Appendix C

Procedure for Determining Safe Mud Window To Prevent Hole Collapse

C.1 WELLBORE FRACTURING PRESSURE (TENSILE FAILURE):

Fracturing of the wellbore is initiated when the rock stress changes from compression
to tension.

By increasing the wellbore pressure, the circumferential (hoop) stress 𝜎𝜃 reduces

accordingly as per Equation 3.35, and, eventually falls under the tensile strength of the
rock. Therefore, fracturing occurs at high wellbore pressures.

The borehole will fracture when the minimum effective principal stress σ3 reaches the
tensile rock strength To i.e.:

𝜎3 ≤ 𝑇𝑜 C.1

Inserting this equation into Equation 3.44, and after some manipulation, the critical
hoop stress can be expressed by:

2
𝜏𝜃𝑧
𝜎𝜃 = 𝜎 + 𝑃𝑃 + 𝑇𝑜 C.2
𝑧 −𝑃𝑃

We insert this equation into the hoop stress element of equation 3.39 and rearrange
the latter for Pwf (i.e. the critical borehole pressure at fracture). The resulting equation is:

2
𝜏𝜃𝑧
𝑃𝑤𝑓 = 𝜎𝑥 + 𝜎𝑦 − 2(𝜎𝑥 − 𝜎𝑦 ) 𝑐𝑜𝑠 2𝜃 − 4𝜏𝑥𝑦 𝑠𝑖𝑛 2𝜃 − 𝜎 − 𝑃𝑃 − 𝑇𝑜 C.3
𝑧 −𝑃𝑜

2𝜏𝑥𝑦
𝑡𝑎𝑛 2𝜃 = 𝜎 C.4
𝑥 −𝜎𝑦

Equations C.4 and C.5 represent the general fracturing equations for a wellbore with
an arbitrary direction. If symmetric conditions exist, all shear stresses may vanish, and
therefore, the fracture may take place at one of the following conditions:

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𝑆𝐻𝑚𝑎𝑥 = 𝑆𝐻𝑚𝑖𝑛
𝛾 = 0° C.5
𝜑 = 0° , 90°

Inserting these conditions and assuming that the rock has a zero tensile strength because it
may contain cracks or fissures. the critical borehole pressure at fracture can be expressed
by:
𝜎𝑥 < 𝜎𝑦
𝑃𝑤𝑓 = 3𝜎𝑥 − 𝜎𝑦 − 𝑃𝑃 𝑓𝑜𝑟 { } C.6a
𝜃 = 90°
𝜎𝑦 < 𝜎𝑥
𝑃𝑤𝑓 = 3𝜎𝑦 − 𝜎𝑥 − 𝑃𝑃 𝑓𝑜𝑟 { } C.6b
𝜃 = 0°
Equations C.6a and C.6b are valid when the borehole direction is aligned with the in-
situ principal stress direction.

C.2 WELLBORE COLLAPSE PRESSURE (SHEAR FAILURE):

While fracturing occurs at high borehole pressures, collapse is a phenomenon
associated with low borehole pressures. Under these conditions, the hoop stress becomes
large, but the radial stress reduces at the same rate as the pressure.

To find the stresses at the wellbore wall, the following steps are applied:

1- Determining the in-situ principal stresses σ1, σ2 and σ3

2- Determining the Mohr-Coulomb failure criterion equations:

1+sin 𝜑 2𝐶 cos 𝜑
𝜎1 = 1−sin 𝜑 𝜎3 + C.7
1−sin 𝜑

3- Determine the cohesion and angle of internal friction from laboratory testing (Triaxial
test) of cores from offset wells, or from petrophysical log if core samples are not
provided.
4- Calculate the failure surface from either Mohr-Coulomb or Mogi-Coulomb equations,
and plot σ1 vs σ3 for a given formation pressure.
5- Calculate stresses at boreholes wall as follows:
a- Transpose the in-situ principal stresses relative to a coordinate system with one
axis parallel to the wellbore axis and a second axis in the horizontal plane,
using equations 3.32 - 3.37.

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 b- Calculate the axial, radial and tangential stresses at the wellbore wall using
equations 3.38 - 3.43.
c- Convert the stresses in (b) to principal stresses so that they can be used in the
failure criteria using equations 3.44 - 3.46.
6- Asses the borehole stability by plotting the failure surface of the failure criterion as a
function of the appropriate stresses. The stability of the wellbore can be deduced by
noting the intersection point of the existing stresses calculated in step (5c) with the
failure envelope.

Notice that the stresses around the wellbore calculated in step (5c) are dependent on
Pw. In order to solve for the minimum fluid pressure gradient inside the wellbore to avoid
shear failure, multiple iterations must be completed. Per the results, the mudweight is
increased or decreased accordingly and the analysis is completed again. This must be
repeated until the minimum mudweight to avoid breakouts is determined.

Also, as in calculating the fracture pressure, If the symmetric conditions of Equation

C.5 exist, the maximum principal stress 𝑆1 will be simplified to:

𝑆1 = 𝜎𝜃 C.8

Also, we determine the orientation of the borehole at which collapse occurs from
equation C.4.

Then the critical borehole pressure at collapse can be expressed by:

𝜎𝑥 < 𝜎𝑦
𝑆1 = 3𝜎𝑥 − 𝜎𝑦 − 𝑃𝑤𝑐 𝑓𝑜𝑟 { } C.9
𝜃 = 90°
𝜎𝑦 < 𝜎𝑥
𝑆1 = 3𝜎𝑦 − 𝜎𝑥 − 𝑃𝑤𝑐 𝑓𝑜𝑟 { } C.10
𝜃 = 0°
Equations C.9 and C.10 are valid when the borehole direction is aligned with the in-
situ principal stress direction.

The minimum principal stress is also expressed by:

𝑆3 = 𝑃𝑤𝑐 C.11

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 And then inserted into Mohr-Coulomb failure criterion equations C.7, and After some
manipulation, the critical borehole pressure at collapse can be expressed by:

1 𝜎𝑥 < 𝜎𝑦
𝑃𝑤𝑐 = 2 (3𝜎𝑥 − 𝜎𝑦 )(1 − sin 𝜑) − 𝐶 cos 𝜑 + 𝑃𝑃 sin 𝜑 𝑓𝑜𝑟 { } C.12
𝜃 = 90°
1 𝜎𝑦 < 𝜎𝑥
𝑃𝑤𝑐 = 2 (3𝜎𝑦 − 𝜎𝑥 )(1 − sin 𝜑) − 𝐶 cos 𝜑 + 𝑃𝑃 sin 𝜑 𝑓𝑜𝑟 { } C.13
𝜃 = 0°

C.3 Example: Wellbore Stability Assessment

Given the following well data for a sandstone reservoir, determine the minimum mud
weight required to prevent hoe collapse if a horizontal well is be drilled.

Cohesion 𝑐 = 1182 𝑝𝑠𝑖

Angle of internal friction 𝜑 = 42.4°

Depth 𝑧 = 9452 𝑓𝑡

Well deviation Angle 𝛾 = 90°

Maximum principal stress 𝜎1 = 1 𝑝𝑠𝑖/𝑓𝑡

𝑝𝑠𝑖
Minimum principal stress 𝜎3 = 6143 𝑎𝑡 9452 𝑓𝑡
𝑓𝑡

Pore pressure 𝑃𝑃 = 3500 𝑝𝑠𝑖

Poisson’s ratio 𝜗 = 0.35

Solution

- Step 1

𝑝𝑠𝑖
𝜎1 = 1 × 9452 𝑓𝑡 = 9452 𝑝𝑠𝑖
𝑓𝑡

𝑝𝑠𝑖
𝜎3 = 6143 𝑎𝑡 9452 𝑓𝑡
𝑓𝑡

- Step 2

Determine the failure envelope using Mohr-Coulomb Criterion:

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 1 + 𝑠𝑖𝑛 𝜑 2𝐶 𝑐𝑜𝑠 𝜑
𝜎1 − 𝑃𝑃 = (𝜎3 − 𝑃𝑃 ) +
1 − 𝑠𝑖𝑛 𝜑 1 − 𝑠𝑖𝑛 𝜑

1 + 𝑠𝑖𝑛 42.4 2 × 1182 𝑐𝑜𝑠 42.4

𝜎1 − 3500 = (𝜎3 − 3500) +
1 − 𝑠𝑖𝑛 42.4 1 − 𝑠𝑖𝑛 42.4
𝜎1 = 5.14𝜎3 − 9130

The reader should note that the previous equation represent a failure envelope for a
rock sample under laboratory Triaxial testing where confining stress (𝜎3 ) and axial stress
(𝜎1 ) are applied.

Plot the envelop to obtain the Mohr-Coulomb failure envelope.

- Step 3

Transpose the in-situ stresses σ1 (9452 psi) and σ3 (6143 psi) using equations 3.32 -
3.37. Here we shall assume:

𝜎2 = 𝜎3

Hence the equations reduce to:

𝜎𝑥 = 𝜎2 𝑠𝑖𝑛2 𝛽 + 𝜎3 𝑐𝑜𝑠 2 𝛽 = 𝜎3

𝜎𝑦 = 𝑐𝑜𝑠 2 𝛼 (𝜎2 𝑐𝑜𝑠 2 𝛽 + 𝜎3 𝑠𝑖𝑛2 𝛽) + 𝜎1 𝑠𝑖𝑛2 𝛼 = 𝜎3 𝑐𝑜𝑠 2 𝛼 + 𝜎1 𝑠𝑖𝑛2 𝛼

𝜎𝑧 = 𝑠𝑖𝑛2 𝛼 (𝜎2 𝑐𝑜𝑠 2 𝛽 + 𝜎3 𝑠𝑖𝑛2 𝛽) + 𝜎1 𝑐𝑜𝑠 2 𝛼 = 𝜎3 𝑠𝑖𝑛2 𝛼 + 𝜎1 𝑐𝑜𝑠 2 𝛼

𝜏𝑥𝑦 = 𝑐𝑜𝑠 𝛼 ∙ 𝑠𝑖𝑛𝛽 ∙ 𝑐𝑜𝑠𝛽(𝜎2 − 𝜎3 ) = 0

𝜏𝑦𝑧 = 𝑠𝑖𝑛 𝛼 ∙ 𝑐𝑜𝑠𝛼(𝜎1 − 𝜎2 𝑐𝑜𝑠 2 𝛽 − 𝜎3 𝑠𝑖𝑛2 𝛽) = 𝑠𝑖𝑛 𝛼 ∙ 𝑐𝑜𝑠𝛼(𝜎1 − 𝜎3 )

𝜏𝑧𝑥 = 𝑠𝑖𝑛 𝛼 ∙ 𝑐𝑜𝑠𝛽(𝜎3 − 𝜎2 ) = 0

For inclination angle 𝛼 = 90° and 𝜎1 = 9452 𝑝𝑠𝑖 and 𝜎3 = 6143 𝑝𝑠𝑖, the above
equations become:

𝜎𝑥 = 𝜎3 = 6143 𝑝𝑠𝑖

𝜎𝑦 = 𝜎3 𝑐𝑜𝑠 2 𝛼 + 𝜎1 𝑠𝑖𝑛2 𝛼 = 6143 𝑐𝑜𝑠 2 90° + 9452 𝑠𝑖𝑛2 90° = 9452 𝑝𝑠𝑖

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𝜎𝑧 = 𝜎3 𝑠𝑖𝑛2 𝛼 + 𝜎1 𝑐𝑜𝑠 2 𝛼 = 6143 𝑠𝑖𝑛2 90° + 9452 𝑐𝑜𝑠 2 90° = 6143 𝑝𝑠𝑖

𝜏𝑥𝑦 = 0

𝜏𝑦𝑧 = 𝑠𝑖𝑛 𝛼 ∙ 𝑐𝑜𝑠𝛼(𝜎1 − 𝜎3 ) = 0

𝜏𝑧𝑥 = 0

- Step 4

Calculate the induced stresses at the bore hole wall. The stresses will be calculated at
a point 𝑎 = 𝑟, where r is the radius of the borehole.

The generalized Kirsch equations reduce to equations 3.38 - 3.43. The equations 3.38
- 3.43 give maximum stresses when cos 2𝜃 = 1° or when 𝜃 = 0°. Hence using an
inclination angle of 𝛼 = 90°, and 𝜎1 = 9452 𝑝𝑠𝑖 and 𝜎3 = 6143 𝑝𝑠𝑖,

𝑃𝑤 = 0.052 × 9 𝑝𝑝𝑔 × 9452 𝑓𝑡, so the equations become:

𝜎𝑟𝑟 = 𝑃𝑤 = 4424 𝑝𝑠𝑖

𝜎𝜃𝜃 = 𝜎𝑥 + 𝜎𝑦 − 𝑃𝑤 − 2(𝜎𝑥 − 𝜎𝑦 ) 𝑐𝑜𝑠 2𝜃 + 4𝜏𝑥𝑦 𝑠𝑖𝑛 2𝜃

= 6143 + 9452 − 4424 − 2(6143 − 9452) + 0 = 17789 𝑝𝑠𝑖

𝜎𝑧𝑧 = 𝜎𝑧 − 𝜗[2(𝜎𝑥 − 𝜎𝑦 ) 𝑐𝑜𝑠 2𝜃 + 4𝜏𝑥𝑦 𝑠𝑖𝑛 2𝜃 − 𝑃𝑤 ] = 6143 − 0.35[2{6143 − 952}]

= 8459 𝑝𝑠𝑖

- Step 5

Express the wellbore stresses as Principal Stresses using equation 3.44 - 3.46:
0.5
𝜎𝜃𝜃 + 𝜎𝑧𝑧 𝜎𝜃𝜃 − 𝜎𝑧𝑧 2 2
𝜎1 + {[ ] + 𝜏 𝜃𝑧 }
2 2
{𝜎2 } = 𝜎𝜃𝜃 + 𝜎𝑧𝑧 𝜎𝜃𝜃 − 𝜎𝑧𝑧 2 0.5
2
𝜎3 − {[ ] + 𝜏 𝜃𝑧 }
2 2
{ 𝑃𝑤 }
0.5
18828 + 8148 18828 − 8148 2
+ {[ ] + 0}
2 2
= 0.5
18828 + 8148 18828 − 8148 2
− {[ ] + 02 }
2 2
{ 4424 }

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 𝜎1 18828
𝜎
{ 2 } = { 8148 } 𝑝𝑠𝑖
𝜎3 4424

- Step 6

Plot the stresses in the Mohr-Coulomb diagram as shown in the following diagram,
the distance from 𝜎3 that make the perimeter of the circle touch the envelope gives the
minimum mud weight required to prevent hole collapse.

From the diagram we can notice that the amount of mud weight required to prevent
hole collapse is smaller than the proposed in step 4, so we must reduce this amount, say to
6 ppg, and recalculate the induced stresses in step 4, then recalculate the principal stresses
in step 5, and so on, until the Mohr circle touch the Mohr-coulomb envelope as following:

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 So the minimum mud weight required to prevent hole collapse if a horizontal well is
be drilled is 6 ppg.

84