HPHT Solutions

Baker Hughes - Drilling and Evaluation

Baker Hughes D&E HPHT Solutions
HPHT Case History
Research and Development Outlook
Christian Liss Wireline HPHT Segment Manager
Dominic Dieseru Wireline Applications and Product Line Manager
Stephen Rounce Wireline Customer Service Manager
Ian Mansfield Marketing Director Reservoir Evaluation
HPHT Wells Summit 2011 - London, November 16th 2011
2011 Baker Hughes Incorporated. All Rights Reserved.

HPHT
Frontier Markets
HPHT drilling & exploration is critical to access
Onshore Shale, long horizontals
Offshore Deep Water, Ultra deep water
Geothermal applications
Cost of developing these wells is high
Reliability of service & equipment critical!
Performance Through Technology
Target extreme service requirements
Apply robust design - modeling & validation
Drive reliability - testing & qualification
Deliver research innovations in Metals,
Sensors, Electronics, Elastomers
2

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Cement

Wireline
Logging

Liner
Hanger

BHI

FES

DD

BHI

MWD

Reamers

BHI

Year

Operator

Well name

TVD
[ft]

Location

2003

Shell

Shark

25,745

Sout Timbalier

2005

Chevron

Cadilac

24,795

Viosca Knoll

2005

Shell

Joseph

25,537

High Island 10

2006

ExxonMobil

Blackbeard

30,067

South Timbalier

BHI

BHI

2008

McMoRan

Blackbeard RE

32,997

South Timbalier

BHI

BHI

2009

BP

Will K

28,404

High Island

BHI

BHI

2009

McMoRan

Ammazzo

25,488 South Marsh Island

BHI

BHI

2009

McMoRan

Davy Jones

29,300 South Marsh Island

BHI

BHI

2010

Armstrong O&G

BP Fee

15,800*

Cameron Parish

BHI

BHI

BHI

2010

McMoRan

Blackbeard East 32,000*

South Timbalier

BHI

BHI

BHI

BHI

BHI

BHI

BHI

BHI

BHI

2011

McMoRan

Davy Jones
Offset

30,700* South Marsh Island

BHI

BHI

BHI

BHI

BHI

BHI

BHI

BHI

BHI

2011

McMoRan

Lafitte Project

23,000*

BHI

BHI

BHI

BHI

BHI

BHI

BHI

BHI

BHI

Eugine Island

BHI

2009 Baker Hughes Incorporated. All Rights Reserved.

BHI
BHI

* ongoing at the creation time of the slide

3

Bits

Fluids

Gulf of Mexico Expertise in Ultra-deep Gas

Case History

BHI

BHI

BHI

BHI

BHI

BHI
BHI

BHI
BHI
BHI

BHI

BHI

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BHI

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BHI

BHI

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BHI

BHI
BHI

Drilling Services
HPHT Challenges & Solutions

2009 Baker Hughes Incorporated. All Rights Reserved.

Circulating vs. Static Temperature

During drilling
Bottom hole = circulating =

operating
Typical decrease: 5-50C
Parameters

Mud coolers
Hole size
Depth
Orientation
Flow rate
Drill string rotation
Cooler Deeper
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HPHT Drilling Services Available

X-tremeBorehole
Motors Temperature
OnTrak

OnTrak

AutoTrak

AutoTrak

LithoTrak

LithoTrak

TesTrak

TesTrak

SoundTrak

SoundTrak

MagTrak

MagTrak

ZoneTrak G/R

ZoneTrak G/R

StarTrak

StarTrak

SeismicTrak

SeismicTrak

X-tremeBorehole
Motors

Rating

10

15
20
Pressure [kpsi]

2009 Baker Hughes Incorporated. All Rights Reserved.

25

30

35

25

50

Temperature Rating

75
100
125
Temperature [C]

150

175

200

HPHT by Design - Development

2009 Baker Hughes Incorporated. All Rights Reserved.

Minimizing Operating Days in High-Temperature Drilling in

Haynesville Shale
Case History

Objectives
Zero HS&E incidents
Identify zone of interest
Minimize operating days while drilling in HT environment
reaching 343F (172C)

Days vs. Depth

11500
12000
12500
6 3/4" Curve
13000
13500

MEASURED DEPTH (ft)

Well Data
USA, Louisiana, Bossier Parish, 2009
Hole Size: 6-in.
Well Type: Horizontal
Formation: Haynesville Shale
Planned Dogleg: 9/100 ft
Mud Type: 15 ppg OBM

14000
6 3/4" Late ral
14500
15000
15500
16000
16500
17000
17500
18000
0

10
DAYS O N JO B

Solution
Service personnel trained in HT operations
High-temperature operating procedures
High-temperature MWD service
Results
Zero HS&E incidents
Identified and successfully placed well into zone of interest
Completed drilling in 18 days
Drilled 6-in. curve (1,064 ft) with net ROP of 11 ft/hr
Drilled 6-in. lateral (4,435 ft) with net ROP of 39 ft/hr
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15

20

SoundTrak Acoustic for PPP application

Case History
Determining accurate subsalt pore pressure in real time

Low sensitivity to hole sizes, formation

Acoustic pore
pressure

Measured
pressures

Modeled
Fracture
gradients

2010 Baker Hughes Incorporated. All Rights Reserved.

temperature and pore water salinity

Small effect on measurement around salt
No false indication of pore pressure
sometimes seen with resistivity around salt
because of changes in formation salinity
Correlation with seismic surveys
Characterization of rock mechanical
properties for wellbore stability and
completion analysis
Calibrate seismic velocities for look ahead
predictions

SeismicTrak Service adds value to PPP

damage or effects
Real time updates of
time-depth profile
Reduces uncertainties in
surface seismic
Place bit on surface seismic
Look below the bit for
pressure ramp detection
Estimate distance to overpressured zone to predict and
mitigate pressure kicks
Reduce drilling hazards and NPT

2011 Baker Hughes Incorporated. All Rights Reserved.

500m
200ms

Seismic data from surface

Not affected by near wellbore

Drilling Fluids

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2009 Baker Hughes Incorporated. All Rights Reserved.

Keys To Success
Experience

Have serviced more than 200wells >400F

Dominate provider to the extreme HPHT segment
Capturing Lessons Learned & incorporating into CPI

Have extensive list of Lessons Learned/Best Practices

HPHT Laboratory capability, to include Specialized Equipment

Have 3 strategically positioned Global labs with capability

Houston, Aberdeen & Kuala Lumpur

Keys To Success
Invert Emulsion Fluid for extreme conditions

MAGMA-TEQ has proven track record

System is stable at BHT +600F (316C).
Aqueous Fluid (Primary or Contingency)

PYRO-DRILL also a proven track record

System is stable to 550F (288C).
Sophisticated modeling capability

Temperature - Presmod
Hydraulics ADVANTAGE Engineering
Bridging BRIDGE-WISE
Down hole stresses BORE-WISE

Drilling of 4 uHPHT wells from a Heavy Duty Jack Up with

Magma-Teq System
Drilling Fluids Specification Process
Well conditions were a step change away
from clients conventional North Sea wells.
Mud was required to be stable at up to
428F and 18.5 ppg
BHDF selected with Magma-Teq system to
provide HPHT fluids for UK and Norway

A multinational drilling fluids development

team was created to further refine the
design of the drilling fluids for the uHPHT
wells campaign:

Problem identification,
Laboratory programs per well and
Chemical selection to optimize reuse.
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Case History
System Performance in the Field
Bottom hole static temperatures were seen
up to 395F
Circulating temperatures were between
275F and 376F
BHP about 17,500 psi
The system was stable under the
conditions encountered in the wells
The rheology was stable and controllable
over long periods of time and despite
extended fishing/pipe recovery operations
No significant fluctuations in fluid density
after prolonged static periods
No dynamic sag despite relatively low
circulation rates

Drilling of 4 uHPHT wells from a Heavy Duty Jack Up with

Magma-Teq System
Optimization of Fluid cost and inventory
Objective: Utilize fluid on more than one well
2,653 bbls from first well used for second well
2,162 bbls from second well used for third well
1,100 bbls added as possibility of losses occurred
3000 bbls returned from third well to be reused
Summary
Mud system was stable under conditions in all
three wells
Negligible NPT caused by mud system
Rheology was stable and controllable despite
extended section times
No significant fluctuations in fluid density after
prolonged static periods
No dynamic sag despite relatively low circ. rates
Successful system on all three wells allowed
optimization of cost and volume control

15

2009 Baker Hughes Incorporated. All Rights Reserved.

Case History

The Magma-Teq System

A high temp. invert emulsion mud
weighted with a mixture of Barite and
Micromax
Micromax is Manganese Tetraoxide
with very fine particle size d50 < 1
Base oil initially Escaid 120, latterly
EDC99DW
Robust Emulsifier package
Specialized HPHT fluid loss additives
Premium Organophilic clay

PYRO-DRILL
KTB project - Ultra Deep HT
Scientific drilling project in Germany.
Performed laboratory evaluations
and presented Fluids
recommendations to KTB.
Assisted at location with the
conversion of an existing major
competitors drilling fluid at 23,623
(7200m) to a PYRO-DRILL
geothermal drilling fluid (referred to
as the KTB-HT system).
Provided technical assistance and
support for remainder of the
operation.
Total depth of the hole was 29,860
(9101m) with a BHT of 482oF (250C)
and 12.5 ppg MW

Advantages
Far lower gas solubility - immediate and
apparent influx detection
Losses easier to manage
Superior HS&E - rig pit room/shakers areas
Environmentally more benign
Simpler waste management
Lower ESD and ECD, less tendency to
generate fracturing
Much higher specific heat
Low compressibility - PVT non-issue
Simpler logistics, can be made up on site
Lower solids volume in fluid - higher base fluid
densities
Multiple make-up brine options
Disadvantages (versus oil mud)
Treatment of high concentrations of CO2 & H2S
Potential for formation stability issues
Potential for rheological instability
(contamination)

Wireline Services

17

2009 Baker Hughes Incorporated. All Rights Reserved.

Nautilus Ultra (HPHT)

Rugged construction

Nautilus UltraTM Open Hole 500F and 30kpsi

Cross-Dipole (XMAC-F1)

Durability at extreme

temperatures lowers NPT

Superior sensors provide
accurate data to aid reserve
estimation
Unique provider of HT crossdipole logging services

Induction Resistivity (HDIL)

Formation
Evaluation

Porosity (CN)
Density (CDL)
Natural Gamma Ray (GR/SL)
Borehole Geomety (XZ-Cal)

Nautilus UltraTM Cased Hole 500F and 35kpsi

Formation
Evaluation

RPM Service
pulsed neutron
Formation evaluation in cased
holes
Production logging and water
velocity determination
Mineralogy behind casing

18

2011 Baker Hughes Incorporated. All Rights Reserved.

HPHT Wireline Services Available

Borehole
Open Hole
FE

Temperature Rating

Cross Dipole

Cross Dipole

Acoustic Imaging

Acoustic Imaging

Formation Coring

Formation Coring

Formation Testing/Sampling

Formation Testing/Sampling

Resistivity Imaging

Resistivity Imaging

Cased Hole FE

Cased Hole FE

Production Logging

Production Logging

Cement Evaluation

Cement Evaluation

Pipe Recovery

Pipe Recovery

19

Borehole
Open Hole
FE

Temperature Rating

10

15
20
Pressure [kpsi]

2009 Baker Hughes Incorporated. All Rights Reserved.

25

30

35

100

200
300
400
Temperature [F]

500

600

HPHT Solutions: Deployment Risk Reduction

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2009 Baker Hughes Incorporated. All Rights Reserved.

World Wide HPHT Fields

Above 150C BHT and 690bar surface pressure

Nautilus Ultra
5 Year Job History

Oregon
246 DegC

Nautilus Ultra

Job History

#Jobs above 350F

100+

Max. BHT:

474F

Max. BHP:

29,000 psi

Max in-hole time:

50+ Hours

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2009 Baker Hughes Incorporated. All Rights Reserved.

Cooper Basin
243 DegC, 843 Bar

Devon
233 DegC, 1447 Bar

Cadillac
222 DegC, 1591 Bar

HPHT Pressure Testing and Fluid Sampling

Objectives
1. Accurate formation pressures
2. Representative formation samples
3. Safe and efficient operation

Challenges
High Temperature up to 388F
High Tension well depth of 5000m
Highly Depleted pressure overbalance up to 8000 psi

23

2011 Baker Hughes Incorporated. All Rights Reserved.

HPHT Pressure Testing and Fluid Sampling

Solution
DRM (Deployment Risk Management)
recommendations
High strength HPHT cable
crush resistant HPHT wireline

Derrick installed Capstan

Friction Reducing Stand-offs
Flywheels
Ultra slim profile standoffs

24

2011 Baker Hughes Incorporated. All Rights Reserved.

HPHT Pressure Testing and Fluid Sampling

Solution
Deploy RCX (Reservoir Characterisation
eXplorer)
Prepared and tested for HT conditions
Fitted with Flywheels to mitigate the risk of
sticking during testing/sampling
Fitted with 10kpsi differential pumps
Single Phase I & Single Phase II tanks
designed for HPHT

25

2011 Baker Hughes Incorporated. All Rights Reserved.

HPHT Pressure Testing and Fluid Sampling

Results:
Effective Wireline Deployment plan
resulted in zero NPT
Pressures (Max Temp 363F)
Acquired 100% of formation
pressures tests requested
Max overbalance on pressure tests: 7000+ psi

Samples (Max Temp 388F)

3 Sample stations completed successfully
Up to 2hrs 10mins pumping at one station
Overbalance of 5000 psi differential

PVT quality/quantity samples

First ever single phase downhole sample from this field
26

2011 Baker Hughes Incorporated. All Rights Reserved.

Geothermal Well, Australia

Case History

Objectives
Locate fractures within the wellbore
Safe Operation
Challenges
BHT ~ 470F (243C)
TD ~ 16,000 ft

Solution
Nautilus Ultra Logging Suite w/ XMAC F1
Results
Successful Wireline conveyed run
Fractures interpreted from
Cross-Dipole analysis

Research & Development

31

2009 Baker Hughes Incorporated. All Rights Reserved.

Component Reliability: Exponential Decline

Current specifications: 150C
Arrhenius equation (reaction rate): 10C = 50% component life

Svante Arrhenius

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2009 Baker Hughes Incorporated. All Rights Reserved.

Electronics: Its easier to go to the moon.

Operating Temperature Specification

Consumer

Industrial

Military &
Space

Oil & Gas

33

-20C

-25C

Inspections

Tests

70C

Assembled Parts

Final Test @ Room Temp

70C

IPC-A-610: Class 1/2

Sample probe

Sub Assy @ Room Temp

-40C

-20C

2009 Baker Hughes Incorporated. All Rights Reserved.

IPC-A-610: Class 3
Sample probe

125C

175C+

IPC-A-610: Class 3
each solder

Sub Assy @ High Temp

Final Test @ Room Temp
Sub Assy @ High Temp
Final Test @ Room Temp

Design for Reliability: Analyze, Test, Validate

Model

Analyze
Mission profiling (thermal & mechanical stresses)
Component selection
Process optimization

Test
Lab qualifications
Component
Board
System

Validate
Root cause analysis
Optimization
Field performance

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2010 Baker Hughes Incorporated. All Rights Reserved.

Analyze,
Design
& Model

Test &
Qualify

Lab

Validate &
Improve

Field

Validation, Testing & Qualification

Celle Technology
Center

Woodlands
Technology Center

Houston Technology
Center

Electronics Design
Innovation

Drilling Simulator &

Drilling Dynamics
Simulation

Model Testing &

Verification

Beta Test Rig

Oklahoma

Model Testing &

Verification

Field Testing &

Systems Integration
Testing

35

HT Electronics Challenges <175oC

Operating ICs onPCB)

175oC Approach Pushing Reliability with

Todays Technology

Optimize PCB board layout for IC cooling

Increase solder resistance to creep

Thermal Flow - ICs on PCB

Thermal management
Move heat away from effected components
(Passive/Forced)
Flask PCBs ( from external thermal loads)

Pre & Post Mfg Component & System Screening

Thermally cycle parts to find early failures

Steps (hrs)
2009 Baker Hughes Incorporated. All Rights Reserved.

Heat Conduction from ICs

Beyond 175C: Enabling Technologies

Packaging & components
Bare dies vs. plastic packaged components
Bonded vs. soldered connections

&

Active cooling
Memory, DSPs, etc.
Sensors
Materials
Corrosion
Sealing
38

2011 Baker Hughes Incorporated. All Rights Reserved.

Extending Survivability - Packaging

Passive Circuit Cooling

Wireline
Today
Passive thermal cooling
Thermal insulation & flasking
Tomorrow
More Hybrids & More active cooling

LWD
Today
Vibration damping
Passive thermal cooling
Tomorrow
More Hybrids & More active cooling

Composite Clam-Shell Top

Component Cavity
Viscoelastic pad
Composite Clam-Shell Bottom

Technology Investment Infrastructure

New Sensor (HT) Development Lab, Houston

Hybrid Electronics Lab, Germany

Finish Fall 2011

Finished 2009

Over $20M in infrastructure investment in HPHT

Electronics design, testing and qualifications;

Data Acquisition, Mfg Automation

IC failure analysis; X-Ray, Ultrasonic, elemental analysis, Thermal imaging diagnostics
Simultaneous Ovens & Shaker Tables,
Test chambers, Pressure Pits (375C, 40K)

41

2010 Baker Hughes Incorporated. All Rights Reserved.

People

Houston, Texas

Celle, Germany

42

2010 Baker Hughes Incorporated. All Rights Reserved.

Houston, Texas

Houston, Texas

Information Technology: Transforming Operations

43

2011 Baker Hughes Incorporated. All Rights Reserved.

Summary

44

2009 Baker Hughes Incorporated. All Rights Reserved.

BHI High Temperature R&D Capabilities

People
100+ engineers on 40+ HT projects
Center of Excellence & HT Materials Department
Leading consultants, Universities, Government labs

Solutions & Practices

30 years experience in flask design, fabrication, testing

Real Time Temp. monitoring of critical components.
Well developed HALT & HASS testing programs
Specific standards, processes and component database

Facilities
Specialized HT labs on Hybrids, Cooling, Fluids, Acoustic,
NMR, Resistivity, Nuclear, Optics.
Testing up to 700F, 40ksi. 100+ HT ovens
IC analysis, X-Ray, Ultrasonic, Elemental, Thermal imaging.

Suppliers and Partners

Industry wide HT contacts and partnerships on advanced
components, IC, DSP, Sensor, PCB and proprietary soldering.
45

2009 Baker Hughes Incorporated. All Rights Reserved.

Solutions on the Market

for all aspects of D&E
Drill Bits,
Directional Services,
MWD/LWD Services,
Drilling Fluids
Open Hole Wireline Services
Cased Hole Wireline Services
Solutions include
Deployment Risk Reduction
Planning, Simulation and Testing
Proven Processes, Procedures and Talent

46

2009 Baker Hughes Incorporated. All Rights Reserved.

Evolving the Portfolio

Additional Services and
Technology
Fit for Purpose HT-Systems for
extreme service specifications
Design for Reliability Focus
in Design, Modeling,
Testing & Qualification
Deliver Research
Innovations in Materials,
Sensors, Electronics,
Nano-Structures and
Manufacturing

Comments/Questions

47 2009 Baker Hughes Incorporated. All Rights Reserved.