Well Engineering and Design 2015course

Experiment No.1

Well Planning

Objective: To Study the complete well planning.

Introduction:

Well planning is the most demanding aspect of drilling engineering that requires the
integration of engineering principles, corporate or personnel or personal philosophies and
experience factors. The concept of well planning vary within drilling industry but the end result
should be a safely drilled minimum cost hole that satisfies the reservoir engineer’ s requirement
for production of fluids.

Objectives:

The objectives of well planning is to formulate a program from many variables foe
drilling a well that is safe, minimum cost and usable form.

Safety:

Safety should be the highest priority in well planning. Personal considerations must be
placed above all other aspects of the well plan. If required the plan must altered during the course
of drilling the well when unforeseen drilling problems endanger the crew, failure to stress crew
safety has resulted in loss of life etc.

The second priority should be safety of the well. The well planned must design to have
minimum risk of the well during drilling life of well.

Minimum cost:

A valid objective of the well planning to have minimum cost of the well without
jeopardizing the safety aspects. In most cases the effective cost can be drastically reduced with a
little effort of proper planning. It is not noble to build steel monuments in the name of safety. The
expenses should be incurred only when they are necessary.

Usable hole:

Drilling a hole to the target if the depth is not completely satisfactory if the final well
configuration is not usable the hole diameter is sufficiently large so an adequate completion can
be made and the hole or producing formation is not irreparably damaged.

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Classification of wells

Wildcat wells: No known geological formation for site selection.

Exploratory wells: Site selection based on seismic data, satellite surveys etc; no known drilling
data in the prospective horizon.

Step out wells: Delineates the reservoir’s boundaries, drilled after a exploratory discovery; site
selection usually based on seismic data.

Infill wells: Drills the known productive portions of the reservoir site selection usually based on
patterns, drainage radius etc.

Re-entry wells: Existing wells reentered to deepen, side track, rework, or re-complete; various
amount of planning required on purpose of re-entry.

Formation pressure:

The formation or pore pressure encountered by the well significantly affects the well
plan. The pressure may be normal, abnormal (high), or sub-normal (low). Normal pressure wells
generally do not create planning problems. The mud weights are in the range of 8.5 – 9.5 ppg.
Kicks and blowout prevention problems should be minimized but not eliminated. Casing
requirement can be stringent even in normal pressure well deeper than 20,000 ft. due to tension/
collapse.

Subnormal pressure wells may require setting additional casing string to cover weak or
low pressured zones. The lower than normal pressure may result from geological or tectonic
factor or from pressure depletion in producing intervals.

Abnormal pressure affects the well plan in many ways including the following-

Casing and tubing design, mud weight and type selection, casing setting depth selection,
cement planning.

Following problems can occurred in high formation pressured wells-

Kicks and blow outs, differential pipe sticking, lost circulation, heaving shales.

Planning cost:

The cost required to plan a well are insignificant in comparison to the actual drilling cost
in many cases, less than $ 1,000 is spent in planning a $ 1 million well. This represent 1/10 or 1
% of the well cost.

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Overview of well planning process:

Well planning is an orderly process. It requires that some aspects of the plan be
developed before designing other items like-

The mud density can be done at any stage during the well planning. However the bit
program is usually based on drilling parameters from offset wells. This can be affected by the
mud plan i.e. the performance of PDC bits in oil muds. The bit sizing can be controlled by casing
program.

Casing and tubing should b considered as an integral design starting from the size of
production casing. The tubing design are drift diameter of the production casing that can be
effected by packer to tubing forces created by tubing tendencies for movement.

The completion plan must be visualized in advance. This affects the size of casing and tubing to
be used. In addition the plan can require the high strength tubing or usually long seal assemblies
in certain situations.

Data sources:

Source of the data should be available for the virtually every well drilled in the field. The
wildcats can be source of seismic data and pore pressure prediction. Common types of data
required by drilling engineers are –

Bit records Mud records Mud logging records

IADC drilling reports Scout tickets Log headers

Production history Seismic studies Well surveys

Geological contours Data base Service company files

Sequence of well planning:

1. Type of well: wildcat, exploratory, step out, relief or re-entry

2. Method of drilling: cable tool drilling, rotary drilling, drilling with downhole motors,
top drive drilling etc.

3. Target rotation and analysis:

i) Vertical well drilling ii) Directional well drilling

iii) Horizontal well drilling iv) Slanted well drilling

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v) Drain hole drilling vi) Curvature drilling

4. Formation characteristics:

i) Formation pressure ii) Formation temperature

iii) Formation condition iv) Formation permeability

v) Formation porosity vi) Formation boundaries

vii) Formation fluid equilibrium

5. Well lithology:

i) Geological structure ii) Rock sequence

iii) Aquifer position iv) Surface soil

v) Pay zone rock vi) Fractures/ fissures

vii) Gas traps viii) Geological faults and folds

ix) Formation dipping

6. Mechanical planning:

i) Overburden pressure ii) compressive strength

iii) Fracture pressure iv) stress failure

v) drillability of rocks vii) rock consolidation

viii) Rock strength

7. Well completion program:

i) Type of well completion: single, dual, multiple string completion.

ii) Casing configuration

a) conductor casing

b) surface casing

c) intermediate casing

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d) production casing

e) liner casing

iii) Casing bit size program

iv) Casing setting depth selection

v) Casing design

vi) Casing cementing program

8. Mud program:

i)Lithological analysis, ii)formation pressure, iii)fracture pressure, iv)Density

planning, v)mud conditioning, vi)hydraulic impacts, vii)flow characteristics,
viii)mud thixotropy, ix)nozzle performance, x)type of mud, xi)functions
of mud, xii)properties of mud.

9. Drill string and bottom hole assemblies:

i) drill pipe, ii) drill collar, iii) positioning the stabilizers,

iv)BHA for build up, v) drop off and tangential drilling.

10. Rig selection:

i) Analysis of static load and dynamic load

ii) Environmental loading

iii) Derrick load capacity and derrick efficiency

iv) Hoisting planning and block and tackle system

v) Derrick leg foundation and stability

vi) Rig sizing

11. Power requirements:

i) Requirement of hoisting power

ii) Requirement of circulation power

iii) Requirement of rotary power

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iv) Requirement of accessory power

v) Total power requirement

vi) Requirement of power source-engines, pumps etc.

vii) Power transmission devices and their layouts etc.

12. Bit planning:

i) Type of bit and its stability: drag bit, rotary roller bits, diamond bits, PDC bits,
core drilling bits, jet bits, mill bits.

ii) Drilling mechanism of the bits in various formations

iii) Drilling energy of bits

iv) Cost per foot analysis of drill bits.

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Experiment No.2

GEO TCHNICAL ORDER

Objective: To Study the preparation of GTO.

Theory:

The various input data are thoroughly analyzed and the GTO prepared, which provides broad
guidelines for drilling of the well. GTO furnishes the following details:

a) General data like well name, well no, area, location, water depth elevation, well type,
category, objective of well etc.

b) Geology and the data consists of the following details like depth, age, formation,
lithology, interval of coring, electrologging, collection of cuttings, angle of dip, oil gas
zone, formation pressure, formation temperature, mud loss/ caving etc.

c) Mud parameters consists of :-

i) Type of mud

ii) Specific gravity

iii) Viscosity

iv) pH

v) % of sand

vi) Filtration loss

d) Drilling design tools:

i) Casing policy

ii) Rise of cement

iii) Time of drilling

iv) Types and size of bit

v) No of bits expected

vi) Meterage/bit

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vii) WOB

viii) RPM of rotary

ix) Stand pipe pressure

x) Pump discharge

xi) Bit nozzle details

xii) Drilling time

xiii) Remarks if any.

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Experiment No.3
Drilling Cost Analysis
Objective:-

Drilling Cost Analysis

Theory:-

The drilling engineer is frequently called uponto predict the cost of a well at a given location.
These predictions are required so that sound economic decisions can be made.

Drilling cost depends primarily on well location and well depth. The location of well will govern
the cost of preparing the wellsite, moving the rig to the location, and the daily operating cost of
the drilling operation, e.g. rig rentals, crew boat & work boat rentals, helicopter rental, well
monitoring services, crew housing, drlling fluid treatment, rig supervision etc. The depth of the
well will govern lithology that must be penetrated and thus the time required to complete the
well.

Drilling costs tend to increase exponentially with depth. Thus, when curve fitting drilling cost
data, it is often convenient to assume the relationship between cost, C, and depth, D, given by,

----------(1)

where the constants a and b depend primarily on the well location. This can be drawn on semilog
or cartesian plots.

When more accurate drilling cost prediction is needed, a cost analysis is based on a detailed well
plan must be made. The cost of tangible well equipment and the cost of preparing the surface
location usually can be predicted accurately. The cost per day of the drilling operations can be
estimated from considerations of rig rental costs, other equipment rentals, transportation costs, rig
supervision costs, and others. The time required to drill and complete the well is estimated on the
basis of rig-up time, drilling time, trip time, casing placement time, formation evaluation and
borehole survey time, completion time and trouble time.

An estimate of drilling time can be based onhistorical penetration rate data from the area of
interest. The penetration rate in a given formation varies inversely with both compressive strength
& shear strength of the rock. Also, rock strength tends to increase with depth of burial because of
the higher confining pressure caused by the weight of the overburdon. When major
unconformities are not present in the subsurface lithology, the penetration rate usually decreases
exponentially with depth. Under these conditions, the penetration rate can be related to depth, D,
by

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-----------(2)

where K and a2 are constants, the drilling time, td, required to drill to a given depth can be
obtained by separating variables and integrating.

Integrating and solving for td

-----------------(3)

As experience is gained in an area, more accurate predictions of drilling time can be obtainedby
plotting depth vs. drilling time from past drilling operations. Plots of this types also are used in
evaluating new drilling procedures designed to reduce drilling time to given depth.

Trip Time:

The time required for tripping operations depends primarily on the depth of the well, the rig being
used, and the drilling practices followed. The time required to change a bit and resume drilling
operations can be approximated using the relation-

------------(4)

where,

tt is trip time required to change bits and resume drilling,

ts is average time required to handle one stand of drillstring,
ls is average length of one stand of drillstring.

The above analysis shows that the time required per trip increases linearly with depth. In
addition, the footage drilled by a single bit tends to decrease with depth, causing the no. of trips
required to drill a given depth increment also to increase depth. So the depth of the next trip gives
the following equation,

---------(5)

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The total bit rotating time, tb, will vary with depth as the bit size and bit type are changed.
Equations (4) & (5) can be used to estimate the total trip time required to drill a given depth using
ts, tb, K & a2.

Formation with high strength requires more no. of bits and to drill a given depth. The time
required per round trip per 1000ft intervals can be approximated from the concerned graph which
is normal cost for 1000ft intervals.

The no. of bits required per 1000ft, N’b, at a given depth can be approximated by deviding the
drilling time per 1000ft, t’d, by the average bit life for that interval:

---------------(6)

The drilling time required to drill from D to (D+1000) can be obtained as,

--------------------(7)

The drilling cost per foot can also be found using,

------------------(8)

where,

Cf is drilled cost per unit depth,

Cb is cost of bit,
Cr is rig cost,
tb is bit run time,
tc is non rotating time,
∆D is footage drilled.

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Example:-

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Experiment No.4
Pore Pressure

Objective:-

TO DETERMINE PORE PRESSURE BY USING D-EXPONENT CURVE AND USING

SONIC LOG

Theory:

The method of correcting or organising b drilling parameters is indication of pore pressure D-

exponent is an example of organised drilling rate.

Mathematical expression:

d = log (Rop/60*RPM)/ log (12*WOB/10^6*B)

d = D exponent
ROP= ft/hr
RPM=rotary speed
WOB= lb
B= Diameter of bit (in)

D' exponent basically attempts to correct ROP b changing RPM, WOB and hole size. D-
exponent is proportional to rock strength and normal pressure formation; it increases with depth
linearly as rock strength increases with depth. For abnormally Pressured shales, D' exponent
deviates from normal trend and actually decreases with depth. Further modification of D-
exponent considering effect of changes in mud wt is
dc=d (NPP/Ecd)

NPP= normal pore pressure gradient (ppg)

ECD= equivalent circulating density (ppg)

In overpressured zone indicates formation becomes less dense and will have higher porosity than
rock at same depth. The decrease in rock strength results in greater ROP and so reduction in D-
exponent.

Pore pressure calculation from D-exponent data:-

1) Plot dc values on semi-log paper against depth.

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2) Establish normal pressure trend line through dc values corresponding to normal pressure
shales which predict dc values corresponding to normal pressure shales which predict dc vales at
a depth in shale section which exhibits normal compaction and normal pore pressure. The trend
line should slope to right to indicate increase dc values
With depth. This slope indicates increasing density and decreasing porosity and reliability in
normally pressured shale.
3) Plot actual dc values alongside to trend line.
4) Calculate pore pressure

There are two methods of it from dc data

1) Eaton method
2) Ratio method

In Eton, record values of normal trend line dc (dcn) an observed dc (dco) at depth of interest.
Record overburden gradient

PP=6ov - (6ov -Pn) (dco/dcn) ^1.2

PP= pore pressure, ppg

Pn=normal pressure, ppg
6ov=overburden pressure, ppg
dco=observed D-exponent
dcn=normal D-exponent

Ratio:-
It does not prefer overburden gradient to calculate pore pressure.

PP=Pn (dcn/dco) ppg

Sonic log:-

These are considered to provide most reliable values because they are unaffected by bore hole
size, formation temp and salinity. Sonic log measures transit time delta t For compression sonic

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wave to travel through formation from transmitter to receiver. Time travelled through ft/in is
termed as interval transit time. In a shale showing normal compaction profile the transit time
should decrease with depth due to decrease in porosity and increase in density. Abnormally
pressured shales have higher porosity and lower density. Hence, delta t values will be higher.

Pore pressure = 60v - (60v - Pn)*(delta to / delta tn) ^3

Where,
delta tn : Normal pore pressure trend line at depth of interest.
delta to : Observed P.P trend line at depth of interest

Resistivity log:-
Shale resistivity increases with depth.
Resistivity of shale depends on following factors:
1.) Porosity
2.) Salinity of pore H2O
3.) Temperature

Porosity is major factor affecting resistivity values. In normal shale, resistivity increases with
depth as porosity decreases.

D – Exponent
Depth
2500 1.6 1.6 2 1.304
2900 1.3 1.8 2.3 1.464
3000 1.0 1.8 2.45 1.614
3200 1.1 2 2.55 1.884
3250 1 2.1 2.6 1.944

Pore pressure =

= 2 – (2 – 1.304)*(

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P.P @ 2900 = 2.3 – (2.3 – 1.464)*

P.P @ 3000 = 2.45 – (2.45 – 1.614)*(

P.P @ 3200 = 2.55 – (2.55 – 1.884)*(

Porosity is the major factor affecting resistivity values. In normal shale, resistivity increases with
depth as porosity decreases.

Sonic Log

Depth
2500 110 55 2 1.304
2900 110 35 2.3 1.464
3000 100 30 2.45 1.614
3200 100 25 2.55 1.884
3250 70 20 2.6 1.944

Pore pressure =

P.P @ 2500 = 2 – (2 – 1.304)*

P.P @ 2900 = 2.3 – (2.3 – 1.464)*

P.P @ 3000 = 2.45 – (2.45 – 1.614)*

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P.P @ 3200 = 2.5 – (2.5 – 1.884)*

P.P @ 3250 = 2.6 – (2.6 – 1.944)*

Experiment No.5
Drill String Design

Objective: To Study Drill String Design.

Theory:

The drill string design involves the determination of length, weight and grades used for
drilling and other operation. It depends upon several factor including hole depth, size, mud
weight, desired safety factor, tension margin of overpull, length and weight of drill pipe and drill
collar.

Design criteria used to select a suitable drill string are:

 Tension
 Collapse
 Shock loading
 Torsion

Drill pipe is subjected to following types of loading:

 Axial loading due to weight carried.

 Radial forces due to wellbore pressure
 Torque due to rotation.
 Cyclic stress reversal when drill pipe is bent as in doglegged holes.

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Hence DP must be capable of withstanding all type of loading and must have a long service life.

Drill pipes are available in three range of length:

1. 18 – 22 ft
2. 27 – 30 ft
3. 38 – 45 ft

The grade of DP available to suit different hole depth and loading requirement are P, E, X-95, G-
105, S-135. These grades are manufactured in different sizes of OD ranging from 2.375” to
6.625”. each grade and size is specified by,

 Nominal weight per foot.

 Inner diameter
 Collapse resistance
 Internal yield pressure
 Pipe body yield strength

Collapse strength:

It is defined as the maximum pressure required to collapse a specimen of drill pipe or

casing.

Internal yield pressure or strength:

The maximum internal pressure required to cause steel to yield is burst pressure.

Pipe body yield strength:

It is the maximum value of force required for plastic deformation of the pipe.

The properties of drill pipe change with time due to stress acting on it which is because
of:

 Combined weight of DP and DC.

 Bending stress due to DP in steps
 Cyclic fatigue stresses

During drill pipe operation, stresses result in pipe wear and reduction in pipe strength of new DP,
hence API has classified DP’s according to wear as follows:

 Mass one -> new DP

 Premium -> pipe having uniform wear and minimum wall thickness of 80% of new DP.
 Mass two -> pipe having minimum wall thickness of 65% with wear on one side
 Mass three -> pipe having minimum wall thickness of 55% with all wear on one side

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Design criteria:

The total weight P carried by the joint of DP at J-J is given by:

P = (weight of DP in mud) + (weight of DC in mud)

= [L dp × W dp + Ldc × Wdc] × BF

Where, BF = 1 – (ρmud / ρsteel ) ------------ 1

Where, ρmud and ρsteel are densities of mud and steel respectively.

DS design is never based on the tabulated yield strength value but 90% of the yield strength to
provide an added safety in resulting design.

Therefore,

Maximum tensile design load = Theoretical yield strength × 0.9

i.e. Pa = Pt × 0.9 ------------ 2

The difference between the above two equations 1 and 2 gives the Margin of Overpull (MOP)

Therefore,

MOP = Pa – P

The design value of MOP range from 50,000 to 100,000 lbs.

The ratio of the equation 1 and 2 gives the actual safety factor as,

SF = Pa / P

= Pt × 0.9 / (Ldp * Wdp + Ldc * Wdc)BF

On simplifying we get,

Ldp = Pt * 0.9 / SF * Wdp*BF – Wdc * Ldc / Wdp

Or in terms of MOP as

Ldp = Pt * 0.9 – MOP/ Wdp * BF – Wdc * Ldc / Wdp

Ldp may be expressed as Lmax that is maximum length of DP that can be selected for a given
loading situation.

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Collapse:

Maximum differential pressure (∆P) across DP exists prior to the opening of the DST tool and is
got using

∆P = Lρ1y / 144 – (L - y) ρ2 / 144

Where,

Y = depth of fluid inside ∆P

L = total length of well

ρ1 = density of fluid outside DP

ρ2 = density of fluid inside DP

A safety factor in collapse can be determined as

SF = collapse resistance / collapse pressure

Shock loading:

It arises whenever slips are set on moving Dp and can contribute to parting of pipe in marginal
designs. Additional tensile force Fs generated by stock loading is calculated from,

Fs = 3200 Wdp

Where, Wdp -> weight DP / Legth

Torsion:

It can be shown that the DP torsional yield strength when subjected to pure tension is
given by,

Q = 0.096167 J Ym / D

Where DP is subjected to both tension and torsion, which is usually the case, the equation
becomes

Qt = 0.096167 J / D √ Ym2 – P2 / A2

Where,

P = total load in tension

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A = cross section area

Strength of drill pipe:

Drill pipe stretches under the action of weight of DC and also its own weight.

Stretch due to weight carried:

Assume that changes in DP diameter are very small such that DP extension is only
significant in the axial direction.

Then if weight of DC is ‘P’

Hook’s law can give

E = (P/A) / (e1 / L)

Where,

E = young modulus of steel

e1 = extension of DP

A = plain end area of DP

We get

e1 = PL / AE = P L / [π / 4(D2 – d2)]E

But Wdp = 3.3993 * π / 4 * (D2 – d2)

Therefore

e1 = PL / (Wdp / 3.3933) * 30 * 10-6

Weight 31.2 kg/m, class-II pipe with a tensile strength of 141.8 tonnes. The length upto which
this pipe can be used is calculated as follows.

Ldp = Pt *0.9/SF*Wdp*kb – WcLc/Wdp

Assuming a safety factor of 1.8

Ldp = 141.8 *1000*0.9/1.8 * 31.2*0.796 - 42.77 *1000/31.2

= 1483 m of E- grade classII pipe

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Total length from bottom;

1] length of DC assembly =180 m

2] length of HWDP = 60m

3]length of E grade classII d/p = 1400m/1640m

4] length of second section of DP: next ,higher grade DP above E grade DP is to be calculated

Consider G grade 19.5 lb/ft, class II DP

Tensile strength of G grade DP= 197576 kgs= 197.6 tonnes

Adjusted wt of grade DP = 31.99 kg/m

Length up to which this grade of pipe can be used is calculated using the same formula and
combining the total wt of E grade pipe in the Wc Lc term

Total wt of E grade pipe = 1400m *31.2 kg/m = 43.7 tonnes

Wt of DC assembly and HWDP = 42.77 tonnes

Therefore total wt = 86.5 tonnes

Ldp = 197.6*1000*0.9/1.8*31.99*0.796 – 86.5 * 1000/31.99

= 1186 m of G grade DP

Since this length is more than the required depth to reach top of the well, this grade is used up to
the top.

Stretch due to own wt : DP also stretches under its own wt when suspended in mud. This can be
calculated by, e2 = L^2/72 * 10^7 ( 489.5 – 1.44ρm1)

Problem:

Data given: Depth = 2700 m, hole size = 12 ¼ “, mud wt = 1.6 gm/cc (kb = 0.796)

S.F. = 1.8 in tension, 1.125 in collapse use 2 stands of HWDP,

Length =60 m, wt = 73.5 kg/m maximum WOB = 25 tonnes

Assume the well to be vertical.

Solution: design calculation:

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1] total length of drill collar assembly: determine air wt of drill collars necessary to maintain a
WOB of 25 tonnes

Wt of DC in air = WOB/SF*Kb *cosα = 39.26 tonnes

Adjust this wt approx in 4 stands or 120m of 8^1/2 * 3’’ drill collars and 2 stands of 6^1/2’’ * 2
^13/16’’ drill collars.

Wt of 8^1/2’’ * 3’’ DC= 251.5 kg/m

Wt of 6^1/2’’ * 2^13/16’’ DC = 136.4 kg/m

Wt of 5’’ HWDP = 73.5 kg/m

Wt of 8^1/2’’ * 3’’ DC = 30.18 TONNES

WT OF 6^1/2’’ * 2 ^13/16’’ DC = 8.18 tonnes

Wt of 2 stands of 5’’ HWDP = 4.14 tonnes

Hence, total wt of DC + HWDP = 42.77 tonnes

Total length of DC assembly = 180 m

2] Length of first section of DP above DC assembly: consider DP of lower grade 5’’, 19.5lb/ft E
grade (NC- 50) adjusted

4] Summary of the drilling assembly design;

i) 8 ^1/2 * 3’’ DC, 169 lb/ft = 120m

ii) 6 ^1/2 * 2 ^ 12/16’’ DC, 91 lb/ft = 60m

iii) 5’’ HWDP

iv) 5’’, 19.5 lb/ft (29 kg/m) E grade (N-50) = 1400 m class- II pipe

v) 5’’, 19.5 lb/ft (29 kg/m) G grade (N-50) = 1400 m class- II pipe

TOTAL = 2700 m

5] MOP calculation: margin of over pull that can be applied in case the string gets

Stuck is calculated as follows:

MOP for E grade DP = Pa – P = (Pt * 0.9) – P = (141.8 * 0.9) –P = (127.6 – P)ton

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P – Buoyant wt of Egrade DP + HWDP + DC assembly

Therefore, P = 0.796 * 86.5= 68.85 tonnes

Subs, MOP for E grade DP = 127.6 – 68.85 = 58.77 tonnes

MOP for G grade DP = 0.9Pt – P

= 0.9 * 197.6 – P

= 177.8 – P

Here, P = Buoyant weight of G & E Grade

DP + HWDP + DC

= 0.796* (33.9 + 86.5)

P = 95.8 tonnes

MOP for G grade = 177.8 – 95.8

= 82 tonnes

So the excess pull to be applied should be based on ‘E’ grade tensile properties

Water cushion within pipe during DST; -

Calculate the collapse pressure (pc) at 2460m (base of E grade Dp) due to a fluid column of
specific gravity of 1.6 gm/cc

Pc = (2460*1.6)/ 10 = 393.6 kg/cm2

Collapse resistance of E grade DP is 335 kg/sq cm. therefore, the pipe must be run empty and a
water cushion may be placed while conducting DST.

Length of water cushion required inside Dp = 10*Pc – collapse strength of Dp sp

gravity of water.

= 10 (393.6 – 335) = 586 m

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Experiment No.6
Rig Hydraulics

Objective:-

TO STUDY THE RIG HYDRAULICS

Theory:-

Proper utilization of hydraulic energy at the drill bit and determination of pressure losses at
various part of drill string is discussed under heading of ‘Rig Hydraulics’. The sequence of fluid
mechanism is very important to Drilling Engineers.

Application of Rig Hydraulics:

1) Calculation of subsurface hydrostatic pressure tending to burst or collapse, the well

tubular or fracture exposed formations.

2) Several aspects of blow out prevention.

3) Displacement of cement slurries.

4) Bit nozzle size selection.

5) Surge pressure due to a vertical pipe movement.

6) Carrying capacity of drilling fluids.

There are two criteria’s:

1) Maximum impact force criteria: For max. I.F the pressure drop across bit is ,

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P (bit) = (n/n+2) * Ps

IF = Q√ϼ * P bit / 58

Where,

ϼ → ppg

Q → gpm

Field method of optimizing bit hydraulics:

The index ‘n’ can only be determined on site and in largely controlled by downhole
conditions. The steps involved are:

1) Prior to pulling bit out of hole for changing, run pump at 4 or 5 different speeds. Record
resulting stand pipe pressure.

2) From nozzle sizes, fluid pressure losses across the bit for each value of Q.

3) Subtract P (bit) from standpipe pressure to get ‘Pc’.

4) Plot Pc Vs Q on log-log paper & get slope ‘n’.

5) Using BHHP and IF criteria’ find nozzle sizes for next bit run.

Pressure drop across bit:

The objective of any hydraulic program is to optimize pressure drop across bit such that max.
Cleaning of bottom hole is achieved. Pressure losses across bit are greatly influenced by nozzle
size. Smaller nozzle size , greater is pressure drop.

Mean velocity Pipe V=q/2.428d²

Annulus V = q/2.448(d2²-d1²)

Flow behavior parameters µp = Ѳ600 – Ѳ300

τ= Ѳ300 - µp

Turbulence criteria Pipe,

NHe =37100*ρ* τy* d²/ µp²

NRe = 928* ρ* Δ* d/ µp

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Annulus

NHe = 24700* ρ* τy*(d2²-d1²)/ µp²

NRe = 757* ρ* V*(d2-d1)/ µp

Laminar Flow frictional Press Losses Pipe dpf/dL= µpV/15000 d² + τy/225d

Annulus dpf/dL = µpV/1000(d2²-d1²) + τy/200(d2-d1)

Turbulent flow frictional

Press loss. Pipe dpf/dL = ρ^0.75-V^1.75 µp^0.25 / 1800d^0.25

Annulus dpf/dL = ρ^0.75-V^1.75 µp^0.25 / 1396(d2-d1) ^1.25

Rig Hydraulics

Total surface pressure available is also called as pump pressure is equal to.

Pp = ΔPs + ΔPdp+ΔPdc+ΔPbit+ΔPdca+ΔPdpa

ΔPd = ΔPdp+ΔPdc+ΔPdca+ΔPdpa+ΔPs.

This is circulating pressure loss accept bit. This is also called as parasitic pressure loss that is
frictional pressure loss to and from the bit;

Pp = ΔPb + ΔPd.

ΔPd has to be minized and ΔPb is be optimized by calculating hydraulic level requirement at
every depth.

There are 2 imp imp criteria to describe rig hydraulics.

1) Max bit hydraulics Hp i.e. pressure loss across bit is simply the difference between pump
pressure (stand pipe pressure) and Δpd.

For optimum hydraulics, bit pr.drop must be a certain fraction of max available surface
pressure.

HHPs = BHHP + HHPc

Pbit = n/n+1.Ps

n = slope of graph Pc vs [Page 140].

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Q : It is desired to estimate proper pump operating condition and bit nozzle sizes for max bit
horse power at 1000ft increments for an interval of the well between surface casing at 4000 ft.
and intermediate casing at 9000ft.The well plan falls for following condition:

Max surface pressure = 3423psi

Max Hp = 1600Hp

Efficiency = 0.85

4.5 in, 16 lbm/ft drill pipe ID=3.826 inch

600ft of 7.5 in 0.D 2.75 in 1.D drill collar surface equipement. Pr.loss = 340ft drill pipe

Hole size = 9.857 in washed to 10.05 inch

Casing 1.D= 10.05 in

Max Annular velocity = 120ft/min.

Mud program

Depth Mud Density PV (CP) Yield point

5000 9.5 15 5

6000 9.5 15 5

7000 9.5 15 5

8000 12.0 25 9

9000 13.0 30 12

PH = Δ Pp q / 1714

Qmax = 1714 * PH *q / Δ Pp q=gpm

qmax = 681gpm

The normally accepted value lies between 1.47 to 1.86.

For the given problem, since pump pressure Vs q is not available, n = 1.75 is assumed.

Now,

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Δ Pd = 1 / 1.75+1 * 3423

= 3423 / 2.75

Δ Pd = 1245 paisa

For annular velocity = 120 ft/min

qmin = 2.448 * [(H.D) ² - (D.P) ²] * min Annular velocity ft/s

= 2.448 * [(10.05) ² - (4.5) ² ]*2 ft/s

= 395.36 gpm.

Although qmax and qmin is known for given condition and assumed ‘ή, we calculate further data
based on convenient flow rate value that lies in between qmax and qmin.

Assume, q = 500 gpm

Bingham plastic model.

Calculate drill pipe pressure drop.

Avg velocity in drill pipe = q/2.44 d^2

= 500/2.448* (3.826) ² ft/s

Vdp = 13.95 ft / s

Head storm number is,

NHe = 37100* ρ* τy*d²/ µp²

= 37100*0.95*5*(3.826) ²/ 15²

= 114650.23

Ref. fig. 4.33 to get critical reynold no. Vs headstorm no. graph.

NRe = 7200

Now,

Reynold’s no. is to be calculated

NRe = 928*ρ*V*d/ μ

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= 31,370

From graph of Moody diagram, we come to know that flow is turbulent.

So, frictional pressure loss in drill pipe is ,

∆ Pdp = [ρˆo.5 * Vˆ1.75* ∆L*(µ)ˆ0.25]/ [ 1800* Dˆ1.25]

= 490 psi

Pressure low in surface = 340 ft of drill pipe

∆ Ps = 38 psi

Mean value in d/c is given by,

˅ = q/ 2.448 d^2

= 500/ 2.448(2.75) ^2 = 27 ft/s

Hed storm no. is

Nhe = 31700* ρ* τy *d^2

= 37100*9.5*(2.75)^2

= 59231

‫ ؞‬Nre = 5800 ………………….(From graph)

Nre = 928* ρ*v d / µ p

= 928*9.5*27*2.75 / 15

= 43,640

‫ ؞‬Flow is turbulent

Mean velocity in annulus outside d/c is

V = q / 2.448 * (d2 ^2 - d1 ^2)

= 500 / 2.448 (10.05^2 – 4.5 ^2)

= 2.53 ft/sec

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NHe = [24700* ρ* τy*(d2-d1) ^2] / µp^2

= [24700*9.5*5*(10.05-7.5) ^2] / 15^2

= 16,018

NRec= 8000………from graph

Nre= 757* ρ* V*(d2-d1) / µp

=757*9.5*2.53(10.05-4.5) /15

=6714

‫ ؞‬Flow is leminar since Nre < Nrec

∆ Pdpa = [µp* V /1000(d2-d1)2 + τy /200(d2-d1)] AL

= [15*2.53 /1000(10.05-4.5)2 +5/200(10.05-4.5)] (5000-600)

∆ Pdpa=25.23 psi

Using procedure similar as before, frictional Pressure losses in other sections are also completed
at diff. depths of 6000,7000, 8000 and 9000 ft.

The results are as follows:

Depth ∆ Ps ∆ Pdp ∆ Pdc ∆ Pdcd ∆ Pdpa ∆Pd

5000 38 490 321 20 25 894

6000 38 601 320 11 11 1004

7000 38 713 320 11 29 1120

8000 51 1116 433 28 75 1730

9000 57 1407 482 27 111 2084

The pressure losses expected at each depth assumed are plotted at assumed flow rate of 500 gpm.
We then draw a line of slope = 1.75 through computed points.

We get flow rate by intersection of lines drawn with ΔPd lines.

The optimum nozzle area (At) opt can be calculated as,

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(∆f)opt = [√8311*10^-5* ρ*q^2] / [√Cd^2*(∆Pb)opt]

Depth D Depth Q ∆ Pd ∆ Pb At Nozzles

(1/32) (gpm) (psi) (psi) (sq in)

0.3776 12.06 5000 530 1245 2178 0.336 12-12-13

0.373 11.93 6000 520 “ “ 0.329 12-12-12

0.366 11.71 7000 500 “ “ 0.316 11-12-12

0.352 11.26 8000 460 “ “ 0.292 11-11-12

0.327 10.48 9000 400 “ “ 0.253 10-10-11

The above table gives nozzle sizes required for max bit hp for any interval.

Q 2.

Determine proper pump operating condition and bit nozzles for max jet impact force for next bit
run. The bit currently in use has 3 12/32” nozzles. The driller has recorded that when 9.6 ppg
mud is pumped at q = 485 gpm, a pump pressure of 2800 psig is observed and when pump is
slowed to a rate of 247 gpm, 900 psig is observed. The pump is rated at 1250 hp and has an ή of
0.91. the qmin to lift cuttings is 225 gpm. The max. allowable surface pressure is 3000psig. Mud
density will remain unchanged in next bit run.

Data: use impact force criteria.

Density q (gpm) pump pressure (psig)

9.6 485 2800

9.6 247 900

Pump: 1250 HP rating, E = 0.91, qmin = 225 gpm, Pmax = 3000 psig

Bit nozzles = 3 nozzles of 12/32”

Solution: At = √ [8.311*10^-5* ρ*q^2] / [d^2* (∆Pb) opt]

∆Pb = 8.311*10^-5* ρ*q^2 / Cd^2*At^2

At = 3*π/4(12/32) ^2 = 0.3313sq in

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Sub in formula,

Q (gpm) ∆Pb (psi) ∆Pd [pump pressure - ∆ Pb]

485 1845 905

247 491 409

If we plot a graph of ∆Pd vs Q on log-log paper, slope can be got , also by calculation ,

We get,

Slope (n) = [log(905) – log(409)/ log(485 – log(247)]

‫( ؞‬n) = 1.178

∆Pdc = Pc = 2/n+2 Pmax = 2/ 30178*3000 = 1888 psig

P opt = 1888 psig.

qmax = 1714*∆PHP (E) / ∆Pp = 1714*(1250)*0.91/3000 = 650 gpm.

From yhe grap of ∆Pd vs Q, we get a Q value of 825 gpm. Corresponding to ∆Pdp optimum
value of 1888 psig.

But q max = 650gpm

Hence, we use q (opt) = 650 gpm

∆Pb = Ps-∆Pd= 3000-1400=1600psi

Nozzle calculation,

At= √ [8.311*10^-5* ρ*q^2] / [Cd^2*(∆Pb)opt]

= √ [8.311*10^-5*9.6*650^2] / [(0.95)^2 * 1600]

At = 0.483 sq in.

D = √ [4At/3π]*32 = 14.48 in

We will use 3 nozzles of 14/32”, 14/32” and 15/32” respectively.

Q 3.

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Prior to changing of bit in a 12 ¼” hole, stand pipe pressure were recorded at different flowrates
with the present bit still on bottom. Present hole depth = 6528 ft and next bit is expected to drill
down to 8000 ft. other relevant data is given below.

The following data:

Present nozzle sizes = 3 of 16/32

Mud wt = 8.7 ppg or 65 pcf

Current flow = 600 gpm

Max allowable surface pressure = 2500 psi

Determine optimum hydraulic parameters for the next using BHHP and IF criteria.

Q (gpm) standpipe pressure Pbit Pc

(psia) psi ∆Pd

300 500 208 292

400 850 370 480

500 1200 575 625

600 1700 830 870

650 1900 980 920

m = 1.47

B.H.H.P criteria → for Q = 600 gpm

Pbit = (n/n+1)Ps = 1488 psi

At = 0.0096 q √ ρmua/∆Pbit = 0.4404 sq in.

D = √4At/3π

D = 0.432

So, nozzle size = 13, 14, 14

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Experiment No.7
Bit Hydraulics

Objective:-

STUDY AND DESIGN OF ROTARY DRILLING BITS, BIT PLANNING, ROP AND DRILL
OFF TEST.

Theory:-

The rate of penetration is achieved with the bit as well as the rate of bit wear. The most important
variables affecting penetration rate are- 1) Bit Type 2) Formation characteristics 3) Drilling fluid
properties 4) Bit operating conditions 5) Bit tooth wear 6) Bit Hydraulics.

1.Bit Type:

For roller cone bits, initial ROP is often highest in a given formation when using bits with
long teeth anf large cone offset angle. However these bits are practical only in soft formations
because of rapid tooth destruction and decline in penetration rate hard formations.

The lowest cost per feet is the objective while achieving highest ROP. Drag bits are
designed to obtain given ROP in hard formations. Drag bits give a wedging type rock failure in
which bit ROP per revolution depends on the no of blades and bottom cutting angle.

Diamond and pcd bits are designed for a given penetration per revolution by the selection
of the size and no of diamond or pcd blanks. The width and no of cutters can be used to compute
the effective no of blades length of the projectors/cutters projecting from bit face, limit the depth
of cut.

2. Formation characteristics:

The elastic and ultimate strength of formation are the most important formation
properties affecting ROP. The shear strength predicted by Mohr failure criteria, sometimes it
gives or is used to characterize the strength of the formation mouter reported the crater volume
produced beneath a single tooth is inversely proportional to both that is compressive and shear
strength of the rock.

The permeability of the formation has a significant effect on ROP. The drilling fluid
filtrate can move into the rock ahead often bit and equalise the pressure differential acting on the
chips formed beneath each tooth. These would tend to promote more expensive elastic mode of
crater formation. The nature of fluids contained in the pore faces of the rock affects these
mechanism, since more filtrate volume would be required to equalise the pressure in rock
containing gas than in rock containing liquid.

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Rocks containing hard abrasive minerals can cause rapid drilling of a bit. The gummy
clay cause mineral can cause the bit to ball up and drill in a very inefficient manner.

3. Drilling fluid properties:

ROP tends to decrease with increase fluid density, viscosity andsolids content ROP
increase with increase in filtration. The fluid viscosity controls the circulatory losses or parasitic
frictional losses and thus the hydraulic energy available of the bit jets for clearing. The chemical
composition of the fluid has an effect by way of hydration rate and bit balling tendency of some
clays on ROP. The presence of colloid size particles less than 1 micron are an order of magnitude
more efficient at plugging of the filtration beneath the bit. The pressure differential has effect on
ROP and has been described for Berea sandstone for clay H2o mud using 1.25” drilling cutter bit
of the rolling type. This is based in the experiment, similarly a no of other graph indicate
decrease in ROP with higher overbalance.

The graphs have been described for drag as well as rolling bits.

4. Operational aspect:

These have been very well explained by the graphs of WOB vs RPM. To optimise the bit
weight exponent and rotary speed exponent, the defailed drill-off test has been described
separately.

5. Hydraulics:

These plays very important role in multilateral and horizontals . On must prefer to the
API manuals and IADC bit selection, once the set of fluid properties are ready. Depending upon
the formation characteristic, depth and drilling data pertaining the mud related difficulties, you
should choose the level of hydraulics. Significant improvement in ROP can be achieved simply
by way off improved jetting action that is for an additional input to drilling as well as more
downhole volumetric floe rate to promote the early life of cutting, hence the bottom hole clean
up must be proportional to ROP. These could be observed by surface observation. This level of
hydraulics achieved at bit is to be decided by way of flounder point. At low bit rate and ROP, the
level of hydraulics required is small.as more weight is applied and cutting generated faster
flouder point is reached eventually where the cutting are not removed as quickly as they are
generated. If the level of hydraulics is observed / increased, a higher bit weight and ROP will be
achieved before floundering occurs. Various graphs of ROP vs Reynolds number function and
hydraulics HP/IF with higher Reynolds no, HHP and jet impact force.

6. Bit wear and bearing conditions:

The tooth length of milled tooth of rolling cutter bit is reduced continuously by abrasion and
chopping. Similarly, you may need to dress up the tipped tooth bit or to carry off hard facing that

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is the process to promote a self sharpening type of tooth wear. The teeth of tungsten carbide
insert type rolling cutter bit facility by breaking rather than abrasion hence the projection and
tooth geometry is an important criterion while selecting used bits. One must follow IADC
selection criteria for old bits.

The type of lubrication and bearing is to be followed as per the maintenance programme
of the bit. The instantaneous rate of bearing wear depend on the current condition of the bit,
proper attention to damage bearing will enhance the life of bearing. Usually a linear rate of
bearing wear is assumed for a given applied force; the bearing life can be expressed in term of
total revolution (RPM) under the applied force, as long as the surface rotary speed is Lough
enough the prevent and excessive rise in temperature. The bearing life is assumed to be linear
with the rotary speed. Price of bit is lowest for non-sealed roller bearing and highest for sealed
journal bearing.

Effect of WOB on bearing life depends on the number and type of bearing, whether or not the
bearing is sealed. Lubrication is accomplished with the drilling fluid for non-sealed bearings,
again the properties of mud also affect the bearing life, as Q increases the ability of mud / fluid to
cool the bearing also increases, however to lift the cutting will also be sufficient to prevent
excessive temperature build up in bearing. Bearing life is estimated by formula given by

db/dt = 1 / ζB (N/60)B1 (W/4db)B2

Where,

b = fractional bearing life that has been consumed

t = time in hours

n = rotary speed in rpm

w = bit weight, 1000 (lb-force)

dB = bit diameter (inches)

B1, B2 = bearing wear exponent

‫ح‬B = bearing constant in hours.

Question 1:

A 8.625” diamond bit containing 270 diamond stones each of 0.23 inch diameter stones of
1.00carat is designed to operate at a depth of penetration of 0.01”. Estimate the overall ROP that
could be obtained if an acceptable bit weight and torque could be maintained at rotary speed of
200 rpm

Answer:

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Cc/Sd = 270/(π/4*8.6252) = 4.621 stone/inch2

Nbe = 1.92 (Cc/Sd) * db * (√di * Lp – Lp2)

= 3.59

The effective ROP is given by

lpe = 0.67 (0.01) = 0.0067 inch

The penetration rate at a rotary speed of 200 rpm is given by

R = (lpe) (nbe) (N)

= (0.0067 / 12) * 3.54 * (60 * 200)

R = 24 ft/hour

Question 2:

Penetration rate for roller cone bit

The approach usually taken is to be assume that the effect of WOB, RPM, Tooth wear, etc on
ROP are independent of one of another and that the composite effect can be computed by
following form of equation

R = F1 * F2 * F3 * F4 --------- Fn

Where,

F1, F2, F3 represent fractional relations between ROP and various drilling variable, These are
based on laboratory or field data.

Reference

Burgoyne young model using 8 functions:

F1 = e 2.303 a1 = K

F2 = e 2.303 a2 (10,000 - D)

F3 = e 2.303 a3 D^0.69(g p - g)

F4 = e 2.303 a4 D (Qp - ρc)

F5 = [(W/db) – (W/db)t / 4 – (W/db)t]

F6 = (N / 60)a6

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F7 = e – a7 * h

F8 = (fj / 1000)a8

In these equation

D = true V D, ft (Tvd)

Gp = pore pressure gradient

Ρc = equivalent circulating density

(W / db) = threshold bit weight per inch of bit

H = fractional tooth dullness

Fj = hydraulic impact force beneath the bit(lbf)

a1 to a8 = constant that must be chosen based on local drilling conditions.

F1 represent formation strength snf bit type effect on ROP. F2 and F3 model the effect of
compaction on ROP. F4 models the effect of overbalance on ROP. F4 model the effect of
overbalance on ROP. F5 and F6 model the effect of WOB and rotary speed. F7 models the effect
of tooth wear on ROP. F8 models the effect of bit hydraulics on ROP.

Question 3:

A 9.875 inch milled tooth opearated at 40000 lbf per inch and 80 RPM is drilling in a shale
formation at a depth of 12000 feet at ROP of 15 feet/hour formation PPG is equivalent to 12 ppg
and ECD of mud at bottom is 12.5 ppg. The computed jet impact force beneath the bit is 1200 lbf
and the computed frictional tooth wear is 0.3 compute the apperent formation drillability ‘f
’using a threshold bit weight of zero and the values of constant for the drilling condition are
given below a2 = 0.00007, a3 = 0.000005, a4 = 0.000003, a5 = 1, a6 = 0.5, a7 = 0.5, a8 = 0.5

Answer:

F2 = e 2.303 * (1000 - D)

= 0.724

F1 = e 2.303 (D^0.69)(g p - q)

= 1.023

F1 = e 2.303 a4D (ap - ρc)

= 0.6606

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F5 = [(W/db) – (W/db)t / 4 – (W/db)t]

F5 = [(40/9.875) / 4]

= 1.013

F6 = (N / 60)a6 (80 / 60)0.5 = 1.155

F7 = e – a7 * h = e – 0.5 * 0.3 = 0.861

F8 = (fj / 1000)a8 = (1200 / 1000)0.5 = 1.095

By formulae,

R = F1 * F2 * F3 * F4 * F5 * F6 * F7 * F8

15 = F1 * 0.724 * 1.023 * 0.6606 * 1.013 * 1.755 * 0.861 * 1.095

F1= 15/ 0.54 = 27.8 ft/hr

Procedure for drill-off test:

1. Select a depth to run a drill off test where a section of uniform litho-logy is expected.
2. While drilling with WOB currently in use, lock the break and determine the time required
to drill off 10% of this weight currently in use.
3. Increase bit weight to initial value of drill off test, these initial values should be at least
20% increase in bit weight over the bit weight currently in use.
4. Drill at this bit weight long enough to establish new bottom hole pattern of bit. The time
allowed is usually one characteristic time per 10% increase on bit weight for example
time interval of twice the characteristic time would be used for 20% increase in bit
weight.
5. Lock brake and maintain constant rotary speed record time, each time the bit weight falls
off 4000 lbs force. If weight indicator is fluctuating, use midpoint of fluctuation as bit
weight continue test until at least 50% of initial bit weight has been drilled off.
6. Make plot of ∆t vs W and R vs W. Using log-log paper. Slope of graph is bit weight
exponent deviation from straight line graph may occur at higher bit weight if bit
floundering occurs or is impending.

Hooke,

‫∞ح‬δ

For axial tension in drill string, the stress change is equal to change in bit weight/ cross section
area of drill pipe.

The change in strain is equal to drill pipe length change per unit length.

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∆W / As = E ∆L / L

∆W L / E As = ∆L

Average penetration rate for change in bit weight (∆W ) can be obtained by dividing above
equation by time interval ∆t to drill off ∆W

R = ∆W L / E As ∆t = ∆L / ∆t

Range to drill pipe have joint about 5% of drill length that have grater cross section area area
than pipe body.

R = ∆W L / E As ∆t * 0.95

Length change of drill collar is small that can be ignored or taken into account.

Using the following data evaluate bit weight expressed and rotary speed exponent

Cross section = 5.275 inch2 E = 30 * 106 psi

Bit Bit R.P.M = 150 Elapsed ROP RPM=100

weight weight time
(Average)
1000 lbs Elapsed ∆t R (ft/hr) Sec Ft/hr
time
76 0 0
72 74 52 52 16.61 54 54 16
68 70 105 53 16.30 114 60 14.4
64 66 160 55 15.70 180 66 13.1
60 62 218 58 14.89 253 73 11.83
56 58 281 63 13.71 334 81 10.66
52 54 352 71 12.16 424 90 9.6
48 50 432 80 10.8 525 101 8.55
44 46 522 90 9.6 641 116 7.44
40 42 626 104 8.30 773 132 6.54
36 38 746 120 7.2

If we express R in ft/hr, ∆t = seconds, we can evaluate detailed table.

Plot of ROP Vs Average WOB constructed.

The evaluation of slope of straight line portion yield value of 1.6 this is bit weight exponent
value below flounder region.

Rotary speed exponent

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Procedure:

If ROP = 13.7 ft/hr for WOB = 58000 lbs and N = 150 rpm on graph.

Reduce N to 100 rpm for these point, we will get ROP = 10.7 ft/hr for some WOB.

R = K N a6

13.7 = K (150) a6

10.7 = K (100) a6

S, K = proportionality constant

1.280 = (150/100) a6

1.280 = (1.5) a6

a6 = ln 1.280/ ln 1.5

a6 = 0.6

Bit weight exponent = 1.6

Rotary speed exponent = 0.61

Conclusion:

These value of bit weight exponent and rotary speed exponent below floundering region gives
optimum ROP and be used to determine highest WOB and RPM in standard equation for ROP.

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Experiment No.8
Casing Shoe Depth Selection

Objective:-

DETERMINATION OF CASING SHOE DEPTH

Theory:-

In this experiment, we are solving the problem of depth selection of casing seat or shoe. The
requirements to approach the selection of depth are:

1. Target Depth
2. Poisson Ratio
3. Overburden Pressure or gradient
4. Formation Fracture Pressure
5. Formation Pressure against depth

Target depth is given to us. If Poisson ratio is not given then it is calculated on depth basis as

Where D=ft

The overburden pressure or gradient is calculated by the formula

Overburden pressure=0.433(1-f) (Sm) +0.433( f) (Sw)

f = porosity

Sm =specific gravity of mineral

Sw= Specific gravity of water

From this given things we now start our calculation part by first calculating the Formation
Fracture Gradient. This is done by two methods:

1. Direct Method
2. Indirect Method

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Theory:

Leak off Test:

Leak off test is to test the formation just below casing shoe to determine fracture gradient of
the formation by pressurizing fluid in casing in increments and recording the pressure when
initial leak-off starts. This is a field method of determining fracture strength of the formation
just below casing seat. This also tests the cement job of casing along with competency of
formation to withstand pressure without fracturing.

Necessity of LOT:

While drilling after intermediate casing, weakest formation is generally near the previous
casing shoe. This formation must stand maximum mud weight to be used to drill open hole,
to control kick and maximum allowable surface pressure to control kick without fracturing
formation at shoe.

Behaviour of pressure vs. volume pumped:

a) LOT is done after drilling fresh hole 4 to 5 m below casing seat

b) Lift the drill string within casing shoe and close BOP around drill pipes
c) Mud is pumped from cementing units and monitor amount of fluid pumped in stages
and record pressure against volume pumped(Incremental volume of mud is 50 to 75
litres)
d) This volume is from pumped interval of 5 to 10 min to enable to record and see
behaviour of formation competency. In no case, pressure should exceed 70% of
casing burst pressure or BOP rated pressure, whichever is less.
e) Stop the pump as soon as drop in pressure is observed. This is pressure to initiate the
formation fracture termed as LOT pressure or formation breakdown pressure. After
LOT, pressure decreases and remains constant. This is known as fracture propagation
pressure. This is equal to minimum horizontal earth stress.

In directional well, formation breakdown pressure can occur at values higher or lower than
fracture propagation depending on hole inclination & azimuth. In deviated well, σ3 is
considerably different from σ2.

Fracture pressure= LOT pressure + Hydrostatic Pressure at shoe

=LOT pressure + ρ d / 10

Max allowable mud weight= LOT pressure×10 / d

Max allowable surface pressure= New mud weight- Old mud weight × d / 10

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Eaton’s Formula:

This is indirect method and Eaton’s formula is derived by Hubbert and Willie method.σ1, σ2 and
σ3 are principal stresses. σ1 acts vertical, σ2 and σ3 are horizontal and directly influence
fracturing rock. So; hydrostatic head should be equal or greater; fracture occur when applied
fluid pressure exceed the sum of min effective stress. Effective stress is defined as difference
between total stress and pore pressure

σ1’= σ1-Pf

σ2’=σ2- Pf

σ3’=σ3-Pf

Now,

Also,

Therefore, ε2=ε3=0

0=

Fracture Pressure=σ3’+Pf

= +Pf

or dividing by depth D

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This is Eaton’s Formula

Where,

F.P. =Fracture Pressure

µ=Poisson’s Ratio

σ1=overburden pressure

Pf=Formation pore pressure gradient

The next step is to find out min mud weight required.

Min mud weight= formation pressure gradient + swab factor

= formation pressure gradient + 0.3 ppg

Min Fracture Gradient=Min mud weight + surge factor

=Min mud weight + 0.3 ppg

Formation Fracture Gradient= Min required fracture gradient + safety factor

= Min required fracture gradient + 0.2 ppg

After calculating all these parameters we plot a graph of depth vs. pressure (MWE), Depth vs.
min mud weight required and depth vs. formation fracture gradient.

Draw a vertical line from point w.r.t. target depth and design formation fracture gradient in
MWE. The point at which the vertical line intersects the fracture pressure gradient is the tentative
casing seat for intermediate casing or liner.

Theory of Differential Stuck Up and Kick tolerance:

Now we check the casing w.r.t. differential sticking point and kick tolerance aspect as we now
have the tentative depth for casing seat.

1) Differential sticking point or differential stuck up pressure will be maximum at

deepest normal pressure zone. the pressure regime is defined as
Pressure
Normal Abnormal Subnormal
2400 psi 3100 psi & above less than 2400 psi

Differential sticking starts at abnormal pressure.

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Differential pressure at tentative depth

= (MWE at tentative depth-1.07)×depth upto which normal pressure exists/10

The pressure is MWE and from this we find another depth (D2) which is depth of casing
seat/shoe to avoid differential sticking point.

2) Kick tolerance aspect:

We consider the aspect as avoid kick in the well. the impact of kick is calculated as

Where,
ρ1= min mud weight required at target depth
D1= Target Depth
D2=Depth from differential sticking point calculation

Now, difference between formation fracture gradient at tentative seat and kick impact tolerance
is between 0.2 to 0.4 ppg or 0.02 to 0.048 MWE

Depth Sp gravity Min reqd Min mud wt Formation Fracture

fract grad press grad pressure

500 1.1 1.076 1.04 1.004

1300 1.15 1.126 1.09 1.054

2250 1.25 1.226 1.2 1.164

2500 1.4 1.376 1.34 1.304 1.74

2900 1.64 1.62 1.6 1.564

3000 1.7 1.676 1.64 1.604 2.16

3050 1.725 1.696 1.66 1.624

3100 1.75 1.726 1.69 1.654

3150 1.77 1.746 1.71 1.674

3164 1.78 1.756 1.72 1.684

3200 1.8 1.776 1.74 1.704

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3250 1.825 1.796 1.76 1.724 2.234

3400 1.9 1.896 1.84 1.804

3550 1.95 1.926 1.89 1.854

4000 2.1 2.076 2.04 2.004

Differential stuck up = ρd/10

= (1.65-1.05) 1300/10

= 72.8 kg/cm^2

= 1033.76 psi

Which is less and hence safe.

Kick tolerance aspect = ρ1+ D1/D2*0.06

= 2.04 + 4000/2850 * 0.06

= 2.124

a = 2.1 – 2.124

= -0.024 not safe

By trial & error take D2 = 2940

Kick tolerance = 2.16 – 2.121 = 0.036

Hence safe 9 5/8” casing shoe depth 2940 m

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Experiment No.9
Casing Grade Selection

Objective:-

CASING GRADE SELECTION

Theory:-

One of the most important factor in casing design is casing material selection in this, we consider
two parameter of material that is,

1. Collapse
2. Burst

Collapse Pressure:

It is the net external pressure imposed on the pipe. The condition when maximum
collapse pressure is taken as basis of design. Maximum worst condition occurs when pipe is
empty and hydrostatic pressure is exerted to pipe from outside H.P increase with depth, hence we
should chose the material considering this also,

P = ρ * d / 10

Burst Pressure:

It is the net interval pressure that is difference between internal and external pressure
acting on pipe for maximum internal pressure. Casing is considered to be filled completely with
gas at B.H.P for minimum external pressure, the hydrostatic load/head of salt water is supposed
to act from outside.

Then, the casing is subjected to maximum burst pressure near the surface where external
pressure is minimum.

It is calculated by two methods:

I. Calculate Psur by considering a kick from next casing shoe depth.

II. Calculate Psur by considering a pressure equivalent to fracture gradient at a casing shoe
depth.

The least of above two values is considered as burst pressure,

Ps1 = B.H.P / e 0.0001138 * S.G * D

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Ps2 = B.H.P / e 0.0001138 * S.G * D

B.H.P = ρ * d / 10

Net burst pressure is minimum of ps1 and ps2

Plot burst load profile as shown in diagram.

We also consider the following factor:

I. Design factor for tension = Pipe body (yield strength) / Total weight in air.
and should be greater than 1.8 to 2.
II. Collapse = Collapse Resistance / Collapse Pressure {>1.25}
III. Burst = Internal yield pressure / Burst pressure at surface >{1.1 kg/cm2}

Problem:

9 5/8”  0 to 2940

 P 110 Weight 47 ppf

Collapse Resistance = 373 kg/cm2

Internal yield = 664 kg/cm2

Pipe body yield = 672 kg/cm2

 N 80 weight 43.5 ppf

Collapse Resistance = 268 kg/cm2

Internal yield = 445 kg/cm2

Pipe body yield = 454 kg/cm2

 P 110 Weight 53.5 ppf

Collapse Resistance = 55.8 kg/cm2

Internal yield = 76 kg/cm2

Pipe body yield = 774 kg/cm2

Solution:
Collapse Pressure = ρ * d / 10

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= 1.68 * 2940 / 10
= 493.2 kg/cm2
Burst Pressure = B.H.P = ρ * d / 10
= 2.1 * 4000 / 10
= 840 kg/cm2

Ps1 = B.H.P / e 0.0001138 * S.G * D

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= 840 / e 0.0001138 * 0.65 * D

= 624.85 kg/cm2

Ps2 = B.H.P / e 0.0001138 * 0.65 * D

= [(2.16 *2940) / 10] / e 0.0001138 * 0.65 * 2940

= 510.9 kg/cm2

Burst Pressure = 510.9 kg/cm2

Saline water = 1.07

I. Kick from next phase = B.H.P / e 0.0001138 * S.G * D

II. For saline water

At surface = 0

At shoe = 1.07 * 2940 / 10

=14.58 kg/cm2

Net burst

At surface = 510.9 kg/cm2

At shoe = 314.58 kg/cm2

That is net = 510.9 – 314.58 = 196.32 kg/cm2

Collapse = 493.7 kg/cm2

Burst = 510.9 kg/cm2

Select casing number 3

I. Collapse = collapse resistance / Collapse pressure

= 558 / 493.5

= 1.13 Grater than 1.125 kg/cm2, hence safe

II. Burst = Internal yield pressure / Burst pressure

= 716 / 510.9

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= 1.5 Grater than 1.1 kg/cm2, hence safe.

III. Design factor for tension = pipe body yield strength / total weight in air
= 774 / 0.079 * 2940
= 3.3 Grater than 1.8 kg/cm2, hence safe.

For P 110, 47 ppf

Collapse resistance / Collapse pressure = 1.125

373 / (ρ * d / 10) = 1.125

373 / (1.69 * d / 10) = 1.125

D = 1962

2940 – 1962 = 978 ft

Now we calculate biaxial effect = Weight of section / Pipe body yield

Weight of section = 978 * 0.78 * 80 / 1000

= 61.3

X axial load = 61.3 / 774

= 0.079

Value of from table = 0.975

Therefore decrease in collapse resistance is = 373 * 0.975

= 363.67 Kg/cm2

363.67 / (1.69 * d / 10) = 1.125

D = 1912 m

2940 – 1912 = 1082m

Again calculate for 1912 biaxial effect weight of section = 1028 * 0.786 * 80 / 1000

= 64.64

X-axial load = 64.64 / 774

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= 0.0835

Value of Y from table = 0.975

Hence, final depth for P110 47 ppf is 1912m

Now for N 80 43.5 ppf

Collapse resistance / Collapse pressure = 1.125

Collapse pressure = Collapse resistance / 1.125

= 268 / 1.125

ρ * d / 10 = 238.22

1.691 * d / 10 = 238.22

D = 1409 m

Buoyed weight of section = [(1027 * 80 + 498 * 70) / 1000] * 0.784

= 92

X = 0.2, Y = 0.922

N 80 cannot withstand burst pressure of 510 kg/cm2

Hence, we plot burst load profile

Therefore collapse pressure resistance = 0.929 * 268

= 248.97

248.97 / (1.69 * d / 10) = 1.125

D = 1309 m = 1300 m

1910 – 1300 = 610 m

Buoyed weight = [(610 * 70 + 1030 * 80 / 1000)] * 0.784

= 98.07

Y2 = 98.07 / 454 = 0.21

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Y1 = 0.922

Therefore collapse pressure resistance = 0.922 * 268

= 247.09

247.09 / (1.69 * d / 10) = 1.125 = 1299.61 = 1300 m

Burst = 445 / 52323 = 0.868 < 1.1

Not used up to surface

445 / 1.1 = 404.5 kg/cm2

From burst load profile, depth = 1000 m

For N 80 top 1000 m

Checking tension = 1030 * 80 + 610 * 70 + 300 * 64.5 / 1000

= 144.48 tonnes

Tension = 454 / 144.48 = 3.1 > 1.8 safe

0 to 1000m, use P 110 47 ppf

Check for tension = 1000 * 70 + 300 * 64.6 + 610 * 70 + 1030 * 80 / 1000

= 214.48

672 / 214.48 = 3.1 > 1.8 hence safe

For 9 5/8″ casing

0 – 1000m P 110 47 ppf

1000 – 1300 m N 80 43.5 ppf

1300 – 1910 m P 110 47 ppf

1910 – 2940 m P 110 53.5 ppf

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Experiment No.10
Cement Slurry Calculation

Objectve:-

CEMENT SLURRY CALCULATION

Theory:-

Cement:

Step 1:

Determine the following

a) Annular capacity of ft3/ft = Dh2 – Dp2 / 183.35

b) Casing capacity ft3/ft = 1 * D2 / 183.35
c) Casing capacity bbl//ft = 1 * D2 / 1029.4

Step 2:

Determine the number of sacks of lead cement sack required

= {(ft to be cemented * annular capacity * excess)/ [(yield/ft3) / sack lead cement]}

Step 3:

Determine number of sacks of tail cement sack required

= {(ft to be cemented * annular capacity * excess)/ [(yield/ft3) / sack lead cement]}

Sack required in casing = number feet into f/s to f/s * casing capacity / (yield of ft3 / sack)

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Calculation:

For 9 5/8″ casing

Class G cement = 15.83 ppg

Lead slurry = 18 m3, specific gravity = 1.9

Tail slurry = 18 m3, specific gravity = 1.96

Cement size from surface = 2200 ft

15.82 = (94 + 0.94 * x) / (3.59 + 0.1128 * x)

X = 44 gal (volume of water)

Volume = 3.59 + (44/100) * 11.28 = 8.6 gal/sack

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Slurry yield = 8.6 / 7.48 gal/ft3 = 1.15 gal/sack

Lead yield = 18 / 0.0283 = 636 ft3 = 636 / 1.15

= 553 sacks

= 553 * 94

= 51986.08 lb

= 51986 * 4.54 * 10-4

= 23.6 tonnes ------------ 1

Tail slurry = 32 m3 / 0.0283 = 1130 ft3

= 1130 / 1.15 = 983 sacks

= 983 * 94

= 92402 lb

= (92402 * 4.54 * 10-4) tonnes

= 42 tonnes ------------- 2

1 m3 / 0.0283 = 35.33 ft3

(35.33 ft3) / (1.15 ft3/sack) = 30.72 sacks

30.72 * 94 = 2888 lb

2888 * 4.54 * 10-4 = 1.3 tonnes ------------- 3

Adding 1, 2 and 3

23.64 + 42 + 1.3 = 66.9 tonnes

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Experiment No.11

Well Control

Objective:-

STUDY OF WELL CONTROL METHODS

Theory:-

1. First note SICP and SIDP pressure.

2. Calculate initial circulating pressure (ICP)

ICP = slope of pump rate pressure + SIDP

3. Find out kill mud weight = original mud weight + (SIDP * 10 / D)

4. Final circulating pressure with kill mud = slow pump rate pressure * (Kill mud
weight/O.M.W)

Therefore slow pump rate pressure measured at 30 SPM, 45 SPM

Drillers Method:

First circulation
a) Bring the pump to kill speed in steps of 5 spm, gradually opening the choke holding
the casing pressure constant.
b) When pump is up to kill speed, maintain drill pipe pressure constant.
c) Circulate out influx from the well maintaining drill pipe pressure constant.
d)When the influx is out, stop the pump reducing the pump speed in steps of 5spm,
gradually close the choke, maintain casing pressure constant. Record pressure, SIDPP
and SICP should be equal to original SIDPP.
Second circulation
a) Line up suction with kill mud.
b) Bring the pump up to kill speed in steps of 5spm,gradually opening the choke holding
casing pressure constant .
c) When pump is at kill speed , pump kill mud from surface to bit, maintaining casing
pressure constant.
d) Pump kill mud from bit to surface , maintaining drill pipe pressure constant equal to
FCP.
e) When the kill mud reaches the surface , stop the pump reducing the pump in steps of 5
spm, gradually closing the choke maintain the casing pressure constant. Record SIDPP,
SICP both should be equal to zero.

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Wait and weight method:

Driller method require two cycle

1. Original mud weight (OMW)

2. Kill mud weight (KMW)

But in this method only one circulation is required with KMW

1) Note SIDP, SICP

2) Find ICP, FCP and new mud weight.
3) Surface to bit, bit to shoe, bit to surface strokes.
4) Pump pressure drop/ 100 strokes = (ICP –FCP/ surface to bit strokes ) x 100.

Procedure:-
a) Line up suction with kill mud.
b)Bring pump up to kill speed in steps of 5spm, gradually opening the choke, holding casing
pressure constant.
c) when the pump is at kill speed, pump kill mud from surface to bit , maintain drill pipe pressure
as per step down schedule ( during this step drill pipe pressure will fall from ICP to FCP ).
d) Pump kill mud from bit to surface, maintain drill pipe constant equal to FCP.
e) When kill mud reaches surface, stop the pump reducing the pump speed in steps of 5 spm,
gradually closing the choke maintaining casing pressure constant. Record SIDPP, SICP both
should be equal to zero

PROBLEM:
SIDP = 500 psi
SICP = 700 psi
Slow pump rate pressure (KRP ) = 550 psi at 30 SPM
Mud Pump Output = 0.107 bbl/Stroke
OMW = 12.8 ppg
Hole Depth = 14325/11520 ft
9 5/8 shoe depth = 12220/10175 ft
5” DP Capacity = 0.0178 bbl/ft
5” HWDP = 420 ft, capacity = 0.0088bbl/ft
DC, 6.25”, 800ft long, capacity = 0.006bbl/ft
Volume open hole / collar = 0.0322 bbl/ft
Volume open hole/ DP/HWDP = 0.0473 bbl/ft
Volume csg/ DP = 0.0493 bbl/ft
Prepare kill sheet

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ρm

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References

1. Gatlin C.; Petroleum Engineering, Drilling and Well Completions, Prentice Hall.

2. Rabia H.; Oil Well Drilling Engineering, Graham Trotman Ltd., London.

3. Azar, J. J., G. Robello Samuel; Drilling Engineering, Penn Well.

4. Drilling Mud and Cement Slurry Rheology Manual; Gulf Publishing Company.

5. Smith.P.K’Cementing’ SPE Pulications 2nd Edition 1976.

6. Mitchel R F (Editor), Drilling Engineering, In Petroleum Engineering Handbook,

Volume 2 , SPE Publication, 2007, 770 pp

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