Helical Pile Applications in Oil and Gas Industry* *an excerpt from the DFI Fall 2010 Technical Presentation by Howard A. Perko, Ph.D., P.E. 1 and Wayne Charlie, Ph.D., P.E. 2 1 Magnum Geo-Solutions, LLC 2 Colorado State University Copyright 2011 – Howard A. Perko, All Rights reserved. May be distributed and printed by express written permission of the author only. MAGNUM Informational Bulletin ISO-HAP1-11A

Copyright © 2011 – Howard A. Perko Why Use Helical Piles? Historic Uses for Pipelines Applications in Oil and Gas Case History: Natural Gas Compressors Case History: Oil Refinery Control Building Case History: Natural Gas Pipeline Supports Case History: Oil Refinery Pipe Rack Retrofit Contact Information Outline

Copyright © 2011 – Howard A. Perko Why Use Helical Piles? Save Money Easy to Transport to Remote Sites Doesn’t Produce Drill Spoil Efficient Design Save Time Rapid Installation No Concrete Curing Set Frames Directly on Piles Proven Technology Invented in 1836 Appears in 2009 IBC ISO2009 Accredited Manufacturer

Copyright © 2011 – Howard A. Perko Historic Uses 1969 Hollander Patent: Helical Piles for Pipeline Buoyancy Control Used for over 40 years for pipeline support. Now Public Domain

Copyright © 2011 – Howard A. Perko Sample Applications Pipeline Supports Control Buildings Fuel Tanks Filter Towers Ancillary Buildings Compressor Platforms Dehydrator Pads Storage Tanks Separators Coalescers Pipe Racks Thrust Blocks Scrubbers Valve Boxes Maintenance Shops …and much more.

Case History: Natural Gas Compressors

Copyright © 2011 – Howard A. Perko Compressor Pad 90 tons Designing the foundations for vibrating machines is not as simple as dividing the weight amongst the piles. The lifespan and maintenance cycle of compressors and other machines is greatly diminished with improper foundation design and excessive vibrations.

Copyright © 2011 – Howard A. Perko Performance For Equipment Operating at 1,000 to 1,400 cpm: Target vibration amplitude = < inches Threshold for repairs = > inches

Copyright © 2011 – Howard A. Perko Vibration Amplification The goal is to design an economical concrete-less helical pile supported foundation whose natural frequency (i.e. stiffness) is far enough away from resonance so as to avoid excessive vibration. A foundation can be designed hard or soft. HARD SOFT Resonance

Copyright © 2011 – Howard A. Perko Vibration Analysis Vertical Spring Constant = 1/k = 1/k shaft + 1/k helix/soil k shaft = A g E / L K helix/soil = D / A (1-ν) / E 0.79 Lateral Spring Constant = k = dP / dδ Driving Frequency = 1, ,400 Hz Vertical = 1,200 Hz Rocking (short) = 1,200 Hz Rocking (long) = 1,200 Hz Lateral = 500 Hz Yawing = 500 Hz Complex design requires special expertise. Gas company employed Dr. Howard Perko from Magnum Geo-Solutions, LLC as the lead consultant. Dr. Wayne Charlie, a professor of soil dynamics from Colorado State University, provided peer review.

Copyright © 2011 – Howard A. Perko Engineering Support Team for Magnum Piering, Inc. Magnum Geo-Solutions, LLC Licensed PE’s in 18 States Project Submittals Design/Build Support Expert Consultation Magnum Geo-Solutions, LLC

Copyright © 2011 – Howard A. Perko Compressor Foundation Plan Resulting plan consisted of a steel mat with 12 vertical piles and 6 battered piles.

Copyright © 2011 – Howard A. Perko Overall Site Layout Compressor platforms were only part of overall foundation plan for gas compressor station. All components (pipe racks, filters, fuel skids, dehydrators, etc.) were constructed on helical piles.

Copyright © 2011 – Howard A. Perko Pile Installation

Copyright © 2011 – Howard A. Perko Example De-Hy Foundation

Copyright © 2011 – Howard A. Perko Pipe Rack Foundations

Copyright © 2011 – Howard A. Perko Compressor Pad Construction

Copyright © 2011 – Howard A. Perko Completed Compressor Pad Helical piles saved $100,000 per compressor pad versus conventional heavy reinforced concrete mat. Compressors were started without incident, vibrations were within target levels, and compressors continue to operate without flaw.

Case History: Oil Refinery Control Building

Copyright © 2011 – Howard A. Perko Control Building Plans Recent regulation changes require blast-proof walls around refinery control buildings. This requires construction of new reinforced concrete enclosures. Use of helical piles does not produce drill spoil. Piles can resist compression and tension.

Copyright © 2011 – Howard A. Perko Control Building Details Jacobs Engineering used helical piles for compression, tension, and lateral loads (by battering) to support the new concrete enclosures.

Copyright © 2011 – Howard A. Perko Helical Pile Details Magnum Geo-Solutions provided engineering support. Magnum Piering, Inc. supplied products. Design compression and tension capacity = 110 kips working.

Copyright © 2011 – Howard A. Perko Installation and Load Tests Load tests passed with good results. Measured 0.28 inches movement at 110 kips design compression and tension loads. Installation was completed on budget and on schedule.

Case History: Natural Gas Pipeline Supports

Copyright © 2011 – Howard A. Perko Foundation Plan Hunt, Guillot & Associates, LLC of Ruston, LA provided design of compressor station with helical piles and concrete pile caps.

Copyright © 2011 – Howard A. Perko Pipeline Support Details

Copyright © 2011 – Howard A. Perko Soil Boring Subsurface conditions consisted of high plastic clay over very stiff lean clay (SPT N>50 bpf).

Copyright © 2011 – Howard A. Perko Installation Photos MH425 helical piles installed on schedule and on budget.

Case History: Refinery Pipeline Supports

Copyright © 2011 – Howard A. Perko Support Detail Several miles of existing pipe lines constructed on timber piles with steel cross members experienced settlement and degradation. This detail showing MH530 piles with threadbar and steel cross beam was submitted as a solution.

Copyright © 2011 – Howard A. Perko Installation Photographs Helical piles were installed on schedule despite challenging work environment. Contractor was able to successfully and safely lift and re-align pipe lines.

Contact Information Magnum Piering, Inc PIER (7437) 6082 Schumacher Park Drive West Chester, OH 45069