Transcript
Page 1: The new HDD Tooling from Herrenknecht - · PDF fileThe new HDD Tooling from Herrenknecht Full Face Hole Opener / Down Hole Jet Pump ... EPB Shield Gripper TBM Single Shield Double

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. 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 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. 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

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Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

Fullface vs. Conventional Reaming Steps

Conventional

Fullface Hole Opening

$

$ $

$

$

$ $

$$

$$

$

$

From min. 12 ¼” From min. 28”→ max. 72”

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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 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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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. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

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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Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

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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Herrenknecht. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

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.

Page 30: The new HDD Tooling from Herrenknecht - · PDF fileThe new HDD Tooling from Herrenknecht Full Face Hole Opener / Down Hole Jet Pump ... EPB Shield Gripper TBM Single Shield Double

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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

Page 31: The new HDD Tooling from Herrenknecht - · PDF fileThe new HDD Tooling from Herrenknecht Full Face Hole Opener / Down Hole Jet Pump ... EPB Shield Gripper TBM Single Shield Double

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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. Pioneering Underground TechnologiesHerrenknecht. Pioneering Underground Technologies

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.

PIONEERINGUNDERGROUNDTECHNOLOGIES


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