Lesson 4 Air, Gas, Mist Drilling

PETE 689 Underbalanced Drilling (UBD)
Lesson 4 Air, Gas and Mist Drilling.

Read:
UDM - Chapter 2.1 - 2.4

Harold Vance Department of Petroleum Engineering
Air, Gas, and Mist Drilling

Gases used in UBD.
Dry air drilling. Nitrogen drilling. Natural gas drilling. Mist drilling.
Optimized hole cleaning.

Gases for UB Drilling

Air. Cryogenic Nitrogen. Membrane Nitrogen. Engine Exhaust. Natural gas.
Gases for UB Drilling

Compressed Air
79% N2 , 21% O2. Corrosion. Fire.
US$3,000 Day. Mod and Demob.

Cryogenic Nitrogen
40 year old technology. Made as a by product of liquid oxygen manufacture. Air replacement. No corrosion. No downhole fires. 99.9% pure N2 7K-40K US$/day.
Cryogenic Nitrogen
Delivery
Bottled gas. Truck. Storage tank on a ship.
Cryogen Nitrogen-Pumping Equipment

Stainless Steel Carbon Steel Vaporizer
Liquid Nitrogen (-320OF)
Pump Gaseous Nitrogen to well 80OF, 0-10,000 psi

Procedure
Determine Gas Volume Required. Convert from Liquid Volume. 1 gallon liquid nitrogen produces 93.12 ft3 of N2 at SCP. 1 m3 of N2 liquid produces 698 m3 of gas at SCP.
Nitrogen Conversion Factors

1 gal of liquid nitrogen is 93.12 ft3 at STC. 1 gal of liquid nitrogen is 0.1333 ft3. 1 liter of liquid nitrogen is 698 litres of gas at STC.
Cryogenic Nitrogen Cost

World-wide 1-3 US $/gal. 0.10 US $/scf. Canada 0.02 US $/scf. South America 1.00 US $/m3.
UB Drilling Gas Alternatives

Nitrogen Membranes
95% N2 , 3-5% O2. Corrosion considerations. Combustion considerations. Approximately 15,000 US $/day. Mob/demob costs.
Membrane Nitrogen
On site manufacture. Dependent on concentration. Directly proportional to pressure and rate. Inversely proportional to gas partial pressure. Driven by dissolution and diffusion.
Individual Hollow Polmeric Gas Separation Fiber
Individual Hollow Polmeric Gas Separation Fiber

Nitrogen Oxygen Water Vapor
Nitrogen
Oxygen and Water Vapor are Fast Gases which quickly permeate the membrane, allowing Nitrogen to flow through the fiber bores as the product stream.
N2 Generating Unit A Bundle Of Fibers

HOLLOW FIBER MEMBRANE
NITROGEN ENRICHED GAS
OXYGEN- ENRICHED AIR
FEED AIR
Equipment Required
Compressor. Filters-fibers will plug if the air is not filtered. NPU or NGU. Controller. Booster(s).
Membrane Nitrogen Production Unit

Drilling Rig
Optional Booster Compressor
Filter and Air Separation Feed Air Membrane System Compressor
1997 Nitrogen Unit.

N2 units with coolers. 8x30x8 high 23,000 psi 1200 scfm N2 at 5% 02
Skid-Mounted Nitrogen Producing Unit (NPU)1998
Weatherford 2000 Nitrogen Generation Unit.

1.
3.
2.
1. 2. 3. 4.
N2 500-600 scfm. 2000 psi comp. 27 gph diesel. 8x20x16 high. Nominal O2 5%
4.
Nitrogen Membrane System 1999
3
1
Procedure
Determine volume requirement. Determine maximum oxygen concentration. Determine effective volume from units. Determine pressure requirement.
Oxygen Concentration
% Oxygen is only partially a valid concept for fire.
Ignition temperatures and water content play a big part.
% Oxygen is important for corrosion.

Recent Combustion Work

Testing:
Alberta Research Council. Counter claims of increased corrosion and combustion with membrane generated N2
Minimum Oxygen for Combustion (with Methane)

% Oxygen Required for Combustion
12.00 11.50 11.00
10.50
10.00 9.50 9.00
8.50
8.00 0 500 1000 1500 2000 2500 3000
Pressure (psia)
Nitrogen Source Selection Cryogenic vs. Membrane

Location. Job duration. Volume requirement. Pressure requirement. Purity requirement.
Operating Cost
Canada USA
Crossover between cryogenic costs and membrane costs is generally about three days of operation. Transportation and mobilization are big items.
Cryogenic Nitrogen Operating Cost

Canada
10,000 US $/day minimum.
40,000 US $/day maximum. (500-1800 scfm for 20 hrs/day).
Flow Path
Exhaust Gas Generating Unit 1980
Exhaust Gas System
Natural Gas for UB Drilling

Available. No downhole fires. No corrosion. Low cost, long term contracts.
Pressure
Determine requirement as for air, but allow for lesser specific gravity. Delivery pressure set at source.
Fuel Gas & Group Gas Pipeline
Natural Gas Pipeline Hook Up

(Lyons, 1984)
Main Pipeline. ~500 Psig Auxiliary line to rig.
Flow to rig.
Choke/Controller
Pipeline Flow
Natural Gas Concerns

May be pressure limited. Heavier hydrocarbons repress foam so be sure that they are stripped out.
Amoco Crossfield Gas Recovery Project
Amoco Crossfield 9-12 Well

88.9 mm Drill Pipe
Drilling Fluid Water = 1000 kg/m3 Viscosity = 1cP
2350 m
KOP = 2250 m 177.8 mm Casing @ 2403 m 155.6 mm Openhole 120.6mm PDM
Elkton: Gas BHP = 7.0 MPa BHT = 80oC
778 m Target TMD = 3181 m

Crossfield Gas Recovery Project

Why it was done:
Increasing public concerns over flaring. Increasing EUB requirements for public consultation and notification.

Perfect fit with Amocos goal of reducing greenhouse gas emissions. Try out new idea and technology. Great plumbing setup.
Gas Recovery Project

RBOPTM Gas Flare System Drilling Rig Choke Manifold
Flare Knockout Vessel
Horizontal Separator Feed Gas Compressors
Produced Gas Compressors Gas Gathering Line

Gas Processing Unit Feed Gas Line
Compression & Scrubber/Filter Units

Feed Gas Compressors Recovery Gas Compressors Scrubber/Filter Unit
Flow Control Manifold
Gas Scrubber & Filter Unit
Gas Recovery Summary

16 14 12 10 8 6 4 2 0 Gas Conserved Gas Flared
MMCFD
Gas Recovery Summary

Gas Conserved
16
Gas Flared
Conserved 92%. Inc. Cost 170k US $. No need to optimize GLRs. 75 MMCFD well.
14 12
10
8 6 4 2 0

Results
Estimated costs were 250k US $, actual cost was 170k US $. Conserved 92% of flow from the well. Eliminated need to optimize the gas/liquid ratios. 75 MMCFD storage well.
Hole Cleaning
Optimizing hydraulics with gasses is primarily concerned with hole cleaning - getting the cuttings that are generated by the bit out of the hole. With gas, rheological properties have very little to do with hole cleaning. Hole cleaning with gasses is almost entirely dependent on the annular velocity.
Drag and Gravitational Forces

Flowing air exerts a drag force on cuttings. Gravitational force on the cuttings Therefore there is a threshold velocity in which the cuttings will be lifted from the wellbore. Threshold velocity increases with size of cuttings.
Hole Cleaning
Compressibility of air (or gas) complicates matters. Frictional pressure increases downhole pressure - decreases velocity downhole. Suspended cuttings increase the density of the air, increasing downhole pressure.
Hole Cleaning
Temperature has an effect on volumetric flow rate. We must pump at a velocity high enough to remove the cuttings, but not too high where we waste energy.
Hole Cleaning Criteria

Terminal Velocity Criteria. Minimum Energy Criteria. Minimum BHP Criteria.
Terminal Velocity Criteria

Gray determined that the minimum velocity of the gas must be at least as high as the terminal velocity of the cutting in order to lift the cutting from the wellbore.
Vc = V f - Vt
Terminal Velocity
Vt = 4gdc
g dc Cd
c f 3Cd f
gravitational acceleration, 32.17 ft/sec2 characteristic particle diameter, ft. drag coefficient. density of cuttings, lbm / ft3 density of fluid, lbm/ ft3
c f
Terminal Velocity
Vt = 3.369
dcTc
P
For flat cuttings

Vt = 4.164 dcTc P
For sub-round cuttings, T and P are at bottom hole conditions in 0R and psia.
Terminal Velocity
Terminal velocity in air drilling is determined mainly by:
cutting diameter, shape, and density. bottom hole temperature and pressure.
Factors Effecting Vt
Shape (roundness). Increased Size. Increased Temperature. Increased Density. Increased Pressure. Increases. Increases. Increases. Increases. Decreases.
Terminal Velocity
As pressure increases Vt decreases. As pressure increases Air velocity decreases. If the mass flow rate of gas remains constant the local air velocity decreases with increasing pressure. The air flow rate required to lift the cuttings increases with increasing BHP.
Friction Pressure
dP dL fm =m + fm mV 2m 2g (Dh Dp) Eq. 2.5
m Vm g Dh Dp
Friction factor of the mixture of air and cuttings. Mixture density, lbm/cu.ft. Mixture velocity, ft/s. Acceleration due to gravity. Hole diameter, ft. Pipe diameter, ft.
Friction Pressure
fm = a + c Weymouth quation. a = 0.14 ( Dh Dp) 0.333
Gou argued that Nikuradse is more correct.
1
a
= 1.14 0.86ln
2 Dh - Dp
= absolute roughness of the pipe.

Friction Pressure
Mixture density of air and cuttings in the annulus is determined by the mass of the cuttings and the density of the air. Air density is a function of the pressure. Mass of the cuttings in the wellbore is a function of: ROP Hole cleaning efficiency.
Friction Pressure
Pressure drops down the drillstring and through the bit play a part in BHP due to temperature effects. Temperature is also effected by:
Formation temperature. Influx of formation fluid (expansion of gas into the wellbore). Mechanical friction. Pressure.
Required injection rates?

Relating downhole air velocities to surface injection rates is quite complex. We need cuttings shape and size to determine terminal velocity. Methods required knowledge of the cutting shape and size.
Minimum Energy Criteria

Probably the most widely used criteria was developed by Angel in 1957. Angel assumed that, for efficient cuttings transport downhole, the kinetic energy of the air striking each cutting should be the same as that of air giving efficient cuttings transport at standard pressure and temperature.

1 2
min V 2min =
1 2
stp V 2stp
Pmin Density of air (or gas) at the minimum
required downhole injection rate, lbm/cuft.
Vmin Air (or gas) velocity downhole, ft/min.

Pstp
Density of air (or gas) at standard temp and pressure, lbm/cuft.
Vstp
Air (or gas) velocity at standard Temp and pressure, ft/min.


Vmin = Vstp Pstp Pmin

Experience from shallow blast holes, drilled in limestone quarrying operations, indicated that cuttings were transported efficiently if the air velocity equaled or exceeded 3,000 feet per minute. This is equivalent to Grays terminal velocity for flat cuttings with a diameter of 0.46 in. and for sub-rounded particles of 0.26 in.

Angel computed the downhole air pressure with eq. 2.5 dP dL = m+
m m V 2m
2g (Dh Dp) 1+
m = a
Wc Wa
Wc
Wa
Mass of cuttings generated in a given time; the mass flow rate of cuttings, lbm/min. Mass of air flowing past any point in the well in given time; the mass flow rate of air, lbm/min.

Pb = P2sabTs2 Ga T Ts
2a G
abT2 G-a
Ps Surface air pressure, lbf/sq.ft, absolute. Ts Surface temperature, 0F. G T h Annular temperature gradient, 0F/100. Downhole temperature = Ts+Gh Hole depth.

a= S Q SQ + 28.8 . ROP . Dh2 53.3Q Gas specific gravity (air=1) Gas flow rate, scf/m
ROP
b= Dh D2
Penetration rate, ft/hr 1.625 x 10-6Q2

(Dh Dp) 1.333 (Dh2 Dp2)2 Hole diameter, ft. Drillpipe diameter, ft.

This was combined with the cuttings transport criterion defined in Eq 2.10 to deduce the minimum air flow rate as a function of hole depth, annular geometry, and penetration rate.
Vmin = Vstp
stp
min Eq. 2.10

To simplify, the average downhole temperature can be used to calculate BHP.
6.61S(Ts + Gh) Q2
(D2h D2p)2 V2stp = (P2s + bT2av) e2ah/Tav bT2av

This was solved numerically for the gas injection rate required to give an annular velocity equivalent in cuttings lifting power to air with a velocity of 3000 ft/min.
A series of charts was generated for different combinations of hole size, drillpipe diameter and penetration rates

Qmin can be approximated by:
Qmin = Qo + NH
Qo N H Injection rate (scfm) at zero depth that corresponds to an annular velocity of 3000 ft/min Factor dependent on the penetration rate (Appendix C) Hole depth, (thousands of feet).
Appendix C
Data for calculating approximate circulation rates required to produce a minimum annular air velocity which is equivalent in lifting power to standard air velocity of 3.000 ft/min. (Angel, 1957).
250
Bottomhole Pressure (psia)
200
150
100
50
2000
4000
6000
8000
10000
12000
Depth (feet)
80 70
60 50 40 30 20 10 0 0
2000
4000
6000
8000
10000
12000
Depth (feet)
7-7/8 hole
6 drill collars
3-1/2 drillpipe
3800 hole depth
Annular Bottomhole Pressuresin An Air Drilled Hole-comparison Of Predictions And Measurements Made While Circulating Off-bottom
45
40
35
30
25
20 500 600 700 800 900 1000 1100 1200 1300
Flow Rate (scfm)

34 32 30 28 26 24 22 20 500
600
700
800
900
1000
1100
1200
1300
Flow Rate (scfm)

3.5
3
Required Rate of Air (scfm)
2.5 2 1.5 1 0.5 0
2000
4000
6000
8000 10000 12000 14000 16000 18000
Depth ( feet) Comparison of air rates recommended by several different cuttings transport analyses (after Guo et al, 199412).
Minimum BHP Criteria

Angel analysis does not predict a minimum BHP, but gives a pressure that decreases monotonically with decreasing air flow rate.
Annulus Pressure Drop
Annulus Air Velocity
The influence of air flow rate on annular pressure drop (after Supon and Adewumi, 19915).
Annulus Pressure Drop

Lesson 4 Air, Gas, Mist Drilling

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Lesson 4 Air, Gas, Mist Drilling

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PETE 689 Underbalanced Drilling (UBD)

Lesson 4 Air, Gas and Mist Drilling.

UDM - Chapter 2.1 - 2.4

Air, Gas, and Mist Drilling

Optimized hole cleaning.

Gases for UB Drilling

Gases for UB Drilling

US$3,000 Day. Mod and Demob.

Cryogen Nitrogen-Pumping Equipment

Pump Gaseous Nitrogen to well 80OF, 0-10,000 psi

Harold Vance Department of Petroleum Engineering

Nitrogen Conversion Factors

Cryogenic Nitrogen Cost

UB Drilling Gas Alternatives

Individual Hollow Polmeric Gas Separation Fiber

Harold Vance Department of Petroleum Engineering

Individual Hollow Polmeric Gas Separation Fiber

Harold Vance Department of Petroleum Engineering

N2 Generating Unit A Bundle Of Fibers

NITROGEN ENRICHED GAS

OXYGEN- ENRICHED AIR

Membrane Nitrogen Production Unit

Optional Booster Compressor

Filter and Air Separation Feed Air Membrane System Compressor

Harold Vance Department of Petroleum Engineering

1997 Nitrogen Unit.

Skid-Mounted Nitrogen Producing Unit (NPU)1998

Harold Vance Department of Petroleum Engineering

Weatherford 2000 Nitrogen Generation Unit.

Harold Vance Department of Petroleum Engineering

Nitrogen Membrane System 1999

Harold Vance Department of Petroleum Engineering

Harold Vance Department of Petroleum Engineering

% Oxygen is important for corrosion.

Recent Combustion Work

Harold Vance Department of Petroleum Engineering

Minimum Oxygen for Combustion (with Methane)

Nitrogen Source Selection Cryogenic vs. Membrane

Harold Vance Department of Petroleum Engineering

Cryogenic Nitrogen Operating Cost

40,000 US $/day maximum. (500-1800 scfm for 20 hrs/day).

Harold Vance Department of Petroleum Engineering

Harold Vance Department of Petroleum Engineering

Exhaust Gas Generating Unit 1980

Harold Vance Department of Petroleum Engineering

Exhaust Gas System

Harold Vance Department of Petroleum Engineering

Natural Gas for UB Drilling

Fuel Gas & Group Gas Pipeline

Harold Vance Department of Petroleum Engineering

Natural Gas Pipeline Hook Up

Harold Vance Department of Petroleum Engineering

Natural Gas Concerns

Harold Vance Department of Petroleum Engineering

Amoco Crossfield Gas Recovery Project

Harold Vance Department of Petroleum Engineering

Amoco Crossfield 9-12 Well

Drilling Fluid Water = 1000 kg/m3 Viscosity = 1cP

KOP = 2250 m 177.8 mm Casing @ 2403 m 155.6 mm Openhole 120.6mm PDM

Elkton: Gas BHP = 7.0 MPa BHT = 80oC

778 m Target TMD = 3181 m

Crossfield Gas Recovery Project

Crossfield Gas Recovery Project