1.02 REFERENCE STANDARDS

A. American Petroleum Institute (API)

1. API RP 13B-1 Recommended Practice for Field Testing

Water-based Drilling Fluids

2. PPI, Chapter 12 (HDD) Plastic Pipe Institute, Horizontal Directional

Drilling

B. American Society of Civil Engineers (ASCE)

1. ASCE MoP-108 Pipeline Design for Installation by Horizontal

Directional Drilling, Manual of Practice 108, Second Edition.

C. ASTM International (ASTM)

1. ASTM A139/139M-16 Electric-Fusion (Arc)-Welded Steel Pipe (NPS

4 and over)

2. ASTM A519 -17 Seamless Carbon and Alloy Steel Mechanical

Tubing

3. ASTM E18-16 Rockwell Hardness of Metallic Materials

4. ASTM F1962-20 Standard Guide for Use of Maxi-Horizontal

Directional Drilling for Placement of Polyethylene Pipe or Conduit Under Obstacles, Including River Crossings

5. ASTM D3350-14 Polyethylene Plastics Pipe and Fittings Materials

D. North American Society for Trenchless Technology (NASTT)

1. Trenchless Technology Horizontal Directional Drilling Guide, 2015.

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2. Trenchless Technology Horizontal Directional Drilling Good Practices Guidelines, Third Edition

E. Pipeline Research Council International

1. PR-277-144507-R01 Installation of Pipelines by Horizontal

Directional Drilling, “An Engineering Design Guide” (2015).

2. PR-227-9424 Installation of Pipelines by Horizontal Directional Drilling, an Engineering Design Guide, (1995).

1.03 REQUIREMENTS

A. Design Criteria: In accordance with Table 33 05 022A – Design Criteria.

Table 33 05 22A – Design Criteria Description Criteria

Bending radius (ft.)

Larger of 1200 x drill rod diameter (in feet) or:

a. 100 feet/inch x outside diameter of pipe (in inches) for steel pipe

b. 100 times outside diameter of pipe (in feet) for HDPE pipe

c. 250 x outside diameter of pipe (in feet) for fusible PVC pipe

Allowable circumferential (hoop) tensile stress 0.5 x specified minimum yield strength Allowable compressive stress 0.5 x specified minimum yield strength Allowable pull (axial) stress 0.67 x specified minimum yield strength Allowable combined stress 0.5 x specified minimum yield strength

Allowable vertical deflection 5 percent for flexible lined and coated steel pipe

B. Installation Loads and Conditions: In accordance with Table 33 05 22B – Installation Loads and Conditions.

Table 33 05 22B – Installation Loads and Conditions

Load Description Value Maximum internal fluid pressure As determined by Contractor, but no greater than

30 psi gage External hydrostatic pressure 0 psi gage Drilling fluid pressure As determined by Contractor and Drill Fluid

Engineer

C. Maintain design criteria and maximum specified installation loads and conditions during installation. Use additional installation loads and conditions as necessary to ensure

33 05 22 - 4 successful HDD Pipe installation. Conduct work in accordance with current industry standards.

1.04 SUBMITTALS

A. Submit the following in accordance Section 01 33 00 – Submittals.

B. RSN 33 05 22-1, Key Personnel Resumes:

1. Include at a minimum:

a. HDD Contractor.

b. Project Engineer registered as a Professional Engineer in the State of New

Mexico.

c. Drilling Fluid (mud) Engineer/Technician.

d. HDD rig operators.

2. Submit personnel changes with a minimum notice of 48-hours to COR:

a. Changes require COR approval prior to work being performed by new personnel.

C. RSN 33 05 22-2, Work Plan:

1. Include:

a. Detailed procedures, safety precautions, and schedule for each site.

b. Drawings and calculations for each site showing:

1) Contractor requested bore path revisions, if proposed.

2) Estimated pullback force on HDD pipe and assumptions for calculating pullback force.

3) Entry, exit, and steepest bend angle for pipe during pullback.

4) Maximum stress and location for each pipe during pullback.

5) Pipe laydown areas for joining/welding and testing prior to pullback.

Include calculations for pipe stress in laydown area prior to pull back.

6) Lift plan for pipe pullback to ensure steel pipe does not undergo excessive tensile stresses as it enters the borehole or at any point in the laydown area.

7) Factor of safety against hydro-fracture along entire alignment.

8) If applicable, conductor casing installation including calculations for casing stresses during installation.

D. RSN 33 05 22-3, Contingency Plans:

1. At a minimum, include for following situations:

33 05 22 - 5

a. Inadvertent drilling fluid migration and release in soil and/or permeable bedrock formations.

b. Equipment malfunction or failure.

c. Pullback forces reach 80 percent of calculated maximum allowable pulling force.

d. Stuck pipe.

e. Damage to existing utilities.

f. Encountering subsurface obstruction.

g. Unexpected geologic conditions.

h. Pipeline misalignment or loss of steering control.

i. Loss of pressure control.

j. Hole collapse.

k. Pipeline collapse.

l. Hole abandonment.

E. RSN 33 05 22-4, Drilling Plan:

1. Include:

a. Size of drill rig, including torque, thrust, and pulling capacities.

b. Shift plan to operate and maintain drill rig and associated equipment.

c. Type of rig, including size of motors and pumps. Include specifications and manufacturer’s data for primary and ancillary equipment to be used. Include information on equipment to be used for conductor casing installation, if applicable.

d. If applicable, conductor casing size, thickness and alignment with details and dimensions of cutting shoe.

e. Description of down-hole survey instrumentation and surface location equipment:

1) Type of tracing equipment, including stated accuracy.

2) Pilot survey equipment, including stated accuracy.

f. Sketch of cable layout for survey instrumentation and location of surface equipment, (if applicable) to survey drill hole.

g. Pilot hole size, each reaming step size, and final hole size.

h. Plan and Profile for HDD crossing if a revision is proposed. Provide a narrative documenting why HDD cannot be performed as shown on drawings and specified.

i. Diameter, type, and grade of drill pipe.

j. Equipment required to obtain, filter, and process water for drilling.

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k. Source and quantity of water required for drilling operations with estimated maximum daily consumption rate.

l. Drilling fluid system, including fluid travel path, return path, planned recycle or reuse plan, filtration equipment and details, sedimentation/settling pond location, and other relevant details.

m. Drilling fluid composition, additives, consistency, and components.

Include:

1) Planned density and viscosity ranges.

2) Plan detailing monitoring of drilling fluid properties and pressure, including frequency.

n. Equipment and procedures for borehole:

1) Cleaning (pigging) or swabbing pass.

2) Equipment and procedures for HDD Pipe cleaning after pullback, prior to final testing.

o. Plans for ballasting product pipe during pull-back, if applicable.

p. Procedure for monitoring alignment for drilling fluid release including waterways.

q. Pipe supports.

r. Plan for pipe fabrication and pullback support; number and sizes of pullback equipment (i.e., number of side booms, cranes, and other support equipment).

s. Diagram of equipment and site layout, including dimensions and required clearances (horizontal and vertical).

t. Plan for site grading including entry and exit pits, and access road preparation including support mats.

u. Sample of daily reports.

v. Drawing of pullback head or shield, swivel, and connections to HDD pipe designed or approved by licensed Professional Engineer familiar with HDD practice and design.

F. RSN 33 05 22-5, Calculations:

1. Design and construction calculations, including:

a. Required pulling force in pounds.

b. Maximum tensile and circumferential (hoop) stress of pipe during pullback and construction.

c. Buckling stability during pullback and construction.

d. Ratio of vertical deflection to outside diameter of pipe from earth loading.

Compressive stress from external hydrostatic pressure and earth load.

e. Combined stresses from pipe curvature and circumferential (hoop) stress.

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f. Total length of pipe relaxation following pullback.

g. Projecting length of HDD Pipe required to prevent retraction below the ground surface due to conduit settlement and Poisson’s effects following pullback.

h. Hydro-fracture analysis performed using standard industry practices including minimum required pressures, maximum anticipated drilling fluid pressures and maximum allowable drilling fluid pressures during drilling and pullback operations. Include factor of safety against hydro-fracture along alignment.

i. Thrust restraint anchor block sizing and design calculations based upon actual HDD entry and exit portal locations and required connection installed to align with Line Pipe.

j. Maximum stresses on pipe while pipe is supported in laydown area prior to pull back operations.

k. Signed and stamped by a licensed Professional Engineer with a minimum of 3 years’ experience in HDD design.

2. If a revision to HDD work is proposed, submit following calculations for approval:

a. Design and construction calculations listed above.

b. Required wall thickness of HDD Pipe.

c. Minimum bending radius for HDD Pipe.

d. Ratio of vertical deflection to outside diameter of pipe from earth loading.

Compressive stress from external hydrostatic pressure and earth load.

e. Signed and stamped by a licensed Professional Engineer with a minimum of

3 years’ experience in HDD design.

G. RSN 33 05 22-6, Photo Documentation:

1. Prior to alteration of site, make digital recordings of area, including entry and exit points.

H. RSN 33 05 22-7, HDD Pipe Retention Plan:

1. Submit stability calculations and methods of securing pipe, including:

a. Equipment to prevent movement during installation and testing.

b. Securing methods may remain in-place at completion of project.

I. RSN 33 05 22-8, Daily Reports:

1. Submit daily reports at end of each work shift. Include:

a. Supervisor on-site, crew members on-site, shifts and time worked.

b. Description of work, tools in use, footage completed.

c. Daily total of drilling fluid used and total to date.

d. Loss of drilling fluid circulation, pressure, or inadvertent fluid return.

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e. Pilot drill deviations and corrections made.

f. Penetration rates for each pilot or reaming pass.

g. Copy of directional survey report and report from tracking system.

h. Data to calculate minimum radius of each 3-joint segment of pilot boring.

i. Disposal quantities of drilling fluid and cuttings.

j. Drilling schedule and plan updates.

k. Details of, and perceived reasons for, unusual events and delays greater than one hour excluding normal breaks.

l. Note any safety incidents, including near misses, in daily report. Include details about measures taken to prevent future incidents.

J. RSN 33 05 22-9, Drilling Fluid Daily Report:

1. Include, per API RP 13B-1:

a. Density of drilling fluid (mud) weight.

b. Viscosities:

1) Apparent viscosity.

2) Plastic viscosity.

3) Yield point.

c. Funnel viscosity: Using Marsh Funnel.

d. Gel strength.

e. Solids and sand content.

f. Water loss: Filtration.

g. Chemical quantity of make-up water and drilling fluid:

1) pH.

2) Chlorides.

3) Hardness.

K. RSN 33 05 22-10, Drill Fluid and Cuttings Management and Disposal Plan:

1. Include:

a. Description of planned haul and disposal methods and location(s).

b. Permitting and Approval from permanent disposal site to dispose of drilling fluid, cuttings, and byproducts at their facility.

c. Details on sub-contractors involved with disposal activities, to include at a minimum: Company name, normal and emergency contact information, and role(s).

d. Drilling fluid composition with Safety Data Sheets (SDS) for each material or component.

e. Additives with SDS.

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f. Cuttings composition, including any byproducts, to be disposed.

g. Intervals of disposing of drilling fluid:

1) Duration between loads.

2) Volume per load.

h. Disposal hauler details, including equipment safety details and procedures, and loss prevention methods to prevent environmental contamination.

i. Estimated daily and total quantities for disposal.

2. Submit changes to OGR for approval prior to implementation.

L. RSN 33 05 22-11, Disposal Report:

1. Include:

a. Quantity of drilling fluid, byproducts, and cuttings hauled from drill sites.

b. Bill of lading and trip ticket for each truck load.

c. Lab sample results in accordance with disposal permit: minimum 1 per drilled site.

M. RSN 33 05 22-12, Fluid Release Contingency Containment Report:

1. Include:

a. Description of equipment and materials.

b. Inventory of equipment and materials to be stockpiled on-site.

c. Sample of a report (quantity of fluid released, location, response time, and clean-up activities required).

2. Required for efforts related to collecting and clean-up after a drilling fluid release has been detected. Submit report to OGR within 48-hours of a drilling fluid release being detected.

N. RSN 33 05 22-13, Final Report:

1. Include:

a. Computerized printout and electronic file of directional survey report and instrumentation report, or equal, made during drilling operation.

b. As-built map of horizontally drilled section showing the “x”, “y”, and “z” coordinates of final pipe location. Spacing between coordinate points shall be at every pipe joint, or 30-foot maximum, whichever is less.

1.05 QUALIFICATIONS

A. Contractor shall have a minimum 5-years' experience on HDD projects of a similar size and scope:

1. Successfully completed at least (3) previous HDD borings of similar size and scope.

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2. Provide contact information (project name, contact name, phone number, and email address) for each of (3) successful projects listed above.

1.06 QUALITY ASSURANCE

A. Perform work in accordance with Horizontal Directional Drilling Good Practices Guidelines and Directional Crossing Contractors Association (DCCA).

B. OGR will be present during required testing. Notify OGR at least 72-hours prior to testing.

PART 2 PRODUCTS

2.01 EQUIPMENT

A. Drill equipment:

1. Directional drill rig of enough size and capacity to perform bore and pullback of pipe.

2. Drill fluid mixing and delivery system of enough capacity to complete boring.

3. Guidance system to accurately guide boring operations:

a. Paratrack 2 system, or equivalent, including Paratrack 2 steering tool, drillers’ console interface, power guide supply and computer as manufactured by Vector Magnetics LLC, www.vectormagnetics.com.

B. In safe operating condition with enough supplies, materials, and spare parts on-hand to maintain system in working order for duration of project.

C. Supply adequate number of trained and competent personnel, including key personnel identified in this Section.

2.02 DRILL SYSTEM

A. Drill Rig:

1. Hydraulically powered system to rotate, push and pull back hollow pipe into ground at a variable angle while delivering a pressurized fluid mixture to a guidable drill (bore) head.

2. Anchor machine to ground or temporary concrete block to withstand pulling, pushing and rotating forces required to complete boring and pipe installation.

System to be designed and stamped by licensed Professional Engineer, registered in the State of New Mexico.

3. Hydraulic power unit: Self-contained, with sufficient pressure and volume to power drilling operations. Hydraulic system shall be free of leaks.

4. Contains a system to monitor and record fluid pressures and flow rates, and a force gage to measure maximum forces during pullback operations.

http://www.vectormagnetics.com/

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B. Drill Head:

1. Steerable by changing the drill heads’ rotation and face angle.

2. Provide cutting surfaces and drill fluid jets.

3. Contains instrumentation to determine orientation and angle of the cutting face.

C. Mud Motors:

1. Adequate power and torque to turn required drilling tools.

2. Capable of withstanding anticipated pressures experienced during boring and reaming operations.

D. Drill Pipe:

1. Constructed of high quality 4130 seamless tubing, Grade D or better, with threaded box and pins.

2. Tool joints hardened to 32-36 Rockwell C (HRC) hardness minimum.

E. Drilling Fluid:

1. Liquid bentonite clay slurry made using clean water.

2. Drilling fluids, muds, and chemical additives: Non-hazardous materials composed and used in compliance with applicable local, State, and Federal environmental regulations.

3. Additives: Environmentally compatible products meeting requirements of Section 01 57 30 – Water Pollution Control. Do not use oil-based drilling fluids or fluid containing additives that can contaminate soil or groundwater.

4. Maximum unit weight of drilling fluid with cuttings to be limited to 10 pounds per gallon (ppg), unless otherwise approved by OGR.

F. Instrumentation:

1. Measure drilling fluid discharge rate and pressure.

2. Measure drill head location during pilot boring, reaming, and pullback operations.

3. Allow OGR access to all instruments and readings.

G. Conductor Casing, if applicable:

1. Steel casing pipe shall be new, smooth wall, carbon steel pipe that conforms to

ASTM A139, Grade “C”.

2. Minimum yield strength of 42,000 psi or greater.

3. Steel casing shall have roundness such that difference between major and minor outside diameter shall not exceed 1 percent of specified nominal outside diameter, or 0.25-inches, whichever is less.

4. Steel casing shall have a maximum allowable straightness deviation in any 10-feet of 1/8-inch.

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5. Steel casing pipe diameter shall be determined by Contractor to suit means and methods. It is expected that casing pipe will be at least 6-inches larger than outside diameter of largest reamer to be used by Contractor.

6. Minimum steel casing pipe wall thickness shall be 0.25-inches.

7. Casing section joints shall be butt welded, lap welded, or welded using butt straps in the field. Each end of casing for butt-welding shall be prepared by providing 1/4-inch 45-degree chamfer on outside edges. Use manufacturer’s specified welding wire or rod.

2.03 FILTER SYSTEM

A. Mixing and Filter System:

1. Self-contained, closed, drill fluid mixing system of sufficient size to mix and deliver drill fluid composed of bentonite clay, potable water, and appropriate additives.

2. Able to molecularly shear individual bentonite particles from dry powder to avoid clumping and ensure complete mixing.

3. Drill fluid reservoir sized for fluid (mud) storage.

4. Filter system capable of removing drilled cuttings and other particles from the fluid, and allow fluid to be re-used, as directed by the drilling fluid (mud) engineer/technician.

a. OGR may require new drill fluid and/or prohibit re-use of drill fluid, if it is determined that the filter system is not performing in a satisfactory manner:

b. Capable of handling and loading filtered cuttings and byproducts from the filter system to hauling equipment without loss or spillage.

5. Continually agitate drill fluid during drilling operations.

2.04 HDD PIPE

A. Conform to requirements of Section 33 11 12 – Steel Line Pipe, except as described below.

B. Smooth wall, carbon steel pipe conforming to ASTM A139, Grade “C” or equivalent:

1. Minimum yield strength of 42,000 psi.

2. Roundness such that difference between major and minor outside diameters shall not exceed 1-percent of specified nominal outside diameter.

3. Maximum allowable straightness deviation in 10-feet of 1/8-inch.

4. Inside diameter: 42.5-inches, with a minimum wall thickness of 0.25-inches.

5. Join segments using full-penetration butt welds.

a. Straight-seam welded pipe. Do not use helical-seam welded steel pipe.

b. Provide 1/4-inch 45-degree chamfer on outside edges at each end of HDD

Pipe to be welded.

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c. Use manufacturer’s specified welding wire or rod.

6. Pipe linings: Tabulation No. 06 in Section 09 96 20 – Coatings.

7. Pipe coatings: Dual-layer Abrasion Resistant Overcoat (ARO) Fusion bonded

Epoxy (FBE) in accordance with Section 09 96 20 - Coatings.

C. Connections to Line Pipe:

1. Install miter bend with articulated steel pipe segments to Line Pipe and HDD Pipe, see drawing 1695-D-61820.

2. Size miter bends in accordance with the applicable Section:

a. 33 11 12 – Steel Line Pipe

b. 33 11 13 – Ductile Iron Pipe

c. 33 11 16 – PVC Pressure Pipe

d. 33 11 18 – HDPE Pressure Pipe

3. Fittings and connections used to connect HDD Pipe to Line Pipe shall conform to Section 33 11 10 – Pipeline General Requirements.

2.05 OTHER EQUIPMENT

A. Pipe Rollers:

1. Support weight of pipe and rolling load forces during pullback operations.

2. Prevent excess sagging, maintain the entry alignment, control the entry angle during pullback, prevent buckling, excess stress and deformation of the pipe.

B. Restrictions:

1. Other devices or placement systems to provide horizontal thrust shall not be used unless approved by OGR prior to commencement of work.

2. Consideration for approval will be made on an individual basis.

3. Proposal will be evaluated for its ability to complete placement without undue stoppage and to maintain line and grade within tolerances.

2.06 THRUST RESTRAINT

A. Design anchor blocks to resist thrust and other loads at either end of the HDD Pipe based on actual angles drilled, and construct them in accordance with the approved Submittal and following requirements:

1. Constructed from reinforced concrete.

2. Sized to resist thrust (based on pipe transient head class as shown on drawings), settlement, and other loads.

3. Encase the miter bend on each end of the HDD Pipe.

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4. Do not use gasketed joints within the anchor blocks.

5. Place concrete in accordance with Section 03 30 00 – Cast-in-Place Concrete.

Provide reinforcement in accordance with Section 03 20 00 – Concrete Reinforcing.

PART 3 EXECUTION

3.01 GENERAL

A. Notify OGR in writing 72-hours in advance of starting work.

B. Do not begin until OGR has inspected job site, and RSNs 33 05 22-1 through 7, 33 05 22-

10, and 33 05 22-12 are approved.

3.02 PHOTO DOCUMENTATION

A. Prior to alteration of work site, make digital recordings of entire area, including entry and exit points:

1. Reclamation issued USB with minimum 720p resolution.

2. Label:

a. Contract number and title.

b. Contractor’s name.

c. Date recording is made.

d. Preface video with this information.

B. OGR may be present during recording:

1. Notify OGR at least 72-hours prior to recording.

2. Perform recording no more than 1-month prior to work.

3.03 PERSONNEL REQUIREMENTS

A. Fluid Technician shall be on-site during entire drilling process.

B. Fluid Engineer is not required to be on-site, but shall be available for consulting, during drilling and pullback process.

3.04 DRILLING PROCEDURES

A. Provide a level work site at locations shown on drawings. Confine activities to designated areas shown on drawings.

B. Conduct a visual survey of entire path to identify possible problem areas.

C. Archeological Compliance:

1. In accordance with Section 01 57 90 – Preservation of Historical and Archeological

Data.

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2. Execute work in accordance with approved Plans.

3. Perform HDD drilling, laydown, and pipe welding at locations shown on drawings.

Contractor shall determine laydown site and pullback direction for HDD location:

a. Prior to drilling operations or placing pipe on ground for welding and pullback, notify Reclamation staff archaeologist in accordance with Section 01 57 90 – Preservation of Historical and Archaeological Data.

D. Environmental Protection: In accordance with Section 01 57 30 – Water Pollution Control.

E. Pipe:

1. Notify OGR at least 48-hours prior to pipe layout.

2. Weld pipe together into one continuous length.

a. If needed, temporary road crossings shall be in accordance with Section 01 55 20 – Traffic Control.

b. Layout and restrain/secure pipe in accordance with approved Plans.

3. Prepare pipe for pullback operation:

a. Verify that no obstructions, edges, weld seams, or other hindrances exist on outside of pipe that would prevent or restrict pullback operation.

b. Notify OGR at least 48-hours prior to pullback to facilitate visual inspection by OGR.

1) Conduct pre-pullback meeting with safety review at least 48-hours prior to pullback.

c. Space rollers as required to prevent deflection, excess stresses, buckling and to control entry and break-over angles.

d. Verify pipe rollers move freely, are in proper alignment, at correct elevation, and will accurately control the direction of pipe during pullback.

e. Place pipe on rollers and make final preparations for pullback operation.

f. Conduct pullback operation in one single, continuous, controlled operation to prevent excess or impact stresses to pipe or equipment.

F. Entry/Exit Angle, Horizontal Alignment and Depth:

1. Stake entry and exit locations on ground, in accordance with approved Plans and as shown on drawings. Pilot drill hole shall follow path shown on drawings, with the following tolerances:

Table 33 05 22C – Pilot Boring Tolerances

Item Tolerance Pilot Entry Angle Allowable increase in angle up to 2 degrees deeper.

Allowable decrease in angle up to 1 degree. Changes outside these tolerances shall be approved by OGR.

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Item Tolerance Pilot Entry Location In accordance with approved Plans. No changes unless approved.

Pilot Exit Angle Allowable increase or decrease in angle up to 2 degrees. Changes outside these tolerances shall be approved by OGR.

Pilot Exit Location Up to 20-feet longer or 10-feet shorter than approved length of HDD boring, as measured at staked location for start and end of HDD, unless approved otherwise.

Up to 10-feet left or right of target exit location.

Pilot depth Within 3-feet above or 3-feet below depths shown on drawings and approved Plans, unless approved by OGR prior to commencement of HDD work.

Pilot Alignment Up to 3 percent per 100-feet horizontal deflection, based upon approved Plans

G. Pilot Hole Drilling:

1. Drill on a bore path with no deviations greater than that specified in

Table 33 05 22C – Pilot Boring Tolerances:

2. Notify OGR within 1-hour if pilot boring deviates more than allowable limits defined above. OGR may require Contractor to abandon pilot boring, pullback, and re-drill from a location along bore path before deviation.

3. Monitor drill string position with precise down-hole survey instruments. Verify location with surface locating equipment.

4. Position in X, Y, and Z-axis relative to ground surface shall be computed from down-hole survey data a minimum of once per drill segment, or on 30-foot intervals, whichever is less.

5. Final survey with survey probe at ground level following exit of pilot hole bit shall be tied-in to existing exit survey stake.

6. Drill at a radius equal to or greater than the Design Criteria in Table 33 05 22A Design Criteria.

7. Document deviations from recorded position of drill string from approved Plans, and those of radius violations.

8. Supply daily reports to document work, listing at a minimum the information required in RSN 33 05 22-8, Daily Reports. Note obstacles, work stoppages, delays, or other relevant details if the work was halted or restarted.

9. If pilot hole fails to meet specified tolerances:

a. Correction at expense of Contractor.

b. Document corrections showing pilot hole meets requirements.

H. Drilling Fluid:

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1. Check once every hour during drilling operations.

2. Ensure drilling fluid pressure does not exceed what can be contained by overburden soil. Control drilling fluid pressures to prevent hydro-fracture of geologic formation.

3. Maintain circulation and recycle drilling fluid throughout drilling process.

4. Contain drilling fluid from drilling operations with metal fluid pans on both sides of boring, and within drilled hole or fluid tanks or trenches.

5. If drilling fluid fractures the geologic formation, creates an inadvertent return, or fluid return loss occurs during pilot hole drilling:

a. Cease drilling for 30-minutes.

b. Inject a quantity of drilling fluid with a viscosity exceeding 120-seconds as measured by Marsh funnel equal to pilot boring hole volume.

c. Wait an additional 30-minutes before resuming drilling operations.

d. If hydro-facture or return anomaly continues, cease operations, and immediately notify OGR.

e. Do not resume drilling operations without approval of OGR.

f. Take required steps as approved in Contractors’ approved Plans.

6. Maintain spill containment measures on-site to contain and collect drill fluid inadvertent releases.

I. Monitoring:

1. Monitor water bodies and ground surface for drilling fluid release or surface settlement along full length of drilling corridor during drilling operations:

a. Supply personnel with communications such as two-way radios.

b. Notify OGR immediately if any signs of release or settlement are observed.

2. Provide personnel to monitor sensitive areas, as determined by OGR, within 500-feet of drill path.

a. Government may designate certain facilities (such as highways or sensitive natural areas) for full-time monitoring by Contractor during drilling operations.

3. Supply OGR 2 two-way radios, or other approved communication systems on Contractor’s frequency with battery chargers prior to commencement of drilling operations.

J. Reaming:

1. Review pilot data with OGR before hole reaming process begins.

a. Do not proceed with hole reaming until OGR approval is received.

33 05 22 - 18

2. Ream pilot hole to a minimum of 50 percent greater than outside diameter of pipe, for pipes larger than 24-inches OD (outside diameter). Ream pilot hole to a minimum of 12-inches greater than the outside diameter of pipe for pipes equal to or less than 24-inches OD (outside diameter).

3. Do not ream more than drilling equipment and fluid system are designed to handle.

Reaming step sizes shall not be greater than 2412-inches in diameter per pass, unless otherwise approved by COR.

K. Conductor Casing Installation, if applicable:

1. Casing shall be rammed open-ended.

2. Soil shoe can be installed on leading edge of casing.

3. Lubrication can be utilized to reduce friction between casing pipe and soil formation. Amount of lubrication directed to outside of pipe shall not be more than required to fill annular space between casing pipe and native formation, as created, unless approved by OGR.

4. Pneumatic pipe driving device selected shall be specifically designed for installing casing pipe through geological material described in geotechnical report.

5. Spoils removal system shall be capable of being operated in a manner which prevents loss of ground during installation.

6. Pipe ramming work shall be executed such that settlement is minimized and in-place casing has full-bearing against earth.

L. Remove drilling fluids and cuttings promptly and haul to an approved disposal facility in accordance with approved Plan.

M. Lost or Lodged Tools:

1. Report to OGR immediately upon discovery.

2. Recover objects prior to pipe pullback operations unless otherwise approved by

OGR.

3. Failure to recover objects lost or lodged down-hole within a reasonable time may cause rejection of drill hole.

N. HDD Pipe fabrication and testing prior to pullback:

1. Complete fabrication of the HDD Pipe for pullback into reamed hole prior to testing.

2. Test pipe on ground or rollers during pre-pullback test. Ensure that:

a. Maximum support spacing is adequate for fabrication and hydrostatic testing.

b. Each support shall have a weight capacity to hold up water-filled pipe with a minimum safety factor of 1.5.

33 05 22 - 19

c. Supports shall be arranged such that they are loaded approximately equally.

Use additional supports, timber pads (under supports) or other means to provide firm support to minimize ground shrinkage, settlement, or consolidation on soft ground.

d. Supports and rollers: closely conform to shape and diameter of pipe.

e. Pre-pullback testing shall consist of a sustained 15-minute hydrostatic test of entire HDD pipe length:

1) Notify OGR at least 48-hours prior to testing.

2) In accordance with the following parts of Section 33 11 10 –

Pipeline General Requirements: 3.10 A. 2., 3., 4., 5. (except d and e), 9., and 10., or as otherwise directed by OGR.

3) Prior to testing, equalize and maintain pressure within pipe for at least 1-hour.

4) Testing is not acceptable if it produces visible signs of leakage or produces a measurable pressure drop:

a) If leakage or pressure drop is observed, notify OGR immediately.

b) Suspend testing, repair, and restart test with approval of

OGR.

3. Support and protect exposed pipe during pullback to move freely and avoid damage during installation:

a. Rollers shall be in good mechanical and physical condition.

b. Government may stop work if insufficient or malfunctioning rollers are being used.

O. Pipe Pullback:

1. Anchor drilling equipment and HDD pipe, during construction and testing to prevent movement per approved Work Plan and HDD Pipe Retention Plan.

2. Pullback pipe through bore hole upon completion of reaming operations as soon as practical. Limit amount of time bored hole remains open before pullback operations.

3. Commence pullback immediately after completion of final swabbing pass.

4. Continue pullback operations without interruption until pipe is installed in bore hole. Install pipe in one continuous string. Once installation begins, do not cease installation until pullback operations are complete.

5. Where more than one pull force value is involved for a given pull section, the lesser shall govern. If the lesser pull force does not successfully pullback pipe, notify OGR to obtain approval to use higher pull force.

6. Do not exceed 60 percent of total allowable pipe stress without prior approval of

OGR.

33 05 22 - 20

7. If the HDD pipe becomes stuck, cease operations for 5-minutes to allow potential hydro-lock to subside and resume pulling operations within 15-minutes. Notify OGR if pipe remains stuck for longer than 1-hour.

8. No hammering device shall be employed to install pipe unless a plan for such activity has been submitted and approved by OGR.

9. Proposal for use of hammering devices will only be considered if other means for completing pullback operations have been exhausted.

10. Use a swivel assembly to connect pull sections and to minimize torsional stress in pull sections. Use a pullback head or shield to reduce the end and connection stresses on pipe.

11. Install pipe in one continuous string with no tie-in welds unless otherwise stated in an approved Plan and approved by COR.

12. Include buoyancy modifications or resisting systems to prevent pipe flotation during pullback operations:

a. Provide OGR at least 24-hours notification after placement of buoyancy modifications or resisting system, but prior to pullback operation.

b. Buoyancy modifications or resisting system shall not create a blockage in

HDD pipe that prevent function. System used shall be capable of being fully removed or cleaned after pullback to restore pipe to full inside diameter.

13. Monitor roller operation during pullback and use side booms or cranes as required to assist movement of pipe.

14. Utilize necessary equipment to lift pullback sections up to reach proper entry angle and safely support pipe in break-over area.

15. If pipe becomes lodged during pullback and cannot be recovered, abandon hole and pipe in accordance with provisions in this Section.

16. Following pullback, install or leave sacrificial length of HDD Pipe projecting above the ground surface at least 3-feet on each end. If not immediately connecting to Line Pipe, install temporary end cap or blind flange on each end to prevent contamination and debris from entering HDD Pipe.

17. When connecting Line Pipe, excavate each end of HDD Pipe to miter bend locations shown on drawings and per approved Plans. Remove and dispose of two temporary end caps or blind flanges and sacrificial lengths of HDD Pipe, if installed.

18. Install and secure fittings, flexible couplings, miter bends, and anchor blocks required at each end in accordance with this section, Drawing 1695-D-61820 and Section 33 11 10 – Pipeline General Requirements.

P. Following installation of the miter bend and fitting/connections, secure pipe against relaxation and settlement effects in accordance with approved Plans.

33 05 22 - 21

1. Mark and document location of each end of HDD Pipe, if connection to Line Pipe is not completed immediately following HDD Pipe pullback. Provide locations to OGR within 24-hours of completing HDD Pipe pullback.

3.05 LEAK TESTING AND INSPECTION

A. In accordance with Section 33 11 10 – Pipeline General Requirements.

B. Conduct pre-pullback testing in accordance with Section 3.04 N above, prior to pullback.

C. Conduct pressure testing pipe after completion of the pullback operation in accordance Section 33 11 10 – Pipeline General Requirements.

D. Acceptance: Results of drill profile survey information and hydrostatic test data will be reviewed by Government to determine acceptability of installed HDD crossing.

3.06 FINAL PIPE CONNECTION AND SITE RESTORATION

A. Depending upon project schedule and construction plan, Line Pipe to HDD Pipe tie-ins may be scheduled for a later date:

1. OGR to notify Contractor if HDD Pipe fitting/connections shall be secured or prepared for Line Pipe connection:

a. If tie-ins will not be done immediately, secure both ends of HDD Pipe to prevent debris, water, or other contamination.

b. If tie-ins are to be done immediately, clean and prepare fitting/connections for installation of Line Pipe.

B. Abandoning a Hole:

1. Abandon pilot hole in case of:

a. Ground subsidence.

b. Inadvertent return or fracture of adjacent HDD paths.

c. Lack of compliance with permit or other job conditions.

2. If a pilot hole is abandoned for conditions other than those listed above, consult OGR for direction on abandoning procedures.

3. Cease operations and notify OGR if any of the above conditions occur:

a. Do not resume operations until directed by OGR.

4. Grout abandoned hole unless directed otherwise by OGR.

C. Remediation of Ground Subsidence and Voids:

1. Check for voids along attempted and final drill corridors.

2. Fill and compact identified voids located along abandoned and final drill path with

Government approved fill material.

33 05 22 - 22

D. Clean-up and Restoration: In accordance with Section 01 74 00 – Cleaning and Waste Management.

END OF SECTION

140R4022B0001 Amendment 003

Steel Line Pipe 33 11 12 - 1

SECTION 33 11 12

STEEL LINE PIPE

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. In accordance with Section 33 11 10 – Pipeline General Requirements.

1.02 PROJECT CONDITIONS

A. Does not include pipe specified in Section 33 21 95 – Steel Manifold Piping for Line Pipe Installations.

1.03 REFERENCE STANDARDS

A. ASTM International (ASTM)

1. ASTM A139/A139M-16 Electric-Fusion (Arc) - Welded Steel Pipe

(NPS 4 and over)

2. ASTM A283/A283M-18 Low and Intermediate Tensile Strength

Carbon Steel Plates

3. ASTM A1011/A1011M-18a Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Allow and High-Strength Low-Allow with Improved Formability

4. ASTM A1018/A1018M-18a Steel, Sheet and Strip, Heavy Thickness Coils, Hot Rolled, Carbon, Structural, High- Strength Low-Alloy, Columbium or Vanadium, and High-Strength Low-Alloy with Improved Formability

5. ASTM E165/E165M-18 Liquid Penetrant Examination for General Industry

6. ASTM E709/E709M-21 Standard Guide for Magnetic Particle Testing

B. American Welding Society, Inc. (AWS)

1. AWS D1.1/D1.1M-20 Structural Welding Code – Steel

C. American Water Works Association (AWWA)

1. AWWA C200-17 Steel Water Pipe: 6-Inch (150mm) and

Larger

Steel Line Pipe

33 11 12 - 2

2. AWWA C205-18 Cement-Mortar Protective Lining and Coating for Steel Water Pipe: 4-Inch (100mm) and Larger - Shop Applied

3. AWWA C206-17 Field Welding of Steel Water Pipe

4. AWWA C207-18 Steel Pipe Flanges for Waterworks Service –

Sizes 4 In. Through 144 In. (100 mm Through 3,600 mm)

5. AWWA C208-17 Dimensions for Fabricated Steel Water Pipe Fittings

6. AWWA C227-11 Bolted, Split-Sleeve Restrained and Non-restrained Couplings for Plain-End Pipe

7. AWWA C604-17 Installation of Buried Steel Water Pipe 4 Inch (100 mm) and Larger

8. AWWA M11-17 Steel Pipe: A Guide for Design and Installation, Fifth Edition

1.04 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 – Submittals.

B. RSN 33 11 12-1, Shop Drawings:

1. Show pipe and fitting fabrication details.

2. Show exact dimensions of joints and proposed joint restraint.

3. Show exact dimensions of welding lead holes and repair method.

4. Show details of factory epoxy lining of joint cement mortar hold back area

5. Provide coupling and restraint details

6. See RSN 33 11 10-2 for further details.

C. RSN 33 11 12-2, Ventilation Plan:

1. Method for ventilating inside of pipe when placing mortar lining for joints.

D. RSN 33 11 12-3, Single Lap Weld Stress Calculations:

1. In accordance with Article 3.02 B. 5.

1.05 GENERAL

A. In accordance with applicable portions of Section 33 11 10 – Pipeline General Requirements.

33 11 12 - 3

PART 2 PRODUCTS

2.01 STEEL LINE PIPE

A. Pipe:

1. Electric fusion (arc) welded helical-seam steel pipe: ASTM A139, Grade C, D, or E.

2. Fabricated in accordance with AWWA C200:

a. Steel plate: ASTM A283, grade C, D or E.

b. Steel Sheet or coil: ASTM A1011, designation SS, Grade 40, 45, or 50; or

ASTM A1018, designation SS, Grade 40 or designation HSLAS-F, Grade 50.

3. Apply heat sheet shrink sleeve as detailed in Section 09 96 20 - Coatings. Install weld seam tape prior to applying sleeve.

B. Inside diameter measured to inside of lining shall not be less than nominal diameter shown on drawings.

C. Minimum Steel Wall Thickness:

1. Greater thickness from the following requirements:

a. Steel Wall Thickness for Handling:

1) Equal to inside diameter (inches) of pipe steel shell divided by 240 for mortar lined and flexible coated steel pipe.

2) In no case shall steel pipe shell thickness be less than 0.135-inches.

b. Steel Wall Thickness for Internal Pressure:

1) Hoop stress of pipe shell. Not to exceed:

a) 50 percent yield strength as defined by grade of steel using the Barlow formula. With pressure defined by Hydraulic Grade Line and pipe centerline as shown on pipeline plan and profile drawings.

b) 75 percent yield strength as defined by grade of steel using the Barlow formula. With pressure defined by pipe transient head class as shown on pipeline plan and profile drawings.

2) Barlow formula as defined by AWWA M11 Equation 4-1.

D. Steel shall be fully killed and conform to fine grain practice.

E. Rubber gaskets: In accordance with AWWA C200.

33 11 12 - 4

2.02 FITTINGS

A. Steel materials: products listed in 2.01A.

B. Minimum steel wall thickness: In accordance with AWWA C200, AWWA C208, and AWWA M-11 but less than 0.135 inches.

C. Welding: AWS D1.1.

D. Lifting eyes and other handling devices: Made part of fitting before lining and coating are applied.

E. Bolts and Nuts: In accordance with AWWA C207, ASME B18.2.1 and FS FF-N-836.

F. Coating and lining in accordance with Section 09 96 20 – Coatings.

G. Cement-Mortar Lining for Specials and Bends Larger than 24-inches:

1. In accordance with AWWA C205.

2. Apply lining with a resultant surface finish, including joints, equal to finish of adjacent pipe.

H. Joints between fittings and steel line pipe:

1. Rubber gasket, welded or flanged joints.

2. Joint dimensions and tolerances: Per pipe manufacturer's joint design.

I. Miter Bends: Fabricate steel bends in accordance with AWWA C208, AWWA M11 and as shown on drawings. Radius of miter bends for line pipe shall be 2.5 times the pipe outside diameter.

J. Pipe Couplings:

1. Coupling types as shown on drawings.

2. Suitable for line pipe materials used.

3. Suitable for cold water pressures of pipe transient head classes and steady state hydraulic grade lines on drawings.

4. Refer to Section 33 11 30 – Steel Manifold Piping for Line Pipe Installations for coupling requirements.

K. Closure Section Joints

1. Restraint requirements shown on drawings.

2. Field welded butt strap joints.

3. Bolted, Split-Sleeve Restrained Couplings for Plain-end:

a. In accordance with AWWA C227.

33 11 12 - 5

b. Refer to Section 33 11 30 – Steel Manifold Piping for Line Pipe Installations for coupling requirements.

L. Tees:

1. Tees for air valves, blowoffs, manholes, and temporary construction line as shown on drawings.

2. Tee length, minimum: As shown on drawings, required for blocking, or in accordance with AWWA C208 whichever is greater

2.03 LININGS AND COATINGS

A. In accordance with Section 09 96 20 – Coatings.

B. Do not field apply mortar lining without COR approval.

C. Fill inside joint recess of cement mortar lined pipe with cement mortar per AWWA C205.

2.04 CONCRETE

A. Concrete in Thrust Blocks and Collars: Section 03 30 00 – Cast-in-Place Concrete.

2.05 FLANGES:

A. In accordance with AWWA C207.

B. Class: Working pressure meets or exceeds head class of attached pipe.

C. Flange bolt pattern shall match bolt pattern of mating flange.

2.06 INSULATED FLANGE

A. Full face gasket insulating kit as manufactured by Pipeline Seal and Insulator, Inc., 6525 Goforth Street, Houston, TX 77021, complete with Linebacker type gasket, Advanced Products and Systems, Inc., P.O. Box 60399, Lafayette, LA 70596-0399, complete with Trojan type gasket, or equal with the following essential characteristics:

1. Gasket:

a. Full face, Type E.

b. Outside diameter same as outside diameter of flange.

c. Retainer:

1) Phenolic or other material suitable for water service as recommend by the manufacturer.

2) Thickness, minimum: 1/8-inch.

3) Dielectric strength, minimum: 500-volts per mil.

33 11 12 - 6

d. Sealing ring: Nitrile.

2. Bolt isolating sleeves:

a. Full length. Extends halfway into both steel washers when installed.

b. Tube thickness: 1/32-inch.

c. Mylar or other suitable material recommended by the manufacturer.

3. Washers:

a. Isolating washers:

1) Phenolic or other material suitable for water service as recommend by the manufacturer.

2) Thickness, minimum: 1/8-inch.

3) Dielectric strength, minimum: 500-volts per mil.

4) Inside diameter: Fit over isolating sleeve.

b. Steel washers:

1) Thickness: 1/8-inch.

2) Inside and outside diameters: Same as isolating washers.

4. No asbestos.

2.07 FLANGE GASKETS:

A. Multi-Swell Style 3760-U as manufactured by Garlock, www.garlock.com or equal with the following essential characteristics:

1. AWWA C207 or ASME B16.21.

2. Flat, full face or ring type.

3. NSF 61 Certified.

4. Suitable for cold water service.

5. Provide flanges suitable for line pipe pressure locations.

2.08 CONTRACTOR SOURCE QUALITY TESTING

A. Pipe and Fittings:

1. Hydrostatic Test:

a. Perform shop hydrostatic test on pipe which stresses steel to 75 percent of minimum yield point of the steel.

b. Hold pressure long enough to allow thorough inspection of welded joints.

c. Repair leaks by rewelding and retesting joints.

d. Test sections prior to forming bell and spigot joints.

http://www.garlock.com/

33 11 12 - 7

e. Repair defects and retest section before applying lining and coating.

f. Government may witness hydrostatic testing and calibration of pressure gauges. Notify Government 30-days prior to performing hydrostatic test.

2. Fittings fabricated from tested steel pipe do not require hydrostatic testing if welds are tested:

a. Weld test: Dye penetrant test in accordance with ASTM E165 or

Magnetic Particle in accordance with ASTM E709.

b. Weld defect repair. Chip, flame gouge, or grind to sound metal; reweld;

and test repaired weld.

B. Joint Testing: Assemble one joint for each pipe diameter to check bell and spigot to check fit prior to coating or lining.

PART 3 EXECUTION

3.01 GENERAL

A. In accordance with applicable portions of Section 33 11 10 – Pipeline General Requirements.

3.02 INSTALLATION

A. Joining Pipe:

1. In accordance with AWWA C604.

2. Verify inside joint gap meets manufacturer’s tolerances as work progresses.

B. Joints for Pipe with Welded Joints:

1. In accordance with AWWA…