The Vermeer D150x300 HDD that Kaiyuan purchased from Balama-Vermeer (China) Company Limited in 2003 is one of Vermeer’s proprietary products combining the company’s experience as market leaders supplying HDD rigs for over ten years. This drill delivers outstanding features such as self-contained climate controlled cabin, computer-controlled hydrostatic power system, and operational flexibility.

Overview

Sinopec’s Yong-Hu-Ning Pipeline Project (the “YHN Project”) involves the construction of a 762 km steel pipeline from Ningbo Port in the south, via Zhejiang Province and Shanghai City, to Nanjing in the north, including the Tian-Hua-Dang River crossing that would be delivered by Kaiyuan, a specialised trenchless pipeline contractor. Although Kaiyuan has employees experienced in non-Vermeer large HDD rigs, it was the first time that the company worked with a Vermeer product, on a construction project. The crossing of the Tian-Hua-Dang River would be the first project for the D150x300’s on Mainland China. This project was a typical long-range river crossing to install a large diameter steel pipeline. The 469 m pipeline would cross under the river for 320 m with the maximum depth up to 16 m mostly through sandy silts.

Process

The self-contained D150x300 was well suited to this project allowing easy and fast set up particularly with the entry point located in a paddy field. Equipment used in the past would have required several days of mobilisation with a significant amount of crane work to get on site, time and cost were considerably reduced for the D150 rig, which took only a few hours to transport to the site and walk itself into place without any additional machinery assistance.

Completion of the pilot bore took 18 hours with a significant amount of time required for wire line connection at each rod. Rods are now available that eliminate the need for manually joining wires at each make up point.

Back reaming was conducted in four passes with 400 mm, 600 mm, 800 mm and finally a 1 metre diameter reamer pulling the pipe in. The well executed pilot bore, combined with properly engineered mud, limited the maximum backreaming force to no more than 50,000 lbs (22,727 kg), with the maximum torque no more than 10,000 ft/lb (13,560 Nm). It took only six hours to pull back the product pipe. The pullback was so quick that the supervisor and Kaiyuan on-site staff praised the Vermeer D150 rig as a new era in large scale HDD “It just like a docile pangolin digging from one bank to another. So beautiful!” said a Kaiyuan Manager, recalling the pullback of steel pipes nearly 500 metres in total length.

As the exclusive Vermeer dealer in China, Balama-Vermeer (China) Company Limited assigned experienced field engineers as they always do, offering 24-hour daily assistance in helping the customer learn, utilise, and maximise the rig’s capability.

Project wrap

Vermeer D150x300 HDD’s first successful performance on Mainland China will considerably enhance users’ confidence to the product. “If each bid section was equipped with construction equipment of such efficiency and quality, the entire construction would be much shortened,” stated the YHN Project Manager, “In this project we saw Vermeer’s powerful usability and performance once again, and we can expect more in future.”

Why the D150x300 succeeds

The large rig is designed with the benefits of its small and medium peers: compact, automatic, and powerful (large torque).

Compact but complex design

The machine arranges all its engine, hydraulic system, crane, rod loader, track, and climate-controlled cab on a single 16.25 m x 2.54 m x 3.53 m body only 34.47 tonnes in weight, allowing transportation on a low platform trailer on any normal road in China. It is differentiated from rigs of other brands due to its special, fully-integrated track chassis with powerful grade ability, and thus enables quick and easy walking in relatively narrow places without using any crane or excavation, considerably saving labour and materials, as well as time and money. Inside the two-person cab all devices are readily available to manipulate the rig and monitor or operate the crane and fluid system. Interfaces are also offered on either of the rig and crane hydraulic controller modules to exchange data with external computers. 360 degree side view as well as top view is available in the cab with air conditioners to deliver enjoyable, convenient, and safe use either in hot summer days or in winter.

Efficient and steady power support

The machine is equipped with a Caterpillar C-12 400 hp V6, electric injector engine, which is the most advanced product of its family with the highest rating and in compliance with Euro-II emission standard, delivering operational cost-effectiveness and reliability. Caterpillar’s proprietary ECM and SEMS electric control modules are also available for automatic monitoring and management of all aspects of engine operation. All the operating parameters are displayed on an in-cab LCD display.

Fans on the machine are capable of adjusting the rpm according to the temperature. In the hydraulic system eight pumps are offered for optimised power distribution, with no interference between any actions - even if there is failure in one place, the overall operation will maintain. World-renowned brands are selected, including the SAUER cam-type plunger pumps for the master hydro pumps, EATON pressure-compensation pumps for the auxiliary pumps, and the France Badland dual-low-speed, large-torque, radial transverse motor for the hydro motor. To deliver perfect matching, the electric control device for each pump is supplied by the pump manufacturer, instead of being configured by the rig designer.

Construction power and flexibility

In addition to the maximum pullback/thrust force of 68,038 kg and the maximum torque of 40,680 Nm@50 rpm, the drill is also designed with a feature to double the pullback/thrust speed. In zero load condition the drive box may accelerate the travel to reduce the changeover time. Three rpm values (50/70/100 rpm) are available on the power unit to satisfy different work conditions. The on-rig crane has the maximum capacity up to 6.35 tonnes. Even at the maximum hoisting radius (7.62 m), it can hoist a 1.18 tonne load. The crane also allows 450 degree turning to facilitate loading and unloading of stems and tooling. Superior breakout capability is offered by Vermeer’s unique hydraulic open top vise, which automatically centralises a stem and clamps it at four points, moving together or individually, with clamping pressure controlled and adjusted numerically. For bolt racks partial replacement is allowable. The machine is designed with unique user-friendliness such as strengthened dual-rack drive chuck, drive box driven by six hydro motors, automatic rod tray, specific port to monitor the hydraulic system, and the hydraulic-extrusion rail floor.

Subtle, intelligent control

An optimised control program running on a state-of-the-art industrial control CPU (CAN-bus control) best simplifies the control system to deliver improved operational stability. A world-leading negative feedback hydraulic system utilises much more engine power. If a Vermeer mud system is equipped, the host operation module may remotely control operation of the system, enabling a single person for all the crane manipulation, rod loading and unloading, mud transportation, and drilling. Moreover, all the data may be displayed on an in-cab LCD display. A patented dual-channel remote locking system has communication coverage up to 1.6 km, to lock rotation, backreaming, and thrusting of the rig. Added to the locking system, both the vise and the gearbox are equipped with ESD devices for improved operational safety. All these features bring the intelligent design of construction machinery up to a new level.