Stuck Pipe Prevention in High Angle Wells

Stuck Pipe in High Angle 12Hole Cause & Prevention
Peter McNaughton Baroid Technical Manager - Kuwait
Agenda
1. Introduction & Reason for the Presentation 2. Causes & Prevention of Stuck Pipe in High Angle 12 hole a. Mud weight b. Hole cleaning c. Monitoring of hole cleaning indicators d. Tripping, circulating & connection practices 3. Kuwait Example, hole cleaning modeling
2010 Halliburton. All Rights Reserved.
Introduction
Reason for this presentation:
Many examples of stuck pipe / tight hole in 12 hole build sections Why? Investigate possible causes. Improve planning & execution of future horizontal wells, e.g. Zubair horizontals & Mauddud/Burgan multilaterals Prevent stuck pipe = save drilling days & increase production Introduce the Two Hat policy, i.e. different thinking & procedures for:
Low angle hole High angle hole
How To Drill Big Diameter High Angle Hole?

High angle 17 & 12 intervals 9.5 - 12 ppg OBM
Understand, model, plan! The principles are the same for your 12 build sections
Causes of Stuck Pipe in Deviated 12 Hole

1. Geology: shale swelling/inhibition & weak formations 2. Borehole instability due to inadequate mud weight 3. Poor hole cleaning practices
Understand the Problem Where Do All the Cavings Come From?

What causes all the cavings in the 12 build section? Inadequate chemical inhibition? Insufficient hydrostatic head after downhole losses? Roof collapse? Directional tectonic stress? Mechanical disturbance of weak formations? Borehole flexing due to surge/swab pressures? Pore pressure penetration? Time? Combination of these?
Reactive Shale Inhibition

Do we have reactive shales in the 12 build section?
Reactive Shale Data Greater Burgan Area Mixed Layer - Illite + Smectite Ahmadi Magwa Burgan NE NW S 14 9 8 4 0 16 10 8 Relative Clay % Illite + Mica Ahmadi Magwa Burgan NE NW S 34 11 14 7 73 18 28 11 Total Reactive Clays, % Ahmadi Magwa Burgan NE NW S 48 20 22 11 73 34 38 19
Field & Location Ahmadi Fm. Wara Fm. Mauddud Fm. Burgan Fm.
Slight to moderate reactive shales exist in 4 formations in the 12 build section

Shale composition typically doesnt change much over wide areas, so Burgan data is relevant for North Kuwait
Inhibit Shale Swelling Mud Formulation

Is reactive clay swelling a problem in the 12 section?
Answer: Do MBT values increase rapidly? Is rheology difficult to control due to clay buildup?
How to control reactive clay swelling?

WBM or OBM to control the shales? Balanced salinity OBM is best for inhibition, but lost circulation in the Shuaiba is the risk Experience has shown that a KCl-Polymer system with 3 6% KCl is appropriate for the 12 build section Glycols, asphaltics etc. are also useful in WBM to:
Reduce pore pressure penetration Increase open hole exposure time (OHET)
What is Pore Pressure Penetration?

Overburden Stress (S) = Matrix Stress () + Pore Pressure (P) Filtrate enters shale thru pores (~1 diameter), bedding planes & micro-fractures This allows fluid pressure to slowly increase in the shale As pore pressure increases, rock strength decreases This is the main reason that shale destabilizes with time Is shale failure in Kuwait time-dependent? If yes, add plugging agents to increase shale capillary entry pressure, or use balanced-salinity OBM
Inadequate Mud Weight

Is the mud weight high enough to control:
Oriented borehole breakout (directional tectonic stress) Collapse of unsupported roof Excessive pore pressure in shales Swabbing pressure on connections or trips Loss of hydrostatic head when downhole losses occur
How to Calculate Correct Mud Density

Correct mud density depends on what?
Maximum expected pore pressure + Safety factor (trip margin), e.g. 0.5 ppg + Borehole collapse factor for deviated hole, e.g. 0.5 ppg / 30of hole angle, + Directional tectonic stress factor, e.g. 0 2.5 ppg, + Formation strength factor e.g. 0 1 ppg
Oriented Borehole Breakout in direction of Minimum Horizontal Stress (Hmin)
Hmax
Hmin
Trip Margin & Rock Strength

Trip Margin Extra hydrostatic pressure is required to allow some swabbing during a trip out of the hole without inducing a well influx (kick) This safety factor allows a safe trip out of the hole, so is called Trip margin Rule of thumb value for trip margin is 0.5 ppg KOCs stated trip margin for drilling fluids = 250 psi above the formation pressure At 10,000ft TVD, 250 psi overbalance = 0.5 ppg Rock Strength Extra mud weight is often required in high angle hole to stabilize weak rock, e.g. coal, fractured shale & loose sand
Mud Weight in Deviated Hole

Higher mud weight is required to stabilize unsupported rock (the roof) in high angle hole
Rule of Thumb - Hole angle versus mud weight Hole angle: 0 - 30 30 - 60 60 - 90 Mud weight increase: 0 0.5 ppg 0.5 1.0 ppg 1.0 1.5 ppg
Oriented Borehole Breakout

Green log plot shows significant hole enlargement in one direction, but not in another Log for the three caliper arms do not overlap, indicating oval hole shape Circle shapes show oval hole shape in an approximate NNW direction. This is the direction of minimum horizontal stress (Hmin) This agrees with the known tectonic stress regime in Kuwait, where the direction of maximum tectonic stress (Hmax) is at an azimuth of 010 045 . Oriented breakout is greatest in the shale (high Gamma Ray values), which is the most stressed lithology. AH-178 - 12 Deviated Hole 4100 4300 ft
Casing Depth
AD-61 Lower well section
Is the casing depth optimized to allow the correct MW to be used? Three big problems in the 12 build section:
Increase MW to control shale pore pressure Increase MW to manage hole angle & tectonic stress Reduce MW due to lost circulation in the Shuaiba
Experience in previous 12-1/4 sections building to high angle shows many hole problems, with stuck pipe common Very difficult to reconcile two opposing mud weight constraints Can we change the casing design?
Hole Cleaning Indicators

Do we have a hole cleaning problem?
Warning signs: - Hole angle > 30 - AV < 120 ft/min - Low pipe rpm - Mud wt < 10 ppg Comments If one or two of these factors are present, then poor hole cleaning is likely. If more than two of these factors are present, then poor hole cleaning is certain to occur.
In Zubair horizontals, two or three of these factors will be present in the 12 build section
Inadequate Hole Cleaning

Cuttings bed buildup on the low side of the hole Inadequate annular velocity Drill pipe size versus hole diameter Insufficient drill string rpm Sliding versus rotating Insufficient hole cleaning cycles Inappropriate mud rheology & rheology specifications Incorrect sweeps & sweeps wrongly applied Hole enlargement Cavings Operator & Contractor lack of awareness
Cuttings Beds
Big cuttings (or cavings) rapidly fall to the bottom of the hole Settled cuttings form a cuttings bed Cuttings beds restrict hole diameter & cause stuck pipe Cuttings beds can suddenly break free, causing annulus pack-off
Flowrate = 900 gpm
Cuttings Bed on low side of hole
High Angle Hole Cleaning: 7 Primary Factors

Hole cleaning factors for deviation > 40(in order of importance) 1. Annular velocity. Minimum 120 ft/min. AV depends on:
Annulus diameter. Big hole diameter = bad; Small pipe diameter = bad. Pump output . More = good Hole enlargement = Bad
2. Cuttings (or cavings) size 3. Drill string RPM. 4. Hole angle. 5. Mud density
Cavings = bad
Big cuttings & cavings cannot be cleaned from a high angle hole High rpm = good. Sliding = bad. High rpm kicks cuttings from the low side of the hole up into the main flow path More = bad More = good (increased buoyancy) Not too thick & not too thin How many bottoms up is needed to clean the hole?
Cuttings beds form on the low side of the hole at angles > 40 Hole cleaning problems do not occur at high mud density
6. Hole rheology
YP & Funnel Vis are useless values at hole angles > 40
7. Hole cleaning cycles
Annular Velocity Target > 120 ft/min

How can we achieve this target through the entire 12 build section:
Use larger diameter drillpipe smaller annular diameter in the high angle section Minimize hole enlargement, e.g.
Prevent borehole breakout by using the correct mud weight Dont back-ream
Minimize ultra-fine low gravity solids content, e.g.

Improve hole cleaning to remove cuttings quickly Use efficient fine shaker screens, mud cleaners & centrifuges to remove solids on the first pass Maintain a tight LGS specification in the mud
Minimum Flow Rate for AV = 120 ft/min
Hole Size
Annular Velocity (ft/min) 120 120 120
Target Flow Rate, Q (gal/min) 5 drillpipe 1130 612 231 5 drillpipe 1104 586 206 6 drillpipe 1038 519 -
16 12 8
Gauge Hole
Washed Out Hole
Cuttings Size
How big is a cutting from a 12 PDC bit (16 mm cutters)? The mud must be able to remove this cutting from the hole
Hole Cleaning Pipe Rotation

Mud flow stream is on the high side of the hole Rotation disturbs the cuttings bed & kicks cuttings from the low side up into the flow stream
Cuttings bed is on the low side of the hole
Zero hole cleaning when sliding in high angle hole High speed rotation provides:
Mechanical disturbance of the cuttings bed, kicking cuttings up into the flow stream Viscous coupling of cuttings to the mud film attached to the rotating pipe
Hole Cleaning Monitoring

How do we measure hole cleaning efficiency?
On-bottom & off-bottom torque (do we measure & graph?) Pick-up & slack-off weight on connections (drag) Quantity, size & shape of cuttings at the shakers
Good hole cleaning angular shape
Poor hole cleaning rounded shape
Good hole cleaning, but shale is caving
Good hole cleaning, but mud weight is too low
Increased cuttings size & quantity when a sweep returns Tight hole on trips Pump pressure spikes indicates annulus pack-off Use PWD tool to monitor ECD caused by cuttings load Compare ROP against cuttings at the shaker Waves of cuttings at the shakers
Torque & Drag Plot - 12 Deviated Hole
Diverging pick-up & slack-off weights indicates a cuttings bed build-up Pick-up & slack-off weights returned to normal after a hole cleaning cycle
Pill/Sweep Report
Mud engineer to report hole cleaning sweeps Recommended to monitor hole cleaning effectiveness
SWEEP & PILL REPORT FORM Operator: xxxx Well: xxxx
Date 2011
Hole Size (in) 17
Bit Depth (m MD) 1255
Tangent Angle () 0
Pill Volume (bbl) 300
Pill Weight (ppg)
Pill Composition & Key Properties 2.5 ppb CMC EHV + 20 ppb Bentonite. Vis = 90 sec/qt.
Results, e.g. Before & After Values: (% increase cuttings at shakers; cuttings/cavings size & lithology; pick-up & slack-off weight; etc.) While POOH at section TD, spotted 300 hi-vis mud to bottom. No drag or overpull while POOH.
6 Feb
8.8
10 Feb
12
1400
10
100
9.5
16 Feb
12
2419
37
50
12.1
KCl/Polymer premix + 22 ppb CaCO3 (C) + 22 ppb CaCO3 (M) + 22 On standby at start of 12 interval. ppb CaCO3 (F) + 25 ppb STEELSEAL + 5 ppb BAROFIBRE + barite Pumped hole cleaning sweep before trip. Cuttings volume increased by ~ 50% when sweep Active mud with 0.25 returned. Some large cuttings/cavings with ppb BAROLIFT rounded edges. Slack-off wt reduced by 10%.
Hole Cleaning Optimum Rheology

What is the optimum mud rheology in high angle hole? Not too thin
Thin mud cannot suspend big cuttings (or cavings) They rapidly fall to the bottom of the hole to form a cuttings bed
Not too thick

Thick mud cannot penetrate the cuttings bed under the drill pipe Thick mud will travel up the high side of the hole
Just right
Intermediate rheology is best Rule of thumb: 6 rpm viscometer value 0.8 1.5 x hole diameter (inches)
For big hole, use 1.2 1.5 x hole diameter For small hole, use 0.8 1.0 x hole diameter
High Angle Hole Rheology Specification

Best rheology specification for high angle hole?
6 rpm Viscometer Dial Reading
Closest measurement to the annulus flow rate past the drillpipe Closest measurement to the most difficult annulus section to clean
Low Shear Rate Yield Point (LSR YP)

Calculates YP using 3 & 6 rpm viscometer values LSR YP = 2 x 3 6 Represents the annulus flow rate past the drillpipe better than Bingham YP Sometimes inaccurate. Small differences in viscometer values can cause big changes in LSR YP.
Herschel-Bulkley Tau Zero (Yield Stress)

Intercept on Y-axis of viscometer dial reading versus viscometer speed True Yield Point Calculated by curve fit to actual mud viscosity profile Gives more accurate hydraulics calculations than Bingham or Power Law
Fluid Viscosity Profile

Which rheology model is most accurate for hydraulics calcs?
80
Measured Points
Viscometer Dial Reading
60
Herschel-Bulkley Power Law Bingham Plastic
40
Bingham YP
20
Herschel-Bulkley model closely fits actual fluid profile
600 rpm = 63 300 rpm = 38 200 rpm = 28 100 rpm = 18 6 rpm = 8 3 rpm = 7
0
H-B Yield Stress (Tau zero)
100
200
300
400
500
600
Shear Rate (rpm)
Fluid Viscosity Profile
6 rpm viscometer reading is the best measure of the fluid viscosity in the open hole annulus where hole cleaning is critical
For 12 hole & 120 ft/min annulus velocity : Annulus shear rate = 2.4 x AV / [Dh Dp] = 40 sec-1 Equivalent viscometer rotor speed = annulus shear rate / 1.703 = 23 rpm
120ft/min annular velocity in 12-1/4 hole
Baroid Recommended Rheology Spec

Recommended rheology spec. for deviated hole Use Yield Point for hole angle < 40 Use 6 rpm viscometer value for hole angle 40 Recommend rheology range for 12 high angle hole 6 rpm viscometer value = 12 16 (for MW < 10 ppg) 6 rpm viscometer value = 10 14 (for MW > 10 ppg)
Hole Cleaning Cycle

1. How many bottoms up (cycles) to clean the hole? 2. What is the Circulation Factor?
Circulation Factor (= minimum circulation volume) Hole Size 17 & 16 12 8 Vertical (<10) 1.5 x B/U 1.3 x B/U 1.3 x B/U 10 - 30 1.7 x B/U 1.4 x B/U 1.4 x B/U 30 - 60 2.5 x B/U 1.8 x B/U 1.6 x B/U > 60 3.0 x B/U 2.0 x B/U 1.7 x B/U Deviation
These are minimum values Actual circulation time will be until the shakers clean up
High Angle Hole Cleaning Secondary Factors

Hole Cleaning Sweeps 1. Good Sweeps:
Best sweep materials are:
Weighted sweeps Provide buoyancy. Best if 4 ppg > MW. Coarse fibres. Fibres form a mat; Sweep is removed by shakers Coarse Barite weighted sweep (Sweep-Wate) Sweep is removed by shakers Keep sweep rheology the same as mud rheology.
2. Bad Sweeps
Hi-vis sweeps are useless in high angle hole Sweep goes up the high side of the hole Cuttings bed remains on the low side of the hole Tandem sweeps cause more harm than good: Low-weight component may rise in the well & cause a kick Low-weight component can cause borehole wall to flex & weaken Hi-vis component is useless in high angle hole Tandem sweeps destabilize mud properties

Circulating Practices Circulate cuttings above the BHA before making a connection Circulate at drilling flow rate & rpm when reaming upwards Circulate at drilling flow rate & low rpm when reaming downwards (to avoid inadvertently kicking off into new hole) Circulate the correct number of bottoms-up cycles, based on:
Circulation factor Drillstring rpm Hole angle Possible hole enlargement
Circulate until the shakers clean up Circulate sweeps all the way out (do not stop pumping) Do not have more than one sweep in the hole at the same time DO NOT BACKREAM unless it is the only way to get out of the hole

The trouble with back-reaming:
Pipe is pulled into the roof of the hole when back-reaming Large cuttings are cut from the roof of the hole This causes several problems:
Hole diameter gets bigger, so annulus velocity reduces Extra large cuttings are generated that must be removed from the hole The extra large cuttings may block the annulus (annulus pack-off) Stuck pipe often occurs when back-reaming, usually after a pack-off occurs

Tripping Practices A cuttings bed will always be present in 12 hole at angles > 40 You will drag cuttings up the hole when you trip (snowplow effect) If tight hole occurs on the trip out:
DO NOT BACKREAM RIH one or two stands Perform a hole cleaning cycle (high rpm & flow rate) POH again If the tight spot is not there, then it was caused by a cuttings bed
Drillstring Failure & Corrosion Monitoring

High angle big diameter hole puts maximum stress on the drill string Weakness caused by corrosion will cause the drillstring to fail Stuck pipe in high angle hole is expensive (expensive tools are lost) Stuck pipe in high angle hole is difficult to fish To prevent drillstring failure in high angle drilling: Use corrosion monitoring & treatment to reduce the risk of failure Blueprint, register & inspect all pipe, crossovers & subs run in the hole Use lubricants (including OBM lubricants) to reduce torque & drag Minimize cumulative dogleg in the upper hole to reduce torque & drag
Case History North Kuwait

AD-61 Abdaly Field, North Kuwait
Horizontal Zubair producer 12 interval with 5 DP Build hole angle to 67 Water base mud (KCl-Polymer- Glycol) Drill with rotary steerable system (RSS) or mud motor Twisted off while reaming tight hole at 10,750 ft. Unable to fish Inadequate hole cleaning partly to blame Similar occurrences in AD-57, including stuck pipe, annulus pack-off & tight hole requiring backreaming
Hole Cleaning in High Angle Wells

Baroids DFG Hole Cleaning Modeling
Calculate cuttings loading in annulus Identifies poor hole cleaning Calculates ECD of mud system & sweeps Optimize rheology & other hole cleaning factors Can be used in real time with PWD tool
Hole Cleaning Rules of Thumb

< 10% cuttings load inMeasured any hole section Depth < 3% total cuttings load in annulus
Flowrate = 900 gpm
Cuttings Bed Height
Fair Hole Cleaning Actual Parameters

Hole cleaning OK. Avg. cuttings concn < 3.0%
0.3 inch cutting. Cuttings bed present. Hole cleaning fair. Max cuttings concn < 10% in the high angle section
MW = 9.0 PV = 20 YP = 25 6 rpm = 10 Tau0 = 7.0 LSR YP = 4 Q = 500 gpm Rpm = 100 Angle = 61
AD-61, 12 Hole at 10,663 ft, Drill w/RSS, Cutting size = 0.3

Poor Hole Cleaning Actual Parameters

Hole cleaning poor. Avg. cuttings concn > 3.0%
inch cutting. Large cuttings bed. Hole cleaning poor. Max cuttings concn > 10% in the high angle section
ECD with cuttings very high

Very Poor Hole Cleaning Actual Parameters

Good Hole Cleaning Optimum Parameters

Poor Hole Cleaning Larger Cuttings
AD-61, 12 Hole at 10,663 ft, Drill w/RSS, 100 rpm, Cutting size = 0.5
Summary
Understand, model & plan for high angle big hole! Two hats: Low angle & high angle hole are completely different Understand:
Geology correct mud type & inhibition Pressures & forces correct mud weight Hole cleaning issues optimize practices optimize or improve equipment
optimize rheology
For interest, compare our findings with SPE 151953, Planning & Well Design for KOCs first North Kuwait Jurassic Well (SA297) Case History, 2012
How Did We Drill This Well w/o Stuck Pipe?

Equipment 4 x 2000HP mud pumps, with 7500 psi fluid ends 7500 psi standpipe 1200 gpm in 17-1/2 hole 800 -900 gpm in 12-1/4 hole PWD tool 5 Derrick 4-panel 514 shakers 2 mud cleaners 3 centrifuges RSS mandatory, rotating at 150 180 rpm 5-7/8 drillpipe (later 6-5/8 DP) Non-rotating stabilizers Roller centralizers to run casing 9000 bbl mud system Mud plant at the rig Cuttings slurrification unit, injection pump & injection well at the rig
Understand, model, plan! Borehole stability analysis Extensive hole cleaning & ECD modeling using DFG Rigsite torque & drag monitoring Optimized rheology Circulate before trips until the hole is clean High weight sweeps (fibres not allowed) OBM lubricant No wiper trips No backreaming, except before running casing

Stuck Pipe Prevention in High Angle Wells

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Stuck Pipe in High Angle 12Hole Cause & Prevention

Peter McNaughton Baroid Technical Manager - Kuwait

2010 Halliburton. All Rights Reserved.

2010 Halliburton. All Rights Reserved.

How To Drill Big Diameter High Angle Hole?

2010 Halliburton. All Rights Reserved.

Causes of Stuck Pipe in Deviated 12 Hole

2010 Halliburton. All Rights Reserved.

Understand the Problem Where Do All the Cavings Come From?

2010 Halliburton. All Rights Reserved.

Reactive Shale Inhibition

Slight to moderate reactive shales exist in 4 formations in the 12 build section

2010 Halliburton. All Rights Reserved.

Inhibit Shale Swelling Mud Formulation

How to control reactive clay swelling?

2010 Halliburton. All Rights Reserved.

What is Pore Pressure Penetration?

2010 Halliburton. All Rights Reserved.

Inadequate Mud Weight

2010 Halliburton. All Rights Reserved.

How to Calculate Correct Mud Density

Oriented Borehole Breakout in direction of Minimum Horizontal Stress (Hmin)

Trip Margin & Rock Strength

2010 Halliburton. All Rights Reserved.

Mud Weight in Deviated Hole

2010 Halliburton. All Rights Reserved.

Oriented Borehole Breakout

2010 Halliburton. All Rights Reserved.

AD-61 Lower well section

2010 Halliburton. All Rights Reserved.

Hole Cleaning Indicators

2010 Halliburton. All Rights Reserved.

Inadequate Hole Cleaning

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Cuttings Bed on low side of hole

2010 Halliburton. All Rights Reserved.

High Angle Hole Cleaning: 7 Primary Factors

YP & Funnel Vis are useless values at hole angles > 40

7. Hole cleaning cycles

Annular Velocity Target > 120 ft/min

Minimize ultra-fine low gravity solids content, e.g.

2010 Halliburton. All Rights Reserved.

Minimum Flow Rate for AV = 120 ft/min

Annular Velocity (ft/min) 120 120 120

Washed Out Hole

2010 Halliburton. All Rights Reserved.

2010 Halliburton. All Rights Reserved.

Hole Cleaning Pipe Rotation

Cuttings bed is on the low side of the hole

Hole Cleaning Monitoring

Good hole cleaning angular shape

Poor hole cleaning rounded shape

Good hole cleaning, but shale is caving

Good hole cleaning, but mud weight is too low

Torque & Drag Plot - 12 Deviated Hole

Hole Size (in) 17

Bit Depth (m MD) 1255

Pill Volume (bbl) 300

Pill Weight (ppg)

2010 Halliburton. All Rights Reserved.

Hole Cleaning Optimum Rheology

Not too thick

2010 Halliburton. All Rights Reserved.