HORIZONTAL

DIRECTIONAL
DRILLING DESIGN
PROJECT 16
CIVE 609

Kwesi Wells
1406940

TABLE OF CONTENTS
1.0 Project Description............................................................................................... 2
2.0 Referenced Documents........................................................................................ 3
3.0 Design Criteria and Assumptions..........................................................................3
4.0 Design Methodology............................................................................................. 3
5.0 Rod by Rod Plan.................................................................................................... 4
6.0 DR Selection......................................................................................................... 6
7.0 Bore Construction Methodology........................................................................... 7
8.0 Drill Fluid Management........................................................................................ 8
9.0 Tooling selection................................................................................................... 9
10.0 Conclusion........................................................................................................ 10
11.0 References........................................................................................................ 10
11.0 Appendix.......................................................................................................... 11

LIST OF TABLE

Table 1 Project Specifications and Guidelines.............................................................2

Table 2: Angles and Radius of Curvature Guidelines...................................................4
Table 3 Simulation Results for Operational Loads.......................................................6
Table 4: Simulation Results for Installation Loads.......................................................7
Table 5 Results of Impact of Rollers and Ballast on Pullback loads for 30" Pipe DR 9. 7
Table 6: Drill Rig Recommended Specifications..........................................................9

1.0 Project Description

The project entails the design of four hundred (400) meters of High Density
Polyethylene (HDPE) pipe for sewer application via Horizontal Direction Drilling
(HDD). Works duration is estimated at fifteen (15) days. Actual drill time is ten (10)
days while mobilization and demobilization is estimated at five (5) days. Designs
were completed to match the specifications and geotechnical information provided
by the client in Table 1.0.
BORE PATH CHARACTERISTICS
Pipe Surface Length (metres)
400
Depth of Cover (metres)
10
Outside Diameter (inches)
30
DRILL ROD CHARACTERISTICS
Drill Rod Diameter (inches)
1.625
Rod Lengths (feet)
10
GEOTECHNICAL INFORMATION
USCS Soil Type
Silt (M) ML
No. of Layers
1
Depth (metres)
20.00
Dry Soil Unit Weight (kN/m3)
16.8297
Saturated Soil Unit Weight (kN/m3)
19.8428
Friction Angle - Phi
10.00
Shear Modulus
999.74
Cohesive (kPa)
30.34
Water Table Height (metres)
6m
EXISTING UTILITIES
Gas Line Diameter 30
80 m from pipe entry point 7m below

Water Line Diameter 34

ground level
Required clearance 1
120 m from pipe entry point 8m below

ground level
Required clearance 1
Table 1 Project Specifications and Guidelines

2.0 Referenced Documents

All design works was completed in adherence with following documents:

1. ASTSM F1962-11 Standard Guide for Use of Maxi-Horizontal Directional

Drilling for Placement of Polyethylene Pipe of Conduit Under Obstacles,
Including River Crossings.
2. Plastics-Pipe Institute Handbook Chapter 12 Horizontal Direction Drilling

3.0 Design Criteria and Assumptions

1. No live loads and internal pressure were considered.
2. Design life cycle of pipe is fifty (50) years.
3. Radius of Curvature should be more than 1200 OD of drill rod.
4. Bore Outside Diameter = Pipe OD + 12
5. Bingham Model was used to calculate annular friction pressure loss.
6. Factor of Safety = 2
7. Pipe Modulus of Elasticity = 28,200 psi
8. Safe Working Pull Stress = 1150 psi
9. Installation duration 12 hours.
10.Poisson Ratio = 0.45
11.Unit Weight of Ground Water = 9.87 kN/m3
12.Specific Gravity of Pipe = 0.955
13.Specific Gravity of Mud Slurry = 1.5
14.Specific Gravity of Ballast = 1.0
15.Overburden Pressure = 22.4 kN/m3 x Depth of Cover

4.0 Design Methodology

A basic model was built using Microsoft Excel program incorporating all key design
requirements, recommendations and assumption. Then various trial runs were
conducted using different pipe dimension ratios under design conditions and
constraints. Outputs from the model allowed us to select the most appropriate
dimension ratio (DR) for the job.

The design campaign was executed in the following steps:

1.
2.
3.
4.
5.
6.
7.
8.

Review of existing soil data

Examine bore characteristics ( length of bore , overcut ratio)
Review drill rod specifications ( length , diameter)
Review applicable design requirements and standards
Design Bore Plan
Conduct Pipe Design and Selection
Calculate Drill Fluid Estimates
Estimate Maximum Bore Pressure Limits
3

9. Recommend and select Equipment and Tooling.

5.0 Rod by Rod Plan

In following best practices the angle and exist angles were selected to ensure
limited stress would be induced during construction. The bore would be initiated
using an entry angle of eight (8) degrees and be completed with an exist angle of
ten (10) degrees. This produced reasonable entry and exist radius of curvatures of
1026 and 657 meters respectively. All these parameters met the industry
recommendations as shown in the Table 2.0:
Bore Parameters
Entry Angle Alpha
Exist Entry Beta
Radius of Curvature Entry

Recommendations
5-10
8-15
> 50

Actual Design
8
10
1026

(meters)
Radius of Curvature Exist

> 50

657

(meters)
Table 2: Angles and Radius of Curvature Guidelines

The rod by rod plan was then drafted using these exist and entry angles. A draft plot
is presented below in Figure 1.

ROD BY ROD PLAN

0

200

400

600

800

1000

1200

1400

-5
-10
-15

DEPTH (FEET)

-20
-25
-30
-35
-40

L4=469.8 ft

L3=466.3 ft

DISTANCE (FEET)

Figure 1: Rod by Rod Plan Plot

A total number of 132 rods would be required from project. Detail coordinates for
each rod are presented in Appendix of this report. All identified obstacles were
avoided and clearances respected. The bore path runs at least 80 feet from the gas
line and 175 feet from the water line. Field information should be confirmed before
actual installation commences. Total length of bore was maintained at 1312 feet
(400 meters)

6.0 DR Selection
With the bore angles confirmed, the next phase was to select the optimum pipe DR.
This design would incorporate three (3) key scenarios during the life cycle of the
pipe:
1. Operational Loads: Under deformed, collapsed, stable bore conditions
2. In-Service Loads: deformed, collapsed, stable bore conditions.
Under different operational loads the highest pressure occurred under risk of
collapse to a value of 180 kPa. This value minus the pressure associated with water
was used to model the earth pressure at 141.12 kPa. A summary of model outputs
are highlighted below in Table 3.0:
DR

Deflectio

Status1

n (%)

Collapse

Stat

Wall

Strength

us2

Compressi

(kPa)
7.3
9.0
11.5
13.0

Status3

ve Stress

(psi)
2.85
Pass
760
Pass
74.70
5.82
Pass
276
Pass
92.10
11.33
Fail
93
Fail
112.57
22.00
Fail
50
Fail
138.15
Table 3 Simulation Results for Operational Loads

Pass
Pass
Pass
Pass

Deflection Limits 7.5%

Maximum Earth Pressure (Collapse) 180 kPa
3
Allowable Wall Compressive Stress 1150 psi
2

Both DR 7.3 and 9.0 met the acceptable design thresholds under operational loads.
DR 11.5 and 13.0 failed under the deflection and collapse strength tests but passed
the wall compressive stress test. This was expected as this criteria rarely controls
the design outcome. The model was then run to calculate the performance of the
pipes under installation loads. This test was done considering no roller and no
ballast. All pipes pass the pullback load test as shown in Table 4.0:

Pipe DR

Maximum

Status1

Unconstrai

Status2
6

Pullback

ned

Stress (psi)

Collapse
Strength

7.3
9.0
11.5
13.0
1
2

(psi)
478.0
Pass
72.65
595.0
Pass
34.11
732.0
Pass
16.58
906.0
Pass
7.88
Table 4: Simulation Results for Installation Loads

Pass
Pass
Fail
Fail

Allowable Maximum Pullback Stress was set at 1150 psi

Minimum unconstrained collapse strength = 21.33 psi (P MUD)

Under installation loads DR 7.3 and 9.0 performed excellent in both scenarios. While
DR 11.5 and 13.0 both passed the pullback loads test but failed the unconstrained
collapse strength test. The final decision was to proceed with DR 9.0 since it would
be the easier pipe to work with and less costly. Further analysis would be done to
observe its performance under different construction methodologies.

7.0 Bore Construction Methodology

Different installation methodologies was explored to look at the impact on the
pullback loads on a 30 pipe DR 9.0. The installation would be considered in
following four scenarios:
1.
2.
3.
4.

No Rollers and No Ballast

With Rollers and no Ballast
With Rollers and ballast
No Rollers and with ballast

All scenarios were run in the simulation to get the best methodology to be used for
installation. The results are presented below in Table 5 below:
Pipe

No Rollers

With Rollers

With Rollers

No Rollers

Sections

and No

and No

and Ballast

and with

Ballast (lbs)
Ballast (lbs)
(lbs)
Ballast (lbs)
TA
93,564
17,697
17,697
93,564
TB
129,544
75,066
41,466
95,945
TC
147,539
117,512
57,968
87,996
TD
158,133
148,118
69,748
79,763
Table 5 Results of Impact of Rollers and Ballast on Pullback loads for 30" Pipe DR 9

Using a construction methodology with roller and ballast the least amount of
pullback load on the pipe occurred. The ballast considered during design was water.
The option of the ballast can be changed if desired but calculations would be
reworked to ensure compliance with best practices. A recommendation is being
made to execute the installation with the assistance of rollers and ballast

8.0 Drill Fluid Management

In keeping with best practices no reamer pass would enlarge the hole greater than
10 . After reviewing the soil characteristics, the following reaming sequence was
recommended:
Reaming Sequence
Pilot Hole
1st Pass
2nd Pass
3rd Pass
4th Pass

Diameter (Inches)
8
18
28
38
42

The drill speed would be set at 60 feet per hour. This would allow sufficient time for
the cutting to be removed and a reasonable pump capacity to be achieved. Total
volume of fluid to be removed is estimated 900 m 3. Pump capacity required to
remove the soil is estimated at 678 L/min. All fluid would be stored in ten 100 m 3 on
the project site.

Using the Bingham Model the maximum bore pressure was

calculated to 197.25 kPa. This is lower than the overburden pressure of 224 kPa.
Fracture during the drilling campaign most likely be avoided.

9.0 Tooling selection

A drill rig matching the below specifications should be used during the installation
stage:
Parameters

Recommended Rig

Maximum Limits

Thrust / Pullback (lbs)

Max Drilling Pressure (psi)
Maximum Pump Capacity Flow

Specifications
100,000
1100 psi
870

80,000
677

(L/min)
Table 6: Drill Rig Recommended Specifications
A special request would have to be made since most of the medium rigs are
outfitted with 20 feet rods and 3- 4 inches drill rods. Since the project calls for 10
feet rods and 1.625. A special outfitting would have to be done to match the
project requirements. A recommended drill rig for the job is a Vermeer D100x140
15. This rig would be able to meet the project requirements. This medium rig must
be used in association with rollers and ballast or only ballast only. If these aids are
not going to be used a larger rig would be needed.
Supereamers design model should be used as this would allow exceptional mixing
action. This type of reamer could be used on Vermeer D100x140. No integration
problems should occur. Also required reaming sizes are available on the market. A
barrel reamer should be used at the hole diameter. This would assist in swabbing
out the hole.
For this borehole project, a recommendation is being made for the drill fluid
composition.
1.
2.
3.
4.

Bentonite Based
Soda Ash Add if the pH of the makeup water is between 8-9
No SAG to enhance the capability of the fluid ( lb per 100 gallons)
Quick TROL LV to enhance the filter cake building ability of the fluid ( lbs
per 100 gallons)

This is just a base recommendation for initiate drill fluid mix. As the project
progresses, adjustments should be made to achieve the desired results.

10.0 Conclusion
The project could be executed within 15 days using a product pipe of 30 OD at DR
9. A medium rig could be used with the assistance of rollers and ballasts to achieve
this bore. This would reduce the installation cost. The design should be peer
reviewed before final approval is construction commences. All owners of buried
pipelines should be informed of the impending works. This would gather information
about exact location of pipelines and any obstacles encountered during their
projects. Environmental and safety regulations should be followed during the works.

11.0 References
American Society Testing Materials (ASTM).1999 Standard Guide for Use of MaxiHorizontal Directional Drilling for Placement of Polyethylene Pipe of Conduit under
Obstacles, Including River Crossings. F1962-11, West Conshohocken, Pa.
Plastics-Pipe Institute Handbook (2014) Horizontal Direction Drilling, Chapter 12,
Irving Texas

10

11.0 Appendix
ROD BY ROD CORDINATES FOR ENTIRE BOREPATH

11

Rod
Number

Angle

Radians

0.000
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
10.000
11.000
12.000
13.000
14.000
15.000
16.000
17.000
18.000
19.000
20.000
21.000
22.000
23.000
24.000
25.000
26.000
27.000
28.000
29.000
30.000
31.000
32.000
33.000
34.000
35.000
36.000
37.000
38.000
39.000
40.000
41.000
42.000
43.000
44.000
45.000
46.000
47.000
48.000
49.000

10.000
9.737
9.474
9.211
8.948
8.684
8.421
8.158
7.895
7.632
7.369
7.106
6.843
6.579
6.316
6.053
5.790
5.527
5.264
5.001
4.738
4.474
4.211
3.948
3.685
3.422
3.159
2.896
2.633
2.369
2.106
1.843
1.580
1.317
1.054
0.791
0.528
0.264
0.001
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

0.175
0.170
0.165
0.161
0.156
0.152
0.147
0.142
0.138
0.133
0.129
0.124
0.119
0.115
0.110
0.106
0.101
0.096
0.092
0.087
0.083
0.078
0.074
0.069
0.064
0.060
0.055
0.051
0.046
0.041
0.037
0.032
0.028
0.023
0.018
0.014
0.009
0.005
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

X
Coordinate
s
9.848
19.704
29.568
39.439
49.317
59.202
69.095
78.993
88.899
98.810
108.727
118.651
128.579
138.514
148.453
158.397
168.346
178.300
188.257
198.219
208.185
218.155
228.128
238.104
248.083
258.065
268.050
278.037
288.027
298.018
308.012
318.006
328.003
338.000
347.998
357.997
367.997
377.997
387.997
397.997
407.997
417.997
427.997
437.997
447.997
457.997
467.997
477.997
487.997
497.997

Y
Coordinate
s
-1.736
-3.428
-5.074
-6.674
-8.230
-9.740
-11.204
-12.623
-13.997
-15.325
-16.607
-17.844
-19.036
-20.181
-21.282
-22.336
-23.345
-24.308
-25.226
-26.097
-26.923
-27.703
-28.438
-29.126
-29.769
-30.366
-30.917
-31.422
-31.881
-32.295
-32.662
-32.984
-33.260
-33.489
-33.673
-33.811
-33.903
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950
-33.950

Table
7: Drill
Rig

12

Recommended Specifications
INPUT DATA
Bore Specs
Pipe Surface Length
(m)
Depth of Cover (m)
Outside Diameter
(inch)
Drill Rod OD (inches)
Drill Rod L (inches)

Meters
400

Feet
1312

10
30

393.7
0.762

1.625
10

0.041275

Angles
Bore Exit Angle (Alpha)
Bore Entry Angle (Beta)

Degrees
8
10

Radians
0.13963
0.17453

OUTPUT DATA
Radius of Curvature
Pipe Entry (m) Rin
Pipe Exit (m) Rout

1025.876984
656.56127

Pipe Sections
L2 - Entry
L4 - Exit
L3 - Horizontal
Total
CALCUATTIONS

Lengths (m)
143.24
114.59
142.17
400.00

BORE
PLAN

Lengths (feet)
469.8
375.9
466.3
1312.00

13

EARTH LOAD CALCULATIONS

INPUT DATA
Soil Layer
Depth
Unit Weight of Soil (dry) (kN/m3)
Unit Weight of Soil (sat) (kN/m3)
Wall friction angle- Phi (degrees)
SM
Cohesive (kPa)
Water Table from Ground (m), H1
Water Height above Pipe Invert (m),
H2
Unit Weight of Ground Water (kN/m3)
Depth of Cover (m)
Modulus of Elasticity (psi)
Safety Factor , N
fo (From Graph)
Poisson Ratio , m
DR
OUTPUT DATA
Earth Loads
Water Pressure (kPa)
Collapsed Borehole
Earth Pressure (kPa)
Only Earth no water
Deformed Borehole
Silo Width (inches)
Silo Width (metres)
Earth Pressure Coefficient K
Constant B
Constant A
Arching Factor k
Earth Pressure (kPa)
Ground Water
Earth Pressure - Collapsed
Earth Pressure - Deformed
Live Load
Internal Pressure
Collapse Strength (psi)
Collapse Strength (kPa)
DEFLECTION CALCULATIONS

1.00
20.00
16.83
19.84
10.00
999.74
30.34
6.00
4.00
9.81
10.00
28200.00
2.00
0.58
0.45
9.00

39.23

180.35
141.12
42.00
1.07
0.70
1.15
0.32
0.59
122.92
39.23
180.35
122.92
0.00
0.00
40.06
276.18
14

INPUTS VARIABLES
OD (inches)
DR
Earth Pressure (kPa)
Modulus of Elasticity (psi)
Modulus of Elasticity (Mpa)
Water Density (lbs/ft3)
Poisson Ratio
Radius of Curvature - Pipe Entry (m)
Radius of Curvature - Pipe Exit (m)

30.000
9.000
141.121
28200
194.432
62.400
0.450
1025.877
656.561

Unit Weight of Ground Water

(kN/m3)

9.807

CONVERSIONS AND CONSTANTS

OD (m)
0.762
OD (mm)
762.000
Earth Pressure (psi)
20.468
Water Density (lbs/in3)
0.036
thickness - t (inch)
3.333
thickness - t (mm)
84.667
Moment of inertia (inch3)
3.086
Radius of Curvature - Pipe Entry
40388.859
(inches)
Radius of Curvature - Pipe Exit
25848.870
(inches)
z
0.000002085913232
Constant A
0.667
Constant B
0.526
OUTPUTS
Earth Load Deflection
0.05574
Buoyant Deflection
0.00246
Reissner Effect
0.000001390611109791190
Net Deflection
5.82%
Allowable Ring Deflection
7.50%

15

WALL COMPRESSIVE STRESS CALCULATIONS

Inputs Variables
Earth Pressure (kPa)
OD (inches)
DR
t (inches)
Conversions and Constants
Earth Pressure (psf)

141.12
30
9
3.333333333
2947.381121

Outputs
Wall Compressive Stress (psi)
Allowable Compressive Stress (psi)

92.10566004
1150

16

Inputs Variables
L1 (m)
L2 (m)
L3 (m)
L4 (m)
Depth of Cover (m)
OD (inches)
DR
Bore Exit Angle
(Alpha)
Bore Entry Angle
(Beta)
Va (no rollers)
Va (rollers)
Vb
Water Density
(lbs/in3)
Pi
S.G of Pipe , Ya
S.G of Mud Slurry ,
Yb
S.G of Ballast Fluid
(water) , Yc

PULLBACK LOAD CALCULATIONS

metres
feet
60
196.8504
143.2394488
469.94571
31
142.17
466.43371
63
114.59
375.95657
05
10
32.8084
30
762
9
0.13962634
0.174532925
0.5
0.1
0.3
0.03612729
3.142
0.955
1.5
1

Conversions and
Constants
Wa (lbf/in)

9.635902902

Wa (lbf/ft)

115.6308348

No Ballast
Wb (lbs/in)
Wb (lbs/ft)

28.6743786
344.0925432

With Ballast (filled)

Wb (lbs/in)
Wb (lbs/ft)

13.22414161
158.6896994

Outputs
Ta
Tb
Tc
Td

0.0000098
1

No Rollers + No
Ballast
93563.41
129543.48
147538.41
158132.07

1.6862830
08

Rollers +
No Ballast
17696.22
75065.76
117511.46
148117.02

Rollers +
Ballast
17696.22
41465.85
57968.11
69747.57

No Rollers
+ Ballast
93563.41
95943.57
87995.05
79762.63

17
Hydrokinetic Force
Tk (lbf)

3393.36

3393.36

3393.36

3393.36

UNCONSTRAINED COLLAPSE STRENGTH CALCULATIONS

Unit Weight of Mud (kN/m3)
Depth of Cover
Modulus of Elasticity (psi)
Safety of Factor , N
fo
r

14.7105
10
28200
2
0.58
0.251455

Tensile Factor Fr

0.851777
70721
0.001953
34.1195
21.33023

Reduced Collapse Strength (psi)

Pmud (Psi)

18

DRILL FLUID CALCULATIONS

Bore Length (m)
Drill Speed
Drill Fluid Ratio

400
80
2.5

Reaming Sequence
(inches)
8
18
28
38
42

Reaming Sequence (m)

Volume of Drill Fluid (m3)

# of Rods
m3 Per Rod
Large Rig (ft/hr)
Drill time per rod (min)
Fluid/Slurry Pump Rate
(m3/min)
Fluid/Slurry Pump Rate
(L/min)
Tanks Volume
# of Tanks Required

893.9478895
132
6.772332496
60
10
0.67723325

Drill Pass
1
Total (min)
Total (hr)
Total (days)

Drill Time
1312
6560
109.3333333
9.111111111

0.2032
0.4572
0.7112
0.9652
1.0668

Volume of Soil
(m3)
12.97339341
52.70441072
93.24626512
133.7881195
64.86696704
357.5791558

Volume of Drill Fluid

(m3)
32.43348352
131.7610268
233.1156628
334.4702988
162.1674176
893.9478895

677.2332496
100
8.939478895

19

Drilling Fluid Output (L/min)

Bore Diameter (mm)
Outside Diameter (mm)

677.2332
1066.8
762

Va (m/s)

0.025781

dP/dL (kPa/m)
Length (m)
Circulation Pressure (kPa)

0.125251
400
50.10058

Hydrostatic Pressure (kPa)

147.15

Total Pressure (kPa)

197.2506

Overburden Pressure (kPa)_1

224

Overburden Pressure (kPa)_2

MAXIMUM BORE PRESSURE CALCULATIONS

180.3494

20