OTD-13/0001

Tracer Wire for HDD
Applications
Prepared by:
Gas Technology Institute
Des Plaines, Illinois
September 2012
FINAL REPORT
OTD 5.11.c / GTI PROJECT NUMBER 21147
Tracer Wire for HDD Applications
Reporting Period:
March 15, 2011 through September 30, 2012
Report Issued:
September 30, 2012
Prepared For:
Operations Technology Development (OTD)
GTI Project Manager:
Kristine Wiley
847-768-0910
[email protected]
GTI Technical Contact:
Dr. Zhongquan Zhou
Principal Engineer
847-768-0901
[email protected]
GTI Project Team: Dennis Jarnecke, Joseph Baffoe, Alan Janos,
Brian Miller
Gas Technology Institute
1700 S. Mount Prospect Rd.
Des Plaines, Illinois 60018
www.gastechnology.org
Legal Notice
This information was prepared by Gas Technology Institute (“GTI”) for Operations Technology
Development (“OTD”).
Neither GTI, the members of GTI, the Sponsor(s), nor any person acting on behalf of any of them:
a. Makes any warranty or representation, express or implied with respect to the accuracy, completeness,
or usefulness of the information contained in this report, or that the use of any information, apparatus,
method, or process disclosed in this report may not infringe privately-owned rights. Inasmuch as this
project is experimental in nature, the technical information, results, or conclusions cannot be predicted.
Conclusions and analysis of results by GTI represent GTI's opinion based on inferences from
measurements and empirical relationships, which inferences and assumptions are not infallible, and with
respect to which competent specialists may differ.
b. Assumes any liability with respect to the use of, or for any and all damages resulting from the use of,
any information, apparatus, method, or process disclosed in this report; any other use of, or reliance on,
this report by any third party is at the third party's sole risk.
c. The results within this report relate only to the items tested.
Page i
Table of Contents
Legal Notice ................................................................................................................................. i
Table of Contents........................................................................................................................ ii
List of Tables ............................................................................................................................. iv
Table of Figures .......................................................................................................................... v
Executive Summary ....................................................................................................................1
Introduction .................................................................................................................................5
Task 1. Product Review and Test Protocol Development ............................................................7
Project Survey.........................................................................................................................7
Product Review .....................................................................................................................11
Review of GTI Previous Research and Test Results .........................................................11
Review of Commercially Available Tracer Wire Products ..................................................11
Test Protocol Development ...................................................................................................15
Critical HDD Application Conditions Potentially Causing Tracer Wire Failure ....................15
Test Protocol .....................................................................................................................16
Task 2. Laboratory Testing.......................................................................................................20
Task 2.1: Tensile Test ...........................................................................................................20
Task 2.2: Linear Taber Abrasion Resistance Test .................................................................23
Task 2.3: Scrape Abrasion Resistance Test ..........................................................................25
Task 2.4: Comparative Analysis of Tensile Properties ...........................................................27
Tensile Properties of Solid Copper, CCS and NEPTCO Trace-Safe Wires ........................27
Task 2.5 Corrosion Evaluation ..............................................................................................30
Accelerated Cyclic Corrosion Test (CCT-1) .......................................................................30
Test Samples ....................................................................................................................30
Corrosion Test and Results ...............................................................................................31
Task 2.6 Rigidity and Springback Evaluation.........................................................................34
Summary ..............................................................................................................................37
Tensile Properties .............................................................................................................37
Abrasion and Scrape Resistance of Wire Insulation Jackets .............................................37
Corrosion Evaluation .........................................................................................................37
Overall Performance Rating ..............................................................................................40
Task 3. Field Tests ....................................................................................................................42
First Field Test at Leaf River, IL ............................................................................................42
Page ii
Review of First HDD Field Installation ...............................................................................42
Wire Samples ....................................................................................................................42
HDD Installation ................................................................................................................42
Inspection: .........................................................................................................................43
Inspection Results: ............................................................................................................43
Second Field Test at Batavia, IL............................................................................................47
Review of HDD project ......................................................................................................47
Wire Samples ....................................................................................................................47
HDD Installation ................................................................................................................47
Inspection: .........................................................................................................................48
Inspection Results: ............................................................................................................48
Summary and Recommendations .............................................................................................49
List of Acronyms .......................................................................................................................51
Appendix I: Tensile Test Results ...............................................................................................52
Laboratory Test Data ............................................................................................................52
Specimens Prepared from Field Installed Wire Samples .......................................................69
Appendix II: Field Installation of Tracer Wires at Leaf River, IL .................................................72
Appendix III: Field Installation of Tracer Wires at Batavia, IL .....................................................79
Page iii
List of Tables
Page
Table 1. The Evaluated Tracer Wire Products .............................................................................3
Table 2. The Overall Performance Chart .....................................................................................4
Table 3. Survey Summary ...........................................................................................................8
Table 4. Summary of the Currently Used Tracer Wire Products for HDD ..................................10
Table 5. Ranking of Tracer Wire Failure* ..................................................................................10
Table 6. Summary of Tracer Wire Product Review ....................................................................12
Table 7. Tensile Test Matrix ......................................................................................................18
Table 8. Linear Taber Abrasion Resistance Test Matrix ............................................................19
Table 9. Scrape Resistance Test Matrix ....................................................................................19
Table 10. Summary of Tensile Test Results with the Ratio of Yield/Ultimate (Y/T) ....................22
Table 11. Continuity and Electrical Resistance Tests of Wire Specimens after 2000 Hour CCT-1
.................................................................................................................................................32
Table 12. Tensile Test Results of the Field Tested Wires after 2000 Hour CCT-1 Test .............33
Table 13. The Results of Wire Rigidity and Springback Evaluation ...........................................36
Table 14. The Overall Performance Chart .................................................................................39
Page iv
Table of Figures
Page
Figure 1. Tensile Test Results of Tracer Wires* ........................................................................11
Figure 2. The Simulated Kink for Tensile Test vs. a Kink on the Field Tested Wire ...................20
Figure 3. Wire Tensile Test Setup .............................................................................................21
Figure 4. Taber Abrasion Test Setup ........................................................................................23
Figure 5. Taber Abrasion Test Results ......................................................................................24
Figure 6. Wire Sample after Scrape Test ..................................................................................25
Figure 7. Scrape Test Results ...................................................................................................26
Figure 8. The Y/T vs. the Ultimate Tensile Strength of Straight Tracer Wires ............................27
Figure 9. Ultimate Tensile Strength of the Straight and Kinked Tracer Wires ............................28
Figure 10. Cyclic Salt Fog Tester .............................................................................................30
Figure 11. The Corroded Pro-Trace-HDD-CCS Test Specimens after 2000 hr CCT-1 Test ......33
Figure 12. Test Setup for Flexibility and Springback Evaluation ................................................35
Figure 13. Tensile Plots of CCS vs. Soft Drawn Solid Copper Wires .........................................38
Figure 14. Break of Insulation Jacket on Field Tested NEPTCO Wire .......................................43
Figure 15. Break of Insulation Jacket (#1) on Field Tested AGAVE-12 AWG Solid Copper Wire
.................................................................................................................................................44
Figure 16. Break of Insulation Jacket (#2) on Field Tested AGAVE-12 AWG Solid Copper Wire
.................................................................................................................................................44
Figure 17. Break of Insulation Jacket (#3) on Field Tested AGAVE-12 AWG Solid Copper Wire
.................................................................................................................................................45
Figure 18. Break of Insulation Jacket (#4) on Field Tested AGAVE-12 AWG Solid Copper Wire
.................................................................................................................................................45
Figure 19. Break of Insulation Jacket (#1) on Field Tested Copperhead-12 AWG Copper Clad
Steel Wire .................................................................................................................................46
Figure 20. Break of Insulation Jacket (#2) on Field Tested Copperhead-12 AWG Copper Clad
Steel Wire .................................................................................................................................46
Figure 21. Break of Insulation Jacket (#3) on Field Tested Copperhead-12 AWG Copper Clad
Steel Wire .................................................................................................................................46
Figure 22. Tensile Plots for Straight and Kinked Paige 14 AWG Copper Wire...........................52
Figure 23.Tensile Plots for Straight and Kinked Paige 12 AWG Copper Wire............................53
Figure 24. Tensile Plots for Straight and Kinked Krist-Tech-E98017 12 AWG Soft Drawn Copper
Wire ..........................................................................................................................................54
Figure 25. Tensile Plots for Straight and Kinked Copperhead-1430SF Super Flex Soft Drawn
Copper Clad Steel Wire ............................................................................................................55
Page v
Figure 26. Tensile Plots for Straight and Kinked Copperhead-1230Y Super Flex Copper Clad
Steel Wire .................................................................................................................................56
Figure 27. Tensile Plots for Straight and Kinked Pro-Trace-HF 12 AWG Copper Clad Steel Wire
.................................................................................................................................................57
Figure 28. Tensile Plots for Straight and Kinked AGAVE-APCS-1201 Fully Annealed Copper
Clad Steel Wire .........................................................................................................................58
Figure 29. Tensile Plots for Straight and Kinked AGAVE-APSR-1201 12 AWG Stress Relieved
Copper Clad Steel Wire ............................................................................................................59
Figure 30. Tensile Plots for Straight and Kinked AGAVE-BT-1201 HDD 12 AWG Copper Clad
Steel Wire .................................................................................................................................60
Figure 31. Tensile Plots for Straight and Kinked Pro-Trace-HDD 12 AWG Copper Clad Steel
Wire ..........................................................................................................................................61
Figure 32. Tensile Plots for Straight and Kinked Copperhead-1245EHS 12 AWG Copper Clad
Steel Wire .................................................................................................................................62
Figure 33. Tensile Plots for NEPTCO Wire (Straight and Kinked) .............................................63
Figure 34. Tensile Plots for Straight and Kinked Copperhead-1230Y High Strength Copper Clad
Steel Wire .................................................................................................................................64
Figure 35. Tensile Plots for Straight and Kinked Krist-Tech-DSA 12 AWG CCS Wire ...............65
Figure 36. Tensile Plots for Straight and Kinked Krist-Tech-Stress Relieved 12 AWG CCS Wire
.................................................................................................................................................66
Figure 37. Tensile Plots for Straight and Kinked Kris Tech 10 AWG Hard Drawn Copper Wire .67
Figure 38. Tensile Plots for KrisTech 10 AWG Soft Drawn Copper Wire* ..................................68
Figure 39. Tensile Plot for Field Tested Copperhead 12 AWG Copper Clad Steel Wire ............69
Figure 40. Tensile Plot for Field Tested Agave 12 AWG Copper Clad Steel Wire (Holiday #1) .69
Figure 41. Tensile Plot for Field Tested Agave 12 AWG Copper Clad Steel Wire (Holiday #2) .70
Figure 42. Tensile Plot for Field Tested Pro-Line HDD 12 AWG Copper Clad Steel Wire..........70
Figure 43. Tensile Plot for Field Tested Paige 12 AWG Solid Copper Wire (Holiday #1) ...........71
Figure 44. Tensile Plot for Field Tested Paige 12 AWG Copper Wire (Holiday #2) ....................71
Figure 45. Four tracer wires used during HDD pipe installation .................................................72
Figure 46. Tracer Wires being Pulled in with Pipe .....................................................................73
Figure 47. Tracer Wires during Pull In .......................................................................................74
Figure 48. Pipe and Wires Crossing Another Existing Conduit ..................................................75
Figure 49. Tracer Wires and Pipe at Exit Point (530’ away from Entry Point) ............................76
Figure 50. Three Tracer Wires being Pulled out of the Ground .................................................77
Figure 51. Three Tracer Wires being Pulled out of the Ground .................................................78
Figure 52. Vermeer HDD Machine at the Job Site .....................................................................79
Figure 53.Tracer Wires before the Installation ...........................................................................80
Page vi
Figure 54. Example of the Rocky Soil Areas .............................................................................81
Figure 55. Example of the Pea Gravel Soil................................................................................82
Figure 56. Example of the Pea Gravel with Concrete ................................................................83
Figure 57. The Sand Area of the Pipe Installation .....................................................................84
Figure 58. Five Tracer Wires Used during HDD Pipe Installation ..............................................85
Figure 59. Tracer Wires being Pulled through the Borehole along with the Pipe .......................86
Figure 60. Pipe and Wires being Pulled out by Backhoe ...........................................................87
Page vii