Smaller Footprint Drilling System for Deep and Hard Rock Environments; Feasibility of Ultra-High-Speed Diamond Drilling

Abstract

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 details the progress at the end of Phase 1 on the program entitled ''Smaller Footprint Drilling System for Deep and Hard Rock Environments: Feasibility of Ultra-High-Speed Diamond Drilling'' for the period starting 1 March 2006 and concluding 30 June 2006. (Note: Results from 1 September 2005 through 28 February 2006 were included in the previous report (see Judzis, Black, and Robertson)). Summarizing the accomplished during Phase 1: {lg_bullet} TerraTek reviewed applicable literature and documentation and convened a project kickoff meeting with Industry Advisors in attendance (see Black and Judzis). {lg_bullet} TerraTek designed and planned Phase I bench scale experiments (See Black and Judzis). Some difficulties continued in obtaining ultra-high speed motors. 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. {lg_bullet} TerraTek concluded Task 3 ''Small-scale cutting performance tests.'' {sm_bullet} Significant testing was performed on nine different rocks. {sm_bullet} Five rocks were used for the final testing. The final tests were based on statistical design of experiments. {sm_bullet} Two full-faced bits, a small diameter and a large diameter, were run in Berea sandstone. {lg_bullet} Analysis of data was completed and indicates that there is decreased specific energy as the rotational speed increases (Task 4). Data analysis from early trials was used to direct the efforts of the final testing for Phase I (Task 5). {lg_bullet} Technology transfer (Task 6) was accomplished with technical presentations to the industry (see Judzis, Boucher, McCammon, and Black).