Secoroc CDS 2.

23 Meter Reverse
Circulation Drilling with Cluster Drill Case
Australia, 2008

Compilation of Notes and Records of the subject case from the following:
TJ Plunkett Vice, President, Secoroc Engineering
Chin Hock Kok, Secoroc Marketing Asia
Tony Brinkley, Service Technician
Ron Reece, Technical Sales, Australia
Report Assembly: Barrow Turner, PM DTH Large Hole Drilling Products
Report Date: April 11, 2012

Sydney Australia: Desalination Project

Total Project - 1.76 Billion AUD

Six 2.23 meter Seawater Inlets

and Outlets
Drilling Contract: 230 Million
AUD
Provide 250 Million liters of
water a day

Project General Scope

The plant extracts drinking water from seawater
using reverse osmosis (RO) technology. It has the
capacity to supply about 250 million litres (ML) of
drinking water per day, supplying 15% of Sydney's
water needs. This may be increased to 500ML per
day in future.
The 1.76bn Australian Dollar project was
undertaken by Sydney Water, a state-owned
statutory corporation of the NSW Government.
Sydney Water prepared an environmental
assessment report in November 2005

Contracts Awarded
In July 2007 a A$1bn contract for the design
and construction of the plant was awarded to
Blue Water Joint Venture (JV). The JV consists
of John Holland, which was responsible for
construction of the plant, and Veolia Water,
which is responsible for operation and
maintenance of the plant and inlet / outlet
structures for 20 years, under a long-term
agreement with Sydney Water.

Today,

Kurnell desalination plant is located in South

Sydney, New South Wales (NSW), Australia. It is
the largest desalination plant operating in the
country and is fully powered by renewable
energy.

Sydney's Desalination Project

Job Requirements

Drill 4 inlet and 2 outlet holes to meet tunnel boring

machine
2.23 meter diameter holes
23 25 meters under water
Drill depth below sea floor, max 30 meters
No cuttings allow in sea due to environmental restrictions
Removed by barge and dumped on shore

Contractor Requirements

Set 2.5 meter casing

Use percussive hammer drilling method
Complete hole in Reverse Circulation

Customer had prior experience in large RC drilling

CDS 2.23 meter RC

Cluster Drill
Project Overview
Sydneys desalination plant is located at Port Botany, Marine Yard. It is
develop by John Holland Group and the main contractor for the entire
plant which includes 2 tunnels is Blue Water. Dempsey Industries is a
subcontractor responsible to finish eight 2.23m holes at a final depth of
28m below sea bed. Water depth is approx. 26m and platform height is
approx. 12m above sea level. Drilling works is undertaken on a raised
hydraulic badge (SEAFOX 6).
CDS2.23M 19T7G
The CDS2.23M 19T7G system had nineteen CS 8 hammer and 10
standard indexing bit and retaining ring. The drill is mounted with 8
collector pipes on the canister to flush up the cuttings which is in turn
suck-up through the RC pipes and ultimately to the discharge pipes and
cyclone where all cuttings are collected in a sump.
The drill string is made up of 6.0m x 381mmRC pipes and 432mm RC
coupling. The RC manifold, collector pipes, discharged system and drill
pipes are design and engineered by Dempsey Industries.

CDS 2.23 meter RC Cluster Drill

SEAFOX 6 Drilling Platform
500 sq meter platform
22 story high
2136 kg
Barge operated at 10-12
meters above sea level

Abrasive Australian Sandstone 60MPA

CDS88RC Cluster Drill

Relocation of barge varied from 2 to 5

weeks per hole.

CDS2.23 meter RC Cluster Drill

Atlas Copco designed 2.23 M
RC cluster drill.
RC pipes through cluster drill.

19 total hammers
Gauge hammers use patented
indexing option.
Patented quick release bit
option not offered for
particular job.

CDS 2.23 meter RC Cluster Drill

Atlas Copco concept image of Reverse Circulation
system
RC Collection Tubes
Primer Feed Tube

CDS 2.23 meter RC Cluster Drill

Manufacture of Cluster drill
Taken during quality inspection

CDS 2.23 meter RC Cluster Drill

Reverse Circulation Flange
Designed by Contractor

CDS2.23 meter RC Cluster Drill

CDS staged with drive flange

Drilling Platform Setup

Drilling Control Panel

2.5 Meter Casing Set for Drilling

RC Pipe Configuration

Air input holes

RC Cuttings Collection Tube

CDS 2.23 meter RC Cluster Drill

Air Packages

14,350 scfm
14 Atlas Copco Twin Air packs on board
Operating in RC held between 180 220psi for seawater backpressure
1 twin used to prime RC

CDS 2.23 meter RC Cluster Drill

Job Details
Australia Sandstone; Abrasive!

Average penetration rates

of 2-4 meters/hour
Due to abrasiveness 1 hole
averaged 2 sets of bits.
AC Customer Center set up
regrind stations for bits.

CDS2.23M RC Cluster Drill

Challenges during start up/testing of System
Air inlet piping system was undersized on
platform
Contained several restrictions
Check valves not properly installed

19 face bits started with self-indexing bits

Changed internal hammers (12 each) bit to non-indexing
to assist in bits in retracting to firing position when on
bottom

RC system not maintenance friendly on platform

Blow down ports of hammers modified
Assisting with quicker start up
Allowing hammers to hold higher pressure during voids

Actions after Testing of CDS and System

Air Systems

There are 14 unit AC- XRV2000 compressors on board with FAD of 14,350 cfm rated at 350 psi. Minimum
pressure valve is set at 225 psi on the compressor. Air is channel through 2 x 150mm pipes to a 2m air
receiver tank. Air outlet from the receiver is channel through 4 x 2 elbow and subsequently to 2 x 6
pipes to the air swivel. The compressor has free flow system with build in check-valve.
Initial Findings

Drill not sitting in flat position, thus, probably half the hammer is hanging on blow mode.

Air flow system too restricted by elbow and reducers especially at outlet of receiver tank.

Compressors set at 350psi, can only ramp up to 250 psi therefore, not delivering maximum FAD.

Compressors not equipped with check valve, air kick back from the system may distort FAD.

Back pressure on the drill hole is 90 psi.

Hammer mudded.

Worn buttons premature. Not enough air to fire all hammers therefore bits were rotary drilling.

Bit splines are in good condition.

Actions

With full support from Timothy Plunkett, Tony Brinkley and Site operation the following corrective
measures were undertaken:

Restricting the blow port to 1 hole x 0.375 (Original holes are 4 each x 0.5)

Further restricting the final blow port to each hammer to 1 x 3/16. Thus, the hammer consumes less air
approx. 550 cfm at 150 psi. This is to ensure the drill continue to run even with some hammers are in blow
mode.

All compressors are now installed with individual check valves.

Outlet pipe of receiver tank modified to 2 each x 6.

All hammers are checked and worn bits are replaced. Bits are redesigned adding flutes.

Site management prepared a list of step by step Standard Operation Procedures guidelines for
operators.

Start-Up

The drill got started Sunday night and the first hole was finished at 04.30 am on Monday with a final depth
of 28m. This made Dempsey and Blue Water happy.

Air system Resistance Receiver tank

Tank outlet 2
Heavy resistance with small
diameter and sharp elbow

Inlet 6

Harsh Air Restriction due to 90 Degree

Elbows (Removed) and small diameter.

Manifold Ready for Outlet

Modifications

Two 6 Outlet Lines added to Assist in

Unrestricted Air Flow

Modified Bits by Adding Flutes in Flat

Section of Face
Facilitate faster cutting removal and less wear
New Style

Original Style
New Flutes

Hammer Modifications on Site

Hammer Casing has 4 each .5 blow ports.

Brazed all 4 closed and drilled one out to 3/16.
This was done on all 19 hammers to prevent off
bottom running.

Chuck and Bit Modifications

All 12 internal (non-gage) hammers were
installed with non-indexing chuck and bit to
help getting all hammers to fire. The seven
gauge hammers continue to be equipped with
indexing chuck and bits to maintain good hole
gauge. The present carbide grade is AF63/2M2
due to fast wear (abrasive sandstone).
Dempsey requested to replace with Dyanite,
which has compressive strength similar to
BH30.

CDS 2.23 meter RC Cluster Drill

Service between holes: Checking Hammers
Sharpening Bits

Atlas Copco Project Success!

Six 2.23 Meter Holes Complete 2.23

30 meters depth in seawater, approx. 27 meters rock

Lets go Home!