New developments for hard rock drilling From hydraulic DTH Hammer to Laser Drilling

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1 New developments for hard rock drilling From hydraulic DTH Hammer to Laser Drilling Celle Drilling,.9.07 Volker Wittig International Geothermal Centre Drilling technology in Geothermal applications Indication of a need for a novel drilling technology low service life of e.g. under 50 hrs. Indication of a need for a Novel Drilling Technology Very low rate of penetration ( m / hr. or less) Deeper and harder formations Very high bit / tool wear Numerous, long and expensive round trips Challenge high ROP together with long tool and bit lifetime

2 Hydraulic DTH mud hammers : basic systems Flow through, internal system e.g. Wassara in Sweden, Hanjin South Korea, all other developments in the past 0 + years already available Drill string 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 Mud flow Drill string Mud flow Complete Hammer simulation + GZB Fluid velocities + pressures Total inner velocitiy variation to 0 bar flow 50 l/min GOAL Velocities under 0 m/sec 8 m/sec Inlet Challenges: High velocities inside Abrasive particles Moving parts and seals 0 m/sec m/sec Outlet

3 DTH percussion drilling + jetting tests with CT GZB 5 Today: partly recirculation and conditioning of drilling fluids for deep drilling with DTH fluid / mud hammers possible Challenge: Sufficient water quality Service life of parts centrifuge unit if needed for finest particles complete lamella type cleaner system sedimentation and mixing tanks reycling unit with desander desilter, shaker type cleaner system overview recirculation system for hydraulic DTH water / mud hammer drilling system

4 excellent process monitoring + control via MWD / drill rig SWD to indicate Geology 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 DTH water hammer very fast drilling and excellent seismic noise source 7 Radial Water Jet Drilling : geothermal and hard rock applications Stimulation method EGS technique Main well multi laterals into formation layers Jetting : forward and backward oriented nozzles

5 Rock Sample Collection GZB +0 different rock types from locations from Germany, France, Iceland +00 rock samples of various size and shape Rock Sample Collection GZB Quarry locations: Testing state of the art RJD technology 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) Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 0 5

6 Development of jet drilling for hard rocks at GZB operating conditions + jetting performance e.g. saturation of rock Challenges: Bit pressure Exit velocity Abrasives Pulsation Development of jet drilling for hard rocks at GZB Jetting results boreholes 4 Rotating and static nozzles rotating nozzle

7 operating conditions and jetting performance Pressure controled conditions Sandstone: SRS6-DO, core diameter 45 mm, Parker Tough hose (0psi, 5m length, ø 6 ) differential pressure: 400, 00 / 00, 00 / 00, 0 Pump pressure: starting with 00 bar, up to 80 bar Nozzle types: rotating and static nozzle, single nozzle ø.80 mm No ROP with all RJD nozzles; single nozzle created holes, rd hole lead to break out i.bogs : insitu Borehole and Geofluid Simulator full downhole reservoir conditions.50 bar 80 C - 0 C m / 0 ft long 50 cm / 0 in Ø Borehole conditions down to 5 km depth pressure casing*/ annulus* BOP* forward moving jet nozzle

8 jetting / drilling setup for optical investigation: High speed camera 0 * Components:. High pressure hose: *behind the wall. Thread adapter: different nozzle designs. 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 0. Laser Back light Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 5 Hydraulic enery to the bit : e.g. Jet velocity measurements Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 6 8

9 Test bench for optical investigations: new drilling technologies frames per second Rotating jet nozzle Appr RPM / 50 Hz 00 frames per second Single nozzle jetting into sandstone Original video length: 0.5 seconds Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 7 Influence of operating conditions on jetting performance Jetability experiments in sandstone rock types: results Sandstone type Jetability Index Minimum Threshold Velocity Total Porosity (dry) Permeability (water) Possoin s Ratio (dry) UCS (dry) Tensile Strength (dry) KI (dry) % Gildehaus.9e e Bad Dürkheim.7e e Dortmund 7.e e Extended Horizontal Jet Drilling for EGS Applications 8 9

10 operating conditions and jetting performance Impact of rock s saturation + confinement on jetting Test setup appr. 0 kw hydr. power at bit nozzle pressure: 0bar - flow rate: 5 l/min - outlet velocity: 60 m/s min saturated min saturated Ruhr Sandstone min unsaturated Innovative Thermal Drilling GZB Application of thermal energy to apply stress penetrate the rock Thermal Drilling Advanced Thermal Drilling GZB LaserJet supported Drilling Plasma Drilling Spallation Main Research topic melting Under investigation and evaluation 00 0

11 Thermal (Laser) Drilling : Thermal rock softening Thermal rock softening may increase ROP in factor to Thermal rock softening + spallation maximum potential of laser drilling Temperature increase Reduction in E modulus 0% Spallation 45% zone 80% Change of the compressive strength of selected type of rocks subjected to high temperatures.(chen, Ni, Shao, & Azzam, 0; Keshavarz, Pellet, & Loret, 00; Pinińska, 007; Sygała et al., 0) Energy comparison of Laser and common drilling methods. Percussive hammers. Rotary standard. Drill-and-blast tunneling 4. Tunnel-boring machines 5. Flame jets 6. Laser spallation 7. Future Laser Drilling Additional Challenge : tool lifetime!!! Rate ROP of penetration, (cm/sec) cm/s J/cm 4 00 J/cm E-04.E-0.E-0.E-0.E+00.E+0.E+0.E+0.E+04.E+05 Specific Power being Sp delivered ecific p ower, by the kw/cm drilling method, kw/cm Comparison of Laser and conventional drilling methods. Modified after (Xu et al., 004) 7 6.E05 J/cm 0000 J/cm 000 J/cm E06 J/cm > 0x ROP Same Specific energy But more specific power

12 Thermal spallation drilling with LaserJet water jet guided Laser transmits energy Excessive, rapid thermal energy Thermal stress Rock weakening + thermal Spallation J/sec=W Laser spallation process principle. Modified after (Preston & White, 94;Fraunhofer IPT) mechanical assistance complete rock destruction Prototype LJD test GZB + Fraunhofer with mechanical assistance 0 KW laser system multi-fluid distribution swivel and four concentric pipe system High power fiber optic cable Cutting transport & wellbore integrity LaserJet water LaserJet Mechanical assistance + Laser cartridge housing LJD schematical setup including mechanical assistance.( Fraunhofer IPT) 44

13 Rock disintegration and drilling via LASER technology combined with monitoring, logging, characterization and analysis of water jet, rock destruction and equipment to determine final drilling parameters Acoustic emission system Laser generator and optical system Central data acquisition system Laser Generator Fiber laser Confining pressure Laser generator and optical system (Fraunhofer IPT) Rock sample Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 5 Rock disintegration / spallation / drilling via FLAME + LASER technology combined with monitoring and analysis of rock destruction to determine drilling parameters Acoustic MWD system Flame Reinforced Rock sample Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 6

14 Development of a new MWD system monitoring + control of rock destruction Challenges: Data processing + interpretation Needs more experience Spallation + melt can be clearly seen Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 7 Laser Jet Drilling : initial lab tests Water-guided Laser Jet cutting + drilling Spallation tests on hard rock (Quartzite) using LaserJet 8 4

15 Drilled Holes spallation analysis + measurement preparation for new MWD Lazed samples D side view Top view D and hole quality evaluation mm Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 9 Depth map generation Image processing / d segmentaion techniques Extracted / drilled volume Hole quality Specific energy ROP Process control Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 0 5

16 Full scale drill GZB with mobile rig : bring the geology to the GZB drill rig + test site subsurface installation of rocks + instrumentation Various investigated methods for sample preparation Rock sample Cementing using a metal frame Reinforced cement Inspection and analysis Using a crane for : Rock handling Rock lifting Rock recovery after the test Crane Curing the cement Removing the metal frame Measurement system installation Removing the cement Inspection and analysis of the drilled sample and borehole wall Sample in manhole placement Full scale drill GZB with mobile rig,5 m *,5 m * m Full MWD system and logging on drill rig Temperature Sensors for Fluids Fluid flows & pressures Measurements Laser Measure ment Measurement while drilling (MWD) Temperature Sensors in rock sample Acoustic sensors Rock sample Rock instrumentation Logging and measurement of rock s and reservoir response / behavior LaserJet Drilling - Status Meeting 6

17 i.bogs autoclave for drilling at reservoir conditions i.bogs specs m / 0 ft sample length possible 40 cm /. ft sample Ø i.bogs unit Sample + jacket.50 bar / 8,000 PSI pressure Pore + global pressure adjusted separately Temp. -0 C to 80 C / 0 F to 60 F drill.bogs drive will be attached to this insitu unit Quelle: GZB drill.bogs specs 0 tons WOB /,000 lbs 4 in drilling Ø possible Nm of torque (8,000 ft.lbs) Full MWD possible Drill.BOGS unit i.bogs with rock sample Under reservoir stress Bohrwerkzeug m Bohrstange Drehgetriebe Vorschub- Hydraulikzylinder Nm Drehmoment 0t Vorschubkraft 50 bar Bohrspülung Führungsschiene

18 Rock destruction + control unit (MWD) for new drilling process Quelle: GZB Quelle: GZB Akustikmessaufnehmer Probenkörper Datenverarbeitung/ -auswertung Datenausgabe (e.g. Spallation) Fußzeiltentext: Menüband "Einfügen" -> "Kopf- und Fußzeile" 5 Complete MATCH.BOGS parts assembly when in full operation Flow loop Downhole Well flow Fluid.BOGS Reservoir fluids i.bogs Reservoir Drill.BOGS Drill rig Downhole-Testing- Device Geofluid.Reactor D = 500 m D = 00 m Flow = 400l/min-00l/sec T = 80 C P = 00 bar Salinity = 00 g/l L = 4m / m B = 4 cm T = -0 C to 80 C P = 5 MPa /.50 bar Blow Out Preventer LPipe = m Torque = Nm Push = 80 kn on rock /.50 bar pore pressure Machine monitoring + control while drilling Innovative MWD system Acoustic unit i.bogs Optische Überwachung mit Ultrahochgeschwindigkeitskamera (0000P/sec) und Doppelpuls-Highspeed-Laser 8

19 Thank you for your attention Do you have any questions? Volker Wittig phone zentrum.de web: zentrum.de 9