To Directorate General of Hydrocarbons OIDB Bhawan, Plot No 2, Sector 73, Noida
November 19, 2013
By OLIVIA OIL CORPORATION Head Office-AB-22, Alberta, Canada
GLOSSARY Bit n : the cutting element at the bottom of the drillstring, used for boring through the rock. Bit record n : a report containing information relating to the operating parameters and performance of the bits run in a well.
Bit sub n : a short length of pipe installed immediately above the bit. The threads on the bit sub accept the pin thread on the bit and the pin thread for the drillcollars. Bottom hole assembly (BHA) n : the part of the drillstring which is just above the bit and below the drillpipe. It usually consists of drill collars, stabilisers and various other components. Bottom hole pressure (bhp) n : the pressure, 1. at the bottom of the borehole, or 2. at a point opposite the producing formation. Cable tool drilling n : an earlier method of drilling used before the introduction of modern rotary methods. The bit was not rotated but reciprocated by means of a strong wire rope. Circulate v : to pump drilling fluid through the drillstring and wellbore, returning to the mud pits. This operation is carried out during drilling and is also used to improve the condition of the mud while drilling is suspended. Core Bit (Core Head) n: A donut shaped drilling bit used just below the core barrel to cut a cylindrical sample of rock. Cuttings n : the fragments of rock dislodged by the bit and carried back to surface by the drilling fluid. Diamond bit n : a bit which has a steel body surfaced with diamonds to increase wear resistance. Directional drilling : n the intentional deviation of a wellbore in order to reach a certain objective some distance from the rig. Drag bit n : a drilling bit which has no cones or bearings but consists of a single unit with a cutting structure and circulation passageways. The fishtail bit was an early example of a drag bit, but is no longer in common use. Diamond bits are also drag bits. Drilling fluid n : the fluid which is circulated through the drillstring and up the annulus back to surface under normal drilling operations. Usually referred to as mud. Drilling line n : the wire rope used to support the travelling block, swivel, kelly and drillstring. Formation fluid n : the gas, oil or water which exists in the pores of the formation. Formation pressure n : the pressure exerted by the formation fluids at a particular point in the formation. Sometimes called "reservoir pressure" or "pore pressure". Insert bit n : a type of roller cone bit where the cutting structure consists of specially designed tungsten carbide cutters set into the cones. Milled tooth bit n : a roller cone bit whose cutting surface consists of a number of steel teeth projecting from the surface of the cones. Roller cone bit n : a drilling bit with 2 or more cones mounted on bearings. The cutters consist of rows of steel teeth or tungsten carbide inserts. Also called a rock bit. R.O.P. abbr : rate of penetration, normally measured in feet drilled per hour. W.O.B. abbr : Weight On Bit. The load put on the bit by the drill collars to improve penetration rate.
Introduction: When drilling with conventional PDC bit only a small portion of diamond cutting element is used during a bit run. The percentage of cutter that contacts formation will depend upon a number of factors including cutter size and amount of depth- of-cut bearing surface. However in most cases only 10% to 40% of the cutter will be used to actually shear the formation. The remaining 60 to 90% of the cutter is locked into the bit body and remains unused during the run. This resulting wear flats generate a high degree of frictional heat which breaks down the carbon bond, the increased temperature causes more wear. A drillers effort is to reduce this wear and generate more ROP (rate of penetration) and RPM (rotations per minute). Also with conventional drilling system the speed of bit at periphery is max and quite sufficient to drill the formation but at the center it is nearly zero thus exposing the drill string directly to solid formation. This can lead to vibrations and thus drill string instability, therefore a danger to entire setup. And, the present PDC bits cannot efficiently drill all range of formations especially the hard carbonaceous rocks. These problems have been together solved with solved with innovation of a stinger element. This comprises of a conical diamond element that is placed at center of bit with additional feature of ultra-thick diamond layer. The bit is modified in design for these cutters to fit inside the bit. The cutters rely on crushing unlike the previous concepts. BACKGROUND - The relatively poor performance of PDC bits in harder formations has been discussed by various authors since the inception of the PDC in the 1970s. Despite the fact that PDC bits tend to start drilling at higher ROP than roller cone or impreg bits, PDCs have been observed to reduce ROP quickly leading to increased Weight On Bit (WOB) and ultimately the pulling of the bit. Steady state testing of early drag bits (Appl et.al, 1962) and PDC cutters (Langveld, 1992) showed that both cutters and bits should last much longer than had been observed in the field. The difficulty of obtaining long bit life in hard rock was discussed by Feenstra (1988) where temperature limitations and impact resistance of the PDCs were highlighted as areas for improvement.
Glowka (1989) stated that wear flats on diamonds require additional force to make a cut since the WOB has to crush additional rock to achieve penetration. The frictional energy generated by the higher WOB on dulled cutters heats up the cutter. This leads to thermal damage and delamination of the PDC and ultimately limits bit performance. Brett et.al,(1990), described bit whirl as the cause of cutter chipping and failure, where chaotic bit motion, due at least in part to unbalanced cutter forces (Weaver and Clayton, 1993), leads to whirling of the bit. Bit whirl resulted in off rotation axis motion and cutters engaging the formation in directions other than perpendicular to their intended direction. Subsequent work by many manufacturers resulted in Anti-Whirl bits with low friction gauge, as described by Warren et.al, (1990) and Clegg (1992). Once the bit balance and whirl issues appeared solved, bit manufacturers set about improving the bit longevity by increasing the diamond volume on a bit through thicker diamond, increased cutter and blade count, increased back-rake, and use of smaller cutters (Sinor et.al, 1998; Mensa-Wilmot and Calhoun, 2000). This tactic, despite generally making the bits drill slower, did appear to make the bits last longer. Discussion of drill string effects that include vibration axially, laterally and torsionally by Langveld (1992) and Warren and Sinor (1994) showed that each of these modes of vibration could significantly damage cutters and the bit as a whole. This work has led to the modeling of the bit and BHA as a single system (Barton et.al 2007) in an effort to fully understand the various forces that affect the ROP and overall bit performance during the drilling process.
Aim: Development of Stinger Element. Objectives: Development of optimized bit design. Selection of appropriate technology. Field Testing. Modified drill string. Statement of Purpose: To reduce the production costs by increasing the bit durability. LIMITATIONS Despite their dominance in oil and gas applications, fixed PDC cutters have an inherent limitation: because most of its cutting edge is fixed into the bit blade, very little of the cutter contacts the formation. Accordingly, more than 60% of the cutters circumferential edge is unused during a bit run.
Methodology: Variable declaration. Development of optimized bit design i. Bit shape. ii. Fluid vents on bit. iii. Size of stinger element. iv. Cutting angle. v. FEA (finite element analysis) modeling.
Selection of appropriate technology. i. ONYX 360 rolling PDC cutter technology. ii. SHARC PDC drill bits. iii. Vertical Turret Lathe.
Field Testing i. Quartz Granite Wash (GW). ii. Feldspar Granite Wash (GW). iii. Highly abrasive Granite Wash (GW).
Modified Drill String. i. CERTIS isolation technology. ii. Control with IRDV. iii. SCAR sampling technology.
EVALUATION OF RISK -
1) a common problem in drilling is that something breaks in fall or down during drilling . for example , drill string twists off and fall to the bottom . a cone can break off the tricone bit or tool such as pipe wrench falls from the the rig floor into the well . This is called fish and cannot be drilled with a normal drill bit due to which drilling has to be suspended . This risk can be mitigitated with the help of spear or overshoot by which the pipe can be retrieved , a tapered mill reamer is also used for overcoming fishing .
2) The drill string can become stuck in the well due to either mechanical problems or differential pipe stucking like adhering of drill pipe to the well walls due to suction . This is a mitigated risk as drill pipe can be cut with a string shot or chemical cutter .
3) Sloughing shale is soft shale along the wellbore that absorbs water from the drillng mud . This is a mitigated risk as chemical such as potassium salts added to drilling mud are used to avoid sloughing shale .
4) unexpected abnormal pressures are the common risks in the subsurface which can't be mitigated .
5) While drilling a well with overbalance , part of the drilling mud liquid with some fines called the mud filterate is forced into the permeable rock adjacent to the wellbore . This is called Formation damage and can't be prevented so is a unmitigated risk during drilling . 6) In some areas corrosive gases such as carbon dioxide and hydrogen sulphide can flow out of the rocks and into he well as it is being drilled . This is is an unmitigated risk .
PHASE WISE DISTRIBUTION OF THE WORK PLAN
PHASE 1: Technological advancements introduced Description: Firstly, the limitations of the conventional bit system and drilling were analyzed. The main problem areas and their root cause were given prime attention. Our research team then got certain ideas and thoughts on basis of research that could prove to be a vital key towards unlocking the mystery. This solution not only solved current problems but also formed basis for certain technological discoveries like the Wireless Logging Tools called Quartet system that provide logging like wireless music telemetry. Requirements: Tentative cost: $ 0.8 million Infrastructure: Smith bits, a Schlumberger company Manpower: A team of 10 researchers including 2 formation engineers , 3 well logging engineers, 2 drilling fluid engineers, 1 geologist, 2 drillers Timeline: 1 year
PHASE 2 : Designing and manufacturing of the bit Description: In this phase, we worked upon the stinger bit design which includes its cutting angle, its revolutionary roller cutting technology with ONYX 360 cutters and stinger element, proper water course for the injection of drilling fluid in the wellbore ,hardness and strength parameters with setting up industrial diamond and PDC material are taken into consideration. All these have developed during Infrastructure: Smith Bits, a Schlumberger company Man Power: 2 HR manager 1 Project manager 3 Finance managers 2 bit designer Time: 2 month
PHASE 3 : Test run and evaluation of results
Description: Confirming greater durability through comprehensive testing. To determine how the new rolling cutter design compared with premium fixed PDC cutters, drilling durability tests were conducted using a granite test formation with an unconfined compressive strength of 30,000 psi. After 90 passes on the test formation, the premium fixed cutters developed extreme wear flats. The ONYX 360 rolling cutters showed virtually no sign of wear after 480 passes, and little wear after 600 passes. Requirements: Tools - conductor casing, drill string, derrick including hoisting system, drill line Materials - test formation Transport: 2 trucks containing cantilevered masts, 1 tool truck transporter Infrastructure: Test rig Tentative cost: $ 2.7 million Manpower: 2 drilling engineer 1 tool pusher 1 company man 1 finance manager 1 supply manager Time: 1 month
PHASE 4: Further modification of the bit according to the results Description: they results obtained under test runs were computed and the bit was further modified with better designs and high strength reinforced materials were used in bit. This new design was further analyzed by the team. Again certain minute problems were removed. These were loaded on the bit and it was again set for test runs. Infrastructure: Smith bits Materials: Substrate, thermally stable poly crystalline diamond, Manpower: Team of 10 researchers including 2 formation engineers, 3 well logging engineers, 2 drilling fluid engineers, 1 geologist, 2 drillers Transport: 1 tool truck transporter Tentative cost: $ 0.3 million Timeline: 4 months
PHASE 5: Successful run Description: After the modifications were adopted on basis of previous test runs, the bit was brought for another run. This process of moving of bit between two positions continues until bit registers a series of successful runs. This in our case was observed as 15 successful runs on succession. After this final results and data were tabulated. And, a factor of safety was introduced and bit was passed tested OK.
Requirements: Tools - conductor casing, drill string, derrick including hoisting system, drill line Infrastructure: Test rig Materials: Test formation Manpower: 2 drilling engineer 1 tool pusher 1 company man 1 finance manager 1 supply manager Transport: 2 tool transporter trucks Tentative cost: $ 2.3 million Timeline: 1 month
S. No. Phase Requirement Description Unit Price (in $) Quantity Total 1 I Manpower Formation Evaluation Engineer 116000 2 232000 2 I Manpower Well Logging Engineer 85000 3 255000 3 I Manpower Drilling Fluid Engineer 84000 2 168000 4 I Manpower Geologist 33000 1 33000 5 I Manpower Driller 28000 2 56000 6 II Manpower HR manager 13000 2 26000 7 II Manpower Project manager 12000 1 12000 8 II Manpower Finance manager 10000 3 30000 9 II Manpower Bit designer 9500 2 19000 10 III Manpower Drilling Engineer 10000 2 20000 11 III Manpower Tool pusher 6000 1 6000 12 III Manpower Company man 30000 1 30000 13 III Manpower Finance manager 5000 1 5000 14 III Manpower Supply manager 9000 1 9000 15 III Manpower Truck driver and assistant 4000 6 24000 16 IV Manpower Formation Evaluation Engineer 38670 2 77340 17 IV Manpower Well Logging Engineer 28330 3 84990 18 IV Manpower Drilling Fluid Engineer 28000 2 56000 19 IV Manpower Geologist 11000 1 11000 20 IV Manpower Driller 9330 2 18660 21 IV Manpower Truck driver and assistant 4000 2 8000 22 V Manpower Drilling Engineer 10000 2 20000 23 V Manpower Tool pusher 6000 1 6000 24 V Manpower Company man 30000 1 30000 25 V Manpower Finance manager 5000 1 5000 26 V Manpower Supply manager 9000 1 9000 27 V Manpower Truck driver and assistant 4000 4 16000 28 I Infrastructure Test rig 110000 1 110000 29 III Infrastructure Test rig 110000 1 110000 30 II Materials Substrate 1200 5 6000 31 II Materials Thermally stable poly crystalline diamond
20000 10 200000 32 III Materials Test formation 12000 5 60000 33 IV Materials Substrate 120 5 600 34 IV Materials Thermally stable poly crystalline diamond
200 10 2000 35 V Materials Test formation 12000 1 12000 36 III Transport Truck 82000 2 164000 37 III Transport Tool Truck Transporter 107000 1 107000 38 IV Maintenance Tool Truck Transporter 38000 1 38000 39 V Transport and Maintenance Tool Truck Transporter 145000 1 145000 40 III Tools Cantilevered Masts 34000 2 68000 41 III Tools Conductor Casing 20000 1 20000 42 III Tools Drill String 500000 2 1000000 43 III Tools Derrick including hoisting system 320000 2 640000 44 III Tools Drill line 100000 4 400000 45 V Tools Conductor Casing 20000 1 20000 46 V Tools Drill String 500000 2 1000000 47 V Tools Derrick including hoisting system 320000 2 640000 48 V Tools Drill line 100000 4 400000
REJECTION RATIO The rejection ratio is defined as the ratio of the number of products not fit for application or rejected to the total number of products manufactured during a specific period of time. During the manufacturing process, some of the bits were not found to be successfully produced due to inefficiency of the production machines. Also some of the bits were found to undergo abrasion due to their exposure to severe operating conditions. Accumulating the reports, approximately 2 out of 100 bits were estimated to be incapable of serving the drilling purpose. Therefore, the rejection ratio, Rejection Ratio = (No. of products rejected)/(Total no. of products manufactured) = 2/100 = 0.02 Hence, Total Cost: $6537782 Cash Plan
PHASE 1 : Description: Technological advancements introduced Total cost: $854000 Time: 1 year PHASE 2 : Description: Designing and manufacturing of the bit Total cost: $293000 Time: 2 months PHASE 3 : Description: Test run and evaluation of results Total cost: $ 2663000 Time: 1 month PHASE 4 : Description: Further modification of the bit according to the results Total cost: $ 296590 Time: 4 months PHASE 5 : Description: Successful run Total cost: $ 2303000 Time: 1 month
Timeline First 3months: $683200 (Phase1) Next 6months: $170800 (Phase1) Next 2months: $293000 (Phase1 Followed by Phase 2) Next 2months: $2692659 (Phase 2) Next 2months: $497231 (Phase2 Followed by Phase 3) Next 4months: $2072700 (Phase 4 and followed by phase 5) Total Budget Total Cost: $6,409,590 1. Manpower: $1,266,990 2. Infrastructure: $220,000 3. Materials: $280,600 4. Transport and Maintenance: $454,000 5. Tools: $4,188,000
TECHNICAL BENEFITS -
1) Revolutionary cutting technology extends PDC bit durability
2) Unique rolling cutter design ensures reliability
3) The rolling cutters orientation in the bit blade relative to its contact with the formation, coupled with the bits drilling force, drives efficient rotation of the cutter. And because the entire diamond edge of the cutter is used, wear is reduced for more sustained rates of penetration and fewer bit replacement trips.
4) Minimizing loading force to drill more efficiently
5) Innovative diamond element increases drilling speed and improves stability
6) Maintain high ROP in hard, abrasive formations
7) minimize vibration during drilling providing extra stability .
8) wireless logging introduced with shorter length of drill string needed and advanced logging in the wellbore . CONCLUSIONS AND RECOMMENDATIONS :- Accelerated abrasion testing leads to the following conclusions: The Stinger cutter exhibits reduced vertical and drag forces compared to conventional shear cutters when tested on the VTL. The Stinger cutter has significantly improved abrasion resistance during extended wet testing on the VTL. The Stinger cutter shows far higher linear footage before burn out in dry/hot testing compared to conventional PDC. Laboratory testing at Terra Tek showed the Stinger bit to successfully cut hard abrasive rocks with no observable wear. All this suggests that Stinger PDCs may represent a significant step toward the goal of long-life bits for hard formations in hot environments. Obviously additional test-driven, iterative improvements to Stinger bit design and understanding are needed to attain the longevity and footage demanded for geothermal applications.
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Today, our real-time technology services and solutions enable customers to translate acquired data into useful information, then transform this information into knowledge for improved decision making-anytime, anywhere. Harnessing information technology in this way offers enormous opportunities to enhance efficiency and productivity. This is a quantum leap from providing traditional 'just- in-case' information to delivering 'just-in-time' knowledge that meets the changing needs of our customers. International teamwork Reflecting our belief that diversity spurs creativity, collaboration, and understanding of customers' needs, we employ approximately 120,000 people representing over 140 nationalities and working in more than 85 countries. Our employees are committed to working with our customers to create the highest level of added value. Knowledge communities and special interest groups with our organization enable teamwork and knowledge sharing unencumbered by geographic boundaries. Technology innovation With 125 research and engineering facilities worldwide, we place strong emphasis on developing innovative technology that adds value for our customers. In 2012, we invested $1.2 billion in R&E.
Olivia Oil Corporation is the worlds leading supplier of technology, integrated project management and information solutions to customers working in the oil and gas industry worldwide.
REFERENCE -
Appl, F.C. and Rowley, D.S.: Drilling Stresses on Drag bit Cutting Edges, presented at the 5th Rock Mechanics Symposium, School of Mines and Metallurgy, University of Minnesota, May 3-5 1962.
Brett, J.F., Warren, T.M. and Behr, S.M.: Bit Whirl A New Theory of PDC Bit Failure, SPE 19571, SPEDE (Dec. 1990), 275-281.
Clayton, R., Chen, S. and Lefort, G.: New Bit Design, Cutter Technology Extend PDC Applications to Hard Rock Drilling, 2004. SPE/IAD. 91840.
Clegg, J.M.: An Analysis or the Field Performance of Antiwhirl PDC Bits, 1992. SP. 23868. Feenstra, R.: Status of Polycrystalline-Diamond- Compact Bits: Part 1 Development, JPT (June 1988), 675-684.
Glowka, D.A.: Use of Single-Cutter Data in the Analysis of PDC Bit Designs: Part 1- Development of a PDC Cutting Force Model, Journal of Petroleum Technology, August 1989. Langeveld, C.J.: PDC Bit Dynamics, 1992. SPE 23867.
Mensa-Wilmot, G. and Penrose, B.: Advanced Cutting Structure Improves PDC Bit Performance in Hard and Abrasive Drilling Environments, 2003. SPE 81167.
Mensa-Wilmot, G, and Ramirez, J.: Unique Polycrystalline Diamond Compact (PDC) Cutter Improves Drilling Efficiency, 1999. SPE 53954. Schell, E.J., Phillippi, D. and Fabian, R.T.; New, Stable PDC Technology Significantly Reduces Hard Rock Cost Per Foot, 2003. SPE/IADC 79797.
Sinor, L.A., Powers, J.R. and Warren, T.M.: The Effect of PDC Cutter Density, Back Rake, Size and Speed on Performance, 1998. SPE/IADC 39306
Warren, T. M., Brett, J.F. and Sinor, L.A.: Development of a Whirl Resistant Bit, SPE 19572, SPEDE (Dec. 1990), 267-274. Warren, T.M. and Sinor, L.A.: PDC Bits: Whats Needed to Meet Tomorrows Challenge, 1994. SPE27978.
Weaver, G.E. and Clayton, R.I.: A New PDC Cutting Structure Improves bit Stabilization and Extends Application Into Harder Rock Types, 1993. SPE/IADC 2574.