HPHT Solutions Drilling and Evaluation
Transcript of 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
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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
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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
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* 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
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0 5 10 15 20 25 30 35
Pressure [kpsi]
Borehole Temperature Rating
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
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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
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Measuredpressures
Acoustic porepressure
ModeledFracturegradients
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500m200ms
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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
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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
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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
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0 100 200 300 400 500 600
Temperature [F]
Borehole Temperature Rating
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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Pressure [kpsi]
Borehole Temperature Rating
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
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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
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Component Reliability: Exponential Decline
Current specifications: 150C
Arrhenius equation (reaction rate): 10C = 50% component life
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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
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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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&=
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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
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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
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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