Performance Drill Bit
Performance Drill Bit
Performance Drill Bit
Industry / DOE Program to “Develop and Benchmark
Advanced Diamond Product Drill Bits and HP/HT Drilling Fluids
to Significantly Improve Rates of Penetration”
Optimization of Deep
Drilling Performance
Drilling in HP/HT Conditions
(DeepTrek Project)
Arnis Judzis, Executive Vice President
TerraTek
June 22, 2006
at PTTC HPHT Workshop, Houston
Presentation topics
1 Solving Operator HP/HT Challenges
Development and Benchmark Testing of Advanced
2 Diamond Product Bits and High Pressure/High
Temperature Fluids to Significantly Improve Rates of
Penetration
3 Commercializing DeepTrek Results
Closure
1 Solving Operator HP/HT Challenges
Impact and Business Benefits
(Industry Input January 31, 2006 Advisors)
• “Some ultradeep prospects will have well costs > $200
million; must quantify benefits of new R&D; AFE challenges
include temperature and low ROP”
• “DeepStar Study for deepshelf GOM noted financial stakes
are high for both costs and for reward”
• “Ultra deep prospects are planned”
• “Window for ultradeep opportunities may close quickly if
wells are not successful”
• “Question is, how can you drill and produce ultradeep
without knowing the phenomenon”
• “Mechanisms of deep and hard rock drilling are unknown”
Technical Challenges
“. . . Deep gas drilling, biggest single threat [for success]”. . .
“ . . . . drilling deep reservoirs and it is slow”. .
“Interest in deep HP/HT continues”. . . .
“Rock cutting process changes at depth and possibly with
temperature”. . . . .
“Ultra deep planned for GOM, no answer yet for some things,
slow”. . . . . .
“Fluid challenges at HP/HT conditions including stability”. . . .
“Need to know state of rock at depth” . . . . .
“Mechanisms of chip hold down, hydraulics and regrinding at
great depth [is unknown]”. .
“Hard rock problems while drilling”
DeepTrek
Phase 1
DeepTrek
Progress to Date
Phase I High Pressure Drilling Plan has been planned
and executed
Tests conditions have been validated against actual
performance from two target applications
Anadarko Basin and
Tuscaloosa Trend
Phase I Data have been reviewed
Phase II objectives are to investigate further the
processes causing low ROP at elevated bottom
hole pressure and to improve upon Phase I
benchmark performance
DEEPTREK ROP
BIT TYPE COMPARISON: CRAB ORCHARD
90 RPM (Impreg at 120 RPM)
300 GPM: 11000psi Confining
90
Linear (4 Blade PDC 11ppg WBM)
80
Linear (TCI 11ppg WBM)
70
Linear (7 Blade PDC 11 ppg WBM)
60 Linear (Impreg 11ppg WBM)
ROP (ft/hr)
50
Linear (7 Blade PDC Water Baseline)
40
30
20
10
0
0 5000 10000 15000 20000 25000 30000 35000 40000 45000
WOB (LBS)
Key Findings
• Phase 1 testing of bestinclass bits and drilling fluids successfully
completed. Wellbore pressure of 11,000 psi first ever largescale testing.
2. Baseline tests with ‘water’ and ‘base oil’ demonstrates high ROP’s possible
before mudding up.
3. Performance of PDC and Impregnated bits show substantial improvements
over roller cone bits in some cases.
4. Analysis of cuttings generally show small size particles.
Deep Drilling (for argument)
At 20,000 foot well pressures
– Mud up reduces ROP by factor of 10
– Different cutter design increases ROP
by factor of 2
2
Industry & U.S. DOE
Development and Benchmark Testing of
Advanced Diamond Product Bits and High
Pressure/High Temperature Fluids to
Significantly Improve Rates of Penetration
Project Manager: TerraTek
Service Company Contributors:
Hughes Christensen
Baker Hughes Drilling Fluids
DEA 148 Contributors:
Aramco
Statoil
BP
Operator Advisors:
Marathon
ConocoPhillips
Chevron
Technical Objectives
• Characterization of applications – (Industry Team has
proposed specific tests)
• Benchmark performance of ‘bestinclass’ products
• Develop aggressive diamond product bits and fluids to
improve ROP
• Test and improve significantly drilling performance via
emerging and newly developed drill bits and fluid systems.
• Commercialization and field deployment
Effects of Borehole Pressure and Rock Type on ROP
90
Rollercone Insert Bits
80
70
60
BonneTerre dolomite Colton SS
ROP (ft/hr)
50 26,000 psi UCS
BonneTerre dol
Mancos shale
40 Carthage marble
30
Carthage marble
20 16,000 psi UCS DeepTrek
Depth
Simulation
10 Colton sandstone
7,600 psi UCS Manco shale
9800 psi UCS
0
0 2000 4000 6000 8000 10000 12000 14000
Borehole Pressure (psi)
Phase I
Rock Selection
* Rock strength tests conducted at Terra Tek
Successful Testing Program (MarchMay 2005)
Test Matrix for DeepTrek Phase 1 Updated: May 17, 2005
Arbuckle Test Series with 11 ppg Waterbase Fluid and Crab Orchard and Carthage Marble Samples
Test # Bit Nozzles Rock Mud Flow Rate HSI Borehole Confining Overburd. Ram RPM
Deep1 PDC 7Blade 312 + 1 Port CO/Carth Water 300 2 HSI 10,000 11,000 12,000 13,000 90
Deep2 Rollercone 315 Carth 11 ppg WB 300 2 HSI 10,000 11,000 12,000 13,000 70110
Deep 3 Rollercone 315 CO 11 ppg WB 300 2 HSI 10,000 11,000 12,000 13,000 70110
Deep4 PDC 7Blade 213, 114 + 1 Port Carth 11 ppg WB 300 2 HSI 10,000 11,000 12,000 13,000 90120
Deep5 PDC 7Blade 213, 114 + 1 Port CO 11 ppg WB 300 2 HSI 10,000 11,000 12,000 13,000 90120
Deep6 Impregnated 0.97 TFA Carth 11 ppg WB 300 0.6 HSI 10,000 11,000 12,000 13,000 60250
Deep7 Impregnated 0.97 TFA CO 11 ppg WB 300 0.6 HSI 10,000 11,000 12,000 13,000 60250
Deep8 PDC 4Blade 313, 112 CO/Carth 11 ppg WB 300 2 HSI 10,000 11,000 12,000 13,000 90
Tuscaloosa Test Series with 16 ppg Oilbase Fluid and Crab Orchard and Mancos Shale Samples
Test # Bit Nozzles Rock Mud Flow Rate HSI Borehole Confining Overburd. Ram RPM
Deep9 PDC 7Blade 312 + 1 Port CO/Mancos Base Oil 300 2 HSI 10,000 11,000 12,000 13,000 90
Deep10 PDC 7Blade 213, 114 + 1 Port CO/Mancos 12 ppg OB 300 2 HSI 10,000 11,000 12,000 13,000 90
Deep11 Impregated 0.97 TFA CO/Mancos 12 ppg OB 300 0.65 HSI 10,000 11,000 12,000 13,000 60250
Deep12 Impregated 0.97 TFA CO/Mancos 16 ppg OB 300 0.9 HSI 10,000 11,000 12,000 13,000 60250
Deep13 PDC 7Blade 315 + 1 Port CO/Mancos 16 ppg OB 300 2 HSI 10,000 11,000 12,000 13,000 90
Deep14 PDC 7Blade 212 + 113 + 1 Port CO/Mancos 16 ppg OB 340 5 HSI 10,000 11,000 12,000 13,000 90
Deep15 PDC 4Blade 314, 115 CO/Mancos 16 ppg OB 300 2 HSI 10,000 11,000 12,000 13,000 90
Deep16 PDC 7Blade 315 + 1 Port CO/Mancos 16 ppg OB 300 2 HSI 5,000 6,000 7,000 8,000 90
Drill Bits (Hughes Christensen)
STR 70 Roller Cone Bit
ST 3554 4Bladed PDC
HC 407 7Bladed PDC
HH 352 Impregnated Diamond
Diamond Product Bits
DEEPTREK ROP
SUMMARY FOR CRAB ORCHARD
6" HC407 W/312 + 1 PORT water
90 RPM (Impreg at 120 RPM)
6" STR70 W/315 11ppg
Water and WBM: 10000psi Confining
6" HC407 W/213+114+1PORT 11ppg
6" ST3554 W/313+112 11ppg
90 6" HH352 W/0.97 TFA 11ppg
Linear (6" ST3554 W/313+112 11ppg)
80 Linear (6" STR70 W/315 11ppg)
70
60
ROP (ft/hr)
50
40
30
20
10
0
0 5000 10000 15000 20000 25000 30000 35000 40000 45000
WOB (LBS)
Lessons Learned / Operator Recommendations
• Hard rock drilling still very important – don’t forget compressive
strengths get very high!
• Select formations that will give you most information in Phase 2
• Mechanisms important – ‘chipping’ or ‘grinding’ mode
• Both design and operational parameters are opportunities
• Economics make drilling performance improvements compelling;
AFE spreads of $200k per day not uncommon and high pressures
with weighted mud seen at 15,000 ft.
• At great depth there may be breakpoint where even insert bit
performance may not be enough due to weight requirements.
• Fluids and hydraulics important also
• Good development options in Phase 2 for bit design and materials
• Data is useful!
Commercializing DeepTrek Results
Opportunities for Improved Drilling
3
Performance (Drilling Fluids & Bits)
PHASE 2 TESTING
• Diamond Product Bits
• Wear resistance
• Cutter configuration for performance
• Cutter geometry
• Aggressiveness
• Cutting mechanisms ‘knowhow’ for permeable and
impermeable rocks
• Materials
• Drilling Fluids
• Heavy Brine
• Alternative Weight Materials
• Alter Suspended Solids Distribution
• Lubricants in Oil Based Mud
DeepTrek Phase 2 Test Matrix
Heavy brine Rock types
Altered solids
distribution
Bit types
MnO 4
Heavy Brine
• Dissolved salts replace suspended weight material
reducing suspended solids
• Private testing drilling Pierre I shale suggest high
drilling efficiency
– 18 lb/gal CsFormate comparable to OBM in
drilling efficiency
– Conclusion uncertain due to lack of simulated
drill solids in CsFormate system
• Manufacturer willing to supply CsFormate system
and add simulated drill solids
• Two tests would evaluate effectiveness of clear
brines in hard rock and sensitivity to drill solids
Alternate Weight Material
• Manganese tetroxide (MnO 4)
• Specific Gravity = 4.8 versus
4.2 for barite
• Spherical particles
• Smaller diameter allows lower 20 microns
viscosity without settling
100
• Tendency toward high fluid 90
loss 80
70
Cumulative %
• Could help differentiate effect 60
of viscosity, fines and fluid loss 50
40
control 30
20 Manganese
• Three tests may be required 10
Tetraoxide
Barite
0
0.1 1 Size (m icrons) 10 100
Business Context
Closure
Optimization of Deep Drilling Performance
1 Solving Operator HP/HT Challenges
Development and Benchmark Testing of
Advanced Diamond Product Bits and High
2 Pressure/High Temperature Fluids to
Significantly Improve Rates of Penetration
3 Commercializing DeepTrek Results
TerraTek
1935 South Fremont Drive
Salt Lake City, UT 84104
Arnis Judzis (801) 5842483, [email protected]