Hole cleaning and drilling rate remain major challenges once it comes to plan and drill workover and development wells. Inadequate hole cleaning is responsible for a large portion of all stuck pipe problems. Approximately 33% of stuck pipe incidents because of bad hole cleaning. The rate of penetration is extremely related to hole cleaning. If optimum hole cleaning can be ensured, that will lead to a high rate of penetration. To ensure perfect hole cleaning, it must be engineered. There are several correlations, mothed, designs, models, tools, charts, fields results, experimental studies and chemical materials to enhance the hole cleaning, but several of them are just based on theory and lack proper experimental data and not feasible in drilling operations. The knowledge of the size of cuttings, size of annulus, flow pattern, and down hole fluid properties cannot determined with high accuracy. This paper will show the influence of hole cleaning on the rate of penetration that will ensure optimum performance and mitigate stuck pipe problem and how the approach was applied during drilling operations. Knowledge from this paper will help in knowing hole cleaning more accurately and therefore facilitate improving drilling rate. The application of approach of Well drilling performance by using carrying capacity index and cuttings concentration in the annulus for ensuring perfect hole cleaning, and achieving enhanced well drilling performance by using optimum drilling parameters that can ensure minimum DSE. The Approach has been validated in the fields, and used to drill in challenging hole sections, and has improved the well drilling performance more than 55% and minimized DSE more than 54%.
Utilization of drilled wells operations’ records is required to perform improvement of performance to minimize drilling cost of planned drilling of new and re-entry wells (workover – wells). Many operators are always interested in finding optimum ways to save on drilling cost. Optimization of Rate of Penetration (ROP) has direct effects on cost reduction. Different Techniques were used to optimize ROP such as regression technique, multiple linear regression technique, neural network, artificial neural network methods, and basic reference of Bayesian networks. There are several factors that will limit application of ROP optimization models in different hole sections with high degree of accuracy. It is the authors’ opinion that modeling on smaller selected section with controlled parameters will give better optimization and validation. In this paper an empirical correlation of rate of penetration (ROP) is presented for a particular hole section. The data selected are from same hole size, formation type and mud type. It is based on monitoring and controlling simultaneously the applied weight on bit (WOB), drill-string's rotation (RPM), Torque (TRQ) and rig pump's flow rate (GPM). During this study will demonstrate the use of this empirical correlation to improve drilling in a hole section by more than 50%. The developed model also has high potential to be automated in real time operating environment to improve drilling performance.
Sustaining field proven technologies in mature fields and maximizing Return of Investment (ROI) is a priority for operators worldwide. Financial constraints such as oil and gas prices, drilling cost, and any intangibles must not burden the success of pushing limits to open new horizons, not just for the present time but also for future generations. Parallel to reaching new limits, we must keep an eye on the safety and engineering behind any step taken toward the limit to push the envelope successfully. Drilling team recently used a a vendor product to maximize production, isolate a loss circulation zone, and push the operating envelop by installing the first 4-1/2Љ open hole completion (Pre-perforated liner) with inflatable open hole isolation packers through a 5-1/2Љ ϫ 7Љ open hole liner (OHL). The vendor product enabled Saudi Aramco to install 5-1/2Љ ϫ 7Љ solid expandable liner installation. The 5-½Љ 18.24 lb/ft solid expandable systems was utilized to isolate a loss zone and reactive shale section, sealing off the problematic interval and allowing an extended lateral section to be drilled through the reservoir. The expandable liner was run through a window cut through 7Љ 26 lb/ft casing and subsequently installed across part of the curve section to isolate the lost circulation zone. The use of the expandable liner enables the ability to drill the remaining build section and horizontal section together with full circulation. This paper describes the challenge and application.
Cuttings concentration in annulus that are generated while drilling due to the rate of penetration have several problems if it is high and has exceeded the maximum limit. Cuttings accumulation in annulus can lead to hole problems such as lost circulation coincident, stuck pipe incidents, and slow drilling rate which still a difficult challenge once it comes to plan, design and drill wells. If a proper hole cleaning efficiency can be achieved, that ultimately will enable the drilling team to have satisfied well drilling performance. To empower hole-cleaning performance, it must be engineered. In this paper, a new real time model of cuttings concentration in annulus (CCA) enhances drilling performance that will ensure optimized improvement and avoid stuck pipe problems. Knowledge from this paper will help in modeling and monitoring cuttings concentration in annulus while drilling precisely and therefore facilitate improving ROP without jeopardizing the well drilling performance. In addition, the paper spoke about the environment impact, drilling waste management and economics and wellbore instability related to cuttings concentration in annulus. Huge number of models, techniques, charts, chemicals, tools, methods, and designs, experimental studies and to enhance the hole cleaning, but these things are just based on theory, lack proper experimental data, not compatible with drilling scenarios and operations. Cutting Concentration in Annulus (CCA) can provide a clue or a knowledge for maximum ROP that is save and compatible with rig equipment limitations such as the knowledge about maximum amount of cuttings generated while drilling that can be transported to surface and that the shale shakers can handle without causing hole troubles. The size of hole sections (OH), ROP, flow rate of mud pump (GPM), annular Velocity, Critical velocity (Vc), Drill pipe size (OD), cuttings rise velocity (Vcr), slip cuttings velocity (Vsc) and transport ratio (TR) properties in certain hole sections were collected and analyzed first to determine the effect of them on hole cleaning and ROP performance. The data selected are from the same hole size, formation type and mud type. The relationships between the collected properties and CCA were t evaluated to determine how strong it is and demonstrate the significance of properties on estimating CCA. CCA was monitored controlled and evaluated to be able to have improved hole cleaning performance to enhancement of the drilling operations and decrease well drilling time. This is the first time to for hole cleaning optimization to lead for ROP improvement by using real time CCA model. The developed model has been validated using field data during drilling hole sections. It has shown high drilling rate performance in the hole sections tested and helped mitigate stuck pipe incidents, increased ROP by more than 52%.
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