Enhanced Hot Water Drill System Overview Jeff Cherwinka LBNL Collaboration Meeting March 21st 2005 Talk Summay Jeff Cherwinka Review Drill System Requirements Design Strategy Hydraulics Summary Review Seasonal Equipment Site (SES) Thermal Plant Subsystems Heaters Review Tower Operations Site (TOS) Logistics and Schedule Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 2
March 21st 2005 System Overview Jeff Cherwinka System Requirements Drill Holes Make water (Rodriguez Well) 16,000 gal/hole for volume replacement 6,000 gal/hole for firn drill loss
2,000 gal/hole for IceTop Time & Talent 2,450 m (8038 ft) deep 45 cm (17.7 in) diameter after 30 hours -> 60 cm (24 in) Straight to within 15 m (50 ft) of vertical Start up - 21 days with 5 people for each of 3 shifts 84 hrs per hole with 5 people per shift -> 30 hrs deep drill Shut down 10 days with 5 people per shift Fuel 115,200 gal per 16 hole season (7200 gal/hole) Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 3 March 21st 2005
System Overview Jeff Cherwinka System Requirements (continued) Automatic Computer controller deep drilling mode (future) Manual mode with control loops (present) Safe Tested Logistic compatibility
Weight < 24,000 pound (10,884 kg) Size < 8 ft (2.44 m) high, 8 ft wide, 34 ft (10.36 m) long Fork lift 8,000 lb, Crane 30,000 lb, Tow 100,000 lb Environmental compatibility Operation: 45 to +38 C, rain or shine, 0 to 3,700 m Storage: -80 to +40 C with some tagged exceptions Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 4 March 21st 2005 MDS leaving Plane System Overview Jeff Cherwinka Design Strategy
Leverage Amanda Experience Major Improvements One piece drill hose big hose reel Automated control Two drilling structures Modular Design
Use the same equipment where it worked Scale up system 100 GPM->200 GPM People with experience MDS Modular Drilling Structures Use identical equipment where possible Multiple smaller units Fuel Efficiency is a design driver Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 6 March 21st 2005 System Overview Jeff Cherwinka Hydraulics Summary
Flow 200 GPM supply, 192 GPM return 8 GPM makeup on average Pressure 950 psi at pump outlet (800 psi actual) 10,500 feet of 2.5 in ID hose at 0.08 psi per foot 3600 psi at bottom of hole Temperature 190 F (88 C) supply, 35 F (2 C) return Power 4.5 MW Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 7 March 21st 2005
SES During Assembly Subsystem Overview Jeff Cherwinka RWS Rod Well Subsystem Maintain water level of Tank 1 Maintain temperature of Tank 1 8 gpm average while drilling Control flow rates to and from the Rod well Water returns from hole just above freezing Control valves and heater firing
Equipment Hose reel for 1-1/2 inch supply and return rod well hose 10 Stinger heaters receive cold water from tank 1 or the rod well return, and deliver hot water to tank 1 or the rod well supply 2 Vane Pumps (5-70 [email protected] psi) supply water to stingers and generator heat recovery 3 Unico drives (10 Hp) for vane pumps and rod well pump 1 Unico drive (3 Hp) for reel motor Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 9 March 21st 2005 RWS Picture
Subsystem Overview Jeff Cherwinka Tank 1 10,000 gallon water storage, 50 F (10 C) Level and Temp stability secondary to Tank 2 Equipment Two 100 GPM transfer pumps (supply to Tank2) Return hose from Hole Supply & Return to RWS Return from Generator also routed to tank 2 Tank 2
10,000 gallon water storage, 70 F (21 C) Stable source of water for main loop Equipment 2 supply hoses from Tank 1 Supply & Return from PHS 4 Charge pumps with supply hoses to HPP Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 11 March 21st 2005 Subsystem Overview Jeff Cherwinka PHS PreHeat Subsystem
Maintain water level of Tank 2 Maintain temperature of Tank 2 Control flow rates from Tank 1 using transfer pumps Control valves and heater firing Equipment 4 Model 75 heaters (3.50 GPH->420,000 BTU/hr) with condensate collection system 7 Stinger heaters (2.0 GPH->220,000 BTU/hr)
2 Vane pumps (5-70 [email protected] psi) supply water to stingers and model 75s 2 Unico drives (10 Hp) for vane pumps 2 Unico drives (3 Hp) for for transfer pumps 2 Electric water heaters (30 kW) to level generator load Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 12 March 21st 2005 Subsystem Overview Jeff Cherwinka HPP High Pressure Pumps Pressurize 200 GPM of cold water to 950 psi Equipment
High Pressure Pumps: 4 positive displacement pumps capable of 35-65 gpm @1600 psi (50 gpm @ 950 psi) 4 Unico Drives (50 Hp) for High Pressure Pumps 4 Unico Drives (3 Hp) for Charge Pumps Supply manifold to combine and instrument flow to MHPs Return manifold combines MHP return and supply to drill Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 13 March 21st 2005 Subsystem Overview Jeff Cherwinka MHP Main Heating Plant (MHP1, MHP2, MHP3, MHP4) Heat 50 GPM from 70 F to 190 F
Pass through 100 GPM Equipment 9 Model 75 heaters (3.50 GPH->420,000 BTU/hr) Condensate collection system gathers 2.5 GPH of water from each running heater, neutralizes, filters, pressurizes and injects the water into the supply manifold Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 14 March 21st 2005 MHP Picture Enhanced Model 75 heater Jeff Cherwinka
4 (8) S.S. Coil Condenser lowers exhaust gas temp captures more energy from combustion products Condensate Collection Molded Combustion Chamber raises combustion temperature producing cleaner burn and gets more energy from fuel Removable Burner Assembly Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 16 March 21st 2005 Subsystem Overview Jeff Cherwinka Generators (Gen1, Gen2, Gen3) Supply up to 300 KW during deep drilling and 80-120 kW during other times Equipment
225 kW engine/generator set derated to 165 kW for altitude Heat recovery system from both engine coolant and exhaust stack into water supplied by the RWS and returned directly to Tank 1 PDM Power Distribution Module Monitor, control, combine, and distribute power from Gen sets. Manual synchronization for paralleling Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 17 March 21st 2005
Deep Drilling Illustration EHWD Assembly, Use, & Disassembly - WBS 1.2.2 Tower Drill Drill Return Cable Reel Hose Reel Drill Supply Hose Reel Return Pump Drill Head with Short Weight Stack and Nozzle 02/11/20 EHWD Assembly, Use, & Disassembly - WBS 1.2.2 18
March 21st 2005 18 Tower Operation Site Overview Jeff Cherwinka Equipment Overview Drill Supply Hose Reel (DSHR): 8800 feet of 2-1/2 ID, 3.75 OD hose on motorized reel with level wind and brake
Drill Supply Cable Reel (DSCR): 9500 feet 1 inch OD cable on motorized reel with level wind and brake Tower: Turn hose and cable from horizontal to vertical, platform for drill assembly, platform for optical module deployment, 5000 lb electric hoist, beam chain hoist Tower Operating Structure (TOS): Doublewide MDS connects to the tower and houses reel controls, control system computer, drill head storage, optical module storage, and work area. Return Hose Reel: Motorized reel to raise and lower return hose and return pump Return Pump cable Reel: Motorized reel for return pump cable Drill Head: Exit nozzle with weights to maintain vertical hole, monitors hole diameter and angle Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 19 March 21st 2005 TOS System Overview
Jeff Cherwinka Other Equipment Drill Control Center (DCC): Control computers, network communication hub and break area Optical Module Lab (OML): Doublewide MDS for preparation of optical modules for deployment. This year it will be used as the temporary counting house Seasonal Equipment Workshop (SEW): Maintenance and repair of equipment and storage of tools and parts Tower Operations Workshop (TOW): Same Anti-Freeze Sled: 1,200 gal of anti-freeze for heater testing, winterization and in case of emergency Compressor: 400 [email protected] for preheating hose and blowing out water or propylene glycol.
Fuel Tanks: 5,000 gal of AN-8 in sled mounted tanks Fuel Tower: Pump filled tank provides gravity feed and distribution of fuel. Existing MilVans: Storage and temporary workshop space Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 21 March 21st 2005 Firn Drill Deep Drill System Overview Jeff Cherwinka Logistics 550,000 pounds of drill equipment 18 person drill team, reducing to 15 7200 gal fuel per hole on average
48,600 pounds per hole 3,888,000 pounds for 80 holes Schedule 92 days per season 21 day start up -> 2005/6 31 days, also pre-season work 56 day drilling (16 holes @ 84 hours each) 2005/6 46 days (10 holes @ 110 hours each) 5 day break 10 day winterize and shut down Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 23
March 21st 2005 Drilling & Deployment Tasks Jeff Cherwinka Mechanical test hole to check for debris Firn Drill to 50 m Prehole check list Deep Drill to 2450 m Ream hole to size (60 cm +/-) Acceptance of hole Setup deployment winch Deploy DOMs and cable Acceptance of string Move TOS to next hole Enhanced Hot Water Drill System Overview LBNL Collaboration Meeting 24 March 21st 2005
Depth vs Time for Season 2004/5 Hole 21A Depth vs Time Plot Effective Drill Time: ~49 h Drill at 3.5 ft/min Ream at 13 ft/min 10 Holes in 46 days with 2004/5 like drill rates Drill & Deployment Cycles 02/11/20 EHWD Assembly, Use, & Disassembly - WBS 1.2.2 26
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