Breakthrough Horizontal Drilling Performance in Pre- Khuff Strata with Steerable Turbines Mike Simpson, Shaohua Zhou, Dave Treece, Carlos Rondon, Tom Emmons, Saudi Aramco; Craig Martin Sii-Neyrfor and Mohammad Tahir, Diamant Drilling Services SPE 90376
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SPE 90376 presentation slides - Turbine drilling with imgregnated diamond bits in hard abrasive sandstones with potassium formate brine
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Breakthrough Horizontal Drilling Performance in Pre-Khuff Strata with
Steerable Turbines
Mike Simpson, Shaohua Zhou, Dave Treece, Carlos Rondon, Tom Emmons, Saudi Aramco; Craig Martin Sii-Neyrfor and
Mohammad Tahir, Diamant Drilling Services
SPE 90376
Outline
Introduction
Economic Importance of Pre-Khuff Reservoirs
Pre-Khuff Geology
Turbo-drilling Experience in Saudi Arabia
Breakthrough Horizontal Drilling Performance
Turbo-drill Runs in Potassium Formate Brines
Conclusions
Introduction
Saudi Aramco Produces 8.1 mmbopd, 6.9 bscfd non-associated Gas &1 mmbpd NGL’s
Introduction
It operates 49 Land and Offshore Drilling & Workover Rigs consisting of:
25 Onshore Oil Rigs
3 Offshore Oil Rigs
21 Land Gas Rigs, 2000 hp or larger
Economic Importance of Pre-Khuff Reservoirs
25% Gas Prod. f/Pre-Khuff – Mostly UnzyUnzy’s Most Abrasive & Problematic to DrillGas Demand will inc. to 12 bscfd by 202550-55% of this must come from the Pre-Khuff Currently Drlg. 47 Gas Wells/year w/18 RigsUtilizes three Workover Rigs & one Snub. U.Unzy Well Design Changed to Horz. in 2003 to meet demand
Pre-Khuff Geology
Pre-Khuff – Formations of Lower Permian Age or older deposited before the Khuff
Include the Unayzah, Jauf, Tawil, Sharawra, Qusaiba, Sarah, Qasim and Saq
Mainly hard and ultra abrasive sandstones interbedded with siltstones and shales
Shales often unstable requiring 1500 psi overbalance to mitigate tight hole
Unayzah A, B & C
Unzy-A has 3000
to 9000 psi UCS (PDC Drillable)
Unzy-B (7000-27,000 on this RMA) Too hard & Abrasive for PDC’s – TCI’s & Impregs Only
Unzy-C 9000-22,000 UCS
Unayzah-A Core from Tinat-6
•Abrasive
• Not as Hard as UNZY-B
•Friable
Internal friction angle (phi): Unayzah reservoir core rock mechanics lab test result
40
45
50
55
60
65
0 2 4 6 8 10 12 14
porosity (%)
inte
rnal
fri
ctio
n a
ng
le (
deg
)
phi (WDYH-1)
phi (GHZL-2)
phi (GHZL-3)
Unayzah Porosity vs. Abrasivity from Offset Core
Unayzah Angle of Internal Friction typically ranges between 42 and 63° for the A, B and C.
BHA: 3 BHA TYPE : VerticalDATE: WELL : TINAT #3
JOB N° : RIG: SF 162 ARAMCOGRAPHIC DESCRIPTION OD (in)ID (in) LENGTH ( ft )SERIAL N°
Drilled 5-7/8” Hole with T-2 Turbine and 5-7/8” STC-K35TX Impreg Bit from 16,135 to 16,147’ (12’). Picked up to make connection and stuck pipe 7’ off bottom on 9/20/97.
Spotted 40 bbl Grease pill - jarred and worked on pipe, no success.
Spotted 1100 gal of HF acid & two 40 bbl EZ-Spot Pills & Worked pipe.
String Shot Backed off @ 15,866’ leaving 274’ of fish (7 DC, NBR, XO, Turbine & Bit) in hole.
Worked on fish a total of 11 days then decided to ST.
Spent another 13 days sidetracking back to 16,147’.
Total Time lost: 23 days
Total Stuck Pipe/Fishing Cost: $690,000
Turbo-drilling Experience in Saudi Arabia - 2nd Run
2 x Spiral Drill Collars4-3/4"2-1/4"62.18122.44ARAMCO
Bit Sub w/ Float Valve4-3/4"2" 3.1560.26ARAMCO
Cross Over Double Pin.4-1/2"1-3/8"1.4457.11ARAMCO
5-13/16"String Stabilizer-- 2-1/4"5.7755.67ARAMCO
5-13/16"Turbine Section 14-3/4"-- 18.2049.9046143
5-13/16"Turbine Section 24-3/4"-- 17.3031.7046122
5-13/16"Turbine Bearing Section4-3/4"-- 12.1914.40Bearing Shaft (Pin-End) Safety Sub 5" 1-3/16"0.901.90 5-7/8"-- 1.001.005-7/8” Impreg bit (Box-Up / T.F.A: =1.00in²)
CUSTOMER:
BIT STUCK – HRDH-642
HRDH-642 12/28/99
4-3/4"-- 0.312.21
Drilled 5-7/8” Hole with T-2 Turbine and 5-7/8” STC-KGRCETPX Impreg Bit from 13,975 to 14,057’ in the Unayzah-B. Picked up to check 9’ Drilling Break f/5-25 fph – Pipe Stuck.
Spotted 50 bbl Hi-Vis and Grease pills & jarred with 25K, no success.
Jarred out of Neyrfor Bit Safety Sub with 60K. Left bottom half of Safety Sub and Impreg bit on bottom (1.57’).
Milled and worked on fish with 5-7/8” Burn shoes, Cobra Mills, Taper Taps and Jars for 21 days and finally broke through.
Total Time lost: 23 days
Total Stuck Pipe/Fishing Cost: $842,000
Turbo-drilling Experience in Saudi Arabia - 3rd RunDrilling Report
Primary Cause of Bit StickingRadial Hole Deformation
elastic hole deformation(E = 2.8 Mpsi, v = 0.3, Biot = 0.8, TVD = 14050 ft
AVERAGE 5-7/8" BIT PERFORMANCE IN UNAYZAH-B For WDHY-1 & 4
BIT TYPE # RUN
AverageFOOTAGE
AverageHOURS
Avg. ROP
Avg.$/FT
DULL GRADET- B
TSP/PDM 1 13 7 1.9 4608 3---3
IMPREG/PDM 7 82 23 3.6 2219 8---8
IMPREG/TURB 2 794 128 6.2 366 3---3
PDC/PDM 14 152 28 5.5 1233 6---5
TCI/PDM 49 124 12 10.6 545 5---8
TSP/PDMIMPREG/PDM
IMPREG/TURB.PDC/PDM
TCI/PDM
4608
13
2219
82
366
794
1233
152
545
1240
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Fo
ota
ge
Co
st,
$/F
T
$/FT FOOTAGE
Turbo-drill Runs in Potassium Formate Brines
Clear “solids free” Liquid the can be used as drilling, spotting, workover or completion fluids
Sodium Formate – up to 85 pcf Potassium Formate up to 98 pcf Cesium Formate up to 144 pcf Used in over 400 wells since introduced by
Shell in 1993 Extends Temperature Range of Conventional
Viscosifiers and Fluid Loss Agents from 240-340º F. Cesium Formate successful up to 429°F
Turbo-drill Runs in Potassium Formate Brines
3rd Horizontal Run: 5-7/8” IADC M842 12 Blade Impreg run on 4-3/4” Turbine in Unzy-B on HRDH-658Suffered Total Failure of Impreg Segment Cutting Structure
Turbo-drill Runs in Potassium Formate Brines
4th Horizontal Run: 5-7/8” IADC M842 8 Blade Impreg run on 4-3/4” Turbine in Unzy-B on HRDH-658Drilled 81’ in 24.5 hrs at 3.31 fph in 93 pcf K-Formate Brine Drilling Fluid
Turbo-drill Runs in Potassium Formate Brines
5th Horizontal Run:
5-7/8” IADC M842 12 Blade Impreg run on 4-3/4” Turbine in Unzy-B on HRDH-658
Drilled 60’ in 16 hrs at 3.75 fph in 102 pcf K-Formate Brine Drilling Fluid
Effect of Overbalance of Rock Confined Compressive Strength
Increased overbalance between formation and Drilling fluid increase confined compressive strength and impede drilling rates
Use of a 102 pcf potassium Formate Brine with excess CaCO3 on HRDH-658:
Lowered Pump Pressures
Decreased Rotating Torque and Drag
Allowed a 11,649’ horizontal section to be drilled with 1500 psi overbalance without differentially sticking the drillstring
Turbo-drill Run in 90 pcf K-Formate Brine on Tinat-3
4-3/4” Steerable Turbo-drill prior to being RIH on Tinat-3
Setting Turbo-drill bearing section in Mouse-hole
Stabbing Power Section onto BearingSection & Making up same
Making up Turbine Sleeve Impreg Bit and checking bearing gap on Turbo-drill
RIH with Turbo-drill Assembly
Record Breaking ROP run in Tinat-3 Unayzah-A
6th Horizontal Run:
5-7/8” M834 Impreg drilled 360’ in 50 hrs @ 7.2 fph with avg cost of $402/ft.
Graded 3-4-WT-A-X-I
Run in 90 pcf Sodium/Potassium Formate drilling fluid
Average 5-7/8" Bit Performance on Tinat-3 in the Unayzah-A
BIT TYPE # RUN
AverageFOOTAGE
AverageHOURS
Avg. ROP
Avg.$/FT
DULL GRADET- B
IMPREG/TURB 1 360 50 7.2 410 1---0
PDC/PDM 3 320 35 9.3 320 5---5
TCI/PDM 2 118 13 8.9 472 2---1
IMPREG/TURB.PDC/PDM
TCI/PDM
410
360320320
472
118
0
100
200
300
400
500
Average Drilling Cost,
$/FT $/FT
FOOTAGE
Potassium Formate Brine Performance in Tinat-3
Lowered Pump Pressures from 4200 to 3400 psi at 220 gpmDecreased Rotating Torque from 9400 to 7600 ft-lbReduced hole drag from 25,000 to 10,000 lbf at the end of the horizontal section
Composition of formate-based drilling fluidComponent Function Concentration
Formate brine Density control
Lubricity
Polymer protection
Biocide
1 bbl
Xanthan Rheology control
Drag reducer
1 ppb
Modified starch and/or ULV PAC
Fluid loss control 4 –8 ppb
Sized calcium carbonate
Bridging agent 20 ppb
Potassium carbonate
pH and corrosion control
2 ppb
Typical properties of formate-based drilling fluid
Property Initial Hot rolling @285oF
Mud density (pcf) 90 90
PV (cp) 24 30
YP (lb/100 ft2) 22 29
Gel (lb/100 ft2) 4/5 7/9
API Filtrate (cc/30 min)
2.4 1.8
HTHP fluid loss (cc/30 min) @ 285oF
13.6 12
ph 10.5 11
Solids Control System for K-Formate Brine
Two Decanting Centrifuges
Two Linear Motion Shale Shakers w/180 & 200 Mesh Screens
Total Solids Content ~ 5%
Drill Solids ~ 0.45%
Potassium Formate Brine Liquor in Individual Bulk Containers (IBC’s)
Potassium Formate Powder in 25 kg sacks
Poor-Boy Brine Recovery System
Drain Lines from Rig Floor
Brine collected in IBC’s for Reuse
Expandable Sand Screen Completion
Well Completed with 1410’ of 4”/230 micron expandable Sand Screens
Run and expanded without major problems.
1
Successful Installation of 1410 ft of Expandable Sand Screens in TINT-3
6' EXY Tieback PBR, 5.625" OD 8TPI S.AcmeThreaded Down
7" x 5-½" EXP Deployment Hanger/Packer5.625" OD 8TPI S.Acme Thread Up x 5-½" 15.5 lb/ft Vam FJL Pin Down
M. Depth of 7" Liner Shoe : 15191 ftM.Depth/Length of 5-7/8" O.H. : 16747 ftTotal Length of O.H. : 1556 ft5-7/8" O.H. Max Inclination : 84.5 degMud : 90 pcf (Na/K/Formate)Total ESS Run Length : 1410 ft (37Jnts)
Top EXP @14482 ft
5-7/8" hole, TD@ 16747 ft
ESS Screenbottom at 1606 ft(131 ft from TD)
7" LinerHanger top @ 14181 ft
@ 14711 ft
Hanger top @ 13465 ft
Bridge Plug top @ 14014 ft
Whipstock top @ 13990 ft
7" Liner Shoe@ 15698 ft
Conclusions
Steerable turbo-drill/Impreg bit drilling has emerged as the most cost effective and HSE friendly manner to drill the Unayzah-B formation if the well can be drilled parallel to the maximum horizontal stress axis.
Trajectory control was improved with consistent reactive torque of 30-35° and a build rate of 0.3°/100’ in the rotating mode.
Conclusions, cont.
IADC 627-737 TCI bits are also cost effective when total revolutions are maintained in the 150,000 to 175,000 total revolutions range.
PDM/PDC drilling appears to be the cheapest way to drill the lower compressive strength Unayzah-A horizontally in the Tinat Area.
Conclusions, cont.
The 90 & 102 pcf potassium formate brines used in Tinat-3 & HRDH-658 provided lower pump pressures, torque and drag values and better bit performance than previously observed with conventional water base drilling fluids.
In HRDH-658 the 102 pcf K-Formate Brine allowed a 1649’ quasi-horizontal section to be drilled with 1500 psi overbalance without differential sticking.
Conclusions, cont.
Plans are to use Impreg/Turbo-drill assemblies over the entire Unayzah build and horizontal sections in conjunction with K-formate brines to further access their applicability and cost savings potential.
Breakthrough Horizontal Drilling Performance in Pre-Khuff Strata with