2008 jornadas de perforaci ón 21 – 23 october 2008 salta, argentina
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Challenging Drilling Applications Demand New Technologies Michael J. Jellison – NOV Grant Prideco ™. 2008 Jornadas de Perforaci ón 21 – 23 October 2008 Salta, Argentina. 1. Challenging Drilling Applications Demand New Technologies M. J. Jellison. Outline - PowerPoint PPT PresentationTRANSCRIPT
Challenging Drilling Applications Demand New TechnologiesMichael J. Jellison – NOV Grant Prideco™
1
2008 Jornadas de
Perforación21 – 23 October 2008
Salta, Argentina
Challenging Drilling Applications Demand New TechnologiesM. J. Jellison
Outline• Deeper Targets and Faster Drilling with New
Connection Technology• Advanced Material Technologies for UDD & ERD• Hardbanding Trends• Ultra-High Capacity Landing String System• What Really Happens to High Strength Drillpipe
When Taking a Sour-Gas Kick• Severe Downhole Friction Heating Driving
Increase in Drillstring Failures• Telemetry (Wired) Drillpipe• Conclusions
2
3rd Gen. DSC(Design Philosophy)
1 2 3 4
2 3/8 to 2 7/8Increased tensile
capacityIncreased torque
capacityOptimized hydraulics
Speed of makeup
3 1/2 to 4 1/2Increased torque
capacitySpeed of makeup
Optimized hydraulics
5 to 5 7/8Speed of makeup
Optimized hydraulics
Increased torque capacity
6 5/8Speed of makeup
Reduced make-up torque
Optimized hydraulics
Drill Pipe Size(inches diameter)
Design Priority(1 - highest; 4 = lowest)
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Starting Thread
2nd Gen. DSC≈ 13 revolutions
3rd Gen. DSC combines two threads opposite 180 degrees apart (double-start) which reduce the revolutions from stab to make-up by 50%.
Start Thread 1
Start Thread 2
3rd Gen. DSC≈ 4 revolutions
3rd Gen DSC run as fast or faster than the API equivalent connection.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
3rd Gen. DSC(Dual-radius Thread Form)
API FH V-.050(0.025-in. root radius)
2nd Gen. DSC(0.042-in. root radius)
3rd Gen. DSC-585(0.065-in. X 0.065-in. dual-root radius)
API FH V-.050(0.025-in. root radius)
2nd Gen. DSC(0.042-in. root radius)
3rd Gen. DSC-585(0.065-in. X 0.065-in. dual-root radius)
API NC V-.038R(0.038-in. root radius)
2nd Gen. DSC(0.042-in. root radius)
3rd Gen. DSC-390(0.052-in. X 0.060-in. dual-root radius)
API NC V-.038R(0.038-in. root radius)
2nd Gen. DSC(0.042-in. root radius)
3rd Gen. DSC-390(0.052-in. X 0.060-in. dual-root radius)
In smaller DP sizes, 3rd Gen. DSC have at least 37% larger thread root radii than API to reduce peak stresses.
In larger DP sizes, 3rd Gen. DSC have at least 160% larger thread root radii than API to reduce peak stresses.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Advanced Metals Drill Pipe
8
Challenging Drilling Applications Demand New Technologies M. J. Jellison
High-Strength Steels
6
0
0.00002
0.00004
0.00006
0.00008
0.0001
0.00012
0.00014
130000 135000 140000 145000 150000 155000 160000 165000 170000
Yield Strength (psi)
Z-140
V-150
147,798 psi
157,135 psi
Yield Strength
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
30 40 50 60 70 80 90
LCVN (ft-lbs)
Z-140
V-150
65.03 ft-lbs
59.60 ft-lbs
NOTE 1: All LCVN tests done with 3/4 size samples.NOTE 2: All LCVN tests done at -4 degrees F.
LCVN Toughness
Z-140 and V-150 provide increased “strength-to-weight” ratio products for current projects and demand is increasing.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
881,775
343,323
040,00080,000
120,000160,000200,000240,000280,000320,000360,000400,000440,000480,000520,000560,000600,000640,000680,000720,000760,000800,000840,000880,000
Jan-
97
Jul-9
7
Jan-
98
Jul-9
8
Jan-
99
Jul-9
9
Jan-
00
Jul-0
0
Jan-
01
Jul-0
1
Jan-
02
Jul-0
2
Jan-
03
Jul-0
3
Jan-
04
Jul-0
4
Jan-
05
Jul-0
5
Jan-
06
Jul-0
6
Jan-
07
Jul-0
7
Jan-
08
Jul-0
8
Jan-
09
Z-140™
V-150™
High-Strength High-Toughness Steels
7
In 3 yrs, probability of NOT meeting stringent, elevated LCVN specifications on Z-140 and V-150 has dropped ½.
Next step is development of UD-165™ products.
2003 2006
Chandler, Jellison, Payne, Shepard, “Performance Driven Drilling Tubular Technologies,” paper SPE/IADC 79872, presented at the 2003 SPE/IADC Drilling Conference, 19 -21 February 2003.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Hardbanding TrendsThe hardband system for critical applications
should incorporate the following features:• The hardband must be casing friendly with no
tungsten carbides in its formulation.• The hardband should be applied in a raised
configuration to maximize tool joint protection and limit contact between the bare steel on the tool joint OD and the well bore.
• Both the pin and box members should include hardband to provide tool joint protection and minimize contact between the tool joint OD and wellbore.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
1st Generation Casing Wear Machine – 2004• Capable of testing
hardband vs. casing only
• Table was “hinged”• A pressure
transducer was used to measure side load
• Load fluctuation was 30-35%
• Table traverses as the hard band rotates
• Water was the only coolant which could be used
Challenging Drilling Applications Demand New Technologies M. J. Jellison
3rd Generation Hardband Test Machine 2007
Capable of simulating both “Open Hole” and “Cased Hole” operations
The Casing or Stone rotates counter Hard Band rotation. This eliminates the need of a traversing table.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Video of 3rd Generation Hard Band Machine
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Hardband Test Results
27.1 26.5
19.918.6
12.1
8.1 7.8
4.9
0
5
10
15
20
25
30
Steel TJ TungstenCarbide
Prod. B Prod. C Prod. E Prod. D Prod. A 4th-Gen.Hardfacing
% o
f C
asin
g W
all T
hic
knes
s L
ost
0.0000
0.00450.0050
0.0080
0.0125
0.00200.0020
0.0100
0.0000
0.0020
0.0040
0.0060
0.0080
0.0100
0.0120
0.0140
RA
DIA
L W
EA
R O
F T
J IN
CA
SIN
G
(In
ches
)
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Casing Wear Comparison Tool Joint Wear Comparison
Loads in Deep-Water & UDD are Heavy!
5Paslay, Pattillo, Pattillo II, Sathuvalli, Payne, “A Re-examination of Drillpipe/Slip Mechanics,” IADC/SPE 99074, Presented at the 2006 IADC/SPE Drilling Conference, 21 – 23 February 2006
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Slip-Crushing (Issue)
9Paslay, Pattillo, Pattillo II, Sathuvalli, Payne, “A Re-examination of Drillpipe/Slip Mechanics,” IADC/SPE 99074, Presented at the 2006 IADC/SPE Drilling Conference, 21 – 23 February 2006
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Slip-Crushing Technologies (Pipe)
10
Reduced tool joint diameter for reduced make-up torque requirements
Tungsten carbide free hardbanding to protect riser/casing
Extended length, thicker wall slip section machined true for increased slip crushing capacity
Internal and external upset (IEU)
High strength grade tube of reduced wall thickness
Pin wall thickness to provide connection tensile capacity
Increased elevator diameter for increased hoisting requirements
Doublediameter box tool joint
Chandler, Jellison, Payne, Shepard, “Performance Driven Drilling Tubular Technologies,” paper SPE/IADC 79872, presented at the 2003 SPE/IADC Drilling Conference, 19 -21 February 2003.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Slip-Crushing Technologies (Slips)
11
1,000 Ton Slip System
Split Flush Mounted Bushing fits into Rotary Table
Solid Internal Bushing Maintains dimensional integrity and minimizes radial forces on the rotary table
Remote Operated Hydraulic Powered Device
Load distribution grooves improve equal weight distribution and reduce point loading in the toe area Extended Slip
Contact Area (20”)
Modified slip and bowl taper reduces transverse loading
Patent-pending LDXL™ system from Access Oil Tools
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Hoisting Capacity (2 Issues!)
Tool Joint Elevator Capacity
Hoisting capacity is also a function of tool joint diameter!
Elevator Tonnage Rating
CONVENTIONAL
UNCONVENTIONAL
12
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Hoisting Technologies (Pipe)
Larger elevator diameter for improved hoisting capacity
Reduced TJ diameter for MUT & fishing considerations
Tong space overshot fishing capable
Double Diameter Tool Joints
Improved Tool Joint Elevator Capacity
13
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Hoisting Technologies (Elevators)
1,000 Ton Elevator System
Replaceable insert bushings
For use with 18˚ taper box tool joints
Patent-pending XP1000™ elevator from Access Oil Tools
Hydraulically actuated
14
Challenging Drilling Applications Demand New Technologies M. J. Jellison
The $$$ Question …
High strength steels are incompatible with H2S influxes
Mud overbalance, high pH values, H2S scavengers are being used
What to do if an H2S kick is taken in spite of these measures ?
circulate kick outand
continue drilling
circulate kick outand
POOH to lay down drill pipe
?
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Laboratory Testing
Samples from field-fatigued drill pipe should be exposed to H2S under downhole conditions and subsequently tested for reduced fatigue performance
Fatigue test should replicate cyclical stresses in drill pipe when rotated in dog legs of ~5°/100ft with an axial load of 90% of tensile yield strength
Samples machined according to established fatigue testing design
Dimensions in mm
Challenging Drilling Applications Demand New Technologies M. J. Jellison
First test results …
Initial conditions were defined as:
samples machined from pipe body – tool joint weld area samples to be rolled for 3 hours in H2S-saturated, 5% K2CO3 solution, top
half of the autoclave filled with 6 bar partial pressure H2S gas (equivalent to 12% H2S) at 80°C, residual stress 90% of yield strength
samples then taken from the (purged) autoclave and kept in 5% clean K2CO3 solution at ambient temperature for transfer to fatigue test
fatigue testing at 90% +/- 10% load for up to 107 cycles
… and resulted in: very few failures with large scatter, some H2S-exposed samples
showing better fatigue life than undamaged base line samples ? ? ?
Challenging Drilling Applications Demand New Technologies M. J. Jellison
And better test results …
Achieved failures in samples at fatigue loads approaching 20-25% of tensile yield strength
Fatigue test results
50
52
54
56
58
60
62
64
66
68
70
1,00E+04 1,00E+05 1,00E+06 1,00E+07 1,00E+08
Load Cycles
Fat
igu
e A
mp
litu
de
(Sig
mam
ax -
Sig
mam
in)
Corroded Samples New Samples
No failure
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Interpretations …
Exposing samples to a KCl solution with a pH of 3 resulted in failures already in the autoclave after 40 to 50 minutes under 90% of yield strength load
K2CO3 solution pH after 3 hour sample immersion was still 10.5 (from originally 11.4) OH– depletion over time ?
Influence of surface roughness is substantial (polished samples vs. drill pipe surface downhole ?)
Results would indicate that if string survives initial exposure little to no effective reduction in fatigue performance should be expected
Initial results tend to validate assumption that with maintaining high pH in the drilling fluid, even substantial H2S concentrations in a gas kick will not materially damage high-strength pipe
Challenging Drilling Applications Demand New Technologies M. J. Jellison
High heat input can be created quickly by contact friction heating downhole
2000 lbf
Casing
Rotating tool joint
150 rpm
Eaton1 showed that temperatures over 1888°F (1031°C) could be reached with side loading of 2000lbf in 2 minutes when rotating against casing at 150 rpm.
1. Eaton, L.P.: “Tool Joint Heat Checking While Predrilling for Auger TLP Project,” Paper SPE/IADC 25776 presented at the 1993 IADC/SPEDrilling Conference, Amsterdam, The Netherlands, February 23-25.
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Case History: March 2006, Onshore, Alberta Canada
• Pin tool joint separated from pipe.• Pipe experienced exaggerated necking at the fracture.• Extended necking required heating while tension was
applied and is not possible with tension alone.
Exaggerated necking at failure location
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Telemetry Drill Pipe Network
Premium Drill Pipe and:1. High-Speed, Bi-Directional Network
2. Allows acquisition from bottom of string
3. Boost and measurements along string
NOTE: Most BHA components can be converted to Intelligent drill string including:• Jars, stabilizers, reamers, drill collars, some float valves etc.
• Temp Rating: 302˚ F• Pressure Rating: 25,000 psi• Speed: 57,000 bps
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Field Test Results
EWR- AFR - Real Time HighJump( Low Frequency)
ohm -m
EWR Ext Shallow Phase Res
0.2 2000
ohm -m
EWR Form Expos T ime
0.2 2000
AFR TVD
feet
200 700
ohm -m
EWR Deep Phase Res
0.2 2000
ROP
feet per hr200 0 ohm-m
EWR Medium Phase Res
0.2 2000
MD 1 : 120
ohm-m N E S W N
AFR Medium 16 LF Mag-T
0 360
0.2 2000
AFR Form Exp Tim e
hours0 20 ohm-m
EWR Shallow Phase Res
0.2 2000200
250
300
350350
250
300
350
400400
300
350
400
450450
350
400
450
500
550
500
550
400
450
500
550
600600
500
550
600
550
600
650
600
650
EWR- AFR - Real Time Negative Pulse( Low Frequency)
ohm -m
EWR Form Expos T ime
0.2 2000
AFR TVD
feet
200 700
ohm -m
EWR Deep Phase Res
0.2 2000
ROP
feet per hr200 0 ohm-m
EWR Medium Phase Res
0.2 2000
MD 1 : 120
ohm-m N E S W N
AFR Medium 16 LF Mag-T
0 360
0.2 2000
AFR Form Exp Time
hours0 20 ohm-m
EWR Shallow Phase Res
0.2 2000200
250
300
350350
250
300
350
400400
300
350
400
450450
350
400
450
500
550
500
550
400
450
500
550
600600
500
550
600
550
600
650
600
650
Telemetry DP Transmitted DataNegative Pulse Data
ROP:100 ft/hrAll data, full resolution
Sliding, no data acquired
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Conclusions• As the search for hydrocarbons extends into deeper and
more remote subterranean targets and ever deeper waters, the demands placed on the drill string accelerate.
• Higher torsional capacities, better strength to weight properties, faster running and tripping speeds are a few of the challenges that must be addressed with the next generation of drill stem technologies.
• Critical ultra-deep, deep-water and ERD projects are already in the planning stages that cannot be efficiently drilled without the latest advances in drill pipe and drill stem designs.
• Papers provide an update on recent developments and highlights some problem areas that are associated with the latest generation of extreme drilling applications.
18
Challenging Drilling Applications Demand New Technologies M. J. Jellison
Challenging Drilling Applications Demand New TechnologiesMichael J. Jellison – NOV Grant Prideco™
1
2008 Jornadas de
Perforación21 – 23 October 2008
Salta, Argentina