Slim-Hole and Coiled-Tubing

Technology
Dr. William J. McDonald
Thomas E. Williams
PTTC Technology Seminar
Lafayette, LA
December 5, 2000
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Drilling Engineering Association

(DEA)

Sponsors

Joint-Industry R&D Projects

28

Members (Operating Companies)

22

Associates (Service Cos and Consultants)

Currently 113 projects

Typical

Most

project: 10-15 participants

successful DEA projects:

DEA-44 Horizontal Well Technology

DEA-67 Slim-Hole and Coiled-Tubing
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DEA-67

Slim-Hole and Coiled Tubing Technology

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Sponsors:

Texaco & BP

Start Date:

January 1, 1992

End Date:

December 31, 2000

Participants:

65

Tasks:

22

Budget:

$3 Million

DEA-67 Tasks
1. Update Software
2. New Software
3. Users Group
4. New Technology
5. Drill-String Design
6. Motors and Bits
7. MWD and Geosteering
8. Well Control
9. UB Drilling/Completion
10. Logging Tools
11. Perforating Systems

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12. Completion Techniques

13. Stimulation Techniques
14. Production/Workovers
15. Through-Tubing
16. Field Tests
17. Case Histories
18. Well-Planning Manual
19. Composite Tubulars
20. Multibranch CT
21. Schools
22. Forums

DEA-67 Deliverables
Major

reports

Computer

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programs

6
9

Forums

Schools

Advances in
Slim-Hole Technology

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Summary
Slimholes:
-Reduce Well Costs 40 to 70%
-Reduce Environmental Costs & Concerns

-Tools and Equipment Exist, and are

Available and Reliable
-Safe
-Do Not Usually Limit Production

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Overview
Historical
Types

Background

of Slim-Holes

Slim-hole

Cost Savings

Evolution

and Experience

Concerns

and Conclusions

Outlook

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93
96

87
90

81
84

75
78

69
72

63
66

57
60

51
54

45
48

39
42

Number of Publications

Publications on Slim Hole

60

50

40

30

20

10

YEAR
9

Stekoll Slimhole
Pumping System (1960)
1 Tee
Rubber Hose

Clamp
Flow Line

Conventional
Stuffing Box

Gas Vent

Polished Rod Liner

2 7/8 Casing

1 EUE Pumping String

Blind Cage
Traveling Barrel Insert Pump

Screen
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Slip-Type Hold-Down
with Rubber Removed
10

Stekoll Field Well (1960)

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11

STEKOLL Field Experience (1960)

Over

1,300 Wells: Kansas, Texas, Canada

1,000
1

to 3,000 Foot Wells

EUE Tubing (Hollow Sucker Rod)

2-1/2

& 2-7/8 Inch Casing

70

BOPD

40

to 50% Reduction in Tubular Costs

17%

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Overall Cost Savings

12

STEKOLL Slimhole
Operations (2-7/8)
Drilling

& Logging

Perforating
Acidizing

Fishing

& Squeeze Cementing

& Fracturing

& Washovers

Sand

Bailing

Dual

Completions

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13

Hollow Sucker Rod Advantage

The hollow sucker rod combines the

function of the sucker rod and the

tubing, so it is no longer necessary to

pull both sucker rods and tubing

when working over wells.

STEKOLL, 1960

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14

STEKOLL System Limitations (1960)

Limited

Slimhole Logging Tools

Workover
Tubing

Concerns

Failures

Resistance

to Slimholes

Resistance

to New Technology

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15

Continuous
Coring

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Rotary
Drilling

Mud Motor

Collar

Core Barrel

Slim-Hole Systems

Downhole
Motor

16

Amoco SHADS Rig

(Continuous Coring)
Drawworks
Sandline
Hydraulic drive

Wireline overshot for

core retrieval

Top drive (0-2250 rpm)

Slim annulus
(<1/2)

Wellbore

Flush-joint
drill rod
4-3/8 core bit
(0-10,000 lb WOB)
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17

Slim-Hole Motor Drilling

in Wyoming
Amoco (1995)

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Microdrill Slim-Hole Rig

(Rotary Drilling)

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Slim-Hole Drilling Site

Slim-Hole Site

160 ft

(BP, 1994)

330 ft

200 ft

Conventional Site

Site Reduced by 75%

390 ft
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22

Material Cost Savings

(3 vs. 8)

80

80%

70

70%

% Savings

60
50
40

40%

30
20
10
0
MUD

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CASING

CEMENT

23

MICRODRILL COSTS
(1500-5000 ft DEPTH)

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24

Slim-Hole Drilling and Completion

Cost Savings

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25

SLIM-HOLE RIG COSTS

(McLAUGHLIN, 1959)
1,000

DAILY COSTS ($)

800

800
5 MEN

625

600

525

4 MEN

4 MEN

400

335

3 MEN
200

9"

6 3/4"

5 5/8"

3 3/4"

HOLE SIZE
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26

SLIM-HOLE CASING AND TUBING COSTS

(McLAUGHLIN, 1959)
7" CASING
2 7/8" TUBING

RELATIVE COST

5 1/2" CASING
2 3/8" TUBING

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4" CASING
1 1/2" TUBING

2 3/8" CASING
NO TUBING

27

40% Savings For 5000-ft WELLS

(BONSALL, 1960)

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28

Savings For 5000-ft Wells (cont.)

SLIM HOLE
($)

CONVENTIONAL % OF TOTAL
($)
SAVINGS

ACID

150

600

LOGGING

850

850

--

PERFORATING

450

350

-1

FRACTURING

3300

4500

LOCATION EXPENSE

2500

2500

--

MUD

1000

1000

--

CORE ANALYSIS

200

200

--

37,470

52,220

100

TOTAL:

2209314X

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DEA-67
29

Cost Savings with Slim Holes

OPERATOR
LOCATION SAVINGS YEAR
Hudson's Bay
Canada
28%
1959
Western Mining
Australia
75%
1984
Oryx
Texas
50%
1991
Elf/Microdrill
Paris Basin
65%
1992
Maraven
Venezuela
20%
1994
Chevron
California
66%
1995
Wilcox Operators
Texas
15%
1995
GUPCO/Amoco Gulf of Suez
20%
1995
Shell
Madagascar
40%
1996
ARCO
Alaska
26%
1996
Remote Coring Operations
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30

SLIM-HOLE COSTS
6.0

(WESTERN MINING, 1984)

WELL COST ($ MM)

2000m TD
DRY HOLE
ONSHORE
4.0
CONVENTIONAL

2.0

0
LOCAL

SLIM HOLE
REMOTE

LOGISTICS
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31

Conoco Indonesia Slim-Hole Costs

(MACFADYEN et al., 1986)
1980-81
(CONV)

1983
(SH)

1985-86
(SH)

12

7,670,000

4,680,000

2,060,000

TOTAL FOOTAGE

18,962

11,740

29,179

AVERAGE DEPTH

3,792

3,913

2,432

2,770,000

960,000

760,000

NO. OF LIFTS

317

187

100

NO. OF DAYS

16

HELICOPTER

PUMA

PUMA

S-58T

NUMBER OF WELLS
AVERAGE WELL COST
DRILLING

DRILLING COST/WELL
LOGISTICS

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32

ORYX
HORIZONTAL SLIM-HOLE COSTS
(HALL AND RAMOS, 1992)

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33

1991-92 ORYX SLIM-HOLE RE-ENTRIES

(HALL AND RAMOS, 1992)
DAYS DEPARTURE LATERAL COST TOTAL COST
18

1458

3.88 (CT)

0.63

38

2018

3.31

0.74

24

2002

1.84

0.41

21

2692

1.46

0.43

20

2242

1.83

0.45

18

1927

2.36

0.50

14

1600

1.75

0.31

22

1900

2.60

0.54

AVG 22

1980

2.38

0.50

1991 CONVENTIONAL COST = 1.00

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34

ORYX'S CONCLUSION (1992)

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35

Domain Energy Slimholes (1995)

Cased Hole

Open Hole

7-7/8 Hole
1518

5-1/2 Casing

9-7/8 Hole
1520

4-3/4 Hole

7-5/8 Casing

4-3/4 Hole
Inflatable
Casing Packer

Cement
10697

TD 10926
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2-7/8
TD 10909
Production Casing

2-7/8
Production Casing
36

Domain Energy Slim-Hole (1995)

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Location:

Green River Basin, WY

Rig Modification:

Bowen S3.5 Power Swivel

Hole Diameter:

4-3/4 inches

Casing Diameter:

2-7/8 inches

Drill Pipe Diameter:

2-7/8 inches

Collar Diameter:

3-1/2 inches - 3 stabilizers

Motor Diameter:

3-3/8 and 3-3/4 inches

Drilling Rate:

Up to 2x increase

Problems:

4 Twist-offs (stabilizer torque)

Successes:

Cementing/Logging/Perforating

Cost Savings:

Breakeven (due to twist-offs)

37

Domain Energy Slim-Hole Problems (1995)

Slim-Hole No. 1

Slim-Hole No. 2

Hole deviation (no stabilizers)

Low ROP (reduced WOB due to hole deviation)
Stuck pipe - 8,085 ft (stabilizer torque)
Fishing - back-off, spear, 4 trips (7 days)
Logging - problem running tool

Slim-Hole No. 3

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Plugged bit nozzles - 1,006 ft

Motor twist-off (stabilizer torque) - 7,071 ft
Fishing - 3 trips

Motor twist-off (stabilizer torque) - 1,004 ft

Fishing - 3 trips (23 hours)
Motor twist-off (stabilizer torque) - 5,187 ft
Fishing - 1 trip (grapple)
Lost cone - 10,871 ft (drilled with rock bit)

38

Unocal Thailand Slim-holes (1999)

Conventional
SSSV

Slimhole

13-3/8 @ 1000
9-5/8 @ 4500

SSSV

Ultra Slim

9-5/8 @ 850
7 @ 2500

SSSV

7-5/8 @ 850
5-1/2 @ 2500

6-1/8 Hole

4-3/4 Hole

2-7/8 TBG
@ 4500

2-7/8 TBG
@ 4500

2-7/8
TBG

7 @ 10000

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39

Unocal Thailand Slimholes (1999)

1.3

1.4

Well Cost ($millions)

1.2
1
0.8

0.75

0.6
0.4
0.2
0
Slimhole

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(4-3/4)

Conventional
(8-1/2)

40

Cumulative Gas Production (MMSCF)

Unocal Gas Production Rates (1999)

Slimhole Wells

Conventional Wells

0.00
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500

1000
1500
Time (days)

2000

2500
41

Unocal, 1997
Slimhole development has completely
Transformed the future of Gulf of Thailand
Operations and has paved the way for
Operators to continue providing a longterm economic supply of gas to the
Kingdom of Thailand

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42

Pemex Slimholes (1998)

Conventional

Slimhole

17-1/2 Drill Bit

150 m

13-3/8 Casing

12-1/4 Drill Bit

150 m

12-1/4 Drill Bit

1650 m

9-5/8 Casing

9-5/8 Casing

8-1/2 Drill Bit

1650 m

7 Casing

2-7/8 Tubing

3000 m
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Packer

Cement

8-1/2 Drill Bit

5-7/8 Drill Bit

7 Casing

3000 m

3-1/2 Tubing
43

Pemex Slimholes (1998)

45

42

Cost Savings (%)

40
35

32

31

30

30
25
20

16

15

13

12

Wellhead

Cement

10
5
0
Mud

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Rig

Casing

Time

Tubing

Bits

Overall
44

Texaco Dual Completion Slimhole

17-1/2 Hole
2,500

13-3/8 Casing

12-1/4 Hole

8,000

9-5/8 Casing

2-7/8 Tubing
10,500

Cement
8-1/2 Hole

12,500
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2-7/8 Tubing
45

Slim-hole Well Concerns

Casing

Program

Drillstring
Fishing

& Milling

Increased
Bit

Torsional Strength
ECD (lost circulation)

Design and Reliability

Downhole

Motors(cost & reliability)

Cementing

(primary & squeeze)

Stimulation

Workovers

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46

Slim-hole Well Non-Concerns

Logging

Perforating
Tubing

buckling & sticking

Wellhead
BHA

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design

design

47

Conclusions
Slimholes:
-Reduce Well Costs 40 to 70%
-Reduce Environmental Costs & Concerns

-Tools and Equipment Exist, and are

Available and Reliable
-Safe
-Do Not Usually Limit Production

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48

High-Power Slim Motors

Long Power Section

Universal Jt

Bearing
Pack

Standard
Power
Sections

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49

Leniek Pumping System (1999)

1-1/2 Hydraulic
Hose
Clamp
Production Line

Stuffing Box
Gas Vent

Hollow Polish Rod

3-1/2 Cemented Tubing
2 Coiled Tubing
Hollow Rod Pump

Screen
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Anchor
50

Leniek CT Pumping System

Conventional

Surface Equipment
1,000 to 5,000 Feet
2-7/8 or 3-1/2 Casing (CT or
Tubing)
1-1/2 CT (Hollow Sucker Rod)
Hollow Polish Rod
Hollow Rod Pump

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51

YPF Installation

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52

Leniek System Advantages

Reduce

Well Construction Cost 50

Percent
Eliminates Tubing Thread Failures
Eliminates Tubing Anchors
Reduce Lifting Costs
Reduce Paraffin Problems
Reduce Casing Wear
Treat Wells Through CT
Eliminate Rod Failures
Allows Ultraslim Holes
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53

Advances in
Coiled-Tubing Technology

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54

Overview
History

& Evolution

Current

Status

Conventional
Coiled

Operations

Tubing Drilling (CTD)

Outlook

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55

Publications on Coiled Tubing

Number of Publications

120
100
80
60
40
20

96

94

92

90

88

86

84

82

80

78

76

74

72

70

68

66

64

YEAR
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56

Evolution
1944

Allied Invasion Europe

1962 Bowen CTU
1975 - 200 Units - 1-1/4
1980 - Improved Pipe/Welding
1983 - Continuously Milled 3000
1987 - Bias-Welded Strips
1992 - 2-3/8 to 3-1/2 OD CT
1999 - 110 ksi CT
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57

Today
750

Units Worldwide

50%

Few

in North America

Pipe Failures

Multiple

CT

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Applications

Pipelines

58

Common Applications
Clean

outs (50%)

Stimulations
Profile

Modifications

Perf/Log
Artificial

Sand

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Lift

Control

59

Coiled-Tubing Applications
Clean-out
Downhole Tools
Stimulation
Nitrogen Lift
Drilling
Logging/Perf
Jetting
Fishing
Cementing

Source: Quality Tubing

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60

Cost Savings with Coiled Tubing

OPERATOR
ARCO Alaska
Fracmaster
BP (North Sea)
Chevron
Amoco (GOM)
BP Alaska
Mobil
Amoco

JOB
SAVINGS YEAR
Cement Squeeze
90%
1987
Pipeline Cleanout
90%
1988
Barium Scale
80%
1990
Velocity String
59%
1992
Zinc Sulphide
94%
1993
Spoolable GL
68%
1993
Fracturing
21%
1994
TT Gravel Pack
80%
1996
Workovers

Completions
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Support Pole

Hybrid Coiled-Tubing/
Snubbing Rig
(Hydrarig)
CT Injector
Injector Trolley

Substructure

Jack Cylinder
Quad BOP

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69

Oman Large-OD CT Completions

Taylor and Conrad (1996)
Slim Concentric
Water Injector

ESP Well
Slip
Connection
ESP cable

Slip connector
Landing nipple
Protector
Motor
Centralizer
7 K55, LTC

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Velocity String
Top CT plug

2-7/8 CT

1-1/2 CT
4-1/2
Tie back

3-1/2 CT

Pump

Gas Lift Well

Gas lift
mandrels
13-3/8
casing

4-1/2
Tie back
2-7/8
EU nipple
5-1/2 x 2-7/8
production
packer

3-1/2
tubing
Gas lift
mandrel
Bottom hole
press. gauge

Sliding
sleeve
circulating
device
7 packer
3-1/2 nipple
7 shoe

Hyd. set
retrievable
packer
Production
packer
2-7/8
EU nipple

70

ARCO Coiled-Tubing Liner

Production tubing

Hydraulic set packer

Open-hole well
(possibly drilled with
coiled tubing)
CT liner

Pre-perforated
CT liner with
optional screen

Pay Zone

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71

CT Steam-Injection System
Coiled Tubing

Injector

Steam
Generator

BOP
Wellhead

Oil Reservoir
Steam
8000

Pearlite
Oil

Oil
Steam

Casing

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Production
Tubing

Slotted
Liner
Concentric CT

2-7/8 CT
1-3/4 CT
Concentric CT
Cross Section

72

Coiled Tubing Drilling

(CTD)

History of CDT

Current Status

Demographics of Current Activity

Advantages and Limitations

Where are we headed with CTD?

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73

Coiled-Tubing Drilling System

Injector

Reel

Power Supply

2 CT with Wireline

Connector

Guidance
System

Whipstock or
Cement Plug Orienter
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Mud
Motor

Bent Sub

Bit
74

Why CTD or Why Not ?

Continuous

Circulation
Pressure Control
Footprint, Environmental
LWD, Geosteering, Joystick Operation
Deepenings, Side-Tracks
Through-Tubing Capable
Costs?
Availability
Acceptance
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75

Brief CTD History

1991

- Elf/Dowell & ORYX/Cudd

1992

- Arco first window & MWD

1994

- First North Sea CTD wells

1994

- Maersk 3000 Horizontal well

1995

- 200+ CTD Wells Worldwide

1999

- 1200 CTD Wells

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76

Schlumberger Electrically-Controlled
CT Drilling System

2" CT

Drilling
Head

Logging/Steering
Sub

Bit
Electric
Orienter

Motor

7-Conductor
Wireline

Schlumberger Viper BHA

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Transocean Hydraulically-Controlled
CT Drilling System

2" CT
Connector

Hydraulic
Orienter

Check Valves/
Release Sub

Bit

Logging/Steering SubMotor

Monoconductor Wireline
1/4" SS Hydraulic Tubing

Transocean Dual-Capillary BHA

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78

Camco Electrohydraulic Umbilical

CT Drilling System
18 AWG
Conductors

Protective
Sheath

Hydraulic
Oil

3/8 x 0.65
Hydraulic Tubing
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Thermoplastic
Insulation
79

Arco CTD History

1990-Initial

interest for PRB ST

1991-Initial

ST effort unsuccessful

1992-94

Oklahoma Window Milling Tests

1992-Successful
1993-Prudhoe

ST in West Texas

program started

1994-95

THUMS Efforts,

1997++

Algeria, Indonesia, CA, NM...

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80

ARCO Summary (1999)

120

120

100
80
60
40
20
0

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11
1
Alaska

California New Mexico

1
Texas

3
Indonesia

1
Algeria

81

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Running 3 1/2 CTC after CTD

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Typical CTD Completion at PRB

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Bottom
Hole Assembly

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101

Surface Testing
17 PPG Fiber F/O Plug
Pilot Hole
Casing Exit
One Step Mill
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1999-2000 CTD Developments

Thru

- 3-1/2 Tubing Operations

Over 30 Slimhole Operations To-date
Fluid Loss/ECD Concerns
Lower Density
Lower Polymer loading
Shale Stabilization Additives
Bi-center Bits

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104

PRB CTD Average Footage

1950

2000

1794

1800

1685

Average Footage

1600
1400

1204

1200
1000
800

817

600
400
200
0

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1995

1996

1997

1998

1999

105

Prudhoe Bay Summary

100 wells 1993-99
Average Cost

1995 - $990M
1996 - $1005M
1997 - $1165M
1998 - $1200M
1999 - $1375M
Harder, Longer Reach Targets
Avg. Production 1400 BOPD
90% success
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Grissom Island
THUMS - Arco Project

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California CTD Project

4/97-

Drilled 7 shallow vertical wells

Fleet

Cementers CTU - unique design

Used

2 7/8 OD CT, 4 3/4 PDMs

Hole

size 6 to 6 1/2 holes, 1 to 9 1/2

Depths
Total

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900-1000 , Ran 3 1/2 casing

time 24 hours/well

114

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Indonesia
Multiple

well program in NW Java Sea

One

ST/ window through 9-5/8 csg- 1997

870

of 6-1/8 hole drilled w/ 2-3/8 CT

Used

tinder barge rig as support

Completed

with cemented 3-1/2 liner

2nd

well discontinued after 500 - shale

3rd

well April - June 1998- lost hole - shale

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Offshore Indonesia

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Current Status of CTD

20

CTUs capable of serious CTD

Less

than 10 CTUs actively drilling

AK,

Oman, Canada, N. Sea,

Venezuela

Currently

active; Schl, Baker, BJ

Fleet
MWD,
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electric/hydraulic BHAs
128

Why CTD or Why Not ?

Continuous

Circulation
Pressure Control
Footprint, Environmental
LWD, Geosteering, Joystick Operation
Deepenings, Side-Tracks
Through-Tubing Capable
Costs?
Availability
Acceptance
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129

What is the Future ?

Underbalanced

operations
All-electric CTD BHA
Composite CT
Pre-programmed, self guided BHA
Smaller BHAs
Through-tubing rotary drilling

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130

Fiberspar Composite Coiled Tubing

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131

Fiberspar Spoolable Products

Production

Tubing - FS PT

Pipe - FS LP
Coiled Tubing -FS CT (for Well
Servicing)
Line

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132

First FS CT Field String

6500 Ft. Length, 1.5 OD

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133

FS CT Field Validation Trails

Halliburton
Energy Services
To date, 6 - CO2
injection well
clean-outs with
acid stimulation
for Altura in W.
TX and Phillips
in NM

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134

FS LP First Commercial Application

TT00-63

Altura, Levelland,
TX
40,000 water
flood installation
2 ID, 1500-psi
WP Fiberspar
LinePipe used
Pipe shipped in
8,000 ft
continuous
lengths

135

Mobile Spooling Unit

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136

Few Fittings
Long

runs were
easily
accomplished with
few or no fittings
to account for
turns
Several long runs
with multiple turns
were successfully
completed in a
single pull

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138

TT00-63

141

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142