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
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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
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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
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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)
Ho
rse
po
we
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
Dri
llin
g R
ate
(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)
Wea
r V
olu
me
(mm
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
Drilli
ng R
ate
(ft
/hr)
• 3 3/8” Motor
• 4 3/4” Bit
• Dolomite
• 1600-1900 ft
TT01-26 20
Comparison to Offset Wells
2098
946.31078
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
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VECTOR OIL TOOL Speed Reducer Shafts and Gears
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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 AGTTurbodrill Turbodrill
Drilli
ng R
ate
(ft
/hr)
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
200
100
60
20
MESH
Solid
s Perc
enta
ge
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
Com
pre
ssiv
e S
trength
(psi
)
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
Wate
r Perm
eabili
ty (
md)
220
0F -
48 H
ours
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
1800
Rotary Conventional High Pressure
Dri
llin
g R
ate
Motor Motor
Red Sandstone 3-1/8” Bit
TT01-26 56 C
em
en
t
Drillpipe or Casing
High Pressure Jets
Drilling Cement
TT01-26 57
Tubing Filled With Cement
TT01-26 58
Tubing After Drilling Cement
TT01-26 59
Cement Drilling Rates
60
1200
0
200
400
600
800
1000
1200
1400
Conventional High Pressure
Ce
me
nt
Dri
llin
g R
ate
s (
ft/h
r)
Motor Motor
TT01-26 60
Barite Scale
High Pressure Jets
Tubing Barite Scale Removal
TT01-26 62
Advanced Coring System
TT01-26 63
Advanced Coring System
Mud Pulse Telemetry
Real-Time Core Height Measurement
Full Closure Valve
TT01-26 64
Real-Time Core Height Measurement
Control Electronics
Receiver
Transmitter
Inner Barrel
Core
Core Bit
Outer Barrel
TT01-26 65
Mud Pulse Telemetry
Safety Joint
Thrust Bearing
Pulser
Flow Restrictors
Control Electronics
Receiver
Inner Barrel
Outer Barrel
TT01-26 66
TT01-26 67
Formations Grains
Mud Particles
Mud Filtrate
Mu
d F
low
Mu
d F
low
A
nn
ulu
s
Dri
ll P
ipe
Fluid
Formation Damage Mechanism
TT01-26 69
Mud Tank
TT01-26 70
Centrifuge Test
TT01-26 71
Desilter Tests
TT01-26 72
Pulser Assembly
TT01-26 73
MWD Pressure TransducerMWD Pressure Transducer
TT01-26 74
ACS MWD Surface Processor
TT01-26 75
Pressure Pulse Encoding Patterns for Various Core Heights
1 SEC
2’ 2’ 2’ 2’ 2’ 2’
CORE HEIGHT = 5’
CORE HEIGHT = 10’
CORE HEIGHT = 20’
CORE HEIGHT = 60’
130 FSI
2’