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Well Planning, Engineering &

Construction
11th 13th Jan 2012
Mike Dyson, GM Well Engineering BG Group

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MSc Petroleum Engineering Well Engineering

Objectives
1. Be able to articulate the basic principles of well planning,
design and construction.
2. Understand how well design and construction contributes
to optimal field development
3. Recognise the basic drilling and completion stages and
equipment used
4. Possess a basic understanding of alternative completion
designs
5. Appreciate well operations safety, costs and operations
management

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MSc Petroleum Engineering Well Engineering

Prerequisites
No prior knowledge of well engineering or drilling is required or assumed

Timing
18 hours of lectures during Spring term

Assessment
This material will be assessed as part of Phase 2 of the Group Field Project

Texts
1. A Primer of Oilwell Drilling, 6th edition, Ron Baker, Published by The
University of Texas at Austin
2. Applied Drilling Engineering, Bourgoyne, Chenevert, Millheim and
Young, Published by SPE
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MSc Petroleum Engineering Well Engineering

Housekeeping

Fire Exits
Alarms
Restrooms
Time schedule
Breaks / Lunches

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MSc Petroleum Engineering Well Engineering

Your Lecturer

Mike Dyson
MA Eng, MBA, Chartered Engineer, FIMechE
30 years experience in Oil & Gas Industry
Well Engineer, onshore and offshore, costs and
planning, remote operations, contracting and
procurement, drilling management, technology
management
Shell and BG Group
Lived and worked in UK, Netherlands, Brunei, Oman
and USA
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MSc Petroleum Engineering Well Engineering

Ways of working
Ask questions!
Ask more questions!
There are no dumb questions!
Timing?
Regular breaks

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MSc Petroleum Engineering Well Engineering

Syllabus
1. Purpose of wells. Well planning.
2. Onshore and offshore drilling and well engineering
3. Rigs and equipment. Drill strings and BHAs. Drill bits and hole-opening. Coring
systems. Hydraulics and hole-cleaning. Drilling practice.
4. Casing and cementing.
5. Special drilling operations. Directional drilling and down-hole motors. Logging
while drilling. High inclination, extended reach and horizontal wells. Slim-hole
operations. Coiled tubing drilling. Fishing.
6. Drilling fluids and fluid systems. Mud system. Mud chemistry. Cuttings cleaning
& discharges. Completion fluids. Environmental concerns & compliance
7. Well control. Well control using mud; Casing selection & design. Primary
cementing. BOPs. Drilling problems & control
8. Completion designs, well testing, sand control, selectivity, smart wells
9. Stimulation operations
10. Well maintenance
11. Drilling and completion costs. Contracts. Learning curves.
12. Safety

MSc Petroleum Engineering Well Engineering

Schedule day one

Purpose of wells
Subsurface recap
Health, Security, Safety & Environment
Well Construction The Well Delivery Process
Drilling Rigs
4 Functions of the Drilling Rig
Rig Floor Equipment
The Drillstring
Pipe Handling Equipment
Bits
Drilling Fluid, SRE & Waste
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MSc Petroleum Engineering Well Engineering

Schedule day two

Well Construction
Casing & Cementation
Directional Drilling
Stuck Pipe
Fishing Operations
Formation Evaluation
Blowouts and Their Causes
Well Control

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MSc Petroleum Engineering Well Engineering

Schedule day three

Drilling a Well (Step by Step)


Casing Design
Deepwater
New Technologies
Completions
Artificial Lift
Stimulation
Workovers and well maintenance
Costs and contracts
Performance and learning curves
Closeout
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MSc Petroleum Engineering Well Engineering

Well Engineering basics


Why a well?
Oil and/or gas production
Water or gas injection
Stopping a blow-out
Obtaining subsurface information

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MSc Petroleum Engineering Well Engineering

Well Engineering basics


Where?
How to get to here?

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MSc Petroleum Engineering Well Engineering

Course Structure
A 360 Degree (slide show) look at Drilling
Operations
Discussions Q&A (things that are obvious to me
after 37 years in the business may not seem
obvious to you therefore ASK
Work simple examples
Drill a simple well on the white board

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MSc Petroleum Engineering Well Engineering

The Origins of Hydrocarbons

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MSc Petroleum Engineering Well Engineering

Looking for Oil

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MSc Petroleum Engineering Well Engineering

Wheres the Oil and


Gas?
How did it get there?
How do we find it?

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MSc Petroleum Engineering Well Engineering

Wheres the Oil?

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MSc Petroleum Engineering Well Engineering

Wheres the Gas?


Rank

Country

Natural gas - proved


reserves (billion cu m)

Russia

47,570

Iran

26,370

Qatar

25,790

Saudi Arabia

6,568

United Arab Emirates

5,823

United States

5,551

Nigeria

5,015

Algeria

4,359

Venezuela

4,112

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Iraq

3,170

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Turkmenistan

2,860

12

Indonesia

2,630

13

China

2,450

14

Norway

2,288

15

Malaysia

2,037

16

Uzbekistan

1,798

17

Kazakhstan

1,765

18

Netherlands

1,684

19

Egypt

1,589

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Canada

1,537

Because of Shale Gas, its a complex picture these days18


MSc Petroleum Engineering Well Engineering

Wheres the Shale Gas?

US energy self sufficient for 40 years


with shale gas reserves ????
http://geology.com/energy/world-shale-gas
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MSc Petroleum Engineering Well Engineering

Wheres the Oil and


Gas?
How did it get there?
How do we find it?

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MSc Petroleum Engineering Well Engineering

Decaying organic material


settles in a water environment.
Organic matter is
covered with silt and
mud.
Under influence of heat
and pressure organic
material and mud turns to
rock. Time, heat & pressure
turns the organic material
into gas and oil

Tectonics move the layers.


Further deposition and
erosion takes place.
Oil & gas seeps into porous
rock.
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MSc Petroleum Engineering Well Engineering

Essential Reservoir Characteristics:


Permeability (natural or created)
Porosity

Photomicrographs of quartzcemented sandstone

Porosity:
Ability to contain
Permeability:
Ability to flow through
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MSc Petroleum Engineering Well Engineering

Wheres the Oil and


Gas?
How did it get there?
How do we find it?

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MSc Petroleum Engineering Well Engineering

Exploration Methods (1)


Gravimetric Survey
relatively cheap
indicates sub-surface
anomalies
provides data for further
more detailed surveys

More dense
(compacted by pressure)

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MSc Petroleum Engineering Well Engineering

Exploration Methods (2) Seismic

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MSc Petroleum Engineering Well Engineering

Exploration Methods (2) Seismic


3D maps constructed from surveys

Survey data converted into computer generated images for


interpretation:
Formation tops
Formation fluids
Surface anomalies
o shallow gas
o abnormal pressures
Prognoses of stratigraphic column
Develop surface maps
Data for planning drilling operations
Uncertainty depends on wells in area or rank wild cat

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MSc Petroleum Engineering Well Engineering

Exploration Methods (2) Seismic


3D maps constructed from surveys

Where would you drill?


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MSc Petroleum Engineering Well Engineering

Surface Map provides areal


position of well (s)..

..Stratigraphic Section
depths of points of interest

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MSc Petroleum Engineering Well Engineering

Only one method to prove economic existence of


hydrocarbons:

DRILL

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MSc Petroleum Engineering Well Engineering

Exploration Well

Discovery Well

Sometimes we miss

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MSc Petroleum Engineering Well Engineering

Important Data Recovered During


Drilling Operations
Cuttings (at the shale shaker)
Analysis for lithology
Hydrocarbon traces
Petrophysical data (logging (LWD or wireline))
Cores
Porosity / Permeability
Samples for testing possible sources of impairment /
need for sand control
Fluid samples and reservoir pressure measurements
Fluids and volumes/rates
Production test reservoir volume & productivity
.All discussed later
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MSc Petroleum Engineering Well Engineering

Exploration Methods (2) Seismic


3D maps constructed from surveys

Shallow Gas Blowout more later


Where would you drill?
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MSc Petroleum Engineering Well Engineering

Health, Safety, Security &


Environment

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MSc Petroleum Engineering Well Engineering

HSSE Goals for BG Wells Team


......................and for you

Zero recordable injuries


Zero High Potential Incidents (HPI)
Zero repeat incidents
Zero discharge to the environment

.........Dont hurt anyone and dont get hurt


...................................Macondo has changed the game

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MSc Petroleum Engineering Well Engineering

My catalogue of near misses


There was little regard for safety in the 70s

Requested to fix derrick light


Elevator lowered on finger
Head caught between DCs
Cathead rope snapped
Lost control of Drawworks
Rig fell over
etc
Bottom Line:

You are responsible for your own and others safety


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MSc Petroleum Engineering Well Engineering

Rules of the Game


If in doubt STOP
Ask questions. Well
construction is a
collaborative business
Share information and
knowledge
Never assume the other
person(s) know(s)
Always ask yourself What
if?
Continuously check and
re-check
Know your barriers

Barriers are Important


.more discussion later

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MSc Petroleum Engineering Well Engineering

Well Construction
The Well Delivery Process

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MSc Petroleum Engineering Well Engineering

Purpose of the Well Delivery Process


Improve quality of wells
Improve companys business performance
How?
Identifies responsible parties for key decisions
Promotes multidisciplinary teamwork
Drives appropriate risk management
Facilitates introduction of new
ideas/approaches
Work to a technical limit
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MSc Petroleum Engineering Well Engineering

The 5 Phases of (Generic) Well


Delivery Process
IDENTIFY
&
ASSESS

OPERATE

EXECUTE

SELECT

DEFINE

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MSc Petroleum Engineering Well Engineering

Step 1
Identify & Assess
Initiate project (an opportunity)
Prepare design concepts
Review field (or well) concept options
Identify field (or well) concept options
Identify long lead items, e.g., special rigs,
special equipment, CRA materials,
Provisional economics

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MSc Petroleum Engineering Well Engineering

Step 2
Select
Feasibility evaluation
Select best option
Confirm the well design meets objectives
information
production rate
life cycle
Economic justification
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MSc Petroleum Engineering Well Engineering

Step 3
Define

Complete detailed well design


Peer review
Develop, optimise and finalise well programme
Complete execution plan

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MSc Petroleum Engineering Well Engineering

Step 4
Execute

Obtain approval for detailed well design


Obtain approval for expenditure
Conduct drill well on paper exercise
Drill the well
Review performance

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MSc Petroleum Engineering Well Engineering

Step 5
Operate
Evaluate operational performance
Complete end of well report
Catalogue learnings; transfer to next well in
sequence
Share learnings

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MSc Petroleum Engineering Well Engineering

Example Drilling Programme


BG Land Well

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MSc Petroleum Engineering Well Engineering

Well Construction
Drilling Rigs

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MSc Petroleum Engineering Well Engineering

Been Around for a Long Time

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MSc Petroleum Engineering Well Engineering

Drilling Rig

Many types
Selection Determined by:
Geographical location
Environment
Depth of well
Type of well
Mobility requirements
Operating cost
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MSc Petroleum Engineering Well Engineering

Drilling Structures Mast & Derrick


Derrick

Mast

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Mast & Derrick

Shallow to
40,000 ft
rating &
more

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Desert Rig Oman

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Desert rig on the Move

Here rig selection driven by:


Infrastructure
Depth rating - shallow
Mobility number of loads
Operating cost

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Here rig selection driven by:


Depth rating - deep
Pressure high => BOPs
Pad drilling (note wheels for
move over wells)
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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Heli-Rig
-

Remote locations no
infrastructure
Saves cost of road
construction
All components, rig
and drilling equipment
flown in
- 3 ton loads

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Arctic Rig Pad Drilling for Extended Reach Wells (ERD)

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Swamp Barge
-

Used in coastal / swanp


locations
Dredging canals
cheaper than cost of
road construction
Components, rig,
drilling equipment and
personnel delivered by
water or helicopter

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Drilling Rig

Flare

Accommodations

Process
Equipment

Jacket

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Draugen : North Sea 250 m water depth

Hibernia: North West Atlantic 150 m water depth

Harsh Environment
- 30 m waves
- 100 knot winds

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Tender
Tender serves
(small) platform
Tender is anchored
Drilling services
provided from
tender

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Critical Issues for Jack-Ups


Water depth (max approx
450 ft)
Air gap
Sea bed
Sub soil (punch through)
Shallow gas

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Jack-Up on Platform
Cantilever over platform
Skid rig X Y to well centres
Well centres as tight as 1.5 m

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

4 legs

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

3 legs
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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Round legs

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Generation

Approx
Water Depth
(ft)

Approx
Water Depth
(m)

Dates

First

600

200

Early 1960s

Second

1000

300

1969-1974

Third

1500

500

Early 1980s

Fourth

3000

1000

1990s

Fifth

7500

2500

1998-2004

Sixth

10000

3000

2005-2011

Tension
Leg

Spar

Deepwater
Drillship

Semis denoted by generation

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Critical Issues for


Semi Sub Drilling Units:
Water depth
Moored to approx 1000 ft
Dynamic positioned beyond
Maximum water depth >10000 ft
Deck loading
Top side equipment package

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Dynamic Positioning

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Ocean Bounty

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Tension leg platform


(Production Facility)
Water depth
910m / 2,985ft

Production capacity
130,000 barrels of oil
and 150mcf gas per day
Total project cost
$900m (including
pipelines)
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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Floating Production, Storage


and Offloading (FPSO) vessels
Remote or deepwater
locations
Seabed pipelines not cost
effective.
Deepest water Espirito
Santo depth of 1,800 m in
the Campos Basin, rated
for 100,000 bpd
Largest Kizomba A
storage capacity of 2.2
million barrels

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

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MSc Petroleum Engineering Well Engineering

Land

Barge

Platform

Gravity
Base

Tender
Assisted

Jackup

Semisubmersible

Tension
Leg

Spar

Deepwater
Drillship

Critical Issues for Drillship

Stability

Deck loading / storage capacity

Remote operations capability

Water depth

> 10000 ft

Dynamic positioned

Top side equipment package

Dual derrick

Riser handling

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MSc Petroleum Engineering Well Engineering

Other Drilling Unit Types - Coiled Tubing


Drilling & Workover Unit
Trailer
mounted

Injector

Coiled Tubing
Crane

Tubing Reel

Stripper
Control Cabin
BOP

Power
Unit

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MSc Petroleum Engineering Well Engineering

Other Drilling Unit Types


Coil over Top Drive

Continuous coiled tubing with


zero connections.
No human contact with the
pipe
Fully automated
Drill with conventional jointed
drill pipe convert in 2
minutes.
Depth rating to 3000 meters
with 3.5 or 4 inch tubing.
Low number of loads fast
move in, rig-up and rig-out.

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MSc Petroleum Engineering Well Engineering

New Technology Drilling Units


Drillmec HH

Hydraulic powered rig


Hydraulic cylinder for hoisting
Vertical pipe racking system
Fast rig up / down
45 ft joints of range 3 drillpipe
Pipe transported in bins (no
hands on pipe)
High automation /
mechanisation on rig floor

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MSc Petroleum Engineering Well Engineering

New Technology Drilling Units


Rack & Pinion
Few loads / small footprint
Can apply WOB by force
Good for shallow wells
Slant wells
Hydraulic or electro motors
High degree of control through PLC
controls
No travelling block
No rig tongs
Small crew

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MSc Petroleum Engineering Well Engineering

Quiz: Rig Costs


Typical Rig Contract & Spread Rates
Operator views rig costs in two ways:
Rate to contractor
Spread rate (includes total operating costs to operator)

Deepwater Drilling Contractor rig rate: 4th-6th


generation semi down to 10000 ft
Shallower water semi rigs for 350 - 2500ft water depth
Jackup Drilling Contractor rig rates: for Gorilla & harsh
environment rated & 350' leg jack-ups,
Independent leg cantilevered jack-ups for up to 350'
water depth
Offshore Platform Drilling Contractor rig rates:
Onshore Rig rates: High Spec Flex-Rig type: Medium
Spec:
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MSc Petroleum Engineering Well Engineering

Quiz: Typical Rig Contract & Spread Rates


Deepwater Floater Drilling Contractor rig rate: US$500k./day (4th-6th
generation) / spread costs incl. rig: US$1,000,000./day. same rate applies if the
rig is drilling, completing, testing, setting templates, and regardless of water
depths deeper than ~2500ft.
Shallow water floater rigs for `350 - 2500ft water depth will have day rates
~$250K/day, and spread rates ~$500K/day, subject to whether moored or
dynamically positioned and distance from shore base.
Jackup Drilling Contractor rig rates: Up to $350K/day for Gorilla & harsh
environment rated & 350' leg jack-ups, with spread rates of up to $500K/day,
depending upon distance from shore base and whether additional support
vessels required.
Independent leg cantilevered jack-ups for up to 350' water depth have rates in
the $50-150K/day range and spread rates of $75-250K/day.
Offshore Platform Drilling Contractor rig rates: Around $25K/day, with spread
rates of $40K/day.
Onshore Rig rates: Depends on location; US High Spec Flex-Rig type: Around
$23K/day, with spread rates of $35K/day. Medium Spec: Around $17K/day, with
spread rates of $25K/day. In Iraq spread rates land rig as high as $70k/day
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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Well Construction
4 Functions of a Drilling Rig

81
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

1.

Hoist & Lower

2.

Rotate

3.

Circulate

4.

Control Pressure

1
4

3
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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Hoist & Lower

84
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Crown Block
Travelling Block & Hook

Drillers Position Brake


MSc Petroleum Engineering Well Engineering

Control

Drawworks

Dead Line
Anchor

85

Hoist & Lower

Rotate

Circulate

Control

Drilling Line

Traveling
Assembly
& Kelly System

Traveling Block
Shock Absorber

Hook
Swivel Bail
Swivel

Kelly Spinner

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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Top Drive
Dolly

Control

Traveling
Block

Motor

Traveling Assembly
Top Drive System Gear Case
- Hydraulic
Drive Shaft
- Electric
(replaces kelly)
IBOP Valves
Pipehandler

Elevator
Links

87
MSc Petroleum Engineering Well Engineering

Derrick & Mast Loads


Ability to withstand two types of loading:
1. Compressive loads
2. Wind loads
Derrick load capacities range from 86,000 to
1,400,000 lb, i.e., shallow workover to ultra
deep drilling

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MSc Petroleum Engineering Well Engineering

Drawworks Horsepower &


Depth Rating
Drawworks HP = hook load x hoisting velocity / 33,000 x e

Hook load, lb
Hoisting velocity of travelling block, ft/min
33,000 = conversion factor ft.lb/min per horsepower
Hook to drawworks efficiency (e) between 80 to 90%,
depending on the number of lines in use).

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MSc Petroleum Engineering Well Engineering

Hypothetical Example
Heaviest load for a given well is 13 3/8 casing run to 10,000ft
Weight casing string in mud = 10,000 x 68 lb/ft = 680000 lbs
x BF (0.9) = 612,000 lbs
If casing needs to be pulled out of hole we have additional
drag (assume 75000 lbs)
Drawworks HP = hook load x hoisting velocity / 33,000 x e
Weight traveling block = 60,000 lbs
Total load = 612,000+75,000+25,000 = 712,000 lbs
Hoisting velocity of travelling block = 45 ft/min
HP = (712,000 x 45 x ).9 / 33000 = 930 horsepower
Repeat for all critical loadings, e.g., POOH @ 15000 ft HP
requires~ 1400 HP
Typical Drawworks range 750 1500 HP (rig capacity)
90
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Kelly Drilling
Rotary Engagement

91
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Kelly Drilling
Rotary Engagement

92
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Traveling Assembly
Top Drive System
(replaces kelly)

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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Rig Rotary Power


Rotary HP = (2 P N T/ 33000) x Tf
N = RPM
T = Torque in ft lbs
Tf = Torque factor depending on drilling
conditions (e.g., deviated well = 2.25
Example:
Rig uses 5 grade E pipe (max torque =
23,180 ft lbs (max run at ~ 50%)
Required rotary speed 150 RPM
Rotary Power = 2xPx(150x12000)/33000
Rotary Power Required = ~ 770 HP
Typical Rotary HP 750 1000 for deep
wells (some top drives >2000 HP )
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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Kelly Drilling Add A Single

95
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Not all Rigs Rotate

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MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Coiled Tubing Drilling Unit


Trailer
mounted

Injector

Coiled Tubing
Crane

Tubing Reel

Stripper
Control Cabin
BOP

Power
Unit

97
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Circulate

98
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Circulate
Pump fluid
around the
system
Remove Drilled
Cuttings
Add drilling
power at the bit
Clean the bottom
of the hole
Cool the Bit

99
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Pumps in Rig Circulating System


High Pressure Reciprocating
Rig Pump (Duplex and
Triplex)
Centrifugal Pumps
Feed pumps for HP Rig
Pump
Feed pumps for Solids
Removal Equipment

100
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Piston Pump Features:


Can handle fluids containing
high percentages of (abrasive)
solids
Valve clearance allows passage
of large solid particles (typically
lost circulation materials)
Ease and simplicity of operation
and maintenance. Liners,
pistons and valves replaced in
the field by the rig crew
Wide range of volume and
pressure using different liner
and piston sizes.
101
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Triplex Pump
Pulsation
Dampers
INLET
OUTLET

102
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How Much Pumping Power?


Power measured as HHP (hydraulic horsepower ,
consumed at bit (useful) and consumed in system
(wasted)
HHP = D P x volume / 1714
Example of hydraulics calculation
Total pressure needed = 4500 psi
Total volume needed = 750 gpm
Pump efficiency 90% (triplex)
Then HHP required = 0.9*(4500 * 750)/1714 = 2190 HHP
Rig will select 2 x 1300 HP pumps

103
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

4 Functions of the Drilling Rig

Control

104
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

BLOWOUTS HAPPEN

But they shouldnt, Barriers


& ..Blowout

Preventers
105
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Well Control
The cased well is a pressure containment system
When pressure gets too high pressure vents
To surface
Down hole

Well is designed to contain maximum expected pressures +


a safety factor
Barriers are put in place to safeguard the well
During operations two barriers must be in place at all times

Barriers include:
Primary ; Drilling fluid, inside a properly cemented casing
Secondary; Blowout Preventers (BOPs) and Valves & Chokes
106
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Well Control Methods


Covered in Detail Later

107
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Control
Equipment

108
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System
(not a barrier / not a
preventer)

109
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System
Diverter

Accumulator

Diverter Lines

Diverter
110
MSc Petroleum Engineering Well Engineering

111
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System

112
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter System
Top hole drilling carries its own
unique risks:

Diverter

Shallow gas
Weak formations
No protective casing

Well CANNOT be completely


closed in.
Diverter System is used for top
hole to divert shallow gas flow.

Diverter system
on driven
conductor pipe
113

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Hydril MSP Series


Top hole drilling carries its own
unique risks:

Shallow gas
Weak formations
No protective casing

Well CANNOT be completely


closed in.

Diverter System is used for top


hole to divert shallow gas
flow.

114
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Diverter Line & Valves

Large bore

Full Opening valves

Ball Valves Best

Gate Valves acceptable

Fast , synchronised
hydraulic actuation

Operates using
regulated pressure at
1500 psi
115

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Preventer System


(Secondary Barrier)

116
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

After setting and


cementing surface casing

Control

Accumulator

Blowout Preventers are


nippled up and pressure
tested
Their purpose is to
contain pressure

Choke
Manifold
BOP Stack
117

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Preventer System


In the event of loss of primary
well control
Accumulator
..(hydrostatic pressure
provided by drilling fluid is less
than formation
pressure).
Blowout Preventer (BOP) is
activated
Flow from well stopped
Primary control re-established
by circulating higher density
fluid into well.

Choke
Manifold

BOP Stack
118
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Blowout Preventer System


Combination of large and small,
high pressure valves placed on
the wellhead at the top of the Accumulator
well.
Controlled from 2 to 3 remote
stations
Operate under hydraulic
pressure supplied from an
accumulator unit.
Different sizes and types of
BOP are used during the phases
of drilling the well.

Choke
Manifold

BOP Stack
119
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

BOP Stack
Annular

Drilling
Spool

Manual
Gate
Valve

Pipe

Blind

Pipe

HCV

Configurations Vary
According to Well Conditions
Size 20 to 7
Pressure 2000 psi to
20000 psi

Choke
line
side

120
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Annular Preventers

121
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Annular

Rotate

Pipe

Control

Manual
Gate
Valve

Pipe

Blind

Circulate

HCV

Choke
line
side
Several Manufacturers

122
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Annular Preventer

Large, bowl-shaped valve


designed to seal the annulus

Donut shaped rubber sealing


element

Seals around any drill string


component, including open
hole

Hydraulically actuated

Hydril GK

13 5/8 bore

5000 psi working pressure


123

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Wear Plate
Packing Unit
Head
Opening Chamber

Piston
Closing Chamber

124
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Commonly used Annular BOP

Element can be split

Choice of materials

Excessive closing pressure


causes extrusion and rubber
loss

Wellbore clearance reduced


with time and wear

Control

Natural rubber Black color


Water base muds
Nitrile rubber Red color NAF muds
Neoprene
Green color NAF muds at very
low temps
125
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Spherical Sealing Element

Shaffer Annular
126
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Cameron D Type

Cameron D Sealing Element

127
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Ram Preventers

128
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Cameron U Preventer
Annular

Pipe

Single
Ram

Ram Type BOP

Blind

Pipe

Double
Ram

129
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Cameron U Preventer

130
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

131
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Variable Bore Rams (Common in Sub-sea BOPs)

132
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Shear Rams

Casing Shear Rams

Circulate

Control

133
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Valve & Chokes

134
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Valves Rated to same pressure as Ram


Preventers

Annular

Manual
Gate
Valve

Pipe Ram

Blind

HCV

Choke
line side

Pipe Ram

Same Valve with


Hydraulic Operator

Cameron FL Gate
Valve
135

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Valves connected to Choke Manifold


with high pressure coflex hose
Annular

Manual
Gate
Valve

Pipe Ram

Blind

HCV

Choke
line side

Pipe Ram

136
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Choke Manifold Rated to same pressure as ram preventer

Main Function
Accumulator

Provide means of
applying controlled
back pressure to the
well whilst circulating
Choke
Manifold
a kick
BOP Stack
137

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Throttle valve at end of the


choke line

Typically 3 ID end connections

Hydraulically powered

Swaco has two circular plates


one rotates

Control

Power Choke
Swaco Super Choke

Also Hand Chokes

Hand Chokes
138
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Choke Control Panel

Air / hydraulic
Remote sensor for
P Standpipe
P choke

Circulate

Control

139
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Hydraulic Accumulator
Koomey Unit
Stores and provides hydraulic
power to operate the BOP
components

Circulate

Control

Accumulator

Choke
Manifold
BOP Stack
140
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Hydraulic Control System


141
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

142
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Gas Outlet
Siphon Break

Mud-Gas Separator (Gas Buster)

Separates gas from mud

Capacity limited by:

Inlet

diameter and height


diameter & length of gas outlet line
diameter & vertical height of mud
leg Mud legs
should be external

Baffles
Access
Cover

1/3
Height

to
Shaker
Mud Leg

Various types in use


Flush

4 Clean Out
143

MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Mud-Gas Separator (Gas Buster)

Vacuum De-gasser

144
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Derrick Vacuum Degasser

145
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Kicks through
the drillstring are
very dangerous
Control Pressure in
the drillstring too
Upper and lower
kelly cocks
Drill string Float
Valve
146
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Drill Pipe Safety Valves

AKA RHKC Kelly cock

Full opening ball valve

Must have lift clamp for stabbing

API Spec 7, Class 2 valves preferred


seals externally applied pressure (2000 psi)
seals pressure from above and below

Consider one piece body for 10K and greater

147
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Drill String Float Valves

Installed in drill string

just above the bit


only OEM valves

Solid flapper prior to


setting surface casing

Fill drill string from top

On live wells (UBD)...

use 2 tandem dart type


valves

Solid Flapper

Ported Flapper

148
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Prevention is better than cure!

Flow Meter
Pit Level
Indicator
Trip Tank

Well Control
Monitoring
System

149
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

For UBD & MPD


RBOP / RH considered as a
barrier
Maximum Operating
Pressures
Rotating Heads - 250 psi
Rotating BOPs - 1000 psi

Capability to bleed/pump
mud to/from trip tank with
well under pressure

Control

To
Transducer

RBOP

Bleed
Valve
From
Trip
Tank

Check
Valve

Closed
Flow Line

Annular

Drill Pipe
Blind

Drill Pipe

Circulate
Through
Choke

150
MSc Petroleum Engineering Well Engineering

Well Construction
Rig Floor Equipment (Old and New)

151
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Rig Floor = Danger Area

Heavy moving objects


High pressure
High energy
Slip & Trip hazards

Falling objects
Etc

1
4

3
152
MSc Petroleum Engineering Well Engineering

Old & New


Rigs engaged in exploration and production in the
U.S. totaled 1,968 for the week ended September 2,
2011
Most are old and use old technology, i.e. kelly and
tongs
However, new builds increasingly use new
technology
High levels of mechanisation remove people from
danger area
Cyber driller
Downhole data
Remote advisory systems
Move to automation
153
MSc Petroleum Engineering Well Engineering

Rig Floor Features

Kelly Drilling Add A Single


154
MSc Petroleum Engineering Well Engineering

Rig Floor Features

Kelly Drilling Add A Single


155
MSc Petroleum Engineering Well Engineering

Rig Floor Features


Mousehole

Rathole

156
MSc Petroleum Engineering Well Engineering

Slips
Designed to support the load off the whole drill
string in the rotary bushing (18 degree taper)

157
MSc Petroleum Engineering Well Engineering

Elevators

Designated by lift
capacity
Pipe Size
Different support
methods
Slips
Square
shoulder
Tapered
internal
Latching method
158
MSc Petroleum Engineering Well Engineering

Hoist & Lower

Rotate

Circulate

Control

Elevators

159
MSc Petroleum Engineering Well Engineering

Rig Tong Technology


Chain
Tongs

Spinning
Chain

Breakout
Tongs

Spinning
Wrench

Torque
Wrench

160
MSc Petroleum Engineering Well Engineering

Rig Tong Technology


Spinning chain & Tong

161
MSc Petroleum Engineering Well Engineering

Iron Roughneck Technology

1975

1986

2003

2006

162
MSc Petroleum Engineering Well Engineering

Iron Roughneck Technology

163
MSc Petroleum Engineering Well Engineering

Racking System Technology

1949

1960s

1975

1986

1990

1994

164
MSc Petroleum Engineering Well Engineering

Running Casing

165
MSc Petroleum Engineering Well Engineering

Running Casing
Casing Running Tool (CRT)

166
MSc Petroleum Engineering Well Engineering

Conventional Drillers Position

167
MSc Petroleum Engineering Well Engineering

New Technology on
the Rig Floor

168
MSc Petroleum Engineering Well Engineering

where is it from?
Auxiliary
Systems

Drilling history

Hoisting
& Lowering

Drilling vs. producing

Rotary

Rig types
Mud
Circulation

Drilling equipment
Drilling
Control

Electronic Drilling System (EDS)


Drilling Screen

Tripping Screen

169
MSc Petroleum Engineering Well Engineering

Pipe Handling

170
MSc Petroleum Engineering Well Engineering

Dual Activity Racking System

171
MSc Petroleum Engineering Well Engineering

172
MSc Petroleum Engineering Well Engineering

The Drillstring

173
MSc Petroleum Engineering Well Engineering

The Drillstring

Rig Floor
Top
DriveEquipment
System

Rotary Table

Upper Kelly
Swivel
etc. Cock
Upper Kelly Cock
Lower
Kelly Saver Sub
Kelly
Lower Kelly Cock
Kelly Saver Sub

Below Rotary Table

Drillpipe
Hevi-weight Drillpipe
X-over subs
Drill Collars
Rotary Jar
(Mud Motor / Turbine / MWD)
Bit

MSc Petroleum Engineering Well Engineering

174

The Drillstring
Drill Pipe Safety Valves

AKA RHKC Kelly cock

Full opening ball valve

Must have lift clamp for stabbing

API Spec 7, Class 2 valves preferred


seals externally applied pressure (2000 psi)
seals pressure from above and below

Consider one piece body for 10K and greater

175
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe
Supports the Bit from the
Surface

Triples In
Fingerboard

Provides Rotation from


the Rotary or Top Drive

On Set-Back

Is a Conduit for the


Drilling Fluid from the
Surface to the Bit

Singles On
Pipe Deck
(Rack)

Pin Thread
Coated

Box Thread
With Thread Protectors
176

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe
Steel tube with weld-on connections
Common sizes 6 5/8, 5, 4, & 3 1/2
Many Grades, E, X, G, S
Properties 5 S 19.5# pipe

max load = 895k lbs


max pres = 23.6k psi
max torque = 60k ft.lbs.

Working range restricted by:


combinations of tension / pressure
& torque
wear & tear on pipe & tool joints
API Spec 5DP

177
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe
Steel tube with weld-on connections
Common sizes 6 5/8, 5, 4, & 3 1/2
Many Grades, E, X, G, S
Properties 5 S 19.5# pipe

max load = 895k lbs


max pres = 23.6k psi
max torque = 60k ft.lbs.

Tooljoint

Working range restricted by:


combinations of tension / pressure
& torque
wear & tear on pipe & tool joints
API Spec 5DP

178
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillpipe manufacture

179
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Bottom-hole assembly (BHA)


Provides weight to the drill bit
Multiple CSA transitions (stress concentrations)
Range from very simple low cost rotary assemblies to very
complex Rotary Steerable (Geo) Systems (RSS)

Vertical / Deviated / Horizontal


Deep, Ultra deep
Extended reach
Horizontal

Multiple components to provide

Stability
Directional control,
Geo-steering,
Bit dynamics control
Measurement systems
180

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Heavy-weight Drillpipe
Run above bottom hole
assembly (BHA)
Thick wall pipe (1)
Can be run in compression,
better able to withstand
cyclic loading
Frequently used in highly
deviated / horizontal wells
Provides weight on bit
(WOB)
Reduce BHA length
Reduced contact area with
borehole
181
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Rotary BHA

182
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Spiral Drill Collars


Provide weight on bit (WOB)
Highly stressed through
drilling forces
Thick wall (ID = 3)
Spiral cut to reduce surface
contact area => differential
wall sticking
API relief groove pin & bore
back box stress relief
Thread roots cold-worked for
resistance to fatigue.
Connections are phosphated
to minimize galling during
makeup
183
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Jar
Insurance Tool
May un-stick a stuck
string

184
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How the jar works

MASS
DC & HWDP

MASS

MASS

BANG !
JAR

BHA
Pull Tension

FIRE

Oil meters past


piston

Piston enters wide


bore and accelerates

IMPACT
End of piston stroke

185
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

String Stabilisers
Centralise the BHA
Keep hole open
Enable straight hole
and deviation control

186
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Measuring/Logging whilst drilling


MWD / LWD
MWD & LWD sensors generate
high volumes of data;
LWD assemblies include;
gamma-ray, multiple resistivity,
density and neutron
Sensors provide formation
images, sonic waveforms and
geo-steering signals
Directional data+ drilling
optimisation data
Wired InteliServ drillpipe has
data rate 57,000 bps bidirectional telemetry
Pulse MWD 24 bps
Wired InteliServ drillpipe
187
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Mud Motors (& Turbines)

188
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Rotary Steerable Systems (RSS)


Steering mechanism
Push or Point bit
Bit walk and bit face
control
bit/formation
interaction
Uses bit rotation,
axial penetration,
tilting motion, and
formation
properties
189
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Rotary Steerable Systems


Non rotating
Sleeve

e.g. Autotrak by Baker Hughes Inteq (BHI)

LWD Triple Combo

Rotating Drive
Shaft

RSS
Steering
Bit Side
Force
mechanism Push
or Point bit
MWD Bit walk and bit
face control
Considers bit
Formation Evaluation
rotation, axial
penetration, tilting
Gamma Ray +
motion, and
Resistivity
formation
properties
Non rotating Sleeve w/
Steering ribs & Inclination Sensors
190

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drillstring float valves

Installed in drill string

just above the bit


only OEM valves

Solid flapper prior to


setting surface casing

Fill drill string from top

On live wells (UBD)...

use 2 tandem dart type


valves

Solid Flapper

Ported Flapper

191
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

The Drillstring
Drill Pipe

6 Heavy Weight Drill Pipe

12 Drill Collars
Jar

3 Drill Collars

2 Non-Mag Spiral Collars (MWD)

UBHO Sub
Motor Assembly 6.75
Adjustable set at 1.5

8.75 Bit
192

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drill String Float Valves

Installed in drill string

just above the bit


only OEM valves

Solid flapper prior to


setting surface casing

Fill drill string from top

On live wells (UBD)...

use 2 tandem dart type


valves

Solid Flapper

Ported Flapper

193
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs
Drive System
The Drillstring

Threaded connections

Drillstrings contain multiple


components with several different
threaded connections
Inter-connections are made with crossovers
A few examples
Drillpipe IF (Internal Flush), e.g., 4
IF,
Drillcollars NC 70
Drillcollars 6 5/8 Reg (Regular)
4 FH (Full Hole)
Pin x Pin connections & Box x Box
connections
It can be a nightmare!
194

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs
Drive System
The Drillstring

Top Drive
Dolly

Traveling
Block

Motor

Traveling Assembly
Top Drive System Gear Case
- Hydraulic
Drive Shaft
- Electric
(replaces kelly)
IBOP Valves
Pipehandler

Elevator
Links

195
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Kelly
Drive
Rotary
Engagement

196
MSc Petroleum Engineering Well Engineering

How far can you Drill?

Determine maximum depth with 5 Grade E pipe in 12 vertical hole


Yield strength grade E = 75,000 psi
CSA = pi (D2-d2)/4 = 5.275 sqin
Max yield = 5.275 X 75,000 = 396,000 lbs (new)
We consider premium grade pipe = 80% of new = 317,000 lbs
We also apply a safety factor ~ 15% = 270,000 lbs available to support load
Because we will encounter some friction resistance d when pulling pipe we apply a
Margin of Overpull ~ 50,000 lbs (depends on expected conditions
We also must consider weight of Drillcollars & HWDP for 12 hole weight on bit ~
55,000 lbs (4,500 lbs per inch of diameter) weight in mud therefore * buoyancy
factor. (well ignore for this example)
Length BHA = 900 ft.
The transition point between drillpipe and BHA is a high stress area. Therefore with
full WOB, we keep the neutral point is in the thick wall BHA at ~80% of total weight
available
Total weight of BHA becomes ~ 66,000 (ignoring buoyancy factor)
Depth you can drill = (317,000 50,000 (MOP)) 66,000 (BHA weight)/21.62lb/ft
(adjusted weight dp to take account of tool joints) = 9297 ft + 900 ft BHA = 10197 ft
197
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Below Rotary Table

Drillpipe
Heavy-weight Drillpipe
X-over subs
Drill Collars
Rotary Jar
(Mud Motor / Turbine /
MWD)

Bit

198
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Circulation System
1. Adds Drilling
Horsepower
2. Removes Cuttings
3. Cools the Bit
4. Controls Pressure

199
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Bits

Two Categories

Roller Cutters

Roller cutters
Fixed Cutters
Steel tooth
Tungsten Carbide inserts

Fixed blade

diamond
polycrystalline diamond
compact

200
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Steel Tooth or Milled


Tooth Bit
MSc Petroleum Engineering Well Engineering

Drive System

Roller Cutter Bits

Tungston Carbide
Insert Bit

201

Bits

BHA

Drillpipe

X-overs

Drive System

Example Milled-tooth
Bit
Long teeth
Wide spacing
Large offset

Cutting action

gouging & scraping

202
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

4 Types of Roller Bit Bearings


1.

2.

3.

4.

Standard Open Bearing

Front row of ball bearings

Back row of roller bearings.


Standard Open Bearing

For Air Drilling

Air injection directly to the cones to


cool the bearings
Sealed Bearing

O-Ring seal with grease reservoir for


bearing lubrication

Barrier against mud and cuttings


Journal Bearing

Strictly oil/grease lubricated with nose


bearings,

O-Ring seal and a

Ball race for maximum performance.


203

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

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MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

4 Types of Roller Bit Bearings


1.

2.

3.

4.

Standard Open Bearing

Front row of ball bearings

Back row of roller bearings.


Standard Open Bearing

For Air Drilling

Air injection directly to the cones to


cool the bearings
Sealed Bearing

O-Ring seal with grease reservoir for


bearing lubrication

Barrier against mud and cuttings


Journal Bearing

Strictly oil/grease lubricated with nose


bearings,

O-Ring seal and a

Ball race for maximum performance.


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MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

206
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

4 Types of Roller Bit Bearings


1.

2.

3.

4.

Standard Open Bearing

Front row of ball bearings

Back row of roller bearings.


Standard Open Bearing

For Air Drilling

Air injection directly to the cones to


cool the bearings
Sealed Bearing

O-Ring seal with grease reservoir for


bearing lubrication

Barrier against mud and cuttings


Journal Bearing

Strictly oil/grease lubricated with nose


bearings,

O-Ring seal and a

Ball race for maximum performance.

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MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

208
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

PolyCrystaline Diamond
Compact (PDC) Bit

Drive System

Diamond Impregnated
(Impreg.) Bit
209

MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

210
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Bit & Hole Opener

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MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Decisions! Decisions!

Which bit works best?


Selection Criteria
Bit Cost
Rig Cost / Capability
Formation
Information
Bit life
Performance History
Previous bit condition
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Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Parameters

Roller Cones
WOB = 4500 lb / in dia max.
ROP dictated by bearing type
Bit life determined by WN number
(weight * total revs)
Diamond / PDC
WOB determined by bit
aggressiveness and torque
developed
High RPM > 150
In combination with motor /
turbines
Role of drilling dynamics / vibration
Check with drill-off test

213
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How would you


grade this one?
What would
you run in the
hole next?

214
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Fluid System


Delivers power (HHP) to
the bit
Cleans the bottom of the
hole to enable the cutters
to cut new formation
Cools the Bit
Carries cuttings to the
surface
Different approaches to
maximize drilling rate
215
MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

Drilling Fluid System


How much should we pump?
Answer sufficient to clean
the hole
Requires velocity and
carrying capacity
Minimum velocity ~ 150
ft/min (depends on mud
viscosity)
In 12 hole min
equivalent volume ~750
GPM
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MSc Petroleum Engineering Well Engineering

Bits

BHA

Drillpipe

X-overs

Drive System

How Much Pumping Power?


Power measured as HHP (hydraulic horsepower ,
consumed at bit (useful) and consumed in system
(wasted)
HHP bit = D P at bit x volume
DP achieved by nozzle size changes, e.g., 3 x 16 (16 /32
)
D Pbit (psi) x Volume pumped (gpm)
Hydraulic plan will aim to maximise HHP when 2/3 HHP is
consumed at bit and 1/33 HHP is consumed in circulation
system
E.g., Total pressure available is 4500 psi
Then HHP bit max = (3000 * 750)/1714
= 1313 HHP
And, total system HHP required is 1970 HHP
Pumps run at 80% of max output. Need 2460 HHP
217
MSc Petroleum Engineering Well Engineering

Drilling Fluid & Solids Removal


Equipment

218
MSc Petroleum Engineering Well Engineering

Where did the mud go?

219
MSc Petroleum Engineering Well Engineering

Drilling Fluid
Mud is VERY IMPORTANT
Poor, badly formulated or badly
maintained drilling fluid (mud) is the
PRIMARY cause of non productive time
(due to stuck pipe) in drilling
operations.

220
MSc Petroleum Engineering Well Engineering

Drilling Fluid
Mud is VERY IMPORTANT
Mud properties strongly influence bit
performance

221
MSc Petroleum Engineering Well Engineering

Drilling Fluid Types & Properties


Three Common Types

Water-based mud (WBM)


Water-base with clays (bentonite) and other
chemicals
Lowest cost, but some formations react ($)
Oil-based mud (OBM):
Base petroleum product, e.g., diesel fuel
Toxic
Very good drilling/formation properties ($$)
Synthetic-based fluid (SBM)
Base synthetic oil
Less toxic
Very good drilling/formation properties ($$$)
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Drilling Fluid Types & Properties

Desired Properties
Thin and free-flowing while the fluid is being
pumped (shear thinning),
Thick when pumping is stopped, "gelling" to
suspend drilled solids.
Non damaging to reservoir

223
MSc Petroleum Engineering Well Engineering

Drilling Fluid Additives


Many substances, both reactive and
inert, are added to drilling fluids to
perform specialized functions.
The most common functions and
additives are as follows:

224
MSc Petroleum Engineering Well Engineering

Drilling Fluid Additives


Alkalinity and pH Control
Designed to control the degree of acidity or alkalinity of the drilling
fluid. Most common are lime, caustic soda and bicarbonate of soda.
Bactericides
Used to reduce the bacteria count. Paraformaldehyde, caustic soda,
lime and starch preservatives are the most common.
Calcium Reducers
These are used to prevent, reduce and overcome the contamination
effects of calcium sulfates (anhydrite and gypsum). The most common
are caustic soda, soda ash, bicarbonate of soda and certain
polyphosphates
Corrosion Inhibitors
Used to control the effects of oxygen and hydrogen sulfide corrosion.
Hydrated lime and amine salts are often added to check this type of
corrosion. Oil-based muds have excellent corrosion inhibition
properties.
225
MSc Petroleum Engineering Well Engineering

Drilling Fluid Additives


Defoamers
These are used to reduce the foaming action in salt and saturated
saltwater mud systems, by reducing the surface tension.
Emulsifiers
Added to a mud system to create a homogeneous mixture of two
liquids (oil and water). The most common are modified lignosulfonates,
fatty acids and amine derivatives.
Filtrate Reducers
These are used to reduce the amount of water lost to the formations.
The most common are bentonite clays, CMC (sodium
carboxymethylcellulose) and pre-gelatinized starch.
Flocculants
These are used to cause the colloidal particles in suspension to form
into bunches, causing solids to settle out. The most common are salt,
hydrated lime, gypsum and sodium tetraphosphates.
226
MSc Petroleum Engineering Well Engineering

Drilling Fluid Additives


Foaming Agents
Most commonly used in air drilling operations. They act as surfactants,
to foam in the presence of water.
Lost Circulation Materials
These inert solids are used to plug large openings in the formations, to
prevent the loss of whole drilling fluid. Nut plug (nut shells), and mica
flakes are commonly used.
Lubricants
These are used to reduce torque at the bit by reducing the coefficient
of friction. Certain oils and soaps are commonly used.
Pipe-Freeing Agents
Used as spotting fluids in areas of stuck pipe to reduce friction, increase
lubricity and inhibit formation hydration. Commonly used are oils,
detergents, surfactants and soaps.
227
MSc Petroleum Engineering Well Engineering

Drilling Fluid Additives

Shale-Control Inhibitors
These are used to control the hydration, caving and disintegration of
clay/ shale formations. Commonly used are gypsum, sodium silicate and
calcium lignosulfonates.
Surfactants
These are used to reduce the interfacial tension between contacting
surfaces (oil/water, water/solids, water/air, etc.).
Weighting Agents
Used to provide a weighted fluid higher than the fluids specific gravity.
Materials are barite, hematite, calcium carbonate and galena.

228
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine
Transmit hydraulic to the bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
229

MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine
Transmit hydraulic to the bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
230

MSc Petroleum Engineering Well Engineering

Cuttings Transport
Good carrying capacity
Transport cuttings to
surface
Mud loggers
determine the depth
where cuttings
originated
Drilled cuttings
retrieved and analyzed
at the wellsite

231
MSc Petroleum Engineering Well Engineering

Cuttings Transport
Requirements
Keep cuttings
in suspension
when pump /
circulation is
stopped by
gelling
Then thin when
circulation
recommences

Formation

232
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine
Transmit hydraulic to the bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
233

MSc Petroleum Engineering Well Engineering

Controlling formation pressures


Pressure = Depth x gradient
= 5000 x 0.6 psi/ft
= 3000 psi.

Fluid
gradient

Formation with High Pressure (Mud gradient too low = kick)


Formation with High Stress (Mud gradient too low = Instability)
Formation with Low Pressure (Mud gradient too high = losses)

Pressure = Depth x gradient


= 7000 x 0.5 psi/ft
= 3500 psi.

Pressure
234

MSc Petroleum Engineering Well Engineering

even more difficult with dynamic pressure

Dilemma
Avoid Losses
Avoid Kicks
Avoid formation
instability

235
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluid

Remove cuttings from well


Suspend and release cuttings
Control formation pressures

Seal permeable formations

Maintain wellbore stability


Minimize formation damage
Cool, lubricate the bit and drilling assembly
Transmit hydraulic energy to tools and bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion

Minimize impact on environment

236
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine
Transmit hydraulic to the bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
237

MSc Petroleum Engineering Well Engineering

Seal permeable formations


Filter cake
prevents losses
through addition
of bridging
agents

Losses
Filter Cake

Total
losses to
Fractures

Filter cake
needs to Plug
pores without
causing excessive
damage

Seepage
losses to
Porous & Permeable
matrix

238
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine
Transmit hydraulic to the bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
239

MSc Petroleum Engineering Well Engineering

Maintain wellbore stability


Borehole
pressure
opposes
formation
pressure

Borehole
Instability

Formation

240
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine
Transmit hydraulic to the bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
241

MSc Petroleum Engineering Well Engineering

Formation Damage (skin)


Reduction in natural formation porosity and permeability
= formation damage
Most common damage
Mud or drill solids invade the formation matrix, reducing
porosity
Swelling of formation clays within the reservoir matrix
reduces permeability
Precipitation of solids due to mixing of mud filtrate and
formation fluids resulting in the precipitation of insoluble
salts
Mud filtrate and formation fluids form an emulsion
For completions: specially designed drill-in fluids or
workover / completion fluids
242
MSc Petroleum Engineering Well Engineering

Formation damage (impairment)


results in lower production rates, lower
ultimate recovery and possibly
uneconomic wells.

Porosity:
Ability to contain
Permeability:
Ability to flow through
243
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine / bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
244

MSc Petroleum Engineering Well Engineering

Transmit Energy to the Bit


Cleaning the
bottom of the hole
to avoid re-drilling
of cuttings
Hydraulic
horsepower
Jetting action
Cleaning bit cutters
Cooling at the bit
245
MSc Petroleum Engineering Well Engineering

Transmit Energy to the Bitand motors

246
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluid

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool, lubricate the bit and drilling assembly
Transmit hydraulic energy to tools and bit

Enable adequate formation evaluation

Minimize corrosion
Facilitate cementing and completion

Minimize impact on environment

247
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine / bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
248

MSc Petroleum Engineering Well Engineering

Enable Formation Evaluation


Low water loss
Avoid flushing away hydrocarbons
Avoid thick wall cake (sticking of logging tools)

Enable gauge hole


Wash outs
Tight hole

Optimum overbalance to avoid differential


sticking
249
MSc Petroleum Engineering Well Engineering

Enable formation evaluation

250
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine / bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
251

MSc Petroleum Engineering Well Engineering

Corrosion Inhibitors
Corrosion leads to loss of casing integrity
(especially opposite aquifers)
Loss of drill string integrity
twist offs

Control the effects of oxygen and hydrogen


sulfide corrosion.
Hydrated lime and amine salts (maintain pH)
Oil-based mud has excellent corrosion inhibition
properties.
252
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine / bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
253

MSc Petroleum Engineering Well Engineering

Fluid Properties for Good Cementation


Properties for efficient mud removal
Condition mud to as low a yield point and gel
strength as practical consistent with:
Cuttings removal
Solids suspension
Hole stability

Condition mud until flowline and suction mud


properties have stabilized at optimum values
Mud conditioning also cools the well
254
MSc Petroleum Engineering Well Engineering

Functions of Drilling Fluids

Remove cuttings from well


Suspend and release cuttings
Control formation pressures
Seal permeable formations
Maintain wellbore stability
Minimize formation damage
Cool and lubricate the bit and drilling assembly
Transmit hydraulic energy to mud motor / turbine / bit
Ensure adequate formation evaluation
Minimize corrosion
Facilitate cementing and completion
Minimize impact on environment
255

MSc Petroleum Engineering Well Engineering

Minimize impact on environment

Avoid OBM & SBM where possible


Special OBM & SBM containment systems
Cuttings cleaning and capture
Cuttings returned for recycling
Drill smaller holes

256
MSc Petroleum Engineering Well Engineering

Measuring & Maintaining Fluid


Properties

257
MSc Petroleum Engineering Well Engineering

Properties Measured

Density

Mud weight ppg

Gradient psi/ft
Viscocity

Centipoise

PV / YP
Gel Strength

10 sec

10 min
Water Loss
PH
Solids Content
Sand Content
Ca++
Also special HPHT
measurements

Drilling Fluid Properties

Fann
Viscometer

and Measurement
258
MSc Petroleum Engineering Well Engineering

Fluid Management System

Tanks and mixers


De-gasser
Shale Shakers
Cyclone De-sander
De-silter
Mud cleaner
Centrifuge
259

MSc Petroleum Engineering Well Engineering

Shale Shakers

Screen
260
MSc Petroleum Engineering Well Engineering

Fluid Management System

261
MSc Petroleum Engineering Well Engineering

De-sander

262
MSc Petroleum Engineering Well Engineering

De-silter

263
MSc Petroleum Engineering Well Engineering

Mud-cleaner

264
MSc Petroleum Engineering Well Engineering

Centrifuge

265
MSc Petroleum Engineering Well Engineering

Mud de-gasser

266
MSc Petroleum Engineering Well Engineering

Well Construction

267
MSc Petroleum Engineering Well Engineering

The Purpose of the Well


Find, acquire and
enable production of
petroleum oil or
natural gas
Provide a reliable
pressure containment
vessel
Provide a means to
safely and
economically produce,
inject or monitor fluids
268
MSc Petroleum Engineering Well Engineering

Purpose of this well


produce oil
Wells come in all sizes
Stripper well (opposite) as
little as 2 bbls (oil) / day
Big oil wells > 50,000 bbl /
day
Big gas wells > 100 million
scf / day

269
MSc Petroleum Engineering Well Engineering

Many types of wells


Exploration wells
Appraisal wells
Production wells
Oil producers.
Gas producers
Reservoir management
Water injectors
Gas Injectors
Co-produced gas
CO2
Reservoir monitoring
Produced water disposal
Waste drilling fluid
Gas storage
270
MSc Petroleum Engineering Well Engineering

Purpose of Casing in combination


with Cement

Structural support for Wellhead


Provide wellbore Stability
Isolate different formations
Provide (with blowout preventer) control of
well pressures during Drilling, Production and
Intervention
Barrier to pressure or flow of fluids from
formation to surface .or formation to
formation
Isolation of loss zones
271
MSc Petroleum Engineering Well Engineering

Casing
Pipe Body & Threads
compatible with the
pressures and fluids
expected.
Thread Connections
STC, LTC, Buttress,
Special gas tight

Typical designation 9-5/8"


53.5# P-110 BTC Range 3
API Specification 5C3 (ISO
/TR 10400)
Standardizes (14 casing sizes)
4.5 inches through 20 inches
("OD")
272
MSc Petroleum Engineering Well Engineering

Typical Casing & Tubing Design


Conductor Casing

Conductor
Surface Casing
Casing
Drilling
Production

Liner
Drilling
Production

Tieback
Production tubing

Annuli
Designation

'D' Annulus
'C' Annulus
Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer
Perforations
Production Liner

273
MSc Petroleum Engineering Well Engineering

Typical Casing & Tubing Design Process


Conductor Casing

Identify all load scenarios


Estimate load parameters
Calculate principal loads
Axial
Internal / external pressure
Bending

Calculate strength to resist loads


Repeat process
There are uncertainties

Load Parameters
Actual Casing strength
Failure modes and consequences
Connection strength

'D' Annulus
'C' Annulus
Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer
Perforations
Production Liner

274
MSc Petroleum Engineering Well Engineering

Cement
Purpose

Requirements

Supports Casing
In combination with casing and
BOPs provides well control
Provides zonal isolation
Helps control corrosion

Oilfield cement manufactured


(API) Specification 10A.
Classes of API cement are A, B,
C, D, E, F, G and H.
Modified to with additives to
deliver required properties
Accelerators
Retarders
Slurry density reducers
Slurry density enhancers
Temperature resistance
Compressive strength
Flow properties
275
Elasticity

MSc Petroleum Engineering Well Engineering

Cementing and casing the well

MSc Petroleum Engineering Well Engineering

Casing Cemention
276
process explained later.

Wellhead
Purpose
Provides pressure-containment
interface (BOPs) during drilling
phase
Provides casing hang-off profiles
during the well construction phase.
Provides tubing hang-off profile for
production tubing
Supports the Christmas tree
In combination with Christmas tree
provides surface flow-control
during production phase

277
MSc Petroleum Engineering Well Engineering

Compact Wellhead
Purpose
Compact multi-bowl wellhead
design
Allows multiple casing strings
to be hung in a single
wellhead component
Reduces installation time and
footprint

278
MSc Petroleum Engineering Well Engineering

Subsea Wellhead
Applications to 10,000 psi WP,
Single trip Casing hangers and seal
assemblies
Five- or six-string casing options
Weight-set, elastomeric parallel bore seal
assemblies
Running tool provides a straightforward
stab, test and tool retrieval.
Passive lockdown high-pressure housing into
the 30" housing.
Guideline or guidelineless operations

279
MSc Petroleum Engineering Well Engineering

Christmas Tree
Purpose
Installed on top of the wellhead
to control the flow of well fluids
during production.
Provides primary and back-up
control facilities for production
Enables wellbore shut-in
Incorporates facilities to enable
safe access for well intervention
operations , e.g., slickline,
electric wireline and coiled
tubing

280
MSc Petroleum Engineering Well Engineering

Flowline

Xmas tree

Cellar

Wellhead

Gas storage
well Etzel
Germany
281

MSc Petroleum Engineering Well Engineering

Completion
Purpose

Enable safe and efficient control of


fluid production through selective
zones

Several Types

Cased hole - perforated


Open hole limits options
Single, dual, triple
Smart

Enables

Remedial isolation
Special treatments

Includes

Plugs, nipples, mandrels

282
MSc Petroleum Engineering Well Engineering

Completion
Purpose

Enable safe and efficient control of fluid


production through selective zones

Several Types

Cased hole perforated


Open hole limits options
Single, dual, triple
Smart

Enables

Remedial isolation
Special treatments

Includes for maintenance and access

Plugs, nipples, mandrels


283

MSc Petroleum Engineering Well Engineering

Completion
Purpose

Enable safe and efficient control of fluid


production through selective zones

Several Types

Cased hole perforated


Open hole limits options
Single, dual, triple
Smart

Enables

Remedial isolation
Special treatments

Includes for maintenance and access

Plugs, nipples, mandrels

284
MSc Petroleum Engineering Well Engineering

Well Construction
Casing & Cementing

285
MSc Petroleum Engineering Well Engineering

Cement
Oilfield cement manufactured to (API) Specification 10A.
Classes of API cement are A, B, C, D, E, F, G and H.
Modified with additives to deliver required properties

Accelerators
Retarders
Slurry density reducers
Slurry density enhancers
Temperature resistance
Compressive strength
Flow properties
Elasticity

286
MSc Petroleum Engineering Well Engineering

Cementing Operations
Cementation is the final Crucial Operation in Securing a
well section
Cement is a Barrier
Must achieve
High quality uncontaminated cement that bonds to casing
and formation
High compressive strength
Well control throughout the operation
Float equipment (flow inside casing)
Prevent channeling (flow outside casing)
Isolation of hydrocarbon zones
Isolation of water zones
Protection from corrosive fluids
287
MSc Petroleum Engineering Well Engineering

Cementing Operations
Good Cementation Achieved Through:
Pre cementation circulation and conditioning of mud
Proper mixing and blending of mix water and cement
Minimise free water
Correct density

High displacement rates


Density difference spacer, lead, main & tail slurry

Effective mud removal


Casing movement (reciprocation or rotation)
Casing centralisation
Concerns
Losses
Not getting casing to bottom

288
MSc Petroleum Engineering Well Engineering

Cementing Operations
Accessories: Float Equipment
Purpose
Prevent back-flow when
cement is pumped in place
Provide landing shoulder
for wiper plugs (Collar)
Provide Guide for Casing
(Shoe)
Enable pressure-test of
Casing after displacement
cement (Collar)
Float Collar

Float Shoe

289
MSc Petroleum Engineering Well Engineering

Cementing Operations
Accessories: Wiper Plugs
Purpose
Remove drilling fluid
residue from casing
(Bottom Plug)
Separate drilling fluid /
spacers from Cement
Wipe cement residue
from casing (Top Plug)
Enable pressure-test of
casing after
displacement; landing on
float collar (Top Plug)
290
MSc Petroleum Engineering Well Engineering

Cementing Operations
Accessories: Cement
Head
Purpose
Enable sequential
release of cement
plugs
Provide circulation
path for drilling fluid,
spacers and cement
291
MSc Petroleum Engineering Well Engineering

Cementing Operations
Accessories: Centralizers,
Scratchers & Wipers
Purpose
centralizers; 2 types
centralize casing &
provide stand-off from
bore hole
minimize channeling,
enable uniform
distribution of cement
scratchers and wipers
scrape wall-cake from
borehole
292
MSc Petroleum Engineering Well Engineering

Cementing Operations
Accessories: Stage
Cementing
Purpose: Cementing with
losses
Reduce effective length
of cement column
Enable cement
placement below &
above loss zone
Isolate hydrocarbon
zones at various levels in
well
293
MSc Petroleum Engineering Well Engineering

Cementing operations equipment


and process

294
MSc Petroleum Engineering Well Engineering

Cementing Operations

295
MSc Petroleum Engineering Well Engineering

Casing & Cementing the Well

Conductor Casing
'D' Annulus
'C' Annulus
Surface Casing

Conductor - driven before rig


arrives
Surface Casing
Casing
Drilling
Production

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Liner
Drilling
Production

Production Tubing

Packer
Perforations
Production Liner

296
MSc Petroleum Engineering Well Engineering

Casing & Cementing the Well

Conductor Casing
'D' Annulus
'C' Annulus

Conductor - driven before rig


arrives
Surface Casing cemented to
surface serves as foundation of
the well. Covers shallow aquifers

Casing
Drilling
Production

Liner
Drilling
Production

Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer
Perforations
Production Liner

297
MSc Petroleum Engineering Well Engineering

Before Casing & Cementing Operations


Drill top hole section and
Circulate Clean

298
MSc Petroleum Engineering Well Engineering

Run Surface Casing

Foundation of the
Well
Requires cement
back to surface
Large displacement
volume if plug
cementation used
Solution is a
stinger using
tubing or drillpipe

299
MSc Petroleum Engineering Well Engineering

Surface Casing
Casing run to bottom
and hung off on
profile on Conductor

300
MSc Petroleum Engineering Well Engineering

Surface Casing
Drillpipe with stinger
assembly run in hole
Stabbed into special
float shoe

Drillpipe Stinger
Cementation

301
MSc Petroleum Engineering Well Engineering

Surface Casing
Circulate and condition
mud
Pump water spacer

Drillpipe Stinger
Cementation

302
MSc Petroleum Engineering Well Engineering

Surface Casing
Mix and pump cement

Drillpipe Stinger
Cementation

303
MSc Petroleum Engineering Well Engineering

Surface Casing
Cement back to surface
Displace drillpipe with
drilling fluid

Drillpipe Stinger
Cementation

304
MSc Petroleum Engineering Well Engineering

Surface Casing
Displace drillpipe with
drilling fluid
Leave 100m cement in
drillpipe to avoid
contamination at shoe

Drillpipe Stinger
Cementation

305
MSc Petroleum Engineering Well Engineering

Surface Casing

Remove drillpipe
Cement fills bottom of
casing
Circulate clean
Wait on Cement (WOC)

Drillpipe Stinger
Cementation

306
MSc Petroleum Engineering Well Engineering

Plug Type Cementation

307
MSc Petroleum Engineering Well Engineering

Casing & Cementing the Well


Conductor - driven before
rig arrives
Casing

Drilling (intermediate)
Production
Cement covers exposed
hydrocarbons (minimum 500ft)
Volume from caliper log
Back to surface not practicable
Liner
Drilling
Production

Conductor Casing
'D' Annulus
'C' Annulus
Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer
Perforations
Production Liner

308
MSc Petroleum Engineering Well Engineering

Casing & Cementing the Well Typical


(simplified) Calculations (Halliburton Red
Book)

Mud density = 87 lb/cuft


Quantity of cement (V1 + V2 + V3) = 748.9 cuft
Slurry weight = 118 pcf (Class H)
Slurry volume = 1.14 cuft/sx 748.9/1.22 = 614 sx
Mix water volume = 5.49 gal/sx = 3821 gal
Casing vol to collar = (13891 80) x 1.5603 gal/ft = 21550 gal
Displacement rate = 300 gpm
Total time for the job = mix time + plug release + displacement
(chase) time
(614/25) + 15 + (21550/300) = 25+15+72 = 112 min
Hmw
D P prior to bumping plug = DP mw/mud + DP cement/mud
1330 ft
= 1330 x (62-87)/144 + 5906 (115-87)/144 = 918 psi
Annular velocity during chase Velocity = Volume/Ann.Area
= 300/ p/4x(8.5 - 7 ) = 316 ft/min (turbulent flow)
Hcmt
2 2
Total mud returns during the job = steel volume + slurry
5906 ft
volume + mix water = 197 + 180+ 30 = 407 bbl (important for
well control)
Next Step for Step Cementation

2
Conductor Casing
'D' Annulus
'C' Annulus
Surface Casing

'B' Annulus

Production Tieback

7 29 lb/ft
Casing

mw r =
62 lb/cuft
'A' Annulus

Intermediate Casing

V3

Mud r =
87 lb/cuft

Production Tubing

v1

v2

Cmt r =
Packer
115
lb/cuft
Perforations
Liner
TD =Production
13900
ft

309
MSc Petroleum Engineering Well Engineering

Production Casing

Plug Cementation

Drilling Fluid from Rig


Pump. Pre cementation,
circulate and condition
drilling fluid in preparation
for cementation.
Condition: develop
optimum cementing
properties, mobilise gelled
fluid, cool hole,

310
MSc Petroleum Engineering Well Engineering

Production Casing

Drilling Fluid from Rig


Pump. Pre cementation,
circulate and condition*
drilling fluid in preparation
for cementation
*Condition: develop
optimum cementing
properties, mobilise gelled
fluid, cool hole,

Plug Cementation

311
MSc Petroleum Engineering Well Engineering

Production Casing
Plug Cementation
Intermediate and
production casings
Pre-calculated volume
circulated between
plugs
Volumes obtained
from caliper logs
Plug Cementation

312
MSc Petroleum Engineering Well Engineering

Production Casing
Place wiper plugs in
cement head.

Plug Cementation

313
MSc Petroleum Engineering Well Engineering

Production Casing
From Cement Unit) Pump preflush
scavenger cement. (slurry
heavier than drilling fluid lighter
than cement slurry) with
objective to remove mud wall
cake and displace drilling fluid.

Plug Cementation

314
MSc Petroleum Engineering Well Engineering

Production Casing
From Cement Unit. Pump
(calculated cement slurry
volume mixed & pumped
on the fly). Cement
properties continuously
monitored and adjusted.

Plug Cementation

315
MSc Petroleum Engineering Well Engineering

Production Casing
Switch to Rig Pump for
high rate displacement

Plug Cementation

316
MSc Petroleum Engineering Well Engineering

Production Casing
Continue displacement
at high rate to create
good mud
displacement

Plug Cementation

317
MSc Petroleum Engineering Well Engineering

Production Casing
First bottom plug
arrives at float collar

Plug Cementation

Bottom plug diaphragm


ruptures
318
MSc Petroleum Engineering Well Engineering

Production Casing
Continue
displacement, cement
rising in annulus.
Anxiously awaiting
bump of top plug.

Plug Cementation

319
MSc Petroleum Engineering Well Engineering

Continue
displacement, until
top plug bumps.
Pressure test casing.
Cement job
completed
Wait on Cement
monitor for flow
Plug Cementation

320
MSc Petroleum Engineering Well Engineering

Overview of
Plug Cementation

321
MSc Petroleum Engineering Well Engineering

Casing & Cementing the Well

Conductor Casing
'D' Annulus
'C' Annulus
Surface Casing

Conductor - driven before rig


arrives
Casing
Drilling (intermediate)
Production
Cement covers exposed
hydrocarbons (minimum 500ft)
Back to surface not practicable
Liner
Drilling
Production

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Liner
Hung off
in
Packer
previous
Perforations
casing

Production Tubing

Production Liner

322
MSc Petroleum Engineering Well Engineering

Directional Drilling

323
MSc Petroleum Engineering Well Engineering

Anyone know where we are?

324
MSc Petroleum Engineering Well Engineering

Why directionally drill?


Access specific reservoir sections / zones
Access difficult reservoir locations.

Under residential area / natural park


Under a lake / near shore
Avoid difficult to drill or troublesome formation, e.g., mobile salt
Avoid high pressure

Allow multiple wellheads from one surface location


Offshore platform / jacket offshore, up to 40 wells (tight spacing)
Pad drilling land wells, reducing environmental impact.
Sub sea template

Relief well drilling


Highly deviated / horizontal wells to increase exposed section
length through the reservoir => higher production

325
MSc Petroleum Engineering Well Engineering

Planning & Preparation


Identify subsurface
targets
Data from:

Seismic
Previous wells
Reservoir model
Petrophysical logging

Select surface location


Surface (Grid) coordinates
Magnetic declination
Depth references
Develop Well trajectory
326
MSc Petroleum Engineering Well Engineering

Well Trajectory (section)


Directional Jargon
Kick off point (KOP)
Build up section
End of Build (EOB)
Tangent section
Drop off section

327
MSc Petroleum Engineering Well Engineering

Well Trajectory (section and plan)


Kick off point
(KOP)
Build up section
End of Curve
(EOC)

Tangent section
Drop off section
328
MSc Petroleum Engineering Well Engineering

Development of
Directional Drilling Systems
Badgering with bent pipe
Whipstock (side-track from casing, e.g., for ML wells)
After deflection made (e.g., 6 10 degrees)
BHA design (stabilizer placement) and drilling practices (WOB / Circ rate)
used to build /drop/hold angle
Simple survey tools
Directional readings; dropped or wireline-conveyed single shot photos
(camera photo of compass and plumb )

Mud motors enabled bit to be rotated independent of the drillstring


Electronic magnetometer/inclinometer data via wireline with orientation
sub above bent sub at the top of the motor

Mud pulse telemetry enabled MWD, transmission of data (directional


(and other)) while drilling
Rotary Steerable Systems point the bit / push the bit technology

329
MSc Petroleum Engineering Well Engineering

How do we know where we are?


3 survey components
measured at any given point
in a wellbore to determine
position:
Measured depth
Inclination
Magnetic azimuth

Consecutive surveys needed


to track the progress and
location of a wellbore

330
MSc Petroleum Engineering Well Engineering

Directional Surveying
Magnetic Single Shot
Every 100 feet stop for wireline
survey
Lower and retrieve camera with
pendulum and magnetic compass
Slow and prone to miss-runs
Non Magnetic DCs

331
MSc Petroleum Engineering Well Engineering

Directional Surveying
Magnetic surveys
Requires non- magnetic
environment
Use non magnetic drill
collars (NMDCs)
Length NMDCs depends
on declination
Corrected for Magnetic
Declination
Corrected for Grid System
Gyro surveys required for
regions of high interference
Inside casing
Close to platform
332
MSc Petroleum Engineering Well Engineering

Directional Surveying
Magnetic surveys
Requires non- magnetic
environment
Use non magnetic drill
collars (NMDCs)
Length NMDCs depends
on declination
Corrected for Magnetic
Declination
Corrected for Grid System
Gyro surveys required for
regions of high interference
Inside casing
Close to platform
333
MSc Petroleum Engineering Well Engineering

Development of
Directional Drilling Systems - Badgering
Badgering with Bent pipe
Bottom Hole Assembly or
"BHA for deviations from
the vertical

Bit is set up with one nozzle


on high side
Bit is orientated in desired
direction
By jetting and sliding hole
angle is built in desired
direction
Intermittent jet and slide
and rotate
334
MSc Petroleum Engineering Well Engineering

Development of
Directional Drilling Systems Whipstock Drilling
Whipstock run,
on drillpipe,
orientated and
set in desired
direction
Drill off the
whipstock
Deflect hole in
desired direction
Used today in
cased hole for
sidetracks with
milling assembly
335
MSc Petroleum Engineering Well Engineering

Milling Window off Whipstock


PU mill string, circulate, record
pressures
Rotate recording drag torque,
slowly move downwards until
contact WS
Mill window

336
MSc Petroleum Engineering Well Engineering

Conventional BHAs
Deviation Drilling before the advent
of mud motors & deflection tools
Build angle 6 to 10 deg (jetting)
RIH build assembly
Hold Assembly
Drop Assembly

337
MSc Petroleum Engineering Well Engineering

Mud Motors with Bent Subs


and
E-line Surveying Revolutionised
Directional Drilling

338
MSc Petroleum Engineering Well Engineering

Deflection / Directional Control Tools

339
MSc Petroleum Engineering Well Engineering

Deflection / Directional Control Tools


Downhole Motor (PDM) & Bent Sub / Bent Housing
Bent housing (integral) or bent sub (directly above)
motor
10 to 30 inclination from axis
Acts as pivot.
Deflection / degree of curvature
Depends on relationship
Bent sub angle / OD motor > hole size
Bent sub angle and Drill Collar OD > hole size
Motor length
340
MSc Petroleum Engineering Well Engineering

Directional Correction

Rebel Tool
Run just above the bit
Long paddles turned
left
Short paddles turned
right
Forerunner of RSS
341
MSc Petroleum Engineering Well Engineering

Mud Motors & Deflection Tools


Revolutionised Directional Drilling

342
MSc Petroleum Engineering Well Engineering

Mud Motors & Deflection / Directional


Control Tools Revolutionised DD

Downhole motor and bent sub / bent housing


MSc Petroleum Engineering Well Engineering

343

Measurement While Drilling (MWD)


Revolutionised Directional Drilling

344
MSc Petroleum Engineering Well Engineering

Measurement While Drilling "MWD"


systems
Real time measurements
Basic trajectory parameters
Inclination
Direction
Tool-face

Additional sensors include:

Pressure,
Gamma-ray
Resistivity
Temperature
Other petrophysical evaluation tools
345

MSc Petroleum Engineering Well Engineering

Measurement While Drilling "MWD" systems


Power Supply
Lithium batteries
Downhole generator (turbine)
Directional Sensor Section
Hole trajectory from sensor stack
3 accelerometers
3 magnetometers

Data Transmission (three methods)


Pressure waves through mud (mud pulse) (+/- 4 bps)
Electromagnetic "EM" signals through the earth to
surface. (+/- 4 bps)
Wired pipe (1 mega bps)
346
MSc Petroleum Engineering Well Engineering

Measurement While Drilling "MWD" systems


Pulse system
Mud pulse opens and closes a valve
Creates either a pressure surge (positive pulse) or
drop (negative pulse).
Range of 10-50 psi are detected at surface at
transducer installed in stand pipe

Continuous signal for directional control


Data stored and encoded for transmission in
data burst decoded into useable information.
No practical depth limitation
Reliant on good drilling fluid
347
MSc Petroleum Engineering Well Engineering

Telemetry - Principles of Positive Mud Pulsers (MWDs)

348
MSc Petroleum Engineering Well Engineering

EM MWD Systems
Uses same sensors and
power supplies
Data transmission via
magnetic pulse or electrical
current through formations
to surface antennas
Data can be transmitted at
any time
Depth limitations, formation
type and power consumption
are concerns
Used for under-balance / air
drilling
349
MSc Petroleum Engineering Well Engineering

Measurement While Drilling "MWD" systems


High rate wired pipe telemetry
Transmit data rates up to 1 mega bps
Upload and download data

Evaluation down-hole environment


Multiple petrophysical logs
Reservoir characterization
Geo steering
Precise navigation of the well bore
Reliability
Expensive
350

MSc Petroleum Engineering Well Engineering

RSS Revolutionised Directional


Drillingand more!

351
MSc Petroleum Engineering Well Engineering

Rotary Steerable Systems


Non rotating
Sleeve

e.g. Autotrak from Baker Hughes Inteq (BHI)


LWD Triple Combo

Bit Side
Force

MWD

Rotating
Drive Shaft

Formation Evaluation
Gamma Ray + Resistivity

Non rotating Sleeve w/


Steering ribs & Inclination Sensors
352
MSc Petroleum Engineering Well Engineering

Rotary Steerable Systems


Advantages
Continuous pipe movement
No need for slide drilling
Better hole cleaning
Reduces / eliminates trips for assembly changes
Permits more complex well paths to be drilled
Allows well track to be kept close to plan
Geosteering following formation changes
Hit smaller targets
Extended Reach Drilling
Can be run with range of petrophysical tools
353
MSc Petroleum Engineering Well Engineering

LWD Revolutionised Drilling

354
MSc Petroleum Engineering Well Engineering

MWD Measurement While Drilling


LWD Logging While Drilling

355
MSc Petroleum Engineering Well Engineering

MWD Measurement While Drilling


LWD Logging While Drilling
LWD Logging While Drilling
Directional measurements (and control in conjunction with
Rotary Steerable Systems)
Formation evaluation (gamma, Resistivity, Sonic, Density
(amongst others)
Downhole dynamics / parameters for optimization
Pressure while drilling
Vibration
RPM

Telemetry
Pulse
Electromagnetic
Wired

356
MSc Petroleum Engineering Well Engineering

Well Trajectories

357
MSc Petroleum Engineering Well Engineering

Conventional Directional Drilling


Build and hold

Build hold and drop


into target

358
MSc Petroleum Engineering Well Engineering

Less conventional directional drilling

Horizontal
Extended Reach
Hook well
Tortuous snake
well

359
MSc Petroleum Engineering Well Engineering

Horizontal Drilling
Advantages
Greater reservoir exposure per well
Geo steering to stay in sweet spot
Fewer wells required for same production
Disadvantages
Increased formation damage
During well life cycle, limited recompletion
options
Isolation of water / gas coning
360
MSc Petroleum Engineering Well Engineering

361
MSc Petroleum Engineering Well Engineering

Extended Reach Wells

How?
Special
Rigs (Power)
BP
Wytch Farm

(M-11) 10.4km components


Lateral Displacement at 1,600m True Vertical
Drillstring
Depth
Large
bore
Sakhalin
Island
Chayvo field
28 January
2011 depth
the worlds
longest
borehole
was drilled
On(Z-12)
measured
11,680
meters
(38,320 ft)
High
strength
tool
joints
Odoptu
Sakhalin-I
with
a measured
total depth
at the
Chayvo
field,field,
contains
17 of the
world's
30 longest
of 12,345
meters (40,502
ft)wells
and a horizontal displacement of
extended-reach-drilling
Aluminium
pipe?
metersField
(37,648
ft).
Al11,475
Shaheen
Qatar
Special synthetic mud systems
BD-04A (World record) measured depth of 12,289 meters
(40,320high
ft) pump
10,902rates
meters
Very
Record horizontal reach
of 10,902 meters (35,770 ft)
(35,770 ft)
steerable
systems
Rotary
Drilled in 36
days
Excellent drilling practices
362
MSc Petroleum Engineering Well Engineering

Extended Reach Wells

On 28 January 2011 the worlds longest borehole was drilled


How?
at the Odoptu field, Sakhalin-I with a measured total depth of

12,345
meters Rigs
(40,502(Power)
ft) and a horizontal displacement of

Special
BP Wytch Farm

11,475 meters (37,648 ft).


Drillstring
(M-11) 10.4km components
Lateral Displacement at 1,600m True Vertical
Depth

Large
bore
Sakhalin
Island
Chayvo field

28 January
2011 depth
the worlds
longest
borehole
was drilled
On(Z-12)
measured
11,680
meters
(38,320 ft)
High
strength
tool
joints
Odoptu
Sakhalin-I
with
a measured
total depth
at the
Chayvo
field,field,
contains
17 of the
world's
30 longest
of 12,345
meters (40,502
ft)wells
and a horizontal displacement of
extended-reach-drilling
Aluminium
pipe?
metersField
(37,648
ft).
Al11,475
Shaheen
Qatar

Special
synthetic mud systems
BD-04A (World record) measured depth of 12,289 meters
(40,320high
ft) pump
10,902rates
meters
Very
Record horizontal reach
of 10,902 meters (35,770 ft)
(35,770 ft)
steerable
systems
Rotary
Drilled in 36
days
Excellent drilling practices

363
MSc Petroleum Engineering Well Engineering

Hook Well Design Drilling Up Hill


Drilled from land to
offshore location
Accessed multiple
reservoirs
Completed with
gravel pack
Maximum hole
angel 167 deg
Used RSS
BSP - Todak Field
MSc Petroleum Engineering Well Engineering

364

Snake Well Design

Access multiple small reservoirs


365
MSc Petroleum Engineering Well Engineering

Multi-lateral Wells
Production tool
Can improve well
economics
Multiple access from single
wellbore
Injection & production
from same wellbore
Different levels of isolation
Applications
Sidetrack (with whipstock)
from existing or purpose
built wells
366
MSc Petroleum Engineering Well Engineering

Multi-lateral Wells
Selective Production
Sealed junction
Zonal isolation
Selective access
Problem areas
Competence of junction seal
Access to laterals
Isolation of laterals

367
MSc Petroleum Engineering Well Engineering

Multilateral well example


Matrix Carbonate Field
Dual lateral producer
Triple lateral injector wells
Total 8300 m open hole
Few options in producer
when water breaks through

368
MSc Petroleum Engineering Well Engineering

Stuck Pipe

369
MSc Petroleum Engineering Well Engineering

What is Stuck Pipe?


When the maximum pull on the drillstring is
reached and the pipe is not moving out of
the hole the string is STUCK.

370
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms


There are several mechanisms for pipe becoming stuck. The most
common mechanisms include the following:
Poor Hole Cleaning
Chemically Active Formations
Mechanical Instability
Overpressured Formations
High Dip Sloughing
Unconsolidated Formations
Mobile Formations
Undergauge Hole
Key Seating
Tectonic Stresses
Differential Sticking
371
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (1)


Differential
Sticking

Caused by DP between porous


& permeable formation and
mud hydrostatic pressure
Frequent problem due to
depleted reservoirs
Recovery possible

Preventive measures?
372
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (1)


differential sticking
Build-up of
Low Gravity Solids

Filtercake

Excess
mud
pressure

String
Permeable
Formation

Gelled,
stagnant
mud
373

MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (1)


differential sticking
build-up of
Low Gravity Solids

Filtercake

Contact Area will


increase with time

Excess
mud
pressure

String

String
Permeable
Formation

Gelled,
stagnant
mud

374
MSc Petroleum Engineering Well Engineering

Differential Sticking Mechanism


In normal drilling operations, mud hydrostatic
pressure exceeds formation pressure.
The pressure differential is usually designed to
be 200-300 psi but in depleted formations it
can be much higher.
The differential pressure in permeable zones
forces filtrate into the permeable rock, leaving
behind a wall cake.
When pipe comes into contact with the
wellbore the pipe surface in the wall cake is
exposed to the lower pressure of the formation
while the rest of the pipe surface is exposed to
mud hydrostatic.
Differential pressure force pulls the pipe firmly
against the wall of the wellbore.
375
MSc Petroleum Engineering Well Engineering

Differential Sticking Mechanism


Thicker wall cake results in a larger
area exposed to the lower pressure
of the formation.
Differential sticking normally occurs
when the pipe is static.
More cake is deposited to form a
bridge, causing significant increase
in effective contact area.
Differentially stuck pipe continues
to get more stuck as time passes.
Quick action is necessary to free it.
376
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (2)


Geo-pressured
Formation

DP

Too large DP fluid / formation


gradient (mud weight too low)
Exacerbated by need for low
mud weight for low pressure
zones
Shale/ Claystone Formations

Indicator; splintery & spalled


cuttings
377
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (3)


Unconsolidated
Zones

Usually top hole problem


Addressed with

High circ rate


Optimal mud weight

378
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (4)

Key Seating

Caused by high dog-legs


Ream out when detected

Run stabilizer on top of


drill collars to open up
hole
379
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (5)


Reactive Formation

Formation incompatibility
with mud filtrate
Addressed by chemical
inhibition WBM
Or use OBM SBM
380
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (6)


Drill String
Vibration

Uncontrolled vibration
results in high impact
loads against well bore
Makes fragile but stable
formations UNSTABLE
381
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (7)


Hole
Cleaning

Frequent problem due to


insufficient pump rate =>
annular velocity
Avoidable with
Increase rig HHP

Optimise pump rates


Good mud properties
382
MSc Petroleum Engineering Well Engineering

Hole Cleaning

Vertical hole - few problems


Problematic between 50
and 65 degrees
Cuttings beds form between
40 and 75 deg
Relatively less problematic
in horizontal holes
383
MSc Petroleum Engineering Well Engineering

Annulus flow regime


LAMINAR
FLOW VELOCITY
PROFILE

384
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (8)


Borehole
Geometry

Irregular hole shape


caused by:
Poor BHA selection

Poor mud system


Poor drilling practices
Formation changes
385
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (9)


Fractured/ Faulted
Formations

Aggravation by: Drillstring surging at


connections / RTs
Losses
Drill String Vibration
Drilling fluid properties

386
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (10)


Mobile Salt Formations

Tectonically stressed and often


requires very (too) high mud
weight to control

387
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (11)


Cement Related

Caused by Poor Cementations


Long rat holes

388
MSc Petroleum Engineering Well Engineering

Stuck Pipe Mechanisms (12)

Driller initiated problems:

RIH or POOH too fast

Undergauged
Hole
MSc Petroleum Engineering Well Engineering

Lack of attention

Dropped junk in hole

Run cones off roller


cone bits

Junk in Hole
389

Identifying Impending Problems

390
MSc Petroleum Engineering Well Engineering

Volume of Cuttings at Shale Shakers


observe and measure

391
MSc Petroleum Engineering Well Engineering

What to look for


CUTTINGS

Shale Shaker
Volume
Size
Type

CAVINGS

392
MSc Petroleum Engineering Well Engineering

First Actions Sticking


1.
2.
3.

4.

5.

Ensure circulation is maintained.


If the string became stuck while moving up, (apply torque) jar
down.
If the string became stuck while moving down, do not apply
torque and Jar up.
Jarring operations should start with light loading (50k lbs) and
then systematically increased to maximum load over a one hour
period. Stop or reduce circulation when; a) cocking the jars to
fire up and b) jarring down. Pump pressure will increase jar
blow when jarring up, so full circulation is beneficial (beware of
maximum load at the jar).
If jarring is unsuccessful consider acid pills, if conditions permit.

393
MSc Petroleum Engineering Well Engineering

PLANNING to avoid Stuck Pipethe


Selection/Change of BHA
Design Simplicity
Keep BHA as short as practically possible
Eliminate and/or lay down tools which are not used or have a
low probability of being used

Size Drill Collars/HWDP - compromise between:

WOB
Rigidity
Annular clearance
Annular velocity across the BHA
Wall contact area

Jar Optimisation
Type of Jar, Placement of Jar, use of 1 or 2 Jars
Awareness of Jar Limitations AND Impact
394
MSc Petroleum Engineering Well Engineering

PLANNING to avoid Stuck Pipethe


Selection/Change of BHA
Dimensions

Accurately measure & gauge (Length, OD and ID)


Bit
Stabilizers
All tools in BHA
Ensure free access for. Free Point Indicator / back-off tools

Downhole Visualization
Record all hole problems / issues
Sketch draw down hole situation
Note BHA change on tripping/drilling

Records
Certification/Inspection/records /Operating Hours
Lay down or change out tools that have reached max. operating
hours (no uncertified tools!!)
395
MSc Petroleum Engineering Well Engineering

PLANNINGTrips
Prior Trips
ToolBox Meeting prior POOH
Discuss potential problems
Provide possible solutions
Have a strategy
Borehole Geometry
Changes in BHA (PDC Bit Gauge Length, Stabilizers, Rigidity, Clearance)
Severe doglegs (key seats)
Precautionary reaming
Max. overpull/set down and when/how to use jar
Keep the String in Free Hole
When observing significant overpull or set down wt, attempt to bring string in
FREE hole first
May require running/pulling 1 or 2 stands
Free movement (up/down/rot) and circulation allows team to decide on next
steps
Surge and Swabs
Avoid poor practices which could accelerate hole instability
Recognise and deal with hole pack-off tendencies
396
MSc Petroleum Engineering Well Engineering

Fishing Equipment

397
MSc Petroleum Engineering Well Engineering

Stuck Pipe & Fishing

398
MSc Petroleum Engineering Well Engineering

How do I get that out?

399
MSc Petroleum Engineering Well Engineering

Fishing the operation of recovering an


object that is:
Stuck during drilling operations
Lost due to mechanical failure
Twist-off
Cones run off
Retrieving completion equipment for
well repair or sidetrack
Junk dropped in hole
Etc.

400
MSc Petroleum Engineering Well Engineering

The Drillstring
Stuck Pipe as per
previous session
How hard can we pull?
How much Torque?
How much pressure?

401
MSc Petroleum Engineering Well Engineering

The Drillstring
Failure Mechanisms
Twist off
Torque
Overpull
Washout => leading to failure
Cyclic loading
Crack propagation (SSC)
Mismatched components
Bit cone failure
Questions
How hard can we pull?
How much Torque
How much pressure
402
MSc Petroleum Engineering Well Engineering

The Drillstring
Lots of pieces to get
stuck, twist off, wash
out, breakand get left
in the hole

403
MSc Petroleum Engineering Well Engineering

Casing & Completion


Conductor Casing
'D' Annulus
'C' Annulus

.and lots of casing and


tubing to retrieve for
repair or well
abandonment

Surface Casing

'B' Annulus

Production Tieback

'A' Annulus

Intermediate Casing

Production Tubing

Packer
Perforations
Production Liner

404
MSc Petroleum Engineering Well Engineering

and if all else fails


when the fish is well and truly stucksome
alternatives
1. Freepoint & back-off charge (drillpipe)
2. Colliding Tool (drillcollars)
3. Chemical Cutter (tubing / casing)

405
MSc Petroleum Engineering Well Engineering

Retrieving Stuck Pipe without


Catastrophic Damage
Free Point Theory
Stretch and torque sensor
determines free point of pipe
from the elastic range of the pipe
material,
Free section of pipe deforms
linearly when pipe is subjected to
a pull or torsion.
FPIT tool measures stretch and
torque over a fixed distance
Amount of free pipe calculated
according to the theoretical
deformation model.
406
MSc Petroleum Engineering Well Engineering

Retrieving Stuck Pipe without


Catastrophic Damage
Disengaging the Fish
The free portion of string
recovered after firing a back-off
shot inside a (free) tool joint
Neutral point evaluated on e-line
and appropriate pull put on string
Left-hand torque applied from
surface (WARNING)
Back off shot usually combined
with Free Point Indicator Tool
Applicable to stuck drillpipe, drill
collars, tubing, or casing.
407
MSc Petroleum Engineering Well Engineering

CCL

Explosive Backoff

BANG!

STRING SHOT PRIMER CORD

Zero

or slightly positive
tension at joint (string in air)
LH torque, 60-75 % of
make-up torque
Charge as recommended
by service provider

408
MSc Petroleum Engineering Well Engineering

Colliding Tool
Severance device for cutting
thick-wall tubulars, drill
collars and HW drill pipe
Cutting technique based on
the colliding shock wave
principle
Precisely timed detonation of
two equal and opposing
shock fronts
409
MSc Petroleum Engineering Well Engineering

Chemical Cutter

Dissolves pipe with clean cut


No debris
No requirement for milling prior to pipe retrieval.
Used when no need to recover threaded connection
Used for special cutting applications where other cutting
methods ineffective or undesirable.
Cut tubing above permanent packers
Cut casing during plug and abandonment operations.

http://www.chammascutters.com/en/how-it-works.html

410
MSc Petroleum Engineering Well Engineering

and then?
either plug and abandon depending on
Value of the fish (RSS and geo-steering
combo ($$$)
Cost of sidetrack ($$$)
Environmental considerations (nuclear
source)
Condition of the fish looking up
or go back with a milling or fishing string
411
MSc Petroleum Engineering Well Engineering

Fishing Tools (Bowen example)

External catch fishing tools


Internal catch fishing tools
Junk retrieval fishing tools
Milling and cutting tools
Accessory tools
Repair and remedial tools

412
MSc Petroleum Engineering Well Engineering

Bowen Series 150 Releasing and Circulating


Overshot with Basket Grapple
Bowl
Bowl

Basket
Grapple
Inner Seal
Mill Control Packer
Outer Seal

Basket
Grapple

Inner Seal
Mill Control
Packer

Outer Seal
Guide
413
MSc Petroleum Engineering Well Engineering

Bowen Series 150 Releasing


and Circulating Overshot
with Spiral Grapple

MSc Petroleum Engineering Well Engineering

Wall Hook

414

Lead Impression Block


Determine the configuration of
the top of the fish
Locate fish position in the well
bore.
More precisely assess fishing
conditions and select the proper
tool or tools
Or abandon fishing
415
MSc Petroleum Engineering Well Engineering

Releasing Spears
Means of engaging a fish
internally
Positive engagement, easy
release from the fish
Easy re-engagement after
spear released

416
MSc Petroleum Engineering Well Engineering

Rotary Taper Tap


Tool of last resort
Internal catch no release
Run with safety joint (to
release)

417
MSc Petroleum Engineering Well Engineering

Fishing Assembly

Overshot (releasing)
Bumper sub
Drill Collars
Hydraulic Jar
Drill Collars
Accelerator
HWDP
418

MSc Petroleum Engineering Well Engineering

Formation Evaluation

419
MSc Petroleum Engineering Well Engineering

Wheres the Oil?

420
MSc Petroleum Engineering Well Engineering

Formation Evaluation
Key activity in well construction
Reliable information is vital for
Investment decisions about development of a
discovered reserve
Well design (size of production tubing)
Combination of many information sources

Cuttings
Cores
Petrophysical logs
Sidewall samples
Repeat formation tests (RFT)
Well Test
421

MSc Petroleum Engineering Well Engineering

Drilled Cuttings & Flow Line Shows


Cuttings retrieved at
predetermined intervals , e.g.,
Every 10 ft above reservoir
Every foot in reservoir
At the Shale shale Shaker
(Mud Logging)

Drilled cuttings retrieved and


analysed at the wellsite and
bagged for lab
Also flow line temperature,
salinity and hydrocarbon
shows
Gas chromatography / gas
detector

422
MSc Petroleum Engineering Well Engineering

Continuous Coring
SAFETY JOINT
STABILISER AND
BEARING ASSEMBLY
DROP BALL

STABILISER
INNER BARREL

CORES

CORE CATCHER,
CORE BIT AND
CORE SHOE
CORE BIT
423
MSc Petroleum Engineering Well Engineering

Continuous Coring
Direct measurement of petrophysical properties
Very Expensive in rig time and thus costs (depending
on length of core drilled per run)
Enables calibration of petrophysical tools
Identification of features below petrophysical
resolution
Core flood testing to evaluate effects of drilling fluid
damage
Actual porosity and permeability measurements
Demands care and attention of wellsite drilling team
424
MSc Petroleum Engineering Well Engineering

Wireline Logging

425
MSc Petroleum Engineering Well Engineering

Wireline Logging
Key Subsurface Properties
Lithology
Porosity
Radioactivity
Permeability
Electrical conductivity
Water / oil saturation
Density
Density Log
Determines rock bulk density
Overall density of rock including
solid matrix and the fluid enclosed
in pores

Gamma Ray
Records naturally occurring gamma
rays in the formations adjacent to
the wellbore.
Standard device used for the
correlation of logs in cased and
open holes.
Resistivity
Records electrical conductivity
Water in rock has various levels of
salt (depends on origins)
Salty water lower resistivity
Hydrocarbons high resistivity
Increasing resistivity indicates
increasing hydrocarbon saturation

426
MSc Petroleum Engineering Well Engineering

MWD Measurement While Drilling


LWD Logging While Drilling

427
MSc Petroleum Engineering Well Engineering

MWD Measurement While Drilling


LWD Logging While Drilling
LWD Logging While Drilling
Directional measurements (and control in conjunction with
Rotary Steerable Systems)
Formation evaluation (gamma, Resistivity, Sonic, Density
(amongst others)
Downhole dynamics / parameters for optimization
Pressure while drilling
Vibration
RPM

Telemetry
Pulse
Electromagnetic
Wired

428
MSc Petroleum Engineering Well Engineering

Rotary Steerable Systems


Non rotating
Sleeve

e.g. Autotrak from Baker Hughes Inteq (BHI)


LWD Triple Combo

Bit Side
Force

MWD

Rotating
Drive Shaft

Formation Evaluation
Gamma Ray + Resistivity

Non rotating Sleeve w/


Steering ribs & Inclination Sensors
429
MSc Petroleum Engineering Well Engineering

Repeat Formation Test (RFT / MDT)

430
MSc Petroleum Engineering Well Engineering

Well Testing
Provides the following:
Productivity
Fluid properties
Fluid composition
Sand potential
Flow potential
Pressure
Temperature
Combining data to prove
reservoir potential, confirm
well performance, and
improve field productivity
431
MSc Petroleum Engineering Well Engineering

Hydraulic Fracturing

432
MSc Petroleum Engineering Well Engineering

Hydraulic Fracturing
May be required to evaluate well flowability
Used in tight low permeability formations
Goal is to create a network of interconnected
fractures that serve as conduits
Enable natural gas and oil to flow from the rock into
the wellbore at economic rates
In combination with horizontal drilling has turned
previously unproductive organic-rich shales into the
largest natural gas fields in the world
Injection rates; up to 15,000 psi and 100 barrels per
minute
433
MSc Petroleum Engineering Well Engineering

Hydraulic Fracturing
Fracture is formed by pumping the fracturing fluid into
the wellbore at a rate sufficient to increase the pressure
downhole to a value in excess of the fracture gradient of
the formation rock.
The pressure causes the formation to crack, allowing the
fracturing fluid to enter and extend the crack farther into
the formation.
To keep fracture open after the injection stops, a solid
proppant, commonly a sieved round sand, is added to the
fracture fluid.
The propped hydraulic fracture then becomes a high
permeability conduit through which the formation fluids
can flow to the well.
434
MSc Petroleum Engineering Well Engineering

MSc Petroleum Engineering Well Engineering

Hydraulic Fracturing

435

Blowouts

436
MSc Petroleum Engineering Well Engineering

Where did my rig go?

437
MSc Petroleum Engineering Well Engineering

Spindletop Spectator Sports, 1902

Photographs courtesy of Texas


Energy Museum, Beaumont,
Texas.
438
MSc Petroleum Engineering Well Engineering

US Land 2002

439
MSc Petroleum Engineering Well Engineering

Desert Rig

440
MSc Petroleum Engineering Well Engineering

Desert Rig

441
MSc Petroleum Engineering Well Engineering

Multi Well Platform - Case for SSSVs

442
MSc Petroleum Engineering Well Engineering

Twisted metal

443
MSc Petroleum Engineering Well Engineering

Coiled Tubing rigs burn too

444
MSc Petroleum Engineering Well Engineering

Workovers also a risk

445
MSc Petroleum Engineering Well Engineering

Call the experts

446
MSc Petroleum Engineering Well Engineering

Jack-up shallow gas

447
MSc Petroleum Engineering Well Engineering

Jack-up shallow gas

448
MSc Petroleum Engineering Well Engineering

Platforms / Jackets

449
MSc Petroleum Engineering Well Engineering

Platform / Jacket With Jack-up

450
MSc Petroleum Engineering Well Engineering

that Sinking Feeling

451
MSc Petroleum Engineering Well Engineering

Platforms / Jack ups

452
MSc Petroleum Engineering Well Engineering

Land Rig going

453
MSc Petroleum Engineering Well Engineering

Land Rig goinggoing

454
MSc Petroleum Engineering Well Engineering

Land Rig goinggoinggone

het Haantje
MSc Petroleum Engineering Well Engineering

455

Avoiding Blowouts

het Haantje
MSc Petroleum Engineering Well Engineering

456

Blowout!
Uncontrolled Flow From a Well
Risk to human life
Risk to the environment
Loss of Company image &
reputation
Loss of assets
Potential recovery costs up to US$100
million (and more )
Potential damage to reservoir in
excess of US$100 million (and more
.)

Cleanup..Billions
457
MSc Petroleum Engineering Well Engineering

How do Blowouts Happen?


Two things must occur:
Primary barrier must fail
Usually loss of hydrostatic
pressure provided by drilling
mud or completion fluid that
(over) balances the reservoir
pressure

Secondary Barrier must fail


Drillpipe safety valve, BOP,
Well-head, valve, etc.

458
MSc Petroleum Engineering Well Engineering

Where do Blowouts Occur?


What type of operations?

459
MSc Petroleum Engineering Well Engineering

Blowout Occurrence by Operational


Phase
SPE

1206 Occurrences
203 Occurrences

SINTEF

41%
31%
27%

25%

23%
13%

11% 12%

8%

el
W
ir

et

io

in

se

2% 2%

C
om
pl

Pr
o

du

ct

io

Ph
a

Ph
a

se

ng
lli
tD
ri
m
en

D
ev

el

op

ko
W
or

Ex
p

lo

ra

t io

ve

D
ri

lli

Ph
a

se

ng

5%

http://www.sintef.no/home/Technology-and-Society/Safety-Research/Projects/SINTEF-Offshore-Blowout-Database/
MSc Petroleum Engineering Well Engineering

460

What Do We Learn/Gain From Blowout


Statistics?

Identify recurring well control problem


areas
Help engineers & supervisors to focus on
design, equipment and procedural
shortcomings
Help training efforts to be focused where
skill gaps exist

461
MSc Petroleum Engineering Well Engineering

What is the Primary Cause


of Drilling & Workover Blowouts?
The Loss of Primary Control
Where are we most vulnerable?
DURING ROUND TRIPS!!!!!!
462
MSc Petroleum Engineering Well Engineering

Overview of Occurrences of Loss


of Primary Control
SPE

SINTEF

40%

Swabbing Is the Primary Cause

30%

21%
17%
14%

12%

11%

13%

11%

8%

7%

ps

s
C
em
en

t in

se
Lo
s

l- u
f il

Im
pr

op

er

cu
er
/W
at

1%

as

4%

tm
ud

H
P
d
te
ec
xp

U
ne

To
o

Lo
w

ud

Sw

ab

W
ei

bi

gh

ng

4%

463
MSc Petroleum Engineering Well Engineering

Why Do We Lose Primary Control?


Main reason:
Human Error (on the rig, but also in the
design phase)

Lack of awareness
Failure to follow procedures
Lack of skills
Failure to communicate

During drilling and workover


operations; swabbing is responsible for
between 30% 40% of all Blowouts
464
MSc Petroleum Engineering Well Engineering

Why Do We Lose Secondary Control?


Main reasons are:
Equipment Failure
Design
Maintenance

Human error
Failure to follow procedures
Lack of knowledge
Lack of skills
Technical
Managing crisis
465
MSc Petroleum Engineering Well Engineering

Overview of Occurrences of Loss


of Secondary Control
SPE

SINTEF

32%

25%

18%

17%

17%
15%

12%

15%

12%
10%

9%

6%

5%

fa
ile
d

2%

ad
W
el
lh
e

Xm

as

tre

si
ng

Sh

fa
ile
d

oe

3%

Fr

ac

tu
r

BO

at

Ca

no

BO

ti
n

Fa

pl
ac

ile
d

P
BO
e
Cl
os
to

ile
d
Fa

to
ile
d
Fa

St
rin

Sa

St
ab

fe
ty

Sa

Va

lv
e

fe
ty

Fa

Va

ile
d

lv
e

3%

466
MSc Petroleum Engineering Well Engineering

Why Do Blowouts Occur?

Blowout

Barriers Fail (equipment failed)


Barriers Fail (well design flawed)
Wrong Decisions (skill / procedures)
Secondary Control is Effective / Not Effective
Primary Control is lost
Well Kicks (incorrect mud weight / procedure)
467
MSc Petroleum Engineering Well Engineering

The Risk Areas

468
MSc Petroleum Engineering Well Engineering

Blowout Frequency (1)


Exploration Drilling
Highest frequency in deep exploration wells

Due to:

Demanding environment
High surface pressures / temperatures
Unexpected high reservoir pressures
Inability to handle high volumes of gas at surface
Kick and Loss problems
Duration of Well Kill
Erosion of surface equipment
Hydrate problems
Lack of skills
469

MSc Petroleum Engineering Well Engineering

Blowout Frequency (2)


Development Drilling
Lack of awareness / complacency
Inadequate well control procedures
Inadequate training
Poorly maintained equipment
Blowout frequency highest after kicks
following round trips
Insufficient overbalance?
Too high tripping speeds
Lack of awareness / complacency
470
MSc Petroleum Engineering Well Engineering

Blowout Frequency (3)


Workover Operations
Why?
No BOP
Improperly maintained / installed BOP equipment
Old wells
Insufficient overbalance?
Not filling the hole
Too high tripping speeds
Inadequate training
Lack of awareness / complacency
Blowout frequency highest during running & pulling
tubing or drillpipe
471
MSc Petroleum Engineering Well Engineering

Contributing Factors
Demanding well designs
Emphasis on drilling
Cheaper
Faster
Deeper

Inadequate well control procedures


Inadequate well control management skills
Technical
Crisis management

Training does not adequately address the most


frequent blowout cause
472
MSc Petroleum Engineering Well Engineering

Preventing Blowouts

Good well design


Maintain and test equipment
Good drilling practices
Vigilance
Close in well when uncertain
Follow procedures
No short cuts
Training & competence development
473

MSc Petroleum Engineering Well Engineering

Why Do Blowouts Occur?


Ensure all barriers are in place
and working = Your job!

Blowout

Barriers Fail (equipment failed)


Barriers Fail (well design flawed)
Wrong Decisions (skill / procedures)
Secondary Control is Effective / Not Effective
Primary Control is lost
Well Kicks (incorrect mud weight / procedure)
474
MSc Petroleum Engineering Well Engineering

Well Control Methods

475
MSc Petroleum Engineering Well Engineering

Well Construction
Drill a Well on Land (Step for Step)

476
MSc Petroleum Engineering Well Engineering

Plan of Action
Order long lead items
Prepare and sign contracts
Prepare & obtain approval of detailed well
design
Obtain approval for expenditure
Conduct drill well on paper exercise
Prepare location
Drill the well
Review performance
477
MSc Petroleum Engineering Well Engineering

Drilling location is selected


and coordinates finalised.

Lithology is known
(development drilling) or
predicted (exploration)
from seismic, nearby wells
or outcrops.
478
MSc Petroleum Engineering Well Engineering

Step 1
Clear the lease
Level & Prepare
the site
Drainage
Mud pits
Construct the
cellar

479
MSc Petroleum Engineering Well Engineering

Step 2
Drill or Drive the
stove pipe with
purpose built rig

Drill/drive
Non rig operation

Provide return path


for drilling fluid
Prevent erosion of
unconsolidated
formation under the
rig
Move the rig in and
rig up
480
MSc Petroleum Engineering Well Engineering

Rapid Rig
Step 2a
Move in rig and
raise mast

481
MSc Petroleum Engineering Well Engineering

Drilling Pad

482
MSc Petroleum Engineering Well Engineering

Step 3
Prepare spud mud
Make up the BHA
Commence drilling
operations
Drill top hole for
conductor casing

483
MSc Petroleum Engineering Well Engineering

Drilling Operations
Step 3a
Commence drilling
operations for 24 hole
Bit Type?
Circulation rate = ?
RPM = ?
WOB = ?

484
MSc Petroleum Engineering Well Engineering

Step 4
Pull out of hole
Rig up for casing
Make up shoe
track (Float Shoe)
and centralizers
Run in to bottom
Hang off

485
MSc Petroleum Engineering Well Engineering

Step 5
Run in hole (RIH) with
internal cementing stinger
Stab (drillpipe) stinger in
shoe
Mix and pump cement
Cement Casing (cement
returns back to surface)
Cement casing
Wait on Cement (WOC)
Remove casing landing
joint

LANDING JOINT

486
MSc Petroleum Engineering Well Engineering

Step 6
Screw on or weld
on casing housing
Nipple up BOP
Test BOP

487
MSc Petroleum Engineering Well Engineering

-- Wellhead Detail --

Wellhead Overview

Special Operations

Supports the weight of the casing


Isolates the casing annuli
Allows access to the annuli

Tubing Spool
BOP's sit here
while drilling

Casing Spools
C-Section

B-Section

A-Section

Surface Wellhead Configuration


MSc Petroleum Engineering Well Engineering

-- Setting Slips --

-- Slips Set --

488

488

Step 7
Nipple up BOP
Test BOP
Plug type
tester
Cup type
tester

489
MSc Petroleum Engineering Well Engineering

Nipple up and
test BOPs
Annular Preventer

Pipe Rams

Wellhead: A and B-Sections

Surface BOP Stack Configuration


MSc Petroleum Engineering Well Engineering

Pipe Rams

490

Step 8.X
Prepare to Drill next
Intermediate Casing
hole section
Log
Run Casing
Cement
Ready to drill
Production Casing
hole section
491
MSc Petroleum Engineering Well Engineering

Step 8.X
Drill Next
Intermediate
Casing hole
section
Log
Run Casing
Cement
Ready to drill
production casing
hole section

INTERMEDIATE

492
MSc Petroleum Engineering Well Engineering

Production Casing Section

493
MSc Petroleum Engineering Well Engineering

The Situation:
Casing Shoe

Intermediate casing run and cemented


Wellhead is installed & tested
10k BOP's are installed
Tested; Procedure?
Ready to drill production interval

Cement

Production Objective

494
MSc Petroleum Engineering Well Engineering

494

Drill Casing Shoe Track & Pocket

Pick up bit and BHA


Trip in hole and drill out cement
Drill 10 ft
Circulate clean (inside the shoe
Why?)
Conduct Leak-off test Why?

Casing Shoe
10 ft of new hole

Production Objective

MSc Petroleum Engineering Well Engineering

495

Conduct Leakoff Test


Shoe Test Example

Purpose:

1800

- Determine formation strength

- Defines maximum mud weight for the next


drilling interval

1600

LOT Pressure

- Cement job quality indicator

1400

Procedure:
- Pressure up on the hole
- Record pressure vs. bbls pumped

(PSI)
PRESSURE
Pressure

- Shut the BOP's

1200

1000

800

- Data should be linear


- Stop when becomes non-linear

600

400

Terms:
-

LOT leak off test


FIT formation integrity test
PIT pressure integrity test
ST shoe test

200

0
0

10

15

20

25

30

Volume pumped / time

496
MSc Petroleum Engineering Well Engineering

496

Drill Ahead

Complete Leak-off Test


Drill ahead (Conduct Drill-off test)
Continue drilling new hole
Encounter unexpected lost
circulation zone
Stop drilling
Observe well, estimate loss
rate
Check mud weight
Assess cause(s) of losses

Lost Circulation Zone

Production Objective

497

MSc Petroleum Engineering Well Engineering

The Losses Problem


Possible outcome;
fluid level drops
and well kicks / well
becomes unstable

Mud
gradient
to balance
normal
pressure

Fractures
Loss
Zone

Normal
reservoir
gradient

Expected
formation
strength
gradient

Source
Rock

Pressure
498
MSc Petroleum Engineering Well Engineering

Lost Circulation Decision Tree


Placement of LCM pills to control losses and achieve a solid base for
running casing / liner, or placing a cement plug

Causes of Lost Circulation:

Losses

- Excessive mud weight (Mud wt > Frac


Grad)

Losses

Pull 4-5 Stands off


bottom

Losses

Allow hole to stand


No Losses

Wash 2-3 Stands above


top of suspected zone

Circ at drilling rate


while rotating on
bottom
<10 bbls/hr

- Reduce mud hydrostatic pressure

- Alternative drilling methods


(managed pressure drilling MPD)

"Definitions"
- Partial or seepage losses

Drill Ahead

POOH to run csg /


liner

Establish magnitude of
losses. RIH 50 ft
above zone

>60 bbls/hr

10-60 bbls/hr
Place LCM as plug in
annulus

POOH to run csg /


liner

Place LCM as plug in


annulus

POOH 3-4 stands &


stage pump rates to drill
rate then ease to bottom

Pill failure

- Plug the fractures with lost


circulation material (LCM)

Drill Ahead

POOH 3-4 stands &


stage pump rates to drill
rate then ease to bottom

Continue Drilling

POOH to run csg /


liner

- Moderate losses
Continue Drilling

Pill failure

Solution:

Drill Ahead
No Losses

- Highly porous formation

- Vugular / fractured formations

Drill Formation

Place Flex-Plug pill as


annular plug
POOH 4-5 stands &
allow pill to soak for 4-5
hrs
Pill
failure

Stage pumps up &


attempt to circulate
while rotating

Drill Ahead

- Severe losses
POOH to run csg /
liner

Drill Formation

Clean Out trip

MSc Petroleum Engineering Well Engineering

Place all LCM pills at gpm's recommended by MWD/LWD


company to achieve maximum clearance though
telemetry package

499

POOH to run csg /


liner

Pump
Gunk
squeeze
or
Diaseal
M

Drill Ahead

Cure losses, pump LCM

Drill ahead to the objective interval

Observe Drilling Break and increased


flow.

Well has kicked (Reservoir / Formation


) pressure higher than expected)

Close in well

Pick up kelly stop circulation

Close Pipe Rams

& Control Well

Record shut-in pressures (Pdp & Pan)

Increase mud weight

Circulate out the kick

Formation fluid influx (kick)

Production Objective

500

MSc Petroleum Engineering Well Engineering

500

Well Kick

501
MSc Petroleum Engineering Well Engineering

Pressure Depth Graph

SIDPP

Shut-in Drill Pipe


Pressure (SIDPP)

SICP

Closed BOP

The SIDPP is a
measure of
the underbalance of the
initial mud
weight

Original Mud Weight

What about
the loss zone?

Depth - TVD

Indicates how
much the mud
weight needs
to be
increased

Shut-in Casing
Pressure (SICP)

Kick Height
(?)

Pressure (psi)

MSc Petroleum Engineering Well Engineering

Original Mud Weight

Influx Volume:
Gas, oil, water or
some combination

502

Drill To TD

Complete well control procedues


Continue drilling through the
objective
Make a wiper trip - Why
Pull out of hole (POOH) for logging
(Logging While Drilling (LWD))
may deliver sufficient information,
otherwise additional wireline logs /
formation tests conducted
503

MSc Petroleum Engineering Well Engineering

Formation Evaluation
Run petrophysical logging tools
Identify
Formation tops
Hydrocarbon potential
Production interval(s)
Caliper log for cement volumes
Determine where to perforate

504
MSc Petroleum Engineering Well Engineering

Post Logging

Complete Logging
Make up BHA
Remove expensive tools Why?
Run in hole for wiper trip
Circulate and condition mud
POOH for casing job

505
MSc Petroleum Engineering Well Engineering

Run and Cement Production Casing

Remove wear bushing


Pick up shoe track and test floats
Run casing to TD
Make up casing hanger
Circulate and condition mud
Carry out plug type cementation
Mix & pump spacers, lead and
tail cement
Bump plugs and pressure test
casing
Nipple down and install the
wellhead (tubing spool)
Energise seals and test

MSc Petroleum Engineering Well Engineering

506

Prepare for Completion

Cement job is complete


RIH to top of cement (TOC)
Drill plugs, float collar & cement to
below perforation interval &
provide a pocket for perforation
guns / gun debris
Scraper run
Displace to completion fluid

507

MSc Petroleum Engineering Well Engineering

507

Prepare for Completion

Cement job is complete


RIH to top of cement (TOC)
Drill plugs, float collar & cement to
below perforation interval &
provide a pocket for perforation
guns / gun debris
Scraper run
Displace to completion fluid

Completion fluids are solids-free liquids


typically brines (chlorides, bromides and
formates), meant to control the well without
damaging the producing formation should
downhole hardware fail,
508

MSc Petroleum Engineering Well Engineering

508

Evaluation of Casing Cementation

Fig 1

Casing Bond Log


(CBL/VDL)

Fig 1
Good Cementation
Low attenuation
Fig 2
Poor Cementation
High attenuation

Fig 2

509
MSc Petroleum Engineering Well Engineering

Complete the Well

Run and set production packer and


tail on wire line with gamma and
CCL
(Alternatively with tubing and
perforating guns in one run (TCP))

510

MSc Petroleum Engineering Well Engineering

510

Complete the Well

Run completion tubing & (optional)


completion equipment (depends on
well type and lift requirements)
Nipples
Gas lift mandrels
Surface Controlled Sub-surface
Safety Valve (SCSSV)
ESP (Electrical submersible
Pump)
Rod pump
Stab into production packer
511

MSc Petroleum Engineering Well Engineering

511

Prepare for and put the Well on


Production

Place isolation plug in tubing


hanger
Remove BOP
Install the production tree
Remove isolation plug
Run guns
Perforate the well
Hook up and put well on
production

512
MSc Petroleum Engineering Well Engineering

512

Connect the well to the reservoir, PERFORATE

Shaped
Charge

Perforating
Gun

Casing
Cement

Perforations are made by firing


shaped charges downhole
through the casing & cement
into the formation, using a
Perforating Gun.

Formation
513

MSc Petroleum Engineering Well Engineering

Connect the well to the reservoir, PERFORATE

Derrick

Logging Truck

Electric
Wireline

Electric
Wireline
Conveyed
Perforating
Guns

Packer

Tubing

Tubing
Conveyed
Perforating
(TCP)
Guns
514

MSc Petroleum Engineering Well Engineering

Will the Well Flow?

Formation damage (impairment)


results in lower production rates, lower
ultimate recovery and possibly
uneconomic wells Perforate beyond the
damage.

Porosity:
Ability to contain
Permeability:
Ability to flow through
515
MSc Petroleum Engineering Well Engineering

Prepare for and put the Well on


Production

Place isolation plug in tubing


hanger
Remove BOP
Install the production tree
Remove isolation plug
Run guns
Perforate the well
Hook up and put well on
production

516

MSc Petroleum Engineering Well Engineering

516

Christmas Tree
Purpose
Installed on top of the wellhead
to control the flow of well fluids
during production.
Provides primary and back-up
control facilities for production
Enables wellbore shut-in
Incorporates facilities to enable
safe access for well intervention
operations , e.g., slickline, electric
wireline and coiled tubing

517
MSc Petroleum Engineering Well Engineering

Flowline

Xmas tree

Cellar

Wellhead
518

MSc Petroleum Engineering Well Engineering

The End
We Drilled and Completed a Well

519
MSc Petroleum Engineering Well Engineering

Organisation

520
MSc Petroleum Engineering Well Engineering

Operator Typical Well Engineering


Organisation
Corporate
C&P

Corporate
HR

C&P

HR

Rig Strategy Parenting


Contracts
Transfers
Category
Packages
Management.
Integrated
Service
contractor
relationships

GM Well
Engingeering

Chief
Engineers

Corporate
HSSE

Business
Improvement

WE
Mgrs

Standards
Drilling /Well
Assurance
Dispensations Planning
Governance
Graduates
Completions
Top Quartile
Career
Projects
Delivery and
Planning
Top Quartile
Performance
Technical
Framework
Audits/Health
Advice
IT/New Ways of
Checks
Training
Working
Liaison/Focal
Self Study
New technology
point Assets
Competence Fluids
Value
Accreditation Subsea
Assurance
Exams
Deepwater & HPHT process
Unconventionals
Performance
Analyst
QA/QC

MSc Petroleum Engineering Well Engineering

HSSE

HSSE
Improvement
Audits,
Health
Checks
Rig
Acceptance
Link to
Corporate
HSSE

521

Operator / Contractor Relationship


Operator

Drilling
Contractor

Contracted
to provide,
maintain
and operate
major
drilling rig
equipment ,
including
BOPs and
drillstring.

Major
Service
Companies

Minor
Service
Companies

Contracted
to provide,
additional
services,
Directional,
Cementing,
Pphys ical
Logging etc

Contracted
to provide,
additional
services,
Inspection,
Mud
logging,
Casing run,
Waste mgt &
disposal,
Coring

Consumables
& Eqt.
Suppliers
Can be
MSCs but
also
specialist
Cos
Provide,
Casing,
Jars.
Fishing eqt.

Integrated Services Providers (ISPs) , e.g., Schlumberger, Halliburton


522
MSc Petroleum Engineering Well Engineering

Whos Who in the Office

523
MSc Petroleum Engineering Well Engineering

Office Based Well Engineering Team


Well Delivery
Manager

Well Engineer
Projects
New technology
Performance
analysis
Failure analysis
Directional QA/QC

Well Engineer
Contracts

Well Engineer
Operations

. Monitors
contract
performance
Contractor HSSE
Equipment &
services
Link to C&P

HSSE
Writes drilling
programme
Liaison with
other disciplines
Liason with rig
Liason with
servcos

Integrated Services Providers (ISPs) , e.g., Schlumberger, Halliburton


524
MSc Petroleum Engineering Well Engineering

Whos Who on the Rig

525
MSc Petroleum Engineering Well Engineering

Rig-based Organisation
Offshore Installation Manager (OIM)
(Company - when drilling on or near production facilities)

Drilling
Supervisor

Wellsite PE
(ADS)

Service
Companies

Company

Contractor
Toolpusher
(OIM)

Drilling
Crew

Rig
Maintenance

Contractor
526

MSc Petroleum Engineering Well Engineering

Company Rep / Drilling Supervisor


Responsible for
implementation of the
companys Safety
Management System
(SMS).
Third Party contractors
who are also
responsible for working
under their own and
Contractors
Management System

Works for Operator


Implementing the
drilling programme
Primary responsibilities
Liaison with WE Dept
Operational safety
Implementing optimal
drilling parameters
Logistics & cost control
Implementing well
control
527

MSc Petroleum Engineering Well Engineering

Safety Management System (SMS)


a systematic, explicit and comprehensive
process for managing safety risks. As with all
management systems, a safety management system
provides for goal setting, planning, and measuring
performance. A safety management system is woven
into the fabric of an organization. It becomes part of
the culture, the way people do their
jobs...

528
MSc Petroleum Engineering Well Engineering

Wellsite PE (ADS)
Training rig-based role
Works for Operator reports
to Company Rep
Liaison for town based PE
Dept.
Primary responsibilities
Data collection & distribution
Collect geological data
Supervise petrophysical
logging
Directional data
Casing tally /Cementing
Etc, etc.

529
MSc Petroleum Engineering Well Engineering

Contractor Rig Superintendent / Toolpusher


Works for Drilling Contractor Accountable to
Rig Manager
In-charge of the rig personnel, logistics.
In some cases (MODU) the OIM
As OIM, Responsible for the safety of the rig
Primary responsibilities
Ensure rig and staff safety
Maintain operability of the rig (uptime)
Protect contractors interests
530
MSc Petroleum Engineering Well Engineering

Driller (& Assistant)


Works for Drilling
Contractor
In-charge of the shift
/crew
primary responsibilities
drive the drawworks
maintain rig safety
maintain optimal drilling
parameters
maintain well control
Note: New generation rigs require different skill sets
MSc Petroleum Engineering Well Engineering

531

Derrickman
Work for Drilling Contractor
Reports to Driller
Primary responsibilities

Work in derrick on monkey


board

Set back / run in pipe during


round trips

Drilling fluid responsibilities


Pump maintenance

532
MSc Petroleum Engineering Well Engineering

Roughnecks (floormen)
Work for Drilling Contractor
Report to Driller
Duties

making pipe connections


maintaining equipment
hands-on checking drilling
fluid/ flow parameters
general rig floor maintenance
duties
Nippling up BOPs

533
MSc Petroleum Engineering Well Engineering

Mud Engineer
Reports to PE

works for Service


Company
responsible for drilling
fluid
measuring and sampling
solids removal equipment
addition of chemicals
optimising and
maintaining fluid
properties

MSc Petroleum Engineering Well Engineering

534

Mud Logger

Gather, clean, sort and


identify drilled cuttings
Monitor well fluids and
identify entrained gasses
Monitor fluid volumes on
rig (kick control)

535
MSc Petroleum Engineering Well Engineering

Tubing/Casing Crew
Work for Service
Company
responsible for
running casing &
tubing completion
equipment
critical make-up torque
hydrostatic testing
while running

536
MSc Petroleum Engineering Well Engineering

Others (Drilling &


Completion Services)

Major Service Providers


Cementers,
http://www.halliburton.com/
Coring
http://www.bakerhughes.com/
MWD Engineers
http://www.weatherford.com/
Directional Driller
Petrophysical loggers http://www.slb.com/
http://www.nov.com/
Completions
Etc
Well Testers
Fraccing
Inspection
Etc
537

MSc Petroleum Engineering Well Engineering

Quiz

Since 1940 the highest weekly US rig count was?


The lowest rig count was?
In Canada the highest weekly rig count was?
The lowest weekly rotary rig count was?
Since 1975 the highest international rig count
was?
The lowest international rig count was?
538
MSc Petroleum Engineering Well Engineering

Answers
Since 1940 the highest weekly US rig count was 4,530
recorded on December 28, 1981.
The lowest rig count of 488 was recorded on April 23,
1999.
In Canada the highest weekly rig count of 718 was
recorded on February 17,2006.
The lowest weekly rotary rig count of 29 was recorded on
April 24,1992.
Since 1975 the highest international rig count was 1,509,
recorded in November 1982
The lowest international rig count of 556 was recorded in
August 1999

539
MSc Petroleum Engineering Well Engineering

US & Canadian Rig Count 1987 - 2010


BAKER HUGHES RIG COUNT (US & Canada)
3000

2410
2500

2000

1500

Series1

1262

1000

500

MSc Petroleum Engineering Well Engineering

09
To
da
y

08

Ours is a cyclical business driven by $/bbl

20

06

05

04

03

02

01

00

99

98

97

96

95

94

93

92

91

90

89

07

20

20

20

20

20

20

20

20

20

19

19

19

19

19

19

19

19

19

19

88

19

19

19

87

540

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