The new HDD Tooling from HerrenknechtFull Face Hole Opener / Down Hole Jet Pump
Simon Herrenknecht, Product Manager Pipeline, Herrenknecht AG
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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 Pipe®Pipe Express®
AVN & AVND Partial-face Excavation Machine
EPB Shield Gripper TBM Single Shield Double Shield
SBX Boxhole Machine Raisebore Rig
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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
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Fullface vs. Conventional Reaming Steps
Conventional
Fullface Hole Opening
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From min. 12 ¼” From min. 28”→ max. 72”
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Fullface vs. Conventional Reaming Steps
Conventional example for drilling a borehole for a 42” Pipeline:
Pilot Hole: 12 ½”
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 ½”
1st Hole opener: 54”
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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 (<R6)
Soft 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.
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Herrenknecht Fullface Hole Opener
Heavy duty & downhole proven bolting system
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Reasons for the Fullface Hole Opening development
Continuous increase of drill pipe dimensions 5” → 5 ½“→ 6 5/8“ → 7 5/8“ → 8 3/4“→ 9 5/8“
Development of “high torque” connections5 ½“FH DS→ 6 5/8“FH DS → 7 5/8“H-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
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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
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Mud & Cutting Flow
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Centralization
Front-Centering
Tool Face-Centering
Gage-Centering
Rear-Centralizer
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Open Design
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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 ½”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
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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
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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 DTH Tool Testing Facility
High Pressure Pump Separation
Test borehole (submergible)
Unit for Rotation and Push/Pull
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1000m (3280 ft) of discharge line circuit
Herrenknecht DTH Tool Testing Facility
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DHJP in artificial borehole loaded with cuttings (dry)
Herrenknecht DTH Tool Testing Facility
DHJP in artificial borehole after the testing (dry)
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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
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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)
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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
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Down Hole Jet PumpSurface Equipment
To Separation
Flow meter, Ball valve, Pressure transducer
Mud hose
Mud swivel
Drill PipeFrom DHJP
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Full Face diameter: 42” & 48”
Product diameter: 30” & 36”
Pilot bores: 12” & 17”
TCI & MT Cutters
Granite, Basalt, Shale & Limestone
Herrenknecht Full Face Hole Opener.Overview: 5 Reference Projects USA.
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Herrenknecht Full Face Hole Opener.Reference Project: Verdigris River Crossing.
Location: Independence, Texas
Project: Flanagan South Pipeline (36“)
Drilling length: 1,757ft. (536m)
Drilling depth: 98ft. | Bend radius: 3,600ft.
Geology: layers of soft soil, shale, limestone
Compressive strength: 15,600psi (108 MPa)
Client: Enbridge
Contractor: Laney 1. Pilot bore: 12”
2. Full Face diameter: 48”
TCI roller cutters
47” centering device
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Herrenknecht Full Face Hole Opener.Reference Project: Arkansas River Crossing.
Location: Cleveland, Oklahoma
Project: Flanagan South Pipeline (36“)
Drilling length: 3,015ft. (920m)
Geology: sandstone, shale, limestone
Compressive strength: 8,000psi (55 MPa)
RQD index: 50-60
Client: Enbridge
Contractor: Laney 1. Pilot bore: 12”
2. Full Face diameter: 48”
MT cutters
47” centering device
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Herrenknecht Down Hole Jet Pump.Reference Project: Malmö Harbor Channel Crossing.
H-165, HK150C Crawler Rig
Location: Malmö, Sweden
Project: District Heating Pipeline
Drilling length: 850ft. (263m)
Pipeline: 40“ HDPE casing pipe with inner steel pipeline for heattransport
Geology: hard limestone, flintstones
Contractor: BAB Rörtryckning AB
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Please feel free to ask questions or give comments.
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