. .- ..--.

11-_1

h 5
/I’
cd CONTRACTOR REPORT
I bu SAND81-7142
Unlimited Release
UC-66~

- Evaluation of High-pressure
Drilling-Fluid Supply Systems
-a

Michael C. McDonald, James M. Reichman, Kenneth J. Theimer

Flow Technology Company
Kent, Washington

Prepared by Sandia National Laboratories, Albuquerque. New Mexico 87 185

and Livermore, California 94550 for the United States Department of Energy
under Contract DE-AC04-76DP00789

Printed October 198 1

O l ~ R l l O NOF THIS DOCMEMI IS UHLMTED

 DISCLAIMER

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by the United Statea Government, any agency thereof or any of their

.
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 ’W
SAND81-7142
UNLIMITED RELEASE

EVALUATION OF HIGH-PRESSURE
DRILLING FLUID SWPLY SYSTEMS*

Michael C. McDonald
James M. Reichman
Kenneth J. Theimer
FLOW TECHNOLOGY COMPANY
A Division o f Flow Industries, Inc.
Kent, Washington

ABSTRACT

A study was undertaken t o help determine the technical and economic

f e a s i b i l i t y o f developing a high-pressure f l u i d - j e t d r i l l i n g system f o r
the production o f geothermal wells. Three system concepts were developed

.
and analysed i n terms o f costs, component a v a i l a b i l i t y , and required
new-component development These concepts included a single-conduit
system t h a t supplies the downhole cutting nozzles d i r e c t l y v i a surface-
* located high-pressure pumps; a single-conduit system u t i l i z i n g low-
pressure surface pumps t o supply and\ operate a high-pressure downhole
pump, which i n turn supplies the cutting nozzles; and a dual-conduit
-a
system supplying surface-generated high-pressure f h i d for c u t t i n g v i a one
-- conduit and low-pressure scavenging f l u i d v i a the other. It is concluded
t h a t the single-conduit downhole pump system concept has the greatest
potential f o r success i n t h i s application.
i

aj *Work performed under Sandia National Laboratories Contract No. 49-8409 f o r

the U.S. Department o f Energy, Division o f Geothermal Energy.

h4
n
BmnrBLtTiON OF THIS DOClwilENT IS UNLlMlTEO
 CONTENTS

N Section Page
1 INTR OOUCT I ON 9
..a
1.1 Case 1 - Single-Conduit Surface Pumping System 9
1.2 Case 2 - Single-Conduit Dounhole Pumping System 13
1.3 Case 3 -
Dual-Conduit Surface Pumping System 13
2 STATE-OF-THE-ART R E V 1 EW 17
2.1 Mud Pumps 17
2.1.1 D r i l l i n g Mud 17
2.1.2 P o s i t i v e Displacement Pumps 18
2.1.3 I n t e n s i f i e r Pumps 18
2.1.4 Pump A v a i l a b i l i t y 19
2.2 Hoses 23
2.2.1 Hydraulic Hoses 23
2.2.2 Conventional O i l F i e l d Hoses 25
2.2.3 F l e x i b l e Pipe 25
2.2.4 Hdse A v a i l a b i l i t y 26
2.3 Drill Pipe and Tool J o i n t s 29
2.3.1 High-Temperature Performance Requirements 29
2.3.2 Torque Loading Requirements 36
244 Swivels 36
2.4.1 Piping Swivels 36
i 2.4.2 dil F i e l d Swivels 39
2.4.3 Steam Swivels 39
1
2.4.4 Hydraulic Swivels 39
2.5 Dowrrhole Punps 39
3 NEW COMPONENT DESIGNS 41
3.1 Mud Pumps 41
3.1 .1 Pump R e l i a b i l i t y 43
3.1.2 N&w Design 43
'dd

5
 CONTENTS (Continued)

Section Page
3.1.2.1 P i s t o n Seal 50
3.1.2.2 Check Valves 50
3.1.2.3 Conclusion 53
3.2 Swivels 53 m

3.2.1 Single-Passage Swivels 53

3.2.2 Dual-Passage Swivels 53 4

3.2.3 Applications 53
3.2.4 Conclusion 56
3.3 Downhole Pump 56
3.3.1 Theory o f Operation 56
3.3.2 C o n t r o l Mechanism 58
3.3.3 Punp Requirements 62
3.3.4 Pump C o n s t r u c t i o n 62
3.3.5 Materials o f Construction 67
3.3.6 D i f f i c u l t i e s i n Design 67
3.4 Dual D r i l l S t r i n g 68
3.4.1 Theory o f Operation 68
3.4.2 Design Problans 68
3.5 Economic Comparison 71
3.5.1 Pumps 73
3.5.2 Hoses 73
3.5.3 Swivel 74
3.5.4 D r i l l String 74
3.5.5 T o t a l Costs 74
4 CONCLUSIONS 75
REFERENCES 77
.

6
 ILLUSTRATIONS

U Figure Page
Case 1: Surface Pumping System 12
Case 2: Downhole Pumping System 14
Case 3: Dual D r i l l S t r i n g System 15
High-pressure Pump C a p a b i l i t i e s 20
State-of-the-Art Hose Performance 24
Dual D r i l l S t r i n g High-pressure C o n d u i t L i n e Losses 28
Effect of Temperature on API Grade E S t e e l D r i l l
Pipe Strength 35
8 Effect of Temperature on API Grade S S t e e l D r i l l
Pipe Strength 35
9 Extra High-pressure Swivel J o i n t s 38
IO O i l F i e l d Swivels 40
11 P o s i t i v e Displacement Pump Diagram 42
12 Check Valve Seating S t r e s s Diagram 44
13 Plunger Seal Flushing Method 45
14 Linear Spool Check Valve Flushing Method 46
15 Rotating Spool Check Valve Flushing Method 47
16 Poppet Check Valve Flushing Method 48
17 Pump Flushing System Diagram 49
18 Rotating Spool Check Valve Flushing System 51
19 Poppet Check Valve Flushing Systems 52
20 Single-Passage Swivel Modified f o r High-Pressure
Service W i t h Water Flushing 54
21 Single-Passage Swivel Modified f o r High-Pressure
S e r v i c e Without Water F1 u s h ing 55
22 Downhole Intensifier Punp System Diagram 57
i 23 Downhole I n t e n s i f i e r Pump Theory of Operation 57
24 I n t e n s i f i e r Punp Flow Diagram 59
.
I
25 Downhole Intensifier Pump O u t p u t a t Various
Piston Ratios 60
26 Downhole Intensifier Pump Control Mechanism 61
27 Dual D r i l l S t r i n g System Design Concept 63
28 Dual D r i l l S t r i n g Components 69

7
 TABLES

Table Page
1 Contract Performance Requirements I O
2 Surface Pumping Requirements 11
3 Mud Pump Manufacturers, Nomenclature, and
Specifications 21
4 Hose Manufacturers, Nomenclature and S p e c i f i c a t i o n s 27
5 Case 1 : Surface Pumps, Single-Conduit D r i l l S t r i n g 30
6 Case 2: Downhole I n t e n s i f i e r , Single-Conduit D r i l l
String 31
7 Case 3 : Surface Punps, Dual-Conduit Drill S t r i n g 32
0 D r i l l Pipe Manufacturers, Nomenclature, and
Specifications 33
9 Swivel Manufacturers, Nomenclature, and
Specifications 37
10 Comparative Equipment Costs ( i n D o l l a r s ) 72
I1 System Advantages and Disadvantages by Case 76
u 1. Introduction
Laboratory and f i e l d tests (Ref. 1) have demonstrated the potential
adyantageq i n terms of speed and economy of using high-pressure f l u i d j e t s fo r
deep geothermal well d r i l l i n g . However, f l u i d - j e t d r i l l i n g a t t h e depths
required for t h i s application (to 10,000 feet) has not proven practicable due
t o a lack of suitable system components, e.g., pumps, swivels, rotary
3 connectors, and hoses.
This deficiency is not readily apparent unless hydrostatic and
-4
hydrodynamic effects produced by 8 column of water contained i n 10,000 feet of
d r i l l s t r i n g are censidered during component selection. Although hydrostatic
pressure increases with depth due t o t h e weight of f l u i d i n s i d e the d r i l l
pipe, it is bsllanced by the weight of the column of mud around t h e outside of
t h e s t r i n g . The n e t r e s u l t is an insignificant change i n relative downhole
.
pressure due t o hydrostatic effects However, the hydrodynamic effect of
f r i c t i o n a l losses both inside and outside t h e d r i l l s t r i n g is extremely
important. Due t o these losses, f l u i d for j e t cutting and chip removal must
be supplied a t a pressure much higher than t h e l o c a l hydrostatic pressures.
Flow 'Industries, Inc. has performed a system feasibility study f o r Sandia
Laboratories based on these considerations. (The system design constraints
specified by t h e contract are l i s t e d i n Table 1.) The study comprised a
review of currently available commerical systems and development of three
conceptual designs f o r both surface and downhole high-pressure d r i l l i n g
systems (15,OW p s i maximum). These designs are referred t o as %ases"
throughout t h e remainder o f t h i s report. Fluid pressure losses due t o
f r i c t i o n have been calculated and the resulting surface pumping requirements
for each case are summarized i n Table 2. Where necessary, new components were
designed and existing components redesigned t o meet the requirements of these
t
cases .
*
-
1.1 Case 1 Single-Conduit Surface Pumping System
The Case 1 system (Figure 1)'is t h e most straightforward and conservative
o f t h e three cases i n t h a t it relies on the use of a single-conduit d r i l l
s t r i n g end surface components rated a t pressures s u f f i c i e n t l y high t o s u s t a i n
t h e total f l u i d flow, both j e t t i n g and scavenging, a t the required downhole

9
 Table 1. Contract Performance Requirements

DOWNHOLE SURFACE SURFACE SURFACE DRILL

REQUIREMENTS PUMP PUMP 'SWIVELS HOSE PIPE

5OO0F SOAK X X
300°F OPERATE X X
212OF OPERATE X X X

15,000-psi MAX X X X X X
300,000-lb TENSION X X
50,000-lb COMPRESSION X X
30,000-ft-lb TORQUE X X

PUMP MUD AND/OR WATER X X X X X

200-hr SEAL LIFE X X X X X
1,000-hr THROW AWAY X X X X X

ON-SITE SEAL REPLACEMENT X X X X

SINGLE CONDUIT X X X

100-rpm ROTATION SPEED X

NO SINGLE SECTION LONGER
THAN 6 0 ft X X

c c
 c * b

c
Table 2. Surface Pumping Require-ts
PUMPING
SURFACE HYDRAULIC SYSTEM
FLOW , PRESSURE, POWER CANDIDATE COST,
GPM PSIG HHP SYSTEM $1,000
CASE 1: SURFACE PUMP
CUTTING AND SCAVENGING 200 (la) 16,500 1,925 GARDNER-DENVER~ 1 750
CUTTING AND SCAVENGING 200 (lb) 11,500 1,342 GARDNER-DENVER~ i,6 30
CUTTING AND SCAVENGING 200 (IC) 9,000 1,050 GARDNER-DENVER~ 1,500

CUTTING AND SCAVENGING 200 (la) 6,500 758 GARDNER-DENVER~ 1,290

CASE 2: DOWNHOLE PUMP
DOWNHOLE PUMP SUPPLY 313 4,400 804 GARDNER-DENVER 465
CASE 3: DUAL DRILL STRING
.
CUTTING JET (WATER OR MUD) 50 20, ooo2 715 GARDNER-DENVER~ 490
CHIP SCAVENGING 150 3,300 289 GARDNER-DENVER . 255
TOTAL: 1,004 TOTAL: 745
BASELINE - CONVENTIONAL
CUTTING AND SCAVENGING 200 3,500 408 HALLIBURTON 291

'MODIFIED FOR HIGH-PRESSURE SERVICE.

'CASE 3 SURFACE PRESSURE: TO OBTAIN 15,000 psi DOWNHOLE AT 10,000-ft DEPTH IS 24,500 psi.
HOWEVER, 20,000 p s i WAS SET AS A PRACTICAL LIMIT FOR EQUIPMENT AVAILABILITY. CASE 3
-.
a PRICES ARE FOR CUTTING WITH WATER ONLY.
 r
L
SINGLE PASSAGE
SWIVEL

1- '
IVIUUrrtvu

SYSTEI.. I

1
I I

MAKE-UP
FLUID
t
SINGLE CONDUCTOR
I t DRILL STRING

10,m ft
(MAX)

1
I

I td 1 DRILLING
BIT

CUlllNG JETS,
CHIP SCAVENGING FLOW,
200 gpm A T
2 9 gpm AT 1,O00 psig 15,000 psid (1a)
lO,OO0 psid (1b)
7,500 psid (1c)
5,000 psid (1d)*

* .ForDownholeMotor
Figure 1. Case 1: Surface Pumping System

12
wprking pressure. Four subcases were i d e n t i f i e d t o study t h e effect of
increasing pressure on system costs. The required pressure drop across the
nozzles For each subcase is as follows:
9. Subcase la: 15,OOO psid
B. Subcase lb: 10,OOO psid
C. Subcase IC: 7,500 psid
D. Subcase Id; 5,000 psid
The flow rate for each subcase i s 200 gpm.
Friction loss i n 10,OOO feet of d r i l l s t r i n g is calculated t o be 500 p s i
and pequired downhole scavenging pressure is 1,000 p s i above hydrostatic
pressure. Therefore, the surface pumping pressure required is 500 p s i +
1,000 p s i = 1,mO p s i above the desired cutting jet pressure drop, or
1 6 , p J p s i for Subcase l a , 11,500 p s i f o r Subcase l b , 9,000 p s i for Sub-
case la, and 6,500 p s i f o r Subcase Id.

-
1.2 Case 2 Single-Conduit Downhole Pumping System
The Oase 2 system u t i l i z e s a s i n g l e c o n d u i t d r i l l s t r i n g and low-pressure
s u r f a c e components t o supply and operate a downhole high-pressure pump located
directly above the b i t . The downhole "intensifier" pump converts t h e energy
Qoqtained i n t h e high-volume, low-pressure flow t o low-yolume, high-pressure
flow for Jet c u t t i n g w i t h t h e spent low-pressure flow used for scavenging
(Figure 2). The downhole pump requires either a ZOO-gpm, 3,OOQpsid primary
flow t o produce B 4O-gpm, 15,000-psid cutting j e t flow and 160-gpm, 1,ooO-psig
scavenging flow (Subcase 2a) or a 200-gpm, 3,750-psid primary flow t o produce
a 59-gpm, 15,OOO=psid c u t t i n g jet flow and 15O-gpm, 1,000-psid scavenging flow
(Subcase 2b).
The pressure loss due t o f r i c t i o n i n 10,000 feet of d r i l l pipe a t 200 gpm
is calculated a t 500 psi. The surface pressure required is, therefore, either
3,000 psid + 1,000 p s i 9 + 500 p s i = 4,500 psig for Subcase 2a or 3,750 psid +
1,000 psig + 500 p s i = 5,250 psig for Subcase 2b.

1.3 Case 3 - Dualdonduit Surface Pumping System

This case $$ based on a dual-conduit d r i l l s t r i n g wherein the t o t a l f l u i d
flow is divided i n t o high-pressure and low-pressure portions for jet cutting
and scavenging, respectively (Figure 3).

13
 MEDIUM PRESSURE
LJ
SINGLE PASSAGE
SWIVEL

MUD PROCESSING
SYSTEM

t
MAKE-UP
FLUID

SINGLE CONDUCTOR
DRILL STRING

10,000 ft
(MAX)

DRILLCOLLARS,
40,000 Ib
CHIP
SCAVENGING FLOW
AT 1OOO psig DOWNHOLE
2a 160 gpm
2b150gpm
INTENSIFIER
PUMP
.
DRILLING
L BIT

CUTTING JETS
15,000 psid
40 gpm 2a
50 gpm 2b

Figure 2. Case 2 Downhole Pumping System

14
 50 gpm
4VJ WATER SUPPLY HIGH PRESSURE

CASE 3a ? PUMPING
SYSTEM
I
CASE 3b
I
MEDIUM PRESSURE 150 gpm (MUD)
PUMPING I DUAL
SYSTEM 3,300 psi PASSAGE
f
SWIVEL

MUD PROCESSING
SYSTEM

t 1
MAKE-UP
FLUID I ( ) DUAL CONDUCTOR
DRILL STRING

OUTER NNER
STRINC STRING
HIGH PRESSURE)

Oft
X)

CHIP
SCAVENGING
FLOW, DUAL CONDUCTOR
150 gpm AT DRILL
COLLVS,
50,000 Ib

DRILLING
BIT

CUTTING
JETS,
50 gpm AT
15,000 psid
L,
Figure 3. Case 3: Dual Drill String System
 The scavenging flow bf 150 gpm a t 1,OOO psig above hydrostatic pressme is r,
supplied by a medimpressure mud pumping system located on the surface,
Fluid pressure losses due t o friction i n the outer passage of 10,000 feet-of
d r i l l string a t a l5O-gpm flow rate are 2,300 psi. Therefoze, the totail
surface pumping pressure requirement for scavenging f l u i d is 1,000 Dsig +
2,300 p s i = 3,300 p i g .
A high-pressure pumping system supplies either watet (Subcase %) or
d r i l l i n g mud (Subcase 3b) t o the cutting jets, A cutting j e t flow of 50 gpm
a t 15,000 p s i supplies the energy required for rapid rock autting. A t a depth
of 10,OOO feet, a total of 8,500 p s i is l o s t t o friction i n the d r i l l string's
inner passage. Therefore a cutting j e t surface pumping pressure of 15,000 p s i
+ 8,500 p s i + 1,000 p s i = 24,000 p s i is required.

16
LJ 2. Stateof-theArt Review
Mud pumping technology f o r o i l i h d u s t r y applications is highly developed
and readily available. This section discwsseS the relevance of this tech-
nology t o the geothermal well d r i l l i n g application.

2.1 Mud Purrps

2.1.1 Drilling Mud

A d r i l l i n g f l u i d for deep well d r i l l i n g operations is commonly referred t o
as "mud" because of its close resemblance t o that material. This mud is
circulated v i a surface pumps through t h e d r i l l s t r i n g t o t h e d r i l l b i t .
Nozzles direct t h e pressurized mud onto the cutting-surface where it may
either act as the primary cutting medium or simply help t o erode material
already loosened by a r o t a t i n g d r i l l b i t . The mud then returns t o t h e surface
v i a t h e annulus between t h e d r i l l s t r i n g and the hole, carrying the entrained
c u t t i n g s from the d r i l l i n g process with it. On the surface, the m u d is
cleaned and conditioned for recirculation .
The muds used for d r i l l i n g operations are carefully formulated to serve a
v a r i e t y of purposes, some of which are as follows (Ref. 2):
A. Washing c u t t i n g s from the d r i l l b i t .
6. Cooling t h e d r i l l b i t .
C. Lubricating t h e r o t a t i n g d r i l l s t r i n g .
D. Balancing high downhole formation f l u i d pressures by means of their
weight.
E. Reducing loss of c i r c u l a t i n g f l u i d i n t o permeable regions.
F. Controlling the acidity of the d r i l l s t r i n g ' s environment and thereby
* reducing metal corrosion.
The cooling function of t h e d r i l l i n g mud is especially important for geo-
I thermal d r i l l i n g operations where downhole temperatures i n excess of 5W°F may
be encountered.
A basic geothermal d r i l l i n g mud may be composed of Bentonite clay and/or
S e p i o l i t e clay suspended i n water (fief. 3). Small percentages of l i g n i t e coal
are sometimes added t o t h i s basic mixture. Also, c a u s t i c soda and surfactants
may be added t o control acidity and reduce hydrodynamic f r i c t i o n , respectively .
A t y p i c a l geothermal d r i l l i n g mud may weigh 9.5 t o 10 pounds per gallon as

17
opposed t o 8.34 pounds per gallon for water alone. A t low shear rates, the
d r i l l i n g mud is a viscous, thixotropic, nowNewtonian fluid. A s shear rates
increase with increased velocity or agitation, the mud begins t o behave i n a
manner more characteristic of a Newtonian f l u i d with dramatically reduced
apparent viscosity. This property helps the mud t o suspend s o l i d s , which i s
one of its primary functions.

2.1.2 Positive Displacement pumps c

Positive displacement mud pumps are generally used t o c i r c u l a t e the

d r i l l i n g mud f o r applications where t h e surface pressure requirement seldom
exceeds 3,000 psi. Such pumps must be capable of near continuous,
around-the-clock operation with minimum down time. There are a g r e a t many
pumps available that are capable of s a t i s f y i n g these requirements. The mud
pumps most commonly used are of the crank-shaft-driven, reciprocating piston
t y p e i n multiple cylinder configurations, e.g., duplex, t r i p l e x , and
quadraplex. (The multiple cylinders tend t o smooth the pressure pulses
associated with reciprocating pumps.) These pumps contain a "power end" that
includes a crankshaft, connecting rods, cylinders, and pistons (or plungers
and a "fluid end" containing check valves and f l u i d passages.
Although some manufacturers rate their equipment a t 4,500 t o 5,600 p s i f o r
continuous opertion (and up t o 20,ooO p s i for intermittent operation),
experience shows that pump reliability is greatly reduced a t d r i l l i n g f l u i d
operating pressures i n excess of 3,500 p s i (Ref. 4). Therefore, a different
type of pump, such as t h e i n t e n s i f i e r pump discussed i n t h e following sub-
section, is needed t o produce t h e higher pressures required for t h e geothermal
well d r i l l i n g application.

2.1.3 I n t e n s i f i e r PumpS
High-pressure i n t e n s i f i e r m u d punps were developed for o i l industry
applications and are used almost exclusively for o i l well cementing,
fracturing, and well k i l l i n g . Therefore, since their duty cycle is short
(usually less than 8 hours) and their i n i t i a l cost high, i n t e n s i f i e r r i g s are
.
generally rented from service companies, e .g , Halliburton, B. 3. Hughes, and
.
Dowell Within their design limitations, they provide excellent reliability
a t very high operating pressures. I n t e n s i f i e r and crankshaft pumps are
 hi similar i n that they both use reciprocating pistons (or plungers) t o
pressurize the working f l u i d and check valves t o d i r e c t the flow. However,
the i n t e n s i f i e r pump pressurizes the working f l u i d by means o f a larger
low-pressure piston t h a t transfers energy from the primary f l u i d t o a smaller
high-pressure piston. The difference i n area o f the two pistons, expressed as
-2’
a r a t i o , represents the factor by which working f l u i d pressure i s increased.
(Refer t o Subsection 3.3 f o r a discussion o f i n t e n s i f i e r pump operating
t
principles.) The primary f l u i d flow may be supplied either by hydraulic punps
or conventional t r i p l e x pumps since the o i l or water used t o power the
i n t e n s i f i e r pump i s normally pressurized only a t 3,000 t o 5,000 psi.
Theoretically, an i n t e n s i f i e r pump can be designed t o produce any desired
output pressure due t o i t s pressure multiplication capability. However, i n
practice i t i s l i m i t e d by material fatigue. While intermittent pressures t o
300,000 p s i are possible, 55,000 p s i i s currently the upper l i m i t f o r
continuous operation (more than 10,000,OOO cycles). Figure 4 i s a graph of
pressure versus flow r a t e f o r selected conventional t r i p l e x and i n t e n s i f i e r
pumps.

.
2 1.4 Rrmp A v a i l a b i l i t y
Conventional mud pumps w i t h maximun continuous operating pressures above
3,000 p s i are available from a number o f manufacturers (Table 3). Many of
these pumps are rated t o 15,000 p s i f o r intermittent operation. However, such
operation may be expected t o shorten the service l i f e o f c r i t i c a l parts, e.g.,
packings, check valves, and fluid-end housings .
Halliburton Services and Towler Hydraulics manufacture trailer-mounted
i n t e n s i f i e r punps f o r use with d r i l l i n g mud. The Halliburton Model HT-loo0
t
i n t e n s i f i e r pumping unit develops 1,800 hhp a t 20,OOO-psi continuous operation .
Halliburton i n t e n s i f i e r s are powered by conventional diesel-driven t r i p l e x
pumps mounted on separate t r a i l e r s . Towler i n t e n s i f i e r s are powered by
&

.
diesel-driven hydraulic power u n i t s Both Halliburton and Towler i n t e n s i f i e r s
use long, overlapping strokes t o produce very smooth output flows,
Flow Industries, Inc. manuFactures a m h h p output low-flow ,
high-pressure i n t e n s i f i e r unit designed f o r use with f i l t e r e d water. The
u n i t s are skid-mounted and consist o f a double-acting i n t e n s i f i e r and an
6.1 electro-hydraulic power unit. Piston sizes are specifically selected for

19
 All PurnDs to Handle Drilling Mud on a
30
Continuous Basis Except ashloted.

25
CASE 3 (HIGH PRESSURE)

C
20

PISE la

PRESSURE, 15
psid

\
\
10

\ rCASEId

. xJ
'\
\

5
X-CASE 2

0 I

0 100 200 300 400 500 600

FLOW RATE, gprn

@ Triplex, Halliburton HT-400D, 258 hhp

@ Triplex, Halliburton HT-400D, 565 hhp, (IntermittantService)
@ Triplex, Gardner-Denver, PZ-7,495 hhp
@ Triplex, Gardner-Denver, PZ-8,675 hhp
@ Triplex, Gardner-Denver, PZ-10,121 5 hhp
@ Intensifier, Towler
@ Intensifier, Towler
@ Intensifier, Halliburton, HT-3000,4400 hhp
@ Intensifier, Halliburton, HT-1000,1800 hhp
@ Intensifier, Flow Tech., 250 hhp (Water Only)
@ Three Intensifiers in Parallel, Flow Tech., 250 hhp, (Water Only)

Figure 4. High-pressure Pump Capabilities

20
 Y. Y, 4 *.

Table 3. Mud Pump Manufacturers, Nomenclatures and Specifications

Pump Type
+ Pressure. F h . Power, Temperature,
Manufacturer Trade Name psi gpm hP OF Applications

B.J. Hughes Triplex 15OOO 160 Oil field cementing

(pacerfiaker) 15OOO 210 Gravel packingservices
8ooO 350
4600 630

Worthmgton Triplex u p t o m up to 3000 1506oO Process Industries

Pump Quintuplex 1000 Pipelines
Septuplex 1600 Petroleum Industry
Nonuplex 1600

Wilson-Snyder Triplex 3180 V8-176

Wilson-Snyder Triplex 3180 18-176 Up to 600 Hot fuel oil

Pumps (hot Quintuplex 5OOO 153-700 Hot Asphalt
hydrocarbons) Corrosive, abrasive
agents

ARAMCO Triplex 3200-5500 148-700 Land OF offshoreflush

12-P-160

Cat Pumps Triplex lo00 60 Injection, spraying,

corp. U n i f l w concept 5OOO 12 hydrostatictesting

Gardner-Denver Triplex PJ-8 3118 128 275 Mud pumps

Quintuplex pt-7 3556 238 550
PZ-8 5381 215 750
PZ-9 5530 279 lo00
PZ-10 5100 400 1350
PZ-11 5595 440 to00

Dwell Triplex Model PT-02 lo500 411 lo00 Water (Dirty)

Schlumberger PW7 Triplex 7 m 4600 Iblmin.

ldeco Duplex-doubleacting 5555 444 1300 Mud pumps

Dresser 4 4 lo00
Triplex xK)o 700 800
N
N

Table 3. Mud Pump Manufacturers, Nomenclature, and Specifications (Continued)

Pump Type
+ Pressure, Flow, Power, Temperature,
Manufacturer Trade Name psi gpm hP OF Applications

Halliburton Intensifier pumps 9000-2m 1800-4400 Continuous, smooth

HT-1000, HT-3000 high pressure supply
HT-400 mud multi purpose 4Ooo 153 275

Aldrich, Ingersoll- Triplex u p to 10 to 2725

Rand Quintuplex 7000 15
Septuplex 5000 400
Nonuplex

National Supply Triplex 7-P-50 1515 571 500 Mud

12-P-160 5000 518 1600 Water
Duplex

Oil Well, Divisionof Triplex Mud

United States Steel Duplex Large variety of pumps
A-560-PT 6Ooo 229
A-850-PT 5Ooo 310
1700-P 4300 475

Skytop Brewster Duplex Mud

B550F. B750F, E1000F 1200-3800 130-650 775-1000
Triplex
B1300T, B1600T 2700-5000 235 - 720 650-1600

Stewart & Air operated 3000 30 60 Water

Stevenson Electric operated
Tools Triplex & Duplex

Valve Control, Simplex 3600 30 Up to 60 Water, hydraulic

Subsidiary of Hydrill Tridlex

Wilson Mfg. Duqlex -

2000 4250 100-595 600-1300 Mud

Baker Sand Centrifugal 1OOOrpm

Control Mud Pump 12 BPM output

NL Rig Equipment Choke System 1m,15000 300

c c
u each application i n order t o produce the desired output flow and pressure a t a
.
reasonable cycle r a t e Integral high-pressure accumulators are provided t o
smooth pressure fluctuations caused by the piston reversals. These u n i t s are
currently used for underground mining applications.
The surface pumping requirements o f each o f the three cases i d e n t i f i e d f o r

z
t h i s study have been summarized i n Table 2. It may be seen t h a t the r e q u i r e
ments o f Subcase l a are beyond the rated performance o f both the Halliburton
s
HT-lo00 and HT-3000 intensifiers. Subcases lb, IC
and I ,
d requirements,
however, may be s a t i s f i e d by either o f these Halliburton intensifiers.
Comparing Tables 2 and 3 shows t h a t Case 2 pressure and flow requirements may
be s a t i s i f e d by any o f the larger conventional pumps, such as the Gardner-
Denver PZ-9. Case 3 high-pressure requirements (Subcase 3a) may be s a t i s f i e d
by water only using three Flow Industries 250-hhp i n t e n s i f i e r s i n parallel;
low-pressure requirements (Subcase 3b) may be s a t i s i f e d by any o f several
available t r i p l e x pumps.
-
2.2 Hoses
High-pressure hoses, i.e., those with rated working pressures above
2,000 psi, can be grouped i n t o three general categories as follows:
A.Hydraulic hoses.
B. Conventional o i l f i e l d hoses.
C. Flexible pipe.
Figure 5 shows the performance o f representative hoses from each category w i t h
the manufacturer's recommended maximum working pressure as a function o f
inside diameter. High-pressure hoses are generally hydrotested a t 1.5 t o 2.0
times the rated working pressure and have safety factors ranging from 2.2 to
4.0, depending on the service requirement.

V* ..
2 2 1 Hydraulic Hoses
Most hydraulic hoses are manufactured and tested i n accordance with the
specifications o f the Society o f Automotive Engineers (%E) .
Hydraulic hoses
w i t h inside diameters o f up t o 2 inches (Figure 5, examples 1 through 5) are
readily available from several sources, e.g. ,
Dynacraft and Parker Specialty .
hoses such as Polyflex (Figure 5, examples 1 and 2) are included i n the
hydraulic hose category although they may be manufactured with smaller inside
diameters and rated f o r higher pressures.

23
 25

CASE 3 (HIGH PRESSURE) 1

' @ w S F = 1 . 5

20

.-
2i
Y
E 15
2
Lu
K
3
v)

%
a
L
[3 10
zY
8
3

CASE 3 (LOW PRESSURE)

0
'I8 'I, 218 'I, v, l'l~l'/z 2 2'12 33'12 4 5 6 8 10 12
HOSE ID,in.

Burst Pressure
Representative Examples: = Safety Factor =
Working Pressure

0 Polyflex 4000 ST, SF = 2.2, Wydrotested at 1.5 x WP

@ Polyflex 2000 ST, SAE 100 R9, SF = 2.5, Hydrotestedat 1.5 x WP
@ Hi-Flex "Power Trak", SF = 3.0
@ Dynacraft 1066, SAE 100 R1 1,SF = 4.0, Hydrotestedat 2,O x WP
@ Dynacraft 1064, SAE 100 R10, SF = 4.0, Hydrotestedat 2.0 x WP
@ Goodyear Flexsteel 10,000 Rotary and Vibrator, Hydrotestedat 2.0 x WP
@ Goodyear Flexsteel7,500 Rotary and Vibrator, Hydrotestedat 1.9 x WP
@ Coflexip FlexiblePipe, Hydrotestedat 1.5 x WP

Figure 5. State-of-the-ArtHose Performance

24
L,
Some manufacturers increase hose pressure r a t i n g s by reducing the safety
factor. For example, hose safety factors of 2.0 t o 2.5 may be acceptable for
systems with minimal pressure surges and flexing. If a safety factor of 2.0
is acceptable, Polyflex 4000 St and Dynacraft 1-inah i n s i d e diameter SAE 100
R 1 1 hose (Figure 5 , examples 1 and 2) would be s u i t a b l e for 10,000-psi service
+.
while Hyflex %inch i n s i d e diameter Power Trak hose (Figure 5 , example 3)
would be s u i t a b l e f o r 7,500-psi service.
?-

2.2.2 Conventional O i l Field Hoses

Goodyear and llhiroyal supply conventional rotary and vibrator hoses for
large-diameter , high-pressure o i l f i e l d applications (Figure 5 , examples 6 and
.
7) These hoses are designed t o provide high-pressure service while surviving
t h e rough handling associated with d r i l l r i g work. Although the sales
l i t e r a t u r e does not provide hose safety f a c t o r s and burst pressures, it does
indicate that t h e hoses are hydrotested a t a generous 1.9 t o 2.0 times the
rated working pressure .
Oilfield hoses are cuqtom fabricated t o s p e c i f i c lengths and provided w i t h
i n t e g r a l f i t t i n g s a t each end. These f i t t i n g s are commonly either nipples
w i t h API male pipe threads or Victaulfc-type grooved ends.

2.2.3 Flexible Pipe

In 1972, Coflexip (a French manufacturing company) developed a f l e x i b l e
pipe for s p e c i a l o i l f i e l d applications that require a f l u i d transport tube
combining t h e high-pressure capability of r i g i d pipe and t h e f l e x i b i l i t y of
conventional hose. Since then, t h i s pipe has come i n t o general use i n o i l
fields around the world for those applications requiring its unique
t
cgpabilities .
Coflexip f l e x i b l e pipe comprises a s p i r a l , interlocking steel band that
**
permits limited flexing while providing exceptional hoop strength , double
crosq-wound bands angled t o provide t e n s i l e strength, and thermoplastic
sheaths t o seal t h e tube, separate the steel layers, and provide an abrasion-
r e s i s t a n t outer jacket. The r e s u l t i n g tube is nearly as f l e x i b l e as
comparably sized rotary hose and stronger than double-extra-strength API 5L ,
LJ Grade B steel pipe.

25
 The smallest f l e x i b l e pipe presently available has an inside diameter o f 2 U
.
inches However, the Coflexip representative i n Houston, Texas states that
smaller sizes can be made i f a market f o r them develops. The 2-inch inside
diameter f l e x i b l e pipe has a burst pressure o f 36,820 psi, or a rated working
pressure o f 15,000 p s i with a safety factor o f 2.5. Working pressures t o
24,500 p s i can be obtained, o f course, i f a safety factor o f 1.5 i s r

acceptable. I n that case, however, secondary safety precautions should be

taken t o avoid i n j u r y t o personnel and/or equipment damage i n a the event o f a i

l i n e failure.
End f i t t i n g s f o r f l e x i b l e pipe assemblies are provided i n accordance w i t h
customer specifications. The connections f o r the end f i t t i n g s , which are
claimed t o be stronger than the pipe i t s e l f , leave a &inch long r i g i d
portion a t each end o f the f l e x i b l e pipe assembly.
Coflexip f l e x i b l e pipe i s , o f course, quite expensive. For example, one
80-foot long section with a 2-1/2-inch inside diameter, 15,000-psi working
pressure, 48-inch minimum bend radius (working), Weyco union ends, l i f t i n g
collars, and a stainless steel outer jacket w i l l cost $41,156 complete, F.O.B.
Houston as of January 1981. It i s d i f f i c u l t t o evaluate the r e l a t i v e worth o f
t h i s product since no hose currently available has comparable performance
characteristics .
2.2.4 Hose A v a i l a b i l i t y
Table 4 l i s t s the high-pressure hoses available f o r t h i s application
together with t h e i r sources.
The Case 1 surface pumping (Subcase l a ) pressure requirements w i l l require
the use o f 2-1/2-inch inside diameter Coflexip f l e x i b l e pipe a t a s l i g h t l y
reduced safety factor. requirements, however, are w e l l
Subcase l b and IC
within the rated capabilities o f Coflexip f l e x i b l e pipe. Subcase I d and
Case 2 requirements can be met using conventional o i l f i e l d rotary hose.
The Case 3 high-pressure requirement (Subcase 3a) i s far beyond the rated
.
c a p a b i l i t y of any available high-pressure hose Coflexip 2-inch inside
diameter f l e x i b l e pipe could s a t i s f y Subcase 3a i f a minimum 1.5 safety factor
i s acceptable. However, i t may be better t o reduce the nozzle pressure and/or
flow requirement and thus the required surface pressure (see Figure 6 ) . For
example, a 2-inch inside diameter f l e x i b l e pipe could transport d r i l l i n g f l u i d b
26
 C

Table 4. Hose Manufacturers Nomenclature and Specifications

Manufacturer Twe Specification

Townley Eng. & Mfg. Series6OOO Highly abrasiveslurry for mining applications
Slurry hoses

DayCo Field hoses 8t hydraulic Up to 10,000 psi, up to 3%in., from -40to 250OF. Rotary hose, vibrator hose, for mud pump,
hoses etc.

The Galer Rubber Co. Hoses & flex fittings Rotary & vibratory hoses. High-pressureoil lines, steam, mud and other material. Up to
I 10.000 psi.
Harrisburg,A Kendaris Rotary& vibratory hoses,
IndustriesCompany couplings 7500 - 10,OOO psi.

Coflexip Flow lines

Up to 15,000 psi test pressure, oil, gas, hydraulic remote, 2-in. ID.
Strataflex Hoses and field
attachablefittings No mud - low, medium, high and extra-high.
Up to 4000 psi, 12OOC. burst = 10,OOO psi.
Gay Hose Hydraulic hose
Up to 5OOO psi, burst = 20,000 psi, OD = 35 in., 93OC.
Parkec Paraflex high press. hose
with kevlar 250 to -7OoF,27,000 psi.

N
v
 25

20

15
SURFACE
PRESSURE
REQUIRED
(PSURF), psi
10

6
- /I1 DOWNHOLE CHIP SCAVENGING PRESSURE, psig

LFRlCTlON PRESSURE DROP, psid

NOZZLE PRESSURE DROP, psid

0
10 20 30 40 50
FLOW RATE, gpm

Figure 6. Dual Drill String High-pressure Conduit Line Losses

28
6, t o t h e t o o l a t an 18,400-psi surface pressure while retaining a safety factor
of 2.0. A t a 10,0001foot depth, t h i s surface pressure would t r a n s l a t e t o
nozzle pressures and flows of 15,000 p s i a t 24 gpm, 12,500 p s i a t 36 gpm, and
10,000 p s i a t 46 gpm as Opposed t o t h e present 15,000 p s i a t 50 gpm r e q u i r e
ment, The Case 3 low-pTessure requirement (Subcase 3b) can be satisfied using
,, hydraulic hose.

a- 2.3 D r i l l Pipe and Tool J o i n t s

Several major d r i l l pipe and tool j o i n t manufacturers were approached for
recommendation? concerning t h e use o f their products i n the conceptual designs
presented i n t h i s report as Cases 1, 2, and 3. Tables 5, 6, and 7 summarize
the recommendations obtained from these manufacturers. It can be seen that
Wheeling-Pittsburgh was most responsive i n t h i s regard. For t h e most part,
the other suppliers simply recommended their standard d r i l l pipe and tool
j o i n t s wihout special considerations. Table 8 comprises a list of manu-
f a c t u r e r s and their products.
It should be noted that metal f a i l u r e due t o hydrogen embrittlernent or
s u l f i d e stress corrosion cracking can occur when d r i l l pipe with a y i e l d
strength higher t h e Grade E encounters sour gas (3s) (Refs. 5 and 6).
Since Case 1 requires high yield strength pipe due t o its high i n t e r n a l
pumping pressures, the pH balance of the d r i l l i n g f l u i d used for t h i s case
must be carefully controlled.

.
2.3 1 High-Temperature Performance Requirements
None of t h e manufacturers queried could provide any data concerning t h e
performance characteristics of their d r i l l pipe and t o o l j o i n t s a t t h e
& specified SOO°F soak and 300OF operating temperatures. Also, the API
s p e c i f i c a t i o n s for standard and high-strength d r i l l pipe (API Specifications
5A and 5AX) specify minimum t e n s i l e and i i e l d strengths a t room temperature
.
4

only Therefore, the high-temperature performance characteristics of d r i l l

pipe and t o o l j o i n t s must be inferred from e x i s t i n g data on the steels
t y p i c a l l y used t o fabricate them. Figures 7 and 8 show t y p i c a l tensile and
yield strengths For medium carbon and chromium/molybdenum steels a t elevated
temperatures (Ref. 7). As shown, these materials may be expected t o
hi experience yield strength reductions of 5%t o 20% a t 500OF and 2% t o 10%a t

29
 Table 5. Case 1: Surface Rmps, Single-Conduit Drill String

CONDITIONS:
10,000 ft WELL DEPTH (MAX)
30,000 ft-lb TORQUE (MAX)
50,000 lb BIT LOAD
* 60,000 lb DEAD LOAD (DRILLING MUD)
* 15,000 psi INTERNAL WORKING PRESSURE (ACTUAL PRESSURES VARY
WITH PARTICULAR SUBCASES)
6 in. OUTSIDE DIAMETER (MAX)
* 2-1/2 in. INSIDE DIAMETER (MIN)
500°F DOWNHOLE TEMPERATURE (SOAK)
300°F DOWNHOLE TEMPERATURE (OPERATE)
200°F SURFACE OPERATING TEMPERATURE
DRILL PIPE RECOMMENDATIONS:
PIPE NOMINAL MIN
LENGTH 8 OD , WEIGHT, API YIELD,
MANUFACTURER FT IN. LB/FT GRADE PSI

WHEELING - 1329 4-1/2 16.60 S 135,000

**
PITTSBURGH 8121
550
4-1/2
DRILL COLLARS
24.60
91.00 -
E 75,000
-
10,000
JONES & - 4-1/2 20.00 G 105,000
LAUGHLIN
U.S. STEEL - 4-1/2 16.60 S 135,000
5 19 50 S 135,000

TOOL JOINT RECOMMENDATION:

NOMINAL
SIZE, JOINT MAX OD, MIN ID,
MANUFACTURER IN TYPE IN IN
4-1/2 FULL HOLE 6 2 4 2 ,
HUGHES
TOOL

* IDENTIFIES CONDITIONS UNIQUE TO THIS CASE.

** THIS WEIGHT DRILL PIPE IS NOT CURRENTLY AVAILABLE. SUGGEST
SUBSTITUTING 20.00 lb/ft GRADE X.

30
W Table 6. Case 2: Downhole Intensifier, Single-Conduit Drill String

CONDITIONS:
10,000 ft WELL DEPTH (MAX)
30,000 ft-lb TORQUE (MAX)
50,000 lb BIT LOAD
* 9,000 lb DEAD LOAD (INTENSIFIER)
* 59,000 lb DEAD LOAD (DRILLING MUD)
3-5000 psig INTERNAL WORKING PRESSURE
6 in. OUTSIDE DIAMETER (MAX)
* 2-314 in. INSIDE DIAMETER (MIN)
500'F DOWNHOLE TEMPERATURE (SOAK)
300'F DOWNHOLE TEMPERATURE (OPERATE)
200'F SURFACE OPERATING TEMPERATURE
DRILL PIPE RECOMMENDATIONS:
PIPE NOMINAL MIN
LENGTH OD, WEIGHT, API YIELD,
MANUFACTURER FT - IN LB/FT GRADE PSI
WHEELING - 1317 4-112 24.60 ** E 75,000
PITTSBURGH 3429 4-112 20.00 E 75,000
4704 4-112 16.60 E 75,000
550 DRILL COLLARS 91.00 E 75,000
10 ,000
JONES & - 4-112 16.60 E 75,000
LAUGHLIN
U.S. STEEL - 4-112 16.60 E 75,000
5 19 50 E 75,000

NATIONAL - , - 4-1/2 16.60 E 75,000

ARMCO
TOOL JOINT RECOMMENDATION:
NOMINAL
SIZE, JOINT MAX OD, MIN ID.,
MANUFACTURER IN TYPE IN IN.
HUGHES 4-112 FULL HOLE 6 2-314
TOOL

* IDENTIFIES CONDITIONS UNIQUE 90 THIS CASE.

** THIS WEIGHT DRILL PIPE IS NOT CURRENTLY AVAILABLE. SUGGEST
SUBSTITUTING 20.0'0 lb/ft GRADE X.

31
 Table 7 . Case 3: Surface Pumps, Dual-Conduit Dtill String

CONDITIONS t
10,000 ft WELL DEPTH (MAX)
30,000 ft-lb TORQUE (MAX)
50#000 lb BIT LOAD
* 8O,OOO lb DEAD LOAD (INNER STRING)
* 48,000 lb DEAD LOAD (DRILLING MUD)
3-5000 psig INTERNAL WORKING PRESSURE
6 in, OUTSIDE DIAMETER (MAX) PaFERRED
3-1/4 in. INSIDE DIAMETER (MIN)
500'F DOWNHOLE TEMPERATURE (SOAK)
300.F DOWNHOLE TEMPERATURE (OPERATE)
200'F SURFACE OPERATING TEMPERATURE
DRILL PIPE RECOMMENDATIONS:
PIPE NOMINAL
LENGTH # OD 8 WEIGHT,
MANUFACTURER FT -IN. LB/FT
WHEELING
PITTSBURGH
- 2533
2389
4-1/2
4-1/2
16.60
24.60 **
3429 4-1/2 20.00
1099 4-1/2 16.60
550 DRILL COLLARS 91.00
1o,-ooo
JONES & - 4-1/2 16.60
LAUGHLIN
( CONTINENTAL-EMSCO )

U o S . STEEL - 4-1/2 16660 E 75,000

5 19 50 E 75,000
NATIONAL - - 4-1/2 16.60
ARElCO

TOOL JOINT RECOMMENDATION:

NOMINAL
SIZE, JOINT MAX OD, MAX ID,
MANUFACTURER IN TYPE IN. IN
HUGHE6 4-1/2 FULL HOLE 6 3
TOOL
* IDENTIFIES CONDITIONS UNIQUE TO THIS CASE.
** THIS WEIGHT DRILL PIPE IS NOT CURRENTLY AVAILABLE. SUGGEST
SUBSTITUTING 20.00 lb/ft GRADE X,

32
 C
c h’
c
Table 8. D r i l l Pipe Manufacturers, Nomenclature, and Specifications

Manufacturer Component Specifications

REMCO Collars, round, spiral, 4145- H steel heat treated, Brinellhardness 285-341, lengths inAPI range II 31.
square
Pipe drill (Hevi-wate) OD up to 5 in., ID up to 3 im - Tensile yield 691,185 Ibs., torsional yield 56,495 Ib. -ft on
& matchingtool joints 3-in. ID x 5-in.OD - weigM49.3Iblft.

ReedTool Tool joints Standard OD up to?% in. with 3-in. ID, Yield strengths = 1,925,520 Ib. tension, 86,800 tb-ft
torsion.
Drill pipe Up to5-11116-in.ODwith4.77-in. ID., Yieldvalues = 78,681 Ib.tension.91.280Ib-fttorsion.
Collars (Hi-Flex), double -
Up to 11-114-in. OD with2-314 to4-112-in. lD highgradechromium-molybdenumaltoysteel -
strength -
Spiral grooves weight up to 318 Iblft.

SMF International Collars, spiral, slick -

(also nonmagnetic)
Kelly fsquare, hex)
Thick-wall drill pipa&
joints
UnitedCasing Steel Drill Pipe
and Pipe Tube Connections
(fivegroups)
VAM joints (connections)
Drill pipe
Yield strength = 100,OOO psi tension, BHN = 285-340 up to 14-in. OD - possible hardfacing -
-
Approx. weight 31 ft. long = 15,4450 Ib IntegralCollars
Up to 6 x 6 in. and 54 in. long - AISt 4145 H alloy steel. Bore up to 3.5 in.
Pipe: AIS11340 modified grade - granular tungstencarbide hardfacing - also nonabrasive
-
chromiurncarbidehardfacing tool joints up to 6-114-in. OD with 550,000 Ib. tensile yield,
40,500 ft-lb torsion.
I
- -
Up to 5-in. OD up to 22.5 b-ft yield strength 712,100 Ib tensile, 57,000 Ib-ft torsion.
-
Ex: Metal-to-metal seal, tool joint types, flush or near-flushtypes (integral no separate
coupling).
Up to 4% -in. OD, max 501,000 ob tensile load on P- 105 model - couplingtorque = 5400 Ib-ft.
- -
6-518-in. maxOD = max internalpress. = 9150 psi ID = 5.9 in. other pipestake up to
23,000 psi internalpressure.

Varel Manufacturing Kelley (square, hexl Chromium-Molybdenumsteel - up to6-in. OD - spec. SAE4140,4142,4145.

Collars Up to 11-in. OD Chromium-Molybdenum - spec. API No. 7 - Min. ID = 1 in.
Joints - -
Weld-on tool joints API screw-on tool joints - hardfaced shrink-on tool joints.

Joy Manufacturing Kelley (square, hex) Upto6-in.N.S.,IDupto3% in.,BHN = 285-341 - yieldstrength: upto1,707,000Ibtensile
Rotary drill pipe substitute on largest size with 171,774 Ib-ft torsion.

Lone Star Tool Kelley (square, hex) BHN = 285-341

Drill Collars Up to6-114-in. OD - AlS14145.
A- 1 Bit & Tool Drill Collars Mills
Drill Pipes Mills
w
0
w'
&

Table 8. Drill Pipe Manufacturers, Nomenclature, and Specifications

(Continued 1

Manufacturer Component Specifications

ARAl Iron Works Drill Pipe Styles EU, 1EU - up to 5% in. nominal size - yield strength 120,000 psi - BHN = 293-341
(wide range), 6-24 Iblft.
Tool Joints AIS1 4137H, Cr- Ni-Mo alloy available - hardfaced, 120,000 psi yield.

Breda Fucine Drill Pipe Licensee of HughesTool Co.

(Italy) Collars, Kelley

Curtis Hoover Drill Pipes

Industries Tool Joints

Drilco, Division of Collars Up to 11-in. OD, 801-8970 lb131 ft, bore = 1% - 3 in. BHN 285-341.
Smith International Kelleys (square, hex) Upto6-in. N.S.
Drill Pipe Heavy wall up to 5-in. N.S., tensile yield = 691,185 Ib on 5-in. OD x 3-in. ID,
Torque = 56,495 Ib-ft, make up torque = 79,400 Ib-ft.

Equipetrol Tool Joints Internalflush, full hole, up to 5-in. nominalsize, shrink fit hardfacing - wide variety.
Heavy-walldrill pipes Range II, Range 111.5-in. N.S., 1 -in. thick walls, 1,266,000 Ibyield, 51,376 Ib-ft torque.
Collars Up to 11-in. OD, 801 -8970 lbl31 ft length.
Kelley (square, hex) Upto6-in. N.S.
(Widerange)

Gotco Industries Tool Joints For up to 5% in. pipe, API hole, extra hole.
Pipe Drill Up to 5% in.

HughesTool Drill Pipe Up to 5% in. OD with 0.4-in. wall thickness, Grade 5 is strongest with o = 135,000 psi,
Y
T = 77,890psi.
Tool Joints &de range with maximum makeup torque = 39,600 Ib-ft.
.-
u)
TENSILE

u" YIELD

m 5 0

I I I I I I I I I I
0 500 lo00
TEMPERATURE, O F

Figure 7. Effect of Temperature on API Grade E'Steel

Drill Pipe Strength

150

-
n I 1 I I I I I I I I
0 500 lo00
TEMPERATURE, O F

Figure 8. Effect of Temperature on API Grade S Steel

Drill Pipe Strength

35
300°F. These reductions i n y i e l d strength are acceptable within the stated
design constraints.

2.3.2 Torque Loading Requirements

The 30,000 ft-lb m a x i m torque requirement specified by t h e contract
design constraints can be satisfied by commercially available d r i l l pipe and
tool joints. The Hughes It90 tool j o i n t provide a torsional y i e l d l i m i t of
39,000 ft-lb; 20.0 l b / f t Grade E pipe and 16.60 l b / f t Grade X pipe provide
d r i l l pipe torsional yield points o f 36,900 ft-lb and 39,000 ft-lb,
respectively. It should be noted, however , that these figures represent
room-temperature values only.

2.4 Swivels
A swivel j o i n t is required t o t r a n s f e r f l u i d ( s ) from the stationary hoses
t o t h e r o t a t i n g d r i l l s t r i n g . The swivel must provide a seal capable of
withstanding the required i n t e r n a l pressures while operating a t a useful speed
of rotation. It may a l s o be required t o support the e n t i r e weight of t h e
d r i l l string. There are a t least four types of swivels with one or more
features t h a t would be useful i n high-pressure geothermal d r i l l i n g
applictions. These are as follows:
A. Piping swivels.
B. O i l f i e l d swivels.
C. Steam swivels.
D . Hydraulic swivels .
Refer t o Table 9 f o r a l i s t i n g of swivel manufacturers and their products.

2.4.1 Piping Swivels

These swivels are used t o connect sections of piping where f l e x i b i l i t y is
required and are often used i n place of hoses (Figure 9 ) . Piping swivels are
rated t o 15,000 p s i non-shock cold working pressure. However, they are
available only i n 2-inch sizes and are designed for l i g h t loads and non-
continuous rotation .

36
 c
+ 3
c
Table 9 . Snivel Manufacturers+ Nomencl&ure, and Specifications

Type or
Manufacturer Trade Name Specifications

SkytoplBrewster Models4-SX. 5-SX ...9-SX - -

Bearing capacity up to 378tons max working pressure = 4500psi lip-type pressureseal -
minimumfluid-passage = 3 in.
Power Swivels -
Hyd. power = 7000 psi, 81.5 gpm - stall torque = 3518 Ib.-ft. 100 rpm

Western Engineering Swivel joints Upo -

t6OOO psi, max temp. 225OF up to &in. flow passage diam. - swiveljoints for 10,000 psi
NHa. with 1500psi also available - seals for 450OF are available.

IndustrialExport Swivels Up to 5OOO psi, dead load rating up to 715 tens, 3-in. fluid passage diam.
(Romania) CH-650, CH-400, etc.

Joy Mfg. -
BAASH R e s s power Speed = 300 rprn - Torque = 7400 Ib.-ft. possible with 130ton unit - up to5OOO psi mud pressure.
swivels Dynamic load of 77 tons at 100 rpm - spindle bore = 2% in.
MR-40185. PS-130-3

King Oil Tools Water w d l swivels Up tc500,OOO tb. bearing capacity at 20 rprn, min. fluid passage range between5 to 8% in.
Oil field swivels (LW series)-
Safe depth up to 7500 ft. with 3%-in. pipe drill, 10.000 ft. with 2-3/8-in. pipedrill.

Lanzagorta international Swivels CM-TL- 120A. Max pressure-= 4500 psi, bearing cape$*/ at 100 rpm between78 to 471 tons - minimumfluid
CM-TL-650, etc. passage up to 3 in.

ARMCO National Supply National Swivel Max working pressure = 5008 psi, load rating = 200-650tons, 3-in. diam. fluid passage,

Bert Industries Swivet Joint Up to 450OF. 6OOO psi, 314-4 in.

FMC SwivelJoints Up ta10.000 psi, alloy steel, dynamic seal good for 450OF. elastomeric packing up to 3 in.
for high pressureand 8 in. for low pressure.

Gardner Denver Swivek 75'550 ton load capacity, 40-471 tons at 100 rpm.
s w - 7 5 - sw-550

Geolograph-Pioneer Swivel Joints u p to 10.000 psi.

(WesternSwivelJoint)

Gray Tool Swivels, heavy, medium & 500 ton - 3-in. min. passage - API rating at 100 rpm = 234 tons.
light duty

w Exxon test& a high-pressure swivel seal (15,000 psi) with 50 to 80 hr life time. (This informationin Terra Tec report to DOE.)
v
SIZE
2”. . . . . . . .
-- B
6 % ~
4%
-
C
--D
6% lO%6 8% I I
--E --F --C --J
3%
-- -- -- --
K I L I M I N
1llH.l 4% I 3% 1 6x6 I 7%
,~
I P
6%
-------------
IQ R ( S 1 T
1 lO’h 6% ’
I V
1313/1~/,10’/i~ 6x6
)
I
W
Z1%6
I
I 7%
X

Figure 9. Extra-High- Pressure Swivel Joints

c h 4
W 2.4.2 O i l Field Swivels
O i l f i e l d swivels have l a r g e bearings t o support d r i l l s t r i n g weight while
.
r o t a t i n g continuously (Figure 10) However, their maximum working pressures
are typically only 3,500 t o 5,000 p s i (see Table 9 ) . The factors that limit
o i l field swivel working pressure are as follows:
li . A. Washpipe stresses.
6. Packing capabilities
c C . Gooseneck stresses .
2.4.3 Steam Swivels
Steam swivels often have multiple passages t o allow steam drums t o be
simultaneously supplied with steam and drained of condensate. These swivels
t y p i c a l l y have a maximum pressure r a t i n g of 250 p s i for steam or 300 p s i for
water .
2.4.4 Hydraulic Swivels
Many hydraulic swivels are provided w i t h multiple passages t o connect
hydraulic l i n e s t o moving , r o t a t i n g , a r t i c u l a t i n g , and extendible hydraulic
machinery. M a x i m working pressures are generally 3,000 p s i , although some
hydraulic swivels are rated t o 6,000 psi.

2.5 Downhole PumpS

I t has been determined t h a t no presently available downhole pump is
cahble of s a t i s f y i n g the Case 2 requirements for geothermal d r i l l i n g .
Therefore, the Case 2 downhole pump component requires a new design and
development effort (refer t o Subsection 3.4).

39
 i

above swivel hody for low center of gravity.

lence and abrasion from mud flow.

WASHPIPE
Hardened and ground to smooth finish for long packinq life.

EASY CHANGE PACKING

Replaceable without removing gOQSeneCk. Packing is easily
lubricated, designed tg withstand high pressures.
UPPER SEAL
Double-acting upper seal holds lubricating oil and keeps out
mud and foreign materials Grease lubricated.
UPTHRUST BEARING
Upthrust and alignment bearing is adjustable by means qf a
threaded nut to take out wear
MAIN BEARING
Large tapered roller main bearing is oversized for long ser-
vice under rugged drilling conditions within the ratqd capacity.
LOWER BEARING
Straight roller bearing is widely spaced from upthrust bear-
ing to provide vertical alignment of stem and body.

Strong, one-piece steel casting transmits loads directly from

bearings to bail Large lube oil capacity as$ures cooler
operation Streamlined housing.

Alloy steel forging heat-treated to develop strength and

toughness.

Bearing conligurqtion shown i s typical ot 125 thru Cools and lubricates rotating parts vfith a fqst-moving stream
550-ton swivels 75-ton bearings are 01 dillerenl of oil. This positive flow of oil is provided by the centrifugal
configuration action of the main bearing as the swivel rotates.

Figure 10. Oil Field Swivels

40
u 3. New Component Designs

3.1 Mud Pumps

Mud pumps used i n d r i l l i n g operations supply f l u i d s both t o flush the
d r i l l b i t and t o carry cuttings t o the surface. The principal components of a
p o s i t i v e displacement mud pump are as follows (refer t o Figure 11):
-
li

A. I n l e t Check Valve The i n l e t check valve opens t o allow low-pressure

supply f l u i d t o e n t e r the high-pressure cylinder during the piston
plunger i n l e t stroke. It closes t o prevent pressurized f l u i d from
entering t h e low-pressure supply l i n e during the o u t l e t (pressure)
stroke.
6. -
High-pressure Cylinder The high-pressure cylinder contains t h e
f l u i d admitted during t h e piston plunger i n l e t stroke u n t i l it has
been pressurized and discharged during the o u t l e t (pressure) stroke.
C. -
Piston Plunger The reciprocating piston plunger pressurizes the
f l u i d admitted t o the high-pressure cylinder. I n t h e diagram given
as Figure 14, t h e Jnlet stroke is downward and t h e o u t l e t (pressure)
stroke is upward.
0. -
Mi*-Pressure Seals The high-pressure seals prevent leakage from
t h e high-pressure cylinder by sealing the annulus between t h e piston
plunger and t h e walls of the high-pressure cylinder.
E. -
Piston Drive The piston drive imparts reciprocating motion t o t h e
piston plunger. The piston drive function may be accomplished either
mechanically by meqns of the crankshaft of a t r i p l e x pump or
hydraulically by means of t h e hydraulic cylinder o f an i n t e n s i f i e r
Pump
F. -
Outlet Check Valve The o u t l e t check valve opens t o permit t h e
discharge o f pressurized f l u i d during t h e piston plunger o u t l e t
(pressure) stroke and closes t o prevent a reverse flow of pressurized
f l u i d dpring the inlet stroke.
-
G. Power Suppl y The power supply is the engine or motor t h a t powers
t h e e n t i r e pumping process v i a t h e piston drive.

41
 A F

’
r

OUTLET OUTLET FLOW

CHECK *
VALVE
’ (HIGH-PRESSURE)

z.

I - PISTON
PLUNGER

HIGH-.PRESSURE
CYLINDER

HIGH-PRESSURE
SEALW

.
PISTON POWER
DRIVE SUPPLY

+
E G

Figure 11. Positive Displacement Pump Diagram

42
W 3.1.1 Pump Reliability
Mud pump reliability decreases as its nwber of operating cycles increases.
This is due t o the wear and material fatigue experienced by the individual
components during prolonged service.
I n any pump, the piston plunger and its seals are the components most
subject t o wear-induced failure. This is especially true of mud pumps where
the working f l u i d is either d r i l l i n g mud or unfiltered water. A s the piston
plunger reciprocates through the seal, particles entrained i n such f l u i d s are
forced between these components and abrade them u n t i l failure occurs.
Check valves and high-pressure cylinders are the most fatigue suseptible
pump components. Check valves experience high seating forces due t o the large
area on which f l u i d pressure acts t o close the valve versus the relatively
small seating area that resists the closing force (Figure 12). Therefore,
high-pressure cyclic stress on the valve seat can exceed material strength and
result i n eventual fatigue failure. Also, working f l u i d particles trapped
between the valve and its seat during closing cause high local stresses that
contribute t o material fatigue.
The cause of high-pressure cylinder fatigue failure is inherent i n its
function. That is, the cyclic containment of pressurized f l u i d within the
cylinder eventually fatigues the cylinder material t o failure. This w i l l
occur more rapidly i n mud pumps unless special attention is given t o high-
pressure cylinder design geometries, materials selection, and finished wall
smoothness.

3.1.2 New Design

To solve the punping reliability problem, a method of flushing the
plunger seals (Figure 13) and check valve seats (Figures 14, 15, and 16) was
devised t o prevent wear caused by mud particles. Flow Industries comsnercial
pumps currently l a s t many hundreds of hours pumping clean water a t 55,000 p s i .
Therefore, it seems realistic t o expect 200 hours of operation a t 15,000 to
20,000 p s i i f a clean f l u s h i n g f l u i d is used. The flushing system, shown
schematically on Figure 17, is comprised of two pumps, a reservoir, and a
series o f orifices to limit flow. The high-pressure pump flushes t h e plunger
seals and check valve seats during the high-pressure (outlet) phase of the mud
W pump cycle. The low-pressure pump supplies flushing water t o the piston

43
 \

FLUID PRESSURE

- VALVE SEAT

VALVEBODY

CHECK VALVE
(Shown in Closed Position)

Figure 12. Check Valve Seating Stress Diagram

44
W WORKING
FLUID

-
*
HIGH PRESSURE
Jc
PISTON

HIGH PRESSURE
CYLINDER

r CLEARANCE
SEAL

FLUSHINGISLL

- -
FLUID
LOW PRESSURE
INLETSTROKE FLUSHlNGlSEAL
FLUID
HIGH PRESSURE
POWER STROKE

*
WEEP
HOLE
/ \

-HIGH- *PRESSURESEAL
*
NOTE:
Cylinder Cap Check Valves
Not Shown

Figure 13. Plunger Seal Flushing Method

cd

45
P
a,

HIGH
PRESSURE
FLUID

4NG

FL.I

CLOSED

Figure 14. Linear Spool Check Valve Flushing Method

 TO PUMP

Side View

Figure 15. Rotating Spool Check Valve Flushing Method

47
 HIGH PRESSURE
SIDE

SEAT

CLEARA

CLEARANCESEAL 1
t
FLUSH FLUID

Figure 16. Poppet Check Valve Flushing Method

48
 5
d
1
E
2
v
h
e
v)
1 v
h
 .

plungers and check valve seats during the low-pressure ( i n l e t ) phase o f the i
mud pump cycle. Check valves are used t o prevent high-pressure water from
entering the low-pressure side.

3.1.2.1 Piston Seal

The flushing f l u i d piston seal (Figure 13) consists o f a high-pressure
?
seal t o prevent seal f l u i d from leaking out o f the pump case, two flushing
f l u i d holes (high and low pressure), a clearance sleeve that directs flushing
r
f l u i d t o the wiper seals, and the wipers seals t h a t prevent p a r t i c l e contami-
nation when the pump i s shut down. A weep hole permits high-pressure seal
f a i l u r e t o be detected by means o f escaping f l u i d .

3.1.2.2 Check Valves

Three check valve concepts employing flushing f l u i d on c r i t i c a l surfaces
were studied.
The l i n e a r spool check valve (Figure 14) operates w i t h a reciprocating
motion and would ordinarily have a spring (not shown) t o ensure t h a t i t
remains closed when there is no f l u i d motion. Seal water i s provided i n two
locations t o maintain clean seal surfaces on both sides o f the p o r t when the
valve i s closed. Since t h i s valve must be large enough t o permit r e a l i s t i c
flow velocities, a great deal o f pumping energy i s wasted i n operating the
valves, i.e., poor volumetric efficiency. (Refer t o Figure 18 f o r instal-
l a t i o n details).
The r o t a t i n g spool check valve (Figure 15) rotates 180 degrees t o
alternate i n l e t and o u t l e t flow i n conjunction w i t h high-pressure p i s t o n
motion. Flushing water i s provided t o keep the bearing surface clean. This
valve i s not automatic and must be controlled by an external linkage system
connected t o the high-pressure piston.
The poppet check valve (Figure 16) is similar i n design t o an automotive
engine valve. Flushing f l u i d can be piped through the stem t o the seals and
seat (Figure 19, d e t a i l A) or manifolded externally (Figure 19, d e t a i l B);
Seating force i s l i m i t e d by externally adjustable stops on the valve stems.
The wear point on t h i s valve seat i s very small and can easily be flushed t o
prevent p a r t i c l e s from damaging the seats while the stops prevent seal over-
stressing due t o high-pressure loading on the seat.
W
- 'e?-...--..--
6
f
 a
t
52
W 3.1.2.3 Conclusion
Flushing the piston seal and check valves appears t o be a feasible method
f o r greatly extending pump l i f e with currently available technology .
3.2 Swivels

3.2.1 Single-Passage Swivels

Custom components are required t o modify single-passage o i l f i e l d swivels
f o r operation a t the higher pressures required f o r t h i s application.
Figures 20 and 21 i l l u s t r a t e the means by which a standard Gardner-Denver
swivel can be modified f o r high-pressure service. Other o i l f i e l d swivel
manufacturers have- comparable designs t h a t could be modified i n a similar
fashion.
The f i r s t concept, Figure 20, u t i l i z e s custom-designed and manufactured
high-pressure dynamic seals and incorporates high-pressure fresh water
flushing. The load bearing components o f the swivel remain unchanged.
The other concept, Figure 21, simply requires an extension o f the
high-pressure r o t a t i n g passage t o which a high-pressure piping swivel is
attached. No flushing water is required since the piping swivel is designed
for mud service and is easily replaceable.

.
3.2 2 Duzll&itssage Swivels
The commercially available dual-passage steam and hydraulic swivels are
not suitable f o r the Case 3 dual d r i l l s t r i n g application. Lack o f load
bearing capability and low operating pressure ratings exclude these components
from further consideration.
A concept for modifying a standard Gardner-Denver o i l f i e l d swivel f o r
dual passage service u t i l i z e s higfi-pressure dynamic seals and high-pressure
fresh water flushing. The low-pressure packing i s retained, however, f o r the
outer low-pressure scavenging flow.

3.2.3 Applications
Subcase l a requires a single-passage swivel with 1 6 , m p s i rating. Since

u no commercial load-bearing swivels capable o f such pressure are available, a

modified o i l f i e l d swivel (Figure 20) would be required.

53
 I ---
0
h(
c
2
f
a
i i
54
(r' b

I EXISTING STEM
(ROTATES)

Figure 21. Single- Passage Swivel Modified for

High- Pressure Service Without Water Flushing
 Subcases l b and ICwould require s i m i l a r l y modified swivel designs f o r
either 11,SOepsi or 9,000-psi service (Figure 20). The requirements for
these &cases could also be satisfied by t h e combined o i l f i e l d swivel and
piping swivel (Figure 21).
Subcases 2a and 2b would simply require conventional o i l field swivels
capable of 5000 p s i service.
Subcases 3a and 3b w i l l require a dual passage swivel with t h e inner
passage rated f o r 20,OOO p s i service. Since commercially available dual-
passage swivels are not s u i t a b l e for d r i l l i n g service, a modified o i l f i e l d
swivel (Figure 21) would be required.

3.2.4 Conclusion
A modified o i l f i e l d swivel is needed for high-pressure geothermal
d r i l l i n g i n every case except Case 2 (Downhole Pump).
During the high-pressure o i l d r i l l i n g tests conducted by Emon, then Esso,
B special swivel packing was developed that withstood "60 t o 200 hours a t

pressures of 10,OOO t o 15,000 p s i when r o t a t i n g a t 150 rpm."

As i l l u s t r a t e d by the design concepts presented i n this section, and
proven by the Exxon tests, the high pressure swivel is beyond the current
state-of-the-art but not beyond the current capabilities of materials and
design.

3.3 Downhole Pump

The downhole pumping system supplies high-pressure f l u i d t o the c u t t i n g
nozzles v i a a high-pressure pump located i n s i d e the d r i l l s t r i n g j u s t above
t h e c u t t i n g nozzles. This system c o n s i s t s of (1) a standard mud processing
system, (2) a medimpressure pumping system (3) a standard single-passage
rotary swivel, (4) a standard medimpressure d r i l l s t r i n g and d r i l l collars,
(5) and a specially designed downhole i n t e n s i f i e r pump (Figure 22).

3.3.1 Theory of Operation

The i n t e n s i f i e r punp uses f l u i d a t a high flow rate
and low(a,)
pressure (P,) t o actuate a large diameter (0,) piston that i n turn reacts
a g a i n s t a smaller diameter to2) pistoneto produce a higher pressure (P2)
a t a lower flow rate (q), i.e., PIQl = P2Q2 (Figure 23).

56
 I

Figure 22. Downhole Intensifier Pump System Diagram

Figure 23. Downhole Intensifier Pump Theory of Operation

57
 However, since a s i n g l e stroke cannot produce a continuous output of
high-pressure c u t t i n g f l u i d , control an8 chedz valves are required t o produce
a reciprocating motion o f the low- and high-pressure pistons (figure 24).
As the piston completes a stroke, the control valve reverses the f l u i d
path t o t h e low-pressure pistons. This reverses the direction of piston
motion and high-pressure f l u i d is produced from the opposite side of the
double-acting i n t e n s i f i e r pump.
For a given surrace pumping system, the area ratio between t h e low-
pressure piston and the smaller high-pressure piston determines the
i n t e n s i f i e r pump output (Figure 25). Therefore, t o achieve a 15,ooO-psi
downhole pressure, 3,000 p s i is required a t t h e i n l e t of an i n t e n s i f i e r pump
with a 5:l area r a t i o (Subcase 2a) or 3,750 p s i for a pump with a 4:l area
ratio (Subcase 2b).
The downhole pump uses a 2-inch diameter low-pressure piston and either a
0.894-inch diameter high-pressure piston, (5:l area ratio, Subcase 2a) or a
1-inch diameter high-pressure piston (4:l area ratio, 'Subcase 2b), i.e.,
n

.
(0 894)L lL
3.3.2 Control Mechanism
The i n t e n s i f i e r pump control mechanism c o n s i s t s of the following:

A. The control i n t e n s i f i e r (Figure 26, 1) that runs syncronously w i t h the

main pump i n t e n s i f i e r s .
6. The s h i f t i n g rod (Figure 26, 2) connects the control i n t e n s i f i e r t o the
p i l o t valve.
C. The shifter (Figure 26, 3) s h i f t s the p i l o t valve a t t h e end of the stroke.
D. The p i l o t valve (Figure 26, 4) controls which s i d e of the main valve is
pressurized through ports A1 and Bl, i.e., i n position 1, A is
pressurized and B is drained; i n position 2, t h e opposite occurs .

50
 I

DRAIN SUPPLY
U FLUID

SUPPLY CONTROL SUPPLY

FLUID VALVE FLUID

T
r i
1

INLET

VALVE VALVE

I \ PISTON

CHECK VALVE

LOW-PRESSURE -
LOW PRESSURE
PISTON CHAMBER

Ib
___,
t

HIGH-PRESSUREP2
OUTPUT LWROW

w Figure24. lntensifier Pump Flow Diagram

59
 /NET PRESSURE \
[313 36nnQPm
nci 1

300

200
FLOW RATE, gpm
4:l RATIO
100 L --- am-"' 1
5000 psi 6:l RATIO
2 1 RATIO
. si
0
0 5 10 15 20

PRESSURE, Kpsi

Figure 25. Downhole Intensifier Pump

Output at Various Piston Ratios

60
 SHIFTING ROD

‘I”

INTENSIFIERS
(16)

Figure 26. Downhole Intensifier Pump Control Mechanism

61
 E. The main valve (Figure 26, 5 ) , alternates pressure and drain i n its ports u
A p and B2 as dictated by the p i l o t valve through ports A1 and Bl,
i .e., a hydraulic shifter instead of mechanical as the pilot valve

3.3.3 Pump Requirements

The 200 gpm required from the surface pump is the theoretical value needed
to achieve the output flows indicated i n Subsection 1.2. In actual operation,
the output flows w i l l probably be s l i g h t l y less than those indicated due to
volumetric inefficiencies caused by &e& valve losses and compression of the
working f l u i d.
3.3.4 Pump Construction
The complete pump assembly (Figure 27) is approximately 100 feet i n length
and consists of the following:

A. -
Top Adapter Sub Joins standard d r i l l pipe t o the pump assembly and
directs the f l u i d flow t o the correct location on the shifter section.
-
8. Shifter Section Part of the control valve system that directs fluid to
one side or the other of the low-pressure intensifier pistons. The c h i p
scavenging mud is discharged from this section.
C. -
Pilot Section Houses the pilot control valve, shifter rod, shifters, and
high pressure inlet check valves.
-
0 . Pump Section Series of sections (16) that house the intensifier pumps.
Each pump may be removed from the system as necessary for d r i l l string
aSsernbly, repair, or t o change system performance characteristics. The
first intensifier is used to operate the control valve system.
-
E. Check Valve Section Houses the output check valves that supply high-
pressure d r i l l i n g f l u i d to the nozzles, The check.valves p r m t reverse
flow from the nozzles back into the intensifiers when they are on the
intake stroke.
-
F. Bottom Adapter Sub Manifolds the dowrhole pump output into one conduit
and adapts back to 4-UZ-inch API tool-joint threads.

62
€ 5
3
rJ \
63
64
h,
65
 I
\ I
r ! !
3
E A
66
 A three-component fastening device is used t o connect the pump sections.
F i r s t , a seal plate is sandwiched between joining sections. The seal p l a t e
seals various conduits and provides pins t o transmit d r i l l s t r i n g torque. The
j o i n t s are sealed by means of O-rings on both sides of the seal plates. To
make the j o i n t secure, a coupling held i n place by a ferrule on t h e upper
c
section is threaded onto the lower section t o p u l l it up t i g h t against the
seal plate. The coupling is designed so that d r i l l s t r i n g rotation w i l l
tighten the j o i n t .
3.3.5 Materials of Construction
Due t o t h e extremely severe downhole environment, special materials w i l l
be used on a l l moving and highly stressed components. The main components as
shown on Figure 27 and their i n i t i a l composition are as follows:

A -
Low-pressure piston 300 series heat-resistant s t a i n l e s s steel .
8 . High-pressure piston -
heat- and wear-resistant titanium carbide or
tungsten carbide.
-
C. High-pressure cylindrical l i n e r 300 series s t a i n l e s s steel.
.
0 Main body - Medium-strength , heat-resistant , low-alloy steel .
-
E. Coupling same as main body.
. -
F Connectors 15-SPH or other high-strength s t a i n l e s s steel alloy.
-
G. Control valveshheck valves tunsten catbide or Carborundum s i n t e r e d
alpha s i l i c o n carbide .
3.3.6 Difficulties i n Design
The downhole pump is very similar t o a standard flow i n t e n s i f i e r system
0
(Figure 24). However, the circumstances under which t h e dbwnhole pump system
must function present unique design problems. The problems of lubrication and
t
contamination would seem t o be of greatest concern r e l a t i v e t o downhole pump
reliability. For example, cbntamination of t h e control valves could cause
f a i l u r e o f the pump i f it is severe enough t o prevent the valves from
s h i f t i n g . These problems w i l l have t o be solved during pump development. The
solutions w i l l be based first on more standard hydraulic f l u i d s and then on
.
f l u i d s l i k e l y t o be encountered i n f i e l d operations
w
67
3.4 Dual D r i l l String
A dual d r i l l s t r i n g has several advantages r e l a t i v e t o the s i n g l e d r i l l
s t r i n g . F i r s t , the dual drill s t r i n g requires only the d r i l l i n g f l u i d t o be
highly pressurized, unlike t h e s i n g l e drill s t r i n g which requires both
high-pressure d r i l l i n g and Scavenging fluid. Second, the dual d r i l l s t r i n g
would provide increased operational safety due t o t h e containment of th e
high-pressure tube within an e s s e n t i a l l y standard d r i l l pipe. Third, t h e d u a l
d r i l l s t r i n g would eliminate some of the complications associated w i t h t h e use
of a downhole i n t e n s i f i e r .

3.4.1 Theory of Operation

Figure 28 is a conceptual design drawing for a dual s t r i n g system. This
design incorporates proven high-pressure sealing techniques , a unique coupling
concept, and solutions t o many o f t h e problems associated with dual d r i l l
s t r i n g systems, e.g., frequent h i g h p r e s s u r e tube misalignment, pinched
O-rings, and lack of positive sealing.
The dual d r i l l s t r i n g system concept shown consists of an outer pipe and
an inner high-pressure tube. The only difference between the outer pipe and a
standard d r i l l pipe is that the female end of the tool j o i n t has been modified
t o accept a support/spacer lug that is part of the inner high-pressure tube,
which is t h e "new component" portion of the design. One end of the high-
pressure tube has a male thread located above the support/spacer lug while the
other end is provided with a s l i d i n g connector. The s l i d i n g connector enables
positive connection of t h e inner high-pressure tubes of two sections before
t h e outer pipe of t h e lower section is made up t o t h e d r i l l s t r i n g . The
sliding connector is provided w i t h a multiple-seal arrangement consisting of
graphite-impregnated teflon' seals. The actual connection between two high-
pressure tubes is made by means of coned seats. Such a sealing method is
currently used a t pressures up t o 60,000 psi.

3.4.2 Desiqn problems

As discussed above, the dual d r i l l s t r i n g concept appears t o offer many
.
advantages for geothermal d r i l l i n g applications Specifically, it seems t o
offer t h e best method of providing small q u a n t i t i e s o f high-pressure f l u i d for
c u t t i n g and l a r g e q u a n t i t i e s of low-pressure f l u i d for chip scavenging . b

68
 I I-
4
i
2
-Q
ti
t;l
3
-J
0
t
r)
69
 .-P
L
-
?.-
!
ti
5
.-a
c
0
0
m
s
N
i
4-
7
f
70
 However, the design o f a dual d r i l l s t r i n g system presents a number o f
u d i f f i c u l t problems that must be solved i n order t o make such a system
practicable.
The 10,000-psi pressure drop experienced by the 50 gpm o f high-pressure
f l u i d as i t travels 10,000 feet downhole requires the surface pumping pressure
t o be 15,000 p s i + 10,000 p s i = 25,000 psi. However, presently available hose
A capable o f the 50-gpm flow r a t e i s pressure rated a t only 18,000 p s i maximum,
or 7,000 p s i less than the pressure required a t the cutting nozzles.
I Therefore, hoses capable o f delivering f l u i d t o the cutting nozzles a t both
the required pressure and flow r a t e must be developed.
Tool j o i n t s f o r the dual d r i l l s t r i n g are another area requiring develop-
ment. A t present, the time required t o make up the extra d r i l l pipe
connection could t r i p l e the overall j o i n t makeup time.

3.5 Economic Comparison

Table 10 compares the costs o f the cases i d e n t i f i e d and described i n the
preceding sections t o determine their economic f e a s i b i l i t y for the high-
pressure geothermal d r i l l i n g application. A llfirst-costll comparison i s deemed
s u f f i c i e n t a t t h i s time since i t i s impractical t o attempt l i f e - c y c l e cost
predictions f o r equipment not yet developed, tested, or operated under
production conditions. A l l comparisons are made assuming continuous (around-
the-clock) operation. Equipment modifications and/oF standby u n i t s are
required t o accomplish t h i s i n some instances. Certain concessions were made
f o r the sake o f practicality. These are as follows:

A. Case 2 (downhole pump) t o t a l flow r a t e i s l i m i t e d t o 200 gpm t o avoid

excessive annular flow rates . This means lower high-pressure flow rates
t downhole .
- B. Case 3 (dual d r i l l s t r i n g ) surface pressures are l i m i t e d t o 20,000 p s i by
z - reducing c u t t i n g j e t f l o w rates a t maximum depths.

Actual vendor quotes are used wherever possible and a l l costs are l i s t
prices as o f Spring 1981. E M discounts and i n f l a t i o n factors are thereby
eliminated .

71
 Table 10. Comparative Equipment Costs (in Dollars)

pumps Hoses (2) Swivel D r i l l String T o t a l Equipment

Surface Downhole 75 t o 80 f t Inner Outer W/Purchased W/Rented
Case Purchased Rented+ ' Lengths M P S -PS
~~ ~

l a 1,750,000 950,000 - 82,000 54,000 - 420,000 2,306 ,OOO 1,506,000

l b 1,630,000 680, OOO - 82,000 54,000 - 420,000 2,186,000 1,236,000

I C 1,500,000 600,000 - 82,000 54,000 - 343,000 1,979,000 1,079,000

I d 1,290,000 600,000 - 82,000 54,000 - 311,000 1,737,000 1,047,000

2 a++ 805 ,M#) 470,000 500,000 12,000 24,000 - 334,000 1,675,000 1,340,000

2 bt 1,290,000 600,000 500, OOO 12,000 24,000 - 334,000 2,160,000 1,470,OOO

3 aft
LP 260,000 160,000
- 9,000
64,000 220,000 473,000 1,598,000 1,528,000
HP 490,000 520,000 82,000

160,OOO
3 btt
LP 260,000
- 9,000
64,000 220,000 473,000 1,813,000 1,528,000
Hp 705 ,Ooo 520,000 82,000

Base 291,000 315,000 - 9,000 24,000 - 311,OOO 635,000 659,000

++Rentals are f o r 30 days excluding mobilization and crew expenses ( t o be comparable with purchased costs). Standby
u n i t s are included on rented pumps f o r redundancy t o get continuous service.
++40 GPM @ 15,000 psi. Extra pump f o r redundancy.
4-50 GPM @ 15,000 psi.
t t 3 3 GPM @I 15,000 psi.
he For system costing purposes, a l l equipment is assumed t o be a t an equal
s t a g e of development. Therefore, a l l design, development, and t e s t i n g costs
are excluded from newly designed equipment such as the following:

A. High-pressure f l u i d end for t r i p l e x pumps.

B. Downhole pump.
C. Swivel modifications .
D. Dual d r i l l string.
.
E High-pressure flushing systems .
The Case 1 subcases are included t o show the effect of increasing pressure on
equipment costs. The base case is presented for comparison w i t h a standard,
low-pressure , d r i l l i n g s i t u a t i o n .
3.5.1 Pumps
Surface pumping requirements for each case can be satisfied by either
rented or purchased equipment. Purchased pumping systems are skid-mounted
systems comprising engines, belts, chain or gear drives, and a l l associated
equipment such as i n l e t and o u t l e t manifolds, charge pump, lube systems,
pulsation dampeners, and controls. Punps operating a t pressures above the
manufacturer's r a t i n g would be modified as described earlier w i t h
high-pressure f l u i d ends, high-pressure seals, and fresh-water flushing
systems. Cost o f the flushing system is included where used.
Rented pumping systems also include a l l associated equipment excluding
personnel and mobilization c o s t s (normally quoted w i t h rented pumps). Rental
costs are for 30 days of continuous operation. Where the equipment is not
s u i t a b l e for continuous operation, standby u n i t s are included t o insure
c
minimal down time. In t h i s way, reliability is held constant for comparison
A

c
purposes .
The downhole pump, of course, is a new design. A l l design, development,
and t e s t i n g costs for this system are excluded.
I

3.5.2 Hoses
The r e l a t i v e costs of approximately 150 t o 160 feet of hose are
presented. A s can be seen, purchase c o s t s vary by nearly an order of
I.'

73
magnitude ($9,000 t o $82,000) as the pressure r a t i n g increases from 4,000 p s i k'
t o 20,000 psi. A l l hoses selected are s u i t a b l e for d r i l l i n g service.

3.5.3 Swivel
Standard or modified swivels are selected depending on t h e service
.
pressure and application Where modified swivels are required, a fresh-water
flushing system is incorporated t h a t uses the same system supplying the
modified pump with flushing water. Therefore, the cost of an additional
flushing system is not included i n t h e swivel cost. Again, design,
development, and t e s t i n g costs of swivel modifications are not included .
3.5.4 Drill S t r i n g
Drill s t r i n g recommendations varied widely from manufacturer t o manu-
facturer. Therefore, i n each case an appropriate conservative design was
.
selected f o r comparison Modifications t o standard d r i l l pipe components are
included i n t h e dual d r i l l s t r i n g (Case 3) costs along with t h e cost of the
inner s t r i n g .
3.5.5 Total Costs
The costs given here are simply a t o t a l of t h e costs for t h e equipment
studied and are not intended t o include a l l equipment required for high-
pressure geothermal d r i l l i n g . The totals are given two ways: with purchased
pumps and w i t h rented pumps. Generally, 30-day r e n t a l is less expensive than
purchasing. However, r e n t a l becomes uneconomical as project length increases
or additional projects arise. I n fact, since most continuous r e n t a l rates are
based on revenue t h a t would be generated by the lucrative fracturing and
cementing business, long-term r e n t a l of o i l f i e l d pumps rapidly becomes
prohibitively expensive.

74
4. Conclusions

The advantages and disadvantages of the systems presented herein are given
i n Table 11. The table shows that Cases 1 and 3 (single- and dual-conduit
surface pumping systems, respectively) would require the least amount of
development time and effort. However, both of these cases have very serious
disadvantages relative to system complexity, personnel safety, and r i g crew
training time. Therefore, despite t h e apparent advantages of Cases 1 and 3,
Case 2 (single-conduit downhole pumping system) actually has the greatest
potential for success i n the geothermal well d r i l l i n g application. Its
advantages i n terms of safety, proven design concept, and fewest system
modifications required make it the logical choice for development.

75
 Table 11. System Advantages and Disadvantages by Case
Advantages Disadvantages

Case 1: Single-Conduit Surface Pumping System

1. Shortest development time 1. Special pumps, hoses, swivels, and

pipe required
2. Easily implemented i
2. D i f f i c u l t t o seal due t o large
3. Lowest development cost diameter pipe j o i n t s required
t
3. Working f l u i d pH must be carefully
controlled t o prevent d r i l l pipe
failure
4. Highest operating costs

5. Most hazardous t o operating per-

sonnel; safety equipment required
Case 2: SingleConduit Downhole Pumping System

1. Safest design 1. Highest development costs

2. A l l components standard except 2. Long development time required

downhole pump
3. Working f l u i d must be carefully
3. I n t e n s i f i e r concept already filtered
proven i n o i l f i e l d service
4. Suitable f o r other well
applications
Case 3: Dual-Conduit Surface Pumping System

1. Easily developed 1. High pressure losses due t o f l u i d

friction
2. Low development costs
2. Lengthy j o i n t makeup procedure
3. D r i l l i n g can continue i f either
inner (high-pressure 1 conduit 3. Two pumping systems required
or nozzles f a i l
4. Two conduits required
5. F u l l 50-gpm flow r a t e cannot be
obtained a t greater depths

6. Hazardous t o operating personnel;

safety equipment required

76
 REFERENCES

1. W. C.Maurer, "High-Pressure Drilling,t1 Journal of Petroleum

Technology, J u l y 1973. (See Appendix A)
2. 0. B. Anderson, "Review of Low Solids Mud Control Gives N e w
Insights," World O i l , Gulf Publishing Co., April 1981.
3. Telephone Conversation w i t h Wayne Patterson, President of
Professional Drilling Fluids Co., Ventura, California, December 23,
1980 .
4. Telephone Conversation with B i l l E l l i o t , then Sales Representative
for Gardner-Denver Petroleum Equibent Division, Whittier,
California, August 19, 1980 .
5. "Sulfide Stress Cracking Resistant Metallic Material for O i l Field
Equipment, Material Requirement," National Association of Corrosion
-
Engineers Technical Practices Committee, NACE Standard MR-01-75,
Revised 1980,
6. R. N. Tuttle, "Guidelines Aid i n Designing for. l-$S Service," The-
O i l and Gas Journal, December 11, 1978.
7. Vroperties of Steels and Wrought Heat-Resisting Alloys a t Elevated
Temperatures," American Society of Metals, Metals Handbook, Vol. 1,
8 t h Edition, January 1975.
8. "Composite Catalog of O i l Field Equipment and Services," World O i l ,
Gulf Publishing Co., 34th Revision, 1980-1981.
9. 1981 U.S. Industrial Directory, Cahners Publishing Co., 1981,
10. '
Corrosion of O i l and Gas Well Equipment, Production Department ,
American Petroleum Institute, 1979.
11. -
Rrogram for the Improvement of Downhole Drilling Motor Bearings and
9-Seals Terra Tek, Sandia Laboratories, Phase 111, Part 1, Final
Report.
12. S, G. Varnado, Geothermal Drilling and Completion Technology
Development Program Quarterly Progress Report, Sandia laboratories ,
A p r i l 1980.
13. P. F, E l l i s , 11 and M. F. Conouer, Materials Selection Guidelines for
Geothermal Energy Utilization Systems, U.So DOE, Geothermal Energy,
January 1981. -

77
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Attn: J. W. Langford
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r Houston, Texas 77001
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. D. E. Pyle

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