10121-4504-01-PR-Evaluating Intelligent Casing HPHT UDW Drilling Applications Maximize Drilling...
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Transcript of 10121-4504-01-PR-Evaluating Intelligent Casing HPHT UDW Drilling Applications Maximize Drilling...
Evaluating Intelligent Casing for HPHT & Ultra Deepwater Drilling
Applications to Maximize Drilling Investment
Dr. Harold Stalford, Professor, AME, Univ. of Oklahoma
Dr. Ramadan Ahmed, Assistant Professor, PE, Univ. of Oklahoma
Victor Hugo Soriano Arambulo, GRA, PE, Univ. of Oklahoma
1
1 RPSEA Funded Project
2 Gulf of Mexico Ultra Deep HPHT Reservoirs Basin Modeling, Drilling &
Completions 2013, American Business Conference, Houston, TX, Nov. 20-21, 2013.
LEGAL NOTICE
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This presentation was prepared by The University of Oklahoma as an account of work sponsored by the Research Partnership to Secure Energy for America, RPSEA. Neither RPSEA members of RPSEA, the National Energy Technology Laboratory, the U.S. Department of Energy, nor any person acting on behalf of any of the entities: MAKES ANY WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED WITH RESPECT TO ACCURACY, COMPLETENESS, OR USEFULNESS OF THE INFORMATION CONTAINED IN THIS DOCUMENT, OR THAT THE USE OF ANY INFORMATION, APPARATUS, METHOD, OR PROCESS DISCLOSED IN THIS DOCUMENT MAY NOT INFRINGE PRIVATELY OWNED RIGHTS, OR ASSUMES ANY LIABILITY WITH RESPECT TO THE USE OF, OR FOR ANY AND ALL DAMAGES RESULTING FROM THE USE OF, ANY INFORMATION, APPARATUS, METHOD, OR PROCESS DISCLOSED IN THIS DOCUMENT. THIS IS AN INTERIM PRESENTATION. THEREFORE, ANY DATA, CALCULATIONS, OR CONCLUSIONS REPORTED HEREIN SHOULD BE TREATED AS PRELIMINARY. REFERENCE TO TRADE NAMES OR SPECIFIC COMMERCIAL PRODUCTS, COMMODITIES, OR SERVICES IN THIS REPORT DOES NOT REPRESENT OR CONSTIITUTE AND ENDORSEMENT, RECOMMENDATION, OR FAVORING BY RPSEA OR ITS CONTRACTORS OF THE SPECIFIC COMMERCIAL PRODUCT, COMMODITY, OR SERVICE.
Outline
Intelligent casing concept
Impact on existing operations and technologies
Benefits and challenges in Ultra Deep-water (UDW)
Early detection and early forecasting
Cost-effectiveness and key performance indicators
Health, safety and environmental issues (HSE)
Conclusions
3
Smart or Intelligent Well: Definitions A well that combines a series of components that collect,
transmit and analyze completion, production and reservoir data, and enable selective zonal control to optimize the production process without intervention. [http://www.welldynamics.com/technology/smartwell_definition.htm]
A well equipped with monitoring equipment and completion components that can be adjusted to optimize production, either automatically or with some operator intervention. [http://www.glossary.oilfield.slb.com]
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Smart or Intelligent Well: Definitions (Cont’d)
A well with implementation of fundamental process control downhole, enabling surveillance, interpretation and actuation in a continuous feedback loop, operating at or near real-time. [ “Introduction to IWS”, Baker Hughes]
Intelligent Well Reliability Group (IWRG): A well equipped with means to monitor specific parameters (e.g., fluid flow, temperature, pressure) and controls enabling flow from all zones to be independently modulated from a remote location.
5
Intelligent Technology in Oil & Gas
Intelligent Well (IW), Intelligent Well Systems (IWS), Intelligent Well Technology (IWT), Intelligent Well Completions (IWC), SmartWell, SmartWell completions, etc.
Components of Intelligent Technologies
- Permanent downhole systems
- Remotely monitored and controlled from surface
- Monitor and control without physical intervention
- Real-Time
- Zonal isolation, multi-zone, field-wide deployments
- Field Optimization for ultimate recovery 6
ICIF Technology1 Pushing boundaries of well “Intelligence” to casing and
beyond.
Exploiting Advanced Technologies - Wireless (as well as wired)
- Passive sensors (as well as active) [e.g., SAW, fiber-optic]
- Distributive sensors (as well as discrete) [e.g., DTS, DSS, DPS, DAS, DCS ]
- HT/HP materials [e.g., piezo-electric, fiber-optic]
- Permanent downhole monitoring
7 1ICIFT Systems Project funded by RPSEA
Intelligent Casing Design Intelligent casing(IC) and intelligent formation (IF) designs
created to maximize drilling investment.
Two-way communication (surface downhole) and power
transmission.
Casing string: Data highway from surface to bottom hole (BH).
Permanent downhole sensors (discrete / distributive).
Enabling a new era of advanced downhole measurements and telemetry
8
ICIF Techniques
Sensors placed inside/on/outside casing/in formation,
monitoring:
Formation and fluid properties,
Drilling dynamics and hole cleaning,
Bottom hole pressure,
Undesirable flow through cement annulus, etc.
Sensor data to surface; commands to downhole actuators , all
via intelligent casing network & system. 9
Lab Prototype ICIFT System (iBITS)
Two-way communication between
surface command and UDW wellbore elements
(continuous, real-time, high data rate)
Note: a lot of elements have been intentionally left out of this cartoon.
10
Fiber Optic Sensing Distributive Temperature Sensing (DTS)
11
Fiber Bragg Gratings (FBGs)
Fiber Optic: Fiber Bragg Gratings (FBGs) Writing FBGs:
12
Fiber-Optic Sensors (Permanent Well Monitoring Systems)
Distributive sensing; Well-developed technology
High-bandwidth; Low-loss transmission medium
High information transmission rates (1x1012 bits/s)[real-time data]
Absence of downhole electronics
Installation from surface to bottomhole (any length)
Freedom from electrical interference (immune to electromagnetic radiation)
Flexible configurations; Greater sensitivity
Cheap; Very thin (e.g., human hair) 13
Wireless Passive SAW Sensors • Temperature, Pressure, etc. • Low Power • Ultra Small Size ( 1 mm diameters) • HT Ranges • Piezoelectric Material
14
Design Factors Considered (Permanent Downhole Sensors)
Minimize: downhole electronics and number of parts Minimize: number of moving parts Use appropriate coatings, packaging technology, & housing Non-electronic sensors (i.e., fiber optic) “Right” mix (electronic, fiber optic, electrode array) Materials for HT/HP UDW applications (e.g., quartz, fiber optic) Fiber optic sensor issues: -must be appropriately coated and protected (otherwise, ingression of OH- molecules into fiber) -drifting (changes of zero offset)
15
Design, Development and Testing
Prototype designs based on state-of-the-art technology :
• Sensors (RFID, SAW-based, Fiber optic-based)
• Power supply (e.g., 1-10 mW power)
• Rock formations & Fluids (drilling/completion)
• Wireless EM transmission frequencies
16
Wireless (Mobile) Hub: SAW Sensors
Bluetooth Low Energy
Mobile Network
Mobile SAW Sensor Hub
Sensor/Control/Communication via bluetooth devices
17
ICIF Features
ICIF system concept: Advances for drilling automation,
completion, production, well intervention operations, etc.
After well completion: ICIF provides continuous monitoring, early
forecasting of production needs, all without well intervention.
Minimizes costly wire-line operations.
18
Impact on Existing Operations and Technologies
System Installation:
During casing runs, normal drilling operations.
Targeted casing string (permanent sensors needed for
optimal/ultimate field recovery).
Successfully tested in 100s of wells in the last 5 years.
2013 SPE 163694 Rahman, et al., Aera Energy LLC
Adopted from drillingcontractor.org
Sensors
Cable
19
Impact on existing …. Cont’d
System Installation-Fiber Optic Cable:
While additional time in casing run is expected, field applications
indicates non-issue. Average running time should not be less than 15
jts/hr.
Cement quality is not affected by the system (challenging or micro-
annulus problems did not occur).
Wellhead sections are not affected because wireless connection made
just below wellhead. 20
Impact on existing …. Cont’d
System Installation (Cont’d):
Allows use of conventional techniques to close well
without problems in case of kick while running casing
(The BOP can be closed hard or soft / no additional
components placed between the BOP and the casing).
21
Impact on existing …. Cont’d
System in service:
No affects on other telemetry systems used during normal drilling
activities (e.g., MWD, Wired Pipe, acoustic, EMWD).
Complements all other downhole technologies of drilling and well
completions.
No concerns: cement drilling out operations, rat-hole, etc.
Drilling is conventional without complexity; will not reduce the
performance of deeper hole sections (NPT = Zero). 22
Impact on existing …. Cont’d
System in service:
Clearance or drift of a casing-not reduced.
Downhole measurements performed during well control activities.
Monitor casing run and cementing job.
Perforation operations are combatable.
Conventional completions are combatable.
Well intervention procedures are combatable.
23
Fiber-Optic DTS Deployed Outside Casing
Over 70 wells with DTS permanent installations
All challenges met with 100% success
Fiber deployed outside casing, cemented in place, no damage
Perforations completion without fiber damage
Control line/fiber pulled through wellhead mandrel
Integrated into “lean” drilling
Cheap enough for “low-cost” 20 BOPD environment
2013 SPE 163694 Rahman, et al., Aera Energy LLC
24
Benefits in Deep-water (UDW) Applications
1. Well intervention not required to get data
Once well completed and deep water rig moved: very expensive well
intervention campaign not required.
Data, power, control lines part of production casing.
Performs in low temperature and high pressure conditions at sea bed.
25
Benefits in Deep-water (UDW) Applications
2. After installation, onsite personnel not required.
Automation enhanced.
Labor force and potential accidents reduced on location.
Remotely monitored and controlled from central control room.
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Benefits in Deep-water (UDW) Applications - Cont’d
3. Measurements during installation & casing runs.
Casing “filling up” is monitored.
Detects float equipment failure.
Drag model updated continuously; detects abnormal
restrictions, locations and causes.
27
Benefits in Deep-water (UDW) Applications - Cont’d
4. Not affected by weather conditions:
Because major system components are at the sea floor, sea weather conditions will
not affect the operation of the system.
5. Permanent well monitoring through the life of the well
Downhole sensors and system designed to last well lifetime.
Monitoring formation stresses and properties with time; assessed for forecast and
early prediction purposes.
28
Benefits in Deep-water (UDW) Applications - Cont’d
6. Early forecasting: well integrity and downhole problems
Casing status: monitored continuously during the life of the well.
Cement conditions/degradation modeled and monitoring to
enhanced future cementing designs.
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Benefits in Deep-water (UDW) Applications - Cont’d
7. Provide advanced planning; detect failure patterns:
Future casing and cementing design improved using real-time data
from intelligent casing wells (e.g., off set). Failure types identified
and minimized for future well applications.
Workovers and/or well intervention jobs can be scheduled in
advanced due to permanent well integrity monitoring of the wells
and therefore reduce costs of production and down time (Workover
will be more pro-active than reactive). 30
Benefits in Deep-water (UDW) Applications - Cont’d
8. Update 4d seismic, fluid levels, pore pressure, stresses and
MEM:
Intelligent casing design provides invaluable information about
mechanical formation properties changes with time.
Helps Geologist, Geophysicists and reservoir engineers with more
accurate data for calculations: changes in fluid levels, pore pressure,
stresses for enhanced Mechanical Earth Model (MEM) for future in-
fill drilling. 31
Benefits in Deep-water (UDW) Applications - Cont’d
9. Designed for difficult environments (high pressure and
high temperature).
Intelligent formation (sensors, readers, cables, etc.) designs for
HPHT wells (e.g., 30,000psi and 400C).
Special coatings and placement improves operation life.
32
Benefits in Deep-water (UDW) Applications - Cont’d
10. Well control monitoring during cement setting
Sensors can be placed in the cement.
Able to detect equivalent circulating densities during pumping cement
in the annulus and therefore prevent high picks of pressure that can
cause loss of circulation and reduction of hydrostatic.
Able to detect equivalent fluid densities after pumping and while the
cement is setting.
Able to detect any flow in the annulus after the cement sets.
33
Benefits in Deep-water (UDW) Applications - Cont’d
11. Proper care exercised in casing run conditions.
Special care plans for handling ICIF system.
Centralizers positions and designs re ICIF system.
Running procedures plans provide integrity of ICIF system.
34
Challenges in Deep-water (UDW) Applications
1. Cementing Job: Intelligent casing designs to allow
Rotations (minimized).
Reciprocations (minimized).
2. Learning Curve:
Rig floor personnel with special training re intelligent casing run.
Create confidence with contractors appreciating value of
intelligent casing design.
35
Early Detection and Forecasting
1. Early detection allows operator to plan interventions in
advance (maximize planning and resources).
Early detection of cement, casing, formation failures; helps forecast
patterns/future work over jobs. No Surprises – Everything expected.
System installed during drilling: Utilized during completion, well
testing, well intervention and production operations.
Maximize global investment and increase rate of return on investment.
36
Early Detection and Forecasting – Cont’d 2. Early forecasting allows operator to modify current casing
and cementing designs.
Statistical analysis performed after Intelligent Casing system installed in several
field wells: design improvements prevents failures in future wells.
Offset well data useful in future drilling programs, reduces costs, improves safety.
3. Minimizes probability of well suddenly shut down.
Today: production wells receive attention after something goes wrong.
Future: technology eliminates unexpected well shut down and side effects.
37
Early Detection and Forecasting – Cont’d
4. Workover campaign structured years in advance!
5. Reduce future “in-fill” drilling problems:
4D Seismic updated from offset wells.
Formation tops and fluid level changes.
Accurate Geomechanics model (MEM).
Non unexpected Drilling events and surprises regarding Mud window.
Low NPT (Non-Productive Time).
38
Early Detection and Forecasting – Cont’d
6. Time to react and plan: Assists industry in pro-active
plans and managements.
7. Improve distributions of the resources of the company
without affecting other projects.
Better planning improves project management of the Operator
Investments less affected by sudden problems (expected in advance).
39
Early Detection and Forecasting – Cont’d 8. Minimize risk and improve operation confidence
Annual budgets: better estimated; Supplementary AFE’s eliminated.
Greater Investors’ trust in Operators performance and proficiency.
9. Good technology to increase Governmental trust on the operator
Technology provides government with facts about operation control, comply current
standards and improvements.
Increases confidence between Operator and Government.
40
Early Detection and Forecasting – Cont’d
10. Low investment – High Results
Costs of the Intelligent Casing design: expected to be less than 10%
of overall casing tubular costs.
Results observed during casing run to bottom hole, before and after
cementing job.
Continuously monitoring wellbore status – Better than ever before! 41
Early Detection and Forecasting – Cont’d 11. Performance
Several Key Performance Indicators established to monitor Intelligent Casing
Design performance (Premature shut down wells, workovers, sand production,
water production, drilling NPTs, well control problems, etc.).
12. No significant change: casing & cementing costs
Casing and cementing designs are not affected substantially by introducing
intelligent technology.
42
Health, Safety and Environmental Issues (HSE)
1. Minimize personnel in location
Less Man-Hours of work.
Less time in boats and helicopter. Fewer frequency of exposure.
Improve drills and evacuation response.
2. Improve Drilling automation
Downhole sensors and data can be send to driller for better response.
Intelligent casing design can be combined by current automation
technology 43
Health, Safety and Environmental Issues (HSE) – Cont’d
3. Minimize unexpected downhole problems.
Quick information – Better analysis – Better response – No injures.
4. Environmentally friendly technology (industry proven).
Avoids environmental contamination.
5. Reduces unexpected blow out risks
Monitors “casing-formation” annulus in real time 24/7
Monitors cement setting and well control barriers performance
(Hydrostatic and downhole valves). 44
Health, Safety and Environmental Issues (HSE) – Cont’d
6. Reduces failures/wireline jobs (less human hrs. exposure)
Wireline jobs minimized.
Wireline BOP procedures are risky and complicated (replaced here
with common drilling BOP practices).
7. Minimizes oil or gas leakage into sensitive environments
No blowouts – No oil spills
45
ICIF Conclusions:
Intelligent casing design: pushes the boundaries of downhole “intelligence” to
maximize return on drilling investment and optimize field recovery.
Incorporates into the current drilling and completion practices.
Installable in almost all scenarios.
Provides great advantages with minimal cost installation.
Reduces risks and improves safety.
46
ICIF Conclusions (cont’d)
Combatable with HP/HT or bad weather conditions.
Potential to eliminate wire-line operations
Improves planning and project management in the field.
Creates more confidence investors and authorities.
Lifetime of well (20 to 30 years).
47
Thank you
Questions?
48
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