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MITIGATES DRILLING-INDUCED FORMATION DAMAGE Moji Karimi1, Jorge Sanguino2, Arturo Gonzalez3, Alvaro Ortiz4 Eric Moellendick5
Copyright 2012, Brazilian Petroleum, Gas and Biofuels Institute - IBP
This Technical Paper was prepared for presentation at the Rio Oi & Gas Expo and Conference 2012, held between September, 1720, 2012, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical Committee of the event according to the information contained in the final paper submitted by the author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute opinion, or that of its Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Oil & Gas Expo and Conference 2012 Proceedings.
Abstract
Casing Drilling is a process in which a well is drilled and cased simultaneously. This innovative technology has been successfully practiced for the past decade. The original purpose of developing Casing Drilling was to eliminate Non Productive Time (NPT) associated with tripping drill pipe and running casing. However, during early implementation of the technology, other benefits were observed while drilling with large diameter casing. This paper reviews four of these advantages which are lost circulation reduction, wellbore strengthening, improved wellbore stability, and drilling-induced formation damage mitigation. Casing Drilling reduces mud loss to the formation in two ways; the Plastering Effect seals off the wellbore and prevents fluid transfer between the borehole and the formation; secondly, in the worst cases where the losses cant be cured, drilling will be continued with minimized losses until the casing reaches the total depth. Reduced mud loss to the reservoir section can be directly correlated to reduced skin due to drilling induced formation damage. This leads to improved productivity of the wells drilled with casing in the reservoir section. As the Plastering creates a less permeable mud cake on the wellbore wall the pressure containment of the borehole is augmented. This process increases the fracture gradient of the formation in near wellbore area which results in a wider operational mud weight window (Wellbore Strengthening). Wells with stability problems are among the best candidates for Casing Drilling. The wellbore stability benefits of Casing Drilling are due to no tripping, less mud formation exposure, gauged well, superior hydraulics and borehole cleaning, etc. With all the mentioned benefits Casing Drilling is a promising option for the complicated challenges of the drilling industry.
1. Introduction
Conventional drilling practice exists, in part, to prevent mechanical and hydraulic damage to the formation. Through balancing mud weight with pore pressure the balance between losses and kicks is normally predefined to drill the well in the safest and most efficient manner possible, maintaining the wellbore and preventing a blowout. Through the application of Casing Drilling many operators have been able to reduce and in some cases completely eliminate lost circulation, wellbore instability, stuck pipe and back-reaming. In general, the application of the Casing Drilling has led to an industry consensus that a comparative strengthening effect exists on the borehole caused by a variety of theorized near borehole effects combined with the techniques used for Casing Drilling. This phenomenon is referred to as Plastering Effect and has been observed in a variety of formation types. In some cases this technique is also capable of improving production through limiting formation damage caused by mud filtrate invasion.
______________________________ 1 Master, Petroleum Engineer - TESCO Corporation 2 Bachelor, Petroleum Engineer - Schlumberger 3 Master, Mechanical Engineer - Schlumberger 4 Master, Electrical Engineer- - Schlumberger 5 Bachelor, Petroleum Engineer - Schlumberger
Particle size distribution analysis, comparing cuttings from Casing Drilling and conventional drilling, shows that smaller particle sizes are generated by Casing Drilling operations. This is due to the casing string grinding effect that pulverizes the cuttings as they travel up the annulus and the Plastering Effect that smears them into the wellbore wall. In other words, cuttings substitute for the lost circulation material. The smooth rotation of the casing plasters the cuttings and thick filter cake into the formation interface with the well. This process leaves no excess space for the drilling fluid to escape into the formation. This is significantly different to conventional drilling where filter cake builds up as particles accumulate on the borehole wall depending on overbalance of the mud and permeability of the formation. Filter cake is often mechanically knocked or scraped off by drill collars and drillpipe connections as they move around the borehole wall.
well control. Using the casing as the drill-string maintains buoyancy in the pipe and reduces surface vibration in larger hole sizes. It also helps keep any low strength formations that are above the lost circulation zones from collapsing and packing off around the pipe. In conventional drilling whenever severe losses are incurred, the drilling process is usually halted until the losses are cured by certain practices such as placing cement plugs. This will result to several hours of NPT. Casing Drilling enables the operator to continue drilling assuring that once the casing is passed the loss zone the trouble is left behind and the well is cased secured and ready to be cemented once the casing reaches the total depth. Moreover, a main parameter influencing the Plastering Effect is the contact time of the casing with the wellbore. With continued drilling the Plastering Effect starts to heal the loss zone and this leaves a chance that returns are back at some point. This is particularly important if the loss zone is in a section above the bit.
circulated most of the time which leaves no chance for cuttings settling at the bottom of the wellbore. The mechanical agitation and consistent circulation could be the reason for much less barite sag problems in Casing Drilling. 4.5. Superior Hydraulics The large diameter of the casing allows for a smaller annular path for fluid to travel up the annulus. This causes an increased pressure loss and a relatively higher ECD at an equivalent flow rate. Casing Drilling hydraulics is designed to use a reduced flow rate to produce an ECD that is only slightly higher than seen in a conventionally drilled interval. Historically, this higher ECD is considered as a negative aspect of hydraulic design due to higher susceptibility of fracturing the formation and lost circulation. However, the process of Casing Drilling utilizes the controlled higher ECD to act against borehole collapse and improves wellbore stability. The higher ECD is also an essential element in Plastering Effect design.
low permeability, low porosity mud cake prevents further invasion and avoids the formation damage due to fluid-fluid and rock-fluid incompatibilities. Reduced mud loss to the reservoir section can be directly correlated to reduced skin due to drilling induced formation damage. This leads to improved productivity of the wells drilled with casing in the reservoir section. The Plastering Effect, as an inherent benefit of Casing Drilling, keeps the producing formation as intact as possible and reduces formation damage. According to Tessari and Warren, an operator in South Texas had leases that were uneconomical to develop when drilled conventionally. Some of the pay zones where depleted to less than 200 psi which resulted to massive amounts of drilling fluid (~3,500 bbl) lost to the reservoir. This caused enough formation damage so that an economical production rate could not be established. The plastering Effect of Casing Drilling offered the possibility to drill the variable pressure zones with much less fluid invasion. The Casing Drilling process did successfully increase both the initial production rate and projected recovery from the 57 wells drilled. Based on the hyperbolic decline analysis of the available data, the ultimate recovery for the Casing Drilling wells was projected to be over two times that for the offset conventional wells. Moellendick (2 8) reports improved production of the Pan American Energys Casing Drilling wells in Cerro Dragon field. A challenge with this field is lost circulation into the depleted reservoir which impeded the potential production. Casing Drilled was successfully applied to drill through multiple depleted formations and the Plastering Effect was able to seal some of the depleted zones. This allowed the operator to successfully reach their target without damaging the reservoir zone by contamination the commingled production zones with drilling mud. The drilling program was identified to enhance productivity rather than a drilling project. For the first time in many years, one of the wells did not require fracturing. Another well has a very low skin factor as a productive indicator. Karimi et al. investigated the influence of cuttings size in Casing Drilling to plug pores for fluid loss control, and thereby reducing formation damage. The PPT (Permeable Plugging Test) analysis determined that the smaller size and wide range of Casing Drilling cuttings make it possible for these particles to readily adhere to the wellbore; this helps seal the pore spaces of the formation and prevent further solids and filtrate invasion. Pore throats can most effectively be plugged when the cuttings are in the proper micron size range as any possible gap between the mud and cuttings PSD can be covered by adding minimal amounts of properly sized lost circulation materials.
Dawson et al. (2010) report the recent success of Casing Drilling in Angsi field in Malaysia. Formations in this area are soft, unconsolidated, and have a history of wellbore instability issues and severe losses. Their conclusions are Casing Drilling brought the additional advantage that if mud losses did occur; the mud system could be switched to seawater while continuing to drill ahead. No time was expended to mitigate incurred losses. The fine drilled solids and continuous drilling of the Casing Drilling process has been effective in combating the wellbore instability issues and essential to the successful application of the Casing Drilling technology, (Dawson et al. 2010). Another study was done by Gallardo et al. (2010) on fluid loss mitigation in the Cashiriari field in Peruvian jungle. Total or partial fluid losses in shallow sections turn conventional drilling into a non-cost-effective way to drill this area. The main purpose in using Casing Drilling in these shallow hole sections was to drill the upper intervals quickly and minimize hole problems resulting from wellbore instability issues. Casing Drilling improves the mechanical seal in the borehole due to the Plastering Effect. The Casing Drilling application was able to meet the planned objectives of drilling the shallow hole sections in a total loss scenario uneventfully, (Gallardo et al. 2010). Beaumont et al. (2010) reported another successful Casing Drilling application in Peruvian fields. The main problem in this area was time-consuming gumbo events in the intermediate hole. Severe drag and tight spots led to high risk trips out-of-hole requiring extensive back-reaming and near-lost hole events in offset wells (severe pack-offs while tripping out). Potential problems associated with hole instability, clay swelling, stuck pipe, hole cleaning, gumbo, surface equipment downtime and seepage losses were entirely mitigated with Casing Drilling application, (Beaumont et al. 2010). Torsvoll et al. (2010) have done a case study on the successful application of Liner Drilling technology in Norwegian Continental Shelf (NCS) where many fields have formation instability and/or depletion history. The planned interval was directionally drilled and the borehole was sealed off by liner and cemented after being drilled, (Torsvoll et al. 2010). According to Rosenberg et al. (2010) Liner Drilling has been successfully practiced in the Gulf of Mexico to mitigate hole instability problems. Previous attempts to drill the problem formation were unable to reach the objective depth because of wellbore instability and lost circulation issues. According to the results, the liner successfully drilled through the unstable formation and was set at the planned depth, minimizing the open hole exposure time, (Rosenberg et al. 2010). Watts et al. (2010) demonstrated that the Plastering Effect of Casing Drilling allows successful drilling through unstable loss zones. If wellbore strengthening can be systematically achieved, then wells can be drilled in known loss areas without contingency strings of casing. In addition, wells drilled in mature fields, where producing horizons have altered pressures, either from depletion or pressure maintenance, can be drilled with fewer casing strings. Their study shows that a significant improvement in fracture gradient can be achieved with the right clearance between the hole and the casing and the proper sized particles added to the mud system. With confidence that strengthening can be achieved to the levels of improvement demonstrated, wells can be evaluated with significant cost savings by eliminating casing strings and preserving hole size for completions or further drilling, (Watts et al. 2010). Jianhua et al. (2009) studied the application of Liner Drilling technology as a solution to hole instability and loss circulation in offshore Indonesia. According to them Liner Drilling was used to drill successfully through the known lost circulation zone with the 7-in. liner cemented in place. This allowed the operator to reach their completion objectives while realizing a savings of more than $1 million (USD), (Jianhua et al. 2009). Avery et al. (2009) completed a study on high angle directional drilling with 9 5/8-in. casing in offshore Qatar. The problem was that the interface between the shale and pay zone formation is often a point where highly conductive faults are encountered. Severe losses of drilling mud often occur at this interface, thus resulting in a dramatic reduction of hydrostatic pressure as the wellbore annulus fluid level falls. This pressure loss causes the unstable formation to collapse in on the drill string and BHA, packing it off and making it practically impossible to retrieve. A potential solution to this problem was to drill the section with casing and a retrievable BHA. The operation was successful and effective, (Avrey et al. 2009). 6
According to Kunning et al. (2009), a non-retrievable rotating Liner Drilling system has been successfully deployed to overcome a challenging highly stressed rubble zone in a GOM ultra deepwater sub-salt application. Using the Liner Drilling technology enabled operators to drill through and isolate a challenging highly stressed rubble zone found adjacent to a problematic tar/bitumen layer. The plan was flawlessly executed, and Liner Drilling technology proved highly effective, (Kunning et al. 2009).
9. References
BEAUMONT E., CREVOISIER L., BAQUERO F., SANGUINO J., HERRERA D., CORDERO E., First Retrievable Directional Casing While Drilling (DCwD) Application in Peruvian Fields Generates Time Reduction and Improves Drilling Performance Preventing Potential Non-Planned Downtime Paper SPE 139339, SPE Latin American & Caribbean Petroleum Engineering Conference, Lima, Peru, 1-3 December, 2010. DAWSON G., BUCHAN A., KARDANI I., HARRIS A., WERCHOULK L., KHAZALI K., SHARIFF A., SISSION K., HERMAWAN H., Directional Casing While Drilling (DCwD) Heralds a Step Change in Drilling Efficiency from a Production Platform Paper OTC 20880, OTC, Houston, Texas, 3-6 May, 2010. FONTENOT KYLE, STICKLER ROBERT D., MOLINA PETE, Improved Wellbore Stability Achieved with Casing Drilling Operations hrough Drilling Fluids Smear Effect, WOCWD-04-31-04, World Oil Casing While Drilling Conference, Houston, 31 March, 2004. GALLARDO H., CASSANELLI J.P., BARRET S., ROMERO P., MUFARECH A., Casing-Drilling Technology (CwD) Mitigates Fluid Losses in Peruvian Jungle Paper SPE 139 SPE Latin American & Caribbean Petroleum Engineering Conference, Lima, Peru, 1-3 December, 2010. HUNT, JOHN M. Petroleum Geochemistry and Geology 2nd ed. W. H. Freeman and Company 1995 pp 271-274. KARIMI MOJI, GHALAMBOR ALI, MONTGOMERY MONTY, MOELLENDICK ERIC, Formation Damage and Fluid Loss Reduction due to Casing Drilling of Casing Drilling Paper SPE 143656 SPE Europian Formation Damage Conference, Noordwijk, the Netherlands, 7-10 June, 2011. KARIMI MOJI.: Wellbore Strengthening and Lost Circulation Prevention due to the Plastering Effect of Casing Drilling in Depleted Reservoirs Masters Thesis, University of Louisiana at Lafayette, fall, 2010. KARIMI MOJI, Plastering Effect of Casing Drilling, Revolutionizing the Drilling Practices, Redefining the Limits Poster Emerging Engineers Conference, SPE-GCS Young Professionals, Houston, Texas, 2-3 June, 2011. LOPEZ E., BONILLA P., CASTILLA A., RINCON J., Casing Drilling Application with Rotary Steerable and riple Combo in New Deviated Wells in Cira Infantas Field Paper SPE 13 8 SPE Annual Technical Conference and Exhibition, Florence, Italy, 19-22 September, 2010. 7
MOELLENDICK. ERIC, Casing Drilling Improves Mature Field Production, Eliminates Fluid Losses, Directionally Drills Wells Drilling Contractor, page 76-79, July/August 2008. MOELLENDICK. ERIC, KARIMI. MOJI, How Casing Drilling Improves Wellbore Stability Paper AADE 11NTCE-64 presented at the 2011 AADE National Conference and Exhibition, Houston, Texas, April 12-14, 2011. ROSENBERG S., GALA D., XU W., Liner Drilling echnology as a Mitigation to Hole Instability and Loss Intervals: A Case Study in the Gulf of Mexico Paper SPE/IADC 128311, the SPE/IADC Drilling Conference, New Orleans, Louisiana, 2-4 February, 2010. SANCHEZ F., TURKI M., NABHANI Y., CRUZ M., HOUQANI S., Casing while Drilling (CwD); a new approach drilling FIQA Formation in the Sultanate of Oman. A Success story Paper SPE 136107, Abu Dhabi International Petroleum Exhibition and Conference, Abu Dhabi, UAE, 1-4 November, 2010. SHOWALTER, T. T. Mechanics of Secondary Hydrocarbon Migration AAPG Bulletin, 63, 723-760. 1979. TESSARI M., WARREN T., JO J. Y., Drilling with Casing Reduces Cost and Risk Paper SPE 1 1819, 2006 SPE Russian Oil and Gas Technical Conference and Exhibition, Moscow, Russia, 3-6 October, 2006. TORSVOLL A., ABDOLLAHI J., EIDEM M., WELTZIN T., RASMUSSEN S.A., KRUEGER S., SCHWARTZE S., FREYER C., HUYNH T., SORHEIMT., Successful Development and Field Qualification of a 9 /8 in and 7 in Rotary Steerable Drilling Liner System that Enables Simultaneous Directional Drilling and Lining of the Wellbore Paper IADC/SPE 128685, IADC/SPE Drilling Conference and Exhibition, New Orleans, Louisiana, 2-4 February, 2010. WATTS R. D., GREENER M. R., MCKEEVER S., SCOTT P.D., BEARDMORE D., Particle Size Distribution Improves Casing-While-Drilling Wellbore Strengthening Results, IADC/SPE 128913, 2010 IADC/SPE Drilling Conference, New Orleans, Louisiana, U.S.A, 2-4 February 2010.