Loading documents preview...
HPHT Solutions Baker Hughes - Drilling and Evaluation • Baker Hughes D&E HPHT Solutions • HPHT Case History • Research and Development Outlook Christian Liss – Wireline HPHT Segment Manager Dominic Dieseru – Wireline Applications and Product Line Manager Stephen Rounce – Wireline Customer Service Manager Ian Mansfield – Marketing Director Reservoir Evaluation HPHT Wells Summit 2011 - London, November 16th 2011 © 2011 Baker Hughes Incorporated. All Rights Reserved.
HPHT Frontier Markets • HPHT drilling & exploration is critical to access – Onshore Shale, long horizontals – Offshore Deep Water, Ultra deep water – Geothermal applications • Cost of developing these wells is high • Reliability of service & equipment critical! Performance Through Technology • Target extreme service requirements • Apply robust design - modeling & validation • Drive reliability - testing & qualification • Deliver research innovations in Metals, Sensors, Electronics, Elastomers 2
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Cement
Wireline Logging
Liner Hanger
BHI
FES
DD
BHI
MWD
Reamers
BHI
Year
Operator
Well name
TVD [ft]
Location
2003
Shell
Shark
25,745
Sout Timbalier
2005
Chevron
Cadilac
24,795
Viosca Knoll
2005
Shell
Joseph
25,537
High Island 10
2006
ExxonMobil
Blackbeard
30,067
South Timbalier
BHI
BHI
2008
McMoRan
Blackbeard RE
32,997
South Timbalier
BHI
BHI
2009
BP
Will K
28,404
High Island
BHI
BHI
2009
McMoRan
Ammazzo
25,488 South Marsh Island
BHI
BHI
2009
McMoRan
Davy Jones
29,300 South Marsh Island
BHI
BHI
2010
Armstrong O&G
BP Fee
15,800*
Cameron Parish
BHI
BHI
BHI
2010
McMoRan
Blackbeard East 32,000*
South Timbalier
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
2011
McMoRan
Davy Jones Offset
30,700* South Marsh Island
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
2011
McMoRan
Lafitte Project
23,000*
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
Eugine Island
BHI
© 2009 Baker Hughes Incorporated. All Rights Reserved.
BHI BHI
* ongoing at the creation time of the slide 3
Bits
Fluids
Gulf of Mexico – Expertise in Ultra-deep Gas Case History
BHI
BHI
BHI
BHI
BHI
BHI BHI
BHI BHI BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI
BHI BHI
Drilling Services HPHT Challenges & Solutions
4
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Circulating vs. Static Temperature During drilling • Bottom hole = circulating =
operating • Typical decrease: 5-50°C • Parameters
• Mud coolers • Hole size • Depth • Orientation • Flow rate • Drill string rotation • Cooler → Deeper 5
© 2010 Baker Hughes Incorporated. All Rights Reserved.
HPHT Drilling Services Available X-tremeBorehole Motors Temperature OnTrak
OnTrak
AutoTrak
AutoTrak
LithoTrak
LithoTrak
TesTrak
TesTrak
SoundTrak
SoundTrak
MagTrak
MagTrak
ZoneTrak G/R
ZoneTrak G/R
StarTrak
StarTrak
SeismicTrak
SeismicTrak
0
6
X-tremeBorehole Motors
Rating
5
10
15 20 Pressure [kpsi]
© 2009 Baker Hughes Incorporated. All Rights Reserved.
25
30
35
0
25
50
Temperature Rating
75 100 125 Temperature [°C]
150
175
200
HPHT by Design - Development
7
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Minimizing Operating Days in High-Temperature Drilling in Haynesville Shale Case History
Objectives • Zero HS&E incidents • Identify zone of interest • Minimize operating days while drilling in HT environment reaching 343°F (172°C)
Days vs. Depth 11500 12000 12500 6 3/4" Curve 13000 13500
MEASURED DEPTH (ft)
Well Data • USA, Louisiana, Bossier Parish, 2009 • Hole Size: 6¾-in. • Well Type: Horizontal • Formation: Haynesville Shale • Planned Dogleg: 9°/100 ft • Mud Type: 15 ppg OBM
14000 6 3/4" Late ral 14500 15000 15500 16000 16500 17000 17500 18000 0
5
10 DAYS O N JO B
Solution • Service personnel trained in HT operations • High-temperature operating procedures • High-temperature MWD service Results • Zero HS&E incidents • Identified and successfully placed well into zone of interest • Completed drilling in 18 days • Drilled 6¾-in. curve (1,064 ft) with net ROP of 11 ft/hr • Drilled 6¾-in. lateral (4,435 ft) with net ROP of 39 ft/hr 8
© 2009 Baker Hughes Incorporated. All Rights Reserved.
15
20
SoundTrak™ Acoustic for PPP application Case History Determining accurate subsalt pore pressure in real time
Low sensitivity to hole sizes, formation
Acoustic pore pressure
Measured pressures
Modeled Fracture gradients
9
© 2010 Baker Hughes Incorporated. All Rights Reserved.
temperature and pore water salinity Small effect on measurement around salt No false indication of pore pressure sometimes seen with resistivity around salt because of changes in formation salinity Correlation with seismic surveys Characterization of rock mechanical properties for wellbore stability and completion analysis Calibrate seismic velocities for look ahead predictions
SeismicTrak Service adds value to PPP
• • • • •
•
damage or effects Real time updates of time-depth profile Reduces uncertainties in surface seismic Place bit on surface seismic Look below the bit for pressure ramp detection Estimate distance to overpressured zone to predict and mitigate pressure kicks Reduce drilling hazards and NPT
© 2011 Baker Hughes Incorporated. All Rights Reserved.
500m 200ms
• Seismic data from surface • Not affected by near wellbore
Drilling Fluids
11
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Keys To Success • Experience
– Have serviced more than 200wells >400ºF – Dominate provider to the extreme HPHT segment • Capturing Lessons Learned & incorporating into CPI
– Have extensive list of Lessons Learned/Best Practices • HPHT Laboratory capability, to include Specialized Equipment
– Have 3 strategically positioned Global labs with capability – Houston, Aberdeen & Kuala Lumpur
Keys To Success • Invert Emulsion Fluid for extreme conditions
– MAGMA-TEQ has proven track record – System is stable at BHT +600°F (316ºC). • Aqueous Fluid (Primary or Contingency)
– PYRO-DRILL also a proven track record – System is stable to ≥550°F (288ºC). • Sophisticated modeling capability
– – – –
Temperature - Presmod Hydraulics – ADVANTAGE Engineering Bridging – BRIDGE-WISE Down hole stresses – BORE-WISE
Drilling of 4 uHPHT wells from a Heavy Duty Jack Up with
Magma-Teq System Drilling Fluids Specification Process • Well conditions were a step change away from clients conventional North Sea wells. • Mud was required to be stable at up to 428°F and 18.5 ppg • BHDF selected with Magma-Teq system to provide HPHT fluids for UK and Norway
• A multinational drilling fluids development team was created to further refine the design of the drilling fluids for the uHPHT wells campaign:
– Problem identification, – Laboratory programs per well and – Chemical selection to optimize reuse. 14
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Case History System Performance in the Field • Bottom hole static temperatures were seen up to 395°F • Circulating temperatures were between 275°F and 376°F • BHP about 17,500 psi • The system was stable under the conditions encountered in the wells • The rheology was stable and controllable over long periods of time and despite extended fishing/pipe recovery operations • No significant fluctuations in fluid density after prolonged static periods • No dynamic sag despite relatively low circulation rates
Drilling of 4 uHPHT wells from a Heavy Duty Jack Up with
Magma-Teq System Optimization of Fluid cost and inventory • Objective: Utilize fluid on more than one well • 2,653 bbls from first well used for second well • 2,162 bbls from second well used for third well • 1,100 bbls added as possibility of losses occurred • 3000 bbls returned from third well to be reused Summary • Mud system was stable under conditions in all three wells • Negligible NPT caused by mud system • Rheology was stable and controllable despite extended section times • No significant fluctuations in fluid density after prolonged static periods • No dynamic sag despite relatively low circ. rates • Successful system on all three wells allowed optimization of cost and volume control
15
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Case History
The Magma-Teq System • A high temp. invert emulsion mud weighted with a mixture of Barite and Micromax • Micromax is Manganese Tetraoxide with very fine particle size d50 < 1μ • Base oil initially Escaid 120, latterly EDC99DW • Robust Emulsifier package • Specialized HPHT fluid loss additives • Premium Organophilic clay
PYRO-DRILL • KTB project - Ultra Deep HT Scientific drilling project in Germany. • Performed laboratory evaluations and presented Fluids recommendations to KTB. • Assisted at location with the conversion of an existing major competitor’s drilling fluid at 23,623’ (7200m) to a PYRO-DRILL geothermal drilling fluid (referred to as the KTB-HT system). • Provided technical assistance and support for remainder of the operation. • Total depth of the hole was 29,860’ (9101m) with a BHT of 482oF (250ºC) and 12.5 ppg MW
Advantages • Far lower gas solubility - immediate and apparent influx detection • Losses easier to manage • Superior HS&E - rig pit room/shakers areas • Environmentally more benign • Simpler waste management • Lower ESD and ECD, less tendency to generate fracturing • Much higher specific heat • Low compressibility - PVT non-issue • Simpler logistics, can be made up on site • Lower solids volume in fluid - higher base fluid densities • Multiple make-up brine options Disadvantages (versus oil mud) • Treatment of high concentrations of CO2 & H2S • Potential for formation stability issues • Potential for rheological instability (contamination)
Wireline Services
17
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Nautilus Ultra (HPHT) • Rugged construction
Nautilus UltraTM Open Hole 500°F and 30kpsi Cross-Dipole (XMAC-F1)
• Durability at extreme
temperatures lowers NPT • Superior sensors provide accurate data to aid reserve estimation • Unique provider of HT crossdipole logging services
Induction Resistivity (HDIL) Formation Evaluation
Porosity (CN) Density (CDL) Natural Gamma Ray (GR/SL) Borehole Geomety (XZ-Cal)
Nautilus UltraTM Cased Hole 500°F and 35kpsi Formation Evaluation
RPM Service pulsed neutron Formation evaluation in cased holes Production logging and water velocity determination Mineralogy behind casing
18
© 2011 Baker Hughes Incorporated. All Rights Reserved.
HPHT Wireline Services Available Borehole Open Hole FE
Temperature Rating
Cross Dipole
Cross Dipole
Acoustic Imaging
Acoustic Imaging
Formation Coring
Formation Coring
Formation Testing/Sampling
Formation Testing/Sampling
Resistivity Imaging
Resistivity Imaging
Cased Hole FE
Cased Hole FE
Production Logging
Production Logging
Cement Evaluation
Cement Evaluation
Pipe Recovery
Pipe Recovery
0
19
Borehole Open Hole FE
Temperature Rating
5
10
15 20 Pressure [kpsi]
© 2009 Baker Hughes Incorporated. All Rights Reserved.
25
30
35
0
100
200 300 400 Temperature [°F]
500
600
HPHT Solutions: Deployment Risk Reduction
21
© 2009 Baker Hughes Incorporated. All Rights Reserved.
World Wide HPHT Fields Above 150°C BHT and 690bar surface pressure
Nautilus Ultra 5 Year Job History
Oregon 246 DegC
Nautilus Ultra
Job History
#Jobs above 350°F
100+
Max. BHT:
474°F
Max. BHP:
29,000 psi
Max in-hole time:
50+ Hours
22
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Cooper Basin 243 DegC, 843 Bar
Devon 233 DegC, 1447 Bar
Cadillac 222 DegC, 1591 Bar
HPHT Pressure Testing and Fluid Sampling Objectives 1. Accurate formation pressures 2. Representative formation samples 3. Safe and efficient operation
Challenges • High Temperature – up to 388°F • High Tension – well depth of 5000m • Highly Depleted – pressure overbalance up to 8000 psi
23
© 2011 Baker Hughes Incorporated. All Rights Reserved.
HPHT Pressure Testing and Fluid Sampling Solution DRM (Deployment Risk Management) recommendations • High strength HPHT cable • crush resistant HPHT wireline
• Derrick installed Capstan • Friction Reducing Stand-offs • Flywheels • Ultra slim profile standoffs
24
© 2011 Baker Hughes Incorporated. All Rights Reserved.
HPHT Pressure Testing and Fluid Sampling Solution Deploy RCX (Reservoir Characterisation eXplorer) • Prepared and tested for HT conditions • Fitted with Flywheels to mitigate the risk of sticking during testing/sampling • Fitted with 10kpsi differential pumps • Single Phase I & Single Phase II tanks designed for HPHT
25
© 2011 Baker Hughes Incorporated. All Rights Reserved.
HPHT Pressure Testing and Fluid Sampling Results: Effective Wireline Deployment plan resulted in zero NPT Pressures (Max Temp 363°F) • Acquired 100% of formation pressures tests requested – Max overbalance on pressure tests: 7000+ psi
Samples (Max Temp 388°F) • 3 Sample stations completed successfully – Up to 2hrs 10mins pumping at one station – Overbalance of 5000 psi differential
• PVT quality/quantity samples • First ever single phase downhole sample from this field 26
© 2011 Baker Hughes Incorporated. All Rights Reserved.
Geothermal Well, Australia
Case History
Objectives • Locate fractures within the wellbore • Safe Operation Challenges • BHT ~ 470°F (243°C) • TD ~ 16,000 ft
Solution • Nautilus Ultra Logging Suite w/ XMAC F1 Results • Successful Wireline conveyed run • Fractures interpreted from Cross-Dipole analysis
Research & Development
31
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Component Reliability: Exponential Decline • Current specifications: 150°C • Arrhenius equation (reaction rate): 10°C ↑ = 50% ↓ component life
Svante Arrhenius
32
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Electronics: It’s easier to go to the moon. Operating Temperature Specification
Consumer
Industrial
Military & Space
Oil & Gas
33
-20°C
-25°C
Inspections
Tests
70°C
Assembled Parts
Final Test @ Room Temp
70°C
IPC-A-610: Class 1/2 Sample probe
Sub Assy @ Room Temp
-40°C
-20°C
© 2009 Baker Hughes Incorporated. All Rights Reserved.
IPC-A-610: Class 3 Sample probe
125°C
175°C+
IPC-A-610: Class 3 each solder
Sub Assy @ High Temp Final Test @ Room Temp Sub Assy @ High Temp Final Test @ Room Temp
Design for Reliability: Analyze, Test, Validate Model
Analyze • Mission profiling (thermal & mechanical stresses) • Component selection • Process optimization
Test • Lab qualifications – Component – Board – System
Validate • Root cause analysis • Optimization • Field performance
34
© 2010 Baker Hughes Incorporated. All Rights Reserved.
Analyze, Design & Model
Test & Qualify
Lab
Validate & Improve
Field
Validation, Testing & Qualification Celle Technology Center
Woodlands Technology Center
Houston Technology Center
Electronics Design Innovation
Drilling Simulator & Drilling Dynamics Simulation
Model Testing & Verification
Beta Test Rig Oklahoma
Model Testing & Verification
Field Testing & Systems Integration Testing
35
HT Electronics Challenges – <175oC Operating IC’s onPCB)
175oC Approach – Pushing Reliability with
Today’s Technology
•Optimize PCB board layout for IC cooling •Increase solder resistance to creep
Thermal Flow - IC’s on PCB
•Thermal management • Move heat away from effected components (Passive/Forced) • Flask PCB’s ( from external thermal loads)
•Pre & Post Mfg Component & System Screening • Thermally cycle parts to find early failures
Steps (hrs) © 2009 Baker Hughes Incorporated. All Rights Reserved.
Heat Conduction from IC’s
Beyond 175°C: Enabling Technologies Packaging & components • Bare dies vs. plastic packaged components • Bonded vs. soldered connections
&
Active cooling • Memory, DSPs, etc. • Sensors Materials • Corrosion • Sealing 38
© 2011 Baker Hughes Incorporated. All Rights Reserved.
=
Extending Survivability - Packaging Passive Circuit Cooling
Wireline Today • Passive thermal “cooling” • Thermal insulation & flasking Tomorrow • More Hybrids & More active cooling
LWD Today • Vibration damping • Passive thermal “cooling” Tomorrow • More Hybrids & More active cooling
Composite Clam-Shell Top
Component Cavity Viscoelastic pad Composite Clam-Shell Bottom
Technology Investment – Infrastructure New Sensor (HT) Development Lab, Houston
Hybrid Electronics Lab, Germany
Finish Fall 2011
Finished 2009
• Over $20M in infrastructure investment in HPHT • Electronics design, testing and qualifications;
Data Acquisition, Mfg Automation IC failure analysis; X-Ray, Ultrasonic, elemental analysis, Thermal imaging diagnostics Simultaneous Ovens & Shaker Tables, Test chambers, Pressure Pits (375C, 40K)
41
© 2010 Baker Hughes Incorporated. All Rights Reserved.
People
Houston, Texas
Celle, Germany
42
© 2010 Baker Hughes Incorporated. All Rights Reserved.
Houston, Texas
Houston, Texas
Information Technology: Transforming Operations
43
© 2011 Baker Hughes Incorporated. All Rights Reserved.
Summary
44
© 2009 Baker Hughes Incorporated. All Rights Reserved.
BHI High Temperature R&D Capabilities • People – 100+ engineers on 40+ HT projects – Center of Excellence & HT Materials Department – Leading consultants, Universities, Government labs
• Solutions & Practices – – – –
30 years experience in flask design, fabrication, testing Real Time Temp. monitoring of critical components. Well developed HALT & HASS testing programs Specific standards, processes and component database
• Facilities – Specialized HT labs on Hybrids, Cooling, Fluids, Acoustic, NMR, Resistivity, Nuclear, Optics. – Testing up to 700F, 40ksi. 100+ HT ovens – IC analysis, X-Ray, Ultrasonic, Elemental, Thermal imaging.
• Suppliers and Partners – Industry wide HT contacts and partnerships on advanced components, IC, DSP, Sensor, PCB and proprietary soldering. 45
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Solutions on the Market … for all aspects of D&E • Drill Bits, • Directional Services, • MWD/LWD Services, • Drilling Fluids • Open Hole Wireline Services • Cased Hole Wireline Services Solutions include • Deployment Risk Reduction • Planning, Simulation and Testing • Proven Processes, Procedures and Talent
46
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Evolving the Portfolio • Additional Services and Technology • Fit for Purpose HT-Systems for extreme service specifications – Design for Reliability Focus in Design, Modeling, Testing & Qualification – Deliver Research Innovations in Materials, Sensors, Electronics, Nano-Structures and Manufacturing
Comments/Questions
47 © 2009 Baker Hughes Incorporated. All Rights Reserved.