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Advanced High-Pressure Coiled-tubing Drilling System

Dr. William C. Maurer

JUNE 1, 2007

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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.

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Project Structure

Phase I – Feasibility study

Phase II – Development of high-pressure motors, bits and other critical components.

Phase III – Field testing and commercialization

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Phase I & II Results

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Coiled-Tubing

Confirmed feasibility of coiled-tubing system

Calculated fatigue life of coiled tubing

Developed improved tubing (QT1200)

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Coiled Tubing Burst Pressure (100,000 psi yield)

CT Diameter (in.)

1.00

1.25

1.50

1.75

2.00

2.375

2.875

3.500

Wall Thk. (in.)

0.109

0.156

0.175

0.188

0.203

0.203

0.203

0.203

Burst Pressure (psi)

20,800

24,160

22,670

20,910

19,800

16,670

13,770

11,310

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0

10000

20000

30000

40000

QT-1000 Incoloy-625 Composite

Bu

rst

Pre

ssu

re (

psi

) CT Burst Pressure

2.00 inch OD

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0

50

100

150

200

6,000 9,000 12,000

1.75"

2.00"

CT FATIGUE LIFE

Fati

gu

e L

ife

(tri

ps)

Internal Pressure (psi)

QT-1000

(based on MEI CTLIFE model)

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Fatigue Test Machine

Hydraulic

Actuator

Curved Bending Form

Pump

Straight

Bending Form

CT Sample

Pressure Controller

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Fig. 7-2 Fatigue Life of 1-1/2” Coiled Tubing (R. Stanley, 2000)

0

50

100

150

200

250

300

350

400

450

500

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000

Internal Test Pressure (psi)

Fa

tig

ue

Lif

e (

cyc

les

)

Actual Cycles for QT-1200

Model Cycles for QT-1000

Model Cycles for QT-800

(0.156” Wall)

Tubing Fatigue Tests

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High-Pressure Motor

Designed HP power section

Developed labyrinth seal

Proved Diamond bearing technology

Laboratory tested motor

Manufactured HP PDC bits

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Motor Labyrinth Seals

Upper Restrictor 5”

5”

Fluid Flow

Lower Restrictor

Shaft Housing

}

}

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Motor Labyrinth Leakage

8.1

12.1

0

2

4

6

8

10

12

14

16

0.004" 0.006"Leakage Clearance (w)

Flo

w R

ate

(g

pm

)

w Four 5” Labyrinths 10,000 psi

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Thrust Load on Bearing 10,000 PSI

34,000 lb Force

Seal

Housing

Thrust Bearing

Bit

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Candidate Bearings

Ball Bearing PDC Bearing

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Bearing Load Comparison

5600

16,800

0

5000

10000

15000

20000

Ball Bearing PDC Bearing

Lo

ad

Ca

pa

cit

y

100 Hours @ 300 rpm

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High-Pressure Coiled Tubing

Motor

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10,000 psi

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High Pressure Jet-Drilling Rates

0

200

400

600

800

1000

1200

1400

1600

Texas Leander Glacier Pecos

1500

780

255

68 110

120 142

910 (WOB=1000 lbs)

Je

t D

rill

ing

Ra

te (

ft/in

)

Cream Limestone

Limestone Bluff Dolomite

Red Sandstone

Bit Weight = 2000 lbs = 10,000 psi = 1,000 psi

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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

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High Pressure Jets

Slots

Formation Damage

Fig. 13 Jet Slotting Stimulation

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Fig. 14 Jet Slots In Glacier Bluff Dolomite

10,000 psi Jet Pressure Axial Velocity 140 in/min

Rotary Speed 6 rpm

Slot

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Cuttings Removal Screen

Borehole Pressure

Drilling Fluid Input

Shaft Seal

Pressure Chamber Formation Pressure

Rock Rock

Choke

Fig. 11 DRC Wellbore Simulator Drilling Stand

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Fig. 12

Effect Of Wellbore Pressure

1010920

0

200

400

600

800

1000

1200

1400

1600

1800

0 psi 2000 psi

Wellbore Pressure

RO

P (

ft/h

r)

Texas Cream Limestone 2000 lb Bit Weight

(High Pressure Drilling)

Wellbore Pressure = 2000 psi Jet Pressure = 9300 psi

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Ce

me

nt

Tubing

High Pressure Jets

Drilling Cement

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Barite Scale

High Pressure Jets

Tubing Barite Scale Removal

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High Pressure Jets

Tubing Open slots

Plugged slots

Jetting slots

Cleaning Slotted Liners

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Predrilled Hole

Reamed Hole

High Pressure Jets

Hole Guide

Hole Reaming/Cleaning

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High Pressure Jets

Casing

Under Reaming

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CT Cement Cleanout Rates

60

1000

0

200

400

600

800

1000

1200

Low Pressure 10,000 psi

RO

P (

ft/h

r)

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Phase III -- Plans

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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

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NEPA

Determine data needed

Develop reporting form

Supply Catoosa data

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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

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Shallow Field Test

Visit Catoosa

Cohen

BJ services (Kelly Falk &/or Jay Albrecht)

Write engineered work plan

Drill Depth 2000 ft

File NEPA documents

Test drilling & slotting system

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Deep Field Test

Modify tools

NEPA

Engineered work plan

Test to minimum depth 8,500 to 10,000 ft

Commercialization plan

Market survey

© 2007 48