3.3 exadaktylos drillability- pps mpega...
TRANSCRIPT
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Operational Programme “Education and Lifelong Learning”Continuing Education Programme for updating Knowledge of
University Graduates:
“Modern Development in Offshore Structures”
3.3 Rock Drillability
George ExadaktylosProfessor of Rock Mechanics & Mining Engineering, School of Mineral Resources
Engineering, Technical University of CreteEmail: [email protected]
AUTh TUC
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Contents
• What is drilling? Drill string design.• Classification of drilling systems. Types of rotary drill bits.• Mechanisms of rock disintegration (sharp & blunt cutters).• Drag bit performance.• Drilling rate or Rate of Penetration(ROP).
Rock drillability
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Drilling (small hole) is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross‐section in solid materials. The drill bit is often a rotary cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the workpiece, cutting off chips from the hole as it is drilled (http://en.wikipedia.org/wiki/Drilling).
What is drilling?
Well drilling (Mining) is the process of drilling a hole (large) in the ground for the extraction of a natural resource such as ground water, brine, natural gas, or petroleum, for the injection of a fluid from surface to a subsurface reservoir (CO2) or for subsurface formations evaluation or monitoring. Drilling for the exploration of the nature of the material underground (for instance in search of metallic ore) is best described as borehole drilling, or 'drilling’. (http://en.wikipedia.org/wiki/Well_drilling). Also Geothermal drilling.
Rock drillability
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(b) Water
Fairhurst & Lacabanne (1957)
Rock drillability
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Churn drill or Spudder: it can drill loose soil or hard rock and make holes 4”-12’’ in diameter over a mile in depth. The hole is advanced by raising and dropping a chisel bit. The cuttings mix with water to make mud which is bailed out at intervals (ROP 2-10 feet/h).
σκαρπέλο
(Herbert ,1955)
Rock drillability
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Contact of bit with rock!
Rock drillability
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Types of rotary drill bits (κοπτικές κεφαλές)
PDC bit Tri-cone rotary bit (rolling cone bit)and cutting tools attached to it.
PDC cutters(κοπτικά εργαλεία) that are mounted on a steel or tungsten carbide matrix body
Teeth made from hard metal (WoC)
Rock drillability
Hard metal sustrate
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Examples of Polycrystalline Diamond Compact (PDC) drag bits. Various configurations of the cutters on the bit
Rock drillability
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Drag bits with steel blades (μεταλλικά ελάσματα)
Rock drillability
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• 3 conical cutting elements• They can rotate on roller and ball
bearings• When the bit is rotated in service, the
cones rotate about their axes through contact with the rock being drilled
• This sets-up a twisting-tearing and chipping-crushing action.
• The teeth of the cones are hard faced to increase the resistance to abrasive wear.
• The rows of teeth on the inner end of each cone interfit with the grooves on the mating cones thus providing a self-cleaning action.
• Cone bits for sticky or soft formations have long, widely spaced teeth, while for harder formations have shorter and more closely spaced teeth.
(Herbert ,1955)
Rock drillability
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• Fragments or chips removed from the hole by the flushing fluid or mud circulating through the bit
Rock drillability
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• Bit sizes range from 33/4 inch to 26 inch;• 77/8 and 83/4 inch are the more popular.
Rock drillability
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• Rotation speeds (ω) vary from 40 – 500 rpm (more frequent 100‐350 rpm).• Speeds may be limited by the rotary power available or the capacity of the pump
to clean out the cuttings.• Note: a harmonic vibration may occur at certain speeds which interferes with
proper drilling and shortens the life of the drill string.
Rock drillability
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• A complete model of the drilling response of drag bits consists from the relations between the weight‐on‐bit WOB, the torque‐on‐bit T, the rate of penetration (ROP) V, and the angular velocity ω.
• The logical step is to study first the mechanics of a single cutter and then compose the whole response model of the bit.
Rock drillability
Response model of the drag bit
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Cutters interaction and cutting profiles
• Forces acting on the cutter depend on rock type, cutter geometry and wear state, position on the bit, cutter interaction with neigboring cutters, cutting speed, rock stress state, and fluid environmnent (Glowka, 1989a).
• Cutting profiles obtained during two bit revolutions as the cutters pass through a radial plane containing the longitudinal axis of the bit. The shaded areas represent the cross‐sectional cut areas for each cutter. All cutters lie on the same plane normal to the longitudinal axis of the bit.
Rock drillability
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The depth to which the cutter penetrates the flat rock surface is a function of the stresses imposed on the rock by the cutter
Penetration of a cutter into the flat surface of the rock (I)Fairhurst & Lacabanne (1957)
Rock drillability
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Penetration of a cutter into the flat surface of the rock (II): Influence of wedge angle (acute angle and obtuse angle)
Fairhurst & Lacabanne (1957)
Rock drillability
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Stavropoulou (2006)
Planning action of a rotary bit
Rock drillability
Cutting direction with constant velocity v=ωrMechanisms of rock disintegration. I. Single sharp cutter
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Mechanisms of rock disintegration. I. Single sharp cutter
sn FFF
WOBFn
2
sF
nFJ
sF
E
Side-view of a cutter with positive rake angle θ Negative rake angle θ
α = width of the cutter (or characteristic dimension)E=‘specific energy’ of cuttingJ = ‘drilling strength’
)tan( s
n
F
F
Clearance angle
Rake angle
Rock drillability
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Log-spiral form of the fracture path
Rock drillability
Cutting direction
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A cutter moves along a helical path due to weight-on-bit W and torque T; angular velocity ω and rate of penetration (ROP) v.
v
p2
ROPv
Fairhurst & Lacabanne (1957)
Rock drillability
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xey Stavropoulou et al (2005)
Approach stage
Steady‐state stage
Rock drillability
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(Glowka, 1989a)
(or p)
Rock drillability
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(Glowka, 1989a)
Rock drillability
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a
bWOB
aROP
bpaWOBF
ROPvp
n
22
22
Rock drillability
• In a simple analysis it turns out the ROP should be a linear function ofWOB (or drilling thrust) with constant ω, and linear increasing with ω for constant WOB.
• A selected ROP can be achieved with a lower WOB and by increasing ω.
ba, = linear regression constants
Simple 1st order model for the prediciton of the rate of penetration of a rotary drill bit
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Kinematics of the failed rock: Estimation of the cutting force Fc for sharp cutter
The single‐cutter models precict such items as cutter forces, temperatures and wear. These predictions are independent of the cutter’s position on the bit.
Stavropoulou (2006)
0
20
40
60
80
100
120
140
160
180
0 0 20 40 60 80 100 120Normal stress, σ
She
ar s
tres
s, τ
Mohr-Coulomb failure criterion with tension cut-off
UTS UCS
1tanф
Rock drillability
Cutting direction
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Passive earth pressure on a wall in contact with a (γ,c,φ) rock. In this case ‘α’is the back rake angle of the sharp tool.
Rock drillability
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Kinematics of the failed rock: Estimation of the cutting force Fc for the blunt cutter
Hypothesis of Fairhurst and Lacabanne (1957) and also by others, that two mechanisms are simultaneously operative: cutting of the rock and frictional contact underneath the cutter.
fs
css
fn
cnn
FFF
FFF
,
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Τhe model of the drag bit & its design
The PDC bit model is a combination of rigorous geometrical relationships used to describe the kinematics of a particular bit geometry and single‐cutter force and wear models.
ω
Rock drillability
Glowka (1989b)
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ω
ω
Rock drillability
Glowka (1989b)
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Rock drillability
Glowka (1989b)
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xOy
xOz
‐Cutters arranged in 3‐arm spriral pattern‐Bit has a relatively flat profile since it applies for hard‐rock drilling
Glowka (1989b)
Rock drillability
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Nose height = 4”
xOy
xOz
Bit diameter = 8.5”
Glowka (1989b)
• Apart of the number of cutters, placement density may be modified locally by moving cutters radially and circumferentially.
• The radial placement of cutters is one of the most important parameters in bit design.
• Typically increasing number of cutters towards the periphery of bit.
Rock drillability
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The radial placement of cut-
v
p2
Glowka (1989b)
Rock drillability
ROPv
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ReferencesFairhurst C. and Lacabanne W. D. Hard rock drilling techniques. Min. Quarry
Engng 157‐161, 194‐197 (1957).Herbert L. N. (1955). Moving the Earth. North Castle Books, Greenwich,
Connecticut.Glowka D. Use of single‐cutter data in the analysis of PDC bit designs: part 1 ‐
development of a PDC cutting force model. J. Petrol. Technol. Aug, 797‐849 (1989a).
Glowka D. Use of single‐cutter data in the analysis of PDC bit designs: part 2 –development and use of the PDCWEAR computer code. J. Petrol. Technol. Aug, 850‐859 (1989b).
Stavropoulou M.C., Giannakopoulos, K. and Exadaktylos G.E. (2005)., A theoretical and experimental study of rock cutting J. Mech. Behavior of Materials. Vol. 16, Nos 1‐2, pp. 131‐150.
Stavropoulou M. (2006). Modeling of small‐diameter rotary drilling tests on marbles, International Journal of Rock Mechanics & Mining Sciences 43 (2006) 1034–1051.
Tsoutrelis C. E. (1969), Determination of the compressive strength of rock in situ or in test blocks using a diamond drill, Int. J. Rock Mech. Min. Sci. Vol. 6, pp. 311‐321.
Rock drillability