EVALUATION OF AERATED DRILLING METHOD AT GEOTHERMAL

DRILLING K-1 WELL Y FIELD

Himawan Ichwana (1)

Ir. Bayu Satiawira, MSi (2)

Ir. Bambang Kustono, Dipl. G.E.T (3)

ABSTRACT

Geothermal wells are usually drilled with bigger diameter, deeper, and are
intended for longer production times than oil or gas wells. In drilling geothermal
well, the most important goal is to reach the final depth safely, quickly, and
economically. But in fact, the purpose above cannot always be achieved due to the
problems that occur during the drilling process such as loss circulation and stuck
pipe. In order to avoid these drilling problem, it can be done by use aerated
drilling method. Aerated drilling in well K-1 performed on hole 17 at depth
689 mMD 1298 mMD, hole 12 at depth 1404 mMD 1423 mMD, 1438
mMD 2200 mMD, and hole 9 7/8 at depth 2201 mMD 3001 mMD.

The use of aerated drilling in all hole sections has yet to provide optimal
results, so it needs to be evaluated and determined the amount of air injection and
mud flow rate required to obtain optimal results.

INTRODUCTION

Aerated drilling defined as the addition of compressed air to the drilling

fluid circulating system which aims to reduce the density of the fluid column in
the wellbore annulus so that the pressure in the wellbore annulus will be balance
or lower than the formation pressure.

This paper will describe the evaluation of the use of aerated drilling
method at K-1 well, Y field in some points of the depth that has problems such as
loss of circulation and stuck pipe. On the section 17 , loss of circulation
occured at the depth 850 mMD, then loss of circulation and stuck pipe occurred at
the depth 1024 mMD. On the section 12 , loss of circulation occurred at the
depth 1533 mMD, then loss of circulation and stuck pipe occurred at the depth
2045 mMD. On the section 9 7/8,
loss of circulation occurred at the
depth 2310 mMD and 3000 mMD.
The evaluation of aerated drilling
method on K-1 well is aimed to
determine whether the use of this
method at K-1 well is already
optimal or not. By observed the
values of Equivalent Circulating
Density (ECD), Equivalent Static
Density (ESD), and Kynetic Energy.
GENERAL FUNDAMENTAL
THEORY
Aerated drilling is a drilling
technique that adds compressed air to
the drilling fluid (aerated mud), to
reduce the drilling fluid density so
that the hydrostatic pressure of the
drilling fluid is lower than the
formation pressure. Aerated drilling
is used to prevent the occurrence of
problems that often occur in
geothermal drilling, such as pinched
pipes, loss of circulation, and
damage to formation. These
problems occur because the reservoir
in the geothermal field has many
fractures, resulting in the condition
of loss of partial losses and total
during the drilling.
Geothermal field temperature
formation is very high between 200-
350C, thus making the
characteristics of drilling mud and
rheological properties will be
affected by high temperatures where
value of the viscosity will be
decreased by the temperature causing
cutting can not be lifted into the
surface, thus settling at the bottom of
the well, and occur stuck pipe.
Therefore, in geothermal wells,
aerated drilling fluids are used to
prevent these problems.
The aeration drilling fluid is a
modified drilling fluid with added
air, foam, and corrosion inhibitors.
The aerated drilling fluid has a lower
density than the usual drilling fluid,
which allows hydrostatic pressure of
the drilling fluid to be balanced or
lower than formation pressure. This
is to prevent those problems during
drilling.
AERATED DRILLING
CALCULATION TECHNIQUE
To keep the drilling fluid
circulation running well during
drilling, the hydraulic pressure in the
well needs to be maintained to keep
it balanced from the formation
pressure. In order to achieve that
condition, the drilling fluid density
needs to be reduced by adding
compressed air into the drilling fluid.
Accurate prediction of shut-in and
flowing bottom hole pressures in
inclined holes present a challenge in
aerated drilling. Hydraulic
calculation is conducted by using
Guo-Ghalambors method.
This method is better than
others, because it has a smaller error
percentage which has been proved.
Guo-Ghalambor creates an equation
which calculates value of injected
fluids, injected gas, solids, and fluid
influx. Based on Guos concept,
cutting transport analysis is
conducted by carrying capacity
method. This method is using a
concept of minimum kinetic energy
needed to lift the cuttings from the
bottom hole to the surface. In this
case, the minimum energy needed to
lift the cuttings is 3 lb-ft/cuft.
As for the success criteria of
aerated drilling method according to
Guo-Ghalambor can be seen in the
following table:
Table 1
The Success Criteria of Aerated
Drilling Method
According to Guo-Ghalambor
OPERATION WINDOW
Making operating windows will
make it easier to determine the
appropriate gas flow rate and mud
flow rate at the desired depth. The
appropriate gas flow rate and mud
flow rate need to be obtained in order
for aeration drilling to run
maximally. Operating windows are
limited by formation pressure,
collapse pressure, wash out area, and
kinetic energy. The required
criterions are, ECD and ESD values
must be under or equal with
formation pressure, because if it
exceeds the formation pressure, it
indicates circulation loss, it must also
be above the collapse pressure to
prevent collapse, and the mud flow
rate is required below the wash out
area limit of 900 gpm, and the value
of kinetic energy produced must be
above the minimum of kinetic energy
required to lift the cuttings, which is
3 lb-ft / cuft.
RESULTS AND DISCUSSION
Aerated drilling used on the section
17 depth 850 mMD, was
conducted by injecting 1400 and
1500 scfm air flow rate and 850 gpm
mud flow rate. At this depth, aerated
drilling has not performed well yet,
because the values of ECD and ESD
still bigger than the formation
pressure, this condition indicates
overbalanced drilling which results
loss of circulation. It can be seen on
the picture 1 and 2 (attachment).
Then based on kinetic energy, the
cuttings can not be lifted to the
surface because the value of kinetic
energy at some depth interval was
still below 3 lb-ft/cuft (picture 3). On
this contidion, cuttings will not be
lifted to the surface due to lack of
energy kinetic needed. And further
this may cause stuck pipe.
Optimization is conducted by
looking to the operation window to
make it easier in order to determine
the gas and mud flow rate, which has
been made for this depth (picture 4).
After injected 2400 scfm and 850
gpm, aerated drilling at this depth
has given optimal results, which
attached on picture 1 and 2, the
values of ECD and ESD has lower
than formation pressure, and kinetic
energy along the flow path already
exceeds the minimum energy needed
(picture 3).
On the section 17 depth
1024 mMD, was conducted by
injecting 2000 scfm air flow rate and
877 gpm mud flow rate. At this
depth, aerated drilling has not
performed well yet, because the
values of ECD and ESD still bigger
than the formation pressure, this
condition indicates overbalanced
drilling which results loss of
circulation. It can be seen on the
picture 5 and 6 (attachment). This
problem makes cuttings can not be
lifted to the surface so that caused
stuck pipe.
After injected 2500 scfm and
877 gpm, aerated drilling at this
depth has given optimal results,
which attached on picture 5 and 6,
the values of ECD and ESD has
lower than formation pressure, and
kinetic energy along the flow path
already exceeds the minimum energy
needed (picture 7).
Aerated drilling used on the
section 12 depth 1533 mMD, was
conducted by injecting 800 and 1000
scfm air flow rate and 717 gpm mud
flow rate. At this depth, aerated
drilling has not performed well yet,
because the values of ECD and ESD
still bigger than the formation
pressure, this condition indicates
overbalanced drilling which results
loss of circulation. It can be seen on
the picture 9 and 10 (attachment).
After injected 1500 scfm and
717 gpm, aerated drilling at this
depth has given optimal results,
which attached on picture 9 and 10,
the values of ECD and ESD has
lower than formation pressure, and
kinetic energy along the flow path
already exceeds the minimum energy
needed (picture 11).
On the section 12 depth
2045 mMD, was conducted by
injecting 1200 scfm air flow rate and
750 and 780 gpm mud flow rate. At
this depth, aerated drilling has not
performed well yet, because the
values of ECD and ESD still bigger
than the formation pressure, this
condition indicates overbalanced
drilling which results loss of
circulation. It can be seen on the
picture 13 and 14 (attachment). This
problem makes cuttings can not be
lifted to the surface so that caused
stuck pipe.
After injected 1200 scfm and
600 gpm, aerated drilling at this
depth has given optimal results,
which attached on picture 13 and 14,
the values of ECD and ESD has
lower than formation pressure, and
kinetic energy along the flow path
already exceeds the minimum energy
needed (picture 15).
Aerated drilling used on the
section 97/8 depth 2310 mMD, was
conducted by injecting 1200 scfm air
flow rate and 800 gpm mud flow
rate. At this depth, aerated drilling
has not performed well yet, because
the value of ECD still bigger than the
formation pressure, this condition
indicates overbalanced drilling which
results loss of circulation. It can be
seen on the picture 17 and 18
(attachment).
After injected 1200 scfm and
610 gpm, aerated drilling at this
depth has given optimal results,
which attached on picture 17 and 18,
the values of ECD and ESD has
lower than formation pressure, and
kinetic energy along the flow path
already exceeds the minimum energy
needed (picture 19).
On the section 97/8 depth
3000 mMD, was conducted by
injecting 1200 scfm air flow rate and
845 and 870 gpm mud flow rate. At
this depth, aerated drilling has not
performed well yet, because the
values of ECD and ESD still bigger
than the formation pressure, this
condition indicates overbalanced
drilling which results loss of
circulation. It can be seen on the
picture 21 and 22 (attachment).
After injected 1200 scfm and
610 gpm, aerated drilling at this
depth has given optimal results,
which attached on picture 21 and 22,
the values of ECD and ESD has
lower than formation pressure, and
kinetic energy along the flow path
already exceeds the minimum energy
needed (picture 23).
CONCLUSIONS
1. Aerated drilling on the
section 17 depth 850 and
1024 mMD were not optimal.
Loss of circulation occurred
at both of depth, and stuck
pipe occurred at 1024 mMD.
2. After optimized by injecting
850 gpm and 2400 scfm at
850 mMD, and injected 2500
scfm and 877 gpm at 1024
mMD, aerated drilling on
section 17 has given
optimal results.
3. Aerated drilling on the
section 12 depth 1533 and
2045 mMD were not optimal.
Loss of circulation occurred
at both of depth, and stuck
pipe occurred at 2045 mMD.
 4. After optimized by injecting DH
717 gpm and 1500 scfm at
1533 mMD, and injected
1200 scfm and 600 gpm at ECD
2045 mMD, aerated drilling
on section 12 has given Ek
optimal results.
ESD
5. Aerated drilling on the
section 9 7/8 depth 2310 and
f = Moody friction factor
3000 mMD were not optimal.
Loss of circulation occurred FLHU
at both of depth.
= Hydraulic diameter of
flowpath (ft)
= Equivalent circulating
density , ppg
= Kinetic energy , lb-f/ft3
= Equivalent static density,
ppg
= Correction factor for liquid
hold up

6. After optimized by injecting g = Gravitation , ft/sec2 (32.2

610 gpm and 1200 scfm at ft/sec2)
2310 mMD, and 3000 mMD,
GLR = Gas Liquid Ratio
aerated drilling on section 9
7
/8 has given optimal results. H = Vertical depth , ft

7. Making operation windows L = Borehole length (measured

will make easier to determine depth), ft
the right values of gas and Pflow = Flowing bottom hole
mud flow rate. pressure, psia

Pfr = Frictional pressure drop,

LIST OF SYMBOLS psia
= Differential pressure, psi PH = Circulation-break bottom
hole pressure, psia
mix = Specific weight of mixture ,
lbf/ft3 PS = Pressure at surface choke,
psia
= the average wall roughness
of flow path , ft (0.004 ft Qf = Formation fluid influx rate,
open hole) bbl/hour

A = Cross-sectional area, in2 Qg = Gas injection rate, gpm

db = Diameter bit, in Qm = Mud injection rate, gpm

Rp = Rate of penetration, ft/hour

Sf = Specific gravity of
formation fluid
Sg = Specific gravity of gas
Ss = Specific gravity of drill
cuttings
Tavg = Average temperature , R
Ts = Surface temperature , R
vmix = Mixture velocity, ft/sec
Wm = Mud density, ppg
REFERENCES
1. Birkisson,F., and Hole H.,
Aerated Fluids for Drilling
of Geothermal Wells,
Iceland Drilling Company,
Germany, 2007.
2. Budi Kesuma Adi Putra, I.,
Drilling Practice with
Aerated Drilling Fluid:
Indonesian and Icelandic
Geothermal Fields, United
Nations University, Iceland,
2008.
3. Finger, John, and Doug
Blankenship, Handbook of
Best Practices for Geothermal
Drilling, Sandia National
Laboratories, California,
2010.
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An Innovation in Designing
Underbalanced Drilling Flow
Rates: A Gas-Liquid Rate
Window (GLRW)
5. Approach, IADC/SPE paper
77237 presented at 2002
IADC/SPE Asia Pacific
Drilling Technology held in
Jakarta, Indonesia, 9-11
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Form Hydraulics Equation
for Aerated Mud Drilling in
Inclined Wells, University
of Louisiana , Lafayette,
2003.
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Aerated Mud and Foam
Drilling Hydraulics in
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1 Lapangan Y

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 ATTACHMENTS

Picture 1

ECD VS Depth Section 17 Depth 850 mMD

Picture 2

ESD VS Depth Section 17 Depth 850 mMD

 Picture 3

Kynetic energy vs Depth Section 17 Depth 850 mMD

Picture 4

Operation Window Section 17 Depth 850 mMD

 Picture 5

ECD VS Depth Section 17 Depth 1024 mMD

Picture 6

ESD VS Depth Section 17 Depth 1024 mMD

 Picture 7

Kynetic energy vs Depth Section 17 Depth 1024 mMD

Picture 8

Operation Window Section 17 Depth 1024 mMD

 Picture 9

ECD VS Depth Section 12 Depth 1533 mMD

Picture 10

ESD VS Depth Section 12 Depth 1533 mMD

 Picture 11

Kynetic energy vs Depth Section 12 Depth 1533 mMD

Picture 12

Operation Window Section 12 Depth 1533 mMD

 Picture 13

ECD VS Depth Section 12 Depth 2045 mMD

Picture 14

ESD VS Depth Section 12 Depth 2045 mMD

 Picture 15

Kynetic energy vs Depth Section 12 Depth 2045 mMD

Picture 16

Operation Window Section 12 Depth 2045 mMD

 Picture 17

ECD VS Depth Section 9 7/8 Depth 2310 mMD

Picture 18

ESD VS Depth Section 9 7/8 Depth 2310 mMD

 Picture 19

Kynetic energy vs Depth Section 9 7/8 Depth 2310 mMD

Picture 20

Operation Window Section 12 Depth 2045 mMD

 Picture 21

ECD VS Depth Section 9 7/8 Depth 3000 mMD

Picture 22

ESD VS Depth Section 9 7/8 Depth 3000 mMD

 Picture 23

Kynetic energy vs Depth Section 9 7/8 Depth 3000 mMD

Picture 20

Operation Window Section 12 Depth 2045 mMD