2008 jornadas de perforaci ón 21 – 23 october 2008 salta, argentina

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


Increased torque capacity

6 5/8Speed of makeup

Reduced make-up torque


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.


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)



API NC V-.038R(0.038-in. root radius)



API NC V-.038R(0.038-in. 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.


Advanced Metals Drill Pipe

8


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.


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.


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.


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


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.


Video of 3rd Generation Hard Band Machine


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

)


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


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


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.


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


Hoisting Capacity (2 Issues!)

Tool Joint Elevator Capacity

Hoisting capacity is also a function of tool joint diameter!

Elevator Tonnage Rating

CONVENTIONAL

UNCONVENTIONAL

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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


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


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

?


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


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 ? ? ?


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


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


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.


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


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


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


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 TechnologiesMichael J. Jellison – NOV Grant Prideco™

1

2008 Jornadas de

Perforación21 – 23 October 2008

Salta, Argentina

2008 jornadas de perforaci ón 21 – 23 october 2008 salta, argentina

Documents

faster drilling

new technologiesmichael

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speiadc drilling conference

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high strength drillpipe