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© 2007 1 © 2007 2 Advanced High-Pressure Coiledtubing Drilling System Dr. William C. Maurer JUNE 1, 2007 © 2007 3 © 2007 4 Project Objective To develop a high-pressure jet assisted drilling system that uses coiled tubing to convey the fluid to the bit and motor avoiding the problems of leaks that occurs with jointed pipe. © 2007 5 Project Structure Phase I – Feasibility study Phase II – Development of highpressure motors, bits and other critical components. Phase III – Field testing and commercialization © 2007 6 Phase I & II Results © 2007 7 Coiled-Tubing Confirmed feasibility of coiledtubing system Calculated fatigue life of coiled tubing Developed improved tubing (QT1200) © 2007 8 Coiled Tubing Burst Pressure (100,000 psi yield) CT Diameter (in.) Wall Thk. (in.) Burst Pressure (psi) 1.00 0.109 20,800 1.25 0.156 24,160 1.50 0.175 22,670 1.75 0.188 20,910 2.00 0.203 19,800 2.375 0.203 16,670 2.875 0.203 13,770 3.500 0.203 11,310 © 2007 9 CT Burst Pressure 40000 Burst Pressure (psi) 2.00 inch OD 30000 20000 10000 0 QT-1000 Incoloy-625 Composite © 2007 10 CT FATIGUE LIFE Fatigue Life (trips) 200 (based on MEI CTLIFE model) 1.75" 2.00" 150 QT-1000 100 50 0 6,000 9,000 12,000 Internal Pressure (psi) © 2007 11 Fatigue Test Machine CT Sample Straight Bending Form Pressure Controller Hydraulic Actuator Curved Bending Form Pump © 2007 12 Fig. 7-2Tubing Fatigue Fatigue Life of 1-1/2” Coiled Tubing Tests (R. Stanley, 2000) 500 Actual Cycles for QT-1200 (0.156” Wall) 450 Model Cycles for QT-1000 Fatigue Life (cycles) 400 Model Cycles for QT-800 350 300 250 200 150 100 50 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 Internal Test Pressure (psi) © 2007 13 High-Pressure Motor Designed HP power section Developed labyrinth seal Proved Diamond bearing technology Laboratory tested motor Manufactured HP PDC bits © 2007 14 Motor Labyrinth Seals } 5” Housing Fluid Flow 5” } Upper Restrictor Shaft Lower Restrictor © 2007 15 Motor Labyrinth Leakage 16 Flow Rate (gpm) 14 Four 5” Labyrinths 10,000 psi w 12.1 12 10 8 8.1 6 4 2 0 0.004" Leakage Clearance (w) 0.006" © 2007 16 Thrust Load on Bearing 10,000 PSI Seal Housing 34,000 lb Force Thrust Bearing Bit © 2007 17 Candidate Bearings Ball Bearing PDC Bearing © 2007 18 Bearing Load Comparison 20000 100 Hours @ 300 rpm 16,800 Load Capacity 15000 10000 5600 5000 0 Ball Bearing PDC Bearing © 2007 19 High-Pressure Coiled Tubing Motor © 2007 20 © 2007 21 10,000 psi © 2007 22 © 2007 23 High Pressure Jet-Drilling Rates Jet Drilling Rate (ft/in) 1600 1500 Bit Weight = 2000 lbs = 10,000 psi = 1,000 psi 1400 1200 910 (WOB=1000 lbs) 1000 800 600 780 400 200 142 255 68 0 Texas Cream Limestone Leander Limestone Glacier Bluff Dolomite 120 110 Pecos Red Sandstone © 2007 24 © 2007 25 Jet Slotting Developed 1-11/16 HP motor Developed jet slotting Developed gear box for jet slotting Confirmed ability to jet in over pressure condition © 2007 26 Fig. 13 Jet Slotting Stimulation Slots Formation Damage High Pressure Jets © 2007 27 Fig. 14 Jet Slots In Glacier Bluff Dolomite 10,000 psi Jet Pressure Axial Velocity 140 in/min Rotary Speed 6 rpm Slot © 2007 28 © 2007 29 Fig. 11 DRC Wellbore Simulator Drilling Stand Cuttings Removal Screen Choke Borehole Pressure Rock Drilling Fluid Input Shaft Seal Pressure Chamber Formation Pressure © 2007 30 Fig. 12 Effect Of Wellbore Pressure 1800 1600 (High Pressure Drilling) Texas Cream Limestone 2000 lb Bit Weight ROP (ft/hr) 1400 1200 1000 Wellbore Pressure = 2000 psi Jet Pressure = 9300 psi 1010 920 800 600 400 200 0 0 psi 2000 psi Wellbore Pressure © 2007 31 Tubing Drilling Cement High Pressure Jets Cement © 2007 32 Tubing Barite Scale Removal High Pressure Jets Barite Scale © 2007 33 Jetting slots Open slots Cleaning Slotted Liners Tubing High Pressure Jets Plugged slots © 2007 34 Hole Reaming/Cleaning Hole Guide Reamed Hole High Pressure Jets Predrilled Hole © 2007 35 Under Reaming Casing High Pressure Jets © 2007 36 © 2007 37 © 2007 38 CT Cement Cleanout Rates 1200 1000 ROP (ft/hr) 1000 800 600 400 200 60 0 Low Pressure 10,000 psi © 2007 39 Phase III -- Plans © 2007 40 Phase III SOW Assemble HP-CT system NEPA Upgrade CT software Shallow field test (Catoosa) Modify tools Deep field test Horizontal well applications Commercialization plan © 2007 41 NEPA Determine data needed Develop reporting form Supply Catoosa data © 2007 42 Upgrade CT Life Develop new algorithms to calculate stresses due to HP Determine effect of HP on fatigue Incorporate new algorithms Incorporate new CT materials © 2007 43 Shallow Field Test Visit Catoosa Cohen BJ services (Kelly Falk &/or Jay Albrecht) Write Drill engineered work plan Depth 2000 ft File NEPA documents Test drilling & slotting system © 2007 44 © 2007 45 © 2007 46 © 2007 47 © 2007 48 Deep Field Test Modify tools NEPA Engineered work plan Test to minimum depth 8,500 to 10,000 ft Commercialization plan Market survey © 2007 49 © 2007 50