Drilling Problems Solving

Drilling” Problems Solving

“Workshop”

For Registration

Engineer: Ahmed Al-Garhy Project Manager World Class Training (WCT) Mobile : 0100 44 923 44 Email : agarhy@ogs.com.eg

Instructor : Eng. Fekry Saleh Fees : $1200 Course Date : 11-14 June 2012 Location : Agiba Petroleum Company - Nasr City

Course Instructor: Eng. Fekry Saleh

Sr. Drilling Advisor (Suez Oil Company “SUCO”)

Eng. Fekry Saleh has 30 years of experience in drilling practices in Egypt, Middle East, North Africa and Ukraine. During his job he served SUCO as drilling advisor, Emtiaz Engineering and Energy (Triple E - EOC) as a general manager plus leading projects in Ukraine and Iraq, NOSPCO- North Sinai Petroleum Co as drilling manager, Petroservices drilling overseas (PSDO) as Drilling contractor operations General manager, Rashpetco (B.G Egypt) as Rosetta drilling Superintendent & project manager, Bapetco Shell as ODT & UBD project manager (drilling operation technical support & under balance drilling project manager), Halliburton / Agiba (Ieoc) as IS project manager, West Ashrafi South -1, Expl. Well, S.W Gulf of Suez, Schlumberger as consultant for Preparation of drilling programs for horizontal wells, for Oil India, Pennzoil (Devon) Egypt as senior drilling engineer (drilling engineering – logistic – materials), Khalda (Apache) as drilling supervisor. (Western Desert), Pennzoil Egypt as senior drilling engineer (G.O.S. area, South West Gabel El Zeit and North July Field, Rashpetco (B.G) as rig supervisor, gas wells (Med. Sea), Geisum as drilling supervisor - G.O.S, Kriti Almine as re-entry and work over, Seagull as rig less W/O wireline, coil tubing, Wepco Ipr as rig supervisor, Western Desert, Petrozeit as tenders / quotation evaluations for all the drilling services, contract format, Deminex as drilling manager, Idku branch, mediterranean concession, shallow and deep water fields, gas wells, Schlumberger as senior drilling engineer Tunisia - Bg P&E, SHergui and Hadrubal-4 Integrated Drilling Projects, Wood Int as Drilling Consultant With Seagull Oil Company (South Hurghada onshore) and G.N.R Oil Company: (Beni Suef onshore) drilling superintendent tenders, Speco as drilling consultant live in schedule (field & office), drilling operations - tender preparation and evaluation (all drilling services) and technical support for Petrozeit (Marathon Egypt), EDC (Egyptian Drilling Company) as drilling consultant, Borais as a directional engineer. Eng. Fekry Started his career as a drilling engineer at GUPCO in 1983.

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Drilling” Problems Solving “Workshop”

Wellbore Drilling Problems:

Well bore instability 1. Mechanical forces a. Pressure differential b. Erosion – Mix of different shale sizes c. Pipe whip numerous of different shape of cutting d. Surge and swap – causes lost of circulation or large quantities of rocks / debris e. Overburden pressure f. Pore pressure g. Swelled shale h. Gumbo Shale i. Movable shale & salt j. Salt dome 2. Tectonic forces a. Fault plan b. Unconformity lines c. Metamorphic rock (hard rock & sharp edges) due to the tectonic friction – Pressure and temperature d. Causes ledges & bridges phenomena inside the well bore.

3. Water adsorption – hydration a. Ability of Argillaceous formation to absorb water i. Swell shale ii. Sloughing shale iii. Unstable young shale (clay), fall in hole in big pieces iv. Caved / enlarged hole due to formation fall over v. Unstable matured shale, cause wet surface, bit and BHA balling / high torque vi. Unstable shale / marl / dolomite & decrease the ROP and the hole cleaning vii. Hole enlargement viii. Poor hole cleaning ix. Stuck pipe x. Bridging and formation fill on string while trips xi. Excessive drilling cutting & excessive fluid entire into well pore – causes increase of the mud treatments cost. xii. Increase cement requirements and poor cement jobs xiii. Poor logging quality & wire line logging problems xiv. Tight hole xv. Hole key seating xvi. Increasing torque and drag xvii. Decrease rate of penetration – bit & BHA balling – Torque – WOB, unstable RPM (slip lock effect) xviii. Instability of the drill string causes string wiping & wash out and pipe twist off xix. Hydrating and dispersing shale in mud - increase the mud rehology / flocculation – Causes pore hole clean / exceed pressure surge and swab effect, increase hole torque, increase the mud treatment cost.

4. Pressurized shale i. Brittle shale; Firm shale fall in the mud – depending on the shale stability could be stable, and could be swelled, and depending on the amount of the fall over amount could cause drilling string mechanical stuck. ii. Abnormal pressurized shale, which is normally above or below high pressure sand and or caused due to tectonics and move the formation up-word – this case could cause hole instability as A) rock fall off B) mechanical stuck C) well control issue. iii. Tectonically stressed shale, moving the shale layers up word with the same formation and overburden pressure causes hole instability.

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Drilling” Problems Solving “Workshop”

5. Formation Shallow gas 6. Abnormal formation pressure

Stuck Pipe & Stuck pipe prevention Causes of stuck pipe a. Differential pressure – Wall Sticking & Prevention i. Control mud weight as low as possible / as practical ii. Control filtration rate to produce a thin compressed filter cake iii. Control drilled solid as low as possible iv. Control drilling as required – to avoid over loading the annulus with cutting v. Add friction reducer additive - Lubricant vi. Spot filter cake removal – pipe lax, or pipe spot for soaking when pipe stuck. vii. With full percussion cut mud weight to minimize the hydrostatic head, and return it back when pipe stuck get free.

2. Mechanical stuck & prevention a. Key Seating i. Use key seat wiper in the string if necessary ii. Do condition trip as hole dictate iii. Control / smooth direction work with low dog leg severity iv. Add friction reducer additive to mud system b. Formation related wellbore instability (shale & Argillaceous formation as: = unconsolidated young clay, swell shale, pressurized shale , Gampo, unstable marl & dolomite, movable salt). i. Improve mud fluid loss ii. Improve mud rehology iii. Improve mud parameter, and remove the drilled solid iv. Operate the solid control equipment as maximum as possible v. Use adequate mud weight to stabilize the hole vi. Adequate circulating rate vii. Condition trips and circulate hole clean as per hole dictate viii. Keep close eye to the shale shaker and let the hole talk to you c. Wellbore geometry (deviation and ledges, excessive dog legs, inadequate hole shape with excessive directional work) i. IAdjust the direction work to have a smooth hole well path, ii. Minimum dog leg severity as possible & using Rotary steerable system to do the smooth direction work all away, mean while keep the string rotating all the time iii. Adequate mud parameter, control fluid loss, and add lubricant additive to the mud system to minimize the friction iv. Keep the drill string in rotating mood as possible. v. Add Key seat wiper and roller reamer to the string if necessary vi. Sweep hole with hi-vis-pill d. Inadequate hole cleaning i. Circulate enough for hole and shale shaker clean ii. Using Hi-Vis / Low-Vis technique as required for adequate hole cleaning iii. Keep mud parameter & rehology excellent iv. Wash & ream each stand before connection v. Minimize the stopping time for connection vi. Use fibrous bills to carry out cutting to surface vii. Control drilling rate as necessary for adequate hole cleaning.

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Drilling” Problems Solving “Workshop”

e. Junk in hole or collapsed casing i. Precautionary wash & ream down before tag the fish / Junk ii. Use Hi vis sweep enough to carry out the milled out junk iii. Move pipe up & down slowly, avoid to fire jar unless it is necessary & last option – and fired it to the opposite direction of the trouble, as possible iv. Select the right milling or fishing tool to fit with the down hole Junk v. Use taper tap or casing opening bomb to open up the collapsed casing f. Cement related i. Wash down the last two – three stand above the estimated top of cement. ii. Do not go deep if cement still green, pull back and wait for cement harden while circulate and reciprocate the string iii. Slowly drill out to the top of soft / moderate cement, and back ream frequently. iv. Treating the mud to be in good condition v. Keeps control drilling until reach to hard cement. vi. Never apply pressure to the annulus while drilling out soft cement, to avoid cement flush set around the drill string. g. Ledges, bridges & formation Cavities due to different formation strength (hard rock between 2 soft or reverse versa) i. Slowly move in / out the drill string while passing the trouble zone ii. Avoid to fire the jar unless it is necessary / last option. iii. Clean out hole prior the trips iv. Wash and ream while move against the trouble zones, with processionals procedure from mechanical stuck A) formation – drilling cutting backing off, or B) string hanging on the ledges and or the bridges h. Tectonics plans (fault & unconformity plan) i. Avoid to rotate in the same depth for long period of time to avoid string cut off – against the hard formation (work as saw with the pipe steel) ii. Slowly move in / out the drill string while passing the trouble zone iii. Avoid to fire the jar unless it is necessary / last option. iv. Clean out hole prior the trips v. Slowly Wash and ream while move against the trouble zones, with processionals procedure from mechanical stuck A) formation – drilling cutting backing off, or B) string hanging on the ledges and or the bridges

Loss of Circulation

Causes of loss of Circulation and loss Circulation prevention 1. Unconsolidated sand & unconsolidated formation a. Use high Bentonitic spud mud while drill the top unconsolidated formation b. Low mud weight as possible c. Control drilling rate, give the mud time to soak & support the unconsolidated formation and build good filter cake d. L.C. Bills as required e. Add some suitable value of loss circulation material to the system to stop the losses. f. Drill out with partial / sever / and or complete loss of circulation with top up the annulus with mud or water – if no shallow gas hazard.

1. Fractured formation a. Low mud weight as possible b. High bentonitic mud spud system c. Drill without return with mud /or water top up in case if no shallow gas hazard. d. Drill then Gunk squeeze or cement plugs until reach to the consolidate formation and or reach to reasonable limit of formation losses to continue drill out to casing point.

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Drilling” Problems Solving “Workshop”

2. Highly permeable formation a. Low mud weight b. Add L.C.M to the system, and replace the consumed materials.

3. Highly porous formation a. Low mud weight b. Sweep hole with Hi concentration LCM pills as required c. Add L.C.M to the system 4. Cavernous and Vugular formation a. Use big bit Nozzles, and Install PBL sub to the string b. Low mud weight as possible c. High bentonitic mud spud system d. Sweep hole with Hi Vis - & Hi concentration LCM pills as required e. Spot Hi-Vis & Hi concentration LCM bills as necessary and wait for soaking into formation. f. Drill without return with mud /or water top up in case if no shallow gas hazard. g. Drill then Gunk squeeze or cement plugs until reach to the consolidate formation and or reach to reasonable limit of formation losses to continue drill out to casing point.

Work Over wells Trouble shooting & policies

1. Killing wells procedures with different completion design 2. L/D X-mass tree & N/U & tested Bop’s ploicy.

3. Unset retrievable packer procedure and complete the well killing procedure 4. POOH & L/D completion - percussions 5. In Case if using a Permanent Packer – Mill out procedure 6. Cement squeeze & P/A formation policy a. Injectivity test b. Perforation intervals

c. Calculate Cement volume / pre-flush , spacer ahead & spacer behind volume d. Braden Head squeeze e. Walk squeeze f. Hesitation squeeze g. Squeeze Using EZSV packer, all perforations are below Packer h. Squeeze Using EZSV Packer, with perforation below and above the Packer 7. Junk milling procedure 8. Estimated – completion tubing tensile (pipe life time, oil Production , formation water “PH” value, producing H2S, Co2, …., values & Injected Emulsifier components) 9. Steel pipe components (Carbon steel, Chrome pipe) .

10. Tubing connection threads API / Premium 11. Tubing Handling over the rig site & rig floor 12. Tubing storage at yard – company base.

13. Recommendation for Tubing & Casing Pipe purchase a. Connection easy handle & compatibility & easy cut and threading with license & minimize cut cross over’s. b. Compatibility with completion accessories connections c. Pipe chemical composition and it commutability with the formation production fluids and gas. d. Mills capabilities to fast easy supply extra pipe as it needs. e. Ease Transportation between steel mills and company. f. Tubing price

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