The new HDD Tooling from Herrenknecht Full Face Hole Opener / Down Hole Jet Pump

Transcription

1 The new HDD Tooling from Herrenknecht Full Face Hole Opener / Down Hole Jet Pump Simon Herrenknecht, Product Manager Pipeline, Herrenknecht AG

2 Herrenknecht Introduction Herrenknecht AG, Germany Founded in 1977 Worldwide marked leader in mechanized tunnelling technology 4,800 employees worldwide SBX Boxhole Machine Raisebore Rig Total output, 1.34 billion Euro (2015) AVN & AVND EPB Shield Gripper TBM Single Shield Double Shield Partial-face Excavation Machine Auger Boring Machine HDD Rig Direct Pipe Pipe Express VSM

3 Herrenknecht Introduction Herrenknecht Tunneling Systems USA Inc. Located in Sumner, Washington 35 employees Sales and Service North America,Cutting tools Worldwide Design of cutters, R & D of cutters 6,5 to 20 diameter cutters 80 different models Manufacturing, Rebuilt & Stock of cutters Approx cutters/year Approx. Inventory level 7.0 Mio USD

4 Herrenknecht Introduction Similar Applications for HDD Cutters within Herrenknecht: Boxhole Drilling Raise Drilling

5 Fullface vs. Conventional Reaming Steps

6 Fullface vs. Conventional Reaming Steps $ $ $ $ $ $ $ Conventional $ $ $ $ $ $ Fullface Hole Opening From min. 12 ¼ From min. 28 max. 72

7 Fullface vs. Conventional Reaming Steps Conventional example for drilling a borehole for a 42 Pipeline: Pilot Hole: 12 ½ 1 st Hole opener: 24 (max. 30 ) 2 nd Hole opener: 36 3 rd Hole opener: 48 4 th Hole opener: 54 Full Face Hole Opening example for drilling a borehole for a 42 Pipeline: Pilot Hole: 12 ½ 1 st Hole opener: 54

8 Hole Opener Design Full Face Cut Replaceable Cutter Replaceable Front Centralizer Tool-Face Cleaning Cutting Scraper Non-Stick Coated Areas

9 Herrenknecht Fullface Hole Opener Hard Rock Soft Rock (<R6) (>R0) Replaceable parts, bearings, sealing (Service) Pressure-compensated Big bearing assembly for higher weight on bit HK offers assistance with the selection by own Geotechnical Dep.

10 Herrenknecht Fullface Hole Opener Heavy duty & downhole proven bolting system

11 Reasons for the Fullface Hole Opening development Continuous increase of drill pipe dimensions 5 5 ½ 6 5/8 7 5/8 8 3/4 9 5/8 Development of high torque connections 5 ½ FH DS 6 5/8 FH DS 7 5/8 H-90 DS Continuous increase of Rig Rotary and Push/Pull power Tandem Operations of two Rigs on one drill string Continuous increase of Mud handling equipment size (Pumps & Recycling) High pricing & risk of HDD in Hard rock

12 Efficiency through Cost Reduction Less drilling tools needed Drilling tools with replaceable cutters Cutters with longer bearing and hub lifetime Saving investment costs Effective wear protected body for a longer lifetime Less tripping operations Less joint changes Less tool changes Saving construction Less cleaning runs costs Increased productivity Less Costs-per-foot

13 Mud & Cutting Flow

14 Centralization Gage-Centering Tool Face-Centering Front-Centering Rear-Centralizer

15 Open Design

16 Requirements to use an HK Full Face Hole Opener Min. 30 = 762mm Min. Pilot bore 12 = 304mm Required Pull force: min. 25to per Cutter Required Torque: knm or higher Min. Drill Pipe: 5 ½ Recommended: 6.5/8 or 7.5/8 Required Mud flow: 2200 lpm = 581 gal/min (30 ) to 4000 lpm = 1056 gal/min (48 ) MT-Cutters are used up to Mpa ( psi) TCI-Cutters are used between 80 Mpa to 350 MPa ( psi)

17 Challenges for the (Full Face) Hole Opening Large Cutting transport Risk of Settlements in the borehole Frac-out risk Over pressurizing of the borehole Fluid losses Natural fractures & fissures in the formation Elevation between Entry & Exit

18 Common Reasons for Frac-Outs Pressure inside the borehole must be higher than the pressure which is generated by the overburden formation and the surrounding ground water pressure Pressure is generated by: Geodetic height Density, Groundwater level Friction losses during pumping thru borehole Viscosity, density, flow rate, wall character, length, cross section Borehole is used as a discharge line to transport cuttings!

19 Drill Pipe used as Discharge Line Borehole (discharge line) Borehole Drill pipe Drill pipe (discharge line)

20 The missing Link: Down Hole Jet Pump (DHJP)

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22 Herrenknecht DTH Tool Testing Facility High Pressure Pump Separation Test borehole (submergible) Unit for Rotation and Push/Pull

23 Herrenknecht DTH Tool Testing Facility 1000m (3280 ft) of discharge line circuit

24 Herrenknecht DTH Tool Testing Facility DHJP in artificial borehole loaded with cuttings (dry) DHJP in artificial borehole after the testing (dry)

25 Requirements to operate an DHJP Min. Borehole diameter: 20 = 508 mm HP-Motive Flow: l/min (400 gal/min 530 gal/min) HP-Motive Pressure: bar (725 psi 870 psi Separation capacity: l/min (792 gal/min 924 gal/min) Recommended Drill Pipes: 6 5/8 Pipesite-swivel, Flow-meter Pipesite Mudreturnline (Pipesite-Rigsite)

26 All Advantages at a Glance Minimum frac-out risk during the reaming operation in HDD Possibility to use a simple and cost saving mud program It is possible to create a 98% clean borehole Immediate formation feedback on the separation plant (1000m = 3280ft = 7 min) Possibility to transport larger cutting sizes Possibility for full-face reaming Works with non or partially filled boreholes Defined return flow direction Flow amounts (in & out the borehole) can be simply monitored and logged Direct connection of the mud flow to the recycling unit (No mud pit pump necessary)

27 Down Hole Jet Pump Mud flow scheme on DHJP DHJP suction flow : v = 800 l/min = 211 gal/min p = 0,x bar = 0,x psi From HP-Pump To Separation Motive flow before DHJP : v = 1800 l/min = 475 gal/min p = 50 bar = 725 psi Motive flow after DHJP : v = 2600 l/min = 687 gal/min p = max. 20 bar = 290 psi

28 Down Hole Jet Pump Surface Equipment Flow meter, Ball valve, Pressure transducer Mud hose To Separation Mud swivel From DHJP Drill Pipe

29 Herrenknecht Full Face Hole Opener. Overview: 5 Reference Projects USA. Full Face diameter: 42 & 48 Product diameter: 30 & 36 Pilot bores: 12 & 17 TCI & MT Cutters Granite, Basalt, Shale & Limestone

30 Herrenknecht Full Face Hole Opener. Reference Project: Verdigris River Crossing. Location: Independence, Texas Project: Flanagan South Pipeline (36 ) Drilling length: 1,757ft. (536m) Drilling depth: 98ft. Bend radius: 3,600ft. Geology: layers of soft soil, shale, limestone Compressive strength: 15,600psi (108 MPa) Client: Enbridge Contractor: Laney 1. Pilot bore: Full Face diameter: 48 TCI roller cutters 47 centering device

31 Herrenknecht Full Face Hole Opener. Reference Project: Arkansas River Crossing. Location: Cleveland, Oklahoma Project: Flanagan South Pipeline (36 ) Drilling length: 3,015ft. (920m) Geology: sandstone, shale, limestone Compressive strength: 8,000psi (55 MPa) RQD index: Client: Enbridge Contractor: Laney 1. Pilot bore: Full Face diameter: 48 MT cutters 47 centering device

32 Herrenknecht Down Hole Jet Pump. Reference Project: Malmö Harbor Channel Crossing. H-165, HK150C Crawler Rig Location: Malmö, Sweden Project: District Heating Pipeline Drilling length: 850ft. (263m) Pipeline: 40 HDPE casing pipe with inner steel pipeline for heat transport Geology: hard limestone, flintstones Contractor: BAB Rörtryckning AB

33 PIONEERING UNDERGROUND TECHNOLOGIES Please feel free to ask questions or give comments.