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9/8/2017 1 New developments for hard rock drilling From hydraulic DTH Hammer to Laser Drilling 1 Celle Drilling, 12.9.2017 Volker Wittig International Geothermal Centre [email protected] 2 2 Drilling technology in Geothermal applications Indication of a need for a novel drilling technology Deeper and harder formations Very low rate of penetration (1 m / hr. or less) Very high bit / tool wear low service life of e.g. under 50 hrs. Numerous, long and expensive round trips Indication of a need for a Novel Drilling Technology Challenge high ROP together with long tool and bit lifetime
19

New developments for hard rock drilling From … · New developments for hard rock drilling From hydraulic DTH Hammer to Laser Drilling 1 Celle Drilling, 12.9.2017 ... DTH percussion

Sep 09, 2018

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Page 1: New developments for hard rock drilling From … · New developments for hard rock drilling From hydraulic DTH Hammer to Laser Drilling 1 Celle Drilling, 12.9.2017 ... DTH percussion

9/8/2017

1

New developments for hard rock drilling

From hydraulic DTH Hammer to Laser Drilling

1

Celle Drilling, 12.9.2017

Volker Wittig

International Geothermal Centre

[email protected]

2 2

Drilling technology in Geothermal applicationsIndication of a need for a novel drilling technology

Deeper and harder formations

Very low rate of penetration

(1 m / hr. or less)

Very high bit / tool wear

low service life of e.g. under 50 hrs.

Numerous, long and expensive round trips

Indication of a need for a Novel Drilling Technology

Challengehigh ROPtogether with

long tool and bit lifetime

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2

Flow through, internal system e.g. Wassara in Sweden, Hanjin South Korea, all otherdevelopments in the past 30 + years already available

3

Hydraulic DTH mud hammers : 2 basic systems

Drill string

Mud flow Mud flow

Closed loop system (“external” tool) percussion section is being powered with hydraulic or electric energy being generated downhole via mud generator tool may be added to any BHA with enough flow e.g. TU Freiberg is working on this design

Drill string

Inlet

Outlet

• Total inner velocitiyvariation 1 to 10 bar

• flow rate @ 250 l/min

• GOAL Velocities under 10 m/sec

Complete Hammer simulation + analysis @ GZBFluid velocities + pressures

28 m/sec

10 m/sec

2 m/sec

Challenges:High velocities insideAbrasive particlesMoving parts and seals

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5

DTH percussion drilling + jetting tests with CT rig @ GZB

Today: partly recirculation and conditioning of drilling fluids for deep drilling with DTH fluid / mudhammers possible

completelamella type

cleaner system

overview recirculationsystem for hydraulic

DTH water / mudhammer drilling

system

reycling unit withdesander desilter, shaker

type cleaner system

sedimentation andmixing tanks

centrifuge unit if neededfor finest particles

Challenge:Sufficient water quality

Service life of parts

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seismic-while-drilling (SWD)• project at GZB together with OGS• seismic while drilling data for• reservoir and drilling prediction

With DTH water / mud hammer

high ROP

excellent seismic data for geology analysis and prediction

economic drilling

little wellbore deviation

water recirculation possible

7

excellent process monitoring + control via MWD / drill rig SWD to indicate Geology

DTH water hammer very fast drilling and

excellent seismic noise source

08.09.2017 8

Radial Water Jet Drilling : geothermal and hard rock applications

1

2

3

4

5

• Stimulation method

• EGS technique

• Main well → multi laterals intoformation layers

• Jetting : forward and backwardoriented nozzles

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08.09.2017 9

Rock Sample Collection GZB

+20 different rock types from locations fromGermany, France, Iceland

+100 rock samples of various size and

shape

08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 10

Rock Sample Collection GZB

Quarry locations:Flechtingen – Permian volcanic rocks/sandstones

Raumünzach / Flossenbürg – Granite

Dortmund – Carboniferous sandstone

Miltenberg – Triassic sandstone

Drackenstein – Jurassic limestone

Nuttlar – Devonian slate

Mendig – Quaternary basalt

Wülfrath – Devonian limestone (Massenkalk)

Testing state of the art RJD technology

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08.09.2017 11

1

2

5

4

3

operating conditions + jetting performancee.g. saturation of rock

Development of jet drilling for hard rocks at GZB

Challenges:

Bit pressureExit velocityAbrasivesPulsation

08.09.2017 12

1

2

3

4

5

Jetting resultsboreholes

Rotating and static nozzles rotating nozzle

Development of jet drilling for hard rocks at GZB

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08.09.2017 13

1

2

5

4

3

operating conditions and jetting performance

• Sandstone: SRS6-DO, core diameter 145 mm, Parker Tough hose (210psi, 5m length, ø 6 )

• differential pressure: 400 , 200 / 300 , 300 / 300 , 0

• Pump pressure: starting with 200 bar, up to 820 bar

• Nozzle types: rotating and static nozzle, single nozzle ø 1.80 mm

• No ROP with all RJD nozzles; single nozzle created 3 holes, 3rd hole lead to break out

1

23

Pressure controled conditions

1.250 bar

180 °C - 10 °C

3 m / 10 ft long

50 cm / 20 in Ø

Borehole conditionsdown to 5 km depth

i.BOGS : insitu Borehole and Geofluid Simulator full downhole reservoir conditions

08.09.2017 14

pressure

forwardmoving jetnozzleBOP*

casing*/annulus*

1

2

3

4

5

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8

08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 15

jetting / drilling setup for optical investigation: High speed camera

Components:1. High pressure hose: *behind the wall

2. Thread adapter: different nozzle designs

3. Nozzle

4. Rock sample: clamping cylinder, applying pre-tension on sample

5. Sample clamping: position fixed by screw

6. Stator: keeps sample clamping in position

7. Jetting qube: optical access through three windows

8. Watertank: high waterlevel -> no air entrainment

9. Camera

10. Laser Back light

1*

234

5

7

8

6 9

10

08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 16

Hydraulic enery to the bit : e.g. Jet velocity measurements

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08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 17

Test bench for optical investigations: new drilling technologies

• 7.000 frames per second• Rotating jet nozzle• Appr. 15.000 RPM / 250 Hz

• 200 frames per second • Single nozzle jetting into sandstone• Original video length: 0.5 seconds

Jetability experiments in sandstone rock types: results

08.09.2017 Extended Horizontal Jet Drilling for EGS Applications 18

Influence of operating conditions on jetting performance

1

2

5

4

3

Sandstonetype

JetabilityIndex

Minimum

Threshold

Velocity

TotalPorosity(dry)

%

Perme-ability(water)

Possoin’sRatio(dry)

UCS(dry)

TensileStrength(dry)

KI(dry)

Gildehaus 2.9e-3 100 23.7 6.3e-13 0.27 53 3.5 0.4

BadDürkheim

2.7e-3 100 19.5 4.5e-14 0.26 30 2.9 0.6

Dortmund 7.1e-4 180 8.7 1.9e-18 0.12 68 7.2 0.8

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Impact of rock´s saturation + confinement on jetting

08.09.2017 19

1

2

5

4

3

operating conditions and jetting performance

2 minsaturated

1 min saturated

2 min unsaturated

Test setup appr. 10 kW hydr. power at bit

• nozzle pressure: 220bar - flow rate: 25 l/min - outlet velocity: 160 m/s

Ruhr Sandstone

2020

Innovative Thermal Drilling Technologies @ GZB

Advanced Thermal Drilling Technologies

@ GZB

Application of thermal energy to apply stress penetrate the rock

Thermal Drilling

LaserJet supported Drilling

SpallationMain

Research topic

Plasma Drilling

meltingUnder

investigation and evaluation

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2121

Thermal (Laser) Drilling : Thermal rock softening

• Thermal rock softening may increase ROP in factor2 to 3

• Thermal rock softening +spallation maximumpotential of laser drilling

Change of the compressive strength of selected type of rocks subjected to high temperatures.(Chen, Ni, Shao, & Azzam, 2012; Keshavarz, Pellet, & Loret, 2010; Pinińska, 2007; Sygała et al., 2013)

Spallation zone10% 45% 80%

Temperature increase Reduction in E modulus

2222

Energy comparison of Laser and common drilling methods

Comparison of Laser and conventional drilling methods. Modified after (Xu et al., 2004)

100

10

1

2 5

0.1

0.01

1.E-04 1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05

Sp ecific p ower, kW/cm2

Rat

e of

pen

etra

tion,

cm

/s

7

6 1.E05 J/cm3

10000 J/cm3

1000 J/cm3 1 E06 J/cm3

100 J/cm3 1

10 J/cm3

4

3

RO

P

(cm

/se

c)

Specific Power being delivered by the drilling method, kW/cm2

1. Percussive hammers

2. Rotary standard

3. Drill-and-blast tunneling

4. Tunnel-boring machines

5. Flame jets

6. Laser spallation

7. Future Laser Drilling

> 10x ROPSame Specific energy

But more specific power

Additional Challenge :

tool lifetime !!!

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2323

Thermal spallation drilling with LaserJet

J/sec=W

Laser spallation process principle. Modified after (Preston & White, 1934;Fraunhofer IPT)

water jet guided Laser transmits energy

Excessive, rapid thermal energy

Thermal stress

Rock weakening +

thermal Spallation

mechanical assistance complete rock destruction

2424

Prototype LJD test setup @ GZB + Fraunhoferwith mechanical assistance

LJD schematical setup including mechanical assistance.( Fraunhofer

IPT)

30 KW laser system

LaserJet water

Mechanical assistance + Laser cartridge housing

multi-fluid distribution swivel and four concentric pipe

system

High powerfiber optic cable

Cutting transport&

wellbore integrity

LaserJet

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08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 25

Rock disintegration and drilling via LASER technology combined with monitoring, logging, characterization and analysis of water jet, rock destruction and equipmentto determine final drilling parameters

Acoustic emission system

Central data

acquisition system

Laser generator

and optical system

Laser Generator

Fiber laser

Laser generator and optical system (Fraunhofer IPT)Confining

pressure

Rock sample

08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 26

Acoustic MWD

system

Reinforced Rock sample

Flame

Rock disintegration / spallation / drilling via FLAME + LASER technology combined with monitoring and analysis of rock destruction to determine drilling parameters

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08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 27

Development of a new MWD systemmonitoring + control of rock destruction

Challenges:Data processing + interpretationNeeds more experienceSpallation + melt can be clearly seen

28

Laser Jet Drilling : initial lab testsWater-guided Laser Jet cutting + drilling

Spallation tests on hard rock (Quartzite) using LaserJet 

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Drilled Holes spallation analysis + measurement preparation for new MWD

Lazed samples 3D side view Top view 3 D and hole quality evaluation

2 mm

08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 30

• Depth map generation• Image processing / 3d

segmentaion techniques

Extracted / drilled

volume

Hole quality

Specific energy

ROP

Process control

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Full scale drill tests @ GZB with mobile rig :“bring the geology to the GZB drill rig + test site”subsurface installation of rocks + instrumentation

15.12.2016 31

Rock sample Cementing using a metal frame

Reinforced cement

Curing the cement

Removing the metal frame

Measurement system installation

Sample in manhole placement

Various investigated methods for sample preparation

Inspection and analysisUsing a crane for :

Rock handling

Rock lifting

Rock recovery after the test Crane

Removing the cement

Inspection and analysis of the drilled sample and borehole wall

Measurement while drilling 

(MWD)

TemperatureSensors in rock 

sample

Fluid flows & pressures

Measurements

Acoustic sensors

Rock sampleRock 

sample

Temperature Sensors for Fluids

Laser Measurement

15.12.2016 LaserJet Drilling - Status Meeting 32

2,5 m *2,5 m * 1 mFull MWD system and

logging on drill rig

Rock instrumentation Logging and

measurement of rock´s and reservoir response / behavior

Full scale drill tests @ GZB with mobile rig

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08.09.2017 33

Quelle: GZB

i.BOGS autoclave for drilling at reservoir conditions

Sample + jacket

drill.BOGS drive will beattached to this insitu unit

i.BOGS specs

3 m / 10 ft sample length possible40 cm / 1.3 ft sample Ø

1.250 bar / 18,000 PSI pressurePore + global pressure adjusted separatelyTemp. -10 °C to 180 °C / 10 °F to 360 °F

drill.BOGS specs10 tons WOB / 22,000 lbs

4 in drilling Ø possible10.000 Nm of torque (8,000 ft.lbs)

Full MWD possible

i.BOGS unit

08.09.2017 34

Drill.BOGS unit

3m BohrstangeVorschub-Hydraulikzylinder

Drehgetriebe

Führungsschiene

Bohrwerkzeug

1250 bar Bohrspülung

10t Vorschubkraft10.000 Nm

Drehmoment

i.BOGS with rock sampleUnder reservoir stress

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Rock destruction + control unit (MWD) for new drilling process

08.09.2017 Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 35

Akustikmessaufnehmer Probenkörper Datenverarbeitung/ -auswertung

Datenausgabe (e.g. Spallation)

Quelle: GZB

Quelle: GZB

L = 4m / 3mB = 42 cmT = -10°C to 180°CP = 125 MPa / 1.250 bar

Complete MATCH.BOGS parts assembly when in full operation

i.BOGSReservoir

Acoustic uniti.BOGS

Machine monitoring +control while drilling

InnovativeMWDsystem

Optische Überwachung mit

Ultrahochgeschwindigkeits-kamera (10000P/sec) und Doppelpuls-Highspeed-Laser

Drill.BOGSDrill rig

Blow Out PreventerLPipe = 3mTorque = 10.000 NmPush = 80 kN on rock / 1.250 bar pore pressure

Fluid.BOGSReservoir fluids

D = 1500 m D = 200 m

Geofluid.ReactorDownhole-Testing-Device

Flow = 400l/min-100l/secT = 180°CP = 100 barSalinity = 300 g/l

Flow loopDownholeWell flow

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Volker  Wittigphone  +49  175  2955930 

Email: volker.wittig@geothermie‐zentrum.deweb: www.geothermie‐zentrum.de

Do you have any questions ?Thank you for your attention