Hybrid Bit Produces Breakthrough Performance and …drillingconference.montanpress.hu/dl/share/hybridbit.pdf · · 2012-06-18SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES

SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALSSPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE Szolnok, Hungary 5-6 June 2012

Hybrid Bit Produces Breakthrough Performance and Savings for Inland

Applicationpp

Author and Presenter:Maurizio Di PasqualeBaker Hughes Inc. - Drilling Bits and Hole Enlargement Optimization EngineerContinental Europe Geomarket

Co-Authors:Georges ITALIANO, Serge PECANTET, N.V. Turske PERENCOEdgardo Calvaresi, Alan Holliday, Gianluca Guerrini, Koray Gozubuyukogullari, Baker Hughes, Inc.

This paper was prepared for presentation at the SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE held in Hungary 5-6 June 2012.

This paper was selected for presentation by a SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE program committee following review of information contained in a preliminary abstract submitted by the author(s). Contents of the presentations have not been reviewed by the SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE and are subject to correction by the author(s).

AgendaAgenda

• Project Background• Project Background

• Objectives of the project

• Available Data

• Application reviewpp– 12.25” Section Objectives

– Performance Issues– Performance Issues

• Solution

• Performance summary

© 2010 Baker Hughes Incorporated. All Rights Reserved. 2

Project BackgroundProject Background

• In January 1996, the operator took over oil fields in the vicinity of Diyarbakir southeast Turkeyvicinity of Diyarbakir, southeast Turkey.

• The operator currently manages 200 wells and seven production gathering stations within a 100 km zoneproduction-gathering stations within a 100 km zone.


Project BackgroundProject Background

• Terdoken-2 is a vertical well located at the Hazro North field near Terdoken and north-east of Diyarbakir.

• Wireline data unvailability of for performing an effective Rock Strength analysis.

• 20-30 days historically to complete the 12 ¼” section– Acceptable performance with TCI bits.

P f ith PDC bit– Poor performance with PDC bits.• Potential drilling time reduction thru a customized bit

solutionsolution.• Conducted a pre-well study focused on the target section.


Project BackgroundTarget section overview


Project Background Offset Data

Kayakoy West - 33BIT NUMBER 3 4 4RR 5 6 6RR 6RR 3RR 8

12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4DIAMETER 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4MFG Comp 1 Baker Baker Baker Baker Baker Baker Comp 1 BakerTYPE 8 bladed 13mm GX18 GX18 GX18 GX18 GX18 GX18 8 bladed 13mm GX18IADC CODE 447 447 447 447 447 447 447SERIAL NUMBER - 5179054 5179054 5179062 5179052 5179052 5179052 - 5179326NOZZLES (1/32¨) 8x14 2x18 1x16 2x18 1x16 2x18 1x16 2x18 1x16 3x16 3x16 6x14+2x12 3x16NOZZLES (1/32 ) 8x14 2x18, 1x16 2x18, 1x16 2x18, 1x16 2x18, 1x16 3x16 3x16 6x14+2x12 3x16DEPTH IN (ft) 1667 1893 2384 3104 3704 4128 4443 4909 4950DEPTH OUT (ft) 1893 2384 3104 4411 4128 4443 4909 4950 5789TOTAL DRILLED (ft) 226 491 720 1307 424 315 466 41 839DRILL. TIME (Hrs) 33.5 37.5 62 84.25 59.25 30.5 47.75 10.5 114ROP (ft/Hr) 6 7 13 1 11 6 15 5 7 2 10 3 9 8 3 9 7 4ROP (ft/Hr) 6.7 13.1 11.6 15.5 7.2 10.3 9.8 3.9 7.4DRIVING MODE Motor Motor Motor Motor Motor Rotary Rotary Motor Rotary

WOB (klb) 15 - 25 25 - 40 25 - 40 20 - 35 20-40 25 - 35 35 - 45 45 - 55 40 - 45RPM 84 - 114 84 - 140 98 - 140 150 96 90 90 - 100 150 110 - 130FLOW RATE (lpm) 2000 - 2200 2000 - 2400 2300 - 2400 2400 2300 2200 2400 2200 2400 - 2500FLOW RATE (lpm) 2000 2200 2000 2400 2300 2400 2400 2300 2200 2400 2200 2400 2500PRES. (psi) 950 - 1150 1050 - 1250 1200 - 1600 2000 - 2500 1900 - 2600 2650 3100 3000 3200FORMATION Gercus Evaporites

Gercus /Kayakoy Kayakoy Evaporites

Kayakoy Evaporites / Kastel Marl Kastel Marl Kastel Marl Kastel Marl Kastel Marl

Kastel Marl /Kastel limy (40ft)

DULL GRADING 1-2-WT-A-X-I-BT-BHA 1-1-WT-A-E-I--NO-BHA 3-8-BT-G/M-E-I-WT-PR LIH 1-1-WT-A-E-I-NO-PR 1-1-WT-A-E-I-NO-PR 1-1-WT-A-E-I-NO-HR 1-2-BT-G-X-I-WT-PR8-8-BT/CC-A-F-N-LT-PN-

TD

- N’7 TCI IADC 447 bit runs (4 bits); N’2 PDC 8 bladed, 13mm bit runs (1 bit)- One LIH (bit#5)- Low average ROP (9 5 ft/hr – 2 89 m/hr)Low average ROP (9.5 ft/hr 2.89 m/hr)- Total 4090ft (1246m) in 389.5 hrs with over 20% NPT (cleaning and DHM

capability)© 2010 Baker Hughes Incorporated. All Rights Reserved. 6

Project BackgroundSummary

Well PlanWell Plan• Vertical Section from (1400m – 2686m)• Motor BHA

Challenges• No offset information for the top part of the sectionNo offset information for the top part of the section

(Kayakoy – Karadut formations)• High bit consumption in Karadut and Kastel formationsg p• Unstable shales

ObjectivesObjectives• Maximize the ROP while reducing the number of bits• Borehole quality for a safe 9 7/8” casing run


Borehole quality for a safe 9 7/8 casing run• Reduce NPT and risk of LIH

Time&Cost Analysis for the offset wellTime&Cost Analysis for the offset well

F HFUSD

oot

our

FootD

age

sage


- 116 KUSD average cost for 12.25” bit run- 53h average drilling time for 12.25” bit run

*rig cost / hr 1670 USD

Risk HazardsRisk Hazards

Hazard/ Event Probability(Frequency)

Impact(e g Cost)

Risk(PxI)

Root Causeof event12 ¼” phase (Frequency) (e.g. Cost) (PxI) of event

Low ROP3

[5/9 bit runs]3: ILT 9 Hard formation, bit selection, weight

transfer

Many bits to drill the vertical section (> 5 bits)

3 3: extra trips, bit cost 9 PR, HRs, PP, DTF, BHA unable to deliver DLS

Pull bit early (with low wear)

3[5/9 bit runs]

3: trips 9 DTF, unable to achieve DLS, change BHA, PR

3 3: NPT, sidetrack 9 -Stuck pipe [6/9 bit runs]

Reaming (more than reasonably expected)

2[5/9 bit runs]

3: NPT, damage hole 6 -

reasonably expected) [ ]

Hole quality (weight transfer, stuck pipe)

2[3/9 bit runs]

3: ILT as low ROP, vibrations, poor logs

6 -


Poor Directional Control (w/ PDC bits)

2 [2/9 bit runs]

3: ILT for correction run 6 DTF, bit selection, weight transfer

Risk Hazards - continuedRisk Hazards continuedHazard/ Event 12 ¼” phase

Probability(Frequency)

Impact(e.g. Cost)

Risk(PxI)

Root Causeof event

JUSTIFICATIONS

Bit damage1

[2/9 bit runs]3: low ROP 3 Interbedded in formation /

vibrations, chert, sliding on motor

Losses1

[1/9 bit runs]2: NPT, cement costs 2 Flowrate, mud weight, formation

Motor Failure1

[1/9 bit runs]1: NPT, extra trip 1 Mud System, Bit Damage,

Vibrations[ ]

Vibrations ? ? ? ?

PROBABILITYPROBABILITY1 2 3

LevelOne run / Seldom

<= Half run/ Sometimes

Every run / Every Time or

Often

MPA

CT

Often

3 1 0 4

2 1 3 0


IM 2 1 3 0

1 1 1 0

Develop SolutionHybrid technology

• A bit that combines RC and FC elements

- Designed to take advantage of the best attributes of both bit types.

- The fast aggressive drilling action of the PDC and the smooth low torque action of the TCI.

• Problem areas between standard PDC and TCI applications

– Interbedded formations– Nodular formations– Directional applications

Stick slip problems– Stick-slip problems– Poor hydraulics

© 2011 Baker Hughes Incorporated. All Rights Reserved.11

SolutionThe 12 25” KG533FXThe 12.25 KG533FX

© 2011 Baker Hughes Incorporated. All Rights Reserved.12

Action PlanPre-run and During the run

Pre-RunId tif d i i d k i t i th li tiIdentify decision and key points in the application• Identify key formations: Karadut and Kastel Marl• To decide if the bit stays in the hole or if it is time to pull it• BHA and Hydraulics• BHA and Hydraulics• In bit sensing module installation• Run Guidelines shared with the operator

During the runWork for tuning the drilling parameters• Start like a PDC bit• Start like a PDC bit

WOB• Requires more than a PDC, but less than a TCI• Start with ½ that typically required for TCIStart with ½ that typically required for TCIRPM• Should not need as much as a PDC to overcome any stick/slip issues


y p• Lower RPM should lead to more hours because of reduced Krevs

Action PlanPre – run Phase

Identify decision and key points in the

33.3 50.1 66.7 100.0 133.3 176.7500 751 1000 1500 2000 2650Footage Drilled

Bit Hours*key points in the application

• Key formations

500 751 1000 1500 2000 2650180000 270360 360000 540000 720000 954000240000 360480 480000 720000 960000 1272000

Footage DrilledKREVS (@90RPM)KREVS (@120RPM)

LOW Risk• Key formations• Decide if the bit stays in the hole or if it is time to pull it

MEDIUM Risk (POOH)HIGH Risk (Authorization required)LIH risk (NOT RECOMMENDED)

it is time to pull it• BHALow speed motorHydraulics• Hydraulics0.451in2 + 0.3312 (3 x 10/32”)Alt ti /B k• Alternative/Backup

417-447 TCI bits• Multisense I t ll d


Installed

ImplementationRun before Kymera - #11, #12 and #13 – 1357m – 1885m

Bit Run #

Type ROP[m/hr]

Footage[m]

BHAType

Formation Reason Pull# [m/hr] [m] Type

11 HCCIADC 417

3.81 523 MSMotor

Shale, Gravel and Dolomite

(Kayakoy)PR

(7 7 BT)IADC 417 (Kayakoy) (7-7-BT)

12 HCCIADC 447

5.28 219 MSMotor

Shale, Gravel and Dolomite

ith Ch tPR

(5 7 BT)IADC 447 with Cherts(Kayakoy)

(5-7-BT)

13 C 13.25 78 MS

M tMarl, Shale,

D l it d DTF13 Comp-1IADC 517

Motor Dolomite and Limestone(Kayakoy-Karadut)

DTF(1-1-WT)

• Inconsistent overall 12 ¼” performance with on MS Motor BHA• High Bit Consumption

Karadut)


• High Bit Consumption• Poor Verticality control

Implementation

• Motor BHA

Run with the Kymera - bit#14 IN @ 1885m

Motor BHA Normal speed motor with AKO 0.8deg VS. straight Low Speed

• Well profile correction from 8deg to 2.8deg • Issues in keeping the well verticaly for highly interbedded formation• Run average ROP 9 m/hr until the mud pumps failure at around 2100m –caused 10h NPTcaused 10h NPT• ROP below 3 m/hr while changing formation over last 20m (shale/marl vs. limestone & shale w/ chert)

Drilled 328m in 78.5 total hoursBit Run # Type ROP

[m/hr]Footage

[m]BHAType

Formation Reason Pull[m/hr] [m] Type

14 HP533X 4.2 328 NSMotor

Limestone, Marl, Shale, Chertsand Calcite

HR


Motor and Calcite (Karadut /

Kastel)

Post Well Analysisf S SPerformance Summary – 12.25” Section

The problem High bit consumption (8 bladed 13 mm PDC & 447 TCI) Poor & scattered offset performances in highly p g yinterbedded formation (Arg. Limestone, Shale, Limestone and Marlstone with radiolarites and micro-nodules chert)

The challenge To Reduce number of bits/trips and increase overall ROP

The solution 12 ¼-in HP533PX Hybrid bit - 3 bladed 16/13mm Quantec™ Cutters& Vanguard ™ HR seal Tricone bearing and Multisense Module

Kayakoy Red Beds and Topand Top Karadut

© 2011 Baker Hughes Incorporated. All Rights Reserved.

Post Well Analysisf S ( # )Performance Summary – 12.25” Hybrid (Bit Run#13)

Vibration Type

Minor<2

Moderate2 5

Severe> 5Type

(RMS severity)

<2(hrs)

2-5(hrs)

> 5(hrs)

RADIAL 199.5 4.4 0TANGENTIAL 199.7 4.2 0LATERAL 191.1 12.83 0AXIAL 203.9 0 0

- Stick Slip levels relevant at beginning of the run

- Mud pumps problems lead to inefficient hydraulics and borehole cleaning

- “Excellent toolface control” – Motoroperators

- “Longest run ever for the reservoir


o ges u e e o e ese ocap section” – operator Co.Man

Post Well Analysisf S ( # )

Operator & Location Perenco TERDOKEN 2 well South East Turkey (Iraq border)

Performance Summary – 12.25” Hybrid (Bit Run#13)

South East Turkey (Iraq border)

Era & Formation Devonian - Karadut (Marly /Shaly DL, chert nodules) & Kastel (MS)

Mud & Hydraulics 1.24sg WBM Polymer; 3x24 + 3x16

A li ti & BHA P f D illi PDMApplication & BHA Performance Drilling PDM with frequent sliding to address severe formation dip and correcting the borehole to the verticality

Run Summary 328 meters drilled @ 4.2 m/hOver 800 Krevs

R lt R l d l t fi bitResults Replaced almost five bit runsROP almost 2 times faster than the offset bit run. Drilled 100% more than offsetC i t t ROP th h


Consistent ROP through interbedded Formations

Case History Baker Hughes #33822

Post Well Analysisf S C # ( )Performance Summary – 12.25” IADC 417, Bit Run #14 (next to Hybrid)

RUN N. 14MFG BHITYPE GX03

IADC CODE 417DEPTH OUT (m) 2259

TOTAL DRILLED (m) 46( )DRILL. TIME (Hrs) 27

ROP (m/Hr) 1.70DRIVING MODE PDM

WOB (klb) 25 - 30( )RPM 90 -95

FLOW RATE (lpm) 2500PRES. (psi) 3000

DULL CONDITION 8-8-BT-A-F-JD/LT-PRDULL CONDITION 8 8 BT A F JD/LT PR

- Bearing failure and loose coneloose cone

- 1/3 lost teeth- Marl and Shale with

t f Ch t


traces of Chert

Post Well Analysis& CTime & Cost Analysis

L t / f th ti


- Lowest c/m for the section- Replaced n’4 TCI bits runs

Summaryy

Replaced almost five 12.25” TCI bit runs

ROP two times faster than offsetROP two times faster than offset

Drilled 100% more than offset

Consistent ROP through interbedded Formations

Overall 12.25” section performance improvementOverall 12.25 section performance improvement

Step change for the 12.25” Section

Optimization process and follow up well done


SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALSSPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE Szolnok, Hungary 5-6 June 2012

Hybrid Bit Produces Breakthrough Performance and Savings for Inland

Applicationpp

Author and Presenter:Maurizio Di PasqualeBaker Hughes Inc. - Drilling Bits and Hole Enlargement Optimization EngineerContinental Europe Geomarket

Co-Authors:Georges ITALIANO, Serge PECANTET, N.V. Turske PERENCOEdgardo Calvaresi, Alan Holliday, Gianluca Guerrini, Koray Gozubuyukogullari, Baker Hughes, Inc.

This paper was prepared for presentation at the SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE held in Hungary 5-6 June 2012.

This paper was selected for presentation by a SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE program committee following review of information contained in a preliminary abstract submitted by the author(s). Contents of the presentations have not been reviewed by the SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES MATERIALS AND EQUIPMENTS CONFERENCE and are subject to correction by the author(s).

Documents

Hybrid Bit Produces Breakthrough Performance and …drillingconference.montanpress.hu/dl/share/hybridbit.pdf · · 2012-06-18SPECIAL DRILLING, WELL COMPLETION, WORKOVER TECHNOLOGIES