Ch.

2
Drilling challenges in Different formations
Prevention action
and
Detection & Remedial actions

Presentation topics
1.1 Introduction
2.2 Downhole deteriorated conditions & Consequences
Pack-off & Bridging
Differential sticking
Loss circulations
2.3 First remedial actions to solve problems
Pack-off & Bridging
Differential sticking
Loss circulations
2.4 Drilling challenges in fms (Shale, Salt & Unconsolidated)
Descriptions
Preventions
Detections
Remedial actions
2.5 Real time monitoring of drilling operationsODC

2.1 Introduction
Drilling challenges includes

Drilling through highly fractured
formation
Unconsolidated formation
Drilling through moveable
formation
Drilling through reactive shale

Problems result
Loss circulation
Differential sticking due to mud cake
Mechanical sticking such as due to
pack-off
Chemical sticking due to swelling

Result:
Health & enviroment, Well plug and abandonment
Increase drilling budget...
Mechanical
-Hydraulic pressure
-Tectonics
Chemical
-Reactive shell
Thermal
-Temperature
Driving Forces
.
Shear
-Collapse
Tensile
-Fracturing
Failure Mechanisms
Causes and Effects of borehole instability
How to manage collapse, fracture and swelling
Solution...approperiate Density & Chemistry of mud
Some consequences:
delay operation time
uncertain formation evaluation
circulation losses
poor cementing
casing deformations
stuck pipe

Cost:
Well instability problem increase 10-15% of
budget..(Several billions USD per year)
Drilling cost /day
Drilling cost.450,000USD/day(Worldwide,2010)

If NPT =3days, 3x450000 lost

If well should be abandoned.all the cost is lost

20% of drilling cost is due to NPT (Statoil report)

Well instability alone increase 10-15% of the well
construction budget

The problem has been and still challenging..

pressure
Fracture
pressure
Pore
weight Mud
Allowable
.
essure
Collapse
Pr
line Median.
h
o
v
o
H
o
Vertical hole axis
How to avoid? Density and Chemistry of drilling fluid
Problems:
Pack-off
Differential sticking
Symptoms
Increase torque
Increase pump pressure
Increase drag
Over-pull
Loss circulation
Increase cutting concentration
Others
Tight well (Mechanical + Chemical means)
Caved well (Mechanical means)

During planning phase
Need to prepare.
-What if problem?----Solution Procedure/Action

What if kick?-----------------------Solution procedure
What if loss circulation?--------Solution procedure
What if Pack-off?-----------------Solution procedure
What if Diff sticking?------------Solution procedure
What if equipment failure?----Solution procedure

Example ..Worst case senario
This is the consequence of kick if not managed...
2.2 Downhole deteriorated conditions &
Consequences

Problems..
Pack-off & Bridging
Differential sticking
Loss circulations


PROBLEM #1 HOLE PACK OFF & BRIDGES
Cement or junk in the hole
PROBLEM #1 HOLE PACK OFF & BRIDGES
Unconsolidated formations

PROBLEM #1 HOLE PACK OFF & BRIDGES

Formation Fractured
& Faulted Formation
Reactive Formation
Pressured Formation

PROBLEM #1 HOLE PACK OFF & BRIDGES
.Settled Cuttings
PROBLEM #2: Differential sticking
Permeable zone covered with mud
cake/a porous, permeable formation
must exist.
Stationary string Increased risk when:
making connection
survey
formation pressure measurements
c
A * P F A =
Sticking force
Length c
DC * x 2 A =
Length c
DC * L A =
|
|
.
|

\
|

=
|
|
.
|

\
|
=

) R R ( R 2
) R R ( R ) t R (
cos
bc 2
c b a
cos
p w p
2
p w
2
p
2
w
1
2 2 2
1
2
o
2
p w p
2
p w
2
p
2
w
p
2
p
) R R ( R 2
) R R ( R ) t R (
1 R 2 cos 1 R 2 X
2

= =
o

PROBLEM #3 LOST CIRCULATION
a: High-permeability unconsolidated
sands and gravel.

b: Cavernous (hollow) zones in
carbonates (limestone or dolomite).

c: Natural fractures, faults and
transition zones in carbonates or
hard shales.

d: Induced fractures from excessive
pressure.

a
b
d
a
d
c
2.3 First remedial actions to solve problems

Pack-off & Bridging
Differential sticking
Loss circulations

Problems
Detection:
Mechanical sticking (Pack-off+ Bridging)
Differential sticking
Symptoms
Increase torque
Increase pump pressure
Increase drag
Over-pull
Loss circulation
Increase cutting concentration
Others
Tight well (Mechanical + Chemical means)
Caved well (Mechanical means)
Real time monitoring

Follow First Actions

If worst/if first
doesn't work, then
follow secondary
Remedial Action/Freeing
Example: First action

Case 1: Solids Induced Pack-off -
First Actions

At the first signs of the drill string torque up and
pack-off symptoms

(a) reduce the flow rate and bleed down the
standpipe pressure

(b) Holding a maximum of 500 psi on the standpipe
and start cycling the drill string up to maximum
make-up torque.

(At this stage do not work the string up or
down).

Continued

(c) Slowly increase pump and see if circulation
improves.

(d) If circulation cannot be established
- increase the standpipe pressure in stages up to
1500 psi and
-continue to apply torque.

(e) If the pipe is not free, commence jarring
operations.



Stuck after a connection or survey with full
unrestricted circulation across a permeable
formation
1. Initially circulate at the maximum
allowable rate. This is to attempt to erode
the filter cake.
2. Apply torque to about 50% of make-up
torque.
3. Pick up to just above the up weight and
perform step 1 again.
4. Repeat 1. & 2. Increasing to 100% make-
up torque until string is freed /or until
preparations have been made to other
operations:
(either - spot a releasing pill or conduct
other operations.)
Case 2: First Actions in the event of Differential Sticking
Differential sticking....continued...illustration.
3 Loss circulation treatment

Loss circulation is the loss for drilling fluid into the
formation.
Uncontrolled fluid loss cost the oil industry a lot.
Loss circulation control materials includes:
LC-lube, mica various fibrous products and CaCO
3
etc..
If the loss rate is higher, treat the mud with pill in
order to reduce loss.



Study at UoS
Example- Effect of particles
0
5
10
15
20
25
R
e
o
p
e
n
i
n
g

p
r
e
s
s
u
r
e
,

M
P
a
.
.
.
Glydril witho ut particles
Glydril+CaCO3(125-250)+SiC (125-250)
0
5
10
15
20
25
30
R
e
o
p
e
n
i
n
g

p
r
e
s
s
u
r
e
,

M
P
a .
.
.
Glydril witho ut particles
Glydril+CaCO3+Felds pa (125-250)
Example: Loss circulation Treatment action procedure
Pill#2 BP
Calcium carbonate(M) 30ppb
Particle 1 (F) 20ppb
Particle 2 (M 20ppb
Mica (F) 20ppb
LC lube 40ppb
Ultraseal / Checklosses 30ppb
Q<If 100bbl/hr (Yes)

Q>100bbl/hr (No)
N
Pill#1 BP= 1/2 Concentration of Pill #2BP

Y
Example: BP-Company pill and Reformulated
0
20
40
60
0 5 10 15
Time, min
P
r
e
s
s
u
r
e
,

M
P
a
BP#2( density =1.33SG) field OBM BP-#2( density =1.5SG)
Bridging experiments
Synergy effect: Bridging test with Check loss and LC lube+
Check loss @250mm slot

0
15
30
45
0 3 6 9 12
Time, min
P
r
e
s
s
u
r
e
,

M
P
a
40lb LC lube+30 lb Check loss
30 lb Check loss
The main conclusion is that when designing a pill, it is important to find out the
system with positive synergy and negative synergy.
In short, you need to do testing of products if possible!
Reformulated and optimized pills
0
20
40
60
2 6 10
Time,min
P
r
e
s
s
u
r
e
,

M
P
a
Optimized BP#2 New Reformulated BP#2 New BP#2
Example...Bridging test results....
0
10
20
30
40
50
0 10 20 30
P
r
e
s
s
u
r
e
,

M
P
a

Time, min
50gm Bentonite + 3%wt Mica
40gm Bentonite + 3%wt Mica
0
10
20
30
40
50
0 5 10 15 20 25 30
P
r
e
s
s
u
r
e
,

M
P
a

Time, min
50gm Bentonite + 3%wt Mica
50gm Bentonite + 5%wt New sol + 3%wt Mica
50gm Bentonite + 3%wt New sol + 3%wt Mica
0
10
20
30
40
50
0 5 10 15 20 25 30
P
r
e
s
s
u
r
e
,

M
P
a

Time, min
40gm Bentonite + 3%wt New sol + 3%wt Mica
40gm Bentonite + 3%wt Mica
40gm Bentonite + 5%wt New sol + 3%wt Mica
Hole cleaning
Hole cleaning problem results
High rotary torque
Hole pack-off (Stuck pipe )
Formation breakdown (Lost circulation)
Slow ROP
Parameters to control....
Pumping hole cleaning pills
Movement of string whole circulating
Flow rate..

2.4 Drilling challenges
.




Descriptions
Detections
Preventions
Remedial actions
I- Reactive shale formation
II- Salt formation
III- Highly Unconsolidated sand formation

I- Reactive shale formation

Description

Shale makeup over 75% of oil and
gas drilled formations and 90% of
wellbore instability problems occur
in shale formations.

Some of the most challenging
drilling problems related to shale
formations are hole enlargement,
stuck pipe, high torque and drag
Dry pellet Pellet + H
2
O = Swelling
Quartz (29.6%) + Feldspar (15.5%) + Calcite
(0.6%) + Bentonite (52.9%) and other
particles (1.4%) with water.
Continued.
Rig site indications-Symptoms

Hydrated or mushy cavings.
Shakers screens blind off, clay balls form.
Increase in low-gravity solids (LGS), PV, YP
An increase in pump pressure.
Circulation is impossible or highly restricted

Preventative action
Use an inhibited mud system.
Eg. Oil Based Mud
Potassium/polymer fluids
KCl/ polymers(e.g partially hydrolyzed polyacrylamide (PHPA)
PAC polymer or a PAC/Starch polymer combination to control
fluid loss.
Potassium/Glycol and Silicate fluids
KCl/Glycol and KCl/Silicate fluids

Action/Freeing

Case 1: See First Actions
Example: Silicate /KCl system

After 24 hrs immersion in H
2
O system
After 24 hrs immersion in Silicate/ H
2
O/KCL system
Modified from Horsrud
et al 1998
North Sea- A
- Bentonite(52.9)
- Calcite (0.6)
- Feldspar (15.5)
- Quartz (29.6)
- Others (1.4)
Swelling in OBM system?- No swelling
II- Salt formation

Description
The mobile formation such as salt
formation squeezes into the well bore
because it is being compressed by the
overburden forces.

Mobile formations results in a
decrease in the well bore size, causing
problems running BHAs, logging tools
and casing.

A deformation occurs because the
mud weight is not sufficient to prevent
the formation squeezing into the well
bore.

Continued.
Rig site indications-Symptoms

Over-pull when moving up
Sticking occurs with BHA at mobile formation depth.
Restricted circulation with BHA at mobile formation
depth
Preventative Action
Maintain sufficient mud weight.


Action/Freeing

Moving up/down
Apply torque

III- Highly Unconsolidated sand formation

Description

An unconsolidated formation falls
into the well bore due to low
bond=> well collapse

Sand or gravel falls into the hole and
packs off the drill string.

This mechanism is associated with
shallow formations.
Example: at about 500m in the central North Sea


Continued.
Rig site indications-Symptoms

Increase in pump pressure
gradual increase in drag
Over-pull on connections.
Shakers blinding
Preventative Action

These formations need an adequate filter cake to help
stabilize the formation.

A method successfully used in the North Sea
to drill 10m,
pull back to the top of the section and
wait 10 minutes.
If the fill is significant then repeat process every 10m.


Action: Case 1: First Actions
2.5 Real time monitoring....
Example IRIS-On shore drilling Center..
EXAMPLE: Real time monitoring of down-hole condition
Summary

Drilling problems cost the industry a lot....

Prevention of a problem is better than cure the problem...

For this ..
During planning phase, engineers are required to
design a safe operational window...

For this...
Engineers are required to have good understaing of
drilling processes, including the physics behind the
process

Exercise
1 Mention typical formation related drilling challenges along
with:
Short description
Rig site inductions/Symptoms
Prevention and first actions
2 Write in short the first action for freeing differential sticking
and solid induced pack-off procedures.

3 What are the conditions for differential sticking? How it
occurs and when and where most?

4 What is lost circulation? How can we hinder? How loss
circulation occurs?



Thanks!
&
Questions`?