Developing a Managed Pressure Drilling Strategy for Casing Drilling Operations

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1 Avance Materials Research Online: ISSN: , Vols. 6-64, pp oi:10.408/ 009 Trans Tech Publications, Switzerlan Developing a Manage Pressure Drilling Strategy for Casing Drilling Operations M. B.Oyeneyin 1,a, V.C. Kelessiis,b, G. Banelis,c an P. Dalamaritis, 1 The Robert Goron University, Abereen, UK University of Crete, Greece a b.oyeneyin@rgu.ac.uk, b kelesii@mre.tuc.gr, c gbanelis@yahoo.gr, palamarinis@isc.tuc.gr Keywors: Casing Drilling; Manage Pressure Drilling; Drilling Hyraulics; Real-Time Visualisation; Desktop Simulator Abstract. Casing rilling can be an effective metho of reucing rilling costs an minimising rilling problems but its uptake aroun the worl has been slow with only a few wells rille so far with casing. Complex geological features like the high overburen on top of shallow unconsoliate reservoirs characteristic of offshore West Africa can benefit from casing rilling when effectively combine with Manage Pressure Drilling technique. For the inustry to evelop a manage pressure rilling capability that will allow toay s generation of complex wells to be rille safely with casing, it is necessary to evelop moels that inclue the effect of eccentricity, rotation an flui rheology at bottom hole conitions on flow an pressure regimes, an to embe these moels within an easy to use, intuitive well esign package for pre planning an as a real time tool to monitor an provie forwar simulations base on real time rig an ownhole ata. The paper presents new results of the theoretical preictions of the wellbore pressure regimes incurre when ifferent types of rilling flui flows in concentric an eccentric horizontal annuli. The concentric an eccentric casing rilling results are compare with parallel preictions from conventional rillstring results from evelope analytical solutions integrate into the VisWELL(DeskTop Simulator), which is use in simulating well operations. Introuction Well engineers face ever increasing technical challenge of rilling in complex environments an complex geological features such as Drilling of high pressure/high temperature wells with very narrow pore pressure-frac pressure winow The rejuvenation of mature, eplete fiels The use of extene reach rilling techniques to evelop marginal an satellite fiels from existing platforms Drilling through massive naturally fracture stratigraphic columns like the Sirte Basin in Libya Drilling through a combination of complex geological features such Platen overlai by Zechstein with potential for alternate losses an well flows as observe in certain parts of Southern North Sea Drilling through shallow unconsoliate reservoirs with very high overburen such as in Gulf of Guinea In many of these challenging environments the use of overbalance rilling techniques becomes ifficult as the tolerance between formation pressure, pressure exerte by the rilling flui an the pressure at which the formation will fracture becomes very tight. This leas, at best to an increase in rilling costs to loss of the well itself or in extreme cases a loss of control of the well. There is an emerging rilling metho known as manage pressure rilling esigne to overcome the ifficulties escribe above an make the rilling of these complex wells both feasible an safe. Manage Pressure Drilling simply involves carry out well construction operations within a strict operating pressure winow. Otherwise known as walking the line or at balance rilling [1], All rights reserve. No part of contents of this paper may be reprouce or transmitte in any form or by any means without the written permission of Trans Tech Publications, (ID: , Pennsylvania State University, University Park, USA-09/05/16,09:40:59)

2 Avance Materials Research Vols MPD involves a rigorous efinition of the entire wellbore pressure profile rather than mere bottom hole pressure analysis. The key to effective MPD is an appreciation of the complexities of the hyraulics (pressure an flow regime) in the wellbore an the relationship with formation pressure an formation fracture pressure. Example of MPD techniques inclue Unerbalance Drilling. Mu Cap Drilling Dual Graient [Variable Density] rilling Back Pressure regulation Annular pump evacuation Circulating Friction Issues on unerbalance rilling were covere in etail at previous MPC presentation []. In this paper the focus is on casing rilling with circulating friction MPD technique. Management of pressure hot spots in complex geological features such as massive naturally fracture stratigraphic features as in Sirte Basin in Libya, High overburen pressure conitions couple with shallow unconsoliate reservoirs in eep water environments offshore West Africa or HP-HT wells with narrow pore pressure-frac pressure operating winows pose further problems of losses, ifferential sticking leaing to non-prouctive time, poor hole quality, sloughing shales/wellbore instability, ifficulty in running casing an increase rilling costs. These problems can be minimise with couple manage pressure rilling with casing. Well construction time is reuce an tripping time is also massively reuce if not eliminate. The evelopment of appropriate strategy for the management of MPD operations incluing engineere choice of which technique to use for well specific conitions require to realising the limit is rather complex an requires an integrate approach to fining the optimum solution to solving the problem. This requires integration of key aspects of wellbore hyraulics, casing string or rillstring ynamics an impact on string eccentricity, string rotary spee, effect of bottom hole conitions on rheology an pressure regimes. The integration of all these factors that allows for effective planning, well specific MPD process an optimisation plus real-time monitoring an iagnosis is the specific objective of the VisWELL. For the inustry to evelop a manage pressure rilling capability that will allow toay s generation of complex wells to be rille safely, efficiently an reuce cost an problems, it is necessary to evelop moels that can be use to carry out effective planning, assess the operating winow an application of each MPD techniques as well as process optimisation an to embe these moels within an easy to use, intuitive well engineering tool that can be use for pre planning an as a real time tool to monitor an provie looking ahea forwar simulations base on real time rig an ownhole ata. This is what has been achieve with the VisWELL. Some of the key issues affecting successful MPD operations are: The appropriate fit-for-purpose MPD technique to use How can these techniques be optimise on a well-by- well basis? What are the operating winows for casing rilling in complex geologies? The effect of rillpipe eccentricity on flow regime, pressure regime an hole cleaning What is the prevailing string eccentricity?

3 458 Avances in Materials an Systems Technologies II The ability to analyse the causes of rillpipe eccentricity an relationship with rillstring torque/rag conitions Ability to analyse the effects of transients The ability to efine the rheological properties of multi phase rilling fluis at bottom hole conitions Eccentricity, couple with rillstring rotation affect the annular velocities in the well an the prevailing multiphase flow patterns as well as pattern profile which then has an effect on hole cleaning an pressure regimes in the wellbore.. The integration of all these factors that allows for effective planning, well specific MPD process an optimisation plus real-time monitoring an iagnosis is the specific objective of the VisWELL. The VisWELL is the prouct name for MPD applications that allows the well engineering team to interact with virtual representation of the well an near wellbore environment. The VWE is unique in that for the first time: The well engineer or team can visualise the complete wellbore an near well bore rilling process in real-time Manipulate these conitions in virtual reality environment Perform sensitivity an parametric stuies in real time. With the VisWELL, the iniviual well engineer or a team working in collaboration can, while planning a well, perform iterative parametric stuies to ientify the operating bounary conitions through simulations. Also by linking the VisWELL with appropriate ownhole sensors, realtime isplay of actual rilling process/operations can be isplaye onsite an linke to company office for system problem iagnosis an optimisation. In preceing papers the results of various parameters on conventional rilling process an its optimisation have been presente [3, 4]. In the follow-up research work specific moels have been evelope to preict prevailing level of eccentricity in extene reach wells. These moels have been couple with hyraulics an hole cleaning analysis moels for conventional rilling operations analysis with or without RPM. The effects of eccentricity an RPM were evelope from first principles base on approximate solutions some highlights of which are presente below. Why Casing Drilling? Drilling with casing has proven to be an effective metho of reucing rilling costs an solving rilling problems. Growing commercial activity shows that rilling with casing is gaining increasing acceptance as a practical metho of reucing rilling costs an solving rilling problems especially in challenging environments. This activity inclues both onshore applications where the entire well is rille with casing an offshore applications especially in the Gulf of Mexico [3]. Most Casing Drilling activity has been focuse on rilling vertical intervals, but interest in rilling with casing in irectional wells is increasing as the processes for rilling straight holes become proven, the benefits of Casing Drilling are emonstrate, an more versatile tools become available. Vertical wells can be rille with casing using a simple system consisting primarily of a special bit attache to the casing that can be rille out to run subsequent casing strings. For irectional holes a retrievable Casing Drilling system is require because of the nee to recover the expensive

4 Avance Materials Research Vols irectional rilling an guiance tools, the nee to have the capability to replace faile equipment before reaching casing point, an the nee for quick an cost effective access to the formations below the casing shoe. Casing rilling system enables a well to be rille an case simultaneously using stanar oilfiel casings as the rillstring. The casing provies hyraulic an mechanical energy to a retrievable rilling assembly suspene from a profile nipple locate near the bottom of the casing. The profile nipple has the same rift iameter as the casing an can be use to lan cementing equipment once the rilling assembly is remove. Typical Casing rilling BHA is as shown in Fig 1 an it is generally mae up of a pilot bit, an unerreamer, MWD, NMDC, stabilizer profile nipple an DLA. Generally, the stanar rilling BHA is connecte to the casing with a DLA [Drilllock] that provies a running/retrievable interface, mechanical attachment to the casing an a hyraulic seal. Successful irectional Casing Drilling operations require more than simply having irectional tools available that can be run below the casing. BHA response may be quite ifferent when rilling with casing as compare to rilling with conventional systems. Torque an rag must be manage through selecting the casing connections, stabilization, an operational practices at the well site. Special surface hanling equipment is often require to make the Casing Drilling process efficient. Soli centralisers can be ae to the casing for irectional performance, casing wear management, ogleg control an centralisation for cementing purposes. Once BHA is lane in the profile nipple, rilling can progress in similar manner to conventional rilling. Casing rilling operation can utilise a top rive for conventional rotary rilling or sliing can be achieve with mu motor cum steerable system for oriente irectional work. There are now stanar casing rive assemblies that easily aapt to top rives an reaily provie casing makeup thus eliminating power tongs, support casing weights thus eliminating elevators an stabbers as well as allowing casing to be rotate to bottom. Merits of Casing Drilling With casing rilling a number of issues associate with conventional rilling operations using stanar rillstrings are eliminate or minimize. Examples of the merits of casing rilling inclue: Time an effort involve in tripping operations are eliminate which reuces well construction an rig times. With attenant reuction in well construction time an cost Casing rilling eliminates the stanar casing running or casing reaming obtaine the stanar process Problems associate with running casing in crooke holes or tortuous extene reach wells are eliminate There is potential for better quality holes an increase penetration rate with casing rilling There has been reporte cases of better well control especially in Gulf of Mexico[3, 4] The lay own of rillpipes an collars becomes irrelevant There is potential for reuce circulation time an circulating pressures There is potential for high annular velocities because of small casing annular clearance. This allows for the minimum annular velocities require for effective hole cleaning being reaily achieve at lower pump rates. There is potential for less ECD problems an better ECD management with casing rilling especially when couple with MPD

5 460 Avances in Materials an Systems Technologies II MPD Hyraulics Consier the Basic U-Tube Analogy of Well Profile as presente in Fig 1. Irrespective of the MPD technique, the following equations represent the overarching hyraulics equation for a typical well. : BHP A [P A ] = BHP B [P B ]...(1) P A & P B are the bottom hole pressures at specific epths in string bore an annular section respectively. From the Figure below, P A = P s1 + P H1 + P H -ΔP LOSS. ΔP LOSS = ΔP LOSS1 + ΔP LOSS + ΔP MOTTOR + ΔP BIT + ΔP Surface...() ΔP Surface is the pressure rop in the stanar rig surface facilities. The correlation for surface facilities pressure rop is presente as : ΔP surface = C*q x * PV y...(3) PV = Drilling flui plastic viscosity ΔP LOSS1, represent the sum of the frictional pressure rop in the bore of the rill string components ΔP MOTOR = Pressure rop in the mu motor if use ΔP Bit = Pressure rop across the rillbit nozzles given as : ρ * q Δ PBIT = 103* C *[ TFA]... (4) [ρ] = Drilling Flui Density, ppg [q] = Operational pump rate, gpm C = Bit Nozzles Discharge coefficient, TFA = Bit Nozzles Total Flow Area, in P s1 P s ρ 3 D5 BORE D1 ρ 1 ρ TD D4 ANNULUS MOTO R BIT D A B Fig 1 : U-Tube Analogy of Well Profile D3

6 Avance Materials Research Vols P H represent the hyrostatic pressure in the appropriate section of the hole an it is a function of the prevailing flui ensity P H = Hyrostatic hea impose by the rilling flui [In fiel units] = 0.05 * ρ *TVD..(5) TVD is the true vertical height of specific flui column, [ft] P B = P s + P H3 + P H4 + P H5 + ΔP LOSSannulus...(6) ΔP LOSSannulus = ΔP LOSS3 + ΔP LOSS4 + ΔP LOSS5...(7) ΔP LOSS epen on flow regime, RPM, eccentricity, an rheology. Rheology in turn epens on the ownhole conition of pressure an temperature. P A = P B = Bottom Hole Circulation Pressure = BHCP ECD at any Depth = BHCP 0.05* TVD...(8) ΔP LOSS represent the frictional losses in either the bore or annulus of the casing string as illustrate in Fig 1. These losses are affecte by string eccentricity in the hole, flui rheology at prevailing pressure an temperature conitions an string RPM Effect of RPM The analysis of the effect of string RPM is base on the premise that string rotation will exert a tangential velocity [a function of angular velocity] on the flui flow over an above the average flui velocity. Thus there is a vector sum velocity here efine as: V T = v M v +...(9) Where v M = Flui mean velocity v = Flui tangential velocity. These velocities impose corresponing shear rates on the rilling fluis thus generating corresponing effective viscosities. Depening on the flui rheology the corresponing effective viscosities appropriate moels have been custom evelope for Bingham Plastic, Power Law an Herschel-Buckley Fluis. Appropriate corrections are also mae for the effect of prevailing wellbore temperature an pressure effect on the rheology using purposely evelope HP-HT moels for flui rheology. For pseuoplastic fluis for example, The flow regime an effective viscosities in rillstring bore can be preicte using the following equation : ρvm Re = μ μ eff eff = Kγ n 1, γ = γ ax + γ tan γ ax 8vm 3n + 1 = 3n γ tan Ωr =

7 46 Avances in Materials an Systems Technologies II π Where Ω = Angular velocity = * RPM 60 = bore iameter of string v m = average flui velocity through the string bore...(10) Effect of Wellbore Pressure an Temperature Effect of wellbore pressure an temperature is compensate for in terms of the effect on rilling flui rheology. Thus at prevailing wellbore pressure an temperature the flui shear stress as measure at room temperature is correcte as follows : τ@ P, T = CF *τ s...(11) τ = Flui shear stress at efine pressure an temperature τ s = Flui shear stress at stanar temperature (60 o F) an stanar pressure (15psi) CF = Correction factor which is a function of pressure an temperature. Effect of Eccentricity It is recognize from outset in this programme of work that in orer to accurately preict the pressure profile in a wellbore, it is essential to preict the prevailing rillstring eccentricity. The string eccentricity is here analyse base on the string loaing an wellbore trajectory an the corresponing pressure regimes. Appropriate moels have been purposely evelope an proceures evelope to establish the eccentricity profiles throughout the measure length of wellbore trajectory. Analysis of the effect of eccentricity is thus carrie out using the following equation : ΔP Eccent = R * ΔP Conc....(1) R = Pressure Graient Ratio This R represents the eccentricity correction factor an it epens on flui rheology an flui flow regime. ΔP Conc = Pressure profile for concentric case ΔP Eccen = Pressure profile for eccentric case. For lamina flow of pseuoplastic flui for example R can be compute from the following equation:

8 Avance Materials Research Vols R Lam 1.5 * e = avg n * 1 e n avg * e avg * n *...(13) e avg = Average Drillstring eccentricity. * e Highlights of Results The major highlights from the simulation results for circulating friction metho are presente in Tables 1 to 4 an Figs 3 to 5. Table 1: Casing vs Drillstring Drilling 10 RPM[300 o F] Casing Drilling Drillstring Drilling Concentric 50% Eccent Concentric 50% Eccent. ECD[ppge] Pump P, psi Table : Effect of RPM & ECCENTRICITY CONCENTRIC CASING 50%ECC CASING 0RPM 10RPM 0RPM 10RPM ECD[ppge] Pump P, psi Table 3: Effect of Temperature[DRILLSTRING] 10 o F 300 o F 400 o F ECD[ppge] Pump P, psi Table 4: Effect of Temperature[CASING DRILLING] 10 o F 300 o F ECD[ppge] Pump P, psi Conclusion In this paper an attempt has been mae to introuce the concept of Manage Pressure Drilling with emphsasis on casing rilling.

9 464 Avances in Materials an Systems Technologies II Results of casing rilliung versus conventional rillstring rilling technique are presente together with the effects of RPM an eccentricity. In orer to optimise the process a new engineering tool for rilliung operations simulation the VisWELL has been evelope.. Drilling engineers live in a ata rich but information poor environment. The use of VisWELL visualisation techniques ais the transition to information richness through real-time ownhole operation moeling, visualisation for well management an real time problem iagnosis an process optimisation by the supervisory team Future evelopments inclue the ability for real-time simulation of well control as well as torque/rag analysis. References [1]. : At balance rilling []. Oyeneyin, M.Babs; Phil Burge, Lisa Hogg an Chris Anerson : The Virtual Well Engineer Answer To Real-time Wellbore Surveillance in Manage Pressure Drilling, Paper No MPC , Proceeings of the Meiterranean Petroleum Conference, pp48-6, (006). [3[.Warren, Tommy, Bruce Houtchens, Garreth Maell: Casing Drilling Technology Moves to More Challenging Applications, Paper AADE01-NC-HO-3 presente at the 001 National Drilling Conference (001) [4]. Tessari, R.M, an Gareth Maell: Casing Drilling A revolutionary approach to reucing well costs. SPE/IADC Paper No 5789 (1999) Casing Drill lock Fig. : Schematic of a Casing Drilling System [After Reference 3] Stabilizer Unerream er Pilot Bit

10 ECD[ppge] COMPARISON FOR CASING VS DRILLSTRING Avance Materials Research Vols ECD, ppge CASING STRING Fig. 3 : Effect of Casing Drilling Vs Drillstring Drilling EFFECT OF RPM & ECCENTRICITY ON ECD ECD, ppge CONC ECCEN RPM 10RPM Fig. 4 : Effect of RPM & Eccentricity on Wellbore Pressure EFFECT OF TEMPERATURE ON ECD ECD, ppge oF 300oF Bottom HoleTemperature Fig. 5: Effect of Temperature on Wellbore Pressure Pr

11 Avances in Materials an Systems Technologies II / Developing a Manage Pressure Drilling Strategy for Casing Drilling Operations /

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