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STUCK PIPE PREVENTION WHILE DRILLING WELLS to LIMESTONE &


SANDSTONE RESERVOIRS-SOUTHERN IRAQ

Conference Paper · September 2013

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Proceedings of the Second International Conference on Water, Energy and the Environment
Kusadası, Turkey September 21-24, 2013, paper#313

STUCK PIPE PREVENTION WHILE DRILLING WELLS to LIMESTONE &


SANDSTONE RESERVOIRS – SOUTHERN IRAQ

T. Eren M. H. Azeez B. A. Tawfeeq

Batman University South Oil Company South Oil Company


Petroleum and Natural Gas Basra Basra
Engineering Department, Iraq Iraq
Batman Turkey

tuna.eren@batman.edu.tr elhussainy2001@gmail.com batoolalmyahe@gmail.com

[3]. This paper is analyzing the stuck pipe events encountered


ABSTRACT during the development drilling campaign from the Southern
Fields in Iraq.
Stuck pipe occurrences are observed to be a common trouble
during the increased drilling operations in the Southern Iraq
Complications related to stuck pipe can account for nearly half of
Oilfields. At the time of the preparation of this paper there were
total well cost, making stuck pipe one of the most expensive
more than 12 rigs actively working in the Field. This paper is
problems that can occur during a drilling operation. Stuck pipe
giving the information about the case studies encountered while
often is associated with well control and lost circulation events;
drilling wells in an Oilfield in Southern Iraq. Examples of
the two other costly disruptions to drilling operations and is a
differential and mechanical stuck pipe occurrences are detailed;
significant risk in high-angle and horizontal wells [4]. The
providing all necessary information to understand whether how
consequences of a stuck pipe event not only is related with the
the stuck pipes had occurred, and how the problem had been
elevated drilling costs, but also with the time lost due to not being
overcome if successful. Most of the stuckpipe occurrences are
able to produce the hydrocarbons within the projected time frame.
attributed to the sloughing and high permeability shale
The stuck pipe events given in this publication are the stuck pipes
formations, overpressured drilling fluid hydrostatic and depleted
encountered in drilling vertically planned wells.
reservoirs. As per industry literature it is widely known that
recovering from a stuck pipe situation is time consuming, costly,
The subsurface formations of the oil and gas field in Southern Iraq
with the high risk of losing the wellbore itself if not to re-drill it
are consisted of sloughing shales, and high permeability
from the beginning. Damages occurring during the drilling course
formations drilling through which is required with relatively dense
due to the stuckpipe occurrences may also create a poor quality
drilling fluids; preparing the recipe for the stuck pipe events. The
well that is not up to the standard that it has been designed in the
brown fields in the area are also with reservoir pays under
first place. In this study a number of stuck pipe occurrences are
depleted states. In some Fields the depletion pressure is almost
given and analyzed as per why the workstring got stuck. It is
35% less than the reference reservoir pressures at the time of the
observed that the most important aspect in order to prevent the
preparation of this document.
occurrence of stuck pipes is considering how situations as such
could happen and make sure the step-wise drilling practices in
effect are prepared appropriately that stuck occurrences are 2. CALCULATIONS FOR DIFFERENTIAL PRESSURE
prevented and made possible to be dealt with. The golden rule is AND HOLE CLEANING
to make the planning and dealing with stuck pipe occurrences in
the simplest way possible. Drilling in the depleted zones, where usually the pressure in the
hole exceeds the pressure within the formation, may cause the
1. INTRODUCTION drillstring to be stuck on the borehole and be embedded in the
filter cake deposited across the well. The force to pull the pipe at
some occasions could get extremely high. Figure 1 gives the
The main objective of drilling oil, gas or a geothermal well is to
drawing of the differential sticking mechanism. Mitchell [5]
ensure that a safe and economically cheapest well is drilled at the
defined the projected width of the contact area is given in
earliest. A bore hole must be large enough for the casing to pass
Equation 1 as follows:
freely with the little chance of getting stuck [1]. Troubles those of
which occur in the course of drilling activities are mostly due to  2r  2hm 2  2rdc 2  2rh  2rdc 2  (1)
W  2rdc sin a cos h 
the times based on stuck pipe problems if not a well control 
 22rh  2rdc 2rdc 

operations [2]. In drilling industry the stuck pipe events are still
the main reason of Non Productive Time (NPT) even though they whereas the differential pressure is calculated using Equation 2,
are largely preventable by effective planning and following
practices. The key is to read the downhole conditions and T
understand early indicative signs. The role of driller is at utmost Pd  (2)
importance for the implementations of the trouble free drilling, CLW

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Proceedings of the Second International Conference on Water, Energy and the Environment
Kusadası, Turkey September 21-24, 2013, paper#313

The drilling parameters acquired through mud logging units are


very useful when analyzing the stuck pipe events not only after
the pipe has stuck, but also an indication of a stuck pipe event is
encountered. In this paper the parameters being given are acquired
through the mud logging units. The data from specific
equipment/machinery is transmitted after being measured by
means of sophisticated transducers/sensors [9].
1400

1200

Flow Rate for Minimum Annular Velocity (gpm)


1000

Figure 1. Differential sticking drawing. 800

The major aims of an effective hydraulics program are: to clean


the cuttings from the hole effectively, and to use most of the 600

hydraulics power available to drill the hole. Failure of cleaning


the wellbore when using conventional drilling fluids could result
400
in accumulation of the cuttings in the annulus of the workstring
and the wellbore, which may result in occurrence of a stuck pipe
incident. Ozbayoglu et al. introduced a model for minimum 200
liquid- and gas-flow rates which can be identified for having an
acceptable cuttings concentration inside the wellbore as well as a
0
preferably low frictional pressure drop for gasified drilling fluids 0 5 10 15 20 25 30
[6], [7]. Annular velocity (AV) is one of the most important Hole Size (in)
factors to achieve a feasible hole cleaning in vertical wells. The
velocity of the drilling fluid shall exceed the velocity of the Figure 2. Flow rate vs hole size for minimum annular
cuttings slipping back to the bottom of the wellbore due to the velocity if df > 12 ppg.
force of gravity pulling the cuttings. One rule of thumb on finding
the right AV for vertical wells is as follows: “the AV has to be at The Southern Oilfields of Iraq consists of lithologies formed of
least twice the slip velocity of the cuttings.” clay and plastic marl formations with high reservoir permeability
in which stuck pipe incidents may be encountered. The depleted
The slip velocity for natural settling of solid particles under reservoir formations may result in encountering circulation losses,
laminar conditions is defined in Equation 3: whereas the naturally fractured vuggy dolomite texture limestone
formations may cause complete losses while the drilling
(3) campaigns.

A field application method for estimating the minimum annular The stuck pipe events which led to the sidetrack operations in
velocity to ensure appropriate wellbore cleaning is being fulfilled given wells located in Southern Iraq are analyzed in this paper. All
is based on Fullerton’s approach, [8]. This method assumes that of the remedial attempts such as pumping acid and lubricant
the diameter of the cuttings is 0.25 in, the cuttings density is 2.5 sg materials to free the stuck pipes were unsuccessful. At the time of
and that the annular fluid velocity should be not less than twice the occurrence of stuck pipe events the use of diesel plugs were
the cuttings settling velocity. The approach is based on the density not allowed as per regulations in the scope of environmental
of the drilling fluid, i.e.: if df≤ 12 ppg (or 1.43 sg) then the concerns.
minimum annular velocity is calculated using Equation 4:
3. LITERATURE SURVEY
(4)
In literature the stuck pipe is defined as the situation in which
If df > 12 ppg (or 1.43 sg) then use of the chart given in Figure 2 drillpipe, collars, casing or tubing which cannot be pulled free
is suggested. from the wellbore. The wellbore diameter shall be large in size to
accommodate the casing string designed to be set in place.
Most of the stuck pipe problems occurred in the Southern Iraq Oil
Fields occurred due to marl and sloughing shales, together with
Most of the time drillstrings shall be designed to have a margin of
excessive drilling fluid density in borehole which resulted in stuck
overpull magnitude which may be in the range of 50,000-100,000
pipe incidents. The representative PPFG chart belonging to the
lbs to account for the extra pull force in case of stuck pipe events
Southern Oil Fields in Iraq is given in Appendix-A. Accurate
PPFG charts are very important for the planning requirements of [10], [11].
the wells and interventions in case of stuck pipe incidents.

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Kusadası, Turkey September 21-24, 2013, paper#313

The stuck pipe events are preventable if the filter cake of the mud cuttings fallout and the complications imposed on well control
is thin and impermeable, filtercakes otherwise could be damaging management.
in addition to the sticky behaviour which may cause differential
stuck pipe events. Other two main groups of stuck pipe events are Bradley et al. [17] stated that establishing a task force could
Solids Induced Packs Offs and Wellbore Geometry Related stuck reduce the costs associated with stuck pipe events up to 70%.
pipe events. Figure 3 gives the mechanisms of pipe sticking. Influence of drilling crew was found to be the most important
factor as compared to introduction of new technologies. Proper
handover practice whilst the shift changes were one of the
significant reasons of the stuck pipe incidents among the
outcomes of the study performed, which also resulted to give the
importance of using top drive systems in reducing the times to
reduce freeing the stuck pipes.

Yarim et al. [18] observed that the majority of the training


material available in the industry is providing information on how
to free the stuck pipe, rather than on how to prevent the
occurrence of the incidents.

Guzman et al. [19] found that most of the hole-cleaning stuck pipe
incidents were directly related to getting stuck while pumping out
of the hole and while back reaming tight spots. They stated that
when the annulus is loaded with cuttings and the string attempted
to be pulled upwards the risk of getting stuck is higher. It was
Figure 3. The mechanisms of stuck pipe occurrences. suggested that the project-specific stuck pipe risks and mitigation
Devereux [12] stated that most of the cases of stuck pipe events; measures are distributed and updated as the project is executed
and risks changed. The innovative approaches suggested in their
i.e. over 90%, are avoidable with good planning and listening to
study resulted in a 37% reduction of stuck-pipe occurrences
the hole. The most important factors in the prevention of stuck
during a year in comparison to the previous year.
pipe occurrences are the training and crew awareness.
The wells which had the stuck in pipe penetrated formations of
Azar and Robello [13] mentioned that use of a top drive system marl and limestone with impeded sloughing shale or layers of
would give the ability of reaming and back reaming in full stands sloughing shale formations. However in the early stages of the
while tripping in or out which minimizes the potential occurrence development campaign it noted that the stuck pipe incidents were
of stuck pipe events. inevitable due to lack of field knowledge and competent field
staff.
Hopkins and Leicksenring [14] stated that real-time drilling data
management systems could reduce stuck pipe occurrences by
continuous monitoring of all the important drilling data trends via 4. STUCK PIPE OCCURENCES
mudlogger’s computer. They suggested that the torque and drag
trends of the hole will indicate for a possible stuck event, and the Some stuck pipe events occurred in the Southern Iraq Oil Fields is
hole will provide more reliable information if the parameters are summarized together with the BHA, and drilling parameter
registered in a status of non-rotating string and no pumps on. The details. The Lithology of the Southern Iraq Oil Fields are similar
literature suggests that if a hole is drilled in the direction of the to that of the given in Appendix-B, after Al-Saeedi et al. [20] in
maximum horizontal stress then hole instability is minimized. which the stratigraphy/lithology of Kuwait is highlighted giving
Explaining this in other words would mean that; where the the troublesome formations. The main drilling problems being
overburden stress is greater than the horizontal stress then a encountered in the area are not limited to the Major Loss Zones in
vertical borehole is more stable than a horizontal one. Dammam and Hartha Formations, Sulphurous water from
Tayarat/Radhuma Formations, and Wellbore Instability problems
Aadnoy et al. [15] presented a mechanistic analysis of in Burgan Formation.
differentially stuck pipe in deviated wells. They derived equations
to estimate the depth of the stuck point in deviated wellbores 4.1. Well-A Stuck Pipe Incident
based on pull and rotation data register. The differential pressure
across the stuck interval is the dominating factor, which stated as The first stuck pipe event is given for Well-A. The drilling was
to be reduced, which can be done by displacing the well with a continuing in 12 ¼ in hole section at the depth of 2235 m, with the
lighter fluid. following parameters: Q = 3200 lpm, SPP = 3104 psi, MW = 1.15
sg. Observed partial losses at this depth, decreased Q step by step
Niznik et al. [16] stated that concentration if would be high from 3300 lpm to 2500 lpm, drilled to 2247 m, lost 285 bbl mud.
enough while drilling then pack-offs and potential stuck pipes can Continued drilling with 2000 lpm down to the bottom of Mishrif
occur in the Qatar's North Field. They mentioned that drilling an (interval: 2214 – 2378 m). Increased the Q to 2400 lpm and drilled
entire section length with total losses had not been attempted due ahead to 2453 m, SPP = 2000 psi, the lost rate ranged between 30
to the higher risk of mechanically sticking the drill string from and 50 bbl/h. Circulated the hole and spot 130 bbl LCM pill.

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Proceedings of the Second International Conference on Water, Energy and the Environment
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POOH to 2407 m. Attempted to pump out, however SPP increased well was sidetracked by means of a back off at 2168 m; following
to 2500 psi. POOH with 40 tons over pull up to 2265 m. Jarred up all of the fishing attempts, including acid pumping.
and down without success. Lost the flow while back reaming.
Workstring stuck at 2265 m. The stuck pipe event that happened in Well-A would have been
prevented should more attention had been put in place. Proper
Figure 4 shows the drilling parameters and sketch of the BHA at hole cleaning practices must have been applied and minimum
the moment of drilling at 2453 m. The Q indicates that the Q was annular flow rate must have been attained. The circulation prior to
reduced at the depth of 2235 m, the depth at which losses the pull out must have been kept longer.
occurred. The Mishrif Formation is in depletion and loss
circulations are expected. It is observed that at the moment of
4.2. Well-B-ST-1 Stuck Pipe Incident
drilling prior to the stuck pipe event; Q was at a magnitude that is
approximately equal to providing minimum annular velocity. It is The second stuck pipe event is given for Well-B. Figure 5 shows
important to remember that the 19 hours drilling process (between the drilling parameters and sketch of the BHA at the moment of
the 2324-2453 m interval) continued with partial losses, 20-90 drilling at 3276 m. The ROP is observed to have increased
bbl/h. following a change in the major drilling parameters at the depth of
3200 m. While drilling 12 ¼ in hole section at 3276 m, the drilling
The losses resulted in reduction in the Q across the Mishrif, even stopped, and without any circulation at the end of almost 60 hours
though the HI-VIS pills and LCM pills were being pumped at of continuous drilling from 3180 m; the string was pulled out to
regular interval, the accumulation of cuttings in the annulus was 3245 m, the tight spot was over pulled 20 tons. Back reamed to
not able to be prevented. Following the Fullerton’s approach the 3139 m. Serviced the top drive for approximately one hour. RIH
minimum flow rate is calculated to be approximately 1940 lpm if to 3167 m, slacked off 15 tons and reamed to 3276 m. Circulated
the hole diameter was 12 ¼ in in diameter, dcuttings = 0.25 in, MW for one hour and half. Pumped out to 3249 m, and back reamed to
= 1.15 sg, whereas the Q through the pump was as low as 2943 m. Attempted to circulate, however annulus packed off, pipe
approximately 2000 lpm. If the actual hole diameter is taken to be stuck.
non-cylindrical; approximately 13.5 in in diameter, the minimum
flow rate would then be approximately 2200 lpm. The drilling
continued across formations consisting of limestone impeded with
shale layers.

Figure 5. WELL-B Stuckpipe-1 information.


As contrary to the case explained in Well-A, in Well-B the drilling
parameters especially the flow rate was rather constant. The stuck
pipe had taken place following the long duration of drilling
Figure 4. WELL-A Stuckpipe information.
without any pumping of HI-VIS pill or adequate circulation. The
annulus has been filled in with cuttings, and the string having been
The calculations reveal that the insufficient flow rate accompanied stopped in the open hole, maintenance of the rig machinery has
with relatively high rate of penetration; resulted in accumulation been performed. The circulation that has been performed for
of excessive cuttings in the annulus, and the stuck pipe event is duration of 1.5 hours is observed not to be enough considering the
observed to have been expected. Even though the bottom up time fact that the hole is from a practical point of view not in gauge.
was 70 mins, and the hole was circulated for two bottoms up, and The circulation should have been kept longer for at least two
whenever the string pulled out, the stuck pipe event occurred at bottoms up as per best petroleum industry practices and
the moment the top of the upper stabilizer came in contact with experience in the Oil Fields of Sothern Iraq. The stuck pipe
the accumulation of cuttings across the Mishrif Formation. The incident occurred was reported to be a solids related pack-off with
string was pulled to 2294 m by 40 ton overpull, beyond the 2268 inadequate hole cleaning.
m depth the overpull attempts were unsuccessful. The circulation
was also lost due to the accumulated cuttings and LCM inside the The stuck pipe event that happened in Well-B-ST-1 would have
string and annulus. The stuck pipe incident occurred was reported also been prevented should more attention had been put in place
to be a solids related pack-off with inadequate hole cleaning. The and maintenance of the rig machinery not performed while the
BHA was across the open hole interval.

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4.3. Well-B-ST-2 Stuck Pipe Incident shear rate viscosity may assist hole cleaning. Properties of the
drilling fluid must be closely monitored; the API fluid loss must
The second stuck pipe occurred in Well-B took place along the be kept as low as possible to prevent the excessive filter cake
deeper sections of the well; after having cored from 3749 m to creation across the permeable levels.
3777 m in 15 hours. Figure 6 shows the drilling parameters and
sketch of the BHA at the moment of coring at 3777 m. When The following best practices are the recommended to prevent
attempted to pump out of hole, after having circulated for two occurrence of stuck pipes while drilling in the Southern Fields of
hours only, noted that the string was differentially stuck at 3775 Iraq:
m. The circulation was performed with a flow rate of 880 lpm.
However the Fullerton’s approach indicates that the minimum a. Periodical High Viscosity pills are suggested to be pumped
flow rate must have been at a rate of 1020 lpm, which reveals that at regular intervals (e.g. 15 m or every two hours) to ensure
the hole cleaning was not at the desired rate. The drilling fluid efficient hole cleaning. The pills will be incorporated into
density was reduced from 1.77 sg to 1.74 sg to have less the mud system and eventually build up a good rheology.
differential pressure across the stuck interval. Attempts to release The drilling fluid rheology may be supplemented with
the string by pulling and slacking off 60 tons did not provide addition of polymer to maintain effective hole-cleaning.
enough pull to free the string. The stuck pipe incident occurred b. While across open hole never keep the workstring stationary,
was reported to be a differential sticking in kind with permeable always ensure the string is reciprocating, rotating and
zone exposed to high overbalance. Successive attempts of circulation in progress if drilling is not continuing.
pumping fluid spots also proved to be unsuccessful. Backed off c. It is suggested that the drilling fluid density is increased to
the string and continued operations performing a sidetrack. 1.20 sg prior to entering the Tanuma and Nahr Umr
Formations. Prior to 50 m or while entering to Nahr Umr;
bridging pills (48 sec/qt) inclusive of sealing and CaCO3
materials are suggested to be pumped not only while drilling
but also when pulling out of hole for any operation in open
hole without bit under rotary table.
d. Equivalent Circulating Density (ECD) shall be monitored.
The following ECD management practices are best
practices: Slow pump start-up and breaking of gels, Max
flow rates only as required for good hole cleaning – reduce
flow rates when drill collars are in front of shales, controlled
drilling fluid, minimized surge/swab pressures.
e. Use of two roller reamer in BHA at optimum distances to
reduce the sloughing and prevent tight spots during reaming,
back-reaming and wiper trips.
f. After having drilled each stand the fresh interval must be
Figure 6. WELL-B Stuckpipe-2 information. reamed good enough after ample circulation.
g. In the event of stuck pipe across a limestone formation
The grade of the DP limited the maximum overpull of 100 tons pumping 22% HCl/HF acid to cover the annulus area from
only. The free point indication tools revealed that the bottom hole the bit the top of the carbonate formation and make sure that
assembly was stuck for a length of approximately 100 m, which the acid pill soaks for duration of two hours while
indicated that the freeing pull force is high above the limits of the attempting to rotate the string.
workstring.
6. CONCLUSIONS
5. RECOMMENDATIONS
One of the important findings of this paper is the fact that the
The string shall be kept in motion whenever applicable at all wells shall be time limited to open-hole exposure and the
times if hole cleaning is calculated to be a problem. The loss zone troublesome formations shall be cased off as early as practicably
shall be determined at the earliest convenience and to the accurate possible. The drilling crew shall be very much attentive to all of
level possible for correct mitigation action. the indications the well could give, and read carefully the
meanings and take the necessary actions in a timely manner to
LCM particles of mean size greater than 1/3 size of the smallest prevent occurrence of stuck pipe events. In order to avoid facing
bit nozzles shall not be used when curing the losses. Rule of costly and long fishing/remedial operations preventing the
thumb states that the LCM concentrations greater than 50 ppb for occurrence of stuck pipes is to share the experience that sees
losses upto 50 bbl/h shall be pumped. Denser concentrations may common acceptance not only among the drilling contractors but
not be effective and though result in having excessive filter cakes. also the operators. It is very important to know that it only
It is observed that correctly sized LCM concentrations work requires small cuttings volume, to get stuck and packed off while
efficiently. pulling upwards.

In case the flow rate is reduced due to the loss circulation, the Each stuck pipe incident or event must be analyzed in detail, and
hole may become dirtier, for this reason elongated periods of the root cause must be put on the table by drilling engineering
circulation may be established. Increasing the yield point and low experts. The necessary recommendations must be issued at the

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earliest and the key findings must be distributed to all parties 9. REFERENCES
involved in the Field development.
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ICWEE’13-6
Proceedings of the Second International Conference on Water, Energy and the Environment
Kusadası, Turkey September 21-24, 2013, paper#313

[19] J. M. Guzman, M. E. Khalil, N. Orban, M. A. Mohiuddin, J. APPENDIX-A: PPFG (Pore Pressure Fracture Gradient) Chart of
Verma, and S. Ganda, “Stuck-Pipe Prevention Solutions in Southern Iraq
Deep Gas Drilling; New Approaches,” SPE Saudi Arabia
Section Technical Symposium and Exhibition, Al-Khobar, PPFG Graph

Saudi Arabia, 2012, pp. 1-9. Pore Gradient, sg

Overburden Gradient
MW_Actual_Zb-202 (Time Analysis)

Reservoir Pressure Gradients, sg


Fracture Gradient Calculated (n=0.25)

[20] M. B. Al-Saeedi,. Al-Mutairi, M. Al-Khaldy, and T. Sheeran, 0 RT


Upper Fars - Dibdiba (Sd,Grv,Cl)
TOC 0 m

“Fastest Deep Well in North Kuwait: Case History of 30 in. CP @

Raudhatain 206,” SPE/IADC Middle East Drilling Technology 250 TOC 250 m

Conference and Exhibition, Abu Dhabi, UAE, 2003, pp. 20- Lower Fars (Ls,Sh)

22. 500
Ghar (Sd,Grv,Ls,Sd)

Dammam (Ls)
A
750

20 in. CSG @
Rus (Anhy,Dol)
Ummer-Radh (Dol)
1000

1250

Tayarat (Dol)

1500

Shiranish (Dol,Marl)

Hartha (Dol,Anhy)
1750
C

Depth (m TVD)
Sadi (Ls) B D A
A 13 3/8 in. CSG @
2000 C
D

Tanuma (Sh,Marl) C
Khasib (Ls,Silt)
Mishrif (Ls)
2250

Rumalia (Ls)

Ahmadi (Sh,Ls)
2500

Mauddud (Ls,Chlk)

2750 Nahr-Umr (Sh,Sst,Ls,Silt,Dol)

3000
Shuaiba (Ls,Marl,Sh,)

Zubair (Sh,Sst,Silt)
B
U-S-St-Mbr(3rdPay)
3250

M-Sh-Mbr
L-S-St-Mbr(4thPay)
L-Sh-Mbr TOC 3452 m
3500 Ratawi (Ls,Sh) B
9 5/8 in. CSG @

Yamama (Ls,Marl)

3750

0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.2
7 in. Liner @
Pressure Gradient (kgf/cm 2/10 m)

ICWEE’13-7
Proceedings of the Second International Conference on Water, Energy and the Environment
Kusadası, Turkey September 21-24, 2013, paper#313

APPENDIX-B: Lithology and Drilling Problems in Middle East,


after Al-Saeedi et al. [20]

ICWEE’13-8

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