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Ultrafast Drilling in the Gulf of Thailand: Putting Science into the Design Process
C.J. Pinto, Unocal Thailand, Ltd., L.E. Pendleton, Consultant, and J.L.Dick, L.A. Sinor, J. Oldham and B. Stauffer, Hughes
Christensen Company
Abstract
A novel PDC bit design, the result of high end numerical
modeling and laboratory testing set the Gulf of Thailand field
record for rate of penetration during its first run by averaging
840 ft/hr over the 5,040 ft section. This was accomplished
while building inclination from 26 up to 56 before dropping
back to 37 at total depth. The bit also made the planned
azimuth turn from 305 to 258. The same design later pushed
the performance record further by averaging 1,023 ft/hr over a
6,144 ft. section. Instantaneous rates in excess of 2,000 ft/hr
were documented over a 1,000 ft section of this hole.
Designing a bit that maximizes rate of penetration while
maintaining a neutral walk tendency in rotate mode is
presented in this paper.
Introduction
The complex and compartmentalized geology in the Gulf of
Thailand requires operators to drill numerous wells at
minimum costs to achieve long term financial success. More
than 1,700 wells have been drilled to date by Unocal in the
Gulf of Thailand, with 253 wells being drilled in 2002 alone
(Figure 1). Unocal, in partnership with PTTEP and MOECO,
has met this challenge by reducing average drilling and
completion costs from $5MM ($10.9MM in todays dollars)
and 68 days in 1980 to completed wells costing less than
$950k and averaging approximately five days (Figure 2). The
dramatic cost reduction has occurred incrementally by
overcoming challenges related to bits, bottom-hole-assemblies
(BHA), casing, downhole tools and wellhead equipment in
addition to completion challenges.1,2,3
Economic success in the intermediate 8-1/2 hole section in
the Gulf of Thailand is overwhelmingly determined by rate of
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not possible and there was significant risk the wells could not
be aligned. Research showed this not to be the case, but the
myth was difficult to dispel. The next obstacle was the
perception that the 2D products would drill the deeper turns
slower than steerable 3D products. This turned out to be true,
however, the amount of time that was made up by 2D products
in the tangent portion of the well more than made up for any
additional time lost due to slower deep turns. In essence, the
section is a race to the finish with time for the whole section
the determinant, not any one components time. The third
problem was that even though the 2D products were faster in
the tangent, they required more attention than a steerable
friendly 3D product. Directional drillers accustomed to
leaving a bit on an azimuth for extended periods of time found
they were constantly having to work to maintain toolface as
desired. They were, however, able to do this and through time
did it much better as familiarity with the bits increased. A final
reason was that the introduction of new bits, away from
known products was difficult. The system was working,
records continued to be broken, thus the system appeared to be
fine. Changing this paradigm had significant risk.
Ultrafast Drilling Bit Design
The bit companies were challenged to provide a bit design that
would allow the highest ROP in the broadest range of 2D
applications. This bit manufacturer used laboratory testing to
bridge the gap and reduce cycle time between modeling and
commercial field results. A unique four bladed PDC bit was
ultimately developed for this field application, commercially
referred to as HC604 or Auger. This product gave the
directional driller the required high ROP while maintaining
azimuthal control in rotary mode.
Designing a bit for ultrafast drilling required the use of high
end numerical modeling and extensive laboratory testing to
achieve the desired bit performance characteristics. Bit face
aggressiveness was maximized while maintaining stability and
steerability. Key design features include:
Face Aggressiveness
Gauge Aggressiveness
Stability
Hydraulics
Cutter size
Steerability
Durability
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ft/hr, 997 ft/hr and 1,023 ft/hr) with the initial record coming
on the very first application of the bit. The latest two field
ROP records are held by the same bit and occurred on its first
and second runs without any repair required between the runs.
The most recent, standing record represents a 30% increase
over the previous matrix body record of 793 ft/hr. During
these runs instantaneous ROPs were recorded in excess of
2,000 ft/hr. One of the major keys to this success was the
neutral, non-reactive nature of the bit in rotating mode in the
tangent section. From Figure 16, it is apparent that along the
completed 7,324 ft interval, only 5 slides were required to
maintain inclination and azimuth. Also in the same run was a
continuous interval of 3,161 ft. which required no corrective
slides at all. Considering that some bits require corrective
slides every third stand, this is a measure of the bits design
matching the field requirements. An additional design feature
netted immediate benefits as the Auger produced minimal bit
face reactive torque, thus when corrective slides were
required, they were achieved quickly needing only partial
stands and little time was lost on toolface reorientation.
It should be further noted that during the second half of 2001
relative to the first half, the Augers ROP improved in wells
with similar well trajectories. The Augers average ROP
improved from 475 ft/hr to 548 ft/hr from the first half of the
year to the second with roughly double the amount of footage
drilled. As the field crews gained familiarity and confidence
with the product they became more aggressive with its
application. The predictability of the bit to produce repetitive
results with similar WOB and RPM inputs was a key enabling
feature of the design. The Auger became the standard for the
2D well category.
There were other benefits realized as well. As the field
personnel became more certain of the ability of aggressive 2D
bits to make deep turns that were previously only the realm of
3D products, they wholeheartedly starting pushing to get more
2D products in the hole. It must be noted that the crews are
provided opportunities to receive monetary incentives based
on performance and safety, thus the adoption of the new
technology was swift. As a result, the field requested a review
of what is considered a 2D well. The rule of thumb is now
that wells with an azimuth turn of under 150 are drillable with
a 2D product. The effort to officially change the category is
also underway.
Conclusions
1) Even within highly successful and continuously
improving operations, significant value creating
opportunities can be overlooked due to perceived
success and resistance to change.
2) There is no way to overstate the importance of data to
overcome perception. Fact based conversations
cannot occur until performance benchmarking exists.
Decisions that are based on facts may be proven
wrong by further data, but are always justified.
3) The sharing of benchmarking data and the metrics by
which bit selection occurs proves highly motivational
to bit companies fueling a highly innovative and
competitive environment.
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300
250
150
100
50
2002
2001
2000
99
98
97
96
95
94
93
92
91
90
89
88
87
86
85
84
YEAR
Figure 1: Historical wells drilled per year by Unocal in the Gulf of Thailand
80
3
40
2
Cost
Days
20
1
0
98
20
00
20
02
96
94
92
90
86
88
82
84
80
$ MM
60
Days
Total Wells
200
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Figure 3: Extensional graben complexes with vertical and lateral fault seals
Figure 4: Plan view for a typical 8-1/2 and 6-1/8 section with high turn and multiple targets
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3D BITS
60%
3D WELLS
27%
2D BITS
40%
2D WELLS
73%
2D BITS
3D BITS
2D WELLS
ONLY
FT.
DRILLED
TOTAL HOURS
AVERAGE
ROP
1ST HALF
259787
641.8
404.8
2ND HALF
81119
209.0
388.1
2002
340906
850.8
400.7
1ST HALF
166307
352.0
472.5
2ND HALF
369474
676.0
546.6
2002
535781
1028.0
521.2
2D BITS
IMPROVE
120.5
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11
120
G445XL - 15 BR
G445XL - 15 BR
G445XL - 20 BR (CSE)
100
G445XL - 40 BR (CSE)
80
Auger
60
40
G445XL - 20 BR (CSE)
100
G445XL - 30 BR (CSE)
G445XL - 30 BR (CSE)
120
G445XL - 40 BR (CSE)
80
Auger
60
40
20
20
10,000
20,000
30,000
40,000
50,000
1,000
2,000
5,000
160
6,000
7,000
G445XL - 15 BR
G445XL - 20 BR (CSE)
G445XL - 30 BR (CSE)
140
G445XL - 15 BR
120
G445XL - 20 BR (CSE)
G445XL - 30 BR (CSE)
100
G445XL - 40 BR (CSE)
Auger
80
60
40
140
Penetration Rate (ft/hr)
4,000
Torque (ft*lbs)
3,000
G445XL - 40 BR (CSE)
Auger
120
100
80
60
40
20
20
0
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
1,000
2,000
3,000
4,000
5,000
6,000
Torque (ft*lbs)
Figure 7: Comparison of ROP and Torque vs. WOB in Carthage Limestone and Mancos Shale as a function of cutter back rake angle
4.65
1"
2.5"
Rotating
6"
4.55
Sliding
12"
4.45
4.35
4.25
4.15
4.05
3.95
3.85
3.75
0
10
20
30
40
50
60
70
80
90
Depth Drilled
Figure 8: Borehole radius as a function of bit gage length in slide vs. rotate mode with a motor
12
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Figure 9: Spiral amplitude and drift diameter variance with gage length.
12 ft/hr
Figure 10: MU variation, f(WOB, Torque and Diameter) vs. depth of cut for the Gulf of Thailand design vs. current
generation PDC bit design. A MU variation less than 5% indicates a stable design.
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Blade profile
Figure 11: Auger junk slot profile vs. standard PDC bit design
Figure 12: ROP comparison in Carthage Limestone and Catoosa Shale vs. cutter size
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12.0
10.0
8.0
6.0
4.0
Roller Cone
2.0
0.0
0
20
40
60
80
100
ALL BITS
Figure 13: Dogleg severity comparison with bit designs utilizing different lateral aggressiveness
2D WELLS
ONLY
FT.
DRILLED
TOTAL
HOURS
AVERAGE
ROP
1ST HALF
426094
993.8
428.8
2ND HALF
449917
885.0
508.4
2002
876011
1878.8
466.3
TOTALS/AVG.
73001
IMPROVED
79.6
Figure 14: Footage drilled comparison between first half and second half of 2002
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Figure 15: Well type vs. bit selection for second half of 2002
Figure 16: Example well showing azimuthal hold during rotate mode and reduction in ROP during corrective slides. Note
only 5 short corrections were required while drilling the 7,324 ft interval.