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This paper was prepared for presentation at the SPE Kingdom of Saudi Arabia Annual Technical Symposium and Exhibition held in Dammam, Saudi Arabia, 25–28
April 2016.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Saudi Aramco has been producing from the Manifa offshore field in the Arabian Gulf since 2011. By
drilling mainly lateral wells, Saudi Aramco has targeted the main reservoir that belongs to the early
Jurassic period. The pay zone is overlaid with weaker interbedded sand/shale formations and carbonate
formations of the upper and lower cretaceous period.
The main challenges that were encountered while drilling these wells included total/partial mud losses
and severe wellbore instability-related issues across the weaker formations overlaying the reservoir
section (pay zone). An advanced geomechanical study was crucial for understanding the nature of the
existing problems faced during drilling and applying the study’s findings for drilling future extended reach
(ERD) wells successfully.
A comprehensive geomechanical study of the field was conducted by constructing a calibrated
post-drill 1-D Mechanical Earth Model (1D-MEM) for selected vertical wells. The study helped in
providing reliable rock mechanical properties and fracture gradients across the problematic formations, a
lack of which was a limiting factor in understanding the nature of the problems while drilling.
For the current study, an integrated workflow was implemented mainly to perform a root cause analysis
of mud losses and to define well inclination (deviation) limits to drill through the problematic formations
to minimize wellbore instability-related issues. Open hole log data was used to construct the 1D-MEMs.
The developed models were further calibrated using all the available data (drilling observations, results
of well testing, core mechanical testing, etc.). Image data was also analyzed to capture the presence of
fractures/faults or related features along the wellbore.
Based on the analysis results, it was concluded that the mud losses in the overlaid carbonate formations
were attributed to the presence of localized open natural fractures or caverns, or vugs. It was also
concluded that most of the wellbore instability-related issues (hole pack-offs, stuck pipe incidents, etc.)
occurred due to insufficient drilling mud weights that were not able to support the rock on the wellbore
wall. The present study helped in better characterization of the problematic formations and also provided
useful information for planning future extended reach (ERD) wells. Some of the provided recommenda-
2 SPE-182833-MS
tions included acquisition of micro resistivity image logs (to identify nature of fracture), implementation
of real-time geomechanics, and optimization of mud rheology, mud weight program, and casing design.
Introduction
The offshore Manifa oil field was discovered in 1957. It is located in the Arabian Gulf (Figure 1)
approximately 200 km northwest of Dhahran. The entire field measures approximately 45 km in length
and 18 km in width, encompassing both onshore and offshore areas with water depths between 4 and 6
m (Carpenter, 2014). Production began in 1964, but due to low crude oil demand, production was stopped
in 1984, and the facilities were mothballed in 1985. In 2006, development of a mega-project at the Manifa
shallow water offshore oil field was kicked off by Saudi Aramco, and included construction of the
required infrastructure and production facilities (Aldossary, 2015). New technologies were pivotal and
central to the Manifa field development; fit-for-purpose technologies were successfully implemented to
overcome numerous challenges in a cost effective and environmentally friendly manner (Xia et al., 2014).
The Manifa reservoir has five main layers, but only two of them are considered as reservoirs targeted for
development. The two intervals contain both heavy oil and relatively lighter crude (Carpenter, 2014). A
typical stratigraphy column (Pollastro et al., 2003) of the Arabian Gulf is shown in Figure 2.
Some of the main challenges encountered during the development drilling were represented by
total/partial mud losses and severe wellbore instability-related issues across the weaker formations
overlaying the reservoir section (pay zone). As a result, proper geomechanical understanding was crucial
to address the nature of the existing problems and use it for drilling future extended reach (ERD) wells
successfully. This could be achieved by constructing calibrated post-drill Mechanical Earth Models
(MEMs) for selected wells from the field/area. The key objectives of this study included a review of the
drilling experience to understand the nature of the problems while drilling, identification of root cause(s)
of the mud losses, construction and calibration of the geomechanical models for the problematic (weak,
interbedded) formations and identification of safe mud weight limits for various well deviations.
Geomechanical Analysis
Five wells were selected to conduct the geomechanical study. Figure 3 presents the location of the selected
wells M-1, M-2, M-3, M-4, and M-5 along with location of the planned extended reach wells (P-1, P-2,
P-3, P-4, and P-5) to be drilled in the near future.
Figure 3—Location of the wells selected for the geomechanical analysis (wells M-1, M-2, M-3, M-4, M-5). Wells P-1, P-2, P-3, P-4, P-5 to
P-5 are the planned extended reach wells.
4 SPE-182833-MS
Figure 4 —The geomechanical analysis for the Manifa field: General workflow.
Based on the workflow, 1D-MEMs for five selected vertical wells M-1, M-2, M-3, M-4 and M-5 (from
the Manifa offshore area) were constructed using open hole conventional log data provided by the Saudi
Aramco team. Drilling-related information (data) of other lateral wells were also incorporated in the
present study, to help in identification of a root cause for the losses occurred during the drilling operations.
SPE-182833-MS 5
Data Audit
Building 1D MEM consists of integrating data from various sources to accurately describe the formations
in terms of geomechanical attributes. A data audit, which is the first step in the generation of 1D MEM,
is conducted to identify completeness, correctness, and availability of the input data that is relevant to the
construction of geomechanical models (Bratli et al., 1983).
In general, the dataset provided for the study was more or less complete and of good quality. Table 1
shows the data that was available for the five selected wells.
The log data necessary for the geomechanical modeling existed in all five analyzed wells. Figure 5
presents the coverage of the open hole logs using the dataset for well M-3 as an example. It included
gamma ray, density, porosity, sonic (compression and shear), resistivity, and caliper.
Figure 5—Well M-3: Open hole logs used as the input for 1D MEM.
6 SPE-182833-MS
Well M-3 was the main well to calibrate the results of the geomechanical analysis since in this well
the following information was acquired and necessary tests took place:
● Image data. Interpretation results of FMI allowed identifying of orientation of the horizontal
stresses.
● Multi-stage and single-stage triaxial tests that were conducted on plugs taken from the Rumaila
(RUML), Wara (WARA), Safaniya (SFNY), Khafji (KHFJ), Shuaiba (SHUB), Biyadh (BYDH),
and Buwaib (BUWB) formations. Most of the plugs were cut from shale intervals, while only a
few plugs came from carbonate and sandstone layers. Using the logs and results of the rock
mechanical tests, correlations to evaluate the elastic and strength rock properties were developed.
● Closure and breakdown pressures from Micro-frac jobs. The closure pressures were utilized to
directly calibrate magnitude of the minimum horizontal stress, while the breakdown pressures
were used for indirect calibration of the magnitude of the maximum horizontal stress.
● Formation pressures measured data points were used to calibrate estimated pore pressure.
The shortcoming was that the log data necessary for the geomechanical analysis existed only in vertical
wells.
Figure 6 —One of the analyzed lateral wells: Summary of the drilling events. The well was drilled with 72 ~ 76 pcf mud weight (OBM).
Partial to total mud losses along with tight hole and hole pack-off incidents were recorded across various formations.
The extracted drilling events (Table 2) were used to understand what caused the problems while
drilling. In addition, they were used to calibrate results of the wellbore stability analysis.
SPE-182833-MS 7
Table 2—Summary of mud losses and tight holes/stuck pipe incidents observed in the analyzed vertical and lateral wells.
From the analysis of the drilling reports, the following became evident:
● Partial to complete losses were encountered across a number of formations (Aruma, Wara,
Maudud, Shuaiba, Safaniya, Khafji and Biyadh). To cure seepage/partial losses, lost control
materials (Marble, Fiber, Mica, etc.) were utilized, while for total losses, cements plugs were
placed to ⬙plug⬙ the problematic intervals.
● Occurrence of mud losses, stuck pipe incidents and tight holes did not depend on drilling direction
(Figure 7). The majority of the most severe wellbore instability-related problems were experienced
at wellbore inclinations higher than 60 degrees.
● Mud weights used for drilling vertical and lateral wells in the problematic formations varied
between 70 and 76 pcf. Oil base mud was utilized.
● Many stuck pipe and tight hole incidents, over-pulls, etc. encountered in shaly layers across the
Aruma, Ahmadi, Safaniya, Khafji, Biyadh and Buwaib formations during pulling out of hole
(POOH), can be explained by inadequate mud weights and non-optimum mud salinity.
● The pipes that were stuck were released in most cases either by working the drill pipe, adding
glycol pills, or by using acid.
8 SPE-182833-MS
Figure 7—Analysis of losses (left plot) and stuck pipe (rightplot) incidents. The plots show that the losses observed while drilling do
not depend on wellbore trajectory (azimuth and inclination). Stuck pipe insidents are encountered more often at wellbore deviations
higher than 60 deg.
Mechanical Stratigraphy
The mechanical response and properties of shale and non-shale formations usually differ significantly
(Figure 8). The classification of mechanical stratigraphy enables us to calculate the rock mechanical
properties using different correlations, if needed. In the current study, the lithology included mainly
carbonate, shale, and sandstone. The differentiation of non-shales from shales was achieved by applying
a threshold of 50 gAPI to the gamma ray log in the analyzed wells. The developed mechanical stratigraphy
(can be observed in Figure 9) was also validated with information provided in the available master/mud
logs.
Figure 9 —Well M-3: Input logs and rock mechanical properties profiles generated using the core-log correlations. The plot shows theb
results of the laboratory measurements.
The rock properties profiles were estimated for all studied wells. Figure 9 shows the resultant elastic
and strength rock properties for well M-3 as an example.
Where z is overburden stress at a specific depth ‘z’, is formation density and g is gravitational
constant.
The overburden stress gradient estimated using the density data in the analyzed wells was close to 1.0
psi/ft.
Pore Pressure
Pore pressure is a vital constituent in 1D MEM, and is critical to the calculation of in-situ horizontal
stresses. In the current study, pore pressure in the shales was estimated by Normal Compaction Technique
(NCT) using Eaton’s method (Figure 10). The main input data was the compressional sonic log. The
normal compaction trend was established based on the analysis of several wells in the area.
SPE-182833-MS 11
Figure 10 —Well M-3: Pore pressure profile calibrated against the available measured pressure points.
In the non-shale formations, the interpolation method was utilized and the resultant profile was
calibrated against the pore pressure measurements. The developed pore pressure model was then applied
successfully to the other studied wells to generate pore pressure profiles.
The estimated average pore pressure gradient was just above the hydrostatic, in the range of 0.47~0.48
psi/ft.
Figure 11(a)—Well M-3: Image data - Composite plot that shows the static and dynamic images along with open hole logs and 3D
borehole shape.
Figure 11 (b)—Images across Maudud formation (from well M-3) where severe mud losses were reported, no karsification signature
appearance on the image log as the interval was plugged with cement and LCM.Major findings from the image interpretation in well M-3
well are listed below:
● No major structure elements across the whole studied interval were identified.
● Orientation of the minimum horizontal stress was identified as 110° NE.
● Structure dip in the upper part across the Shuaiba Formation all the way to the topmost part of the Wasia showed very gentle dip
magnitude (around 2°) with scattering in dip azimuth.
● Complete losses occurred while drilling Maudud formation, the massive response on the image log could be due to the cement plug
placed across this loss interval to control the well. This loss interval might have been due to the existence of large cavern/karst.
● The Shuaiba Formation did not show any indication that it contributed to the mud losses (due to its massive, non-fractured/non-vuggy
nature).
SPE-182833-MS 13
Figure 12—Well M-3: Image data - Orientation of the identified borehole breakouts.
(Equation 3)
Here, x and y are the two horizontal strains that may be compressional (i.e., for tectonic compression)
or extensional (i.e., -ve, to represent lateral spreading), and can be treated simply as calibration factors that
can be adjusted to best-match the resulting stress estimates to any leak-off test data or specific modes of
rock failure seen in image logs, etc. (Desroches et al., 1999).
Therefore, the most rigorous process available for estimating the complete state of in-situ stress in the
ground (i.e., magnitudes, order, and directions) at a single well location, and particularly to determine the
magnitude of H, involves some initial estimate of the range of possible stresses (Hyett et al., 1986), as
constrained by limit state or other mechanics considerations, that is then further constrained and refined to
generate a more specific prediction. This is further calibrated by increasing degrees, using as much information
as is available, to achieve a final model that is internally consistent with and calibrated to all available data and
stress indicators (Plona et al., 2002). The complete process is illustrated in Figure 13 (a).
14 SPE-182833-MS
Figure 13—(a) General process for determining in-situ stress magnitudes at a single well location (b) profile of min horizontal stress
magnitude calibrated using micro-frac test data. The track on the right shows profile for in-situ stresses (SigV, Sigh, and SigH).
For the current study, stress modeling started with analysis for well M-3 where measured closure and
breakdown pressures were available from micro-frac tests. The horizontal stress magnitudes were
modeled using Equations 2 and 3. The magnitude of the minimum horizontal stress (Sigh) was calibrated
using the closure pressure that varied between 106 and 120 pcf (0.73 ~ 0.83 psi/ft). The magnitude of
maximum horizontal stress (SigH) was calibrated indirectly using the available formation breakdown data.
Fine tuning of the model was achieved by adjusting the strain terms in the equations for the horizontal
stresses, to best match the breakouts observed on the image and caliper logs in well M-3. The same strains
were applied to obtain stress profiles in the rest of the analyzed wells. The model was further fine-tuned
by matching the results of the modeling with the drilling observations.
Wellbore Stability
For the current study, the wellbore stability analysis was conducted for the following reasons:
● The results of the wellbore stability analysis can tell how good the 1D MEM is by comparing the
predicted wellbore (in)stability with the drilling events and observed hole condition from image
and caliper logs (Bratli et al., 1983). The prediction was compared to actual rock failure shown on
image and/or caliper logs and the drilling events in order to ensure that all model parameters are
well-constrained and are of reasonable accuracy.
● Getting better understanding if there were geomechanics-related reasons behind the instability-
related events (tight holes, stuck pipe incidents, etc.) observed while drilling. The calibrated results
SPE-182833-MS 15
of the wellbore stability analysis allowed to identify reasons behind some of the observed problems
encountered while drilling.
The wellbore stability analysis includes modeling of the shear and tensile failures in the wellbore.
Several methods exist for predicting shear rock failure. The most commonly used failure criterion are
Mohr Coulomb, Mogi Coulomb, and Modified Lade. For the current study, a Mogi Coulomb failure
criterion was used. It used the unconfined compressive strength, modified from the log prediction to
account for plasticity and other effects, and the angle of internal friction to locate the failure envelope. The
equations are:
(Equation 4)
Where
1, 2 and 3 are three principal stresses, is angle of internal friction and UCS is the unconfined
compressive strength.
The maximum tensile stress criterion predicts failure as soon as the minimum effective stress in the
wellbore vicinity reaches the tensile strength (TSTR) of the rock.
(Equation 5)
The results of the wellbore stability analysis were organized into mud weight window. Figure 14 shows
the mud weight window for well M-3 as an example.
The wellbore stability analysis results suggested the following:
● The predicted rock failure overall agreed well with the caliper log and wellbore instability-related
drilling events.
● The shale layers present in the Aruma, Ahmadi, Wara, Safaniya, Biyadh, and Buwaib formations
were characterized by relatively lower strength. The breakouts observed in the formations could
be explained by inadequate mud weight (being on low side).
● The mud losses in the Mauddud Formation were due to presence of open fractures and/or caverns.
The mud weights used to drill this formation were not expected to either create drilling-induced
fractures or open any closed natural fractures.
16 SPE-182833-MS
Figure 14 —Well M-3: Mud weight window. The plot shows the measured pore pressure, closure and breakdown pressures.
Sensitivity Analysis
A mud weight window includes four parameters: kick pressure (equals pore pressure), breakout pressure,
seepage losses pressure (equals minimum in-situ pressure) and breakdown pressure. The breakout and
breakdown pressures are trajectory-dependent, meaning that they will change with a change in trajectory
and inclination.
To evaluate the impact of deviation and azimuth on the trajectory-dependent parameters of the mud
weight window, sensitivity analysis was conducted on critical depths across the problematic formations
(especially shale and weak sandstone). Fig. 15 (a) shows the mud weight window versus well inclination
for single depths in the Wara and Buwaib formations. Fig. 15 (b) presents stereo plots for the Aruma
formation.
SPE-182833-MS 17
Figure 15 (b)—Well M-3: Stereonet plot of breakout and breakdown mud weight vs. orientation and deviation.
Table 4 —General information of various well categories for planned ERD wells.
Saudi Aramco provided trajectories and formation tops for five planned wells (P-1, P-2, P-3, P-4, and
P-5) and requested to have optimized mud weight programs for safe drilling. Based on the results of the
current geomechanical analysis, geomechanical modeling was conducted for the planned trajectories and
recommendations for safe and stable drilling were issued (Figure 16). Table 5 shows the mud weight
recommendations that can help to minimize the wellbore instability-related issues while drilling through
the problematic zones.
SPE-182833-MS 19
Figure 16 —Planned ERD wells: wellbore inclinations and azimuths along with recommended mud weights.
Table 5—Summary of the mud weight recommendations for planned ERD wells (based on the sensitivity analysis and review of the
drilling experience).
*Note: The above recommendations are based on casing the shallow shaly formations till the Wara
20 SPE-182833-MS
formations to identify presences of natural fractures and distinguish between open or closed
fractures.
● Acquire sonic, density, caliper and resistivity logs in 12 ¼ inch section in lateral wells and conduct
pre-drill wellbore stability analysis for at least one of the upcoming wells.
● Construct pre-drill wellbore stability analysis for at-least one of the upcoming wells.
● Implement real-time geomechanics (RTGM) monitoring to update pre-drill MEM in real time (this
will require logging while drilling sonic, density, caliper logs are required).
● There are uncertainties where the sensitivity analysis results are concerned, since the modeling was
based only on datasets from vertical wells and to calibrate the model better than necessary to
analyze and model at least one highly deviated well.
● Perform geomechanical lab tests on rock samples to obtain rock properties and strength for the
Aruma, Rumaila, Ahmadi, and Safaniya formations.
● Using the available techniques, it is recommended to identify presence, type and dimensions of
fractures or vugs. Based on the data generated, LCM material can be properly sized for curing mud
losses.
Acknowledgment
The authors would like to express their thanks and appreciation to Saudi Aramco for granting permission
to publish this material and to the Schlumberger’s Geology team for providing feedback on the image
interpretation.
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