Smaller Footprint Drilling System for Deep and Hard Rock Environments; Feasibility of Ultra-High-Speed Diamond Drilling
The two phase program addresses long-term developments in deep well and hard rock drilling. TerraTek believes that significant improvements in drilling deep hard rock will be obtained by applying ultra-high rotational speeds (greater than 10,000 rpm). The work includes a feasibility of concept research effort aimed at development that will ultimately result in the ability to reliably drill 'faster and deeper' possibly with smaller, more mobile rigs. The principle focus is on demonstration testing of diamond bits rotating at speeds in excess of 10,000 rpm to achieve high rate of penetration (ROP) rock cutting with substantially lower inputs of energy and loads. The significance of the 'ultra-high rotary speed drilling system' is the ability to drill into rock at very low weights on bit and possibly lower energy levels. The drilling and coring industry today does not practice this technology. The highest rotary speed systems in oil field and mining drilling and coring today run less than 10,000 rpm - usually well below 5,000 rpm. This document provides the progress through two phases of the program entitled 'Smaller Footprint Drilling System for Deep and Hard Rock Environments: Feasibility of Ultra-High-Speed Diamond Drilling' for the period starting 30 June 2003 and concluding 31 March 2009. The accomplishments of Phases 1 and 2 are summarized as follows: (1) TerraTek reviewed applicable literature and documentation and convened a project kick-off meeting with Industry Advisors in attendance (see Black and Judzis); (2) TerraTek designed and planned Phase I bench scale experiments (See Black and Judzis). Improvements were made to the loading mechanism and the rotational speed monitoring instrumentation. New drill bit designs were developed to provided a more consistent product with consistent performance. A test matrix for the final core bit testing program was completed; (3) TerraTek concluded small-scale cutting performance tests; (4) Analysis of Phase 1 data indicated that there is decreased specific energy as the rotational speed increases; (5) Technology transfer, as part of Phase 1, was accomplished with technical presentations to the industry (see Judzis, Boucher, McCammon, and Black); (6) TerraTek prepared a design concept for the high speed drilling test stand, which was planned around the proposed high speed mud motor concept. Alternative drives for the test stand were explored; a high speed hydraulic motor concept was finally used; (7) The high speed system was modified to accommodate larger drill bits than originally planned; (8) Prototype mud turbine motors and the high speed test stand were used to drive the drill bits at high speed; (9) Three different rock types were used during the testing: Sierra White granite, Crab Orchard sandstone, and Colton sandstone. The drill bits used included diamond impregnated bits, a polycrystalline diamond compact (PDC) bit, a thermally stable PDC (TSP) bit, and a hybrid TSP and natural diamond bit; and (10) The drill bits were run at rotary speeds up to 5500 rpm and weight on bit (WOB) to 8000 lbf. During Phase 2, the ROP as measured in depth of cut per bit revolution generally increased with increased WOB. The performance was mixed with increased rotary speed, with the depth cut with the impregnated drill bit generally increasing and the TSP and hybrid TSP drill bits generally decreasing. The ROP in ft/hr generally increased with all bits with increased WOB and rotary speed. The mechanical specific energy generally improved (decreased) with increased WOB and was mixed with increased rotary speed.
- Research Organization:
- Terratek, Incorporated
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- FC26-03NT15401
- OSTI ID:
- 1015446
- Country of Publication:
- United States
- Language:
- English
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Smaller Footprint Drilling System for Deep and Hard Rock Environments; Feasibility of Ultra-High-Speed Diamond Drilling
SMALLER FOOTPRINT DRILLING SYSTEM FOR DEEP AND HARD ROCK ENVIRONMENTS; FEASIBILITY OF ULTRA-HIGH SPEED DIAMOND DRILLING