Advanced Drilling: A Technology Focus Area for ConocoPhillips
Transcript of Advanced Drilling: A Technology Focus Area for ConocoPhillips
“Copyright 2006 by ConocoPhillips Company. All rights reserved. No part of this publication may be reproduced in any form
without the express permission of ConocoPhillips Company.”
Advanced Drilling: A Technology Focus Area for ConocoPhillips
Michael WheatallDrilling Engineering and Operations Manager, Upstream TechnologyConocoPhillips, Inc.
Advanced Drilling: COP Focus AreasAdvanced Drilling: COP Focus Areas
• Drilling with Casing• Coiled Tubing Drilling• Extended Reach/Multi-Lateral/Designer Wells• HPHT Drilling• Managed Pressure Drilling• Wellbore Strengthening
Drilling with CasingDrilling with Casing
• World’s 1st DWC and Surface BOP from floating rig
• Conventional time: 91 hrs
• With CWD and Surface BOP: 29 hrs
Types of Casing Drilling2000+ Casing Sections
Types of Casing Drilling2000+ Casing Sections
51%
31%
18%
Non-RetrievableBHA Liner Drilling
(surface liners andtrouble zones)
Non-Retrievable BHACasing Drilling
(conductors, vertical wells,and drillable bits)
Retrievable BHACasing Drilling
(directional, multiple bit runs andformation evaluation)
Why Drill With Casing?Why Drill With Casing?CONVENTIONAL
DRILLING PROCESSSince 1901
CASING DRILLING PROCESS1998 – Future
CABLE TOOL PROCESS1850 – 1930
Rock Destroying slow FAST FAST
Hole Cleaning slow FAST FAST
Tripping FAST slow FAST
Stabilizer
Underreamer
Stabilizer
ponycollar
PDC Bit
External BHA
Crimp-on Stabilizer
Crimp-on Stabilizer
Crimp-on Stabilizer
CasingStabilization
ProfileNipple
Casing
Internal BHA
DLA
Stabilizer
SpacerCollar
How Do You Drill With Casing?How Do You Drill With Casing?
Lobo TrendLobo Trend• Casing Drilling began in 2001 to reduce trouble time• 120 wells (1.6 million feet of hole) have been drilled with casing• Lost circulation was almost completely eliminated• Zero stuck pipe incidents• An active drilling program continues where casing drilling candidates are selected based on expected problems.• The need to drill directionally is increasing.
BMT EastBMT East
Spud to Cementing of Intermediate Casing
200 - 300 sack balanced cement plug
7”Csg.
May 200210 days
8,103’
Casing Drilled
9 5/8”Csg.
4 1/2”Csg.
5 1/2”Liner
5,145’
7”Csg.
9,400’
Conv. Offset 2
9 5/8”Csg.
3 1/2”Csg.
Sept 200119 days
5 1/2”Liner
7”Csg.
6,917’
8,162’
Conv. Offset 1
9 5/8”Csg.
3 1/2”Csg.
7”Csg.
7,985’
5,272’
8,185’
Conv. Offset 3
9 5/8”Csg.
4 1/2”Csg.
BMT East C2 WellBMT East C2 Well
7”Csg.
$7,000 Trouble
8,143’
Casing Drilled
9 5/8”Csg.
4 1/2”Csg.
Conventional
9 5/8”Csg.
$184,000 Trouble
4,380’
Conventional Rig• Drilled & set surface csg• Lost circ at 4,380 ft• Could not cure lost circ.• Temp. abandoned well
Casing Drilling Rig• Moved over well• Drilled out plugs• Cured lost circ. by drilling ahead• Well completed
Casing Drilling CuttingsCasing Drilling Cuttings
Smear EffectSmear Effect
Whole Mud Sieve Analysis
0
10
20
30
40
50
8 20 50 100
140
200
>200
API Sieve Size
% S
olid
s R
etai
ned
Casing DrilledConventional Drilled
Fine
Ultr
a Fi
ne
Coa
rse M
ediu
m
Casing Drilling BenefitsCasing Drilling Benefits
• Safer operations – well control, pipe handling• Reduced trip time• Reduced open hole trouble time – 50% (Lobo)• Reduced drilling time - 15% (Lobo)• Reduced Cost• Uses conventional bits, BHAs and casing• Enhances UB and Managed Pressure Drilling
techniques
Less Subtle BenefitsLess Subtle Benefits• Don’t fight problems, case them off instead
• Rig loads smaller– Hydraulics needs are less– No overpull needed– No setback area
• “Drill pipe” (casing) is always new
Retrievable Casing DrillingBottom Hole Assembly
7” Casing SectionVertical Wells
DLA(Drill LockAssembly)
8 jts7 5/8-in.casing
7-in.23 lbmcasingto surf
TandemCasing(internal)Stabilizer
SpacerDrill CollarCasing
shoe
Under reamer(6 1/8 to 8 7/8”)
Tandem(external)Stabilizer
6 1/8” PDC bit
ConocoPhillipsWell 83
Casing Directional DrillingBottom Hole Assembly
with Steerable Motor
Under reamer(6 1/4 to 8 7/8-in.)
Bent Housing Motor4 ¾-in. then 5 ½-in.(1.5 deg bend)
casingshoe
TandemCasingStabilizer
Drill LockAssembly(DLA)
7-in.23 lbmcasingto surf
non-magdrill collar
VibrationsMonitoringsub
MWD
Float sub
6 ¼-in. PDC bit(3x15 nozzles)
Under reamer(6 1/8 to 8 7/8”)
TandemCasingStabilizer
DLA(Drill LockAssembly)
7” 23 lbCasingto surf
Casingshoe
Tandem(external)Stabilizer
Drill Collar
Filter sub
4 ¾-in. RotarySteerable System
94 ft67
5200 lbs
3 ½ IF
Conoco PhillipsWell 89
Casing Directional DrillingBHA w/ Rotary Steerable
for VerticalityTotal LengthStick-out Length
Hanging weight(in mud)
connections
SpacerDrill Collar
6 1/8-in. PDC bit(4x10 nozzles)
Well 91: Full Directional Test
-1200
-1000
-800
-600
-400
-200
0
200-600 -400 -200 0 200
Easting (E/-W), ft
Nor
thin
g (N
/-S),
ft
0
1000
2000
3000
4000
5000
6000
7000
0 1000 2000
Displacement, ftTV
D, f
tHorizontal PlotVertical Plot
target
Well 91Well 91
Well 79Well 79
SurfLoc
SurfLocTD
Conoco PhillipsWell 91
Casing Directional DrillingBottom Hole Assembly
With Rotary Steerable System
Jet Sub(1x10 nozzle)
Under reamer(6 1/8 to 8 7/8”)
6-in. StraightMotor
TandemCasing(internal)Stabilizer
DLA(Drill LockAssembly)
8 jts7 5/8-in.casing
7-in.23 lbmcasingto surf
Tandem(external)Stabilizer
MWD system
Filter sub
4 ¾” RotarySteerable System
6 1/8” PDC bit(4x10 nozzles)
Total LengthStick-out Length
Hanging weight(in mud)
112 ft85
6200 lbm
Casingshoe
RSS Drilling EfficiencyRSS Drilling Efficiency
• ROP was within 10% of offset vertical well• Casing drilling benefits captured:
– No lost circulation events– Minimal reaming time– No difficulties in setting casing– OBM not required
• Eliminated difficulty of Casing Drilling with steerable motor– No sliding problems– No motor stalling problems
• However – Vibrations were significant – Multiple RSS washouts
Key QuestionKey Question
• Can the straight hole benefits and initial directional successes realized in the Lobo Field be transferred to directional casing drilling in a higher cost offshore environment, such as Norway?
2005 Field Test Objectives2005 Field Test Objectives
• Directionally drill with larger casing sizes used at Eldfisk (10-3/4” & 7-5/8”)
• Identify and correct any problems with new tools
• Provide information required to qualify equipment and tools for use in Norway
• Perform directional casing drilling on a conventional rig similar to Norway platform rig
Split Block
Swivel with space forWireline BOP
Top Drive System
Casing Drive System
10 ¾-in. casing
7-5/8” Test Summary7-5/8” Test SummaryDisplacement (ft)
True
Ver
tical
Dep
th (
ft)
Previously drilled wellw/10 ¾” casing to 3769ft
600ft HZ drill 844 ftw/7 5/8” csg
TD 4884 ft
DLA/UR set/retrieval testsplanned at 0, 45, and 90 deg
0
500
1000
1500
2000
2500
0 600 1200 1800 2400 3000 3600
10-3/4” Test Summary10-3/4” Test Summary
0
500
1000
1500
2000
2500
3000
3500
4000
4500
-500 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
DisplacementTr
ue V
ertic
al D
epth
(ft)
13 3/8” csg @2003ft
KOP: Build to 50 deg testing different rates (planned)
TD 5000ft
Actual Total Depth of the test was 2966 ft, with 15 degrees of inclination built.
(planned depth)
ConclusionsConclusions
• Both Directional Casing Drilling tests were a cost effective “dress rehearsal” for Eldfisk Norway
• Directional Casing Drilling technology was successfully transferred to new casing sizes
• Rotary steerable system in the pilot hole provides effective directional control
• Vibrations in the BHA are better understood, their effects have been reduced
On to Norway!On to Norway!
• Two Eldfisk wells will be casing drilled in May 2006
– 50 degree maximum angle
– 10-3/4” to 5100 ft (md)
– 7-5/8” to 10800 ft (md)
Coiled Tubing Drilling
• CTD is Drilling with One Long Joint• Still Need All Drilling Equipment
– Shelter– Solids Control– Pumps, Tanks, – Mast... Etc
• Combined CT/Rig
1st Generation Alaska CTD OperationWith Drilling Platform
Courtesy ConocoPhillips
Courtesy BP and ConocoPhillips
Coiled Tubing Drilling UnitCoiled Tubing Drilling Unit
Conventional Drilling packageConventional Drilling package
Arctic Coiled Tubing UnitArctic Coiled Tubing Unit
2nd Generation CTD in Alaska
Work Over UnitWork Over Unit
3rd Generation CTD Unit: Alaska
Courtesy BP, ConocoPhillips and Schlumberger
• Workover Rig in Grey• CTU in Orange• Unitized and Self-Powered
• Sister Rig Added to CTD Fleet
CTD: Why all the Interest?
0
27.52%
55.04%
82.56%
110.07%
137.59%
165.11%
192.63%
New W
ellNew
Well
New W
ellNew
Well
New W
ellNew
Well
Sidetrac
kSidetr
ack
Sidetrac
kSidetr
ack
Sidetrac
kSidetr
ack
Sidetrac
kSidetr
ack
Sidetrac
kSidetr
ack
Sidetrac
kCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/TCTD S/T
Wel
l Cos
t Pe
rcen
tage
100%
73%
31%
Program Dev. Costs - $/bblNew Wells - 100% $/BblSidetracks - 113% $/BblCTD S/T’s - 69% $/Bbl
Reserves Development Costs
Greater Kuparuk Area Greater Kuparuk Area
CTD Historical Well Count(includes incomplete wells)
0
5
10
15
20
25
30
1998 1999 2000 2001 2002 2003 2004 2005
# Wells
# Laterals
High Rate 1D-11High Rate 1D-11
• Multi-lat C sand lateral & maintained motherbore
• First Two-window/two-lateral design – allows future isolation and re-entry into each lateral
• Longest KRU CTD Lateral on record:
Lat 1 : 2,202’ / 2,015’Lat 2 : 2,812’ / 2,584’
Initial well tests >5,500 bopd!
2005 CTD Accomplishments at GKA2005 CTD Accomplishments at GKA
Extended Reach Records for 2” CT (1D-34)
• Drilled depth 18350’ md (2.2:1)• Lateral length 2630’ md• Window milling depth 15721’ md• OH sidetrack depth 17935’ md
Pushing the Envelope: 1Q-04 Quad LateralPushing the Envelope: 1Q-04 Quad Lateral• 5224’ drilled footage• Lower quality A-sand• <20OAPI oil• Maximize pay exposure
Casing Drilling and CTD:
Proven Yet Still Evolving Technologies
What’s Next? …
Casing Drilling and CTD:
Proven Yet Still Evolving Technologies
What’s Next? …
Remote Land-Based Exploration WellsRemote Land-Based Exploration Wells
Challenged Economics for Rotary Drilling:
– Market driven drilling cost inflation– Mature basins: smaller structures/reserves– Shorter drilling seasons (Canada/Alaska)– Tighter environmental restrictions– Difficult logistics is major cost driver
Our ChallengeOur Challenge
Reduce cost of remote land-based exploration drilling by 50% while meeting formation evaluation requirements.
Plan of Attack: Think SmallPlan of Attack: Think Small
• Smallest hole sizes possible– Reduce materials and logistics cost
• Existing technologies and equipment• Leverage ConocoPhillips expertise
– Casing drilling– Coiled tubing drilling
• Requirements– 10,000’ depth capability– Formation evaluation
Rig Options StudiedRig Options Studied• Mining Industry Coring Rigs
– Depth limitations– Slow drilling in overburden– Major modifications to mud system and well control
• 1990’s Vintage Slim Hole Rigs (4-3/4” min hole size)– Small footprint – Rolligon, truck or heli-transportable– Lengthy move and set-up– Inefficient drilling (lacks automation)
• Automated Small Conventional Rig– Swift move and set-up– Drill efficiently– Reduced personnel exposure– Large, heavy load while moving
Western Canada Shallow GasWestern Canada Shallow GasFit for Purpose Hybrid Coil/Rotary Rig
Hybrid CT/Rotary Drilling UnitsHybrid CT/Rotary Drilling Units
• Wells drilled and cased in about one day– Two wells per day possible
• Typical 3000’ Well:– 7 inch surface casing
• 8-1/2” hole drilled with 3-1/2” CT or DP– 4-½ inch production casing
• 6” hole size drilled with 3-1/2” CT
Western CanadaWestern Canada
Coil Tubing Drilling Rigs
15 17 22 2536
67
020406080
2000 2001 2002 2003 2004 2005
Year
Hybrid Rig Count
CanadaCanadaWells Drilled by Rig Type
0
5000
10000
15000
20000
25000
2000 2001 2002 2003 2004 2005
Num
ber o
f Wel
ls
Hybrid Drilled Wells Conventionally Drilled Wells
Small FootprintSmall Footprint
Drilling with CT - Mast Down DesignDrilling with CT - Mast Down Design
Automated Pipe Handling SystemAutomated Pipe Handling System
Automated Pipe Tub TrailerAutomated Pipe Tub Trailer
Touch Screen Control PanelTouch Screen Control Panel
Drilling with CT - Mast Up DesignDrilling with CT - Mast Up Design
Automated Rig ControlsAutomated Rig Controls
Automated Pipe Rack with SkateAutomated Pipe Rack with Skate
Top DriveTop Drive
Zero Discharge Mud SystemZero Discharge Mud System
MovingMoving
Moving Moving
But … Can these Rigs Drill a 10,000’ Exploration Well?
But … Can these Rigs Drill a 10,000’ Exploration Well?
• 4500’ maximum depth with 3-1/2” CT
• 6000’ maximum depth with 2-7/8” CT
• Low capacity mast (150-200 klb)
• Small mud pump (650-850 hp)
Approach: Think Small & Work Well Design from the Bottom Up
Approach: Think Small & Work Well Design from the Bottom Up
• 4-1/8” final hole size– 3-3/4” bi-center bit (helps with ECD)– Contingency liner option (3-3/16”)– Extensive experience with this hole size to 18,000’ md
• Drilling Tools: proven and available– Wireline telemetry – Bent housing mud motors – MWD/GR/Resistivity
• 2-1/4” wireline logging tools• Conventional coring equipment• Complete with 2-3/8” or 2-7/8” SL tubing
Slim Hole Design
No Intermediate Casing
4-1/2” x 2-3/8”
Final Hole Size: 4-1/8”
Slim Hole Design
No Intermediate Casing
4-1/2” x 2-3/8”
Final Hole Size: 4-1/8”
Slim Hole Design
Intermediate Casing
7” x 4-1/2” x 2-3/8”
Final Hole Size: 4-1/8”
Slim Hole Design
Intermediate Casing
7” x 4-1/2” x 2-3/8”
Final Hole Size: 4-1/8”
Main Issue: Hybrid Rig LimitationsMain Issue: Hybrid Rig Limitations
• 4500’ depth limitation based on 3-1/2” CTD to TD
• 3-½” CT marginal for 8-1/2” surface hole drilling
• 10,000’ of 3-½” CT too much for current hybrid rigs and difficult to move
• Increases final hole size beyond needed 4-1/8”
Solution: Casing/Coil HybridSolution: Casing/Coil Hybrid
• Integrate casing drilling technology
• Casing drill surface hole and intermediate hole– Eliminates need for large diameter CT– Casing drilling plus slim hole design greatly extends
depth range for mast and pumps– Retrievable BHA not needed for straight hole sections
• 2-3/8” coil tubing to drill final 4-1/8” hole– Extends rig capacity 10,000’ depth
Formation Evaluation OptionsFormation Evaluation Options
• 2-1/4” Wireline Logging Tools– Array induction– Dual Laterolog– Compensated neutron– Compensated photo-density with PE– Compensated sonic– Standard gamma ray – MFT (pressure tester only) on wireline– High Resolution Micro Imager
• Conventional Coring • Well Test through Tubing
Summary: Casing/Coil Hybrid Advantages (over conventional rotary drilling)
Summary: Casing/Coil Hybrid Advantages (over conventional rotary drilling)
• Automated Rig Benefits– Reduced personnel exposure – Fast move and rig-up– Small location size– Top drive
• Slim Hole Well Design Benefits– Reduced tangible costs– Reduced mud and cement volumes– Reduced cuttings and waste fluid disposal– Reduced hauling– Facilitates zero discharge
Casing/Coil Hybrid AdvantagesCasing/Coil Hybrid Advantages
• Casing Drilling Benefits– Smaller rig, less fuel, reduced emissions – Reduced trip time– Reduced trouble time (smear effect and no
tripping)– No drill string – reduced hauling
• Coiled Tubing Drilling Benefits– Faster drilling (no connections)– Reduced trip time– Managed Pressure Drilling/Underbalanced Drilling– Facilitates use of Oil Based Mud
ConclusionsConclusions
• Cost reduction goal is achievable
• Casing/Coil Hybrid Drilling Concept is feasible using current technology and available equipment
• Other Applications Possible …
QUESTIONS?