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Saudi Aramco: Drilling Optimization
Saudi Aramco: Drilling Optimization
DRILLING OPTIMIZATION
5.0 HYDRAULICS
5.1 Hydrostatic Pressure
5.2 Frictional Pressure Determination
5.3 Optimization of Bit Hydraulics
DRILLING OPTIMIZATION
Roller cone drill bits are classified by a four-digit IADC code. The first
number is called the series. Series 1 through 3 designates milled tooth bits.
Series 4 through 8 is reserved for insert bits. The following table depicts what
type of formation each series is best suited to drill.
SERIES FORMATIONS
1 Soft formations with low compressive strengths and high drillability.
2 Medium to medium hard formations with high compressive strength.
3 Hard semi-abrasive and abrasive formations.
4 Soft formations with low compressive strengths and high drillability.
5 Soft to medium formations with low compressive strength.
6 Medium hard formations with high compressive strength.
7 Hard semi-abrasive formations with high compressive strength.
8 Extremely hard and abrasive formations.
The second numeral in the bit IADC classification is the cutting structure type.
These numbers range from 1 to 4 and subdivide each series from soft to hard
formation application. For example, a 1-2 type bit is slightly softer than a 1-3
type bit.
The third and final number in the bit IADC classification is the feature. The
following table shows what each feature represents.
Features
1 2 3 4 5 6 7 8 9
Standard Roller Roller Sealed Sealed Sealed Sealed Directional Other
roller bearing, bearing, roller roller friction friction
bearing Air gauge bearing bearing, bearing bearing,
protected gauge gauge
protected protected
.
Therefore, a bit with an IADC code of 5-3-7 describes a bit that will drill soft to
medium formations with low compressive strengths and has a sealed friction
bearing with gauge protection.
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The fourth digit denotes features such as motor (M), enhanced cutting
structure (W), lug pads (L), etc., that are optional and not captured in the
Saudi Aramco database.
Cutter Density: 1 to 4 for PDC bits and 6 to 8 for surface set diamond bits.
For the PDC bits 1 represents the lightest cutter density and 4 the heaviest
cutter density that generally is proportional to the blade count. For surface set
diamond bits (i.e. Impregnated bits), 6 denotes diamond size >3 stones per
carat and 8 represents diamond size <7 stones per carat.
Cutter Size: For PDC bits 1 indicates <25mm cutters, 2 indicates 14 to 24mm
cutters, 3 indicates 8 to 13mm cutters and 4 indicates less than 8mm cutters.
For surface set diamond bits 1 indicates “Natural diamond”, 2 is “TSP
material”, 3 is “Combination of diamond material” and 4 is “Diamond
impregnated”
Example: A PDC bit with IADC M431 is built with a matrix body, heavy set
cutting structure, 13 mm cutters and flat profile.
The selection of the best available bit for a given job, like the selection of
drilling fluid or drilling cement composition, can only be determined by trial
and error. Fortunately in Saudi Aramco, there is sufficient offset information
to effectively select the proper bits types for given formations. Reference
chart below for generalized IADC codes for given formation types.
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The initial selection of bit type in a wildcat area can be made on the basis of
what is known about the formation characteristics and its drillability. The
drillability of a formation is its measure of how easy the formation is to drill. It
is inversely related to the compressive strength of the rock. Drillability tends
to decrease with depth in a given area. The abrasiveness of the formation is
the measure of how rapidly the cutting structure will wear when drilling the
formation. Shown in the following table is a listing of roller cone bit types
often used to drill various formations.
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Since bit selection is largely done by trial and error, it is important to carefully
evaluate a dull bit when it is removed from the well. This is a necessary part
of the bit selection process and cannot be overstressed.
PDC bits are being utilized more and more for all drilling applications. When
a PDC bit is called for in a Drilling Program, the following procedure should
be followed.
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Preparation to run a PDC bit begins with examination of the previous bit
in the hole. If the old bit has just a few lost or damaged cutters/inserts,
there should be no problem as they will probably have been broken up
and embedded in the hole wall or washed out during hole cleaning.
More severe damage or a grossly under gauge bit means that the hole
should be conditioned with a roller cone bit and a junk basket. It is
generally a good drilling practice to use a junk basket during the last run
before going into the hole with a PDC bit.
i) Carefully remove the bit from its box and place it on a piece of
plywood or a rubber mat. Never roll or stand a PDC bit directly on
steel decking such as the rig floor as PDC cutters are brittle and
easily chipped.
ii) The bit serial number should be recorded, together with the bit
type and diameter.
iii) The bit should be closely examined for damage possibly caused
during transit or if it is a rerun bit. The inside of the bit should also
be inspected at this stage in case any debris which might block a
nozzle is left inside.
iv) Check that correct size nozzles are already in place.
i) The bit should be rotated at low speed with no more than 60 RPM
to avoid premature damage to cutters while creating the bottom
hole pattern.
ii) The bit should be slowly set on bottom with no more than 4,000
lbs. weight on bit (WOB) to establish a bottom hole pattern. If the
bit does not drill off after a few minutes, then the weight should be
increased until it does. This weight should be maintained until the
bit has drilled at least its own length.
iii) The weight on bit can then be increased (up to the recommended
maximum WOB) until the desired penetration rate is reached or
until a weight increase no longer improves the rate of penetration.
As a general rule, the optimum weight necessary for a PDC bit is less
than one-half that required for a roller cone bit. In extremely soft or
plastic formations, the bit will drill off quickly and make the first few feet
in only a few minutes even at light WOB. In harder formations, it may
take considerably longer to drill the first foot. Since only some of the
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cutters will initially be in contact with the formation until the bit has
bedded in, it is crucial that weight not be added too quickly; otherwise,
these cutters may be overloaded and fail.
Making Connections
Optimizing Drilling
High performance PDM’s are motors that have extended power sections. The
additional power sections offer significantly higher torque than conventional motors
while still maintaining bit RPM. The main advantages to using these types of
motors for drilling straight holes are as follows:
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2.1 Considerations
In order to maximize the penetration rate, the drilling parameters used must
be analyzed and agreed upon prior to starting the job. The primary factors
that influence performance will be the type of motor, the bit and the
hydraulics. Based on availability, the bit should be matched to the motor or
vice versa. Factors to consider are:
A) Bit Type: number of blades, cutters, type and size of cutters, nozzles.
B) Motor Type: maximum speed and torque for the required bit and hole
size.
C) Hydraulics: attention should be paid to hole cleaning, pressure drops
and motor performance.
D) Rig Pumps and Pressure ratings: the rig must be able to offer
consistently high flow rates in order to maximize the speed and torque
available from the motor.
If the above factors are not optimized for the job, then the maximum benefit
may not be derived from using a performance motor. As with all drilling
operations, it is imperative that comprehensive pre-job planning is done
involving the PDM company, the bit supplier, the operator’s drilling
engineers/foreman and the drilling contractor in order to ensure the highest
probability of success.
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RSS have entered the local spotlight recently owing to their potential for
revolutionizing the way directional wells are drilled. RSS can be categorized by
their mode of operation. There are two steering concepts for these systems:
push-the-bit and point-the-bit.
At a short distance behind the bit (approximately 1 ft), three actuators (called
“pads”) are positioned around the circumference of the biasing unit (BU) for
the purpose of applying lateral force to the formation. The outward stroke of
these pads is limited by mechanical stops (“kickers”) so that the deviation of
the centreline of the BHA is controlled to a set limit. For example, if the hole
must be drilled in a build direction, the pads are activated to push on the low
side of the hole; for a drop condition, the pads would push against the high
side of the hole, etc.
This rotary steerable system exploits the raw power of the mud to drive the
pads out. At the heart of this actuation system is a simple rotary valve which
opens and closes the supply of mud to the pad actuators in symphony with
the drillstring rotation. Once set, the position of the push-point is maintained
no matter how the drillstring rotates. This is achieved by a control system
called the control unit (CU) that sits above the BU in a collar.
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The figure below shows a point-the-bit RSS. This system operates by placing
a relative bit offset “bend” in the system, much like a standard motor
assembly. This bend is held geostationary (nonrotating) with respect to the
formation. To further understand the point-the-bit principle, one can make
comparisons to conventional drilling systems that use motors or turbines. A
bent housing and stabilizer on the bearing section allows the motor to drill in
either an oriented (sliding) or a rotary mode. In the rotary mode, both the bit
and the drillstring rotate. The rotation of the drillstring negates the effect of
the bent housing, and the bit drills an overgauge straight path parallel to the
axis of the drillstring above the bent housing. In the sliding mode, only the bit
rotates. The motor changes the well course in the direction of the bent
housing and the drillstring slides down the hole behind the bit. In the point-
the-bit system, the bent housing is contained within the collar of the tool. This
bent housing is controlled by means of an electric motor that rotates counter
to the direction of and at the same velocity as the drillstring. This control
allows the bent housing to remain geostationary while the collar is rotating.
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The integrated power section rotates the bit and allows drillstring rotation to
be slowed. Stick/slip and other damaging vibration modes common to
conventional rotary drilling are reduced and all available energy is used to
drill the hole optimally. Casing wear and drillstring fatigue is reduced owing to
slower drillstring rotation, minimizing the chance of drillstring or casing failure.
All external parts rotate at drillstring speed, reducing drag. The rotation also
helps clean and condition the hole, lowering the risk of differential or
mechanical sticking.
Powered RSS plays a key role in improving penetration rate and optimizing
the drilling operation. In addition to tangible time savings, it offered benefits
such as reduced tortuosity, better hole cleaning and improved LWD log
quality. Elimination of sliding enabled the use of relatively aggressive PDC
bits which were otherwise being used for performance vertical drilling only.
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Section Drilled
with Motor
Section Drilled
with Powered
RSS
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A) Choose a depth to run the drill off test where a section of uniform lithology is
expected.
B) While drilling, increase the bit weight approximately 20% over the weight that
was being used while drilling and lock the brake.
C) While maintaining a constant rotary speed, record the time it takes for the bit
to drill off 4,000# of bit weight. If the weight indicator is fluctuating, use the
mid-point. Continue the test until at least 50% of that weight is drilled off.
E) If time permits, repeat the test using a different rotary speed and compare the
results.
B it W e ig h t T o ta l T im e
(1 0 0 0 # ) (s e c ) D e lta -t
76 0 -
72 52 52
68 105 53
64 152 47
60 210 56
56 281 63
52 352 71
48 432 80
44 522 90
40 626 104
36 746 120
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130
120
110
100
90
Delta t
80
70
60
50
40
30
72 68 64 60 56 52 48 44 40 36
Bit Weight
From this data, the optimum weight on bit for this formation type would be 64,000#.
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5.0 HYDRAULICS
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As indicated, the total pressure is a result of frictional pressure losses from the
surface equipment, the drillpipe, the drill collars, the bit, the drill collar annulus,
and the drillpipe annulus. The total pressure gives no indication whether the flow
pattern in the system is laminar or turbulent, however. The flow patterns inside
the drillstring are usually turbulent while the flow pattern in the annulus can be
either. The pressure drop in the bit results from fluid acceleration and not solely
frictional forces.
Equivalent circulating density (ECD) is the fluid pressure the bottom of the hole
experiences while the mud is being circulated and should be considered,
especially when the formation being drilled through allows only small mud weight
tolerances and mud weights are critical.
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5.3.1 Introduction
Field studies have shown that cross flow beneath the face of the bit is
the most effective parameter in hole cleaning. Cross flow is at its
highest when jet impact force is maximum. The pressure loss across
the bit is simply the difference between the standpipe pressure and
the circulating pressure. For maximum jet impact force, the pressure
loss across the bit should approximate 48% of the available surface
pressure. In other words, if the available pump pressure is 3000 psi,
for a jet impact force hydraulic model one would size the jet nozzles to
create a 1440 psi pressure drop across the bit at the required flow
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Optimum bit hydraulics is obtained when, for a given flow rate, the bit
hydraulic horsepower assumes a certain percentage of the available
surface horsepower. For the maximum hydraulic horsepower model,
the pressure loss across the bit should approximate 65% of the total
available surface pressure. In other words, if the available pump
pressure is 3000 psi, for a hydraulic horsepower hydraulic model, size
the jet nozzles to create a 1950 psi pressure drop across the bit at the
required flow rate. This hydraulic model is usually applied where
there is an unlimited amount of available pump horsepower or surface
pressure.
AT (in2) = 0.00342 ρQ 2
P
bit
4A T
dN = 32
nπ
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Example:
Calculate the bit nozzle sizes required for the following set of
conditions:
Solution:
AT (in2) = 0.00342
75 300 2 = 0.281 sq. in.
1000
40.281
33.14
dN = 32 = 11.05
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6.1 Introduction
The previous paragraphs summarily dealt with the process of optimizing rate
of penetration (ROP) as a means of drilling optimization. However, a
significant percentage of drilling time is expended on non-footage activities,
also known as ‘dead time’ or ‘flat time’ operations. The UDC, which covers
the entire operating time from spud to completion of the well, is therefore the
ultimate tool for holistic drilling optimization. The UDC is usually field- and
well-type specific and has to be based on data obtained from drilling the
same stratigraphical sequence.
1) Break down the entire drilling and completion operation from spud to rig
release into discrete steps.
2) Collate the time (in hrs) elapsed from the start to the end of each
discrete step for each of the wells.
3) Select the best (least) time for each operation as your UDC time.
4) Plot the UDC curve using the cumulated UDC time on the x-axis and
depth on the y-axis.
The UDC should be updated whenever a new record is set both in terms of
high ROP and minimal dead time. The new (record) time for that particular
activity is substituted in the UDC and the curve updated.
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A sample UDC curve for a PWI slim hole design well for the Nuayyim field is
depicted below:
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