TOR-ERD Study For Block 56 PDF
TOR-ERD Study For Block 56 PDF
TOR-ERD Study For Block 56 PDF
-DRAFT-
Prepared by:
Page
1.4 Specific Training of Drilling Team Members Necessary for Efficient ERD Drilling.... 4
Figures:
Attachments:
A. Drilling Basics
B. Sinusoidal Buckling and Countermeasures
C. Well Profile Options for ERD Wells
D. Hole Cleaning and Cuttings Transport in ERD Wells
E. Torque and Drag in ERD Wellbore – Modeling Torque and Drag
F. Wytch Farm Case Study – Elements of a Successful ERD Program
The purpose of this document is provide background information on extended reach drilling
(ERD) and describe Terms Of Reference (TOR) for a comprehensive ERD study for Block 56.
See Attachment A for an excellent discussion of basic drilling concepts and a simple figure
showing all major components of the drilling operation.
Directional drilling is the ability to steer the drill-stem and bit to a desired bottomhole location
and has been in use for the last half century. Prior to that time the only option was to drill wells
vertically. Directional wells are initially drilled straight down to a predetermined depth and then
gradually curved at one or more different points to penetrate one or more given target reservoirs.
Directional drilling is usually accomplished with the use of a fluid-driven downhole motor,
which turns the drill bit.
Directional drilling also allows multiple production and injection wells to be drilled from a single
surface location such as a gravel pad or offshore production platform, thus minimizing cost and
the surface impact of oil and gas drilling, production, and transportation facilities.
The limitations of directional drilling are primarily dependent upon maximum hole angle, rate of
angle change, and torque or friction considerations. In directional drilling, it is now common for
the horizontal displacement of the bottomhole location to be twice the vertical depth of the well.
That is, a well with a vertical depth of 7,000 ft. could have a bottom hole horizontal displacement
of 14,000 ft. from the drill site.
The proposed vertical depth of the Block 56 wells is approximately 7,000 feet (2,200 meters).
See the well design proposed by PlusPetrol in environmental impact assessment for Block 56 at:
http://www.minem.gob.pe/archivos/camisea/estudios/pluspetrol/L56_Cap_2_Anexo_I.pdf.
These will be directionally drilled wells. However, the amount of horizontal displacement will
be quite modest, approximately 2,500 feet (less than 1,000 meters).
The type of geology or rock that must be drilled in order to reach a target may also limit
directional drilling. Coal and shale deposits tend to collapse and cause the drill string to get
stuck. This is more likely to happen in wells that take longer to drill, such that the downhole
formations are exposed to the drilling mud and drill string longer. Stuck pipe can also occur in
directional wells when the borehole becomes oval from the drill pipe constantly laying on the
downside part of the wellbore. The pipe gets lodged in the groove cut on the bottom of the hole.
The most common cause of hole collapse is the chemical difference between in-formation
saltwater and the drilling mud.
From: Society of Petroleum Engineers Paper No. 59204, To the Limit and Beyond - The Secret of World-Class Extended-
Reach Drilling Performance at Wytch Farm, IADC/SPE Drilling Conference, New Orleans, February 2000.
Use of a consistent team to see the project through can be critical to its success given the
inherently long planning and implementation time associated with an ERD drilling program.
ERD programs generally push rig systems and available technologies to their limits. For this
reason, a core design team that includes all of the relevant disciplines is critical. This team must
consist of the lead drilling engineer, reservoir engineer, geologist, completions engineer and
drilling operations representative. By designing a team in this manner, each aspect of the
program is given its fare stake in the ERD design. Having drilling operations staff involved from
the beginning helps to pave the way for acceptance of new ideas into the field by giving them
ownership in the program.
Constraints to successful ERD include downhole drill string and casing movement, applying
weight to the drill bit, possible buckling of casing or drill string, and running casing successfully
to the bottom of the well.
Running normal-weight drill pipe to apply weight to the bit in ERD can lead to buckling of the
drill pipe and rapid fatigue failure. Conventional drilling tools are prone to twist-off, because of
unanticipated failure under the high loads of an ERD well. Torque can be significantly reduced
with the use of non-rotating drill pipe protectors. Advanced equipment for an ERD well may
include wider diameter drill pipe, additional mud pumps, enhanced solids control, higher
capacity top drive, more generated power and oil-based drilling fluids. ERD requires longer hole
sections, which requires longer drilling times. The result is increased exposure of destabilizing
fluids to the wellbore. Water-based muds may not provide the inhibition or confining support of
oil-based muds in an ERD application.
ERD has been instrumental in developing offshore reserves from shore at Wytch Farm, U.K. The
original development plan called for the construction of a $260 million artificial island in the
bay. Other successes with ERD include the North Sea, Gulf of Mexico, South China Sea, and
North Slope Alaska. The current ERD horizontal displacement record of over 11 kilometers was
established on the Sahkalin II project (Russia) in early 2005.
The following paragraphs prepared by Schlumberger provide an excellent summary of the state
of drilling knowledge of Camisea gas deposits. Schlumberger is PlusPetrol’s drilling consultant
for Camisea. Schlumberger is also the leading ERD consultant in the oil industry. The complete
text is available at the Schlumberger website at:
http://www.oilfield.slb.com/content/services/resources/casestudies/drilling/nds_camisea_pluspetr
ol_peru.asp?
Schlumberger’s No Drilling Surprises (NDS) services helped PlusPetrol reduce drilling time and
improve hole quality, saving them approximately $10 million on three wells in Peru’s San
Martin field, which is located in the Camisea blocks in the tectonically active foothills of the
Andes. The major drilling problems avoided or resolved in achieving the savings included
wellbore instability and poor bit and bottomhole assembly (BHA) performance. The
collaboration between the NDS team, PlusPetrol, and other service providers also helped reduce
other problems resulting from drilling fluid loss, hole cleaning, and reactive clays.
Prior to drilling the first of the three San Martin wells, the NDS team analyzed previous drilling
problems in the area and created a plan for reducing drilling risk. A mechanical earth model
created from drilling, wireline, geological, and seismic data was used to find the root causes of
the drilling problems in offset (initial) wells. Based on the results, the NDS team recommended a
casing and mud program that would minimize hole instability problems. The mud program
recommended adjustment of mud weights to better manage wellbore stability and the use of
blocking additives to increase stability in microfractured formations.
To reduce tripping (removing drill string from wellbore) non-productive time, the BHA and drill
bits were configured to drill each hole section in a single run. A full-rotation PowerDrive*
rotary steerable system was used to improve hole cleaning and hydraulics and maintain the well
trajectory in hard formations. Because of the improved hole quality achieved, there was a high
success rate in running production liners to total well depth in the first attempt.
PlusPetrol Senior Drilling Engineer J. Casanelli said, “The NDS process involves looking at
data all the time, compares it with the offset and plan, and lets us know the deviations from the
plan. It provides a process for the understanding of problems and the best practices to solve
them.”
1.4 SPECIFIC TRAINING OF DRILLING TEAM MEMBERS NECESSARY FOR EFFICIENT ERD
DRILLING
Operators can significantly reduce risks by making an attempt to move up the learning curve
prior to detailed planning for an ERD well. This may include drilling warm-up wells and
In the case of Block 56, it would make practical sense to drill the shortest ERD wells first (6 km
to 7 km horizontal distance) to develop the expertise to efficiently drill the longer ERD wells.
The Schlumberger “No Drilling Surprises” discussion provides an excellent roadmap of how to
progressively increase drilling efficiency in a Camisea drilling campaign.
Training is perhaps one of the most important tools to reduce risk. It is essential that all
personnel be fully trained in ERD operations. It should not be assumed that ‘conventional’
drilling experience is adequate. K&M has found that conventional drilling practices are
generally not appropriate for ERD wells. Perhaps more importantly, the misconceptions and
drilling practices that can be “gotten away with” on conventional wells cannot, necessarily, be
tolerated on ERD wells.2
This comment is especially relevant to Camisea. PlusPetrol has extensive experience with
directional drilling but no direct experience carrying out ERD drilling campaigns. Therefore
comprehensive training of the drilling team in ERD procedures and practices would be
absolutely essential to minimize avoidable problems during the drilling program.
The figure at left represents the
“wholistic balance” approach that is
necessary to maximize the efficiency
of an ERD program.3 Compromises
must be made in a variety of areas to
ensure maximum efficiency of the
drilling progam.
Existing “fly” (helicopter portable) rig(s) built by Parker Drilling (Houston) for PlusPetrol for
use at Camisea should be sufficiently robust, with modifications, to be utilized in an ERD
drilling campaign based on either a: 1) brute force approach or 2) rig-limited approach.
The following excerpt addresses the differences between the “brute force” and “rig-limited”
approaches to drilling ERD wells.4
1
K&M Technology Group, Drilling Design and Implementation for Extended Reach and Complex Wells – 3rd
Edition, 2003, p. 34.
2
Ibid, p. 35.
3
Ibid, p. 90.
4
Ibid, p. 36-37.
As discussed later, and shown in one of the example wells at the end of this manual, drilling
13½” x 9⅞” hole to total depth may prove to be a safer and more efficient option as opposed to
using a conventional 17½” x 12¼” x 8½”plan. The 9⅞” hole will afford much faster drilling
than the 12¼” due to the improved hole cleaning conditions and directional control. As a result,
the 9⅞” hole can be drilled further than the 12¼” hole before casing must be set due to
hydraulics, torque or power limitations. Further, if ECD’s at TD are a problem, then 9⅞” hole
to TD will have lower ECD's than 8½” hole drilled beneath 9⅝” casing.
Another good example of using an aggressive approach to reduce risk is to use “over-sized”
drillpipe. Instead of limiting the drillpipe size for full strength over-shot fishing capability, the
risk of having a twist-off may be exponentially reduced by using larger drillpipe. For example,
4” drillpipe has about 50% greater torque capability compared to 3½”, while having a
substantially higher tension rating, and about 50% greater flowrates are possible. This results
in better rate of progress due to improved bit hydraulics, better motor performance (steerable
motors in slim hole often do not have sufficient flowrate for good operation) and improved hole
cleaning. The net effect is not only reduced cost, but the risk of having to fish the drillpipe due to
hole conditions is markedly reduced because of the improved drilling performance.
The required rig capabilities for drilling ERD wells are now becoming clearer as the industry
drills more challenging wells with smaller rigs and improved technologies. The required rig
capability depends very much on the drilling strategies and practices that will be used.
Generally speaking, if ‘off-the-shelf’ conventional practices and technology are used, then
significantly more capability is required from the rig, than if strategies and technologies are
used that are specifically aimed at improved hole cleaning performance.
In the table below a comparison is made between two very different rigs that are drilling very
similar ERD wells, to highlight what can be achieved. The biggest difference between the two
programs is that the smaller rig forces the drilling team to work within its limitations to come up
with design solutions to drill the well; whereby the larger rig has enough "grunt" to simply
overcome many of the difficulties with brute force.
5
Ibid, p. 38.
In order to achieve this, not only do drilling and tripping practices have to be considered, but
everything from bit selection to directional drilling equipment must be designed around
maintaining good hole cleaning at all times.
Note that higher flowrates of 1,000 – 1,200 gpm are always preferred if possible. However, it is
the author's view that in the case of flow rate, where more is better, a lot more may not
necessarily be a lot better. There have been a number on instances on K&M's recent ERD
projects where a point of diminishing returns seems to be realized with increasing flow rates.
Although only limited evidence can be cited to support this, personal observations of wells that
had higher flowrate capability did not show any significant improvement in performance, despite
very high flow rates. Although, the authors do not subscribe to the theory of high annular
velocities washing out (eroding) the wellbore, there is the risk of ECD induced ‘fatiguing’ of the
wellbore at "ultra-high" flow rates (e.g. >1,200 gpm in 12¼" hole). Certainly, achievable
penetration rates (whereby the hole is kept in good condition with respect to cuttings loading)
seem to reach an optimum level dependent upon mud properties and good drilling practices.
Hydraulics limitations do not necessarily mean that performance is going to be greatly affected.
Techniques have been developed whereby the hole is drilled "efficiently" rather than "fast" and
performance curves for these operations rival (and often beat) those drilled with substantially
more pumping power. This topic is expanded further in a number of sections in this text.
Obviously, more pumping capacity is preferred when designing or selecting a rig for ERD
drilling (either via three rig pumps or two larger pumps). Three pumps may provide a
redundancy benefit over a two-pump system. This becomes particularly relevant in deep 17½”
and 12¼” hole sections. In most ERD wells drilled in the industry today, however, the addition
of the third pump to the rig specifications needs to be justified on an efficiency basis. The global
message is that these wells can be drilled with two pumps, but they can be drilled faster and
more efficiently with three.
However, there are many occasions that a smaller rig capability is desirable. A classic scenario
that K&M has encountered is that the ‘required’ rig capability, based on conventional practices,
proves to be too large and heavy to be economically viable. Often it is not the rig cost that
drives the project economics, but rather the production platform size, and cost that is required to
support the drilling rig.
6
Ibid, p. 39.
Equivalent Circulation Density (ERD) Discussion:7 Careful attention should be paid to fluid
properties for any ERD application. If ECD’s are critical, the fluid should be as thin as possible
within hole cleaning restraints, and then further thinned prior to running and cementing casing.
In particular, the fluid should have very good shear thinning capability. It may be necessary that
hole cleaning properties take a back seat to ECD management with practices adopted to allow
for this shortcoming.
If ECD’s are a problem in the production hole, one effective approach is to use a tapered
drillstring to reduce annular pressure drops. ERD projects may require three or more separate
drillstring sizes (4” x 5” x 5½”) to manage ECD fluctuations, while maintaining the necessary
torque and hydraulics capabilities. In these particular wells, normal pumping operations would
have generated circulating annular pressures that exceed the fracture gradient. A purpose
designed mud system, a tapered drillstring and a tapered casing plan would all help to reduce
these pressures.
Tooljoint selection is also critical to ECD’s. As already mentioned, in 8½” hole, the tooljoint
clearance is quite small and will have a significant effect on annular pressures. Hole sizes
larger than 8½” are not as sensitive to tooljoint size.
It is common to apply heavyweight drillpipe or larger outside diameter (OD) drillpipe in shallow
ERD wells to overcome buckling problems. Alternately, the drillpipe can be stiffened by the
addition of non- rotating drillpipe protectors (NRDPP’s). If NRDPP’s or larger OD drillpipe is
used, then the ECD effect should be allowed for. NRDPP’s add approximately 1 psi per unit, as
a general rule. An option may be to use ‘winged drillpipe’ to provide stiffness while not
increasing drag (as will occur with HWDP). The ‘winged drillpipe’ is significantly stiffer while
not increasing ECD’s as much as the other solutions.
7
Ibid, p. 159-168.
1. Evaluate three ERD drill pad location alternatives beginning with location that is most
protective of environment and still technically feasible. Assume all Pagoreni A, B, and C
wells will be drilled from a single location. The current world record ERD horizontal
distance of over 11 km. Numerous ERD wells have been drilled in the 10- to 11-km
horizontal distance range. An ERD drilling pad in the vicinity of proposed Campamento
9 is the “best case” ERD alternative. Maximum horizontal distance from Campamento
km 9 to Pagoreni C is ~10.5 km. All wells drilled from this location would range from 7
to 10.5 km in horizontal distance. See Figure ERD-1.
4. Evaluate each ERD location assuming rig-limited ERD will be used and assess technical
feasibility in this light.
5. Evaluate each ERD location assuming “brute force” ERD will be used and assess
technical feasibility of accordingly.
6. Make maximize use of existing data developed in the San Martin drilling campaign in
this ERD analysis. See Schlumberger discussion of San Martin at: www.slb.com/oilfield
8
PlusPetrol, Block 56 Extended Reach Drilling Wells Feasibility Analysis, PowerPoint presentation, May 2005, p. 9.
CLEANOUT AND • Cleanout and completion running (drag risk plots, rollers, buckling, etc.)
COMPLETION
• Required rig equipment (top drive, pumps, drawworks, power, solids
EQUIPMENT
control, etc.)
SPECS
• Other equipment required (drillpipe size, drilling tools etc.)
INDUSTRY • Comparison with other relevant ERD wells to establish feasibility
BENCHMARKING • Compare well design and rig capabilities
TIME AND COST • ± 40% time and cost estimate based on Preliminary Well Design
ESTIMATES