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DRILLING SIMULATION

INTRODUCTION
BASIC DRILLING SYSTEM
1.1. 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.
The complete, circuitous path that the drilling fluid travels starting at the:
- main rig pumps
- surface piping
- standpipe
- kelly hose (rotary)
- kelly
- drillpipe
- drill collars
- bit nozzles
- openhole and casing strings
- flowline
- mud-cleaning equipment
- mud tanks
- positive displacement main rig
pumps
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
1.2. 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.
There are two types of rotating source:
1. Rotary Table
The revolving or spinning section of the drillfloor that provides power to turn the
drillstring in a clockwise direction (as viewed from above). The rotary motion and
power are transmitted through the kelly bushing and the kelly to the drillstring.
Almost all rigs today have a rotary table, either as primary or backup system for
rotating the drillstring. Top drive technology, which allows continuous rotation of the
drillstring, 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.

2. Top Drive
A device that turns the drillstring. 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 drillstring itself. The topdrive 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 drillstring 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.


1.3. Hoisting System
The main objective of this system is to provide lifting and dropping force towards drill
string and any components around rig floor.
Several components of this system are:
- crown block
- travelling block
- mast
- substructure (sub)
- prime mover
1.4. 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 (drillpipe, casing or tubing) and others are fitted with hardened steel shearing
surfaces that can actually cut through drillpipe.
1.5. 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 (drawworks, 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.
2. KICK AND BLOW OUT

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
identifed.
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

The occurence 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.
3. SWABBING
Swabbing is a condition that arises when pipe is pulled from the well and produces a
temporary bottomhole 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
4. WELL CONTROL PROCEDURE (HARD SHUT IN * REMOTE CHOKE IS ALWAYS CLOSE
DURING DRILLING & TRIPPING)
1.6. SHUT-IN PROCEDURE WHILE DRILLING
1. When any indication is observed while drilling that the well maybe flowing, raise the
drill with pumps on until spaced out, stop rotating drill string.
2. Stop pumping and check for flow, if positive;
3. Close annular or upper pipe rams.
4. Open BOP upstream choke valve.
5. Call supervisor and commence plotting a graph of shut in drill pipe & casing pressure.
Check pit volume again.


1.7. SHUT-IN PROCEDURE WHILE TRIPPING
1. When a possible sign is observed, set top tool joint in the slips.
2. Check for flow.
3. Install a full opening Safety valve on the drill pipe. Close the valve once it is installed.
4. CLOSE annular BOP.
5. Open BOP upstream choke valve.
6. Alert supervisors.
7. Read and record pressures on SICP & SIDP
8. The operator's representative will have to decide whether to kill in situ, or strip back
to bottom.
9. If operator decided to strip to bottom, stab IBOP (Gray valve) & open full opening
safety valve. Ready to strip drill string to bottom.

























OBJECTIVES

The objectives of this experiment are as follow:
1. To conduct drilling operation simulation by using DrillSim 500.
2. To identify any kick indications by using DrillSim 500.
3. To control any kick confronted during drilling operations.

































PROCEDURES
Drilling Test
1. Took slow pump rate pump#1 20 spm / 5 psi, 30 spm / 235 psi
2. Took slow pump rate pump#2 20 spm / 5 psi, 30 spm / 235 psi.
3. Increased mud pump 1 & 2 to achieve total of 600 gpm (8-1/2 hole size)
4. Rotary speed was set to 100 rpm.
5. Handbrake was used to lower the drill string until bit touches bottom.
6. Increased and maintained WOB at 35.000 lbs.
7. Continued drilling by adjusting WOB at 35.000 lbs by adjusting handbrake at every
time.
8. Kick indication at all operation time is identified.
9. Continued to kick procedure when kick is encountered.

Well Control Drillers Method
1. Monitored surface instrumentation. Once positive kick detected, follow step 2.
2. Picked up off bottom & spaced out (ensure tool joint is not across ram). Rotary is
stopped.
3. Pump 1 and 2 were stopped. Closed BOPs Annular or Upper Ram. Opened BOP
upstream choke valve.
4. Final (stabilized) SIDPP and SICP were read and recorded. Final pit gain was also read
and recorded. Adjusted the remote choke to maintain the SICP constant while
bringing the pump up to 20 or 30 strokes per minute simultaneously.
When the casing pressure is stabilized, new circulating drill pipe pressure were read
and recorded. Adjusted the remote choke to maintain the initial circulating drill pipe
pressure constant until the influx (the kick) is out. Once influx out, pump is stopped
& remote choke was completely closed while maintaining the last CP constant. (If no
further influx enter the well bore, theoretical SICP & SIDP should be the same)
5. Increased mud weight to kill mud weight.
Kill MW = (SIDPP + 150 psi overbalance)/(0.052*vert. depth) + original MW
Remote choke was opened and started pump at 20 or 30 strokes per minute while
maintaining SICP constant. Once desired pump rate reached, continued to maintain
SICP constant until kill mud reached the bit. Once kill mud reach bit, FCP (final drill
pipe circulating pressure) is started to maintained constant until kill mud reached
surface.
6. When the kill mud reached surface, pump is stopped & then remote choke is closed.
SIDPP, SICP and pit volume are read and recorded. (SIDPP & SICP should be zero if
the well is dead). BOP upper ram is opened, BOP upstream choke valve is closed and
flow check well.

3. Well Control Engineers Method
1. Monitored surface instrumentation. Once positive kick detected, follow step 2.
2. Picked up off bottom & spaced out (ensure tool joint is not across ram). Rotary is
stopped Pump 1 and 2 are stopped. BOPs Annular or Upper Ram is closed. BOP
upstream choke valve is opened.
1. Read and recorded final (stabilized) SIDPP and SICP. Read and recorded final pit gain.
Prepared kill sheet.
3. Increased the mud weight to kill mud weight.
Kill MW grad = ((SIDPP + 150 psi overbalance/ 0.052*vert.depth) + original MW)
Opened remote choke and slowly bring pump to kill rate to 20 or 30 spm.
Remote choke is adjusted to maintain casing pressure constant.
When the pump is up to kill rate and casing pressure stabled, followed the drill pipe
pressure schedule and maintain it by remote choke adjustment according to the kill
sheet.
4. When the kill mud is at the bit, maintained FCP (final drill pipe circulating pressure)
constant until kill mud reached surface.
5. When the kill mud reached surface, pump is stopped and the remote choke is closed.
Read and recorded SIDPP, SICP and pit volume. (SIDPP & SICP should be zero if the
well is dead). Open the BOP annular or upper ram, close BOP upstream choke valve
and flow check well.















RESULT

Besides starting the experiment, some test have been carried out on the equipment
that we going to use- DrillSim 500.The pump 1 and pump2 have been tested at 20 spm and
30 spm respectively.
Pump1
20 spm = 123 psi
30 spm = 234 psi
Pump 2
20 spm = 127 psi
30 spm = 233 psi

In this experiment, we do the Drilling Test. All procedures are conducted accordingly.
Then, we moved to the well control Drillers method. First and foremost, the well is drilled
by increasing bit rotation. At a depth around 6000ft, we are aware of positive kick. At the
moment kick was detected.
1. Top drive system is stopped.
2. Pump 1 and 2 are stopped
3. BOPs annular or Upper Ram is closed then BOP upstream choke valve is
opened. (Reminder: Closed BOPs annular first just followed by opened
choke.) If not, blowout may happen.
4. Quickly recorded final stabilize value of SIDPP and SICP as well as pit gain.
Remote choke is adjusted to maintain SICP constant.
5. Pull up the drill bit by pulling up the drawworks, and let the drill bit on the
above of the surface of the bottomhole. At the same time, the pump is
bringing up to 20 strokes per minute simultaneously.
6. Calculate kill mud density by using formula

Kill mud weight = (SIDPP/depth) 0.52 + original mud weight

KMW = (273/6000) 0.52 + 12.20
KMW = 13.56

7. SICP is maintained constant until kill mud reached the bit and filling up the
outside wellbore.
8. When kill mud reach the bit, FCP is maintained until kill mud reached the
surface (can be noticed when there is sudden decrease in mud out weight it
showed at the moment the gas is coming out).
9. After kick are successfully controlled by using killing mud, we continue the
drilling as usual following the procedure.
























DISCUSSION

As our main objectives of this experiment are:
1. To conduct drilling operation simulation by using DrillSim 500.
2. To identify any kick indications by using DrillSim 500.
3. To control any kick confronted during drilling operations.
We are going to discuss the procedure of controlling a kick and interpret the result
obtained from the experiment. In this experiment, we face kick when drilling process is
carrying. What is is kick basically? Kick is actually caused by imbalance hydrostatic
pressure between formation or formation fluid and the wellbore, therefore causing the flow
of the formation fluid (usually is gas) out of the formation to balance up the pressure. There
are two ways that can cause the imbalance of pressure between the formation and the
wellbore. First, kick happened if the mud weight is low compare to the formation pressure.
The hydrostatics pressure exerted by the mud/fluid column not sufficiently/effectively
enough to balance up the formation pressure. Mud weight low is only happen when the
mud density is low or light and this low density of mud exerted the pressure on the
formation is not capable to balance the pressure of the formation when it drilled deeper. In
our experiment this kind of kick happen when the drill bit reach 6000ft of depth, it probably
a different type of rock layer which given a higher pressure compare to the above layer. As
physics theory mentioned high pressure fluid flow into the low pressure area, thus the
formation fluid flow into the mud. If the mud is not properly control , blow out may happen.
This type of kick also known as underbalanced kick. The second way a kick can occur is if
dynamic and transient fluid pressure effects, usually due to motion of the drillstring or
casing, effectively lower the pressure in the wellbore below that of the formation. This
second kick type could be called an induced kick.
Once the kick is occurred, we must follow up some crucial procedure in to order to
control well and stop any influx of mud into the well. In this experiment, kick occurred we
had to shut-in the well using the BOP/ blow out preventer. Then we used Drillers method to
control and prevent the blowout of the kick.
There are two methods in to order to control the kick are driller method and
engineers method. For the experiment we are carrying, we used the driller method to
control the kick to prevent blowout happen. Driller method is basically a two complete
circulation method; once the kick is spotted, the drill string have to be trip up a short
distance, top drive system is stopped but the pump is still operating to pump out the kick
(fluid from the formation) by the old mud, and the old mud is then circulated using kill
weight mud (new mud). In this experiment, we choose driller method over the engineer
method due to its simplicity and it have less risk than engineer method and engineer
method involved a lot of complex calculation.
Besides the two methods, kick indicators also can be classified into two groups:
positive and secondary. Engineers can easily notice the positive indicator of a kick when
there is increase in pit volume for the mud and also increase in flow rate going out of the
mud to the surface. If the positive indicator once confirmed, immediate action must be
taken to shut-in the well. But for the secondary indicator of a kick, can be detected when
there is decreasing in circulating pressure, gradual increase in Drilling rate, increasing in gas
cutting and last but not least increasing in water cutting or chloride. There are differences
between positive and secondary indicators, because once the secondary indicators is
detected, several steps should be taken to verify if the well is indeed kicking or not. In this
experiment the simulator has an automated alarm which goes on as soon as a kick is
detected so when the alarm went on we encountered a kick with an increase of the pit
volume.
After detecting the kick the first step was to shut-in the well and start with
procedure of controlling the well using the Drillers method. Our aim was to control the well
and prevent the potential blow out and also preventing further influx from entering the
wellbore. According to the Drillers method the shut-in drill pipe pressure (SIDPP), shut-in
casing pressure (SICP) and pit volume should be recorded.
We recorded the SIDPP pressure, SICP pressure and the pit volume. All these reading
are essential for the procedure of controlling the well for example:
SIDPP pressure is used to calculate the Kill mud weight, SICP pressure is used to
determine the controlling method and pit volume is used to specify the type of the influx
(water, gas or oil).
After taking the readings of SIDPP, SICP and pit volume, we started pumping the kick
out by the old mud while adjusting the choke to maintain the SICP constant between 0 and
200 psi. After the SICP is stabilised the choke is adjusted to maintain the SIDPP until the
influx is out. When the influx is out, we change the mud weight by changing the density of
the mud by calculating the kill mud weight using the below equation:
KMW = + OMW
KMW is kill mud weight
OMW is the original mud weight =12.20 ppg
TVD true vertical depth=6000 ft
SIDPP the shut=in drillpipe pressure =273 psi
KMW = 13.56 ppg
The kill mud weight is then circulated into the wellbore from the pit, the pump will
pump the kill mud weight to the bottom of the drill bit, but when the new mud is
transferring, we have to maintain the pressure (FDP) until the new mud reached the surface
by controlling the choke. Once the mud reached the surface the pump was stopped and
choke was closed but the SIDPP and SICP were not zero which meant that the well is not
dead yet; the readings are shown above. As thee choke was opened and closed finally the
SIDPP and SICP were both zero. The flow was checked. Finally the well is dead and the
drilling operation can be resumed. The key point here is that during the kick control the well
bore pressure is maintained slightly higher than the formation pressure.


























ANSWER TO GIVEN QUESTIONS
1. Explain the correlation between bottom hole temperature and hydrostatic
gradient.

Bottom hole temperature is an important factor affecting cement thickening time,
rheological properties, compressive strength development and set time. Pressure gradient
is the change per unit of depth.

2. There are a variety that can cause abnormal formation fluid pressure. List 4 of the
principal causes.
- Depositional Effects
- Diagenetic Processes
- Tectonic Effects
- Structural Causes and
- Thermodynamic Effects

3. What is MAASP stands for? When is the right time to re-calculate this parameter?
MAASP stand for Maximum Allowable Annulus Surface Pressure, is an absolute upper limit
for the pressure in the annulus of an oil and gas well as measured at the wellhead. If the
mud weight is changed, MAASP has to be recalculated.

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.
- Pulling pipe too fast
- Poor Mud Properties ( density)
- Heaving or swelling Formations
- Large OD tools ( outer diameter tools)

5. List at least 2 causes of the increase in rate of penetration during drilling.
- Increase in bit weight
- Increase in rotary speed
- Increase in fluid circulation rate, the rate of mud flowing from nozzle
- Use suitable bit which the diameter, type , condition , and jet configuration is
suitable with the rock.

6. Mention at least 5 components of drill stem.
Drill stem is the string of drill pipe that transmits power from the surface down to the drill
bit in well drilling. The components are:
- Drill String
- Swivel
- Sub
- Kelly
- Drill Collar
- Packer
- Drill bit
- Tool joint


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 shoes is at 4000 ft TVD
a. What is the maximum pressure that the exposed formations below the
shoe can support?
(CSGTVD x MUDWT x 0.052) + Surface pressure
= (4000 x 10.6 x 0.052) +1100
= 3305 psi
b. What is the Fracture Gradient?
Fracture gradient = Max. Press. + CSGTVD
= 3305 + 4000
= 0.826 psi/ft
c. What is the maximum mud weight?
Max Mud Weight = Fracture gradient + 0.052
= 0.826 + 0.052
= 15.88 ppg
d. If drilling was resumed and the mud weight was increased to 12.6 ppg.
Calculate M.A.A.S.P
MAASP = (Max mud weight Drilling mud weight) x 0.052 x CSGTVD
= (15.88 12.6) x 0.052 x 4000
= 682 psi

8. Given the following data:
Depth 10000ft TVD
Bit size 8
Shoe depth 8500ft TVD
Mud weight 12.6 ppg

Collars 600ft. Capacity = 0.0077 bbl / ft
Metal displacement = 0.03 bbl / ft
Drill-pipe 5 capacity = 0.0178 bbl / ft
Metal displacement = 0.0476 bbl / ft
Casing / pipe annular capacity = 0.0476 bbl / ft
Casing capacity = 0.0729 bbl / ft
One stand of drill-pipe = 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?

Total depth = number * one stand drill-pipe length
= 10 * 94
= 940 ft

Pulling dry pipe (psi/ft) =




Since it is removed dry, no mud is being carried out.

Pulling dry pipe (psi/ft) =



Mud Gradient = 0.052 * Mudweight
= 0.052 * 12.6
= 0.6552 psi/ft

Metal Displacement = 0.0476 bbl/ft
Casing Capacity = 0.0729 bbl/ft
Pulling dry pipe (psi/ft) =


= 1.2327 psi/ft
Reduction in Pressure = Pulling dry pipe * Depth
= 1.2327 * 940
= 1158.74 psi


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

Total depth = number * one stand drill-pipe length
= 5 * 94
= 470 ft
Since it is removed wet, mud is being removed too.

Pulling wet pipe (psi/ft) =




Pulling wet pipe (psi/ft)

=



=




Metal Displacement = 0.0476 bbl/ft
Casing Capacity = 0.0729 bbl/ft
Drill pipe capacity = 0.0178 bbl/ft
Pulling wet pipe (psi/ft) =



= 5.713 psi/ft
Reduction in Pressure = Pulling dry pipe * Depth
= 5.713 * 470
= 2685.11 psi
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?
Dry pipe volume = (


)
= (

)
= 3.175 barrel





REFERENCE

http://www.scribd.com/doc/4209107/ABERDEEN-Drilling-Schools-Well-Control

http://www.offshore-mag.com/articles/print/volume-66/issue-1/drilling-completion/new-
drilling-process-increases-rate-of-penetration-footage-per-day.html

http://en.wikipedia.org/wiki/MAASP

Rotary Drilling Handbook, sixth edition ,J.E.Brantly (ed.) Palmer Pub ,New York City

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