Working with R&D Solutions, Ulterra’s CounterForce® recently set a new South Australian offset record. Read R&D Solutions article here to learn the full details.
Featured in the June issue of Oilfield Technology, Ulterra discusses how customized bit development for RSS reduces tool failure.
Most RSS tools are highly susceptible to failure due to vibration, which is one of the most common reasons the BHA must be tripped. Ulterra’s CounterForce® technology uses the cutting structure to reduce vibrations at the bit, which increases efficiency and reduces bit damage.
This article was sourced for a recent article in Hart’s E&P magazine, which can be found here.
Working, Together: RSS-Tailored Bit Designs Improve Drilling Performance
Written by: Aron Deen, Levi Sasser, and Chris Gooch
Nearly all new technologies struggle in their infancy to gain adoption due to high cost, problematic reliability, lack of understanding, and marginal value proposition. Over years of learning, development and refinement these hurdles reduce, and with each step new opportunities open up. This has been the case for rotary steerable systems (RSS), which is finding new value in this historic downturn.
Another facet of technology adoption is the availability of compliments. For example, smartphones need great apps for customers to realize their true value. In much the same way, RSS need to have great drill bits designed to work with them in order for operators to realize their maximum value.
To be sure, there are certainly some hurdles in working across company lines on product development. For example, gauge pad configuration is one of the many aspects of bit designs that are customized to work perfectly with differing RSS tools. Different lengths, steps, tapers, helix angles, and wear protection may be advantageous for a particular RSS application, but producing such a specific product requires a significant investment of engineering resources and capital. And once created, such a bespoke asset should not be blindly forced into an improper application to the detriment of another operator. The only long-term path over such hurdles is for service companies to jointly commit to focus first on performance for the customer.
World Record RSS runs in Eagle Ford
In South Texas, operators and RSS tool developers have toiled for the last few years to uncover the full value proposition of being able to steer while rotating. In theory, this should allow operators to capture all of the benefits of highly directional wells without the inefficiency of regularly having to interrupt operations to orient and slide at low ROP – and have better hole quality to go along with it. The increased complexity of the systems, however, requires all components to work together seamlessly. The primary challenge for operators has been maintaining ultra-tight windows in lateral applications of the extended-reach horizontals in the Eagle Ford. RSS has made those complex well designs a possibility.
Ulterra’s willingness to partner with RSS makers has contributed to great runs. After working with Weatherford to design an Eagle Ford bit tailored to Weatherford’s Revolution® RSS, there has been a huge improvement in vibration and torque, which has drastically reduced the chance of tool failure. At the same time, the bit is increasing ROP, setting distance records, and coming out of the hole in pristine condition.
In a run in Live Oak County, TX, the bit set three global footage records for the Revolution RSS by drilling 16,234 feet in one run. The extended-reach well had a total depth of 22,700 feet. Reaching out that far is a big challenge, and accomplishing it with one bottom-hole assembly had been previously unheard of. With the Ulterra bit and Weatherford RSS working together the BHA was able to stay on bottom for 192 hours.
Reduced Vibration, Improved Efficiency in Abu Dhabi
In a recent well in Abu Dhabi, a major operator encountered difficulty drilling through a troublesome series of formations in an ADMA brownfield while utilizing the AutoTrak X-treme™ motorized RSS from Baker Hughes. Based on data from their CoPilot™ system, vibration was identified to be one of the major performance limiting factors in two bits that had failed to complete the section. As this was the case, the operator turned to Ulterra to provide a custom solution.
One of the unique design technologies that Ulterra has to combat lateral vibration at the bit is CounterForce®, a novel cutter arrangement methodology that allows the cutters to work together to redirect vibrational energy back into the rock. By pairing this technology into a U713M bit design along with the RSS, the operator was able to complete the interval.
The Ulterra bit delivered, allowing the RSS assembly to drill 824 feet to section TD at an ROP of 23 ft/hr. This run was 66% faster than the average of the two previous bit runs in mother hole and 230% faster than the average of the two previous bit runs in pilot hole. According to the operator, this performance saved three trips. The dull condition was also excellent with only minimal abrasive wear to some of the cutters on the nose and shoulder.
More importantly to the operator, the MSE calculations from the CoPilot down hole measurement tool showed that the Ulterra bit, with CounterForce technology, achieved this using 14% less energy to drill compared to the previous runs that had mostly drilled in softer, easier formations. Vibration levels were also dramatically reduced in the most difficult formation where it causes the most issues. Compared to other bit runs, lateral vibrations and whirl were reduced by 84% and 31% respectively, while stick-slip was reduced by 88%.
Best for Best
Some RSS makers, such as Weatherford, Gyrodata, Scout Downhole, and others, focus their energy and expertise on their tools and services while leaving complimentary performance parts to other experts. Others produce their own OEM (original equipment manufacturer) drill bits, and obviously they will often recommend them with self-benefiting reasons. However, in high-cost, high-performance applications, which are often identifiable by the use of RSS, “stock” equipment is seldom the best option.
As a PDC drill bit company, Ulterra is always excited for the opportunity to tackle new and unique problems. Our mission is to be the most trusted employer and supplier of PDC drill bits in the industry, and to reward that trust with industry leading consistency, performance and relentless, rapid improvement. There are many great car makers, but they all rely on other companies for the best tires in the world. While Ulterra doesn’t make RSS tools, the evidence is growing that we do make the best bits for them.
Partnering with Weatherford to design a bit tailored for their Revolution® RSS tool in the Eagle Ford, Ulterra set back to back to back world footage records using the 8.75” U516M CounterForce®. Continued Partnership with Weatherford’s Revolution RSS has led to huge improvements in vibration and torque, which has drastically reduced the chance of tool failure.
On a four well pad in Live Oak County, TX, the CounterForce U516M set three global footage records for the Revolution RSS by drilling 16,234 feet in one run. (According to Weatherford, this is the most footage they have drilled with one BHA anywhere in the world.) The extended-reach well had a total depth of 22,700 feet, reaching out that far, however, is a big challenge, and this performance is unheard of with one bottom-hole assembly. With the Ulterra bit and Weatherford RSS working together the BHA was able to stay on bottom for 192 hours.
This is just one example of how Ulterra is building our reputation on proven performance throughout the world’s drilling basins. Although we don’t make RSS tools, evidence is growing that we do make the best bits for them.
In its mission statement, Ulterra states that it strives to be the most trusted employer and supplier of drill bits. That trust given to Ulterra by its employees is not taken lightly, and one of the ways Ulterra shows its commitment is through their dedication to safety. This can be seen through recent press releases regarding safety milestones within its Fort Worth manufacturing facility. [Read full story here]
With these continued safety initiatives, Ulterra is proud to announce yet another extraordinary safety milestone within Ulterra’s Leduc Manufacturing Plant, by achieving 365 days without a recordable incident as of April 30th, 2016. This is the second time the Leduc Manufacturing Plant has achieved this goal.
This milestone would not be possible without its plant employees making safety a priority in their daily routine and for their dedication in creating an extremely safety-conscious workplace. While Ulterra’s safety performance has continued to make us a viable company in difficult industry times, the ultimate goal is that all employees go home at the end of the day to their family and friends. This achievement could not have been accomplished had we not had total commitment from all employees on the floor, machinists, plant management, and office personnel. Daily safety meetings have been essential to ensure that all employees have a clear understanding of the potential hazards that accompany their jobs and how to resolve such hazards. With 100% dedication to our safety program, Ulterra looks forward to setting more safety goals.
With safety being a cornerstone in Ulterra’s foundation, it proves to the industry that Ulterra takes pride in every detail of its company. The Leduc facility is evolving daily to continue this streak and move forward to its next milestone of two years.
As seen in the American Oil & Gas Reporter in the April 2016 issue, Ulterra discusses recent success when partnering with rotary steerable companies to match our bits to their tools. Adding CounterForce® to customized bit designs reduced drilling vibrations and increased ROP on both PowerDrive and AutoTrak™ systems.
By: Josh Criswell, West Texas Sales Engineer
In the past six months, operators drilling in the Wolfbone area of the Delaware Basin have been looking more to rotary steerable systems (RSS) to reduce the time spent drilling lateral wells. RSS have become a more affordable option due to their reduced cost in the down market.
Ulterra was challenged to create a bit design that was capable of finishing extended laterals in one run while encountering shales with varying carbonate content. This new design must rotate exceptionally well, be able to produce accurate corrections on a motorized push-the-bit system, and withstand the higher RPM capabilities of new rotary steerable systems.
This resulted in Ulterra’s 8.5” U616S built to dominate these intervals. The U616S features Ulterra’s CounterForce® technology which provides smooth torque responses providing longer life for expensive rotary steerable components. CounterForce also redirects vibrations back into the formation, creating a much more efficient cutting structure that produces higher ROP. The U616S also features an extended gauge pad to help the bit track in long laterals and reduce corrective actions. This new CounterForce design features a steel construction that increases the junk slot area by nearly 12% from its matrix counterpart and allows lower cuttings evacuation times producing higher ROP.
After its first two runs, Ulterra’s 8.5” U616S CounterForce completed both intervals successfully in one run producing an average ROP 15% higher than competitor designs. The ability to complete the interval in one run while producing higher ROP allowed Ulterra to save the operator an average of $7.24/ft for a total of $67,049 in a lateral well.
The API 7-1 Monogram is somewhat standard among major players in the industry, but Ulterra is very unique in that we include service (repair) in our API Q1 and ISO 9001 scope of registration, hence the reason you will now be seeing a “Certified Repair” sticker on the bit cans. The goal of these stickers is to highlight Ulterra’s commitment to having the highest quality PDC bits in the world.
By: Tyler Browder, National Account Representative
In previous months, the typical wellbore design for a major operator in the Delaware Basin had been a 3 string well utilizing a 13 ½” surface hole, 9 ⅞” intermediate, and 6 ¾” production. With the current down market, the operator like every other operator has been looking for other ways to bring down cost and have better efficiency. One way they sought partially increased performance was by bumping up to a bigger casing profile, yet still utilizing a 3 string well design by drilling a 16” surface, 12 ¼” intermediate, and 8 ½” production hole. They saw a large step change in performance in the 8 ½” production hole, but saw a substantial decrease in efficiency in the now 12 ¼” intermediate section. The performance change was great enough in the production hole to make the operator explore ways to optimize performance in the intermediate to make it more economical.
This new 12 ¼” deep intermediate was taking an average of 5 BHA’s to reach section Total Depth (TD), running almost every bit company possible and not seeing any positive results. After a hand full of wells, the operator dedicated the top part of the section to a competitor and the bottom hole (the demanding interval) to Ulterra’s U616M. The U616M had the fastest average ROP in the top section of the interval as well, but they saw faster instantaneous ROP with the competitor bit and thought they could improve and achieve a higher average…. that didn’t happen. Ulterra started looking into Rock Strength Analysis (RSA) and Electronic Drilling Recording (EDR) data to come up with an overall game plan of how to attack this interval. There were several meetings with the engineering team over this project which combined our bit knowledge with their overall knowledge of the application. Ulterra chose a bit and recommended parameters to try and achieve a more PDC friendly environment within this interbedded formation, reaching almost 30,000 KSI in some parts. Ulterra proved that the U616M was the fastest bit on the 1 trial run the operator had at the beginning of the program. We recognized that we could get much deeper with the U616M in the drill out BHA with optimized drilling parameters, coupled with the right bit design and cutter technology for the interval. Ulterra showed that if the operator can get deeper on BHA #1 the chances of achieving a 2-3 bit interval would be greatly increased due to the outstanding performance we were already seeing in the bottom section of the interval, and with the U616M dull conditions when pulled at section TD.
Ulterra did just that.
In the drill out, the U616M made it from 2,073 ft to 8,469 ft in one run at 113.2 ft/hr. In the previous offset well, the first competitor bit made it to 7,000 ft at 98 ft/hr, while the second tripped at 8,000 ft averaging 48 ft/hr. So with one bit Ulterra drilled 469 ft further and at a much faster pace than 2 competitor bits. Ulterra then went in for the second BHA in this interval and made it all the way to section TD at 10,193 ft at 111.2 ft/hr. With this well using 100% Ulterra it drilled 4.6 days faster than the average well of this design, and 2.27 days faster than the Best Demonstrated Performance (BDP) well. This was all achieved from a great transparent working relationship between the operator, the service company, as well as great bit designs from the men behind the scenes.
On January 15, 2016, Ulterra successfully completed the annual surveillance audit for maintaining the API Spec Q1 registration, ISO 9001, and API 7-1 Monogram license. The audit was a success and resulted in Ulterra being able to retain existing quality certifications. The API Spec Q1 and ISO 9001 registrations apply to the design, manufacture, and servicing of PDC matrix and steel body drill bits. Ulterra maintains these certifications to let our customers know that we are serious about the quality of our design, manufacture, and repair process of PDC drill bits.
- The API Spec Q1 9th Edition registration means that Ulterra’s facilities conform to the quality system requirements of API Spec Q1, as confirmed by API.
- The ISO 9001:2008 registration means that Ulterra’s facilities conform to the quality system requirements of ISO 9001, as confirmed by the APIQR (American Petroleum Institute Quality Registrar).
- The API Spec 7-1 Monogram License means that Ulterra’s quality management system (QMS) is in compliance with API Spec Q1 and that Ulterra meets the technical product requirements of API Spec 7-1. The API 7-1 Monogram mark on products is a warranty by Ulterra to API and its purchasers that the marked products comply in every aspect with API 7-1 at the time of manufacture.
The API 7-1 Monogram is somewhat standard among major players in the industry, but Ulterra is very unique in that we include service (repair) in our API Q1 and ISO 9001 scope of registration. That means that we are the only major bit company to hold our repaired bits to the same high standards of new bits.