Neyrfor Turbodrills

Putting Putting

thethe

PowerPower

to to Work.Work.

AN INTRODUCTION TO TURBODRILLS

Brief Turbodrill History & Background

•First applied to Drilling in USSR in 1924

•First licensed in the West in 1956 (Neyrpic)

•Turbodrills built by Neyrfor, Preussag, Dresser, Christensen, and others………..but Neyrfor dominate market

•Neyrfor introduce first Oilfield Steerable Drilling System in 1982

•Weir (Scottish Engineering Company) buy Neyrfor in 1991

•Smith International buy Neyrfor in 2002

Downhole Motor Basic Principles

SOME SIMPLE PHYSICS & FACTS THAT APPLY TO ALL HYDRAULIC MOTORS (i.e. PDM’s & TURBODRILLS)

•Hydraulic Motors transform hydraulic energy into mechanical energy

•You DON’T get more power out than you put in!

•Power out is generally around 55 – 65 % of power in

•Efficiency, and maintaining efficiency is main factor in delivering performance

•Improving Efficiency by design and material science is the key to improving Performance & Reliability

Downhole Motor Basic Principles

•Mechanical Horsepower = (Speed x Torque) / 5252

•Hydraulic Horsepower = (Pressure Drop x Flow) / 1714

•Motor Horsepower = Hydraulic Horsepower x Efficiency

HORSEPOWER CALCULATION FOR ANY DOWNHOLE MOTOR

(IMPERIAL UNITS)

Turbodrill / PDM Comparison

What’s the difference?

6-3/4” M2PXL (2:3 Lobe)

BHI Quoted Figures

@ 530 gpm with 1160 psi differential pressure

With a 60% efficiency gives a max of 215 HP output

In reality differential pressure more likely to be around 400 – 600 psi (usually less when sliding)

So with a 60% efficiency and 600 psi differential pressure the max HP output = 111

NB. Efficiency with PDM’s deteriorates rapidly with operating hours


Sii Neyrfor 6-5/8” FBS T1 MKII Turbodrill

@ 530 gpm will give 1676 psi (with 10ppg mud)

With a 55% efficiency gives a max of 285 HP output

So 30% + more power than PDM assuming a PDM differential pressure of 1160 psi

If actual PDM differential is only 600 psi (i.e.more like reality)……..then the Turbodrill offers 150% + more Horsepower!!

NB. Efficiency with Turbodrills deteriorates very slowly, typically having only very slight reduction even after several hundred hours


Moving Air

Very Basic Aero Foil Theory

Turbodrill Basic Characteristics

LIFT (i.e. “Power”) is created by Differential Pressure

Higher Pressure beneath the wing & Lower Pressure above

HYDRAULIC POWER IN

Axial Thrust

Rotation

TorqueRotation

FIXED

BLADES

(i.e.Flow x Pressure)


FIXED

BLADES

MOVING

BLADES

0

0.25

0.5

0.75

1

0 0.5 1

Speed

To

rqu

e /

Po

wer

Power

Torque

Nominal Speed Runaway SpeedStall


Torque / Speed / Power Relationship

Standard Turbodrill Components

Conventional T3 (3 Motor Section) Turbodrill

Overall length could be 70+ ft (dependent on tool size i.e. OD)

Downward

Thrust

Mud

Flow

Rotor Blading

Disk

Stator Blading

DiskStator

Blading Disk

Rotor Blading

Disk

Assembly makes up

One Motor Stage

Motor Section

Turbine Body

Turbine Shaft

Turbine Blading Disc Arrangement


Turbine Body

Moving Disc

Fixed Disc

Moving Disc

Spacer Front Bearing

Labyrinth

Thrust Bearing

Flexible Shaft

Bent Housing

Front Bearing Stabiliser

Bit Box Stabiliser

Turbine Elastomer Axial Bearing Arrangement


Turbodrill Design Remit (1990’s)

Reduce Overall Tool length Closer to MWD / LWD Tools

Improve Efficiency Higher Power Output & Reliability

Incorporate Bent Housing Apply benefits to DD Applications

Provide Pressure Profile Enable Positive Feedback to Driller

Address Hole Quality Issues Eliminate Hole Spiralling

REQUIREMENT REASON

Turbodrill Evolution

Turbine Blade Design

essure

Nominal Pressure

Drilling Range

Turb

ine

Pre

ssur

e D

rop

Torq

ue

Bit Speed

Turbodrill EvolutionPressure Profile Blades


PDC Bearings Races

Dramatic Improvement in Efficiency & Reliability!!

Thrust >110,000 Lbs

(With Standard 9-1/2” T3(Mk1), pumping 750 Gpm)

W.O.B. ± 30,000 Lbs

80,000 Lbs

Turbodrill EvolutionAXIAL THRUST

Around 3% of Flow exits to Annulus or with TSH tools (Hollow Shaft) is diverted down centre of shaft and passes into Bearing SectionTurbine

Shaft

Pressure Equalising Leakage Flow

Micro Annulus

Balance Drum

Housing

Main Mud Flow into Turbodrill

Balance Drum Assembly

Motor Section

Main Flow to Motor Section


Turbine Thrust Balance Drum

Turbodrill EvolutionTurbine Thrust Balance Drum (TS B)

Tur

bine

Bla

de

Hyd

raul

ic D

iam

eter

‘Db’

Bal

ance

Dru

m

Dia

met

er ‘D

d’

Thrust area for blades & Shaft

Thrust area for Balance Drum

Resultant Thrust area

FLOW

THRUSTTHRUST

6-5/8” : Thrust reduced by 50%

9-1/2” : Thrust reduced by 70%

THRUST EFFECTS?

NB. For 4-3/4” & smaller tools Balance Drum not required as thrust is much less & can be balanced by WOB.

Metallic Radial Bearings

Lower Radial Bearing

Have been successfully run

with BHST in excess of

260°C

LaserCarb™coating (Sleeve)

WallCarb™lining (Bush)



Flexible Titanium Shaft

Adjustable Bent Housing

Thrust Balance Drum

FBS Turbodrill Typical Layout

Turbine Stages

Interchangeable Stabiliser

Flexible Titanium Shaft

PDC Thrust Bearings

Lower Bearing Stabiliser

Lower Radial Bearing

Pin-Ended Shaft

Box Connection Bit With Integral Turbine Sleeve

Bent Housing

Single Motor Section


Current FBS Turbodrill Tool Sizes


2-7/8” 3.25 – 4.0”

3-3/8” 3.75 – 5.375”

4-3/4” 5.625 – 6.75”

6-5/8” 7.625 – 9.875”

9-1/2” 12.0 – 17.5”

TOOL SIZE HOLE SIZE

Steerable Turbodrills

Stabilisation

Varying Interchangeable “Mid-Point” Stabiliser size allows accurate control of inclination (Build / Hold / Drop) in Rotary Mode.

String Stabiliser directly on top of Turbine can also be sized to help “fine tune” the assembly

Lower Bearing Stabiliser (Generally 1/16 – 1/8” UG)

Adjustable Bent Housing

Long Gauge Box Connection Bit

Steerable Turbodrills

Reactive Torque

TurbodrillPDM

Hole QualityWhy is Hole Quality important?

# PROVEN TO BE MAJOR FACTOR IN ABILITY TO SLIDE #

ADDITIONALLY………………

•Ensures good transmission of WOB

•Reduces Torque & Drag

•Facilitates better Hole Cleaning

•Helps to reduce Stuck Pipe Incidents

•Allows easier running of Logging Tools

•Provides better quality Logging data (Pad based tools)

•Allows easier running of Casing / Liner / Core Barrels etc.

•Allows easier running of Completion Equipment

Basically Better Overall Drilling Efficiency

Hole Quality

Unstabilised Vs. Stabilised

Unstabilised (Slick) PDM can allow excessive lateral movement of the bit which can lead to very poor hole quality & spiralling

Stabilised Turbodrill with Long Gauge Box Connection Bit minimises lateral movement resulting in superior hole quality

and minimal risk of problematic spiralling

LONG GAUGE PIN CONNECTION.

NEAR BIT STABILISER. BOTTOM BEARING

STABILISERBOX END SHAFT

LONG GAUGE PIN CONNECTION.

SHORT GAUGE PIN CONNECTION

BOX END SHAFT

BIT BOXSTABILISER

BOTTOM BEARINGSTABILISER


BOX-UPLONG GAUGE BIT.


Hole Quality

Bit “Overhang” Configurations

Hole Quality

Spiralling

Ultrasonic Image & Calliper Log Mechanics of BHA in Spiral Hole

RESULT: Severe Torque & Drag and possible damage to BHA and String in Rotary Mode

Or Constant “Hanging Up” when Sliding!

Hole Quality

Hole Spiralling

Turbine with Bit Box Stabiliser (NEW)

Turbine with Box-Up Bit The Best Solution to combat Hole Spiralling

Turbine with what’s left of Bit Box Stabiliser Showing Effect of Spiralling in an Abrasive Formation

MAINTAINING VERTICALITY

•Drilling with Speed & Power – Low WOB Requirement

•Intermediate Stabiliser dictates Inclination Trend

Eg. In 8-1/2” Hole

8-7/16” LBS x 8-7/16” Intermediate Stab x 8-1/2” SS or RR

Will drop inclination or maintain verticality

AZIMUTH

0 100 200 300

INCLINATION

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

0 1 2 3 4 5

DLS

0 1 2 3 4 5

MAINTAINING VERTICALITY

TURBINE

POWER V

OPERATOR: Suncor Energy

COUNTRY: Canada

WELL: Panther 14-25

HOLE SIZE: 12 ¼”

TURBINE TYPE: 9 ½” T1B

Turbine Assembly

Maintained Inclination between 0 & 0.5 Deg. Over 1050 meters

MINIMISING VIBRATION

Vibration level Vibration level w/Turbodrillw/Turbodrill

Vibration level Vibration level w/PDMw/PDM

Global Turbine Mean Time Between Failure(All Tools 1990 – August 2005)

•Total Number Runs 5,808

•Total Footage Drilled 3,697,457

•Total Drilling Hours 322,956

•Total Operating Hours 413,259

•Total Number Failures 148

•MTBF 2,792 Hours

•MTBF % 2.55%

BHA

Bit Wear

Company Request

Core PointHole Problems

LIHLogging

MWD

TD Section

Turbine

WashoutOthers

Penetration Rate

Rig RquipmentBOP Test

Build IntervalApprox 3°/100’ Build IntervalApprox 3°/100’

Geo-SteeredInterval

Geo-SteeredInterval

8 ½” Hole 8 ½” Hole

Cromer Knoll

Limestone

Cromer Knoll

Limestone

SkaggerakSandstone Reservoir

SkaggerakSandstone Reservoir

BP ETAP Project – North Sea – Marnock Field

8-1/2” Intervals to be drilled from + 65º, landed horizontal and geo-steered to TD

Wells were to be completed by running sand screens

• Well 22/24a-A03

• Short 1” Gauge PDC Bits on PDM for Build

• Drilled to TD in 2 runs

• Total of 3,642 ft at average of 36.4 ft/hr

• Well 22/24a-A03




• Well 22/24a-A03z




• Well 22/24a-A03z




• Unable to run sand screens to bottom due to hole condition• Unable to run sand screens to bottom due to hole condition

• Unable to run sand screens to bottom due to condition of hole• Unable to run sand screens to bottom due to condition of hole

Initial Two Wells Drilled With PDM’s

• Well 22/24a-A02 - Drilled Build & Horizontal in One Run to TD

• Total of 3,862 ft turbine drilled at average of 29.3 ft/hr

• Well 22/24a-A02 - Drilled Build & Horizontal in One Run to TD


• Sand screens run on all wells with no problems!• Sand screens run on all wells with no problems!

• Well 22/24a-A04z - Open Hole Sidetrack


• Well 22/24a-A04z - Open Hole Sidetrack


• Well 22/24a-A01zz - Sidetrack One Run to TD

• Total of 1,827 ft turbine drilled at average of 42 ft/hr

• Well 22/24a-A01zz - Sidetrack One Run to TD

• Total of 1,827 ft turbine drilled at average of 42 ft/hr

• Well 22/24a-A04 - Sidetrack One Run to TD


• Well 22/24a-A04 - Sidetrack One Run to TD


Then…..6-5/8” FBS Steerable Turbine + Box Up PDC Bits

0

1000

2000

3000

4000

5000

6000

7000

JULY15-97A JUL15-15AST1 J15-95 J 15-98

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

FTG ROP av.

TD176

S88H

VP

AR445

TD19H

M73BP

M65BP

EHP51

M65

0.0 50.0 100.0 150.0 200.0 250.0

J ULY15-97A

J UL15-15AST1

J 15-95

J 15-98

TD19H M73BP M65BP

EHP51 M65

TD176 AR445

S88HVP $ 99.7

$ 202.8

$245.7

$ 180.1

Drilled shoe and 2742 ft vertically and then kicked off and built angle to 42º in single run!

New Field Record in 12-1/4” Hole For Gupco In Egypt

9-1/2” FBS Steerable Turbine with Smith Bits S88BHVPX PDC Bit

4545 ft at 33.6 ft/hr

Lowest 12-1/4” CPF in Field

S88BHVPX

TYPICAL UBD SIDETRACK APPLICATIONS

A 4-3/4” TS1(Mk3) Steerable Turbodrill with 1.25° bend completed an open-hole ST with an impregnated diamond bit in 6” hole. The Turbodrill made 3,902 ft in horizontal mode, first drilling 754 Ft then pulling back for the ST before drilling another 3,148 Ft to TD.

Steered footage = 2,647 Ft (68%) – on the ST run only, giving excellent steering & drilling performance along a very demanding well profile. Overall ROP for job = 37.3 Ft/hr

Total Turbodrill circulation time = 262 hours.

Sidetracking: Low-head application-1.25° Bend with typical UBD steerable tool

Location : UK S-North-Sea Depth In : 19,200 Ft Formation : Rotliegendes SST Diamond Bit : S280 G89YMud Type : WBM Mud Weight : 8.6 ppgFlow : 220 Gpm WOB : 2-12 KlbsBHP : 1600 Psi Surface press. : 3,400 Psi

COILED TUBING + UNDERBALANCED DRILLING APPLICATION

A 3-3/8” T2(Mk2) Steerable Turbodrill was used on 2” Coiled Tubing to complete a well extension in 3-7/8” hole: in a live, producing UBD well.

519 Feet of new hole was drilled at an average ROP of >25 Ft/hr With all objectives being met.

World First: steerable Turbodrill on Coiled Tubing- In live, producing UBD well

Location : Norway Depth In : 12,800 Ft Formation : MudST/ SST Diamond Bit : D 72 / 901-UMud Type : Brine Mud Weight : 8.6 ppgFlow : 90 Gpm WOB : 1-3 KlbsBHP: ± 700 psi Surface pressure: 3,900 psi

N.B.: ROP was >x 2.5 best PDM run (same Formations & TVD)

BHT was 167° C

6-5/8” Steerable Turbine Achievement

Statfjord Field Norway

Section Drilled in Single Run

Best Offset – 4 Runs with PDM

Dropped & Built from 22.5° - 90°

Turned from 158° - 30°

Cut 9.5 Days from AFE

http://marketing.corp.smithbits.com/vault/web/photos/PS5791.jpg

WORLD RECORD

A 4-3/4” TS1XL(Mk3) Steerable Turbodrill powered a Smith MA32CTPX PDC bit to a new world footage record for a single run in 6” hole. The Turbodrill made 4,487 Ft in a horizontal well for Shell in the Southern Sector of the North sea. The well was drilled Low-head with Base Oil, steering 1,345 Ft (30%) from 55° to 88°.

Average ROP was 31.6 Ft/hr.

Total Turbodrill circulating time = 198 hours

10 days rig time saved.

4 ¾” TS1XL sets World PDC Record:

Depth In : 8,911 Ft Depth Out : 13,398 Ft

Footage : 4,487 Ft Average ROP : 31.6 Ft/hr

Rotated : 3,142 Ft (70%) Steered : 1,345 Ft (30%)

– longest 6” PDC run

MA 32 CTPX

4-3/4” FBS T1-MK2 COMPLETES THE LONGEST RUN EVER IN THE CAMBRIAN RA IN ALGERIA

On a recent Horizontal well for Sonahess a 4-3/4” FBS T1-Mk2 Turbodrill in association with a 6” impregnated bit drilled 960 m of Cambrian Ra in one run on El Agreb field with an average ROP of 4.2 m/hr.

Best PDM performance in the Cambrian Ra was 588 m drilled at 2.9 m/hr with a high speed motor

NEW RECORD IN ALGERIA FOR TURBODRILL - 960M DRILLED IN ONE RUN

Additionally: Drilled out 7” Liner Equipment and completed final build up to Horizontal in same single run!

WORLD RECORD

A 4-3/4” TS1XL Steerable Turbodrill powered a Smith KGR50CTPXX impregnated diamond bit to a new world record footage for a single run in 6” hole. The Turbodrill made 6,478 ft in a horizontal well for Shell Expro in the Southern Sector of the North sea and beat the previous Sii Neyrfor record by 1,333 ft.

Total Turbodrill circulating time = 308 hours

4 ¾” TS1XL sets World Record in S.North Sea:

Depth In : 10,676 Ft Depth Out : 17,154 Ft

Footage : 6,478 Ft Average ROP : 33.1 Ft/hr

Rotated : 5,224 Ft (81%) Steered : 1,254 Ft (19%)

TURBODRILLING SUMMARY

Features Benefits High Power Output Capability Maximise ROP

All Metallic Construction Reliability with no Heat Constraints

Different Blade Types Adaptability to suit the Application

Modular Units (Bearings/Motors/Stabs) Rig-Site Interchangeable

Interchangeable “mid-point” Stabiliser Predictable Rotary Trends

Pin-Ended Shafts - Box-Up Bits Proven Hole Quality / Steerability

Bit Choice to suit Formation Not the Motor Minimal trade off in sliding ROP

Exceptionally Low Vibration Levels Protects Bit, BHA, MWD etc.

RELIABLE DOWNHOLE POWER – WHERE & WHEN YOU WANT IT!

Neyrfor Turbodrills

Documents

pdm differential pressure

psi differential pressure

motor horsepower

power inefficiency

psiif actual pdm differential

x flow

hydraulic energy

max hp output