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Vallourec Group
Increasing Hole Cleaning Efficiency While Drilling
Addressing ECD in ERD Wells
AmericanBusinessConferences
Luc Van Puymbroeck
Why does drill pipe matter?
Cost of Hole Cleaning
Factors affecting Hole Cleaning
Hydroclean Solutions
Case History & Applications
Conclusion
Content
Horizontal Drilling USA Extended Laterals Congress 2014
2
Why spend time thinking about drill pipe?
Globally more than $2 Billion NPT is lost yearly to stuck pipeand loss circulation alone
That’s 2X the amount the industry spends to buy drill pipe in the first place
Stuck Pipe
Loss Circulation
Drilling NPT classification chart
3
Horizontal Drilling USA Extended Laterals Congress 2014
Consequences of poor hole cleaning
Torque & Drag
Tight Hole
Controlled ROP
Reaming and back-reaming
Additional cleanup time
Loss circulation (ECD)
Excessive wiper trips
Ineffective sweeps
Stuck Pipe
Side Track
Recovered Cuttings vs Actual Footage
Leads to None Productive Time
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Horizontal Drilling USA Extended Laterals Congress 2014
Holistic approach to well engineering & planning
Make hole cleaning the center of the wheel
Think hole cleaning before T&D
Optimize the drill string
HoleCleaning
Rig
Drill PipeFluids
BHA
Drilling
Practices
Casing
Trajectory
Target
Well
Procedures
Torque& Drag
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Horizontal Drilling USA Extended Laterals Congress 2014
Key elements of Hole Cleaning
● Drilling Fluids Properties
Rheology, Inhibition, Solids …..
● Bits & BHA Designs
Allowable RPM, % rotation, by-pass area, ROP. …
● Hydraulics
Available GPM, pressure limits, ECD, shaker loading limits, …
● Rig Systems
Limitations for top drive ( RPM vs Torque) , solids control, pumps, etc…
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Horizontal Drilling USA Extended Laterals Congress 2014
General observations in ERD ● Everyone has similar problems
● Perception of recipe for success
High Flow Rate ( > 1000 gpm in 12 ¼” )
Gauge hole
Continuous rotation & RSS is necessary for HC
Slow ROP
Optimized mud properties
Sweeps compensate for less-then-ideal of the aboveWhile there is truth in each concept,the general philosophy behind each is one misguiding
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Horizontal Drilling USA Extended Laterals Congress 2014
... drill pipe
broke…
What
happen ?No issues drilling – High ROP sections
Increased reaming & Circulation @ cnx
POH with increased Drag
Enlarged hole
Cutting beds accumulation & ledges
Déja-vu good drilling and hole problems
What could we have done differently?
Horizontal Drilling USA Extended Laterals Congress 2014
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By addressing the risks of (poor) hole cleaning
Large holes are inefficient to clean and have cutting transport challenges
Small holes have annular pressure challenges and need time to clean
Focusing drilling efficiency and safety
Holes do not have to be 100% clean but clean enough to maintain trouble-free operations
Horizontal Drilling USA Extended Laterals Congress 2014
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Cutting behavior & Hole Cleaning mechanism
Horizontal Drilling USA Extended Laterals Congress 2014
Saltation Flow
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Effects of rotation in 12 ¼” hole
● Rotation alone is not sufficient
Big difference between 100 & 120 RPM
Step changes occurs at 120 & 180 RPM
Independent of hole size & pipe size
Independent of mud type
120 is minimum acceptable RPM to clean
“big holes”. Not recommended RPM
Rules change in < 8 ½”
- Based on observations , not on theory or model- Significant change @120 & 180 RPM- If operating near critical speed, adjust RPM accordingly
Rotary speed
Cu
ttin
g V
olu
me
s
Viscous Coupling
● Rotary Speed is critical for Viscous coupling
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Horizontal Drilling USA Extended Laterals Congress 2014
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Effects of flow rate in 12 ¼” Hole
● Flow rates > 750 GPM needed for large conveyor belt zone
LargeSmall
Dead Zone
● Flow Rates > 1000 GPM have diminished returns
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Horizontal Drilling USA Extended Laterals Congress 2014
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High angle “Rules of Thumb” ● Rotary Speed
● Flow Rates
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Horizontal Drilling USA Extended Laterals Congress 2014
Placement of 1 Hydroclean per 2 stands
Hydroclean - Mechanical Hole Cleaning Device
Min RPM 60 - 70
Increase Hole Cleaning efficiency thru degradation of cutting beds at low RPM
Scooping of cutting beds from low side
Recirculating cuttings above the drill string
Transporting of cuttings to surface“Conveyor” belt effect.
HIGH VELOCITYFLUID
Horizontal Drilling USA Congress 2014
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15
Drilled 12 ¼” section in 7 days
Saved 20 hours
• 12 ¼’’ Hole
• Interval drilled : 1765m with PDM
• Inclination: 70 degree
• Spaced 50jts x 5 ½ Hydroclean + 5 ½ DP
• 1 MCD per 2 stands over 2635m
9 5/8 shoe @3026m
13 3/8 shoe @ 1275m
10
Hydroclean case history15
New drill pipe for horizontal ERD
16
Shallow ER wells with ECD
issues demands different pipe
Hydroclean scallops machined in each Tool Joint of the drill string
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Horizontal Drilling USA Extended Laterals Congress 2014
Vallourec Group17
9 5/8 Csg shoe at 4921 ft
TD 20,000 ft
Hole Size = 8 ½
Torque & Drag & Buckling Analysis
Horizontal Drilling USA Extended Laterals Congress 2014
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Stiff String T&D comparison on 20 kft ERD well5’’ NC50 S135 DP versus 5” EIS S135 H Max
H Max Hook POOH/RIHReduction of Drag : max 5% POOH & max 15% RIH
Potential to increase ERD envelope
Hydroclean MaxHydroclean Max
Higher TJ stand off w/ H Max reduces side force on the tube and increase on TJ with better distribution
Benefits
Dual OD tool joint does not compromise DP performance
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Horizontal Drilling USA Extended Laterals Congress 2014
• Drill faster and safer Lower T&D friction factors Reduce cleanout time Better ECD control Decrease residual cutting beds
Save rig time Fewer wiper trips Reduce reaming & back-reaming Cut down sweeps and bottom’s up cycles Better tripping times
Extend Service Life Less wear and repairs
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2 2 4 5 6 7 11 12 12 13 17 22 2946 51
97
129149
160182 188
263
Stuck pipe Work pipe Reaming Other CirculatingFig. Rig activity histogram
8 ½ hole 6000 ft horizontal Drilling with PDM Onshore USA
Hours
Well example candidate
More than 50% total time spent on other activities than drilling
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Horizontal Drilling USA Extended Laterals Congress 2014
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Hydroclean™Max
Drill PipeHydroclean™
Drill PipeHydroclean™
Heavy Weight
Hydroclean has shown to increase
overall drilling performance
Used mainly Offshore For large hole & high deviated wells
Required well planning with KPIs
A new drill pipe with Hydroclean in
the TJ has been developed for ERD
Applicable in horizontal wells Economically justifiable Onshore 5” Prototype is ready for field test
Conclusions20
Vallourec GroupVallourec Group
Thank YOU
21
Increasing Hole Cleaning Efficiency While DrillingAddressing ECD in ERD Wells
Horizontal Drilling USA Extended Laterals Congress 2014Luc Van Puymbroeck
22
Class 1: Cleaning efficiency KPI i’s:
Average cuttings size Average cuttings return rate Total bottom’s up circulating time
Class 2: Time saving KPI i’s:
Total tripping time Total backreaming tiem Total non productive time Average ROP
Class 3: Operational safety KPI i’s:
Average connection over-pull Average tripping over-pull Pack-off occurrence number Average friction factor Average RPM
Class 4: Well bore quality and stability KPI I’s:
Average ECD or dynamic pressure values Total backreaming time Total over-pull time Casing run time Average flow rate
Publications
SPE 134269 – 21-23 February 2006 – Miami
Experimental Studies on the Effect of Mechanical
Cleaning Devices on Annular Cuttings Concentration
and Applications for Optimizing ERD Systems
IADC World Drilling 2007 – 14 June – Paris
Maximizing Drilling Efficiency in High-Angle Wells with
new Hole Cleaning – Torque & Drag Reduction
Systems
IADC/SPE 59143 – 19-22 September 2010 - Florence
Improved Hole Cleaning and Reduced Rotary Torque
by New External Profile on
Drilling Equipment
Key Performance Indicators