After the successful completion of PBO, we were invited by IRIS to participate in the development of methods, equipment and tooling for the Alaska Transportable Array (ATA), a component of USARRAY. This 5 year project, finished in 2017, encompassed the installation of 280 seismic monitoring stations across the state of Alaska and into the Canadian Yukon Territory, and marks a major milestone in drilling technology and remote construction logistics.
Our role included development of drilling and construction methods, designing and building ultralight helitransportable drill rigs, personnel training, furnishing special materials and tooling, construction and consulting services. This team effort resulted in the successful development of lightweight shallow cased borehole technology, opening the door to high quality data being produced by remote stations that are relatively inexpensive, quick and easy to build, and can be achieved in any ground type from glacial moraine and permafrost to solid rock.
Development of a drilling system for this project presented an extremely challenging problem, as it contained two predefined parameters that seemed to be mutually exclusive:
1 Develop a system capable of drilling shallow boreholes (3m) in any type of ground found in Alaska, ranging from solid granite, permafrost, frost shattered rock to loess (frozen glacial dust), sands, gravels and cobbles. These types of drilling conditions typically require very powerful, heavy equipment and lots of compressed air and fluids.
2 Make this system transportable in one or two loads by High Performance Light Helicopter (Bell 406, ASTAR B2, MBB B0105). Original weight limit was around 1200#, and this was increased to around 1800# later in the project. For comparison, a typical rig for drilling in these conditions would weigh a minimum of 25000#.
Bedrock
Permafrost
Sands and gravels
Shattered
Glacial Moraine
The work began with the only method which would work within the initial weight requirements , using a modified Mobil ultralight rig running bare continuous flight auger in an uncased hole. As auger drilling requires significant downpressure, torque, and relatively soft ground, we had limited success with this method.
(Left) Drilling frozen sand and gravel at Point Barrow AK (approx 70 north). Open hole drilling requires stable ground conditions. After removal of auger, a 6" sched 40 PVC casing is installed and grouted into borehole.
In order to drill rock, The rig was modified to run an 7" diameter core barrel, similiar to those used in concrete coring. This method also had limited success, as fractured rock caused loss of water circulation, and retrieval of drilled core was very difficult. Additionally, coring takes a lot of water, which of course had to be transported in by helicopter.
(Left) Injecting a foaming agent to reduce water consumption.
left to right: Hammer sleeve, hammer, pilot and ring bit, back rod
After working with the above methods, we proposed developing a more comprehensive system which could install a cased borehole in any of the ground types encountered so far. This system would incorporate a small percussion hammer encased in a shroud and running an oversized overburden pilot and ring bit, and would install a thin wall 6 5/8" od steel casing to the required depth using a relatively small air compressor (see percussion overburden methods). Drilling with a casing (rather than an open hole) eliminates the loss of uphole velocity, enabling the cuttings to be ejected from the hole, and keeping the hole from caving in softer materials. After the hole is drilled, the hammer is pulled out, leaving the casing in the hole.
After completion of borehole and extraction of drill tooling, an aluminum grout plug fitted with a check valve and a sealing ring is inserted and locked into the casing shoe at the bottom of the hole. Grout is pumped through this disc, filling the annulus between casing and the surrounding soil or rock. This grout bond couples the bottom of the casing to the surrounding formation, creating an ideal environment for the seismometer.
left to right: Pilot Bit, casing, casing shoe, ring bit
Pilot locked into ring bit
Grout plug and casing shoe (shoe is shown without casing)
Grout plug locked into casing shoe
The existing Gen 1 drill was modified to run the new overburden system, using a separate air compressor.
(left) Installing a site east of Delta AK. The system was a success, with only one drawback: Compressor had to be flown in a separate load.
Percussion drilling with cased borehole system
Grouting after completion of borehole
After successful testing of the cased borehole tooling, the next step was to develop a drill with an onboard compressor that could be flown with existing aircraft (approx 1200# max payload). The only solution that could meet this criteria was a twin engine air cooled unit which eventually proved too lightweight and problematic to be of practical use.
Equipped with large low pressure tires, the Gen 2 drill could be transported by helicopter, fixed wing aircraft or towed by ATV
'Long line' helicopter transport of gen 2 drill rig after completing site at Knik glacier
Towing with ATV
With additional lift capacity, it was now possible to build a robust rig that would satisfy all of the requirements: Onboard air, reliability, sufficient power, robust design.
The gen 3 drill has two front outriggers and 4 vertical jacks which are deployed after landing. Wheels can also be attached, and the front outriggers pulled together to accommodate a hitch for towing. A fuel efficient, turbo diesel 3 cylinder engine is direct coupled to a Rotocomp air compressor, and also a two section hydraulic pump for drill power. The drill mast is raised hydraulically, and fixed into place with an adjustable brace. Drill mast is adjustable vertically in both directions. Robust all aluminum frame, onboard air, single turbo diesel engine, auto start, cold weather package and custom built hydraulic drill controls make this rig a valuable asset for remote installation of shallow cased boreholes. After the successful deployment of this rig ("BLUE"), a second rig ("PURPLE") was built and added to the project.
All Aluminum frame
Towable
Modular omponents
BLUE at work in AK
PURPLE at work in AK
Operator's side
Happy crew