IADC/SPE 167921

First Application of Turbodrill and Hybrid Bit to Optimize Drilling Times in

Cretaceous Formations with High Chert Content in Mexico South Region
R. Varela, Schlumberger; F. Guzman, Neyrfor; D. Cruz, Smith Bits; N. Atencio, F. Iturrizaga, R. May,
Schlumberger; R. Solano, R. Perez, Pemex

Copyright 2014, IADC/SPE Drilling Conference and Exhibition

This paper was prepared for presentation at the 2014 IADC/SPE Drilling Conference and Exhibition held in Fort Worth, Texas, USA, 4–6 March 2014.

This paper was selected for presentation by an IADC/SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not
been reviewed by the International Association of Drilling Contractors or the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily
reflect any position of the International Association of Drilling Contractors or the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any
part of this paper without the written consent of the International Association of Drilling Contractors or the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of IADC/SPE copyright.

Abstract
This paper highlights the design, execution, and evaluation of the first application of turbodrill and hybrid bit to drill
cretaceous formations with up to 40% chert content in Mexico South region. The complex cretaceous formations
in the Terra field presents many drilling challenges: mud losses, gas influxes, hard [Unconfined Compressive
Strength (UCS) 15 – 30 ksi] and abrasive formations, difficulty building inclination, low rate of penetration (ROP)
requiring many runs of 8-½” tungsten carbide insert (TCI) bits.

The goal of a new drilling system application was to reduce trips for TCI bit changes due to drilling hours
limitations, optimize flat times, reduce rotary steerable system (RSS) failures, deliver a wellbore with minimal
tortuosity to enhance wellbore evaluation and running liner operations, and eliminate the risk of fishing for lost
cones.

To meet these objectives the use of turbodrilling and hybrid bit technologies was evaluated. Hydraulic simulations
were run to determine if the mud pumps could deliver the required hydraulic power to the turbine, a drill string
design was performed to avoid fatigue failures and increase on-bottom rotating hours in a high temperature
environment, directional requirements were analyzed to estimate the dogleg severity (DLS) in carbonates with
chert nodules to be able to reach the proposed well objective.

The turbodrill and hybrid bit application drilled 1240 ft, which is the longest run in the field eliminating two trips
when compared with TCI bit runs. The turbodrill application successfully built inclination and turned the wellbore
at the planned DLS. Additionally, increased service life of the managed pressure drilling (MPD) rotary head and
top drive washpipe was observed. Casing wear was reduced due to the low drill string revolutions per minute
(rpm) on surface which was corroborated with the low amount of steel recovered in the shale shakers magnets.
Trips to surface were without drag and 7” liner was run immediately after logging, eliminating a wiper trip.

The Terra field has an aggressive development plan and lessons learned from this application will reduce drilling
times and meet regional objectives to boost production from hard carbonates reservoirs. Horizontal wells are now
being drilled, turbodrills and hybrid bits demonstrated to be viable solutions for this technical challenge in southern
Mexico region.

Introduction
Terra field is located near to the Oxiacaque, Nacajuca city, Tabasco State, Mexico, and produce out of the
“septentrional” basin (Figure 1). The reservoir zones belong to Jurassic and Cretaceous formations, pay zones
belong to Jurassic Superior Kimmerigdiano (JSK) and Middle Cretaceous (KM) formations. Reservoir pressures
are around 7500 to 8000 psi and temperatures around 302 ºF.
2 IADC/SPE 167921

Figure 1: Terra field location.

The 8-1/2” borehole of Terra 21 well was planned to be drilled through Cretaceous formations (Figure 2), the main
lithology is mudstone, and chert presence is found in the lower part of Superior Cretaceous “San Felipe” (KSSF),
Superior Cretaceous “Agua Nueva”, and Middle Cretaceous (KM). Analyzing the offset wells data, the UCS
ranges from 15-30 ksi (Figure 3). Because of the formation hardness, nine to fifteen trips were normally required
to drill the whole section, of which four to six TCI bit changes required to drill only formations with chert presence.

Figure 2: Terra 21 well schematic.

IADC/SPE 167921 3

UCS Terra 21
14500

15000

15500

16000

Depth (ft MD)

16500

17000

17500

18000
5000 10000 15000 20000 25000 30000 35000 40000
UCS (psi)

Figure 3: UCS 8-1/2” borehole of Terra 21.

To reduce drilling times and drilling trips, the use of a turbodrilling system was proposed and its feasibility
analyzed to estimate possible time improvements. Due to the different lithologies encountered, the hybrid bit was
estimated to be the best option to combine good performance and durability.

Theory and Definitions

Recently hybrid bits have been developed with the main purpose of maximizing ROP in heterogeneous
formations (Figure 4). This new bit design combines two drilling mechanism: shear and grinding cutting, the first
mechanism achieved through the application of polycrystalline diamond compact (PDC) cutters by shearing the
rock with a range of angular stresses. Once these cutters wear out, the diamond impregnated matrix grinds the
rock with high rotational velocities to continue drilling, resulting in a longer run and with a higher ROP compared
to conventional PDC bits and TCI roller cone bits (Figure 5).

Figure 4: 8-1/2” Hybrid bit.

Shear Grind
mechanism mechanism
Figure 5: Hybrid bit drilling mechanism.
4 IADC/SPE 167921

Turbines convert the hydraulic power from the mud to mechanical rotating power at the bit. When compared to
downhole motors and RSS, the turbine rotates the bit at higher revolutions, and thanks to its high on-bottom rpm,
low surface rpm are possible. The internal components of a turbine are all metallic; this is why it is possible to use
turbines in High Pressure High Temperature (HPHT) environments with high reliability, with a higher mean time
between failures (MBTF) than conventional downhole motors and RSS. The Turbine delivers improved borehole
quality and has exceptional toolface control.

Turbines consist of two sections: the bearing section, and the power section. The bearing section is made of PDC
pads which allows mechanical lubrication and is able to support the axial force exerted by the power section. The
titanium internal shaft transmits mechanical rotating power to the bit. The power section consists of a rotor and a
stator, composed of blades. The rotor converts the hydraulic power to mechanical power and the stator redirects
the fluid to the next stage. A power section consists of many stages depending of power requirements (Figure 6).

Figure 6: Turbine bearing and power section.

Description and Application of Equipment

To assess the feasibility of the turbodrilling system, the following parameters were considered:
1. The maximum pump pressure was limited to 4000 psi since: The drilling rig has three mud pumps with a
maximum input of 1600 hp and fluid ends of 5000 psi working pressure; the high pressure mud lines and
standpipe have a working pressure of 5000 psi.
2. An oil based mud (OBM) system was used to drill the section. Based on the offset wells the programed
mud weight was planned from 13.35 to 14.19 ppg.

Hydraulic simulations were run with these parameters to determine the type of turbine which will deliver the
highest power to the bit. The turbine selected was 6-5/8” 122 stages with blades of negative differential pressure.
2
From the simulations, the minimum flow rate was determined at 353 gpm to generate a power of 3.5 hp/in which
is considered appropriate for the application as per global field experience (Figure 7).
IADC/SPE 167921 5

Figure 7: 6 5/8” Turbine selected.

To increase on bottom rotating hours, the 6-1/2” drill collars connections NC46, part of the drilling rig equipment,
were replaced with 6-3/4” drill collar connections NC50 with better mechanical properties and a bending strength
ratio within the recommended range to reduce the probability of fatigue failures.

Based on experiences around the globe, low weight on bit (WOB) is required. The amount of drill collars in the
BHA were optimized to avoid pressure losses in the reduced inside diameter (ID), and thus increasing the
hydraulic power in the turbine. Six 6-3/4” drill collars were planned with a maximum WOB of 26.5 kips.

To drill this section, both 5” 19.5 lb/ft S135 and 5-1/2” 24.7 lb/ft S135 where available. In spite of the reduced ID
with the 5” drill pipe which increases pressure losses, this drill pipe was chosen because of reduced contact
pressure which minimizes casing wear of the 9-7/8” production casing. The planned BHA is shown in Figure 8.
Field Name Terra Borehole Name Terra 21 Hole Size (in) 8.500
Structure Name Terra 1 Site Pemex BHA Name BHA Depth In (m) 4516.00
Well Name Terra 21 #04B_8.5_turbina+LWD+MWD_ Depth Out (m) 5000.00
OD Bot Size Bot FN OD
Bot Type Cum. Cum.
Serial (in) Max OD (in) Gender (in) Length
Desc. Manu. Length Weight
Number ID (in) Top Size Top FN Length (m)
Top Type (m) (ton)
(in) (in) Gender (m)
5.750
1 Bna Hibrida 8 1/2 ", 2.250 8.500 4.500 REG Box 0.46 0.46 0.0
6-5/8" T1 Steerable Turbodrill - 6.625 4.500 REG Pin 0.000
2 Bearing 8 3/8", Motor 8 1/4" (BH 1.5º) 5.500 8.375 4.500 NC50 (4 1/2 IF) Box 0.00 11.99 12.45 1.8
6.750 4.500 NC50 (4 1/2 IF) Pin 6.750
3 Estab. 6 3/4" x 8 1/4" 2.500 8.250 4.500 NC50 (4 1/2 IF) Box 0.68 1.75 14.20 2.0
6.750 4.500 NC50 (4 1/2 IF) Pin 6.750
4 VCP 6 3/4" 2.750 6.750 4.500 NC50 (4 1/2 IF) Box 0.60 0.81 15.01 2.2
6.750 4.500 NC50 (4 1/2 IF) Pin 6.750
5 UBHO 6 3/4" 3.375 6.750 4.500 NC50 (4 1/2 IF) Box 0.90 0.85 15.86 2.3
6.750 4.500 NC50 (4 1/2 IF) Pin 0.000
6 DC C/LWD 6 3/4" 3.250 6.910 4.500 NC50 (4 1/2 IF) Box 0.00 6.74 22.60 3.1
6.750 4.500 NC50 (4 1/2 IF) Pin 0.000
7 DC C/MWD 6 3/4" 3.880 6.870 4.500 NC50 (4 1/2 IF) Box 0.00 10.08 32.68 4.8
6.500 4.500 NC50 (4 1/2 IF) Pin 0.000
8 DC Monel 6 3/4" 2.750 6.750 4.500 NC50 (4 1/2 IF) Box 0.00 9.19 41.87 6.2
6.750 4.500 NC50 (4 1/2 IF) Pin 0.000
9 DownHole Filter 6 3/4" 2.875 6.750 4.500 NC50 (4 1/2 IF) Box 0.00 2.33 44.20 6.5
6.750 4.500 NC50 (4 1/2 IF) Pin 0.000
10 6 x Drill Collars 6 3/4" (6 joints) 2.813 6.750 4.500 NC50 (4 1/2 IF) Box 0.00 56.45 100.65 15.6
6.500 4.500 NC50 (4 1/2 IF) Pin 6.625
11 Martillo 6 3/4" 2.500 6.625 4.500 NC50 (4 1/2 IF) Box 0.62 5.72 106.37 17.0
6.750 4.500 NC50 (4 1/2 IF) Pin 0.000
12 3 x Drill Collars 6 3/4" (3 joints) 2.813 6.750 4.500 NC50 (4 1/2 IF) Box 0.00 28.24 134.61 21.7
5.000 4.500 NC50 (4 1/2 IF) Pin 0.000
13 15 x 5" HWDP (15 joints) 3.000 6.500 4.500 NC50 (4 1/2 IF) Box 0.00 140.21 274.82 33.1
4.855 4.500 NC50 (4 1/2 IF) Pin 0.000
14 5" 19.50 DPS, Premium (474 joints) 4.276 6.625 4.500 NC50 (4 1/2 IF) Box 0.00 4729.72 5004.54 208.5
Figure 8: Planned BHA.
6 IADC/SPE 167921

As part of our risk management plan, a hazard analysis and risk control (HARC) was performed to identify risks
based on offset wells, and implement the proper prevention and mitigation plans. The turbine fishing diagram was
checked to ensure availability of appropriate fishing tools in case of a stuck pipe. Loss circulation materials (LCM)
particle size distribution and concentrations where thoroughly revised and checked against the turbine limitations,
with the logging while drilling (LWD) and measurement while drilling (MWD) being the limiting tools. An additional
concern was the cutting sample analysis, due to prior past perceived negative experience. This was examined,
and in spite of having fine ground cuttings the conclusion was that it is still possible to have accurate lithology
analysis. There was a risk of being unable to build angle in hard carbonate rock, as a prevention it was planned to
run at the beginning with a bent housing (BH) of 1.5° and the second run with a BH of 1°. As a mitigation measure
a RSS was available as backup.

Presentation of Data and Results

The first run with turbine (BH: 1.5°) and hybrid bit was from 14839 ft to 15755 ft drilling totally the Superior
Cretaceous Mendez (KSM) formation and entering 85 ft to Superior Cretaceous “San Felipe” (KSSF) formation
with an average ROP of 12.5 ft/h, mud weight started at 14.02 ppg and was reduced to 13.77 ppg. At 15755 ft a
pump pressure loss from 4150 psi to 3680 psi was observed, the mud pump was changed but the pressure was
not restored, rig personnel cleaned mud pumps filters, and checked mud pump valve seats but still pressure was
not reestablished, it was decided to pull out of the hole (POOH) to discard the risk of any washout on the BHA.
Hybrid bit dull grading was 0-1-CT-G-X-I-NO-PP (Figure 9).

Figure 9: Photos of hybrid bit when POOH due to pump problems.

Because of the low dull grading, the same bit was re-run and the turbine was changed to a BH of 1°. BHA was
RIH and mud weight reduced to 13.35 ppg and drilling operations were resumed. Pump pressure was around
4050 psi with 365 gpm. Drilling at 15797 ft the mudloggers started to observe sporadic fragments of gray and
white chert, this belong to the lowest part of KSSF formation, from 15846 ft the chert content went up to 30%,
then at 15928 ft it was observed up to 40% of chert. At 15951 ft the top of Superior Cretaceous “Agua Nueva”
(KSAN) formation was identified which is known for having the highest chert content (Figure 10).

Chert Content vs Depth

50%
KSSF Formation KSAN Formation
45%
40% 40%
40%

35%
Chert Content [%]

30% 30% 30% 30% 30% 30% 30%

30%

25%
20% 20%
20%

15%
10% 10%
10%

5% Traces
0%
15800 15850 15900 15950 16000 16050 16100
Depth MD [ft]

Figure 10: Chert content versus depth.

Beginning at 16027 ft mudloggers observed very fine cuttings, meaning that the diamond body structure of the
hybrid bit started to cut formation and the PDC cutters worn out. The hybrid bit drilled in total 325 ft of formation
with chert content. Drilling at 16079 ft with mud weight of 13.35 ppg and an ECD of 13.77 ppg with a back
pressure of 25 psi through the MPD equipment, flow rate was 375 gpm and pump pressure around 4050 psi.
Drilling was suspended because of an increase of pump pressure when applying WOB and a very low ROP,
which was due to the bit ringing out. Rig personnel checked the mud pumps, but in this occasion the hybrid bit
IADC/SPE 167921 7

was worn out. The BHA was POOH and hybrid bit dull grading was 3-4-RO-N/S-X-I-LT/BT-PR, the main dull
characteristic was ring out on the bit nose and shoulder (Figure 11).

Figure 11: Photos of hybrid bit at the end of the run.

The average ROP on bottom was 8.96 ft/h and the total meters drilled was 1240 ft, the longest run in the Terra
field.

Comparing the Terra 21 well with an offset well drilled in the same pad, the Terra 3 well, Terra 21 with turbine and
hybrid bit drilled a longest section of KSM and it did one run to drill KSM, KSSF, and part of KSAN; instead of 3
runs compared with RSS and two PDC bit plus one TCI bit in the Terra 3 well (Figure 12).

14800 14800

15000 15000

15200 15200
ft TVD

ft TVD

15400 15400 KSSF

KSSF
15600 15600 KSAN

15800 15800
KSAN

16000 16000
0 50 100 150 200 0 50 100 150 200
Minutes Minutes

Terra 21 Terra 3

Figure 12: Minutes per foot of drilling speed versus true vertical depth (TVD).

The Terra 21 drilled KSM, KSSF, and KSAN with an average ROP of 7.36 ft/h comparing to the Terra 3 with a
ROP of 5.71 ft/h (Figure 13). Terra 21 drilled with one bit KSM, KSSF and 131 ft of KSAN formation, a second run
was made with turbine and impregnated bit drilling 230 ft in KSAN and KM. The Terra 21 well drilled 269 ft of
chert in the formations KSSF and KSAN more than the offset well Terra 3 and with the highest chert content in the
pad.
8 IADC/SPE 167921

ROP by formation
14.00 1600
12.66
12.00 1400

1200
10.00
8.30 1000

Feet Drilled
ROP [ft/h]
8.00 7.20 7.36
6.43 800
5.71
6.00
600
4.00 3.44 3.55
400

2.00 200

0.00 0
KSM KSSF KSAN Avg ROP
Formations

Terra 21 Terra 3 Feet Drilled Terra 21 Feet Drilled Terra 3

Figure 13: ROP comparison by formation.

The second run was made with turbine and an impregnated bit (Figure 14), drilling 230 ft with an average ROP of
3.18 ft/h, it is compared to run with TCI bit of 249 ft and average ROP of 3.64 ft/h in the Terra 3 well. Even though
it did a similar footage and ROP compared to TCI bit with RSS, we eliminate the risk of lost cones in the well. It is
consider a normal run, but not a success compared to the use of a hybrid bit.

Figure 14: Impregnated bit used in the second run.

Turbodrill system built angle from 15.63° to 28.19° with a maximum DLS of 2.70 deg/100ft. The well was originally
drilled to the right of the planed azimuth of 196.11° but because of the natural tendency of the turbine to turn the
wellbore to the left, the well finished with an azimuth of 177.09° and a center to center (ct-ct) distance of only
31.86 ft (Figure 15). This natural tendency while drilling hard chert can be planned ahead to avoid correcting the
wellbore orientation with slide drilling and therefore achieve higher ROP.
IADC/SPE 167921 9

Beginning of the run

End of the run

Figure 15: Turbodrill directional performance.

Drilling to the total well depth, all trips to surface were performed with low drag. In theory, turbodrilling produces a
borehole with less tortuosity. This was confirmed with the caliper log run (Figure 16). After analyzing the results of
the caliper, the 7” liner was immediately run without the need of a wiper trip, as normally performed in offset wells.
The 7” liner reached bottom without drags problems.

Figure 16: Terra 21 3D caliper log.

10 IADC/SPE 167921

With the turbodrilling system, the drill string rpm were around 40 rpm, reason why there was less torque on
surface compared with the commonly used RSS which requires 120 rpm on surface. In the Terra 21 well, the
average torque on surface was around 3000 lb-ft, average WOB of 8 kips with maximum values of 20 kips as
planned in the design phase. Comparing to the offset well, Terra 3, drilled with RSS and PDC bit the average
drilling torque on surface was 12500 lb-ft, average WOB 29 kips for the first two runs, then the third run with RSS
and TCI bit average drilling torque was 7000 lb-ft and average WOB 36 kips. The turbodrill application had a lot
less surface torque and WOB which means less loads on the BHA and drill pipes.

Due to the low rpm on surface, the casing wear was reduced by 85%. Figure 17 shows a graph of the metal
recovered on the shale shakers magnets. The metal recovered per day with the turbodrilling system ranged from
zero pound to a maximum of 0.74 lb, as opposed to the RSS which ranged from zero pound to maximum of 2.27
lb.

Metal recovered on Magnets of the Shale Shakers

2.50
Turbo-drilling RSS
Pounds of metal recovered

2.00

1.50

1.00

0.50

0.00

Date

Figure 17: Metal recovered on magnets of the shale shakers.

Additionally, an increased in service life of the bearing element of the (MPD) rotary head was observed. In the first
two runs with turbodrilling, the bearing element was replaced after 247 rotating hours and 9783 ft stripping. With
the RSS, the first failure occurred when the bearing element completed 56 rotating hours and 19846 ft stripping,
the second bearing element failed at 52 rotated hours and 7093 ft stripping. The washpipe on the Top Drive also
increased the rotating hours with the turbodrilling system, the first one lasting 140 hours and the second one 240
hours. When drilling with RSS system the washpipe presented three failures: first at 65.5 rotated hours, then at
170.5 rotated hours, the last at 66 rotated hours.

The Terra 21 well was planned to 85.53 days based on past experience of Terra 3 well which in reality last 109.83
days to drill the 8-1/2” borehole. After the application of the turbodrilling system with hybrid bit the Terra 21 well
last 72.52 days to drill the 8-1/2” borehole which means 13 days of rig time savings (Figure 18).
IADC/SPE 167921 11

Time versus Depth Curve

14500

15000

15500
Depth [ft MD]

16000

16500

17000

109.83 days
85.53 days
17500
72.52 days

18000
0 20 40 60 80 100 120
Days

Terra 21 (real time) Terra 21 (plan time) Terra 3 (real time)

Figure 18: Time versus depth curve comparison.

Conclusions
The first application of turbine and hybrid bit successfully drilled 8-1/2” borehole through carbonates with high
unconfined compressive strength and high chert content. The drilling time was reduced by 15.2% (13 days). The
ROP was increased by 29% when compared with offset well Terra 3. The system drilled 1240 ft, the longest run in
the field, eliminating two trips comparing TCI bit runs.
The amount of steel recovered in the magnets of the shale shaker was also reduced because of the lower rpm in
surface when compared with RSS applications. The reduced casing wear guarantees the production casing
integrity through the life of the well. Additionally, an increased service life of MPD sealing element and top drive
washpipe was observed, consequently reducing non-productive time NPT.
The turbodrill system deliver a better borehole quality as demonstrated in the 3D caliper, and by the drag
reduction observed on trips to surface, allowing the 7” liner to be run immediately after logging and eliminating a
wiper trip.
The reduced weight on bit and reduced surfaced torque incremented the BHA rotating hours on bottom in a high
temperature environment, due to reduced stress on the BHA, reduced fatigue levels on connections was
determined, incrementing the time between BHA inspection.
The lessons learned from the first application will be indispensable to assure success in the following wells of the
southern Mexico region.
The reduced drilling times will help the region to meet objectives and boost production from Cretaceous and
Jurassic formations.

Acknowledgments
The authors would like to thank the Samaria-Luna asset management for permission to publish the information
contained in this paper, and for the support to deploy new technology in wells of the Mexico South region.

References
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Drilling Time in Granite Wash Laterals. Paper SPE/IADC 163408 presented at the SPE/IADC Drilling Conference
and Exhibition, The Netherlands, 5-7 March.
12 IADC/SPE 167921

Donal, H. et al. 2010. A new Approach to Drilling Hard Chert Contaminated Carbonate Formations in Kazakhstan.
Paper SPE 139412 presented at the SPE Caspian Carbonates Technology Conference, Kazakhstan, 8-10
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