CHAPTER-7

AIR DRILLING

It has been shown conclusively that air or gas is a better drilling fluid than
liquids.The use of air or gas as a circulating medium was introduced in the early
1950s. Even though initial attempts were crude, significant increasing penetration
rate and bit 1ife were obtained. Since these initial attempts, development of air and
gas drilling techniques have expanded and are widely accepted today as a method to
reduce drilling times and cut cost of many wells. Along with the time and resultant
money savings, other advantages such as immediate and continuous hydrocarbon
detection, minimum damage to liquid sensitive pay zones, better control of lost
circulation and cleaner cores are obtained.
Todays air drilling technology is attributed to many drilling people whose
initiative and accumulative experience have refined the method and determined
situations where the techniques most applicable. The lack of understanding, rather
than experience, is often the reason for not accepting air drilling. Drilling with air
does involve special consideration in the use of equipment and drilling techniques that
are not commonly encountered with other drilling media. For example, air, unlike
fluids, compresses readily and requires a somewhat more sophisticated engineering
approach to achieve the desired results.
Air is the ultimate low density drilling media. In order to achieve optimum
results and greatest economy from air drilling, there are several factors which should
be considered. Hard formations which are dry or produce relatively few formation
liquids provide the best results while air drilling. When the formation is completely
dry, or the influx of liquids is slight enough to be absorbed in the air stream, the drill
cuttings return to the surface in the form of dust. Also, this allows for immediate
and continuous evaluation of hydrocarbons.


Other proven advantages for the use of air are as follows:
-low cost,
-increased penetration rate.
-longer bit life,
-better control in cavernous and lost circulation areas
-minimum damage to liquid sensitive pay zones.
The fact that the drill string will always be on bottom when gas is encountered is
a big advantage in well control. If the hole is gas free when a trip is made, it will be
gas free when the new bit is returned to bottom. Mud-filled holes will sometimes
allow gas to unknowingly enter the wellbore on trips, because of reduced hydrostatic
pressure, and create well control problems. Gas already penetrated during air drilling
operations will enter the wellbore on trips; however, this gas is always a known
quantity and can easily be jetted away from the rig and operating personnel by using
jets on the blooie line. The biggest enemy air drilling has is large water-bearing
formations. The rate of formation water influx which can be handled is not defined.
When water is encountered, mist(foam), aeratedor slug drilling can be used. Mist
drilling can handle up to about 200 barrels per hour water influx. When surface
pressures exceed the limit of the air compressor equipment, aerated or slug drilling
can accommodate larger volumes of water.
Other disadvantages to air drilling are as :
(1) down hole fires and explosions are possible,
(2) sloughing of formations (when dry or wet) ,
(3) soft formations.
These disadvantages will reduce the efficiency of air drilling; however, with air
equipment available today, they can be handled. Increased penetration rate is among
the first benefits noticed when air is used as a circulating medium. This increased
penetration rate is due to the low density of air or gas which minimizes hydrostatic
pressure and aids fracturing at all times. Differential pressure in this example is the
difference between fluid column pressure and pore fluid pressure using drilling mud.
Subjecting the rock to compressive loads greater than its ultimate strength does
actual rock removal or cutting. As the bits rotate, the rock is caused to fail or
fracture under, this dynamic loading. Crushed formation or chips literally explode off
bottom and are swept into the air stream and are carried to the surface. This
explosion or rapid manner in which chips are removed from bottom is a result of
maximum differential pressure into the well-bore.
Because of poor understaning of the wellbore hydraulics involved in air
drilling,the operating conditions are not optimal and consequently costs are higher in
terms of rig time,personnel time, and equipment. Moreover,various post-drilling
wellbore repair operations must often be performed to repair the damage done to
the formation in the pay zone region in an improperly designed air drilling operation.
Chips, which are removed from the bottom, exist in a range of sizes from fine
to coarse. As these particles start up the annulus, the larger sizes are ground and
pulverized by the drill string. Also, the high velocity forces the cuttings to collide
with each other, the tool joints and the wall of the hole. These actions reduce the
drill cutting sizes to the small dust-like particles seen at the surface. Routing drill-
off tests can be run to obtain the optimum penetration rate. It is suggested, because
of the faster penetration rates with air that a drill-off test be conducted over at
least 60 feet. That is, apply the same weight on the bit and rotary speed over 60
feet and average the penetration rate. Then change either, W.O.B. or R.P.M. and
repeat the process. This procedure averages out thin formation changes and will
provide the optimum penetration rate. Bit performance is an important factor in any
drilling operation. In air drilling, select the bit with the best gauge protection.

Equipments used in air drilling
Conversion of a conventional rotary rig to an air drilling operation is a simple
matter.Most of the liquid and solids handling equipment, normally used for mud
drilling can be removed for an air drilling operation, the liquid handling equipment
should consist of one mud pump, a centrifugal transfer pump and about 1,500 barrels
of water storage (steel mud pits can be used for water storage).
A valve manifold is welded to the stand pipe on the rig floor. The hardware
valves and lines in this manifold should be sized and pressure rated to provide
minimum friction losses and maximum operating pressures.
A rotating drilling head (rotating blowout preventer) is essential. The rotating
head maintains a constant seal around all rotating elements in the drill string except
large diameter pieces such as large drill collars. Leaking of air or gas may occur
around the drill string. For this reason precautions should be taken to detect this
leakage as soon as it occurs.
The rubber seal unit will seal around any shape (kelly or drill pipe). This packing
element rotates with the drill string. This allows the drill cutting or dust to be
directed out the flanged outlet and away from the rig via line.
Proper alignment of the rotating head is essential. RMS will save time on
connections and prevent wear on the rubber element and bearing structure. A method
for proper alignment of the rotating head is to set a drill collar on the clips in the
rotary table and center the drill collar in the rotating head. Centering can be done by
using a steel tape line and measuring from the inside diameter of the rotating head to
the outside diameter of the drill collar.
Corrections in alignment can be made with chain sand boomers. When the
rotating head is properly aligned and centered, braces can be attached to the head
and to the substructure. Welding these braces will prevent movement and
misalignment during drilling operations. Keeping the kelly well lubricated while drilling
can extend the life of the rubber element in the rotating head. Pouring water and/or
liquid soap on top of the rubber element after each connection easily does this. Oil
can be used for kelIy lubrication; however, oil tends to pack cuttings in the rotating
head which can restrict air flow. Other blowout control equipment is no different
from that normally used for mud drilling. A double ram BOP stack sized to meet
anticipated pressure requirements is sufficient.
A rotating blowout preventer or stripper head of some type is normally used on
top of the other blowout preventer equipment to prevent the return dust-laden air
from striking and passing through the rotary table and subjecting it and various
other rig parts to unnecessary wear and abrasion.
When air drilling is being carried on in populated areas, dust control is
essential. Although there is no method of complete control, several satisfactory
solutions have been developed. Cyclone separators are about 75% effective and are
acceptable under some circumstances. Probably the most effective control method is
the use of a water spray device on the end of the flow line. If sufficient water is
properly applied, almost all of the dust is wet down and carried off as mud.
For todays air drilling operations, air compressors are available which provide
adequate air volumes along with portability. The most commonly used oil field air
compressor is a positive displacement, double acting, reciprocating, two or three-
stage type compressor. This type compressor offers a wide range of sizes and
pressure ratings necessary for an efficient drilling operation. Also, this type
compressor has been designed for continuous operation. Package units consisting of
two or more compressors can be put together. The number of compressors in a
package will depend on the air volume required to dril1 the hole efficiently. Generally,
one air compressor, available on todays market, for oil field drilling will put out from
400 to 1200 cubic feet of air per minute at 300 to 320 psig maximum pressure. The
positive displacement type air compressor is rated according to piston size and the
output is dependent upon the altitude at which the compressor will operate. The
compressor manufacturers can provide data on volume output at varying operating
pressures. However, a sure way to know what air volume is being pumped is to actually
measure the air output at drilling pressures.
Some points that to be remembered for optimum compressor operation are as follows
:
-Compressors should be located in the direction of prevailing winds to maximize
circulation and minimize dust intake from exhaust lines. They should be located about
200 ft from the rig floor to permit cooling of the air before it reaches the rig floor.
-The engine exhaust should be directed away from the compressor to provide
maximum cooling. This also explains the purpose in locating compressors in a series or
line arrangement. This prevents the discharge of hot exhaust gas from hitting
another compressor.
-Battery and oil filters should be checked regularly because of evaporation from the
batteries and collection of dust in the oil bath. An added precaution should be the
use of automatic shutdown devices to prevent excessive temperatures.
-An adequate starting system is required, particularly during cold weather.
-Air pressure gauges should be located on the rig floor and be kept under constant
surveillance by the driller. Any sudden change in pressure may indicate water
encroachment, caving formations or changes in penetration rates.
Bits used with air or gas drilling are standart types.Generally hard-formation
types are preferable to soft-formation types because of longer wear and more
footage per bit.In general, long-tooth bits offer little age per bit.In general, long-
tooth bits offer little advantage over short-tooth types in drilling rates.
Air requirements for operation may vary; however under most conditions a flow
volume of 1400 cfm is required for an inlet pressure of 350 psi. Under normal
operating conditions the hammer will strike about 1800 blows per minute under the
inlet pressure of 350 psi.
High bit weights increase penetration rate but decrease bit life substantially.
The magnitude of bit weight required will be a function of formation hardness. A
steel weld between the bit legs to prevent cracking has modified bits for use with
the hammer drill. As with conventional air drilling it is desirable to have increased the
circulation channels in the bit. Also needed with air drilling is a drill-pipe float to
prevent the backflow of cuttings or water when making a connection.
Field Results
The results of using air and gas drilling in the field actually need no
explanation, since it is common knowledge that drilling rates with this medium may be
10 times those obtained using fluids. Frequently the question is asked Why is the
drilling rate increased when using air or gas ?. The increase in penetration rate is
believed to be a result of reducing the hydrostatic pressure on the formation. This
belief is justified by the many field and laboratory results that show a reduction in
drilling rate as fluid weight is increased. The decrease in drilling rate as hydrostatic
pressure or mud weight is increased. These are typical results for porous and
impermeable shale sections. There is some indication that other factors are present
when drilling with air or gas because of the 10-fold increase noted in drilling rates.
The percussion or hammer drill has been used in many localities and the results
with air indicate substantial increases in rates of penetration over the conventional
rotary with air. When percussion drills were used with liquids, the rates of
penetration were not as good as with conventional rotary tools. This was believed due
to the formation changing from brittle to plastic failure under high hydrostatic
pressures. With air and without the associated hydrostatic pressure of a column of
liquid, penetration rates with percussion tools have been higher than rotary tools.
The air/gas/foam drilling, in underbalanced or slightly overbalanced condition,
is a very promising technology with a large field of application in Brazil. The recent
experiences have shown the following advantages:
-minimization or no damage in sensitive zones,
-increment in well productivity,
-elimination of fluid losses during drilling, and
-increase in penetration rate in hard formations.

In the case of the wells in Parana Basin, the most important feature of the
light weight fluid drilling technique was that underbalanced or near balanced
condition allowed several gas shows to be detected in different formations making
clear the importance of this technique in detection of hydrocarbon zones.
On the other hand, some R&D initiatives are still necessary, particularly for
the following key topics:
-multiphase hydraulics modeling,
-reservoir-wellbore interaction,
-improvement of the surface equipment, mainly four phase separators,
-cuttings trans-port, and
-adaptation of the technique to deep-water fields.
In addition, as foam-drilling technology reduces the hydrostatic head of the
drilling fluid column, the risk of wellbore collapse appears as a major concern. Even
though the literature presents a considerable number of underbalanced operations
successfully con-ducted in unconsolidated sands, wellbore mechanical stability studies
must be carried out to guide the selection of future applications.
Use of the underbalanced technique with coiled tubing drilling did not present
the expected results. Future use of the combined techniques will depend on new
developments and also on successful operations occurred elsewhere. It must be
noticed that right now the vast majority of underbalanced drilling operations
worldwide has been conducted using jointed pipes. The recent drilling operations with
lightweight fluids in Brazil has showed that the key to a successful operation resides
on careful planning, well trained personnel and good equipment design. Besides that, it
is also extremely important to have accurate screening criteria since not all areas are
technically or economically suitable for application of the technology.
As a consequence of the promising results obtained in most of the operations
performed in the last four years, approximately 20 wells per year are expected to be
drilled in the next two years in Brazil using air/gas/foam drilling.