Directional Drilling Training Manual

Section 13 - Drilling Problems

Document Type

UOP Template (Word 6 PC)

Software Source File Other Source File

Microsoft Word 6.0 for Windows NT DDTM_13.DOC TM.DOT

Author Author info

Mike Smith Anadrill Technique 200 Gillingham Lane Sugar Land TX 77478-3136 Tel: + 1 281 285 8859 Fax: + 1 281 285 8290/4155 email: msmith@sugar-land.anadrill.slb.com

Review & approval

Revision History

05 Dec 96 06-Dec-96

2nd Revision Final review and approval MJS

Provisory - 06 Dec 96

Confidential

Directional Drilling

Table of Contents

13

Drilling Problems

Page

13.1 AN OVERVIEW ................................................................................................................13-1 13.1.1 Differential Sticking .............................................................................................13-2 13.1.1.1 Warning Signs .............................................................................................13-5 13.1.1.2 Stuck Pipe Identification .............................................................................13-5 13.1.1.3 Preventive Actions ......................................................................................13-6 13.1.1.4 Rig Site Preparation ....................................................................................13-6 13.1.2 Borehole Deterioration .........................................................................................13-6 13.1.2.1 Warning Signs .............................................................................................13-8 13.1.2.2 Stuck Pipe Identification .............................................................................13-8 13.1.2.3 Preventive Actions ......................................................................................13-8 13.1.3 Dog Legs and Key Seats.......................................................................................13-8 13.1.3.1 High Friction Factors While Drilling and Tripping ....................................13-9 13.1.3.2 Warning Signs .............................................................................................13-9 13.1.3.3 Preventive Actions ......................................................................................13-9 13.1.4 Key Seats ..............................................................................................................13-9 13.1.4.1 Warning Signs .............................................................................................13-10 13.1.4.2 Stuck Pipe Identification .............................................................................13-10 13.1.4.3 Preventive Actions ......................................................................................13-10 13.1.4.4 Rig Site Preparation ....................................................................................13-11 13.1.5 Drill String Failures Due to Excessive Reverse Bending.....................................13-11 13.1.5.1 Preventive Actions ......................................................................................13-11 13.1.6 Equipment Compatibility......................................................................................13-12 13.1.6.1 Preventive Actions ......................................................................................13-12 13.1.7 Borehole Stability .................................................................................................13-12

List of Figures
Figure 13-1 Figure 13-2 Figure 13-3 Figure 13-4 Figure 13-5 Figure 13-6 Figure 13-7 Figure 13-8

Page

Differential sticking............................................................................................ 13-3 Development of filter cake ................................................................................. 13-3 Effect of drill solids on filter cake...................................................................... 13-4 Filter cake bridging............................................................................................. 13-4 Erosion of filter cake .......................................................................................... 13-5 Effect of hole deviation & mud weight on borehole stability ............................ 13-7 Development of key seats................................................................................. 13-10 Key seat wiper and string reamer. .................................................................... 13-11

List of Tables
No list of figures.

Page

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-i

Drilling Problems

13 Drilling Problems
About this chapter

The development of new technologies in the past 10 years, like the MWD systems for real-time surveying, steerable systems for an effective control of trajectory, PDC bits for efficient drilling of long sections, mud and hydraulic systems for improved control of hole cleaning and borehole stability, etc. have transformed directional drilling into a common practice. There are a few serious problems which may arise during the course of drilling a directional well. The probability of certain drilling problems arising (e.g. differential sticking) is increased by virtue of the well being deviated. The causes and implications of differential sticking are discussed here, as well as solutions and possible preventive measures. This is very relevant to the DD, particularly in areas which are prone to differential sticking. Dog legs and key seats are discussed here in detail. As mentioned elsewhere in this manual, it is the DDs responsibility to ascertain the clients limit on dog leg severity at the beginning of the project. The consequences of high dog leg severity at a shallow depth often do not become apparent until much deeper in the well. Problems caused by borehole instability due to poor hydraulics and mud conditioning are outlined. Increases in Drag, particularly when drilling with a PDM, directly concern the DD. In high-angle wells, it often becomes very difficult to "slide".
Objectives of this Chapter

On completing this chapter the directional driller should be able to do the following exercises: 1. Describe the main causes of differential sticking. 2. Explain how the API Filtrate (Water Loss) influences the chances of getting differentially stuck. 3. Describe the precautions the DD should take or recommend when about to drill in an area known for differential sticking. 4. Explain why the chances of borehole instability are influenced by hole inclination. 5. List the drilling (and other) problems arising from high dog leg severity in a deviated well. 6. Explain what the DD should do if his survey indicates an unacceptably-high dog leg severity in the interval just drilled.

13.1 An Overview
The development of new technologies in the 80s, like the MWD systems for real-time surveying, steerable systems for an effective control of trajectory, PDC bits for efficient drilling of long sections, mud and hydraulic systems for improved control of hole cleaning and borehole stability, etc. have transformed directional drilling into a common practice.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-1

Drilling Problems But, if we compare the performance and drilling conditions of vertical and directional wells, it is possible to identify some particular problems related to deviated boreholes. In this chapter we analyze the most common directional drilling problems and possible solutions.

13.1.1 Differential Sticking

Differential pressure sticking occurs only across a permeable zone, such as sand. One or a combination of the following mechanisms will be responsible for sticking: Pipe sticking occurs when part of the drill string rests against the wall of the borehole, which is the case in directional wells, imbedding itself in the filter cake. The area of the drill pipe in contact with filter cake is then sealed from the full hydrostatic pressure of the mud column. The pressure difference between the mud column pressure and the formation pressure acts on the area of the drill pipe in contact with the filter cake to hold the drill pipe against the wall of the borehole.

Overpull due to differential pressure sticking can be calculated from the product of differential pressure, contact area, and a friction factor as follows: Overpull = (Mud Pressure - Formation Pressure) xContact Area x Friction Factor where Overpull Mud Pressure Formation Pressure Contact Area Friction Factor (lbs.) (psi) (psi) (sq in) (no unit)

Example: If there is a 6 ppg differential pressure across a sand at 7000 ft. T.V.D. (Mud Pressure - Formation Pressure) = 0.052 x 7000 x 6 = 2184 psi. Say we have a contact of 3 inches of drill collar circumference across a sand which is 10 thick. That gives a contact area of 360 square inches. From experience, the friction factors vary from 0.15 to 0.50. We will use 0.15 for this example. Overpull = = = 2184 psi - 360 in2 x 0.15 117,936.00 lbs. 118000 lbs.

An extra overpull of 118 lbs. on top of the normal friction in the wellbore can easily mean the difference between being free and being stuck. This example also used a relatively thin sand of 10 feet. We should actually use the projection of the contact area onto the horizontal plane to be precise. This is more difficult to visualize and is not used here for simplicity.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-2

Drilling Problems
Borehole Wall

Mud Pressure

Contact Area Mud Cake Formation Pressure

Figure 13-1

Differential sticking

Filter Cake Thickness The thicker the filter cake, the larger the contact area with the drill collars and the higher the resulting differential sticking force. The following illustrates the formation of a filter cake.

Many factors affect the rate of growth and the final thickness of the filter cake. 1. A higher differential pressure will increase the rate of growth of the filter cake. The final thickness of the cake will be larger in order to seal off the higher pressure.

Figure 13-2

Development of filter cake

2. As the amount of drill solids in the mud increases, the filter cake becomes more porous and permeable. This results in a faster rate of growth of the filter cake and a larger final thickness. The ideal situation would be a thin, hard filter cake made up of mud solids only.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-3

Drilling Problems

High Drill Solids

Mud Pressure

Low Drill Solids

Mud Pressure

Pore Pressure Mud Solids Drill Solids Permeable Formation With a high amount of drill solids, the filter cake tends to be more porous and permeable and the final thickness of the cake tends to be larger.

Pore Pressure

Permeable Formation With low amounts of drill solids, the filter cake tends to be thin and tough which reduces the chances of differential sticking.

Figure 13-3

Effect of drill solids on filter cake

3. The lower the water loss or filtrate of the mud, the thinner and harder the filter cake. In the case of drilling into a sand after undergoing a pressure regression, the differential pressure is so high that sufficient mud cake can be formed to stick the BHA while drilling. The best defenses in these cases are proper pore pressure detection, lowering the mud weight if possible or setting casing. If the pipe stays motionless (for example, taking surveys in a directional well) for a period of time adjacent to the sand, the situation gets worse. The filter cake tends to bridge around the pipe, thus increasing the contact area. The filter cake in contact with the pipe is no longer in direct contact with the mud and the friction factor increases by virtue of more water being filtered out of the filter cake. The end result is that a much greater overpull is required to free the drillstring.

Mud Pressure

Contact Area

Bridging Mud Cake Formation Pressure

Figure 13-4

Filter cake bridging

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-4

Drilling Problems Filter cake erosion occurs while drilling due to the drill pipe rubbing against the borehole wall. This only affects a small portion of the circumference of the wellbore. Wiper trips pull the stabilizers and bit through the filter cake and will scrape off a significant amount. The best disruption of filter cake is reaming, where most of the cake will be removed.
Drill Pipe Erosion Wiper Trip Reaming

Drill Pipe Erosion While drilling, the drill pipe is pressed against one side of the hole. The rotation of the pipe wears away a section of filter cake.

Wiper Trip A wiper trip will pass the stabilizers and the bit across the formatioin scraping away a large portion of the filter cake

Reaming Reaming does the best job of scraping awaw the filter cake but is very time consuming.

Figure 13-5
13.1.1.1Warning Signs

Erosion of filter cake

Permeable formations in open hole, if known. Thick filter cake on mud tests. High differential pressure (1500 psi) across the permeable formations, if known. High torque/overpull after pipe is held motionless. Higher overpull on connections. Well developed area with depleted reservoirs. (Talk to Company Man).

13.1.1.2Stuck Pipe Identification

The pipe was stationary just before sticking usually at a connection while drilling or tripping Full circulation is possible and pump pressure is unaffected. BHA is adjacent to thick, permeable formation. Pressure overbalance at BHA. Stuck forces get larger with time.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-5

Drilling Problems
13.1.1.3Preventive Actions

1. Pre-well Planning: Identify any permeable formations which may lead to differential sticking. Estimate the pressure of permeable formation, using nearby welldata and any available RFT, DST or producing well data. If there is a chance of high differential pressure, consider a change in casing design. Plan the use of lubricants ahead of time. Spotting fluid must be on location when differential sticking occurs, otherwise it is useless. Studies show that spotting fluid must be in place within 4 hours otherwise the chances of the pipe becoming free are greatly reduced. Plan on having high quality mud cleaning equipment on the rig to control mud solids. Minimize OD of drill collars used to minimize the contact area with the mud cake. However, annular velocities and borehole cleaning need to be taken into account when reducing the ODs of drill collars.

13.1.1.4Rig Site Preparation

Keep the mud weight at the lowest safe level. This will keep differential pressure across permeable formations at a minimum. Keep track of the differential pressure across permeable formations as accurately as possible. This requires maintaining a record or plot of the pressure profile for the entire open hole section. Maintain a tough, thin filter cake and keep drilled solids content to a minimum. Use spiral drill collars and minimize unstabilized sections of the BHA. If hole drag is not a problem, consider using under-gauge stabilizers on drill collars to keep them away from the borehole. Keep the pipe moving at all times. Reciprocating is the preferred motion as it allows you to monitor overpulls. When possible, begin pipe motion in a downward direction. Minimize length of BHA. Use heavy weight drill pipe instead of a long section of unstabilized drill collars. Avoid surveying methods which result in pipe remaining static for long periods (use MWD). Frequent wiper trips through the permeable zones will scrape the filter cake and may prevent it from becoming too thick.

13.1.2 Borehole Deterioration

One of the keys for a successful drilling operation, in vertical and directional drilling, is to control mechanically and chemically the formations being drilled, mainly the shales, in order to avoid sticking problems. These problems can be associated with any one of the following cases

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-6

Drilling Problems Chemically active formations Overpressured formations High dip sloughing Unconsolidated formations Mobile formations Mechanical Stability

The behavior of vertical and directional wells in the first 5 cases above is similar; they are controlled with the implementation of the correct mud system and operational procedures. The formation mechanical stability is a concern when drilling directional wells in general and high inclination or horizontal wells in particular. When a borehole is drilled, the process may be thought of as one of replacing the rock which was originally in the hole with drilling mud. This causes a disturbance to the in-situ stress state local to the hole because a column of rock which supported three, probably different, principal stresses (three axes, i.e. two horizontal and one vertical) is replaced by fluid in which the three principal stresses are equal and, typically, lower than any of the stresses in the original rock column. Unbalanced conditions will generate borehole problems; lost circulation or hole instability problems (e.g. sloughing or caving). The directional drilling plan, deviation and azimuth, is a very important factor in the borehole stability. Over the last years the industry has studied the borehole stability process to define, at the planning stage, the borehole stability problems that would be faced during the actual drilling operation. The intention is to identify the in-situ stress state where the well is to be drilled, to calculate the stresses that will occur at the borehole wall when the well is drilled and to substitute the borehole wall stresses into shear and tensile failure criteria to see whether failure occurs. It was found that for a particular formation the upper and lower formation stability limits (fracture initiation pressure and sloughing/caving pressure) are greatly affected by the hole inclination and azimuth.

20 19 18 Fracture - Loss of Circulation

Mud Weight (ppg)

17 16 15 14 13 12 11 10 0 10 20 30 40 50 60 70 80 90 Hole Deviation (deg) Sloughing - Caving Safe Working Area

Figure 13-6

Effect of hole deviation & mud weight on borehole stability

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-7

Drilling Problems This figure shows the formation behavior, for a set of given conditions, changes with the hole inclination. It is possible to see that safe drilling conditions are achievable in inclinations up to 60. Beyond that point, unstability situations would be unevitable. The same type of analysis can be done for a well to be drilled; knowing the lithology, formation characteristics and borehole trajectory, a set of plots can be generated: This type of representation consists of three tracks: the first track gives the mud weight which causes tensile failure of the borehole, that is the fracture initiation pressure (FIP); the second track gives the maximum and minimum mud weights which can be used in the hole without causing shear failure of the walls; the third track combines the FIP and the shear failure limits on mud weight to give the maximum and minimum mud weights which can be used to drill the well. It is possible to see that a vertical well can be drilled without any borehole stability problems within a wide range of mud weight values; however, at 50 inclination the operation becomes risky, because of a narrower safe mud weight range and a totally unstable ledge at 2672m.
13.1.2.1Warning Signs

1. Formation stability problems in previous wells. 2. New directional well with higher inclination than normal.
13.1.2.2Stuck Pipe Identification

1. Use of electric logs for formation stability problem identification. 2. Planning phase.
13.1.2.3Preventive Actions

1. Plan borehole trajectory, inclination and azimuth, within a safe range. 2. Follow a pre-planned mud program. 3. If totally unstable formations are identified, have a contingency plan (short trips, mud lubricity, etc.)

13.1.3 Dog Legs and Key Seats

In order to drill a directional well it is necessary to make controlled dog legs to change borehole trajectory to reach a desired target. Dog legs are necessary but, simultaneously, they have been recognized as a major contributing factor for drilling, logging, completion and production problems, for example. High friction factors while drilling and tripping (torque and drag). Key seats. Failure of drill string components due to excessive reverse bending. Casing wear. Extra time to run wire line logs Problems to run casing and ECP. Bad cement bond on dog leg high side. Difficult to set mechanical production packers. Reduced life time of tubing and sucker rods.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-8

Drilling Problems When a deflecting tool is run in the hole, the directional driller must have permanent control of the dog legs being generated, in order to take immediate remedial actions to correct unexpected high dog leg values before continuing to drill. Once a high dog leg has been created, efforts must be made to reduce the dog leg before drilling ahead. In this section, the drilling related problems are analyzed.
13.1.3.1High Friction Factors While Drilling and Tripping

Friction factors are used to evaluate the planned maximum drilling and tripping stresses while rotating or sliding, to be able to select the proper components to drill the well. Any deviations from the plan, by making higher dog legs, could result in stopping the drilling operation without reaching the desired T.D.; this is particularly important in extended reach and horizontal wells. The value of the dog leg is defined by the combination of several factors: Deflecting tool configuration (bent sub/housing angle, distance between stabilizers). BHA design. Drilling parameters. Formation characteristics (dip angle, formation strength, compactation, stratigraphy). Borehole trajectory (inclination and azimuth)

Not all the factors are under our control. Formation characteristics can be estimated, but they are an unknown until we drill them. For this reason, sometimes higher than expected dog legs are obtained from a planned BHA, generating more drag and torque.
13.1.3.2Warning Signs

Unexpected changes of borehole trajectory (inclination and/or azimuth).

13.1.3.3Preventive Actions

Make a comprehensive plan, including torque and drag simulation. Use previous directional wells data in the same area to identify possible dog leg problems. MWD surveys help to detect immediate borehole trajectory changes, so immediate remedial action should be taken.

13.1.4 Key Seats

Dog legs, even severe ones, do not cause immediate problems as the drill collars are under compression and accommodate themselves to the new trajectory A key seat is caused by the drill string in tension, normally drill pipe rubbing against the formation in the dogleg. If the lateral force at the contact point between the drill string in tension and the formation is larger than the formation strength, the body and tool joints of drillpipe start wearing a groove into the formation about the same diameter as the tool joints. The wear is confined to a narrow groove because the high tension in the drill string prevents sideways movement. During a trip out of the hole, the BHA may be pulled into one of these grooves, which maybe too small for it to pass through (see diagram below).

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-9

Drilling Problems Key seats are associated with doglegs, as the drill string will be forced into contact with the formation. The more severe the dogleg and the higher it is up the hole, the greater the side load will be and so the faster a key seat will develop. Other than doglegs, ledges are features which provide points of continuous contact. Further variations include key seats at the casing shoe, where the groove is made in metal instead of rock. Development of key seats is dependent upon the number of rotating hours and the formation strength.

Section A-A After creating a dogleg, the drillstring is forced against the borehole wall. Pipe rotation causes a groove to be worn into the formation. Depending on the strength of the formation, the groove will eventually wear deep into the formation as shown in section A-A. When tripping out of the hole, the drill collar will become wedged in the groove since they have a larger O.D. than the drill pipe.

Figure 13-7
13.1.4.1Warning Signs

Development of key seats

Large doglegs at shallow true vertical depth compared to T.D. Sticking will occur while tripping out. Overpull likely to be erratic as tool joints pass through key seat.

13.1.4.2Stuck Pipe Identification

First large OD section of BHA reached dogleg. Circulation unaffected. Rotation may be possible.

13.1.4.3Preventive Actions

Planning: Avoid severe doglegs. Directional driller should be given maximum dogleg tolerances vs TVD guideline for planning the well. Incorporate key seat reamer (string reamer) into the BHA design if high torque and drag is not a problem.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-10

Drilling Problems

Figure 13-8
13.1.4.4Rig Site Preparation

Key seat wiper and string reamer.

Minimize dogleg severity. Follow maximum dogleg severity guidelines. Ream any severe doglegs, before key seats have an opportunity to develop. If a key seat is suspected or expected to develop, consider using a key seat reamer in the drill pipe to wipe the build section or dogleg. Minimize the number of correction runs. It is better to make one large correction run close to target than numerous changes with a steerable assembly at shallow TVDs. As soon as problem is recognized, attempt to correct by hole opening run. A high-lubricating pill set at stuck point level will be helpful to free the stuck drill string. Jar down when attempting to get free.

13.1.5 Drill String Failures Due to Excessive Reverse Bending

The stress to which the drill string components are subjected when rotating through a dogleg change from tension to compression every 1/2 turn, accelerates fatigue wear. As a result the life of the drill pipe and drill collar connections will be reduced or rig time is likely to be lost due to wash outs, twist offs, etc.
13.1.5.1Preventive Actions

Have superior grade quality tubulars. Apply recommended make up torque to connections using proper equipment. Implement a systematic pipe inspection system. Use an adequate safety factor. Make a proper torque and drag plan.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-11

Drilling Problems

13.1.6 Equipment Compatibility

Modern directional drilling practices require the use of new technology; bits, downhole motors, MWD systems, solids control system, pumps, etc.; it is common to have multiple suppliers for these elements. The operational requirements and limits are different for each one. The drilling performance can be seriously affected if the right parameters are not used. Special care must be taken in the following areas: Maximum and minimum GPMs Pressure losses through the drillstring. RPM. Weight on bit. Maximum operating pressure. Operating changes, if formation changes occur. Downhole static and circulating temperatures. Length of the bit run. Initial and final surface pressures.

13.1.6.1Preventive Actions

Know the technical and operational specifications of every tool run in the hole. Know the technical and operational specifications of the rig and surface system. Make hydraulic calculations before running in the hole. Verify the compatibility of the BHA elements. Define the expected formations and lithology to be drilled during the bit run.

13.1.7 Borehole Stability

Packing off:

Poor hydraulics and mud conditioning will lead to the hole packing off. Solids will build up in the mud and plug up the annulus while in turbulent flow. Remedy: Shut down the pumps, thereby reducing ECD and annular velocity. Attempt to free pipe by jarring down and, if possible, rotating. If circulation can be established, bring pumps up to speed very slowly and circulate the hole clean.
Mud Motor Sliding:

When a mud motor is in sliding mode, it becomes very difficult to maintain a constant WOB. In the worst case, all the surface weight can be slacked off with no change in WOB. This is due to high sliding friction (Drag).
Remedy:

To improve the sliding condition, add walnut hulls to the mud system. This helps to keep the PDM and BHA off the borehole wall and hence allow sliding to continue. Sweeping the hole with a low-vie pill and LCM should help to reduce friction. (The LCM must be fine-to-medium, well-mixed). As a last resort, POOH and run a hole opener through the problem section.

Provisory - 07 Dec 96

Confidential

Directional Drilling

13-12