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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
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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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Flow through, internal system e.g. Wassara in Sweden, Hanjin South Korea, all otherdevelopments in the past 30 + years already available
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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
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excellent process monitoring + control via MWD / drill rig SWD to indicate Geology
DTH water hammer very fast drilling and
excellent seismic noise source
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Radial Water Jet Drilling : geothermal and hard rock applications
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• 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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operating conditions + jetting performancee.g. saturation of rock
Development of jet drilling for hard rocks at GZB
Challenges:
Bit pressureExit velocityAbrasivesPulsation
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1
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3
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Jetting resultsboreholes
Rotating and static nozzles rotating nozzle
Development of jet drilling for hard rocks at GZB
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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
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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*
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3
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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*
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5
7
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6 9
10
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Hydraulic enery to the bit : e.g. Jet velocity measurements
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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
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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
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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
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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
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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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Development of a new MWD systemmonitoring + control of rock destruction
Challenges:Data processing + interpretationNeeds more experienceSpallation + melt can be clearly seen
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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
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• 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