PDB 3033: DRILLING ENGINEERING

Jan 2018 Semester

LAB REPORT

DRILLING SIMULATOR

Members: ID:

Mohd Fazriq Hafizin Bin Jamaludin 24162

Ahmad Mahyuddin b Mohd Sirhan 23488

Ahmad Najib Bin Abu Hassan 23910

Afir Mohamed 24789

Mohd Shafiz Martin 24188

Lab Session Date: 2nd August 2018

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1.0) INTRODUCTION
Drilling is the cutting process of making a hole through the subsurface rocks by using
a drill bit. Throughout the drilling process, numerous systems are used simultaneously on board
one drill rig to perform drilling operation. Well control system, power system, hoisting system
and circulating system are among those systems used in drilling operation.

Oil well control is the management of dangerous effect caused by the unexpected
release of formation fluid, such as natural gas and/or crude oil, upon surface equipment of oil
or gas drilling rigs and escaping into the atmosphere. Basically, oil well control involves
preventing the formation fluid, usually referred to as kick, from entering into the wellbore
during drilling.

Formation Fluid can enter the wellbore if the pressure exerted by the column of drilling
fluid is not great enough to overcome the pressure exerted by the fluid in the formation being
drilled. Oil well control also includes monitoring a well for sign of impending influx of
formation fluid into the wellbore during drilling procedures, to stop the well from flowing when
it happens by taking proper remedial actions.

Failure to manage and control these pressure effects can cause serious equipment
damage and injury, or even loss of life. Improperly managed well control situations can cause
blowouts, which are uncontrolled and explosive expulsion of formation fluid from the well,
potentially resulting in a fire.

1.1) Basic Drilling System

Basic drilling systems are divided into five systems, as in figure below:

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1.1.1) Rotating System:

The main objectives of this system is to create rotation force towards drill bit at the bottom
hole and provide helps when tightening and loosing pipe connection. In order to drill ahead,
the bit has to be rotated to its maximum allowable rotating penetration. Therefore, the rotary
system is used to rotate the drill string, hence the drill bit. There are two types of rotating
source:

a) Rotary Table with a Kelly System

The revolving or spinning section of the drill floor that provides power to turn
the drill string in a clockwise direction (as viewed from above). The rotary motion and
power are transmitted through the kelly bushing and the kelly to the drill string. Almost
all rigs today have a rotary table, either as primary or backup system for rotating the
drill string. Top drive technology, which allows continuous rotation of the drill string,
has replaced the rotary table in certain operations. A few rigs are being built today with
top drive systems only and lack the traditional kelly system.

Figure 17.4 and 17.5 shows the rotary system and close up view of how the Kelly fits
into the rotary table.

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 b) Top Drive System
A device that turns the drill string. It consists of one or more motors (electric or
hydraulic) connected with appropriate gearing to a short section of pipe called a quill,
that in turn may be screwed into a saver sub or the drill string itself. The top drive is
suspended from the hook, so the rotary mechanism is free to travel up and down the
derrick. This is radically different from the more conventional rotary table and kelly
method of turning the drill string because it enables drilling to be done with three joint
stands instead of single joints of pipe. It also enables the driller to quickly engage the
pumps or the rotary while tripping pipe, which cannot be done easily with the kelly
system.

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1.1.2) Power System:

The source of power for the rig location is provided by the Power System. On modern
rigs, the prime mover consists of one to four or more diesel engines. These engines commonly
produce several thousand horsepower. Typically, the diesel engines are connected to electric
generators.

The electrical power is then distributed by a silicon-controlled-rectifier (SCR) system

around the rig site. Rigs that convert diesel power to electricity are known as diesel electric
rigs. Older designs transmit power from the diesel engines to certain rig components (draw
works, pumps and rotary table) through a system of mechanical belts, chains and clutches. On
these rigs, a smaller electric generator powers lighting and small electrical requirements. These
older rigs are referred to as mechanical rigs or more commonly, simply power rigs.

1.1.3) Circulating System:

The main objective of circulation system is to pump fluid through the whole active fluid
system, including the borehole and all the surface tanks that constitute the primary system.
During the drilling operation, the driller and mud engineer will pump a fluid to carry the drill
cuttings from the face of the bit to the surface.

The complete, circuitous path that the drilling fluid travels starting at the:

 main rig pumps

 surface piping
 standpipe
 kelly hose (rotary)
 kelly
 drill pipe
 drill collars
 bit nozzles
 open hole and casing strings
 flowline
 mud-cleaning equipment
 mud tanks
 positive displacement main rig pumps

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 Functions of Drilling Fluids:

 Lift up cuttings
 To cover the underground pressure
 To restrain the well bore
 To create mud cake and prevent filtrate loss
 To lubricate drill bit and drill string
 Down hole information gathering media and well
logging
 To transfer hydraulic force to downhole motor

1.1.4) Hoisting System:

The main objective of the hoisting system is used to raise and lower the drill string and
casing into and out of the well. The hoisting system is large pulley system which is used to
lower and raise equipment into and out of the hole.

Several components of this system are:

a) crown block
b) travelling block
c) mast
d) substructure
e) prime mover

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1.1.5) Pressure Control System:

The objective of this system is to prevent blowout and maintain kick during drilling and
tripping. The equipment is called Blowout Preventer (BOP). BOP is a large valve at the top of
a well that may be closed if the drilling crew loses control of formation fluids. By closing this
valve (usually operated remotely via hydraulic actuators), the drilling crew usually regains
control of the reservoir, and procedures can then be initiated to increase the mud density until
it is possible to open the BOP and retain pressure control of the formation.

BOPs come in a variety of styles, sizes and pressure ratings. Some can effectively close
over an open wellbore, some are designed to seal around tubular components in the well (drill
pipe, casing or tubing) and others are fitted with hardened steel shearing surfaces that can
actually cut through drill pipe.

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1.2) Kick and Blowout

A kick is defined as any undesirable flow of formation fluids from the reservoir to the
wellbore that occurs as a result of a negative pressure differential across the formation face.
Meanwhile, Blow Out happens if the kick is reaching the surface and uncontrollable. Wells
kick because the reservoir pressure of an exposed permeable formation is higher than the
wellbore pressure at that depth.

Blow out can happen in almost every oil and gas operation such as:

 Drilling Operation
 Work over Operation
 Well Service Operation (Maintenance)

There are many situations which can produce this downhole condition. Among the most likely
and recurring are:

 Low density drilling fluid.

 Abnormal reservoir pressure.
 Swabbing.
 Not keeping the hole full on trips.
 Lost circulation

Kick indicators are classified into two groups: positive and secondary. Anytime the well
experiences a positive indicator of a kick, immediate action must be taken to shut-in the well.
When a secondary indicator of a kick is identified, steps should be taken to verify if the well is
indeed kicking.

The "Positive Indicators of a Kick" are:

 Increase in Pit Volume

 Increase in Flow rate

Immediate action should be taken to shut-in the well whenever these indicators are
experienced. It is not recommended to check for flow after a positive indicator has been
identified.

The "Secondary Indicators of a Kick" are:

 Decrease in Circulating Pressure

 Gradual Increase in Drilling Rate
 Drilling Breaks
 Increase in Gas Cutting
 Increase in Water Cutting or Chlorides

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The occurrence of any of these indicators should alert the Drilling Representative that the well
may be kicking or is about to kick. These indicators should never be ignored. Instead, once
realized, steps should be taken to determine the reason for the indication.

Decision tree that can be used to decide how to control a kick.

1.3) Swabbing

Swabbing is a condition that arises when pipe is pulled from the well and produces a
temporary bottom hole pressure reduction. Many downhole conditions tend to increase the
likelihood that a well will be swabbed-in when pipe is pulled. Several of these are discussed
below:

 Pulling Pipe Too Fast

 Poor Mud Properties
 Heaving or Swelling Formations
 Large OD Tools

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1.4) Well Control Procedure
(HARD SHUT IN * REMOTE CHOKE IS ALWAYS CLOSE DURING DRILLING
& TRIPPING)

1.4.1) Shut -In Procedure While Drilling

1. Stop rotation
2. Raise string to shut-in position (time permitting)
3. Stop the pumps and flow check; if well flow; proceed without delay to next step
4. Close annular/open remote controlled choke line valve (HCR)
5. Notify man in charge
6. Check space out and close pipe rams and lock
7. Bleed off pressure between pipe rams and annular (if possible)
8. Record annulus and drill pipe pressure and pit gain

1.4.2) Shut-In Procedure While Tripping

1. Set slips below tool joint (no tool next to the shear ram)
2. Install full opening safety valve and close same
3. Close annular/open remote controlled choke line valve (HCR)
4. Notify man in charge
5. Make up Kelly or top drive (insert a pup joint or single between safety valve and
top drive) and open safety valve
6. Read annulus and drill pipe pressure and pit again

2.0) OBJECTIVE OF EXPERIMENT

The objectives of this experiment are as follow:

 To conduct drilling operation simulation by using DrillSim 500.

 To identify any kick indications by using DrillSim 500.

 To control any kick confronted during drilling operations

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3.0) PROCEDURES

3.1) Drilling Test

 Take slow pump rate pump#1 20 spm / xxxx psi, 30 spm / xxxx psi
 Take slow pump rate pump#2 20 spm / xxxx psi, 30 spm / xxxx psi.
 Increase mud pump 1 & 2 to achieve total of 600 gpm (8-1/2” hole size)
 Setting rotary speed to 100 rpm.
 Use handbrake to lower the drill string until bit touches bottom.
 Increase and maintain WOB at 35.000 lbs.
 Continue drilling by adjusting WOB at 35.000 lbs by adjusting handbrake at every time.
 Identify if there is any Kick indication at all operation time.
 Continue to kick procedure when kick is encountered.

3.2) Well Control Drillers Method (WHEN A KICK IS DETECTED)

1. Monitor surface instrumentation. Once “positive” kick detected, follow step 2.
2. Pick up off bottom & space out (ensure tool joint is not across ram). Stop rotary.
3. Stop pump 1 and 2.
Close BOP’s Annular or Upper Ram. Open BOP upstream choke valve.
4. Read and record final (stabilized) SIDPP and SICP. Read and record final pit gain.
Adjust the remote choke to maintain the SICP constant while bringing the pump up to
20 or 30 strokes per minute simultaneously.
5. When the casing pressure is stabilized, read and record the new circulating drill pipe
pressure. Adjust the remote choke to maintain the initial circulating drill pipe pressure
constant until the influx (the kick) is out.
6. Once influx out, stop pump & close remote choke completely while maintaining the
last CP constant. ( If no further influx enter the well bore, theoretical SICP & SIDP
should be the same)
7. Increase mud weight to kill mud weight.
Kill MW = (SIDPP + 150 psi overbalance)/(0.052*vert. depth) + original MW

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 Open remote choke and start pump at 30 strokes per minute while maintaining SICP
constant. Once reach desired pump rate, continue to maintain SICP constant
until kill mud reach bit.
Once kill mud reach bit, start to maintain FCP (final drill pipe circulating pressure)
constant until kill mud reach surface
8. When the kill mud reach surface, stop pump & then close remote choke.
Read and record SIDPP, SICP and pit volume. (SIDPP & SICP should be zero if the
well is dead)
Open the BOP Upper ram, close BOP upstream choke valve and flow check well.

3.3) Well Control Engineers Method

 Monitor surface instrumentation. Once “positive” kick detected, follow step 2.

 Pick up off bottom & space out (ensure tool joint is not across ram). Stop rotary.
Stop pump 1 and 2.
Close BOP’s Annular or Upper Ram. Open BOP upstream choke valve.
1. Read and record final (stabilized) SIDPP and SICP. Read and record final pit gain.
Prepare kill sheet.
 Increase the mud weight to kill mud weight.
Kill MW grad = ((SIDPP + 150 psi overbalance/ 0.052*vert.depth) + original MW)
Open remote choke and slowly bring pump to kill rate to 20 or 30 spm.
Adjust remote choke to maintain casing pressure constant.

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4.0) RESULTS

PUMP Strokes per Minute (SPM) Slow Circulating Pump

Pressure(SCP), PSI
Slow Pump Rate 1 30 127
30 226
Slow Pump Rate 2 30 127
30 198
Slow Pump Rate 1+2 120 2500
Table 1: Pump rate (spm)and respective pressures (psi)

Current mud weight in use = 9.5 ppg

TVD when the kick happened = 6000.2 ft

1. When The Annular is closed and choke is open

SIDP = 210 psi
SICP = 450 psi
Pit gain = 5 bbl

2. Slow circulating pump at 30 spm is set.

Initial Circulating Drill Pipe pressure = SIDP + SCP = 210 + 198 = 408 psi

3. After the influx is out

SIDP=SICP=210 psi
Initial Circulating Drill Pipe pressure = SIDP + SCP = 210 + 198 = 408 psi (kept
constant)

𝑆𝐼𝐷𝑃+10 𝑝𝑠𝑖 210+10

4. KMW = 𝑂𝑀𝑊 + (0.052)(𝑇𝑉𝐷) = 9.5 + (0.052)(6000.2) = 10.2 𝑝𝑝𝑔

overbalance of 10 psi.

𝐾𝑀𝑊 10.2
5. FCP = 𝑆𝐶𝑃𝑥 𝑂𝑀𝑊 = 198𝑥 = 211.96 𝑝𝑠𝑖
9.5

6. After KMW is reached surface

SIDP = SICP = 0

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5.0) DISCUSSION OF RESULTS
5.1) Analysis

A ‘kick’ is any unwanted flow of formation fluids from the reservoir to the well bore that
occurs as a result of a negative pressure differential across the formation. This occurs when the
wellbore pressure is less than the formation pressure. The difference in pressure will cause a
build-up along the well and rises to the surface if it is failed to be controlled and will lead to a
blowout. The fundamentals of the drilling simulation are to drill a virtual well using a drilling
simulator, identify a kick during the drilling process and remove the kick. To eliminate the
kick there are two different methods that are commonly used. They are The Engineer’s Method
and The Driller’s Method. In this lab session, we have decided to go for The Driller’s Method
to stop and recover from the kick.

The Driller’s Method requires two circulations. The pressure influx is circulated out
using the Original Mud Weight (OMW) in the first circulation. Circulating drill pipe pressure
is held constant during the first circulation in order to maintain the Bore Hole Pressure (BHP).
If the pressure decreases too low, another kick might happen and if the pressure is too high, the
formation may be damaged. The pressure influx is stopped by increasing the mud weight or
more commonly called Kill Mud Weight (KMW) if it is found that OMW is insufficient in
stopping the pressure influx from building up. To maintain the BHP, keep the casing pressure
only after kill mud is seen to have returned to the surface during the second circulation.

It was observed that during drilling at depth of 1000 ft, a kick was detected. It can be
seen on the monitor of the drilling simulator that there was a pressure build up in the form of a
yellow colored fragment as the result of the well bore pressure is lesser than the formation
pressure (underbalance pressure). The well was shut in to prevent further pressure build-up
from entering the wellbore. Both pumps were stopped from operation. Then, the Annular or
the Upper Ram of the Blow Out Preventer (BOP) was closed and consequently the BOP
upstream choke valve was opened. The Shut-In Drill Pipe Pressure (SIDPP), Shut-In Casing
Pressure (SICP) and the pit volume were observed and recorded.

Both pumps were then made to operate by gradually increasing the pressures to 30 spm
with a 5 spm interval increment as we adjusted the choke as we tried maintaining the SICP
between 330 psi and 400 psi. Once the SICP reached 357 psi, the choke was then adjusted
accordingly to maintain the SIDPP until the pressure influx is pumped out. The choke was then
closed once the pressure influx was completely pumped out. Both SIDPP and SICP readings
were almost equal which confirmed that there was no more pressure build-up at the well bore.
The mud weight was then increased by using an equation as followed to calculate KMW.

KMW = [(SIDPP + 150) / (0.052 * TVD)] + OMW, where

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OMW = 9.5 ppg

TVD = 6000.2 ft

SIDPP = 220 psi

KMW = 10.2 ppg

By gradually increasing the mud pump to 30 spm and maintaining SICP, the new mud
was circulated in the well bore until it reached the drill bit. Once it reached the drill bit, pressure
was maintained between 220 psi and 408 psi until the kill mud reached the surface. The mud
pump was then stopped and the choke closed once the kill mud reached the surface. With both
SIDPP and SICP showed zero readings it meant that the well was already dead. The difference
in flow was calculated and it was found to be 0.03 bbl. Drilling operation then continued by
maintaining the well bore pressure making it slightly higher than the formation pressure.

5.2) Errors

A few errors had been identified in this experiment which may have affected the data to some
significance.

 The lever controlling the hoisting movement of the drill string and bit was not carefully
controlled during drilling causing damage to drill bit due to excessive weight on bit.
 Slips, which are thong –like devices which keeps the drilling string in place were not
released during the start of drilling.
 Miscommunication between mud pump operator, choke operator, driller and BOP
operator. This may cause the kick to go out of control and the well to blowout if not
taken care of.
 Analog remote choke and mud weight indicator may cause parallax error

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5.3) Modifications

To remove the errors, modifications are introduced. Following are some of the modifications:

 The lever should be controlled carefully not to exceed 100 000 psi so that the drill bit
does not damage by observing the pressure panel. The lever should also be lowered in
a constant speed as moving upwards.

 Slips are to be released at designated times and should be instructed by one of drilling
team members

 Giving everyone in the group certain responsibilities of equipment to avoid

communication errors from occurring.

 Replace both analog indicators with digital ones to remove parallax error and improve
accuracy.

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6.0) ANSWER TO GIVEN QUESTIONS

1. Explain the correlation between bottom hole temperature and hydrostatic

gradient.

Bottom hole temperature is the temperature in the borehole at total depth at the
time it is measured. In log interpretation, the bottom hole temperature (BHT) is taken
as the maximum recorded temperature during a logging run or preferably the last of
series of runs during the same operation. BHT is the temperature used for the
interpretation of logs at total depth. Farther up the hole, the correct temperatures
calculated by assuming a certain temperature gradient or hydrostatic gradient. The BHT
lies between Bottom hole circulating temperature and the bottom hole static
temperature. Bottom hole temperature is also an important factor affecting cement
thickening time, rheological properties, compressive strength development and set
time.
Pressure gradient is the change per unit depth. Increase in temperature at the
bottom hole indicates the increase in pressure. The increase is due to the pore pressure
and formation fluid pressure at increasing depth. Water is included in formation
pressure. As water column increase with depth, the pressure at the bottom is higher at
the top. This increase in pressure is consistent at descending depth. Hydrostatic gradient
is pressure at a specific point in water column will drop with a constant value at depth
interval.

2. There are varieties that can cause abnormal formation fluid pressure. List 4 of the
principal causes.

 Under-compaction of sediments
 Tectonic activity
 Presence of salt structure
 Depositional effect
 Thermodynamic effect

3. What is MAASP stands for? When is the right time to re-calculate this parameter?
MAASP stands for Maximum Allowable Annulus Surface Pressure. It is an
absolute upper limit for the pressure in the annulus of an oil and gas well as measured
at the wellhead. This parameter will be re-calculated when casing is full with original
mud and the mud weight is changed. There are four different times in an annulus may
be over pressured and be re-calculated by MAASP. Among them are burst of the outside
casing, collapse of the inside casing, fracturing of the formation at the shoe, and
overpressure of the surface equipment.

4. A well can be induced to flow by swabbing which happens due to the reduction of
bottom hole pressure when pulling pipe. List 3 conditions that can cause swabbing.

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  High viscosity, gel strength and density of mud which cause the high
friction
 Reduction of height of mud column, high drill string pulling speed will
create a temporary piston like condition
 The size of the drilling equipment being tripped is almost the same size
as hole

5. List at least 2 causes of the increase in rate of penetration during drilling.

 Increase in rotation speed

 Optimum or sufficient weight on bit (WOB) is applied
 Applying Fast drill Process (FDP) which uses real time analysis of the
energy consumption of the drilling system – (example of technique
developed by ExxonMobil, the world’s leading Oil and Gas company)
 The usage of suitable bit accordingly to the formation drilled
 Suitable mud weight is used

6. Mention at least 5 components of drill stem.

 Drill collar
 Drill pipe
 Kelly
 Stabilizers
 Surface resonant vibrator
 Rotary reamer
 Heavy wall drill pipe

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 7. Shown below is a pressure versus volume plot of a leak off test

The leak off was carried out with a 10.6 ppg mud. The casing shoe is at 4000ft TVD

a. What is the maximum pressure that the exposed formations below the shoe can
support?
P(frac) = P {before fracture} + {0. 052 x MW x TVD}
= 1100 psi + (0.052 x 10.6ppg x 4000ft)
= 3304.8psi

b. What is the “Fracture Gradient”?

Fracture Gradient = (Pfrac / TVD)
= (3304.8psi/ 4000ft)
= 0.8262 psi/ft

c. What is the maximum mud weight?

MW(max) = P/ (0.052 x TVD)
= 3304.8 / (0.052x4000ft)
= 15.89 ppg

d. If drilling was resumed and the mud weight was increased to 12.6 ppg.
Calculate M.A.A.S.P
MAASP = (maximum mud weight allowed - present mud weight) x 0.052 xTVD
= (15.89 - 12.6) ppg x 0.052 x 4000ft
= 684.32psi

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 8. Given the following data:

Depth 10000ft TVD

Bit size 8 ½”
Shoe depth 8500ft TVD
Mud weight 12.6 ppg

Collars – 600ft. Capacity = 0.0077 bbl / ft

Metal displacement
Drill-pipe 5” capacity
Metal displacement
Casing / pipe annular capacity
Casing capacity
One stand of drill-pipe
= 0.03 bbl / ft
= 0.0178 bbl / ft
= 0.0476 bbl / ft
= 0.0476 bbl / ft
= 0.0729 bbl / ft
= 94 ft

Assuming the 12.6 ppg mud givens an over-balances of 200 psi

a. If 10 stands of pipe are removed “dry” without filling the hole, what would be
the resultant reduction in bottom-hole pressure?

Pressure drop per foot {psi/ft}

= [MW x 0.052 x Metal displacement]
[Casing capacity - Metal displacement]

= [12.6ppg x 0.052 x 0.0075bbl/ft]

[0.0729bbl/ft - 0.007sbbrft]

= 0.075psi/ft

Resultant reduction in bottom-hole pressure

= 0.075psi1ft x 10 std x 94std/ft

= 70.5psi

b. If 5 stands of pipe had been pulled “wet” without filling the hole, the resultant
reduction in bottom-hole pressure would be.

Pressure Drop per foot Tripping

= 12.6ppg x 0.052 x 0.03bbl/ft
0.0729 bbl/ft x 0.03bbl/ft
= 0.458 psi/ft

Resultant reduction in bottom-hole pressure

= 0.458psi/ft x 5std x 94 std/ft
=215.26 psi

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 c. If prior to tripping a 20-barrel slug of 14.6 ppg mud was displaced to prevent
a wet trip, what would be the expected volume return due to the U-tubing of
the heavy mud?

Slug Volume
Length of slug in drill pipe = Drill pipe capacity

20bbl
= 0.0178 bbl/ft

= 1123.60

Hydrostatic Pressure = mud weight x 0.052 x Desired length of drill pipe

= 14.6 ppg x 0.052 x 2 x 94 ft

= 142.73 psi

Hydrostatic Pressure
Slug weight = + mud weight
0.052 × slug length

142.73 psi
= + 14.6psi
0.052 ×1123.60 ft

= 17.04 ppg

Slug volume × Slug weight

Volume gained = - Slug volume
mud weight
20 bbl × 17.04 ppg
= – 20bbl
14.6 ppg

= 3.342 bbl

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 7.0) REFERENCES

1. http://webcache.googleusercontent.com/search?q=cache:4oQ3oCzeLBIJ:www.encyc
lo.co.uk/define/MAASP+maasp&cd=4&hl=en&ct=clnk&gl=my&source=www.goog
le.com.my

2. http://webcache.googleusercontent.com/search?q=cache:iheMVNHGYHEJ:www.hor
izonresource.net/content/UNDERBALANCED%2520DRILLING%2520OVERVIE
W.htm+conditions+that+can+cause+swabbing&cd=7&hl=en&ct=clnk&gl=my&sour
ce=www.google.com.my

3. http://www.scribd.com/doc/50495081/31/Shut-In-Procedure-while-Tripping

4. http://www.glossary.oilfield.slb.com/Display.cfm?Term=kick

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