Thursday, May 20, 2010
Horizontal drilling
History
Many prerequisites enabled this suite of technologies to become productive. Probably the first requirement was the realization that oil wells (or water wells, but since they are shallower, most development was in the oil industry) are not necessarily vertical. This realization was quite slow, and did not really grasp the attention of the oil industry until the late 1920s when there were several lawsuits alleging that wells drilled from a rig on one property had crossed the boundary and were penetrating a reservoir on an adjacent property. Initially, proxy evidence such as production changes in pre-existing wells was accepted, but such cases fueled the development of small diameter tools capable of surveying wells during drilling.
Measuring the inclination of a wellbore (its deviation from the vertical) is comparatively simple, requiring only a pendulum. Measuring the azimuth (direction with respect to the geographic grid in which the wellbore is running from the vertical), however, was more difficult. In certain circumstances, magnetic fields could be used, but could be influenced by metalwork used inside wellbores, as well as the metalwork used in drilling equipment. The next advance was in the modification of small gyroscopic compasses by the Sperry Corporation, who were making similar compasses for aeronautical navigation. Sperry did this under contract to Sun Oil (who were involved in a lawsuit as described above), and a spin-off company "Sperry Sun" was formed, which brand continues to this day, absorbed into Halliburton. Three components are measured at any given point in a wellbore in order to determine its position: the depth of the point (measured depth), the inclination at the point, and the magnetic azimuth at the point. These 3 components combined are referred to as a "survey". A series of consecutive surveys are needed to track the progress and location of a wellbore. Many of the earliest innovations such as photographic single shot technology and crow's feet baffle plates for landing survey tools were developed by Robert Richardson, an independent directional driller who first drilled in the 1940s and was still working in 2008.(JPT, vol 17, issue 4, pg.32)
Prior experience with rotary drilling had established several principles for the configuration of drilling equipment down hole ("Bottom Hole Assembly" or "BHA") that would be prone to "drilling crooked hole" (initial accidental deviations from the vertical would be increased). Counter-experience had also given early directional drillers ("DD's") principles of BHA design and drilling practice which would help bring a crooked hole nearer the vertical.
Combined, these survey tools and BHA designs made directional drilling possible, but it was perceived as arcane. The next major advance was in the 1970s, when downhole drilling motors (aka mud motors, driven by the hydraulic power of drilling mud circulated down the drill string) became common. These allowed the bit to be rotated on the bottom of the hole, while most of the drill pipe was held stationary. Including a piece of bent pipe (a "bent sub") between the stationary drill pipe and the top of the motor allowed the direction of the wellbore to be changed without needing to pull all the drill pipe out and place another whipstock. Coupled with the development of "Measurement While Drilling" MWD tools (using mud pulse telemetry or EM telemetry, which allows tools down hole to send directional data back to the surface without disturbing drilling operations), directional drilling became easier. Certain profiles could not be drilled without the drill string rotating at all times.
The most recent major advance in directional drilling has been the development of a range of Rotary Steerable tools which allow three dimensional control of the bit without stopping the drill string rotation. These tools [Revolution] from Weatherford Drilling Services, Well-Guide from Gyrodata, PowerDrive from Schlumberger, AutoTrak from Baker Hughes, PathMaker from PathFinder Energy Services (An Operating Division of Smith International, Inc), GeoPilot & EZ-Pilot from Sperry Drilling Services/Halliburton) have almost automated the process of drilling highly deviated holes in the ground. They are costly, so more traditional directional drilling will continue for the foreseeable future.
Until recently the drive toward reducing the high cost of these devices has been led from outside the "Big Three" oilfield service companies such as the mid sized company from West Texas - Black Viper, a company specializing in custom directional equipment and drill bits that is also designing their own low cost, low maintenance rotary steerable system, and by entrepreneurs and inventors working essentially alone.
Benefits
Directional wells are drilled for several purposes:
- Increasing the exposed section length through the reservoir by drilling through the reservoir at an angle
- Drilling into the reservoir where vertical access is difficult or not possible. For instance an oilfield under a town, under a lake, or underneath a difficult to drill formation
- Allowing more wellheads to be grouped together on one surface location can allow fewer rig moves, less surface area disturbance, and make it easier and cheaper to complete and produce the wells. For instance, on an oil platform or jacket offshore, up to about 40 wells can be grouped together. The wells will fan out from the platform into the reservoir below. This concept is being applied to land wells, allowing multiple subsurface locations to be reached from one pad, reducing environmental impact.
- Drilling a "relief well" to relieve the pressure of a well producing without restraint (a "blow out"). In this scenario, another well could be drilled starting at a safe distance away from the blow out, but intersecting the troubled wellbore. Then, heavy fluid (kill fluid) is pumped into the relief wellbore to suppress the high pressure in the original wellbore causing the blowout.
Most directional drillers are given a well path to follow that is predetermined by engineers and geologists before the drilling commences. When the directional driller starts the drilling process, periodic surveys are taken with a downhole camera instrument ("single shot camera") to provide survey data (inclination and azimuth) of the well bore.
These pictures are typically taken at intervals between 30-500 feet, with 90 feet common during active changes of angle or direction, and distances of 200-300 feet being typical while "drilling ahead" (not making active changes to angle and direction)
During critical angle and direction changes, especially while using a downhole motor, an MWD (Measurement While Drilling) tool will be added to the drill string to provide continuously updated measurements that may be used for (near) real-time adjustments.
These data indicate if the well is following the planned path and whether the orientation of the drilling assembly is causing the well to deviate as planned. Corrections are regularly made by techniques as simple as adjusting rotation speed or the drill string weight (weight on bottom) and stiffness, as well as more complicated and time consuming methods, such as introducing a downhole motor.
Such pictures, or surveys, are plotted and maintained as an engineering and legal record describing the path of the well bore. The survey pictures taken while drilling are typically confirmed by a later survey in full of the borehole, typically using a "multi-shot camera" device.
The multi-shot camera advances the film at time intervals so that by sealing the camera instrument into a tubular housing and dropping the assembly into the drilling string (down to just above the drilling bit), and then withdrawing the drill string at time intervals, the well may be fully surveyed at regular intervals (approximately every 90 feet being common, the typical length of 2 or 3 joints of drill pipe, known as a stand, since most drilling rigs "stand back" the pipe withdrawn from the hole at such increments, known as "stands".)
With modern technology great feats can be achieved. Whereas 20 years ago wells drilled at 60 degrees through the reservoir were achieved, horizontal drilling is now normal.
Drilling far from the surface location still requires careful planning and design. The current record holders manage wells over 10 km (6 miles) away from the surface location at a depth of only 1600–2600 m (5,200–8,500 ft). These are wells drilled from a land location to underneath the sea (Wytch Farm (BP), south coast of England, ARA (Total), south coast of Argentina (TFE) Dieksand (RWE), north coast of Germany, Chayvo (ExxonMobil), east coast of Sakhalin Island, Russia, and most recently Al Shaheen (Maersk Oil Qatar AS), Offshore Qatar.[1]
Disadvantages
Until the arrival of modern downhole motors and better tools to measure inclination and azimuth of the hole, directional drilling and horizontal drilling was much slower than vertical drilling due to the need to stop regularly and take time consuming surveys, and due to slower progress in drilling itself (lower rate of penetration). These disadvantages have shrunk over time as downhole motors became more efficient and semi-continuous surveying became possible.
What remains is a difference in operating costs: for wells with an inclination of less than 40 degrees, tools to carry out adjustments or repair work can be lowered by gravity on cable into the hole. For higher inclinations, more expensive equipment has to be mobilized to push tools down the hole.
Another disadvantage of wells with a high inclination was that prevention of sand influx into the well was less reliable and needed higher effort. Again, this disadvantage has diminished such that, provided sand control is adequately planned, it is possible to carry it out reliably.
Stealing oil
In 1990, Iraq accused Kuwait of stealing Iraq's oil through slant drilling. Such claims are doubted to have been serious enough to justify war or the occupation of Kuwait, since the limits of directional drilling (at the time) made it unlikely that any such well could have been drilled much more than a mile from the surface location.[dubious ] Even doing so would have involved drilling sites close to the border and the use of sophisticated and easily identifiable equipment and personnel for extreme distances.[citation needed] The United Nations redrew the border after the 1991 Gulf war that liberated Kuwait from a seven-month Iraqi occupation under former leader Saddam Hussein. It placed 11 oil wells, some farms and an old naval base that used to be in Iraq on the Kuwaiti side.[2]
In the mid-twentieth century, a slant-drilling scandal occurred in the huge East Texas Oil Field.[3]
New technologies
Between 1985 and 1993, NCEL (now the NFESC) of Pt Hueneme, California developed horizontal drilling technologies.[4] These technologies are capable of reaching 10 000–15 000 ft (3000–4500 m) and may reach 25 000 ft (7500 m) (approximately the distance from Kuwait to Iran, across the coast area of Iraq) when used under favorable conditions.
Source
Tuesday, May 18, 2010
A drilling rig is a machine which creates holes (usually called boreholes) and/or shafts in the ground. Drilling rigs can be massive structures housing equipment used to drill water wells, oil wells, or natural gas extraction wells, or they can be small enough to be moved manually by one person.[citation needed] They sample sub-surface mineral deposits, test rock, soil and groundwater physical properties, and also can be used to install sub-surface fabrications, such as underground utilities, instrumentation, tunnels or wells. Drilling rigs can be mobile equipment mounted on trucks, tracks or trailers, or more permanent land or marine-based structures (such as oil platforms, commonly called 'offshore oil rigs' even if they don't contain a drilling rig). The term "rig" therefore generally refers to the complex of equipment that is used to penetrate the surface of the Earth's crust.
Drilling rigs can be:
Small and portable, such as those used in mineral exploration drilling, water wells and environmental investigations.
Huge, capable of drilling through thousands of meters of the Earth's crust. Large "mud pumps" circulate drilling mud (slurry) through the drill bit and up the casing annulus, for cooling and removing the "cuttings" while a well is drilled. Hoists in the rig can lift hundreds of tons of pipe. Other equipment can force acid or sand into reservoirs to facilitate extraction of the oil or natural gas; and in remote locations there can be permanent living accommodation and catering for crews (which may be more than a hundred). Marine rigs may operate many hundreds of miles or kilometres distant from the supply base with infrequent crew rotation.
Petroleum drilling industry
Petroleum drilling rig. Capable of drilling thousands of feet
Modern Oil Driller La Pampa Argentina
"Oil and Natural Gas drilling rigs can be used not only to identify geologic reservoirs but also to create holes that allow the extraction of oil or natural gas from those reservoirs. Primarily in onshore oil and gas fields once a well has been drilled, the drilling rig will be moved off of the well and a service rig (a smaller rig) that is purpose-built for completions will be moved on to the well to get the well on line. This frees up the drilling rig to drill another hole and streamlines the operation as well as allowing for specialization of certain services, i.e., completions vs. drilling." Ref. (Innovative Energy Services (Katy, TX))
History
Antique drilling rig now on display at Western History Museum in Lingle, Wyoming. It was used to drill many water wells in that area—many of those wells are still in use.
Antique Drilling Rigs in Zigong, China
Until internal combustion engines came in the late 19th century, the main method for drilling rock was muscle power of man or animal. Rods were turned by hand, using clamps attached to the rod. The rope and drop method invented in Zigong, China used a steel rod or piston raised and dropped vertically via a rope. Mechanised versions of this persisted until about 1970, using a cam to rapidly raise and drop what, by then, was a steel cable.
In the 1970s, outside of the oil and gas industry, roller bits using mud circulation were replaced by the first efficient pneumatic reciprocating piston Reverse Circulation RC drills, and became essentially obsolete for most shallow drilling, and are now only used in certain situations where rocks preclude other methods. RC drilling proved much faster and more efficient, and continues to improve with better metallurgy, deriving harder, more durable bits, and compressors delivering higher air pressures at higher volumes, enabling deeper and faster penetration. Diamond drilling has remained essentially unchanged since its inception.
Mobile drilling rigs
In early oil exploration, drilling rigs were semi-permanent in nature and the derricks were often built on site and left in place after the completion of the well. In more recent times drilling rigs are expensive custom-built machines that can be moved from well to well. Some light duty drilling rigs are like a mobile crane and are more usually used to drill water wells. Larger land rigs must be broken apart into sections and loads to move to a new place, a process which can often take weeks.
Small mobile drilling rigs are also used to drill or bore piles. Rigs can range from 100 ton continuous flight auger (CFA) rigs to small air powered rigs used to drill holes in quarries, etc. These rigs use the same technology and equipment as the oil drilling rigs, just on a smaller scale.
The drilling mechanisms outlined below differ mechanically in terms of the machinery used, but also in terms of the method by which drill cuttings are removed from the cutting face of the drill and returned to surface.
Drilling rig classification
There are many types and designs of drilling rigs, with many drilling rigs capable of switching or combining different drilling technologies as needed. Drilling rigs can be described using any of the following attributes:
by power used
mechanical - the rig uses torque converters, clutches, and transmissions powered by its own engines, often diesel
electric - the major items of machinery are driven by electric motors, usually with power generated on-site using internal combustion engines
hydraulic - the rig primarily uses hydraulic power
pneumatic - the rig is primarily powered by pressurized air
steam - the rig uses steam-powered engines and pumps (obsolescent after middle of 20th Century)
by pipe used
cable - a cable is used to raise and drop the drill bit
conventional - uses metal or plastic drill pipe of varying types
coil tubing - uses a giant coil of tube and a downhole drilling motor
by height
single - can drill only single drill pipes. The presence or absence of vertical pipe racking "fingers" varies from rig to rig.
double - can hold a stand of pipe in the derrick consisting of two connected drill pipes, called a "double stand".
triple - can hold a stand of pipe in the derrick consisting of three connected drill pipes, called a "triple stand".
by method of rotation or drilling method
no rotation includes direct push rigs and most service rigs
rotary table - rotation is achieved by turning a square or hexagonal pipe (the kelly) at drill floor level.
top drive - rotation and circulation is done at the top of the drillstring, on a motor that moves in a track along the derrick.
sonic - uses primarily vibratory energy to advance the drill string
hammer - uses rotation and percussive force
by position of derrick
conventional - derrick is vertical
slant - derrick is slanted at a 45 degree angle to facilitate horizontal drilling
Drill types
There are a variety of drill mechanisms which can be used to sink a borehole into the ground. Each has its advantages and disadvantages, in terms of the depth to which it can drill, the type of sample returned, the costs involved and penetration rates achieved. There are two basic types of drills: drills which produce rock chips, and drills which produce core samples.
Auger drilling
Auger drilling is done with a helical screw which is driven into the ground with rotation; the earth is lifted up the borehole by the blade of the screw. Hollow stem Auger drilling is used for environmental drilling, geotechnical drilling, soil engineering and geochemistry reconnaissance work in exploration for mineral deposits. Solid flight augers/bucket augers are used in construction drilling. In some cases, mine shafts are dug with auger drills. Small augers can be mounted on the back of a utility truck, with large augers used for sinking piles for bridge foundations.
Auger drilling is restricted to generally soft unconsolidated material or weak weathered rock. It is cheap and fast.
Cable tool water well drilling rig in Kimball, West Virginia. These slow rigs have mostly been replaced by rotary drilling rigs in the U.S.
Percussion rotary air blast drilling (RAB)
RAB drilling is used most frequently in the mineral exploration industry. (This tool is also known as a Down-The-Hole Drill.) The drill uses a pneumatic reciprocating piston-driven 'hammer' to energetically drive a heavy drill bit into the rock. The drill bit is hollow, solid steel and has ~20 mm thick tungsten rods protruding from the steel matrix as 'buttons'. The tungsten buttons are the cutting face of the bit.
The cuttings are blown up the outside of the rods and collected at surface. Air or a combination of air and foam lift the cuttings.
RAB drilling is used primarily for mineral exploration, water bore drilling and blast-hole drilling in mines, as well as for other applications such as engineering, etc. RAB produces lower quality samples because the cuttings are blown up the outside of the rods and can be contaminated from contact with other rocks. RAB drilling at extreme depth, if it encounters water, may rapidly clog the outside of the hole with debris, precluding removal of drill cuttings from the hole.
This can be counteracted, however, with the use of 'stabilisers' also known as 'reamers', which are large cylindrical pieces of steel attached to the drill string, and made to perfectly fit the size of the hole being drilled. These have sets of rollers on the side, usually with tungsten buttons, that constantly break down cuttings being pushed upwards.
The use of high-powered air compressors, which push 900-1150cfm of air at 300-350psi down the hole also ensures drilling of a deeper hole up to ~1250m due to higher air pressure which pushes all rock cuttings and any water to the surface. This, of course, is all dependent on the density and weight of the rock being drilled, and on how worn the drill bit is.
Air core drilling
Air core drilling and related methods use hardened steel or tungsten blades to bore a hole into unconsolidated ground. The drill bit has three blades arranged around the bit head, which cut the unconsolidated ground. The rods are hollow and contain an inner tube which sits inside the hollow outer rod barrel. The drill cuttings are removed by injection of compressed air into the hole via the annular area between the innertube and the drill rod. The cuttings are then blown back to surface up the inner tube where they pass through the sample separating system and are collected if needed. Drilling continues with the addition of rods to the top of the drill string. Air core drilling can occasionally produce small chunks of cored rock.
This method of drilling is used to drill the weathered regolith, as the drill rig and steel or tungsten blades cannot penetrate fresh rock. Where possible, air core drilling is preferred over RAB drilling as it provides a more representative sample. Air core drilling can achieve depths approaching 300 meters in good conditions. As the cuttings are removed inside the rods and are less prone to contamination compared to conventional drilling where the cuttings pass to the surface via outside return between the outside of the drill rob and the walls of the hole. This method is more costly and slower than RAB.
Cable tool drilling
SpeedStar Cable Tool Drilling Rig, Ballston Spa, NY
Cable tool rigs are a traditional way of drilling water wells. The majority of large diameter water supply wells, especially deep wells completed in bedrock aquifers, were completed using this drilling method. Although this drilling method has largely been supplanted in recent years by other, faster drilling techniques, it is still the most practicable drilling method for large diameter, deep bedrock wells, and in widespread use for small rural water supply wells. The impact of the drill bit fractures the rock and in many shale rock situations increases the water flow into a well over rotary.
Also known as ballistic well drilling and sometimes called "spudders", these rigs raise and drop a drill string with a heavy carbide tipped drilling bit that chisels through the rock by finely pulverizing the subsurface materials. The drill string is composed of the upper drill rods, a set of "jars" (inter-locking "sliders" that help transmit additional energy to the drill bit and assist in removing the bit if it is stuck) and the drill bit. During the drilling process, the drill string is periodically removed from the borehole and a bailer is lowered to collect the drill cuttings (rock fragments, soil, etc.). The bailer is a bucket-like tool with a trapdoor in the base. If the borehole is dry, water is added so that the drill cuttings will flow into the bailer. When lifted, the bailer closes and the cuttings are then raised and removed. Since the drill string must be raised and lowered to advance the boring, casing (larger diameter outer piping) is typically used to hold back upper soil materials and stabilize the borehole.
Cable tool rigs are simpler and cheaper than similarly sized rotary rigs, although loud and very slow to operate. The world record cable tool well was drilled in New York to a depth of almost 12,000 feet. The common Bucyrus Erie 22 can drill down to about 1,100 feet. Since cable tool drilling does not use air to eject the drilling chips like a rotary, instead using a cable strung bailer, technically there is no limitation on depth.
Reverse circulation (RC) drilling
Reverse Circulation (RC) rig, outside Newman, Western Australia
Track mounted Reverse Circulation rig (side view).
RC drilling is similar to air core drilling, in that the drill cuttings are returned to surface inside the rods. The drilling mechanism is a pneumatic reciprocating piston known as a hammer driving a tungsten-steel drill bit. RC drilling utilises much larger rigs and machinery and depths of up to 500 metres are routinely achieved. RC drilling ideally produces dry rock chips, as large air compressors dry the rock out ahead of the advancing drill bit. RC drilling is slower and costlier but achieves better penetration than RAB or air core drilling; it is cheaper than diamond coring and is thus preferred for most mineral exploration work.
Reverse circulation is achieved by blowing air down the rods, the differential pressure creating air lift of the water and cuttings up the inner tube which is inside each rod. It reaches the bell at the top of the hole, then moves through a sample hose which is attached to the top of the cyclone. The drill cuttings travel around the inside of the cyclone until they fall through an opening at the bottom and are collected in a sample bag.
The most commonly used RC drill bits are 5-8 inches (12.7–20.32 cm) in diameter and have round metal 'buttons' that protrude from the bit, which are required to drill through shale and abrasive rock. As the buttons wear down, drilling becomes slower and the rod string can potentially become bogged in the hole. This is a problem as trying to recover the rods may take hours and in some cases weeks. The rods and drill bits themselves are very expensive, often resulting in great cost to drilling companies when equipment is lost down the bore hole. Most companies will regularly re-grind the buttons on their drill bits in order to prevent this, and to speed up progress. Usually, when something is lost (breaks off) in the hole, it is not the drill string, but rather from the bit, hammer, or stabiliser to the bottom of the drill string (bit). This is usually caused by a blunt bit getting stuck in fresh rock, over-stressed metal, or a fresh drill bit getting stuck in a part of the hole that is too small, owing to having used a bit that has worn to smaller than the desired hole diameter.
Although RC drilling is air-powered, water is also used, to reduce dust, keep the drill bit cool, and assist in pushing cutting back upwards, but also when collaring a new hole. A mud called liqui-pol is mixed with water and pumped into the rod string, down the hole. This helps to bring up the sample to the surface by making the sand stick together. Occasionally, 'super-foam' (AKA 'quik-foam') is also used, to bring all the very fine cuttings to the surface, and to clean the hole. When the drill reaches hard rock, a collar is put down the hole around the rods which is normally PVC piping. Occasionally the collar may be made from metal casing. Collaring a hole is needed to stop the walls from caving in and bogging the rod string at the top of the hole. Collars may be up to 60 metres deep, depending on the ground, although if drilling through hard rock a collar may not be necessary.
Reverse circulation rig setups usually consist of a support vehicle, an auxiliary vehicle, as well as the rig itself. The support vehicle, normally a truck, holds diesel and water tanks for resupplying the rig. It also holds other supplies needed for maintenance on the rig. The auxiliary is a vehicle, carrying an auxiliary engine and a booster engine. These engines are connected to the rig by high pressure air hoses. Although RC rigs have their own booster and compressor to generate air pressure, extra power is needed which usually isn't supplied by the rig due to lack of space for these large engines. Instead, the engines are mounted on the auxiliary vehicle. Compressors on an RC rig have an output of around 1000 cfm at 500 psi (500 L·s−1 at 3.4 MPa). Alternatively, stand-alone air compressors which have an output of 900-1150cfm at 300-350 psi each are used in sets of 2, 3, or 4, which are all routed to the rig through a multi-valve manifold.
Diamond core drilling
Multi-combination drilling rig (capable of both diamond and reverse circulation drilling). Rig is currently set up for diamond drilling.
Diamond core drilling (exploration diamond drilling) utilises an annular diamond-impregnated drill bit attached to the end of hollow drill rods to cut a cylindrical core of solid rock. The diamonds used are fine to microfine industrial grade diamonds. They are set within a matrix of varying hardness, from brass to high-grade steel. Matrix hardness, diamond size and dosing can be varied according to the rock which must be cut. Holes within the bit allow water to be delivered to the cutting face. This provides three essential functions; lubrication, cooling, and removal of drill cuttings from the hole.
Diamond drilling is much slower than reverse circulation (RC) drilling due to the hardness of the ground being drilled. Drilling of 1200 to 1800 metres is common and at these depths, ground is mainly hard rock. Diamond rigs need to drill slowly to lengthen the life of drill bits and rods, which are very expensive.
Core samples are retrieved via the use of a lifter tube, a hollow tube lowered inside the rod string by a winch cable until it stops inside the core barrel. As the core is drilled, the core lifter slides over the core as it is cut. An overshot attached to the end of the winch cable is lowered inside the rod string and locks on to the backend, located on the top end of the lifter tube. The winch is retracted, pulling the lifter tube to the surface. The core does not drop out the inside of the lifter tube when lifted because a "core lifter spring," located at the bottom of the tube allows the core to move inside the tube but not fall out.
Diamond core drill bits
Once a rod is removed from the hole, the core sample is then removed from the rod and catalogued. The Driller's offsider screws the rod apart using tube clamps, then each part of the rod is taken and the core is shaken out into core trays. The core is washed, measured and broken into smaller pieces using a hammer or sawn through to make it fit into the sample trays. Once catalogued, the core trays are retrieved by geologists who then analyse the core and determine if the drill site is a good location to expand future mining operations.
Diamond rigs can also be part of a multi-combination rig. Multi-combination rigs are a dual setup rig capable of operating in either a reverse circulation (RC) and diamond drilling role (though not at the same time). This is a common scenario where exploration drilling is being performed in a very isolated location. The rig is first set up to drill as an RC rig and once the desired metres are drilled, the rig is set up for diamond drilling. This way the deeper metres of the hole can be drilled without moving the rig and waiting for a diamond rig to set up on the pad.
Direct push rigs
Direct push technology includes several types of drilling rigs and drilling equipment which advances a drill string by pushing or hammering without rotating the drill string. While this does not meet the proper definition of drilling, it does achieve the same result - a borehole. Direct push rigs include both cone penetration testing (CPT) rigs and direct push sampling rigs such as a PowerProbe or Geoprobe. Direct push rigs typically are limited to drilling in unconsolidated soil materials and very soft rock.
CPT rigs advance specialized testing equipment (such as electronic cones), and soil samplers using large hydraulic rams. Most CPT rigs are heavily ballasted (20 metric tons is typical) as a counter force against the pushing force of the hydraulic rams which are often rated up to 20kn. Alternatively, small, light CPT rigs and offshore CPT rigs will use anchors such as screwed-in ground anchors to create the reactive force. In ideal conditions, CPT rigs can achieve production rates of up to 250–300 meters per day.
Direct push drilling rigs use hydraulic cylinders and a hydraulic hammer in advancing a hollow core sampler to gather soil and groundwater samples. The speed and depth of penetration is largely dependent on the soil type, the size of the sampler, and the weight and power the rig. Direct push techniques are generally limited to shallow soil sample recovery in unconsolidated soil materials. The advantage of direct push technology is that in the right soil type it can produce a large number of high quality samples quickly and cheaply, generally from 50 to 75 meters per day. Rather than hammering, direct push can also be combined with sonic (vibratory) methods to increase drill efficiency.
Hydraulic rotary drilling
Oil well drilling utilises tri-cone roller, carbide embedded, fixed-cutter diamond, or diamond-impregnated drill bits to wear away at the cutting face. This is preferred because there is no need to return intact samples to surface for assay as the objective is to reach a formation containing oil or natural gas. Sizable machinery is used, enabling depths of several kilometres to be penetrated. Rotating hollow drill pipes carry down bentonite and barite infused drilling muds to lubricate, cool, and clean the drilling bit, control downhole pressures, stabilize the wall of the borehole and remove drill cuttings. The mud travels back to the surface around the outside of the drill pipe, called the annulus. Examining rock chips extracted from the mud is known as mud logging. Another form of well logging is electronic and is frequently employed to evaluate the existence of possible oil and gas deposits in the borehole. This can take place while the well is being drilled, using Measurement While Drilling tools, or after drilling, by lowering measurement tools into the newly-drilled hole.
The rotary system of drilling was in general use in Texas in the early 1900s. It is a modification of one invented by Fauvelle in 1845, and used in the early years of the oil industry in some of the oil-producing countries in Europe. Originally pressurized water was used instead of mud, and was almost useless in hard rock before the diamond cutting bit.[1]. The main breakthrough for rotary drilling came in 1901, when Anthony Francis Lucas combined the use of a steam-driven rig and of mud instead of water in the Spindletop discovery well.[2]
The drilling and production of oil and gas can pose a safety risk and a hazard to the environment from the ignition of the entrained gas causing dangerous fires and also from the risk of oil leakage polluting water, land and groundwater. For these reasons, redundant safety systems and highly trained personnel are required by law in all countries with significant production.
Sonic (vibratory) drilling
A sonic drill head works by sending high frequency resonant vibrations down the drill string to the drill bit, while the operator controls these frequencies to suit the specific conditions of the soil/rock geology. Vibrations may also be generated within the drill head. The frequency is generally between 50 and 120 hertz (cycles per second) and can be varied by the operator.
Resonance magnifies the amplitude of the drill bit, which fluidizes the soil particles at the bit face, allowing for fast and easy penetration through most geological formations. An internal spring system isolates these vibrational forces from the rest of the drill rig.
Limits of the technology
An oil rig
Drill technology has advanced steadily since the 19th century. However, there are several basic limiting factors which will determine the depth to which a bore hole can be sunk.
All holes must maintain outer diameter; the diameter of the hole must remain wider than the diameter of the rods or the rods cannot turn in the hole and progress cannot continue. Friction caused by the drilling operation will tend to reduce the outside diameter of the drill bit. This applies to all drilling methods, except that in diamond core drilling the use of thinner rods and casing may permit the hole to continue. Casing is simply a hollow sheath which protects the hole against collapse during drilling, and is made of metal or PVC. Often diamond holes will start off at a large diameter and when outside diameter is lost, thinner rods put down inside casing to continue, until finally the hole becomes too narrow. Alternatively, the hole can be reamed; this is the usual practice in oil well drilling where the hole size is maintained down to the next casing point.
For percussion techniques, the main limitation is air pressure. Air must be delivered to the piston at sufficient pressure to activate the reciprocating action, and in turn drive the head into the rock with sufficient strength to fracture and pulverise it. With depth, volume is added to the in-rod string, requiring larger compressors to achieve operational pressures. Secondly, groundwater is ubiquitous, and increases in pressure with depth in the ground. The air inside the rod string must be pressurised enough to overcome this water pressure at the bit face. Then, the air must be able to carry the rock fragments to surface. This is why depths in excess of 500 m for reverse circulation drilling are rarely achieved, because the cost is prohibitive and approaches the threshold at which diamond core drilling is more economic.
Diamond drilling can routinely achieve depths in excess of 1200 m. In cases where money is no issue, extreme depths have been achieved because there is no requirement to overcome water pressure. However, circulation must be maintained to return the drill cuttings to surface, and more importantly to maintain cooling and lubrication of the cutting surface.
Without sufficient lubrication and cooling, the matrix of the drill bit will soften. While diamond is the hardest substance known, at 10 on the Mohs hardness scale, it must remain firmly in the matrix to achieve cutting. Weight on bit, the force exerted on the cutting face of the bit by the drill rods in the hole above the bit, must also be monitored.
A unique drilling operation in deep ocean water was named Project Mohole.
Causes of deviation
Most drill holes deviate from the vertical. This is because of the torque of the turning bit working against the cutting face, because of the flexibility of the steel rods and especially the screw joints, because of reaction to foliation and structure within the rock, and because of refraction as the bit moves into different rock layers of varying resistance. Additionally, inclined holes will tend to deviate upwards because the drill rods will lie against the bottom of the bore, causing the drill bit to be slightly inclined from true. It is because of deviation that drill holes must be surveyed if deviation will impact on the usefulness of the information returned. Sometimes the surface location can be offset laterally to take advantage of the expected deviation tendency, so the bottom of the hole will end up near the desired location. Oil well drilling commonly uses a process of controlled deviation called directional drilling (e.g., when several wells are drilled from one surface location).
Rig equipment
Simple diagram of a drilling rig and its basic operation
typically includes at least some of the following items: See Drilling rig (petroleum) for a more detailed description.
Blowout preventers: (BOPs)
The equipment associated with a rig is to some extent dependent on the type of rig but (#23 & #24) are devices installed at the wellhead to prevent fluids and gases from unintentionally escaping from the borehole. #23 is the annular (often referred to as the Hydril, which is one manufacturer) and #24 is the pipe rams and blind rams.
Centrifuge: an industrial version of the device that separates fine silt and sand from the drilling fluid.
Solids control: solids control equipments for preparing drilling mud for the drilling rig.
Chain tongs: wrench with a section of chain, that wraps around whatever is being tightened or loosened. Similar to a pipe wrench.
Degasser: a device that separates air and/or gas from the drilling fluid.
Desander / desilter: contains a set of hydrocyclones that separate sand and silt from the drilling fluid.
Drawworks: (#7) is the mechanical section that contains the spool, whose main function is to reel in/out the drill line to raise/lower the traveling block (#11).
Drill bit: (#26) device attached to the end of the drill string that breaks apart the rock being drilled. It contains jets through which the drilling fluid exits.
Drill pipe: (#16) joints of hollow tubing used to connect the surface equipment to the bottom hole assembly (BHA) and acts as a conduit for the drilling fluid. In the diagram, these are stands of drill pipe which are 2 or 3 joints of drill pipe connected together and stood in the derrick vertically, usually to save time while Tripping pipe.
Elevators: a hinged device that is used to latch to the drill pipe or casing to facilitate the lowering or lifting (of pipe or casing) into or out of the borehole.
Mud motor: a hydraulically powered device positioned just above the drill bit used to spin the bit independently from the rest of the drill string.
Mud pump: (#4) reciprocal type of pump used to circulate drilling fluid through the system.
Mud tanks: (#1) often called mud pits, provides a reserve store of drilling fluid until it is required down the wellbore.
Rotary table: (#20) rotates the drill string along with the attached tools and bit.
Shale shaker: (#2) separates drill cuttings from the drilling fluid before it is pumped back down the borehole.
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