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Deep Drilling Problems - Maurer · PDF file 2015-11-05 · Deep Drilling Problems DOE Deep Trek Workshop Houston, TX March 20, 2001 Dr. William C. Maurer . TT01-26 2 Deep Well Drilling

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  • A Noble Drilling Corporation Subsidiary

    TT01-26 1

    Deep Drilling Problems

    DOE Deep Trek Workshop Houston, TX

    March 20, 2001

    Dr. William C. Maurer

  • TT01-26 2

    Deep Well Drilling Time Breakdown (GRI Report, 1990)

    TRIPPING

    21.88%

    CONDITION MUD

    5.19%

    REAMING

    2.50%

    DRILLING

    48.45%

    BOP

    3.40%

    WAIT TIME

    2.70%

    TESTING &

    LOGGING

    6.79%

    TROUBLE TIME

    4.00%

    RUNNING

    CASING

    5.09%

  • TT01-26 3

    Deep Drilling Concept Rankings (GRI Report, 1990)

    PDC/TSD Bits

    Slim Holes

    Roller Cone Bits

    Down Hole Motors

    Top Drives

    Coiled Tubing

    Optimized Drilling

    MWD Equipment

    Automated Rig

    High Pressure Jets

    Casing While Drilling

    Explosive Drills

    Thermal Drills

    Drilling Concept Ranking

    31.10

    30.98

    29.58

    28.20

    28.13

    27.70

    26.45

    25.48

    23.70

    21.03

    18.30

    13.70

    11.53

  • TT01-26 4

    Deep Well Drilling/Completion Problems

    Problem

    Low drilling rates

    Short bit life

    Slow trips

    High casing costs

    Motor failures

    MWD failures

    High drilling cost

    Casing wear

    Hard rock, chip hold-down

    Abrasive rock, impact loading

    Deep wells

    Multiple strings, deep wells

    High temperature

    Vibrations, high temp

    Large rig, low ROP, casing

    Long drilling time

    Cause

  • TT01-26 5

    Deep Well Drilling/Completion Problems (Cont.)

    Problem

    Mud thermal degradation

    High mud ECDs

    Poor cement bond

    Lost circulation

    Cementing liners

    Packer failures

    Corrosion

    Underbalanced Drilling

    >3500F

    Small holes, long intervals

    Poor mud displacement

    High cement density

    Sealing lap joints

    Small diameter, high temp

    High Temp, CO2, H2S

    Gas compressibility

    Cause

  • TT01-26 6

    High-Power Motor

  • TT01-26 7

    DOE High-Power Motor Design

    Stronger Bearings and Shaft

    Increased Rotor/Stator Interference

    Additional Stages

    Stronger Universal

  • TT01-26 8

    DOE Motor In Dynamometer

  • TT01-26 9

    Motor Performance Comparison

    0

    10

    20

    30

    40

    50

    60

    70

    80

    0 500 1000 1500 2000 2500 3000 3500

    Differential Pressure (psi)

    H o

    rs e

    p o

    w e

    r

    DOE

    Motor

    Conventional

    Motor

    Size: 3-3/8" Motors Rotor/Stator: 4:5 Flow: 110 gpm

  • TT01-26 10

    Laboratory Drilling Rates DOE Slim Hole System

    25

    50

    0

    10

    20

    30

    40

    50

    60

    Conventional DOE Motor

    D ri

    ll in

    g R

    a te

    ( ft

    / h

    r)

    Motor

    Carthage Marble 3 3/8” Motors 110 GPM

    4 3/4” Bit

  • TT01-26 11

    Hybrid PDC/TSP Bits

  • TT01-26 12

    DOE Hybrid TSP/PDC Bit

  • TT01-26 13

    Drilling Rates

    97

    890

    1380

    0

    200

    400

    600

    800

    1000

    1200

    1400

    Roller TSP PDC

    Leuders Limestone

    3 in. Bits 10,000 WOB 800 rpm 60 gpm

    Atmospheric

  • TT01-26 14

    Cutter Wear Volume vs. Rock Volume Removed 20 rpm, water cooled, Sierra White Granite,

    0.06 in. DOC, 0.08 in/rev feed rate

    8000

    0

    1

    2

    3

    4

    5

    6

    7

    0 2000 4000 6000 10000 Rock Volume Removed (cc)

    W ea

    r V

    o lu

    m e

    (m m

    3 )

    PDC

    TSP

  • TT01-26 15

    Catoosa Test Site

  • TT01-26 16

    DOE Motor In Derrick

  • TT01-26 17

    Attaching Hybrid Bit to DOE Motor

  • TT01-26 18

    Hybrid Bit After Drilling “The Wall”

  • TT01-26 19

    Field Drilling Rates

    23

    48

    0

    10

    20

    30

    40

    50

    60

    Conventional DOE Motor

    D ri lli

    n g R

    a te

    ( ft

    /h r)

    • 3 3/8” Motor

    • 4 3/4” Bit

    • Dolomite

    • 1600-1900 ft

  • TT01-26 20

    Comparison to Offset Wells

    2098

    946.3 1078

    0

    500

    1000

    1500

    2000

    2500

    Offset 1 Offset 2 Hybrid

    Footage Drilled/Bit

  • TT01-26 21

    High Power Geared Turbodrill

  • TT01-26 22

    Advanced Geothermal Turbodrill (AGT)

    Bearing Pack Speed Reducer Turbine

  • TT01-26 23

    Blade

    Movement

    Rotor Blading

    Stator

    Turbodrill Blade Schematic

  • TT01-26 24

    Turbodrill Blade Schematic

    Turbine Shaft

    Stator Blading

    Turbine Blading

    Housing

  • TT01-26 25

  • TT01-26 26

    Planet Gears Sun Gear

    Ring Gear

    Planetary Gears

  • TT01-26 27

    VECTOR OIL TOOL Speed Reducer Shafts and Gears

  • TT01-26 28

    7500

    900

    85

    1100

    Rotary Speed Torque

    With Gear Box

    Without Gear Box

    (RPM) (ft-lbs)

    Turbodrill Performance

  • TT01-26 29

    Turbodrill Drill Stand

  • TT01-26 30

    Drilled Rock Sample

  • TT01-26 31

    12 1/4” Carbide Roller Bit Texas Pink Granite

    42 45

    92

    0

    10

    20

    30

    40

    50

    60

    70

    80

    90

    100

    Rotary LANL AGT Turbodrill Turbodrill

    D ri lli

    n g R

    a te

    ( ft

    /h r)

  • TT01-26 32

    Advanced Geothermal Turbodrill (AGT) Field Test

  • TT01-26 33

    Christensen Bit

  • TT01-26 35

    Peak Drilling Rates

    76

    207

    0

    50

    100

    150

    200

    250

    Conventional TUBODRILL

  • TT01-26 36

    Geothermal Multi-Lateral Well

    Natural Fractures

  • TT01-26 37

    Deep Well Lightweight Mud

  • TT01-26 38

    Lightweight Mud

    LIGHT WEIGHT

    MUD MUD HOLLOW SPHERES

    5.84 ppg 8.5 ppg 3.17 ppg

    0.70 S.G. 1.02 S.G. 0.38 S.G.

  • TT01-26 39

    Glass Beads

  • TT01-26 40

    Particle Sizes in Unweighted, Water-Based Mud

    (After Bourgoyne Jr. et al, 1986)

    .01 0.1 1 10 100 1000 10,000

    SILT FINE SAND

    COARSE SAND

    GRAVEL

    2 0 0

    1 0 0

    6 0

    2 0

    MESH

    S o lid

    s P e rc

    e n ta

    g e

    MICRONS

    Bentonite Small Hollow Spheres

  • TT01-26 41

    Golden State Drilling Rig Mud System

  • TT01-26 42

    Mud Returns

  • TT01-26 43

    Lightweight Cement

  • TT01-26 44

    Foam Cement Photomicrograph

  • TT01-26 45

    Lightweight Cement

  • TT01-26 47

    Lightweight Cement Compressive Strengths

    Class H Cement

    6 8 10 12 14

    400

    800

    1200

    1600

    C o m

    p re

    ss iv

    e S

    tr e n g th

    ( p si

    )

    Slurry Density (Lb/Gal)

  • TT01-26 48

    6

    10-1

    10-0

    101

    102

    103

    7 8 9 10 11 12 13 14

    Density (Lb/Gal) *NMF = No Measurable Flow

    W a te

    r P e rm

    e a b ili

    ty (

    m d )

    2 2 0

    0 F -

    4 8 H

    o u rs

    Base: Class H Cement + 0.1% Diacel LWL, 5.2 gal water/sk; 15.6 lb/gal

    Foam: 1.5% Halliburton Foam Additive +

    0.75% Halliburton Foam Stabilizer

    Foamed and Cured at 1000 psi N2

    Lightweight Cement Water Permeabilities

  • TT01-26 49

    High Pressure CT Jet Drill

  • TT01-26 50

    High Pressure Drilling Mechanism

    Bit

    Jets PDC Cutter

    Rock Ledges

  • TT01-26 51

    10,000 psi

    High Pressure Motor

  • TT01-26 52

  • TT01-26 53

    CT High Pressure Jet Drilling Rate

    150

    300

    1600

    0

    200

    400

    600

    800

    1000

    1200

    1400

    1600

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