New products

Vol. 232 No. 8

Heat- and abrasion-resistant PDC cutters

National Oilwell Varco has introduced ReedHycalog Helios Thermal Tough Cutters, a range of thermally abrasion-resistant PDC cutters that have been re-engineered from the ground up.  This technology has been designed specifically for material with NOV’s deep leach technology to significantly reduce cutter degradation and allow the bit to drill farther and faster. The entire cutter-rock interaction has been studied and finite element analysis has been employed to provide a more complete, durable rock-cutting solution.
Since putting this new technology into effect, engineers have been able to significantly improve overall bit performance, in many cases enabling operators to reach TD with one bit. Numerous bit runs have proven successful in the Bakken, Haynesville and Barnett shale plays as well as challenging applications in the Middle East.  The cutters have achieved 194% increases in the average footage drilled and over 100% increases in penetration rate. In some cases, 52% decreases in cost per foot have been realized.

Fractured reservoir analysis software

Golder Associates has released Version 7.4 of FracMan, a discrete fracture network (DFN) analysis and modeling package for the oil and gas industry. Major developments in the new release include new and improved fracture data analysis tools, simulation of both natural and hydraulic fractures and their interaction, well estimated ultimate recovery (EUR) calculations and new modules to improve uncertainty assessment. The data analysis improvements include automatic tool kits for converting between differing fracture intensity measures (1D, 2D and 3D); the incorporation of tools to edit properties and boundary conditions of meshes used for flow simulations through the fracture networks to more realistically simulate flow in a wider variety of settings, such as when there is interference from nearby wells; and the ability to automatically adjust fracture intensity for truncated distributions of aperture, size and permeability.  FracMan Version 7.4 also includes additional fractal analyses, critical stress analysis and fracture orientation analysis tools that can be used to make even more geologically realistic DFN models where scaling and regional stresses impact the fracturing. The improvements to geological fracture simulation include new capabilities for modeling fluvio-deltaic and volcanic reservoirs, and improved spatial simulation of fracture properties and geometry conditioned to well measurements.

Vertical proppant storage

Reducing the carbon footprint of oilfield operations is a strong driver in site management. Halliburton has introduces the SandCastle PS-2500 proppant silo, which provides several benefits: It reduces the size of the pad required to store proppant; uses solar panels for power, reducing emissions; enables greater onsite proppant storage volumes than traditional units; improves material inventory with an integral weighing system; and improves reliability through design simplicity. The unit offers a reduced footprint with no volume compromise as compared with traditional horizontal proppant storage units. Space is saved by orienting the unit vertically once on location, as opposed to remaining in the horizontal (road) position during operation. The SandCastle unit is able to transition itself from the horizontal to the operating position under its own power provided through a solar power system completely housed within the PS-2500 silo. The unit requires no external power source to operate, eliminating the diesel engine normally required for each conventional proppant handling/storage container. The unit has a total working volume of 2,500 sacks (250,000 lb), divided into two separate bins. Proppant can be discharged from either bin at a rate of more than 200 sacks per minute, allowing for a variety of downhole proppant concentrations at the high rates typically required in the fracturing of shale plays. It includes an integrated weighing system that enables proppant volumes to be monitored in real time.

Flameless joining of stainless steel

The Viega ProPress system is available for joining stainless steel piping in sizes from 1/2 in. to 4 in. using a unique press technology to secure pipe connections in less than 7 seconds. The system provides a faster, more reliable, flameless way to make watertight and gas-tight stainless steel connections. The system is available in two stainless steel grades, 304 and 316, and with more than 600 fitting configurations. Three unique sealing elements are available: EPDM, HNBR and FKM. The EPDM sealing element is used in any type of water system and for low-pressure steam; the HNBR sealing element is designed for fuel oil and gas systems; and the FKM sealing element is used for applications where increased chemical resistance is required, as well as for low-pressure steam.

Piggyback clamp to improve diver safety

Trelleborg Offshore has introduced a new diver-friendly piggyback clamp designed to improve safety during installation. The system includes the use of edge-treated banding and a new fastening system that eliminates sharp edges, reducing the risk of cuts to the diver. The innovative design, which negates the need to pass the band around the carrier pipe to secure the piggyback line, reduces handling and improves installation efficiency and time. Manufactured from marine-grade polypropylene, the piggyback saddle can fit carrier pipelines from 20 in. to 42 in. and line sizes from 11/4 in. to 31/2 in. The one-size-fits-all design helps streamline purchasing, enabling bulk ordering.

Wellbore cleaning for high-cost environments

Baker Hughes has introduced a wellbore cleanup and displacement system designed to improve efficiency and reduce operational risks in high-cost environments such as deepwater applications; horizontal, extended-reach, and deviated wells; deep wells; and wells with high dogleg severity. The X-Treme Clean XP system is the latest-generation cyclone-based system, which removes debris efficiently with the industry’s highest allowable mandrel rotation speed, a non-rotating tool string, a large circulation area, advanced debris-carrying capabilities and higher-than-drill pipe tensile and torque ratings. The system mandrel has an allowable rotation speed rated to 150 rpm versus 60–100 rpm for typical cleaning systems, and is designed to achieve the highest cleaning efficiency for every application. Studies indicate that cleaning efficiency increases significantly at 90–120 rpm. Only the mandrel rotates; other system components such as the scraper blades, brush and stabilizers do not rotate, minimizing damage to the casing, liner or riser. Additional features include helical-shaped scraper and brush tools that double the cleaning area and increase the annular circulation area, allowing fluid to circulate at high rates to reduce circulation and displacement time.