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MSE = 480 x Tor x RPM + 4 x WOB ...(2) been drilled using the FDP process, including 11, 17-1/2"; 6,
Dia2 x ROP Dia2 x 12-1/4"; and 2, 8-1/2" sections on 4 rigs. Training and
surveillance practices are currently being established on the
Teale also observed that the numeric value of MSE was remaining rigs.
approximately equal to the compressive strength of the rock. Because of similarity in lithology and design between
This was true because the tests were conducted at atmospheric wells, any performance improvements that can be achieved are
conditions where the rock failed in a highly efficient, brittle likely to apply uniformly to most wells and have a significant
failure mode. Peak bit efficiencies under field conditions are financial impact on the total program. A continuous multi-
usually much lower, often in the 30-40% range3. This year program is expected so that increased drilling
inefficiency results in a MSE measurement that is around three performance will significantly accelerate production volumes
times the rock strength. For operational reasons, an adjusted during the course of a major capital expansion. The gains in
MSE (MSEadj) was created so the value plotted at the rig site each interval have been substantial.
would be closer to the known rock strength. The EFFM that
the operator uses is 0.35. Table 1
Relative Enhancement
MSEadj = MSE x EFFM ...(3) Average Average
Offset Well FDP Well
This is a controversial practice because the mechanical 17-1/2" Directional 32 fph 71 fph
efficiency of a bit may vary greatly from the assumed 35%, 12-1/4" Vertical 23 fph 65 fph
12-1/4" Directional 21 fph 76 fph
depending on a variety of factors. However, the practice has 8-1/2" Directional 18 fph 50 fph
generally served its purpose in operations. Drillers often
know the rock strength from bit vendor analysis or geologic Figures 4 and 5 show the previous performance along
studies. Adjusting the displayed value so it is close to rock with wells drilled in the current FDP program. The gains
strength when the bit is at peak efficiency provides a tangible shown are notable. Because non-drilling time is included in
frame of reference to give the driller some sense that the bit is the footage per day calculated, the actual increase in
performing well. instantaneous ROP has been even greater than indicated.
However, the statement that MSEadj should equal rock There was no single dominate ROP limiter identified in the
strength is not taken too literally. There are additional sources North Field. The improvements in performance occurred as a
of error, other than uncertainty in the peak mechanical result of continuous analysis and adjustment of WOB and
efficiency used to adjust the MSE. A major one arises from RPM by field personnel to minimize MSEadj, and through
the use of surface torque to calculate MSEadj. The value redesign of numerous well design and equipment related ROP
eventually becomes inflated by torsional friction, and in limiters by the engineering staff. A variety of these are
directional wells the baseline trend may eventually become discussed below.
several times the rock strength. However, because MSEadj is
used only as a trending tool in this particular drilling Bit Structure Cleaning (Bit Balling)
optimization process, the absolute value is not critical. What Bit structure cleaning and bit balling are terms used to
is essential is only that the value be consistent so a baseline describe build up of material on the bit that inhibits transfer of
trend can be established. In field tests, the MSEadj has a portion of the WOB to the cutting structure. The greater the
remained relatively unchanged for an efficient bit during ROP loss of weight transfer, the lower the depth of cut and the
step tests from 50-600 fph. It is the stability of the MSEadj greater the reduction in ROP. Balling is often associated with
value when the bit is operating in its peak efficiency range that shales, but MSEadj analysis showed that it occurred in many
allows MSE to be used effectively as an optimization tool. If soft limestones in the North Field. The problem was
the MSE is close to the apparent baseline trend, the drill team significant in Cretaceous limestones in the 17-1/2" hole, and it
knows the bit is efficient and that ROP will increase reliably was particularly unexpected in Jurassic limestones in the 12-
simply by raising the WOB and RPM. If MSEadj is 1/4" and 8-1/2" intervals.
significantly above the baseline trend the bit is foundering and Figure 6 shows an example rig site display from the
the cause of founder must be diagnosed and addressed by the 12-1/4" interval. The MSEadj is plotted in the left hand track.
drill team before an increase in ROP can be achieved. A The initial MSEadj is around 25ksi. The drilling system is
number of examples plots are provided in this paper. using the same amount of energy as if this soft rock had a
compressive strength of 25ksi. The team correctly diagnosed
Qatar North Field Drill Wells high energy loss due to moderate balling and reduced the
The location of the Qatar North Field is shown in Figure 1. WOB from 25k lbs to 8 k lbs at 5100 ft. The MSEadj showed
Figure 2 shows the stratigraphy and a typical wellbore an immediate improvement in bit efficiency and the ROP
configuration, and Figure 3 shows unconfined rock increased from 80 fph to around 100 fph.
compressive strength data for a typical well. The majority of Note that the initial ROP was already acceptable.
wells are similar in lithology, hole size, casing configuration, Lacking the MSEadj diagnostics, the driller would not have
and casing setting points. They differ primarily in inclination suspected that a higher ROP might be possible by reducing the
and throw. About 10% of the wells are vertical, with the WOB. The example also illustrates how MSEadj is used as a
remainder varying from 55 to 60 degrees of inclination to relative indicator of performance, rather than as an absolute,
approximately 10,000 ft TVD. To date, 50,000 ft of hole has
IPTC 10607 3
quantitative value. After the WOB was reduced the MSEadj When the bit is not rotating around its precise center it
value remained around 15 ksi, while the soft limestones are loses cutting efficiency. This motion across the bottom of the
expected to have comparable or lesser strength. As discussed hole is referred to as whirl and even small levels of whirl may
above, there are a variety of reasons why the MSE might not have a significant impact on ROP. Figure 7 shows and MSEadj
equal rock strength, even when the bit is at its peak efficiency. test in which whirl is observed. The display is from a
The field process for using MSEadj is to adjust parameters and downhole vibrations monitoring system that has been
simply observe whether the MSEadj increases or declines. modified to show MSEadj along with real time vibrations data.
Parameters are eventually maintained at the point at which Initially the MSEadj value is around 50 ksi in rock with a
MSEadj is at its minimum. compressive strength less than 30 ksi. However, this is a
Once the driller has optimized parameters within his directional well and the high energy consumption may be
control, engineering redesign is required to achieve further largely due to drill string drag. It is necessary to vary drilling
gains. After it was recognized that balling occurred in the soft parameters and observe the MSEadj response relative to the
limestones, nozzles and flow rates were modified to achieve baseline trend in order to know whether the bit was initially
the highest hydraulic horsepower per square inch (HSI) efficient, or not.
possible with the available rig equipment. The changes were At 13:12 hrs the WOB was increased from 12k to 14k
were sufficient to eliminate the bit structure cleaning problems lbs. The MSEadj immediately declined from 50ksi to around
that were encountered. 40 ksi. This response suggests the bit was initially foundering
Table 2 and became more efficient as weight was applied. If the bit
Redesigned Hydraulics efficiency had not changed, the MSEadj would not have
changed. The ROP did not increase simply because the WOB
Prior Redesigned
HSI (hp/in2) HSI (hp/in2) was raised, but because the bit became fundamentally more
efficient at the higher load. This is why the ROP increase
17-1/2" Section 0.4-0.6 1.5-2.0
12-1/4" Section 0.7-1.5 2.5-3.5
(100%) was disproportionate to the increase in WOB (16%).
8-1/2" Section 0.7-1.5 2.5-4.0 The improvement in efficiency with increasing WOB is an
expected response of a bit suffering from whirl. The lateral
Hydraulic horsepower at the bit can be changed by vibrations display also confirms there was initially a low level
either increasing the volume of flow through the bit, or of whirl, which was reduced to the minimum level that could
reducing the nozzle size so the pressure drop and velocity for a be detected when the WOB was increased.
given flow are increased. Both consume the available pump The WOB continued to be raised slowly as drilling
horsepower so the engineer must decide which to give progressed from 13:12 to 13:57 hrs and the MSEadj continued
preference to in the hydraulic design. In general, flow rate is to decline. At 13:57 the WOB was increased further and the
emphasized in directional wells where hole cleaning is the MSEadj and ROP improved again. It is of interest that whirl is
priority. Because the pumps were already operating at their being reduced further, but the downhole vibrations monitoring
contract horsepower output when bit balling was observed, it tool is not set up to report this. The MSEadj is capable of
was necessary to reduce flow rate in order to increase the displaying the effects of a low level of bit vibration that
nozzle pressure drop and HSI. Hole cleaning concerns would common LWD tools do not show in real time. The advantage
have likely discouraged this without quantitative MSEadj data that downhole accelerometers have is that they clearly indicate
to demonstrate the potential value in ROP. To date, there has the type of vibration that is occurring, while some
been no increase in circulating time or hole cleaning problems experimentation is required to determine this from the MSEadj
associated with the reduced pump rates, but the team curve. The advantage of the MSEadj curve is that it clearly
continues to model cleaning efficiency. With improved shows the degree to which the vibration is affecting drilling
hydraulics, the founder point for balling has now been performance. In this manner, the two tools are
elevated to allow consistent application of 25-45k lbs WOB complementary.
where cleaning was an issue, rather than 5-25k lbs. Figure 8 shows another example of whirl from the mud
The ROP in the operator's 12-1/4" and 8-1/2" holes is logger's display. The WOB was initially 25k lbs, which is a
no longer limited by balling. There may still be some reasonable value for an 8-1/2" PDC bit, but the MSEadj is
opportunity in the 17-1/2" hole to further increase HSI. Given extraordinarily high at 500ksi. The WOB was raised slowly to
the rig hydraulic limitations, the next step taken to mitigate 35k lbs and the MSEadj declined to 200 ksi while the ROP
balling would normally be to reduce blade count to further increased from around 25 fph to 75 fph. The WOB is now
increase the junk slot area. However, experimentation will be near the manufacturer's recommended limit for this
required to determine whether vibrational stability of the bit application. In this example, vibrational energy loss still
can be maintained with reduced blade count in the interval. appears to significant and further optimization efforts will
facilitate even higher WOB to reduce this energy loss. Whirl
Lateral Vibrations (Whirl) is common in harder formations in the North Field wells, such
When the bit vibrates it loses cutting efficiency and the MSEadj as the Hith anhydrite, Khail anhydrite and Khuff dolomites
clearly shows the resulting increase in energy consumption. and anhydrites. Steps have been taken in each to redesign the
Though the use of the term "founder" has traditionally referred system to improve bit efficiency. The 1.22 degree motors
to bit balling, the operator now applies this term to vibrations, have been replaced with 0.78-1.0 degree settings to reduce
as well. The MSEadj curve has been used to diagnose rotational imbalance that creates some of the whirling
vibrational founder due to both whirl and stick slip. tendency. In some intervals, the trajectory and target sizes
4 IPTC 10607
have been modified to allow steerable motors to be replaced bent housing motor creates a bending force that would be
by high torque straight motors. Figure 9 shows the MSEadj expected to result primarily in bit whirl. However, whirl and
curve from an 8-1/2" hole in which a 0.78 AKO motor was stick slip are very often coupled. It is assumed lateral force
pulled and replaced by a straight motor. The MSEadj declined associated with whirl increases the drag between BHA and
from around 80 ksi to 30 ksi. Despite the fact that the WOB borehole, which increases the total torque available to generate
was reduced from 40k to 20 k lbs, the ROP increased from 50 stick slip.
to over 100 fph.
The greatest design change relative to motors was in Axial Vibrations (Bit Bounce)
the 17-1/2" hole. A low angle, bent housing motor was used Axial vibrations were observed in the hardest dolomite and
that had a small build tendency while rotating. The natural anhydrite stringers, though its occurrence was infrequent.
build tendency was used to sustain a catenary build rate while Figure 12 shows the onset of axial vibrations when a stringer
applying high WOB to mitigate whirl. The sliding time for was encountered and the WOB was raised from 10 to 25 k lbs.
directional corrections was reduced from 20-30% to 3-7%. The MSEadj climbed to 35 ksi, but this value may be close to
The step change in performance shown in Figure 4 is due to the rock strength in these hard dolomite stringers so the bit
the combination of reduction in sliding time, reduced does not appear to have become extremely inefficient. When
vibrations while rotating the low angle motor, and the ability WOB was reduced to 15-20 k lbs, axial vibration declined and
to use MSEadj while rotating to mitigate whirl and stick slip. ROP increased accordingly. In addition, proper management
Other important design changes included extending bit of axial vibration preserved bit cutting structure and allowed a
gauge lengths to improve lateral stability, utilizing near bit longer, faster bit run with less cumulative cutter damage.
stabilizers that rotating with the bit on straight assemblies
rather than sleeve stabilizers, and utilizing high torque motors Conclusions
so that the system is not limited by motor differential when the Bit performance is highly dependent on the manner in which
whirl is effectively mitigated. A measure of the success of the bit is used. Real time analysis of mechanical specific
whirl mitigation efforts is that despite the high WOB that is energy helps the driller to select WOB, RPM and hydraulics
now being applied, bit grades are often improved. The most that achieve the most efficient bit performance. When bit
recent record 12-1/4" interval was drilled with one bit that performance is constrained by factors beyond the driller's
graded 1-1-CT-S-X-I-NO-TD (10-15 ksi formations). control, the MSEadj curve provides digital documentation the
drilling engineer requires to redesign the system, and to cost-
Torsional Vibrations (Stick Slip) justify this redesign. The combination of bit efficiency and
Stick slip was persistent and occurred in all directional vibrations data is particularly useful in illuminating causes of
intervals. Torsional vibration, or stick slip, occurs when the founder.
torque applied at the end of the string reaches a critical level The insights MSEadj and vibrations monitoring provide
that tends to excite the given string. Consequently, the do not, in themselves, improve drilling performance. An
primary mitigation is to reduce the bit torque to a level that understanding of the causes of bit founder and appropriate
doesn't excite the string. This is accomplished by reducing the mitigations is also essential, as well as a work flow that
WOB. Increasing the rotary speed also helps to maintain ensures learnings are captured and that continuous redesign is
angular momentum. In Figure 10, the initial MSEadj in this occurring. The operator has trained over 180 personnel in
section of the 12-1/4" hole is in excess of 100ksi. Downhole basic bit mechanics and the Fast Drill Process. The majority
vibrations monitoring tools are showing a high level of stick of these have been contractor personnel. Though real time
slip and a moderate level of whirl. As the WOB is reduced data is provided to the office, the MSEadj analysis and decision
from 45k lbs to 35k lbs the bit becomes significantly more making process is rig-based. Training and rig-based decision
efficient and the MSEadj declines to less than 10 ksi. The making have been key elements in the effectiveness of the
instantaneous ROP increased from 25 fph to over 200 fph. work process in the North Field.
Figure 11 shows a series of MSEadj tests during which
stick slip was initiated at a fairly consistent WOB. Each time Acknowledgements
WOB approached 40k lbs, MSEadj rose sharply and the ROP We thank RasGas Company Ltd. for permission to publish this
fell. Downhole tools confirmed onset of stick slip and a paper. The performance results reflect the quality of real time
moderate amount of whirl during each event. In other cases, analysis and engineering redesign achieved by each of the rig
stick slip was mitigated by increasing rotary speed first, then teams. Thanks to the many drillers, rig crew, service company
reducing WOB if this was not effective. The highest personnel, rig supervisors, and others who have contributed
combination of bit speed and WOB that can be achieved greatly to this effort.
without developing whirl or stick slip will result in the highest
ROP.
In these examples, it was possible for the driller to
manage vibrations effectively with changes in operating
parameters, alone. However, a number of design changes had
been made that had helped to create the low-vibrations
operating window for the driller to work within. The
reduction in angle setting on the motor, discussed above, also
resulted in a reduction in stick slip. Unbalanced mass in the
IPTC 10607 5
Nomenclature
ROP Rate of penetration, ft/hr
RPM Bit rotating speed, revolutions per minute
Tor Torque, ft-lbs
WOB Weight on bit, lbs force
EFFM Mechanical efficiency, ratio
MSE Mechanical specific energy, psi
MSEadj Adjusted mechanical specific energy, psi
Dia Bit diameter, inches
References
1. Dupriest, F. and Keoderizt, W. " Maximizing Drill Rates with
Real-Time Surveillance of Mechanical Specific Energy", SPE
paper No.92194 presented at annual Drilling Conference,
Amsterdam, Netherlands, 23-25 February, 2005
2. Teale, R.: "The Concept of Specific Energy in Rock Drilling,"
Intl. J. Rock Mech. Mining Sci. (1965) 2, 57-73
3. Pessier, R.C. and Fear, M.J., "Quantifying Common Drilling
Problems with Mechanical Specific Energy and Bit-Specific
Coefficient of Sliding Friction", IADC/SPE paper No.24584
presented at 67th Annual Conference and Exhibition
Washington D.C., 4-7 October, 1992
6 IPTC 10607
Figure 7: Decline in MSEadj reflected immediate improvement in bit Figure 10: Plot showed the significant effect that stick slip and
efficiency when WOB was raised. Downhole tools showed coupled whirl may have on bit efficiency and ROP. Reduction in
reduction in whirl. WOB was effective.
Figure 8: MSEadj indicated that increasing WOB was effective in Figure 11: MSEadj and downhole monitoring tools showed stick
mitigating whirl. ROP increased from 25 fph to 60 fph as WOB slip occurred consistently at the same WOB in the given
was increase from 25 k-lbs to 38 k-lbs. formation. Maximized ROP by drilling ahead with WOB just below
this value.
8 IPTC 10607