The new HDD Tooling from Herrenknecht - ??The new HDD Tooling from Herrenknecht Full Face Hole Opener / Down Hole Jet Pump ... EPB Shield Gripper TBM Single Shield Double Shield

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  • The new HDD Tooling from HerrenknechtFull Face Hole Opener / Down Hole Jet Pump

    Simon Herrenknecht, Product Manager Pipeline, Herrenknecht AG

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Herrenknecht Introduction

    Herrenknecht AG, Germany

    Founded in 1977

    Worldwide marked leader in mechanized tunnelling technology

    4,800 employees worldwide

    Total output, 1.34 billion Euro (2015)

    Auger Boring

    MachineVSM

    HDD Rig Direct PipePipe Express

    AVN & AVND Partial-face Excavation Machine

    EPB Shield Gripper TBM Single Shield Double Shield

    SBX Boxhole Machine Raisebore Rig

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    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. 10.000 cutters/year

    Approx. Inventory level 7.0 Mio USD

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    Herrenknecht IntroductionSimilar Applications for HDD Cutters within Herrenknecht:

    Boxhole Drilling Raise Drilling

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    Fullface vs. Conventional Reaming Steps

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Fullface vs. Conventional Reaming Steps

    Conventional

    Fullface Hole Opening

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    $ $

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    $ $

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    $

    From min. 12 From min. 28 max. 72

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Fullface vs. Conventional Reaming Steps

    Conventional example for drilling a borehole for a 42 Pipeline:

    Pilot Hole: 12

    1st Hole opener: 24 (max. 30)

    2nd Hole opener: 36

    3rd Hole opener: 48

    4th Hole opener: 54

    Full Face Hole Opening example for drilling a borehole for a 42 Pipeline:

    Pilot Hole: 12

    1st Hole opener: 54

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Hole Opener Design

    Full Face Cut

    Replaceable Cutter

    Replaceable Front Centralizer

    Tool-Face Cleaning

    Cutting Scraper

    Non-Stick Coated Areas

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    Herrenknecht Fullface Hole Opener

    Hard Rock (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.

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Herrenknecht Fullface Hole Opener

    Heavy duty & downhole proven bolting system

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Reasons for the Fullface Hole Opening development

    Continuous increase of drill pipe dimensions 5 5 6 5/8 7 5/8 8 3/4 9 5/8

    Development of high torque connections5 FH DS 6 5/8FH DS 7 5/8H-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

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Efficiency through Cost Reduction

    Less drilling tools needed

    Drilling tools with replaceable cutters

    Cutters with longer bearing and hub lifetime

    Effective wear protected body for a longer lifetime

    Less tripping operations

    Less joint changes

    Less tool changes

    Less cleaning runs

    Increased productivity

    Saving construction costs

    Saving investment costs

    Less Costs-per-foot

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Mud & Cutting Flow

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Centralization

    Front-Centering

    Tool Face-Centering

    Gage-Centering

    Rear-Centralizer

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    Open Design

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Min. 30 = 762mm

    Min. Pilot bore 12 = 304mm

    Required Pull force:min. 25to per Cutter

    Required Torque: 70-90 kNm or higher

    Min. Drill Pipe: 5 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 65-80 Mpa (9.500 11.600 psi)

    TCI-Cutters are used between 80 Mpa to 350 MPa (11.600 50.700 psi)

    Requirements to use an HK Full Face Hole Opener

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    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

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    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!

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    Drill Pipe used as Discharge Line

    Borehole (discharge line)

    Drill pipe

    Borehole

    Drill pipe (discharge line)

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    The missing Link: Down Hole Jet Pump (DHJP)

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  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Herrenknecht DTH Tool Testing Facility

    High Pressure Pump Separation

    Test borehole (submergible)

    Unit for Rotation and Push/Pull

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    1000m (3280 ft) of discharge line circuit

    Herrenknecht DTH Tool Testing Facility

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    DHJP in artificial borehole loaded with cuttings (dry)

    Herrenknecht DTH Tool Testing Facility

    DHJP in artificial borehole after the testing (dry)

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Min. Borehole diameter: 20 = 508 mm

    HP-Motive Flow: 1500-2000 l/min (400 gal/min 530 gal/min)

    HP-Motive Pressure: 50-60 bar (725 psi 870 psi

    Separation capacity: 3000-3500 l/min (792 gal/min 924 gal/min)

    Recommended Drill Pipes: 6 5/8

    Pipesite-swivel, Flow-meter Pipesite

    Mudreturnline (Pipesite-Rigsite)

    Requirements to operate an DHJP

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    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)

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Down Hole Jet PumpMud flow scheme on DHJP

    DHJP suction flow : v = 800 l/min = 211 gal/minp = 0,x bar = 0,x psi

    Motive flow before DHJP : v = 1800 l/min = 475 gal/minp = 50 bar = 725 psi

    FromHP-Pump

    To Separation

    Motive flow after DHJP : v = 2600 l/min = 687 gal/minp = max. 20 bar = 290 psi

  • Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

    Down Hole Jet PumpSurface Equipment

    To Separation

    Flow meter, Ball valve, Pressure transducer

    Mud hose

    Mud swivel

    Drill PipeFrom DHJP

  • Herrenknecht. Pionee