# Presentation: 109473

## DISPOSABLE FIBER OPTIC TELEMETRY SYSTEM FOR E&P APPLICATIONS

**Presented by:**
**David Borns, Sandia National Laboratories**
**505-844-7333**
**Djborns@sandia.gov**

## Project Objective?

**Create the Simplest, Smallest, Lightest, ****	****	****High-bandwidth Telemetry System for Use While Drilling****	**

## Program Outline:	

**Initial funding by internal research dollars**
**Funded by GTI**
**Combined effort by Sandia National Laboratories**
**Geomechanics group**
**Geothermal group**
**Project Details:****	****	****3 year  ($1.3 Million) **
**Status: ****	****	****	****Completing year 3**
**Initial patent issued:****	****# 6,041,872**

## Breaking the Bandwidth Bottleneck	

**Breaking the Bandwidth Bottleneck****	**

## A Golden Age of Instrumentation

**Smarter, Smaller, Lighter, Cheaper, Low power**
**Chips- moving toward 0.1 micron features, Cray scale power on a chip**
**MEMS- integration of mechanical systems and electronics at the chip scale**
**On chip chemistry laboratories**

*The closer you look, *
*                    **the more you learn*

## Do We Really Need High Bandwidth??A small sample of what could be done 

-   Diagnosis While Drilling
-   Look Ahead
-   Plug Bug
-   Bit Stabilization

## Diagnosis While Drilling

**U.S. Oil/Gas drilling expenditure exceeds $10 Billion/year.**
**Drilling cost/ft exhibits exponential increase with depth for deep wells**
**Commercial implementation of a systems approach to drilling based on integrated downhole and surface data**

*Oil and Gas Journal, * Jan 1997

## Diagnostics-While-Drilling (DWD) -       A feedback system for real-time control and optimization

***High-Speed Data Link*** - carries information and control signals between surface and downhole
***Drilling Advisory Software*** - acquires, analyzes, and displays data in real time, showing drilling conditions and system performance
***Driller ****- *uses traditional methods and DAS to control drilling
***Drill Rig/Drill Pipe*** - primary component the driller uses to interact with the drilling process

**Diagnostics-While-Drilling (DWD) ****-       *****A feedback system for real-time control and optimization***

## DWD provides many benefits

**Tremendous reductions in drilling costs**
**Increased ROP and bit life**
**Fewer problems (stuck pipe, stuck casing, tool failures)**
**Less casing through multilateral completions, fewer casing runs**
**Reduced logging costs**
**Enhanced safety**
**Detailed knowledge of downhole conditions while drilling**
**Cost-effective access to hard-to-reach hydrocarbon resources**
**Deep gas**

## Bit dynamics limit current drilling systems

- WOB measured at the surface appears constant, even though WOB measured at the bit cycles through zero.

- Torque starts to cycle upon entering a new lithology at Catoosa, failing a PDC bit (*after Warren*).

- WOB

## Possible Downhole Measurements

**Bit accelerations -- bit bounce and whirl**
**WOB, torque, bending -- formation change, performance**
**Pressure -- hydraulics, kicks, plugged nozzles**
**Temperature -- mud condition, kicks, compensations**
**Hole direction -- directional drilling**
**Tool condition -- bit/motor wear**
**Formation sensors -- logging-while-drilling**

## Data-Rate Tradeoff: At least 100 kbit/s necessary for DWD

*Dysfunctions:*  Bit bounce, whirl, stick/slip, torque shocks, axial acceleration problems, lateral acceleration problems, bending, cutting efficiency (gage, etc.)
*Basic Measurements:*  WOB, torque, bending, pressure (annular, internal), acceleration (3 axes), temperature, magnetic field

## DWD is not MWD

**DWD takes much more data, at a much higher data rate (15-100 kbits/sec), than MWD.**

## Real time bit control	

-  Drilling is machining rock
-  Active control of chatter leads to faster machining rates, lower costs
-  Five-fold increase in cutting rates, in metal with active control
-  Requires high bandwith, for control signals

## What is our Approach?	

**Adapt missile guidance technology**
**Unarmored Optical Fiber**
**Entirely Contained in Drill String **
**Disposable (One-use, No Retrieval Time) **
**Million Bits Per Second or Higher Data Rates**

## Examples of Fiber Cassettes

- Photo Courtesy James Holt, Redstone Arsenal

- 8 inches

## Deployment System!

- Photo Courtesy James Holt, Redstone Arsenal

**Deployment System!**

## Challenge:	

**               **

**Can this.....Survive This ??**

## Heart of the System	

**Fiber Cassette**
**12,000 - 15,000 ft of fiber**
**20 -30 inch long**
**2.5 inch diameter**

## Winding the Fiber

## Goals of prototype development

**Test deployment tool**
**Test pipe adding system**
**Demonstrate top-down and bottom up deployment**
**Data transmission**
**Two fiber types: ****	**
**multimode**
**single mode**

## Sketch of Top Drive Setup

**Sketch of Top Drive Setup**

- Mud

- Signal sub

- Rotating coil

- Non rotating coil

- Logging cable (~30ft)

- Standard connector

- Output Signal

**Notes:**
Remove blue dotted line . It interferes with diagram

## Sub for Non-Contacting Data Transmission

**Data transmitting coils**

## Deployment Mode -- Top-Down 

**Fiber deployment starts at top**

##                     Deployment Apparatus

**Approx. 10 ft. length**
**Less than 100 lbs.**
**Present version up to 4 km of fiber capacity**
**Designed for 5 inch drillpipe**

## Friction Brake

**Friction Brake**

**Notes:**
New slide

## Support Dogs

**Support Dogs**

**Friction Brake**

**Lift Point**

## Tool Insertion

**Tool contains 4,000 to 14,000 feet of fiber**
**Insertion is done once **
**Tool controls fiber deployment**
**Houses fiber to electronics conversion**
**Low pressure drop across tool**

**Notes:**
Line one changes 400 --> 4000

## Challenge:

- Add Stand of Drillpipe without
- Interferring with Operations

## Slide 30

**Notes:**
Edit master slide to move or lose the blue horizontal line. It is too distracting on this slide. Cuts right across the figure elements

## Data:

- _Data:_
- 100 Kbits/sec
- Top down deployment
- 500 GPM

## Fiber Removal:End of Test

## Tasks Accomplished

**Deployment in the bottom-up and top-down deployment mode with multimode fiber**
**Adding stands of pipe was successfully demonstrated with both fiber types**
**Circulation and drilling were done successfully with the multimode fiber**
**High speed, real time data transmission**

## Status

**Survivability demonstrated**
**Deployment technology demonstrated**
**Pipe-adding technique demonstrated**
**Non-contacting signal coupling demonstrated**
**Commercialization process underway**
**Oil and Gas Partnership Proposal funded for fiber in coiled tubing-- CTES and GTI**

**Notes:**
Replaced Next Steps slide

## Costs:	

**Tool-  Prototype cost about $50,000**
**Fiber- in large quantities, $0.06/foot**

## The closer you look, 

**Greatly Simplified Logistics for MWD and LWD**
**Access to Real-Time Data**
**Expanded Opportunities for Services**

*The closer you look, *
*                    **the more you learn*