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High-Pressure Jet Kerf Drilling Shows Significant Potential To Increase ROP

High-Pressure Jet Kerf Drilling Shows Significant Potential To Increase ROP. 2005 SPE ATCE Dallas, Texas October 9-12, 2005 By John H. Cohen—Maurer Technology Inc. Greg Deskins—Maurer Technology Inc. Dr. John Rogers—U.S. Department of Energy (Morgantown, WV). Drilling Time Study.

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High-Pressure Jet Kerf Drilling Shows Significant Potential To Increase ROP

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  1. High-Pressure Jet Kerf Drilling Shows Significant Potential To Increase ROP 2005 SPE ATCE Dallas, Texas October 9-12, 2005 By John H. Cohen—Maurer Technology Inc. Greg Deskins—Maurer Technology Inc. Dr. John Rogers—U.S. Department of Energy (Morgantown, WV)

  2. Drilling Time Study • Drilling Consumes Majority of Rig Time • Increased Depth = Increased Drilling Time • For all wells, drilling time 33% • For wells >14,000 ft, drilling time 50% • To Reduce Costs, ROP Must Increase • ROP Increase Must be Significant

  3. Drilling Time Breakdown BOP – 3% Well Depths >14,000 ft Wait Time – 3% Test & Log – 7% Trouble – 4% Running Casing – 5% Drilling – 49% Tripping – 22% From Andersen (1990) Conditioning Mud – 5% Reaming – 3%

  4. Reducing Drilling Costs • Drilling is Single Largest Cost Item • Increased Drilling Efficiency Best Way to Reduce Costs • Rate Increases Must Be Large (2X or Greater) • Jet-Assisted Drilling Meets These Criteria

  5. Previous Jet Drilling R&D • Exxon (1960s) • Showed that jets alone could remove rock • 15,000 psi at depths up to 12,000 ft • Flow Drill (1980s) • Ultra HP 30,000-40,000 psi • Concentric drill pipe • Shell (1970s) • Gulf – Erosion Jets (1970s)

  6. Jet Kerf Drilling • High-Pressure Jets Erode Grooves in Rock • Mechanical Cutters Break Rock Ledges • Pressures Range from 5,000–15,000 psi • Can Drill Many Formation at High ROPs • Increases ROP 2X to 4X Conventional Rates

  7. Jet Kerf Drilling

  8. High-Pressure Jet Kerf Rates 1600 Bit Weight = 2000 lb 10,000 psi 1,000 psi 1400 1200 1000 Jet Drilling Rate (ft/hr) 800 600 400 200 110 0 Texas Cream Limestone Leander Limestone Glacier Bluff Dolomite Pecos Red Sandstone

  9. Jet Kerf Drilling Video

  10. Original System Concept • Coiled Tubing (CT) to Deploy Jet Kerfing BHA • HP mud motor • Kerfing bit • CT Routinely Used with HP Fluids • No Tool Joints (Fewer Leak Paths) • Fast Trips

  11. Jet Kerfing with CT CT Reel Injector Head HP Pump HP Flow Returns Returns HP Motor High-Strength Coiled Tubing Jet Kerfing Bit

  12. Field Test I – Catoosa • CT-Deployed System • Problems Making Up BHA • Problems with CT Ballooning Due to HP • Daily Equipment Cost High

  13. No Derrick on CT Rig

  14. CT Equipment On Site

  15. High-Pressure Pumps

  16. Catoosa Test Summary • Time Lost Making Up BHA • High Equipment Costs • Severe CT Fatigue and Ballooning Problems • Downhole Well Conditions Not Known • Failed to Test Jet Kerfing Drilling • Additional Field Tests Sought

  17. Field Test II – RMOTC • At DOE-operated Rocky Mountain Oilfield Testing Center (Casper, Wyoming) • Rotary Drilling • Option for Deeper Drilling • Rig Upgrades Required for HP Service • Jointed Drill Pipe with Double-Shoulder Tool Joints • Variety of Formations Drilled

  18. RMOTC Rig • Cooper 550 Rig • Rated to 275 kip • 7000’ depth • Pulls doubles

  19. Cost to Upgrade Rig Upgrade for High-Pressure (HP) Service Cost HP Kelly Hose (10,000 psi) $16,200 HP 150-ton Drilling Swivel $33,500 HP Swivel Joints (Chicksans) $10,600 Stand Pipe Master Valve 3-1/16" (15,000 psi) $11,800 Stand Pipe Fill Up Valve 2-1/16" (15,000 psi) $5,300 Gooseneck, unions, hardline, tees, and misc. $16,700 Welding and X-ray $1,650 Labor $10,000 New HP Pump $500,000 TOTAL: $605,750

  20. Upgraded HP Swivel

  21. High-Pressure Pump

  22. Double-Shoulder Tool Joint

  23. RMOTC Bit Runs Formation Jet Kerf ROP (ft/hr) Conv. Rate (ft/hr) Ratio JKD to Conv. Bit 1 – Run 1 (Cleaning out sand from well) – – – Bit 2 – Run 1 Crow Mountain Sand 156 120 1.3 Bit 2 – Run 1 Crow Mountain Sand / Alcova Limestone 49.8 13.5 3.7 Bit 2 – Run 1 Red Peaks Shale 55.1 14.8 3.7 Bit 2 – Run 2 Red Peaks Shale 77.7 12.9 6.0 Bit 1 – Run 2 Red Peaks Shale 61.9 13.3 4.7 Bit 3 – Run 1 Red Peaks Shale 66.0 13.8 4.8 Bit 3 – Run 2 Red Peaks Shale 39.8 14.1 2.8 Bit 3 – Run 2 Goose Egg 39.3 14.1 2.8 Conv. Bit Goose Egg – 10.4 –

  24. Jet Kerf Drilling Rates

  25. Increase in ROP

  26. High-Pressure Kerf Bit (6½”)

  27. Rapid Erosion of Nozzles

  28. Washout in Side of Bit 3

  29. Sectioned Bit Eroded Nozzle Port

  30. Solution – Extended Nozzle High-velocity fluid US Patent No. 6,142,248

  31. Summary of RMOTC Tests • Drilled Multiple Formations at High ROP (>5X) • Used Conventional Rotary Drilling • No Equipment Problems • Nozzle Erosion Only Major Issue

  32. Economic ModelConditions & Assumptions • Defined Base-Case Well • 28 total days on site • 24 drilling days • Value based on rig rate of $10,000/day • Hole Sizes for Kerf Drilling ≤6½” • 1/3 of Drilling Days for Kerf Drilling

  33. Daily rig cost $10,000 Total days per well 28 Drilling days per well 24 Small hole drilling days (≤6½”) 8 Cost per well $280,000 Wells per year 13.0 Base-Case Well

  34. Well Cost with Jet Kerfing $245 Daily Rig Rate = $10,000 $240 $240 $235 $232 $230 $227 Cost per Well ($1000) $225 $220 $220 $215 $210 2X ROP 2.5X ROP 3X ROP 4X ROP Drilling Rate

  35. Well Cost including Payback $290 1 Year Payback 2 Year Payback $282 $280 $273 $270 $266 $262 $259 $260 $254 $248 $250 Cost Per Well ($1000) $240 $240 $230 $220 $210 2X ROP 2.5X ROP 3X ROP 4X ROP Drilling Rate

  36. Faster ROP = More Wells Per Year 18 30 16.6 28.0 16.1 15.7 16 15.2 25 23.2 22.7 14 24.0 13.0 22.0 12 20 10 Wells Per Year Days Per Well 15 8 6 10 4 5 2 0 0 Base Case 2X ROP 2.5X ROP 3X ROP 4X ROP Drilling Rate

  37. Conclusions • Increased ROP is Key Factor in Reducing Total Well Costs. • JKD Can Significantly Increase ROP. In Field Tests, System Drilled 1.3–6X Faster than Conventional. • JKD Successful in Variety of Formation Types.

  38. Conclusions (cont’d.) • JKD Can Be Accomplished Using off-the-Shelf Equipment to Upgrade Rotary Rigs for HP Operation. • HP Kerfing Bits will Require Anti-Erosion Nozzles to Increase Bit Life. • Safety Issues for Handling HP Fluids Successfully Addressed on Field Tests.

  39. The End

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