Drilling Engineering Problems and Solutions

M.E. Hossain is a professor at Nazarbayev University, Kazakhstan, where he is in charge of starting a new program in petroleum engineering. Previously, he was Canada's first Statoil Chair at Memorial University of Newfoundland (MUN), Canada. Dr. Hossain authored/co-authored nearly 200 research articles, including seven books, focusing on reservoir characterization, enhanced oil recovery (EOR), drilling engineeering and environmental sustainability. M. Rafiq Islam is the President of Emertec R&D Ltd. and an adjunct professor at Dalhousie University, where he was Canada's first Killam Chair in Oil and Gas. He has over 30 years of experience in teaching and research, during which time he has supervised over 150 graduate and undergraduate students and postdoctoral fellows and completed over $20 million of funded research. During his career, he has published nearly 800 research papers and dozens of books and research monographs on topics ranging from petroleum engineering to economics. He is the founding executive editor of Journal of Nature Science and Journal of Characterization and Development of Novel Materials, and serves on the editorial board of a number of journals. Previously, he held editorial positions with SPE, AIChEJ, JCPT, JPSE, and others.

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• Foreword xviiAcknowledgements xix1. Introduction 11.1. Introduction of the Book 11.2. Introduction of Drilling Engineering 21.3. Importance of Drilling Engineering 21.4. Application of Drilling Engineering 31.5. Drilling Problems, Causes, and Solutions 31.5.1 Common Drilling Problems 51.6. Drilling Operations and its Problems 41.7. Sustainable Solutions for Drilling Problems 61.8. Summary 8References 82. Problems Associated with Drilling Operations 112.1. Introduction 112.2. Problems Related to Drilling Methods and Solutions 122.2.1. Sour Gas Bearing Zones 122.2.1.1. How to Tackle H2S 122.2.2. Shallow Gas-Bearing Zones 172.2.2.1. Prediction of Shallow Gas Zone 182.2.2.2. Identification of Shallow Gas Pockets 192.2.2.3. Case Study 202.2.3. General Equipment, Communication and Personnel Related Problems 242.2.3.1. Equipment 242.2.3.2. Communication 282.2.3.3. Personnel 302.2.4. Stacked Tools 312.2.4.1. Objects Dropped into the Well 322.2.4.2. Fishing Operations 342.2.4.3. Junk Retrieve Operations 452.2.4.4. Twist-off 462.2.5. Difficult-to-drill Rocks 482.2.6. Resistant Beds Encountered 482.2.7. Slow Drilling 492.2.7.1. Factors Affecting Rate of Penetration 502.2.8. Marginal Aquifer Encountered 622.2.9. Well Stops Producing Water 622.2.10. Drilling Complex Formations 632.2.11. Complex Fluid Systems 632.2.12. Bit Balling 642.2.13. Formation Cave-in 662.2.14. Bridging in Wells 672.2.14.1. Causes of Bridging in Wells 692.2.14.2. Warning Signs of Cutting Setting in Vertical Well 702.2.14.3. Remedial Actions of Bridging in Wells 702.2.14.4. Preventive Actions 712.2.14.5. Volume of Solid Model 712.3. Summary 73References 733. Problems Related to the Mud System 773.1. Introduction 773.2. Drilling Fluids and its Problems with Solutions 783.2.1. Lost Circulation 793.2.1.1. Mechanics of Lost Circulation 863.2.1.2. Preventive Measures 883.2.1.3. Mud Loss Calculation 903.2.1.4. Case Studies 923.2.2. Loss of Rig Time 953.2.3. Abandonment of Expensive Wells 963.2.4. Minimized Production 973.2.5. Mud Contamination 973.2.5.1. Sources and Remediation of the Contamination 993.2.6. Formation Damage 1043.2.6.1. Prevention of Formation Damage 1133.2.6.2. Quantifying Formation Damage 1163.2.7. Annular Hole Cleaning 1183.2.7.1. New Hole Cleaning Devices 1203.2.8. Mud Cake Formation 1223.2.8.1. Filtration Tests 1233.2.8.2. Mud Cake Removal Using Ultrasonic Wave Radiation 1243.2.8.3. Wellbore Filter Cake Formation Model 1253.2.9. Excessive Fluid Loss 1263.2.10. Drilling Fluid Backflow 1283.3. General Case Studies on Lost Circulation 1283.3.1. Lessons Learned 1303.4. Summary 130References 1314. Problem Related to Drilling Hydraulics 1394.1. Introduction 1394.2. Drilling Hydraulics and its Problems and Solutions 1414.2.1. Borehole Instability 1474.2.1.1. Hole Enlargement 1484.2.1.2. Hole Closure 1504.2.1.3. Fracturing 1504.2.1.4. Collapse 1514.2.1.5. Prevention and Remediation 1534.2.2. Proper Hole Trajectory Selection 1544.2.3. Drill Bit Concerns 1564.2.3.1. Bit Balling 1564.2.4. Hydraulic Power Requirement 1574.2.5. Vibration 1604.3. Overall Recommendations 1614.3.1. The Rig Infrastructure 1614.3.2. Problems Related to Stuckpipe 1624.3.3. Mechanical Pipe Sticking 1634.3.4. Borehole Instability 1644.3.4.1. Bottom Hole Pressure (mud density) 1654.3.4.2. Well Inclination and Azimuth 1654.3.4.3. Physical/chemical Fluid-rock Interaction 1654.3.4.4. Drillstring Vibrations 1664.3.4.5. Drilling Fluid Temperature 1664.4. Summary 168References 1685. Well Control and BOP Problems 1715.1. Introduction 1715.2. Well Control System 1725.3. Problems with Well Control and BOP and their Solutions 1745.3.1. Kicks 1745.3.1.1. Warning Signals of Kicks 1775.3.1.2. Control of Influx and Kill Mud 1805.3.2. Blowout 1975.4. Case Studies 1995.4.1. Blowout in East Coast of India 1995.4.1.1. Solutions 2015.4.1.2. Causes of the Blowout 2035.4.1.3. Lessons Learned and Recommendations 2045.4.2. Deepwater Horizon Blowout 2055.4.2.1. Solutions 2075.4.2.2. Reasons Behind the Blowout 2145.4.2.3. Lessons Learned and Recommendation 2175.5. Summary 218References 2196. Drillstring and Bottomhole Assembly Problems 2216.1. Introduction 2216.2. Problems Related to Drillstring and their Solutions 2236.2.1. Stuck Pipe 2236.2.1.1. Free Point – Stuck Point Location 2246.2.1.2. The Most Common Causes of Stuck Pipe 2276.2.1.3. Prevention of Stuck Pipe 2296.2.1.4. Freeing Stuck Pipe 2306.2.1.5. Measures to Reduce Stuck Pipe Costs 2316.2.1.6. Some Examples of Field Practices 2316.2.2. Drillpipe Failures 2346.2.2.1. Twist-off 2376.2.2.2. Parting and other Failures 2406.2.2.3. Collapse and Burst 2406.2.2.4. Tension Load 2456.2.2.5. Fatigue 2546.2.3. Problems Related to Catches 2566.2.4. Fishing Operation 2576.2.4.1. Stuck Pipe Fishing 2576.2.4.2. Fishing for a “Twist-off ” 2576.2.5. Failures Caused by Downhole Friction Heating 2586.2.5.1. Heat Check Cracking 2596.3. Case Studies 2746.3.1. Vibration Control 2746.3.1.1. Execution 2766.3.1.2. Lessons Learned 2786.3.2. Twist-off 2796.4. Summary 280References 2807. Casing Problems 2857.1. Introduction 2857.2. Problems Related to Casing and their Solutions 2867.2.1. Casing Jams during Installation 2877.2.2. Buckling 2877.2.2.1. Buckling Criteria 2887.2.2.2. General Guideline 2927.2.3. Temperature Effect 2927.2.4. Casing Leaks 2947.2.5. Contaminated Soil/Water-Bearing Zones 2977.2.6. Problem with Depth to Set Casing 2997.2.6.1. Special Considerations of a Surface Casing 3017.2.6.2. Practical Guideline 3047.2.6.3. Influence of Casing Shoe Depth on Sustained Casing Pressure (SCP) during Production 3067.3. Case Studies 3117.3.1. Case Study – 1 (Casing Jamming) 3137.3.1.1. Lessons Learned 3147.3.2. Case Study – 2 (Casing Installation Problems) 3147.3.3. Case Study – 3 (Casing Installation Problems in an Offshore Field) 3167.3.3.1. Lessons Learned 3167.3.4. Case Study – 4 (Leaky Casing) 3187.3.4.1. Repair Alternatives 3197.3.4.2. Setting Patches 3207.3.4.3. Results and Lessons Learned 3217.3.5. Case Study – 5 (Use of Gel for Water Leaks) 3237.3.6. Case Study – 6 (Unusual Lithology) 3257.3.6.1. Case 1: Leak below Production Packer 3277.3.6.2. Case 2: Casing Shoe above Unsealed High Pressure Formation 3297.3.6.3. Case 3: Casing Shoe set in Weak Formation 3327.3.6.4. Case 4: Leak below Production Casing Shoe   3347.3.6.5. Lessons Learned and Recommendations 3367.3.7. Case Study – 7 (Surface Casing Setting) 3407.2.7.1. Leak-off Tests. 3417.2.7.2. Reduction System. 3447.3 Summary 347References 3478. Cementing  Problems 3538.1. Introduction 3538.2. Problems Related to Cementing and their Solutions 3548.2.1. Leaks due to Cement Failure 3558.2.1.1. Preventive Methods 3588.2.2. Key Seating 3628.2.2.1. Prevention 3638.2.2.2. Remediation 3648.2.3. Cement Blocks 3668.2.4. Problems Related to Mud/Cement Rheology 3668.2.4.1. Contamination with Oil-based Mud 3678.2.4.2. Problem Related to Eccentric Annulus 3708.2.4.3. Flow Regime of Cement Displacement 3728.2.4.4. Improper Mud Cake Removal during  Cementing 3748.2.4.5. Poor Mixing and/or Testing of Cement Slurry 3758.2.5. Blowout Potentials 3798.2.5.1. Overall Guidelines 3818.3. Good Cementing Practices 3828.3.1. Drilling Fluid 3838.3.2. Hole Cleaning 3848.3.3. Gel Strength 3848.3.4. Spacers and Flushes. Contents. 3868.2.5. Slurry Design 3888.2.6. Casing Rotation and Reciprocation 3908.2.7. Centralizing Casing 3918.2.8. Displacement Efficiency 3928.2.9. Cement Quality 3938.2.10. Special Considerations 3948.3. Case Studies 3948.3.1. Causes of Cement Job Failures 3948.3.2. Casinghead Pressure Problems 3988.3.3. Cases of Good Cement Jobs 4018.3.3.1. Good Case I 4028.3.3.2. Good Case II 4038.3.3.3. Good Case III 4038.3.3.4. Good Case IV 4068.3.3.5. Good Case V 4098.3.4. Cases of Failed Cement Jobs  4138.3.4.1. Failed Cementing Case 01 4168.3.4.2. Failed Case 02 4178.3.4.3. Failed Case 03 4288.3.4.4. Failed Case 04 4298.4. Summary 440References 4409. Wellbore Instability Problems 4439.1. Introduction 4439.2. Problems Related to Wellbore Instability and their Solutions 4449.2.1. Causes of Wellbore Instability 4459.2.1.1. Uncontrollable Factors 4459.2.1.2. Controllable Factors 4539.2.2. Indicators of Wellbore Instability 4649.2.2.1. Diagnosis of Wellbore Instability 4659.2.2.2. Preventative Measures 4659.3. Case Studies 4699.3.1. Chemical Effect Problems in Shaley Formation 4699.3.1.1. Geological Considerations 4709.3.1.2. Drilling Problems 4709.3.1.3. Instability Mechanism 4719.3.1.4. Instability Analysis 4739.3.1.5. Shale Hydration 4759.3.1.6. Dynamic Effects 4799.3.1.7. Lessons Learned from Countermeasures 4809.3.2. Minimizing Vibration for Improving Wellbore Stability 4819.3.3. Mechanical Wellbore Stability Problems 4839.2.3.1. Case Study for Well X-51 (Shale Problems). 4839.2.3.2. Case Study for Well X-53 (Shale and Sand Problems). 4869.2.3.3. Case Study for Well X-52 (Successful Case). 4899.2.3.4. Lessons Learned. 4919.3 Summary 493References 49410. Directional and Horizontal Drilling Problems 49710.1. Introduction 49710.2. Problems Related to Directional Drilling their Solutions 49910.2.1. Accuracy of Borehole Trajectory 50110.2.1.1. Guidelines and Emerging Technologies 50710.2.2. Fishing with Coiled Tubing 50810.2.3. Crookedness of Wells/Deflection of Wells 50910.2.3.1. Causes of Crookedness 51110.2.3.2. Outcomes of Crooked Borehole and Possible Remedies 51510.2.4. Stuck Pipe Problems 51710.2.5. Horizontal Drilling 52010.2.5.1. Problems Associated with Horizontal Well Drilling 52310.2.5.2. Unique Problems Related to Horizontal Well Drilling 52610.3. Case Studies 52710.3.1. Drilling of Multilateral and Horizontal Wells 52710.3.2. Directional Drilling Challenges in Deepwater Subsalt 53910.2.2.1. Description of the Reservoir. 54010.2.2.2. Planning of Drilling. 54110.2.2.3. Drilling Operations. 54210.2.2.4. Planning the Sidetracks. 54310.2.2.5. Lessons Learned. 54510.3. Summary 545References 54511. Environmental Hazard and Problems during Drilling 54911.1. Introduction 54911.2. Problems Related to Environment during Drilling 55011.2.1. Environmental Degradation 55111.2.1.1. Acoustics (Noise) 55111.2.1.2. Air Quality 55211.2.1.3. Contamination during Drilling 55411.2.1.4. Cultural Resources 55611.2.1.5. Ecological Resources 55611.2.1.6. Environmental Justice 55711.2.1.7. Hazardous Materials and Waste Management 55811.2.1.8. Health and Safety 55911.2.1.9. Land Use 56011.2.1.10. Paleontological Resources 56011.2.1.11. Socioeconomics 56111.2.1.12. Soils and Geologic Resources 56111.2.1.13. Transportation 56211.2.1.14. Water Resources 56211.2.2. Drill Cutting Management 56311.2.2.1. Regulatory Aspects of Drill Cutting Disposal 56711.2.3. Subsidence of Ground Surface 57011.2.4. Deep Water Challenges 57311.2.4.1. Narrow Operational Window 57311.2.4.2. Marine Drilling Riser 57311.2.4.3. Shallow Formation Hazards 57411.2.4.4. Risk Analysis of Offshore Drilling 57511.3. Case Studies 57911.3.1. Effect of Drilling Fluid Discharge on Oceanic Organisms  57911.3.1.1. Observations and Lessons Learned 58211.3.2. Long-term Impact on Human Health 58411.3.2.1. Lessons Learned 59011.4. Summary 590References 59012. Summary and Conclusions 59512.1. Summary 59512.2. Conclusions 59612.2.1. Chapter 1: Introduction 59612.2.2. Chapter 2: Problems Associated with Drilling Operations 59712.2.3. Chapter 3: Problems Related to the Mud System 59812.2.4. Chapter 4: Problem Related to Drilling Hydraulics   60012.2.5. Chapter 5: Well Control and BOP Problems 60112.2.6. Chapter 6: Drillstring and Bottomhole Assembly Problems 60212.2.7. Chapter 7: Casing Problems 60412.2.8. Chapter 8: Cementing Problems 60612.2.9. Wellbore Instability Problems 60812.2.10. Chapter 10: Directional and Horizontal Drilling Problems 61112.2.11. Chapter 11: Environmental Hazard and Problems during Drilling 612Index 615