DISPOSABLE FIBER OPTIC TELEMETRY SYSTEM FOR E

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DISPOSABLE FIBER OPTIC TELEMETRY SYSTEM FOR EP
APPLICATIONS

• Presented by
• David Borns, Sandia National Laboratories
• 505-844-7333
• Djborns_at_sandia.gov

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Project Objective?

• Create the Simplest, Smallest, Lightest,
  High-bandwidth Telemetry System for Use While
  Drilling

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Program Outline

• Initial funding by internal research dollars
• Funded by GTI
• Combined effort by Sandia National Laboratories
• Geomechanics group
• Geothermal group
• Project Details 3 year (1.3 Million)
• Status Completing year 3
• Initial patent issued 6,041,872

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Breaking the Bandwidth Bottleneck
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A Golden Age of Instrumentation

• Smarter, Smaller, Lighter, Cheaper, Low power
• Chips- moving toward 0.1 micron features, Cray
  scale power on a chip
• MEMS- integration of mechanical systems and
  electronics at the chip scale
• On chip chemistry laboratories

The closer you look, the
more you learn
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Do We Really Need High Bandwidth??A small
sample of what could be done

• Diagnosis While Drilling
• Look Ahead
• Plug Bug
• Bit Stabilization

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Diagnosis While Drilling

• U.S. Oil/Gas drilling expenditure exceeds 10
  Billion/year.
• Drilling cost/ft exhibits exponential increase
  with depth for deep wells
• Commercial implementation of a systems approach
  to drilling based on integrated downhole and
  surface data

Oil and Gas Journal, Jan 1997
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Diagnostics-While-Drilling (DWD) - A
feedback system for real-time control and
optimization
DWD Tool acquires and conditions data from
downhole sensors High-Speed Data Link - carries
information and control signals between surface
and downhole Drilling Advisory Software -
acquires, analyzes, and displays data in real
time, showing drilling conditions and system
performance Driller - uses traditional methods
and DAS to control drilling Drill Rig/Drill Pipe
- primary component the driller uses to interact
with the drilling process
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DWD provides many benefits

• Tremendous reductions in drilling costs
• Increased ROP and bit life
• Fewer problems (stuck pipe, stuck casing, tool
  failures)
• Less casing through multilateral completions,
  fewer casing runs
• Reduced logging costs
• Enhanced safety
• Detailed knowledge of downhole conditions while
  drilling
• Cost-effective access to hard-to-reach
  hydrocarbon resources
• Deep gas

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Bit dynamics limit current drilling systems
WOB

• WOB measured at the surface appears constant,
  even though WOB measured at the bit cycles
  through zero.

Torque starts to cycle upon entering a new
lithology at Catoosa, failing a PDC bit (after
Warren).
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Possible Downhole Measurements

• Bit accelerations -- bit bounce and whirl
• WOB, torque, bending -- formation change,
  performance
• Pressure -- hydraulics, kicks, plugged nozzles
• Temperature -- mud condition, kicks,
  compensations
• Hole direction -- directional drilling
• Tool condition -- bit/motor wear
• Formation sensors -- logging-while-drilling

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Data-Rate Tradeoff At least 100 kbit/s necessary
for DWD
Dysfunctions Bit bounce, whirl, stick/slip,
torque shocks, axial acceleration problems,
lateral acceleration problems, bending, cutting
efficiency (gage, etc.) Basic Measurements
WOB, torque, bending, pressure (annular,
internal), acceleration (3 axes), temperature,
magnetic field
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DWD is not MWD

• DWD takes much more data, at a much higher data
  rate (15-100 kbits/sec), than MWD.

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Real time bit control

• Drilling is machining rock
• Active control of chatter leads to faster
  machining rates, lower costs
• Five-fold increase in cutting rates, in metal
  with active control
• Requires high bandwith, for control signals

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What is our Approach?

• Adapt missile guidance technology
• Unarmored Optical Fiber
• Entirely Contained in Drill String
• Disposable (One-use, No Retrieval Time)
• Million Bits Per Second or Higher Data Rates

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Examples of Fiber Cassettes
8 inches
Photo Courtesy James Holt, Redstone Arsenal
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Deployment System!
40 km of fiber!
Photo Courtesy James Holt, Redstone Arsenal
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Challenge
Can this..Survive This ??

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Heart of the System

• Fiber Cassette
• 12,000 - 15,000 ft of fiber
• 20 -30 inch long
• 2.5 inch diameter

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Winding the Fiber
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Goals of prototype development

• Test deployment tool
• Test pipe adding system
• Demonstrate top-down and bottom up deployment
• Data transmission
• Two fiber types
• multimode
• single mode

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Sketch of Top Drive Setup
Mud
Output Signal
Non rotating coil
Rotating coil
Signal sub
Logging cable (30ft)
Standard connector
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Sub for Non-Contacting Data Transmission
Data transmitting coils
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Deployment Mode -- Top-Down
Fiber deployment starts at top
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Deployment Apparatus

• Approx. 10 ft. length
• Less than 100 lbs.
• Present version up to 4 km of fiber capacity
• Designed for 5 inch drillpipe

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Friction Brake
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Lift Point
Support Dogs
Friction Brake
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Tool Insertion

• Tool contains 4,000 to 14,000 feet of fiber
• Insertion is done once
• Tool controls fiber deployment
• Houses fiber to electronics conversion
• Low pressure drop across tool

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Challenge
Add Stand of Drillpipe without Interferring with
Operations
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(No Transcript)
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Data 100 Kbits/sec Top down deployment 500 GPM
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Fiber RemovalEnd of Test
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Tasks Accomplished

• Deployment in the bottom-up and top-down
  deployment mode with multimode fiber
• Adding stands of pipe was successfully
  demonstrated with both fiber types
• Circulation and drilling were done successfully
  with the multimode fiber
• High speed, real time data transmission

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Status

• Survivability demonstrated
• Deployment technology demonstrated
• Pipe-adding technique demonstrated
• Non-contacting signal coupling demonstrated
• Commercialization process underway
• Oil and Gas Partnership Proposal funded for fiber
  in coiled tubing-- CTES and GTI

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Costs

• Tool- Prototype cost about 50,000
• Fiber- in large quantities, 0.06/foot

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Benefits to Industry

• Greatly Simplified Logistics for MWD and LWD
• Access to Real-Time Data
• Expanded Opportunities for Services

The closer you look, the
more you learn