Laboratory Testing Of High-Pressure Coiled-Tubing Drilling System Dr. William C. Maurer June 1, 2007

High-Pressure Drilling 1970s & 1980s High Pressure Bits Drill 2 to 3 Time Faster Exxon Shell Gulf Oil Flow Drill Pressure - 10,000 to 15,000 psi

Exxon Jet Bit

Exxon HP Field Test

4 3/4” High Pressure Bit

8” High Pressure Bit

Grooves Cut by HP Tests

High Pressure Problems Connections Joint Leaks Washouts High Maintenance Pump Rig

High Pressure Solutions Coiled Tubing No Joints Eliminates Washouts Improved Equipment Pumps Rigs Motors Bits

High Pressure Drilling Mechanism Bit PDC Cutter Jets Rock Ledges

Critical Components Coiled Tubing CT Rig PDM Motors Bits Fatigue Life At High Pressures CT Rig High Pressure Components PDM Motors Bearing And Motor Loads Bits Correct Nozzle Placement

CT Fatigue Life Fatigue Life (trips) Internal Pressure ( psi ) (based on MEI CTLIFE model) 200 1.75" 2.00" 150 QT-1000 100 Fatigue Life (trips) 50 6,000 9,000 12,000 Internal Pressure ( psi )

Fatigue Test Machine CT Sample Hydraulic Actuator Straight Curved Bending Form Bending Form Pump Pressure Controller

Fatigue Life of 1-1/2” Coiled Tubing (R. Stanley, 2000) 500 Actual Cycles for QT-1200 (0.156” Wall) 450 Model Cycles for QT-1000 400 Model Cycles for QT-800 350 300 Fatigue Life (cycles) 250 200 150 100 50 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 Internal Test Pressure (psi)

First Reel of QT 1200 CT

Fiberspar Composite CT Production Tubing - FS PT Line Pipe - FS LP Coiled Tubing -FS CT (for Well Servicing) Fiberspar Spoolable Products Update – May 1999 Fiberspar Spoolable Products, Inc. has successfully launched two new continuous composite tubular products this year, Fiberspar Coiled Tubing (FS CT) and Fiberspar LinePipe™ (FS LP). In March, Halliburton Energy Services using their coiled tubing unit located in Odessa, TX successfully ran the first composite coiled tubing for downhole well servicing. The composite coiled tubing is designed for extended fatigue life over steel, high working pressures, corrosion resistance and lightweight, weighing in at 1/3rd the weight of similar sized steel. The first FS CT string is 1.5” OD with a 1” ID and is 6700’ long. It is rated to 7,500-psi working pressure. The goal was to pick several candidate wells to run field validation trails on the new tubing design. The tubing had been extensively tested in full-scale tests at Halliburton’s research facility in Duncan, OK. Three injection wells used for the alternating injection of CO2 and water were selected for clean out and acid stimulation by an oil company located in West Texas. The wells had wellhead pressures ranging from 1500-psi to 2500-psi, were completed with 2.875” tubing and were approximately 5200 ft. deep. The jobs were completed successfully. These jobs were followed with three more successful CO2 and water injection well clean outs by an oil company in New Mexico. Use of FS CT for well intervention has met expectations to date, and Halliburton plans to continue the field validation phase while planning full commercial introduction of larger string sizes in the 2” to 2.875” OD sizes.

Swivel Test Stand Hydraulic Motor Transducer Swivel

Hydra-Rig High Pressure Swivel Torque vs Pressure 500 450 400 350 300 Torque (ft. lbs) 250 200 150 100 50 2000 4000 6000 8000 10000 12000 14000 Pressure (PSI)

High Pressure CT Motor PDC Thrust Bearings PDM Multilobe 2 3/8” CT Rotor/Stator (3 1/8”) 2 3/8” CT Solid Rotor High Pressure Jet Bit Radial Bearings/ Flow Restrictors Solid Titanium Flexshaft Filter

Thrust Load on Bearing 10,000 PSI Seal Housing 34,000 lb Force Thrust Bearing Bit

Thrust Bearings Diamond Roller

Bearing Load Comparison 20000 16,800 100 Hours @ 300 rpm 15000 Load Capacity 10000 5600 5000 Ball Bearing PDC Bearing

Damaged Ball Bearings

Labyrinth Seal Outer Sleeve Inner Sleeve

Motor Labyrinth Leakage 8.1 12.1 2 4 6 8 10 12 14 16 0.004" 0.006" Leakage Clearance (w) Flow Rate (gpm) Four 5” Labyrinths w 10,000 psi

Radial Bearing Outer Sleeve Inner Sleeve

Motor Dynamometer Test Stand Nozzle Sub Dynamometer Fluid Inlet Flex Shaft Leak Tank Motor

Motor Dynamometer Test

Effect of Bit Pressure Water 10 Bearings

Effect of Bearing Type Water 10,000 psi 10 Bearings

Effect of Number of Bearings Water 10,000 psi

Effect of Drilling Fluid 10,000 psi 3 Diamond Bearings

Start-Up Torque vs Pressure Torque (ft. lbs.)

10,000 psi

High Pressure Jet-Drilling Rates 1500 Bit Weight = 2000 lbs = 10,000 psi = 1,000 psi 910 (WOB=1000 lbs) Jet Drilling Rate (ft/in) 780 142 255 120 68 110 Cream Limestone Limestone Bluff Dolomite Red Sandstone

Differential Pressure and Drilling Rate (Moffit, 1991) 70 60 7-7/8 Tricone Bit 30,000 Lbs WOB 50 60 Rpm 40 Austin Chalk p b Drilling Rate (Ft/Hr) 30 Mancos Shale 20 10 Colton Sandstone p p 1000 2000 3000 4000 Differential Pressure ( psi )

DRC Wellbore Simulator Drilling Stand Cuttings Removal Screen Choke Borehole Pressure Drilling Rock Rock Fluid Input Shaft Seal Pressure Chamber Formation Pressure

Effect Of Wellbore Pressure (Conventional Drilling) Wellbore Pressure = 0 psi Jet Pressure = 300 psi Texas Cream Limestone 2000 lb Bit Weight

Effect Of Wellbore Pressure (High Pressure Drilling) Texas Cream Limestone 2000 lb Bit Weight Wellbore Pressure = 2000 psi Jet Pressure = 9300 psi

Initial Bottom Hole Pattern

Modified Jet Bit

Final Bottom Hole Pattern

Additional Applications

Jet Slotting Stimulation Slots Formation Damage High Pressure Jets ROCK

Jet Slots In Glacier Bluff Dolomite 10,000 psi Jet Pressure Slot

Drillpipe or Casing Drilling Cement High Pressure Jets Cement ROCK

Tubing After Drilling Cement

Cement Drilling Rates Motor Motor

Cement Drill Cuttings (10,000 psi)

John Martin (Quality Tubing) Mel Hightower (ARCO) Acknowledgements DOE (William Gwilliam) Garry Collins (Marathon) Mike Dearing (Stewart & Stevenson) John Martin (Quality Tubing) Mel Hightower (ARCO) Rod Stanley (Quality Tubing) John Misselbrook (BJ Services)

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