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

2. 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

3. Exxon Jet Bit

4. Exxon HP Field Test

5. 4 3/4” High Pressure Bit

6. 8” High Pressure Bit

7. Grooves Cut by HP Tests

8. High Pressure Problems
Connections
Joint Leaks
Washouts
High Maintenance
Pump
Rig

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

10. High Pressure Drilling Mechanism
Bit
PDC Cutter
Jets
Rock Ledges

11. 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

12. 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 )

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

14. 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)

15. First Reel of QT 1200 CT

16. 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.

17. Swivel Test Stand
Hydraulic Motor
Transducer
Swivel

18. 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)

19. 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

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

21. Thrust Bearings
Diamond
Roller

22. Bearing Load Comparison
20000
16,800
rpm
15000
Load Capacity
10000
5600
5000
Ball Bearing
PDC Bearing

23. Damaged Ball Bearings

25. Labyrinth Seal
Outer Sleeve
Inner Sleeve

26. 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

27. Radial Bearing
Outer Sleeve
Inner Sleeve

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

29. Motor Dynamometer Test

30. Effect of Bit Pressure
Water
10 Bearings

31. Effect of Bearing Type
Water
10,000 psi
10 Bearings

32. Effect of Number of Bearings
Water
10,000 psi

33. Effect of Drilling Fluid
10,000 psi
3 Diamond Bearings

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

36. 10,000 psi

38. 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

39. 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 )

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

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

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

44. Initial Bottom Hole Pattern

45. Modified Jet Bit

46. Final Bottom Hole Pattern

47. Additional Applications

48. Jet Slotting Stimulation
Slots
Formation
Damage
High
Pressure Jets
ROCK

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

50. Drillpipe or Casing
Drilling Cement
High
Pressure Jets
Cement
ROCK

51. Tubing After Drilling Cement

52. Cement Drilling Rates
Motor
Motor

53. Cement Drill Cuttings (10,000 psi)

54. 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)

55. Visit our web site: www.maureng.com
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