HDD Rigs get Simpler, Smarter

Since late 2003, horizontal directional drilling (HDD) contractors have been enjoying a much calmer business environment in a market poised for steady growth. This growth is enhanced by increasingly advanced drill rigs that improve efficiency and simplify operation. According to several manufacturers, the future of HDD appears bright, since this time around the players — and the equipment — are smarter.

"It's been an education," says Gaylord Richey, territory manager, Astec. "We as manufacturers are smarter than we were 10 years ago. We're building more powerful machines with improved electronics. Engineers who spec the jobs have a better understanding about areas where they can best utilize HDD. Overall, we're better educated — manufacturers, engineers and operators. Today, the industry is more viable than it was the first time around. More avenues are open, and we'll see more steady growth."

Cruise control

Smarter equipment comes in the form of increased automation and more advanced electronics. "In the last few years, there have been several advancements to simplify operation and to help operators, particularly those who are new, make fewer mistakes," says Ed Savage, trenchless segment manager, Vermeer. "They allow the rig to do more of the work so there is less reliance on operator judgment."

While an HDD rig isn't necessarily difficult to operate, it does take concentration on the part of the operator, especially on long bores in varying ground conditions where it's harder to maintain speed and flow rates. That's where rigs with auto drill or cruise control can help. This feature is similar to cruise control in your car or truck. Once the optimum speed is determined, the operator can set the machine to automatically hold that speed. The speed can also be recalled for installation of successive rods.

"Once you get started drilling, you can just flip a button and the machine will monitor the pressures of both rotation and thrust," says Savage. "Through varying conditions, it will automatically make adjustments to maintain that speed."

Keeping a constant speed is important for retaining just the right amount of drilling mud in the hole to lubricate the product and turn the soil into cuttings. "Setting the cruise control on the pullback, when timing is especially critical, prevents the operator from over pulling or under pulling," adds Richard Levings, senior project manager for HDD for Ditch Witch.

"That way, they get the most consistent rate of installation with the right amount of mud flow. It also allows for better productivity, and it's easier on the rig because the machine is applying the force."

Cruise control provides the added benefit of enhancing operator comfort. "It reduces a lot of fatigue in the tough or long bores where it takes a lot of time to pull back or bore out one drill rod," says Savage. "It also takes some of the human error out of the process."

"Drillers sit for hours trying to find just the right spot, then hold it so the pipe comes back at just the right speed," adds Richey. "Now, instead of having to find that ‘sweet spot' and hold it, they can hit a button and let go of the controller. Overall, it speeds the entire drilling process. Rigs have really come a long way as far as cutting down on the fatigue and allowing for better performance of the drill."

Some of the improved performance can also be attributed to microprocessor control of the hydraulics and engine. "It keeps them relative to each other," Richey says. "If you need more power, the microprocessor talks to the engine and asks for more power. The engine adjusts to what the operator and the job call for. It's the same with hydraulics. The microprocessor helps extend the life of the engine and hydraulics because the machine controls everything.

"In the construction industry, HDD is still in its infancy," he continues. "We're continually finding ways to simplify the process and make it more accurate, efficient and a lot easier on the guys in the field."