HPHT Solutions Drilling and Evaluation

8/9/2019 HPHT Solutions Drilling and Evaluation

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HPHT Solutions

Baker Hughes - Drilling and Evaluation

Christian Liss Wireline HPHT Segment ManagerDominic Dieseru Wireline Applications and Product Line Manager

Stephen Rounce Wireline Customer Service Manager

Ian Mansfield Marketing Director Reservoir Evaluation

HPHT Wells Summit 2011 - London, November 16th 2011

Baker Hughes D&E HPHT Solutions

HPHT Case History

Research and Development Outlook

2011 Baker Hughes Incorporated. All Rights Reserved.


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HPHT

Frontier Markets

HPHT drilling & exploration is critical to access

Onshore Shale, long horizontals

Offshore Deep Water, Ultra deep water

Geothermal applications

Cost of developing these wells is high

Reliability of service & equipment critical!

Performance Through Technology

Target extreme service requirementsApply robust design - modeling & validation

Drive reliability - testing & qualification

Deliver research innovations in Metals,

Sensors, Electronics, Elastomers

2009 Baker Hughes Incorporated. All Rights Reserved.2


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Gulf of Mexico Expertise in Ultra-deep Gas

Case History

Year Operator Well nameTVD[ft]

LocationFluids

Bits

Reame

rs

DD

MWD

FES

Liner

Hange

r

Wirelin

e

Loggin

g

Cement

2003 Shell Shark 25,745 Sout Timbalier BHI BHI BHI BHI

2005 Chevron Cadilac 24,795 Viosca Knoll BHI BHI BHI BHI

2005 Shell Joseph 25,537 High Island 10 BHI BHI BHI BHI

2006 ExxonMobil Blackbeard 30,067 South Timbalier BHI BHI BHI BHI BHI

2008 McMoRan Blackbeard RE 32,997 South Timbalier BHI BHI BHI BHI

2009 BP Will K 28,404 High Island BHI BHI BHI BHI BHI

2009 McMoRan Ammazzo 25,488 South Marsh Island BHI BHI BHI BHI BHI

2009 McMoRan Davy Jones 29,300 South Marsh Island BHI BHI BHI BHI BHI BHI

2010 Armstrong O&G BP Fee 15,800* Cameron Parish BHI BHI BHI BHI BHI

2010 McMoRan Blackbeard East 32,000* South Timbalier BHI BHI BHI BHI BHI BHI BHI BHI BHI

2011 McMoRanDavy Jones

Offset30,700* South Marsh Island BHI BHI BHI BHI BHI BHI BHI BHI BHI

2011 McMoRan Lafitte Project 23,000* Eugine Island BHI BHI BHI BHI BHI BHI BHI BHI BHI


* ongoing at the creation time of the slide


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Drilling Services

HPHT Challenges & Solutions



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Circulating vs. Static Temperature

During drilling

Bottom hole = circulating =operating

Typical decrease: 5-50C Parameters

Mud coolers

Hole size

Depth

Orientation

Flow rate

Drill string rotation

Cooler Deeper



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0 25 50 75 100 125 150 175 200

Temperature [C]

Borehole Temperature Rating

OnTrak

AutoTrak

LithoTrak

TesTrak

ZoneTrak G/R

StarTrak

SeismicTrak

SoundTrak

MagTrak

X-treme Motors

HPHT Drilling Services Available


0 5 10 15 20 25 30 35

Pressure [kpsi]


OnTrak

AutoTrak

LithoTrak

TesTrak

ZoneTrak G/R

StarTrak

SeismicTrak

SoundTrak

MagTrak

X-treme Motors


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HPHT by Design - Development



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Minimizing Operating Days in High-Temperature Drilling in

Haynesville Shale Case History

Well Data USA, Louisiana, Bossier Parish, 2009

Hole Size: 6-in. Well Type: Horizontal Formation: Haynesville Shale Planned Dogleg: 9/100 ft

Mud Type: 15 ppg OBM

Objectives Zero HS&E incidents Identify zone of interest

Minimize operating days while drilling in HT environment

reaching 343F (172C)

Solution Service personnel trained in HT operations

High-temperature operating procedures

High-temperature MWD service

Results

Zero HS&E incidents Identified and successfully placed well into zone of interest Completed drilling in 18 days

Drilled 6-in. curve (1,064 ft) with net ROP of 11 ft/hr Drilled 6-in. lateral (4,435 ft) with net ROP of 39 ft/hr


Days vs. Depth

11500

12000

12500

13000

13500

14000

14500

15000

15500

16000

16500

17000

17500

18000

0 5 10 15 20

DAYS ON JOB

MEASUREDDEPTH(ft

6 3/4" Cur ve

6 3/4" Late ral


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Low sensitivity to hole sizes, formation

temperature and pore water salinity

Small effect on measurement around salt

No false indication of pore pressure

sometimes seen with resistivity around salt

because of changes in formation salinity Correlation with seismic surveys

Characterization of rock mechanical

properties for wellbore stability and

completion analysis

Calibrate seismic velocities for look aheadpredictions

SoundTrak Acoustic for PPP applicationCase History

Determining accurate subsalt pore pressure in real t ime

9 2010 Baker Hughes Incorporated. All Rights Reserved.

Measuredpressures

Acoustic porepressure

ModeledFracturegradients


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500m200ms

2011 Baker Hughes Incorporated. All Rights Reserved.

SeismicTrak Service adds value to PPP

Seismic data from surface Not affected by near wellbore

damage or effects

Real time updates oftime-depth profile

Reduces uncertainties insurface seismic

Place bit on surface seismic

Look below the bit for

pressure ramp detection

Estimate distance to over-pressured zone to predict and

mitigate pressure kicks

Reduce drilling hazards and NPT


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Drilling Fluids



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Keys To Success

Experience Have serviced more than 200wells >400F

Dominate provider to the extreme HPHT segment

Capturing Lessons Learned & incorporating into CPI

Have extensive list of Lessons Learned/Best Practices

HPHT Laboratory capability, to include Specialized Equipment

Have 3 strategically positioned Global labs with capability

Houston, Aberdeen & Kuala Lumpur


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Keys To Success

Invert Emulsion Fluid for extreme conditions MAGMA-TEQ has proven track record

System is stable at BHT +600F (316C).

Aqueous Fluid (Primary or Contingency)

PYRO-DRILL also a proven track record

System is stable to 550F (288C).

Sophisticated modeling capability

Temperature - Presmod Hydraulics ADVANTAGE Engineering

Bridging BRIDGE-WISE

Down hole stresses BORE-WISE


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Drilling of 4 uHPHT wells from a Heavy Duty Jack Up with

Magma-Teq System Case History

Drilling Fluids Specification Process

Well conditions were a step change awayfrom clients conventional North Sea wells.

Mud was required to be stable at up to428F and 18.5 ppg

BHDF selected with Magma-Teqsystem toprovide HPHT fluids for UK and Norway

A multinational drilling fluids developmentteam was created to further refine the

design of the drilling fluids for the uHPHTwells campaign:

Problem identification,

Laboratory programs per well and

Chemical selection to optimize reuse.

System Performance in the Field

Bottom hole static temperatures were seenup to 395F

Circulating temperatures were between275F and 376F

BHP about 17,500 psi

The system was stable under the

conditions encountered in the wells

The rheology was stable and controllable

over long periods of time and despiteextended fishing/pipe recovery operations

No significant fluctuations in fluid density

after prolonged static periods

No dynamic sag despite relatively lowcirculation rates



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Drilling of 4 uHPHT wells from a Heavy Duty Jack Up with

Magma-Teq System Case History

Optimization of Fluid cost and inventory Objective: Utilizefluid on more than one well

2,653 bbls from first well used for second well

2,162 bbls from second well used for third well

1,100 bbls added as possibility of losses occurred

3000 bbls returned from third well to be reused

Summary

Mud system was stable under conditions in all

three wells

Negligible NPT caused by mud system

Rheology was stable and controllable despite

extended section times No significant fluctuations in fluid density after

prolonged static periods

No dynamic sag despite relatively low circ. rates

Successful system on all three wells allowed

optimization of cost and volume control


The Magma-Teq System

A high temp. invert emulsion mudweighted with a mixture of Barite and

Micromax

Micromax is Manganese Tetraoxide

with very fine particle size d50 < 1

Base oil initially Escaid 120, latterlyEDC99DW

Robust Emulsifier package

Specialized HPHT fluid loss additives

Premium Organophilic clay


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KTB project - Ultra Deep HTScientific drilling project in Germany.

Performed laboratory evaluations

and presented Fluids

recommendations to KTB.

Assisted at location with the

conversion of an existing majorcompetitorsdrilling fluid at 23,623

(7200m) to a PYRO-DRILL

geothermal drilling fluid (referred to

as the KTB-HT system).

Provided technical assistance and

support for remainder of theoperation.

Total depth of the hole was 29,860

(9101m) with a BHT of 482oF (250C)

and 12.5 ppg MW

PYRO-DRILL

Advantages

Far lower gas solubility - immediate and

apparent influx detection

Losses easier to manage

Superior HS&E - rig pit room/shakers areas

Environmentally more benign

Simpler waste management

Lower ESD and ECD, less tendency to

generate fracturing Much higher specific heat

Low compressibility - PVT non-issue

Simpler logistics, can be made up on site

Lower solids volume in fluid - higher base fluid

densities

Multiple make-up brine options

Disadvantages (versus oil mud)

Treatment of high concentrations of CO2 & H2S

Potential for formation stability issues

Potential for rheological instability

(contamination)


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Wireline Services



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Nautilus Ultra (HPHT)

Rugged construction Durability at extreme

temperatures lowers NPT

Superior sensors provide

accurate data to aid reserveestimation

Unique provider of HT cross-

dipole logging services


Nautilus UltraTM Open Hole 500F and 30kpsi

FormationEvaluation

Cross-Dipole (XMAC-F1)

Induction Resistivity (HDIL)

Porosity (CN)

Density (CDL)

Natural Gamma Ray (GR/SL)

Borehole Geomety (XZ-Cal)

Nautilus UltraTM Cased Hole 500F and 35kps i

Formation

Evaluation

RPM Servicepulsed neutron

Formation evaluation in casedholes

Production logging and water

velocity determinationMineralogy behind casing


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HPHT Wireline Services Available


0 100 200 300 400 500 600

Temperature [F]


Cross Dipole

Acoustic Imaging

Formation Coring

Formation Testing/Sampling

Production Logging

Cement Evaluation

Pipe Recovery

Resistivity Imaging

Cased Hole FE

Open Hole FE

0 5 10 15 20 25 30 35

Pressure [kpsi]


Cross Dipole

Acoustic Imaging

Formation Coring

Formation Testing/Sampling

Production Logging

Cement Evaluation

Pipe Recovery

Resistivity Imaging

Cased Hole FE

Open Hole FE


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HPHT Solutions: Deployment Risk Reduction



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World Wide HPHT FieldsAbove 150C BHT and 690bar surface pressure


Nautilus Ultra Job History

#Jobs above 350F 100+

Max. BHT: 474F

Max. BHP: 29,000 psi

Max in-hole time: 50+ Hours

Nautilus Ultra

5 Year Job History Cooper Basin243 DegC, 843 Bar

Devon

233 DegC, 1447 Bar

Cadillac

222 DegC, 1591 Bar

Oregon

246 DegC


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HPHT Pressure Testing and Fluid Sampling

Objectives1. Accurate formation pressures

2. Representative formation samples

3. Safe and efficient operation

Challenges

High Temperature up to 388F

High Tension well depth of 5000m

Highly Depleted pressure overbalance up to 8000 psi



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HPHT Pressure Testing and Fluid Sampling

SolutionDRM (Deployment Risk Management)

recommendations

High strength HPHT cable crush resistant HPHT wireline

Derrick installed Capstan Friction Reducing Stand-offs

Flywheels

Ultra slim profile standoffs



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Geothermal Well, Australia Case History

Solution

Nautilus Ultra Logging Suite w/ XMAC F1

Results

Successful Wireline conveyed run

Fractures interpreted from

Cross-Dipole analysis

Objectives Locate fractures within the wellbore

Safe Operation

Challenges

BHT ~ 470F (243

C)

TD ~ 16,000 ft


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Research & Development



28/41

Component Reliability: Exponential Decline

Current specifications: 150C

Arrhenius equation (reaction rate): 10C = 50% component life


Svante Arrhenius


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Electronics: Its easier to go to the moon.

Operating Temperature Specification Inspections Tests

-25C 70CIndustrialIPC-A-610: Class 1/2

Sample probeSub Assy @ Room Temp

-40C 125CMilitary &

Space

Sub Assy @ High Temp

Final Test @ Room Temp

IPC-A-610: Class 3

Sample probe

-20C 175C+Oil & GasSub Assy @ High Temp

Final Test @ Room Temp

IPC-A-610: Class 3

each solder

-20C 70CConsumer Assembled Parts Final Test @ Room Temp



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Design for Reliability: Analyze, Test, Validate


Model

Lab

Field

Analyze

Mission profiling (thermal & mechanical stresses)

Component selection

Process optimization

Test

Lab qualifications Component

Board

System

Validate

Root cause analysis

Optimization

Field performance

Test &Qualify

Validate &Improve

Analyze,Design& Model


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Validation, Testing & Qualification

Electronics Design

Innovation

Model Testing &

Verification

Drilling Simulator &

Drilling Dynamics

Simulation

Model Testing &

Verification

Field Testing &

Systems Integration

Testing

Celle TechnologyCenter

WoodlandsTechnology Center

Houston TechnologyCenter

Beta Test RigOklahoma


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Beyond 175C: Enabling Technologies

Packaging & components Bare dies vs. plastic packaged components

Bonded vs. soldered connections

Active cooling

Memory, DSPs, etc.

Sensors

Materials

Corrosion

Sealing


&=


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Extending Survivability - Packaging

Viscoelastic pad

Composite Clam-Shell Bottom

Composite Clam-Shell Top

Component Cavity

Wireline

Today

Passive thermal cooling

Thermal insulation & flasking

Tomorrow More Hybrids & More active cooling

LWD

Today

Vibration damping

Passive thermal cooling

Tomorrow

More Hybrids & More active cooling

Passive Circuit Cooling


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Technology Investment Infrastructure

Over $20M in infrastructure investment in HPHT Electronics design, testing and qualifications;

Data Acquisition, Mfg Automation

IC failure analysis; X-Ray, Ultrasonic, elemental analysis, Thermal imaging diagnostics

Simultaneous Ovens & Shaker Tables,

Test chambers, Pressure Pits (375C, 40K)

New Sensor (HT) Development Lab, Houston

Finish Fall 2011

Hybrid Electronics Lab, Germany

Finished 2009


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People


Celle, Germany

Houston, TexasHouston, Texas

Houston, Texas


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Information Technology: Transforming Operations



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Summary



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BHI High Temperature R&D Capabilities

People 100+ engineers on 40+ HT projects

Center of Excellence & HT Materials Department

Leading consultants, Universities, Government labs

Solutions & Practices

30 years experience in flask design, fabrication, testing

Real Time Temp. monitoring of critical components.

Well developed HALT & HASS testing programs

Specific standards, processes and component database

Facilities

Specialized HT labson Hybrids, Cooling, Fluids, Acoustic,

NMR, Resistivity, Nuclear, Optics. Testing up to 700F, 40ksi. 100+ HT ovens

IC analysis, X-Ray, Ultrasonic, Elemental, Thermal imaging.

Suppliers and Partners

Industry w ide HT contacts and partnerships on advanced

components, IC, DSP, Sensor, PCB and proprietary soldering.



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Solutions on the Market

for all aspects of D&E

Drill Bits,

Directional Services,

MWD/LWD Services,

Drilling Fluids Open Hole Wireline Services

Cased Hole Wireline Services

Solutions include

Deployment Risk Reduction

Planning, Simulation and Testing

Proven Processes, Procedures and Talent


Evolving the Portfolio

Additional Services and

Technology

Fit for Purpose HT-Systems for

extreme service specifications

Design for Reliability Focusin Design, Modeling,

Testing & Qualification

Deliver Research

Innovations in Materials,

Sensors, Electronics,

Nano-Structures andManufacturing


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Comments/Questions

HPHT Solutions Drilling and Evaluation

Documents