The Drilling Technologies Challenge is fundamentally tied to the performance limitations and operational costs associated with managing vibrations, torque, drag, and hole cleaning in modern drilling operations. These issues are exacerbated by the increasing complexity of well designs, particularly in extended reach, horizontal, and deeper wells.
Key Challenges:
- Vibration in the drill string can lead to equipment fatigue, reduced rate of penetration (ROP), higher non-productive time (NPT), and increased operational costs.
- Stick-slip can occur when friction between the bit and formation causes the bit to intermittently “stick” and then suddenly break free, leading to oscillations.
- Torsional vibration (twisting of the drill string) and lateral vibration (side-to-side movement) both contribute to energy loss, reduce tool life, and decrease drilling efficiency.
- Torque is the rotational resistance encountered while turning the drill string and drag refers to the frictional forces between the drill string and the wellbore. These increase with wellbore tortuosity and deeper drilling, causing energy inefficiencies and potential damage to equipment.
- High drag can also result in difficulty in tripping (raising and lowering the drill string), and drilling efficiency can be compromised due to the high friction forces encountered.
- The friction between the drilling equipment and casing can lead to abrasion and damage to the casing, increasing costs for repair and maintenance. This is particularly problematic in deviated or horizontal wells where the geometry of the well increases the risk of contact.
- Hole cleaning is crucial to prevent the accumulation of cuttings in the wellbore, which can lead to sticking of the drill bit, blockages, and reduced ROP.
- Effective hole cleaning becomes more difficult in extended reach and horizontal wells, where the cutting transport capabilities of the fluid are challenged by increased distances and larger amounts of cuttings.
Economic Implications:
The economic calculation for drilling success now goes beyond just cost per meter or foot drilled. Companies need to consider:
- Increased drilling time caused by vibration-related inefficiencies.
- Higher operational costs due to increased energy consumption and equipment wear.
- Increased risk of damage to drilling tools, casing, and even the wellbore, leading to costly repairs.
- Reduction in ROP leading to longer well construction times and higher costs per well.
- Higher maintenance and replacement costs for equipment affected by vibration and wear.
Potential Solutions and Advances:
- Advanced Vibration Mitigation Tools (X3DTM):
- Our unique X3D active damping tool has been developed and deployed to absorb all modes of vibrations before they can affect the drill string or BHA.
- Torque & Drag Reduction as well as Casing Wear Prevention Technologies (XTRTM):
- Our robust XTRTM non-rotating sleeve subs will help reduce the friction coefficient acting on the drill string along the critical areas of the wellbore, either in cased or open hole applications.
- We are also seeing more applications of reduced string generated stick-slip in the open hole.
- Enhanced Hole Cleaning Techniques (XHCTM):
- Our unique XHC agitation tool is deployed along the long tangent sections of the well to ensure that cuttings remain suspended and are carried to the surface efficiently.
Looking Ahead:
- Sustainable Practices: Reducing vibration and friction not only increases operational efficiency but also helps minimize energy consumption (MSE) and emissions, aligning with the growing push for sustainable drilling practices and a greener future.
In conclusion, addressing vibration, torque, drag, casing wear, and hole cleaning challenges is essential for maintaining economic viability in today’s complex drilling environments. By adopting advanced technologies and strategies, operators can significantly improve well delivery performance, reduce costs, and enhance overall efficiency in increasingly challenging drilling scenarios.