The new HDD Tooling from Herrenknecht

Full Face Hole Opener / Down Hole Jet Pump

Simon Herrenknecht, Product Manager Pipeline, Herrenknecht AG

Herrenknecht Introduction

Herrenknecht AG, Germany

 Founded in 1977
 Worldwide marked leader in
mechanized tunnelling technology

 4,800 employees worldwide SBX Boxhole Machine Raisebore Rig

 Total output, 1.34 billion Euro (2015)

AVN & AVND EPB Shield Gripper TBM Single Shield Double Shield Partial-face
Excavation Machine

Auger Boring HDD Rig Direct Pipe®

Machine Pipe Express®
VSM

Herrenknecht. 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

Herrenknecht. Pioneering Underground Technologies

 Herrenknecht Introduction
Similar Applications for HDD Cutters within
Herrenknecht:

Boxhole Drilling Raise Drilling

Herrenknecht. Pioneering Underground Technologies

Fullface vs. Conventional Reaming Steps

Herrenknecht. Pioneering Underground Technologies

Fullface vs. Conventional Reaming Steps

$
$ $ $ $ $
Conventional
$
$
$ $ $ $ $

Fullface Hole Opening

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

Herrenknecht. 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”

Herrenknecht. Pioneering Underground Technologies

 Hole Opener Design

 Full Face Cut

 Replaceable Cutter
 Replaceable Front Centralizer
 Tool-Face Cleaning
 Cutting Scraper
 Non-Stick Coated Areas

Herrenknecht. Pioneering Underground Technologies

Herrenknecht Fullface Hole Opener

Hard Rock Soft Rock

(<R6) (>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 Technologies

Herrenknecht Fullface Hole Opener

 Heavy duty & downhole

proven bolting system

Herrenknecht. 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” connections

5 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

Herrenknecht. Pioneering Underground Technologies

Efficiency through Cost Reduction

 Less drilling tools needed

 Drilling tools with replaceable cutters
 Saving investment
 Cutters with longer bearing and hub lifetime costs
 Effective wear protected body for a longer lifetime

 Less tripping operations

 Less joint changes
 Less tool changes  Saving construction
 Less cleaning runs costs

 Increased productivity
Less Costs-per-foot

Herrenknecht. Pioneering Underground Technologies

Mud & Cutting Flow

Herrenknecht. Pioneering Underground Technologies

Centralization

Gage-Centering

Tool Face-Centering

Front-Centering

Rear-Centralizer

Herrenknecht. Pioneering Underground Technologies

Open Design

Herrenknecht. Pioneering Underground Technologies

 Requirements to use an HK Full Face Hole Opener

 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)

Herrenknecht. 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 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!

Herrenknecht. Pioneering Underground Technologies

Drill Pipe used as Discharge Line

Borehole Borehole
(discharge line)

Drill pipe Drill pipe

(discharge line)

Herrenknecht. Pioneering Underground Technologies

The missing Link: Down Hole Jet Pump (DHJP)

Herrenknecht. Pioneering Underground Technologies

Herrenknecht. Pioneering Underground Technologies
 Herrenknecht DTH Tool Testing Facility

High Pressure Pump Separation

Test borehole (submergible)

Unit for Rotation and Push/Pull

Herrenknecht. Pioneering Underground Technologies

Herrenknecht DTH Tool Testing Facility

1000m (3280 ft) of discharge line circuit

Herrenknecht. Pioneering Underground Technologies

Herrenknecht DTH Tool Testing Facility

 DHJP in artificial borehole loaded  DHJP in artificial borehole after

with cuttings (dry) the testing (dry)

Herrenknecht. Pioneering Underground Technologies

 Requirements to operate an DHJP

 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)

Herrenknecht. 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 Technologies

 Down Hole Jet Pump
Mud flow scheme on DHJP

DHJP suction flow :

v = 800 l/min = 211 gal/min
p = 0,x bar = 0,x psi

From To
HP-Pump Separation

Motive flow before DHJP : Motive flow after DHJP :

v = 1800 l/min = 475 gal/min v = 2600 l/min = 687 gal/min
p = 50 bar = 725 psi p = max. 20 bar = 290 psi

Herrenknecht. Pioneering Underground Technologies

 Down Hole Jet Pump
Surface Equipment

Flow meter, Ball valve,

Pressure transducer
Mud hose

To Separation
Mud swivel

Drill Pipe
From DHJP

Herrenknecht. Pioneering Underground Technologies

Herrenknecht Full Face Hole Opener.
Overview: 5 Reference Projects USA.
 Full Face diameter: 42” & 48”
 Product diameter: 30” & 36”
 Pilot bores: 12” & 17”
 TCI & MT Cutters
 Granite, Basalt, Shale & Limestone

Herrenknecht. Pioneering Underground Technologies

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
1. Pilot bore: 12”
 Contractor: Laney
2. Full Face diameter: 48”
 TCI roller cutters
 47” centering device

Herrenknecht. Pioneering Underground Technologies

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
1. Pilot bore: 12”
 Contractor: Laney
2. Full Face diameter: 48”
 MT cutters
 47” centering device

Herrenknecht. 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 heat
transport
 Geology: hard limestone, flintstones
 Contractor: BAB Rörtryckning AB

Herrenknecht. Pioneering Underground Technologies

 PIONEERING
UNDERGROUND
TECHNOLOGIES

Please feel free to ask questions or give comments.

Herrenknecht. Pioneering Underground Technologies