Basic design methodology for a new small multistage Turbodrill (turbine down hole motor) optimized for small size Coiled Tube (CT) Turbodrilling system for deep hard rocks mineral exploration drilling is presented. Turbodrill is a type of axial turbomachinery which has multistage of stators and rotors. It converts the hydraulic power provided by the drilling fluid (pumped from surface) to mechanical power through turbine motor. For the first time, new small diameter (5-6 cm OD) water Turbodrill with high optimum rotation speed of higher than 2,000 revolutions per minute (rpm) were designed through comprehensive numerical simulation analyses. The results of numerical simulations (Computational Fluid Dynamics (CFD)) for turbodrill stage performance analysis with asymmetric blade's profiles on stator and rotor, with different flow rates and rotation speeds are reported. This follows by Fluid-Structural Interaction (FSI) analyses for this small size turbodrill in which the finite element analyses of the stresses are performed based on the pressure distributions calculated from the CFD modeling. As a result, based on the sensitivity analysis, optimum operational and design parameters are proposed for gaining the required rotation speed and torque for hard rocks drilling.

Turbodrill (turbine down hole motor) has been recently proposed by the authors as the preferred drive mechanism with high rotation speed for hard rocks drilling for deep mineral exploration applications. Turbodrill is a type of hydraulic axial turbomachinery in which turbine motor section has multistage of rotors and stators that convert the hydraulic power provided by the drilling fluid to mechanical power with diverting the fluid flow through the stator vanes to rotor vanes. This paper presents a methodology for designing multistage turbodrills with asymmetric rotor and stator blades configurations. The numerical simulation approach and the simulations results carried out using computational fluid dynamics (CFD) code for the proposed small size model of turbodrill stage with different drilling fluid (mud) types and various mass flow rates are presented. As a result optimum operational parameters are proposed for gaining the required rotation speed and torque for hard rocks drilling.

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The need to drill deep boreholes more efficiently for mineral exploration has raised the attention to investigate the feasibility of recent drilling technologies for such applications. The two principal methods of reverse circulation (RC) and diamond core drilling are usually used in combination by mine operators are subjected to certain limitations and inefficiencies. Considering that delivering large volume of reliable samples from deep zones to the surface in shortest possible time is of paramount importance in mineral exploration, then drilling small size holes as fast as possible and delivering the small chip samples to the surface would be a good alternative with several advantages over conventional drilling methods. As a result, the Coiled Tube (CT) Turbodrilling technology is proposed here followed by presenting detailed calculations for the system required power and hydraulics and also bottom hole assembly selection suitable for hard rocks mineral exploration applications.