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HDD HORI ZONTAL DI RECTI ONAL DRI LLI NG.

TRENCHLESS TECHNOLOGY FOR A SAFE AND EFFI CI ENT


I NSTALLATI ON OF PI PELI NES.
HERRENKNECHT AG | UTI LI TY TUNNELLI NG | TRAFFI C TUNNELLI NG HDD
011_eBroschre_HDD_120410oc_Fassung 04
CONTENTS.
Frame rigs: High power-to-weight ratio.
The economical alternative.
Large diameters safely laid.
Seven river crossings in Azerbaijan.
Trailer rigs: well underway.
Economical to transport, easy to rig-up and rig-down.
Through difficult geology at high speed.
11 days for 1,500 meters of pipeline installation in Brazil.
F RAME RI GS
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Underground supply pipelines:
The lifelines of civilization.
Pipeline construction made easy:
Reaching the target in three stages with HDD.
Full Service HDD:
All inclusive.
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HE RRE NKNE CHT
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T RAI L E R RI GS
Pipe Thruster: additional power.
Extending the range of HDD applications.
Faster than the monsoon.
Rapid pipeline insertion for project success in India.
Direct Pipe: Reaching the target in one step.
Bore hole excavation and installation of the pipeline
at the same time.
Brine extraction made easy.
Outfall pipeline at the Rysumer Nacken.
Crawler rigs: mobility in difficult terrain.
Caterpillar tracks for extraordinary maneuverability.
Strong and maneuverable in tight spaces.
Sea outfall installed on Frances Mediterranean coast.
Modular rigs: delivered to the jobsite
in 20-foot containers.
Transported to the jobsite in parts.
World record in Saudi Arabia.
3,048 meters laid below the seabed.
XXL River crossing.
Successful installation of a 56-inch pipeline in Turkmenistan.
P I P E T HRUST E R
19
18
20
CRAWL E R RI GS
12
14
13
15
MODUL AR RI GS DI RE CT P I P E

21
16
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011_eBroschre_HDD_120410oc_Fassung 04
UNDERGROUND SUPPLY PI PELI NES:
THE LI FELI NES OF CI VI LI ZATI ON.
The demand for energy around the world is growing continuously. Energy can be saved in a sustainable
way by using increasingly efficient technology; some of the demand can be covered by renewable
energy sources. In the next few years, however, most of it will continue to come from fossil fuels and
this trend is increasing. In 2011, the worldwide daily demand for oil will be 11 billion liters, and this will
have increased by 1.4 billion liters by 2018. Demand for gas is expected to see an even more dramatic
development. By 2018, it is expected to rise by nearly a quarter from a 2011 level of around 3,200 billion
cubic meters.
The way ahead for new infrastructures leads underground. A modern, global pipeline network is
needed to distribute oil and gas efficiently. This includes developing infrastructures to connect new oil
and gas deposits and to link up as yet undersupplied regions. There is also a need to renovate existing
pipelines and turn them into efficient supply corridors. The extent of this need around the world is shown
by the fact that almost 125,000 kilometers of pipeline are currently under construction or in planning.
As a technology and market leader in mechanized tunnelling, Herrenknecht offers an economic,
rapid and safe solution wherever pipelines need to be laid underground Horizontal Directional Drilling
(HDD) technology. This trenchless technology allows obstacles such as rivers, mountains, roads and
residential areas, as well as difficult terrain and nature protection zones to be crossed underground. The
resulting underground pipelines are also better protected against external influences.
4 | 5
Drilling for progress. For more than 30 years. In addition to HDD, Herrenknecht offers a large number
of other procedures and technologies for the production of supply and disposal tunnels (Utility Tunnelling,
< 4.2m). For more than 30 years, our machines have been creating new pipeline systems around the
globe to supply people with oil, gas, water and electricity, to remove sewage and to provide communi-
cation lines. We both optimize tried-and-tested technologies, such as classic pipe jacking, and develop
new innovative methods such as Direct Pipe, which is described in more detail on pages 20 to 21.
Our range of products also includes tailor-made machines for traffic tunnels (Traffic Tunnelling,
> 4.2m) and state-of-the-art vertical deep drilling rigs (Herrenknecht Vertical). We see ourselves as
a reliable partner in teamwork tunnelling for all projects where our products are used. Comprehensive
services for all aspects of tunnel boring activities complement our range.
No matter which technology you choose: Herrenknecht will always provide you with the optimum
solution. Anytime. Anywhere.
011_eBroschre_HDD_120410oc_Fassung 04
3
2
1
Direction of Operation
None-Magnetic
Drill Stern
Survey
Cable
Survey
Tool
Jet Bit
Drill Line
Reamer
Direction of Operation
Drill Pipe
Reamer
Direction of Operation
Drill Pipe Swivel Pipeline
PI PELI NE I NSTALLATI ON MADE EASY:
REACHI NG THE TARGET I N THREE STAGES WI TH HDD.
HDD is the ideal procedure for laying pipelines quickly, economically and without impacting the environ-
ment. The trenchless drilling method with only one start and exit point, means several kilometers of
pipelines can be laid beneath rivers, cities, mountains and the countryside. The surface along the pipeline
route remains totally untouched. No congestion along trafc arteries, no construction sites in cities, no
negative impact on nature.
As simple as it is convincing. In the HDD method, pipelines are laid in three stages.
First, a pilot drill is carried out from the entry point. In this process step, a computer-controlled
surveying system located behind the drilling bit steers the drill string along the planned route to the exit
point on the other side of the obstacle to be crossed. The surveying system, the steering and the drilling
tools can be adapted to any soil conditions, thus ensures the success of a project.
In the second stage, reaming the pilot drill, the drilling diameter is successively enlarged. To achieve
this, the drill bit is replaced by a reamer. The reamer is equipped with jets and cutting tools, enabling it
to remove the soil both hydraulically and mechanically. Depending on the soil conditions, a mixture of
water and bentonite or other additives can be used for hydraulic excavation. This both supports the bore
hole and reduces frictional forces, while allowing the excavated material to be transported to a separation
plant on the surface.
Finally, the prefabricated pipeline or pipe bundle is pulled-back from the exit point into the enlarged
and cleaned bore hole. To do this, the pipeline is connected to the pipe string and pulled back to the
entry point. When the pipeline appears at the entry point, it has reached its nal and safe position and
the pipeline installation is complete.
The right rig for any job. The maxi and mega rigs developed and manufactured by Herrenknecht are
positioned directly at the entry point from where they pull back the pipe string into the bore hole. The
rigs exert pulling forces of between 60 and 600 tonnes (600 and 6,000kN) and achieve a maximum torque
of between 30 and 150 kilo Newton meters, depending on the model. All Herrenknecht HDD rigs have
their own diesel powered energy supply housed in sound-proofed 20ft containers. The capacity of these
power packs, as we call them, can vary from 300 to more than 1,300 kilowatts, depending on the
application.
These rigs are remarkable not only for their performance capacity but also for their construction
design. We offer frame, trailer, crawler and modular rigs. Information on choosing the best concept for
your project can be found in the following pages.
6 | 7
011_eBroschre_HDD_120410oc_Fassung 04
HI GH POWER- TO- WEI GHT RATI O:
HERRENKNECHT FRAME RI GS.
Frame rigs are used whenever high power-to-weight ratios are required. They do not have their
own transport system, so they are accordingly light and can be loaded onto any common
trailer with a simple crane, and transported by truck. A crane is also necessary to unload and
align them on the jobsite. Herrenknecht frame rigs are, like all other rigs, available with pull-
ing forces of 60 to 600 tonnes.
Tried and tested in practice. Frame rigs are simple and robust, thus making an important
contribution to the economical completion of a project for example in Azerbaijan.
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A B C D E F G
A B C D E
1
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Projektion
Oberfchen-
angabe nach
DIN ISO 1302
HK250F
HERRENKNECHT
Fax: 07824/3403
Tel.: 07824/302-0
HERRENKNECHT AG
Schlehenweg 2
D-77963 Schwanau
www.herrenknecht.de
Tunnelvortriebstechnik
H-006
kg Gewicht/
Projekt
Freimatoleranzen
22246 30038098
Skizze
Werkstof
/
1
Zeichnung
Format
Weber D.

A3_E

Benennung
Index
Mastab
Zeichnungsnummer

Name Datum
Geprft
Bearbeitet
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
250T ZUGKRAFT
1364-700-000-00
Blatt Nr.
1
HORIZONTALBOHRMASCHINE
Artikelnummer
16.03.2010
Maschinentyp
8 | 9
FRAME RI G I N AZERBAI JAN:
LARGE DI AMETERS SAFELY LAI D.
HK250F
Bore hole diameter: 62
Max. torque: 90kNm
Installed power: 440kW
Max. pull force: 2,500kN, 250t
SOL UTI ON
BAKU-TBI LI SI -CEYHAN PI PELI NE PROJECT,
SOUTH-CAUCASUS PI PELI NE PROJECT,
AZERBAI JAN
Geology: clay, silt, sand
Pipeline lengths: from 570 to 1,102m
(total 6,140m)
Pipeline diameter: 42"
Particularities: length and diameter of the
bore holes, difficult access to construction site,
tight schedule
REQUI REMENT
Challenging requirements. In recent years,
several large-diameter oil and gas pipelines
have been built in Southeast Europe. The
1,760-kilometer-long BTC pipeline is one of
them. This 42-inch pipeline transports oil
from the Caspian Sea to the Mediterranean
coast, crossing Azerbaijan, Georgia and Tur-
key along its route. With a length of almost
1,100 kilometers, the SCP gas pipeline runs
parallel to the BTC pipeline and also has a
diameter of 42 inches. A Herrenknecht HDD
rig was used to cross seven rivers and ducts
in Azerbaijan.
High reliability. With its low weight and
easy transportation, the Herrenknecht
HK250F frame rig met the requirements in
Azerbaijan exactly. At the same time, it was
able to prove its reliability since no less than
seven crossings with lengths ranging from
570 to 1,102 meters were necessary three
for the BTC pipeline and four for the SCP line.
In just over seven months, a total of 6,140
meters of these two, 42-inch pipelines were
laid safely, allowing the project to be com-
pleted on schedule, despite the tight time
constraints.
TURKEY
AZERBAI JAN
GEORGI A
BAKU
Caspian
Sea
011_eBroschre_HDD_120410oc_Fassung 04
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A B C D E F G
A B C D E
1
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4

Projektion
Oberfchen-
angabe nach
DIN ISO 1302
HK250T
HERRENKNECHT
Fax: 07824/3403
Tel.: 07824/302-0
HERRENKNECHT AG
Schlehenweg 2
D-77963 Schwanau
www.herrenknecht.de
Tunnelvortriebstechnik
H-106
kg Gewicht/
Projekt
Freimatoleranzen
30000 30128704
Skizze
Werkstof
/
1
Zeichnung
Format
Weber D.

A3_E

Benennung
Index
Mastab
Zeichnungsnummer

Name Datum
Geprft
Bearbeitet
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
250T ZUGKRAFT
2467-700-000-00
Blatt Nr.
1
HORIZONTALBOHRMASCHINE
Artikelnummer
17.03.2010
Maschinentyp
Trailer rigs come into their own particularly whenever long distances must be mastered
quickly and simply. All Herrenknecht trailer rigs are mounted on a 2 or 3-axle chassis, which
can be pulled by any articulated truck with a standard kingpin and the necessary pneumatic
and electronic equipment. This means they can be used at all sites which can be reached on
mostly paved roads.
Optimized design for optimum performance. The design of Herrenknecht trailer rigs means
they can be put into operation quickly and easily. There is no need for a crane, either to position
the rig precisely at the jobsite or to align it with the optimum drilling angle. This saves high
ancillary costs and reduces the amount of space required on site. The innovative engineering
design also means that the rigs weight was reduced, making transport quicker and cheaper.
Tried and tested in practice. Trailer rigs can be transported economically and rigged-up and
rigged-down easily. These advantages have proved their worth both in Brazil and elsewhere.
WELL UNDERWAY:
HERRENKNECHT TRAI LER RI GS.
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Projektion
Oberfchen-
angabe nach
DIN ISO 1302
HK250T
HERRENKNECHT
Fax: 07824/3403
Tel.: 07824/302-0
HERRENKNECHT AG
Schlehenweg 2
D-77963 Schwanau
www.herrenknecht.de
Tunnelvortriebstechnik
H-106
kg Gewicht/
Projekt
Freimatoleranzen
30000 30128704
Skizze
Werkstof
/
1
Zeichnung
Format
Weber D.

A3_E

Benennung
Index
Mastab
Zeichnungsnummer

Name Datum
Geprft
Bearbeitet
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
250T ZUGKRAFT
2467-700-000-00
Blatt Nr.
1
HORIZONTALBOHRMASCHINE
Artikelnummer
17.03.2010
Maschinentyp
10 | 11
TRAI LER RI G I N BRAZI L:
THROUGH DI FFI CULT GEOLOGY AT HI GH SPEED.
Pretty big. In this project, a large-scale pipe-
line was constructed for a mineral oil com-
pany in Esprito Santo, a State on Brazils
southeast coast. Two pipelines of 77 kilome-
ters in length were installed close to the city
of Linhares to transport liquid gas and naph-
tha from a renery to the port. The construc-
tion company chose to use Herrenknecht
HDD equipment to cross the Monsaras and
Rio Doce rivers.
Pretty quick. A Herrenknecht type HK250T
HDD rig was used to lay the two parallel,
8-inch pipelines underground. It had already
successfully installed pipelines with a total
HK250T
Bore hole diameter: 2x 14
Max torque: 90kNm
Installed power: 440kW
Max. pull force: 2,500kN, 250t
SOL UTI ON
CONSTRUO E MONTAGEM DE DUTOS
CACI MBAS BARRA DO RI ACHO, BRAZI L
Geology: sand, clay, loam
Pipeline lengths: 2x 1,505m, 2x 1,701m
Pipeline diameter: 2x 8"
Particularities: difficult accessibility of construc-
tion site in the Brazilian rainforest
REQUI REMENT
MANAUS
LI NHARES
BRAZI L
Atlantic
Ocean
length of 19.5 kilometers in the Amazon
Basin, Brazil, as part of the Urucu-Manaus
pipeline project. Despite difcult geological
conditions, it also proved its worth near Lin-
hares. The rst two 1,505 meter long cross-
ings were completed in just 11 days. Thanks
to daily performances of up to 530 meters,
subsequent crossings, each of 1,701 meters
in length could also be completed in a remark-
able time only 15 days. And the pro ject
overall was brought to a rapid and successful
end. The expensive, complex and dangerous
transportation of gas and gasoline by truck
is now a thing of the past.
011_eBroschre_HDD_120410oc_Fassung 04
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Maschinentyp
17.03.2010
Artikelnummer
HORIZONTALBOHRMASCHINE
1
Blatt Nr.
1703-700-000-00
150T ZUGKRAFT
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
Bearbeitet
Geprft
Datum Name

Zeichnungsnummer
Mastab
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Benennung

A3_E

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Format
Zeichnung
1
/
Werkstof
Skizze
30068347 31000
Freimatoleranzen
Projekt
Gewicht/ kg
H-042
Tunnelvortriebstechnik
www.herrenknecht.de
D-77963 Schwanau
Schlehenweg 2
HERRENKNECHT AG
Tel.: 07824/302-0
Fax: 07824/3403
HERRENKNECHT
HK150C
Oberfchen-
angabe nach
DIN ISO 1302
Projektion

MOBI LI TY I N DI FFI CULT TERRAI N:
HERRENKNECHT CRAWLER RI GS.
Herrenknecht HDD rigs with crawler systems are mainly used on construction sites which
cannot be accessed by trucks and cranes, whether for space reasons or because of the ground
conditions. Their caterpillar tracks mean the rigs remain fully mobile in such conditions, so
they can be maneuvered quickly and easily into the desired starting position.
Tried and tested in practice. The extraordinary mobility of crawler rigs means they can reach
almost any construction site. This was a decisive advantage, for example, in France.
FRANCE
SAI NT- JEAN- CAP- FERRAT
12 | 13
CRAWLER RI G I N FRANCE:
STRONG AND MANEUVERABLE I N TI GHT SPACES.
A tight construction site. In Saint-Jean-
Cap-Ferrat between Nice and Monaco, a 50
year old sewage system needed to be ex-
tended. The start point for a sea outfall to be
drilled using the HDD method was located
at Pointe de la Causinire, right next to a
narrow coastal road at the bottom of a villa-
covered mountain side. The access roads to
the construction site were narrow and wind-
ing, space was tight on the steep jobsite.
Since there are many corals on the seabed,
nature protection regulations meant the ex-
cavated material could not be removed with
bentonite as usual.
Success all down the line. A mobile, type
HK150C Herrenknecht crawler rig was navi-
gated to the jobsite with great precision and
positioned to lay the pipe string from the
shore out into the sea. The pipeline route
required an steep entry angle of 22 degrees.
This was no problem for the rig and the job-
site which was designed to cope with this
entry angle. The excavated material was
blown out of the bore hole using compressed
air from compressors and clean water. After
pilot drilling and several reaming steps of
the bore hole the pipeline was successfully
installled.
SEA OUTFALL SAI NT-JEAN-CAP-FERRAT,
FRANCE
Geology: sand, weathered rock
Pipeline length: 110m
Pipeline diameter: 24"
Particularities: narrow access road and space con-
straints, steep drilling angle, no bentonite allowed
REQUI REMENT
HK150C
Bore hole diameter: 34
Max torque: 70kNm
Installed power: 440kW
Max. pull force: 1,500kN, 150t
SOL UTI ON
011_eBroschre_HDD_120410oc_Fassung 04
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Maschinentyp
18.03.2010
Artikelnummer
HORIZONTALBOHRMASCHINE
1
Blatt Nr.
2465-700-000-00
HK400T ZUGKRAFT
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
Bearbeitet
Geprft
Datum Name

Zeichnungsnummer
Mastab
Index
Benennung

A3_E

Weber D.

Format
Zeichnung
1
/
Werkstof
Skizze
30128723 48000
Freimatoleranzen
Projekt
Gewicht/ kg
H-100
Tunnelvortriebstechnik
www.herrenknecht.de
D-77963 Schwanau
Schlehenweg 2
HERRENKNECHT AG
Tel.: 07824/302-0
Fax: 07824/3403
HERRENKNECHT
HK400M
Oberfchen-
angabe nach
DIN ISO 1302
Projektion

DELI VERED TO THE JOBSI TE I N 20- FOOT CONTAI NERS:
HERRENKNECHT MODULAR RI GS.
In extremely remote regions with limited infrastructures, transporting a complete rig can be
impossible. For such cases, Herrenknecht has designed modular rigs which are a completely
unique and tested product innovation. They can be dismantled into individual modules and
transported in standard 20-foot containers to be reassembled on arrival at the jobsites. This
means that Herrenknecht maxi and mega rigs can be used almost anywhere.
Dismantled and transported. As a rule, Herrenknecht modular rigs are separated into three
modules for transport; each of these modules weighs a maximum of 28 tonnes. The modules
are then simply put together at the jobsite and xed hydraulically. An optional remote-con-
trolled crawler provides mobility on the jobsite making the use of a bulky and therefore ex-
pensive-to-transport crane unnecessary.
Tried and tested in practice. Modular rigs can be put into operation in difcult terrain. For
example, on a causeway off the coast of Saudi Arabia.
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Maschinentyp
18.03.2010
Artikelnummer
HORIZONTALBOHRMASCHINE
1
Blatt Nr.
2465-700-000-00
HK400T ZUGKRAFT
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
Bearbeitet
Geprft
Datum Name

Zeichnungsnummer
Mastab
Index
Benennung

A3_E

Weber D.

Format
Zeichnung
1
/
Werkstof
Skizze
30128723 48000
Freimatoleranzen
Projekt
Gewicht/ kg
H-100
Tunnelvortriebstechnik
www.herrenknecht.de
D-77963 Schwanau
Schlehenweg 2
HERRENKNECHT AG
Tel.: 07824/302-0
Fax: 07824/3403
HERRENKNECHT
HK400M
Oberfchen-
angabe nach
DIN ISO 1302
Projektion

14 | 15
MODULAR RI G I N SAUDI ARABI A:
WORLD RECORD I N AL- JUBAI L.
Longer than ever before. Al-Jubail is one of
the centers of the oil processing industry in
Saudi Arabia. The city is located in the east-
ern part of the country, directly on the Gulf
coast. To feed the black gold from the off-
shore oil eld safely to the renery on land,
two parallel pipelines, each with a length of
3,048 meters, had to be laid beneath the
seabed the longest crossing ever to have
been completed using the HDD procedure
until then.
As reliable as ever. The two pipeline routes
were drilled from two sides. A Herrenknecht
trailer rig completed a third of the route
starting from the renery and going out to
sea. The HK400M modular rig was put into
operation on the causeway from where it
created two thirds of the route towards the
port. It completed both the subsequent
reaming step and the pull-back of the com-
plete 3,048m long pipeline along the entire
route with absolute reliability this, al-
though the weight of the pipelines was
around 1,500 tonnes, with diameters of 24
and 30 inches. To backup the pipeline pull-
back in an emergency, the Herrenknecht
Pipe Thruster was on standby to provide ex-
tra push and pull force along the extremely
long sections.
HK250T/ HK400M/ HK500PT
Bore hole diameter: 32, 42
Max. torque: 90kNm, 120kNm
Installed power: 440kW, 880kW, 330kW
Max. push/pull force: 2,500kN, 250t;
4,000kN, 400t; 5,000kN, 500t
SOL UTI ON
BERRI CAUSEWAY PI PELI NES PROJECT,
SAUDI ARABI A
Geology: silt, sand, gravel, clay, coral
Pipeline lengths: 2x 3,048m
Pipeline diameter: 24", 30"
Particularities: longest pipeline route so far drilled
using the HDD procedure
REQUI REMENT
SAUDI ARABI A
AL- JUBAI L
011_eBroschre_HDD_120410oc_Fassung 04
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Maschinentyp
18.03.2010
Artikelnummer
HORIZONTALBOHRMASCHINE
1
Blatt Nr.
2465-700-000-00
HK400T ZUGKRAFT
Diese Unterlage (Zeichnung) ist unser Eigentum. Jede Vervielfltigung, Verwertung oder Mitteilung an dritte Personen ist
strafbar und wird gerichtlich verfolgt (Urhebergesetz, gegen unlauteren Wettbewerb, BGB). Alle Rechte aus 7 PG vorbehalten.
Bearbeitet
Geprft
Datum Name

Zeichnungsnummer
Mastab
Index
Benennung

A3_E

Weber D.

Format
Zeichnung
1
/
Werkstof
Skizze
30128723 48000
Freimatoleranzen
Projekt
Gewicht/ kg
H-100
Tunnelvortriebstechnik
www.herrenknecht.de
D-77963 Schwanau
Schlehenweg 2
HERRENKNECHT AG
Tel.: 07824/302-0
Fax: 07824/3403
HERRENKNECHT
HK400M
Oberfchen-
angabe nach
DIN ISO 1302
Projektion

MODULAR RI G I N TURKMENI STAN:
XXL RI VER CROSSI NG.
HK250T/ HK400M/ HK750PT
Bore hole diameter: 14", 72"
Max. torque: 90kNm, 120kNm
Installed power: 440kW, 880kW, 330kW
Max. push/pull force: 2,500kN, 250t;
4,000kN, 400t; 7,500kN, 750t
SOL UTI ON
AMU DARYA RI VER CROSSI NG,
TURKMENI STAN
Geology: sand, sandstone, loam
Pipeline length: 1,705m
Pipeline diameter: 8", 56"
Particularities: Record diameter in combination
with pipeline length
REQUI REMENT
TURKMENI STAN
UZBEKI STAN
AFGHANI STAN
A real challenge. The Malay-Bagtiyarlyk gas
pipeline was built to take natural gas from
Turkmenistan to China. On the around
200-kilometer-long section in Turkmenistan,
the Amu Darya River had to be crossed near
the border with Uzbekistan and Afghanistan.
The pipeline, with a diameter of 56 inches
(drilling diameter 72 inch) and a drilling
length of 1,705 meters, would have been a
real challenge for any HDD equipment. In
addition, an 8-inch cable duct had to be laid.
In addition, the Pipe Thruster was on standby
in order to push or pull the pipe string with
a force of up to 750 tonnes, if required.
A real masterly performance. The construc-
tion company relied on two Herrenknecht
HDD rigs plus additional equipment to deal
with this mammoth project: a type HK250T
Trailer Rig, a HK400M Modular Rig and the
Pipe Thruster HK750PT. In an initial work
phase, the 8-inch cable duct was installed
quickly and safely. Subsequently, a pilot hole
was drilled for the gas pipeline and then
enlarged in several reaming and cleaning
steps up to a diameter of 72 inches. Finally,
the 56-inch pipeline could be pulled in. The
success of this project also constitutes a
further Herrenknecht milestone, since an
HDD crossing with such a diameter in com-
bination with such a length had never been
realized before.
KARABEKAUL
16 | 17
011_eBroschre_HDD_120410oc_Fassung 04
ADDI TI ONAL POWER:
HERRENKNECHT PI PE THRUSTER.
HDD can offer a wide range of applications, thanks to the broad product portfolio of rigs
with various designs and performance levels. And whenever the HDD procedure reaches its
limits for example on extremely long crossings with large pipe diameters the Herrenknecht
Pipe Thruster offers the necessary extra power reserves. Installed at the target pit, it pushes
the pipe string with a thrust force of up to 750 tonnes towards the entry point. Furthermore,
it ensures that the forces acting on the pipeline are distributed in a better way, since the
pipeline is pulled (by the HDD rig) and pushed (by the Pipe Thruster) at the same time.
Wide range of applications. For large diameters, long crossings, difcult geologies or in
stucked situations, the existing HDD equipment can be supplemented by a Pipe Thruster. The
pipes are always handled with the specially developed clamping segments which are suitable
for almost all pipe coatings and diameters of 20 to 60 inches. A further advantage of the Pipe
Thruster is its mobility. It can be installed quickly and simply both in densely built-up areas
and in inaccessible terrain.
Tried and tested in practice. The Pipe Thruster signicantly extends the range of application
for HDD. Furthermore, the Pipe Thruster delivers the necessary thrust for the innovative Direct
Pipe method, which is described on pages 20 to 21.
18 | 19
PI PELI NI NG I N I NDI A:
FASTER THAN THE MONSOON.
Under time pressure. India wants to be-
come more independent from energy imports
and thus increase the consumption of its
own natural gas. An initial large-scale pro-
ject is the east-west pipeline which will
bring gas from the deposits off Indias east
coast to the cities in the west over a stretch
of 1,400 kilometers. For one of the most dif-
cult sections in the east the crossing of
the Godavari River around 2,500 meters of
pipeline had to be laid underground. The
work had to be completed in only three
months, before the monsoon rain led to ex-
treme high water.
2x EPB2400AH/ HK500PT
Diameter: 3,000mm
Max. torque: 1,020kNm (EPB2400AH)
Max. push/pull force: 5,000kN, 500t
SOL UTI ON
EAST WEST GAS PI PELI NE, GODAVARI
RI VER CROSSI NG, I NDI A
Geology: sand, fine sand, silt, clay
Pipeline length: 2,475m
Pipeline diameter: 48"
Particularities: tight schedule, length of the
pipeline strings
REQUI REMENT
With high pressure. Initially, two Herren-
knecht EPB machines worked their way
from each of the rivers banks to the center
shaft on a river island using the pipe-jacking
method. After completion of pipe jacking,
the Pipe Thruster pushed the entire pipe
string, with a length of around 2,500 meters
and a total weight of around 2,000 tonnes,
forward into the protection tunnel with
an average force of 80 tonnes and a maxi-
mum speed of ve meters per minute. This
meant that the project was completed much
more quickly than with conventional proce-
dures and above all: just before the mon-
soon began.
I NDI A
RAJAHMUNDRY
011_eBroschre_HDD_120410oc_Fassung 04
REACHI NG THE TARGET I N ONE STEP:
WI TH HERRENKNECHT S DI RECT PI PE

.
Direct Pipe is a new pipe laying method for pipelines. It combines the advantages of the
tried-and-tested Microtunnelling method and HDD opening up new application potentials.
Using Direct Pipe, a Microtunnelling machine can both excavate a hole in one single, almost
continuous work phase and simultaneously lay a prefabricated pipe string. Potential obstacles
are removed by the machines cutting wheel and a cone crusher.
A strong team. The force necessary for tunnelling with the Direct Pipe method is provided
by the Pipe Thruster. The Pipe Thruster pushes the pipeline forward with four clamping seg-
ments which hold the pipe from outside. The force is transmitted via the pipeline to the cut-
terhead of the Microtunnelling machine. When compared to the HDD method, Direct Pipe
enables the machine to be navigated with a very high degree of target accuracy and to be
equipped for any geology stable or less stable with the corresponding excavation tools.
Tried and tested in practice. Direct Pipe allows the quick installation of product pipes and
pipelines from only one access side. These advantages have proved their worth both in Worms
and in Emden.
Convincing concept. Subterranean storage
caverns for natural gas were built in the vi-
cinity of the city of Leer, Lower Saxony. This
required ushing out salt mines to produce
huge cavities. In order to drain the resulting
brine, a 42-kilometer-long pipeline had be
laid to the Ems River near the city of Emden.
The nal 283 meters of outow pipe at the
Rysumer Nacken articial dune eld were be
built using the new single-step Direct Pipe
method.
AVN1000XB/ HK750PT
Bore hole diameter: 51"
Max. torque: 150kNm (AVN1000XB)
Max. push/pull force: 7,500kN, 750t
SOL UTI ON
RYSUMER NACKEN BRI NE FEED-I N
CONSTRUCTI ON, GERMANY
Geology: sand, silt, clay, gravel, wood, stones
Pipeline length: 283m
Pipeline diameter: 48"
Particularities: Target pit in the Ems River
REQUI REMENT
Convincing performance. The AVN1000XB
Herrenknecht Direct Pipe machine worked
its way through the underground with the
help of a Pipe Thruster, which provided push
and pull forces of up to 750 tonnes with
the pipeline directly in tow. The team pro-
ceeded very quickly with performances of up
to nine meters per hour and reached the
target structure in the Ems River safely. The
PE-coated 48-inch pipeline was ready for
use and put into operation after the comple-
tion of the entire 42-kilometer-long pipe-
line. An absolutely convincing result in terms
of both economic efciency and environ-
mental protection.
DI RECT PI PE

I N EMDEN:
BRI NE EXTRACTI ON MADE EASY.
EMDEN
20 | 21
GERMANY
011_eBroschre_HDD_120410oc_Fassung 04
ALL I NCLUSI VE: FULL SERVI CE HDD.
To make sure that each individual project can be brought rapidly and safely to success,
Herrenknecht offers individual tailor-made service packages, which include all services required
onsite. Everything from base equipment, separation plants and mud pumps to training specialist
and maintenance and service packages. We offer the full range from individual services to
complete jobsite set-up. We also develop customized solutions for special projects and make
them available quickly and reliably.
Well equipped to a high standard. In addition to the basis equipment, Herrenknecht also
offers its customers other HDD equipment. Including high pressure mud pumps, bentonite
mixing plants, separation plants, pipe racks with cranes and mobile break-out units. The pipe
racks are equipped with a hydraulic crane, enabling the loading/unloading and storage of the
drilling rods during drilling operations. The mobile break-out units are mainly used to make-up
and break-out rods and/or drilling tools on the pipe side safely and efciently. They are supplied
with energy from a small stand-alone diesel-driven hydraulic power pack, which can also drive
the mud pit pump in the mud pit. The pumps also form part of the additional equipment which
can be provided by Herrenknecht.
Triplex pumps are used as high-pressure mud pumps which can be driven by the efcient,
low-emission diesel engines of leading manufacturers. The pumping unit is housed in a 20-foot,
sound-proof container and can be operated from the control cabin. The pumps have a capac-
ity ranging from 500 to 2,800 liters per minute, with a pressure of up to 100 bar.
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Separation made easy. Separation plants are used to separate solids and uids from the
drilling mud which accrues on site during the pilot drilling and the reaming steps of the bore
hole. To feed the ushing uid back to the mud circuit and to deposit the excavated material,
Herrenknecht offers its customers innovative separation plants, which are specially adapted
to the HDD method and can be operated directly at the jobsite. Modern ltering technology,
hydro-vacuum cyclones, a vertical clarifying tank and centrifuges form an integrated recycling
concept and ensures the removal of critical ne particles. The equipment has a capacity of up
to 4,000 liters per minute. This means that we can offer our clients the right solution for all
requirements.
Clearing the way. Herrenknecht offers an entire range of additional HDD equipment to make
sure that all our customers HDD projects are a success. Our portfolio includes drill rods, drill
bits and reamers as well as surveying systems, generators and all further necessary equipment.
This also includes our steering and visualization systems which provide a high degree of reli-
ability and a range of adjustments. These systems record and save all data and turn it into a
clear graphic interface making values such as pulling forces, torque or speed available at
any time.
We have the right people. Herrenknechts experienced specialists offer you professional site
support so that our HDD rigs can render the best performance possible anywhere in the world.
This includes training the construction site team comprehensively to operate our machines
and giving them all the knowledge they need about how our systems work. We can also sup-
port a project from beginning to end (if required), including all maintenance and services.
Making sure you always prot from our experience and expertise. Anytime. Anywhere.
011_eBroschre_HDD_120410oc_Fassung 04
Herrenknecht AG
D-77963 Schwanau
Phone +49 7824 302-0
Fax +49 7824 302-3640
utility@herrenknecht.com
WWW. HERRENKNECHT.COM
Herrenknecht is the technology and market leader
in the eld of mechanized tunnelling. Herrenknecht
is the only company worldwide to deliver high-tech
tunnel boring machines for all ground conditions
and all diameters ranging from 0.10 to 19 meters.
Herrenknecht also develops solutions for vertical
and inclined shafts.
Around the globe our tailor-made machines
create tunnel systems for water and wastewater,
gas, oil, electricity and telephone cables (Utility
Tunnelling), as well as high-performance infra-
structure systems for road, metro and railway trafc
(Trafc Tunnelling). Herrenknecht tunnel boring
machines successfully achieved nal breakthrough
beneath the Gotthard mountain range (Switzerland),
after excavating more than 85 kilometers of the
worlds longest railway tunnel. They are forging
ahead with large diameter road tunnels and the
largest metro lines. Our machines help to cross under
water with supreme accuracy and to lay pipelines
throughout continents.
The Herrenknecht Group employs around
3,300 people worldwide. With 68 domestic and
overseas subsidiaries and associated companies
working in related elds the group prots from a
team of innovative specialists, providing integrated
solutions with project-specic equipment and
service packages dedicated to the project and
the customer.

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