Documente Academic
Documente Profesional
Documente Cultură
the
Power
to Work.
An Introduction to Turbodrill
Components & Evolution
Formation of Smith Turbodrilling Business
Sii Neyrfor Formed in August 2002
Perth
Engineering (2) Inventory & Assembly (2) Turbodrill Assembly (8) Sales w/o Assembly (3)
•Lithology
•Formation Strength
•Faults Formation
Characteristic
What
•Milled Tooth Determines
•TCI ROP?
•PDC
•Impreg Drill Bit
Power
Type
Supplied •WOB
•RPM
•Hydraulics
ROP v DOC
200
150
100 RPM
ROP (ft/hr)
200 RPM
100
500 RPM
1000 RPM
50
0
0.005 0.01 0.02 0.05
Depth of Cut (in)
Depth Of Cut
The purpose of a downhole motor is to increase the amount
of mechanical power available at the bit. The benefits are:
Motor
Section
Turbine
Body
rd
nwa
Dowhrust
T
Assembly
makes up
One Motor Stage
Turbine
Shaft
Generally………..
Turbines - Higher Power Potential
- Higher Pressure Drop Required
- Higher Bit Speed / Lower Torque Delivery
- Harder Formations
- Deeper / Smaller Hole
- Diamond Bits and Heavier Set PDC Bits
- Lower Flow Rates and Bit Hydraulics
- Higher Temps / Robust and Reliable
- Excellent Hole Quality
Nominal
Torque Power Pressure
0.75
Runaway Stall
Pressure
0.5
Torque
Power
0.25
1500
Pressure
1000
500
0
Stall On Bottom Off Bottom
MK1 Blades MK2 Blades
If Turbines are so good……Why don’t we use them all the time?
12¼” Hydraulically disadvantaged, needs a large pressure drop to generate useful torque output -
pressure that is seldom available.
Insufficient torque output for efficient PDC operation in larger hole sizes – stalling or scraping
4500
3500
PRESSURE (PSI)
3000
1500
1000
500
0
500 550 600 650 700 750 800 850 900 950
FLOW RATE (GPM)
In 8½” section and below hydraulics are better
Good turbine hydraulics – enough pressure available for effective turbine drilling power
4500
3500
Typical Achievable Turbine Flow
PRESSURE (PSI)
3000
1500
1000
500
0
300 350 400 450 500 550 600
FLOW RATE (GPM)
Misconceptions… The Truth…
• ”Turbines will turn too fast for PDC • PDC are still 37% of our world-wide
bits!” market today.
• In some cases, an aggressive
impreg run at high-speed may be the
right solution…
• “Turbines won’t keep hole vertical.” • All turbines come stabilized full-
gauge
• “We’ll need to ream very often.” • No, turbodrilling gives much better
calipered hole, reaming is not
necessary
• “Turbine will affect MWD readings.” •By the contrary, turbines are
balanced and generate less
vibrations and shocks
Misconceptions… The Truth…
• “Turbines won’t permit to circulate with • Most of common LCM will go through
LCM” our tools at a wide range of
concentration
• “Turbine have a big tendency to stall” • Not if you use the correct parameters,
even less with pressure-reactive blades
• “If it stalls too often, it will be damaged” • The metallic materials used means that
there is no damage, apart from a slight
pressure change, nothing will happen to
the turbine
Vibration Comparison:
t
Straight Hole Turbodrill 58 f
t Balance
38 f Drum
Port
REQUIREMENT REASON
t Balance
38 f Drum
Port
(Now Obsolete)
FBS Steerable Turbodrill
Typical Layout
Thrust Balance Drum
Turbine Stages
Interchangeable Lower
Bearing Stabiliser
Pin-Ended Shaft
Stator
Stator Blading
Blading Disk
Disk
Mud
Rotor Flow
Blading
Disk
Motor
Section
Turbine
Body
rd
nwa
Dowhrust
T
Assembly
makes up
One Motor Stage
Turbine
Shaft
Turbodrill Blades & Stage Assembly
• Converts Flow to Rotary Movement
• Typically 100 stages per Turbodrill.
• Number and type optimized for particular applications
• Principal difference with PDM’s – all Metallic
Stage
(Assembly)
Stator
Rotor
Turbodrill Evolution
Turbine Blade Design
Turbodrill Configurations &
Components
Forces and Load Support Turbodrill Hydraulic Thrust
80,000 Lbs
Weight on Bit
(For 9-1/2” T3(Mk1), 750 Gpm, OBM)
Turbodrill Components
Moving
Disc
Thrust
Bearing
Moving
Disc
Labyrinth
Spacer Front
Bearing
Flexible
Shaft
Fixed
Disc Bent
Housing
Front Bearing
Stabiliser
WallCarb™
lining
(Bush)
LaserCarb™ Highest recorded
coating
Temperature when
(Sleeve)
successfully
using a Turbine –
± 260°C
± 95 %
Flow Port
Turbodrill Evolution
Turbine Thrust Balance Drum (TS B)
Motor Section
Micro
Annulus
Pressure Equalising
Leakage Flow
Main Flow to
Motor Section
Turbine Blade
Balance Drum
Diameter ‘Dd’
THRUST EFFECTS?
Resultant
6-5/8” : Thrust reduced by 50% Thrust area
9-1/2” : Thrust reduced by 70%
Turbodrill Evolution
Turbine Thrust Balance Drum (TS H)
With a TS H tool the shaft is hollow.
The TSH Balance Drum Housing
has a field-changeable nozzle to
bypass a chosen % of the flow – or
can be blanked-off. (Leakage flow
through shaft)
Tooling, Nozzle-Carrier & nozzles
shown below.
Leakage Flow to
Annulus?
TSB : Yes
TSH : NO
Turbodrill Evolution
Flexible Titanium Shaft
Direction of flow
Turbodrill Configurations &
Components
Rig Site Interchangeable Stabilisers
Intermediate Stabiliser
(Rig-changeable)
Borehole Image with typical profile Borehole Image with typical profile
generated by PDM + Rockbit generated by Turbine + long gauge bit
Well bore quality: Hole Spiralling 1…
Well bore quality: Hole Spiralling 2…
Well bore quality: Hole Spiralling problems…
Turbine Stabilisation in the 80’s
Effect of Spiralling - 1
Bit-Box Stabiliser
Effect of Hole Spiralling - 2
Box-Connection Bit with Protected Sleeve
The Perfect Fit…
4.6Ft *
2.6Ft *
LONG GAUGE BOX END BOTTOM BEARING
PIN CONNECTION. SHAFT STABILISER
2.2Ft*
SHORT GAUGE
PIN CONNECTION BIT BOX BOTTOM BEARING
STABILISER STABILISER
1.4Ft*
BOX-UP BOTTOM BEARING
LONG GAUGE BIT. STABILISER
Entrance Angle
(Stator:
FIXED)
(Rotor:
MOVING)
Rotation
(C.W. looking down)
(Stator:
FIXED)
Exit Angle
Turbine Blade Design
Hydraulic Components:
HYDRAULIC
POWER IN
(Flow x Pressure)
FIXED
Rotation
Axial
Thrust
FIXED
Rotation
Sufficient Pressure-drop (i.e. Power) for the application?
Steerable applications:
Impreg. Bits : 3.5 Hp/in² min.
(more hole angle? – then more power..)
Mechanical Hp/in²
(Part-copy of hydraulics sheet ‘HYDRO7E’)
B it
3%
6 1/ 2 " D C
B it 4%
3%
6 1/ 2 " D C
T urbo drill 4% T urbo drill BHA in 8 ½ hole
5 1% 6 1%
Putting
the
Power
to Work.
Geared Turbodrills
An Introduction ……….
Hydraulic Motors: General
Input Output
Mechanical
Hydraulic
Energy
Energy
Black Box Motor
Pressure Torque
Flow Speed
4500
3500
PRESSURE (PSI)
3000
1500
1000
500
0
500 550 600 650 700 750 800 850 900 950
FLOW RATE (GPM)
9-1/2” Geared Turbodrill
9.1/2" Turbodrill Torque V's Pressure Available
35000
30000
Torque (Ft-lbs)
Geared Turbodrill
Turbine Stall
25000
20000
15000
10000 Standard Turbodrill
5000
0
1000 1500 2000 2500 3000 3500
9 ½” Gear Unit
• 8 Planet Gears
(foreground)
• Input Sun Gear shown
at left of image
• Output shaft attached to
the Planet Carrier
shown at right of image
Gear Turbodrill advantages
Can operate in either of two modes:
1. Increased torque compared to direct drive turbodrill
2. Equivalent torque regime
– If operating with equivalent torque, hydraulic
requirements are greatly reduced
i.e. Less pressure requirement (Typically 35 – 50%)
(Animation!)
Geared Turbodrill Facts
..
. 9 5/8 PDM
.
.
.
.
..
.
. 1-2 lobes
315 2417 145 350
5 stages
9 ½ Geared
Turbine
60 Stages
305 9040 285 995
9 ½ Geared
Turbine
87 Stages 305 13275 385 1325
Geared Turbodrill: General Description
20
GEAR REDUCED TURBINE RUNS
15
10
ROTARY RUNS
5 PDM RUNS
0
0 100 200 300 400 500 600 700
-500
16 " ho le t o 1555 m
Run #1: (Limestone / Chalk)
-1000
W OW
Drilled 306m in 11.5 hrs
-1500
13 3 / 8 " casing at 1550
m
Run #1 ROP: 26.6 m/hr
-2000 T wist o f f B HA Rotary Assembly
Run #2: (Clay, Silt, Limestone)
DEPTH (m)
through Chert