Well Engineering Notes.pdf

Well Planning, Engineering & Construction 11th – 13th Jan 2012 Mike Dyson, GM Well Engineering BG Group

1 MSc Petroleum Engineering – Well Engineering

Objectives 1. Be able to articulate the basic principles of well planning, design and construction. 2. Understand how well design and construction contributes to optimal field development 3. Recognise the basic drilling and completion stages and equipment used 4. Possess a basic understanding of alternative completion designs 5. Appreciate well operations safety, costs and operations management

2 MSc Petroleum Engineering – Well Engineering

Prerequisites No prior knowledge of well engineering or drilling is required or assumed

Timing 18 hours of lectures during Spring term

Assessment This material will be assessed as part of Phase 2 of the Group Field Project

Texts 1. A Primer of Oilwell Drilling, 6th edition, Ron Baker, Published by The University of Texas at Austin 2. Applied Drilling Engineering, Bourgoyne, Chenevert, Millheim and Young, Published by SPE 3 MSc Petroleum Engineering – Well Engineering

Housekeeping • • • • •

Fire Exits Alarms Restrooms Time schedule Breaks / Lunches

4 MSc Petroleum Engineering – Well Engineering

Your Lecturer • • • •

Mike Dyson MA Eng, MBA, Chartered Engineer, FIMechE 30 years experience in Oil & Gas Industry Well Engineer, onshore and offshore, costs and planning, remote operations, contracting and procurement, drilling management, technology management • Shell and BG Group • Lived and worked in UK, Netherlands, Brunei, Oman and USA 5 MSc Petroleum Engineering – Well Engineering

Ways of working • Ask questions! • Ask more questions! • There are no dumb questions! • Timing? • Regular breaks

6 MSc Petroleum Engineering – Well Engineering

Syllabus 1. Purpose of wells. Well planning. 2. Onshore and offshore drilling and well engineering 3. Rigs and equipment. Drill strings and BHAs. Drill bits and hole-opening. Coring systems. Hydraulics and hole-cleaning. Drilling practice. 4. Casing and cementing. 5. Special drilling operations. Directional drilling and down-hole motors. Logging while drilling. High inclination, extended reach and horizontal wells. Slim-hole operations. Coiled tubing drilling. Fishing. 6. Drilling fluids and fluid systems. Mud system. Mud chemistry. Cuttings cleaning & discharges. Completion fluids. Environmental concerns & compliance 7. Well control. Well control using mud; Casing selection & design. Primary cementing. BOPs. Drilling problems & control 8. Completion designs, well testing, sand control, selectivity, smart wells 9. Stimulation operations 10. Well maintenance 11. Drilling and completion costs. Contracts. Learning curves. 12. Safety

7

MSc Petroleum Engineering – Well Engineering

Schedule – day one • • • • • • • • • • •

Purpose of wells Subsurface recap Health, Security, Safety & Environment Well Construction – The Well Delivery Process Drilling Rigs 4 Functions of the Drilling Rig Rig Floor Equipment The Drillstring Pipe Handling Equipment Bits Drilling Fluid, SRE & Waste 8

MSc Petroleum Engineering – Well Engineering

Schedule – day two • • • • • • • •

Well Construction Casing & Cementation Directional Drilling Stuck Pipe Fishing Operations Formation Evaluation Blowouts and Their Causes Well Control

9 MSc Petroleum Engineering – Well Engineering

Schedule – day three • • • • • • • • • • •

Drilling a Well (Step by Step) Casing Design Deepwater New Technologies Completions Artificial Lift Stimulation Workovers and well maintenance Costs and contracts Performance and learning curves Closeout 10

MSc Petroleum Engineering – Well Engineering

Well Engineering basics • Why a well? – Oil and/or gas production – Water or gas injection – Stopping a blow-out – Obtaining subsurface information

11 MSc Petroleum Engineering – Well Engineering

Well Engineering basics • Where? How to get to here?

12 MSc Petroleum Engineering – Well Engineering

Course Structure • A 360 Degree (slide show) look at Drilling Operations • Discussions Q&A (things that are obvious to me after 37 years in the business may not seem obvious to you – therefore ASK • Work simple examples • Drill a simple well on the white board

13 MSc Petroleum Engineering – Well Engineering

The Origins of Hydrocarbons

14 MSc Petroleum Engineering – Well Engineering

Looking for Oil

15 MSc Petroleum Engineering – Well Engineering

Where’s the Oil and Gas? How did it get there? How do we find it?

16 MSc Petroleum Engineering – Well Engineering

Where’s the Oil?

17 MSc Petroleum Engineering – Well Engineering

Where’s the Gas? Rank

Country

Natural gas - proved reserves (billion cu m)

1

Russia

47,570

2

Iran

26,370

3

Qatar

25,790

4

Saudi Arabia

6,568

5

United Arab Emirates

5,823

6

United States

5,551

7

Nigeria

5,015

8

Algeria

4,359

9

Venezuela

4,112

10

Iraq

3,170

11

Turkmenistan

2,860

12

Indonesia

2,630

13

China

2,450

14

Norway

2,288

15

Malaysia

2,037

16

Uzbekistan

1,798

17

Kazakhstan

1,765

18

Netherlands

1,684

19

Egypt

1,589

20

Canada

1,537

Because of Shale Gas, it’s a complex picture these days18 MSc Petroleum Engineering – Well Engineering

Where’s the Shale Gas?

“ US energy self sufficient for 40 years with shale gas reserves” ???? http://geology.com/energy/world-shale-gas 19 MSc Petroleum Engineering – Well Engineering

Where’s the Oil and Gas? How did it get there? How do we find it?

20 MSc Petroleum Engineering – Well Engineering

Decaying organic material settles in a water environment. Organic matter is covered with silt and mud. Under influence of heat and pressure organic material and mud turns to rock. Time, heat & pressure turns the organic material into gas and oil

Tectonics move the layers. Further deposition and erosion takes place. Oil & gas seeps into porous rock. 21 MSc Petroleum Engineering – Well Engineering

Essential Reservoir Characteristics: • Permeability (natural or created) • Porosity

Photomicrographs of quartzcemented sandstone

Porosity: Ability to contain Permeability: Ability to flow through 22 MSc Petroleum Engineering – Well Engineering

Where’s the Oil and Gas? How did it get there? How do we find it?

23 MSc Petroleum Engineering – Well Engineering

Exploration Methods (1) Gravimetric Survey • relatively cheap • indicates sub-surface anomalies • provides data for further more detailed surveys

More dense (compacted by pressure)

24 MSc Petroleum Engineering – Well Engineering

Exploration Methods (2) Seismic

25 MSc Petroleum Engineering – Well Engineering

Exploration Methods (2) Seismic 3D maps constructed from surveys

•

• • • •

Survey data converted into computer generated images for interpretation:  Formation tops  Formation fluids  Surface anomalies o shallow gas o abnormal pressures Prognoses of stratigraphic column Develop surface maps Data for planning drilling operations Uncertainty depends on wells in area or rank wild cat

26 MSc Petroleum Engineering – Well Engineering

Exploration Methods (2) Seismic 3D maps constructed from surveys

Where would you drill? 27 MSc Petroleum Engineering – Well Engineering

Surface Map provides areal position of well (s)……..

……..Stratigraphic Section depths of points of interest

28 MSc Petroleum Engineering – Well Engineering

Only one method to prove economic existence of hydrocarbons:

DRILL

29 MSc Petroleum Engineering – Well Engineering

Exploration Well

Discovery Well

Sometimes we miss

30 MSc Petroleum Engineering – Well Engineering

Important Data Recovered During Drilling Operations • Cuttings (at the shale shaker) • Analysis for lithology • Hydrocarbon traces • Petrophysical data (logging (LWD or wireline)) • Cores • Porosity / Permeability • Samples for testing possible sources of impairment / need for sand control • Fluid samples and reservoir pressure measurements • Fluids and volumes/rates • Production test – reservoir volume & productivity ……….All discussed later 31 MSc Petroleum Engineering – Well Engineering

Exploration Methods (2) Seismic 3D maps constructed from surveys

Shallow Gas Blowout – more later Where would you drill? 32 MSc Petroleum Engineering – Well Engineering

Health, Safety, Security & Environment

33 MSc Petroleum Engineering – Well Engineering

HSSE Goals for BG Wells Team ......................and for you • • • •

Zero recordable injuries Zero High Potential Incidents (HPI) Zero repeat incidents Zero discharge to the environment

.........Don’t hurt anyone and don’t get hurt ...................................Macondo has changed the game

34 MSc Petroleum Engineering – Well Engineering

My catalogue of near misses There was little regard for safety in the ‘70’s

• • • • • • •

Requested to “fix derrick light” Elevator lowered on finger Head caught between DC’s Cathead rope snapped Lost control of Drawworks Rig fell over etc Bottom Line:

You are responsible for your own and other’s safety 35 MSc Petroleum Engineering – Well Engineering

Rules of the Game • If in doubt STOP • Ask questions. Well construction is a collaborative business • Share information and knowledge • Never assume the other person(s) know(s) • Always ask yourself “What if?” • Continuously check and re-check • Know your barriers

Barriers are Important …….more discussion later

36 MSc Petroleum Engineering – Well Engineering

Well Construction The Well Delivery Process

37 MSc Petroleum Engineering – Well Engineering

Purpose of the Well Delivery Process • Improve quality of wells • Improve company’s business performance How? • Identifies responsible parties for key decisions • Promotes multidisciplinary teamwork • Drives appropriate risk management • Facilitates introduction of new ideas/approaches • Work to a technical limit 38 MSc Petroleum Engineering – Well Engineering

The 5 Phases of (Generic) Well Delivery Process IDENTIFY & ASSESS

OPERATE

EXECUTE

SELECT

DEFINE

39 MSc Petroleum Engineering – Well Engineering

Step 1 Identify & Assess • Initiate project (an opportunity) • Prepare design concepts • Review field (or well) concept options • Identify field (or well) concept options • Identify long lead items, e.g., special rigs, special equipment, CRA materials, • Provisional economics

40 MSc Petroleum Engineering – Well Engineering

Step 2 Select • Feasibility evaluation • Select best option • Confirm the well design meets objectives • information • production rate • life cycle • Economic justification 41 MSc Petroleum Engineering – Well Engineering

Step 3 Define • • • •

Complete detailed well design Peer review Develop, optimise and finalise well programme Complete execution plan

42 MSc Petroleum Engineering – Well Engineering

Step 4 Execute • • • • •

Obtain approval for detailed well design Obtain approval for expenditure Conduct drill well on paper exercise Drill the well Review performance

43 MSc Petroleum Engineering – Well Engineering

Step 5 Operate • Evaluate operational performance • Complete end of well report • Catalogue learnings; transfer to next well in sequence • Share learnings

44 MSc Petroleum Engineering – Well Engineering

Example Drilling Programme BG Land Well

45 MSc Petroleum Engineering – Well Engineering

Well Construction Drilling Rigs

46 MSc Petroleum Engineering – Well Engineering

Been Around for a Long Time

47 MSc Petroleum Engineering – Well Engineering

Drilling Rig

Many types Selection Determined by: • Geographical location • Environment • Depth of well • Type of well • Mobility requirements • Operating cost 48 MSc Petroleum Engineering – Well Engineering

Drilling Structures Mast & Derrick Derrick

Mast

49 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Mast & Derrick •

Shallow to 40,000 ft rating & more……

50 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Desert Rig Oman

51 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Desert rig on the Move

Here rig selection driven by: • Infrastructure • Depth rating - shallow • Mobility – number of loads • Operating cost

52 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Here rig selection driven by: • Depth rating - deep • Pressure – high => BOP’s • Pad drilling (note wheels for move over wells) 53 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Heli-Rig -

Remote locations – no infrastructure Saves cost of road construction All components, rig and drilling equipment flown in - 3 ton loads

54 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Arctic Rig – Pad Drilling for Extended Reach Wells (ERD)

55 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Swamp Barge -

-

Used in coastal / swanp locations Dredging canals cheaper than cost of road construction Components, rig, drilling equipment and personnel delivered by water or helicopter

56 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

57 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

58 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Drilling Rig

Flare

Accommodations

Process Equipment

Jacket

59 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Draugen : North Sea 250 m water depth

Hibernia: North West Atlantic 150 m water depth

Harsh Environment - 30 m waves - 100 knot winds

60 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Tender • Tender serves (small) platform • Tender is anchored • Drilling services provided from tender

61 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Critical Issues for Jack-Ups • Water depth (max approx 450 ft) • Air gap • Sea bed • Sub soil (punch through) • Shallow gas

62 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Jack-Up on Platform • Cantilever over platform • Skid rig X – Y to well centres • Well centres as tight as 1.5 m

63 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

4 legs

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

3 legs 64

MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Round legs

65 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

66 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Generation

Approx Water Depth (ft)

Approx Water Depth (m)

Dates

First

600

200

Early 1960’s

Second

1000

300

1969-1974

Third

1500

500

Early 1980’s

Fourth

3000

1000

1990’s

Fifth

7500

2500

1998-2004

Sixth

10000

3000

2005-2011

Tension Leg

Spar

Deepwater Drillship

Semis denoted by “generation”

67 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Critical Issues for Semi Sub Drilling Units: • Water depth • Moored to approx 1000 ft • Dynamic positioned beyond • Maximum water depth >10000 ft • Deck loading • Top side equipment package

68 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Dynamic Positioning

69 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Ocean Bounty

70 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Tension leg platform (Production Facility) Water depth 910m / 2,985ft

Production capacity 130,000 barrels of oil and 150mcf gas per day Total project cost $900m (including pipelines) 71 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Floating Production, Storage and Offloading (FPSO) vessels • Remote or deepwater locations • Seabed pipelines not cost effective. • Deepest water Espirito Santo depth of 1,800 m in the Campos Basin, rated for 100,000 bpd • Largest Kizomba A storage capacity of 2.2 million barrels

72 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

73 MSc Petroleum Engineering – Well Engineering

Land

Barge

Platform

Gravity Base

Tender Assisted

Jackup

Semisubmersible

Tension Leg

Spar

Deepwater Drillship

Critical Issues for Drillship • Stability • Deck loading / storage capacity • Remote operations capability • Water depth • > 10000 ft • Dynamic positioned • Top side equipment package • Dual derrick • Riser handling

74 MSc Petroleum Engineering – Well Engineering

Other Drilling Unit Types - Coiled Tubing Drilling & Workover Unit Trailer mounted

Injector

Coiled Tubing Crane

Tubing Reel

Stripper Control Cabin BOP

Power Unit

75 MSc Petroleum Engineering – Well Engineering

Other Drilling Unit Types Coil over Top Drive

• Continuous coiled tubing with zero connections. • No human contact with the pipe • Fully “automated “ • Drill with conventional jointed drill pipe “convert in 2 minutes.” • Depth rating to 3000 meters with 3.5 or 4 inch tubing. • Low number of loads fast move in, rig-up and rig-out.

76 MSc Petroleum Engineering – Well Engineering

New Technology Drilling Units Drillmec HH • • • • • •

Hydraulic powered rig Hydraulic cylinder for hoisting Vertical pipe racking system Fast rig up / down 45 ft joints of range 3 drillpipe Pipe transported in bins (no hands on pipe) • High automation / mechanisation on rig floor

77 MSc Petroleum Engineering – Well Engineering

New Technology Drilling Units Rack & Pinion • Few loads / small footprint • Can apply WOB by force • Good for shallow wells • Slant wells • Hydraulic or electro motors • High degree of control through PLC controls • No travelling block • No rig tongs • Small crew

78 MSc Petroleum Engineering – Well Engineering

Quiz: Rig Costs Typical Rig Contract & Spread Rates • Operator views rig costs in two ways: • Rate to contractor • Spread rate (includes total operating costs to operator)

• Deepwater Drilling Contractor rig rate: 4th-6th generation semi down to 10000 ft • Shallower water semi rigs for 350 - 2500ft water depth • Jackup Drilling Contractor rig rates: for Gorilla & harsh environment rated & 350' leg jack-ups, • Independent leg cantilevered jack-ups for up to 350' water depth • Offshore Platform Drilling Contractor rig rates: • Onshore Rig rates: High Spec Flex-Rig type: Medium Spec: 79 MSc Petroleum Engineering – Well Engineering

Quiz: Typical Rig Contract & Spread Rates • Deepwater Floater Drilling Contractor rig rate: US$500k./day (4th-6th generation) / spread costs incl. rig: US$1,000,000./day. same rate applies if the rig is drilling, completing, testing, setting templates, and regardless of water depths deeper than ~2500ft. • Shallow water floater rigs for `350 - 2500ft water depth will have day rates ~$250K/day, and spread rates ~$500K/day, subject to whether moored or dynamically positioned and distance from shore base. • Jackup Drilling Contractor rig rates: Up to $350K/day for Gorilla & harsh environment rated & 350' leg jack-ups, with spread rates of up to $500K/day, depending upon distance from shore base and whether additional support vessels required. • Independent leg cantilevered jack-ups for up to 350' water depth have rates in the $50-150K/day range and spread rates of $75-250K/day. • Offshore Platform Drilling Contractor rig rates: Around $25K/day, with spread rates of $40K/day. • Onshore Rig rates: Depends on location; US High Spec Flex-Rig type: Around $23K/day, with spread rates of $35K/day. Medium Spec: Around $17K/day, with spread rates of $25K/day. In Iraq spread rates land rig as high as $70k/day 80 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Well Construction 4 Functions of a Drilling Rig

81 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

82 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

1.

Hoist & Lower

2.

Rotate

3.

Circulate

4.

Control Pressure

1 4

2

3 83 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Hoist & Lower

84 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Crown Block Travelling Block & Hook

Driller’s Position “Brake” MSc Petroleum Engineering – Well Engineering

Control

Drawworks

Dead Line Anchor

85

Hoist & Lower

Rotate

Circulate

Control

Drilling Line

Traveling Assembly & Kelly System

Traveling Block Shock Absorber

Hook Swivel Bail Swivel

Kelly Spinner

86 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Top Drive Dolly

Control

Traveling Block

Motor

Traveling Assembly Top Drive System Gear Case - Hydraulic Drive Shaft - Electric (replaces kelly) IBOP Valves Pipehandler

Elevator Links

87 MSc Petroleum Engineering – Well Engineering

Derrick & Mast Loads Ability to withstand two types of loading: • 1. Compressive loads • 2. Wind loads Derrick load capacities range from 86,000 to 1,400,000 lb, i.e., shallow workover to ultra deep drilling

88 MSc Petroleum Engineering – Well Engineering

Drawworks Horsepower & Depth Rating Drawworks HP = hook load x hoisting velocity / 33,000 x e

• • • •

Hook load, lb Hoisting velocity of travelling block, ft/min 33,000 = conversion factor ft.lb/min per horsepower Hook to drawworks efficiency (e) between 80 to 90%, depending on the number of lines in use).

89 MSc Petroleum Engineering – Well Engineering

Hypothetical Example • Heaviest load for a given well is 13 3/8” casing run to 10,000ft • Weight casing string in mud = 10,000 x 68 lb/ft = 680000 lbs x BF (0.9) = 612,000 lbs • If casing needs to be pulled out of hole we have additional drag (assume 75000 lbs) • Drawworks HP = hook load x hoisting velocity / 33,000 x e • Weight traveling block = 60,000 lbs • Total load = 612,000+75,000+25,000 = 712,000 lbs • Hoisting velocity of travelling block = 45 ft/min • HP = (712,000 x 45 x ).9 / 33000 = 930 horsepower • Repeat for all critical loadings, e.g., POOH @ 15000 ft HP requires~ 1400 HP • Typical Drawworks range 750 – 1500 HP (rig capacity) 90 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Kelly Drilling Rotary Engagement

91 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Kelly Drilling Rotary Engagement

92 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Traveling Assembly Top Drive System (replaces kelly)

93 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Rig Rotary Power Rotary HP = (2 P N T/ 33000) x Tf N = RPM T = Torque in ft lbs Tf = Torque factor depending on drilling conditions (e.g., deviated well = 2.25 Example: Rig uses 5” grade E pipe (max torque = 23,180 ft lbs (max – run at ~ 50%) Required rotary speed 150 RPM Rotary Power = 2xPx(150x12000)/33000 Rotary Power Required = ~ 770 HP Typical Rotary HP 750 – 1000 for deep wells (some top drives >2000 HP ) 94 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Kelly Drilling – Add A Single

95 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Not all Rigs Rotate

96 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Coiled Tubing Drilling Unit Trailer mounted

Injector

Coiled Tubing Crane

Tubing Reel

Stripper Control Cabin BOP

Power Unit

97 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Circulate

98 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Circulate • Pump fluid around the system • Remove Drilled Cuttings • Add drilling power at the bit • Clean the bottom of the hole • Cool the Bit

99 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Pumps in Rig Circulating System • High Pressure Reciprocating Rig Pump (Duplex and Triplex) • Centrifugal Pumps • Feed pumps for HP Rig Pump • Feed pumps for Solids Removal Equipment

100 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Piston Pump Features: • Can handle fluids containing high percentages of (abrasive) solids • Valve clearance allows passage of large solid particles (typically lost circulation materials) • Ease and simplicity of operation and maintenance. Liners, pistons and valves replaced in the field by the rig crew • Wide range of volume and pressure using different liner and piston sizes. 101 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Triplex Pump Pulsation Dampers INLET OUTLET

102 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How Much Pumping Power? • Power measured as HHP (hydraulic horsepower , consumed at bit (useful) and consumed in system (wasted) • HHP = D P x volume / 1714 • Example of hydraulics calculation • Total pressure needed = 4500 psi • Total volume needed = 750 gpm • Pump efficiency 90% (triplex) Then HHP required = 0.9*(4500 * 750)/1714 = 2190 HHP Rig will select 2 x 1300 HP pumps

103 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Control

104 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

BLOWOUTS HAPPEN

But they shouldn’t, Barriers & …..Blowout

Preventers 105 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Well Control • The cased well is a pressure containment system • When pressure gets too high pressure vents – To surface – Down hole

• Well is designed to contain maximum expected pressures + a safety factor • Barriers are put in place to safeguard the well – During operations two barriers must be in place at all times

• Barriers include: – Primary ; Drilling fluid, inside a properly cemented casing – Secondary; Blowout Preventers (BOP’s) and Valves & Chokes 106 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Well Control Methods Covered in Detail Later

107 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Control Equipment

108 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System (not a barrier / not a preventer)

109 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System Diverter

Accumulator

Diverter Lines

Diverter 110 MSc Petroleum Engineering – Well Engineering

111 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System

112 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System Top hole drilling carries its own unique risks: • • •

Diverter

Shallow gas Weak formations No protective casing

Well CANNOT be completely closed in. Diverter System is used for top hole to divert “shallow gas” flow.

Diverter system on driven conductor pipe 113

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Hydril MSP Series Top hole drilling carries its own unique risks: • • •

Shallow gas Weak formations No protective casing

Well CANNOT be completely closed in.

Diverter System is used for top hole to divert “shallow gas” flow.

114 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter Line & Valves 

Large bore



Full Opening valves



Ball Valves Best



Gate Valves acceptable



Fast , synchronised hydraulic actuation



Operates using regulated pressure at 1500 psi 115

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Preventer System (Secondary Barrier)

116 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

After setting and cementing surface casing

Control

Accumulator

Blowout Preventers are “nippled up” and pressure tested Their purpose is to “contain’ pressure

Choke Manifold BOP Stack 117

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Preventer System • In the event of loss of primary well control………… Accumulator …..(hydrostatic pressure provided by drilling fluid is less than formation pressure)………. • Blowout Preventer (BOP) is activated • Flow from well stopped • Primary control re-established by circulating higher density fluid into well.

Choke Manifold

BOP Stack 118 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Preventer System • Combination of large and small, high pressure valves placed on the wellhead at the top of the Accumulator well. • Controlled from 2 to 3 remote stations • Operate under hydraulic pressure supplied from an accumulator unit. • Different sizes and types of BOP are used during the phases of drilling the well.

Choke Manifold

BOP Stack 119 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

BOP Stack Annular

Drilling Spool

Manual Gate Valve

Pipe

Blind

Pipe

HCV

Configurations Vary According to Well Conditions Size 20” to 7” Pressure 2000 psi to 20000 psi

Choke line side

120 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Annular Preventers

121 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Annular

Rotate

Pipe

Control

Manual Gate Valve

Pipe

Blind

Circulate

HCV

Choke line side Several Manufacturers

122 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Annular Preventer •

Large, bowl-shaped valve designed to seal the annulus

•

Donut shaped rubber sealing element

•

Seals around any drill string component, including open hole

•

Hydraulically actuated

•

Hydril GK •

13 5/8” bore

•

5000 psi working pressure 123

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Wear Plate Packing Unit Head Opening Chamber

Piston Closing Chamber

124 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

•

Commonly used Annular BOP

•

Element can be split

•

Choice of materials

•

Excessive closing pressure causes extrusion and rubber loss

•

Wellbore clearance reduced with time and wear

Control

Natural rubber Black color Water base muds Nitrile rubber Red color NAF muds Neoprene Green color NAF muds at very low temps 125 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Spherical Sealing Element

Shaffer Annular 126 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Cameron “D” Type

Cameron D Sealing Element

127 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Ram Preventers

128 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Cameron U Preventer Annular

Pipe

Single Ram

Ram Type BOP

Blind

Pipe

Double Ram

129 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Cameron U Preventer

130 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

131 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Variable Bore Rams (Common in Sub-sea BOP’s)

132 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

•

Shear Rams

•

Casing Shear Rams

Circulate

Control

133 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Valve & Chokes

134 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Valves Rated to same pressure as Ram Preventers

Annular

Manual Gate Valve

Pipe Ram

Blind

HCV

Choke line side

Pipe Ram

Same Valve with Hydraulic Operator

Cameron FL Gate Valve 135

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Valves connected to ‘Choke Manifold” with high pressure coflex hose Annular

Manual Gate Valve

Pipe Ram

Blind

HCV

Choke line side

Pipe Ram

136 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Choke Manifold – Rated to same pressure as ram preventer

Main Function Accumulator



Provide means of applying controlled back pressure to the well whilst circulating Choke Manifold a kick BOP Stack 137

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate



Throttle valve at end of the “choke line”



Typically 3” ID end connections



Hydraulically powered



Swaco has two circular plates – one rotates



Control

Power Choke Swaco Super Choke

Also Hand Chokes

Hand Chokes 138 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

•

Choke Control Panel

•

Air / hydraulic Remote sensor for • P Standpipe • P choke

•

Circulate

Control

139 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Hydraulic Accumulator “Koomey Unit” Stores and provides hydraulic power to operate the BOP components

Circulate

Control

Accumulator

Choke Manifold BOP Stack 140 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Hydraulic Control System 141 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

142 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Gas Outlet Siphon Break

Mud-Gas Separator (Gas Buster) •

Separates gas from mud

•

Capacity limited by:

Inlet

• diameter and height • diameter & length of gas outlet line • diameter & vertical height of “mud leg” Mud legs • should be external

Baffles Access Cover

1/3 Height

to Shaker Mud Leg

• Various types in use Flush

4” Clean Out 143

MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Mud-Gas Separator (Gas Buster)

Vacuum De-gasser

144 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Derrick Vacuum Degasser

145 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

• “Kicks” through the drillstring are very dangerous • Control Pressure in the drillstring too • Upper and lower “kelly cocks” • Drill string Float Valve 146 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Drill Pipe Safety Valves •

AKA RHKC “ Kelly cock”

•

Full opening ball valve

•

Must have lift clamp for stabbing

•

API Spec 7, Class 2 valves preferred • seals externally applied pressure (2000 psi) • seals pressure from above and below

•

Consider one piece body for 10K and greater

147 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Drill String Float Valves 

Installed in drill string • •

just above the bit only OEM valves



Solid flapper prior to setting surface casing



Fill drill string from top



On “live” wells (UBD)... •

use 2 tandem dart type valves

Solid Flapper

Ported Flapper

148 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Prevention is better than cure!

Flow Meter  Pit Level Indicator  Trip Tank 

Well Control Monitoring System

149 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

• • •

•

Rotate

Circulate

For UBD & MPD RBOP / RH considered as a barrier Maximum Operating Pressures • Rotating Heads - 250 psi • Rotating BOPs - 1000 psi

Capability to bleed/pump mud to/from trip tank with well under pressure

Control

To Transducer

RBOP

Bleed Valve From Trip Tank

Check Valve

Closed Flow Line

Annular

Drill Pipe Blind

Drill Pipe

Circulate Through Choke

150 MSc Petroleum Engineering – Well Engineering

Well Construction Rig Floor Equipment (Old and New)

151 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Rig Floor = Danger Area

• Heavy moving objects • High pressure • High energy • Slip & Trip hazards

• Falling objects • Etc

1 4

2

3 152 MSc Petroleum Engineering – Well Engineering

Old & New • “Rigs engaged in exploration and production in the U.S. totaled 1,968 for the week ended September 2, 2011” • Most are old and use old technology, i.e. kelly and tongs • However, new builds increasingly use new technology • High levels of mechanisation – remove people from danger area • “Cyber” driller • Downhole data • Remote advisory systems • Move to automation 153 MSc Petroleum Engineering – Well Engineering

Rig Floor Features

Kelly Drilling – Add A Single 154 MSc Petroleum Engineering – Well Engineering

Rig Floor Features

Kelly Drilling – Add A Single 155 MSc Petroleum Engineering – Well Engineering

Rig Floor Features Mousehole

Rathole

156 MSc Petroleum Engineering – Well Engineering

Slips Designed to support the load off the whole drill string in the rotary bushing (18 degree taper)

157 MSc Petroleum Engineering – Well Engineering

Elevators • •

•

•

Designated by lift capacity Pipe Size Different support methods • Slips • Square shoulder • Tapered internal Latching method 158 MSc Petroleum Engineering – Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Elevators

159 MSc Petroleum Engineering – Well Engineering

Rig Tong Technology Chain Tongs

Spinning Chain

Breakout Tongs

Spinning Wrench

Torque Wrench

160 MSc Petroleum Engineering – Well Engineering

Rig Tong Technology Spinning chain & Tong

161 MSc Petroleum Engineering – Well Engineering

Iron Roughneck Technology

1975

1986

2003

2006

162 MSc Petroleum Engineering – Well Engineering

Iron Roughneck Technology

163 MSc Petroleum Engineering – Well Engineering

Racking System Technology

1949

1960’s

1975

1986

1990

1994

164 MSc Petroleum Engineering – Well Engineering

Running Casing

165 MSc Petroleum Engineering – Well Engineering

Running Casing Casing Running Tool (CRT)

166 MSc Petroleum Engineering – Well Engineering

Conventional Driller’s Position

167 MSc Petroleum Engineering – Well Engineering

New Technology on the Rig Floor

168 MSc Petroleum Engineering – Well Engineering

where is it from? Auxiliary Systems

Drilling history

[

Hoisting & Lowering

Drilling vs. producing

]

Rotary

Rig types Mud Circulation

Drilling equipment Drilling Control

Electronic Drilling System (EDS) Drilling Screen

Tripping Screen

169 MSc Petroleum Engineering – Well Engineering

Pipe Handling

170 MSc Petroleum Engineering – Well Engineering

Dual Activity Racking System

171 MSc Petroleum Engineering – Well Engineering

172 MSc Petroleum Engineering – Well Engineering

The Drillstring

173 MSc Petroleum Engineering – Well Engineering

The Drillstring 

Rig Floor Top DriveEquipment System 

 



Rotary Table 

 



Upper Kelly Swivel etc. Cock Upper Kelly Cock Lower Kelly Saver Sub Kelly Lower Kelly Cock Kelly Saver Sub

Below Rotary Table       

Drillpipe Hevi-weight Drillpipe X-over subs Drill Collars Rotary Jar (Mud Motor / Turbine / MWD) Bit

MSc Petroleum Engineering – Well Engineering

174

The Drillstring Drill Pipe Safety Valves •

AKA RHKC “ Kelly cock”

•

Full opening ball valve

•

Must have lift clamp for stabbing

•

API Spec 7, Class 2 valves preferred • seals externally applied pressure (2000 psi) • seals pressure from above and below

•

Consider one piece body for 10K and greater

175 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe …Supports the Bit from the Surface

Triples In Fingerboard

…Provides Rotation from the Rotary or Top Drive

On Set-Back

…Is a Conduit for the Drilling Fluid from the Surface to the Bit

Singles On Pipe Deck (Rack)

Pin Thread Coated

Box Thread With Thread Protectors 176

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe Steel tube with weld-on connections  Common sizes 6 5/8”, 5”, 4”, & 3 1/2”  Many Grades, E, X, G, S  Properties 5” “S” 19.5# pipe 

  

max load = 895k lbs max pres = 23.6k psi max torque = 60k ft.lbs.

Working range restricted by:  combinations of tension / pressure & torque  wear & tear on pipe & tool joints  API Spec 5DP 

177 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe Steel tube with weld-on connections  Common sizes 6 5/8”, 5”, 4”, & 3 1/2”  Many Grades, E, X, G, S  Properties 5” “S” 19.5# pipe 

  

max load = 895k lbs max pres = 23.6k psi max torque = 60k ft.lbs.

Tooljoint

Working range restricted by:  combinations of tension / pressure & torque  wear & tear on pipe & tool joints  API Spec 5DP 

178 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe manufacture

179 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Bottom-hole assembly (BHA) • Provides weight to the drill bit • Multiple CSA transitions (stress concentrations) • Range from very simple low cost rotary assemblies to very complex Rotary Steerable (Geo) Systems (RSS) • • • •

Vertical / Deviated / Horizontal Deep, Ultra deep Extended reach Horizontal

• Multiple components to provide • • • • •

Stability Directional control, Geo-steering, Bit dynamics control Measurement systems 180

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Heavy-weight Drillpipe • Run above bottom hole assembly (BHA) • Thick wall pipe (1”) • Can be run in compression, better able to withstand cyclic loading • Frequently used in highly deviated / horizontal wells • Provides weight on bit (WOB) • Reduce BHA length • Reduced contact area with borehole 181 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Rotary BHA

182 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Spiral Drill Collars • Provide weight on bit (WOB) • Highly stressed through drilling forces • Thick wall (ID = 3”) • Spiral cut to reduce surface contact area => differential wall sticking • API relief groove pin & bore back box stress relief • Thread roots cold-worked for resistance to fatigue. • Connections are phosphated to minimize galling during makeup 183 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Jar • Insurance Tool • May un-stick a stuck string

184 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How the jar works

MASS DC & HWDP

MASS

MASS

BANG ! JAR

BHA Pull Tension

FIRE

Oil meters past piston

Piston enters wide bore and accelerates

IMPACT End of piston stroke

185 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

String Stabilisers • Centralise the BHA • Keep hole open • Enable straight hole and deviation control

186 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Measuring/Logging whilst drilling MWD / LWD • MWD & LWD sensors generate high volumes of data; • LWD assemblies include; gamma-ray, multiple resistivity, density and neutron • Sensors provide formation images, sonic waveforms and geo-steering signals • Directional data+ drilling optimisation data • Wired “InteliServ” drillpipe has data rate 57,000 bps bidirectional telemetry • Pulse MWD 24 bps Wired “InteliServ” drillpipe 187 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Mud Motors (& Turbines)

188 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Rotary Steerable Systems (RSS) • Steering mechanism Push or Point bit • Bit walk and bit face control bit/formation interaction • Uses bit rotation, axial penetration, tilting motion, and formation properties 189 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Rotary Steerable Systems Non rotating Sleeve

e.g. Autotrak by Baker Hughes Inteq (BHI)

LWD Triple Combo

Rotating Drive Shaft

RSS • Steering Bit Side Force mechanism Push or Point bit MWD • Bit walk and bit face control • Considers bit Formation Evaluation rotation, axial penetration, tilting “Gamma Ray + motion, and Resistivity” formation properties Non rotating Sleeve w/ Steering ribs & Inclination Sensors 190

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillstring float valves 

Installed in drill string • •

just above the bit only OEM valves



Solid flapper prior to setting surface casing



Fill drill string from top



On “live” wells (UBD)... •

use 2 tandem dart type valves

Solid Flapper

Ported Flapper

191 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

The Drillstring Drill Pipe

6× Heavy Weight Drill Pipe

12× Drill Collars Jar

3 Drill Collars

2 Non-Mag Spiral Collars (MWD)

UBHO Sub Motor Assembly 6.75” Adjustable set at 1.5º

8.75” Bit 192

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drill String Float Valves 

Installed in drill string •

•

just above the bit only OEM valves



Solid flapper prior to setting surface casing



Fill drill string from top



On “live” wells (UBD)... •

use 2 tandem dart type valves

Solid Flapper

Ported Flapper

193 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs Drive System The Drillstring

Threaded connections • •

•

•

Drillstrings contain multiple components with several different threaded connections Inter-connections are made with crossovers A few examples • Drillpipe IF (Internal Flush), e.g., 4 ½” IF, • Drillcollars NC 70 • Drillcollars 6 5/8” Reg (Regular) • 4” FH (Full Hole) • Pin x Pin connections & Box x Box connections It can be a nightmare! 194

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs Drive System The Drillstring

Top Drive Dolly

Traveling Block

Motor

Traveling Assembly Top Drive System Gear Case - Hydraulic Drive Shaft - Electric (replaces kelly) IBOP Valves Pipehandler

Elevator Links

195 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Kelly Drive Rotary Engagement

196 MSc Petroleum Engineering – Well Engineering

How far can you Drill? • • • • • • • •

• •

• •

Determine maximum depth with 5” Grade E pipe in 12 ¼” vertical hole Yield strength grade E = 75,000 psi CSA = pi (D2-d2)/4 = 5.275 sqin Max yield = 5.275 X 75,000 = 396,000 lbs (new) We consider “premium” grade pipe = 80% of new = 317,000 lbs We also apply a safety factor ~ 15% = 270,000 lbs available to support load Because we will encounter some friction resistance d when pulling pipe we apply a Margin of Overpull ~ 50,000 lbs (depends on expected conditions We also must consider weight of Drillcollars & HWDP for 12 ¼” hole weight on bit ~ 55,000 lbs (4,500 lbs per inch of diameter) weight in mud therefore * buoyancy factor. (we’ll ignore for this example) Length BHA = 900 ft. The transition point between drillpipe and BHA is a high stress area. Therefore with full WOB, we keep the “neutral point is in the thick wall BHA at ~80% of total weight available Total weight of BHA becomes ~ 66,000 (ignoring buoyancy factor) Depth you can drill = (317,000 – 50,000 (MOP)) – 66,000 (BHA weight)/21.62lb/ft (adjusted weight dp to take account of tool joints) = 9297 ft + 900 ft BHA = 10197 ft 197 MSc Petroleum Engineering – Well Engineering

Bits



BHA

Drillpipe

X-overs

Drive System

Below Rotary Table   

  



Drillpipe Heavy-weight Drillpipe X-over subs Drill Collars Rotary Jar (Mud Motor / Turbine / MWD)

Bit

198 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Circulation System 1. Adds Drilling Horsepower 2. Removes Cuttings 3. Cools the Bit 4. Controls Pressure

199 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Bits •

Two Categories • •

•

Roller Cutters • •

•

Roller cutters Fixed Cutters Steel tooth Tungsten Carbide inserts

Fixed blade • •

diamond polycrystalline diamond compact

200 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Steel Tooth or Milled Tooth Bit MSc Petroleum Engineering – Well Engineering

Drive System

Roller Cutter Bits

Tungston Carbide Insert Bit

201

Bits

BHA

Drillpipe

X-overs

Drive System

•

Example Milled-tooth Bit • Long teeth • Wide spacing • Large offset •

Cutting action •

gouging & scraping

202 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

4 Types of Roller Bit Bearings 1.

2.

3.

4.

Standard Open Bearing • Front row of ball bearings • Back row of roller bearings. Standard Open Bearing • For Air Drilling • Air injection directly to the cones to cool the bearings Sealed Bearing • O-Ring seal with grease reservoir for bearing lubrication • Barrier against mud and cuttings Journal Bearing • Strictly oil/grease lubricated with nose bearings, • O-Ring seal and a • Ball race for maximum performance. 203

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

204 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

4 Types of Roller Bit Bearings 1.

2.

3.

4.

Standard Open Bearing • Front row of ball bearings • Back row of roller bearings. Standard Open Bearing • For Air Drilling • Air injection directly to the cones to cool the bearings Sealed Bearing • O-Ring seal with grease reservoir for bearing lubrication • Barrier against mud and cuttings Journal Bearing • Strictly oil/grease lubricated with nose bearings, • O-Ring seal and a • Ball race for maximum performance. 205

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

206 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

4 Types of Roller Bit Bearings 1.

2.

3.

4.

Standard Open Bearing • Front row of ball bearings • Back row of roller bearings. Standard Open Bearing • For Air Drilling • Air injection directly to the cones to cool the bearings Sealed Bearing • O-Ring seal with grease reservoir for bearing lubrication • Barrier against mud and cuttings Journal Bearing • Strictly oil/grease lubricated with nose bearings, • O-Ring seal and a • Ball race for maximum performance.

207 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

208 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

PolyCrystaline Diamond Compact (PDC) Bit

Drive System

Diamond Impregnated (Impreg.) Bit 209

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

210 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Bit & Hole Opener

211 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Decisions! Decisions!  

Which bit works best? Selection Criteria • Bit Cost • Rig Cost / Capability • Formation • Information • Bit life • Performance History • Previous bit condition 212

MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Parameters      

Roller Cones WOB = 4500 lb / in dia max. ROP dictated by bearing type Bit life determined by WN number (weight * total revs) Diamond / PDC WOB determined by bit aggressiveness and torque developed High RPM > 150  In combination with motor / turbines Role of drilling dynamics / vibration Check with drill-off test 

 

213 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How would you grade this one?  What would you run in the hole next? 

214 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Fluid System • Delivers power (HHP) to the bit • Cleans the bottom of the hole to enable the cutters to cut new formation • Cools the Bit • Carries cuttings to the surface • Different approaches to maximize drilling rate 215 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Fluid System • How much should we pump? • Answer – sufficient to clean the hole • Requires velocity and carrying capacity • Minimum velocity ~ 150 ft/min (depends on mud viscosity) • In 12 ¼” hole min equivalent volume ~750 GPM 216 MSc Petroleum Engineering – Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How Much Pumping Power? • Power measured as HHP (hydraulic horsepower , consumed at bit (useful) and consumed in system (wasted) • HHP bit = D P at bit x volume • DP achieved by nozzle size changes, e.g., 3 x 16 (16 /32 “) • D Pbit (psi) x Volume pumped (gpm) • Hydraulic plan will aim to maximise HHP when 2/3 HHP is consumed at bit and 1/33 HHP is consumed in circulation system • E.g., Total pressure available is 4500 psi Then HHP bit max = (3000 * 750)/1714 = 1313 HHP And, total system HHP required is 1970 HHP Pumps run at 80% of max output. Need 2460 HHP 217 MSc Petroleum Engineering – Well Engineering

Drilling Fluid & Solids Removal Equipment

218 MSc Petroleum Engineering – Well Engineering

Where did the mud go?

219 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Mud is VERY IMPORTANT Poor, badly formulated or badly maintained drilling fluid (mud) is the PRIMARY cause of non productive time (due to stuck pipe) in drilling operations.

220 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Mud is VERY IMPORTANT Mud properties strongly influence bit performance

221 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Types & Properties Three Common Types •

•

•

Water-based mud (WBM) • Water-base with clays (bentonite) and other chemicals • Lowest cost, but some formations react ($) Oil-based mud (OBM): • Base petroleum product, e.g., diesel fuel • Toxic • Very good drilling/formation properties ($$) Synthetic-based fluid (SBM) • Base synthetic oil • Less toxic • Very good drilling/formation properties ($$$) 222

MSc Petroleum Engineering – Well Engineering

Drilling Fluid Types & Properties

Desired Properties • Thin and free-flowing while the fluid is being pumped (shear thinning), • Thick when pumping is stopped, "gelling" to suspend drilled solids. • Non damaging to reservoir

223 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Additives Many substances, both reactive and inert, are added to drilling fluids to perform specialized functions. The most common functions and additives are as follows:

224 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Additives Alkalinity and pH Control • Designed to control the degree of acidity or alkalinity of the drilling fluid. Most common are lime, caustic soda and bicarbonate of soda. Bactericides • Used to reduce the bacteria count. Paraformaldehyde, caustic soda, lime and starch preservatives are the most common. Calcium Reducers • These are used to prevent, reduce and overcome the contamination effects of calcium sulfates (anhydrite and gypsum). The most common are caustic soda, soda ash, bicarbonate of soda and certain polyphosphates Corrosion Inhibitors • Used to control the effects of oxygen and hydrogen sulfide corrosion. Hydrated lime and amine salts are often added to check this type of corrosion. Oil-based muds have excellent corrosion inhibition properties. 225 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Additives Defoamers • These are used to reduce the foaming action in salt and saturated saltwater mud systems, by reducing the surface tension. Emulsifiers • Added to a mud system to create a homogeneous mixture of two liquids (oil and water). The most common are modified lignosulfonates, fatty acids and amine derivatives. Filtrate Reducers • These are used to reduce the amount of water lost to the formations. The most common are bentonite clays, CMC (sodium carboxymethylcellulose) and pre-gelatinized starch. Flocculants • These are used to cause the colloidal particles in suspension to form into bunches, causing solids to settle out. The most common are salt, hydrated lime, gypsum and sodium tetraphosphates. 226 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Additives Foaming Agents • Most commonly used in air drilling operations. They act as surfactants, to foam in the presence of water. Lost Circulation Materials • These inert solids are used to plug large openings in the formations, to prevent the loss of whole drilling fluid. Nut plug (nut shells), and mica flakes are commonly used. Lubricants • These are used to reduce torque at the bit by reducing the coefficient of friction. Certain oils and soaps are commonly used. Pipe-Freeing Agents • Used as spotting fluids in areas of stuck pipe to reduce friction, increase lubricity and inhibit formation hydration. Commonly used are oils, detergents, surfactants and soaps. 227 MSc Petroleum Engineering – Well Engineering

Drilling Fluid Additives

Shale-Control Inhibitors • These are used to control the hydration, caving and disintegration of clay/ shale formations. Commonly used are gypsum, sodium silicate and calcium lignosulfonates. Surfactants • These are used to reduce the interfacial tension between contacting surfaces (oil/water, water/solids, water/air, etc.). Weighting Agents • Used to provide a weighted fluid higher than the fluids specific gravity. Materials are barite, hematite, calcium carbonate and galena.

228 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine Transmit hydraulic to the bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 229

MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine Transmit hydraulic to the bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 230

MSc Petroleum Engineering – Well Engineering

Cuttings Transport • Good carrying capacity • Transport cuttings to surface • Mud loggers determine the depth where cuttings originated • Drilled cuttings retrieved and analyzed at the wellsite

231 MSc Petroleum Engineering – Well Engineering

Cuttings Transport Requirements • Keep cuttings in suspension when pump / circulation is stopped by gelling • Then thin when circulation recommences

Formation

232 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine Transmit hydraulic to the bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 233

MSc Petroleum Engineering – Well Engineering

Controlling formation pressures Pressure = Depth x gradient = 5000 x 0.6 psi/ft = 3000 psi.

Fluid gradient

Formation with High Pressure (Mud gradient too low = “kick”) Formation with High Stress (Mud gradient too low = “Instability”) Formation with Low Pressure (Mud gradient too high = losses)

Pressure = Depth x gradient = 7000 x 0.5 psi/ft = 3500 psi.

Pressure 234

MSc Petroleum Engineering – Well Engineering

…even more difficult with dynamic pressure

Dilemma • Avoid Losses • Avoid Kicks • Avoid formation instability

235 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluid • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures

•

Seal permeable formations

• • • • • • •

Maintain wellbore stability Minimize formation damage Cool, lubricate the bit and drilling assembly Transmit hydraulic energy to tools and bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion

•

Minimize impact on environment

236 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine Transmit hydraulic to the bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 237

MSc Petroleum Engineering – Well Engineering

Seal permeable formations Filter cake prevents losses through addition of bridging agents

Losses Filter Cake

Total losses to Fractures

Filter cake needs to Plug pores without causing excessive damage

Seepage losses to Porous & Permeable matrix

238 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine Transmit hydraulic to the bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 239

MSc Petroleum Engineering – Well Engineering

Maintain wellbore stability Borehole pressure opposes formation pressure

Borehole Instability

Formation

240 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine Transmit hydraulic to the bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 241

MSc Petroleum Engineering – Well Engineering

Formation Damage (skin) • Reduction in natural formation porosity and permeability = formation damage • Most common damage • Mud or drill solids invade the formation matrix, reducing porosity • Swelling of formation clays within the reservoir matrix reduces permeability • Precipitation of solids due to mixing of mud filtrate and formation fluids resulting in the precipitation of insoluble salts • Mud filtrate and formation fluids form an emulsion • For completions: specially designed drill-in fluids or workover / completion fluids 242 MSc Petroleum Engineering – Well Engineering

Formation damage (impairment) results in lower production rates, lower ultimate recovery and possibly uneconomic wells.

Porosity: Ability to contain Permeability: Ability to flow through 243 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine / bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 244

MSc Petroleum Engineering – Well Engineering

Transmit Energy to the Bit • Cleaning the bottom of the hole to avoid re-drilling of cuttings • Hydraulic horsepower • Jetting action • Cleaning bit cutters • Cooling at the bit 245 MSc Petroleum Engineering – Well Engineering

Transmit Energy to the Bit…and motors

246 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluid • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool, lubricate the bit and drilling assembly Transmit hydraulic energy to tools and bit

•

Enable adequate formation evaluation

• •

Minimize corrosion Facilitate cementing and completion

•

Minimize impact on environment

247 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine / bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 248

MSc Petroleum Engineering – Well Engineering

Enable Formation Evaluation • Low water loss – Avoid flushing away hydrocarbons – Avoid thick wall cake (sticking of logging tools)

• Enable gauge hole – Wash outs – Tight hole

• Optimum overbalance to avoid differential sticking 249 MSc Petroleum Engineering – Well Engineering

Enable formation evaluation

250 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine / bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 251

MSc Petroleum Engineering – Well Engineering

Corrosion Inhibitors • Corrosion leads to loss of casing integrity (especially opposite aquifers) • Loss of drill string integrity – twist offs

• Control the effects of oxygen and hydrogen sulfide corrosion. • Hydrated lime and amine salts (maintain pH) • Oil-based mud has excellent corrosion inhibition properties. 252 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine / bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 253

MSc Petroleum Engineering – Well Engineering

Fluid Properties for Good Cementation • Properties for efficient mud removal • Condition mud to as low a yield point and gel strength as practical consistent with: – Cuttings removal – Solids suspension – Hole stability

• Condition mud until flowline and suction mud properties have stabilized at optimum values • Mud conditioning also cools the well 254 MSc Petroleum Engineering – Well Engineering

Functions of Drilling Fluids • • • • • • • • • • • •

Remove cuttings from well Suspend and release cuttings Control formation pressures Seal permeable formations Maintain wellbore stability Minimize formation damage Cool and lubricate the bit and drilling assembly Transmit hydraulic energy to mud motor / turbine / bit Ensure adequate formation evaluation Minimize corrosion Facilitate cementing and completion Minimize impact on environment 255

MSc Petroleum Engineering – Well Engineering

Minimize impact on environment • • • • •

Avoid OBM & SBM where possible Special OBM & SBM containment systems Cuttings cleaning and capture Cuttings returned for recycling Drill smaller holes

256 MSc Petroleum Engineering – Well Engineering

Measuring & Maintaining Fluid Properties

257 MSc Petroleum Engineering – Well Engineering

Properties Measured •

•

•

• • • • • •

Density • Mud weight ppg • Gradient psi/ft Viscocity • Centipoise • PV / YP Gel Strength • 10 sec • 10 min Water Loss PH Solids Content Sand Content Ca++ Also special HPHT measurements

Drilling Fluid Properties…

Fann Viscometer

…and Measurement 258 MSc Petroleum Engineering – Well Engineering

Fluid Management System • • • • • • •

Tanks and mixers De-gasser Shale Shakers Cyclone De-sander De-silter Mud cleaner Centrifuge 259

MSc Petroleum Engineering – Well Engineering

Shale Shakers

Screen 260 MSc Petroleum Engineering – Well Engineering

Fluid Management System

261 MSc Petroleum Engineering – Well Engineering

De-sander

262 MSc Petroleum Engineering – Well Engineering

De-silter

263 MSc Petroleum Engineering – Well Engineering

Mud-cleaner

264 MSc Petroleum Engineering – Well Engineering

Centrifuge

265 MSc Petroleum Engineering – Well Engineering

Mud de-gasser

266 MSc Petroleum Engineering – Well Engineering

Well Construction

267 MSc Petroleum Engineering – Well Engineering

The Purpose of the Well • Find, acquire and enable production of petroleum oil or natural gas • Provide a reliable pressure containment vessel • Provide a means to safely and economically produce, inject or monitor fluids 268 MSc Petroleum Engineering – Well Engineering

Purpose of this well – produce oil Wells come in all sizes… • Stripper well (opposite) as little as 2 bbls (oil) / day • Big oil wells > 50,000 bbl / day • Big gas wells > 100 million scf / day

269 MSc Petroleum Engineering – Well Engineering

Many types of wells • Exploration wells • Appraisal wells • Production wells • Oil producers. • Gas producers • Reservoir management • Water injectors • Gas Injectors • Co-produced gas • CO2 • Reservoir monitoring • Produced water disposal • Waste drilling fluid • Gas storage 270 MSc Petroleum Engineering – Well Engineering

Purpose of Casing …in combination with Cement • • • •

Structural support for Wellhead Provide wellbore Stability Isolate different formations Provide (with blowout preventer) control of well pressures during Drilling, Production and Intervention • Barrier to pressure or flow of fluids from formation to surface ….or formation to formation • Isolation of loss zones 271 MSc Petroleum Engineering – Well Engineering

Casing • Pipe Body & Threads compatible with the pressures and fluids expected. • Thread Connections – STC, LTC, Buttress, – Special gas tight

• Typical designation 9-5/8" 53.5# P-110 BTC Range 3 • API Specification 5C3 (ISO /TR 10400) – Standardizes (14 casing sizes) – 4.5 inches through 20 inches ("OD") 272 MSc Petroleum Engineering – Well Engineering

Typical Casing & Tubing Design Conductor Casing

• Conductor • Surface Casing • Casing • Drilling • Production

• Liner • Drilling • Production

• Tieback • Production tubing

Annuli Designation

'D' Annulus 'C' Annulus Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer Perforations Production Liner

273 MSc Petroleum Engineering – Well Engineering

Typical Casing & Tubing Design Process Conductor Casing

• Identify all load scenarios • Estimate load parameters • Calculate principal loads • Axial • Internal / external pressure • Bending

• Calculate strength to resist loads • Repeat process • There are uncertainties • • • •

Load Parameters Actual Casing strength Failure modes and consequences Connection strength

'D' Annulus 'C' Annulus Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer Perforations Production Liner

274 MSc Petroleum Engineering – Well Engineering

Cement Purpose

Requirements

• Supports Casing • In combination with casing and BOP’s provides well control • Provides zonal isolation • Helps control corrosion

• Oilfield cement manufactured (API) Specification 10A. • Classes of API cement are A, B, C, D, E, F, G and H. • Modified to with “additives” to deliver required properties • Accelerators • Retarders • Slurry density reducers • Slurry density enhancers • Temperature resistance • Compressive strength • Flow properties 275 • Elasticity

MSc Petroleum Engineering – Well Engineering

Cementing and casing the well

MSc Petroleum Engineering – Well Engineering

Casing Cemention 276 process explained later.

Wellhead Purpose • Provides pressure-containment interface (BOP’s) during drilling phase • Provides casing hang-off profiles during the well construction phase. • Provides tubing hang-off profile for production tubing • Supports the Christmas tree • In combination with Christmas tree provides surface flow-control during production phase

277 MSc Petroleum Engineering – Well Engineering

Compact Wellhead Purpose • Compact multi-bowl wellhead design • Allows multiple casing strings to be hung in a single wellhead component • Reduces installation time and footprint

278 MSc Petroleum Engineering – Well Engineering

Subsea Wellhead • Applications to 10,000 psi WP, • Single trip Casing hangers and seal assemblies • Five- or six-string casing options • Weight-set, elastomeric parallel bore seal assemblies • Running tool provides a straightforward stab, test and tool retrieval. • Passive lockdown high-pressure housing into the 30" housing. • Guideline or guidelineless operations

279 MSc Petroleum Engineering – Well Engineering

Christmas Tree Purpose • Installed on top of the wellhead to control the flow of well fluids during production. • Provides primary and back-up control facilities for production • Enables wellbore shut-in • Incorporates facilities to enable safe access for well intervention operations , e.g., slickline, electric wireline and coiled tubing

280 MSc Petroleum Engineering – Well Engineering

Flowline

Xmas tree

Cellar

Wellhead

Gas storage well Etzel Germany 281

MSc Petroleum Engineering – Well Engineering

Completion Purpose •

Enable safe and efficient control of fluid production through selective zones

Several Types • • • •

Cased hole - perforated Open hole – limits options Single, dual, triple Smart

Enables • •

Remedial isolation Special treatments

Includes •

Plugs, nipples, mandrels

282 MSc Petroleum Engineering – Well Engineering

Completion Purpose 

Enable safe and efficient control of fluid production through selective zones

Several Types    

Cased hole – perforated Open hole – limits options Single, dual, triple Smart

Enables  

Remedial isolation Special treatments

Includes for maintenance and access 

Plugs, nipples, mandrels 283

MSc Petroleum Engineering – Well Engineering

Completion Purpose 

Enable safe and efficient control of fluid production through selective zones

Several Types 

  

Cased hole – perforated Open hole – limits options Single, dual, triple Smart

Enables  

Remedial isolation Special treatments

Includes for maintenance and access 

Plugs, nipples, mandrels

284 MSc Petroleum Engineering – Well Engineering

Well Construction Casing & Cementing

285 MSc Petroleum Engineering – Well Engineering

Cement • Oilfield cement manufactured to (API) Specification 10A. • Classes of API cement are A, B, C, D, E, F, G and H. • Modified with “additives” to deliver required properties – – – – – – – –

Accelerators Retarders Slurry density reducers Slurry density enhancers Temperature resistance Compressive strength Flow properties Elasticity

286 MSc Petroleum Engineering – Well Engineering

Cementing Operations Cementation is the final Crucial Operation in Securing a well section • Cement is a Barrier • Must achieve – High quality uncontaminated cement that bonds to casing and formation – High compressive strength – Well control throughout the operation – Float equipment (flow inside casing) – Prevent channeling (flow outside casing) – Isolation of hydrocarbon zones – Isolation of water zones – Protection from corrosive fluids 287 MSc Petroleum Engineering – Well Engineering

Cementing Operations Good Cementation Achieved Through: • Pre cementation circulation and conditioning of mud • Proper mixing and blending of mix water and cement – Minimise free water – Correct density

• High displacement rates – Density difference spacer, lead, main & tail slurry

• • • •

Effective mud removal Casing movement (reciprocation or rotation) Casing centralisation Concerns – Losses – Not getting casing to bottom

288 MSc Petroleum Engineering – Well Engineering

Cementing Operations Accessories: Float Equipment • Purpose – Prevent back-flow when cement is pumped in place – Provide landing shoulder for wiper plugs (Collar) – Provide Guide for Casing (Shoe) – Enable pressure-test of Casing after displacement cement (Collar) Float Collar

Float Shoe

289 MSc Petroleum Engineering – Well Engineering

Cementing Operations Accessories: Wiper Plugs • Purpose – Remove drilling fluid residue from casing (Bottom Plug) – Separate drilling fluid / spacers from Cement – Wipe cement residue from casing (Top Plug) – Enable pressure-test of casing after displacement; landing on float collar (Top Plug) 290 MSc Petroleum Engineering – Well Engineering

Cementing Operations Accessories: Cement Head • Purpose – Enable sequential release of cement plugs – Provide circulation path for drilling fluid, spacers and cement 291 MSc Petroleum Engineering – Well Engineering

Cementing Operations Accessories: Centralizers, Scratchers & Wipers • Purpose – centralizers; 2 types – centralize casing & provide stand-off from bore hole – minimize channeling, enable uniform distribution of cement – scratchers and wipers scrape “wall-cake” from borehole 292 MSc Petroleum Engineering – Well Engineering

Cementing Operations Accessories: Stage Cementing • Purpose: Cementing with losses – Reduce effective length of cement column – Enable cement placement below & above loss zone – Isolate hydrocarbon zones at various levels in well 293 MSc Petroleum Engineering – Well Engineering

Cementing operations – equipment and process

294 MSc Petroleum Engineering – Well Engineering

Cementing Operations

295 MSc Petroleum Engineering – Well Engineering

Casing & Cementing the Well

Conductor Casing 'D' Annulus 'C' Annulus Surface Casing

• Conductor - driven before rig arrives • Surface Casing • Casing • Drilling • Production

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

• Liner • Drilling • Production

Production Tubing

Packer Perforations Production Liner

296 MSc Petroleum Engineering – Well Engineering

Casing & Cementing the Well

Conductor Casing 'D' Annulus 'C' Annulus

• Conductor - driven before rig arrives • Surface Casing – cemented to surface – serves as foundation of the well. Covers shallow aquifers

• Casing • Drilling • Production

• Liner • Drilling • Production

Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer Perforations Production Liner

297 MSc Petroleum Engineering – Well Engineering

Before Casing & Cementing Operations Drill top hole section and Circulate Clean

298 MSc Petroleum Engineering – Well Engineering

Run Surface Casing

• Foundation of the Well • Requires cement back to surface • Large displacement volume if “plug” cementation used • Solution is a “stinger” using tubing or drillpipe

299 MSc Petroleum Engineering – Well Engineering

Surface Casing • Casing run to bottom and “hung off” on profile on Conductor

300 MSc Petroleum Engineering – Well Engineering

Surface Casing • Drillpipe with stinger assembly run in hole • Stabbed into special float shoe

Drillpipe Stinger Cementation

301 MSc Petroleum Engineering – Well Engineering

Surface Casing • Circulate and condition mud • Pump water spacer

Drillpipe Stinger Cementation

302 MSc Petroleum Engineering – Well Engineering

Surface Casing • Mix and pump cement

Drillpipe Stinger Cementation

303 MSc Petroleum Engineering – Well Engineering

Surface Casing • Cement back to surface • Displace drillpipe with drilling fluid

Drillpipe Stinger Cementation

304 MSc Petroleum Engineering – Well Engineering

Surface Casing • Displace drillpipe with drilling fluid • Leave 100m cement in drillpipe to avoid contamination at shoe

Drillpipe Stinger Cementation

305 MSc Petroleum Engineering – Well Engineering

Surface Casing

• Remove drillpipe • Cement fills bottom of casing • Circulate clean • Wait on Cement (WOC)

Drillpipe Stinger Cementation

306 MSc Petroleum Engineering – Well Engineering

Plug Type Cementation

307 MSc Petroleum Engineering – Well Engineering

Casing & Cementing the Well • Conductor - driven before rig arrives • Casing • • • •

• Drilling (intermediate) • Production Cement covers exposed hydrocarbons (minimum 500ft) Volume from caliper log Back to surface not practicable Liner • Drilling • Production

Conductor Casing 'D' Annulus 'C' Annulus Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer Perforations Production Liner

308 MSc Petroleum Engineering – Well Engineering

Casing & Cementing the Well Typical (simplified) Calculations (Halliburton Red Book) • • • • • • • • • • • • • •

•

Mud density = 87 lb/cuft Quantity of cement (V1 + V2 + V3) = 748.9 cuft Slurry weight = 118 pcf (Class H) Slurry volume = 1.14 cuft/sx 748.9/1.22 = 614 sx Mix water volume = 5.49 gal/sx = 3821 gal Casing vol to collar = (13891 – 80) x 1.5603 gal/ft = 21550 gal Displacement rate = 300 gpm Total time for the job = mix time + plug release + displacement (chase) time (614/25) + 15 + (21550/300) = 25+15+72 = 112 min Hmw D P prior to bumping plug = DP mw/mud + DP cement/mud 1330 ft = 1330 x (62-87)/144 + 5906 (115-87)/144 = 918 psi Annular velocity during chase Velocity = Volume/Ann.Area = 300/ p/4x(8.5 - 7 ) = 316 ft/min (turbulent flow) Hcmt 2 2 Total mud returns during the job = steel volume + slurry 5906 ft volume + mix water = 197 + 180+ 30 = 407 bbl (important for well control) Next – Step for Step Cementation

2 Conductor Casing 'D' Annulus 'C' Annulus Surface Casing

'B' Annulus

Production Tieback

7” 29 lb/ft Casing

mw r = 62 lb/cuft 'A' Annulus

Intermediate Casing

V3

Mud r = 87 lb/cuft

Production Tubing

v1

v2

Cmt r = Packer 115 lb/cuft Perforations Liner TD =Production 13900 ft

309 MSc Petroleum Engineering – Well Engineering

Production Casing

Plug Cementation

Drilling Fluid from Rig Pump. Pre cementation, circulate and condition drilling fluid in preparation for cementation. Condition: develop optimum cementing properties, mobilise gelled fluid, cool hole,

310 MSc Petroleum Engineering – Well Engineering

Production Casing

Drilling Fluid from Rig Pump. Pre cementation, circulate and condition* drilling fluid in preparation for cementation *Condition: develop optimum cementing properties, mobilise gelled fluid, cool hole,

Plug Cementation

311 MSc Petroleum Engineering – Well Engineering

Production Casing Plug Cementation • Intermediate and production casings • Pre-calculated volume circulated between plugs • Volumes obtained from caliper logs Plug Cementation

312 MSc Petroleum Engineering – Well Engineering

Production Casing Place wiper plugs in cement head.

Plug Cementation

313 MSc Petroleum Engineering – Well Engineering

Production Casing From Cement Unit) Pump preflush “scavenger” cement. (slurry heavier than drilling fluid lighter than cement slurry) with objective to remove mud wall cake and displace drilling fluid.

Plug Cementation

314 MSc Petroleum Engineering – Well Engineering

Production Casing From Cement Unit. Pump (calculated cement slurry volume mixed & pumped “on the fly”). Cement properties continuously monitored and adjusted.

Plug Cementation

315 MSc Petroleum Engineering – Well Engineering

Production Casing Switch to Rig Pump for high rate displacement

Plug Cementation

316 MSc Petroleum Engineering – Well Engineering

Production Casing Continue displacement at high rate to create good mud displacement

Plug Cementation

317 MSc Petroleum Engineering – Well Engineering

Production Casing First ‘bottom” plug arrives at float collar

Plug Cementation

Bottom plug diaphragm ruptures 318 MSc Petroleum Engineering – Well Engineering

Production Casing Continue displacement, cement rising in annulus. Anxiously awaiting “bump” of top plug.

Plug Cementation

319 MSc Petroleum Engineering – Well Engineering

Continue displacement, until top plug “bumps”. Pressure test casing. Cement job completed Wait on Cement – monitor for flow Plug Cementation

320 MSc Petroleum Engineering – Well Engineering

Overview of Plug Cementation

321 MSc Petroleum Engineering – Well Engineering

Casing & Cementing the Well

Conductor Casing 'D' Annulus 'C' Annulus Surface Casing

• Conductor - driven before rig arrives • Casing • Drilling (intermediate) • Production • Cement covers exposed hydrocarbons (minimum 500ft) • Back to surface not practicable • Liner • Drilling • Production

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Liner • Hung off in Packer previous Perforations casing

Production Tubing

Production Liner

322 MSc Petroleum Engineering – Well Engineering

Directional Drilling

323 MSc Petroleum Engineering – Well Engineering

Anyone know where we are?

324 MSc Petroleum Engineering – Well Engineering

Why directionally drill? • Access specific reservoir sections / zones • Access difficult reservoir locations. – – – –

Under residential area / natural park Under a lake / near shore Avoid difficult to drill or troublesome formation, e.g., mobile salt Avoid high pressure

• Allow multiple wellheads from one surface location – Offshore platform / jacket offshore, up to 40 wells (tight spacing) – Pad drilling land wells, reducing environmental impact. – Sub sea template

• Relief well drilling • Highly deviated / horizontal wells to increase exposed section length through the reservoir => higher production

325 MSc Petroleum Engineering – Well Engineering

Planning & Preparation • Identify subsurface targets • Data from: – – – –

Seismic Previous wells Reservoir model Petrophysical logging

• Select surface location – Surface (Grid) coordinates – Magnetic declination – Depth references – Develop Well trajectory 326 MSc Petroleum Engineering – Well Engineering

Well Trajectory (section) Directional Jargon • Kick off point (KOP) • Build up section • End of Build (EOB) • Tangent section • Drop off section

327 MSc Petroleum Engineering – Well Engineering

Well Trajectory (section and plan) • Kick off point (KOP) • Build up section • End of Curve (EOC)

• Tangent section • Drop off section 328 MSc Petroleum Engineering – Well Engineering

Development of Directional Drilling Systems • “Badgering” with bent pipe • Whipstock (side-track from casing, e.g., for ML wells) – After deflection made (e.g., 6 – 10 degrees) – BHA design (stabilizer placement) and drilling practices (WOB / Circ rate) used to build /drop/hold angle – Simple survey tools – Directional readings; dropped or wireline-conveyed “single shot photos” (camera photo of compass and plumb )

• Mud motors enabled bit to be rotated independent of the drillstring – Electronic magnetometer/inclinometer data via wireline with orientation sub above bent sub at the top of the motor

• Mud pulse telemetry enabled MWD, transmission of data (directional (and other)) while drilling • Rotary Steerable Systems – point the bit / push the bit technology

329 MSc Petroleum Engineering – Well Engineering

How do we know where we are? • 3 “survey” components measured at any given point in a wellbore to determine position: – Measured depth – Inclination – Magnetic azimuth

• Consecutive surveys needed to track the progress and location of a wellbore

330 MSc Petroleum Engineering – Well Engineering

Directional Surveying Magnetic Single Shot • Every 100 feet stop for wireline survey • Lower and retrieve camera with pendulum and magnetic compass • Slow and prone to miss-runs Non Magnetic DC’s

331 MSc Petroleum Engineering – Well Engineering

Directional Surveying • Magnetic surveys • Requires non- magnetic environment • Use non magnetic drill collars (NMDC’s) • Length NMDC’s depends on declination • Corrected for Magnetic Declination • Corrected for Grid System • Gyro surveys required for regions of high interference • Inside casing • Close to platform 332 MSc Petroleum Engineering – Well Engineering

Directional Surveying • Magnetic surveys • Requires non- magnetic environment • Use non magnetic drill collars (NMDC’s) • Length NMDC’s depends on declination • Corrected for Magnetic Declination • Corrected for Grid System • Gyro surveys required for regions of high interference • Inside casing • Close to platform 333 MSc Petroleum Engineering – Well Engineering

Development of Directional Drilling Systems - Badgering • “Badgering” with Bent pipe – Bottom Hole Assembly or "BHA“ for deviations from the vertical

• Bit is set up with one nozzle on “high side” • Bit is orientated in desired direction • By jetting and sliding hole angle is built in desired direction • Intermittent “jet and slide” and rotate 334 MSc Petroleum Engineering – Well Engineering

Development of Directional Drilling Systems – Whipstock Drilling • Whipstock run, on drillpipe, orientated and set in desired direction • Drill off the whipstock • Deflect hole in desired direction • Used today in cased hole for sidetracks with milling assembly 335 MSc Petroleum Engineering – Well Engineering

Milling Window off Whipstock • PU mill string, circulate, record pressures • Rotate recording drag torque, slowly move downwards until contact WS • Mill window

336 MSc Petroleum Engineering – Well Engineering

Conventional BHAs Deviation Drilling before the advent of mud motors & deflection tools • Build angle 6 to 10 deg (jetting) • RIH build assembly • Hold Assembly • Drop Assembly

337 MSc Petroleum Engineering – Well Engineering

Mud Motors with Bent Subs and E-line Surveying Revolutionised Directional Drilling

338 MSc Petroleum Engineering – Well Engineering

Deflection / Directional Control Tools

339 MSc Petroleum Engineering – Well Engineering

Deflection / Directional Control Tools • Downhole Motor (PDM) & Bent Sub / Bent Housing • Bent housing (integral) or bent sub (directly above) motor • 10 to 30 inclination from axis • Acts as pivot. • Deflection / degree of curvature • Depends on relationship • Bent sub angle / OD motor > hole size • Bent sub angle and Drill Collar OD > hole size • Motor length 340 MSc Petroleum Engineering – Well Engineering

Directional Correction

Rebel Tool • Run just above the bit • Long paddles turned left • Short paddles turned right • Forerunner of RSS 341 MSc Petroleum Engineering – Well Engineering

Mud Motors & Deflection Tools Revolutionised Directional Drilling

342 MSc Petroleum Engineering – Well Engineering

Mud Motors & Deflection / Directional Control Tools Revolutionised DD

Downhole motor and bent sub / bent housing MSc Petroleum Engineering – Well Engineering

343

Measurement While Drilling (MWD) Revolutionised Directional Drilling

344 MSc Petroleum Engineering – Well Engineering

Measurement While Drilling "MWD" systems • Real time measurements • Basic trajectory parameters – Inclination – Direction – Tool-face

• Additional sensors include: – – – – –

Pressure, Gamma-ray Resistivity Temperature Other petrophysical evaluation tools 345

MSc Petroleum Engineering – Well Engineering

Measurement While Drilling "MWD" systems Power Supply • Lithium batteries • Downhole generator (turbine) Directional Sensor Section • Hole trajectory from sensor stack – 3 accelerometers – 3 magnetometers

Data Transmission (three methods) • Pressure waves through mud (mud pulse) (+/- 4 bps) • Electromagnetic "EM" signals through the earth to surface. (+/- 4 bps) • Wired pipe (1 mega bps) 346 MSc Petroleum Engineering – Well Engineering

Measurement While Drilling "MWD" systems Pulse system – Mud pulse opens and closes a valve – Creates either a pressure surge (positive pulse) or drop (negative pulse). – Range of 10-50 psi are detected at surface at transducer installed in stand pipe

• Continuous signal for directional control • Data stored and encoded for transmission in data burst decoded into useable information. • No practical depth limitation • Reliant on good drilling fluid 347 MSc Petroleum Engineering – Well Engineering

Telemetry - Principles of Positive Mud Pulsers (MWDs)

348 MSc Petroleum Engineering – Well Engineering

EM MWD Systems • Uses same sensors and power supplies • Data transmission via magnetic pulse or electrical current through formations to surface antennas • Data can be transmitted at any time • Depth limitations, formation type and power consumption are concerns • Used for under-balance / air drilling 349 MSc Petroleum Engineering – Well Engineering

Measurement While Drilling "MWD" systems • High rate wired pipe telemetry • Transmit data rates up to 1 mega bps • Upload and download data – – – – – – –

Evaluation down-hole environment Multiple petrophysical logs Reservoir characterization Geo steering Precise navigation of the well bore Reliability Expensive 350

MSc Petroleum Engineering – Well Engineering

RSS Revolutionised Directional Drilling……and more!

351 MSc Petroleum Engineering – Well Engineering

Rotary Steerable Systems Non rotating Sleeve

e.g. Autotrak from Baker Hughes Inteq (BHI) LWD Triple Combo

Bit Side Force

MWD

Rotating Drive Shaft

Formation Evaluation “Gamma Ray + Resistivity”

Non rotating Sleeve w/ Steering ribs & Inclination Sensors 352 MSc Petroleum Engineering – Well Engineering

Rotary Steerable Systems Advantages • Continuous pipe movement • No need for slide drilling • Better hole cleaning • Reduces / eliminates trips for assembly changes • Permits more complex well paths to be drilled • Allows well track to be kept close to plan • Geosteering – following formation changes • Hit smaller targets • Extended Reach Drilling • Can be run with range of petrophysical tools 353 MSc Petroleum Engineering – Well Engineering

LWD Revolutionised Drilling

354 MSc Petroleum Engineering – Well Engineering

MWD Measurement While Drilling LWD Logging While Drilling

355 MSc Petroleum Engineering – Well Engineering

MWD Measurement While Drilling LWD Logging While Drilling • LWD Logging While Drilling • Directional measurements (and control in conjunction with Rotary Steerable Systems) • Formation evaluation (gamma, Resistivity, Sonic, Density (amongst others) • Downhole dynamics / parameters for optimization – Pressure while drilling – Vibration – RPM

• Telemetry – Pulse – Electromagnetic – Wired

356 MSc Petroleum Engineering – Well Engineering

Well Trajectories

357 MSc Petroleum Engineering – Well Engineering

Conventional Directional Drilling Build and hold

Build hold and drop into target

358 MSc Petroleum Engineering – Well Engineering

Less conventional directional drilling • • • •

Horizontal Extended Reach Hook well Tortuous “snake well

359 MSc Petroleum Engineering – Well Engineering

Horizontal Drilling Advantages • Greater reservoir exposure per well • Geo steering to stay in sweet spot • Fewer wells required for same production Disadvantages • Increased formation damage • During well life cycle, limited recompletion options • Isolation of water / gas coning 360 MSc Petroleum Engineering – Well Engineering

361 MSc Petroleum Engineering – Well Engineering

Extended Reach Wells •

How? • Special Rigs (Power) BP Wytch Farm ••

(M-11) 10.4km components Lateral Displacement at 1,600m True Vertical Drillstring Depth • Large bore Sakhalin Island Chayvo field 28 January 2011 depth the world’s longest borehole was drilled • On(Z-12) measured 11,680 meters (38,320 ft) • High strength tool joints Odoptu Sakhalin-I with a measured total depth • at the Chayvo field,field, contains 17 of the world's 30 longest of 12,345 meters (40,502 ft)wells and a horizontal displacement of extended-reach-drilling • Aluminium pipe? metersField (37,648 ft). Al11,475 Shaheen Qatar • Special synthetic mud systems • BD-04A (World record) measured depth of 12,289 meters (40,320high ft) pump 10,902rates meters • Very • Record horizontal reach of 10,902 meters (35,770 ft) (35,770 ft) steerable systems •• Rotary Drilled in 36 days • Excellent drilling practices 362 MSc Petroleum Engineering – Well Engineering

Extended Reach Wells •

On 28 January 2011 the world’s longest borehole was drilled How? at the Odoptu field, Sakhalin-I with a measured total depth of

12,345 meters Rigs (40,502(Power) ft) and a horizontal displacement of • Special BP Wytch Farm

11,475 meters (37,648 ft). •• Drillstring (M-11) 10.4km components Lateral Displacement at 1,600m True Vertical Depth

• Large bore Sakhalin Island Chayvo field

28 January 2011 depth the world’s longest borehole was drilled • On(Z-12) measured 11,680 meters (38,320 ft) • High strength tool joints Odoptu Sakhalin-I with a measured total depth • at the Chayvo field,field, contains 17 of the world's 30 longest of 12,345 meters (40,502 ft)wells and a horizontal displacement of extended-reach-drilling • Aluminium pipe? metersField (37,648 ft). Al11,475 Shaheen Qatar

•

Special synthetic mud systems BD-04A (World record) measured depth of 12,289 meters (40,320high ft) pump 10,902rates meters • Very • Record horizontal reach of 10,902 meters (35,770 ft) (35,770 ft) steerable systems •• Rotary Drilled in 36 days • Excellent drilling practices •

363 MSc Petroleum Engineering – Well Engineering

Hook Well Design – Drilling Up Hill • Drilled from land to offshore location • Accessed multiple reservoirs • Completed with gravel pack • Maximum hole angel 167 deg • Used RSS BSP - Todak Field MSc Petroleum Engineering – Well Engineering

364

Snake Well Design

Access multiple small reservoirs 365 MSc Petroleum Engineering – Well Engineering

Multi-lateral Wells Production tool • Can improve well economics • Multiple access from single wellbore • Injection & production from same wellbore • Different levels of isolation Applications • Sidetrack (with whipstock) from existing or purpose built wells 366 MSc Petroleum Engineering – Well Engineering

Multi-lateral Wells Selective Production • Sealed junction • Zonal isolation • Selective access Problem areas • Competence of junction seal • Access to laterals • Isolation of laterals

367 MSc Petroleum Engineering – Well Engineering

Multilateral well example Matrix Carbonate Field • Dual lateral producer • Triple lateral injector wells • Total 8300 m open hole • Few options in producer when water breaks through

368 MSc Petroleum Engineering – Well Engineering

Stuck Pipe

369 MSc Petroleum Engineering – Well Engineering

What is Stuck Pipe? • When the maximum pull on the drillstring is reached and the pipe is not moving out of the hole – the string is STUCK.

370 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms There are several mechanisms for pipe becoming stuck. The most common mechanisms include the following: • Poor Hole Cleaning • Chemically Active Formations • Mechanical Instability • Overpressured Formations • High Dip Sloughing • Unconsolidated Formations • Mobile Formations • Undergauge Hole • Key Seating • Tectonic Stresses • Differential Sticking 371 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (1) Differential Sticking

• Caused by DP between porous & permeable formation and mud hydrostatic pressure • Frequent problem due to depleted reservoirs • Recovery possible

• Preventive measures? 372 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (1) – differential sticking Build-up of Low Gravity Solids

Filtercake

Excess mud pressure

String Permeable Formation

Gelled, stagnant mud 373

MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (1) – differential sticking build-up of Low Gravity Solids

Filtercake

Contact Area will increase with time

Excess mud pressure

String

String Permeable Formation

Gelled, stagnant mud

374 MSc Petroleum Engineering – Well Engineering

Differential Sticking Mechanism • In normal drilling operations, mud hydrostatic pressure exceeds formation pressure. • The pressure differential is usually designed to be 200-300 psi but in depleted formations it can be much higher. • The differential pressure in permeable zones forces filtrate into the permeable rock, leaving behind a wall cake. • When pipe comes into contact with the wellbore the pipe surface in the wall cake is exposed to the lower pressure of the formation while the rest of the pipe surface is exposed to mud hydrostatic. • Differential pressure force pulls the pipe firmly against the wall of the wellbore. 375 MSc Petroleum Engineering – Well Engineering

Differential Sticking Mechanism • Thicker wall cake results in a larger area exposed to the lower pressure of the formation. • Differential sticking normally occurs when the pipe is static. • More cake is deposited to form a bridge, causing significant increase in effective contact area. • Differentially stuck pipe continues to get more stuck as time passes. • Quick action is necessary to free it. 376 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (2) Geo-pressured Formation

DP

• Too large DP fluid / formation gradient (mud weight too low) • Exacerbated by need for low mud weight for low pressure zones • Shale/ Claystone Formations

• Indicator; splintery & spalled cuttings 377 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (3) Unconsolidated Zones

• Usually top hole problem • Addressed with

• High circ rate • Optimal mud weight

378 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (4)

Key Seating

• Caused by high dog-legs • Ream out when detected

• Run stabilizer on top of drill collars to open up hole 379 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (5) Reactive Formation

• Formation incompatibility with mud filtrate • Addressed by chemical inhibition WBM • Or use OBM SBM 380 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (6) Drill String Vibration

• Uncontrolled vibration results in high impact loads against well bore • Makes fragile but stable formations UNSTABLE 381 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (7) Hole Cleaning

• Frequent problem due to insufficient pump rate => annular velocity • Avoidable with • Increase rig HHP

• Optimise pump rates • Good mud properties 382 MSc Petroleum Engineering – Well Engineering

Hole Cleaning

• Vertical hole - few problems • Problematic between 50 and 65 degrees • Cuttings beds form between 40 and 75 deg • Relatively less problematic in horizontal holes 383 MSc Petroleum Engineering – Well Engineering

Annulus flow regime LAMINAR FLOW VELOCITY PROFILE

384 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (8) Borehole Geometry

• Irregular hole shape caused by: • Poor BHA selection

• Poor mud system • Poor drilling practices • Formation changes 385 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (9) Fractured/ Faulted Formations

• Aggravation by:• Drillstring surging at connections / RT’s • Losses • Drill String Vibration • Drilling fluid properties

386 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (10) Mobile Salt Formations

• Tectonically stressed and often requires very (too) high mud weight to control

387 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (11) Cement Related

• Caused by Poor Cementations • Long rat holes

388 MSc Petroleum Engineering – Well Engineering

Stuck Pipe Mechanisms (12) •

Driller initiated problems:

•

RIH or POOH too fast

Undergauged Hole MSc Petroleum Engineering – Well Engineering

•

Lack of attention

•

Dropped junk in hole

•

Run cones off roller cone bits

Junk in Hole 389

Identifying Impending Problems

390 MSc Petroleum Engineering – Well Engineering

Volume of Cuttings at Shale Shakers – observe and measure

391 MSc Petroleum Engineering – Well Engineering

What to look for… CUTTINGS

Shale Shaker • Volume • Size • Type

CAVINGS

392 MSc Petroleum Engineering – Well Engineering

First Actions Sticking 1. 2. 3.

4.

5.

Ensure circulation is maintained. If the string became stuck while moving up, (apply torque) jar down. If the string became stuck while moving down, do not apply torque and Jar up. Jarring operations should start with light loading (50k lbs) and then systematically increased to maximum load over a one hour period. Stop or reduce circulation when; a) cocking the jars to fire up and b) jarring down. Pump pressure will increase jar blow when jarring up, so full circulation is beneficial (beware of maximum load at the jar). If jarring is unsuccessful consider acid pills, if conditions permit.

393 MSc Petroleum Engineering – Well Engineering

PLANNING to avoid Stuck Pipe…the Selection/Change of BHA • Design Simplicity – Keep BHA as short as practically possible – Eliminate and/or lay down tools which are not used or have a low probability of being used

• Size Drill Collars/HWDP - compromise between: – – – – –

WOB Rigidity Annular clearance Annular velocity across the BHA Wall contact area

• Jar Optimisation – Type of Jar, Placement of Jar, use of 1 or 2 Jars – Awareness of Jar Limitations AND Impact 394 MSc Petroleum Engineering – Well Engineering

PLANNING to avoid Stuck Pipe…the Selection/Change of BHA • Dimensions – – – – –

Accurately measure & gauge (Length, OD and ID) Bit Stabilizers All tools in BHA Ensure free access for. Free Point Indicator / back-off tools

• Downhole Visualization – Record all hole problems / issues – Sketch draw down hole situation – Note BHA change on tripping/drilling

• Records – Certification/Inspection/records /Operating Hours – – Lay down or change out tools that have reached max. operating hours (no uncertified tools!!) 395 MSc Petroleum Engineering – Well Engineering

PLANNING………Trips Prior Trips • ToolBox Meeting prior POOH – Discuss potential problems – Provide possible solutions • Have a ‘strategy’ Borehole Geometry – • Changes in BHA (PDC Bit Gauge Length, Stabilizers, Rigidity, Clearance) • Severe doglegs (key seats) • Precautionary reaming • Max. overpull/set down and when/how to use jar Keep the String in ‘Free’ Hole – • When observing ‘significant’ overpull or set down wt, attempt to bring string in FREE hole first • May require running/pulling 1 or 2 stands • Free movement (up/down/rot) and circulation allows team to ‘decide’ on next steps Surge and Swabs – • Avoid poor practices which could accelerate hole instability • Recognise and deal with hole pack-off tendencies 396 MSc Petroleum Engineering – Well Engineering

Fishing Equipment

397 MSc Petroleum Engineering – Well Engineering

Stuck Pipe & Fishing

398 MSc Petroleum Engineering – Well Engineering

How do I get that out?

399 MSc Petroleum Engineering – Well Engineering

Fishing – the operation of recovering an object that is: • Stuck during drilling operations • Lost due to mechanical failure • Twist-off • Cones run off • Retrieving completion equipment for well repair or sidetrack • Junk – dropped in hole • Etc.

400 MSc Petroleum Engineering – Well Engineering

The Drillstring • Stuck Pipe as per previous session • How hard can we pull? • How much Torque? • How much pressure?

401 MSc Petroleum Engineering – Well Engineering

The Drillstring Failure Mechanisms • Twist off • Torque • Overpull • Washout => leading to failure • Cyclic loading • Crack propagation (SSC) • Mismatched components • Bit cone failure Questions • How hard can we pull? • How much Torque • How much pressure 402 MSc Petroleum Engineering – Well Engineering

The Drillstring Lots of pieces to get stuck, twist off, wash out, break…and get left in the hole

403 MSc Petroleum Engineering – Well Engineering

Casing & Completion Conductor Casing 'D' Annulus 'C' Annulus

….and lots of casing and tubing to retrieve for repair or well abandonment

Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer Perforations Production Liner

404 MSc Petroleum Engineering – Well Engineering

…and if all else fails… …when the fish is well and truly stuck…some alternatives… 1. Freepoint & back-off charge (drillpipe) 2. Colliding Tool (drillcollars) 3. Chemical Cutter (tubing / casing)

405 MSc Petroleum Engineering – Well Engineering

Retrieving Stuck Pipe – without Catastrophic Damage Free Point Theory • Stretch and torque sensor determines free point of pipe from the elastic range of the pipe material, • Free section of pipe deforms linearly when pipe is subjected to a pull or torsion. • FPIT tool measures stretch and torque over a fixed distance • Amount of free pipe calculated according to the theoretical deformation model. 406 MSc Petroleum Engineering – Well Engineering

Retrieving Stuck Pipe – without Catastrophic Damage Disengaging the Fish • The free portion of string recovered after firing a back-off shot inside a (free) tool joint • Neutral point evaluated on e-line and appropriate pull put on string • Left-hand torque applied from surface (WARNING) • Back off shot usually combined with Free Point Indicator Tool • Applicable to stuck drillpipe, drill collars, tubing, or casing. 407 MSc Petroleum Engineering – Well Engineering

CCL

Explosive Backoff

BANG!

STRING SHOT PRIMER CORD

• Zero

or slightly positive tension at joint (string in air) • LH torque, 60-75 % of make-up torque • Charge as recommended by service provider

408 MSc Petroleum Engineering – Well Engineering

Colliding Tool • Severance device for cutting thick-wall tubulars, drill collars and HW drill pipe • Cutting technique based on the colliding shock wave principle • Precisely timed detonation of two equal and opposing shock fronts 409 MSc Petroleum Engineering – Well Engineering

Chemical Cutter • • • • •

Dissolves pipe with clean cut No debris No requirement for milling prior to pipe retrieval. Used when no need to recover threaded connection Used for special cutting applications where other cutting methods ineffective or undesirable. – Cut tubing above permanent packers – Cut casing during plug and abandonment operations.

http://www.chammascutters.com/en/how-it-works.html

410 MSc Petroleum Engineering – Well Engineering

…and then? either plug and abandon depending on • Value of the fish (RSS and geo-steering combo ($$$) • Cost of sidetrack ($$$) • Environmental considerations (nuclear source) • Condition of the fish looking up • …or go back with a milling or fishing string 411 MSc Petroleum Engineering – Well Engineering

Fishing Tools (Bowen example) • • • • • •

External catch fishing tools Internal catch fishing tools Junk retrieval fishing tools Milling and cutting tools Accessory tools Repair and remedial tools

412 MSc Petroleum Engineering – Well Engineering

Bowen Series 150 Releasing and Circulating Overshot with Basket Grapple Bowl Bowl

Basket Grapple Inner Seal Mill Control Packer Outer Seal

Basket Grapple

Inner Seal Mill Control Packer

Outer Seal Guide 413 MSc Petroleum Engineering – Well Engineering

Bowen Series 150 Releasing and Circulating Overshot with Spiral Grapple

MSc Petroleum Engineering – Well Engineering

Wall Hook

414

Lead Impression Block • Determine the configuration of the top of the fish • Locate fish position in the well bore. • More precisely assess fishing conditions and select the proper tool or tools • Or abandon fishing 415 MSc Petroleum Engineering – Well Engineering

Releasing Spears • Means of engaging a fish internally • Positive engagement, easy release from the fish • Easy re-engagement after spear released

416 MSc Petroleum Engineering – Well Engineering

Rotary Taper Tap • Tool of last resort • Internal catch – no release • Run with safety joint (to release)

417 MSc Petroleum Engineering – Well Engineering

Fishing Assembly • • • • • • •

Overshot (releasing) Bumper sub Drill Collars Hydraulic Jar Drill Collars Accelerator HWDP 418

MSc Petroleum Engineering – Well Engineering

Formation Evaluation

419 MSc Petroleum Engineering – Well Engineering

Where’s the Oil?

420 MSc Petroleum Engineering – Well Engineering

Formation Evaluation • Key activity in well construction • Reliable information is vital for – Investment decisions about development of a discovered reserve – Well design (size of production tubing) – Combination of many information sources • • • • • •

Cuttings Cores Petrophysical logs Sidewall samples Repeat formation tests (RFT) Well Test 421

MSc Petroleum Engineering – Well Engineering

Drilled Cuttings & Flow Line Shows • Cuttings retrieved at predetermined intervals , e.g., – Every 10 ft above reservoir – Every foot in reservoir – At the Shale shale Shaker (Mud Logging)

• Drilled cuttings retrieved and analysed at the wellsite and bagged for lab • Also flow line temperature, salinity and hydrocarbon shows • Gas chromatography / gas detector

422 MSc Petroleum Engineering – Well Engineering

Continuous Coring SAFETY JOINT STABILISER AND BEARING ASSEMBLY DROP BALL

STABILISER INNER BARREL

CORES

CORE CATCHER, CORE BIT AND CORE SHOE CORE BIT 423 MSc Petroleum Engineering – Well Engineering

Continuous Coring • Direct measurement of petrophysical properties • Very Expensive in rig time and thus costs (depending on length of core drilled per run) • Enables calibration of petrophysical tools • Identification of features below petrophysical resolution • Core flood testing to evaluate effects of drilling fluid damage • Actual porosity and permeability measurements • Demands care and attention of wellsite drilling team 424 MSc Petroleum Engineering – Well Engineering

Wireline Logging

425 MSc Petroleum Engineering – Well Engineering

Wireline Logging Key Subsurface Properties • Lithology • Porosity • Radioactivity • Permeability • Electrical conductivity • Water / oil saturation • Density Density Log • Determines rock bulk density • Overall density of rock including solid matrix and the fluid enclosed in pores

Gamma Ray • Records naturally occurring gamma rays in the formations adjacent to the wellbore. • Standard device used for the correlation of logs in cased and open holes. Resistivity • Records electrical conductivity • Water in rock has various levels of salt (depends on origins) • Salty water lower resistivity • Hydrocarbons high resistivity • Increasing resistivity indicates increasing hydrocarbon saturation

426 MSc Petroleum Engineering – Well Engineering

MWD Measurement While Drilling LWD Logging While Drilling

427 MSc Petroleum Engineering – Well Engineering

MWD Measurement While Drilling LWD Logging While Drilling • LWD Logging While Drilling • Directional measurements (and control in conjunction with Rotary Steerable Systems) • Formation evaluation (gamma, Resistivity, Sonic, Density (amongst others) • Downhole dynamics / parameters for optimization – Pressure while drilling – Vibration – RPM

• Telemetry – Pulse – Electromagnetic – Wired

428 MSc Petroleum Engineering – Well Engineering

Rotary Steerable Systems Non rotating Sleeve

e.g. Autotrak from Baker Hughes Inteq (BHI) LWD Triple Combo

Bit Side Force

MWD

Rotating Drive Shaft

Formation Evaluation “Gamma Ray + Resistivity”

Non rotating Sleeve w/ Steering ribs & Inclination Sensors 429 MSc Petroleum Engineering – Well Engineering

Repeat Formation Test (RFT / MDT)

430 MSc Petroleum Engineering – Well Engineering

Well Testing Provides the following: • Productivity • Fluid properties • Fluid composition • Sand potential • Flow potential • Pressure • Temperature • Combining data to prove reservoir potential, confirm well performance, and improve field productivity 431 MSc Petroleum Engineering – Well Engineering

Hydraulic Fracturing

432 MSc Petroleum Engineering – Well Engineering

Hydraulic Fracturing • May be required to evaluate well flowability • Used in tight low permeability formations • Goal is to create a network of interconnected fractures that serve as conduits • Enable natural gas and oil to flow from the rock into the wellbore at economic rates • In combination with horizontal drilling has turned previously unproductive organic-rich shales into the largest natural gas fields in the world • Injection rates; up to 15,000 psi and 100 barrels per minute 433 MSc Petroleum Engineering – Well Engineering

Hydraulic Fracturing • Fracture is formed by pumping the fracturing fluid into the wellbore at a rate sufficient to increase the pressure downhole to a value in excess of the fracture gradient of the formation rock. • The pressure causes the formation to crack, allowing the fracturing fluid to enter and extend the crack farther into the formation. • To keep fracture open after the injection stops, a solid proppant, commonly a sieved round sand, is added to the fracture fluid. • The propped hydraulic fracture then becomes a high permeability conduit through which the formation fluids can flow to the well. 434 MSc Petroleum Engineering – Well Engineering

MSc Petroleum Engineering – Well Engineering

Hydraulic Fracturing

435

Blowouts

436 MSc Petroleum Engineering – Well Engineering

Where did my rig go?

437 MSc Petroleum Engineering – Well Engineering

Spindletop Spectator Sports, 1902

Photographs courtesy of Texas Energy Museum, Beaumont, Texas. 438 MSc Petroleum Engineering – Well Engineering

US Land 2002

439 MSc Petroleum Engineering – Well Engineering

Desert Rig

440 MSc Petroleum Engineering – Well Engineering

Desert Rig

441 MSc Petroleum Engineering – Well Engineering

Multi Well Platform - Case for SSSV’s

442 MSc Petroleum Engineering – Well Engineering

Twisted metal

443 MSc Petroleum Engineering – Well Engineering

Coiled Tubing rigs burn too…

444 MSc Petroleum Engineering – Well Engineering

Workovers – also a risk

445 MSc Petroleum Engineering – Well Engineering

Call the experts…

446 MSc Petroleum Engineering – Well Engineering

Jack-up shallow gas

447 MSc Petroleum Engineering – Well Engineering

Jack-up shallow gas

448 MSc Petroleum Engineering – Well Engineering

Platforms / Jackets

449 MSc Petroleum Engineering – Well Engineering

Platform / Jacket With Jack-up

450 MSc Petroleum Engineering – Well Engineering

…that Sinking Feeling

451 MSc Petroleum Engineering – Well Engineering

Platforms / Jack ups

452 MSc Petroleum Engineering – Well Engineering

Land Rig …going…

453 MSc Petroleum Engineering – Well Engineering

Land Rig …going…going…

454 MSc Petroleum Engineering – Well Engineering

Land Rig …going…going…gone

het Haantje MSc Petroleum Engineering – Well Engineering

455

Avoiding Blowouts

het Haantje MSc Petroleum Engineering – Well Engineering

456

Blowout! Uncontrolled Flow From a Well • Risk to human life • Risk to the environment • Loss of Company image & reputation • Loss of assets – Potential recovery costs up to US$100 million (and more …) – Potential damage to reservoir in excess of US$100 million (and more ….)

• Cleanup…..Billions 457 MSc Petroleum Engineering – Well Engineering

How do Blowouts Happen? • Two things must occur: – Primary barrier must fail • Usually loss of hydrostatic pressure provided by drilling mud or completion fluid that (over) balances the reservoir pressure

– Secondary Barrier must fail • Drillpipe safety valve, BOP, Well-head, valve, etc.

458 MSc Petroleum Engineering – Well Engineering

Where do Blowouts Occur? What type of operations?

459 MSc Petroleum Engineering – Well Engineering

Blowout Occurrence by Operational Phase SPE

1206 Occurrences 203 Occurrences

SINTEF

41% 31% 27%

25%

23% 13%

11% 12%

8%

el W ir

et

io

in

se

e

2% 2%

C om pl

Pr o

du

ct

io

n

n

Ph a

Ph a

se

ng lli tD ri m en

D ev

el

op

ko W or

Ex p

lo

ra

t io

n

ve

r

D ri

lli

Ph a

se

ng

5%

http://www.sintef.no/home/Technology-and-Society/Safety-Research/Projects/SINTEF-Offshore-Blowout-Database/ MSc Petroleum Engineering – Well Engineering

460

What Do We Learn/Gain From Blowout Statistics? •

• •

Identify recurring well control problem areas Help engineers & supervisors to focus on design, equipment and procedural shortcomings Help training efforts to be focused where skill gaps exist

461 MSc Petroleum Engineering – Well Engineering

What is the Primary Cause of Drilling & Workover Blowouts? The Loss of Primary Control Where are we most vulnerable? DURING ROUND TRIPS!!!!!! 462 MSc Petroleum Engineering – Well Engineering

Overview of Occurrences of Loss of Primary Control SPE

SINTEF

40%

Swabbing Is the Primary Cause

30%

21% 17% 14%

12%

11%

13%

11%

8%

7%

ps

s C em en

t in

g

O

se Lo s

l- u f il

Im pr

op

er

cu er /W at

1%

G

as

4%

p

tm ud

H P d te ec xp

U ne

To o

Lo w

M

ud

Sw

ab

W ei

bi

gh

ng

t

4%

463 MSc Petroleum Engineering – Well Engineering

Why Do We Lose Primary Control? Main reason: • Human Error (on the rig, but also in the design phase) – – – –

Lack of awareness Failure to follow procedures Lack of skills Failure to communicate

• During drilling and workover operations; swabbing is responsible for between 30% – 40% of all Blowouts 464 MSc Petroleum Engineering – Well Engineering

Why Do We Lose Secondary Control? Main reasons are: • Equipment Failure – Design – Maintenance

• Human error – Failure to follow procedures – Lack of knowledge – Lack of skills • Technical • Managing crisis 465 MSc Petroleum Engineering – Well Engineering

Overview of Occurrences of Loss of Secondary Control SPE

SINTEF

32%

25%

18%

17%

17% 15%

12%

15%

12% 10%

9%

6%

5%

fa ile d

2%

ad W el lh e

Xm

as

tre

e

si ng

Sh

fa ile d

oe

3%

Fr

ac

tu r

e

BO

at

P

Ca

no

BO

P

ti n

Fa

pl ac

e

ile d

P BO e Cl os to

ile d Fa

to ile d Fa

St rin

g

Sa

St ab

fe ty

Sa

Va

lv e

fe ty

Fa

Va

ile d

lv e

3%

466 MSc Petroleum Engineering – Well Engineering

Why Do Blowouts Occur?

Blowout

Barriers Fail (equipment failed) Barriers Fail (well design flawed) Wrong Decisions (skill / procedures) Secondary Control is Effective / Not Effective Primary Control is lost Well Kicks (incorrect mud weight / procedure) 467 MSc Petroleum Engineering – Well Engineering

The Risk Areas

468 MSc Petroleum Engineering – Well Engineering

Blowout Frequency (1) • Exploration Drilling • Highest frequency in deep exploration wells

• Due to: • • • • • • • • •

Demanding environment High surface pressures / temperatures Unexpected high reservoir pressures Inability to handle high volumes of gas at surface Kick and Loss problems Duration of Well Kill Erosion of surface equipment Hydrate problems Lack of skills 469

MSc Petroleum Engineering – Well Engineering

Blowout Frequency (2) • Development Drilling – Lack of awareness / complacency – Inadequate well control procedures – Inadequate training – Poorly maintained equipment – Blowout frequency highest after kicks following round trips • Insufficient overbalance? • Too high tripping speeds • Lack of awareness / complacency 470 MSc Petroleum Engineering – Well Engineering

Blowout Frequency (3) • Workover Operations – Why? • No BOP • Improperly maintained / installed BOP equipment • Old wells • Insufficient overbalance? • Not filling the hole • Too high tripping speeds • Inadequate training • Lack of awareness / complacency – Blowout frequency highest during running & pulling tubing or drillpipe 471 MSc Petroleum Engineering – Well Engineering

Contributing Factors • Demanding well designs • Emphasis on drilling • Cheaper • Faster • Deeper

• Inadequate well control procedures • Inadequate well control management skills • Technical • Crisis management

• Training does not adequately address the most frequent blowout cause 472 MSc Petroleum Engineering – Well Engineering

Preventing Blowouts • • • • • • • •

Good well design Maintain and test equipment Good drilling practices Vigilance Close in well when uncertain Follow procedures No short cuts Training & competence development 473

MSc Petroleum Engineering – Well Engineering

Why Do Blowouts Occur? Ensure all barriers are in place and working = Your job!

Blowout

Barriers Fail (equipment failed) Barriers Fail (well design flawed) Wrong Decisions (skill / procedures) Secondary Control is Effective / Not Effective Primary Control is lost Well Kicks (incorrect mud weight / procedure) 474 MSc Petroleum Engineering – Well Engineering

Well Control Methods

475 MSc Petroleum Engineering – Well Engineering

Well Construction Drill a Well on Land (Step for Step)

476 MSc Petroleum Engineering – Well Engineering

Plan of Action • Order long lead items • Prepare and sign contracts • Prepare & obtain approval of detailed well design • Obtain approval for expenditure • Conduct drill well on paper exercise • Prepare location • Drill the well • Review performance 477 MSc Petroleum Engineering – Well Engineering

Drilling location is selected and coordinates finalised.

Lithology is known (development drilling) or predicted (exploration) from seismic, nearby wells or outcrops. 478 MSc Petroleum Engineering – Well Engineering

Step 1 • Clear the lease • Level & Prepare the site • Drainage • Mud pits • Construct the cellar

479 MSc Petroleum Engineering – Well Engineering

Step 2 • Drill or Drive the stove pipe with purpose built rig • •

Drill/drive Non rig operation

•

Provide return path for drilling fluid • Prevent erosion of unconsolidated formation under the rig • Move the rig in and rig up 480 MSc Petroleum Engineering – Well Engineering

Rapid Rig Step 2a • Move in rig and raise mast

481 MSc Petroleum Engineering – Well Engineering

Drilling Pad

482 MSc Petroleum Engineering – Well Engineering

Step 3 • Prepare spud mud • Make up the BHA • Commence drilling operations • Drill top hole for conductor casing

483 MSc Petroleum Engineering – Well Engineering

Drilling Operations Step 3a • Commence drilling operations for 24” hole • Bit Type? • Circulation rate = ? • RPM = ? • WOB = ?

484 MSc Petroleum Engineering – Well Engineering

Step 4 • Pull out of hole • Rig up for casing • Make up shoe track (Float Shoe) and centralizers • Run in to bottom • Hang off

485 MSc Petroleum Engineering – Well Engineering

Step 5 • Run in hole (RIH) with internal cementing stinger • Stab (drillpipe) stinger in shoe • Mix and pump cement • Cement Casing (cement returns back to surface) • Cement casing • Wait on Cement (WOC) • Remove casing “landing joint”

LANDING JOINT

486 MSc Petroleum Engineering – Well Engineering

Step 6 • Screw on or weld on casing housing • Nipple up BOP • Test BOP

487 MSc Petroleum Engineering – Well Engineering

-- Wellhead Detail --

Wellhead Overview

Special Operations

• Supports the weight of the casing • Isolates the casing annuli • Allows access to the annuli

Tubing Spool BOP's sit here while drilling

Casing Spools C-Section

B-Section

A-Section

Surface Wellhead Configuration MSc Petroleum Engineering – Well Engineering

-- Setting Slips --

-- Slips Set --

488

488

Step 7 • Nipple up BOP • Test BOP • Plug type tester • Cup type tester

489 MSc Petroleum Engineering – Well Engineering

Nipple up and test BOP’s Annular Preventer

Pipe Rams

Wellhead: A and B-Sections

Surface BOP Stack Configuration MSc Petroleum Engineering – Well Engineering

Pipe Rams

490

Step 8……….X • Prepare to Drill next “Intermediate Casing” hole section • Log • Run Casing • Cement • Ready to drill “Production Casing” hole section 491 MSc Petroleum Engineering – Well Engineering

Step 8……….X • Drill Next Intermediate Casing hole section • Log • Run Casing • Cement • Ready to drill production casing hole section

INTERMEDIATE

492 MSc Petroleum Engineering – Well Engineering

Production Casing Section

493 MSc Petroleum Engineering – Well Engineering

The Situation: Casing Shoe

• Intermediate casing run and cemented • Wellhead is installed & tested • 10k BOP's are installed • Tested; Procedure? • Ready to drill production interval

Cement

Production Objective

494 MSc Petroleum Engineering – Well Engineering

494

Drill Casing Shoe Track & Pocket • • • • •

Pick up bit and BHA Trip in hole and drill out cement Drill 10 ft Circulate clean (inside the shoe – Why?) Conduct Leak-off test – Why?

Casing Shoe 10 ft of new hole

Production Objective

MSc Petroleum Engineering – Well Engineering

495

Conduct Leakoff Test Shoe Test Example

Purpose:

1800

- Determine formation strength

- Defines maximum mud weight for the next drilling interval

1600

LOT Pressure

- Cement job quality indicator

1400

Procedure: - Pressure up on the hole - Record pressure vs. bbls pumped

(PSI) PRESSURE Pressure

- Shut the BOP's

1200

1000

800

- Data should be linear - Stop when becomes non-linear

600

400

Terms: -

LOT – leak off test FIT – formation integrity test PIT – pressure integrity test ST – shoe test

200

0 0

5

10

15

20

25

30

Volume pumped / time

496 MSc Petroleum Engineering – Well Engineering

496

Drill Ahead • • • • •

Complete Leak-off Test Drill ahead (Conduct Drill-off test) Continue drilling new hole Encounter unexpected lost circulation zone Stop drilling • Observe well, estimate loss rate • Check mud weight • Assess cause(s) of losses

Lost Circulation Zone

Production Objective

497

MSc Petroleum Engineering – Well Engineering

The Losses Problem Possible outcome; fluid level drops and well kicks / well becomes unstable

Mud gradient to balance normal pressure

Fractures Loss Zone

Normal reservoir gradient

Expected formation strength gradient

Source Rock

Pressure 498 MSc Petroleum Engineering – Well Engineering

Lost Circulation Decision Tree Placement of LCM pills to control losses and achieve a solid base for running casing / liner, or placing a cement plug

Causes of Lost Circulation:

Losses

- Excessive mud weight (Mud wt > Frac Grad)

Losses

Pull 4-5 Stands off bottom

Losses

Allow hole to stand No Losses

Wash 2-3 Stands above top of suspected zone

Circ at drilling rate while rotating on bottom <10 bbls/hr

- Reduce mud hydrostatic pressure

- Alternative drilling methods (managed pressure drilling – MPD)

"Definitions" - Partial or seepage losses

Drill Ahead

POOH to run csg / liner

Establish magnitude of losses. RIH 50 ft above zone

>60 bbls/hr

10-60 bbls/hr Place LCM as plug in annulus

POOH to run csg / liner

Place LCM as plug in annulus

POOH 3-4 stands & stage pump rates to drill rate then ease to bottom

Pill failure

- Plug the fractures with lost circulation material (LCM)

Drill Ahead

POOH 3-4 stands & stage pump rates to drill rate then ease to bottom

Continue Drilling

POOH to run csg / liner

- Moderate losses Continue Drilling

Pill failure

Solution:

Drill Ahead No Losses

- Highly porous formation

- Vugular / fractured formations

Drill Formation

Place Flex-Plug pill as annular plug POOH 4-5 stands & allow pill to soak for 4-5 hrs Pill failure

Stage pumps up & attempt to circulate while rotating

Drill Ahead

- Severe losses POOH to run csg / liner

Drill Formation

Clean Out trip

MSc Petroleum Engineering – Well Engineering

Place all LCM pills at gpm's recommended by MWD/LWD company to achieve maximum clearance though telemetry package

499

POOH to run csg / liner

Pump Gunk squeeze or Diaseal M

Drill Ahead •

Cure losses, pump LCM

•

Drill ahead to the objective interval

•

Observe “Drilling Break” and increased flow.

•

Well has “kicked” (Reservoir / Formation ) pressure higher than expected)

•

Close in well



Pick up kelly – stop circulation

 Close Pipe Rams 

& Control Well

 Record shut-in pressures (Pdp & Pan) 

Increase mud weight



Circulate out the kick

Formation fluid influx (kick)

Production Objective

500

MSc Petroleum Engineering – Well Engineering

500

Well Kick

501 MSc Petroleum Engineering – Well Engineering

Pressure Depth Graph

SIDPP

Shut-in Drill Pipe Pressure (SIDPP)

SICP

Closed BOP

The SIDPP is a measure of the underbalance of the initial mud weight

Original Mud Weight

What about the loss zone?

Depth - TVD

Indicates how much the mud weight needs to be increased

Shut-in Casing Pressure (SICP)

Kick Height (?)

Pressure (psi)

MSc Petroleum Engineering – Well Engineering

Original Mud Weight

Influx Volume: Gas, oil, water or some combination

502

Drill To TD • • • • •

Complete well control procedues Continue drilling through the objective Make a “wiper trip” - Why Pull out of hole (POOH) for logging (Logging While Drilling (LWD)) may deliver sufficient information, otherwise additional wireline logs / formation tests conducted 503

MSc Petroleum Engineering – Well Engineering

Formation Evaluation • Run petrophysical logging tools • Identify • Formation tops • Hydrocarbon potential • Production interval(s) • Caliper log for cement volumes • Determine where to perforate

504 MSc Petroleum Engineering – Well Engineering

Post Logging • • • • •

Complete Logging Make up BHA • Remove expensive tools – Why? Run in hole for “wiper trip” Circulate and condition mud POOH for casing job

505 MSc Petroleum Engineering – Well Engineering

Run and Cement Production Casing • • • • • • • • • •

Remove wear bushing Pick up shoe track and test floats Run casing to TD Make up casing hanger Circulate and condition mud Carry out plug type cementation Mix & pump spacers, lead and tail cement Bump plugs and pressure test casing Nipple down and install the wellhead (tubing spool) Energise seals and test

MSc Petroleum Engineering – Well Engineering

506

Prepare for Completion • • •

• •

Cement job is complete RIH to top of cement (TOC) Drill plugs, float collar & cement to below perforation interval & provide a pocket for perforation guns / gun debris Scraper run Displace to completion fluid

507

MSc Petroleum Engineering – Well Engineering

507

Prepare for Completion • • •

• •

Cement job is complete RIH to top of cement (TOC) Drill plugs, float collar & cement to below perforation interval & provide a pocket for perforation guns / gun debris Scraper run Displace to completion fluid

Completion fluids are solids-free liquids typically brines (chlorides, bromides and formates), meant to control the well without damaging the producing formation should downhole hardware fail, 508

MSc Petroleum Engineering – Well Engineering

508

Evaluation of Casing Cementation

Fig 1

•

Casing Bond Log (CBL/VDL)

•

Fig 1 Good Cementation Low attenuation Fig 2 Poor Cementation High attenuation

• •

• • •

Fig 2

509 MSc Petroleum Engineering – Well Engineering

Complete the Well •

•

Run and set production packer and tail on wire line with gamma and CCL (Alternatively with tubing and perforating guns in one run (TCP))

510

MSc Petroleum Engineering – Well Engineering

510

Complete the Well •

•

Run completion tubing & (optional) completion equipment (depends on well type and “lift” requirements) • Nipples • Gas lift mandrels • Surface Controlled Sub-surface Safety Valve (SCSSV) • ESP (Electrical submersible Pump) • Rod pump Stab into production packer 511

MSc Petroleum Engineering – Well Engineering

511

Prepare for and put the Well on Production

• • • • • • •

Place isolation plug in tubing hanger Remove BOP Install the production tree Remove isolation plug Run guns Perforate the well Hook up and put well on production

512 MSc Petroleum Engineering – Well Engineering

512

Connect the well to the reservoir, PERFORATE

Shaped Charge

Perforating Gun

Casing Cement

• Perforations are made by firing shaped charges downhole through the casing & cement into the formation, using a Perforating Gun.

Formation 513

MSc Petroleum Engineering – Well Engineering

Connect the well to the reservoir, PERFORATE

Derrick

Logging Truck

Electric Wireline

Electric Wireline Conveyed Perforating Guns

Packer

Tubing

Tubing Conveyed Perforating (TCP) Guns 514

MSc Petroleum Engineering – Well Engineering

Will the Well Flow?

Formation damage (impairment) results in lower production rates, lower ultimate recovery and possibly uneconomic wells Perforate beyond the damage.

Porosity: Ability to contain Permeability: Ability to flow through 515 MSc Petroleum Engineering – Well Engineering

Prepare for and put the Well on Production • • • • • • •

Place isolation plug in tubing hanger Remove BOP Install the production tree Remove isolation plug Run guns Perforate the well Hook up and put well on production

516

MSc Petroleum Engineering – Well Engineering

516

Christmas Tree Purpose • Installed on top of the wellhead to control the flow of well fluids during production. • Provides primary and back-up control facilities for production • Enables wellbore shut-in • Incorporates facilities to enable safe access for well intervention operations , e.g., slickline, electric wireline and coiled tubing

517 MSc Petroleum Engineering – Well Engineering

Flowline

Xmas tree

Cellar

Wellhead 518

MSc Petroleum Engineering – Well Engineering

The End We Drilled and Completed a Well

519 MSc Petroleum Engineering – Well Engineering

Organisation

520 MSc Petroleum Engineering – Well Engineering

Operator – Typical Well Engineering Organisation Corporate C&P

Corporate HR

C&P

HR

• Rig Strategy • Parenting • Contracts • Transfers • Category • Packages Management. • Integrated Service contractor relationships

GM Well Engingeering

Chief Engineers

Corporate HSSE

Business Improvement

WE Mgrs

• Standards • Drilling /Well • Assurance • Dispensations Planning • Governance • Graduates • Completions • Top Quartile • Career • Projects Delivery and Planning • Top Quartile Performance • Technical Framework • Audits/Health Advice • IT/New Ways of Checks • Training Working • Liaison/Focal • Self Study • New technology point Assets • Competence • Fluids • Value • Accreditation • Subsea Assurance • Exams • Deepwater & HPHT process • Unconventionals • Performance Analyst • QA/QC

MSc Petroleum Engineering – Well Engineering

HSSE

• HSSE Improvement • Audits, Health Checks • Rig Acceptance • Link to Corporate HSSE

521

Operator / Contractor Relationship Operator

Drilling Contractor

Contracted to provide, maintain and operate major drilling rig equipment , including BOP’s and drillstring.

Major Service Companies

Minor Service Companies

Contracted to provide, additional services, Directional, Cementing, P’phys ical Logging etc

Contracted to provide, additional services, Inspection, Mud logging, Casing run, Waste mgt & disposal, Coring

Consumables & Eqt. Suppliers Can be MSC’s but also specialist Co’s Provide, Casing, Jars. Fishing eqt.

Integrated Services Providers (ISP’s) , e.g., Schlumberger, Halliburton 522 MSc Petroleum Engineering – Well Engineering

Who’s Who in the Office

523 MSc Petroleum Engineering – Well Engineering

Office Based Well Engineering Team Well Delivery Manager

Well Engineer Projects • New technology • Performance analysis • Failure analysis • Directional QA/QC

Well Engineer Contracts

Well Engineer Operations

• . Monitors contract performance • Contractor HSSE • Equipment & services • Link to C&P

• HSSE • Writes drilling programme • Liaison with other disciplines • Liason with rig • Liason with servco’s

Integrated Services Providers (ISP’s) , e.g., Schlumberger, Halliburton 524 MSc Petroleum Engineering – Well Engineering

Who’s Who on the Rig

525 MSc Petroleum Engineering – Well Engineering

Rig-based Organisation Offshore Installation Manager (OIM) (Company - when drilling on or near production facilities)

Drilling Supervisor

Wellsite PE (ADS)

Service Companies

Company

Contractor Toolpusher (OIM)

Drilling Crew

Rig Maintenance

Contractor 526

MSc Petroleum Engineering – Well Engineering

Company Rep / Drilling Supervisor • Responsible for – implementation of the company’s Safety Management System (SMS). – Third Party contractors who are also responsible for working under their own and Contractor’s Management System

• Works for Operator • Implementing the drilling programme • Primary responsibilities – Liaison with WE Dept – Operational safety – Implementing optimal drilling parameters – Logistics & cost control – Implementing well control 527

MSc Petroleum Engineering – Well Engineering

Safety Management System (SMS) “…… a systematic, explicit and comprehensive process for managing safety risks. As with all management systems, a safety management system provides for goal setting, planning, and measuring performance. A safety management system is woven into the fabric of an organization. It becomes part of the culture, the way people do their jobs……………...”

528 MSc Petroleum Engineering – Well Engineering

Wellsite PE (ADS) • Training rig-based role • Works for Operator– reports to “Company Rep” • Liaison for town based PE Dept. • Primary responsibilities • Data collection & distribution • Collect geological data • Supervise petrophysical logging • Directional data • Casing tally /Cementing • Etc, etc.

529 MSc Petroleum Engineering – Well Engineering

Contractor Rig Superintendent / Toolpusher • Works for Drilling Contractor Accountable to Rig Manager • “In-charge” of the rig personnel, logistics. • In some cases (MODU) the OIM • As OIM, Responsible for the safety of the rig • Primary responsibilities • Ensure rig and staff safety • Maintain operability of the rig (uptime) • Protect contractors interests 530 MSc Petroleum Engineering – Well Engineering

Driller (& Assistant) • Works for Drilling Contractor • “In-charge” of the shift /crew • primary responsibilities • drive the drawworks • maintain rig safety • maintain optimal drilling parameters • maintain well control Note: New generation rigs require different skill sets MSc Petroleum Engineering – Well Engineering

531

Derrickman  Work for Drilling Contractor  Reports to Driller  Primary responsibilities 



Work in derrick on “monkey board” 

 

Set back / run in pipe during round trips

Drilling fluid responsibilities Pump maintenance

532 MSc Petroleum Engineering – Well Engineering

Roughnecks (floormen)  Work for Drilling Contractor  Report to Driller  Duties 

making pipe connections  maintaining equipment  hands-on checking drilling fluid/ flow parameters  general rig floor maintenance duties  Nippling up BOP’s 

533 MSc Petroleum Engineering – Well Engineering

Mud Engineer  Reports to PE 

     

works for Service Company responsible for drilling fluid measuring and sampling solids removal equipment addition of chemicals optimising and maintaining fluid properties

MSc Petroleum Engineering – Well Engineering

534



Mud Logger   

Gather, clean, sort and identify drilled cuttings Monitor well fluids and identify entrained gasses Monitor fluid volumes on rig (kick control)

535 MSc Petroleum Engineering – Well Engineering



Tubing/Casing Crew Work for Service Company  responsible for running casing & tubing completion equipment  critical make-up torque  hydrostatic testing while running 

536 MSc Petroleum Engineering – Well Engineering



Others (Drilling & Completion Services)          

 Major Service Providers Cementers,  http://www.halliburton.com/ Coring  http://www.bakerhughes.com/ MWD Engineers  http://www.weatherford.com/ Directional Driller Petrophysical loggers  http://www.slb.com/  http://www.nov.com/ Completions  Etc Well Testers Fraccing Inspection Etc 537

MSc Petroleum Engineering – Well Engineering

Quiz • • • • •

Since 1940 the highest weekly US rig count was? The lowest rig count was? In Canada the highest weekly rig count was? The lowest weekly rotary rig count was? Since 1975 the highest international rig count was? • The lowest international rig count was? 538 MSc Petroleum Engineering – Well Engineering

Answers • Since 1940 the highest weekly US rig count was 4,530 recorded on December 28, 1981. • The lowest rig count of 488 was recorded on April 23, 1999. • In Canada the highest weekly rig count of 718 was recorded on February 17,2006. • The lowest weekly rotary rig count of 29 was recorded on April 24,1992. • Since 1975 the highest international rig count was 1,509, recorded in November 1982 • The lowest international rig count of 556 was recorded in August 1999

539 MSc Petroleum Engineering – Well Engineering

US & Canadian Rig Count 1987 - 2010 BAKER HUGHES RIG COUNT (US & Canada) 3000

2410 2500

2000

1500

Series1

1262

1000

500

MSc Petroleum Engineering – Well Engineering

09 To da y

08

Ours is a cyclical business – driven by $/bbl

20

06

05

04

03

02

01

00

99

98

97

96

95

94

93

92

91

90

89

07

20

20

20

20

20

20

20

20

20

19

19

19

19

19

19

19

19

19

19

88

19

19

19

87

0

540