Advances in Drilling Technologies

Dipl.-Ing. Volker Wittig, MS International Geothermal Center ( GZB ) Bochum, GERMANY Bochum School of Geothermal Technology University of Applied Sciences Hochschule Bochum
DGK Bochum 2011 1st Bochum International Workshop of the International Geothermal Center

INTERNATIONALES GEOTHERMIEZENTRUM INTERNATIONAL GEOTHERMAL CENTER

German Universities
Bochum School of Geothermal Technology GZB

Institutions and Organisations Associated International Universities

Bochum University Appl.Sc. Host of the International Geothermal Center Central R&D Department of Bochum University Administration of IGL Academic Education Ba / Ma Sc. Programs

Public Bodies, Universities, Administr., Governmental Org., Chambers

Technical University of Istanbul

Non-profit Association of Public Institutions Scientific Management of the IGL, Networking, Communication

INTERNATIONALES GEOTHERMIEZENTRUM INTERNATIONAL GEOTHERMAL CENTER

Institutions and Organisations

Bochum School of Geothermal Technology

GZB

Geothermal Economy Association

Bochum University AS

Public Bodies, Universities, Administr., Governmental Org., Chambers

Companies

Central R&D Department of Bochum University Administration of IGL Academic Education Ba / Ma Sc. Programs

Non-profit Association of Public Institutions Scientific Management of the IGL, Networking, Communication

Profitoriented; Construction Drilling, Utilities, Consultants Financing of the Branch Office; Marketing; Sponsoring

Bauconsult & Sachverstndigen Bro Dr.- Ing. Ulrich Gttler

DBT
DEUTSCHE BOHRTECHNIK

INTERNATIONALES GEOTHERMIEZENTRUM INTERNATIONAL GEOTHERMAL CENTER

Institutions and Organisations

Bochum School of Geothermal Technology

GZB

Geothermal Economy Association

Energetikum

International Geotechnology Laboraties (IGT)

Bochum University AS

Public Bodies, Universities, Administr., Governmental Org., Chambers

Companies

Construction Industry, TechnologyProviders, Chamber of Crafts

ResearchInstitute national & international

Central R&D Department of Bochum University Academic Education Ba / Ma Sc. Programs

Non-profit Association of Public Institutions Management of the IGT, Networking, Communication

Profitoriented; Construction Drilling, Utilities, Consultants Financing of the Branch Office; Marketing; Sponsoring

Educational Institution financed by the Economy / Companies

13 Mio. EUR Invest by GER/EU UniversityIndustry Joint Research Labs for Geotechnologies

INTERNATIONALES GEOTHERMIEZENTRUM INTERNATIONAL GEOTHERMAL CENTER

shallow rig BO-REX 40 ton pull < 2.000 m

Corporation Infrastructure Surface Drilling CT-Drilling Conclusions LABORATORIES

CT rig up to 90 ton pull > 5.000 m

> 100 year old technology to break hard rock

(much like diesel / combustion engine in cars)

Howard Hughes

introduction of tricone bit beginning of 20th century

revolution in oil drilling (Gold Rush) : drilling >10 x (. 100 x) faster

PDC bits have (more recently) brought some improvement, but only in FAVORABLE, homogenous, softer geology

> 100 year old technology to break hard rock

(much like diesel / combustion engine in cars) introduction of tricone bit beginning of 20th century PDC bits have brought some improvement, but only in FAVORABLE, homogenous, softer geology

TODAY : new DTH fluid hammer drilling with PCD studded bits do greatly improve efficiency

 new drilling technology needed

hammer design : Rock mechanical properties

are inhomogenous and depend on temperature, pressure, scale and strain rate

higher ROP more efficient more economic

Today : need to be able to drill deeper + faster harder (crystalin) rock ( > 200 MPa) geothermal, deep tight gas / oil reserves, natural resources

R&D work at GZB in Bochum 2 main aspects

new BHA design / drilling process needed DTH hammer with rotation instead of using drill string made up out of multiple rods (jointed pipe) use one continuous pipe or string Coiled Tubing (CT) Both are known, yet have to be improved and fit together for deep (hard rock) drilling

DTH (air) hammer

Decades of proven technology rescue 33 Chile 2010: very fast pneumatic DTH air hammer system drills to 800 m (Center Rock Inc.) (Schramm T 130 Rig + CRI DTH hammer magazine from 5,5 26 hole size) Air hammer well known as standard in shallow hard rock drilling (< 200 m ground water table)

high ROP in hard rock BUT: depth limitation + very inefficient

physical comparison DTH air + water air (gas) is compressible

> 3 4 x more power required very high speed of return air / flow
20-30 m/s ~1m/s

Air
15-30 l/s @ 12-20 bar 300-400l/s @ 1 bar(a)

Water
4-6 l/s @ 120-180 bar 1 bar(a)

depth limitation due to low specific density of air

20-30 m/s

~1m/s

AIR
expanding air (gas) large caverns, voids, erosion explosions possible e.g. city of Stockholm no more DTH air hammer drilling allowed

WATER

20-30 m/s ~1m/s

rising velocities

ground water will be pumped (geyser)

hydraulic DTH fluid Hammer

over 2 decades of successful hydraulic DTH water hammer drilling (mining, dam projects, special construction tasks)

@ GZB During past decade: GZB in Bochum starts working on a hydraulic (DTH) drilling program: - hydraulic DTH water / fluid hammer introduction of water hammer to (shallow) geothermal drilling - GeoJetting ultra high pressure drilling or cutting

DTH water hammer shallow drilling (< 400 m) 200 bar ROP 1-2 m/min (130 mm hole )

DTH water hammer geothermal drilling in Bochum shallow drilling < 200 m depth x 30 holes 180 bar ROP 1-2 m/min (130 mm hole )

DTH water hammer < 200 bar @ 12 20 m / hr

full material recycling sample taking

Water Management filter- and sedimentation stages for mud return

Special tooling for DTH water hammer drilling

Hydraulic DTH hammer tooling to: optimize the process + ROP Minimize wear and tear velocities need to be designed carefully depending on geology, rod dimensions and bit design various hard metal + PCD studs available for bits

Geothermal Project in Stockholm, Sweden (Hsselby beach) 2010

Project participants
Bohrunternehmen: BPS Borr & Pumpservice AB Bohrlochvermessung: SB Logging AB

14 Bohrungen; Tiefe: 250 m; Pneumatischer Imlochhammer; Atlas Copco

Quelle: Eniro Sverige

15 Bohrungen; Tiefe 220 m; Hydraulischer Imlochhammer; Wassara

DTH hammer AIR

DTH hammer water

Passive Stabilizer (Fhrungsrippen)

Splmedium: Luft (+ etwas Wasser) Arbeitsdruck: 15 35 bar Schlagfrequenz: < 30 Hz Splungsgeschw. : 20 30 m/s Rotation: 40 80 U/min

Splmedium: Klarwasser / Fluide Arbeitsdruck: 40 180 bar Schlagfrequenz: ca. 70 Hz Splungsgesch. : ~ 1 m/s Rotation: 80 150 U/min

power compressor to water pump: Faktor 3

energy consumption while drilling down to 220 m

L/m

ROP appr. 0,7 m/min in > 250 MPa rock

L/m

Diesel consumption while drilling with conventional air hammer (left) and high pressure water (right, blue) down to 220 m deapth

DTH air hammer (compressor) requires 4 x more energy than DTH water hammer

Bohrtiefe 130 m

Deviation from vertical drilling axis

borehole deviation while drilling to 210 m with DTH air hammer (red) and DTH water hammer (blue)

Abstand 14 m Splungsaustritt

DTH water hammer < 5 - 10 deviation ca. 5 x straighter than DTH air

DTH fluid hammer tools can be guided relatively tight

1-2mm

guides / ribbs on outer water hammer casing + smaller annulus result in > 5 x straighter drilling

Deviation from vertical drilling axis

light colors: DTH air - dark colors: DTH water

360/0 330 30

300

60

radial geothermal system GeoStar

270 240

90

120

210 180

150

L = 50-300 m
60 90

30

radial directional drilling with straight hydraulic DTH hammer technology

problems with current DTH water hammers

water

quality requirements are too high no drilling fluid (re-)circulation possible too many and expensive parts valve control somewhat like a 4 stroke engine still low efficiency at appr. 25 % sensitive to wear flow rate is low relative to possible drill speed requires good / tight seals due to high pressure regime

new DTH fluid hammer at GZB

run

on lower pressure increase flow rates > 70 % hydraulic efficiency possible suitable for drill mud full circulation fewer parts more like 2 stroke engine easier maintanance few or no seals because of controlled leakage in the system

CT drilling

> 3 decades standard in oil & gas industry for service / intervention work Fast, short trip times, continuous Coiled Tubing operation possible experience with DTH hammer drilling in hard rock feasibilities for grass root drilling conductor, surface casing with BOP possible

Guide Arch Injector Head

BOP

Basic components of a CT rig

hydraulic DTH hammer possible

CT + DTH water hammer drilling

last decade : CT + DTH water hammer drilling in Norway and Iceland up to 2.500 m depth 2 3/8 coil up to 5 hole W-100 hammer Griffith 3 3/4 motor some (motor) dampening system drilling in hard gneiss > 200 MPa

CT drilling improvements
avoid buckling + helical lock up HTT concept to move coil (earth worm) avoid peak forces underneath the injector head DTH fluid hammer vibrations help (horizontal) move of coil (Baker et. al.) Monobore concept energy to bit : pressure + flow is transformed in BHA to crush rock, very low axial force needed Needs specially built rig Complete drilling system

source: university of Hannover)

source: university of Hannover)

CT drilling improvements new coil materials

more flexibel larger possible > 50 % lighter weight in air excellent spoolability earth worm principle possible fatigue resistant: >18.000 cycles without failure Chemically resistant low inner surface roughness: less pressure drop, improved flow

CT Drilling System at GZB versatile CT rig with DTH fluid hammer and (flexible) coil
+ HTT with earth worm principle built in axial forces attack all along the string

Future Generation:
Drilling with very high pressure water technique + abrasives 1.500 bar @ 80 l/ min for all depths + geologies

(abrasive) GeoJetting drilling /cutting technology

Corporation Infrastructure Tooling CT-Drilling Cooperations GEOSTAR GEOJETTING (Patent) High-Waterpressure Drilling System (80l / Min @1.600 bar with/-out abrasives)

Future Generation: (abrasive) GeoJetting drilling technology

DTH fluid / mud hammer with GeoJetting booster

- DTH mud / fluid hammer speeds up hard rock drilling by factor 5 10 - built in pressure booster enables (abrasive) GeoJetting action of the hammer drill bit will increase ROP even more through cutting / jetting action

Summary
current drilling techniques : DTH air hammer, DTH water hammer need new DTH hammer system for drilling in hard rock current CT + hammer drilling technolgy innovative CT + DTH mud hammer for jointed pipe and coil

future generation GeoJetting hammer : DTH fluid hammer with booster function

Thank you very much any questions ?