Deep Drilling Problems

Transcription

1 A Noble Drilling Corporation Subsidiary Deep Drilling Problems Dr. William C. Maurer DOE Deep Trek Workshop Houston, TX March 20, 2001 TT

2 TROUBLE TIME 4.00% TESTING & LOGGING 6.79% WAIT TIME 2.70% Deep Well Drilling Time Breakdown RUNNING CASING 5.09% (GRI Report, 1990) TRIPPING 21.88% BOP 3.40% CONDITION MUD 5.19% REAMING 2.50% DRILLING TT % 2

3 Deep Drilling Concept Rankings (GRI Report, 1990) Drilling Concept 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 Ranking TT

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 Cause 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 TT

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 Cause >350 0 F Small holes, long intervals Poor mud displacement High cement density Sealing lap joints Small diameter, high temp High Temp, CO 2, H 2 S Gas compressibility TT

6 High-Power Motor TT

7 DOE High-Power Motor Design Stronger Bearings and Shaft Increased Rotor/Stator Interference Stronger Universal Additional Stages TT

8 DOE Motor In Dynamometer TT

9 Horsepower Motor Performance Comparison Size: 3-3/8" Motors Rotor/Stator: 4:5 Flow: 110 gpm DOE Motor Conventional Motor Differential Pressure (psi) TT

10 Drilling Rate (ft/hr) Laboratory Drilling Rates DOE Slim Hole System Carthage Marble 3 3/8 Motors 110 GPM 4 3/4 Bit Conventional Motor DOE Motor TT

11 Hybrid PDC/TSP Bits TT

12 DOE Hybrid TSP/PDC Bit TT

13 Drilling Rates Leuders Limestone 3 in. Bits 10,000 WOB 800 rpm 60 gpm Atmospheric Roller TSP PDC TT

14 Wear Volume (mm3) Cutter Wear Volume vs. Rock Volume Removed 20 rpm, water cooled, Sierra White Granite, in. DOC, 0.08 in/rev feed rate PDC 3 2 TSP Rock Volume Removed (cc) TT

15 Catoosa Test Site TT

16 DOE Motor In Derrick TT

17 Attaching Hybrid Bit to DOE Motor TT

18 Hybrid Bit After Drilling The Wall TT

19 Drilling Rate (ft/hr) Field Drilling Rates 3 3/8 Motor 4 3/4 Bit Dolomite ft Conventional DOE Motor TT

20 Comparison to Offset Wells Footage Drilled/Bit Offset 1 Offset 2 Hybrid TT

21 High Power Geared Turbodrill TT

22 Advanced Geothermal Turbodrill (AGT) Bearing Pack Speed Reducer Turbine TT

23 Turbodrill Blade Schematic Stator Blade Movement Rotor Blading TT

24 Turbodrill Blade Schematic Turbine Shaft Stator Blading Turbine Blading Housing TT

25 TT

26 Planetary Gears Sun Gear Planet Gears Ring Gear TT

27 VECTOR OIL TOOL Speed Reducer Shafts and Gears TT

28 Turbodrill Performance With Gear Box Without Gear Box Rotary Speed (RPM) Torque (ft-lbs) TT

29 Turbodrill Drill Stand TT

30 Drilled Rock Sample TT

31 Drilling Rate (ft/hr) 12 1/4 Carbide Roller Bit Texas Pink Granite Rotary LANL AGT Turbodrill Turbodrill TT

32 Advanced Geothermal Turbodrill (AGT) Field Test TT

33 Christensen Bit TT

34 Peak Drilling Rates Conventional TUBODRILL TT

35 Geothermal Multi-Lateral Well Natural Fractures TT

36 Deep Well Lightweight Mud TT

37 Lightweight Mud MUD HOLLOW SPHERES LIGHT WEIGHT MUD 1.02 S.G S.G. 8.5 ppg 3.17 ppg 0.70 S.G ppg TT

38 Glass Beads TT

39 Solids Percentage Particle Sizes in Unweighted, Water-Based Mud (After Bourgoyne Jr. et al, 1986) MICRONS ,000 Bentonite Small Hollow Spheres MESH SILT FINE SAND COARSE SAND GRAVEL TT

40 Golden State Drilling Rig Mud System TT

41 Mud Returns TT

42 Lightweight Cement TT

43 Foam Cement Photomicrograph TT

44 Lightweight Cement TT

45 Compressive Strength (psi) 1600 Lightweight Cement Compressive Strengths Class H Cement Slurry Density (Lb/Gal) TT

46 Water Permeability (md) F - 48 Hours Lightweight Cement Water Permeabilities Base: Class H Cement + 0.1% Diacel LWL, 5.2 gal water/sk; 15.6 lb/gal Foam: 1.5% Halliburton Foam Additive % Halliburton Foam Stabilizer Foamed and Cured at 1000 psi N TT01-26 Density (Lb/Gal) *NMF = No Measurable Flow 48

47 High Pressure CT Jet Drill TT

48 High Pressure Drilling Mechanism Bit PDC Cutter Jets Rock Ledges TT

49 High Pressure Motor 10,000 psi TT

50 TT

51 Drilling Rate CT High Pressure Jet Drilling Rate Red Sandstone 3-1/8 Bit Rotary Conventional High Pressure Motor Motor TT

52 Drillpipe or Casing Drilling Cement High Pressure Jets Cement TT

53 Tubing Filled With Cement TT

54 Tubing After Drilling Cement TT

55 Cement Drilling Rates (ft/hr) Cement Drilling Rates Conventional Motor High Pressure Motor TT

56 Tubing Barite Scale Removal High Pressure Jets Barite Scale TT

57 Advanced Coring System TT

58 Advanced Coring System Mud Pulse Telemetry Real-Time Core Height Measurement Full Closure Valve TT

59 Real-Time Core Height Measurement Control Electronics Receiver Transmitter Inner Barrel Outer Barrel Core Core Bit TT

60 Mud Pulse Telemetry Safety Joint Thrust Bearing Pulser Flow Restrictors Control Electronics Receiver Inner Barrel Outer Barrel TT

61 TT

62 Mud Flow Formation Damage Mechanism Drill Pipe Formations Grains Mud Flow Annulus Mud Particles Mud Filtrate Fluid TT

63 Mud Tank TT

64 Centrifuge Test TT

65 Desilter Tests TT

66 Pulser Assembly TT

67 MWD Pressure Transducer TT

68 ACS MWD Surface Processor TT

69 Pressure Pulse Encoding Patterns for Various Core Heights 130 FSI 1 SEC CORE HEIGHT = CORE HEIGHT = 10 CORE HEIGHT = 20 CORE HEIGHT = 60 TT