CHAPTER 6

DRILLING

6.1.1

INTRODUCTION

Drilling engineering department is charged to ensure the operation can proceed without
or with minimum problems. An effort to plan the operation with current and latest
technologies is required to gain the best result and safely drilled. So, as drilling
operations, this department ready to face any future problems and try to overcome it as
good as possible. Drilling department involves in selection of rig, designing casing, drill
string and bit selection. At the same time, it also does planning for mud and cementing
program.

This chapter explains the well construction and drilling engineering at Ara Field. All data
were from the simulation output generated earlier in reservoir engineering and from log
interpretation from petrophysic department. Ara Field consists of 3 exploration well
which be used as the basis to find knowledge in order to develop the field development
plan. This field is located offshore east coast of Peninsular Malaysia with water depth of
approximately 75m.
The unconsolidated formation of the Ara Field defined in mud log and core analysis
indicates this formation have tendency to brittle. Therefore extra precaution needs to be
considered during making the selection for the drilling program.

The formation and fracture gradients are very important in determining the pore pressure
and fracture pressure in certain depth in order to achieve better result for the mud design,
cementing design, casing design and BOP selection. Accurate predictions of these
parameters are necessary to avoid drilling problems.

6.1.2 Objectives

The objectives of drilling department are as follows:

To select the suitable drilling rig

To come out with well trajectories from drainage plan

To determine the appropriate casing setting depth

To design casing with suitable grade

To select drill string configuration

To design drilling mud

To design cementing program

To select suitable blow out preventer (BOP)

6.2

RIG SELECTION

The rig selection for the field development drilling campaign is based on the following
criteria:

Water depth

Platform configuration

Economic factor

Technical capability

The selection of rig was done after comparing a few types of drilling rig. Table 2 shows
the evaluation made between three types of platform to be used. Ratings are given to this
possible platform between 1 to 4 stars as greater number of stars indicates the most
suitable platform to be used. From the rating, jack -up rig acquired most number of stars,
due to its compatibility to the field.
Most of the wells in Malaysia usually uses jack-up rig as it is the simplest form of drilling
rig an especially used for shallow water depth and unconsolidated sand. The selection is
made based on the sea water level of the Malay Basin/Penyu Basin which is at 75 m or

250 ft which are classified as shallow water. Furthermore jack-up rig is mobile and can
be easily towed.

Since Ara Field is located at the offshore east coast of Peninsular Malaysia, it more
exposed to the hurricane during monsoon season. As a result, drilling barge cannot be use
due the lack of ability to withstand the movement of water for open environment.
Table 1: Comparison between types of rig
TYPES
SPECIFICATION
Drilling Barge
Water depth up to 3700 m
Usually used for exploration or deep
water drilling
Independent
Jack - Up
Water depth up to 120 m
Mobile, anchored on sea bed via jacklike leg
Commonly used in Malay/Penyu Basin
reservoirs/ Shallow sea environment
Reasonable renting and constructing
Cost
Can
withstand
harsh
environment/Monsoon weather
Semi-submersible
Water depth in ranges 60 3000 m
Have columns and pontoons for
buoyancy
Mobile
Expensive to rent or build

RATINGS
***

****

**

Jack up rig that being used in South East Asia (Malaysia/Indonesia) region is GSF
Parameswara. Table 3 below explained the basic information about this rig. Drilling
Engineering Department proposed to use this rig in Ara Field.

Table 2: GSF Parameswara

GSF Parameswara

Figure 1: Parameswara Jack Up

Design

Baker Marine BMC 300 IC

Overall

212 by 210 by 26 ft.

dimensions
Legs (3)

423 ft. long triangular

Quarters

118 persons

capacity
Operating

300 ft.

water depth
Jacking system
Cantilever

BMC electrically driven rack and pinion system

45 ft. by 24 ft.

envelope
Maximum

4,837 kips *

variable load
(drilling)

* 300 ft. WD; 70 knot wind; 30 ft. wave; 1.5 knot current

Drilling Equipment
Derrick

170 ft. by 30 ft. MH-Pyramid Standard, with a static hook load

capacity of 1,300,000 lbs. with twelve lines (1-1/2 in. drilling line)

Drawworks

Ideco E-2100E, 2,000 hp, driven by two GE 752 DC motors,

complete with Baylor 7838 electric brake

Rotary table

Ideco LR-375-E with independent drive using a GE 752 DC motor

with 2-speed transmission
National PS2-650/750 Power Swivel with 750 ton casing/tripping

Top drive

load path and 650 ton drilling load path. Comes with open loop
cooling system 2-speed gear box with 49,000 ft. lbs. continuous
torque.
Three each National Oil well 12-P-160 Mud Pumps; 1600 input

Mud pumps

HP at 120 SPM, each driven by two GE 752 DC traction motors,

rated to 7,500 psi with plungers and high pressure liners. High
pressure mud piping rated to 7,500 psi.
Two Brandt single deck scalping shakers cascading onto four

Solids control

Derrick FLC 2000 linear motion separators with one configured to

take the underflow from the Desilter, allowing it to function as a
mud cleaner or fourth shaker as operations require.

Power Equipment
DC

AC

Four Ross Hill SCR units, each rated at 1,500 amps, powering
eight GE 752 DC motors
Four Cat 3516-A diesel engines, 1,615 hp, driving four Cat SR-4,
2,000 kva generators

Storage Capacities
Liquid mud

2,267 bbl., including processing tank

Brine

1,540 bbl.

Bulk material

9,150 cu. ft.

Other Equipment
Cranes

Three FMC Link belt ABS 218A cranes with 100 ft. booms, rated
for 42 tons at 24 ft. radius

Special Features
Tender mode

Drill floor/substructure can be skidded onto an adjacent platform

to position the rotary 106 ft. maximum from the rig transom with
10 ft. transverse movement either side of CL

CTU

240 kip conductor tensioning unit

Source: (Transocean, 2013)

6.3

DRAINAGE PLAN- WELLBORE TRAJECTORIES

Drainage plan has been proposed by the reservoir Engineer to help the driller by
provide a visual data the locations of each well. Drive mechanism will be able to push
the oil into the formations due to low resistance of fluid to flow (low viscosity).

6.3.1 Well Drainage

Reservoir Engineering department classify that there are 11 wells that have high
possibility on producing oil which proposed in Plan C. They were grouped with P1P11 as shown in figure below. Decision of rig location is based on the optimum total
along the well length or the center of the surrounded well. Besides, the distance
between wells is also need to be considered to avoid the collision occur between well.

Figure 6.2 Drainage plan for Ara's Field

From the coordinates of the productions well with reference on rig location, at, the Kick Of
Point (KOP ) is selected at 550 ft and True Vertical Depth (TVD) value at 6785 ft.

6.3.2 Wellbore Trajectories

Build and hold type of well will be used to design the trajectory of wells. This design
will be used due to the simple calculation is required compared to any other of
directional well. Kick off Point (KOP), Build up Rate (BUR) and tangent section is
required to determine the total horizontal displacement and inclination for each well.
Ls type is also be used to avoid any collision occur between the producing wells.

This well is drilled vertically till 550m as for kick off-point and build up section has
been made where the 30 for every 100 ft. This value are constant, thus form the arc of
a circle. This will gives a safe clearance from all existing wells, keeps the maximum
inclination within desired limits.
WELL 1
Kick Off Point: 550 ft

Length of Build Section:

Length of Hold Section:
Total Length:
Inclination Angle:

Figure 6.3 Wellbore trajectories for well

Table 3: Summary of well trajectories

Well

KOP
(ft)

Measured
Depth (ft)

1
2
3
4
5
6
7
8
9
10
11
12
13
14

550
550
550
550
550
550
550
550
550
550
550
550
550
550

6.4

Casing Design

Length of
Build
Section (ft)

Length of
Hold
Section
(ft)

Total Length
(ft)

Inclination
Angle (Degree)

6.4.1 Casing Setting Depth

The casing design that applied to Ara Field are based on well associated pressure, casing
effectiveness and well performance suitable to casing performance to the specification,
completion requirements and safety requirements. Selection of casing was made on reference
to the minimum performance properties which suit the API standards for drilling. Casing

setting depth was designed based on the formation pressure and the fracture pressure.

By applying Graphical Method (Figure 4), pore pressure and fracture gradient was
plot in defining the type of casing used at different depth. Fluid gradient by layer will
be uses to determine the pressure by multiple it with depth for that layer. Fracture
pressure be calculated by using Eatons and Mitchells equation, About 1.0 ppg was
added as the safety margin for the pressure so that the risk for casing to collapse or
burst due to the formation or fracture formation can be reduced.

The safety factors (SF) used in the casing design is as follows:

Burst

-1.1 of the casing burst resistance

Collapse

-1.0 of the casing collapse resistance

Tension

- 1.3 of the tension rating of the casing

Figure 6.5 Graphical Method to determine casing setting depth

Table 5: Casing setting depth (TVD) for each well

Well
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Conductor (ft)
500
500
500
500
500
500
500
500
500
500
500
500
500
500

Surface (ft)
2560
2560
2560
2560
2560
2560
2560
2560
2560
2560
2560
2560
2560
2560

Intermediate (ft)
4350
4350
4350
4350
4350
4350
4350
4350
4350
4350
4350
4350
4350
4350

Production (ft)
6785
6785
6785
6785
6785
6785
6785
6785
6785
6785
6785
6785
6785
6785

To determined grade that suitable for each casing, burst, collapse and tension of the
casing should be analysis with consideration of certain assumption so that it can be
used without any risks. The grades choose also considered cost and weight factor and
are selected based on Schlumberger i-Handbook.

Table 6: Casing program detail for Ara field.

Casing Program

Depth (ft)

Casing ID (in.)

Casing Grade

Nominal
Weight

Conductor
Casing
Surface casing
Intermediate
casing
Production
casing

0 - 500

20

J55

94

0 - 2560

16

J55

84

0 - 4350

10 3/4

J55

51

0 - 6785

7 5/8

C90

29

Conductor

Surface

Intermediate

Figure 6.5: Casing grade

Production

6.5

Drilling Fluid Design

By convert the formation and fracture pressure to the ppg, amount of mud weight can
be determine by setting the depth of the casing. Due to the regulations and
environmental issues regarding the usage of oil based mud, water based mud will be
used for the drilling program.
The main purpose of drilling mud can be summarized as below:

Act as cooling agent for the rotating bit

Transport cutting to surface

Maintaining overbalance pressure to commence well bore stability

Table 7 shows the mudweight been used according to depth.

Table 7: Drilling fluid system
Casing

Size (inch)

Drilling Fluid

Depth (ft)

System

Mudweight
(ppg)

Conductor

20

WBM

0 - 500

9.45

Surface

16

WBM

500 - 2560

9.45

Intermediate

10 3/4

WBM

2560 - 4350

12.78

Production

7 5/8

WBM

4350 - 6785

13.955

Standard WBM can cause shale instability as water can react with the shale.
WBM Polyol mud is the best option which is commonly used. Compared to other
WBM systems, this mud requires low volumes of additive, highly inhibitive and costeffective.

This material is non-toxic and passes the current environment protocol.

Table 7 indicates the increasing density of mud. This can be done by addition of
Barite. Solids from formation also can increase the mud density; therefore this solid
must be separated out using solid control method.

6.6

Bit and Drill String Selection

6.6.1 Drill Bit Selection

The drill bit selection is influenced by the casing program used. Basically, the bit
used is slightly larger than the casing size and the next bit used has to be smaller
than the next casing installed. For Ara field, the selection of drill bit is show below.

Table 8: Drill bit size for Ara field development

Casing

Casing Size

Drill Bit Size

Program

(in)

(in)

Conductor

20

26

Surface

16

20

Intermediate

10 3/4

14 3/4

Production

7 5/8

9 1/2

Drilling department proposed using roller cone drill bit because of the
economy consideration and this type of cone is widely used in this area.

this

formation contains lithology of soft to moderately hard formation. Therefore design of

the cutting structure of the bit is based on the hardness of the formation.

Table 9: Summary of bit design

Formation

Bit Type

Cutting Structure

Soft

1-1-1

Long teeth, widely spaced

Shorter teeth, spaced closer

Medium Hard

2-1-1

together to provide resistance to

breakage

Hard

3-1-1

Short stubby teeth, closely

packed for crushing action

6.6.2 Drill String Selection

Drill string is a very important component of the rig. The main functions are to
provide conduit for the circulating drilling fluid, transmits the rotary torque to the bit
to do the drilling and suspend the bit. The drill string consists of drill pipe, drill
collars, the kelly and various other pieces of equipment such as stabilisers and
reamers, which are included in the drill string just above the drill bit as shows in
figure below.

As there are well that drill directionally, drill string must be equipped with deflection
tools which used to change the direction of the bit. The formation is not defined as
hard formation with no blocking structure and to avoid time consuming operation,
drilling engineering department proposed to used Rotary Steering Drilling Systems. It
consist of stabilized positive displacement steerable mud motor, a stabilizer and a
directional surveying system which monitor the hole azimuth, inclination and toolface
on real time basis. In this system, it is possible to rotate the drillstring even when
drilling directionally. This is more desirable as can easier transport cuttings from
wellbore when drillstring is rotating.
Table 9: Components of drill string

Figure 6.7 Drill string configurations

Table 10: Functions of drillstring component

No

Components

Functions

Travelling

Hanging the swivel and drill tools when drilling

block

Hanging the elevator bail and elevator to trip the drill

tools on the round trip

Swivel

Finishing the other drilling and auxiliary job

Supports the weight of the drill stem during drilling

Permit the drill stem to rotate (more than 200 rpm)

Provides a passageway for the drilling mud to get into

the drill stem

Kelly

Transmits the rotation of the rotary table to the drill

string

Conducts drilling fluid from the swivel to the drill

stem

Drill Pipe

To transmits rotary motion and drilling mud under

high pressure to the drill bit

Drill collar

It provides weight on bit during drilling

It maintains weight to keep the drill string from being

subjected to buckling forces (keep the drill pipe in
tension)

It helps provide the pendulum effect which causes the

drill bit to drill more nearly vertical hole

Helps to support and stabilize the bit so that it will

drill new hole that is aligned with the hole already
drilled

Mud motor

To provide additional power to the bit while drilling

To create eccentric motion in the power section of the

motor which is transferred as the concentric power to
the drill bit

Drill bit

Used to create cylindrical holes, almost always of

circular cross-section

Stabilizer

To improve the straight drilling capability of the drill

string especially in formation that tends to deflect the
bit.

Tool joint

Connect two individual drill pipe with threaded rotary

shouldered.

6.7

Cementing Design

Cementing is performed by circulating cement slurry through the inside of the casing
and out into the annulus through the casing shoe at the bottom of the casing string.
Cementing is very important in the drilling because:

Prevent contamination of fresh water well zones.

Prevent unstable upper formations from caving-in and sticking the drill string
or forming large caverns.

Provides a strong upper foundation to use high-density drilling fluid to

continue drilling deeper.

Isolates different zones that may have different pressures or fluids - known as
zonal isolation, in the drilled formations from one another.

Seals off high pressure zones from the surface, avoiding potential for a
blowout

Prevents fluid loss into or contamination of production zones.

Provides a smooth internal bore for installing production equipment.

Primary cementing is the first cementing operation performed after the casing
has been run in the hole. This is accomplished by pumping cement slurry down
inside casing and displaced it out into the annular space between the casing and the
borehole. The cement is then allowed to set before drilling is resumed or the well is
completed. The single stage primary cementing will be accomplished by pumping
one batch of cement slurry down the casing between two wiper plugs. The bottom
plug which is has a hollow core sealed by a rupture disk will be run in the string first
and set on top of the float collar to displace the remaining drilling fluid inside the
casing to minimize the contamination cement slurry by the fluid. Cement slurry will be
injected in between the bottom plug and the top plug and displaced by displacing

fluid. Increasing pressure due to compression of the cement slurry will break the
rupture disk, allowing the cement to pass through and fill up the annular space.

Figure 5.6: Single stage cementing

The proposed cementing program is the 16 surface casing will be cemented

up to the seabed which is about more than 75 m below the derrick floor which means
cemented along the surface casing. The 10 3/4 casing will be cemented up to 100
feet above the 16 surface casing shoe setting depth. The conductor pipe will not be
cemented since it is driven into the formation.

Based on the well trajectories, the required amount of cement for the
development of Ara field is 93015.12 sacks of cement. The detailed calculations in
determining the amount of cement required is shown in Appendix X.

Table 10: Summary of cement used

Parameters
Cement Used

Value
Class G

Slurry density (ppg)

15.8 (Standard)

Yield value (ft3/sk)

1.05

Mix water volume (gal/sk)

4.3

Number sack needed

7795.09

Volume water needed (gal)

33518.89

Volume water needed (ft3)

4480.82

Advantages of G-cement:

Cement powders which are compatible with most additives

Can be used over a wide range of temperature and pressure

Most common type of cement and is used in most areas

The water which is used to make up the cement slurry is known as the mix-water.
These amounts of water are based on:

The need to have a slurry that is easily pumped

The need to hydrate all of the cement powder so that a high quality hardened
cement is produced

The need to ensure that all of the free water is used to hydrate the cement
powder and that no free water is present in the hardened cement.

Table 6.7.1 Volume of Cement (ft3)

Figure 6.7. 1 Volume of cement per casing

6.8

Well Control-BLOW OUT PREVENTER (BOP)

The main function of a blowout preventer is to furnish a means of closing off the
annular space between the drill pipe and casing. It is not always possible to predict the
exact magnitude of pressures which will be encountered in the drilling of a well.
Consequently it is not uncommon to encounter pressure greater than those imposed by
the drilling fluid, with the result that formation fluids flow into the bore hole and
eventually to the surface. This effect is called a blowout, and is one of the most feared
and expensive accidents which can occur in well drilling.

The Bottom Hole Pressure (BHP) with safety factor 2, is calculated for BOP rating
determination.

Surface Casing Shoe

BHP = 2560 ft x 9.45 ppg x 0.052 = 1257.984 psi
BHP@safety factor = 1257.984 psi x 2
= 2515.968 psi
Intermediate Casing shoe
BHP = 4350 ft x 12.78 ppg x 0.052 = 2890.83 psi
BHP@safety factor = 4923.603 psi x 2
= 5781.16 psi
Production Casing shoe
BHP = 6785 ft x 13.955 ppg x 0.052 = 4923.603 psi
BHP@safety factor = 4923.603 psi x 2
= 9847.20 psi
Table 6.8.1 BOP selection
Casing Size

BOP Riser Size

BOP Pressure Rating

16

18-3/4

50000 psi

13 3/8

18-3/4

10000 psi

7 5/8

18-3/4

10000 psi

6.9

Potential Hazard and Problem

5.5.1

Shallow Gas

From log, there was shallow gas within the reservoir. The presence of shallow is due
to the basis that shallow gas can occur at any depth and might be produced during
production.
5.5.2

Lost Circulation

The tendency of lost circulation occurs based on the type of formation is

unconsolidated formation/ soft formation which is having a lot high permeability zone.
The circulation fluid will lost through the high permeability zone.
5.5.3

Stuck Pipe

The drill string will stuck if the total amount background friction and force bottom hole
assembly is more than the maximum over pull or hoisting system stuck cause
overload.

5.5.4

Presence of CO2 and H2S Gases

From the production test the concentration of H2S is less the 1ppm for first and
second production test, while the percentage of CO2 is 1.2% for first production test
and 0.8 % for second production test.
5.5.5

Kick Capacity

A kick may be defined as an unscheduled influx of formation fluids. For a kick to

occur:

Wellbore pressure is less than pore pressure

A reasonable level of permeability

A fluid that can flow

5.5.6

Well Control

Improved well control by reduced the risk of stuck pipe, tool or pump failures. Also
easier kick detection and well kill, excellent in avoid hydration with install the hydrate
inhibition. Every completion activities must clean to avoid any accident occur. The rig
spread costs also must try to be reduced as much as possible.

5.5.7

Abnormal Pressure

The well pressures are expected to have abnormal pressure that occur from the
formation normal faults and thrust faults are the result of various stress imbalances in
the crust and superficial sediments that observed from seismic data. They are often
caused by, helped by, or linked to overpressure.

REFERENCES

http://www.scribd.com/doc/29792554/57/TRAVELLING-BLOCK
Hussain Rabia, Well Engineering and Construction
Petronas Procedures and Guidelines for Upstream Activities (PPGUA)
Drilling Engineering, Heriot Watt Institute of Petroleum Engineering, Heroit Watt
University
Steve Devereux, Practical Well Planning and Drilling Manual, Penwell.

Transocean. (2013). Fleet Specifications Of GSF Parameswara Retrieved 5 July

2013, from http://www.deepwater.com/fw/main/Parameswara191C16.html?LayoutID=17