SUMMARY LETTER REPORT ON WORK ORDER NO. 9 TASK ORDER NO. 21

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03624A000900050001-6
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 24
• Document Creation Date: December 27, 2016
• Document Release Date: February 27, 2013
• Sequence Number: 1
• Publication Date: November 26, 1963
• Content Type: REPORT

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SUMMARY LETTER REPORT
ON
WORK ORDER NO. 9
TASK ORDER NO. 21 4i so
CONF1OENTIAL
November 26, 1963
CONFIDENTIAL
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February 13i,1964
Dear Sir:
This summary letter report describes the research conducted under
Work Order No. 9, Task Order No. 21, during the period from June 27 through
November 26, 1963. This work consisted of an investigation of the primary
design factors related to a proposed method of penetrating overburden by a
remote controlled, electrically powered "mole" that would tow a wire elec-
trical conductor.
Introduction
Over the past several years, the Sponsor has been interested in
tunnelling and boring by a variety of methods. We have conducted various
research programs directed toward the study and development of equipment
utilizing digging, drilling, pushing, and pulling to produce holes. The
configurations of these equipments have been strongly influenced by the length
and diameter of the desired holes, the amount and type of power available, and
the conditions under which the operations were expected to take place.
Work Order No. 9, Task Order No. 21, was set up as a result of the
need described by the Sponsor for a device to tow a wire conductor through
overburden. A device that would be considered satisfactory would be remotely
controlled and powered by indigenous electrical energy, probably 220-volt,
single-phase, 50-cycle current. It would have a range of up to 50 ft and if
possible, would be guided to within a 1-sq-ft area at the maximum range.
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The hole formed immediately adjacent to the "mole" would be the minimum50X1
needed by the "mole" and could collapse or be filled in around the conductor
following the passage of the "mole". The device, consisting of the "mole"
and a control box, would be portable, having minimum weight and volume compat-
ible with the desired performance.
Summary and Conclusions
A review of commercially available equipment uncovered no device
which could be utilized directly or could be easily modified for this purpose.
It was also concluded that a device which operated in a substantially straight
line and was not guided after once started would be most practical at present
because of the lack of commercially available orientation-sensing and guidance
devices.
A promising concept consisting of an auger powered by an external
motor through rigid sectioned shafting was evolved. There are indications
that this device would have sufficient accuracy to meet the mission objectives.
It is strongly recommended, however, that the potential accuracy be the first
item'investigated in any further development work.
Engineering Activity
The engineering activity began with a limited review of the state
of the art to determine what devices were commercially available and their
limitations. After no applicable devices were found, a few preliminary
experiments were performed to explore the amount of payer which would be
required for a "mole"-type unit. The results of these experiments and the
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state-of-the-art review were the basis for the mid-project decision
restricting the consideration to units which operated in a substantially
straight line and were not subjected to additional guidance, in contrast to
guided units. The remainder of the effort was then directed toward the
evolution of concepts related to "straight line"-operating devices.
State-of-the-Art Review
Information was requested from about 46 companies, as listed in
Table 1; even though many of these companies were not engaged in the
manufacture of the type of equipment of interest, it was anticipated that?
?they might be able to provide further leads. Information obtained previously
from other companies in connection with similar projects for the Sponsor was
also reviewed. Table 2 is a partial listing of the U. S. patents checked;
many other patents not listed were reviewed by means of the "Patent Gazettes"
in our library. Approximately 35 articles were also scanned for pertinent
information.
In general, most of the information available pertained to pipe
pushers, drills, trenchers, tunnelling machines, mining machines, and
electric moles, none of which have the characteristics necessary for the
application of interest.
A commercial device the "Kret" pneumatic missile, was uncovered
that is not considered applicable because of the operating noise level and
air requirements; nonetheless, the information available on this device
suggests that the accuracy obtainable with a pre-aimed nonguided unit may
be acceptable for the application of interest. The "Kret" is a 4-1/4-ft
long, 3-1/2-in.-diameter, 64-lb missile propelled by means of a piston ram
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TABLE. 1. COMPANIES CONTACTED FOR INFORMATION
Airdox-Cardox Products Co.
305 N.lAichigan Avenue
Chicago, Illinois
American Kret Corporation
225 East 46th Street
New York 17,. New York
Baker Oil Tools Inc.
P. O. Box 9274, Terminal Annex
Los Angeles, California
Bell Telephone Laboratories
Columbus, Ohio
Bell Telephone Laboratories
Murray Hill, New Jersey
Bico, Inc.
3118 Valhalla Drive
Burbank, California
Cavins Co.
2853 Cherry Avenue
Long Beach, California
? Central Mine Equipment
6200 N. Broadway
St. Louis, Missouri
Centromor
Motokawska 49
Warsaw, Poland
Foushee & Heckendorn
Cedar Point, Kansas
Earthworm Boring Machine, Inc.
1415 14th Street, P. O. Box 1100
Santa Monica, California
George E. Failing Co.
Enid, Oklahoma
Geo-Drill Co.
P. O. Box 6-E
Bridgeville, Pennsylvania
Hardsocg Manufacturing Co.
800 West Samantha
Ottumwa, Illinois
Highway Trailer Company
Edgerton, Wisconsin
Houston Engineers, Inc.
1412 Ennis
Houston, Texas
Hydrauger Corp. Ltd.
Co. 681 Market
San Francisco, California
Charles Machine Works, Inc.
603 Birch Street
Perry, Oklahoma
Chicago Pneumatic
8 East 44th Street'
New York 17, New York
Construction Machinery
Waterloo, Iowa
Hyster Company
2905 N.E. Clockamas
Portland, Oregon
Ingersoll-Rand
11 Broadway
New York 4, New York
International Manufacturing &
Equipment Co., Inc.
52 Church
New York, New York
Co. Joy Manufacturing Co.
Dept. 8, Oliver Building
Pittsburgh, Pennsylvania
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TABLE 1. COMPANIES CONTACTED FOR
INFORMATION (Continued)
KA-MO Tools, Inc.
Cicero, Illinois
Kenco Manufacturing Co.
Kenco Building
5212 Telegraph Road
Los Angeles, California
Line Scale Co., Inc.
3757 N.W. 37th
Oklahoma City, Oklahoma
Long Company
Oak Hill, West Virginia
Long-Airdox Co.
305 North Michigan Avenue
Chicago, Illinois
E. J. Longyear Co.
76 South 8th Street
Minneapolis, Minnesota
McCulloch Corp.
6103 W. Century Boulevard
Los Angeles, California
The Mine & Smelter Supply
Denver Division
P. O. Box 9041, 3800 Race Street
Denver 16, Colorado
J. R. Prewitt & Sons, Inc.
Pleasant Hill, Missouri
Ranney Water Systems, Inc.
Columbus, Ohio
Reichdrill Division
Chicago Pneumatic Tool Co.
Howard Sti-eet:
Franklin, Pennsylvania
The Salem Tool Co.
767 South Ellsworth Avenue
Salem, Ohio
Sprague & Henwood, Inc.
Scranton 2, Pennsylvania
Templeton Henly & Co.
2545 Gardner Road
Broadview, Illinois
Trainer Associates, Inc.
62 Young Avenue
New Castle, Delaware
Western Alloy Products Co.
Co. 348 North Avenue
Grand Junction, Colorado
Mobile Drilling, Inc.
906 North Pennsylvania Avenue
Indianapolis, Indiana
Peterson Engineering Co., Inc.
46o Kifer Road
Santa Clara, California
Pitnam Industrial Products Co.
6o8 5th.Avenue
New York 20, New York
Wilcox Manufacturing Co.
Raleigh, West Virginia
Hugh B. Williams Manufacturing Co.
833 Lovett Street
Dallas, Texas
Young Engine Corporation
P. O. Box 532
Canton 1, Ohio
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?
.1,932,o68
TABLE 2. IDENTIFICATION OF SOME OF
U. S. PATENTS REVIEWED
1,210,925
2,153,680
2,531,909
2,721,059
1,285,712
2,165,666
2,588,068
2,726,064
1,295,969
2,182,477
2,619,340
2,733,057
1,310,274
2,196,260
2,623,387
2,742,264
1,311,142
2,197,019
2,625,375
2,742,265
1,311,143
2,207,505
2,625,376
2,743,085
1,326,480
2,211,223
2,633,334
2,745,648
1,388,545
2,234,451
2,639,931
2,747,839
1,462,997
2,271,005
2,646,962
2,749,101
1,511,957
2,274,431
2,647,726
2,750,154
1,532,243
2,292,098
2,656,148
2,750,175
1,639,219
2,300,016
2,664,273
2,750,176
1,650,103
2,319,512
2,665,117
2,751,203
1,699,936
2,325,565
2,670,180
2,753,154
1,812,719
2,338,351
2,675,213
2,756,020
1,835,191
2,380,156
2,684,834
2,756,036
1,865,853
2,384,397
2,688,465
2,756,037
1,923,015
2,397,070
2,692,754
2,758,825
2,400,853
2,693,345
2,765,154
1,943,103
2,404,605
2,698,169
2,776,824
1,948,733
2,435,934
2,699,328
2,783,037
1,993,366
2,466,709
2,712,920
2,783,971
2,027,063
2,492,794
2,715,524
2,790,968
2,083,834
2,495,073
2,715,526
2,798,707
2,128,240
2,529,246
2,720,391
2,798,710
2,136,152
2,149,345
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driven by compressed air. The device pierces a continuous hole through
subsoil by compressing the ground around the pointed missile head so as to
form a pseudo-casing. It was reported that on a drive 109 ft long the missile
emerged within 4 in. of the target point. This is approximately the same accu
racy claimed for horizontal small-diameter drilling units.
Another important factor illustrated by the "Kret" literature is
that the initial penetration level must be below a "critical depth" which
varies with the type of soil; otherwise, the missile may tend to ride as it
progresses and hence may break through the surface before reaching the target.
This same philosophy can probably be applied to any "straight line"-operating
device which functions by compressing the subsoil, as opposed to devices such
as drills which remove the soil.
Exploration of Power Requirements
Since no commercial device which was considered applicable was
uncovered, it was decided to explore the power requirements for the ?type of
device of interest, in order to obtain some indication as to the feasibility
of performing the mission with reasonably sized drive units, without over-
loading the power source. Accordingly, preliminary experiments were
performed to obtain order-of-magnitude values for the forces involved in
penetrating the subsoil and for the frictional drag resulting when a wire-
conductor type of element was towed through the subsoil.
One experiment was directed toward exploring the compressive force
involved in displacing and penetrating the soil by means of a pointed object.
In this experiment, a 2-3/8-in.-diameter, 56-in.-long pipe was pushed into
a hillside by means of a "Portapower" hydraulic jack; a conical nose cone,
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machined to a 1200 included angle, was mounted on the pipe prior to pushing.
The force necessary to push the pipe increased steadily up to about 700 lb
at a penetration distance of about 36 in. and stayed constant at this
value until the rear-end cap on the pipe entered the soil. This force
corresponds to a soil compressive pressure of 160 psi based on the projected
area of the nose cone. Of course, the taper angle of the nose cone could
have been varied to either increase or decrease this force within a reasonable
range. A decrease in the included angle of the nose cone would have resulted
in a decrease in the compressive load and an increase in the frictional drag.
The interrelationship of these two factors was not investigated.
Another experiment was conducted to estimate the torque necessary
to rotate an auger-type unit into the soil. In this experiment, a 2-3/4-in.-
diameter spiral metal drill rotated by means of a torque wrench was drilled
vertically into the ground. The soil in which this test was performed was
about 3 ft from the edge of a river and hence was very moist; it consisted
generally of dark clay and contained rocks up to 1/2 in. in diameter. Because
of the moisture content, the soil packed very easily and adhered to the drill,
thus resulting in torque values which were higher than would be expected in
the application of interest.
The torque values obtained were generally as follows: The torque
required to rotate the drill increased to about 20 ft-lb, at which time the
drill was self supporting. The torque remained at the 20 ft-lb level until
the drill flutes were filled with clay; then it increased to 30 to 35 ft-lb
and remained at that level until the flutes were below the surface of the ground.
The torque then increased to about 50 to 6o ft-lb and remained conbtant for the
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rest of the test. On occasion a maximum torque value of 80 ft-lb was
obtained; this was attributed to the rocky nature of the clay.
In a third experiment to explore the frictional drag, a 1/2-in.-
diameter rubber hose, simulating the conductor cable, was pulled through a
44-in.-long
box which contained an earth-gravel mixture including some stones
as large as 3 to 4 in. in diameter. A spring scale was used to pull the
hose through the mixture, and simultaneously to measure the frictional drag
force. With a loose earth-gravel mixture, the force required was 18 lb or
4.9 lb/ft of buried cable. With the earth-gravel mixture packed by tamping
with a shovel, the force increased to 25 lb or 6.8 lb/ft of buried cable.
The values would probably be higher if damp soil had been used.
However, it is assumed that (1) the cable which would be used in the proposed
application would be smaller than 1/2 in. in diameter, and (2) that the
desired mole-type device would leave a hole which was open or filled with
loose soil. Thus, for the proposed application, a frictional drag value
of 6 to 7 lb/ft would be conservative and perhaps even ultraconservative.
In view of the relatively low values obtained for these forces
and for the frictional drag, we consider that a "mole-type device which
would penetrate the soil and tow a conductor cable into position is feasible.
Further, it appears that the power needed might be supplied by one man.
Mid-Project Decision
In the light of the foregoing results, consideration was given to
the difficulties and high costs involved in the development and ultimate
fabrication of a unit which would be guided, as had originally been specified,
in contrast with one which would be aimed and then would travel in a
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substantially straight line. The major pros and cons are summarized briefly
in the following.
"Straight Line" Device. In the operation of a "straight line"
device if an obstacle such as a large rock were encountered, the device
would have to be removed or retracted and another attempt made after moving
to a new, slightly displaced starting point. In view of the fact that, in
general, several attempts might be necessary to achieve a satisfactory
emplacement, mission definition becomes a primary consideration.
As defined by the Sponsor, the mission would consist of a drive
from Point "A" to Point "B", Point "A" being accessible for a period of 12
to 24 hr and Point "B" being continually accessible. During some cursory
experiments with a dynamite auger as discussed later, the drive rate obtained
was approximately 1 ft/min for six drives including the extraction time
between drives. Thus, it appears that within a 12-hr period, several attempts
to achieve a satisfactory emplacement could be made; for example, for distances
of 50, 100, and 150 ft, the number of attempts possible would be approximately
14, 7, and 4, respectively.
The possible accuracy of a "straight line" device can only be esti-
mated based on the reported performance of commercial devices. As discussed
above, the "Kret" missile reportedly has been within 4 in. of the target on
a 109-ft drive. Most of the horizontal-drill-unit manufacturers who were con-
tacted stated that the accuracy of a horizontal drill unit depends on the skill
and "feel" of the operators and on the drilling conditions such as type of drill
bit, drilling fluid, and soil type. However, most of them indicated that an
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accuracy similar similar to that reported for the "Kret" is attainable. It is
reasonable to assume, therefore, that"straight-line"devices could achieve
a desirable accuracy.
The development and per unit costs for "straight line" devices can
be expected to be relatively low because of the possibility of utilizing
off-the-shelf components. The utilization of standard components would also
increase the reliability of the "straight line" devices.
Guided Devices. A guided device might consist of two units:
(1) a boring unit, which would progress through the ground, and would
contain sufficient instrumentation to sense.its position and orientation
relative to some fixed point and also a means for varying the boring
direction; and (2) a control unit, which would provide a readout of the boring-
unit position and orientation, and would include a set of controls to actuate
the direction-changing mechanism in the boring unit.
Essentially, a guided device can be considered to be a "straight
line" device to which has been added (1) position- and orientation-sensing
equipment, and (2) direction-modification equipment. For the successful
application of guided devices, these two types of equipment would have to
be developed; this would be time consuming and expensive. Nothing is
currently available that could be easily modified to perform these functions.
In the oil-well drilling field, which is where most of the past pertinent
improvements have occurred, the accepted practice is to drill a hole,
remove the drill unit, and survey the hole by various means to determine
its location. Wedging devices are then generally used to change the
direction of drilling, if necessary. Because of the necessity of evolving
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and developing both the sensing equipment and the directional-control equipment,
the procurement costs of the first device would probably be higher by a factor
of 10 or more than the cost of obtaining the first "straight line" unit.
After a detailed discussion of the above with the Sponsor, it
was mutually agreed that the remaining effort should be directed toward the
evolution of concepts for a "mole"-type unit; and that the effort should be
concentrated on the "straight line" type of device. At the same time, the
Sponsor indicated that a device with a range of 110 to 150 feet (as opposed
to the originally indicated range of 50 ft) would be useful.
Preliminary Concepts Considered
Figures 1 through 4 illustrate schematically the major parts of
four concepts evolved that are representative of the preliminary concepts
considered for application as "straight line" devices. The "counter-rotating
auger" as shown in Figure 1 would consist of two augers with opposite helix
angles and a center nonrotating section- The two.augers would be designed
So that atingle motor would drive both, thus balancing the rotational forces.
The center section would have fixed guide vanes which would resist differences
in the rotational forces. With such a unit, one major problem would be the
difficulty of achieving rotation of the two augers under conditions where the
soil texture varied significantly, i.e., was fairly heterogeneous.
The "bootstrap" concept, illustrated in Figure 2, would consist of
concentric sliding cylinders propelled by means of a floating motor and ball
screw arrangement which would extend and contract the cylinders. In the
position shown in Figure 2, as the ball screw shaft extended to the left,
the front pawls would close, the rear pawls would open and bear on the soil,
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1l4..
a.)
,
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and the front cylinder would be moved to the left. Reversal of the motor
direction would cause the ball screw shaft to extend to the right; as a
result, the front pawls would open and bear on the soil, the rear pawls would
close, and the rear cylinder would be pulled to the left. This cycle would
then be repeated. Although motors and motor components are available that
might be modified for this application (Raco Machine Co., Bethel Park,
Pennsylvania), the associated development work makes this concept less
desirable than the recommended concept described below.
Figure 3 is a sketch of a concept consisting of an auger head
driven by means of a flexible shaft. The guide cylinder would be long
enough to guide the auger generally in a straight line. The auger tip and
guide cylinder would be disposable, i.e., they would be driven into the
final position and left there. The flexible shaft would unscrew from the
auger tip when the motor was reversed. Figure 4 illustrates a similar
concept, with the addition of two modifications. The flexible shaft would
be contained on a reel such as is frequently used with sewer-cleaner systems.
Further, the flexible shaft would be enclosed in a "STEM" (Storable Tubular
Extendable Member) unit of the type developed by DeHavilland Aircraft of
Canada for use as an extendable antenna for orbiting satellites; this wOuld
allow the use of a relatively small-diameter flexible shaft and would
eliminate the tendency for the shaft to kink.
Recommended Concept
Analysis of the above-outlined four preliminary concepts resulted
in a fifth concept, which appears to combiner the better features of the
above concepts. The equipment based on this concept, as illustrated in
Figure 5, would consist of a motor drive unit coupled to short sections of
hollow, rigid shaft, at the front end of which would be mounted a small-diameter
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hollow auger. The shaft sections would be added as the auger progressed
through the soil. All joints would be pinned or locked to achieve assembly;
accordingly, when the motor is reversed, the auger could be "screwed" out of
the soil. The rotational speed of the auger would be chosen such that the
auger would essentially progress forward through stationary earth rather than
progressing by transferring earth from the front to the rear of the hole.
The conductor cable would either be attached to the inside of the auger before
starting the drive or would be pushed through the auger by means of a small
stiff wire, after completion of the drive.
A number of preliminary experiments were subsequently performed
with a 2-3/4-in.-diameter dynamite auger, shown in Figure 6, to explore the
feasibility of a rigid shaft system. For these tests the auger was welded
to a 12-ft-long 3/8-in.-diameter steel rod. The auger was then drilled
into a rock-filled levee along the river. In view of the fact that the
soil in the levee contained considerable large and small rocks, and other
potential obstacles, it was not expected that long drives could be made.
For one experiment ,.a torque wrench was used to rotate the auger.
Approximately 25 to 30 ft-lb of torque were required to rotate the auger
until a solid obstacle was met, at a penetration distance of 6 ft. A torque
of 6o ft-lb was insufficient to drive the unit further. A torque of 15 to
30 ft-lb was required to screw the auger out of the hole. About 10 to 15
minutes were involved in running the auger in and out with the torque wrench.
In a second experiment, a 3/4-in, electric drill motor was used to
rotate the auger. The drill motor was powered through a Variac, to reduce
the speed to approximately 150 rpm. At a 6-ft penetration distance, the
motor stalled and a torque of 50 to 55 ft-lb was necessary to break it free.
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,1
i
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The motor was then used to achieve a total penetration distance of 8 ft, at
which point a solid obstacle was met, and the test was discontinued.
In a third experiment, the 3/4-in, electric drill motor was
operated at its full speed of 250 rpm. A total penetration distance of
10 ft was attained on this drive. The motor stalled twice during the .
drive, but it was possible to break the auger loose with a torque of 45 to
55 ft-lb. It was not possible to back the auger out of the hole because,
in view of the rotational speed used to drive the unit, the earth was packed
"solidly" behind the auger in the hole. A 1-1/2-ton chain jack was used to
extract the auger.
A series of six additional preliminary experiments, an electric
impact wrench with a zero speed capacity of 80 ft-lb was used to drive the
auger. The six tests achieved penetration distances of 3, 5, 1, 8, 5, and
10 ft. It was possible to remove the auger in five of the six drives merely
by reversing the impact wrench. The total time used for the 'six drives,
including the time for pulling out the auger at the end of one of the 5-ft
drives with a 1-1/2-ton chain jack, was approximately 1-1/2 hr.
In view of the results of these ten preliminary experiments,
it is considered feasible to use an auger at the end of a rigid shaft to
penetrate the soil for considerable horizontal distances. Although the
longest drive made was 10 ft, we believe that longer drives, for example,
for distances of 100 to 150 ft, are feasible using this type of system.
The soil drilled during these experiments was far from typical of what
would probably be encountered under normal conditions, as Outlined by the
Sponsor. Also, the auger used in these experiments was of the type prescribed
for removing dirt for dynamite holes, and was not designed for penetrating
soil by a "screw in" action. It is considered that an auger could be designed
specifically to provide the desired type of penetration.
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CONFIDEN"I'"1
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On the basis of this preliminary investigation, no major problems
are envisioned in the successful development of a rigid-shaft auger system
for the application of interest.
Future Work
It is recommended that further work be done to develop the rigid-
shaft auger system into a practical, reliable tool. In this connection,
efforts should be concentrated in four areas: (1) verification of the
accuracy achievable in "hitting the target area", (2) selection and/or
development of a proper auger, (3) design of the shafting and joints, and
(4) selection of a drive unit. Probably the most expeditious development
program would consist of the following: The initial work would involve a
preliminary selection and assembly of commercially available components.
This preliminary system would then be used to empirically verify the
accuracy achievable and to better define the requirements for the auger,
shaft and joints, and the drive unit. These results would be used as a
basis for the selection of components and the subsequent development of an
experimental system. Evaluation of this system would conclude this develop-
ment effort.
We would appreciate any comments regarding our efforts under
Work Order No. 9, and would be glad to arrange a Meeting to discuss the
further development of the recommended rigid-shaft auger system.
Sincerely,
In Triplicate
CthIFIDENTiAL
50X1
50X1
Declassified in Part - Sanitized Copy Approved for Release 2013/02/27: CIA-RDP78-03624A000900050001-6