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SEGMENT DRILLING
CHAPTER ROTARY DRILLING BITS
BIT TYPES 1
DRAG BITS 1
DIAMOND BITS 3
- BIT CONSTRUCTION 3
POLYCRYSTALLINE DIAMOND COMPACT BITS 6
- PDC BIT WHIRL 11
ROLLING CUTTER BITS 13
- BIT DESIGN 13
- CUTTERS 16
- BEARINGS 18
- BIT BODY 20
BIT ENHANCEMENTS 22
BIT SELECTION 29
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The process of drilling a well requires the use of drilling bits. The drilling engineer is
responsible for the selection of the best drilling bit for a given situation and the
optimization of the bit operating conditions. The performance of drilling bits has a direct
impact on the total cost of drilling a well. It is, therefore, important for the drilling
engineer to learn the fundamentals of bit design so that he can understand the differences
among the various types of bits available.
BIT TYPES
Rotary drilling bits are classified according to their design as either drag bits or rolling
cutter bits. Drag bits consist of fixed cutter blades that are an integral part of the body of
the bit and rotate as an unit with the drill string. Rolling cutter bits have two or more
cones containing cutting elements, which rotate about the axis of the cone as the bit is
rotated at the bottom of the hole.
DRAG BITS
The design features of the drag bit include the number, size and shape of the cutting
blades or stones, the size and location of the water courses and the metallurgy of the bit
and cutting elements. Drag bits drill by plowing cuttings from the bottom of the hole like
a farmers plow cuts in the soil. There are two types of drag bits; diamond bits and
polycrystalline diamond cutter (PDC) bits. An advantage of drag bits over rolling cutter
bits is that they do not have any rolling or moving parts, which require strong and clean
bearing surfaces. This feature is especially important in drilling small hole sizes, where
space is not available for designing strong bit cutter elements and bearings needed for a
rolling cutter. Also, since drag bits are made of one solid piece of steel, there is less
chance of bit breakage and leaving junk in the hole.
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DIAMOND BITS
Diamond drilling bits are quite expensive and may cost three or four times as much as
roller cone insert bits. They are used to drill hard and abrasive formations when they
offer economic advantage over other types of bits. The most important advantage of a
diamond bit is that it drills more hole than any other bit over its rotating life, thus fewer
round trips are required. Diamond bits drill at lower penetration rates than other bits.
Therefore, to be cost effective a diamond bit must drill at a reasonable rate of penetration;
otherwise, the time lost in rotating would cancel out the savings in round trips.
Bit Construction:
Diamond bits have three major components:
Refer to the design nomenclature in Fig (1). The crown is made of tungsten carbide
powder bonded together with nickel copper alloy binder. The use of the tungsten carbide
alloy offers resistance to the corrosion and abrasion caused by the high pressure drops
across the bit face, long bit runs and high solid content in the drilling mud. The shape of
the crown is determined by the graphite mold in which it is furnaced. During this process,
the nickel copper alloy also binds the crown to the steel bit blank. The blank is then
machined, threaded and welded to a properly heat treated shank which has been
machined for the appropriate API pin connection.
The face or crown of the bit consists of many natural diamonds set in the tungsten
carbide matrix. The diamonds come in various sizes and grades for a range of
applications. Some natural diamonds are mechanically or chemically treated to provide
smoother cutting surface for improved wear resistance. Small reclaimed natural diamonds
are used for gauge protection.
Under proper bit operation only the diamonds contact the bottom of the hole leaving a
small clearance between the matrix and the hole bottom. Fluid courses (Fig 2) are
provided in the matrix to direct the flow of drilling fluid over the face of the bit. These
courses must be small enough so that some of the fluid is forced between the matrix and
the hole bottom, thereby cleaning and cooling the diamonds. There are two types of
hydraulic flow patterns; the radial flow and the feeder collector shown in Fig (2). The
radial flow pattern is used in soft formation bits. The fluid flows from the bit's axis
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toward the shoulder through a series of parallel or expanding fluid courses keeping the
cuttings off the bit's face in shale and soft formations. The feeder collector flow pattern is
used in hard formation diamond bits where the fluid flows across diamond pads from
high pressure feeders into low pressure zones.
Open Flow
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Sharp-nosed crown
profile
Large diamond size
Radial flow hydraulics
Used in soft
formations
Blunt-nosed crown
profile
Medium diamond size
Feeder collector
hydraulics
Used in hard
formations
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An important design feature of a diamond bit is its shape or crown profile (Fig 3). A bit
with a long taper assists in drilling a straight hole and allows the use of higher bit
weights. On the other hand, a short taper is easier to clean because the hydraulic energy is
concentrated over a smaller surface area. A more concave bit face is used in directional
drilling to assist in increasing the angle of deviation of the borehole from vertical.
The size and number of diamonds used in a diamond bit depends on the hardness of the
formation to be drilled. Bits for hard formations have many small (0.07 - 0.125 carat)
stones, while bits for soft formations have a few large (0.75 - 2 carat) stones. Examples of
diamond bits for soft and hard formations are shown in (Fig 4). If the diamonds are too
large the unit loading on the diamond points will be excessive, resulting in localized heat
generation and polishing of the cutting edge of the stones.
The design of the water-course pattern cut in the face of the bit and the junk slots cut in
the side of the bit face controls cuttings removal and diamond cooling. Diamond bits are
designed to operate at a given flow rate and pressure drop across the face of the bit.
Experiments by bit manufacturers indicated the need of 2.0-2.5 bhp/sq. in. of hole bottom
with 500-1000 psi pressure drop across the face of the bit to clean and cool the diamond
adequately. The pressure drop can be measured as the difference between the pump
pressure with the bit off bottom and the pump pressure measured while drilling. The bit
manufacturer usually provides the approximate circulating rate required to establish the
needed pressure drop across the bit face.
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In the mid-1970's a new type of drag bit had been made possible by the introduction
polycrystalline diamond compact (PDC) as a bit cutter element. The compact consists of
a thin layer of synthetic diamond about 0.5 mm thick bonded through high-pressure,
high-temperature process to a tungsten carbide disc. The diamond layer consists of small
diamond crystals which have random orientations for maximum strength and wear
resistance. As shown in (Fig 5), the polycrystalline diamond compact is bonded to a
tungsten carbide body matrix.
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During drilling the diamond compact maintains a sharp cutting edge as it wears. The
PDC cutter's self sharpening effect results in long bit life and high rates of penetration.
PDC bits are evolving rapidly. They perform best in soft, firm and medium - hard
nonabrasive formations that are not "gummy". Bit balling is a serious problem in very
soft, gummy formations, and rapid cutter abrasion and breakage are serious problems in
hard, abrasive formations.
The bit shape or crown profile is an important design feature in PDC bits. There are three
basic crown profiles for PDC bits: short taper, long taper and non-taper profiles (Fig 6).
Short taper bits have a tapered crown with a relatively blunt nose. This design allows
more cutters to be distributed toward the outside of the bit for a more even wear pattern
on the cutters. The short taper bit also provides rotational and directional stability while
drilling build curves in directional or horizontal wells. The high cutter density enhances
bit life at higher rotational speeds, on down hole motors or in large hole sizes. The short
parabolic shape provides a relatively small surface area for easy cleaning.
Bits with non-taper have the least surface area which minimizes the number of cutters
required to provide full coverage. The weight on bit is distributed evenly on the cutters.
Because of the reduced surface area, the available hydraulic horsepower is more
concentrated which improves hole cleaning. These features provide high penetration rates
in soft to medium formations. Non-taper bits are usually used to drill 9" or smaller holes.
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d/4
EXPOSURE
Fig. 8 Cutter orientation expressed in terms of exposure, back rake and side rakes
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Typically, nozzles are positioned and oriented to clean a group of PDC cutters. In some
designs each nozzle can be dedicated to a single PDC cutter.
Other important features of a PDC bit include the size, shape and number of cutters used
and the angle of attack between the cutter and the surface of the exposed formation. The
number of cutters on a bit depends on the formation being drilled. Generally, the greater
cutter concentration, the lower is the wear rate and slower the rate of penetration. High
number of cutters are usually placed on hard formation bits to reduce the load per cutter
and the cutter breakage. Fewer cutters are placed on soft formation bits to reduce chances
of bit balling.
Cutter orientation is defined in terms of back rake, side rake and chip clearance or cutter
exposure (Fig 8).
Back rake is the angle that the face of the cutter makes with the vertical. Back rake angle
o o
can be varied from 0 to 30 to match the drilling mechanics of the formation. Cutters
with small or no back rake are suited for soft formations where the aggressive cutter
orientation can improve ROP. Cutters with greater back rake are used in harder
formations to shear rock more efficiency and resist impact damage. Increasing the back
rake makes the bit less responsive to variations in weight on bit. This widens the
operational range of the bit and makes it more versatile for directional and horizontal
drilling.
The side rake angle assists in directing the cuttings formed towards the junk slots and the
annulus. The angle can be varied to enhance the bit's cleaning efficiency.
Cutter exposure is the distance between the cutting edge and the bit face. The exposure of
the cutter provides room for the cuttings to peel off the bottom without impacting against
the bit body and packing in front of the cutter. Soft formation PDC bits have full
exposure for maximum rate of penetration. In hard formations partial exposure may be
desirable to increase cutter durability.
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Anti-whirl Standard
Anti-whirl Standard
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Fig. 12 Cutter layout and orientation designed to create a net imbalance force to
counter bit whirl forces and create a stable rotating condition
The three-cone rolling cutter bit is the most common bit type currently used in rotary
drilling. This bit is available with a large variety of tooth design and bearing types and
thus is suited for a wide variety of formation characteristics.
Bit Design:
Rolling cutter bits consist of three major components:
the cutters
bearings and
the bit body
Fig (13) shows a rolling cutter bit with the various parts labeled.
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Cutters:
The cutters or teeth, which are
placed or machined on the outer
surfaces of the cones are the parts of
the bit that break the rock. The
cones are mounted on bearings
which run on pins that are an
integral part of the bit body. See
(Fig 13). The drilling action of a
rolling cutter bit depends to some
extent on the offset of the cones. As
shown in Fig (14), the offset of the
bit is a measure of how much the
cones are moved so that their axes
do not intersect at a common point
in the center of the hole. Offsetting
causes the cones to slip as they
Fig. 14 Offsetting cone centerlines from rotate and scrape the hole bottom
the center of bit rotation to much like a drag bit. This action
increase penetration rates in soft tends to increase penetration rate in
formations soft formations. In hard formations
where the rock must be fractured or
broken, scraping contributes little to rock removal. In addition scraping against a hard
formation is very abrasive and can wear the teeth down quickly. For these reasons hard
formation bits are designed with little or no cone offset. Cone offset angle is expressed as
the angle the cone axis would have to be rotated, to make it pass through the center line
o
of the hole. Cone offset angles vary from 4 for bits used in soft formations to zero for
bits used for extremely hard formations.
The cutting elements on the bit cones are either milled tooth cutters or tungsten carbide
insert cutters. The milled tooth cutters are machined on the cones. The cones are made of
forgings of nickel molybdenum alloy steel. The cones are hardened by special processing
and heat treating to produce a 0.07 to 0.13 deep hard case on the teeth. All steel tooth
cones have tungsten carbide hardfacing material applied to the gage surface. Tungsten
carbide hardfacing is applied to the teeth as dictated by the intended use of the bit.
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The tungsten carbide cutting elements are made of sintered tungsten carbide teeth which
are pressed into holes drilled in the cone surfaces. The positioning of the teeth on the
cones of a roller cone bit is very important. The inner rows of teeth are positioned on the
cones so that they intermesh. A relief ring is cut into the surface of one cone to provide
space for the tooth rotation of an adjoining cone. This intermeshing allows more room for
a stronger bit design, provides self cleaning action and prevents bit balling as the bit
turns. The outer rows of teeth, the heel teeth, do not intermesh. These teeth do the hardest
job because more rock must be removed from the outer most annular ring of the hole
bottom. Because the heel teeth have a more difficult job, they may wear excessively
causing the bit to drill an undersized hole. This causes a misalignment of the load on the
bearings and premature bit failure. Premature failure of the next bit is likely if the hole
remains undersized. Bit manufacturers offer different heel tooth designs to provide the
gauge protection needed.
Another important feature in the positioning of teeth on bit cones is the pitch. Pitch is the
distance between adjacent teeth on a bit cone. If the pitch is the same for all teeth on a
given row, then the teeth will impact the formation in the same location on each rotation
and prevent the bit from making hole. To prevent this from happening, the pitch between
teeth is varied.
The shape and height of the teeth on a bit cone has a large effect on the drilling action of
a rolling cone bit. Milled tooth bits used for soft formations have offset cones and long,
widely spaced teeth. Long teeth give maximum penetration into the formation and
generate large cuttings. The scraping action provided by the offset cones removes the
drilled material. The wide spacing of the teeth promotes bit cleaning and prevents bit
balling. Tooth wear is a problem in soft formation bits because of the scraping action of
the offset cones. This problem is minimized by adding tungsten carbide hard facing to the
teeth. When tungsten carbide inserts are used, abrasion is not a concern because of the
exceptional wear resistance of tungsten carbide. Long and widely spaced insert usually
chisel or conical in shape, are used for maximum penetration.
In drilling medium hard formations, rolling cutter bits are designed to drill by a
combination of crushing and scraping action. Milled tooth breakage becomes a problem
because higher bit weights are required. So the teeth are shorter and less pointed. Wide
tooth spacing is still required to permit adequate cleaning of the bit. The teeth on insert
bits are more closely spaced to reduce load on each tooth. The inserts are more conically
shaped and blunter.
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In hard formations the failure mechanism of the rock is primarily, by crushing. Drilling
hard formations require heavy bit weights which cause severe bending forces on the
teeth. Therefore the bit teeth are short, stubby and closely spaced to minimize breakage.
Because there is little scraping action, hardfacing is only applied on the gauge row of
teeth. In rolling cutter insert bits the inserts are spherical or elliptical and set deeply into
the cone to reduce their tendency to pop out.
Bearings:
The purpose of the bit bearings
is to allow the cones to turn on
the pin with minimum friction.
The most inexpensive bearing
assembly consists of nonsealed
roller-type outer bearing and a
ball-type bearing. Refer to Fig
(15). The roller bearing is the
most heavily loaded member
and tends to wear out first. The
ball bearings carry some of the
axial and thrust loads and serve
to hold the cone in place on the
bit. Since the bearings are
neither sealed nor lubricated
drilling mud is free to enter into
the bearing area and erode the
metal of the rollers and races
and cause the cones to become
Fig. 15 Non-lubricated ball & roller bearings loose. A loose bearing cannot
used in the steel tooth of rock bit evenly distribute the load and
finally become damaged. Non-
sealed roller bearings are adequate to last as long or longer than the cutting structures. In
some areas the bearings are not adequate to varying degrees. This type of bearing
assembly is used in steel tooth bits for drilling shallow top hole sections.
The intermediate cost bearing assembly in rolling cutter bits is the sealed bearing
assembly which was introduced in carbide insert bits. In this type of bit the bearings are
maintained in a grease environment to minimize wear and prolong life of bearings. In
addition to the ball and roller bearing elements, this bearing requires a grease reservoir,
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pressure compensator, connecting passage and seal as shown in Fig (13a). The
compensator allows the grease pressure to be maintained equal to the hydrostatic pressure
at the bottom of the hole. The seal keeps the grease in place and prevents drilling fluid
from entering the bearing area. As the bit wears, the seals eventually fail and allow
drilling fluid to enter the bearings and accelerate bearing wear.
The carbide tooth cutters still out lasted the lubricated ball and roller bearings. This led to
the development of the journal bearing bit. Fig (13a). In this type of bit the roller
bearings are removed and the cone rotates in contact with the journal bearing pin. Instead
of a series of rollers, the journal bearing consists of two circular bearing surfaces which
mate within very close tolerances of each other. A thin layer of grease must separate the
two surfaces to prevent galling. This type bearing has the advantage of greatly increasing
the contact area through which the weight on the bit is transmitted to the cone. Also, by
eliminating one of the components (the rollers), additional space becomes available for
strengthening the remaining components. Journal bearing bits require effective grease
seals, special metallurgy, and extremely close tolerances during manufacture. Silver
inlays in the journal help to minimize friction and prevent galling. While journal bearing
bits are much more expensive than the standard or sealed bearing bits, much longer bit
runs can be obtained, thus eliminating some of the rig time spent on tripping operations.
High rotational speeds in motor drilling shorten the operating life of conventional
elastomer seals. Hughes developed the metal-face seal (ATM) which enables the bit to
run long hours at high rpm. The metal-face seal withstands high temperatures and
provides greater bearing reliability even in abrasive environments.
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Bit body:
Bit bodies consist of the
threaded connection which
attaches the bit to the drill
stem, the bearing pins on
which cones are mounted,
the lubricant reservoirs
which contain the lubricant
supply for the bearings and
the watercourses through
which the drilling fluid flows
to clean the cuttings from the
hole.
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BIT ENHANCEMENTS
Bit enhancements are made to increase the operating life of the rolling cone bit. Fig (18)
shows an insert bit with gage enhancement. Ovoid shaped inserts are placed on the heel
row and carbide button inserts on the gage row. The inserts are made from extremely
wear resistant tungsten carbide grade and protect the gage of the bit from abrasive wear.
In high-speed directional or abrasive applications, tungsten carbide particle hard facing
and/or flat tungsten carbide inserts are applied along the shirtail to protect against
excessive gage wear as shown in Figs (19) and (20). Wear pads can also be added to the
outer diameter of a rolling cone bit to minimize wear on the bit leg and body. Flat
tungsten carbide inserts are pressed into the pad to provide a wear resistant surface as
shown in Fig (21).
For diamond bits, the number 6 represents diamond sizes larger than 3 stones per carat; 7
represents 3 stones to 7 stones per carat; and 8 represents sizes smaller than 7 stones per
carat. Thus the diamond size becomes smaller as the digit increases from 6 (soft
formation) to 8 (hard formation).
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Fishtail Long
Short Medium
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The third digit designates the size or type of cutter. For PDC bits 1 indicates cutter larger
than 24 mm in diameter, 2 represent 14-24 mm, 3 indicates 13.3 mm (1/2), and 4 is used
for the smaller 8 mm in diameter. For diamond bits the third digit represents diamond
type, with 1 indicating natural diamonds; 2 to TSP material; 3 represents mixed natural
diamonds and TSP, and 4 applies only to the highest density bit, indicating an
impregnated diamond bit.
The fourth digit gives the basic description of bits profile. The number 1 represents both
fishtail PDC bit and flat TSP and natural diamond bits. Numbers 2, 3 and 4 indicate
increasingly longer bit profiles as shown in Fig (22). Classification systems for PDC and
diamond bits are shown in Tables (1) and (2).
The second character refers to cutting structure type. Each series is divided into 4 types
or degrees of hardness. Type 1 for the softest formation in the series and type 4 for the
hardest formation.
The third character describes the bearing and gage protection. There are 7 categories of
bearing and gage protection design as shown in Table (3). Categories 8 and 9 are
reserved for future use.
The fourth character is optional and describes special features available. There are 16
alphabetic characters as shown in Table (3).
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3 < 14 R426(M) TD2A1(M) DS39(M) S93(M) B935(M) R482(M) PD1(S) DS48(S) S10(S) HZ232(M) LX201(M) DS26(S) S45(S)
Z426(M) B2S(M) LX101(M) DS31(S)
1 > 24 R535(M)
3 < 14 TD5A1(M) B927(M) AR435(M) TD268(M) DS23(S) MX42(M) R435(M) PD2(S) S85(S) B272(M) Z528(M)
TD260(M) DS49(M) S43(S)
1 > 24
3 < 14 TD290(M) HZ352(M) R437(M) LX401(M) D247(M) S35(M) S292(S) R419(M) LX271(M) DS18(M) B102(M)
B352(M) Z437(M) LX301(M) R429(M) TD115(M) DS19(M) B362(M)
Z429(M) LX291(M) DS20(M)
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1 NAT D411 TB26 828 N4S D41 TB521 D262 TB601 901 N39 T51 TB593 901DT
D331 730 N50 T54 TB703
D311 753
7 744
2 TSP SST 828TSP TT521 263 P443 S248 TT601 243 P341 TT593
S226 223 P343
3 - 7 SPC
2 TSP
8
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While one mechanism may be dominant for a given bit design, more than one mechanism
is usually present.
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BIT SELECTION
Unfortunately, the selection of the best bit to drill a given formation is made by trial and
error. The criterion used for selecting a bit is based on the drilling cost per unit interval.
The best bit for drilling a given formation is the bit that would give the least drilling cost.
The drilling cost per foot. C is,
Cb + C r ( T b + T c + T t )
C = ...........................(1)
L
where,
C: drilling cost, $/ft
Cb: cost of bit, $
Cr : rig cost, $/hr
Tb: rotating time, hrs
Tc: non-rotating time (connection time), hrs
Tt: tripping time to change bit, hrs
L: interval drilled, ft
The initial selection of bit type can be made on the basis of formation drillability and
abrasiveness. Drillability is a measure of how easy the formation is drilled and it is
inversely related to the compression strength of the rock. The abrasiveness of the
formation is a measure of how rapidly the teeth of a milled tooth bit wear when drilling
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1. High-cost bits tend to be more applicable when the daily rig operation cost is high.
2. Rolling cone bits are the most versatile bits and are good initial choice.
3. When using a rolling cone bit:
a) Use the longest tooth suitable for the application.
b) When the rate of tooth wear is much less than the rate of bearing wear, select a
longer tooth size, a better bearing design, or apply more bit weight.
c) When the rate of bearing wear is much less than the rate of tooth wear, select a
shorter tooth size, a more economical bearing design, or apply less bit weight.
4. Diamond drag bits perform best in nonbrittle formations having a plastic mode of
failure, especially in the bottom portion of a deep well, where the high cost of tripping
operations favors a long bit life, and a small hole size favors the simplicity of a drag
bit design.
5. PDC drag bits perform best in uniform sections of carbonates or evaporites that are not
broken up with hard shale stringers or other brittle rock types.
6. PDC drag bits should not be used in gummy formations, which have a strong tendency
to stick to the bit cutters.
Diamond bits are used only in special situations to drill extremely hard and abrasive
formations in deep exploratory wells. Diamond bits are not in the SAMS and are acquired
when the need arises. PDC bits are being developed for use in horizontal and highly
deviated wells. Since PDC bits have no moving parts they will last longer than the
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roller cone bits especially when run at high rpms with a downhole motor. One
disadvantage of PDC bits is that they cannot be steered easily when drilling the curved
sections of a deviated well in the sliding mode. The bit, if it is not properly designed,
tends to take a large bite into the formation and stalls the bottom hole motor. When this
happens, the bit is pulled out and replaced with a roller cone bit. For this reason, a
considerable amount of time and effort is required to select the most suitable PDC bit for
a particular formation.
Example:
Rig PA-235 used a Smith 8-1/2 MF-2 rolling-cone insert bit type code 5-1-7 with a
motor to drill the curved section across the Hith and Arab-A formations in HRDH-308.
The bit drilled from 6987 to 7582 in 61.5 hours. The daily rig operating rate is $11,000
and the Saudi Aramco overhead is $6500 per day. Assuming a bit price of $5800 and
tripping time of 1 hr per 1000 ft (round trip) what is the drilling cost per foot ?
Solution:
Cb = $5800.
7582
Tt = = 7.58 hrs
1000
Tb + Tc = 61.5 hrs.
11,000 + 6500
Cr = = $729 / hr
24
From Eq (1)
5800 + 729( 615
. + 7.58)
C = = $ 94.4 per foot
595
Problem:
Rig P-235 conducted a trial test to evaluate the performance of an 8-1/2 Reed EHP53A
bit type code 5-3-7 in drilling the curved section across the Hith and the Arab-A
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formations in HRDH-314 which is located near HRDH-308. The regular price of the bit
is $7000, however, since this was a trial test Saudi Aramco was able to purchase the bit at
50% discount. The bit drilled the interval from 6767 to 7612 in 67.5 hrs. Which bit
should be used to drill the Hith and Arab-A in Haradh, MF-2 or EHP53A?
The tooth wear of insert bits is a measure of the combined cutting structure reduction due
to lost, worn and broken inserts. For example, if 50% of the inner inserts are broken
and/or lost and the remaining inner inserts have no reduction in height, the bit is
graded T-4 in column 1. If 50% of the outer inserts are lost and the remaining inserts on
the outer rows have 50% reduction in height, the bit is graded T-6 in column 2.
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In column 3 a two-letter code is used to indicate the major dull characteristic of the
cutting structure. Table (5) lists the two-letter codes to be used in this column.
Table (5)
DULL CHARACTERISTICS
Some of the dull characteristics listed in Table (5) are self explanatory. More detailed
description of the two-letter codes can be obtained from bit companies. Examples of
some of the dull characteristics are shown in Figs (26) through (29).
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In column 4 a letter or number code is used to indicate the location on the face of the bit
where the cutting structure drilling characteristic occurs. Table (6) lists the codes to be
used for describing locations on roller cone bits.
TABLE (6)
LOCATION (ROLLER CONE BITS)
Column 6 (G-Gage) is used to report on the gage of the bit. The letter I (IN) indicates
no gage reduction. If the bit does have a reduction in gage it is to be recorded in 1/16th of
an inch. The Two Thirds Rule is correct for three-cone bits.
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The Two Thirds Rule, as used for three-cone bits, requires that the gage ring be pulled so
that it contacts two of the cones at their outermost points. Then the distance between the
outermost point of the third cone and the gage ring is multiplied by 2/3s and rounded to
the nearest 1/16th of an inch to give the correct diameter reduction.
Column 8 (R-Reason Pulled) is used to report the reason for terminating the bit run.
Table (7) lists the two-letter or three-letter codes to be used in this column.
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TABLE (7)
REASON PULLED OR RUN TERMINATED
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Example:
Describe the bit in Fig (30). The
bit was pulled out of the hole
because of low penetration rate.
The seals were found effective
and the bit in gauge.
Solution:
The bit looks to have been
dulled by encountering a harder
formation than the bit was
designed for. This is indicated
by the heavy tooth breakage on
the inner rows, and by the fact
the bit was pulled for
penetration rate. The reduced
penetration rate was caused by
Fig. 30 tooth breakage occurring when
the bit encountered the hard
formation. Excessive weight on
bit also could cause the dull to
have this appearance. Because
of the heavy tooth breakage in
the inner rows, the grade for
column 1 would be 7. The
inserts on the outer row have
little tooth wear but none are
broken, Therefore, the grade for
column 2 is 1. Since the dull
characteristics of the cutting
structure are broken teeth, a
BT code is used in column 3.
An M code is used in column
4 because the broken teeth are
on the middle rows. Since the
Fig. 31 seals are effective a letter E is
used in column 5. A letter I is
used in column 6 to indicate
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that the bit was in gauge. Another characteristic of the cutting structure in addition to
broken teeth is the worn teeth on the outer row. Therefore, a WT code is entered in
column 7. Finally, since the bit was pulled out because of low ROP, a PR code is entered
in column 8. So the bit description is 7, 1, BT, M, E, I, WT, RP.
Problem:
Describe the dull bit shown in Fig (31). When pulled the bit was 2/16 under gauge and
the seals were still in satisfactory condition. The bit was pulled when a specified number
of hours had elapsed.
bit type
formation properties
drilling fluid properties
bit weight and rotary speed
bit hydraulics
BIT TYPE
Penetration rate is highest when using bits with long teeth and large cone offset angle.
These bits are practical only in soft formations. The lowest cost per foot drilled usually is
obtained by using the longest teeth that are consistent with bearing life at optimum bit
operating conditions.
Drag bits such as diamond and PDC bits are designed to obtain a given penetration rate
by the selection of the number and size of the diamonds or the PDC blanks. The
penetration rate of PDC bits also depends on the back rake angle and the exposure of the
blanks.
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FORMATION CHARACTERISTICS
The ultimate compressive strength of the rock is the most important rock property that
affect penetration rate. The higher the compressive strength the lower the penetration
rate. The mineral composition of the rock has some effect on penetration rate. Rocks that
contain abrasive minerals can cause rapid dulling of the bit teeth. Rocks that contain
gummy clays can cause the bit to ball up and drill inefficiently.
The permeability of rock also affects penetration rate. In permeable rock, the drilling
fluid filtrate can move into the rock ahead of the bit and equalize the pressure differential
acting on the chips formed beneath each tooth and increase the penetration rate.
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Penetration rate tends to decrease with increasing viscosity and solids content and
tends to increase with increasing filtration rate. Increasing the viscosity increases the
frictional losses in the drillstring and thus decrease the hydraulic energy available at the
bit for cleaning the bottom of the hole. The solid content of the mud controls the pressure
differential across the zone of crushed rock beneath the bit. Increasing the solid content
decreases the filtration rate and therefore increases the differential pressure. As
mentioned earlier, an increase in the differential pressure results in a decrease in the
penetration rate.
Fig. 33 Exponential relation between penetration rate and overbalance for rolling
cutter bits
Many studies have been conducted on the effect of differential pressure (overbalance) on
the penetration rate. Bourgoyne and Young observed that the relation between
differential pressure and penetration rate can be represented by a straight line on a semi
log paper as shown in Fig (33). The equation for the straight line is given by
R
log ( ) = 0.000666 (Pbh - Pf) ......................................(2)
Ro
where,
Ro = penetration rate at zero overbalance, ft/hr
R = penetration rate, ft/hr
Pbh = bottom hole pressure, psi
Pf = Formation pore pressure, psi
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R2 6
D ( 1 2 )
= e 80.6 10 ................................................(3)
R1
where,
1 = equivalent circulating mud density, lb/gal
R1 = penetration rate ft/hr for equivalent circulating mud density 1
D = depth, ft.
Example:
A 12000 ft deep well is being drilled at a penetration rate of 20 ft/hr using 12 lb/gal mud.
Estimate the penetration rate if the mud density is increased to 13 lb/gal.
Solution:
R1 = 20 ft/hr
1 = 12 lb/gal
2 = 13 lb/gal
From Eq (3),
6
D ( 1 2 )
R 2 = R1 e80.6 10
6
= 20 e 80.6 10 12000 (1213)
= 7.6 ft/hr
Problem
The Jilh formation in HRDH-604 was drilled at a rate of penetration of 4.9 ft/hr using
105 pcf mud. The mud weight was decreased to 102 pcf at 9383 ft and drilling continued
to 9538 ft. How long did it take to drill the interval 9383-9538 ft?
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of the bit cones will lock and cause a sudden increase in the rotary torque needed to
rotate the bit. When this happens the bit should be pulled out. When the penetration rate
decreases rapidly as bit wear progresses, it may be advisable to pull the bit before it is
completely worn. If the lithology is somewhat uniform, the total cost can be minimized
by minimizing the cost of each bit run. In this case, the best time to terminate the bit run
can be determined by keeping a current estimate of the cost-per-foot for the bit run,
assuming that the bit would be pulled at the current depth. Even if significant bit life
remains, the bit should be pulled when the computed cost-per-foot begins to increase.
However, if the lithology is not uniform, this procedure will not always result in the
minimum total well cost. In this case, an effective criterion for determining optimum bit
life can be established only after enough wells are drilled in the area to define the
lithologic variations.
Example:
Determine the optimum bit life for the bit run described in the table below. The lithology
is known to be essentially uniform in this area. The bit cost is $800, the rig cost is
$600/hr, and the trip time is 10 hrs.
Cumulative Cumulative
Footage Drilled Drilling Time (Tb + Tc)
ft hrs
0 0
30 2
50 4
65 6
77 8
87 10
96 12
104 14
111 16
The cost per foot is calculated by using Eq (1). For the first interval the cost per foot is
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The cost per foot that would result if the bit were pulled at the various depths is as
follows,
0 0 0.00
30 2 266.66
50 4 184.00
65 6 160.00
77 8 150.65
87 10 147.12
96 12 145.83
104 14 146.15
111 16 147.75
The cost per foot is plotted versus the footage in Fig (34). Note that the cost per foot
during the first 12 hours decreased from $266.66/ft to $145.83/ft. After 12 hrs the cost/ft
increased to $147.75/ft. Therefore, the optimum time to pull out the bit is after 12 hours.
280
Drilling Cost ($/ft)
260
240
220
200
180
160
140
120
0 20 40 60 80 100 120
Footage (ft)
Fig. 34 The cost per foot when the bit is pulled at various depths
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Problem:
A 17 ATX-11 H bit was used to drill the Jilh in HWYH-200. Given the data below,
determine the optimum time to terminate the bit run. Assume $24,500 bit cost, $790/hr
rig cost and tripping speed of 2000 ft/hr.
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3420 L w
R = .................................................................(4)
EAs t
where:
2. After proper break in, select a starting rpm which is less than the recommended
maximum normal rpm. Measure rpm by counting revolutions of the rotary table.
3. Ensure that the weight indicator has been properly zeroed. Place on the bit the
maximum weight recommended by the manufacturer. Make sure that the product of
the selected bit weight in 1000 lbs times the rpm does not exceed the bearing
capability or the WN number of the bit as recommended by the manufacturer. The WN
number is the product of the weight on bit in 1000 lb times rpm recommended by
manufacturer.
4. Lock the brake. By using a stop watch, measure the time in seconds required to drilloff
2000 lb increments. The average weight corresponding to the shortest time is the
optimum bit weight for that rotary speed.
5. Repeat the test for various rotary speeds. Make sure that weight rpm product does
not exceed the WN number. Pick the optimum bit weight and rpm which corresponds
to the shortest time. If the shortest time occurs at different weights and rpms, use the
lowest weight or rpm. This will save bearing wear.
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Example:
A drilloff test was conducted in UTMN-242 across the Arab-D at a constant speed of 72
rpm and 7300 ft using a Hughes 6-1/4 J-33 bit run on 3-1/2 drill pipe (ID= 2.764 in).
Using the test data below, construct a table of penetration rate versus weight on bit.
25 0
23 20
21 21
19 26
17 29
15 30
Solution:
The penetration rate can be calculated using Eq (4),
3420 L w
R =
EAs t
24 23.0
22 21.9
20 17.7
18 15.8
16 15.3
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Problem:
The drilloff test of the previous example was repeated at 5 different rpms as shown
below. What is the optimum bit weight and rpm? The WN number for 6-1/4 J-55 bit is
2550.
25-23 20 20 14 15
23-21 21 21 19 25
21-19 27 26 26 29
19-17 27 29 27 27
19-17 27 29 27 27
17-15 32 30 29 29
A rotary-weight response test is usually conducted to confirm the results of the drilloff
test. The response test is more reliable than the drilloff test and takes about one hour to
run. The procedure for conducting a response test is as follows:
1. Pick the optimum weight obtained in the drilloff test and measure the time to drill
one foot. Compute the rate of penetration in ft/hr.
2. Keeping the weight on bit constant repeat step for various rpms. Make sure the
weight rpm product does not exceed the WN number. Plot rate of penetration versus
rpm. Pick the optimum rotary speed from the graph.
3. Keep the rpm constant at the optimum rotary speed obtained in step #2 and repeat the
test for various bit weights. Calculate the rate of penetration. Plot rate of penetration
versus bit weight. Pick the optimum bit weight from the plot.
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Problem:
A rotary-weight response test was conducted to confirm the results of the drilloff test of
the pervious example. The test data are tabulated below. Determine the optimum bit
weight and rpm for drilling the Arab-D using 6-1/4 J-33 bit.
60 180 18 262
72 141 20 212
82 123 22 187
90 127.5 24 166
97 147 25 146
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SURFACE HANDLING
New bits should be ordered without nozzles and stored in their boxes. Serial numbers and
date of arrival should be recorded. Re-run bits should be cleaned and stored with pipe
coating on the threads.
Before a new bit is run in the hole, the drilling representative should check the bit and
confirm it is of the correct type and size and has no missing inserts or protruding seals.
Grease reservoir equalization ports should not be clogged. The drilling representative
should witness the installation of new nozzles. Never force a nozzle into the bit. Measure
nozzle size with a nozzle gauge. The bit should be made up using a properly sized bit
breaker. The threads should be cleaned, greased and properly torqued.
When in the open hole the bit should be run with care in areas which were tight in the
previous bit run. Tight holes may be reamed at low bit weight and high RPM and
pumping rate. Excessive reaming can damage teeth on the outer row where all the bit
weight is applied during reaming.
When the bit is on bottom, wash the last two joints and avoid running into fill which may
plug the bit. Start the pump slowly and avoid pressure surges which could blow the
nozzles out of the bit. Start drilling with low weight and rpm for few feet to enable the bit
establish a bottomhole pattern. Do not exceed the rpm and weight recommended by bit
manufacturer.
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CHAPTER DRILL STRING DESIGN
DRILL PIPE 1
DRILL PIPE DESCRIPTION 2
SELECTION OF TOOL JOINTS 7
BUOYANCY 8
DRILL COLLARS 29
COLLAR SIZE SELECTION 30
WEIGHT ON BIT CALCULATIONS 32
THE PRESSURE-AREA METHOD 41
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FATIGUE DAMAGE 59
SEGMENT DRILLING
CHAPTER DRILL STRING DESIGN
The drill string is an important part of the rotary drilling process. It serves several
purposes which include the following:
The drill string consists primarily of the drill pipe and the bottom-hole assembly (BHA).
The drill pipe can contain conventional drill pipe and heavy-weight drill pipe (HWDP).
The BHA may contain the following major components:
drill collars
stabilizers
jars
reamers
shock subs
bit
The BHA may also include downhole motors, non-magnetic drill collars for directional
surveys, monitoring-while-drilling (MWD) tools, float subs, junk subs and crossovers.
The major parts of the drill string are discussed in detail below.
DRILL PIPE
The longest section of the drill string is the drill pipe. Each joint of drill pipe consists of
the tube body and the tool joint (connection). Drill pipe joints are available in three
length ranges:
Range Length, ft
1 18-22
2 27-30
3 38-45
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Drill pipe is generally described by tube OD, nominal weight, pipe grade, type tool joint,
thread connection and classification. For example, a 5 drill pipe can be described as,
Tube OD is simply the plain end (tube) outside diameter. Common drill pipe sizes and
other dimensional data can be found in Table (1) of API RP7G and are shown in Table
(1). The average length of the tube is normally 29.4 ft.
The nominal weight is the weight per foot including the weight of an API regular
connection. The number serves no real purpose other than identification because drill
pipe does not have API regular connection. The actual weight per foot or adjusted
weight of the drill pipe is listed in Table (8) and (9) of API RP7G. The actual weight
depends on the type of connection and pipe grade. As the grade (minimum yield strength)
increases the actual weight increases because the upset has more metal in it. The actual
weight of the 5 drill pipe in the above example is 20.89 lb/ft. The actual weight for
grade G pipe is 21.92 lb/ft.
The pipe grade states the minimum yield strength of the metal which is the tensile stress
that will result in 0.5% strain. Grade E drill pipe has a yield strength of 75,000 psi. The
minimum strength can be converted to a more usable strength in pounds by multiplying
the minimum yield in psi by the cross-sectional area of the metal. From Table (1) the ID
of 5 19.5 # DP is 4.276 in and the cross-sectional area of the pipe wall is,
(52 4.276 2 )
A= = 5.271 in 2
4
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TABLE 1
DRILL PIPE TUBE DIMENSIONS
1 2 3 4 5 6 7 8 9 10
Nom. size Nom. Nom. Nom. (Ao) (Ai) (Z) 1
(OD) weight ID wall OD. (in) Section Area (in2) Section
Modulus
(in) (lb/ft) (in) (in) Min. Max OD ID Wall (in3)
2-3/8 4.85 1.995 0.190 2.344 2.406 4.430 3.125 1.305 0.661
6.65 1.815 0.280 2.587 1.843 0.867
2-7/8 6.85 2.441 0.217 2.844 2.906 6.492 4.679 1.812 1.121
10.40 2.151 0.362 3.634 2.858 1.602
3-1/2 9.50 2.992 0.254 3.469 3.531 9.621 7.031 2.590 1.962
13.30 2.764 0.368 6.000 3.621 2.572
15.50 2.602 0.449 5.317 4.304 2.923
4-1/2 13.75 3.958 0.271 4.478 4.545 15.904 12.303 3.600 3.592
16.60 3.826 0.337 11.497 4.407 4.272
20.00 3.640 0.430 10.406 5.498 5.116
22.82 3.500 0.500 9.621 6.283 5.673
5-1/2 19.20 4.892 0.304 5.473 5.555 23.758 18.796 4.962 6.111
21.90 4.778 0.361 17.930 5.828 7.031
24.70 4.670 0.415 17.128 6.629 7.844
6-5/8 25.20 5.965 0.330 6.592 6.691 34.472 27.945 6.526 9.786
27.72 5.901 0.362 27.349 7.123 10.578
(1) Z = (/32){(OD4 - ID4)/OD}
Table (2)
Common Grades of Drill Pipe
Grade Yield Strength, psi
E 75,000
X 95,000
G 105,000
S 135,000
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The tool joint and type of upset are part of the drill pipe description. Tool joints are
screw-type connectors that join the individual joints of drill pipe. Each joint of drill pipe
is fitted with a pin (male thread) and box (female threads) tool joints or connectors. As
was mentioned above, there are three types of tool joints which are widely used.
1 - IEU (Internal-External Upset) - The tool joint OD is larger than the OD of the
drillpipe and the tool joint ID is less than the ID of the drillpipe. Generally, IEU
tool joints are the strongest available. The large OD and small ID of the tool joint
cause relatively high external and internal pressure losses. A schematic diagram
of IEU connector is shown in Fig (1c). The dimensions of the tool joint can be
obtained from API SPEC 5D Table 6.1.
2 - IF (External Upset) - The tool joint ID is the same as the ID of the drill pipe to
minimize internal pressure losses. The upset is on the OD of the tool joint as
shown in Fig (1b).
3 - IU (Internal Upset) - The tool joint ID is less than that of the drill pipe. The small
ID causes relatively higher internal pressure losses. The tool joint OD is the same
as the OD of the drill pipe. This type is called slim-hole drill pipe because of
the small OD.
Mechanical properties of new tool joints are listed in Table (8) of API RP7G. Tool joints
for 4-1/2 16.6 # grade E drill pipe are shown in Table (3).
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Table 3
Mechanical Properties of New Tool Joints and New Grade E Drill Pipe
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Mechanical Properties
Tensile Torsional
Drill Pipe Data Tool Joint Data Yield, lb Yld, ft-lb
Nom Nom Approx Drift
Size Wt Wt* Type OD ID Diam Tool Tool
in. lb/ft lb/ft Upset Conn in. in. in. Pipe Joint Pipe Joint
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Table 4
Rotary Shouldered Connection Nomenclature
(Connections in the same column are interchangeable, though not identical)
(From T.H. Associates)
CURRENT API NAME
NC-26 NC-31 - - NC-38 NC-40 NC-46 NC-50
OBSOLETE API NAME
Internal Flush (IF) 2-3/8 2-7/8 - - 3-1/2 - 4 4-1/2
Full Hole FH - - - - 4 - -
OTHER OBSOLETE NAME
Extra Hole (XH) - - 2-7/8 3-1/2 - - 4-1/2 5
Double Streamline (DSL) - - 3-1/2 - - 4-1/2 - 5-1/2
Slim Hole (SH) 2-7/8 3-1/2 - 4 4-1/2 - - -
External Flush (EF) - - - 4-1/2 - - - -
Semi-Internal Flush - - - - - - - 5
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The classification of drill pipe is based on wear. As new drill pipe is rotated in the hole it
wears and, therefore, it must be reclassified according to its wear. Exterior wear includes
OD wear, dents and mashes, slip area crushing, cuts, pitting and corrosion. The working
strength is reduced because of loss in cross-sectional area. The drill pipe is inspected
periodically to detect cracks, pits, reduction in wall thickness and other defects.
Inspection methods include electromagnetic inspection of pipe body to locate cracks and
pits, sonic inspection to measure wall thickness, visual inspection to detect mashes and
caliper measurements.
The API has established guidelines for pipe classes in API RP7G. The classes are
summarized as follows:
The factors that must be considered in the selection of tool joints are outside diameter,
inside diameter, tensile and torsional ratings and cost. Tool joints with large OD and
small ID will result in high pressure losses inside and outside the drill pipe. Large OD
tool joints have better wear characteristics. The OD of the tool joint should be small
enough to facilitate fishing the tool joint with standard fishing tools. One rule of thumb in
the selection of tool joints is that when all other factors are equal the larger the tool joint,
the better it will perform. In the selection of tool joints the operating engineer or
supervisor must rely on the advice of the technical personal who represent the tool joint
manufacturer. These people are knowledgeable in the design and operation of the tool
joints. However, they may not be familiar with the conditions of the well. This may cause
a problem, but it is the responsibility of the engineer to prevent such occurrence. To do
this, the engineer should (1) be familiar with the tool joint design and operation, (2) be
able to clearly communicate his needs to the sales representative, and (3) ensure that the
people advising him are knowledgeable and clearly understand the problem.
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Buoyancy
Drill strings and subsurface well equipment are subjected to forces created by the
hydrostatic pressure of the fluid in the well. The effect of the hydrostatic pressure is
called buoyancy. Buoyancy is understood most easily for a vertical solid bar of circular
cross-section immersed in liquid as shown in Fig (4). Hydrostatic pressure acting on one
side of the bar is balanced by an equal pressure acting on the opposite side. Thus the net
force exerted by the fluid is the force F acting upward on the bottom end of the bar. The
magnitude of the force is given by,
Surface of liquid
F
Fig (4)
Fig (5)
f
F = PA = LA .........................................................................(1)
144
where,
P = hydrostatic pressure, psi
A = cross-sectional area of bar, in2
L = depth below surface of liquid, ft
f = weight of fluid, 1b/ft3
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The weight of the steel bar in air can be expressed as the volume times density, or
A
W= L s ............................................................................(3)
144
A f
Wf = L s LA
144 144
LA s f
Wf = 1 = W 1 f
144 s s
s f
Wf = W ..................................................(4)
s
490 f
Wf = W ...............................................(5)
490
Example (1)
A drill string which consists of 6000 ft of 5,19.5 lb/ft drill pipe (ID = 4.276 in) and 500
ft of 9 OD x 3 ID drill collars is suspended in a well filled with 80 pcf mud. Calculate
the weight of the string in the fluid (a) by using Eq (2), and (b) by using Eq (5).
Solution
a) The hydrostatic forces acting on the drill string are shown in Fig (5). The force F1 is
acting downward at the shoulder areas between the drill pipe and drill collars. The
force F2 is acting upward on the wall cross-sectional area of the drill collars.
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9" Drill
80
Pressure at 6500 ft = x 6500 = 3611 psi Collars
F2 6500
144 3" ID
Weight DC =
314
.
4 x 144
( )
9 2 32 x 500 x 490 = 96,162 lb
490 80
b) Buoyancy factor = = 0.836
490
From Eq (5),
Wf = W x 0.836 = 203,797 x 0.836 = 170,524 lb
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Example (2)
A 6000 of 3-1/2 14.69 lb/ft actual weight drill pipe (ID = 2.76 in) got stuck in the well
while spotting a cement plug as shown in Fig (6). The weight of the mud in the well is 75
pcf. What is the weight of the drill pipe in the mud.
Solution
CEMENT
Fig (6)
DRILL STRING DESIGN
A drill string should be designed to deliver sufficient weight to the bit and provide
sufficient torsional and tensile strength to withstand the vigorous and dynamic conditions
of drilling. The drill string should also withstand burst and collapse pressure loads and be
designed to minimize hole stability problems. There are many factors that must be
considered in the design of the drill string. These factors are:
Total depth
Hole size
Mud weight
Over pull
Bottom hole assembly
Hole angle
Pipe weights and grades
Corrosive environment
Ability to fish tools out of hole
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The drill string is designed so that the uppermost joint of each section of drill pipe is
loaded to no more that 80% of the minimum tensile yield strength of that particular
weight and grade pipe for a single size and grade drill pipe. The total load exerted on the
top joint of the drill pipe consists of the buoyed weight of the drill pipe plus the buoyed
weight of the bottom hole assembly (heavy-weight drill pipe plus drill collars) and the
margin of overpull (MOP). The MOP is the desired amount of load in excess of the
buoyed weight of the drill string to account for hole drag and provide excess pull
capacity in the event the drill string becomes stuck in the hole. The amount of overpull
ranges from 50,000 to 100,000 lb. The design criterion can be expressed as,
Solving Eq (6) for the maximum length of drill pipe that can be used,
0.8Y MOP LCWC Bf L HW H Bf
L= ...............................(7)
WBf
If the drill string consists of two sections of drill pipe of different grade and weight, then
the maximum length of the second drill pipe section (top section) is,
where,
L1 = length of first section of drill pipe (lower section), ft
W1 = actual weight of first section of drill pipe, lb/ft
L2 = length of second section of drill pipe, ft
W2 = actual weight of second section of drill pipe, lb/ft
Y2 = minimum tensile strength of second section of drill pipe (top section), lb.
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In drill string design the pipe of the lowest grade (weakest) is placed on bottom. Each
section of drill pipe is designed starting with the BHA and working upwards. This design
is checked at various depths, for often the most critical section of hole is not at TD, but
further up the hole due to mud weight changes.
Example
A vertical Khuff well is to be drilled to a total depth of 15000 ft by using 5 19.5# grade
G and S drill pipe with FH connections. The mud weight at 7000 ft is 70 pcf and
increases to 90 pcf at 15000 ft. The BHA (heavy weight drill pipe plus drill collars) is
1200 ft long and weighs 150,000 lb in air. Calculate the length of each section of drill
pipe assuming 100,000 lb overpull.
Solution
The actual weights and strengths of the drill pipe are obtained from API RP7G Table (9).
Actual wt, lb/ft Tensile Strength, lb 80% Tensile Strength, lb
5, 19.5# G, FH 22.46 553,833 443,066
5, 19.5#, S, FH 23.4 712,070 569,656
489 70
Buoyancy factor for 70 pcf mud = = 0.856
489
489 90
Buoyancy factor for 90 pcf mud = = 0.815
489
Since the length of the BHA and the G drill pipe (1200 + 11162) is greater than 7,000
ft, there is no need to use grade S drill pipe when drilling to 7000 ft TD.
Now, for a TD of 15,000 ft, the length of the first drill pipe (grade G) is calculated by
using Eq (7),
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Maximum Pull
The maximum pull that can be exerted on stuck drill pipe should not exceed 80% of the
maximum tensile strength of the weakest grade drill pipe. The maximum pull for each
crossover point must be calculated to determine the maximum pull that can be exerted on
the drill string. The calculation procedure is illustrated in the following example.
Example
If the drill string in the previous example becomes stuck at the bit at 14000 ft, what is the
maximum pull that can be exerted on the DP at the surface?
Solution
With the bit at 14000 ft the drilling assembly would consist of the following:
Section 80% Tensile
Section Length, ft Air weight, lb Strength, lb
14,000 ft
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First we check the maximum pull on the weakest DP. The maximum pull that can be
exerted on the top of grade G DP without exceeding 80% of Grade G tensile strength
is 443,066 lb.
Now the maximum pull that can be exerted on top of grade S DP is,
Max pull = 443,066 + 17245 = 460,311 lb.
Since 460,311 lb are less than 80% of the grade S tensile strength (569,656 lb), then it
is safe to pull 460,311 lb. So when we pull 460,311 lb at the surface the pull exerted on
top of Grade S DP is 460,311 lb. The pull exerted on top of Grade G DP is 460,311
minus the weight of grade S DP, or 460,311-17245 = 443,066 lb.
Slip Crushing
Slips exert hoop compression on the drill pipe which can deform the pipe if conditions
are unfavorable. A unit tensile stress St from hanging weight will result in a hoop stress
Sh that is a function of many factors such as slip length, coefficient of friction between
slips and bowl, pipe diameter and others. The slip crushing constant is defined for a given
set of conditions as the ratio Sh/St. Slip crushing constants for a variety of conditions are
listed in Table (6).
Table (6)
SLIP CRUSHING CONSTANTS
Slip Coefficient Pipe Size-Inches
Length of 2-3/8 2-7/8 3-1/2 4 4-1/2 5 5-1/2
In Friction Minimum Ratio Sh.St
12 0.06 1.27 1.34 1.43 1.50 1.58 1.66 1.73
0.08 1.25 1.31 1.39 1.45 1.52 1.59 1.66
0.10 1.22 1.28 1.35 1.41 1.47 1.54 1.60
0.12 1.21 1.26 1.32 1.38 1.43 1.49 1.55
0.14 1.19 1.24 1.30 1.34 1.40 1.45 1.50
16 0.06 1.20 1.24 1.30 1.36 1.41 1.47 1.52
0.08 1.18 1.22 1.28 1.32 1.37 1.42 1.47
0.10 1.16 1.20 1.25 1.29 1.34 1.38 1.43
0.12 1.15 1.18 1.23 1.27 1.31 1.35 1.39
0.14 1.14 1.17 1.21 1.25 1.28 1.32 1.36
A coefficient of friction of 0.08 between slips and bowl is normally used. If the pipe is
not stuck, the maximum tension carried by the slips is the working load, Pw, which is the
buoyed weight of the drill pipe and BHA. In order to prevent any deformation of the
pipe, the working load Pw times the crushing constant should be less than 0.8Y, or
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Sh
x Pw 0.8Y ..................................................(9)
St
Example
Will the slips cause any deformation of DP in the previous two examples. Assume
coefficient of friction of 0.08 and slip length of 16 in.
Solution
a) When drilling at 7000 ft the buoyed weight of the drill string is,
Air Buoyed
Section Length, ft Weight, lb Weight, ft
239,909
From Table (6), the crushing constant for 5 DP and 16 slip length is 1.42
Substituting in Eq (9),
b) With the bit at 15,000 ft the buoyed weight of the drill string is as follows:
Buoyed
Section Length, ft AirWeight, lb Weight, lb
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At 15000 ft the drill pipe that will be in the slips is the grade S pipe whose yield
strength, Y, is 712,070 lb.
Substituting in Eq (9),
c) When the bit becomes stuck at 14000 ft, the grade S drill pipe will be inside the slips.
From the previous example, the maximum allowable pull was calculated to be 460,311
lb. Substituting in Eq (9),
Since the above equality is not true, then the pipe will be deformed if it is set in the slips
with 460,311 lb of tensile force exerted on it. Normally, when pull is applied to release
stuck drill pipe, the pipe is not set in the slips and, therefore, no damage will occur to it.
If it is required to have the DP set in the slips, how much maximum pull can be exerted
without deforming the pipe?
From Eq (9),
0.8 x 712,070 = 1.42 x P
569,656
P= = 401166
, lb
142
.
Collapse Pressure
The drill pipe may at certain times be subjected to external pressure which is higher than
the internal pressure. This condition usually occurs during drill stem testing and may
collapse the drill pipe. The differential pressure (external pressure minus internal
pressure) required to produce collapse is calculated for various sizes and grades of new
and used drill pipe and is presented in API RP7G Tables (3), (5) and (7). Collapse
pressure ratings for new drill pipe are presented in Table (7). The tabulated collapse
pressure ratings must be divided by a safety factor in order to establish the allowable
collapse pressure.
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Pc
= Pac ...........................................................(10)
S. F.
where,
Pc = theoretical collapse pressure rating from tables, psi
Pac = allowable collapse pressure, psi
S.F. = safety factor = 1.1 to 1.2
If the drill pipe is subjected to an axial tensile load, the collapse pressure ratings from the
tables must be derated. The effective collapse corrected for tension load can be calculated
from the equation,
Nominal Collapse ( 4 3Z 2 Z )
Effective Collapse = ...............(11)
2
Tension Load, lb
where, Z =
Area of Metal x Ave Yield Strength
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E 85,000
X 110,000
G 120,000
S 145,000
Table (7)
New Drill Pipe Collapse and Internal Pressure Data
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Nom
Weight
Size Thds & Collapse Pressure Based on Internal Pressure at
OD Couplings Minimum Values, psi Minimum Yield Strength. psi
in. lb. E 95 105 135 E 95 105 135
2-3/8 4.85 11040. 13984. 15456. 19035. 10500. 13300. 14700. 18900.
6.65 15599. 19759. 21839. 28079. 15474. 19600. 21663. 27853.
2-7/8 6.85 10467. 12940. 14020. 17034. 9907. 12548. 13869. 17832.
10.40 16509. 20911. 23112. 29716. 16526. 20933. 23137. 29747.
3-1/2 9.50 10001. 12077. 13055. 15748. 9525. 12065. 13335. 17145.
13.30 14113. 17877. 19758. 25404. 13800. 17480. 19320. 24840.
15.50 16774. 21247. 23484. 30194. 16838. 21328. 23573. 30308.
4-1/2 13.75 7173. 8412. 8956. 10283. 7904. 10012. 11066. 14228.
16.60 10392. 12765. 13825. 16773. 9829. 12450. 13761. 17693.
20.00 12964. 16421. 18149. 23335. 12542. 15886. 17558. 22575.
22.82 14815. 18765. 20741. 26667. 14583. 18472. 20417. 26250.
5-1/2 19.20 6039. 6942. 7313. 8093. 7255. 9189. 10156. 13058.
21.90 8413. 10019. 10753. 12679. 8615. 10912. 12061. 15507.
24.70 10464. 12933. 14013. 17023. 9903. 12544. 13865. 17826.
6-5/8 25.20 4788, 5321. 5500. 6036. 6538. 8281. 9153. 11768.
27.70 5894. 6755. 7103. 7813. 7172. 9084. 10040. 12909.
Note: Calculations are based on formulas in API Bulletin 5C3.
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Example
A drill stem test is conducted using 5 19.5# grade G drill pipe and a packer set at
13000 ft. The DP-casing annulus has a surface pressure of 3000 psi and is filled with 90
pcf mud. The DP has 3000 ft of water cushion above the packer. The DP at 13000 ft has a
tensile load of 50,000 lb. Will the DP
collapse at 13000 ft? Use a S.F. of 3000
1.125. psi
Solution air
62.4
Internal Pressure at 13000 ft = x (13000 10000) = 1299 psi
144
From Table (7), the collapse pressure rating of 5 19.5 G pipe = 12999 psi.
Since the DP is under tension, then we have to derate the collapse pressure rating by
using Eq (11).
Z= Tensile Load, lb
Area of metal x Avg. Yield Strength, psi
Area of Metal =
314
.
4
(
52 4.276 2 ) = 5.27in 2
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50,000
Z= = 0.079
5.27 x 120,000
From Eq (11),
Nominal Collapse
Effective Collapse = 4 3Z 2 Z
2
12999
= 4 3 x 0.079 2 0.079 = 12,455 psi
2
12455
The allowable collapse = = 11071 psi
1125
.
Since the collapse load 9826 psi is less than the allowable collapse, then the drill pipe
will not collapse.
Burst Pressure
The differential pressure acting across the drill pipe wall due to an internal pressure
greater than the external pressure is known as the burst load. The maximum burst load
normally occurs at the depth where there is no external pressure, or backup. This
normally occurs at the surface just below the wellhead where there is often no surface
pressure. Burst pressure rating for various sizes and grades of new drill pipe are shown in
Table (7). As in the case of the collapse pressure, a safety factor of 1.125 must be used
to determine the maximum allowable burst load.
Example
A well is to be acidized by using 5 19.5# G drill pipe and bottom hole packer set at
13000. The 15% HCl (67 pcf) will be pumped at maximum surface pressure of 8000 psi.
The DP-casing annulus is filled with 90 pcf mud.
a) Determine the worst burst load.
b) Will the drill pipe burst?
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Solution
a) Burst load at 13000 ft = Internal pressure - External pressure
67
Internal Pressure = x 13000 + 8000 = 14,048 psi
144
90
External Pressure = x 13000 = 8125 psi
144
8000 psi
Burst load = 14048 - 8125 = 5923 psi
Now let us calculate the burst load at the surface.
Acid
Burst load = DP Surface Pressure - Surface
annular pressure = 8000 - 0 = 8000 psi. 90 pcf
mud
Since 8000 psi is greater than 5923 psi, the worst
burst load is at the surface.
Packer 13000'
b) The burst rating of 5 19.5# G drill pipe from
Table (7) is 13304 psi
13304
The allowable burst pressure = = 11825 psi
1125
.
Since the burst load of 8000 psi is less than the allowable burst of 11825 psi, then the
drill pipe will not burst.
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Tool joints are made up by applying sufficient makeup torque to force the pin and box
shoulder tightly together and make a seal. This is accomplished when makeup stretches
the pin and compresses the box shoulder as shown in Fig (7). Makeup torque is
determined by the tool joint OD and ID and not by the properties and dimensions of the
drill pipe tube. For a given pin ID the makeup torque increases as the tool joint OD
increases. Similarly, for a given tool joint OD the makeup torque decreases as the pin ID
increases. The standard makeup torque is the torque that would stress the weaker pin or
box to 60% of its minimum yield strength of 72,000 psi. (Minimum yield strength of all
tool joints is 120,000 psi regardless of the grade of the drill pipe). Recommended
makeup torque of tool joints can be obtained from Figs 1-25 in API RP7G.
Recommended torques for various selected sizes of NC -50 tool joints are shown in
Table(5). Tool joints should be selected such that the makeup torque exceeds the
maximum torsional load anticipated during drilling operations.
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Table 5
Tool Joint Make-up Torque
For NC-50 Connection, ft-1b
1 2 3 4 5 6 7 8 9 10 11
OD(in.)
6- /8
5
6- /16
9
6- 6-7/16 6-3/8 6-5/16 6- 6-3/16 6-1/16 6
ID (in.)
2-3/4 38040 36170 34190 32240 30290 28370 26500 24660 21020 19240
2-7/8 36400 36170 34190 32240 30290 28370 26500 24660 21020 19240
3 34680 34590 34190 32240 30290 28370 26500 24660 21020 19240
3-1/16 33800 33710 33630 32240 30290 28370 26500 24660 21020 19240
3-1/8 32890 32810 32720 32240 30290 28370 26500 24660 21020 19240
3-1/4 31020 30950 30870 30790 30290 28370 26500 24660 21020 19240
3-3/8 29090 29020 28940 28870 28790 28370 26500 24660 21020 19240
3-1/2 27080 27010 26940 26870 26800 26740 26500 24660 21020 19240
3-5/8 24990 24930 24870 24800 24740 24680 24620 24550 21020 19240
3-3/4 22840 22780 22720 22660 22610 22550 22490 22430 21020 19240
Example
A 5 19.5 # grade E drill pipe with 6-5/16 OD x 3-3/4 ID NC-50 tool joints will be
used to drill a horizontal well where the anticipated torque is 20,000 ft.-lb.
Solution
a) From Table (5) the recommended makeup torque of NC-50 6-5/16 OD x 3-3/4 ID
tool joint is 22550 ft-lb. Since the anticipated torsion of 20,000 ft-lb is less than the
makeup torque then the tool joint dimensions are adequate.
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b) From Table (5) the makeup torque of 6-1/16 OD x 3-3/4 ID tool joint is 21020 ft-
lb which is higher than the anticipated torque of 20,000 ft-lb. If the OD of the tool
joint wears down to 6 OD, the makeup torque drops to 19240 ft-lb which is
unacceptable as it is less than the
anticipated torque. Therefore, the
smallest OD that can be tolerated is
6-1/16 or a wear of about .
Example
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Solution
So the new tensile capacity of tool joint is now weaker than that of the drill pipe. Now
the tensile loads should be limited to less than 500,000 lb.
The torque applied to DP while drilling should not exceed the tool joint make up torque
listed in API RP7G Table (10).
If a tensile load is exerted on the drill pipe, the torsional strength values in Table (8) must
be derated. The torsional yield strength under tension may be calculated from the
following equation,
0.09616 J P2
Q= Y2 ...........................................(13)
OD A2
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where.
Q = minimum torsional yield strength, ft-lb
Example
A well is being drilled using 12000 ft of 5 19.5# G drill pipe and BHA which weighs
150,000 lb in air. The weight on bit is 60,000 lb and the mud weight is 90 pcf. What is
the maximum torque that can be applied to the drill pipe at surface? Use a safety factor of
1.2.
Solution
First calculate the tensile load exerted on the drill pipe at surface.
489 90
Buoyancy factor = = 0.815
489
J=
314
.
32
( )
54 4.276 4 = 28.5
A=
314
.
4
( )
52 4.276 2 = 5.27 in 2
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Table (8)
New Drill Pipe Torsional and Tensile Data
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Nom.
Weight
Size Thds & Torsional Data Tensile Data Based on Minimum Values
OD Couplings Torsional Yield Strength, ft-lb Load at the Minimum Yield Strength, lb:
in. lb. E 95 105 135 E 95 105 135
2-3/8 4.85 4763. 6033. 6668. 8574. 97817. 123902. 136944. 176071.
6.65 6250. 7917. 8751. 11251. 138214. 175072. 193500. 248786.
2-7/8 6.85 8083. 10238. 11316. 14549. 135902. 172143. 190263. 244624.
10.40 11554. 14635. 16176. 20798. 214344. 271503. 300082. 385820.
3-1/2 9.50 14146. 17918. 19805. 25463. 194264. 246068. 271970. 349676.
13.30 18551. 23498. 25972. 33392. 271569. 343988. 380197. 488825.
15.50 21086. 26708. 29520. 37954. 322775. 408848. 451885. 580995.
4-1/2 13.75 25907. 32816. 36270. 46633. 270034. 342043. 378047. 486061.
16.60 30807. 39022. 43130. 55453. 330558. 418707. 462781. 595004.
20.00 36091. 46741. 51661. 66421. 412358. 522320. 577301. 742244.
22.82 40912. 51821. 57276. 73641. 471239. 596903 659734. 848230.
5-1/2 19.20 44074. 55826. 61703. 79332. 372181. 471429. 521053. 669925.
21.90 50710. 64233. 70944. 91278. 437116. 553681. 611963. 786809.
24.70 56574. 71660. 79204. 101833. 497222. 629814. 696111. 894999.
6-5/8 25.20 70580, 89402. 98812. 127044. 489464. 619988. 685250. 881035.
27.70 76295. 96640. 106813. 137330. 534199. 676651. 747877. 961556.
From Eq (13),
0.09616 x 28.5 282,1652
Q= 105,000 2
= 49,507, ft - lb
5 5.27 2
49507
Allowable torque = = 41,256 ft - lb
1.2
The combined load capacity of the tool joint should be checked, as it may be weaker than
the drill pipe. Refer to API RP7G Tables 8,9 and 10.
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The effect of torsion on the tensile capacity of 5 19.5 lb/ft premium class drill pipe of
different grades is shown in Fig (7b). The graph is constructed by using Eq (13) using
adjusted OD for premium class pipe.
DRILL COLLARS
Drill collars are large diameter-small bore steel pipes which posses great weight and
great stiffness. Drill collars are run above the bit and make up the predominant
component of the bottom hole assembly. Some of the functions of drill collars are:
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Drill collar sizes range from 3 to 12 OD in increments of 1/4. The inside diameter
varies from 1 to 3-1/4. The weight per foot can be obtained from published tables or
calculated by using a steel density of 489 lb per ft3. The length of a drill collar joint is
normally about 30 ft.
Example
Calculate the weight of a 9 OD x 3 ID x 30 ft long drill collar.
Solution
The area of metal cross section =
314
.
4 x 144
( )
9 2 32 ft 2 = 0.392 ft 2
Woods and Lubinski pointed out that using an unstabilized bit and small OD drill collars
can cause an undersized hole, making it difficult to run casing. They determined that the
actual drift, or useful diameter, of the hole would be equal to the bit diameter plus the
drill collar diameter, divided by two,
Bit OD + Collar OD
Drift diameter =
2
The above equation can be rewritten to determine the minimum drill collar OD which
would insure passage of casing with its larger coupling diameter. Substituting casing
coupling diameter for drift diameter,
Bit OD + Collar OD
casing coupling OD =
2
or,
Minimum Collar OD = 2 (Casing Coupling OD) - Bit OD ....... (14)
Table (9)
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Table (9) lists the sizes of drill collars recommended for popular hole sizes. It should be
noted that the collar sizes in Table (9) are the minimum sizes, and larger sizes are
preferable. As a general rule, the largest drill collars that can be washed over and fished
out should be selected. Table (10) lists the largest drill collar sizes that can be washed
over and fished out. Large drill collars are preferred because fewer drill collars and less
tripping time would be required. Also, large drill collars are stiffer and have less
tendency to buckle or bend. This characteristic promotes even load distribution on the bit
for better bit performance and lessens hole deviation problems. The stiffness of pipe is
related to its moment of inertia,
I=
314
.
64
( )
OD 4 ID 4 .. ............................................(15)
It can be seen that the stiffness is proportional to the fourth power of the pipe diameter.
Example
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Solution
Moment of inertia for the 9 x 3 drill collar is,
I=
314
.
64
(
9 4 34 ) = 318
I=
314
.
64
(
6.54 2.254 = 86 )
Note that by increasing the drill collar OD by a factor of 1.38, the stiffness increased by a
factor of 3.69. In other words, if the 9 in diameter drill collar is deflected 1 in under a
certain load, the 6.5 in diameter drill collar would deflect 3.69 in under the same load.
The buoyancy factor method ensures that buckling is restricted to the drill collars and
no buckling occurs in the heavy-weight drill pipe (HWDP) or drill pipe above the
drill
collars. Buckling is a problem that must be avoided at all times. Buckling in HWDP or
DP induces stresses in the pipe which will cause premature pipe fatigue and pipe failure.
The required collar length to provide a desired weight on bit can be calculated as follows,
WOB x SF
Lc = .................................................(16)
BF x Wc x COS
where,
WOB = desired weight on bit, lb
SF = safety factor (1.1-1.15)
BF = buoyancy factor
Wc = drill collar weight in air, lb/ft
= maximum hole angle at BHA, degrees
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Table (10)
Minimum Drill Collar Sizes that
Can Be Caught with Overshot and/or
Washed Over with Washpipe
Hole Overshot Washpipe Maximum fish OD
size, In. Size, In. Max. Size, In Max. fish to catch and/or
catch, In OD, In washover, In.
6-1/8 *5-3/4 5-1/8 5-1/2 4-3/4 4-3/4
6-1/4 *5-3/4 5-1/8 5-3/4 4-7/8 4-7/8
6-3/4 *6-3/8 5-1/4 6 5-1/8 5-1/8
7-7/8 *7-3/8 6-1/4 7-3/8 6-1/2 6-1/4
8-3/8 *7-7/8 6-3/4 7-5/8 6-3/4 6-3/4
8-1/2 *8 6-7/8 7-5/8 6-3/4 6-3/4
8-3/4 *8-1/4 7-1/8 8-1/8 7-1/8 7-1/8
9-1/2 *9 7-7/8 9 8 7-7/8
9-7/8 *9-1/8 8 9 8 8
10-5/8 *9-3/4 8-5/8 9-5/8 8-1/2 8-1/2
11 10-1/2 8-7/8 10-3/4 9-5/8 8-7/8
12-1/4 11-3/4 10-1/8 11-3/4 10-1/2 10-1/8
13-3/4 12-3/4 11-1/4 12-3/4 11-1/2 11-1/4
14-3/4 13-3/4 12 13-3/8 12 12
17-1/2 15-1/8 13-3/8 26 14-1/2 13-3/8
20 16-3/4 14-3/4 18-5/8 17-3/8 14-3/4
24 20-1/4 16-3/4 21 19-1/2 16-3/4
26 24-3/4 22 21 19-1/2 19-1/2
*Overshots are not full strength and are limited in pulling, torsional and jarring strain.
Note: Some sizes of Overshots and Washpipe may not be available.
As we will see later, the drill collar length calculated by Eq (16) is not enough to provide
all the desired weight on the bit, and, therefore, the remainder of the weight will be
provided by the HWDP or DP above the drill collars.
Lubinski defined the buckling neutral point as the point in the drill collar string below
which the pipe is buckled or will have a tendency to buckle, and above which no
buckling will occur. The buckling neutral point should not be confused with the axial
stress neutral point, the point where the axial stress is equal to zero (compressive and
tensile stresses are zero). The buckling neutral point is calculated by the following
equation,
WOB
Buckling Neutral Point = ...................................(17)
BF x Wc
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Equation (17) states that no buckling occurs above the drill collars as long as the weight
on the bit does not exceed the buoyed weight of the drill collars.
It can be seen from Eq (16) that the buoyancy factor method considers only forces related
to weight on bit and the weight of the drill collars and does not take into account the
hydraulic forces acting on the bottom end of the drill collars and on the shoulder areas
between the drill collar and the HWDP or DP as shown in Fig (10). The hydraulic forces
are a result of the hydrostatic pressure of the mud and are computed by multiplying the
hydrostatic pressure times the respective section area. In some cases it may be necessary
to calculate the axial stress in the drill string or locate the axial stress neutral point. When
axial stress must be determined, all forces acting on the BHA must be considered
including the hydrostatic forces.
F T
HWDP
W 1
L F T
H
F 1
P 1
W 2
W 2
L L C
DC C
P 2
F 2
WOB WOB F 2
Fig
Fig(8)
(8) Fig
Fig (9)
(9)
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the bottom end of the drill collars. The total weights of the HWDP and DC are denoted
by W1 and W2 respectively. The tensile force acting at the cut off point in the HWDP is
denoted by FT. Now for the system to be in static equilibrium, the forces acting upward
must be equal to the forces acting downward, or
FT + WOB + F2 = W1 + W2 + F1 ..................................(18)
If we define,
W1 = LH WH
W2 = LC WC
F1 = P1 (A2-A1)
F2 = P2 A2
To determine the axial stresses in the drill collars consider the free body diagram in Fig
(9). Note that in this case there is no hydrostatic force acting on the top of the drill collars
because there is no change in diameter (no shoulder area). Adding the forces gives,
FT + WOB + F2 = W2
FT + WOB + A2 P2 = LC WC
Solving for FT,
FT = LCWC - WOB - A2P2 ..........................................(20)
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Example
A vertical Khuff well is drilled to 7600 ft with a mud weight of 103 pcf and WOB of
70,000 lb utilizing 10 OD x 3 ID drill collars and 5-1/2 OD x 3.375 ID 62.7 lb/ft
HWDP.
a) Calculate the length of drill collars required to provide 70,000 lbs WOB using the
buoyancy factor method. Assume safety factor of 1.1.
c) Which parts of the BHA will buckle when weight is applied on the bit?
d) Determine the axial stress 2 ft below the top of the drill collars.
e) Determine the axial neutral point.
Solution
a) WOB = 70,000 lb
489 103
BF = = 0.789
489
WC =
314
.
4 x 144
( )
10 2 32 x 489 = 242.6 lb / ft
SF = 1.1
cos = cos (0) = 1.0
From Eq (16),
70,000 x 11
.
Length of drill collars = = 402.3 ft
0.789 x 242.6 x 10
.
402.3
or 14 drill collars
30
WOB 70,000
b) Buckling neutral point = = = 365.7 ft
BF x Wc 0.789 x 242.6
The buckling neutral point is 365.7 ft from bottom end of drill collars or 36.6 ft
below the top of the drill collars.
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c) All pipe below the buckling neutral point will buckle, i.e., the bottom 365 ft of the
drill collars will buckle. The top 36.6 ft of the drill collars and all the HWDP will
not buckle because they are above the buckling neutral point.
d) Since we need to calculate the axial stress in the drill collars below the cross over
between the drill collar and HWDP then Eq (20) must be used.
LC = 402.3 - 2 = 400.3 ft
WC = 242.6 lb/ft
WOB = 70,000 lb
A2 =
314
.
4
( )
10 2 32 = 7143
. in 2
103
P2 = x 7600 = 5436 psi
144
Substituting in Eq (20),
FT = 400.3 x 242.6 - 70,000 - 71.43 x 5436 = - 361,180 lb
Since FT is negative then the axial force is a compressive force. This means that the
drill collars are all in compression.
e) Since the drill collars are in compression, the point of zero axial stress must be in
the HWDP. The axial neutral point can be calculated by using Eq (19) and setting
the value of FT equal to zero, or
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A1 =
314
.
4
(
55. 2 3375
. 2 ) = 14.8 in 2
WH = 62.7 lb/ft
To answer the first question let us go back to the Buoyancy Factor method and Eq (16)
which was used to calculate the length of the drill collars. This simple equation considers
only the mechanical forces acting on the BHA, namely, the WOB and the weight of the
drill collars, and does not take into account the hydraulic forces F1 and F2. In order to
analyze the problem correctly, both the mechanical and the hydraulic forces should be
taken into account. Referring to Fig (11), the forces that contribute weight to the bit are
the forces that are acting downward, namely, F1 and the weight of drill collars LCWC. In
the previous example F1 = 291,531 lb and the weight of drill collars is 402.3 x 242.6 or
97,598 lb for a total of 389,129 lb. The force F2(388,293 lb) acts upward and cancels out
some of the downward force. So the net force acting downward is 389,129 - 388,293 or
836 lb. It is obvious that the available weight of 836 lb is much less than the desired
weight on bit (70,000 lb).
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So when the driller slacks off 70,000 lb weight on the bit, where does the remaining
69,164 lb (70,000-836) come from? The answer is that they come from the HWDP or DP
directly above the drill collars. The length of HWDP required to provide 69164 lb of
weight is 69164 divided by 62.7 lb/ft or 1103 ft, which is equal to the length of HWDP
that is in compression. Therefore, the answer to the first question is that the HWDP is in
compression because it is providing some (or most) of the weight on the bit. The fraction
of the total WOB that is provided by the HWDP depends on the total depth and mud
weight. The fraction of the WOB contributed by the HWDP or DP above the drill collars
increases as well depth and mud weight increase, and visa versa.
Normally, if an axial compressive force is exerted at the end of a pipe, the pipe tends to
buckle or bend. In the previous example the HWDP is under compression but we said it
is not buckled because it is above the buckling neutral point. So how can we have a pipe
under compression but not buckled? Lubinski has shown that buckling of drill strings can
be induced only by mechanical compressive forces and that hydraulic compressive
forces do not cause buckling (the reader is cautioned that this applies only to drill string
assemblies and does not apply to tubing strings landed into bottom hole production
packers). In the previous example if there were no hydraulic forces F1 and F2, the weight
of the drill collars would have been more than enough to provide 70,000 lb on the bit,
and the HWDP would have been in tension. What caused the HWDP to be in
compression are the hydraulic forces F1 and F2, and these forces do not cause buckling.
The drill collars are buckled because of the reaction force WOB acting upward on the
bottom end of the drill collars. This force is a mechanical force and causes buckling.
Example
4000 psi
A 7000 ft string of open ended 5 19.5# (ID =
4.276) drill pipe is run in a cased well filled F2
with 90 pcf mud. The BOP was closed on the
DP at the surface and 4000 psi surface pressure
was applied in the DP.
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Solution
a) There are two hydraulic forces acting on the DP. A compressive force (F1) is acting
upward on the bottom end and an upward tensile force (F2) acting on the top of the
DP.
F1 = P1 A1
90
P1 = x 7000 + 4000 = 8375 psi
144
A1 =
314
.
4
( )
52 4.276 2 = 5.27 in 2
P2 = 4000 psi
F2 = 4000 x 14.35 = 57,412 lb
44136 = L x 22.46
L = 1965 ft
The axial neutral point is 1965 ft above the bottom end of the DP. This means that the
bottom 1965 ft of the drill pipe are in compression and the remainder is in tension.
c) The drill pipe will not buckle because the compressive force F1 acting on the bottom
end is a hydraulic force which does not cause buckling.
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Most drilling engineers and drillers use the Buoyancy Factor method and Eq (16) to
calculate the number of drill collars required to apply a desired weight on the bit. They
erroneously believe that all the weight on bit is provided by the drill collars calculated
from Eq (16) and that the DP or HWDP above the drill collars is always in tension. As
we have shown above, all these concepts are incorrect. The sources of these
misconceptions are errors and confusing statements made in some drilling books, service
company literature and drilling seminars and courses.
In summary, if the drilling engineer or driller decides to use the Buoyancy Factor
method, he must remember the following:
The number of drill collars calculated by the Buoyancy Factor method is not enough
to provide all the WOB. Some of the WOB will be provided by the DP or HWDP
directly above the drill collars. For this reason the DP or HWDP above the drill
collars will be in compression but not buckled. It is an acceptable practice to use
HWDP or DP in compression as long as it is not buckled.
The buckling neutral point is always near the top of the drill collars. The drill collars
below the neutral point will have a tendency to buckle. The drill collars and HWDP
above the neutral point will not buckle as long as the actual weight applied on the bit
while drilling does not exceed the WOB used in the calculations. If the actual WOB
exceeds the WOB used in the calculations then the number of drill collars must be
increased, otherwise, the HWDP or DP above the drill collars will buckle. DP or
HWDP should never be used in a buckled condition.
Unlike the Buoyancy Factor method, the Pressure-Area method takes into account all the
forces acting on the BHA including the hydraulic forces. Consider the free body diagram
in Fig (12). A force balance yields,
F1 + W = F2 + WOB
W = F2 + WOB - F1
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HWDP
A2 P2 + WOB P1 ( A2 A1 ) P
Lc = ....... 21 2
Wc WOB
F2
Fig (12)
Example
Solution
A2 P2 + WOB P1 ( A2 A1 )
LC =
WC
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WOB 70,000
Buckling Neutral Point = = = 365.7 ft
Wc x BF 242.6 x 0.789
c) All drill collars below the buckling neutral point will buckle. The top 321.7 ft of drill
collars and HWDP will not buckle.
d) Consider the free body diagram on the right
FT
F T + WOB + F2 = F 1 + W F1
Neutral point
F T = 0 (neutral point)
Substituting the values of the variables,
The axial neutral point is at the top of drill collars. This WOB
F
2
means that the DP or HWDP on top of drill collars is in
tension.
A comparison between the Buoyancy Factor method and the Pressure-Area method is
shown in Fig (13). It can be seen that the drill collar length calculated by the Pressure-
Area method is almost twice that calculated by the Buoyancy Factor method and,
therefore, is enough to provide all the weight on the bit. For this reason, only the drill
collars are in compression while the HWDP is in tension. The buckling neutral point is
the same in both cases. Either of the two methods can be used to calculate the length of
the drill collars. However, the Pressure-Area method has the following disadvantages:
Requires more drill collars to keep the HWDP or DP in tension. This serves no
useful purpose because whether the pipe above the buckling neutral point is in
tension or compression is irrelevant to fatigue damage, if the pipe is not buckled.
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The need to procure, transport, maintain, inspect and handle the extra drill collars
increase the cost of the drilling operation.
Adding more drill collars reduce the available overpull.
Adding more drill collars increases the weight of the drill string and the tensile
stress in the drill pipe at all depths. The increase in stress will increase the rate of
fatigue attack and reduce the life of the drill pipe.
H WD P
Ax ia l Str e s s in T ension
N e u tr a l Po in t
Ax ia l Str e s s
N e u tr a l Po in t
6913'
1103'
C ollars in
H WD P in C ompression
C ompr ession but not buckled
( N ot Buckled)
7198' 687'
Bu c k lin g
N e u tr a l Po in t
402' 365'
C ollars in
C ompr ession
and Buckled
7600'
7600'
Fig (13)
F ig (13)
In the past, the two main components of the drill string consisted of the drill pipe and the
drill collars. The point where the relatively small OD and flexible drill pipe connects to
the large stiff drill collars is called the transition zone. Field studies have shown that
almost all of the drill pipe fatigue failures are the result of an accumulation of fatigue
damage occurring when the drill pipe joints were run in the transition zone, or were
stressed above the endurance limit in crooked holes. Downhole data has indicated that the
large change in diameter at the transition zone caused accelerated fatigue damage as a
result of the concentration of cyclic bending stress reversals in the bottom joints of the
flexible drill pipe, since the stiff drill collars bend very little from these stress reversals.
Field tests indicated that fatigue build up in the drill pipe in the transition zone is related
to the relative stiffness of the drill collar and the adjacent drill pipe. The stiffness ratio of
two sections of pipe in the drill string is expressed by the equation,
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SR =
( I / C) lower
( I / C) upper
where,
I = moment of inertia =
314
.
64
(
OD 4 ID 4 ) C = external radius =
OD
2
OD = outside diameter, in ID = inside diameter, in
The field tests showed that the higher the stiffness ratio at the transition zone the greater
the fatigue build up. Criteria for permissible stiffness ratio varies between different
operators and areas. The following maximums are typical:
For shallow or routine drilling or low failure rate experience, keep stiffness ratio
below 5.5.
For more severe drilling or for significant failure rate experience, keep SR below
3.5.
In order to reduce the stiffness ratio and increase service life of the drill pipe, heavy
weight drill pipe having the same OD as the drill pipe and a wall thickness of up to 1 in
and weight up to 78 lb/ft is used between the drill pipe and the drill collars. The number
of joints used varies between 15 to 21 joints. Use of heavy weight drill pipe offers the
following advantages:
Reduces drilling cost by eliminating drill pipe failures in the transition zone.
reduces tendency to become differentially stuck. This is due to the fact that large
diameters are easier to stick than small diameters.
Heavy weight drill pipe normally has the same external dimensions as the regular drill
pipe. In some types of HWDP the tool joints are longer and, in some types, an extra mock
tool joint is located in the center of the joint as shown in Fig (12). Dimensions and
weights of HWDP vary for different manufacturers. Typical dimensions are shown in
Table (11).
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Table (11)
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The bottom hole assembly (BHA) is the part of the drill string below the drill pipe. It
consists of several types of components or tools which provide different functions. The
most common components of the BHA are drill collars, stabilizers, shock absorbing subs,
jars, reamers, heavy weight drill pipe and the bit. The drill collars and HWDP were
discussed in the previous sections, and the remaining components are described
individually below. This section provides the reader with a general understanding of the
concepts involved and how certain assemblies will react under average conditions. It is
the responsibility of the drilling engineer to apply these concepts to his own particular
case and gain practical experience to continue improving the selection of BHAs in his
area of concern.
The purpose of the BHA is to drill a usable hole economically. This objective is achieved
with the proper selection of the drill bit and drill collars which are required to provide
high bit weights to improve the penetration rate. Stabilizers are needed to minimize the
rate of hole angle change and prevent the formation of doglegs and key seats. Shock
absorber play an important part to prolong the service life of the bit and drill pipe. Down
hole drilling jars may be needed to unstick the BHA.
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Fig (15)
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Stabilizers
Stabilizers are used to centralize the drill collars in the hole and increase its rigidity or
stiffness. This increases the ability of the drill collars to drill a smooth and straight hole
and reduces the undesirable bit movement, such as bit wobble, which reduces bit life.
Stabilizers also provide some reaming action and wipe the walls of the hole to ensure a
full-gauge hole. There are several types of stabilizers which are described below.
The most common type of stabilizers is the steel body spiral stabilizer. These stabilizers
shown in Fig (15) have wings or blades that are an integral part of the stabilizer body.
The blades make a 360o contact with the well bore. The outer surfaces of the blades are
curved to fit the curvature of the well bore wall. This bearing surface provides bore hole
wall contact and permits the stabilizers to hold the drill collar assembly centered in the
hole. The outer surface of the blades are covered with hard metal such as tungsten
carbide to resist erosion. The stabilization efficiency of the stabilizer increases as the OD
of the stabilizer blades approaches bit diameter. For 6 through 12-1/4 holes sizes the
blade diameter is equal to the bit diameter or 1/32 under gauge. For 13-3/4 through 17-
1/2 hole sizes the blade diameter is equal to bit diameter or 1/16 under gauge. When
the spiral blade stabilizer becomes worn, the bearing surfaces are built up by welding on
a layer of hard metal that is then machined to the correct OD. The length and width of the
blades depend on hole size and type of formation. For 14-3/4 to 26 hole sizes the blade
length varies from 18 to 36, whereas for 6 to 12-1/4 holes sizes the blade length is
about 12. Large blade areas are needed to provide adequate support in soft formations.
Thicker blades increase the torque and are harder to mill over if the stabilizer becomes
stuck.
There are two types of spiral blade stabilizers: the integral blade stabilizer and the
replaceable sleeve stabilizer. The blades of the integral blade stabilize are an integral
part of the stabilizer body. Whenever the stabilizer has worn down to an unacceptable
condition the entire stabilizer is sent to the shop for reconditioning. This stabilizer is
sturdier than the replaceable sleeve stabilizer and is suitable for hard and abrasive
formations. The replaceable sleeve stabilizer consists of the mandrel and the spiral
sleeve. When the blades wear out, the sleeve can easily be detached from the mandrel at
the rig and replaced with a reconditioned or new sleeve. Saudi Aramco uses both types of
stabilizers; the integral blade stabilizer is used in the small hole sizes whereas the sleeve
stabilizer is used in large holes.
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The replaceable wear pad (RWP) stabilizer shown in Fig (16) consists of four 3 ft long
vertical (straight) replaceable pads. Large diameter, pressed-in tungsten carbide compacts
on the surface of the pad prolong wear and keep the stabilizer in gauge. The long pads
provide large contact area which make the stabilizer suitable for areas of extreme
deviation tendencies. The wear pads can be changed easily at the rig. The stabilizer may
be resized to a different hole size by replacing the pads with a set that has been
manufactured to a different diameter.
The RWP stabilizer is good for deviation control. However, the RWP stabilizer is
difficult to wash over because of the inserts used and it generates higher torque than the
spiral stabilizer because of its longer pad length. The RWP stabilizer is not used in Saudi
Aramco drilling operations.
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A third type of stabilizers is the non-rotating stabilizer shown in Fig (17). It consists of
a mandrel and a polyurethane stabilizer sleeve which is
free to rotate on the mandrel
Reamers
The basic function of the reamer is to open an under-
gauge hole to its original full-gauge size. Most reamers
today have roller cutters which are free to rotate on their
own axes. A three-point reamer has three roller cutters
spaced 120o apart on the reamer body as shown in Fig
(18). A six-point reamer has two rows of roller cutters and
are staggered such that the six rollers are spaced around
the reamer body 60o apart. Various types of cutters are
available, ranging from mill-toothed cutters, flat faced
cutter from medium to hard formations and tungsten
3 PT. Reamer 6 PT. Reamer
Fig (18)
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Reamers are often run as a near bit stabilizer. Stabilizers may cause excessive torque due
to the dragging action of the blades. Roller reamers prevent this action. If roller reamers
are used as a stabilizer in a packed-hole assembly, hard cutters should be used to ensure
that they maintain full gauge.
Shock Absorbers
Shock absorbers are used between the bit and drill collars to reduce the vertical
oscillation (bouncing) of the drill string. Field studies have shown that the frequency of
the oscillations was consistently three oscillations per revolution with a three cone bit. It
is believed that the bit does not drill the bottom of the hole evenly (completely flat) with
a resulting condition of high and low places, the number of high and low places being the
same as the number of cutters on the bit. The peak-to-peak amplitude is approximately
0.5 inch. This bottom hole condition could account for the three oscillations per
revolution when drilling with a three cone bit.
Fig (19)
The studies show that the placement of a shock absorber between the bit and the drill
collars can almost completely eliminate the vertical oscillations as shown in Fig (19).
Vertical bouncing causes fluctuations in the bit load which has adverse effect on bit
footage. Field tests have shown that the use of shock absorbers increases the bit footage
(bit life). The use of the shock absorbers has also shown substantial reduction in drill
collar connection failures in hard formations by dampening the high fluctuating
buckling
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loads imposed by bit vibrations. Unfortunately, shock absorbers are prone to mechanical
failure due to the complexity of the device and the fact that it cannot be made as strong as
the drill collars.
For maximum effectiveness, the shock tool should be placed immediately above the bit to
minimize the amount of unsprung mass below the tool. It is important that the tool is
placed in a position where it is exposed to minimum side loading or bending stress.
Ideally, the tool should have the same degree of stabilization at both ends to minimize
buckling.
The principle of operation of a Griffith shock absorber can be explained with the aid of
Fig (20). Vibrations from the bit cause the shaft to move down inside the mandrel and
compress the spring (compression stroke). Some of the vibration force will not be
transmitted to the drill string above the tool because some of that force has been stored as
energy in the spring, thus reducing the shock or impact on the drill string. As the shaft
moves up (expansion stroke) the oil below the spring support between the shaft and
mandrel is forced to flow through a small restriction to the upper chamber. The flow of
oil generates high pressure drop which is converted to heat, thus dissipating some of the
vibration energy into heat.
D r ill C o lla r
S h a ft
S p ri n g
S p rin g S u p p o r t
O uter M an dr e l
O il
O -r in g
Seal
attac hed
to s haf t
D r i l l C o l l ar
(b ) (a )
E xpa nti on S tr oke C om pr e s s i on s tr oke
F i Fig
g (2(20)
0)
S cSchematic
he m a ti c of
o faaGriffith
G ri ffi th S ho Absorber
Shock c k A b s o rb e r
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Jarring Devices
Jars are placed in the BHA to generate upward or downward impact loads to free stuck
pipe or release a fish. There are many factors which affect the decision of when to use
jars and where to position them for maximum benefit. Jars should be used when:
The most common type of hydraulic jars operates on a time delay sequence wherein
hydraulic fluid is metered through a small opening for the initial extension of the
mandrel. After moving a small distance over several minutes, the fluid opening size
increases dramatically and the jar opens unrestrained. Finally, when the jar has reached
the end of its stroke a tremendous jolt is achieved by rapidly decelerating the collars and
drill pipe above the jars that had built speed during the unrestrained portion of the
opening cycle. The magnitude of the jars impact depends on the tension applied to the
jars when they are fired.
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The time required for a hydraulic jar to fire depends on the type of hydraulic fluid used,
the size of the metering hole and the temperature of the hole. Repeated firing of jars
generally increases the hydraulic fluid temperature and, therefore, lowers the viscosity of
the fluid and the time required for firing to occur to a point where the jar becomes
useless.
Mechanical Jars
Another common type of jars are mechanically operated ones. These are preset at surface
or in the shop to fire at a given tension. While they do not allow various jarring tensions,
there is no time delay present as in the case of hydraulic jars. To increase or decrease the
jarring tension, the jars must be tripped to surface, in other words the string must become
unstuck.
As was mentioned earlier, the purpose of the bottom hole assembly is to drill a useful
vertical hole with full gauge, smooth bore and free of doglegs and ledges. The simplest
bottom hole assembly is the slick assembly which consists of a bit and drill collars and no
stabilizers as shown in Fig (22). In the vicinity of the bit, the string does not contact the
wall of the hole. At some distance above the bit, the string contacts the wall. Above the
point of contact the string lies on the low side of the hole. With no weight on the bit,
the
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In general there are three types of bottom hole assemblies: slick, pendulum and packed
BHA. The slick BHA consists of a bit and drill collars without stabilizers. This BHA is
suitable for formations which have mild crooked hole tendencies. Slick bottom hole
assemblies are seldom used.
The pendulum BHA is used primarily to reduce or maintain hole deviation. The
pendulum technique relies on the force of gravity to deflect the hole to vertical. The force
of gravity, F sin I in Fig (22), is related to the length of drill collars between the drill bit
and the point of tangency. The along-hole component of the force F is F cos I, which
attempts to maintain the present hole direction.
The pendulum BHA consists of a bit, several drill collars to provide the pendulum force
and one or more stabilizers. Lubinski presented charts for determining the location of the
first stabilizer from the bit and the weight that can be applied on the bit to maintain
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1. Mild Crooked Hole Packed BHA The packed BHA results from the
A typical BHA is shown in Fig (25a). This is basic idea that three points cannot
contact and form a curved hole.
used for formations which have mild crooked Fig. (24)
hole tendency that produce little or no
deviation such as hard and isotropic rocks. The three-point stabilization is provided at
Zone-1, immediately above the bit, at Zone 2, immediately above a short, large OD
drill collar; and at Zone 3, on top of a standard length drill collar. This type of BHA is
commonly used in Saudi Aramco drilling operations. If a vibration dampener (shock
absorber) is required, it should be placed at Zone-2 for maximum effectiveness.
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Stabilizer
Zone III
Stabilizer 30 ft Drill Collar
Fig (25)
Packed Hole Assembly for (a) Mild, (b) Medium,
(c) Severe, Crooked Hole Tendencies, (After Wilson, 1979)
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FATIGUE DAMAGE
Most drill pipe failures are a result of fatigue damage. Drill pipe will suffer fatigue when
it is rotated in a section of hole in which there is a change of hole angle and/or direction,
commonly called a dogleg. The amount of fatigue damage depends upon the tensile load
in the pipe at the dogleg, the severity of the dogleg and the dimension and properties of
the pipe. Since tension in the pipe is critical, a shallow dogleg in a deep hole often
becomes a source of difficulty. Rotating off bottom is not a good practice since additional
tensile load results from the suspended drill collars.
Lubinski and Nicholson have published methods of calculating forces on tool joints and
conditions for fatigue to occur. Curves are published in API RP7G to determine the
maximum permissible dogleg severity above which fatigue damage will occur for a given
tensile load below the dogleg. The curves are based on the following equations,
432,000 b tanh( KL )
C= .....................................(22)
314
. ED KL
T
K=
EI
where,
C = maximum permissible dogleg severity, deg/100 ft
E = Youngs modulus, psi (30 x 106 for steel).
D = OD of pipe, in
L = half the distance between tool joints, 180 in for 30 ft joint.
T = buoyant weight suspended below the dogleg, lb
b = maximum permissible bending stress, psi
I = moment of inertia =
314
.
64
(
D4 d4 )
d = drill pipe ID, in
The maximum permissible bending stress, b, is calculated from the buoyant tensile
stress t,
T
t = ..........................................................(23)
A
where,
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If doglegs of sufficient magnitude are present, it is good practice to string ream the
dogleg area. This reduces the severity of the hole angle change and reduces fatigue.
Corrosive conditions have detrimental effect on the fatigue life of drill pipe. In corrosive
environment, the dogleg severity calculated from Eq (22) should be reduced to a fraction
of the calculated value (0.6 for very severe corrosive condition). The fatigue life of steel
drill pipe may be increased by maintaining a mud pH of 9.5 or higher.
Example
A 5 19.5# Grade E, R-2 drill pipe and 600 ft of 9 x 2.5 drill collars are used to drill a
well at 11,600 ft. A dogleg developed at 3,000 ft. What is the maximum dogleg severity
that can be allowed at 3,000 ft to avoid fatigue damage?
Drill pipe ID = 4.276 in
Mud weight = 80 pcf
Actual drill pipe weight = 22.6 lb/ft
Weight on bit = 60,000 lb
Weight of collars = 200 lb/ft
Solution
489 80
Buoyancy factor = = 0.836
489
The tensile load at the dogleg = [(11,000 - 3000) 22.6 + 600 x 200] 0.836 - 60,000
T = 191,468 lb
A=
314
.
4
(
52 4.276 2 ) = 5.27 in 2
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191,468
t = = 36,318 psi
5.27
10 0.6 2
b = 19,500 - (36,318) - 2 (36,318 - 33,500) = 19,500 - 5420 - 10.6 = 14,069 psi
67 ( 670 )
I=
314
.
64
(
54 4.276 4 ) = 14.26
T 191,468
K = = = 0.0211
EI 30 x 10 6 x 14.26
From Eq (22),
432000 14069 0.9989
C= 6
x = 3.4 deg / 100 ft
314
. 30 x 10 x 5 38
.
Therefore, in order to avoid fatigue damage the dogleg severity at 3000 ft should be less
than 3.4 deg/100 ft.
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As was discussed in the previous sections, the drill string in vertical wells is designed so
that the mechanical weight on the bit is provided by the drill collars. The buckling neutral
point should always be below the top of the drill collars to prevent any buckling to the
DP and HWDP. The drill pipe in vertical hole should always be in tension because drill
pipe has very low resistance to buckling. A small mechanical compressive force of few
thousand pounds will buckle the drill pipe. It is common practice in drill string design
that the drill pipe should not be rotated in a buckled condition as this will cause rapid
fatigue failure.
In drilling inclined and horizontal wells there are two additional factors, which are not
present in vertical wells, that must be considered. These are
(1) the frictional forces between the drill string and the hole and
(2) the ability to use the drill pipe or HWDP to provide weight on the bit without
buckling.
Because of the hole geometry some or all of the weight of the drill string in inclined or
horizontal wells is exerted on the low side of the hole. This will create a frictional force
or drag between the drill string and the hole that will require additional force or pull to
move the drill string up or down the hole. The frictional force will also increase the
torque that is required to rotate the drill string. The second factor that must be considered
in the design of the drill string is the fact that drill pipe can be used in compression to
provide weight on the bit. In inclined and horizontal wells the drill pipe can tolerate
significant levels of compression without buckling in small-diameter holes. The reason
that the drill pipe in inclined holes is so resistant to buckling is that the hole is
constraining and supporting the pipe throughout its length. The low side of the hole
forms a trough that resists even a slight displacement of the pipe from its initial straight
configuration. The effect of gravity and the curving sides of the hole form a restraint
against buckling.
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Ff = W ...................................................................................... (26)
where,
Ff = frictional force, lb
= coefficient of friction, dimensionless
W = normal force acting perpendicular to the surface, lb
Therefore, the force Ft required to slide the object should be slightly greater than Ff or,
The force Fx is the weight component acting parallel to the hole axis and is equal to,
The force Ft required to move the drill pipe is determined by making a force balance,
forces acting up must equal forces acting down, or
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Ft = Fx + Ff
Ft = W cos + W sin .....................(31)
The frictional force or drag always acts in the opposite direction of the pulling force Ft. If
the drill pipe is lowered into the hole, the frictional force will act in a direction opposite
to that shown in Fig (27).
Example
A 5, 19.5# drill pipe is in a tangent section 2000 ft long inclined at an angle 60 deg from
vertical. The mud weight is 90 pcf and the coefficient of friction is 0.25.
(a) How much drag does the section of drill pipe contribute while tripping out of the
hole?
(b) What is the tension required to move the drill string up hole assuming no drag?
(c) How much tension (pull) is required to move the drill string up hole?
Solution
Fn = W sin
490 90
Buoyancy factor = = 0.815
490
W = 2000 x 19.5 x 0.815 = 31785 lb
Fn = 31785 sin60
= 31785 x 0.866
= 27525 lb
Ff = 27525 x 0.25
= 6881 lb
(b) By doing a force balance along the wellbore axis in Fig (27),
Ft = Fx + Ff
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Ff = 0, and
Ft = Fx = W cos
(c) Ft = Fx + Ff
Fx = W cos = 15892 lb
From Eq (30)
Ff = Fn = W sin
= 2000 x 19.5 x 0.815 x 0.25 x 0.866
= 6881 lb
Ft = 15892 + 6881
= 22773 lb
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[( ) + (F + W sin ) ]
1
2 2 2
Fn = Ft sin t ................................... (32)
where
Fn = resultant normal force, lb
Ft = axial tension on lower end of element, lb
= average inclination angle, degrees
= change in inclination angle, radians (1 deg = 0.0174 radians)
= change in azimuth, radians
W = buoyed weight of element, lb
( )
The first term in Eq (32) Ft sin is the normal force due to change in azimuth, the
second term Ft is the normal force due to change in angle of inclination, and the third
term W sin is the normal force due the weight of the element. If there is no change in
azimuth and angle of inclination then and are zero and Eq (32) will reduce to
Fn = W sin
which is the same as Eq (28).
Calculation of Drag
Calculation of drag across a hole of constant inclination and azimuth (tangent section) is
simple as was illustrated by the above example problem. Calculation of drag across a
curved section is more complex. The drill string is divided into small elements 100 to 50
+ ft long and the drag is calculated across each element. The total drag is the sum of the
drag across all elements.
The drag across an element is the coefficient of friction times the normal force, or
Ff = Fn ..................................................................................... (33)
Referring to Fig (28), if the tension at the bottom of the element is Ft, then the tension at
the top of the element is (by force balance),
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It should be noted here that is the average of the angles of inclination at the bottom
and top of the element. The value of Fn is calculated by Eq (32) for each element. in
Eq (32) is the inclination at the bottom of the element minus the inclination at the top of
the element. is calculated in a similar manner. The value of Ft + Ft for the first
element (bottom most element) becomes Ft for the second element. The calculation
process is repeated for all elements to the surface. The value of Ft + Ft for the last
element at surface will be the total tension that must be applied to move the string up
hole. The total tension is the sum of all drag forces and the weight components parallel to
the hole axis, or
(F ) + W
n n
Total tension Ft = f n cos n .......................................... (37)
n =1 n n =1
Calculation of drag forces in an inclined wellbore with curved section is illustrated by the
following example.
Example
Given:
Well bore
9-5/8 40# casing at 5000 ft
Total Depth = 10,000 ft
Hole Size = 8-1/2
Kick off Point = 5000 ft
Build Rate = 10 deg/100 ft
End of Build at = 5600 ft
Tangent Section = 5600 to 10,000
Inclination across tangent section = 60 deg
Azimuth = 0 deg north (surface to 5000 ft)
Azimuth is changed at the rate of 5 deg / 100 ft from 5000 ft to 5600 ft
Azimuth = 30 deg from 5600 ft to 10,000 ft
Mud Weight = 90 pcf
Coefficient of friction = 0.25 in open hole and 0.2 in casing
Drill String
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Drill pipe 5 OD, 5.276ID, 19.5# normal weight 20.89# adjusted weight
Drill Collars 7 OD, 2.25 ID, 117.42#, 400 ft long
With the drill string at bottom, calculate:
a) The tension at surface required to move the drill string up hole
b) Total drag force when moving string up hole
c) The hook load when the string is off bottom and not moving
Solution
The first step is to divide the drill string into small elements from bottom to top as shown
in Table (12). The drill collars are considered as one element since there is no change in
inclination or azimuth across them. The drill pipe in the tangent section from 9600
5600 is also taken as one element for the same reason. The drill pipe in the curved
section from 5600 to 5000 is divided into twelve 50-ft elements because the inclination
and azimuth change across the curved section. The last element is the vertical section
from 5000 to surface. The entries in the columns are defined as follows:
Column # 1: element sequence number
Column # 2: depth of the bottom of the element
Column # 3: element length in feet
Column # 4: angle of inclination in degrees at the bottom of the element
Column # 5: average angle of inclination across the element, or angle at bottom of
element plus angle at top of element divided by 2.
Column # 6: change in angle of inclination across the element in radians, or angle at
bottom of element minus angle at top of element. Multiply answer by
0.0174 to convert from degrees to radians.
Column # 7: azimuth at bottom of element in degrees.
Column # 8: change in azimuth in radians, or azimuth at bottom minus azimuth at
top multiplied by 0.0174.
Column # 9: buoyed weight of the element which is the weight in air times the
buoyancy factor. For drill pipe use the actual or adjusted weight per
foot.
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Column # 10: tension force Ft at the bottom of the element. In this case since the drill
string is off bottom Ft = 0 for element # 1. If the string is on bottom
then Ft is a compressive force equal to the weight on bit.
Column # 11: normal force Fn calculated by using Eq (32).
Column # 12: Ft calculated by Eq (35).
Column # 13: tension at the top of the element and is equal to the value of Col# 11
plus the value of Col# 12.
Fn = (F sin ) + (F + W sin )
t
2
t
2
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= 0 + (0 + 38278 W sin 60 )
2
= 33149 lb
Column # 12: Ft is calculated by Eq (35)
Ft = Wcos + Fn
= 38278cos60 + 0.25 x 33149
= 27426 lb
Column # 13: Ft + Ft = 0 + 27426 = 27426 lb
This is the tension at the top of the drill collars which is equal to the
tension Ft at the bottom of element # 2
= 58977 lb
Column # 12: Ft from Eq (35)
Ft = Wcos + Fn
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Column # 1: This is the last element. It is the DP in the vertical section from surface
to the kick off point at 5000 ft.
Column # 2: Depth of lower end is at 5000 ft.
Column # 3: Length is 5000 ft.
Columns # 4 through 8: All values are zero because the pipe is vertical
Column # 9: W = 5000 x 20.89 x 0.815
= 85126 lb
Column # 10: Tension at bottom end is 110427 lb
b) The total drag force is the sum of all drag forces generated by all elements, or
15
Total Drag Force = F
n =1
n
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This is the sum of all normal forces times the friction coefficient. The sum of all
normal forces is obtained by adding all values of Fn in Col # 11 which is 195176 lb.
Therefore,
Total Drag = 195176 x 0.25
= 48794 lb
c) The hook load when the pipe is static is 195553 - 48794
= 146,759 lb
The hook load is also equal to
15
Hook load = W Cos
n =1
n n
T
Ff = Fn ............................................................................... (38)
V
where,
T = Trip speed, in/sec
Fn = Normal force, lb
= Coefficient of friction
V = Resultant speed = T 2 + A2
A = Angular speed, in/sec
rpm
= D x 3.14 x
60
D = Diameter, inch
Example
In the previous example, what would be the approximate total drag if the drill string was
pulled out while rotating it at 100 rpm? Assume a tripping speed of 2000 ft/hr
ft 12in 1hr
T = 2000 = 6.66 in/sec
hr ft 3600 sec
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5 3.14 100
A= = 26.16 in/sec
60
T
Drag = Fn
V
6.66
= 48794 x = 12040 lb
26.99
This shows that rotation decreases drag force.
Ff = Wcos
Note that in this case Ff is acting in the opposite direction of Wcos because the
movement is downward
Wsin = Wcos
sin 1
=
cos
1
tan =
1
cr = arctan ................................................................. (39)
Where cr is the critical hole angle in degrees.
Example
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At which hole angle the drill string cannot move downward by its own weight when
drilling a tangent section where the coefficient of friction is 0.30
Solution
1
cr = arctan
0.3
= arctan 3.33
= 73.3 degrees
Calculation of Torque
The torque required to turn the drill string is calculated by the following equation,
A
Torque = Fnr ............................................................ (40)
V
where
T = Torque, ft-lb
Fn = normal force as defined by Eq (32)
r = Radius of drill string component ft (for drill collars use outer radius of collar,
for DP, HWDP and casing use outer radius of tool joint)
= Coefficient of friction
A = Angular speed as defined in Eq (38)
V = Resultant speed as defined in Eq (38)
+
If the drill string is not tripped while
rotating, then T = 0 and A is equal to V and
M + M
Equation (40) reduces to
Fn
Torque = Fnr ........................... (41)
M If the torque acting on the lower end of the
drill string element is M, then the torque
, acting at the top of the element is M + M
as shown in Fig (29). The torque increment
W
M is
Fig. (29) Torque acting on a M = Fnr ...............................(42)
drillstring element
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where Fn is the normal force exerted on the element. The torque required to turn the
entire drill string is the sum of all torque increments for all the elements. Torque
calculations are illustrated by the following example
Example
In the last example,
a) Calculate the surface torque required to turn the string off bottom with no tripping.
b) Calculate the torque while drilling. Use a bit torque of 2000 ft-lb. Drill pipe tool
joint OD is 6.625 in.
Solution
The drill string is divided into small elements as was done for calculating drag.
Calculations are tabulated in Table (13). The data in columns 10, 11 and 13 are
calculated in the same manner as was done for the drag calculations in the previous
example. For drag calculations the tension increment Ft in column 12 is calculated by
Eq (35)
Ft = Wcos + Fn
where Fn in the incremental drag caused by moving the element uphole. However, since
in this example there is no tripping, the drag increment due to uphole or downhole
movement is zero, and the tension increment Ft is
Ft = Wcos ............................................................... (43)
Column 14 is the torque at the bottom of the element. If the string is off bottom the
torque is zero. For the case of drilling the torque is the bit torque which have to be
estimated. The torque increment M in Column 15 is the torque resistance exerted by
the element and is calculated by using Eq (42). Column 16 is the torque at the top of the
element which is M + M. The torque at the top of the element ( M + M ) is the
torque at the bottom of the next element. The calculations are repeated for all elements to
the surface.
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Column # 14. The torque at bottom of element in this case is zero because the drill
string is off bottom (no bit torque)
Column # 15. Torque increment M
M = Fnr
OD of DrillCollar 7
r= = =3.5 in
2 2
3.5
= =0.2916 ft
12
M = 33149 x 0.25 x 0.2916 = 2416 ft-lb
Column # 16. Torque at top of element #1 is M + M = 0 + 2416 ft-lb = 2416 ft-lb
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For element # 15 since the inclination angle is zero, the normal force Fn is zero and the
torque increment, M is also zero. In other words, drill pipe in vertical hole can be
turned with no or very little torque. So the torque at top of element # 15 (the surface) is
equal to torque at top of element #14 which is 11032 ft-lb
To calculate the friction coefficient during tripping out of hole, the pick up load is read
from the weight indicator. The reading from the weight indicator includes the weight of
the kelly and travelling equipment. In calculating drag forces, the tension at the top of the
drill pipe below the kelly, is required. Thus, it is necessary to subtract the weights of the
traveling equipment and kelly from weight indicator reading. The tension at the top of
the drill pipe, the drill string and wellbore geometry data are entered in the computer
program. The program calculates the tension required to pick up the drill pipe by using
different coefficients of friction until the calculated tension is equal to the tension read by
the indicator. The coefficient of friction at which the calculated tension is equal to the
measured tension is the correct coefficient to use for that wellbore. To ensure accurate
results, the weight indicator must be calibrated to give accurate readings. Also accurate
weights of the traveling equipment and kelly must be known.
The friction coefficient can also be determined by measuring the torque while turning the
drill string off bottom. The torque must be in foot-pounds rather than amperes. The
coefficient of friction where the measured torque is equal to the calculated torque is the
correct coefficient for the wellbore. Most rigs are not equipped with calibrated torque
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Friction coefficients depend on the mud type and whether the hole is cased or open.
Friction coefficients from a number of similar wells must be compared to verify useful
values for prediction use. Typical ranges of friction coefficients are shown in Table (14).
Table (14 )
Coefficients of Friction
Torque and drag arise not only from friction, but also from the effects of hole tortuosity,
cuttings accumulations, swelling shale, differential sticking, and other mechanical
impediments to drill string movement. Thus, the friction coefficient in the torque and
drag programs could more accurately be considered a drag coefficient or coefficient
factor, that is, a composite coefficient that includes all factors affecting torque and drag.
Furthermore, the drag coefficients for rotational movement, for axial movement or for a
combination of the two, will often be different, and may also vary with the direction of
movement. Finally, because these mechanical impediments to string movement
frequently change with changing hole conditions, friction coefficient will also fluctuate,
particularly for axial movement.
Dogleg Severity: As seen from Equation (32), the change in inclination and azimuth
influence the normal force acting on the pipe. The larger the change in either, meaning
increasing dogleg severity, the larger the normal force and the larger the increase in drag
due to that point. Smaller doglegs lead to less torque and drag.
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Mud Lubricity: Mud lubricity is a term generated from a lab test (on a specific piece of
equipment) that is intended to mimic the drill pipe/casing interaction. The lubricity is
scaled opposite the friction factor, increasing lubricity reduces the friction factor. The
measurement is a lab test, and the results do not always directly correlate with field
observations. The mud lubricity, as measured in the lab, strongly influences the friction
factor, or coefficient of friction, between the pipe and casing, or pipe and borehole, but
does not always accurately reflect the influence of the specific material, be it pipe or
formation. It is usually assumed, based on the mathematical model, that raising the mud
lubricity will generally lower torque and drag by lowering the coefficient of friction. This
is not always the case, because the source of the torque or drag may be generated by a
factor not included in the mathematical model. These factors are discussed below.
Cutting Beds: There is no provision in the mathematical model for the local influence of
cutting beds. Cuttings beds will locally change the effective coefficient of friction, and
can be modeled in that manner if the location, length and friction factor of the cuttings
bed is known. Unfortunately, these parameters continually change in the presence of a
cuttings bed. The typical technique is to deduce the presence of a cuttings bed when
unexplained trends in torque and drag develop in well. This would be seen very
practically on trip out of the hole when pick-up weight begins increasing during the trip,
rather than decreasing, then suddenly returns to the baseline trend.
Drilling Tools: Once again, there is no provision in the mathematical model for the
impact of individual drilling tools. It is not hard to imagine that the influence of a
stabilizer on drag would be much greater than that of a similar length of drill pipe or drill
collar and that the interaction of the stabilizer with the wellbore may include additional
components than does the simple model we have been working with.
Drilling tools can greatly impact torque and drag are stabilizers, drill pipe protectors, bit
type (roller cone vs. drag type), drill collars (flex vs. slick) and hard banding on drill
pipe.
Deep Kick-off Point: By lowering the kick-off point, the tension in the pipe is lowered
and the normal force reduced. This will reduce the drag and torque generated at the point.
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Raise Mud Lubricity: As mentioned in prior section, raising the lubricity of the mud
corresponds to lowering the coefficient of friction between the pipe and casing or pipe
and bore hole. This can be accomplished by 1) changing mud type. Oil based mud
generally has a lower lubricity than does water based mud. 2) Adding a lubricant. 3)
Adding a mechanical aid to the mud, such as drilling beads or walnut hulls. Beads are
typically very expensive, but have the benefit of being environmentally safe.
Remove Cutting Beds: Quite often the presence of cuttings beds will dramatically
increase the torque and drag observed in a well. The cuttings beds can be identified by
various means, and the effect of a cutting bed can only be changed by eliminating the
bed.
Minimize DLS in Tangent Section: A smoothly drilled tangent section will help
minimize the torque and drag on a well. Because the tangent section represents the major
length of a well, cumulative DLS in this section can greatly impact the total drag and
torque generated in the well.
Soft Type Hard Banding: Tungsten carbide hard banding on drill pipe greatly increases
the effective coefficient of friction, as well as causes casing wear. Current technology for
hard banding is to apply a softer metal for hard banding, which minimizes casing wear
and drag, while still protecting tool joints.
Drill Pipe Protectors: Non-rotating drill pipe protectors have been demonstrated to
dramatically reduce torque when placed in the build section of well. These protectors
(Western Oil Tool) work by effectively reducing the normal force on the drill pipe
through the build section by providing standoff from the casing and by creating a fluid
bearing between the drill pipe and protector.
Flex Drill Collars: Flex drill collars provide standoff from the bore hole, thus
minimizing the differential sticking force on the collar. This in turn eliminates the need to
use stabilizers, which create a large amount of drag, to prevent differential sticking.
Tapered edges on the flex collars also reduce drag.
Minimize use of Stabilizers: It has been found the use of conventional stabilization
techniques are not necessary, and even detrimental, on horizontal, high angle, and
extended reach wells. Stabilizers cause a large downward drag force which reduced or
prevents transfer of weight-on-bit, thus affecting penetration rate. In addition, the
movement of stabilizers is much more of a slip/stick motion, which leads to rapid
application of weight-on-bit and subsequent stalling of a positive displacement motor.
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Calculation of Buckling
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EIWK b sin
Fcrit = 2 ............................................................. (44)
12r
Equation (44) is used to predict the onset of buckling of pipe in a straight inclined hole.
For pipe in vertical hole the critical buckling force is,
EIW 2 K 2 b
Fcrit = 1.94 3 ............................................................ (45)
144
Example
Calculate the critical sinusoidal buckling force for 5 19.5 # drill pipe in (a) 8-1/2
vertical hole and (b) in 8-1/2 deviated hole where the angle of inclination is 60 degrees.
Mud Weight = 90 pcf
Drill pipe ID = 4.276 in4
Actual air weight = 20.89 lb/ft
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Solution
a) E = 30 106 psi
I =
64
(5 4.276 4 ) = 14.262 in4
3.14 4
From Eq (45),
b) From Eq (44),
It can be seen from the above example that drill pipe in vertical holes has small resistance
to buckling. The critical buckling force is so small that it is assumed to be zero. This is
the reason in vertical drilling the drill pipe should be kept in tension to prevent buckling.
The critical buckling force in the inclined hole in the above example is large (34,677 lb).
This means that it will require a compressive force of 34677 lb to buckle the drill pipe
into a sinusoidal shape. The critical buckling force increases with the angle of inclination
until it reaches a maximum at an angle of inclination of 90 deg. The reason that the drill
pipe in an inclined hole is so resistant to buckling is that the low side of the hole forms a
trough that resist even a slight displacement of the pipe from its initial straight
configuration. The effect of gravity and the curving sides of the hole form a restraint that
resists buckling. Because of its ability to withstand large mechanical compressive loads
without buckling , drill pipe and HWDP are used in compression to provide weight on bit
while drilling inclined and horizontal holes.
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The critical buckling load in a curved wellbore of increasing angle (build section) is
always higher than that in a straight wellbore of the same inclination. Positive wellbore
curvature has a stabilizing effect on pipe in mechanical compression because
compression increases the side load of the pipe against the outside of the wellbore curve.
This is added to the stabilizing effect of the pipe weight at any angle. Therefore, a drill
string in a positive build section, being mechanically compressed from straight hole
sections above and below must buckle first in one or the other of the straight sections.
The amount of mechanical compression that a uniform string can carry without any
where buckling will be limited by the critical buckling loads in the straight sections
above and below a positive build section, not in the build section itself. In a dropping
wellbore the critical buckling load of drill pipe can be more or less than that in a straight
well bore of the same inclination angle. The critical buckling loads of pipe in a curved
wellbore can be estimated by the following equation.
rWK bsin
Ktest = .................................................................... (47)
12 EI
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Example
Calculate the critical buckling force for the 5 19.5# drill pipe in the previous example in
a build section drilled at a build rate of 5 degrees per 100 ft. Assume same angle of
inclination of 60 degrees.
Solution
Since this is a build section then Eq (46) will be used to calculate the critical buckling
force.
5 deg deg
K = BR = = 0.05
100 ft ft
0.05
= deg/inch
12
0.05
= x 0.01744 radians / inch
12
= 0.0000727 radians/inch
2
2 4.278 108 0.0000727 4.278 108 0.0000727 4.278 108 20.89 0.816 0.866
Fcrit= +2 +
1.75 1.75 12 1.75
It can be seen from the above example that the critical buckling force in the build section
is 2.45 times (85128/34677) the critical force in the straight (tangent) section of the same
angle of inclination of 60 degrees. Therefore, a drill string in a wellbore which has a
build section will buckle first below the build section (below end of build) or above the
build section (above the kickoff point). So the amount of mechanical compressive force
that a drill string can carry without buckling is limited by the straight sections below and
above the build section.
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Helical Buckling
As the mechanical compressive force increases beyond the critical sinusoidal buckling
force, the tubular will take the shape of a helix as shown in Fig (31). Helical buckling
will occur at compressive loads which are 1.4 times the critical force for sinusoidal
buckling. Once the tubular takes the shape of a helix it will be forced against the wall of
the wellbore and additional drag forces will develop. The drag forces will ultimately
prevent the tubular from sliding down the wellbore. This condition is called lock-up.
Drill pipe should never be rotated when it is buckled.
Example
What is mechanical compressive force required to helically buckle 5, 19.5 # drill pipe in
8-1/2 wellbore inclined at 60 degrees?
Solution
From the previous example, the critical sinusoidal buckling force for 5 DP was
calculated to be 34,677 lb. Therefore, the force required to initiate helical buckling is
34677 x 1.4 = 48547 lb.
Bending
Bending is a point load, that is the effect of bending occurs at the point of bending, and
the stress it generates is localized. The force or stress generated by bending is additive to
the existing tensile force or stress in the tubular at the point of bending, but does not
increase the tensile force in the tubular at other points. Bending does not affect the
hookload on the drill string.
The maximum stress on the convex side of the pipe caused by bending is given by,
z = 218BRd
and the equivalent force caused by bending is,
Fb = 64 BRdW ............................................................... (50)
Where
Fb = Bending force, lb
BR = Dog leg severity or build rate, deg / 100 ft
d = Outside diameter of tubular, in
W = Weight of tubular in air, lb/ft
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The total tensile force in the pipe is the bending force plus the existing tensile force at
that point, and the sum should remain below the tensile strength of the tubular. Bending
forces become important at high build rates such as in drilling short radius horizontal
wells.
Example
A short radius sidetrack is performed in a well by using 2-7/8, 6.85 lb/ft grade E drill
pipe. The axial tensile force in the drill pipe in the build section as a result of applying
weight on bit is 10,000 lb. The maximum build rate in the build section is expected to
reach 110 degrees per 100 ft. Is it safe to use this drill pipe for drilling the short radius
hole? Tensile strength for grade E pipe is 75,000 psi, drill pipe ID= 2.441 in.
Solution
The force caused by bending in the build section is,
Fb = 64 x 110 x 2.875 x 6.85 = 138644 lb
Total axial force = 10,000 + 138644
= 148644 lb
Tensile strength of drill pipe is
Y = 75000
3.14
4
(2.8752 2.4412 )
= 135,833 lb
Since the total axial force exceeds the tensile strength of the drill pipe, the drill pipe will
fail and therefore, it is not safe to use it for drilling.
Fatigue
Most drill pipe failures are related to fatigue, and result from the cyclical forces induced
on the pipe during rotation. Fatigue implies a change in material properties with the total
number of revolutions of the drill pipe. During rotation in a dogleg, the drill pipe
experiences variable stress levels along a given circumference, and if the stress variation
is severe enough, the metallurgy of the pipe will eventually be altered.
Fatigue is not well understood, once fatigue occurs, the life of a given tubular is very
difficult to predict. Most efforts are concentrated on operating below the conditions
which cause fatigue.
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The essential factors in fatigue failure are tension in the pipe at the dogleg, dogleg
severity, and number of revolutions (cycles) made by the pipe in a given DLS and under
a given tensile load. The failure model is mathematically presented by Eq (22). The
model does not guarantee elimination of failure but it provides an engineering basis in
drill string design.
The design approach in high angle and horizontal wellbores differs from the approach in
vertical wells in the following respects:
a) In high-angle holes, traditional BHA components are often eliminated. Bit
weight is likely to be applied by running normal weight drill pipe in
compression, a practice never recommended in vertical holes.
b) For a given measured depth, surface tension load from hanging weight
decreases in a high-angle hole due to wall support, but torque and drag required
to move the drill string are higher compared to vertical holes. The load limit for
the drill string will be its tensile capacity in a vertical hole, but is more likely to
be its torsional capacity in horizontal and extended reach holes.
c) In vertical wells, loads are calculated based on hanging weight. Friction effects
are often small and are traditionally ignored. In horizontal wells, friction effects
will probably be large enough that they cannot be ignored.
d) Drill string design for vertical holes is a once-through calculation. In horizontal
and ER wells, drill string design is an iterative process.
Thus the problem is to determine where and at what bit weight the drill pipe will first
begin to buckle. If this bit weight is sufficient to drill the well, buckling can be avoided
by staying below it. If the bit weight needed causes the pipe to buckle, then heavy weight
drill pipe should be run in the buckled sections.
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Fig. (32)
As was mentioned above, the critical buckling load in a curved section is greater than that
across tangent and vertical sections. Therefore, buckling of drill pipe will initiate in the
tangent section (below the tangent point) or above the kickoff point. The maximum
weight that can be applied on the bit without buckling the drill pipe is determined in two
steps:
1. Calculate the maximum weight that can be applied on the bit without buckling
the drill pipe below the tangent point refer to Fig (32)
2. Calculate the maximum weight that can be applied on the bit without buckling
the drill pipe above the kickoff point. The lower of the two weights is the
correct weight to be used for drilling.
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F1 = LHWH BF cos
F2 = LBHAWBHA BF cos
HWDP
The maximum weight on bit that can be
applied without buckling the drill pipe is Drag F1
If the hole below the tangent point is horizontal, then cos 90=0 and
WOB < DF Fcrit Drag............................................................. (52)
For sliding mode drilling the drag force is calculated as was described previously. For
rotary mode drilling, the drag force is small and is assumed to be zero.
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Fcrit
Kickoff Point
F4
DP
Tangent Point
DP
Drag
HWDP
F3 BHA
F1
F2
WOB
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Since the inclination angle across the build section is not constant the value of F4 is
computed by dividing the build section into small increments and adding the effective
weights of all the increments.
n
F4 = WDPBF L
n 1
nDP cos n ....................................................................... (54)
A simpler way of calculating the effective weight of the drill pipe across the build section
is by using the following equation,
(
5729.6 sin t sin
WDPBF
)
F4= ........................................................... (55)
BR
where,
BR = Build rate, degrees per 100 ft
t = Inclination angle at tangent point (end of build), degrees.
= Inclination angle at kickoff point, degrees
F + F1 + F2 = WOB + DRAG
F1 = LHWH cos BF
F2 = LBHAWBHA cos BF
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If drilling in the rotary mode, the drag force is zero. If the calculated value of F is less
than the critical buckling force Fcrit of the drill pipe, then the drill pipe will not buckle. If
F is greater than the Fcrit, then the drill pipe will buckle.
1. Calculate the drag forces and torque by using a computer program such as
Landmark Well Plan.
2. Calculate the sinusoidal critical buckling force below the tangent point and above
the kickoff point.
3. Calculate the maximum WOB that can be applied without buckling the DP below
the tangent point using Eq (51)
4. Calculate the maximum WOB that can be applied without buckling the DP above
the kickoff point by using Eq (53). Take the lower of the two values. If the WOB is
not sufficient then add more HWDP in the drilling assembly.
5. Calculate the actual forces on DP below the tangent point and above the kickoff
point. Include bending forces and check for fatigue if the build rate is high. If the
actual forces exceed 90% of the DP yield strength, then select a DP with higher
yield strength.
6. Check the actual torque at all depths and make sure it is less than the makeup
torque of DP
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Example
You are drilling a build and hold wellbore with the following characteristics:
Hole Geometry:
Hole size = 8-1/2 @ 8000 ft
Casing = 9-5/8 40# @ 7000 ft
Kickoff point = 5500 ft
Angle at KP = 0 Deg
Build rate = 5 deg/100 ft
Tangent point = 7000 ft
TD = 8000 ft
TVD = 6865 ft
TVD at top of BHA = 6841 ft
Tangent angle = 75 deg
Mud weight = 75 pcf
Drill String
Drilling assembly = 90 ft, 82.68 lb/ft 6 OD, 2.25 ID
HWDP = 90 ft, 49.7 lb/ft, 3 ID, 5 OD
DP = 5, 22.26#, grade E, 4.276 ID
Bit at 8000 ft
Drag Forces
BHA = 2200 lb
HWDP = 1300 lb
DP in tangent section = 5200 lb
DP in build section = 5400 lb
Buckling DF = 0.9
a) What is the maximum rotary mode bit weight that can be applied without buckling
the drill pipe?
b) What is the maximum sliding mode bit weight that can be applied without buckling
the drill pipe?
c) What is the maximum rotary mode bit weight that can be applied if the DP is to
remain in tension?
d) Calculate the actual stress in the DP at top of HWDP when applying 27431 lb
WOB in rotary mode.
e) What is the mechanical force at top of HWDP that will cause buckling?
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Solution
a) Lets first calculate by using Eq (51) the maximum WOB that will not cause
buckling above the drilling assembly.
Calculate critical buckling force by using Eq (44)
E = 30 10 6 psi
I=
64
(5 4
4.276 4 ) = 14.26 in 4
From Eq (51)
0.9 x 38482 + 979.4 + 1624 0 > WOB
WOB < 37237 lb
Now lets calculate the maximum weight on bit for no DP buckling above the
kickoff point by using Eq (53)
From Eq (44)
Fcrit = 0 lb (because = 0, sin0=0)
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LHWHKBcos = 979.4 lb
LBHAWBHAKBcos = 1624 lb
LDPWDPKBcos = (8000 90 90 7000) X 22.26 X 0.846 X 0.258
= 3984 lb
F4 = effective weight of DP in build section
From Eq (55)
5729.6(sin 75 sin 0)
F4 = 22.26 x 0.846 (
5
= 20844 lb
Drag = 0 lb (rotary mode)
From Eq (53)
WOB < 0 + 1624 + 979.4 + 3984 + 20844 0
< 27431 lb
So the maximum WOB that can be applied without buckling the DP while drilling
at 8000 ft in rotary mode is the smaller of the two values or 27,431 lb.
b) To calculate the maximum WOB in the sliding mode we repeat the calculations
made in part (a) keeping in mind that the drag forces are not zero.
Maximum WOB for no DP buckling above the drilling assembly using Eq (51) is,
0.9 x 38482 + 979.4 + 1624 drag > WOB
Drag = drag of BHA + drag of HWDP
= 2200 + 1300 = 3500 lb
WOB < 33,737 lb
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c) If the DP is to remain in tension, the WOB can be provided only by the effective
weights of the BHA and the HWDP
WOB < 1624 + 979.4
WOB < 2603.4 lb
It can be seen from the above example that only 2603 lb can be applied on the bit if
the DP is to remain in tension, whereas if the DP is used in compression (but below
the critical buckling force) 27, 431 lb can be applied on the bit. Applying 27,431 lb
of WOB with the DP in tension requires a very long HWDP which will increase the
cost and the torque and drag that are associated with it. Therefore, the benefit of
using DP in compression in horizontal drilling is that the BHA weight is kept low
which in turn helps reduce torque and drag.
d) Draw a free body diagram of the drilling assembly below the drill pipe. Show all
mechanical and hydrostatic pressure forces acting on the drilling assembly as
shown Fig (36).
F
DP
F1
HWDP
F4
F2
BHA
F5
F3
WOB
Fig. (36)
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75
P1 = 6818 = 3551 psi
144
75
P2 = 6841 = 3563 psi
144
75
P3 = 6865 = 3575 psi
144
A1 =
4
(4.276 2
32 ) = 7.28in 2
A2 =
4
(6 2
2.252 )
4
(5 2
32 )
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43540
Actual axial stress = = 8261 psi
5.27
The stress is less than the minimum compressive strength of grade E drill pipe
which is 75,000 psi.
Note:
The actual force F calculated above (43540 lb) is greater than the critical buckling
force Fcrit (38482 lb). However, this does not mean that the DP will buckle. The
reason is that the force F is a combination of mechanical forces and hydrostatic
forces. Only the mechanical component of F will cause buckling. See part (e)
below
e) Do a force balance as in part (d) but do not include the hydrostatic forces. Use
only the mechanical forces which are the effective buoyed weight of the string
and WOB.
F + F4 + F5 = WOB
F4 and F5 in this case are the effective buoyed weights of HWDP and BHA
F4 = 90 x 49.7 x cos75 x 0.846 = 979 lb
F5 = 90 x 82.68 x cos75 x 0.846 = 1629 lb
F = WOB F4-F5
= 27431 979 1629 = 24823 lb
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The mechanical force F is less than Fcrit, therefore, the DP at top of HWDP will not
buckle.
In the previous discussion it was emphasized that drill pipe can be used in
compression to provide weight on bit as long as the mechanical compressive force
is less than the critical buckling force required to initiate sinusoidal buckling (Fcrit).
Field practice has shown that drill pipe can tolerate sinusoidal buckling when there
is no rotation, that is, when drilling in the sliding mode. This means that
mechanical compressive forces up to 1.4 Fcrit, which is the force required to initiate
helical buckling in the sliding mode, can be applied on drill pipe while drilling in
the sliding mode. In rotary drilling mode the mechanical compressive force should
not exceed Fcrit. The mechanical compressive force should never exceed 1.4 Fcrit in
any drilling mode. In other words, helical buckling must be avoided at all times.
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CHAPTER HYDRAULICS
HYDROSTATIC PRESSURE 1
HYDRAULIC POWER 20
PRESSURE DROP ACROSS BIT NOZZLES 20
HYDRAULIC IMPACT FORCE 21
SEGMENT DRILLING
CHAPTER HYDRAULICS
Fluid mechanics is very important for the drilling engineer. Large fluid pressures are
developed in the long wellbore and drill strings by the drilling fluid. The presence of
these pressures must be considered in almost every well problem. In this chapter the
relations to determine subsurface fluid pressures are presented for
1) the static condition in which the wellbore fluid and drill pipe are at rest, and
2) the circulating operation in which fluids are pumped down the drill pipe and up the
drill pipe-hole annulus.
Some of the important drilling applications of the fundamental concepts are also
presented. These applications are
1) calculations of subsurface hydrostatic pressures,
2) pressure losses in circular pipe and annuli, and
3) bit nozzle size selection.
HYDROSTATIC PRESSURE
The hydrostatic pressure of the drilling fluid is an essential feature in maintaining control
of a well and preventing blowouts. It is defined as the static pressure of a column of fluid.
The hydrostatic pressure of a mud column is a function of the mud weight and the true
vertical depth of the well. Remember that the true vertical depth is used and not the
measured depth. The formula to calculate hydrostatic pressure in the units common for
Saudi Aramco is:
D
PH = ............................. (1)
144
where,
PH = hydrostatic pressure, psi
= mud weight, pcf
D = vertical depth, ft
Drilling operations often involve several fluid densities, pressures resulting from fluid
circulating and induced surface pressures during kick control operations. For practicality
these different pressures are put into a common descriptive system called equivalent
mud weight. This provides the same pressures in a static system with no surface
pressure.
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NEWTONIAN MODEL
The fluid property responsible for frictioned drag when one layer of fluid is caused to
slide over another is called viscosity. Viscosity is defined as the ratio of the shear stress
to the resulting shearing rate. In Fig (1), the shear stress acting on the moving upper plate
is,
F
= .............................................. (3)
A
where,
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where,
dv
= shear rate =
dy
If the viscosity of a fluid is influenced only by temperature and pressure, the fluid is
called Newtonian. Some of the Newtonian fluids are water, gases and thin oils. For a
Newtonian fluid the ratio of shear stress to shear rate is constant, namely . A plot of
shear stress versus shear rate for a Newtonian fluid is a straight line with a slope equal to
as shown in Fig (2)
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All fluids which do not have a direct proportionality between shear stress and shear rate
at constant temperature and pressure are classified as non-Newtonian fluids. Examples of
non-Newtonian fluids are, drilling mud, clay suspensions, cement slurries and viscous
gelled fracturing fluids. The viscosity of these fluids will vary with the magnitude of
applied shear stress.
At higher average flow velocities when the fluid particles move down stream in a chaotic
motion so that voticies and eddies are formed in the fluid, the flow is called turbulent. In
turbulent flow there is no orderly shear between fluid layers but a random shearing and
impact of the fluid masses caught up in the swirls and eddies of the flow.
In turbulent flow, the velocity profile is flatter and the velocity gradient near the pipe
wall is much larger than the laminar flow profile for a corresponding value of average
velocity.
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Reynolds Criterion
The magnitude of the dimensionless Reynolds number indicates whether the pipe flow of
a Newtonian fluid is laminar or turbulent. The Reynolds number is defined by,
123.9 (dv )
NR = .................................. (5)
where,
NR = Reynolds number, dimensionless.
d = diameter of pipe, in.
v = velocity, ft/sec.
= fluid density, pcf
= viscosity, cp
When the Reynolds number exceeds the critical value of approximately 2100 in round
pipes, turbulent flow starts, while for lower values of NR the flow is laminar.
Example
Water is circulated down 3.5 drill pipe (ID= 2.76). Calculate the maximum pumping
rate in bbl/min that will maintain laminar flow.
Solution
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d = 2.76 in
= 62 pcf
= 1 cp
NR = 2000
For laminar flow the Reynolds number should not exceed 2100,
123 .9 2 .76 62 v
2100 =
1
Solving for v,
2100
v= = 0 .099 ft / sec
123 .9 ( 2 .76 ) 62
( 2 . 76 ) 2
Flow rate = Av = 0 . 099
4 144
= 0.0041 ft3/sec
0.0041 60
= = 0.04 bbl / min
5.61
Laminar Flow
The frictional losses (pressure loss) in laminar Newtonian flow in circular pipes can be
calculated from the equation,
Lv
= .......................... (6)
1500 d 2
= viscosity, cp
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For annular flow, the pressure loss of Newtonian liquids is expressed in practical
engineering units by the equation,
Lv
= ............................... (7)
1000 ( d 2 d 1 ) 2
where,
d2 = inside diameter of outer pipe, in
d1 = outside diameter of inner pipe, in
Turbulent Flow
The pressure loss of Newtonian fluids in pipe is calculated by using the Fanning
equation,
fL v 2
= ................................... (8)
193 d
where f is the Fanning friction factor which depends on the Reynolds number and
surface condition of the pipe. The value of f can be obtained from the plot shown in Fig
(4).
fL v 2
= ................................................ (9)
193 d e
where,
de = equivalent diameter = 0.816 (d2-d1)
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Example
A workover rig is circulating brine in the tubing-casing annulus at a rate of 200 gpm.
Calculate the pressure loss in 1000 ft of annulus using the following data:
Solution
200
Annular velocity = = 4 .4 6 ft / sec.
2 .4 4 8 ( 4 .8 9 2 2 2 .3 7 5 2 )
123.9(66)( 4.46)(2.05 3)
NR = = 93594 (turbulent )
0.8
From Eq.(9)
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0 . 0050 1000 66 4 . 46 2
= = 16 . 5 psi
193 2 . 053
( y ) = p
where y is the positive intercept on the shear stress axis and p is the plastic viscosity.
Unlike a Newtonian fluid, a Bingham plastic fluid will not deform (or flow) continuously
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until the applied shear stress exceeds a certain minimum value y which is known as
the yield point. After the yield point value has been exceeded, equal increments of
additional shear stress will produce equal increments of shear rate in proportion to the
plastic viscosity p. The plastic viscosity and the yield point specify completely the flow
properties of a Bingham plastic fluid. At least two experimental determinations of shear
rate at different values of applied shear stress are necessary to define the flow curve. The
Bingham plastic model is used to approximate the behavior of drilling fluids and cement
slurries.
where 600 is the dial reading with the viscometer operating at 600 rpm and 300 is the
dial reading at 300 rpm. The yield point Y in 1b/100 ft2 is computed using.
A third parameter called the gel strength, in units of lb/100 ft2 is obtained by noting the
maximum dial reading when the viscometer is turned at a low rotor speed of 3 rpm. If the
reading is obtained after the mud is allowed to remain static for 10 sec. the dial reading
obtained is called the initial gel. If the mud is allowed to remain static for 10 minutes the
maximum dial reading is called the 10 min gel strength.
The frictional pressure loss of Bingham plastic fluids in laminar pipe flow can be
calculated from the equation,
p Lv YL
= 2
+ ....................................... (14)
1500d 225d
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p Lv YL
= 2
+ ....................... (15)
1000( d 2 d 1 ) 220( d 2 d 1 )
fL v 2
= .............................................. (16)
193 d
The frictional pressure loss for turbulent annular flow can be obtained from the equation,
Lf v 2
P = ....................................... (19)
157 .8( d 2 d 1 )
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= K n .............................................. (20)
A plot of Eq. (20) is shown in Fig (7). The constants K and n characterize the flow
behavior of the fluid. K is the consistency index which corresponds to the viscosity of a
Newtonian fluid and n is the flow behavior index which indicates the degree of departure
from Newtonian behavior. The value of n ranges between zero and 1.
A logarithmic plot of shear stress versus shear rate is linear as shown in Fig (6). The
slope of the line is n and the intercept on the stress axis defines K at =1.
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The consistency curves of most drilling fluids are intermediate between the ideal
Bingham plastic and power-law flow models. Low - solid, polymer fluids and oil-base
muds tend towards power-law behavior, whereas high-solid muds and untreated and
flocculated clay muds act more like Bingham plastic fluids.
The frictional pressure loss in pipe for a power-law or pseudoplastic fluid in laminar flow
is
1
n
LKv n 3+
P = n ............................... (22)
144000d 1+ n .0416
where,
n = 3.32 log 600
300
5 1 0
K = 300
5 1 1n
1
n
Kv n L 2+
P = n ........ (23)
144000 ( d 2 d 1 ) 1+ n 0 .0208
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The Reynolds number for a power-law fluid flowing in a pipe is defined as,
n
11912 v 2 n 0 . 0416 d
NR = ...................
K 3+ 1
n
(24)
A plot of the friction factor f versus the Reynolds number for a power-law fluid is
shown in Fig (8). The critical Reynolds number, above which the flow is turbulent, is a
function of the index n. For example, for an n value of 0.2 the critical Reynolds number
is 4200.
The frictional pressure drop in a circular pipe for a power-law fluid in turbulent flow is,
f v 2 L
P = .................................... (26)
193 d
f v 2 L
P = .............................. (27)
157.8 ( d 2 d 1 )
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Example
A 67 pcf bentonite clay drilling fluid is circulated down 5 open ended drill pipe which
is inside a 9 58 casing at the rate of 5 BPM. Calculate the frictional pressure loss per
1000 ft of drill pipe and 1000 ft of annulus given the following:
Casing ID = 8.9 in
Drill pipe ID = 4.27 in
Dial reading at 600 rpm = 34.5
Dial reading at 300 rpm = 24.5
Solution
q 5 x 42 gpm
v= 2
= = 4 .7 ft / sec.
2.448 d 2.448 x 4 .27 2
= 600 300 = 34.5 24.5 = 10cp
p
f v 2 L
From Eq (16) pressure loss per 1000 ft =
1 93 d
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1 01 . 2 v ( d 2 d 1 )
NR = , Eq (18 )
p
If a drilling fluid is allowed to remain static it will develop a gel strength which will
require higher pressure to initiate circulation. The circulation pressure decreases with
time until a steady frictional pressure loss is observed.
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The frictional pressure loss equations presented in the previous sections do not take into
account the thixotropic behavior of the mud and, therefore, should not be used to
calculate the pressure required to initiate circulation. In some cases, the pressure required
to initiate circulation is greater than the pressure required to sustain circulation at the
desired rate. The pressure required to start circulation is
L g
P = (For pipe) ............................. (28)
300d
and
L
P =
g
(For Annulus) ................. (29)
300 ( d 2 d 1 )
Example
Compute the pressure at the casing seat at 3000 ft when a mud having a density of 67 pcf
and a gel strength of 50 lb/100 ft2 just begins to flow. The casing has an ID of 10 in and
the drill pipe OD is 5 in.
Solution
Using Eq (29) the pressure required to initiate circulation in the annulus is,
50 3000
P = = 100 psi
300 (10 5 )
Pressure at casing seat is the hydrostatic mud pressure plus circulation pressure,
67
P = 3000 + 100 = 1495 psi
144
When the drilling fluid becomes severely gelled in an annulus of small clearance,
excessive pressures may be required to break (start) circulation. In some cases, the
pressure required to initiate circulation may exceed the fracture pressure of the exposed
formation. To reduce the pressure requirements, the drill string can be rotated before the
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pump is started. In addition, the pump speed can be increased very slowly while the drill
string is rotated.
HYDRAULIC POWER
If the flow rate q is expressed in gpm and the pump pressure P is expressed in psi, the
hydraulic power output of the pump is,
q
H = ............................... (30)
1714
where H is expressed in hydraulic horsepower .
Example
A 70 pcf mud is circulated in a well at a rate of 500 gpm and 3000 psi surface pumping
pressure. The pressure loss in the drill pipe is 1500 psi. Determine
(a) the hydraulic horsepower developed by the pump and
(b) the power lost due to viscous forces in the drill pipe.
Solution
a) From Eq (30), the power output of the pump is.
3000 500
H = = 875 Hp
1714
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q 2
= .......................................... (31)
8 1000 A 2
where,
= pressure drop, psi
= mud density, ppg
A = total cross sectional area of nozzles, in2
where,
A = the cross sectional area of a nozzle, in2
q = the flow rate through a nozzle, gpm
q 3
H = ....................... (33)
138.83 10 6 A 2
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where,
q = flow rate, gpm
C = discharge coefficient (0.95)
= mud density, pcf
Pb = pressure drop across bit, psi.
Example
A 90 pcf mud is flowing through a bit having three 13/32 in nozzles at the rate of
400 gpm.
Solution
( 13 32 ) 2
a) Cross sectional area of one nozzle = = 0 . 129 in 2
4
Total area of nozzles = 3 .129 = 0.388 in2
90 400 2
From Eq (31) pressure drop across bit = = 1181 psi
81000 ( 0 .388 ) 2
400
b) Flow rate through one nozzle = = 133.3gpm
3
133 . 3
From Eq (32) velocity through a nozzle = = 331 . 5 ft / sec
3 . 117 . 129
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36 ,800
+ 1 1 .... (35)
d
V = 0.0561 a
s
s f
d
f S ( a ) 7.48 2 f
s
f d s
YP d s
Where a = PV for water based mud, for polymer based fluid, a = PV + 5 .
v
where,
f = fluid density, pcf
s = cutting density, pcf
PV = Plastic viscosity, cp
YP = Yield point, lb/100 ft2
v = annular velocity, ft/sec
a = apparent viscosity, cp
Example:
A surface hole is to be drilled to 3,500 ft. Many wells in the same area have experienced
loss circulation problems due to insufficient cuttings removal. If the chosen annular
velocity is 60 ft/min. will the hole be cleaned adequately?
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Solution:
Since the mud is water based, use the plastic viscosity as the apparent viscosity
Using Eq.12, PV = 52 - 31 = 21 cp
21 36 ,800 ( 0 . 25 ) 157 67
Vs = 0 . 0561 2 + 1 1 = 0 . 76 ft / sec
67 0 . 25 ( 21 ) 7 . 48 67
67 0 . 25
Since the chosen annular velocity will be 60 ft/min = 1 ft/sec, is greater than the slip
velocity the pump rate is sufficient to move the cuttings up hole and out of the annulus.
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d = ...................................... (36)
m+1
where P is the total pressure loss in the circulating system and Pd is the parasitic
pressure loss to and from the bit,
where,
Ps = Pressure loss in surface equipment
Pdp = Pressure loss in drill pipe
Pdc = Pressure loss in drill collars
Pdca = Pressure loss in drill collar annulus
Pdpa = Pressure loss in drill pipe annulus
m = constant approximately equal to 1.75
Since the total pressure loss is the pressure loss across the bit Pb plus the parasitic
pressure loss then for maximum horsepower at the bit the pressure drop across the bit
should be,
Pb = P - Pd
or
P
Pb = P -
m+1
mP
= ............................................. (38)
m+1
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Pb = P - Pd
2P
= P -
m+2
m
= P ......................................... (40)
m+ 2
As a rule of thumb bit power should be in the range of 2.5 to 5 HP per square inch of bit
area. In hole sizes 12 " and greater bit power of 5 to 6 HP/ in2 may be used.
The engineer should not be overly concerned about which criterion, bit power or impact
force is best. There is not a great difference in the application of the two procedures. If
the bit horsepower is maximum the jet impact force will be within 90% of the maximum
and vice versa.
Graphical Solution
The selection of bit nozzle sizes can be simplified by graphical techniques. In the case of
turbulent flow the parasitic pressure loss in the drill string can be represented by the
equation
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Shown in Fig (9) is a summary of the conditions for the selection of bit nozzle sizes using
the various hydraulic parameters. The conditions for proper pump operations and bit
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nozzle sizes occur at the intersection of the parasitic pressure loss line and the path of the
optimum hydraulics. The path of optimum hydraulics has three straight-line segments as
shown in Fig(9). Segment 1, defined by q = qmax, corresponds to the shallow portion of
the well where the pump is operated at maximum rate and pressure for the convenient
pump liner size and horsepower rating. Segment 2, defined by constant parasitic pressure
loss Pd, corresponds to the intermediate portion of the well where the flow rate is
reduced gradually to maintain Pd / Pmax at the proper value for maximum bit hydraulic
horsepower or impact force. Segment 3, defined by q = qmin, corresponds to the deep
portion of the well where the rate is reduced to the minimum value that will efficiently
lift the cuttings to the surface. In Fig (9), the intersection of the parasitic pressure loss
line and the path of optimum hydraulics occurs in Segment 2. This corresponds to bit at
intermediate depth. Since parasitic pressure loss increases with depth, a shallow bit run
would intersect in Segment 1 and a deep bit run would intersect in Segment 3. Once the
intersection point is obtained the proper flow rate, qopt is read from the graph. The proper
pressure drop across the bit corresponds to Pmax - Pd on the graph at the intersection
point. The proper nozzle area is calculated from the equation
q opt
2
Example
Determine the proper pump operating conditions and bit nozzle sizes for maximum jet
impact force for the next bit run given the following:
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Solution
The two parasitic pressure loss values are plotted on log-log paper to define the parasitic
pressure loss line.
lo g 9 0 6 lo g 4 0 9 0 .3 4 5
m = = = 1 .1 8
lo g 4 8 5 lo g 2 4 7 0 .2 9 3
Segment 1
q
Hp =
1714 E
1714 H p E 1714 1250 .91
qmax = = = 650 gpm
Pmax 3000
Segment 2
Segment 3
qmin = 225 gpm
The path of optimum hydraulics is determined by plotting the three segment lines as
shown is Fig (10).
It can be seen that the path of optimum hydraulic line intersects the parasitic pressure loss
line in Segment 1 at
qopt = 650 gpm
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Thus
Pb = 3000 - 1300 = 1700 psi
q 2
Aopt = 2
= 0.47 in2
C Pbopt 90000
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In the previous example the impact force criterion was not used to select the nozzle size
because the segment 2 line which represents the conditions of maximum impact force did
not intersect the parasitic pressure loss line. If the impact force criterion were used, the
parasitic pressure loss would be 1886 psi. From the graph, the corresponding rate is 850
gpm. The pump pressure required to deliver 850 gpm is,
1714 EH P
P =
q
72 850 2
A = = 1.25 in2
( 0 .95 ) 2 407 90000
The use of the impact force criterion in this example provides a higher pumping rate.
However, a high rate does not always mean better cleaning. The high rate resulted in a
larger nozzle area of 1.25 in2 and thus a lower bit pressure drop of 407 psi and a lower
impact force of 920 lb compared to 1438 lb impact force obtained by using the qmax
criterion. This shows that the qmax criterion is the correct method to use in this example.
Example
Estimate proper pump operating conditions and bit nozzle sizes for maximum bit
horsepower while drilling at 2000 ft and 5000 ft. The well plan calls for the following
conditions:
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Pump
1000 psi maximum surface pressure at 1000 ft.
1500 psi maximum surface pressure at 5000 ft.
800 hp maximum horsepower input.
0.90 pump efficiency.
Drill string
5 19.5 #/ft (4.276 in ID) drill pipe
600 ft of 9 in OD x 2.5 in ID drill collars for 17.5 in hole
600 ft of 6 in OD x 2.5 in ID for 8 hole
Surface Equipment
Equivalent to 580 ft of 5 DP
Hole Sizes
Mud Properties
600 300
Depth Mud Weight, pcf Reading Reading
2000 64 29 22
5000 75 38 27
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Solution
29
= 3.32 log = 0.398
22
510 300 510 x 22
K = = = 937 .6
511 n
511 0 .398
From Eq (24)
0 .398
11912 64 11.17 1.602 .0416 4 .276
NR =
937.6 3+ 1
.398
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f v 2 L
=
1 93 d
. 004 64 11 . 17 2 1400
=
193 4 . 276
= 55 psi
From Eq (23)
. 398
14572 6 4 0.906 1.602
. 0208 (17 . 5 9 )
NR =
937.6 1
2+
. 398
= 237 (flow is laminar)
From Eq (22),
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.398
1
2+
937 .6 .906 .398 .398
.0208
Pressure loss = 600
144000 (17 .5 9 ) 1 .398
= 1.6 psi.
.398
1
2+
937.6 .726 .398 .398
Pressure loss = 1400
144000 (17.5 5)1.398 .0208
= 1.997 psi
Pressure loss in surface equipment is equivalent to pressure loss in 500 ft of drill pipe,
53 . 8 580
Pressure loss = = 22 . 2 psi
1400
Parasitic pressure loss at 500 gpm = 53.8 + 228 + 1.6 +1.99 + 22.2 = 307.6 psi
The above calculations are repeated for a flow rate of 700 gpm
The parasitic pressure loss at 700 gpm = 502 psi
The parasitic pressure loss is plotted versus rate on log-log paper in Fig (11).
The slope of the line is,
log 502 log 307 .6
m = = 1.455
log 700 log 500
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Segment 1
1714 H p E 1714 800 .9
qmax = = = 1234 gpm
Pmax 1000
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Segment 2
From Eq (34) for optimum bit horsepower the parasitic pressure loss is,
1 1000
Pd = P m ax = = 407 psi
1 + 1.455 2 .455
Segment 3
For a minimum annular velocity of 55 ft/min, the minimum flow rate is,
(
qmin = 2.448 v d 22 d 12 )
where v is in ft/sec.
Therefore,
55
qmin = 2.448
60
(
17 .5 2 5 2 )
= 630 gpm
The path of optimum hydraulics is plotted in Fig (11). Note that the path intersects
the parasitic pressure loss line at qmin = 630 gpm. Therefore, the optimum pumping
rate should be 630 gpm.
The parasitic pressure drop at 630 gpm is 425 psi (from graph).
64 630 2
Aopt = = 0 .737 in 2
0 .95 2 575 90000
0 .737
Area of one nozzle = = .246 in 2
3
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4A 4(.246)
Diameter of nozzle = = = 0.56 in
3.14 3.14
= 1 8 3 2 in
Parasitic pressure losses are calculated at 500 and 700 gpm using power-law model.
600
n = 3.32 log
300
38
= 3.32 log = 0.492
27
f = 0.0048
f v 2 L
Pressure loss =
193 d
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f = 0.0032
From Eq (25)
.492
14572 75 6.154 1.508 .0208(8.5 6.25)
NR =
640.4 1
2+
.492
= 2934 (turbulent flow)
f = 0.007
From Eq (27),
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500
v = = 4.32 ft/sec.
2 .4 4 8 ( 8 .5 2 5 2 )
.4 9 2
14572 75 4.32 1.508 .0 2 0 8 (8.5 5 )
NR =
640.4 1
2+
0 .4 9 2
= 2139 (flow is laminar)
From Eq (23),
.492
1
2+
640 .4 ( 4 .32 ) .492 .492 4400
. 0208
Pressure loss =
1 .492
144000 (8 .5 5 )
= 82 psi
Pressure loss in surface pipe is equal to pressure loss in 580 ft of 5 drill pipe
239 580
Presssure loss = = 31 . 5 psi
4400
The parasitic pressure losses at 500 and 700 gpm are plotted on log-log paper in Fig
(12).
log1192 log706
m = = 1.553
log700 log500
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Segment 1
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Segment 2
For optimum bit horsepower the parasitic pressure loss is,
1 Pm ax
d = = 587 psi
1 + 1.553
Segment 3
Minimum flow rate is,
120
q min = 2 .448
60
(8 .5 2 5 2 ) = 231 gpm
The path of optimum hydraulics is plotted in Fig (12). The path intersects the
parasitic pressure loss line at qopt = 445 gpm and parasitic pressure loss Pd of 587
psi.
Pbit = Pmax - Pd
= 1500 - 587
= 913 psi
75 445 2
Aopt = = 0 . 446 in 2
0 . 95 2 913 90000
0 .4 46
Area of one nozzle = = 0 .14 9 in 2
3
4 . 149
Diameter of nozzle = = 0 . 435 in
3 . 14
14
= in
32
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Example
a) In the previous example calculate the bit horsepower per square inch while drilling at
5000 ft
b) If the maximum pressure is maintained at 1500 psi, would increasing the pumping
rate from 445 to 600 gpm increase the bit horsepower?
Solution
a) The bit horsepower is calculated by using Eq (33),
3
q 3 75 445
H = 6 2
= 6 2
= 265 H
1 38 .83 10 A 1 38 .83 10 .0446
x 8 .5 2
Area of bit = = 56.7 in2
4
265
Bit horsepower/in2 = = 4.7 hp/in2
56 .7
b) From the graph in Fig (12), the parasitic pressure loss at 600 gpm is 940 psi.
75 600 3
H = = 218 hp
138.83 10 6 ( .95 ) 2 ( .77 ) 2
218
Bit Horsepower/in2 = = 3.85 hp/in2
56.7
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Therefore, the bit horsepower would decrease from 4.2 to 3.46 hp/in2 if the pumping rate
is increased from the optimum rate of 445 to 600 gpm. This shows that the maximum bit
horsepower that can be obtained is 4.2 hp/in2 at an optimum pumping rate of 445 gpm.
Increasing or decreasing the pumping rate (while maintaining maximum pressure of 1500
psi) would give less horsepower at the bit.
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Example
A well is being drilled at 5000 ft using 10 ppg mud and three 14/32 (0.4375) nozzles.
The driller recorded that when the mud is pumped at 500 gpm a pump pressure of 1860
psi is observed, and when the rate is increased to 700 gpm a pump pressure of 3470 psi is
observed. (a) Calculate the parasitic pressure loss at each pump rate, (b) Calculate the
slope of the parasitic pressure loss line.
Solution
3.14 .4375 2 3
a) Total area of nozzles = = 0.450 in2
4
q 2
P =
8100 A 2
75 500 2
=
81000 .45 2
= 1267 psi
75 700 2
= = 2482 psi
81000 .45 2
0 . 222
=
0 . 146
= 1.5
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INTRODUCTION 1
CASING DESCRIPTION 2
DIAMETER 2
LENGTH RANGE 2
API CASING & TUBING WEIGHT DESCRIPTION 3
CASING GRADES 4
- PROPERTIES OF TUBULAR MATERIAL 4
YIELD STRENGTH 4
HARDNESS OF STEEL 5
HEAT TREATMENTS 6
CHEMICAL COMPOSITION 7
- API CASING GRADES 8
- NON-API CASING GRADES 9
- SAUDI ARAMCO NON-API CASING GRADES 10
CONNECTIONS 11
API CASING CONNECTIONS 11
SAUDI ARAMCO API CASING CONNECTIONS 11
- API SHORT / LONG THREAD & COUPLING 11
- API BUTTRESS THREAD & COUPLING 12
PROPRIETARY CONNECTIONS 13
SAUDI ARAMCO PROPRIETARY CONNECTIONS 13
- VAM CONNECTION 13
- NS-CC CONNECTION 14
- VETCO LS, RL-4S, & DRIL-QUIP S-60 CONNECTIONS 14
CORROSION 16
CORROSION MITIGATION 16
SULFIDE STRESS CRACKING 17
SAUDI ARAMCO APPLICATIONS IN H2S SERVICE 19
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TYPES OF CASING 28
CONDUCTOR CASING 28
SURFACE CASING 28
INTERMEDIATE CASING 28
LINER 28
PRODUCTION CASING 28
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CASING DESIGN
INTRODUCTION
From the earliest days of wells dug in the ground for various purposes, the need for some
means of supporting the walls of the hole has been recognized. Many wells of ancient
times were lined or cased with rock. Over the years casing technology has developed
from rock to plaster to wood and then to steel. The functions of casing can be
summarized as follows:
1. To keep the hole open and to provide a support for weak, or fractured formations. If
the hole is left uncased, the hole may fall in and the redrilling of the hole may become
necessary.
2. To isolate porous media with different fluid/pressure regimes from contaminating the
pay zone. This is basically achieved through the combined presence of cement and
casing, so production from a specific zone can be made.
4. To provide a passage for oil and gas; most production operations are carried out
through special tubing which is run inside the casing.
5. To provide a suitable connection with the wellhead equipment (e.g. christmas tree).
The casing also serves to connect the blowout prevention equipment which is used to
control the well while drilling.
6. To provide a hole of known diameter and depth to facilitate the running of testing and
completion equipment.
By the year 1900 the regular oil field products had been reasonably well standardized.
The earliest American Petroleum Institute (API) specifications on oil well casing were
issued in 1924. Beginning about 1930 and continuing for the next several years,
specifications were published in several issues of API standards 5-A to cover lengths,
sizes, weights, threads, joints, and grades of the steel. In the following years many
improvements have been made in thread and coupling design as well as higher pipe
grades.
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CASING DESCRIPTION
Diameter
There are three types of diameter designations. They are outer diameter, inner diameter
and drift diameter. The outer diameter is the diameter of the casing measured from outer
wall across to outer wall and is the diameter measurement casing is identified with. The
inner diameter is the diameter of the casing measured from inner wall to inner wall. The
third type of diameter is the drift diameter, which is the guaranteed minimum diameter of
the casing, the drift diameter is important because it indicates whether the casing is large
enough for a specified size of bit to pass through.
Length Range
API has established three length ranges with limits and tolerances as shown below. API
specifications for casing and tubing designate the length range of each joint. There are
three length ranges for casing:
Casing is mostly run in R-3 lengths. These longer lengths reduce the total number of
threaded connections needed for the casing string. Since casing is usually run in single
joints (instead of doubles or triples), the longer R-3 lengths are easier to handle.
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Plain-end weight per foot is the weight per foot of the pipe
body excluding the threaded portion and coupling.
The plain end weight of casing can be calculated by knowing the outer and inner
diameter of the pipe and the density of steel (489 lb/ft3):
W (lb/ft) =
4 144
(
De 2 Di 2 489)
( 2 2
)
= D e D i 2.67 . . . . . . . . . . . . .. . . . . . . . . . . .(1)
where,
De: outside diameter, in.
Di: inner diameter, in.
The difference between nominal weight and average weight is generally small and most
design calculations are performed by using nominal weight per foot.
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Casing Grades
Steel pipe grades are identified by letters and numbers which indicate various charac-
teristics of the pipe steel. It is a specification according to its yield stress, ultimate tensile
strength, chemical composition, heat treatment or other characteristics. There are many
grades of steel that make up oilfield tubulars.
Yield Strength
The strength of a steel is usually indicated by its minimum yield strength or ultimate
tensile strength. Casing and tubing are manufactured mostly from ductile steels. Whereas
brittle steels fracture without appreciable deformation, ductile steels can withstand
significant plastic deformation prior to fracture.
Axial strain is defined as the ratio of the test sample axial elongation to the original
length of the sample:
Hooke's Law defines stress as the product of the elastic constant or Young's modulus
of elasticity (E) and strain:
Stress = E x strain
6
Young's Modulus for steel is typically 30 x 10 psi.
Figure 1 is a stress-strain diagram for a typical ductile steel. Point 'A' represents the yield
strength or elastic limit of the steel. If the steel is stressed below the elastic limit, it will
return to its original shape upon unstressing or unloading the test sample. Below the
elastic limit, the stress-strain curve is linear.
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The API specifies that the yield stress (yield strength) is the tensile stress required to
produce a total elongation of 0.5% of the tensile test sample length. This is shown by
point 'B' in the diagram. Stresses greater than the elastic limit cause permanent
deformation of the steel and the steel will not return to its original shape when the load is
taken away.
If a steel is stressed beyond its yield strength, it will deform plastically until its ultimate
strength is reached as shown by point 'C'. The ultimate strength is the maximum stress
that the steel can sustain before it begins to fail. Beyond this point the material will
continue to deform plastically (with a reducing stress) until complete failure (breakage)
occurs as shown by point 'D'.
STRESS
(psi)
A - Elastic Limit
B - API Specified Minimum Yield
C - Ultimate Strength
D - Failure
STRAIN (%)
0.5%
Hardness of Steel
Hardness is the measure of a steel's yield point in compression. When a material is
required to resist wear, corrosion, erosion or plastic deformation, it may be necessary to
specify a specific hardness. Hardness generally increases with increasing material
ultimate tensile strength. Very hard materials are brittle and will crack or fracture easily.
Hardness is determined by a test where a load is applied with a small ball or pointed
object. The hardness of the material is then expressed by the depth of the indentation
caused by the pointed object. The "Rockwell C", "Brinell", or Charpy hardness scales
are used to quantify the degree of hardness of an oilfield tubular material. Hardness can
be expressed by a Charpy Impact Test, where a weighted pendulum is dropped onto a
sample and the amount of impact it takes to break the sample is measured. This amount
of impact must exceed a minimum standard.
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Heat Treatments
Mechanical properties of steel such as yield stress, ultimate tensile strength, ductility, or
hardness can be achieved by controlling the heat treating portion of the manufacturing
process and chemical composition of the steel. Heat treating affects changes in the
microstructure, or grain structure of the steel which directly affects its mechanical
properties. Heat treating is an operation involving heating and/or cooling the solid steel
tubular to develop the desired steel microstructures.
Normalizing
The steel is heated to 1600-1700 oF and then cooled in air to produce a uniform
microstructure and to alter mechanical properties.
Hot Rolled
The tubing or casing is shaped or rolled to the desired OD at a very high temperature.
Hot rolling does not cause changes in the microstructure as in the cold rolling process
above. Hot rolling produces a steel similar to the normalized condition.
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Chemical Composition
The chemical composition of steel directly affects all of its mechanical properties and
corrosion resistance. Steels can be classified according to chemical composition as
follows:
Carbon Steels
These steels are considered to be a mixture of iron and carbon with up to 2% carbon
content. The high carbon steels contain up to 2% carbon, like J-55, while the low
carbon steels, like L-80, contain as low as 0.25% carbon. Carbon steels can contain
other elements such as manganese or silicon in small quantities. Most tubulars are
made of carbon steel.
Alloy Steels
These steels contain significant quantities of alloying elements other than carbon. A
steel is considered an alloy steel when the content of either manganese, silicon or
copper exceeds 1.65%, 0.6% and 0.6% respectively. A steel is also considered an
alloy if there is a minimum content specified for aluminum, boron, cobalt, chromium,
niobium, molybdenum, or nickel. Alloy steels are less susceptible to corrosion and
more expensive than carbon steel.
Low-Alloy Steels
Low-alloy steels contain less than 5% metallic alloying elements.
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The grade of steel is denoted by a letter of the alphabet followed by the minimum yield
stress of the particular steel. For example, the API grade L-80, which is a common grade
used by Saudi Aramco, has a minimum yield stress of 80,000 psi as shown by point "A"
in Figure 2. In other words, it can support a stress of 80,000 psi with an elongation of
0.5%.
STRESS
(psi)
B - API Specified Maximum Yield
95,000
80,000
C - API Minimum Ultimate Strength
STRAIN (%)
0.5%
The 'L' is a distinguishing prefix to avoid confusion between different steel grades. The
letter in conjunction with the number designates such parameters as the maximum yield
strength and minimum ultimate yield strength. In L-80 the maximum yield strength is
shown by point "B" as 95,000 psi which is 15,000 psi higher than the minimum yield
stress. The minimum ultimate strength is shown by point "C" as 95,000 psi. Note that
there is no maximum ultimate strength specified.
N-80, another API grade (see Figure 3), also has a minimum yield stress of 80,000 psi,
but is different from L-80 in that the former has a greater maximum yield stress of
110,000 psi (shown by point "B"). This is 30,000 psi higher than the minimum yield
stress and twice the tolerance of L-80. The minimum ultimate strength of 100,000 psi is
also higher as shown by point "C". Whereas N-80 has no hardness specification, L-80 has
a hardness specification of 23 HRC. The tight tolerance on yield strength and hardness
allow the L-80 to be more suitable for H2S service than N-80 grade tubulars.
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STRESS
(psi) B - API Specified Maximum Yield
STRAIN (%)
0.5%
Casing sizes 24" and larger commonly have grade designations such as X-42, X-56, X-
60, and B. These are API designations specified under the Line Pipe Specifications.
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The rating of these proprietary products are generally calculated using API formulas or
are consistent with API methods. Also, such parameters as drift diameter, wall thickness
tolerance, length range, and weight tolerance are kept the same as, or are consistent with
API specifications.
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CONNECTIONS
Oilfield tubulars may be equipped with plain ends (no threads), have API specified
threaded connections or proprietary (non-API) threaded connections.
With the exception of Extreme-Line, male (or pin) threads are machined on plain-end
pipe and later made up with a coupling.
A reduced OD (special clearance) coupling is offered on some sizes and weights to allow
for additional clearance between pipe and hole. While providing this additional
clearance, special clearance couplings often reduce the rating of the connection, usually
in tension or internal yield and test pressure.
EXTERNALLY THREADED PIN
Saudi Aramco API Casing
INTERNALLY THREADED COUPLING (BOX)
Connections
Several API connections are used in
Saudi Aramco drilling and
workover operations. A brief ROUND
description of the most popular CRESTS 60 deg
AND
connections used are as follows: ROOTS
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The STC design is the same except that the coupling and the threaded pins are shorter.
This design is externally threaded on both ends of a non-upset pipe. The single lengths
are joined with an internally threaded coupling.
The thread profile has rounded threads and roots with a 60 angle between the thread
flanks as shown in the figure. The thread density is 8 threads per inch (8 RD) on a 0.0625
inch per inch taper. When the coupling is made up, small voids exist at the roots of each
thread. Thread compound must be used to fill these voids in order to obtain a seal. LTC is
not made in casing sizes larger than 13-3/8 because of the possibility of joint pull-out
that can occur with the heavier weight casing.
Figure 5 shows the BTC design. This design is externally threaded on both ends of a non-
upset pipe (as in the STC and EXTERNALLY THREADED PIN
LTC). The single lengths are INTERNALLY THREADED COUPLING
joined with an internally
threaded coupling.
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Thread compound must also be used in order to obtain a seal with BTC. BTC is also run
in horizontal wells where doglegs can cause high bending loads on the larger size
casings. But BTC leak resistance is lower that that of LTC and STC.
Proprietary Connections
Proprietary connections are available which offer premium features not available on API
connections.
TORQUE SHOULDER
VAM Connection
A proprietary connection which METAL TO METAL
is very popular with Saudi SEAL FACE
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make up torque and a non-turbulent bore (see Figure 6). It has become a standard
completion tubing for the high pressure Khuff gas wells. Also, due to its superior joint
and bending strength, it is used as the completion liner for the horizontal wells.
NS-CC Connection
The NS-CC (Nippon Steel Connection for Casing) is a proprietary connection used by
Saudi Aramco in the Khuff Gas wells (see Figure 7). It is stocked in 7", 9-5/8" and 13-
3/8" sizes. This connection is noteworthy for its gas leak tightness, low hoop stress, high
joint strength (equivalent to API buttress thread), high collapse strength and easy
stabbing design. Its two step pin nose which incorporate a primary and reserve torque
shoulder and metal to metal seal make it a good candidate for the deep, high temperature,
high pressure Khuff Gas service.
TWO-STEP PIN NOSE DESIGN
pin/box mating shoulder has a 30 degree taper (see Figure 8). This results in the open end
of the box being captured by the tapered shoulder of the pin, and prevents the box from
ballooning at the pin/box interface during periods of high internal pressure and large
bending moments.
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REVERSE SHOULDER
"O" RING SEAL ON PIN
ELEVATOR SHOULDER
FIGURE 8
The Vetco RL-4S connection features dual stabbing guides and a high stab angle for easy
stabbing. Self locking, four start thread forms allow fast quarter-turn makeup.
The Dril-quip S-60 connection features easy stabbing, no cross-threading, fast makeup,
low torque and high pressure sealing. Both of these connections save rig time and are
used in 24 and larger casing sizes.
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CORROSION
The presence of CO2 and H2S accompanied by water, can cause corrosion of the exposed
tubulars. In addition, H2S can cause stress corrosion cracking.
Corrosion Mitigation
When CO2 or H2S are dissolved in water, they will create an acidic solution. These
solutions react with the iron in the pipe causing local pitting which can eventually eat a
hole in the pipe. Some of the ways of combating this corrosion are as follows:
1. Plastic Coatings
Plastic coating on the pipe which is exposed to the produced fluids is one method
of corrosion prevention. There are a variety of coating materials and thicknesses
for the different chemical components and temperatures of the produced fluid.
The application of a coating to the inside of the pipe can reduce its effective drift
diameter. This will make it necessary to coordinate the plastic coating thickness
with the proposed through tubing work.
Saudi Aramco carries a stock of internally plastic coated (IPC) tubulars in the 4-
1/2" and 7" sizes.
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Saudi Aramco maintains a stock of 4-1/2", 7" and 9-5/8" high alloy Chrome-13
tubulars for use in the gravity water injection wells (see section entitled
"Properties of Tubular Materials" for more information about CR-13 casing).
3. Chemical Inhibition
An inhibitor may periodically be pumped into a well to form a film on the pipe.
This treatment is being performed in Wasia water supply wells. If there is no
means to circulate down the inhibitor while producing the well, it will be
necessary to shut in the well and pump down the tubing. In a gas lift installation,
the inhibitor may be pumped into the gas system. Where wells are completed with
concentric strings, the inhibitor can be continuously pumped down one string,
with the produced fluid carrying the inhibitor into the other string.
In order to prevent stress corrosion cracking in tubulars due to the presence of H2S,
certain design criteria can be applied.
1. Steel Properties
One of the principal factors governing the resistance of tubulars to stress
corrosion cracking is the physical properties of the steel. Through extensive
testing it has been determined that the higher strength carbon steels are more
susceptible to sulfide stress cracking.
The API Specification 5CT lists two steel grades, L-80, and C-95 which have a
restricted yield strength range of 15,000 psi. This restricted range has the net
effect of holding down the maximum strength of the steel while maintaining an
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In addition to the API grades, there are proprietary grades used in H2S service.
Most of these have a minimum yield strength from 80,000 psi to 90,000 psi, with
a controlled yield strength range of 15,000 psi. This is the same range as API
restricted yield grades.
2. Temperature Susceptibility
Another factor in susceptibility of tubulars to sulfide stress cracking is the
temperature of the steel when it is exposed. It has been shown that at elevated
temperatures, the higher strength steels are not susceptible to sulfide stress
cracking. NACE Specification MR-10-75 refers to the use of API grade, P-110
and proprietary grades to a maximum 140,000 psi yield strength in an H2S
environment where the temperature during exposure is not less than 175 F. The
use of API grades N-80, C-95 and proprietary grades up to a maximum yield
strength of 110,000 psi can be used in temperatures above 150 F.
3. Other Factors
Other factors effecting sulfide stress cracking are the level of stress in the steel
and the time of exposure. Lower stress levels reduce the chance of sulfide
cracking. The steel chemical and mechanical properties, in addition to the time
and temperature at exposure and the tensile stress level, determine the
susceptibility of the steel to sulfide stress cracking.
4. Design Considerations
In deep, high pressure gas wells where both internal pressure and tension would
normally require high strength steels, design of casing and tubing strings becomes
difficult with the restriction of the minimum yield strength to 90,000-95,000 psi
in an H2S environment. Application of restricted yield strength steel grades
dictates thicker-wall pipe in order to handle the high tension and internal pressure
loads. A well with a high bottom hole temperature can use P-110 and/or X-125
casing and P-105 tubing in the lower section of the hole up to a point where the
static
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By using high strength steel on the bottom, the wall thickness can generally be
reduced, thus decreasing the total weight of the string. This is particularly
important with the upper section of the string requiring lower strength steel, the
reduced weight on the bottom sections will further reduce the weight required at
the surface.
Proprietary (non-API) grades such as C-95VTS, and NT-90HSS are also used in
Saudi Aramco high pressure sour Khuff gas applications where a high yield
strength is required.
With the large expense of tubular products to drill and complete an oil or gas well, it is
important that the proper shipping, handling, storage, and running practices be followed
to ensure that the investment made in tubulars yields its maximum benefit. Leaky joints
are one cause of trouble which can be attributed to many forms of improper care.
API Recommended Practice for Care and Use of Casing and Tubing (RP-5C1) lists
common causes of trouble for casing and tubing. Of these, over half are related to poor
shipping, handling, and running practices.
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Burst
The burst loads on the casing must be evaluated to ensure the internal yield resistance of
the pipe is not exceeded. The burst load is the force applied by the fluid inside the casing
which acts to rupture the pipe in the absence of external pressure. The loads are normally
caused by mud hydrostatic pressure inside the casing and perhaps some surface pressure.
Fluids on the outside of the casing, called back-up fluids, supply a hydrostatic pressure
that helps resist pipe burst. The resulting effective burst pressure is the internal pipe
pressure minus the external pressure. Burst conditions are established and the least
expensive pipe that will satisfy the burst pressure is tentatively selected. The API burst
pressure rating of casing is given by:
Y t
Pi = 1.75 m (2)
De
Where Ym is the minimum yield strength of the pipe, t is the wall thickness in inches and
De is the outer diameter in inches.
Example:
Solution: From Table 2, Ym for J-55 casing is 55,000 psi. The ID of 7 23# casing in
7 6.366
6.377, therefore, t = = 0.317 in.
2
0.317
Pi = 1.75 55,000 = 4360psi
7
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Collapse
The primary collapse loads are supplied by the column of fluid on the outside of the
casing which act to collapse the pipe. These fluids are usually the mud and possibly the
cement slurry in which the casing was set. Since the column of mud increases with depth,
collapse pressure is the highest at the bottom of the hole section and is zero at the surface.
The formula to calculate the hydrostatic pressure acting at a particular depth is:
where m is the density of the fluid in pcf, and h is depth in feet. Never allow the
hydrostatic pressure to exceed the collapse rating of the casing. The worst case design
conditions are when the casing is void of fluid and the external force (collapse load) is
the maximum mud weight when the casing was run. In designing for collapse, the casing
is assumed empty for surface casing, production casing and partially empty for
intermediate casing. Once the casing is cemented and the cement is set the cement acts to
help increase the collapse resistance. There are four formulas to calculate the collapse
rating of casing (Pc) depending on the ratio of the pipe outer diameter to wall thickness.
For:
Table 3
Grade D/t Ratio
H40 16.44 and less
J & K55 14.8 and less
C75 13.67 and less
N80 13.38 and less
C95 12.83 and less
P105 12.56 and less
P110 12.42 and less
Pc = 2Ym[((D/t)-1)/(D/t)] (4)
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For:
Table 4
Grade A B C D/t Ratio
H40 2.95 0.0463 755 16.44 to 26.62
J & K55 2.99 0.0541 1205 14.8 to 24.99
C75 3.06 0.0642 1805 13.67 to 23.09
N/L80 3.07 0.0667 1955 13.38 to 22.46
C95 3.125 0.0745 2405 12.83 to 21.21
P105 3.162 0.0795 2700 12.56 to 20.66
P110 3.18 0.082 2855 12.42 to 20.29
Pc = Ym[A/(D/t)-B]-C (5)
For:
Table 5
Grade A B D/t Ratio
H40 2.047 0.03125 26.62 to 42.7
J & K55 1.99 0.036 24.99 to 37.2
C75 1.985 0.0417 23.09 to 32.05
N80 1.998 0.0434 22.46 to 31.05
C95 2.047 0.049 21.21 to 28.25
P105 2.052 0.0515 20.66 to 26.88
P110 2.075 0.0535 20.29 to 26.2
Pc = Ym[A/(D/t)-B] (6)
And for:
Table 6
Grade D/t Ratio
H40 42.7 and greater
J & K55 37.2 and greater
C75 32.05 and greater
N80 31.05 and greater
C95 28.25 and greater
P105 26.88 and greater
P110 26.2 and greater
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Example:
A string of 9-5/8 53.5# L-80 casing is to be set in 75 pcf mud at a depth of 6000 ft. Calculate
the collapse rating for this casing, assume that the casing is empty. Then determine if the
casing can safely be set to this depth in order to satisfy a safety factor for collapse of 1.125.
Ym = 80,000 psi, ID = 8.535 in.
Therefore since the collapse load at 6000 (3125 psi) is less than the allowable collapse
(5880 psi), then it is safe to run.
Tensile Force
The tensile load of the pipe is the weight of the casing which acts to pull the pipe apart.
The tension is always the greatest at the surface and decreases with depth due to the
casing weight below the point of interest. In designing a casing string the upper most
joint of the string is considered to have the maximum load on it since it has to carry the
total weight of the casing string. Tensile loads are used to select pipe couplings.
Tension loads are computed using the buoyant forces acting on the pipe and the pipe
weight. The buoyancy force acts on the bottom joint of the casing and results in a
reduction in the hanging weight of the casing. The buoyant forces are defined as the
forces acting on submerged equipment due to hydrostatic pressure. The weight of the
casing in fluid is given by:
MW
Wf = Wa 1
489
where,
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Example:
Calculate the body yield strength of 7 in, 26-lb/ft J-55 casing with long threads &
couplings (LT&C).
Solution:
To calculate the joint strength of a given thread depends on grade, size and weight of the
casing and on the effective size of the threads. Formula (9) is for minimum strength of a
joint failing for fracture and formula (10) is for minimum strength for a joint failing for
thread pullout. The lesser of the two values govern.
0.74D 0.59 U p Yp
Pullout strength: Pj = 0.95A jp L + (10)
0.5L + 0.14D L + 0.14D
where:
Pj = minimum joint strength, lb.
Ajp = cross sectional area of pipe under the last perfect thread at pin, sq. in.
= 0.7854 [(D-0.1425)2-d2] for eight round threads
D = nominal outside diameter of pipe, in.
d = nominal inside diameter of pipe, in.
L = engaged thread length, in.
Yp = minimum yield strength of pipe, psi.
Up = minimum ultimate strength of pipe, psi.
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Biaxial Effects
The combination of stresses due to the weight of the casing and external pressures is referred
to as biaxial stresses. Biaxial stresses can reduce collapse resistance of the casing and must
be accounted for in designing deep wells. The collapse resistance, Pcc under tensile loading is
given by the following formula:
WPc (AYm)
2
Pcc = 4 3 1 (11)
2AYm W
Where Pcc = minimum collapse pressure under axial tension stress (psi); Pc = collapse
resistance with no tensile load (psi); W = weight supported by the casing (lb) ; Ym = average
yield stress of steel (psi) with zero load, A = cross sectional area.
Biaxial loading generates forces within the surfaces of the casing which reduce the casing
collapse but increase its burst resistance. This equation can be represented in tabular form,
showing the percentage reduction in collapse resistance for a given unit weight carried by the
casing, see below.
Table 8
Tensile ratio = weight carried Remaining collapse
yield strength resistance (%)
0 100.0
.01 99.5
.05 97.3
.1 94.5
.15 91.8
.2 88.5
.25 85.0
.3 81.3
.35 77.7
.4 76.0
.45 69.5
.5 65.0
.55 60.2
.6 55.8
.65 50.0
.7 44.5
.75 38.5
.8 32.0
.85 25.0
.90 17.8
.95 9.0
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1.0 0
To use Table 8, determine the ratio between the weight to be carried by the top joint of
the weakest casing and the yield strength of the casing. Then from the table determine the
corresponding reduction in collapse strength.
Example:
A 13-3/8 68# K-55 casing string with an average yield strength 1,069,000 lb, weighs
250,000 lb in air and is to be run in a well that contains 75 pcf mud. The ID of the casing
is 12.415 in. What is the corrected weight of the casing and what is the collapse rating
reduced due to biaxial loading?
Solution:
Corrected weight (W) is: 250,000 lb [1 - (75/490)] = 211,735 lb
The biaxial effect on the collapse rating of the pipe is: 211,735/1,069,000 = .198 and
looking at Table 8 on page 41 for this ratio we can see that the collapse resistance needs
to be multiplied by a 0.885 correction factor. So instead of a collapse rating of 1950 psi
for this casing, it is actually 1726 psi once the biaxial effect is included.
We can also solve this by using equation (11), where W = 211,735 lb; Pc = 1950 psi; and
Ym = 55,000 psi, A = t(OD-t) = 19.435 in2.
WPc (AYm) 211,735 1950 (19.435 55,000)
2 2
Pcc = 4
3 1 = 4 3 1 = 1728 psi
2AYm W 2 19.435 55,000 211,735
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SAFETY FACTORS
Exact values of loading are difficult to predict through out the life of the well. For
example, if mud of 75 pcf is on the outside of the casing during the running of the casing,
this value cannot be expected to remain constant for the entire life of the well. The mud
will become deteriorated with time and will reduce this value to perhaps a saltwater value
of 64 pcf. Therefore, calculations of burst values assuming a column of mud at 75 pcf
are not realistic throughout the life of the well. If the initial casing design is marginal,
then over a period of time in the event of a gas leak the casing may burst.
Since casing design is not an exact technique and because of the uncertainties in
determining the actual loadings as well as the deterioration of the casing itself due to
corrosion and wear, a safety factor is used to allow for such uncertainties in the casing
design and to ensure that the rated performance of the casing is always greater than any
expected loading. In other words the casing strength is always down rated by a chosen
safety factor value.
The safety factor is determined by the ratio of the body resistance to the magnitude of the
applied pressure.
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TYPES OF CASING
CONDUCTOR CASING
This string of casing serves several purposes. It prevents erosion around the rigs
foundation where the surface sand is weak, it makes the cellar more stable, provides a
good start for subsequent drilling and to circulate drilling fluids through to the surface.
The conductor casing setting depth is usually based on the amount required to prevent
washout of the shallow borehole when drilling to the depth of the surface casing and to
support the weight of the surface casing. The conductor also protects inner casings from
corrosion. A diverter can be installed on the conductor to divert flow in case of a shallow
kick. Normally when the surface sand is stable this string of casing is not necessary.
SURFACE CASING
This string of casing protects shallow fresh water sands from possible contamination, it
prevents cave-in of unconsolidated, weaker, near surface sediments and in the event of a
kick, it allows the flow to be contained by the BOPs. It also supports and protects from
corrosion any subsequent casing strings run in the well.
INTERMEDIATE CASING
Intermediate casing is similar to surface casing in that its function is to permit the final
depth objective to be reached safely. This casing string is run to isolate problem zones,
i.e. abnormal pressured, lost circulation, sloughing or caving zones between the surface
casing depth and the production casing depth. More than one intermediate string can be
set if necessary.
LINER
A liner is a different type of casing profile in that it does not extend from the bottom of
the well to the surface but is suspended from the bottom of the next largest casing string.
Normally it only extends a few hundred feet above the last casing shoe depth. A liner
can be used for drilling purposes to isolate problem zones or production or both. The
principal advantage of the liner is its lower cost.
PRODUCTION CASING
This string of casing is run across the production zone. Its purpose is to provide isolation
between zones and in case a tubing leak occurs, it will contain the production fluid until
remedial work can be performed to repair the leak. A typical casing configuration of an
Arab-D well is shown in Fig (9).
Figure 9
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DEPTH GEOLOGIC
TVD HORIZONS
725 KHOBAR
900 RUS 18-5/8" SURFACE CSG @ 950'' (50' INTO RUS)
1000
1125 UER
1500
2500
2650 L.A.S.
13-3/8" INTERMEDIATE CSG @ 2700' (50' INTO LAS)
3000
3500
3900 SHUAIBA
4000
4100 BIYADH
7" LINER HANGER @ 4200'
9-5/8" INTERMEDIATE CSG @ 4400' (300' INTO BIYADH)
4500
5000
5500
5760 SULAIY
6000 CEMENT
6500
7000
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S P
F= + (1 ) . . . . . . . . . . . . . . . . . . . . . . . . . .(12)
D D
where:
S
If the overburden stress gradient is assumed to be equal to 1.0 psi/ft, Eq. (12)
D
P
reduces to, F = + (1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(13)
D
The pore pressure and fracture pressure gradients can be expressed in terms of equivalent
mud density in pcf, by using Eq. 14.
Example:
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The static reservoir pressure (pore pressure) at 8000 ft is 3700 psi. What is the equivalent
mud density in lb/ft3 (pcf)?
Solution:
The pressure gradient is pressure divided by depth, or,
3700
Pressure gradient = = 0.46 psi/ft; and Equivalent Density = 0.46 x 144 = 66 pcf
8000
The pore pressure and fracture pressure gradients expressed in equivalent mud density
are plotted versus depth as shown in Fig. (10). A line representing the planned mud
density is also plotted. The planned mud density is chosen to provide trip safety margins
above the anticipated formation pore pressure, to allow for reductions in effective mud
weight created by upward drill pipe movement (swabbing) during tripping operations.
The safety margin allows for errors made in estimating the pore pressure. A commonly
used margin of error is 4 pcf or one that will provide 200-500 psi of excess (overbalance)
mud hydrostatic bottom hole pressure over the formation pore pressure. Similarly, a 4 pcf
kick margin is subtracted from the true fracture gradient line to obtain a design fracture
gradient line. If no kick margin is provided, it is impossible to take a kick at the casing
setting depth without causing a fracture and a possible underground blowout.
To reach the desired depth objective, the effective drilling fluid density shown at Point a
is chosen to prevent the flow of formation fluid into the wellbore. To carry this drilling
fluid density, without exceeding the fracture gradient of the weakest formation exposed
within the wellbore, the protective intermediate casing string must be extended to at least
a depth at Point b. This is, where the fracture gradient is equal to the mud density to drill
to Point a. Similarly, to drill to Point b and set intermediate casing, the drilling fluid
density shown at Point c will be needed and will require surface casing to be set at least
to the depth at Point d. If possible, a kick margin is subtracted from the true fracture-
gradient line to obtain a design fracture-gradient line. If no kick margin is provided, it is
impossible to take a kick at the casing-setting depth without causing a fracture and a
possible underground blowout.
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Conductor
9,000
15,000
Depth Objective Production
A
Other factors such as the protection of fresh ground water reservoirs, the presence of lost
circulation zones, pressure depleted zones that tend to cause pipe sticking problems, and
governmental regulations can also affect casing setting depths. Experience in some areas
might determine where the best casing seat might be in order to get a good cement job.
The conductor casing setting depth is based upon the amount require to prevent shallow
washout of the shallow borehole when drilling to the depth the surface casing is set and
to support the weight of the surface casing. The conductor casing must be able to sustain
pressures that might be encountered during diverting operations without washing out
around the outside of the conductor. The conductor is often driven into the ground with a
big hammer, the resistance of the ground determines how much conductor is set. The
casing driving operation is stopped when the number of blows per foot exceeds some
specified number.
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Example:
Solution:
1. Calculate the equivalent mud density for the pore pressure gradient:
PorePressure 457
Equivalent mud density @ 1000 = 144 = 144 = 65.8 pcf
Depth 1000
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Equivalent mud densities for the remaining depths are tabulated below. The planned mud
density is found by adding 4 pcf to the pore pressure equivalent mud density. Similarly,
the design fracture equivalent mud density is obtained by subtracting 4 pcf from the
fracture gradient equivalent mud density.
The pore-pressure equivalent mud density, the planned mud density, the fracture gradient
equivalent density and the fracture design equivalent mud density are plotted in Fig (11).
From the graph, it can be seen to drill to a depth of 15,000 ft, a 128.3 pcf mud will be
required (Point A). This, in turn, requires intermediate casing to be set at 11,700 ft (Point
B) to prevent fracture of the formation above 11,700 ft. Similarly, to drill safely to a
depth of 11,700 ft to set intermediate casing, a mud density of 110 pcf is required (Point
C). This requires surface casing to be set at 6,600 ft (Point D). Because the formation at
6,600 ft is normally pressured, the usual conductor casing depth of 180 ft is appropriate.
Surface casing is set at 2000 ft to protect the freshwater aquifers.
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2,000
4,000
Design Fracture
Gradient
6,000
D
Depth, ft
8,000
Fracture
Mud Density
Gradient
10,000
Pore
Pressure
C
12,000 B
14,000
Figure 11
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Table (9) provides commonly used bit sizes for drilling a hole which various API casing
strings generally can be placed safely without getting casing stuck. In Table (10) are casing
IDs and drift diameters for various standard casing sizes and wall thicknesses. The pipe
manufacturers assures that a bit smaller than the drift diameter will pass through every joint
of casing bought. In most instances, bits larger than the drift diameter but smaller than the ID
will also pass, but this is not good practice.
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Commonly Used Bit Sizes That Will Pass Through API Casing
Table 10
Casing Size OD Weight Per Internal Drift Common Bit Sizes
inches Ft, lb/ft Diameter, in Diameter, in inches
4 1/2 11.6 4.0 3.875 3 7/8
13.5 3.92 3.795 3 3/4
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The most commonly used bit sizes are highlighted in Tables 9 and 10. Selection of casing
sizes that permit the use of commonly used bits is advantageous because the bit
manufacturers make readily available a much larger variety of bit types and features in
these common sizes.
Example:
Using the data in the previous example, select casing sizes (ODs) for each casing string.
A 4-1/2 tubing size is required to produce the well at optimum flow rate.
Solution:
A 5-7/8 overshot fishing tool is required to catch the coupling on 4-1/2 tubing. The
overshot must be able to pass through the drift diameter of the production casing.
Therefore from Table (10), the 7 OD casing has drift diameters larger than 5-7/8. So a
7 OD production string is desired. From Table (9), a 8-1/2 bit is required to drill the
hole for 7 casing. From Table (10), the 9-5/8 casing is the smallest OD casing that has
a drift diameter larger than 8-1/2. Therefore the size of the intermediate casing string at
11,800 is 9-5/8. From Table (10), a 12-1/4 bit will pass through the drift diameter of
the 13-3/8 casing. A 17-1/2 bit is needed to drill the hole for the 13-3/8 casing.
Finally, Table (10) shows that a 17-1/2 bit will pass through 18-5/8 casing to be set at
2000.
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It is often impossible to predict the various loading conditions that a casing string will be
subjected to during the life of a well. The assumed design load must be severe enough
that there is a very low probability of a more severe situation actually occurring and
causing casing failure. When appropriate, the effects of casing wear and corrosion should
be included in the design criteria. These effects tend to reduce the casing thickness and
greatly increase the stresses where they occur.
The casing design criteria used by various drilling companies differ significantly and are
too numerous to include in this text. Instead, design criteria that are representative of
current drilling engineering practice are presented.
To achieve a minimum casing design, the most economical casing and coupling that will
meet the design loading conditions must be used for all depths. Because casing prices
change so frequently, a detailed list of prices in this text is not practical. In general,
minimum cost is achieved when casing with the minimum weight per foot in the
minimum grade that will meet the design criteria is selected. For this illustration, only
API casing and couplings will be considered in the example applications. It will be
assumed that the cost per foot increases with the burst strength and that the cost per
connector increases with increasing joint strength.
As stated before, casing strings serve several functions and therefore drilling conditions
for surface casing are different from that for intermediate casing or liners. Thus each type
of casing string will have different design criteria. General design criteria will be
presented for surface casing, intermediate casing and production casing.
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Surface Casing
Design loading conditions for surface casing are illustrated in Fig 10 for burst, collapse,
and tension considerations. The high internal pressure loading condition used for the
burst design is based on a well control condition assumed to occur while circulating out a
large kick. The high external pressure loading condition used for the collapse design is
based on a severe lost circulation problem. The high axial tension loading condition is
based on assumption of stuck casing while the casing is run in the hole before cementing
operations.
BURST COLLAPSE TENSION
Normal Press.
Empty
GAS
Mud
Lost Circ. Mud
Z
Gas
Kick
GAS
Lost Circulation
Fig. 10
Drilling casing design loads for burst, collapse, and tension
The burst design should insure that formation fracture pressure at the casing shoe will be
exceeded before the casing burst pressure is reached. Therefore, this design uses
formation fracture as a safety pressure release mechanism to assure that casing rupture
will not occur at the surface and endanger lives. The design pressure at the casing seat is
equal to the fracture pressure plus a safety margin to allow for an injection pressure that
is slightly higher than the fracture pressure. If the fracture gradient is not known, a
gradient of 1.0 psi/ ft may be safely assumed. The pressure inside the casing is calculated
assuming that all of the drilling fluid in the casing is lost to the fractured formation,
leaving only formation gas in the casing. The pressure at the surface is the bottom hole
fracture pressure plus a safety margin, less the hydrostatic pressure of the gas column. If
gas gradients are not known, it is practical to assume a minimum gas gradient of 0.10
psi/ft for pressures originally shallower than 10,000 ft and 0.15 psi/ft for pressure sources
deeper than 10,000 ft. If the formations below the surface casing do not have any gas,
then gradients of the formation fluids (oil or water) should be used. The external
pressure, or back-up pressure outside the casing that helps resist burst, is assumed to be
equal to the normal formation pore pressure. The beneficial effect of cement or higher
density mud outside the casing is ignored because of the possibility of both a locally poor
cement bond and mud degradation that occur over time. A safety factor of 1.1 is used to
provide an
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additional safety margin during transportation and handling of the pipe. The burst load at
the casing seat is the fracture pressure plus a safety margin minus formation pore-
pressure (back-up pressure). The burst load at the surface is the surface pressure inside
the casing. The burst load line is defined by two points; burst load at the casing seat and
the burst load at the surface. Connecting the two points gives the burst load line in the
casing from top to bottom. Multiplying the burst loads at the two points by a safety factor
determines the burst design line.
The collapse design is based on the most severe lost-circulation problem that is felt to be
possible or on the most severe collapse loading anticipated when the casing is run. For
both cases, the maximum possible external pressure that tends to cause casing collapse
results from the fluid that is in the hole when the casing is placed and cemented. The
beneficial effect of the cement and of possible mud degradation is ignored, but the
detrimental effect of axial tension on collapse-pressure rating is considered. The collapse
rating should be de-rated above the neutral point using Eq. (11). Below the neutral point
the casing is in compression and adjustment of the collapse rating is not required. The
depth of the neutral point of a casing string in mud can be calculated by the following
formula:
W
Dn = Dt 1 (14)
489
where, Dn = depth to neutral point, ft
Dt = setting depth of casing string, ft
W = mud weight, pcf
When correcting the collapse-pressure rating of the casing, it is recommended that the
axial tension be computed as the hanging weight of the casing for the hydrostatic
pressures present when the maximum collapse load is encountered plus any additional
tension put in the pipe during and after landing. The beneficial effect of pressure inside
casing can also be taken into account by the consideration of a maximum possible
depression of the mud level inside the casing. A safety factor generally is applied to the
design-loading condition to provide an additional safety margin. The minimum fluid
level in the casing while it is placed in the well depends on field practices. The casing
usually is filled with mud after each joint of casing is made up and run in the hole, and an
internal casing pressure that is roughly equivalent to the external casing pressure is
maintained. However, in some cases the casing is floated in or run in at least partially
empty to reduce the maximum hook load before reaching bottom. If this practice is
anticipated, the maximum depth of the mud level in the casing must be used in collapse
calculations.
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Tension design requires a consideration of axial stress present when the casing is run,
during cementing operations, when the casing is loaded in the slips, and during
subsequent drilling and production operations. The design load is usually based on
conditions that occur when the casing is run. It is assumed that the casing becomes stuck
near the bottom of the hole and that a minimum amount of pull, in excess of the casing
weight in mud, is required to pull the casing free. A minimum safety factor criterion is
applied such that the design load will be dictated by the maximum load resulting from the
use of either the safety factor or the overpull force whichever is greater. The minimum
overpull force tends to control the design in the upper portion of the casing string, and the
minimum safety factor tends to control the lower part of the casing string. Once the
casing design is completed, maximum axial stress anticipated during cementing, casing
landing, and subsequent drilling operations should also be checked to ensure that the
design load is never exceeded.
When the selection of casing weight and grade in a combination string is determined by
collapse, a simultaneous design for collapse and tension is best. The greatest depth at
which the next most economical casing can be used depends on its corrected collapse-
pressure rating, which in turn depends on the axial tension at that depth. Therefore, the
corrected collapse-pressure rating cannot be computed until the axial tension is
calculated. It takes an iterative procedure, in which the depth of the bottom of the next
most economical casing section is first selected on the basis of uncorrected table value of
collapse resistance, to be used. The axial tension at this point is then calculated, and the
collapse resistance is then corrected. This allows the depth of the bottom of the next
casing section to be updated for a second iteration. Several iterations may be required to
arrive at a solution.
Intermediate Casing
Intermediate casing is similar to surface casing in that its function is to permit the final
depth objective of the well to be reached safely. When possible, the general procedure
outlined for surface casing is also used for intermediate casing strings. However, in some
cases, the burst-design requirements in Fig (10) are extremely expensive to meet,
especially when the resulting high working pressure is in excess of the working pressure
of the surface BOP stacks and choke manifolds for the available rigs. In this case, the
operator may accept a slightly larger risk of loosing the well and select a less severe
design load in which the burst limitation is equivalent to the BOP stack rating. The
design load remains based on an underground blowout situation assumed to occur while a
gas kick is circulated out. However, the acceptable mud loss from the casing is limited to
the
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maximum amount that will cause the working pressure of the surface BOP stack and
choke manifold to be reached. If the existing surface equipment is to be retained, it is
pointless to design the casing to have a higher working pressure than the surface
equipment.
When the surface burst-pressure load is based on the working pressure of the surface
equipment, Pmax, internal pressure at intermediate depths should be determined, as shown
in Fig 11. BURST
Pmax
Normal Press.
Dm Dlc
MUD
Fracture
Gas
GAS
Fig. 11
Modified burst design load for intermediate casing
It is assumed that the upper portion of the casing is filled with mud and the lower portion
of the casing is filled with gas. The depth of the mud/gas interface, Dm, is determined
with the following relationship.
144(Pi Pmax ) g D lc
Dm = (15)
m g m g
where Pi , in psi, is the injection pressure opposite the fractured zone, m and g are the
densities of the mud and gas in pcf, and Dlc is the depth of the fractured zone in ft. The
density of the drilling mud is determined to be the maximum density anticipated while
drilling to the depth of the next full-length casing string. This permits the calculation of
the maximum intermediate pressures between the surface and the casing seat. The depth
of the fractured zone is determined from the fracture gradient vs. depth plot to be the
depth of the weakest exposed formation. The injection pressure is equal to the fracture
pressure plus an assumed safety margin to account for a possible pressure drop within the
hydraulic fracture.
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Example:
A gas exploration well has 13-3/8 casing set at 6200 ft. Design a 9-5/8 casing string to
be set at 10,400 ft in 73 pcf mud that will be subjected, in the event of a kick, to a
formation pressure gradient of 0.57 psi/ft from the next hole drilled to a TD of 13,900 ft.
Collapse
At the casing shoe collapse pressure = (73 pcf x 10,400 ft)/144 = 5272 psi
It is obvious that the 53.5# will have to be run on bottom. The question is how
much 53.5# do we need to run before we can switch over to the less expensive
lighter weight casing.
Taking the collapse figure for the 47# we can calculate the deepest point to which
this weight casing can be run and still satisfy the collapse requirements with the
1.125 SF.
(4750 psi/1.125) (73 pcf/144 in2/ft2) = 8,330 ft
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Burst:
The burst pressure at the shoe is: internal pressure - external pressure or:
A gas kick is expected for this well, since G is 0.1 psi/ft, we get:
Burst at shoe =
[7923 psi - ((13,900 ft-10,400 ft) x 0.1 psi/ft)]-(10,400 ft x 0.507 psi/ft)) = 2300 psi
Pf - (TD x G) or: 7923 psi - (13,900 ft x 0.1 psi/ft) = 6533 psi x 1.1 S.F. = 7186 psi
By comparing 7186 psi with what the burst rating for 43.5# C-75 of 5930 psi, we
can see that some heavier weight 47# L-80 and 53.5# C-95 casing is required for
the top of the string instead of the 43.5#. We can calculate the amount required
by each with:
(Burst at surface - casing burst rating)/mud gradient = (7186 - 5930) / (73/144) = 2,478
and since the burst rating for 47# L-80 is 6870 psi which is less than 7186 psi we
then calculate how much 53.5# C-95 is required at the surface in order to satisfy
the burst requirement. (7186 - 6870) (73/144) = 623 ft
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Therefore, from the previous collapse design we adjust the design for burst
considerations and we can see that 47# and 53.5# casing is needed at the top of
the string. We now have a casing design, in the order going in the hole, of:
Next we need to check the tensile strength of the design to ensure that this design
will pass the tensile design criteria.
Tension
The suitability of the selected design will be investigated by considering the total
tensile load resulting from the buoyant weight of the string.
Starting from the bottom, the weight carried by each section is as follows:
To ensure that the selected design meets the safety factor for tension of 1.6 we
divide the cumulative weight of each pipe section into the tensile rating of each
grade. We then come up with a design factor:
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From these results we can see that the design exceeds the tensile safety factor of
1.6.
Biaxial Effects
Finally we need to check the weakest grade for biaxial collapse correction. Grade
C-75 43.5# is the weakest grade, carrying a buoyant load of: 303,900 lb. By
dividing this load by the yield strength of 942,000 lb we can see:
303.9 kips / 942 kips = 0.32
Looking at Table 8 on page 25 we see that the collapse reduces to 79% of its
original value of 3750, or 2963 psi. Therefore, rechecking the collapse safety
factor for that casing grade at that depth of 2478 ft we get: 2963 psi / [2478 ft x
(73 pcf/144 in2/ft2 )] = 2.3, then since the safety factor is still greater than 1.125,
the biaxial effect on collapse did not change the casing design.
Production Casing
Example burst and collapse design loading conditions for production casing are
illustrated in Fig. 12. The example burst-design loading condition assumes that a
producing well has an initial shut-in BHP equal to the formation pore pressure and a
gaseous produced fluid in the well. The production casing must be designed so that it will
not fail if the tubing fails. A tubing leak is assumed to be possible at any depth. It
generally is also assumed that the density of the completion fluid in the casing above the
packer is equal to the density of the mud left outside the casing. If a tubing leak occurs
near the surface, the effect of the hydrostatic pressure of the completion fluid in the
casing would negate the effect of the external mud pressure on the casing. Mud
degradation outside the casing is neglected because the formation pore pressure of any
exposed formation would nearly equal the mud hydrostatic pressure.
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The collapse-design load shown in Fig. 12 is based on conditions late in the life of the
reservoir, when reservoir pressure has been depleted to a very low (negligible)
abandonment pressure. A leak in the tubing or packer could cause the loss of the
completion fluid, so the low internal pressure is not restricted to just the portion of the
casing below the packer. Thus, for design purposes, the entire casing is considered
empty. As before, the fluid density outside the casing is assumed to be that of the mud in
the well when the casing was run, and the beneficial effect of the cement is ignored.
BURST COLLAPSE
GAS IN PRODUCTION
TUBING CASING
TUBING AT
NEGLIGIBLE MUD DENSITY
PRESSURE CASING WAS RUN
COMPLETION
FLUID LEAK IN TUBING
OR PACKER
FORMATION CAUSES LOSS
PRESSURE OF COMPL FLUID
DEPLETED
FORMATION
PRESSURE
Fig. 12
Production casing design loads for burst and collapse
In the absence of any unusual conditions, the tension design load criteria for production
casing are the same as for surface and intermediate casing. When unusual conditions are
present, maximum stresses associated with these conditions must be checked to
determine whether they exceed the design load in any portion of the string.
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points.
10,000
Setting Depth
2300 psi 2530 psi
12,000
0 1 2 3 4 5 6 7 8
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The first section of pipe is selected based on the collapse requirement at the setting depth.
In this example 53.5# C-95 has a collapse rating of 8960 psi which is off the chart. The
collapse rating of the next weaker section is plotted on the appropriate collapse design
line and the changeover depth read at the intersection on the graph. A vertical line for the
first section is drawn from the casing setting depth to the changeover depth and a
horizontal line is drawn from the intersection of the second collapse rating plotted on the
design line to the 6533 psi 7186 psi
collapse rating of the 0 53.5# C-95
first section.
Subsequent segments 2000
are similarly 1.1.25 S.F.
47# L-80
determined. 4000
Collapse Line
Concurrently burst
ratings are plotted and 1.1 S.F.
Burst Line
43.5# C-75
10,000
ratings are reduced by Setting Depth
2300 psi 2530 psi 5931 psi
the effect of tension on
collapse. 12,000
0 1 2 3 4 5 6 7 8
At changeover depths above the cement top, the axial stress is calculated. Where the pipe
is in tension, a percent of rated collapse is read from Table 8 based on the axial tension.
Using the percent of rated collapse multiplied by the changeover depth adjusts the depth
to the correct depth. The collapse design factor at the bottom of the weaker section then
is calculated to determine if the collapse design requirements are sufficient. If the depth
is not correct, the design factor calculated times the depth used will adjust the changeover
point to the correct depth. By repetition the correct depth will finally be selected. If the
pipe is not in tension, plot the collapse rating of the next weaker section in collapse on
the design line and continue the design as before.
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As the design continues upward from the bottom a depth will be encountered where
collapse no longer controls the design. Above this depth the design will be controlled by
burst or tension. If burst controls the design, the burst ratings of the casing are plotted on
the burst design line and the burst loads are read from the burst load line at the
corresponding depth. Changeover depths are read directly from the graph. If tension is
controlling the design, the changeover depth is calculated directly. The changeover depth
is calculated by using the tension rating divided by 1.6 and subtracting the buoyed weight
of the pipe below; from this remainder divide by the buoyed weight per foot of the pipe
used to determine the footage of pipe to be used.
Example:
Graphically design a 13-3/8 intermediate casing string to a depth of 6,250 ft. The mud
weight is 67 pcf.
For burst considerations, use an injection pressure gradient that is equivalent to a mud
density of 2.5 pcf greater than the fracture gradient of 104 pcf, and a safety factor of 1.1.
Assume any kick will be composed of gas with a 0.1 psi/ft gradient. The normal
formation pore pressure for the area is 0.46 psi/ft.
For collapse considerations, assume that a normal pressure, lost circulation zone could be
encountered as deep as the next casing seat, that no permeable zones are present above the lost
circulation zone, and use a safety factor of 1.125. Also assume that the axial tension results
only from the hanging weight of the casing under prevailing borehole conditions. The next
hole section will be drilled to a depth of 10,000 ft with 73 pcf mud.
For tension considerations, use a minimum over-pull of 100,000 lb. or a safety factor of
1.6, whichever is greater.
Grade Weight (lb./ft) Collapse (psi) Burst (psi) Yield Strength (kips)
K-55 LT&C 54.5 1,130 2,730 853
K-55 BT&C 68 1,950 3,450 1,069
N-80 BT&C 72 2,670 5,380 1,661
N-80 BT&C 85 3,870 6,360 1,951
Solution:
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Burst: The fracture gradient at 6,250 ft. is equivalent to 104 pcf. For an injection-
pressure gradient that is 2.5 pcf greater than the fracture pressure:
6,250(104 + 2.5)
Pinj = = 4,622 psig
144
Since the formation gas gradient is 0.1 psi/ft, the surface casing pressure for the design
considerations is,
4,622 (0.1 6,250 ) = 3,997 psig
The external pressure at the surface is zero. For a normal pore pressure of 0.46 psi/ft, the
external pressure at the casing seat is,
The pressure differential that tends to burst the casing is: 3,997 psig at the surface and
1,747 psig (4,622-2,875) at the casing seat. Multiplying each of these pressures by a
safety factor of (1.1) yields a burst design load of 1.1 (3,997) = 4,397 psig at the surface,
and 1.1 (1,747) = 1,921 psig at the casing seat. Graphically draw the burst line from
4,397 psig at the surface to 1,921 psig at 6,250 ft. in bold, as shown in Fig. (A). Plot
the burst resistance values for the above grades of casing as shown in Fig. (A) also in
bold.
( max gp )
Dm = D lc
max
Where,
Dm is the depth to where the mud level will fall
Dlc is the lost circulation depth
gp is the pore pressure gradient of the lost circulation zone
max is the maximum mud density anticipated in drilling to Dlc
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Dm =
(73 (0.46 144)) 10,000 = 926 ft.
73
For these conditions the mud level could fall 926 ft. down the inside of the 13-3/8
casing. The internal pressure is assumed to be zero at 926 ft. and,
(6,250 926) 73 = 2,700 psig at the casing seat.
144
However, for this example lets consider the worse possible scenario, that the entire
contents of the casing are lost to a lost circulation zone at 10,000 ft. Therefore, the
internal pressure would be zero at 6,250 ft., the casing seat. The pressure differential that
67
tends to collapse the casing is zero at the surface and, 6,250 = 3,908 psig at 6,250 ft.,
144
the casing seat. Multiplying this pressure by a safety factor of 1.125 yields a collapse-
design load of zero at the surface and 2,908 1.125 = 3,271 psig at 6,250 ft. Graphically
draw the collapse line from 0 at the surface to 3,217 psig at 6,250 ft., as shown in Fig.
(A). Plot the collapse resistance values for the above grades of casing as shown in Fig.
(A).
Pressure, psi
85#
-2250
Collapse
-3250
Burst
-4250
-5250
-6250
Figure A
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The first section of pipe is selected based on the collapse requirement at the setting depth.
In this example, 85# N-80 is the only casing type to satisfy the collapse requirement of
3,217 psig, having a collapse rating of 3,870 psig. A vertical line for the first section
(85#) is drawn from the casing setting depth (6,250 ft.) to the changeover depth for the
next lower weight casing, that lies to the right of the collapse design line, 72# at 5,100 ft.
A horizontal line is drawn from the intersection of the second collapse rating plotted on
the design line to the collapse rating of the first section. The collapse rating of the next
weaker section is plotted on the appropriate line and the changeover depth read at the
intersection on the graph. Subsequent segments are similarly determined. Concurrently
burst ratings are plotted and vertical and horizontal lines are drawn, see Fig. (B).
Based on the combined burst and collapse satisfaction, Figure B indicates the following
casing selection.
Pressure, psi
0 1000 2000 3000 4000 5000 6000
0
-250
K-55 K-55 N-80 K-55 K-55 N-80
54.5# 68# 72# 54.5# 68# 72#
-1250
N-80
Depth, Feet
85#
-2250
Collapse
-3250
Burst
-4250
-5250
-6250
Starting
Figure B
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Tension: The third step in the casing design is to check the tension design requirements
for the preliminary casing design found to satisfy the burst and collapse strength
requirements. The design loading condition for tension was specified to be while the
casing is run, when the well contains 67-pcf mud. If bending and shock loading is
ignored, the casing design is obtained by comparing the buoyed tensions of each section
multiplied by a safety factor of 1.6, with the buoyed tensions plus 100,000 lb. of each
section, assuming the casing was stuck in the borehole near the bottom and 100,000 lb. of
pull was imposed. Then select the larger of the two results (see table below) and insure
that these results are below the lowest value of either the body or coupling yield strength
of each selected casing section.
The above table indicates the casing selection satisfies tension requirement.
Biaxial Effects: The weakest grade of the selected casing should be checked for biaxial
effects as follows:
Buoyant Weight carried by weakest joint
Tensile Ratio =
Yield strength of body or coupling
Since the weakest grade is 68# K-55, the buoyant weight to be supported by the top joint
of that section is 248.5 kips.
248.5 1,000
Tensile ratio = = 0.232
1,069,000
Table 8 shows that the collapse resistance of the casing is reduced to approximately 86%
of its original value, PC = 1,950 for K-55, 68 lb/ft casing.
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Therefore safety factor in collapse for top joint of K-55, 68 lb/ft casing is
1,677
SF = = 1.51
1,107
An extra two joints of the heaviest casing is placed on top for drift control. Therefore the
following casing string meets the design criteria.
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The centralizers on a casing string are used to provide clearance between the casing and
the wall of the hole. The clearance is called standoff. The major function of a centralizer
is to centralize the casing in the hole and to prevent it from lying against the wall, thus
providing a reasonable uniform cement layer around the casing.
Centralizer spacing should be sufficiently close to keep the casing to wall clearance at
some acceptable minimum distance. The casing couplings or various types of attachable
stops control the vertical travel of the centralizer.
(WF)b ( 2
= Wcs + 0.0062963 mi d i mo d o
2
)
( 2 2
T = 0.0062963 TVD mi d i mo d o coso) CS S
CS
F = 2Tsin DLS + (WF)b CSsin
2
F
CS =
0.0175T DLS + (WF)b sin
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References
1. Bulletin on Performance Properties of Casing, Tubing, and Drill Pipe, Bull. 5C2, Dallas:
API, (1970)
2. Adams, N., Drilling Engineering, Tulsa: Penn Well Publishing, (1985)
3. Bourgoyne, Chenevert, Milhelm, Young, Applied Drilling Engineering, Richardson, TX.:
SPE, (1986)
4. Brantly, J.E., History of Oil Well Drilling, Gulf Publishing Co., (1971)
5. Craft, Holden, Graves, Well Design: Drilling and Production, New Jersey: Prentice-Hall,
(1962)
6. Mian, M.A., Petroleum Engineering, Vol II, Tulsa: Penn Well Publishing, (1992)
7. Rabia, H., Oilwell Drilling Engineering, London: Graham & Trotman Ltd., (1985)
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CEMENT TESTING 5
DENSITY 5
FREE WATER 6
THICKENING TIME 6
FLUID-LOSS RATE 9
COMPRESSIVE STRENGTH 10
RHEOLOGICAL PROPERTIES 12
CEMENT ADDITIVES 12
ACCELERATORS 14
RETARDERS 15
FLUID-LOSS ADDITIVES 16
ADDITIVES TO INCREASE DENSITY 17
DISPERSANTS 18
SILICA 18
DEFORAMERS 19
ADDITIVES TO DECREASE DENSITY 19
SEGMENT DRILLING
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PRIMARY CEMENTING 32
PLANNING A CEMENT JOB 32
TYPE AND VOLUME OF CEMENT 32
CEMENT ADDITIVES 39
CEMENT MIXING 41
PREFLUSHING 43
CEMENT PLACEMENT TECHNIQUES 44
CEMENT DISPLACEMENT 50
LINER CEMENTING 52
LINER EQUIPMENT 53
CEMENTING TECHNIQUES 55
RUNNING AND CEMENTING PROCEDURE 56
FLOW CALCULATIONS 58
BINGHAM PLASTIC MODEL 59
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In well drilling operations cement slurry is placed around the casing strings and liners by
mixing powdered cement, water and additives on the surface and pumping it by hydraulic
displacement into the annular space between the casing and the wellbore. When the
cement slurry sets, it forms a rigid solid that exhibits favorable compressive strength
characteristics.
In designing a casing cementing job, the drilling engineer is responsible for selecting the
cement composition and displacement techniques so that the cement slurry will fill the
entire annular space behind the casing and achieve adequate compressive strength soon
after it is placed at the desired location in the well. This minimizes the waiting time after
cementing. The cement slurry must be designed such that it will remain pumpable until it
is placed at the desired location. The density of the cement slurry must be adequate to
control any movement of pore fluid while at the same time not cause any formation
fracture.
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Table 1
Principal Components of Portland Cement
_________________________________________________________________________________________________________________________________________________________________________
Standard Typical
Compound Formula Designation % (Wt)
_________________________________________________________________________________________________________________________________________________________________________
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There are eight API cement classes. Table 2 provides a summary of the chemical
composition, grind and special properties of some of these API cements. Most oil-field
operations use class A, C, G, or H. The different classes of API cement and their
compositions are shown below and in Table 2.
Class A: Intended for use from surface to a depth of 6,000 ft when special
properties are not required. Available only in Ordinary type (similar to
ASTM C150, Type I).
Class B: Intended for use from surface to a depth of 6,000 ft when conditions
require moderate to high sulfate resistance. Available in both Moderate
type (similar to ASTM C150, Type II) and High Sulfate Resistant types.
Class C: Intended for use from surface to a depth of 6,000 ft when conditions
require high early strength. Available in Ordinary type and in Moderate
and High Sulfate Resistant types.
Class D: Intended for use at depths from 6,000 to 10,000 ft and at moderately high
temperatures and pressures. Available in both Moderate and High Sulfate
Resistant types.
Class E: Intended for use at depths from 10,000 to 14,000 ft and at high
temperatures and pressures. Available in both Moderate and High Sulfate
Resistant Types.
Class F: Intended for use at depths from 10,000 to 16,000 ft and at extremely high
temperatures and pressures. Available in High Sulfate Resistant types.
Class G: Intended for use as a basic cement from the surface to a depth of 8,000 ft
as manufactured. With accelerators and retarders it can be used at a wide
range of depths and temperatures. It is specified that no additions except
calcium sulfate or water, or both, shall be interground or blended with the
clinker during the manufacture of Class G cement. Available in
Moderate and High Sulfate Resistant types.
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Class H: Intended for use as a basic cement from the surface to a depth of 8,000 ft
as manufactured. This cement can be used with accelerators and retarders
at a wide range of depths and temperatures. It is specified that no additions
except calcium sulfate or water, or both, shall be interground or blended
with the clinker during the manufacture of class H cement. Available only
in Moderate Sulfate Resistant type.
Table 2
Typical Composition and Properties of
API Classes of Portland Cement
Wagner
API Compounds (percentage) Fineness
Class C3S C2S C3A C4AF (sq cm/gm) Property
Two of the byproducts of cement hydration are calcium hydroxide [Ca(OH)2] crystals
and heat. The [Ca(OH)2] crystals cause the cement to be very basic (high pH). Because of
this, a cement sheath will provide corrosion protection for the steel casing.
The heat given off during the hydration reaction is sometimes used to detect the top of
cement by temperature logging. The time at which the slurry achieves its maximum
temperature depends on the particular slurry and its curing conditions, but generally is
between 3 and 12 hours.
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CEMENT TESTING
Physical properties of drilling cement slurry are measured according to test procedures
established by the API (American Petroleum Institute). These properties are used by
drilling personnel to formulate the specifications of cement when designing a cementing
job. Cement slurry testing is normally done by cementing service companies or by Saudi
Aramco lab, however, it is important for the drilling engineer to understand the nature of
these tests so that be can interpret cement specifications and test results properly.
DENSITY
The density of a cement slurry is
important for well control and the
prevention of lost circulation
while cementing. Density is also
a useful field monitor of whether
or not the slurry has been mixed
with the designed water
requirement. With the appropriate
additives, cement slurries can be
designed with densities ranging
from about 60 pcf to about 150
pcf.
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measurement (at about 30 psi pressure). Errors of 7-15 pcf may occur using the
unpressurized balance.
In the field, in-line radioactive densitometers are often used to monitor density as the
cement slurry is pumped.
FREE WATER
The water added to the dry bulk cement is used both as a reactant in the hydration
reaction and to provide fluidity to the slurry. When properly mixed, about 2/3 of the
water is involved in the chemical reaction while 1/3 provides fluidity. All of the water in
a properly mixed slurry, however, is either bound to the cement particles by chemical
bonds or loosely attracted to the cement particles to form a stable suspension. If excess
water is added, the cement particles will settle, leaving a layer of free water above the
suspension.
Excessive cement free water may lead to the formation of water pockets in a well,
especially on the high side of deviated wells, Also, since excessive free water indicates
solids settling, it may result in difficulty in mixing and displacing the slurry.
Procedures for determining the free water content of a cement slurry have been specified
by the API. There are two types of tests: a specification test conducted at 80 oF and a new
(tentative) operating free water test conducted under downhole conditions. Under the API
specification procedure, the maximum allowable free water is 1.4% (3.5 ml water from
250 ml of cement).
THICKENING TIME
Perhaps the most important property of a cement slurry for well applications is its
thickening time. The thickening time provides an indication of the length of time the
slurry will remain pumpable. A thickening time that is too short can result in the cement
setting inside the casing, tubing or drill pipe with severe economic consequences. A
thickening time that is too long, on the other hand, can necessitate an unduly long and
costly delay waiting for the cement to set.
The API defines the thickening time of a cement slurry to be the time required for the
slurry to reach 100 Bearden units of consistency (Bc), using the methods of API Spec 10.
One hundred Bearden units of consistency is roughly equivalent to a viscosity of 100
poise. Cement is considered to be unpumpable at this viscosity.
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TABLE 3
EXAMPLE CONSISTOMETER SCHEDULE
(Schedule 6-10,000 ft (3050 m) casing cement specification test)
_____________________________________
Time Pressure Temperature
(minutes) (psi) (kg/cm2) (oF) (oC)
_____________________________________
0 1,250 88 80 27
2 1,600 113 84 29
4 1,900 134 87 31
6 2,300 162 91 33
8 2,600 183 94 34
10 3,000 211 98 37
12 3,300 232 101 38
14 3,700 260 105 41
16 4,000 281 108 42
18 4,400 309 112 44
20 4,700 330 116 47
22 5,100 359 119 48
24 5,400 380 123 51
26 5,700 401 126 52
28 6,100 429 130 54
30 6,400 451 133 56
32 6,800 478 137 58
34 7,100 499 140 60
36 7,480 526 144 62
_____________________________________
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The temperature and pressure of the slurry sample in the consistometer chamber is
increased to the pressures and temperatures and time schedule in Table (3). When the
final temperature and pressure are reached, they are held constant until the test is
completed, that is when a consistency of 100 Bearden Units is reached.
The API schedules have proven to be accurate and reliable over many years. However,
there are certain situations where the API cementing schedules may not be appropriate. If
unusual temperature conditions are encountered, such as geothermal gradients outside the
0.9-1.9 oF/100 ft API range, highly deviated wells or offshore cementing through long
risers, it may be necessary to develop a cement testing schedule using computer
simulation.
The thickening time of a cement slurry is generally selected to be equal to the job time
plus a safety factor. The job time is the estimated time required to mix the slurry and
pump it into place. Usual practice is to employ a 50-100% safety factor, depending on the
type of job and the experience in the area. Through the use of the appropriate additives,
well cement slurries have been designed with thickening times as short as 60 minutes or
as long as 12 hours.
FLUID-LOSS RATE
The rate at which a cement slurry loses water through a permeable barrier when a
differential pressure is imposed is referred to as filtration rate or fluid-loss rate. The water
lost is the water that does not take part in the chemical reaction, that is, the water required
for slurry fluidity.
When this water is lost, the slurry viscosity increases, and the slurry loses its fluidity. In
addition, as water is lost, the concentration of the cement particles increases. This may
result in the formation of cement bridges which restrict or prevent flow in areas of narrow
clearance.
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Because the water lost is that used to maintain slurry fluidity, there is still sufficient
water to complete the hydration reaction. In fact, because the cement particles are closer
together, the strength of a slurry that has lost water is greater than the strength of the
parent slurry (that is, the slurry that did not lose any water).
Testing procedures for fluid loss rates are given in API Spec 10. There are two types of
tests:
1) low temperature/low pressure (LT/LP) and
2) the well-simulation or high temperature/high pressure (HT/HP)
The HT/HP fluid-loss rate of a neat cement slurry (i.e. just cement and water) is on the
order of 1000-2000 cc/30 min. However, through the use of certain additives, the fluid-
loss rate can be adjusted to lower values. Table (4) presents some general fluid loss
guidelines for different cementing operations.
Table 4
Guidelines for Cement Slurry Fluid-Loss Rates
_______________________________________________
HT/HP Fluid-Loss Rate
Operation (cc/30 min.)
_______________________________________________
Casing Cementing 300-450
(past high permeablility formation)
Liner Cementing 100
Squeeze Perforation or 50
Repair Channels
_______________________________________________
The API procedure for measuring fluid loss uses a 325-mesh screen as a filtration
medium. A pressure of 1000 psi is applied on the slurry sample and the volume filtrate in
30 minutes is measured.
COMPRESSIVE STRENGTH
The compressive strength of set cement is the stress required to cause failure of the
cement under a uniaxial compressive load. Fig (3) shows the compressive strength
development for a class A cement. The rate of strength development depends on the
type
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of cement, the type and concentration of additives and the curing temperature. However,
75-80% of the ultimate compressive strength is generally achieved within 3 days.
Similarly, laboratory experiments indicate that a well should not be perforated until the
cement has achieved at least 2000 psi compressive strength. Above this value, the tests
indicate that perforating does not damage the cement bond.
The API testing procedures for determining compressive strength are in API Spec 10.
These tests use conventional compressive strength testing equipment. An Ultrasonic
Cement Analyzer (UCA) is also available for making non-destructive compressive
strength measurements. The UCA is based on the measurement of the travel time of
ultrasonic waves pulsed through a cement sample. While the UCA provides a useful time
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RHEOLOGICAL PROPERTIES
The rheological properties of cement slurry allows the drilling engineer to compute the
frictional pressure losses in pipe and annulus from the flow of cement slurry and the
annular velocity required to establish laminar, plug or turbulent flow.
Cement slurry is a non-Newtonian fluid, that is it does not exhibit a direct proportionality
between pressure loss and flow rate at constant temperature and pressure. The behavior
of non-Newtonian fluids can be expressed by the Bingham plastic model or the power-
law model. For cement slurries the power-law model is more accurate than the Bingham-
plastic model; therefore, the results are closer to the exact behavior of the cement slurry
in the well. Cement slurry flow calculations are presented in the section on Flow
Calculations.
CEMENT ADDITIVES
Cement additives are solid or liquid chemicals that are mixed with cement slurry to
change its properties so that it will meet cementing specifications of a particular job.
Solid additives are free-flowing powders that either can be dry blended with the cement
before transporting it to the well or can be dispersed in the mixing water at the job site.
Liquid additives are mixed with the mixing water at the job site.
The volume of slurry obtained by mixing one sack of cement with water and additives is
called the yield, and is expressed in cu. ft/sack. Calculation of the cement yield is
illustrated in the following example.
Example
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It is desired to mix a slurry of Class G cement containing 6.6% bentonite, 0.1% CFR-3
friction reducer and 0.9% Halad-22A fluid loss additive. Determine
(a) the weights of bentonite, CFR-3 and Halad-22A to be mixed with one sack of cement
(b) volume of mix water
(c) slurry yield and
(d) slurry density.
Solution
a) Weight of bentonite per sack of cement = 94 lb 0.066 = 6.2 lb.
Weight of CFR-3 = 94 lb 0.001 = 0.094 lb
Weight of Halad 22A = 94 lb 0.009 = 0.846 lb
b) The volume of mix water per sack is the sum of the water requirements for cement
and each additive which can be obtained from the Halliburton Cementing Tables
(Red Book) as follows:
c) The slurry yield is the sum of the volumes of cement, water and all the additives per
sack of cement. The volumes are calculated by dividing the weight by the density of
each additive from Halliburton Tables,
1.439 ft3/sack
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157.980 lb
157.98
Density = = 109.78 lb/ft3
1439
.
Problem
It is desired to mix a slurry of Class G cement containing 35% silica flour, 0.3% Halad
413, 0.45% Halad 344 and 0.8 HR-15 retarder. Determine (a) the quantity of each
additive per one sack of cement, (b) volume of mix water in gal, (c) slurry yield, and (d)
slurry density. Water requirements and specific gravity of additives are as follows:
ACCELERATORS
The additive most commonly used to accelerate the set of cement is calcium chloride
(CaCl2). This compound is used in the concentration range 1 to 4%. The effect of CaCl2
concentration on thickening time is shown in Fig (4).
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RETARDERS
Retarders are additives that delay the set of cement. Most commercially available
retarders are organic materials. Table 5 presents a summary of the generic types of
organic retarders. Retarders are generally used in the concentration range of 0.1 to 1.0%.
Since retarders are generally composed of heat-sensitive organic molecules, particular
attention should be paid to the recommended temperature range for using the retarder.
Information on specific retarders is available from cementing company literature.
Another additive that will retard the set of cement at certain concentrations is sodium
chloride (NaCl). At concentrations greater than about 18% (by weight of mix water),
NaCl will act as retarder. Sodium chloride is incompatible with most fluid loss additives,
has an increased tendency for slurry foaming, a limited extent of retardation, and has to
be used in large concentrations to be effective as a retarder.
Table 5
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HB D-S
FLUID-LOSS ADDITIVES
Fluid-loss additives are used to reduce the rate of fluid loss from cement. There are two
basic types of fluid loss additives: polymers and bentonite.
Polymers function primarily by plugging the pore space in the cement filter cake.
Polymeric fluid loss additives
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Table 6
Additives to Increase Density
These additives generally increase the slurry density because they have a high specific
gravity and/or a low water requirement in comparison to the cement. Hematite is more
commonly used than barite because it has a higher specific gravity and a lower water
requirement. A pumpable slurry with a density as high as 20 ppg can be achieved with
hematite.
Although Oklahoma #1 sand has a lower specific gravity than cement, it can increase
slurry density (up to 17.5 ppg) because of its zero water requirement.
Since these weighting additives dilute the cement particles, the final strength of the set
cement will be lower than that of a neat cement. Reductions in compressive strength can
be minimized by using a reduced water content in conjunction with a dispersant. This
method is discussed further in the next section below.
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DISPERSANTS
Dispersants (also called thinners or turbulence inducers) are used to reduce slurry
viscosity or increase slurry density.
Dispersants are also helpful for increasing slurry density. Because dispersants thin the
slurry, when a dispersant is present a pumpable slurry can be formulated with a lower
water requirement than normally recommended for the neat cement. By adding a
dispersant and reducing the water content, slurry densities as high as 17.5 ppg can be
achieved without the addition of barite or hematite (Table 7).
Table 7
Use of Dispersants to Increase Class G Slurry Density
An advantage of using this technique for increasing slurry density is that cement particles
are not diluted. In fact, since the concentration of cement particles is increased, the
strength of the set cement will be higher than that of a neat cement.
SILICA
On being cured at temperatures in excess of 250 oF, one of the components of Portland
cement (C2S) undergoes a change in structure that results in a significant loss in
compressive strength and a significant increase in permeability. This phenomenon is
called strength retrogression.
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DEFOAMERS
Excessive foam makes it difficult to maintain slurry density control and can cause other
problems, such as air locking of the pumps. This is often a problem in slurries
containing salt. Chemical foam inhibitors, which minimize air entrainment and foaming
are available. These materials can be obtained in liquid or solid form.
With the exception of foam cements, these compounds have no known detrimental
effects on other cement properties.
Perhaps the most widely used additive to decrease slurry density is bentonite. Bentonite
in cement lowers density chiefly because of its high water requirement. Where as each
pound of Class G cement requires 0.05 gal water, each pound of bentonite requires 0.69
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gal water. Thus, for example, the density of a Class G cement can be lowered from 15.8
ppg (neat) to 12.8 ppg by the addition of 12% bentonite. Because of loss of compressive
strength, bentonite is generally not used at concentrations greater than 12%.
When bentonite is dry blended with the cement, the high calcium content of the cement
prevents full hydration of the bentonite. If bentonite is prehydrated, i.e. allowed to
hydrate in fresh water before being added to the cement, it will have a greater capacity
for water. One part by weight of bentonite prehydrated in the mix water has an effect that
is essentially equivalent to 3.6 parts by weight of bentonite dry blended with the slurry.
In other words, if the bentonite is to be prehydrated (usually 2-12 hours is sufficient) the
amount of bentonite can be reduced by the factor 3.6.
To obtain ultra light weight slurries, ceramic spheres, glass beads, or foam can be used.
Although ceramic spheres and glass beads are relatively expensive, slurry densities as
low as 8.3 ppg can be achieved while maintaining good compressive strength properties.
However, because the spheres will crush at sufficiently high hydrostatic pressure
(generally around 4000 psi), there are density and depth limitations associated with their
use.
Ultra lightweight slurries can also be achieved by incorporating air or nitrogen into the
cement as a foam. Using foam, slurry densities as low as 9 ppg can be achieved while
maintaining good strength properties in the cured cement.
Table 8
Additives to Lower Density
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CHEMICAL ENVIRONMENT
The parameters which make up the chemical environment of the cement include
a) Mix water
b) Wellbore fluids and
c) Formation fluids
Mix Water
The primary functions of water in a cement slurry is to carry the cement solids down the
hole and react with the cement to form a rigid solid. Ideally, the water for mixing cement
should be reasonably clean and free of soluble chemicals, organic matter and other
contaminates. Inorganic materials such as chlorides, sulphates, hydroxide, carbonates
will accelerate the setting of cement, the rate depends on the concentration of the
material. Organic chemicals from decomposed plant life will retard the setting of cement.
If potable water is not available, the purest water available may be useable but the slurry
must be tested in the laboratory before it is pumped in the hole. In Saudi Aramco UER
water from drilling water supply wells (TDS = 2-3 Mppm) is used for mixing cement on
most onshore wells.
Wellbore Fluids
Contamination or dilution of cement by drilling and workover fluids may damage the
cementing system. The best way to combat the detrimental effects of drilling fluids is to
use wiper plugs and spacers. Wiper plugs help eliminate contamination of the cement
inside the casing, and flushes help to clean the annular space between the casing and the
formation and minimize mixing of cement and drilling fluid in the annulus. Composition
of spacers must be compatible with the drilling fluid and cement.
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Formation Fluids
Formation brines containing sodium sulphates, magnesium sulphate and magnesium
chloride react with the hard cement and can cause eventual deterioration of the cement
sheath behind the casing. The rate of attack depends on the concentration of the sulphate
salts in the formation water. Sulphate attack is most pronounced at temperatures of 80 to
120 oF. Lowering the Tricalcium Aluminate (C3A) content in the cement increases the
sulphate resistance of the cement.
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There are two methods for determining the slurry temperature history:
To use the API Cementing Schedules, it is necessary to know only the type of job
(casing, liner, or squeeze), the well depth, and BHST. The job type and well depth are
used to select the appropriate schedule type. The BHST is used to calculate the
temperature gradient from Eq (1).
Once the temperature gradient is known, the particular schedule for that gradient can be
identified. The BHCT is the highest (final) temperature for that gradient.
As mentioned earlier, for unusual conditions such as highly deviated wells or offshore
cementing through long risers, it may be necessary to use computer simulation to develop
a cement testing schedule.
PORE PRESSURES
The pore pressures of the fluid-bearing formations also affect the design of the cement
job. The density of the cement should be such that the hydrostatic pressure exceeds the
pore pressure at all depths in the well. Generally, this will be the case if the cement
density exceeds the drilling fluid density used to drill the well. However, in deep wells,
such as Saudi Aramcos Khuff wells, mud weights as high as 140 pcf are required to keep
deep high-pressure formations under control. In this case additives should be added to the
cement to being its density slightly above 140 pcf.
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FORMATION PERMEABILITY
Another factor to consider when designing a cement job is the formation permeability
that the cement may see. Long intervals of high permeability formation increase the
potential for fluid loss from the cement. This may cause high slurry viscosities leading to
increased pumping pressures and lost circulation or perhaps total loss of slurry mobility.
It should be recognized, however, that the drilling fluid filter cake or particle plugging
from the drilling fluid may reduce the permeability that the cement sees. However, any
broach in this shield (i.e. by fracturing or erosion) could lead to disaster without the
appropriate cement fluid-loss control.
In Saudi Aramco fluid loss additives are used in Arab-D wells when cementing 4-1/2
liners across the Arab-D or 7 liners across the permeable Biyadh, Sulaiy and Arab-
A,B,C formations.
FORMATION INTEGRITY
Another fundamental consideration in designing a cement job is formation integrity. The
breakdown fracture pressure (often expressed as a fracture pressure gradient) will limit
the density of the cement and/or the surface pumping pressure that can be used without
losing returns. Losing returns while cementing is generally undesirable because
Since some cement is lost to the formation, the top of cement (TOC) may
not be high enough to cover all necessary zones.
Fracturing could expose the cement to high permeability and lead to a costly
bridge-off in the annulus.
Information on formation integrity can often be obtained from the Daily Drilling Reports
for the well. If returns were lost while drilling, the mud weight being used at the time
provides some indication of the formation integrity. More direct information may be
available from pressure integrity test (PITs).
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HOLE GEOMETRY
Hole geometry is another important factor in designing a cement job. The hole geometry
can influence the cement job in a number of ways. For example:
The hole size, casing size, and desired top of cement will affect the volume
of cement to be pumped.
The amount of annular clearance may affect the amount of fluid loss control
required to prevent bridging. It may also limit the pumping rate to prevent
excessive friction pressures.
The angle of deviation may necessitate reducing the free water content of
the slurry to prevent high-side water pockets. The deviation angle may also
affect the placement of centralizers.
For many wells the hole geometry is obtained from caliper logs. In those wells where
caliper logs are not run, the size of the annulus can be roughly estimated from a fluid
caliper. In this method, the volume required to pump a marker pill down the casing and
up the annulus is monitored. The annular volume is then obtained by subtracting the
casing volume.
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Floating Equipment
The guide shoe shown in Fig (8) is an open ended device
attached at the bottom end of the casing to direct the casing away
from ledges and minimize sidewall caving as the casing is lowered
in deviated sections of the hole. The outer body of the guide shoe
is made of steel which has the same strength as the casing while
the nose is made of drillable concrete. Circulation is established
down the casing through the open end of the guide shoe. Some
types of guide shoes have side ports which allow circulation if the
casing is set on bottom.
The float shoe, Fig (9), is a guide shoe equipped with a spring-
loaded back pressure valve which is enclosed in plastic and
concert. The valve, which is closed by the spring or by the
hydrostatic pressure of the fluid column around the casing,
prevents fluids from entering the casing while pipe is lowered into
the hole. Float shoes may also be used to reduce the load on the
derrick by allowing the casing to be floated into the hole. This is
done by lowering the casing empty or partially filled with water or
drilling fluid. In Saudi Aramco float shoes are used on all casings
string except the shallow conductors set at 100 ft from the
surface.
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Float collars are normally placed one to three joints above the float
shoe in the casing string and serve the same function as the float
shoe. The float collar, Fig (10), serves as a back up to the float shoe
in the event the back pressure valve in the float shoe fails to provide
the necessary seal. The space between the float collar and the float
shoe serves as a trap for contaminated cement or mud that may
accumulate from the wiping action of the cementing plug. The
contaminated cement is thus kept away from the shoe, where the
best cement bond is required. When the cementing plug reaches
(bumps) the float collar during cement displacement a pressure
buildup is observed at the surface indicating that the cement
displacement is complete.
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For large casing strings, float shoes may be obtained with a special stab-in device that
allows the cement slurry to be pumped through the drill pipe (this method of cementing is
called inner-string cementing). This device, shown in Fig (11), eliminates the need for
large cementing plugs and for leaving large amount of cement inside the casing above the
shoe. The tool offers another advantage in cementing large casing across loss circulation
zones which is discussed later in this chapter. In Saudi Aramco inner-string float shoes
are used for cementing 18-5/8 conductors.
Since holes are rarely straight, the pipe will generally be in contact with the hole at
several places. Centralizers are installed around the casing to center the casing in the
hole and create a uniform annular flow area and minimize variations of resistive drag
forces in this flow area. In addition, centralizers keep the pipe away from the wall and
minimize differential sticking. Cementing casing without centralizers results in
ineffective cement job, Fig (14), since the cement slurry tends to preferentially flow in
the large annular space with the least flow resistance. Centralizers should be spaced to
provide a minimum standoff of 70%, where,
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Stage-cementing tools are used for cementing the casing in two or three stages. Stage
cementing is used to lessen the possibility of breaking the formation during cementing
and to cement the casing above existing lost circulation zones.
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The stage tool most commonly used in Saudi Aramco consists of 3-4 ft inflatable packer
element and cementing side ports above the packer. The stage tool is installed at a
specific point in the casing as the casing is being run in the hole. Cement slurry is placed
around the casing from the casing shoe to 100-200 ft above the stage tool (first stage).
Refer to Fig (18). Once the first stage shutoff plug seats in the shut-off baffle, a free-
falling opening plug is dropped down the casing. After the plug seats in stage tool,
pressure is applied on the plug to move a sleeve and expose inflation ports of the
inflatable packer. A specified pressure is applied and the packer is inflated by pumping
mud into the packer rubber element which will make a seal with the outer casing. Higher
pressure is applied which will rupture a disk and open the side ports above the packer.
Mud is circulated through the ports to remove any cement above the packer. Cement
slurry is then placed through the ports from the packer to the surface followed by a
closing plug which closes a sleeve over the side ports. After the cement sets, the opening
and closing plugs are drilled out with a bit and the stage tool is pressure tested to ensure
the side ports are shut off.
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Fig. 18 Multiple-stage cementing tool with free-falling plug for cementing a hole
in two stages
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PRIMARY CEMENTING
The success of a primary cement job cannot be over emphasized. A poor cementing job
can result in a failure to isolate zones and can be very costly during the producing life of
a well. Failure to isolate between zones can result in
The type of cement used by Saudi Aramco is Class G cement which is manufactured
locally to API specifications. The properties of the cement slurry can be tailored by the
use of additives to meet the requirements of shallow and deep wells. One sack of dry
Class G cement weighs 94 lbs and yields 1.15 cubic feet of 118 pcf neat slurry when
mixed with 5 gals of water. Addition of additives changes the weight (density) and yield
of the cement slurry. Calculation of cement weight and yield were discussed on page
(12).
The weight of the cement slurry must be little heavier than the mud weight and should
exert a hydrostatic pressure which is greater than the pore pressures of the formations to
be cemented. A cement slurry of 118 pcf is used in Saudi Aramcos normal cementing
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jobs. In cases where there is a concern that the cement column may fracture a
weak
formation, then a lighter weight or multiple weight cement may be used. The light weight
slurry (101 pcf is normally used by Saudi Aramco) is pumped first as the lead slurry
followed by the heavier weight cement tail slurry. The volumes of the cement slurries are
designed such that the heavy cement occupies the annulus from the casing shoe to the
weak formation and the lighter slurry from the weak formation to the surface. If there is
still danger that the light cement may break the formation, then the casing should be
cemented in two stages with the stage tool placed above the weak formation.
The volume of cement required to cement the casing must be calculated by the drilling
engineer prior to the cementing job. The cement volume is usually based on past
experience and regulatory requirements in the area. As little as 300 ft cement fill up has
been used behind relatively deep casing strings. In Saudi Aramco the practice is to
cement the casing from the shoe to the surface wherever it is economically possible.
The volume of cement is based on the size of casing and the diameter of the open hole. It
is usually necessary to include more slurry than theoretically required because of hole
enlargement while drilling. The excess factor to be used is based on prior experience in
the area. Hole volume can be calculated from an open hole caliper. If a caliper is not
available, the open hole volume can be estimated by pumping a marker and circulating it
back to the surface. The following guidelines may be used in calculating the cement
volumes for cementing casing and liners:
Casing:
a) An excess factor of 10-15% is used for cementing casing inside
casing.
c) When a stage tool is used, the excess factor should result in 200-300 ft
of cement rise above the stage tool.
Liners:
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3-1/2" DP
300'
liner hanger
@ 6700'
cement
latch collar
@ 7520'
TD = 7600'
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Example No 1
Calculate the number of sacks of 118 pcf G neat cement required to cement a 4-1/2
11.6# liner across the Arab-D as shown in Fig (19). The volume of the open hole from
the caliper log is 135 ft3.
Given:
7 casing ID = 6.276 in
4-1/2 liner ID = 4.0 in
Solution
42
Volume of cement inside liner below latch collar = (7600 7520) = 6.97 ft 3
4 144
Volume of annulus between open hole and liner = open hole volume - liner volume
or
4.52
Vol. of annulus = 135 (7600 7000)
4 144
= 135 - 66.23
= 68.77 ft3
(6.276 2 4.52 )
Vol. of annulus between liner and 7 casing = (7000 6700)
4 144
= 31.3 ft3
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Vol. = (6.276 2 35
. 2 ) 300
4 144
= 44.4 ft3
Total vol. of cement slurry = 6.97 + 68.77 + 31.3 + 44.4
= 151.44 ft3
15144
.
Number of sacks =
115
.
= 132 sacks
5" DP
ID = 4.276"
6700' long
8-1/2" hole
(a) (b)
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Example No 2
A 7 casing string is to be cemented inside an 8-1/2 hole section which is known to have
severe hole enlargements across shale sections. Refer to Fig (20 b). Before the drill string
was pulled out of the hole, the foreman pumped a dyed mud pill and circulated it out to
the surface by pumping a total of 560 bbls of mud as shown in Fig (20 a). The 7 casing
is to be cemented with 101 pcf 1.68 ft3/sk yield lead G cement from the 9-5/8 shoe to
the surface and 118 pcf neat G cement from TD to the 9-5/8 casing shoe. Calculate the
lead and tail cement volumes.
Given:
Solution
First we have to calculate the volume of the open hole. Since it took 560 bbls of fluid to
circulate the dyed marker to surface, we can say that,
4.267 2 22
6700 + 300 + Vol.
4 144 4 144
of DC-openhole + Vol. of DP-open hole +
(8.8352 52 ) 3141 ft3
4000 =
4 144
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Since the volume of the annulus between the DP and drill collars and the open hole is
1310 ft3,
The volume of the open hole = 1310 + outside vol. of DP + outside vol. of DC
52 (6 2 x 300)
= 1310 + (3000 300) +
4 x144 4 144
= 1736 ft3
If there were no enlargements in the 8-1/2 open hole, the volume of the hole would be,
8.52
Vol. of gauge hole = (7000 4000)
4 x144
= 1181 ft3
Vol. of cement between 7 casing and open hole = Vol. of open hole - Vol. of 7
liner
72
= 1736 (7000 4000)
4 144
= 934 ft3
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(8.8352 7 2 )
Vol. between 7 and 9-5/8 casing = 4000
4 144
= 633 ft3
CEMENT ADDITIVES
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possible it can be estimated by using Fig (21). The drilling engineer is also responsible
for providing the cementing lab with a sample of water to be used by the rig in mixing
the cement.
Fluid loss additives should be added to the cement to control the fluid loss of the slurry
when cementing casing or liners across permeable formations. Failure to control the fluid
loss will cause cement dehydration and bridging in the casing-hole annulus and may
result in total failure of the cementing job. The fluid loss of the cementing slurry should
be low enough to keep the slurry pumpable during the entire cement job. The value of the
fluid loss is determined by experience and depends on the permeability of the formation
and size of the casing-hole annulus. The higher the permeability and the smaller the
annulus the lower the fluid loss. General guidelines for fluid loss values are shown in
Table (4). It should be noted that fluid loss additives are fairly expensive and should be
used prudently. Other additives discussed on pages 12-20 such as accelerators, silica
flour, dispersants and gas blocking agents, should be added to the cement as required.
Example
The static bottom hole temperature of an Arab-D well is 210 oF at 7000 ft. Estimate the
bottom hole circulating temperature at 7000 ft.
Solution
Assume the static temperature at the surface is 80 oF, then,
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CEMENT MIXING
The purpose of the mixing system is to proportion and blend the dry cement and additives
with the water and supply to the wellhead a cement slurry with predictable properties.
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The drilling engineer is responsible for selecting the type of cement mixer. There are
three types of mixers available. The most widely used mixer is the jet mixer shown in
Figs (22a & 22b). It consists of funnel-shaped hopper, a mixer bowl and mixing tub. The
mixer forces a stream of water through a jet and into the bowl where it mixes with
cement from the hopper to form a slurry. The slurry is forced into the discharge line then
into the mixing tub from which it is taken to the cementing pumps. The density of the
slurry is checked by taking samples from the mixing tub. Slurry density can be changed
by varying the water / cement ratio.
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The recirculating cement mixer (RCM) mixes more uniform slurry with more accurate
density. The Halliburton RCM shown Fig (23) consists of a two-compartment 8-bbl
mixing tub equipped with a turbine agitator in each compartment. The rate of dry cement
is controlled by the cement control value. The water rate is controlled by the mixing
manifold on top of the tub. The slurry is blended by the agitator in the first compartment
on the right, recirculated by a centrifugal pump and weighed by a densometer. Any
variations in density are corrected by the operator. When the first compartment is full, the
slurry flows over a weir to the second compartment. Flowing over the weir helps remove
entrained air. The second compartment already contains same slurry at the desired
weight. The combined slurries are blended further by the agitator to insure a uniform
mixture. The slurry is then pumped into the well.
The batch cement mixer gives the most accurate density and is used for critical cementing
jobs were good isolation between zones is essential. In Saudi Aramco the batch mixer is
used for cementing short liners across the producing zones and in cement squeezing
operations. The batch mixer consists of a tank and paddle mixers. A measured volume of
mix water is placed in the mixer and the required amount of cement is added. The slurry
is mixed with the paddles until the desirable density is obtained.
PREFLUSHING
Preflushes or spacers are pumped ahead of the cement to minimize mixing and gellation
in the annulus between the cement and the mud and also aid in the removal of mud cake.
Preflushes have various characteristics, depending on the mud system, and various
functions. Some contain additives to thin the mud and penetrate and loosen the wall cake,
some contain abrasive material to scour the hole; and some have high viscosity to remove
drilling mud by buoyancy. Spacer composition is normally provided by the service
company.
For simple water base muds, water is an excellent spacer since it is cheap, easy to put
into turbulence and has little effect on the setting of cement. The volume of the spacer
should be 300-500 ft of annular fill or enough volume to give a 10-minute contact time
except when the hydrostatic head of the cement column in the annulus is reduced
excessively. Studies indicate that when turbulent flow is attained, a contact time of 10
minutes or more provides excellent mud removal.
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Most of the primary cement jobs are performed by the displacement method, that is by
pumping the cement slurry down the casing and up the annulus. Fig.s (24 a, b, c & d)
below illustrate the four cement placement methods used by Saudi Aramco.
1. Displacement method
The surface, intermediate and production
casings are usually cemented using the normal
single stage displacement method. The cement
is pumped down the casing through the casing
shoe using a top and bottom wiper plugs as
shown in Fig (24a) (bottom plug is not used in
Saudi Aramco cementing operations). The
displacement fluid, mud or water, is pumped
behind the top plug until the plug bumps the
float collar.
Fig. 24 (a) Normal
Displacement
Method
2. Stage Cementing
Stage cementing is performed by the
displacement method in two or three stages.
Refer to Fig (24b). It is commonly used in
wells that require long columns of cement and
where weak formations cannot support the
hydrostatic head of the cement. Stage
cementing is also used to cement casing above
loss circulation zones. One disadvantage of
stage cementing is that the casing cannot be
reciprocated or rotated after the first stage. For
more information see Page 29.
Fig. 24 (b) Two Stage
Cementing
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4. Annulus Cementing
Cement is pumped through tubing or small-
diameter pipe run between the casings or
between casing and hole to bring top of cement
to the surface. This is done when the cement
during a primary cementing job does not reach
the surface because of a shallow loss circulation
zone or other reasons. This types of cement
placement technique is called top cement job.
To bring the top of cement above a shallow loss
circulation zone to the surface may require
performing several top jobs. The cement must
be given enough time to harden after each job. Fig. 24 (d) Outside
Usually cement baskets are installed around the Cementing
casing above the loss circulation zone to help
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Example
An 18-5/8 conductor is to be cemented at 600 ft across the Neogene aquifer which has a
loss circulation zone at 400 ft. The static fluid level of the aquifer is at 300 ft. Refer to
Fig (25).
a) What type of cement placement technique would you use? Explain why.
b) What is the volume in sacks of 118 pcf Class G cement that should be used? ID of
casing is 17.755 in.
Solution
a) Lets try to use the standard displacement technique. In this method the cement will
be pumped down the casing followed by the cementing plug. The plug will be
displaced with water from surface until it bumps the float collar at 520 ft. Since there
is a L.C. zone at 400, the cement will not be able to rise in the annulus above 400 ft.
Now lets make pressure balance calculations after the plug bumps the float collar.
Refer to Fig (26).
62.4 118
Pc = 520 + 80
144 144
= 225 + 65
= 290 psi
Since the casing pressure is greater than the annulus pressure, the water level in the
casing will drop and displace the cement below the float collar into the annulus until
the pressures inside the casing and annulus are equal. This will result in a wet shoe
(no cement around the shoe) which is not acceptable. Refer to Fig (27). Therefore, in
order to use the displacement method and have a cemented shoe we have to
underdisplace the cement so that pressures inside and outside the casing are equal.
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Cement
600' 600'
24" Hole
195' Cement Baskets
Water
300' Fluid Level 300' Fluid Level
Water Water
325' Water
Cement
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So we displace the cement by 325 ft of water. The water level will drop inside the
casing until the pressures inside and outside the casings are equal as shown in Fig
(28). There is no need to use a float collar or a cementing plug.
62.4 118
Pc = 325 + 80
144 144
= 206 psi
62.4 118
Pa = 100 + 200
144 144
= 206 psi
The annulus above the basket is cemented by the top job technique.
b) The volume of cement required is equal to the volume inside the casing plus the
volume in the annulus from the shoe to the loss circulation zone, or
17.7552
Vol. inside casing = 80
4 144
= 137 ft 3
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512
Number of sacks =
115
.
= 445 sacks
DP
Water
LC zone @ 400'
Cement
600'
Float Shoe Plug
A better way to cement the casing is by using the inner-string technique as shown in
Fig (29). The cement is pumped in the drill pipe and followed by the cementing plug.
The plug is displaced with water until it reaches and seats in the float shoe where it
makes a seal and stops the water from entering the float shoe. After the plug seats in
the float shoe, the drill pipe is pulled out leaving the plug on bottom. This method
provides good cement around the shoe with very little cement inside the casing. The
volume of cement to be used is,
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CEMENT DISPLACEMENT
The displacement of the mud in the casing-hole annulus by the cement slurry is the most
important and critical phase of the primary cementing job. A successful cement job is one
in which the cement slurry displaces all the mud from the casing-hole annulus. The
predominant cause of cement job failure is channels of gelled mud remaining in the
annulus after the cement is in place. Laboratory and field research show that the factors
discussed below all contribute to the success of the cement job during the displacement
period.
Pipe centralization creates a uniform annular flow area and aids mud displacement in the
annulus. Centralizers do not provide perfect casing-hole concentricity. Flow pattern in an
eccentric annulus is not uniform and the highest velocity occurs in the side of the hole
with the largest clearance as shown in Fig (14). If the casing is close to the wall as in Fig
(14), it may not be possible to pump the cement at a rate high enough to develop uniform
flow throughout the annulus. Casing strings should be centralized to achieve at least 70%
standoff.
Pipe movement, either rotation or reciprocation, is a major driving force for mud removal
and should be used during primary cementing wherever possible. During rotation, (15-25
rpm) cement-casing drag forces are more effective than during reciprocation, as they tend
to pull the cement into the bypassed mud column instead of along side it as shown in Fig
(30). Centralizers that allow pipe rotation should be used if the casing is to be rotated.
Reciprocating the casing in 20 ft strokes can cause changes in standoff as centralizers
move across wellbore irregularities. Care must be taken not to swab in the well during
casing reciprocation. This lateral movement alters the flow area and aids in the
displacement of bypassed mud.
Fig. 30 Rotational displacing drag forces aids in the removal of by-passed mud
in the narrow side of an eccentric annulus
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Conditioning the mud before cementing to reduce the gel strength, plastic viscosity and
yield point greatly improves the displacement efficiency of the mud. It also reduces
displacement drag forces to erode and remove bypassed mud by reducing casing to mud
and wellbore to mud drag forces. The mud should be circulated and conditioned until the
desired gel strength and viscosity are obtained.
High displacement rates promote mud removal and improve displacement efficiency if
cement can be pumped in turbulent flow up the annulus. Conditions that may prevent
turbulent flow include limited pumping capability and formation conditions that may
limit downhole pumping pressures. Dispersants can be added to the cement to lower
friction pressure and attain turbulent flow at lower displacement rates. If turbulent flow is
difficult to obtain then the cement should be pumped in plug flow (Reynolds number of
100-200). Displacement rates required to induce turbulent or plug flow can be calculated
by using flow equations presented in the Flow Calculations section.
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LINER CEMENTING
A liner is a casing string that is usually used to case-off the open hole below an existing
casing string, and which does not extend to the surface. In Saudi Aramco 4000-5000 ft 7
liners are set at the top of the producing Arab-D formation and extend to 200 ft above the
9-5/8 x 13-3/8 DV stage tool as shown in Fig (31). Sometimes a short 4-1/2 liner is
also set across the Arab-D formation to shut off water producing zones and super
permeability stringers. Liner cementing is one of the most difficult operations associated
with drilling and completion. If a liner is not effectively cemented, the wells capability
to produce will likely be reduced and the advantages of liner installation will not be
26 CONDUCTOR
DV TOOL
18-5/8 CASING
DV TOOL
13-3/8 CASING
9-5/8 CASING
oil 7 LINER
ARAB-D
realized.
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Liner Equipment
A liner is normally run on drill pipe
that extends from the liner setting tool
to the surface. Special tools are
available to perform various running,
setting and cementing operations. The
following equipment is discussed from
the float shoe to the cementing
manifold. Equipment locations are
shown in Fig (32).
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The liner setting tool, which is a rental item furnished by liner hanger service company,
provides the connection between the drill pipe and the liner hanger. A packoff bushing
and slick joint are inserted into the liner to provide a seal between the setting tool and the
liner. Once the hanger is set and the liner is cemented, the setting tool is released from
the hanger and pulled out to surface. The liner wiper plug is attached at the bottom of the
setting tool with shear pin arrangement. The function of the plug is to separate the cement
from the displacing fluid. Once the plug latches in the latch collar it provides a pressure
seal and allows pressure testing the liner above the latch collar or inflating the external
casing packer. The drill pipe plug is dropped in the drill pipe after all the cement has been
pumped. The plug is displaced by the drilling fluid until it latches with the liner wiper
plug at the bottom of the setting tool. Higher pressure is applied to shear the wiper plug
from the setting tool and both plugs are displaced with drilling fluid until they latch in the
latch collar.
Cementing Techniques
A good liner cement job is one that allows drilling to the next casing point without
having to squeeze the liner shoe or the top of the liner. The cement job should also
provide an effective seal (if required) between the open hole and liner such that remedial
cement squeeze jobs are not required.
Studies have shown that 1-1.5 clearance between the liner and open hole resulted in
successful liner cement jobs. A way to increase clearance would be to drill larger holes or
run smaller liners. Another solution is to underream the open hole. Centralizing the liner
is very essential for a successful cement job. The centralizers should be spaced out to
provide at least a 70% stand off.
Liner movement during cementing greatly enhances cement placement efficiency and
displacement of mud in the liner hole annulus. Special liner hanger equipment is now
available which permit liner reciprocation or rotation while cementing. The maximum
liner length that can be suspended and rotated below a rotating liner hanger should be
confirmed with the manufacture. Short liners run across the Arab-D in Saudi Aramco are
rotated while cementing. If it is not possible to rotate liner while cementing, the liner
should be rotated while circulating and conditioning the mud.
Wide temperature variations across a long liner require special cement formulation. It
may be necessary to retard the cement to compensate for high temperatures at the bottom.
But, at the same time, it is necessary that the cement set at the lower temperature at the
top of the liner in a reasonable time. The cement thickening time should be long enough
to allow reversing out the cement above the hanger if required.
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Fluid loss additives are usually required especially across permeable formations to
prevent cement dehydration and bridging in the annulus. Fluid loss of 50-100 ml is
recommended for cementing a production liner where isolation behind the liner is
required. If isolation behind the liner is not essential, the amount of fluid loss should be
low enough to prevent cement dehydration and bridging and is based on experience and
economic considerations.
Cement volume for a liner cementing job should be based on the caliper log volume and
an excess amount that will result in a rise of less than 500 above the hanger. This excess
serves to remove the mud from the overlap and allows high quality cement to take its
place. Excessive cement columns above the hanger may prevent pulling out the setting
tool out of the cement. If a caliper survey is not available the hole volume may be
estimated by pumping a marker.
As in the case of casing cementing, after the liner is run to bottom the mud should be
circulated at least one hole volume and conditioned until low plastic viscosity and yield
values are obtained. It is recommended that the cement be batch mixed to obtain the
correct slurry density. Spacers should be used ahead of the cement and the cement should
be pumped in turbulent or plug flow if possible. Laminar flow should be avoided. It is
recommended that the cement be pumped by using the service company cement unit to
insure displacement accuracy.
1) With the bit on bottom circulate and condition mud. Make short trip and circulate
out any fill.
2) Make up and run the liner with float shoe on bottom and latch collar 2-4 joints
above shoe.
3) Centralize the liner to provide at least 70% stand off. Fill liner with drilling fluid
while running in hole.
4) Make up hanger on top of liner. Install setting tool in hanger and run liner on drill
pipe. Rabbit each stand of DP while RIH. Fill drill pipe before entering openhole.
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5) In deep wells, stop and break circulation at least once half way in the open hole.
Prior to circulating, reciprocate liner to break gel strength. Start slowly with low
pump pressure. If hydraulic liner hanger is used, circulating pressure should be well
below the setting pressure of the hanger.
6) If rotating hanger is used, rotate liner prior entering open hole and record torque.
7) Tag bottom and install cementing head. Reciprocate and break circulation at low
rate and pressure. Circulate at higher rate at least one hole volume. Record weight
of liner and drill pipe.
8) Set hanger. Slack off weight on the hanger to ensure hanger is set.
9) Release setting tool from hanger but keep setting tool stung in hanger. Set 10,000 lb
weight on hanger while cementing.
10) Batch mix cement to the programmed weight. Use retarders, fluid loss and other
additives as required. Measure slurry weight using pressurized mud balance.
12) Drop drill pipe plug. Pump drilling fluid and displace plug and cement using
service company pumps. Slow down pumping rate when DP plug approaches the
liner wiper plug. Continue displacing cement until DP plug latches and shears liner
wiper plug. Note increase in pressure on surface. Continue displacing cement until
liner wiper plug and DP plug latch into latch collar. Reduce pumping rate before
latching into latch collar and note increase in surface pressure when bumping the
latch collar.
13) Bleed pump pressure and check for flow back. Pull out setting tool to top of hanger
and reverse out excess cement above hanger. If reversing out is not required, pull
out setting and observe U-tube effect.
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FLOW CALCULATIONS
The flow properties of wellbore fluids are classified as Newtonian or non-Newtonian.
Newtonian fluids are fluids such as oil or water which exhibit a direct and constant
proportionality between shear rate (which related to velocity or flow rate) and shear
stress (which is related to flowing pressure drop) as long as the regime is laminar. In a
fluid of this type, viscosity is independent of shear rate at constant temperature and
pressure. A Newtonian fluid will begin to flow immediately when pressure is applied.
When pressure is released, the fluid returns to its previous state. See Fig (34).
Non-Newtonian fluids are fluids like mud, cement slurries and heavy asphaltic oil. These
are rheologically complex and are described as Bingham plastics or power-law fluids.
These fluids do not exhibit direct proportionality between shear rate and shear stress.
Some types of non-Newtonian fluids, such as drilling fluid, do not start to move when a
force is applied.
The two mathematical models commonly used to describe the flow behavior of drilling
fluids and cement slurries are the Bingham-plastic model and the power-law model.
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where 600 and 300 are the dial reading at 600 and 300 rpm.
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is,
S s = K ( S r ) n......................................................................... (5)
where,
The constant K is related to viscosity of the fluid, the larger K value the more viscous the
fluid. The constant n characterizes the degree of the fluids non-Newtonian behavior. The
valve of n for a non-Newtonian fluid is less than one and for a Newtonian fluid is one.
In placing cement slurry down hole the preferred method, where hole conditions permit,
is to thin the cement slurry and mud so that turbulent flow is induced. Turbulent flow will
result in high displacement efficiency and increases the probability of moving mud from
hole restrictions and reduces contamination of the cement sheath. Since the power-law
model yields more accurate results than the Bingham plastic model, a summary of the
frictional pressure loss equations for the power-law model in turbulent flow is presented
below.
The n and K constants are determined from the Fann viscometer as,
600
n = 3.32 log ....................................................... (7)
300
510 300
K = ..................................................................
(511)n
(8)
where the unit of K is equivalent centipoise or dynes per secn per 100 cm2.
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For pipe flow, the Reynolds number is calculated from the equation,
89100 v 2 n
n
0.0416d
NRe = 3 + 1 / n .........................................(9)
K
where,
q
v = average pipe velocity = ft / sec
2.448d 2
d = inside diameter, in
q = flow rate, gpm
= density, (lb/gal)
The Reynolds number is plotted versus the Fanning friction factor in Fig (36). The
critical Reynolds number, above which the flow is turbulent, is a function of the flow-
behavior index n. It is recommended that the critical Reynolds number for a given n
value be taken from Fig (36) as the starting point of the turbulent flow line for the given n
value. For example, the critical Reynolds number for n = 2 is 4200.
NRe = .........................(10)
K 2 +1/ n
n
n 3+1/
n
LKv
0.0416
P = ...............................................(12)
144000 d 1 + n
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n
n 2 +1/
n
LKv
0.0208
P = ......................................(13)
144000 (d2 - d1) 1 + n
where,
L f v2
P = ............................................................. (14)
2 5 .8 d
L f v2
P = .......................................................... (15)
21.1 (d 2 - d 1)
where,
f = fanning friction factor from Fig (36), dimensionless.
Example
A 600 ft 4-1/2 liner is to be cemented inside a 6-1/4 hole across the Arab-D reservoir to
shut off production from the super permeability zone. A 118 pcf Class G cement slurry
with fluid loss additive will be used to cement the liner. In order to have good cement job
that will provide isolation between the super permeability zone and the top of the Arab-
D, the liner will be rotated while cementing and the cement is to be pumped and
displaced in turbulent flow. a) At what rate the cement should be pumped in order to have
turbulent flow?, b) calculate the annular pressure loss across the liner. The Fann meter
dial readings were measured by Halliburton as 600 = 209 and 300 = 122.
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Solution
600
a) n = 3.32 log
300
209
= 3.32 log
122
= 0.776
510 300
K =
511n
510 122
=
5110.776
= 492
From Fig (36), for n = 0.776 turbulent flow will start at NRe of 2000. Using Eq (10),
we set the value of NRe = 2000 and solve for the average velocity v, or
2000 =
K 2 +1/ n
d1 = 4.5 in
d2 = 6.25 in
118
=
7.48
= 15.7 ppg
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From Eq (11),
q
v =
2.448 ( d2 2 - d12 )
In order to have turbulent flow in the annulus the rate should be 12.1 BPM or greater.
b) From Eq (15), the frictional pressure drop in the liner-hole annulus is,
L f v2
P =
21.1 (d 2 - d 1 )
From Fig (36), for NRe = 2000 and n = 0.776, the valve f is 0.0105.
Substituting in Eq (15),
Problem
Using the same slurry in the previous example, calculate the minimum rate to achieve
annular turbulent flow for cementing 7 liner inside 8.5 hole.
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INTRODUCTION 1
CAUSES OF KICKS 1
HOLE NOT FULL OF MUD 2
SWABBING DURING A TRIP 2
INSUFFICIENT MUD WEIGHT 3
SPECIAL SITUATIONS THAT REQUIRE EXTRA CARE 3
- LOSS CIRCULATION 3
- DRILL STEM TESTING 3
- DRILLING INTO AN ADJACENT WELL 3
- EXCESSIVE DRILLING RATE THROUGH A GAS SAND 4
WELLBORE MECHANICS 8
PRESSURE RELATIONSHIPS 8
INFLUX BEHAVIOR 11
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KICK IDENTIFICATION 20
SEGMENT DRILLING
CHAPTER WELL CONTROL
INTRODUCTION
Blowouts or the uncontrolled flow of oil and gas have long been a serious problem in
drilling operations. If blowouts are not quickly brought under control they can cause
casualties, environmental damage and economic losses. For these reasons, drilling
personnel must be able to recognize the warning signs of potential blowouts, to plan
effective well killing operations, and to take positive action to control the well. The
catastrophic problems associated with uncontrolled blowouts can be avoided if the kick
is detected before a large volume of formation fluid enters the wellbore.
The purpose of this chapter of Well Control is to explain why and how wells kick and
to describe in detail the recommended method of well control.
CAUSES OF KICKS
A kick is the entry or influx of formation fluids from a permeable formation into the
wellbore. The goal of well control operations is to prevent a well kick from becoming a
blowout (uncontrolled flow of formation fluid).
An understanding of why wells kick coupled with the ability to recognize and evaluate
the surface warning signs that indicate possible kick occurrence will substantially
increase the probability of successfully controlling the well.
The two conditions that must be present in the wellbore for a kick to occur are:
1) the pressure inside the wellbore at the face of the kicking formation must be less than
the pore pressure of the formation, and
2) the kicking formation must have sufficient permeability to allow flow into the
wellbore.
Since formation permeability cannot be controlled, drilling personnel should utilize all
techniques at their disposal to ensure that the pressure inside the wellbore is always
greater than the formation pressure.
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Most kicks occur when one or more of the following conditions exist:
If no mud is added to the hole as the pipe is pulled, it is possible to reduce the
hydrostatic pressure of the mud column to less than the formation pressure. When this
happens, a kick can occur.
To prevent this loss in hydrostatic pressure, it is only necessary to fill the hole on a
regular schedule or continuously with a trip tank to replace the metal volume of the
pipe being pulled, and to replace the mud lost through seepage.
The metal volume of the pipe being pulled can be calculated, but the mud additions
necessary to replace the seepage losses can be predicted only be comparison to the
mud volume schedule required to keep the hole properly filled on previous trips. For
this reason, it is imperative that a record of mud volume required versus the number
of stands pulled on every trip be maintained on the rig.
Some loss in hydrostatic mud pressure due to swabbing cannot be avoided; however,
the pressure reduction should not exceed the overbalance pressure of the mud
column.
Swabbing pressure is a function of pipe-pulling speed, mud properties, and annular
clearances.
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A) Loss of Circulation
Loss of circulation can cause the mud level in the hole to drop. This reduction in
height of the mud column reduces the hydrostatic well bore pressure and could
result in a well kick if the wellbore pressure becomes less than the pore pressure
of a permeable formation.
During the course of the test, the borehole or casing below the packer and at least
a portion of the drill pipe or tubing is filled with formation fluid. At the
conclusion of the test, this fluid must be removed by proper well control
techniques to return the well to a safe condition.
Failure to follow the correct procedures to kill the well could lead to a blowout.
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of a previously completed well, the formation fluid from the completed well will
enter the wellbore of the drilling well, causing a kick. This is an extremely
dangerous situation and could easily result in an uncontrolled blowout.
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If the pump rate is held constant, the flow from the annulus should be constant. If the
annulus flow increases without a corresponding change in pump rate, the additional
flow is caused by formation fluid feeding into the wellbore.
Faster penetration rates due to increasing pore pressures are usually not as abrupt as
drilling breaks, but they can be. In order to be sure that the gradual increases in pore
pressure are recognized, a penetration rate versus depth curve is usually required to
highlight the trend of increasing pressures.
The lowering of pump pressure and increase in pump speed is also characteristic of a
hole in the drill string commonly referred to as a washout. Until a determination can
be made whether a washout or kick has occurred, a kick must be assumed.
6. GAS-CUT MUD
Gas-cut mud often occurs during drilling operations and can be considered one of the
early warning signs of a potential kick; however, it is not a definite indication that a
kick has occurred or is impending. An essential part of analyzing this signal is being
able to determine the downhole conditions causing the mud to be gas-cut. Gas-cut
mud occurs as a result of one or more of the following downhole conditions:
A) Drilling a gas-bearing formation with the correct mud weight in the hole.
B) Swabbing while making connections or making a trip.
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C) Feed-in of gas from a formation having a pore pressure greater than the
hydrostatic pressure exerted by the mud.
A) Drilled Gas
When the hydrostatic pressure exerted by the mud is greater than the pore
pressure of a gas-bearing formation being drilled, there will be no feed-in of gas
from the formation. Nevertheless, gas from the drilled cuttings will mix with the
mud causing the mud returns to be cut.
Quite often when the drilled gas reaches the surface, the annular preventer must
be closed and the mud circulated through the open choke manifold. This prevents
the expending gas from belching mud through the bell nipple. If this belching
is permitted, the hydrostatic head will be reduced due to loss of mud from the
hole.
C) Gas Flow
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Feed-in from a gas sand while drilling is a serious situation. The formation pore
pressure must exceed the hydrostatic pressure of the mud plus the circulating
friction losses in the annulus for gas from the formation to flow into the wellbore
while drilling. Once feed-in begins, continued circulation without the proper
control of surface pressures may induce additional flow, since the density of the
hydrostatic column (annulus) is continually lessened by the flow of formation
fluid.
Unless mud continues to flow from the annulus, drilling can usually be resumed without
increasing the mud weight. If the mud continues to flow, even slightly, the well should be
shut in and checked for pressure.
Once feed in is detected and the well is shut in, the formation fluid must be properly
circulated out before resuming normal operations. A complete understanding of the
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pressure relationships in the wellbore during killing operations as well as the correct
operational procedures to kill the well are essential.
WELLBORE MECHANICS
The primary objective in
circulating out a kick is to 520 PS I
establish and maintain a 735 PSI
constant bottom hole
D R ILL
pressure slightly greater PIPE C ASIN G
than the pressure of the
kicking formation during
the entire well killing
operation. This is
necessary to prevent
additional feed in from
occurring while the kick is
being circulated out and to
minimize the pressure
imposed on the casing or
formations in the open
hole. As a basis for 10# / G AL 10#/G AL.
considering well control MUD MUD
methods, this section
contains a review of the
pressure relation ships that
exist in the wellbore and
20 B B L. G AS EN TR Y
the behavior of the
different fluids that can be
present. 10,000 ft B H P 5720 PSI
FO R M ATIO N 5720 PSI
A) Pressure Relationships
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After a kick is detected and the well shut in, no more formation fluid can flow into
the wellbore after pressures stabilize (except in the case of an underground blowout).
At this point, the well is in a pressure balanced condition.
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On the drill pipe, the gage pressure and hydrostatic pressure of the mud act in a
downward direction. These pressures are exactly balanced by the formation pressure
acting upward.
Drill pipe gage pressure + Hydrostatic pressure of the mud = Formation pressure
The casing pressure is greater than the drill pipe pressure because the gas influx does
not exert as much hydrostatic pressure as the same height of mud in the drill pipe.
The drill pipe provides a direct link to the bottom-hole pressure since the gage
pressure can be read at the surface and the drill pipe should contain only mud of
known weight. The drill pipe usually has a float (back pressure value) above the bit
which will prevent the influx from entering the drill pipe. If we begin circulating this
well under controlled conditions to maintain a constant bottom-hole pressure and do
not increase the mud weight, the well can be shut in at any time, and the shut in drill
pipe pressure will still be 520 psi. The drill pipe pressure which will be required to
maintain a constant bottom hole pressure is dependent on the mud weight inside the
drill pipe under stabilized shut in conditions.
In the annulus, the pressure relationships are not predictable because of the presence
of the formation fluid. The casing pressure that will be required to maintain a
constant bottom hole pressure is dependent upon the type of formation fluid and the
height or vertical length of formation fluid present in the annulus. Under actual
conditions you really dont know for sure either the type or the height of formation
fluids. This is the reason we use the drill pipe pressure for well control.
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B) Influx Behavior
Water, which is nearly incompressible, does not expand to any appreciable extent as
the pressure is reduced. Because of this property, the pumping rate and returns rate
will be equal as the water kick is circulated from the wellbore provided no further
water influx is permitted. The casing pressure will change with a constant bottom
hole pressure as the water height in the annulus changes with the hole geometry. The
casing pressure will also change as the lighter water is displaced and the heavier mud
replaces it in the annulus. Increases in mud weight during the kill operation will also
cause changes in the casing pressure. Nearly all water influxes contain some solution
gas which will make the surface pressures form the same pattern as seen during a gas
kick, but to a lesser degree.
Oil, like gas-charged salt water, behaves essentially like a gas influx.
Gas, is a highly compressible fluid. The volume occupied by a certain amount of gas
is a function of both temperature and pressure.
For instance, consider a barrel of gas at the bottom of a 10,000 foot well. The bottom
hole temperature is 240 oF and the well is full of 9.0 ppg mud which provides a
hydrostatic pressure of 4680 psi on the gas. This same barrel of gas will expand to
occupy a volume of 202 barrels under surface conditions of 14.7 psi and 80 oF.
Temperature also affects the volume, but to a lesser extent (for the wellbore
temperature range) and in the opposite direction. In the above example, the barrel of
gas would have occupied 261 barrels at the surface if the temperature was held
constant at 240 oF while the pressure was reduced from 4680 psi to 14.7 psi.
If that barrel of gas were not allowed to expand in a controlled manner as it was
circulated up the wellbore, it would maintain its initial pressure of 4680 psi as it
moved up the annulus, and would create excessive wellbore pressures.
The pressure relationships outlined in this section are the basis for effective well
control. The Drill Pipe Pressure Method applies these principles and, in so doing,
assures that a constant bottom-hole pressure is maintained throughout the killing
circulation.
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In order to appreciate the dangers of using the constant pit level method to control the
well, it is necessary to review the basic pressure relationships which are caused by the
presence of a gas kick in a wellbore.
Ft x 1000
0
SURFACE PRESSURE = ZERO PRESSURE AT TOP
OF GAS = 4166 PSI
6
P = 75 / 144 X 8000 = 4166 PSI
PRESSURE AT TOP OF GAS
BUBBLE IS 4166 PSI
8
GAS
BHP = 8532 PSI
0.1 X 2000 = 200 PSI = 122.6 PCF
BHP = 4366 PSI
10
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In Figure 3, a gas influx has entered the wellbore, but no further flow is taking place
because the hydrostatic pressure of the 75 pcf mud (4166 psi) plus the hydrostatic
pressure of the gas (200 psi) exactly equal the bottom hole pressure of 4366 psi. If it were
possible to insert a pressure gage at the top of the bubble, the gage would read 4166 psi.
Using the constant pit level method, the gas is circulated to the top of the well. Since the
volume of the gas bubble has not been allowed to change, the pressure at the top of the
bubble has remained constant at 4166 psi.
The hydrostatic pressure caused by the density of the gas and mud still exerts a combined
pressure of 4366 psi on the bottom of the hole, but now the gas pressure of 4166 psi must
be added so that the total pressure exerted on the bottom of the hole is 8532 psi. Had this
situation occurred on a drilling well, lost returns could certainly have been expected.
Excessive pressure buildups will result when the constant pit level method is used for
well control.
SID PP x 144
= ... (1)
TD
where,
= kill mud weight, pcf
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The maximum allowable surface casing pressure that will not burst the casing at shoe
depth is,
The lower of the two values of Pmax from Eq (4) or Eq (5) must not be exceeded during
the killing operation.
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The drill pipe pressure method is the recommended procedure for killing any well if the
well has been successfully shut-in without loss of returns. The kill procedure is
summarized as follows:
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6. Determine the circulating drill pipe pressure. This can be done by holding the casing
pressure constant at the shut in value and pumping down the drill pipe at constant
and reduced rate of 0.5 to 2.5 BPM. As the pump starts, the casing pressure tends to
increase. The choke on the annulus is manipulated to keep the annulus pressure
constant at the shut-in value. By holding the annulus pressure constant at the shut-in
value for the short time required to bring the pump to the desired speed, the bottom
hole pressure remains essentially constant and no additional influx will enter the
wellbore. With the pump running at the desired constant speed (rate) and the casing
pressure maintained constant at the shut-in value, read and record the drill pipe
circulating pressure
The bottom hole pressure is common to both the annulus and drill pipe, and is being held
constant by holding the casing pressure constant. (The drill pipe pumping pressure
read at this point is that pressure necessary to maintain a constant bottom hole
pressure). This is true as long as the pump rate and mud weight remain the same.
The difference between the shut-in and pumping drill pipe pressure is the pressure
necessary to cause the mud to circulate at the desired rate.
Changes in drill pipe pressures due to choke manipulation will usually require
approximately 2 seconds per 1000 feet of well depth to register on the stand pipe
gauge; however, this lag in response time can be longer if the mud is contaminated or
a large gas kick is present.
7. Once the drill pipe circulating pressure becomes stabilized at the desired casing
pressure, hold the drill pipe pressure constant by adjusting the annulus choke.
Continue to pump original mud at the same CONSTANT rate and circulate out the
kick to surface.
8. Pump kill mud of heavier density to the bit, make downward correction in the drill
pipe pressure as described in the following section.
9. Continue circulating at CONSTANT pumping rate until mud of the required density
to kill the well occupies the wellbore.
In the above procedure the kick is circulated out in Step # 7 using the original mud
weight and then kill mud is circulated to kill the well. This approach of weighting up the
mud, called the Drillers Method, offers the advantages of relative speed and
simplicity, but
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If sufficient barite is available on the well site, Step # 7 may be deleted and the well
killed by circulating kill mud as in Step # 8. This method of weighting up the mud, called
the Wait-and-Weight Method, will result in lower surface casing pressures and requires
less time since the well is killed in one circulation. The drill pipe pumping pressure
should be adjusted to correct for the increase in hydrostatic pressure and frictional
pressure losses as a result of pumping the heavier kill mud. The procedure for adjusting
the drill pipe circulating pressure is described in the following section.
The change in pressure drop through the bit increases linearly with mud density. Also,
the frictional pressure loss in the drill string for the usual case of turbulent flow can be
assumed to increase linearly with mud density without introducing a large error. Since
the annular pressure losses are small, the frictional pressure loss due to a change in mud
density can be approximated using
i
Pf = Pi f ............................................ (7)
i
where,
Pf = increase in frictional pressure, psi
f = final kill mud weight, pcf
i = original mud weight, pcf
Pi = initial frictional pressure in drill string, psi
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The net decrease in circulating drill pipe pressure required to offset the increase in
hydrostatic pressure and frictional pressure loss between the surface and the bit is given
by
P = Ph Pf
L P
= ( f i ) i .................................... (8)
144 i
Since this relation is linear with respect to mud density increase, it is convenient to
calculate only the final circulating drill pipe pressure corresponding to the final kill mud
density reaching the bit. Intermediate drill pipe pressures are determined by means of
graphical interpolation.
Example
A 20-bbl kick is taken at a depth of 10,000 ft. After the pressures stabilized, an initial
drill pipe pressure of 520 psig and an initial casing pressure of 720 psig were recorded.
The ID of the 9100-ft 5 drill pipe is 4.276 and the ID of the 900-ft drill collars is 2.5
Original mud weight of 72 pcf was pumped down the drill pipe at a constant rate of 20
strokes per minutes and a pressure of 1300 psi while holding the casing pressure constant
at the initial shut-in value of 720 psi. The pump factor is 0.2 bbl/stroke. Calculate,
a) the bottom hole circulating pressure that should be maintained constant during the kill
operation,
b) the kill mud weight that will provide 150 psi overbalance,
c) the drill pipe pressure schedule required to keep the bottom hole pressure constant as
the density of mud in drill pipe increases from the initial value of 72 pcf to the final
kill mud density.
Solution
a) The bottom hole circulating pressure is the initial shut-in drill pipe pressure plus the
hydrostatic pressure of the mud. Bottom hole pressure
72
Bottom hole pressure = 520 + 10000 = 5520 psi
144
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150 x144
Mud weight to overbalance formation pressure = 79.5 + = 816
. pcf
10000
. ( 4.276)
314
c) Capacity of drill pipe = = 0.0177 bbl / ft
4 x144 x5.61
. ( 2.5)
2
314
Capacity of drill collars = =.00607bbl / ft
4 x144 x5.61
The frictional pressure drop in drill pipe while pumping 72 pcf mud at 20 strokes/min
is
Pi = 1300 520 = 780 psi
The total drill pipe pressure change required to maintain the bottom hole pressure
constant as the mud weight increases from 72 to 81.6 pcf is given by Eq (8)
10000 780
= ( 816
. 72)
144 72
= 562 psi
Thus, the final circulating drill pipe pumping pressure when kill weight mud reaches
the bit is,
1300 562 = 738 psi
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The initial circulating drill pipe pressure is 1300 psi and the final pressure when the
kill mud reaches the bit after pumping 832 strokes is 738 psi. Assuming linear
relation, intermediate values of drill pipe pressures can be obtained graphically as
shown in Fig (4).
For example, after pumping 400 strokes (80 bbls of kill mud) the drill pipe circulating
pressure should be 1030 psig in order to maintain constant bottom hole pressure.
KICK IDENTIFICATION
The annular pressure profile that will be observed during well control operations depends
to a large extent on the composition of the kick fluids. In general, a gas kick causes
higher annular pressures than a liquid kick. This is true because a gas kick
1) has a lower density than a liquid kick and
2) must be allowed to expand as it is pumped to the surface.
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Both of these factors result in a lower hydrostatic pressure in the annulus. Thus, to
maintain a constant bottom hole pressure, a higher surface annular pressure must be
maintained using the adjustable choke.
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A pressure balance on the initial well system for a uniform mud density i , is given by,
i TD i Li fLf
SIDPP + = SICP + +
144 144 144
If the kick volume is smaller than the annular volume opposite the drill collars, the length
of the kick can be expressed in terms of the kick volume and the annular capacity
opposite the drill collar,
V f x 1029.4
Lf = .................................. (10)
2
Doh Ddc
2
Substituting in Eq (9),
=
144( SIDPP SICP) Doh
2
(
Ddc2 ) + ..................... (11)
i
f V f x 10294
.
where,
TD = Total depth, ft
Vf = Volume of kick, bbl
Ddc = OD of drill collars, in
Doh = Diameter of hole, in
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If the volume of the kick is larger than the annular volume opposite the drill collars, then
the length of the kick becomes,
L =L +
(V f )
Vdc 1029.4
.............................. (12)
f dc D Ddp
2
oh
2
where,
Vdc = Annular volume opposite drill collars, bbl
Ddp = OD of drill pipe, in
Ldc = Length of drill collars, ft
The density of the kick f is obtained by substituting Eq (12) into Eq (9). If the calculated
kick density is less than 22 pcf then the kick fluid is gas, and a kick density greater than
60 pcf indicates that the kick fluid is predominantly liquid.
Several factors can cause large errors in the calculation of kick fluid density when the
kick volume is small. Hole washout can make the determination of kick length difficult.
In addition, the pressure gauges often do not read accurately at low pressures. Also, the
effective annular mud density may be slightly greater than the mud density in the drill
pipe because of entrained drilled solids. Furthermore, the kick fluid is mixed with a
significant quantity of mud and often cannot be represented accurately as a slug. Thus,
the kick density computed using Eq (9) should be viewed as only a rough estimate.
Some improvement in the accuracy of the kick density calculation can be achieved if the
volume of mud mixed with the formation fluids is known. The minimum mud volume
that was mixed with the kick fluids can be estimated using the expression
Vm = qt d
where q is the flow rate of the pumps, and td is the kick detection time before stopping the
pump and closing the blowout preventer.
The mean density of the kick-contaminated zone mix can be computed from Eq (11) by
using Vmix instead of Vf . The density of the kick fluid can be calculated from the mixture
equation,
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mixVmix Vmi
= ................................. (14)
f Vf
Example
A well is being drilled at a vertical depth of 10,000 ft while circulating a 9.6-lbm/gal mud
at a rate of 8.5 bbl/min when the well begins to flow. Twenty barrels of mud are gained
in the pit over a 3 minute period before the pump is stopped and the blowout preventers
are closed. After the pressures stabilized, an initial drill pipe pressure of 520 psig and an
initial casing pressure of 720 psig are recorded. Compute the density of the kick fluid.
The total capacity of the drill string is 130 bbl. The size of the hole is 10.25 in. The drill
pipe OD is 5 in and the OD of the 900 ft of drill collars is 8.125 in.
Solution
The annular volume opposite 900 ft of drill collars is
V dc =
314 (
. 10.25 2 8125
. 2 900 ) = 34.14 bbl
4 x 144 x 5.61
If it is assumed that kick fluid entered as a slug, then volume of kick is less than the
annular volume opposite drill collars. Thus Eq (11) is used to calculate the density of
kick fluid.
f =
(
144 ( 520 720) 10.252 8125
. 2 ) + 9.6 x 7.48 = 17.18 pcf
20 x1029.4
If it is assumed that the kick fluids are mixed with the mud pumped while the well was
flowing,
Vmix = 20 + Vm
bbl
Vm = 8.5 x 3 min = 255
. bbl
min
Vmix = 20 + 25.5 = 45.5 bbl
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Since the volume of kick is larger than the annular volume around the drill collars, the
length of kick is calculated by using Eq (12),
Using Eq (9), the density of contaminated kick (kick fluid + mud) is,
. 255
44.27 x455 . x9.6 x7.48
= = 9.15 pcf
f 20
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In Fig (6) the gas kick is shown to have moved up from the bottom of the hole to a new
position. A pressure balance on the new well system yields,
Pf = Pb + Pg + Pa + CP .................................. (15)
where,
Pf = formation pressure, psi
Pb = hydrostatic pressure of mud column below gas bubble, psi
Pg = pressure of the hydrostatic column of gas, psi
Pa = hydrostatic pressure of mud column above gas bubble, psi
CP = casing surface pressure, psi
Since Pf = Pb + Pgb
Pgb = Pf - Pb
where Pgb is pressure at bottom of gas bubble.
The volume of the gas kick at the new position is calculated from the real gas law,
V f Pf Tbg Z g
Vg = .................................. (16)
Pgb T f Z f
where,
Vg = Gas volume at new position, ft3
Vf = Gas volume at initial position at TD, ft3
Zf = Gas compressibility factor at reservoir conditions
Zg = Gas compressibility factor at the new position conditions
Tf = Reservoir temperature, degree Rankine
Tbg = Temperature at bottom of gas bubble, degree Rankine
The density of the gas at the new position is also determined from the real gas law as,
f Pgb Tf Z f
g = ......................................... (17)
Pf Tg Zg
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The length of the gas bubble is calculated from Eq (10). From the pressure balance Eq
(15) the casing surface pressure is
Lb b L g g La a
CP = Pf .......................... (18)
144 144 144
where,
Lb = Length of mud column below gas bubble, ft
Lg = Length of gas bubble, ft
La = Length of mud column above gas bubble, ft
b = Density of mud below gas bubble, pcf
a = Density of mud above gas bubble, pcf
g = Density of gas at new position, pcf
Example
Consider the kick described in the previous example. Refer to Fig (7).
a) Compute mud density required to kill the well.
b) Compute the pressure at the casing seat located at 3,500 ft for initial well conditions.
c) Compute pressure at casing seat after circulating 170 bbls of kill fluid in the annulus
while maintaining the bottom hole pressure constant through the use of adjustable
surface choke.
d) Compute the new surface casing pressure after circulating 170 bbls kill mud in the
annulus.
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Solution
a) From Eq (2), the kill mud density with zero overbalance is
520 x144
= + 9.6 x7.48 = 79.3 pcf
10,000
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9.6 x 7.48
P = 720 + 3500 x = 2465 psi
144
The region above the kill mud in the annulus contains 130 bbls of 9.6 ppg mud which
130
was displaced from the drill pipe. The length of this column is = 1670 ft .
.0778
The region above 9.6 ppg mud is the gas. The approximate pressure of the gas is
needed to compute the gas volume and length.
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This pressure occurs at a depth of 10000 - 2646 - 1670 = 5684 ft. The temperature of
the gas at 5684 ft is
(10000 5684)
Tbg = 200 - 0.1 x
100
= 195.6 oF
= 195.6 + 460 = 655.6 oRankine.
34
The length of the gas region is = 437 ft
.0778
718
.
d) Casing surface pressure = 2316 - 3500
144
= 570 psi
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CHAPTER BLOWOUT PREVENTER EQUIPMENT
INTRODUCTION 1
GENERAL REQUIREMENTS 1
BLOW OUT PREVENTERS 1
ANNULAR PREVENTERS 2
HYDRIL GK 2
HYDRIL 3
DIVERTER SYSTEMS 6
RAM PREVENTERS 7
HYDRIL 7
- PIPE RAM 8
- BLIND RAM 10
- SHEAR RAM 10
STACK ARRANGEMENTS 16
ARRANGEMENTS 16
STACKS WITH TWO RAM PREVENTERS 19
ARRANGEMENT LOGIC 20
STACKS WITH THREE RAM PREVENTERS 21
ARRANGEMENT LOGIC 21
BOP ARRANGEMENT - ONE PIPE SIZE 23
BOP ARRANGEMENT - TWO PIPE SIZES 24
"CLASS A" SAUDI ARAMCO 3000 PSI BOP STACK 26
"CLASS A" SAUDI ARAMCO 10,000 PSI BOP STACK 27
SUMMARY 29
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CHAPTER BLOWOUT PREVENTER EQUIPMENT
SEGMENT DRILLING
CHAPTER BLOWOUT PREVENTER EQUIPMENT
INTRODUCTION
General Requirements
The purpose of a blowout control system is to maintain control of the well when wellhead
pressures develop, and this requires a means of closing the hole, controlled release of fluids, and
a means of pumping into the hole.
The first requirement implies having large valves (BOPS) attached to and supported by casing
cemented in the well. In addition, the casing must be of sufficient burst strength and set at such a
depth that the estimated formation strength is enough to resist rupture. There must be provisions
for closing the well with and without pipe in the hole, a means of closing around drill pipe when
it is present, and a means of stripping pipe in or out of the hole. Pipe in this case may be drill
pipe, drill collars, tubing, or casing.
Controlled release of fluids requires valves, chokes, and lines which allow mud, gas, oil, or water
to bleed or flow at necessary rates under varying pressures, with further provision for directing
these fluids to waste pit, separator, flow box, or mud tanks as desired.
When drill pipe is in the hole, mud is usually pumped through the mud circulation system; but
under excessive pressures or when pipe is out of the hole, additional pump-in connections
become necessary. In addition, a power source and control system for quickly closing the BOPs
and other control valves are needed for even the simplest low-pressure systems.
The annular BOP provides quick positive closing action with simplified controls to keep drilling
fluids in the hole when a blowout threatens. The universal seal feature of the annular blow out
preventer permits closing and sealing on virtually anything in the well bore; drill pipe, kelly, tool
joints, collars, tubing or casing. The annular can strip (move pipe with pressure on the annular)
any pipe, close the annulus or close the open hole if needed. The annular blowout preventer will
be discussed in the annular section.
The ram blowout preventer is essentially a specialized valve to close the wellbore. Similar in
operation to a gate valve the ram BOP has gates called rams which meet at the center of the hole
and close off the hole. These rams are designed to seal around pipe (pipe rams) or seal the
wellbore completely without pipe in the hole (blind or shear rams). The ram blowout preventer
will be discussed in the ram preventer section.
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Annular Preventers
Annular preventers are composed of specially designed, steel-reinforced resilient elements that
can seal around any cylindrical or nearly cylindrical objects that go through the BOPs. They will
also seal over the open hole, and can pass drill-pipe tool joints without severe damage to the
sealing element. Because of their flexibility, the annular preventers are often referred to as
Universal Preventers.
Wear Plate
Packing Unit
Head
Opening Chamber & Port
Piston
Referring to Figure 1;
1. The wear plate serves as an upper non sealing wear surface for the movement of the packing
unit.
2. The packing unit is the compressible element that closes around the pipe or closes on open
hole to seal the wellbore .
3. The head is the part of the annular preventer that is removed when the packing unit needs to
be replaced. The head is secured either by threads (Figure 2) or by latching (Figure 3).
4. The opening chamber accepts pressured hydraulic fluid to move the piston down.
5. The piston is the part that applies proper forces on the packing unit to effect a seal.
6. The closing chamber accepts pressured hydraulic fluid to move the piston up.
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Screwed Head
Threads
Latched Head
Latch
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Annular preventers are actuated by applying hydraulic pressure to the closing chamber through
the closing port. The pressured hydraulic fluid forces the wedge shaped piston upward causing
the packing unit to move upward and inward thus squeezing it into the wellbore to seal on open
hole or around whatever pipe is in the hole. To open the hole or annulus, hydraulic pressure is
removed from the closing port and applied to the opening port. The pressured hydraulic fluid
forces the piston down which allows the packing unit to relax. The resilient construction of the
packing unit allows it to return to its original shape.
Drill pipe can be rotated and tool joints stripped through the closed packing unit, while
maintaining a full seal on the pipe. Stripping is the act of moving the pipe in or out of the hole
through the closed packing unit without losing control of the well while there is pressure in the
wellbore. Longest packing unit life is obtained by adjusting the closing chamber pressure just
low enough to maintain a seal on the pipe with a slight amount of drilling fluid leakage as the
tool joint passes through the packing unit. This leakage indicates the lowest usable closing
pressure for minimum packing unit wear.
Well fluid should not be the only lubrication during stripping through any annular preventer.
Drilling mud or gel (bentonite) and water are excellent lubricants and will not react with rubber.
The element should be lubricated continuously during stripping operations.
Use of an annular preventer adds capabilities not possible with the ram type arrangement alone.
The advantages are that:
1. Closure can be made on drill collars or casing.
2. Closure can be made on tool joints or on the kelly.
3. Closure can be made on any segment of a tapered drill string.
4. Closure can be made on swab, logging and perforating lines and tools.
5. Drill pipe can be reciprocated.
6. Faster well closure is possible because the pipe does not need to be positioned.
7. The string can be stripped in or out of the hole.
8. A back-up for both blind rams and pipe rams is provided.
Life of the sealing element is shortened by repeated closure. For this reason, testing should be
less frequent than normal for ram preventers. Closure on open hole tends to shorten the sealing
element's life. To extend element life when testing the annular preventer, it should be closed with
less than normal operating pressure, and always with pipe in the hole.
If a kick occurs while running casing, ram-type preventers should be used for closure where
available. In the absence of correctly sized rams, annular preventers must be used. Some casing
sizes may be deformed and even crushed by annular preventers that are closed at pressures
recommended for closure on drill pipe. Closing pressures to avoid casing damage vary with
casing size, preventer size, preventer model and manufacturer. These recommendations are
included in the operating and maintenance manual for each preventer and should be kept at the
rig site.
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Old elements can be removed and new elements inserted with drill pipe in the hole by vertically
cutting the elements in a groove between metal segments. The cut is opened to permit the
element to be wrapped around the pipe. Cutting will not affect the sealing ability
When the well pressure is high enough, the preventer will not leak well fluids even if the closing
pressure were bled to zero. For example, a 13-5/8 GK closed on 4-1/2 drill pipe will leak at
zero closing pressure if well pressure is 1700 psi or less. At higher well pressures it will not leak.
High closing pressures, especially when combined with high well pressure and pipe movements,
can destroy a GK element. This is particularly true of the larger models because of the high
closing force caused by the larger piston area. There have been instances where 7-1/16 GKs
have been closed at 3000 psi without severe seal damage; however, such high pressures can
damage the element and are not required for a seal. Closing pressures of 3000 psi on 13-5/8 and
larger will often blow the seal out of a GK preventer. If there is concern about an annular
preventer's sealing around drill pipe, use a ram preventer. Generally, drilling contractors keep a
GK Hydril adjusted at 700-900 psi when closing on pipe. If closing on wireline or open hole,
closing pressure is adjusted to about 1100 psi.
There is a relatively large selection of annular preventers available (see Table 3):
Three types of resilient elements are available (Table 1): natural rubber, nitrile rubber, and
neoprene rubber. Natural rubber should be used only when drilling with water-base drilling
fluids without added oil. This material gives the longest life under such conditions, but always
leaves a question about performance if closure is necessary on flowing oil. The synthetic
resilient elements are for use with mud containing oil. Nitrile rubber is limited to use at
temperatures above 20F, and neoprene is used for temperatures down to -30F.
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Diverter Systems
A diverter system is a large, low-pressure annular preventer with large relief (discharge) lines to
divert produced well fluids away from the rig while regaining control of a shallow gas flow. It
may be used with drive pipe, conductor pipe, or with short surface strings that have not been set
deeply enough for the well to be shut in, i.e. where broaching would occur, making a true shut in
impossible. When properly designed, a diverter system allows the crew to work on the rig floor
with less chance of fire or of being hit by debris blown from the well.
30"
Annular
Hydraulic Control Hydraulic Control
10-3/4" OD x 10.05" ID Gate Valve 10-3/4" OD x 10.05" ID
Gate Valve
Diverter Line Emergency Diverter Line
Pump In
Valve Bore 6 1/8" Connection Valve Bore 6 1/8"
30"
2" WECO Union 600 MSS
Outlet for 2" Valve Flanges
Figure 4 is a Saudi Aramco diverter system. A true diverter system, by definition, closes the
annular and opens the HCR (Hydraulically Controlled Remote) valve at the same time. The well
cannot be shut in because it cannot hold the shut in pressure; the formation at the conductor shoe
will fracture. This action would lead to an underground blowout which is more difficult to kill.
The underground fracture could come to the surface thereby causing a blowout with no means of
control and possible loss of the rig.
On land rigs, the flowline is run to the reserve pit. These lines should be at least 100 ft long,
discharging the effluent a safe distance from the rig. The minimum line ID should be 7 in.
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RAM PREVENTERS
The ram preventer is the result of some eighty years of development. The first ram preventers
were developed in the early 1900s. The ram preventer will only seal on the specific condition
for which the ram block is designed.
Ram Body
Seal Seat
Bonnet Seal
Ram Block
Emergency Piston
Rod Packing
Bonnet &
Bonnet Bolts
Fluid Connection
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6. The emergency piston rod packing which is a grease injection port that allows a seal to be
made on the piston rod should the primary seal begin to leak.
7. The bonnet seal which is an elastomeric seal that prevents wellbore fluid under pressure from
escaping.
8. The seal seat which is a replaceable part that stops wear on the ram body by the operation of
the ram block. It can be replaced in the field.
9. There are two types of ram blocks with packer seals:
I. Ram blocks that seal on pipe (Figure 6) or wireline in the hole. The block is
specifically designed for a particular size of drill pipe, tubing, casing or wireline.
Block Body
Ram Packer
Ram blocks designed for pipe should not be closed without pipe in them because the
sealing elements may be damaged by extrusion.
Ram Packer
Pipe
Ram Packer
Pipe
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The pipe ram block can also be a variable bore block (Figure 9) which can seal on a
size range.
Ram Body
Ram Packer
with Inserts
Variable rams became available by 1979. These rams extend the versatility of the
ram-type preventer by sealing on pipe of various sizes. This flexibility could
eliminate the need for changing rams when running a tapered string or when testing
with tubing. Variable rams use steel fingers that move inward to seal around pipe
smaller than the ram body.
All manufacturers of ram preventers offer variable bore rams (Figure 9) which can
close and seal on a range of pipe diameters. These rams can be especially useful when
a tapered string is in use or when substructure space limitations restrict the addition
of another ram preventer. Also if aluminum drill pipe is being used an effective seal
cannot always be assured with regular pipe rams because the diameter of the pipe is
larger near the tool joints than at the middle of the joint.
Variable bore rams have limited hang off potential, depending on the size of pipe on
which they are sealing. For example Cameron variable bore rams (13-5/8 U for 5 to
2-7/8) will support 450,000 pounds of 5 drill pipe or 150,000 pounds of 3-1/2 drill
pipe. Most variable bore rams are constructed in a similar fashion with the key
element being a feedable rubber packer.
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II. Ram blocks that can be closed on open hole. There are two types of rams which do
not have pipe openings and can be closed on open hole. The most widely used is the
blind rams (Figure 10);
Ram Block
Ram Packer
the other is the shear ram. The shear ram (Figures 11 & 12) is designed to cut through
tubing, drillpipe or casing and it has the ability to seal on open hole. Shear rams are
used mostly in a subsea stack.
Ram Body
Packer
Seal
Lower Blade
Ram Body
Ram Packer
Upper Blade
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Rams are interchangeable between ram-type preventers of the same design and
pressure rating. Casing rams are usually substituted for pipe rams when casing is run.
Most pipe rams can be locked in the closed position, operated manually and
hydraulically and support the weight of the entire drill string. Pipe rams cannot be
installed upside down because they are designed to hold pressure from one direction
only.
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The assembly working pressure should be equal to the maximum possible surface pressure, and
any choice will be arbitrary to some extent. The safest approach is to assume the maximum
possible surface pressure to be the maximum anticipated bottom-hole pressure less gas gradient
to the surface. When fracturing at the casing seat would limit pressure in the hole, the maximum
possible surface pressure is the fracturing pressure less a gas gradient to the surface. For a very
dry gas, 0. 1 psi/ft gradient may be used if the well is no deeper than 10,000 ft, and 0.15 psi/ft
may be used for deeper wells. Casing burst strength should be designed accordingly, with wear
factor included.
Known conditions may allow these requirements to be reduced. If formations are known to
contain only oil or water, the working pressure of the preventer need not be greater than
anticipated bottom-hole pressure less 0.2-0.3 psi/ft.
These conservative assumptions may lead to over design of the blowout prevention equipment in
some cases; however, it is certainly safer than assuming a maximum surface pressure based on
an arbitrary amount of mud left in the hole.
The design principles stated cannot be followed in many deep, abnormally pressured wells, since
probable pressures exceed the maximum working pressure of available equipment. Therefore,
some risk must be taken if the well is to be drilled. Experienced and well-trained drilling crews
decrease these risks.
For production strings, the BOPs and casing should have ratings higher than surface tubing
pressure.
Rotating heads and strippers will have a lower rating than will the rest of the well-control
system. It is generally accepted that annular preventers with a pressure rating 5000 psi lower
than that of ram preventers can be used on stacks with 10,000 psi and higher ram preventers.
This is accepted because the ram BOPs can be used if these lower pressure items are in use and
well pressure approaches their limitation.
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Table 2
BOP Sizes and Sealing Components
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BOP Sizing
Table 2 lists the API recommended blow-out-preventer sizes and flanges for different working
pressures.
The preventers must be selected with a vertical bore capable of passing the casing and, in some
cases, the casing hanger. Working pressure must be equal to or greater than the least of the
anticipated maximum surface pressure, the burst-pressure rating of the casing, or the formation-
breakdown pressure at the base of the casing. Many preventers have connections that can be used
for choke and kill lines in lieu of a drilling spool. There is no standardization of component
design except for those listed in Table 2. Each manufacturer selects and designs components he
considers best.
API Std 6A relates to working pressure, flange connections, plant test pressures, materials,
throughbore dimensions, and marking of BOPS.
Table 3
Sizes and Pressure Ratings for Hydril Annular Blowout Preventers
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Table 4
Sizes and Pressure Ratings for Hydril Ram-Type Preventers
Bore Working
Size (in) Pressure (psi)
7-1/16 3,000; 5,000; 10,000; 15,000
9 3,000; 5,000
11 3,000; 5,000; 10,000
13-5/8 3,000; 5,000; 10,000
16-3/4 10,000
18-3/4 10,000
20-3/4 3,000
21-3/4 2,000
Table 5
Sizes and Pressure Ratings Available for
Cameron Type U Rams
Working Vertical
Size (in) Pressure (psi) Bore
7-1/16 3,000 7-1/16
7-1/l6 5,000 7-1/16
7-1/16 10,000 7-1/16
71/16 15,000 7-1/16
11 3,000 11
11 5,000 11
11 10,000 11
11 15,000 11
13-5/8 3,000 13-5/8
13-5/8 5,000 13-5/8
13-5/8 10,000 13-5/8
13-5/8 Model B 15,000 13-5/8
16-3/4 Model B 3,000 16-3/4
16-3/4 Model B 5,000 16-3/4
16-3/4 10,000 16-3/4
18-3/4 10,000 18-3/4
21-1/4 2,000 21-1/4
20-3/4 3,000 20-3/4
21-1/4 10,000 21-1/4
26-3/4 3,000 26-3/4
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STACK ARRANGEMENTS
A BOP stack is several blow out preventers connected together one on top of the other. The
normal BOP stack consists of:
1. annular preventer
2. ram preventer - blind
3. ram preventer - pipe
4. drilling spool (optional) This is also known as a drilling cross
5. kill line, choke line and fill line
6. bell nipple
A large number of stack arrangements are possible, including those using duplicate preventers,
kill lines, choke lines, and relief lines. Duplicate ram preventers are necessary if tapered drill
strings are used, and high-pressure hook-ups usually have an extra preventer, alternative choke
and kill lines connected to the casing head, choke manifolds, and multiple chokes. When
preventers are equipped with side outlets, the drilling spool may be omitted, and kill and choke
lines attached to connections on the preventer.
With the large number of ram arrangements possible, a convenient method of designation was
needed. This was supplied by API Bulletin D13. For example,
5M- 13-5/8-RSRA
indicates, in order, the working pressure (5000 psi), minimum bore (13-5/8), and the
arrangement of the stack from bottom to top (RSRA). In this system, R indicates a ram-type
preventer (blind or pipe rams, not designated), S the drilling spool, and A an annular preventer.
Other designations are Rd for a double ram-type preventer, and G for a rotary stripper head for
gas, air, or aerated-fluid drilling.
Attempts at standardization were made by API in Bulletin D13, while API RP53, which
superseded the Bulletin, presented several arrangements that are acceptable without designating
one as preferable. API RP53 has been discontinued. Although a large number of stack
arrangements may be possible, these can be reduced to several arrangements that are preferred.
Inability to standardize on the "most preferred" arrangement stems from the advantages and
disadvantages of one arrangement of ram preventers not being outstanding over any of the
others.
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The following discussions assume that the BOP stack has pressure and that there are no
problems with the well such as lost circulation or a hole in the drill string.
1. Normal kill down drill pipe using either pipe ram (Figure 14).
This is a prime requirement regardless of the geometry of the drill string.
ANNULAR
PIPE RAM
1K 1C
PIPE RAM
EMERGENCY KILL FLOWLINE SECONDARY CHOKE FLOWLINE
CHECK VALVE MANUAL VALVE
3K 3C
HCR VALVE HCR VALVE
MANUAL VALVE
4K 4C
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ANNULAR
PIPE RAM
1K 1C
PIPE RAM
EMERGENCY KILL FLOWLINE SECONDARY CHOKE FLOWLINE
CHECK VALVE MANUAL VALVE
HCR VALVE 3K 3C HCR VALVE
MANUAL VALVE
4K 4C
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Rotary Hose
5000 psi WP
Pressure Kelly
Gauge Lower Kelly Cock
Kelly Saver Sub
4 1/16" Stand
Pipe Valve
Annular
Blind Rams
2 1/16" Kill Line
3 1/16" Min. ID
Drilling Cross
Pipe Rams
Casing Head
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The logic for the arrangement of a stack with two ram preventers is illustrated in the following
discussion. Here, a spool was used, but using the side outlets on the preventer would serve the
same purpose with fewer flanged connections.
Where only two sets of rams are used, there are four arrangements for the blowout preventer
stack as shown next. The discussion assumes the well is under pressure. Symbols are the API
designations just discussed, but listed from top down.
1 2 3 4
R-Blind R-Blind R-Pipe R-Pipe
S-Spool R-Pipe R-Blind S-Spool
R-Pipe S-Spool S-Spool R-Blind
Advantages:
Numbers 1 and 2: With drill pipe in the hole, the upper rams may be changed to pipe rams.
When this is done, the drill pipe may be reciprocated through the upper rams while
maintaining the lower rams as a reserve.
Number 1: With two pipe rams and some pipe in the hole, the drill pipe can be stripped
back to bottom.
Number 1: If a leak develops above the rotary, the drill pipe may be suspended in the
lower rams; and by closing the upper blind rams, the hole can be circulated. Also, this
holds for Number 2, if there is sufficient distance between rams to place a tool joint box.
Number 1: Since most kicks occur with some pipe in the hole, the lower pipe rams may be
closed for repairs to the drilling spool or flowline.
Numbers 1, 2, and 3: When the blind rams are closed, these permit use of the drilling spool
flowlines and chokes.
Numbers 2 and 3: With either of the rams closed, these permit the use of the choke
flowlines and chokes.
Numbers 2 and 3: By application of the double-type preventers, a low substructure height
may be used. This is especially so if outlets of the preventer are used in lieu of the drilling
spool.
Numbers 3 and 4: Drill-pipe rams can be changed to casing rams while the drill pipe is out
of the hole.
Number 4: If any serious leaks develop in the stack, the drill pipe can be set on bottom or
dropped and the well closed in as a last resort.
Number 4: There are a minimum number of flanges exposed below the blind rams.
Numbers 2, 3 and 4: When the pipe rams are closed, the choke line is available for use.
Number 4: When the blind rams are closed, all of the previous connections can be stripped
off or repaired.
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Primary Disadvantages:
Numbers 1, 2, and 3: If the blind rams are closed, there would be no control if a leak
occurred around the drilling spool.
Numbers 2 and 3: There are more flanges exposed to well pressure.
Numbers 1 and 4: With bottom rams closed, circulation involves secondary casing-head
connections.
Flanges are considered weak points in any hookup; therefore, where side outlets are used,
Numbers 2 and 3 are not considered the best arrangements by many because the drilling spool
introduces an extra flange. However, the primary choke and kill line connections should be
available when either blind or pipe rams are closed (Numbers 2 and 3). Overall, Number 2 is
probably the most popular, however Saudi Aramco uses Number 1.
Arrangement Logic
The drilling business is often a series of compromises, both in equipment and practices. This is
certainly true with BOP stack arrangements.
Consider placement of blind rams in a three-ram surface BOP stack. If blind (or shear) rams are
placed at the bottom of the stack, with no flowlines below, then the BOP stack has the advantage
of a "master" valve for open hole situations, or a last resort valve if all else fails during a kick.
But this placement also imposes limitations on stack utility.
For example, drill pipe cannot be hung off on pipe rams below the blind ram and the well killed
by circulating through the drill stem. This arrangement may also force placement of pipe rams so
close together that adequate space is not available for ram-to-ram stripping. If blind rams are
placed at the top of the ram BOP stack, they can be replaced with pipe rams for ram to ram
stripping operations to either protect the lower pipe ram or, in the event of a tapered string, to
furnish the pipe ram size that will fit the size of drill pipe being stripped. But this arrangement
also presents a problem because it prevents utilizing the blind ram as a master valve in open hole
situations for repair of items above it, or changing to casing rams. It also may force spacing of
pipe rams so close that ram-to-ram stripping is impossible.
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The question arises as to how to best maximize advantages of both of these placements and
minimize disadvantages. The two compromise arrangements illustrated herein place blind rams
on top for tapered string drilling and in the middle when one size drill pipe is being used. This
allows hanging off pipe in the pipe rams and circulating through the drill stem (with proper
placement of kill and choke lines); adequate clearance for ram-to-ram stripping; and partial
utilization of the blind ram as a master valve for equipment repair (top ram change to casing size
obviously being safer with the blind ram in the middle).
Arranging rams is important, but choke and kill flowline (wing valves) placement is equally
important to fully utilize the BOPs. Again, compromises are made between the most
conservative position of having no flowlines below the bottom ram and a middle road position of
arranging the flowlines for maximum BOP usage.
Figures 17 and 18 illustrate two BOP and wing valve arrangements. Activities possible with each
of these two arrangements are summarized at the bottom of the figures and further illustrated in
Figures 14 and 15. Before reviewing Figures 14 and 15, general observations can be made about
both arrangements.
1. No spools are used. Choke and kill wing valves are connected directly to side outlets integral
with the BOP ram body This reduces connections and chances of flange leaks.
2. A standard size 13-5/8 inch, flanged double ram is mounted on top of a single-ram unit. This
provides sufficient space for shearing above a standard 5-inch NC50 connection hung in the
bottom pipe ram, as illustrated in Figure 15. This is the best arrangement for use with a
single drill-pipe size.
Notes B2 and C1 on the bottom of Figure 18 (arrangement for tapered strings) indicate that space
between the blind rams and small pipe rams limits certain activities. For tapered string
application, this space problem could be eased by stacking the single-ram unit on top of the
double-ram unit. However, Figure 18 shows the double on top. This illustrates another
compromise, since in the field it would not be practical to rearrange the BOP stack before
picking up a smaller drill string.
Some contractors prefer to assemble the single on top so that the annular and single can be
separated from the double for handling. Trade offs may be necessary in this matter. The primary
aim here is not to debate each point, but to emphasize importance of critically reviewing BOP
arrangements.
Double-ram units can be specially ordered with enough room between rams to hang off and
shear. This special height double-ram unit could be put on bottom, best satisfying both single
and tapered string application. Here we consider standard height double and single BOP units
only, with no spools or special stacks, so the most practical compromise is to place the double-
ram unit on top (Figures 17 and 18).
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ANNULAR
PIPE RAM
1K 1C
PIPE RAM
EMERGENCY KILL FLOWLINE SECONDARY CHOKE FLOWLINE
CHECK VALVE MANUAL VALVE
3K 3C
HCR VALVE HCR VALVE
MANUAL VALVE
4K 4C
ACTIVITIES POSSIBLE
A. Normal kill down drill pipe using either pipe ram (Figure 14)
1. Choke flowlines 2C and 3C below each pipe ram.
Note: Location of primary choke flowline 2C at alternate location 1C will allow all previously mentioned activities but is somewhat
more exposed to mechanical damage.
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ANNULAR
BLIND RAM
SECONDARY KILL FLOWLINE 1C
CHECK VALVE 1K
HCR VALVE Sm PIPE RAM PRIMARY CHOKE FLOWLINE
MANUAL VALVE MANUAL VALVE
2K HCR VALVE
2C
PIPE RAM
EMERGENCY KILL FLOWLINE SECONDARY CHOKE FLOWLINE
CHECK VALVE MANUAL VALVE
3K 3C
HCR VALVE HCR VALVE
MANUAL VALVE
4K 4C
ACTIVITIES POSSIBLE
A. Normal kill down drill pipe using either, pipe ram (Figure 14)
1. Choke flowlines 2C and 3C below each pipe am.
Note: Relocation of kill flowline 2K as shown required to accomplish kill procedures mentioned in items B3 and C2.
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4. Inboard valves adjacent to the BOP stack on all flowlines are manually operated "master"
valves to be used only for emergency Outboard valves should be used for normal killing
operations. Hydraulic operators are generally installed on the primary (lines 2K and 2C in
Figure 17 and lines 1K and 2C in Figure 18) choke and kill flowline outboard valves. This
allows remote control during killing operations. During normal drilling, secondary (lines 3K
and 3C in Figures 17 and 18) choke and kill flowline "master" valves should be left closed
to prevent mud solids buildup. Conversely master values in the primary kill and choke
flowlines must be open so that fluid passage to the choke manifold can be controlled
remotely. Also, being able to operate the primary choke flowline valve remotely allows the
.well to be closed "softly" on a kick. Hydraulic valve replacement is always possible.
5. No choke or kill flowlines are connected to the casing head outlets, but valves and unions
are installed. This provides:
Reserve outlets for emergency use only.
Relief opening to prevent pressuring the casing and open hole should a casing head
plug tester leak during BOP testing.
It is not good practice to flow into or from a casing head outlet. If this connection is
ruptured or cut out, there is no control. Therefore, primary and secondary choke and kill
flowlines should all be connected to heavy duty BOP outlets (or spool outlets), with
wellhead outlets used only in an emergency.
6. Figures 17 and 18 do not illustrate flowline variations such as relief lines direct from BOP
to a gas/mud separator, or outlets for gauges or remote pump connections. These have merit,
but were excluded to prevent diversion from the primary purpose of illustrating flowline
locations that provide a high degree of utility during killing operations.
Notations on Figures 17 and 18 illustrate various activities possible with the two subject
arrangements. Certain limitations are also listed.
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Rotary Hose
5000 psi WP
Kelly
Pressure
Gauge Lowr Kelly Cock
Kelly Saver Sub
4 1/16" Stand
Pipe Valve Mud Flow Line
Rotating Head
Annular
Check Valve
Pipe Rams
2-1/16" 5M Kill Line Blind Rams
Drilling Cross
4-1/16" ID 5M
4 1/16" x 2 1/16" Choke Line
Pipe Rams
DSA Flange
Manual
HCR
Casing Head
Figure 19 is a suggested stack arrangement for the rigs working for Saudi Aramco while drilling
production wells. In reviewing the previous discussion the arrangement is satisfactory however
there needs to be another kill and choke flowline connected below the lower pipe ram. The valve
arrangement should be reversed to make it complete.
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Rotary Hose
5000 psi WP
Kelly
Lower Kelly Cock
Pressure
Gauge Kelly Saver Sub
4 1/16" Stand
Pipe Valve Mud Flow Line
Rotating Head
Annular
Check Valve
Drilling Cross
2-1/16" 10M Kill Line 4-1/16" 10M
Choke Line
Blind Rams
Master Pipe Rams
Manual
HCR
Casing Head
Emergency 2-1/16"
Kill Line Laid To At
For Connection Least 60 FT. From
to Emergency Wellbore.
Pump
With similar logic, the stack configuration presented in Figures 20 and 21 can be developed.
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ANNULAR
PIPE RAM
1K 1C
BLIND RAM
2K 2C
SECONDARY KILL FLOWLINE PRIMARY CHOKE FLOWLINE
CHECK VALVE DRILLING SPOOL MANUAL VALVE
HCR VALVE HCR VALVE
MANUAL VALVE 3K 3C
BLIND RAM
4K 4C
6K 6C
Figure 21.
Figure 20 is a the Saudi Aramco arrangement as illustrated in the Saudi Aramco well control
handbook. This handbook is received when the actual well control course is taken. Figure 21 is a
simpler illustration that is used to describe some of the different scenarios that this four ram
configuration can accomplish.
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Neither one of these options are good because 5C is an emergency connection and 6C is a
connection of last resort. If the upper pipe ram and the upper blind ram were swapped then the
kill could be accomplished while keeping the connection 5C in reserve. The lower blind rams are
still in place to close on an open hole and the upper blinds or the upper pipe rams can be changed
to casing rams.
Changing the lower blind ram to a pipe ram would allow stripping without using the master
pipe ram.
Changing the upper blind ram to a pipe ram would allow the stripping without using the
master pipe ram. This can only be accomplished if there is enough room between the two rams
to accommodate a tool joint. Normally this is not the case with double pipe rams unless they
have been specifically designed for a stripping operation.
For tapered string operation the lower blind ram becomes the small pipe ram for normal kill
operation and for ram to ram stripping the upper pipe ram can be changed to fit the smaller pipe.
The stack arrangement versatility changes by using varibore rams. In Saudi Aramco four ram
arrangement the blind rams theoretically do not have to be removed if varibore rams are used. Or
if put in place of the upper pipe ram and the lower blind ram, there would be emergency large
pipe rams and stripping capability exists for all pipe sizes all the time; however, what are the
disadvantages?
Evaluating stack redundancy and flexibility becomes more tedious as the stack becomes more
complicated. Also, the chances of standardization decrease.
Summary
The BOP stack must be designed so that all elements will pass the casing, casing hanger, and bit.
The preventers should correspond as nearly as practical to the casing size. Adapter spools have
extra flanges that may leak, and should be avoided if possible. Large preventers on smaller
casing spools may have adequate pressure rating, but vibration of the large mass results in severe
stress on the casing head and should be avoided.
A separate fill-up line to the bell nipple should be used to fill the well during trips. Kill lines
should not be used as fill-up lines because of increased erosion; if a check valve is not installed
or if it plugs, the fill line would have to be shut in before the well could be shut in. Also, the kill
line is more likely to plug if left filled with mud instead of clean water.
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When flowing into or from the well, only the heavy duty BOP outlets should be used, not the
casing valves. In squeeze or kill operations, for example, some service companies recommend
using the casing valve outlets. This is not a good practice because if the casing valves or outlets
to the valves erode or rupture, a kick cannot be controlled.
The stacks should be anchored with adjustable rods to derrick legs or other suitable support to
minimize vibration and allow alignment. The tie rods should be as level as possible; otherwise,
movement will still occur. On barges, jackups, and other platforms with long, unsupported
casing lengths, the wellhead casing should be secured to the drive pipe.
Locking screws should be provided with stem extensions, universal joints (if needed), and hand
wheels. The hand wheels should be located outside the derrick substructure.
When handling or moving stack elements, the flanges should be covered with steel or wooden
plates, or mounted on a skid. Side outlets should be plugged and care exercised to avoid
damaging control lines on hydraulic cylinders.
Substructure height must be sufficient to accommodate the complete stack. Cellars are frequently
dug and concreted to house casing heads, thereby lessening substructure height requirements.
Drilling spools and preventers should not be below ground, as this requires bends in the choke
flowline and results in poor access. Leaking gas or oil in a cellar is particularly dangerous for
personnel working there because gas may displace all air. About three feet of space is required
for the bell nipple to accept the flowline and prevent overflow. About 10 feet of substructure
height is required for a double ram preventer, an annular preventer and flow stack, and the
requirement may go as high as 30 feet when all elements discussed for a deep well are included
in the stack.
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Figure 22
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Gas Busters:
The typical gas buster (Figure 23) or poorboy
degasser is constructed at the rig site or obtained
from the local rental tool company. Gas busters are
easy to use and maintain and should be cleaned
periodically. Never circulate cement returns through
Mud out
a gas buster. Most gas busters are constructed from a
length of large diameter pipe with a series of internal
baffles to cause the gas to break free of the drilling
fluid. A siphon arrangement at the bottom permits
mud to flow to the shale shaker while maintaining a
fluid head to hold the gas in the upper part. The gas
vent pipe at the top should be large enough to permit
gas to be vented at a safe distance away from the rig
floor without much back pressure. Gas busters have
a tendency to shake when gas cut mud is circulated
through them so they should be well anchored. Short
fat gas busters are generally preferred over the tall
skinny variety.
Figure 23
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Safety Valves
Safe operation requires that full opening safety valves (Figure 24)
to fit each size of drill pipe and collar in use be kept in the open
position on the rig floor. Then, should the well begin to flow
when the kelly is not connected the correct size can be stabbed
into the drill pipe tool joint and made up. Installing a valve as a
precaution is good practice when the drill pipe is left in the slips
for any length of time that requires the kelly to be disconnected.
Care should be taken that all valves have the proper threads and
they will go through the BOPs and casing so that they could be
stripped into the hole below a back pressure valve (inside BOP).
Note that the term full opening does not mean that the ID of the
valve is the same as the pipe but that the bore through the valve is
not restricted.
Figure 24
Inside BOP
This is a back pressure or float valve that allows stripping or
running drill pipe into the hole without fluid flow upward through
the valve. It can be stabbed and made up on the drill pipe only at
very low flow rates. The best method is to stab and close the full
opening safety valve then install the inside BOP if the decision is
made to go back in the hole. The dart type inside BOP (Figure 25)
is one of the more widely used tools. The dart is used to hold the
tool open, making it possible to install the tool while the mud is
flowing from the well. Releasing the dart permits the valve to
close. The upper sub is then removed and additional drill pipe
may be added as desired.
Figure 25
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Drilling Chokes
The prime function of a drilling choke (Figure 26) is to create a resistance to flow on the well
which will increase the bottom hole pressure sufficiently to control formation flow while the
well is circulated. Chokes are available in either positive or adjustable styles for flow control
with a variety of sizes and pressure ranges. An adjustable choke regulates pressure better than a
positive choke which has a fixed opening. Hydraulic chokes are easier to adjust and permit
accurate regulation of the choke pressure. An important feature of most hydraulic drilling chokes
is that the choke can be placed in the choke manifold but is controlled remotely from a panel
which displays the casing and drill pipe pressure.
Figure 26
Trip Tank
In order to keep the hole full on trips, measuring and monitoring the mud volume put in the hole
is necessary. The measurement is most accurately determined through the use of a trip tank. The
trip tank can be any tank or pit in which the mud volume can be measured to within 1/2 barrel,
with the measuring gauge visible to the driller on the floor.
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There are two types of trip tanks; the gravity type and the circulating type. The gravity trip tank
is installed above the flow line and uses the head of fluid in the tank to fill the hole intermittently
as pipe is pulled from the hole. The circulating trip tank, installed below the flow line, uses a
centrifugal pump to pump mud into the well from the tank as pipe is pulled from the well. In this
arrangement, returns from the well flow back into the trip tank. The pump should run
continuously while tripping so that the hole fill can be monitored at all times. Intermittent filling
only provides information once every several stands. Figures 27 and 28 are schematics of
circulating trip tanks.
Figure 27
Stroke Counters
In the absence of a trip tank, the pump stroke counter offers the driller an alternative means of
measuring fluid volume used to fill the hole on trips. In order to use the stroke counter properly,
the driller must know two things. First, the driller must know the fluid displacement for the
particular pipe and hole size being used. Second, the volume discharged per stroke of the pump
in operation must be known. This information gives the driller the ability to check for the correct
fill volume required while tripping.
Using the stroke counter to measure hole fill is less accurate than using the trip tank therefore it
is not preferred. There is a tendency to use the kill line for filling the hole when the rig pumps
and stroke counters are used. This action is never recommended. The kill line is an emergency
piece of equipment that should not be used for routine trip hole fills. Stroke counters provide a
means of correctly displacing special fluids or lost circulation pills. A stroke counter is
especially useful to determine pumped volumes while executing well control problems.
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Figure 28
Gas Detectors
Gas detectors are usually found in mud logging units to detect formation gas which can indicate
abnormal pressure sections and hydrocarbon bearing formations. Rig supervisors should monitor
trip gas, connection gas, and background gas for any significant change. Gas detectors can be
misleading if absolute values of the gas unit rather than relative trends and magnitudes are used
to interpret formation problems.
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Choke Manifold
The choke manifold (Figure 29) is the assembly of pipe, valves and chokes that allow the well to
be controlled remotely or manually, to safely discharge the pressured formation fluid from the
wellbore.
The valves and the hydraulically actuated drilling choke are all open in the preferred fluid
routing. The hydraulically actuated gate valve next to the wellhead is closed. When a kick is
detected the hydraulically actuated gate valve is opened and the drilling choke is closed at the
same time that the blowout preventers are closed.
One of the manually actuated gate valves on the buffer tank will be connected to flowline that
goes to the gas buster or to a degasser. A flowline to the flare pit is connected to one of the other
valves.
There is a pressure transmitter to send pressure information to the control console and a pressure
gauge as a backup.
The check valve is part of the kill line. Although this diagram shows two manual valves on the
kill line, in most cases one of them is a remote controlled valve.
The lead target on the buffer is to stop erosion of the metal when the kick fluid is being
circulated through the manifold.
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Pressure Transmitter
Pressure Gauge
Hydraulically Actuated
Drilling Choke
Buffer Tank
Manually Actuated
Gate Valve
Cross
Manually Actuated
Hydraulically Actuated Drilling Choke
Gate Valve
Lead Target
To Flare
Weco Unions
Emergency Flare
Min. 3" Line
To Mud Pit
Instrument Flange
8"
To Gas Buster
Spacer Spool
3 1/8" x 5M
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CHAPTER FISHING OPERATIONS
INTRODUCTION 1
ECONOMICS OF FISHING 7
AVOIDING HAZARDS 8
SEGMENT DRILLING
CHAPTER FISHING OPERATIONS
FISHING TOOLS 21
RELEASING OVERSHOT 21
RELEASING SPEAR 22
OIL JARS 23
MILLING TOOLS 24
TAPER TAP 26
JUNK BASKETS 27
REVERSE CIRCULATING JUNK BASKETS 28
FISHING MAGNETS 29
PACKER RETRIEVING TOOLS 30
WASHOVER OPERATIONS 32
SEGMENT DRILLING
CHAPTER FISHING OPERATIONS
INTRODUCTION
A fish is defined as any undesirable tool, piece of equipment, or other object found in the cased
or uncased wellbore that stops or retards routine operational progress.
Fishing can be defined as any operation required to remove undesirable objects (the fish) from
the wellbore. Fishing requires the use of specialized procedures and equipment to remove,
retrieve, or sidetrack a fish so that normal drilling or completion operations may continue.
Almost every fishing job presents special problems requiring proper analysis, creative thinking,
and the exercise of good judgement to successfully accomplish the objective. Often, fishing jobs
require many tools and frequent trips with the work string, which may consume much rig time
and can result in high operational costs.
Tools and equipment are lost in the hole for a variety of reasons. In drilling operations, common
causes of fishing are a result of
which inadvertently fall or are otherwise left in the wellbore. Each of these different types of
'fish' require special tools and techniques for retrieval. To explain and discuss all the tools and
techniques as applied to the variety of fishing operations would require a large volume;
therefore, this discussion of the fundamentals must be limited to the most common problems and
the generally accepted methods of retrieval.
The costs and inherent risks when fishing make it imperative that the operations and engineering
personnel involved communicate freely. Predictions of the additional cost and risks associated
with certain types of fishing operations may make it necessary to change the whole job plan and
the final objective.
For relatively simple, straightforward fishing jobs such as the recovery of pipe inadvertently
dropped or left in the hole, an overshot can be used for a reasonably fast and inexpensive
recovery. For a more complicated job such as the recovery of stuck or cemented pipe, or the
recovery of several wireline tools - special fishing tools and skills will be required. When cases
such as these arise, an experienced fishing tool operator should be considered.
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1. JUNK IN HOLE
Junk lost in the hole is considered to be a frequent cause of fishing operations. There are
many possible causes for loose junk to be lost in the hole, however, the most frequent
causes are
the loss of a rock bit cone and bearings
hand tools or other miscellaneous objects that are inadvertently dropped from
the surface
the loss of roller reamer parts
the loss of a hole opener arm and cone
the loss of an underreamer arm
the loss of a pilot bit during hole opening operations
If at all possible, the first step in the recovery of loose junk lost in the hole is to identify
what it is. This may be readily determined if something has been left in the hole on a trip
or has been dropped into the hole accidentally. If the type and configuration of the junk is
not known, an impression block should be considered. Once the type and size of the
object is determined, a decision can be made if it can be recovered as a single whole
piece or whether the object must be milled or otherwise broken-up. It is generally
preferable to recover the junk whole rather than in pieces, however, this is not always
possible.
2. PARTED STRING
One frequent reason for a fishing job results when there is a twist-off and the drill string
parts due to metal fatigue. Rough handling, scarring by tong dies, improper make-up
torque, corrosion and erosion resulting in a washout in the tube body or cracks that form
and enlarge under constant bending and torsional stresses during drilling operations. The
most common place for this to occur is at the connection of a drill collar, at a crossover,
or drillpipe tool joint where the higher stress level generates a crack. Connection fatigue
is commonly found at the base or thread roots on the box or pin connection. When a box
failure occurs, a dutchman (the box end thread) is left still threaded onto the pin end
connection and recovered when the parted string is pulled. Although not as common, the
drill pipe tube can sometimes fail in a long tear or split.
Surface signs of a twist-off include loss of drill string weight, lack of penetration,
reduced pump pressure, increased pump speed, reduced torque, and increased rotary
speed.
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There is a tendency for shale sections to absorb water from the mud causing
the shales to swell and break off into the hole and lodge around tool joints,
drill collars and stabilizers causing the drill string to become stuck. Otherwise,
the shales or clays swell up from the adsorption of the free water becoming
very sticky and when trying to pull the BHA back through this section the
drill string may become stuck.
3.1.2. TAPERED or UNDERGAUGE HOLE
- A tapered hole results from wear on the bit gauge when drilling hard and
abrasive formations. When a new bit and BHA is run back into the hole, the
full gauge bit could become stuck when the string is lowered into the
tapered and undergauge hole. Extra care should be taken when running a
PDC or diamond bit. Always ream through a suspect section of hole with
caution if the previous bit was pulled undergauge.
- Undergauge hole frequently occurs across shale formations. If the formation
swells but does not slough off, the deformed layer may close in around the
drill pipe, cutting off circulation and restricting clear passage of the tool
joints, stabilizers and drill collars. A buildup of mud solids can have the
same effect, especially in a permeable zone where water is lost to the
formation. Periodic wiper trips up across the problem zone is necessary to
prevent the formation from closing in around the pipe while drilling.
3.1.3. ABNORMAL PRESSURE and BLOWOUTS
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- When drilling into a abnormally pressured shale or a plastic salt zone with
insufficient mud density, the plastic flow into the wellbore can cause the
string to pack-off around the pipe and become stuck.
- When a blowout occurs, a large volume of sand or shale is driven uphole by
the formation fluids entering the wellbore packing off around the drillstring.
This can occur in both cased and open hole. It is usually caused by the settling
out of solids in the mud.
When fluid circulation to the surface is lost into a weak, low pressure, zone or
a fractured and cavernous formation, the drill cuttings can accumulate at the
lost circulation interval and pack-off around the pipe.
3.1.7. KEYSEATING
Crooked pipe, often results from dropping the drill string or applying
excessive weight to stuck pipe, may jam against the hole wall and become
impossible to raise, lower, or rotate.
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This can usually occur when spotting cement plugs or when cementing liners
and is most prevalent in deep hot holes where the cement can flash set due
to insufficient quantity of chemical retarder that is required to prolong the
setting time of the slurry.
This occurs in open hole when the drillstring comes in contact with a permeable
formation. It is caused by a high hydrostatic pressure creating a differential force
that holds the pipe in a thick filter cake across the permeable zone. It often occurs
when rotation has stopped prior to making a connection. Differential sticking
occurs only across a permeable zone, such as sand, and the friction resistance may
be a function of the filter cake thickness.
The extra force necessary to pull the pipe loose from the wall may be calculated
by the formula below -
F = DP x Ac x Cf
It can readily be seen by calculating the forces in two hypothetical situations that
the pull necessary to free the pipe frequently exceeds the tensile strength of any
pipe available.
EXAMPLE 1
Assume that drill pipe contacts the filter cake in a width of 3 inches along a 25 ft
permeable sand interval with a differential pressure of 1600 psi and a friction
coefficient of 0.2.
This force must be added to the normal hook load in order to pull the pipe free. In
many cases, the total load would exceed the safe pull on the pipe.
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EXAMPLE 2
Assume that 8-1/4 drill collars are stuck in a 12 hole with a 14.5 ppg high water-
loss mud. It is quite possible that shortly after the drill collars become stuck that
one-third of the circumference of the drill collars is imbedded across a permeable
sand in a thick filter cake leaving two-thirds of the drill collars exposed to the
hydrostatic pressure of the mud column. At 11,000 ft, the estimated pore pressure
of the permeable sand is 7000 psi and the mud density in use is 95 pcf. The
calculated overpull to free the stuck drill collars is calculated as follows:
F = [HP - PP (psi)] x [1 ft x 12 in x 1 C] x Cf
ft 3
8.25
C=2x x
2
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Normally the sticking occurs when the drill pipe is not in motion, and usually full
or partial circulation can be accomplished.
ECONOMICS of FISHING
Some fishing jobs can go on for months before the fish is retrieved. After a certain period,
however, the cost of fishing operations and lost drilling time become prohibitive. Therefore, a
truly successful fishing job should not only be an operational success, but an economic success
as well.
Decisions made during fishing operations should address an economical solution to the problem
in the well. Obviously, a shallow hole with little rig time and equipment invested can justify only
the cheapest fishing operation. When the lost equipment and tools to be recovered represent a
large capital investment, more time and expense can be justified. Generally, once these costs
reach about one half of the cost of sidetracking and re-drilling, fishing operations should be
abandoned. One approach used to calculate the number of rig days that should be allowed for
fishing uses the following equation:
D= V f +Cs
R+Cd
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CHAPTER FISHING OPERATIONS
AVOIDING HAZARDS
The secret to a succesful drilling program is to avoid the hazards that historically have led to
fishing jobs.
Take all precautions to ensure that objects are not dropped into the wellbore.
Monitor the drilling torque carefully and learn the limitations of the drilling assembly .
Begin with a full inspection (including electro-magnetic) of the drillstring and BHA.
Continue a routine maintenance and inspection program of the BHA by monitoring
operating hours in service. If indoubt, leave it out.
Condition the hole and drilling mud prior to bit or BHA trips. Circulate a high- viscous
sweep if required to unload the hole of excessive drill cuttings. If required, spot a high
viscous pill on bottom to adequately suspend solids and contain loose, unconsolidated
formation.
Prior to drilling into a potential loss circulation zone, circulate a high viscous sweep to
unload the hole of excessive drill cuttings and reduce the effective mud density.
Make routine wiper conditioning trips to gauge the overall hole stability and the
condition of possible water sensitive and tight shale sections.
Carefully ream out any suspected undergauge hole.
Formulate a plan to recover a downhole assembly should it become stuck or parted.
Inventory and inspect all fishing tools that may be required immediately. Order missing
or defective parts.
Can the BHA components be fished? What tools are required?
Can it be washed over? What tools are required?
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CHAPTER FISHING OPERATIONS
Regardless of the cause, the success or failure of the fishing job greatly depends on the degree of
preparedness taken prior to commencement of drilling operations. The following factors should
be considered when preparing for a fishing job -
1. CRITICAL INFORMATION
The costs and inherent risks of fishing make it imperative that the following critical well
information and BHA data be recorded in advance of drilling operations startup.
Continue to update the information as required.
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The hole should be conditioned and the drilling fluid should have the desired properties
before starting in the hole with fishing tools. It may be necessary to make a trip with a bit to
condition the hole and circulate out fill that has covered the fish. Always circulate and flush
the hole first with a high viscous pill to unload drill cuttings and spot a balanced high
viscous pill above the fish to suspend solids prior to trip out for fishing tools.
Once it is evident that fishing operations must be conducted, it is necessary to learn and
acquire all relevant information about the fish that is to be recovered. Determine
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When pipe becomes stuck in the wellbore for any reason, one of the first steps is to determine at
what depth the sticking has occurred. When retrieving production tubing from a well, it is often
common to find that the tubing is stuck, with the seal unit seized, or locked, up in the production
packer bore due to scale or an abundance of solids that have settled around the outside of the seal
unit in the tubing- casing annulus.
Stretch in pipe can be measured and a calculation made to estimate the depth to the top of the
stuck pipe. All pipe is elastic and all formulae and charts are based on the modulus of elasticity
of steel, which is approximately 30,000,000 lb/sq. in. If the length of stretch in the pipe with a
given pull is measured, the amount of free pipe can be calculated or determined from a chart
available in data books.
Since all wellbores are crooked to some extent, there is friction between the pipe and the
wellbore. Steps should be taken to reduce this friction to a minimum. The pipe should be worked
for a period of time by pulling approximately 10%-15% more than the weight of the string and
then slacking off an equal amount. There are certain techniques that reduce error in estimating
stuck points from stretch data. It is also necessary to assume certain arbitrary conditions. Stretch
charts and formulaes do not take into consideration drill collars or heavy weight drill pipe.
First, pull tension on the pipe at least equal to the normal hook load (air weight) of the pipe prior
to getting stuck. This should then be marked on the pipe as point "a". Next, pull additional
tension which has been predetermined within the range of safe tensional limits on the pipe. Now
slack off this weight back down to the hook load weight. Mark this point "b". It will be lower
than point "a". This difference is accounted for by friction of the pipe in the wellbore.
Next pull additional tension on the pipe to a predetermined amount within the safe working
limits of the string. Mark this point as "c". Then pull additional tension on the pipe in the same
amount used to determine points "a" and "b" and slack off to tension used to locate point "c".
Mark this point "d".
The mid-point between "a" and "b" and between "c" and "d" will be the marks used. Measure the
distance between these average marks and use this number as the stretch in inches. The amount
of free pipe can be determined by using the following formula:
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where K = constant
This method of estimating the stuck point of pipe is not completely reliable and accurate as there
are many variables caused by friction, doglegs, hole angle, and pipe wear. However, it frequently
indicates the cause of sticking such as possible areas of a key seat or differential sticking in open
holes and collapsed tubing or tubing leaks in producing wells.
In addition to the basic formula provided above for calculating the amount of free pipe, there are
reference manuals available that provide stretch charts from which the length of free pipe can be
read directly. The same procedures and precautions, as outlined above, should be followed to
obtain the pipe stretch with a predetermined pull over the string weight.
Accuracy of the charts and the formula is approximately the same, as both are affected by the
same problems of hole friction, loss of material in used pipe, and the accuracy of weight
indicators. Note, however, that the modulus of elasticity of all grades of steel is the same. The
grade of the pipe does not affect its stretch. Also, when pipe is stuck, buoyancy forces are not
effective. Immediately when the pipe is freed, the buoyant forces are again in effect and should
be considered accordingly.
Example
A 13,000 feet of 23 #/ft casing is stuck near the bottom of the well. A differential load of
55,000lb was applied on the pipe which resulted in a stretch of 42in. What is the depth of the
free point?
Solution
1.4
K= = 0.0608
23
Pull = 55000 lb
Stretch = 42 in
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1000000 x 42
Length of free pipe =
0.0608 x 55000
= 12559 ft
2. Free-Point Instruments
Electric wireline service companies run instruments on conductor lines inside the stuck drillpipe
or tubing and are able to accurately determine the stuck point of pipe. The instruments are highly
sensitive electronic devices which measure both stretch and torque movement in a string of pipe.
This information is transmitted through the electric conductor cable to a surface panel in the
control unit where the operator interprets the data.
The basic free-point instrument consists of a mandrel which encompases a strain gauge or
microcell. At the top and bottom of the instrument are friction springs, friction blocks, or
magnets, which hold the tool rigidly in the pipe. When an upward pull or torque is applied at the
surface, the pipe above the stuck point stretches or twists. The change in the current passing
through the instrument is measured by the microcell and transmitted to the surface for
interpretation. When the instrument is run in stuck pipe, there is no movement of the pipe,
therefore there is no tension or torque transmitted to the instrument. In turn, the gauge at the
surface shows no change in its reading.
Free-point indicators are frequently run with collar locators and in combination with string shots,
chemical cutters, and jet cutters. This combination run saves expensive rig time, and it will also
maintain a continuous sequence in measuring so that there is less chance of a misrun in cutting
or backing-off.
Since fishing operations usually begin as soon as the pipe is parted following the free-point
determination, it is a good practice to have the fishing tool supervisor or operator on the location
during the free-point and back-off or cutting operations. Frequently there are suggestions that
can be made to improve the fishing situation when the fishing operator is present to observe the
free-point and parting operations.
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1.Back-Off - Unscrewing the pipe at a selective threaded joint above the stuck point using a
prima cord explosive run on an electric wireline.
Back-off is the procedure of applying left-hand torque to a pipe string and firing a shot of prima
cord explosive across a tool joint which produces a concussion to effectively partially unscrew
the threads. The back-off method of parting pipe is probably the most popular of all,
particularlly in drill pipe. Tool joints on drill pipe, drill collars, and other drilling tools have
coarse threads, large tapers and seal by the flat surfaces or faces. These characteristics make the
back-off method attractive as it leaves a threaded connection looking up, making it possible to
screw back into the fish with a jarring work string.
Tubing or other coupled pipe does not lend itself to back-off in the same way as drill pipe.
Tubing threads are usually fine, at least eight per inch; there is only a small taper, and the
threads are commonly in tension with a high degree of thread interference. Furthermore, there is
a high chance of damaging the fine threads such that cross-threading will likely occur if
attempting to screw back into the fish.
To prevent an accidental back-off in a loose connection up the hole, the pipe should first be
tightened by applying right-hand torque and then reciprocating the pipe while holding the
torque. Once the pipe is made up, left-hand torque is introduced in the string. This torque must
also be "worked down" by reciprocating the pipe as the torque is increased. This action
distributes the torque throughout the string and assures that there is left-hand torque at the point
of back-off.
Theoretically just prior to firing the string shot, the pipe at the back-off point should be in a
neutral condition, with neither tension nor compression. Since this condition is very difficult to
obtain, any choice should lead toward slight tension in the pipe. Since buoyancy is not effective
in the stuck pipe, air weight of the string is used in calculations. However, the moment the pipe
starts to spin free, buoyancy produces an upward lifting force against the free pipe string. The
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left-hand torque is held, and the determined weight of the string is picked up when the string-
shot is fired. The concussion at the joint momentarily loosens the threads and the pipe begins to
unscrew. It usually must be manually unscrewed completely and then the freed pipe can be
removed from the well.
When ordering a string-shot, the service company needs to know the size and weight of pipe to
be backed off, the approximate depth of the stuck point, the weight of the mud or fluid in the
hole, and the temperature of the well. This information will dictate the strength of the charge
needed as well as the type of fuse.
2.Jet Cut - A cut made by an explosive shaped with a concave face and formed in a
circle. It is also run and fired on an electric line.
The jet cutter is a shaped charge of explosive which is run on an electric wireline. The modified
parabola face of the plastic explosive is formed in a circular shape to conform to the shape and
size of the pipe to be cut. When an explosive such as this is used to cut pipe, the end of the pipe
is flared, and it is necessary to mill over and remove this flare if the pipe is to be fished with an
overshot from the outside.
The jet cutter is often used when abandoning a well during salvage operations or when low fluid
level, heavy mud, or cost would preclude the use of the chemical cutter. Jet cutters are available
for practically all sizes of tubing, drill pipe, and casing.
There is a possibility of damage to an adjacent string or to casing if the pipe to be cut is touching
at the point where the cut is made.
3.Chemical Cut - An electric wireline tool and procedure that uses a propellant and a chemical,
halogen fluoride, to burn a series of holes in the pipe thereby weakening it
such that it is easily pulled apart.
This method of cutting pipe is the most recent innovation. It was patented and for years was an
exclusive process of one wireline company. Today it is available through most electric wireline
service companies for practically all sizes of tubing and drill pipe and most popular sizes of
casing. All wireline cuts are generally economical because rig time is reduced to a minimum.
The big advantage of the chemical cut is that there is no flare, burr, or swelling of the pipe that is
cut. Therefore, no dressing of the cut is necessary in order to catch it on the outside with an
overshot or on the inside with a spear.
The chemical cutting tool consists of a body having a series of chemical flow jets spaced around
the lower part of the tool. The tool contains a propellant which forces the chemical reactant
through the jets under high pressure and at high temperature to react with the metal of the pipe.
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Electric current ignites the propellant which forces the chemical, halogen fluoride or bromide
trifluoride, through the reaction section which heats the chemical and forces it out the jets. The
tool also contains pressure-actuated slips to prevent a vertical movement of the tool up the hole
and insure a successful cut.
The chemical cutting tool may also be explained as producing a series of perforations around the
periphery of the pipe. The reaction of the chemical produces harmless salts which do not damage
adjacent casing. The products of the chemical reaction are harmless and are rapidly dissipated in
the well fluid.
The chemical cutter will not operate successfully in dry pipe and requires at least one hundred
feet of fluid above the tool when a cut is made. Since it is not necessary to apply torque to the
pipe when chemically cutting as compared with the string shot back-off, it is a safer process for
rig personnel.
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Pip e c ut w ith
exp losive Jet Cutte r
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Ch e m i c a l Cut t e r
Pi p e cu t w i t h a
Ch emi c al Cu t t er .
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4. Mechanical Cut - A cut made with a set of knives installed in a tool and run on a small
diameter work string. This is referred to as an internal or inside cut.
Internal mechanical pipe cuts are most common when removing sections
of casing and wellhead equipment during final well abandonment
operations.
The internal cutter is made on a mandrel with a wickered sleeve or split nut fitted to threads on
the mandrel. This allows the slips to be released and the tool to set at any specific depth desired.
Friction blocks or drag springs are fitted to the mandrel to furnish back-up for this release
operation. As weight is applied to the set tool, knives are fed out on tapered blocks, and as the
tool is rotated, they engage the pipe and cut it in two.
Upon reaching the desired cutting depth, the internal cutter is anchored by slowly rotating to the
right while slowly lowering the work string. The wiper blocks resist rotation and lowering by
maintaining friction on the pipe and continued lowering of the work string until the slips, which
move upward and outward, engage and anchor the cutter to the pipe wall. The mandrel is free to
travel downward under the knife blocks forcing the knives upward and outward to start the cut.
Slight weight additions are applied while slowly rotating to the right. The main spring in the
upper part of the cutter is partially compressed by the applied weight and assists in maintaining a
uniform feed to the knives and to help absorb any shock that may accidentally be applied to the
work string causing the knives to gouge or to break.
Cutting is accomplished by slow rotation to the right with just enough weight being gradually
applied to feed the knives into the metal. For best operation, the work string is lowered in 1/16"
intervals (never more than 1/8") a total of 1-1/4" on the work string to complete the cut. Free
rotation, with little or no reverse torque, indicates that the cut is completed. To prove the cut,
increase the rotating speed; and if there is no increase in torque noted, it will indicate that the cut
has been successfully completed.
Care should be exercised not to hurry the cutting operation, as excess weight will cause the
knives to dig into the pipe burning the knife points or possibly even breaking the knife blades.
Fishing tool operators will usually run a bumper sub above the cutter so that excessive weight is
not exerted on the knives causing them to break or dig into the pipe.
To release the cutter, raise the work string one foot. This will cause the grip jaws to engage the
wickered sleeve, and now the tool is ready to be raised or lowered, as desired.
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Internal Cutter
Mandrel
Knife
Knife
Block
Main
Spring
Slips
Bowl
Wiper Block
& Spring
Bottom
Nut Running In Cutting
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FISHING TOOLS
Releasing Overshot
The Releasing Overshot is used to externally engage and retrieve all
sizes of tubing, drill pipe, and casing.
Top Sub The overshot is designed to assure positive external engagement
over a large area of the fish and is ruggedly built to withstand severe
jarring and pulling strains without damage or distortion to either tool
or fish.
Packer Most overshots consist of a bowl, top sub, guide and the grapple or
slip, a control, and packoff. The overshot bowl is turned with a taper
on a helical spiral internally and then the grapple, which is turned
Bowl
with an identical spiral and taper, is fitted to it.
Spiral
Grapple Overshots are very versatile and may be fitted for a variety of
problems. Mill controls may be used to dress the area that the
Grapple grapple will catch in order to remove burrs and splinters on the pipe.
Control When the pipe has been "shot off" or parted in such a way to heavily
damage it, it may be necessary to fit a mill extension, or mill guide,
to the overshot bowl so that extensive milling can be accomplished
for the catch to be made on the same trip in the hole. These
extensions, or guides, are "dressed" inside with tungsten carbide and
Guide can mill off a substantial amount of material so that the "fish" is
trimmed down to the grapple size.
Controls may also be designed with a pack-off, or packer, that seals
off around the fish and allows the circulating fluid to be pumped
through the fish to aid in freeing the stuck fish.
To properly engage an overshot on a fish, slowly rotate the overshot as it is lowered onto the
fish. The pump may be engaged to help clean the fish and also to indicate when the overshot
goes over the object. Once this has been indicated by an increase in pump pressure, stop the
pump, as there may be a tendency to kick the overshot off the fish. Set the grapple with gradually
increasing, light upward blows. An excessively hard upward impact may strip the grapple off the
fish and cause the wickers to be dulled, resulting in a misrun and trip to replace the grapple.
To release overshots, it is first necessary to free the two tapered surfaces, bowl, and grapple,
from each other. This freeing of the grapple or "shucking" can be accomplished by jarring down
with the fishing string. Usually a bumper sub is run just above the overshot and is used for this
purpose. After bumping down on the overshot the grapple is usually free and the overshot can be
rotated to the right and released from the fish. If a large amount of the fish has been swallowed,
it may be necessary to free or " shuck" the grapple more than once.
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Releasing Spear
Usually a spear is not the first choice, as the spear will have a
smaller internal bore than an overshot which limits running of some
tools and instruments through it for cutting, free-pointing, and in
Mandr el some cases, backing-off.
The most popular spears in use today are built on the same
principles as overshots with a tapered helix on the mandrel and a
matching surface on the inside of the grapple. The slip, or gripping
surface is on the outside surface of the spear so that it will catch and
grip the inside of the pipe that is being fished. Due to the design
with the small bore in the mandrel, spears are usually very strong.
Gr appl e
The spear is run inside the fish and positioned. The slips are released
by action of the J-slot by using left-hand torque, moving the drill
string down a short distance, and then picking it back up slowly.
This action releases the slips so they can slide up over a taper on the
body of the spear as the spear is moved uphole. The slips move
Rel ease outward engaging the inner wall of the fish.
Ri ng
In order to release a spear, it is rotated to the right. If the grapple is
frozen to the mandrel, it may be necessary to bump down to free or
'shuck' the grapple. Usually a bumper sub is run just above the spear
Nut and this can be used to effectively jar down and free the grapple.
The spear is a very versatile tool, in that it can be run in the string
above an internal cutting tool if desired or in combination with other
tools. Milling tools may be run below the spear to open up the pipe
so that the spear can enter and catch the fish.
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Oil Jars
Jars are impact tools used to strike heavy blows either up or down upon
a fish that is stuck. Jars fall into two categories as to use: drilling jars
and fishing jars. Jars can further be classified as to the basic principle
of operation; either hydraulic or mechanical.
Oil Jars are very effective in freeing stuck fish as the energy stored in
the stretched drill pipe or tubing is converted to an impact force, which
can be varied according to the pull exerted on the string. The oil jar is
designed to strike a blow upward only, while an additional tool, the
bumper sub is designed to strike a blow downward on the fish.
The oil jar consists of a mandrel and piston operating within a hydraulic
cylinder. When the oil jar is in the closed position, the piston is in the
down position in the cylinder where it provides a very tight fit and
restricts the movement of the piston within the cylinder. The piston is
fitted with a set of packing which slows the passage of oil from the
upper chamber to the lower chamber of the cylinder when the mandrel
is pulled by picking up on the work string at surface. About half way
through the stroke, the piston reaches an enlarged section of the cylinder
and is no longer restricted so the piston moves up very quickly and
strikes the mandrel body. The intensity of this impact can be varied by
the amount of strain taken on the work string. This variable impact is
the main advantage of the oil jar over the mechanical jar for fishing.
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Milling Tools
Sometimes a packer or fish cannot be removed from the wellbore intact. It is then necessary to
reduce the fish to small pieces that can be circulated to the surface. Mills dressed on the bottom
with tungsten carbide have been used extensively for this purpose and with good results. Flat
bottom mills are often used to mill over the slip segments and packer element on permanent
production packers. Milling tools are available in a number of sizes and design shapes for
various applications. Some common types of mills are shown below.
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Pilot mills are used to mill casing inside the hole. New metal
technology has improved the milling performance and increased
the rate of penetration by four to twelve times compared to
conventional tools. This performance represents a dramatic
reduction in costs for milling tubing and casing strings.
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Taper Tap
Fish
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Junk Baskets
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Fishing Magnets
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Packer Retrieval
Cutting over and retreving permanent production packers is a very common job during workover
operations. A Packer Milling tool, such as the unit shown below, is designed to mill over and
retrieve the production packer from the wellbore in one trip.
Junk
Basket
Packer
Milling
Retainer Tool
Retainer
Retrieved
Production Milling
Production
Portion
Packer Shoe Packer
of Packer
Catch
Sleeve
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Retrieving tools are made in several designs, but most can be operated
through a J on the mandrel with springs to provide back-up for
operation. The retriever is run in the retracted position and is small
enough to go through the packer bore. It is then set so that the grapple
or catch sleeve is extended so that it will not come back through the
packer bore. After the slips and packing element have been milled up,
the catch sleeve will catch the remaining packer body and it will be
removed with the milling tool by pulling tension in the work string to
dislodge the packer from the casing.
When a seal bore extension and tail pipe assembly is run below the
packer, a millout extension must also be included below the seal bore
extension in order to accommodate the catch sleeve. The millout
extension should be twice the length of the packer to fully
accommodate the stinger and catch sleeve when the mill has cut
through the entire packer.
If the packer is small such as in 4-1/2 O.D. casing a rotary mill shoe
should be selected rather than a milling and retrieving tool of this type,
as a tool of this size would be weak. After the top packer slips are
milled, the packer is retrieved with a taper tap or spear.
Fig (4)
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WASHOVER OPERATIONS
Very often it is not enough merely to catch hold of the fish and pull. In those cases,
washpipe and a rotary shoe can be used to rotate over the fish to remove annular material
that may be causing it to stick and free up a section of stuck pipe so that it may be
retrieved. The outside diameter of the washpipe must be small enough to run inside the
casing, and its inside diameter must be large enough to fit over the fish. Washpipe is
heavy N-80 grade casing cut into Range 2 lengths for ease of handling and equiped with
special threads with good characteristics for torquing and strength. Washpipe is usually
flush joint both inside and outside for maximum clearance. The length of run in the well
must normally be limited to a few hundred feet. The rotary shoe is placed on the end of
the washpipe to drill-up and circulate out any material around the fish.
Washover
Pipe
Casing
Rotary
Shoe
Tubing
Fish
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The rotary shoe run on the bottom of the washpipe string should be designed for the particular
job. Tooth-type shoes are usually used if cuttings, fill, formation, or cement is to be cut. The
teeth are shaped with a straight leading edge, and all the surfaces of the teeth are dressed with a
wear material, usually tube borium, to prevent excessive wear and erosion from the fluids
circulation.
If steel, such as the tool joints tube or junk must be cut by the rotary shoe it is dressed with
tungsten carbide in a configuration that is appropriate for the particular job. Care should be
exercised in designing the shoe since it is necessary to have sufficient circulation to keep the
carbide cool as well as wash away the cuttings. If the job is inside casing no cutting carbide
should be allowed to remain on the outside as this will damage the casing. In some cases, smooth
brass is applied on the outside diameter of the shoe to provide a bushing which reduces the
friction and prevents damages to the casing. Tungsten carbide is applied to the bottom of the
shoe and if possible to the inside diameter. Where it is possible to apply the carbide with a small
shoulder inside the shoe, the chances of retrieving some or all of the fish inside the pipe are
improved. This would save a trip with another tool to recover what has been washed over.
The length of the washpipe string is most important. Realizing that the washpipe string is large
stiff and smooth length becomes extremely important in preventing sticking. There is no rule or
gauge for determining the maximum length but a judgment must be made based on careful
consideration of the hole conditions.
Long washpipe strings can be used for washing soft fill around stuck pipe. In washing over drill
pipe cemented inside casing only 100-150 ft of washpipe could be run at one time. When longer
washpipe is run, it may become stuck and increase the cost of the fishing operation.
When the entire length of fish cannot be covered in one washover, it is necessary to part the
string that has been freed from that which remains in the hole. This can be accomplished by one
of several methods:
1. An overshot can be run after the washpipe has been removed and left-hand torque applied
and the fish backed off with a string-shot.
2. An external or outside cutter can be run on the washpipe instead of the rotary shoe and
the fish cut off above the lowest point that has been freed.
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Wireline Spears
One of the most challenging of fishing
operations may be the recovery of
wireline and the tools or instruments
run with it.
WIRELINE
CENTER SPEAR
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