2012 AAPL ANNUAL MEETING SPONSORS PLATINUM GOLD SILVER SAN FRANCISCO SEMINAR GOLF A wholly owned...
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Transcript of 2012 AAPL ANNUAL MEETING SPONSORS PLATINUM GOLD SILVER SAN FRANCISCO SEMINAR GOLF A wholly owned...
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2012 AAPL ANNUAL MEETING SPONSORSPLATINUM
GOLD
SILVER
SAN FRANCISCO SEMINAR GOLF
A wholly owned subsidiary of ExxonMobil
BRONZE
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58th Annual Meeting - San Francisco
June 13-16, 2012
Downhole Drilling Problems:Drilling Mysteries Revealed!
Kelli Fereday, BP
AAPL - Copyright © 2012. All Rights Reserved.
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Today’s Goal
Drillers have a term for downhole problems that can not be diagnoosed or understood:
The objective of this session is to turn these mysteries into understandable and solvable opportunities for improvement
AAPL - Copyright © 2012. All Rights Reserved.
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Downhole Drilling Problems
• Industry Prevalence• Types of Drilling “Trouble Time” • Impact on Well Safety, Time, and Cost• Causes and Diagnosis of Drilling Problems• Examples and Remedies for Common Problems
– Downhole Failures– Stuck Pipe– Lost Circulation– Wellbore Stability– Well Control– Q&A
AAPL - Copyright © 2012. All Rights Reserved.
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Typical Drilling Time Breakdown
Productive Time50%Non-Productive
Time25%
Invisible Lost Time25%
“Making Hole!Inefficient
Drilling Problems
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Impact on the Industry• Biggest Impact - HSE
– Many drilling problems are also associated with increased risk to personnel
Example: Stuck Pipe May Require Jarring which can lead to dropped
objects
Example: Lost Circulation may lead to Lost of Well Control, resulting in
potential Damage to the Environment, Fire and/or Harm to Personnel
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Impact on the Industry• Efficiency
– Estimates are as much as 10-40% (25% on average) of drilling time is non-productive time!
– US Rig Count ~1980 rigs, projected need by 2017 is 2500, or approximately a 25% increase
– Imagine being able to close that gap through improvements in drilling performance alone.
– US E&P Budget is about $170BB annually - > $$$
Baker Hughes Rig Countwww.bakerhughes.com
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How do we diagnose NPT?• Drilling Reports
– Rig Morning Reports– Mud Reports– Cuttings Analysis
• Downhole and Surface
Measurements• Benchmarking
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Sources of NPT – Deepwater Industry Example
DownholeProblems
EquipmentProblems
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Top Sources of Downhole Problems
1. Downhole Equipment Failures
2. Downhole Cement Problems
3. Stuck Pipe
4. Lost Circulation
5. Wellbore Stability
6. Well Control
Likely Related
to Geology
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Downhole Equipment Failures
• A single equipment failure can– Compromise the integrity of the well– Cost Millions of Dollars to Repair
• Common Equipment Failures– Casing– Drillpipe– Downhole Motors– Downhole Measurement Tools
• MWD• LWD
Vector Motorswww.nov.com
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Downhole Cement Problems• Cement Left in Pipe
– Premature Setting– Surface Equipment Pump
Failures
• Cement Not Setting Properly– Cement never sets – “Bad
Shoe” or “No Shoe Test”– Cement allows for gas
migration– Cement seeps away into faults
or fractures – “Partial or Total Losses”
Picture from Halliburton website:
generic example of a cemented wellbore
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Stuck Pipe
1. Differential Sticking– Pressure-related – The pipe is “sucked” up against the
formation due to a difference in pressure
2. Mechanical Sticking– A mechanical obstruction– Could be from the formation, wellbore
geometry, or tool failure
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Differential Sticking – A Pressure Problem
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Mechanical Sticking – Dirty Wellbore
• Too many “solids” in the wellbore!– Indications:
• higher pump pressure• fill on bottom• more “pull” required to move pipe• excessive cuttings on shakers• restricted circulation
• Why?– Unconsolidated Formations– Poor Hole Cleaning
• Prevention– maximise flow rates and rpm– Better mud properties– drill more slowly
Formations Fall in on the pipe!
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Mechanical Sticking – Obstructions
• Obstructions– Indications:
• more “pull” required to move pipe• can still circulate• Increased torque• Unable to “make hole”
• Why?– Junk in the Wellbore– Hole Geometry
• Prevention– equipment QA/QC– housekeeping– correct drillstring/BHA design
Tool Failures or Junk in Hole
Doglegs or Underguage Hole
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Stuck Pipe – How do we get free?
• Pull Harder (but don’t break it)• Jar on Pipe• Cut Pipe and Fish• Increase or decrease circulation• Pump other types of fluids or
chemicals
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Lost Circulation• Conventional drilling utilizes
continuous fluid flow down the drillpipe to:– Remove cuttings– Maintain pressure– Cool the bit
• Key indicator in understanding what is happening downhole
• Circulation must be maintained at all times
• If the circulation is interrupted because fluid is flowing into the formation, that is called “Lost Circulation”
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Lost Circulation - Causes
Induced
Natural
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Lost Circulation - Solutions
Prevention
LCM
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Wellbore Stability
• An unstable wellbore can result in:– Stuck Pipe– Lost Circulation– Loss of the entire wellbore
• 2 Main causes are:– Chemical Instability
• Reactive Formations– Mechanical failure of wellbore
• Faults• Insufficient Mud Weight
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Well Control• Well Control means the ability to keep the hydrocarbons where
they belong at all times – in the ground.• Common terms
– “Taking a Kick”– Blowout
• Most dangerous downhole problem
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Well Control• What causes loss of well control?
– Multiple Barrier Failures
• Equipment Failures• Loss of fluid pressure in the pipe
counteracting the natural pressure existing in the formation
• Industry Methods dealing with Well Control– Wellbore Monitoring– Well Kill Methods - how to safely remove
hydrocarbons from the wellbore• Circulating Methods• Non-circulating Methods
Mud BOP
Pre
ssu
re
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Industry Challenges• The Great Crew Change
• Well Complexity
2000 2006 2012203040506070
43 50 60
Peak Age of Petroleum Engineers
Pete Stark, VP of industry relations for IHS
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Technology Game-Changers
• Rig Automation• Advanced Downhole Tools• Real-time montioring• Managed Pressure Drilling• Simulators for Training
www.weatherford.com
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Q&A