RULES-OF-THUMB

FOR KHALDA CO. MAN

ON THE RIG
BY Murchison Drilling Schools
2006

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 CONTENTS

I. INTRODUCTION 1

II. MUD RELATED RULE-OP-THUMBS 2

III. TRIPPING RULES-OP-THUMB 14

IV. CASING, CEMENTING AND PLUG SETTING 22

V. CEMENT MIX 37

VI. VOLUME AND CAPACITY 38

VII. HYDRAULICS 44
VIII. ESTIMATING HYDROSTATIC HEAD (PRESSURE)
IX. ESTIMATING STRENGTH OF STEEL CABLE 60
X. ESTIMATING STRENGTH OF ROPE 61
XI. MAKE UP LOSS IN LINE PIPE WITH STANDARD 8 ROUND THREAD
XII. CENTRIFUGAL PUMPS
XIII. BOP ACCUMULATORS 66
XIV. KICK TOLERANCE 69
XV. WATER HAMMER EFFECT 73
XVI. SHALES 75
XVII. LOST CIRCULATION 81
XVIII. DIAMOND BITS 89
XIX. DIRECTIONAL DRILLING 96
XX. STUCK PIPE 107
XXI. DRILL STEM TESTING (DST) 114
XXII. DRILL STRING DESIGN 121
XXIII. LOGGING RULES FOR DRILLING 137
XXIV. GAS KICKS AND BUBBLE RISE TO SURFACE 143
XXV MUD VOLUME BUILDING FORMULAS 162
XXVI. ESTIMATING PRODUCTION RATE (BPD) 168
XXVII. ESTIMATING GAS WELL FLOW RATE (MCFD) 169
XXVIII.ESTIMATING HORSEPOWER REQUIRED TO COMPRESS GAS 170
XXIX. THE TEMPERATURE DROP ACROSS A PRESSURE REGULATOR 171
XXX.A ELONGATION DUE TO TEMPERATURE 172

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XXX.B ELONGATION DUE TO STRETCH AND THE PISTON (BUOYANCY) 174
XXX.C TEMPERATURE CONVERSION 180
XXX.D DEPRECIATION OF EQUIPMENT 181
XXXI. APPENDIX A: CROSS REFERENCE A-1
XXXI. APPENDIX B: ABBREVIATIONS B-1

I. INTRODUCTION

The first introduction was written before starting to write a chapter on rules-of-thumb for the
Murchison Drilling Schools Operational Manual. It was an introductory comment about the
usefulness of about ten rules-of-thumb. However, after starting to jot down a few rules-of-
thumb about key drilling operations and practices two things were found wrong. One, a single
chapter would not do justice to rules about a subject as broad as drilling and; secondly, rules-of-
thumb or rules applying to certain drilling operations require more elaboration and examples
than originally planned.

Rules-of-thumb have been handed down from one drilling boom to the next and it is difficult to
know to whom the credit should be given. Thanks go out to those that made good observations-
-took time to simplify the approach--and passed them on down unselfishly. The rules-of-thumb
in this book are mostly the result of those drilling people that laid the foundation for the drilling
industry we have today.

This book includes rules on: Mud; Tripping; Casing and Cementing; Volumes and Capacity;
Hydraulics; Pressure; Strength of Rope and Steel Cable; Centrifugal Pumps; BOP
Accumulators: Kick Tolerance; Water Hammer Effect; Shales; Lost Circulation; Diamond Bits;
Directional Drilling; Stuck Pipe; Drill Stem Testing; Drill String Design; Logging; Gas Kicks;
Volume Building; Estimating Producing and Gas Plow Rate; Production Rules on Compressing
Gas and Temperature Drop Across A Pressure Regulator; Pipe Elongation Due to Temperature,
Stretch and The Piston Effect; Temperature Conversion; and Equipment Depreciation.

The book has many examples which simplify the use of the formulas and rules. You should be
able to make quick approximations and in many cases you may find that these ball-park
numbers are better than the so-called accurate numbers. Practically, everyone has a calculator,
however, some calculations can be done in your head. These simplified rules are very useful
when a supervisor is on the rig floor or taking a report over the phone or radio.

In summary, you will find many time-tested guidelines that provide historical background
experience collected by many people over several years.

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II. MUD RELATED RULE-OF-THUMBS

A. Yield Point (YP) or Yield Value (YV)

In general YV is a measure of the attractive forces between clay particles and has the
greatest influence on operating practices while drilling.

1. Trip Margin (or Operating Mud Weight) sufficient to drill and trip pipe out of
hole.

Rule: Divide the hydraulic diameter (diameter of hole minus diameter of pipe) times
11.7 into the yield value. This number is the trip margin in pounds per gallon
(ppg). This trip margin is added to the mud weight required to balance
formation pressure under static (non-circulating or non-tripping) conditions.

Formula: T = (Yield Value) + MW

1 1.7 (Dh - DP )

Where: T = The over balance (mud weight) required to

overcome swab and negative surge effect, ppg

Dh = Diameter of hole, in

DP = Diameter of drill pipe, in

Yield Value =300 Reading minus PV lb/1OO ft2

Example: A 14.5 ppg MW is required to balance formation pressure. The mud has a
yield value of 20. Calculate estimated MW to balance formation pressure while
tripping pipe (to offset swabbing/negative surge). Hole size is 8.5" and DP is5”

20
= + 14.5 = 15 ppg
11.7 (8.5-5)

2. Equivalent Circulating Density (ECD)

The ECD is the effective mud weight on the formation due to the total effect of the mud
weight plus the friction loss in the annular space between the pipe and the hole while
circulating.

Rule: For (ppg): Multiply the YV by 0.1 and divide the hydraulic diameter (diameter
hole minus diameter of pipe) into the number. Add this number to the mud
weight to arrive at ECD.

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 For (pcf): Multiply the hydraulic diameter (diameter hole minus diameter of
pipe) by 2 and divide this number into the YV. Add this value to the mud
weight to arrive at ECD.

Formula(s): ECD (ppg) = (YV x 0.1) + MW

(Dh - DP )

ECD (pcf) = 2 (Dh - DP ) + MW

YV

Example: Calculate the estimated ECD if the 15 ppg mud has a YV of 20. The hole size is
8-1/2 inches and the DP OD is 5 inches.

ECD = (20 x 0.1) + 15 = 15.57 ppg

(8.5 - 5)

3. Pressure loss in the annulus (rule-of-thumb version of Bingham plastic equation).

Rule: Multiply depth times YV and divide by the product of 225 times the hydraulic
diameter (diameter hole minus diameter pipe).

Formula :P loss = (Depth x YV)

ann 225 (Dh - DP )

ECD = MW + PRESSURE LOSS

(Depth x .052)

Example: Estimate the pressure loss in the annulus and the ECD. The MW is 15 ppg and
the YV is 20. The depth is 12,000 feet and the hole size is 8-1/2 inches with 5 inch
DP.

ECD = 15 + 20 = 15.5 ppg

11.7 (8.5 - 5)

4. Other Facts and Rules-of-Thumb About Yield Value (YV)

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 a. YV (high side) = mud weight (ppg). Note: oil muds run higher yield values
b. YV is very temperature sensitive and therefore should be reported at same
temperature each test so that monitoring trends can be effective

-c. YV affects overbalance (trip margin) requirements

d. YV affects surge or swabbing
e. YV affects hole cleaning (balance flow ate (Q) and YV)

1) YV of 3-5 on big hole for drill chips

2) YV of 8-10 in 8-1/2 or smaller hole to help suppress turbulence
3) YV of spud mud should be 12 or higher
4) YV of hole sweep should be 12 or higher
5) YV of directional holes should be higher (use trial & error to establish)

-f. YV (lb/100ft2) = 300 reading minus plastic viscosity (on a Fann Viscometer)
g. YV in high weight muds gives a good trend on solids (along with PV or solids test)
h. YV units are lbs/100ft2 (same as gel strengths)
i. High yield values and gel strengths may be desired to prevent or minimize bridging,
poor hole cleaning, drag, high torque and to minimize barite settling. Low yield
values and gel strengths, however, provide better drill-ability, lower swab/surge
pressures and facilitate better solids separation with surface solids control
equipment.

B. Plastic Viscosity (PV)

- In general the PV depends primarily on the solids content (size, type and concentration).

1. Plastic Viscosity High (PV) in Weighted Water-base Mud

Rule: PV = multiply MW (ppg) by 2 (to 2.5)

Formula: PV = MW x 2.5

Example: What would be the high side for the PV in a 15 ppg mud?

PV = 15 x 2.5 = 37.5 cps

high

2. Plastic Viscosity (PV) in Weighted Oil (or Oil Invert) Base Mud

Rule: PV = multiply MW (ppg) by 2.5 (to 4)

Formula: PV = MW x 4

Example: What would be the high side for PV in a 15 ppg mud?

PV = 15 x 4 = 60 cps high

3. Plastic Viscosity (PV) for Water Base Muds by Weight Ranges

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 Rule: Choose weight range and simply plug in MW (ppg) and complete the
arithmetic.

Formula(s):

a. Mud Weights Less Than 14 ppg

1) PV high = (3.4 x MW) - 19

2) PV low =(2 x MW) - 14

b. Mud Weights Greater Than 14 ppg but Less Than 17 ppg

1) PV high = (5 x MW) - 40

2) PV low = (4.33 x MW) - 47

c. Mud Weights Greater Than 17 ppg but Less than 18.4 ppg

1) PV high = (8.57 x MW) - 100

2) PV low = (8.57 x MW) - 118

d. Mud Weights Greater Than 18.4 ppg

1) PV high = (16.67 x MW) - 249

2) PV low = (16.67 x MW) - 267

Example: Estimate high and low ranges for PV in:

a. 13 ppg mud: PV high = (3.4 x 13) - 19 = 25

PV low = (2 x 13) - 14 = 12

b. 15 ppg mud: PV high = (5 x 15) - 40 = 35

PV low = (4.33 x 15) - 47 = 18

4. Other Facts and and Rules-of-Thumb About Plastic Viscosity (PV)

a. PV should be kept low as possible by maintaining low solids (particularly minimizing

fine solids <1 micron).
b. PV is very temperature sensitive and therefore should be reported at a standard
temperature each time it is tested. If temperature is not standardized the trend of PV,
used to analyze hole problems, can’t be used.

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 c. PV(cps) = 600 Reading - 300 Reading on a Fan Viscometer.
d. PV is related to solids (type, size. and concentration).
e. PV has a tremendous influence on cut points in hydrocyclones and shaker screen
capacity.

C. Funnel Viscosity (FV)

The funnel viscosity is an easy test and is made by rig personnel. The FV can be an early
indicator of possible mud and hole problems. A change in the FV trend should alert rig
people to make further mud analyses to pinpoint the cause of the FV trend change (or mud
problem). A hole problem corresponding to a FV trend change can be used the same way.

1. Funnel Viscosity (FV) Approximate Value

Rule: The FV is approximately four times the MW.
Formula: FV = 4 x MW
Example: What is the estimated FV for a 10 ppg mud?
FV = 4 x 10 = 40 sec/qt.

2. Funnel Viscosity to Serve As Base For LCM Pill

Rule: Add 25 to the viscosity of water (26 sec/qt) to get minimum viscosity for LCM
base.

Formula: FV min = 26 sec/qt + 25 = 51 sec/qt

Example: Is a 60 sec/qt FV enough to suspend and tie-up LCM in a pill?

Yes, because 60 sec/qt > 51 sec/qt. However, the thicker (more viscous) the
base is the better the pill is as long as the pump can handle it. Less plugging of
DC’S and bit nozzles take place when viscous mud is used for the LCM base. LCM
should be mixed fresh into the base mud just prior to pumping the pill.

3. The funnel viscosity will be approximately the apparent viscosity plus the viscosity of
water. (Apparent viscosity is the 600 rpm reading divided by 2 on a Fann
Viscometer.)

Rule: Add the apparent viscosity to the viscosity of water to obtain the FV within 2 to 3
sec/qt.

Formula: FV = 26 sec/qt + Reading at 600

2

Example: What is the estimated FV if the apparent viscosity is 15 cps.

FV = 26 + 15 = 41 sec/qt.

D. Apparent Viscosity (AV)

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 The apparent viscosity is an indicator of the total effect of solids and attractive forces within
a mud and is very much like the funnel viscosity.

1. AV = 600 reading (on fan Viscosmeter) divided by 2.

2. AV LCM base = minimum of 25 cps for LCM base

3. AV = Reacts much like the FV. That is to say that it can show mud changes but won1t
tell why the mud viscosity has changed. By looking at the PV, YV, Gels, W.L., and the
mud chemistry the reason (or cause) for change can be pinpointed.

E. Solids

A general rule is to keep solids as low as possible. Keep commercial solids (bentonite) and
drill solids at a proper ratio. Solid can be better analyzed if the mud MBT (Methylene Blue
Test) is known. The MBT shows the bentonitic type solids. By knowing the type mud and
all the retort analysis a breakdown of fine and coarse solids can be made. Fine solids (solids
less than one micron) are twelve times more detrimental to rate of penetration than coarse
solids and consequently should be kept at the required minimum to give colloidal properties.
The drill solids and bentonite ratio (ds/b) should be kept at approximately 2 to 1 (2:1).
1. Optimum Percent Solids (Low Density Solids)

Rule: Multiply the mud weight (ppg) by 7.5 and add the correction for oil by
multiplying percent oil volume by 0.1. Subtract the correction for salt. The salt
correction can be estimated by multiplying ppm CL by 0.61 and dividing by
10,000. Subtract 62.5 from the corrected total value.
Formula: (LDS) = [(7.5 x MW) +(0.1 x vol. % oil) ]- [(0.61 x PPM CL)/1000] - 62.5

Example: What is the estimated percent solids corrected for oil and salt. Given: MW
= 9.0; CL = 20,000 ppm; Oil = 5%

% LDS = [(7.5 x 9.0) + (0.1 x 5)] – [(0.61 x 20000 )/10000] - 62.5 = 4.3 %

2. Optimum Percent Solids (Weighted Mud)

Rule: Subtract 6 from MW (ppg) and multiply by 3.2.
Formula: OPT Percent Solids = (MW-6) x 3.2 (for weighted mud)
Example: What is optimum percent solids in a 15 ppg mud.
OPT Percent Solids = (15-6) x 3.2 = 28.8%
3. Rough Estimate For Percent Solids by Volume in Weighted Mud
Rule: Multiply MW (ppg) by 2
Formula: Percent Sol (weighted) = MW x 2
Example: Estimate percent solids in a 15 ppg mud.

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 % Sol = 15 x 2 = 30%
4. Drill Solids and Bentonite Ratio
Rule: Subtract the MBT from the total low density solids
to get drill solids. Divide the MBT (bentonitie type solids) into drill solids.

Formula: DS = TS - MBT
DS/B = DS
MBT

Example: What is the DS/B ratio. Given: MW = 9.5; MBT = 14; Total low density solids
= 80 ppb

DS = 80 - 14 = 66 ppb

DS/B = 66 /14 = 4.7 : 1 (Ideal is 2:1)

5. Analyze the effect of solids on rate of penetration (ROP) comparing a control well with
a planned well.

a. Rule: calculate fine solids on control well:

Mud Types (General) Factors

Dispersed Mud = Factor of 0.8

Gel + H2O = Factor of 0.13
Gel + 1120 + Polymer = Factor of 0.06

Fines are solids less than one micron.

Coarse are solids greater than one micron.
To get fines multiply MBT by factor (based on mud type).
Total solids = drill solids + colloidal solids + inert solids.
Fine solids = MBT x factor
coarse solids = total solids - fines.

b. Calculate coarse solids on control well . Subtract fine solids from total solids.

c. Calculate fines and coarse on proposed well.

d. Plug in fines and coarse into the ROP formula for the control and proposed well (formula
below) to calculate change in drill ability (ROP).

Formula:

ROP = ROP x { [1 - ( 0.0133 F2 + 0.00114 C2 )] / [1 - ( 0.0133 F1 + 0.00114 C1 )] }

M2 M1

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 Fine = MBT x Factor

Coarse = Total Solids - Fines

Where: ROP = ROP on proposed well

M2

ROP = ROP on control well

N1

F2 = Fine solids (<1 micron) on proposed well

F1 = Fine solids (< 1 micron) on control well

C2 = Coarse solids (>1 micron) on proposed well
C1 = Coarse solids (>1 micron) on control well
MBT = Methylene Blue Test

Example: Calculate the change in formation drill ability (ROP increase or decrease)

Given:

Control Well:

ROP = 20 ft/hr
MBT Mi = 15 lb/bbl
Solids = 79 lb/bbl
MW = 9.5 ppg
Mud Type = Dispersed

Proposed Well Mud Properties'

ROP = ?
MBTM2 = 12 lb/bbl
Solids = 45 lb/bbl
Mud Type = Polymer (non-dispersed)

1) Fines (F1) =15 x 0.8 ( mud factor) = 12 ppb

2) Coarse (C1)= 79 - 12= 67 ppb
3) Fines (F2) =12 x 0.06 (polymer) = 0.72 ppb
4) Coarse (C2)= 45 - 0.72 = 44.28 ppb

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 5) ROP= 20 x 1 - (0.0133 x 0.72 + 0.00114 x 44.28)
M2 1 - (0.0133 x 12 + 0.00114 x 67)

= 24.6 ft/hr

Formula: For percent ROP reduction compared with water:

% ROP Reduction = 100 (0.0133 x Fines + 0.00114 x Coarses)

6. Analyze solids control equipment (and system) to ascertain it is doing an efficient job.
By keeping up with water additions and by monitoring mud out and mud in, any
break down in the solids control system can be detected in the early stages.

Rule: Evaluate hydrocyclone desilters by calculating:

(1) GPM underflow
(2) barrels per day treated by bank of hydrocyclones
(3) pounds of solids dumped (discharged from underflow) per day; and
(4) the amount of mud that would be required to be dumped (jetted) to equate to
solids discharged with hydrocyclones. Note: This analysis is simple and can be
made more than once during a day to establish a trend comparison.
The required data is: GPM underflow rate; underflow mud weight; and
feed mud mud weight.

Formula(s):

(1) Calculate GPM underflow (discharge) rate. This can be done by measuring the seconds
for one quart of discharge from one cyclone and multiply times the number of cyclones
in the system.

GPM = (sec/qt)(number of cyclones)/15

(2) Calculate the barrels per day underflow (discharge).

BPD - (GPM)(34.29)

(3) Calculate the pounds of solids discharged by hydrocyclones.

Solids (lbs) = (BPD)(68.30)(MWu -8.34)

Discharged

(4) Calculate the volume of mud that would have to be dumped to equate to solids
discharged by hydrocyclones.

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 Volume (bbl) (Solids Discharged)(21 .66~MWP)
Mud Equivalent (9O9.72)(MWP~8 .34)

Where: GPM = Total discharge from hydrocyclone

system (gallons per minute)

Sec/qt = Discharge from one hydrocyclone measured into a viscosity

cup (seconds per quart)

No. of hydrocyclones = Total number of hydrocyclones

BPD = Barrels per day of volume discharged from hydrocyclones

Solids (lbs)
Discharged = Pounds of solids discharged per day through hydrocyclones

Volume (bbl)
Mud Equivalent = The volume of mud that would be required to be
dumped to equal to solids dumped

MWu = Mud weight of underflow discharge, ppg

MW P= Mud weight of feed mud (system mud), ppg

F. Mud Weight (Density)

Rule: Maintain mud weight high enough to support the walls of the hole for hole stability.
Maintain mud weight high enough to avoid influx of formation fluids that cause
mud contamination, corrosion, kicks or blowouts.

Rule: Maintain mud weight low enough to permit faster drilling, avoid lost circulation,
and minimize differential pressure sticking.

Rule: Approximately one barrel of volume is gained in the mud tanks when 15 sacks of
barite is mixed (100 lb sack). The specific gravity of barite is approximately 4.25
and this equates to approximately 1500 lbs per barrel.

G. Water Loss (Filtration)

Rule: Remember that low filtrate may be desired to minimize

tight hole caused by thick filter cake, differential pressure sticking and formation
productivity damage. However, high filtrate will minimize chip hold-down and
provide better drillability. This is particularly true if fine solids (<1 micron) are
minimized by running lower MBT's.

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H. Shale Hydration and Dispersion

Rule: In surface or intermediate hole dispersion of clay and shale solids may be desired in
water-based muds for easier control of mud viscosity, gel strengths and filtration
without having to add commercial solids. However, inhibition of shale swelling and
prevention of dispersion of cuttings by inhibition or encapsulation is desired for
borehole stability, low mud maintenance costs, and protection against formation
productivity damage. The time to drill a section (open hole exposure) and problems
associated with shale hydration, such as heaving shale, influence the mud program.
As a general rule short exposure (less than 7 days) won’t cause many associated
drilling problems to dispersion and shale hydration. On the other hand, longer
exposure to dispersion and shale hydration can cause severe hole enlargement, poor
cement jobs, hole cleaning problems and stuck pipe. Area knowledge is very
important in the planning and optimization process.

III. TRIPPING RULES-OF-THUMB

Ideally, drilling people would like to keep bottom hole hydrostatic pressure constant during the
trip out (POH) and the trip in (RIH). However, this is impossible from the operational standpoint
because of swab and surge pressures. Most of the tripping rules-of-thumb are closely associated
with maintaining a safe hydrostatic overbalance that neither causes a kick nor lost circulation.

A. Pulling Out of Hole

1. Slug Mud Weight

Rule: Slug mud weight is generally one ppg higher than the hole mud weight with
the objective being to unbalance the DP/annulus U-tube by enough to pull dry
pipe. The condition of the mud, related to drill solids, and/or the mud weight
range could influence the drilling man to accept less than one pound per gallon.
For example, if the mud weight was greater than 18 ppg or the mud had high
solids a 0.5 ppg slug mud weight would be acceptable. The length (or volume)
would be double if the slug mud weight was 0.5 ppg compared to 1.0 ppg.

Example: The mud weighs 10 ppg; a slug MW of 11 ppg is desired to unbalance the
U-tube by two stands (188 feet of top DP).

Example: The mud weighs 18.0 ppg; a slug MW of 18.5 ppg is desired to unbalance
the U-tube by one stand (94 feet of top DP).

2. Dry Pipe Versus Wet Pipe

When tripping the pipe out of the hole the mud level falls in the annulus because metal volume
is being removed from the hole. Pressure is lost because the fluid level is down and

14
consequently the hydrostatic pressure is lower. The following rule assumes the driller is not
circulating across the wellhead:

Rule: Pulling wet pipe (no slug) causes approximately four times more pressure loss, per
increment of pipe, than pulling dry pipe (good slug).

Example' Calculate pressure loss if five stands (94 ft/std) are POH. The casing size is 9-5/8
with 0.0732 bbl/ft volume capacity; the mud is 15 ppg; the DP is 5", 19.5 ppf, XH,
Grade "S" with an adjusted weight of 22.5 ppf and a capacity of 0.0170 bbl/ft.

Difference: Wet pipe AP = 192 psi = 4.2 times more pressure loss
Dry pipe AP 46 psi

3. Metal Displacement

When pipe is pulled out of the hole or run in the hole volume of pipe metal has to be
considered in the trip plan.

Rule Divide the adjusted weight of pipe (tool joints, collars, etc. taken into consideration
for adjusted wt) by 2748 (weight of steel in pounds per barrel).

Formula: bbl/ft (metal disp.) = Adjusted wt pipe (lb/ft)

2748 (lb/bbl)

Where: Adjusted weight = approximate weight of tube plus the upsets (tool joints) taken
from RP7G (pages 14-18).

Example: Calculate the metal displacement in barrels per foot for 5", 19.5, XH, Grade "S"
DP. The adjusted weight (approx. wt.) from page 18 of RP7G is 22.6 lb/ft.

bbl/ft = 22.6 lb/ft = 0.0082 bbl/ft

2748 lb/bbl

For five stands:

Volume (bbl) = 5 std x 94 ft x 0.0082 bbl/ft

= 3.85 bbl per 5 stands

POOH = hole would require this volume.

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 RIH = hole should give up this volume.

4. Trip Margin

A trip margin is required when pulling out of the hole (P0H) because of negative surge and
swabbing.

Rule: (Refer to II A 1.0)

Formula : MWT = Yield Point + MW bal

(ppg) 11.7 (Dh - Dp)

Where: MWT = Mud weight that includes trip margin

MW bal = Mud weight to balance formation pressure but has no overbalance

Yield Point = Mud property (300 reading - PV)

Dh = Diameter of hole

Dp = Diameter of pipe

SWABBING IS CHARACTERIZED
On Trips When you cannot put a volume of drilling fluid into the hole equal to the displacement
of the pipe being removed without gaining fluid

After Trips Trip gas or water or oil cut drilling fluids or a combination

SWABBING MUST BE DETECTED EARLY BECAUSE the more formation fluid

allowed to enter, the more sever the kick.

The only way to detect swabbing in its early stages is to accurately measure the amount of
drilling fluid pumped in the hole to replace the drill pipe being removed from the hole.

5. Tripping in Top Hole With Low Pressure Overbalance or Pulling Wet Pipe

Rule: When working with small pressure overbalances or when pulling wet pipe mud should
be circulated across the wellhead (out of trip tank and return to trip tank).

Formula: Length of pipe that can be POH for the overbalance (trip margin) in the mud
hydrostatic.

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L= overbalance (psi)
pressure loss per foot of pipe (psi/ft)
Where:

Overbalance = Formation pressure-hydrostatic pressure Mud Gradient = MW (ppg) x .052,

in psi/ft

psi/ft = (mud gradient)(met.displ)

(dry) (csg vol - met. displ)

psi/ft = (mud gradient)(met displ. + pipe cap.)

(wet) csg. vol. (met. displ. + pipe cap)

Note: Pipe capacity: see Chapter VI, Section D.

Example: Calculate the length of pipe that could be POH (without circ across WH) if a 9.0
ppg mud was being used in a normally pressured formation (0.465 psi/ft). The depth is 2,000
feet. DP is 5", 19.5 ppf, XH, "E", (pulled dry).

APob = 2000 (9 x .052) - 0.465 x 2000

= 6 psi overbalance

Met. Displ bbl/ft = 22.9 lb/ft = 0.0076 bbl/ft

2748 lb/bbl

psi/ft dry = (9 x 0.052 ) x 0.00 76 = 0.05422 psi/ft

0.0732 – 0.0076

L= 6 = 110 ft
0.05422

If more than 110 feet (a little more than 1 stand) of pipe is POH before filling hole a
loss of hole stability will result. This could include bridges (hole sloughing), stuck
pipe, tight hole which require back reaming and possibly a flow.

B. Running Pipe In Hole

1. Surge Pressure

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 When induced lost circulation is analyzed closely, it is found to be closely associated
with pipe movement and tripping practices a big percent of the time. By closely
monitoring a metal displacement schedule, formation break down from surge can be
caught in the early stages.

When pipe is moved (up or down) surge and swab pressures develop. Velocity rate
(fluid flow) is usually calculated to evaluate laminar or turbulent flow profiles and then
pressure loss is calculated. Surge pressure can be approximated with the following rule-
of-thumb formula (results are usually a little low).

IV: CASING, CEMENTING AND PLUG SETTING

Casing and cementing, whether it be a primary or a secondary job, requires special emphasis be
placed on planning. The planning periods are' :
1) items to plan and look at before reaching casing point
2) items to plan and look at after reaching casing point
3) items to plan and look at while running casing
4) items to plan and look at while circulating on bottom prior to cementing
5) items to plan and look at while implementing the cement plan; and
6) items that have to be looked at when secondary cementing (plugs, squeezes and etc.) are
required. All check list items and the list varies from one area of the world to another area.
Some of the following rules-of-thumb may be of use in implementing the various phases.

A. Circulating Time Before Cementing (Phase 4)

This is one of the most critical phases of the cementing operation.

Rule:

1. Circulate long enough to stabilize hole trends such as drag, torque (if rotating), possible
losses and etc.;

2. Circulate long enough to clean hole;

3. Circulate long enough to cool hole (this will minimize a lot of flash setting because
cement may not be designed for a long-static buildup temperature);

4. Circulate at least the casing volume times 1-1/2; and

5. Circulate at rate the cement will be mixed and displaced with to evaluate this rate.

Formulas:
Circulating Volume to circ. = 1.5 (Casing Cap. x Casing Length)
Circulating rate = (ann. velocity while drlg.) x (ann. Vol between hole & csg)

Circulating time = Volume to Circ (bbl)

Circulating Rate (bbl/min)

18
Note: Casing Capacity in bbl/ft
Annular Volume of open hole in bbl/ft

Example: How long should we circulate and at what rate? Given: Hole size - 12-3/4
inches; casing size 9-5/8, 47 lb/ft; mud 13 ppg depth 12,000 feet; drag when pipe
was first on bottom and reciprocated was 50,000 lbs AW over hook load;
annular velocity (while drilling before running casing) was 150 ft/min; no abnormal temperature
is expected; and by circulating with 1.5 times the casing volume the hole temperature should be
cool enough.

circ. vol = (0.0732 bbl/ft x 12,000 ft) 1.5 = 1318 barrels

circ. rate = (150 ft/min) x (12.75**2 – 9.625**2) = 10 bbl /min

1029.4
circ. Time = 1318 bbl = 132 minutes
10 bbl/min
Answer: Circulate approximately 2-1/2 hours at 10 bpm.

B. Influencing Factors or Why Casing Strings Are Run

Running casing at exactly the correct time requires the wmidas touch" or a lot of "area
experience." However, when casing is run and cemented (properly) at the right place, future
drilling operations are greatly simplified. Lost circulation is the number one drilling
problem in the world and much of the L.C. in abnormal pressure zones results from poor
casing seat selection, setting casing off bottom or getting poor cement jobs that do not
isolate casing shoe-annulus from open hole below.

Rule: Some of the rules-of-thumb governing when to run casing are:

1. Set casing every time mud weight changes 1- 1.5 ppg (this is formation pressure equated to
MW).
2. Set casing if kick tolerance is less than 1.0 ppg (this is kick intensity--how much MW
increase could it tolerate without lost circulation). This rule is greatly influenced by kick
size (kick tolerance is greater for a 10 bbl kick than for a 30 bbl kick).
3. Government regulations (i.e., MMS and COGLA). For example, COGLA wants 25% of
hole to be cased at all times. The MMS influences surface casing setting depth.
4. Set casing before hole stability in open hole deteriorates. (For example, it would be
impractical to have 25 day drilling program to reach casing point if a 15 day shale was exposed.)
Formulas:

AMW change = (MW form. Equiv. – MW hole (or last csg point)

If AMW > 1.5 Run Casing

Run Casing = Kick tolerance < 1 ppg (evaluate several kick sizes, refer to Chp. XIV)

Where:

AMW change = the change in mud weight caused by increasing or decreasing

formation pressure

19
MW form. equiv. = formation pressure is expressed as an equivalent mud weight, i.e.:
FP/(0.052 x TVD)

MW hole = mud weight at last casing shoe or before change in formation

pressure, ppg

kick tolerance = the maximum kick MW that can be tolerated based on leak
off test at previous casing shoe

Example: Pressure is increasing. Shale densities, d' exponents, and resistivity measurement
indicate the mud weight equivalent of the formation is 16 ppg. The last casing was set in a 14
ppg environment, and the MW is now 15 ppg in the hole. Would you run casing based on the 1-
1/2 ppg rule?

Answer Look at L.0.T. at last shoe and evaluate kick tolerance for several kick sizes
based on maximum allowable pressure (calculated from leak-off-test). The old 1-
1/2 ppg rule was used mostly before we started testing shoes as we do today. Kick
tolerance will be discussed in Section XIV.

C. Mix Water For Cement

The cement quality is very much dependent on the cement being mixed at the correct
weight. Too much water affects compressive strengths; too little water affects pumpability;
excessive water causes cement to have high porosity and permeability; free water causes
pockets, hot spots and corrosion.

Rule: Base mix water requirements on neat cement plus the water required for the
admixes (gel, etc). Use cement weight as control on correct mix water being added.

Water requirements for neat cement:

Class Gal/Sack Slurry Density

'A' or 'B' 5.2 15.6 ppg
'G 5.0 15.8 ppg
H 4.3 16.4 ppg
D. Contact Time

Spacers are used to move mud out of the casing annulus, in front of cement, to minimize
cement contamination and improve bonding. Much discussion has been given to cement
placement technique (turbulent versus plug flow). The objective of placement technique is
to minimize contamination, channeling and lost circulation, and to maximize bonding and
fill (correct cement top). With these objectives in mind I endorse the following approach'
place the spacer in turbulence but keep the cement at same annular velocity used while
drilling.

Rule: Contact time is the time that the pre flush spacer in turbulent flow is in contact
with a critical formation. Normally seven to ten minutes contact time is required
(750-1000 feet). Remember that the spacer must be compatible at the mud

20
 interface, which many times may require what two separate spacers be used, such as
when using an oil mud.
Formulas'

Pump Output (BPM) = Ann Vel (ft/min) x Ann Vol (bbl/ft) (mix and displacement rate)

Spacer Fluid (to give required contact time) (bbl) = Contact Time (min) x Mix Rate
(bbl/min)

Example: How much spacer fluid is required to give a 7 minute contact time? The mud in
the hole is 9.5 ppg and the spacer is water. How much overbalance is lost from
spacer if cement weight is ignored? The mix rate to give correct ann. vel. and put
spacer in turbulence is 10 bpm. Ann Vol = 0.0679 bbl/ft.

Spacer Volume = 7 min x 10 bbl/min (bbl)

= 70 bbl required to give seven minute "Contact Time"

AP(H20 vs. Mud) = (MWh - MWp) 0.052 x length spacer

= (9.5 - 8.33) 0.052 x 70/ 0.0679 = 63 psi

E. Cement Plugs Leaving Cementing Head

Plan plug dropping!? The correct use of cement plugs can make the difference between the
success or failure of a cement job. The correct implementation of cement plug program
ranks in the top ten of items that affect the overall cement job.

Rule' Make sure you plan' the loading of the plug(s); who will drop the plugs; how the plug
will be dropped (shutting down? on the run?); how you will know if the plug has left the
cementing head (radioactive nail and Geiger counter? Other telltale indicators?); what
pressure strokes or volume you will have when the plug is about to land in float or
baffle collar and; how much extra volume or pump strokes you will pump if the plug
doesn’t land.

Formulas'

Vol. to Bump Plug = Length of Casing to landing place (ft) x Casing

Capacity (bbl/ft)
Strokes to Bump Plug with Rig Pump = Volume to bump plug (bbl)
pump output (bbl/stk)

Pressure to Land Plug

AP mud vs cmt = (cement wt - mud wt) .052 x (calc. L cmt)

21
 Where'

AP mud vs cmtCalc. pressure to land plug (u-tube pressure). If circ. pressure at displacement
rate is recorded prior to the cement job a dynamic pressure can be used (circ press + U-tube
press).

Calc. L cmt =Length of cement that is planned behind casing (minus FS to shoe length if calcu-
lating bottom or one stage).

Est. Top of Cement (Dtc) from "P mud vs cmt

If AP is less than pre-calculated pressure

Dtc = Est. Top of Cmt + AP mud vs cmt

AG mud vs cmt

If AP is greater than pro-calculated pressure

Dtc = Est. Top of Cmt - AP mud vs cmt

AG mud vs cmt

Where: Dtc = Depth of Top of Cement behind Casing

AG = (wt. of cmt - wt. of mud) .052 (ppg)

Examyle: Calculate the volume of mud and the pressure to land the top plug on the first
stage: Given: Casing size 9-5/8", 47 lb/ft; shoe a 12,000 ft; FC a 11,920 ft; DV
collar a 6000 feet; mud wt - 9.5 ppg; cement wt - 15.4 ppg; cement calculated to
reach DV at 6000 feet; pump out put checked to be 0.095 bbl/stroke.

Vol. to bump plug = 11,920 (ft) x 0.0732 (bbl/ft) = 872.5 bbl

Strokes to bump plug = 872.5 bbl = 9185 strokes

0.095 bbl/stk
APmud vs cmt = (12,000 - 6000) - 80) x (15.4 - 9.5) .052) (ft) = 1816 psi (u-tube)

Note: If 800 psi circ press a disp rate had been prerecorded, the dynamic pressure
just prior to landing the plug would have been 2600 psi + (1816 + 800).

22
 Example: If the pressure to land the plug (above example) had been 200 psi low what
would the estimated top of the cement be on the first stage?

Dtc = 6000 feet + 200 psi =6652 ft +

(15.4 - 9.5) .052

F. Compressibility Volume When Testing Casing

The casing pressure test should be plotted (volume vs. pressure) as part of the drill out
procedure.This mpressibility plot can be utilized when measuring the
leak off vs. formation capability test below the casing. Interpretation
of the leak off test is greatly enhanced if compressibility is preplotted.

Rule: In water base muds it requires about 1% of casing volume (or volume being
compressed) to reach 3000 psi. Oil is about twice as compressible as water and
therefore the compressible volume can be estimated by multiplying the water based
mud volume times the oil percent factor (i.e., 10 percent oil = 1.10 as factor).

Formulas:

Compressibility Volume For Waterbased Mud (Vcw, bbl )

= (pres applied @surface)(vol. being compressed)
300,000

Compressibility Volume For Mud With Oil (Vco, bbl) = Vcw [1.0 + (percent oil/100)]

Example' How much volume would it take to pressure up to 2000 psi on 9-5/8", 47 lb/ft
casing? Assume no drill string is in the casing (open casing above a FC a 11,920).

(2000 psi)(11,920 x 0.0732)

Vcw =
300,000

= 5.82 (say 6.0 bbl)

Example: If the example above had the same data except that the mud was a invert oil
emulsion with 70% oil, what would the Vco (compressibility volume) be?

Vco= 5.82 x (1.0 + 70/100) = 9.9 bbl

G. Safe Water Spacer For A Balanced Kick-off Plug

23
 Kick-off plugs should have good compressibility to successfully achieve the plug
objectives. Contamination of plug, with mud, will limit its compressibility (and usefulness).
Water can act as a spacer fluid ahead and behind the plug (balanced).

Rule: The length of water that can be safely utilized should be based on overbalance
(hydrostatic). The amount of overbalance that can be sacrificed and the difference
between the weights of mud and water will determine the length (and volume) of
water spacer.

Formula:

L = allowable overbalance
water spacer (mud wt - 8.34) 0.052

Volume water ahead = (L water spacer ft) (ann vol next to setting string and hole bbl/ft)

Volume water behind = (L water spacer ft )(setting string capacity bbl/ft)

Example: How many feet of water spacer (Lwater ) can be used on this kick off plug.
Given: hole size 8-3/4 (caliper); dp (setting string) - 4-1/2; dp cap - 0.0142 bbl/ft;
mud - 14 ppg; overbalance - 200 psi; overbalance that is allowable - 100 psi.

L water spacer = 100 psi = 340 ft

(14 - 8.34) .052

Volume water ahead = (340 feet) ( (8.75**2 - 4 .5**2)) = 18.6 bbl

1029.4

Volume water behind (To balance water ahead) = (340 ft)(0.0142 bbl/ft) = 4.828
bbl

H. Things That Help Avoid Contamination of Kick off plug

As previously discussed the number one associated problem with kick off plugs is mud
contamination.

Rule' Utilize techniques and equipment to minimize contaminating.

24
 1. Use a mixing sub on bottom of setting string. Do not use open ended pipe. A
culled joint of drill pipe (with a good connection) can be orange-peeled on
bottom and slotted. This sub can also be utilized for lost circulation plugs or
pills.

2. Use a bypass off of surface cementing head. This bypass is kept closed until
cement starts out of setting string or until u-tube reverses from having positive
pressure to negative pressure (u-tubing). The bypass is then opened and the
plug u-tubed into place by keeping setting string full of displacement fluid.
When the plug balances fluid will then come out the bypass line. This keeps
you from over-displacing and contaminating the plug. This step is the real key
to minimizing contamination of cement plug.

3. Use viscous pills or dirty plugs to support off bottom cement plugs. Off-bottom
plugs want to shift positions or migrate and this shifting causes contamination.
Make sure viscous pill has a high yield value (yield point). A dirty plug is a
few sacks of cement (10 to 15 sacks) that are displaced without any spacer.
Cement contaminates and flocculates the mud. Pull the pipe a few feet above
the dirty plug and set a proper balanced plug.

Formula:

Vol. F.P. x (Mud wt-fluid wt) .052 Surface Pressure =

setting string (cap. setting string)(bbl/ft)

(~P surf~

Where: ~P surf = U-Tube Pressure caused by different weight fluids, psi

-Vol F.P. = Volume of fluid being pumped (i.e., 1120, cement, etc.) in barrels

Fluid wt. = Weight of fluid being pumped, ppg

Example: What would the positive u-tube pressure be on the setting string if the setting string
had the lead 1120, cement and tail-in water. Given: 4-1/2 setting string (0.0142
bbl/ft); mud wt.- 14 ppg; cement wt -16 ppg; lead 1120 -
18.6bbl; cement- 22.3 bbl of tail-in water - 4.8 bbl.

Lead Water Cement Tail-in Water

AP surf = 18.6 (14-8.33)O.052 + x22 (14~16).052 + 4.8(14~8.33).052

0.0142 0.0142 0.0142

= 323 psi (AP surface pressure resulting from length of all fluids in setting string
(3218 feet))

25
I. Cement For First Cement Plug In A Lost Circulation Zone

When setting a cement plug for the first time in a zone for lost circulation, it is very easy to
underdesign the quantity of cement needed. This will be a costly error because of rig time and
material cost.

Rule' Until more knowledge about a zone is learned, a good rule-of-thumb is the volume of
cement the setting string will hold at the point of setting (bottom of setting string).

Formula'

Cement Required Length of setting x vol. of setting

(cu ft) string (ft) string cu ft/ft

Example: How many Cu ft of cement is required for the first plug in this zone if the bottom of
the setting string is placed at 6000 feet. Given' setting string is 5", 19.5 lb/ft, XH,
Grade "E" (0.0983 cu ft/ft)

6000ft

Cement Required = 6000 ft x 0.0983 cu ft/ft

(cu ft)

590 cu ft

If yield (cu ft/sk) was 2.7 cu ft/sk (L.C. cmt)

Sacks = 590 cu ft + 2.7 cu ft/sk

219 sacks
If mix 1120 (gal/sk) was 7.0 gal/sk

Mix H20 = (219 sacks x 7.0 gal/sk) + 42 gal/bbl

= 36.5 bbl of mix H20

Note' If mix H20 is used as guide to mixing so many sacks out of a big cement bin,
it is very important to mix cement at its correct design weight.

J. Testing Liner and Squeezing Liner if Flow is Observed

It is a difficult task to isolate gas with a liner. Many techniques have been tried (and
some work part of the time) but liner-lap leaks is still one of the most prevalent gas-cap
problems. I recommend a high quality cement (batch-mixed if possible) and a longer
liner lap ( 500 feet). Some operators cement the liner with a combination primary-
secondary squeeze approach. With this approach the liner is cemented partially (60-
75%) using conventional techniques and with a modified RTTS (Champ tool) the liner is
squeezed after the primary job is completed.

26
 Rule: When testing a liner top use a reverse test and evaluate whether the liner top will
flow into test string. Simulate a lower mud weight (approximately what the liner
top will be exposed to) by using a RTTS (or similar tool). If squeezing is
necessary use a high quality (low water-loss) cement and use a walking squeeze
approach. Hesitation methods can be very misleading.

Formula:

L = (Mud Wt - Test MW Equivalent)Depth of Liner Top

H2O (Mud Wt - 8.33)

Where:

L = Water to simulate some equivalent mud wt.

H2O at top of liner (in test string).

Note: If top of liner is given as TVD (directional well) the measured depth
can be calculated

¼ by dividing TVD by cosine of avg. drift angle.

Mud Weight = Mud weight in hole, ppg

Depth of Liner Top =Feet (convert to measured depth to arrive at volume calculated)

AP check : (~20x0 . 052x8.33) + (Depth Liner-L1120 )MW x .052

Equiv MW check : AP check x 19.23
Depth Liner

Example' The hole contains 18.0 ppg mud and the top of the liner is 15,000 feet. How
much water is required to be circulated into test string to simulate 13.0 ppg (te.t
equivalent mud weight)? (VD and MD same.)

L = (18 - 13) 15,000

H20 (18 - 8.33)

- 7,756 feet

Note' If the 15,000 foot depth was the TV,D (directional well) with an average
angle of 250, the measured depth for volume calculations would have been

27
 16,551 feet or, 15,000/COS 250. If the length of H20 calculated (7756 feet)
had been at the same avg. angle (250), the length of H20 would be 8558 ft.,
or 7,756/COS 250.

 AP check (7,756x0.052x8.33) + (15,000-7,756)18 x .052

10,140 psi

Equiv. MWcheck = 10,140 x 19.23 = 13 ppg

15,000
V: CEMENT MIX

Cemt can be mixed with sand and gravel to build a pad with the following rule..

Rule: For a ratio of 1:2:4 one cubic yard of blend can be designed with the following
formulas.

Cement = = 6.28 bags of cement

Sand = 6.28 x 2 x 0.035 = 0.44 cu yd of sand

= 1200 lb sand

Gravel = 6.28 x 4 x 0.035 = 0.88 cu yd of gravel = 1800 lb gravel

Inches to Yards = inches

36 in/yd

Feet to Yards = feet

3 ft/yd

Example: How many cu yards of cement blend (cmt, sand and gravel) is needed to
build a tool-pad with dimensions of 20 ft x 10 ft x 4 inches thick?
(L) (W) (D)

4 in 20 ft 10 ft
Method 1 cu yd = 36 in/yd )x(3 ft/yd )x(3 ft/y)

= 2.47 cu yd

28
Requ ire.ent S
Cement: 6.28 bags x 2.47 = 15.5 sacks
Sand: 0.44 cu yd x 2.47 = 1.09 cu yd (2964 lbs)
Gravel:0.88 cu yd x 2.47 = 2.17 cu yd (4446 lbs)

VI: VOLUME AND CAPACITY

Volume and capacity calculations make up a high percentage of all rig calculations. The
following rules-of-thumb will simplify some of the arithmetic and the numbers (results) are
generally acceptable.

A. Open Hole Volume

The rule-of-thumb gives approximately 3% more volume than the more precise method.
Most open hole is a little out-of-gauge which makes the method acceptable.

RULE OF THUMB FOR

HOLE VOLUME

BBL/1OOO Ft= (D)2

AND

VOLUME = (D)2 xL bbl

1000

SURFACE TO BIT TRAVEL TIME

(Cdp X Ldp) + (Cdc + Ldc)

T= P out put x SPM
Where:

C Capacity of Drilipipe (bbl/ft)

CdP = Capacity of Drillcollars (bbl/ft)
Ldc = Length of Drillpipe (feet)
LdP = Length of Drillcollars (feet)
dc
P = Pump Output bbls/stroke
output
5PM = Strokes Per Minute

Rule: Square the hole size (inches) and divide by 1000 to convert to barrels per foot.
Multiply by length (feet) to get barrels.

Formula'

29
 V OH - (Diameter of Hole)2 x Length (ft)
1000
Where' V OH = Volume of open hole, barrels Diameter of hole given in inches.

Example: What is estimated volume of 1000 feet of 12-1/4 inch hole?

V OH = (12.25)2 x 1000 = 150 barrels

1000

B. Annular Volume in Open Hole

The rule-of-thumb will give about 3% more annular volume.

Annulus with Open Hole.

Rule: Square the hole size (inches) and subtract the square of the pipe size (inches).
Divide by 1000 and multiply by length of hole section (feet).

Formula:

(Dh2 - D 2) x Length (ft)

Ann. Vol0~ = 1000

Where:Dh and D = Diameter of hole and diameter of pipe in

p
open hole, inches

Example: What is estimated volume of 1000 feet of annulus if Dh =

12-1/4 inches and D = 5 inches?

VOH = (150 -25 )1000 =125 bbl

1000

C. Volume of Vertical Cylindrical Tank

This formula gives accurate results for a cylindrical tank (vertical). Note: Do not use for
horizonal cylindrical tank (refer to Murchison Oper. Drlg. Manual - Rig Math Chapter for
horizontal tank calculation).

30
 Rule: Square the diameter of the tank (feet) and multiply by factor 0.14. The results are
in barrels per foot.

Formula:

Vol cyl.tank (Tank diameter)2 0.14 (ft)= (bbl/ft)

Example: How much water is in the tank if the diameter measures 12 feet and the height of
fluid is 12 feet?

Vol (bbl) = (12)2 0.14 x 12 ft = 242 bbl

D. Capacity of Pipe

This formula does not take into consideration tool joints and therefore over estimates the
volume by approximately 1 .0%t

RIG CALCULATIONS

1 Area Calculations Formulae

CIRCLE: A =0.7854 D2

HOLLOW CYLINDER:

A = 0.7854 [OD)2 (ID)2]

(depending on what grade drill pipe is being calculated because high

grade tool joints have smaller ID).

Rule: Square the ID of the pipe (inches) and either multiply by

0.097 to get bbl/100 ft or by 0.545 to get cu ft/100 ft.

Formula(s):

cap (bbl/100 ft) = (ID of pipe)2 0.097

cap (cu ft/100 ft) = (ID of pipe)2 0.545

Example: What is the volume per 100 feet if the ID of pipe is

4.276 inches?

capacity (bbl/100 ft) = (4.276)2 0.097= 1.77

capacity (cu ft/100 ft) = (4.276)2 0.545= 9.96

31
Note: The exact volume for 5, 19.5, XH drill pipe is:

Grade E = 0.017464 bbl/ft Grade X = 0.017268 bbl/ft Grade G = 0.017176 bbl/ft

Grade S = 0.017010 bbl/ft

E. Capacity of Annulus Between Concentric Pine Strings

The formula does not take into consideration upsets (tool joints) and therefore will be off
between 0.5% and 2%.

Rule: Square the ID (inches) of outer string and subtract the square of the OD (inches) of
inner string. Multiply the ID Of results by either the factor 0.097 for bbl/100 ft or
by ~Outer~ the factor 0.545 for cuft/100 ft. String

Formula' .
cap (bbl/100 ft) = (D12 - D22) 0.097
cap (cuft/100 ft) = (D12 - D22) 0.545 .
Where' D1 = ID of outer string, inches

D2 = OD of inner string, inches

Example: What is the annular capacity per 100 ft if the outside String
string is 4-1/2, 10.5 IbIft (ID = 4.052 inches) and inner
string is 2-3/8 (OD = 2.375 inches)?

cap (bbl/100 ft) = (4.0522 - 2.3752) 0.097 = 242 bbl

cap (cuft'100 ft) = (4.0522 - 2.3752) 0.545 = 5.87

F. Capacity of Annulus, Two Inner Strings in Casing

There is no allowance made for couplings and therefore calculations Day be off between
0.5% to 2%.

Rule: Square the ID (inches) of the outer string and subtract the OD (inches) of inner
strings. Multiply the results by either 0.097 to get bbl/100 ft or 0.545 to get
cuft/100 ft.
Formula:

cap (bbl/100 ft) = (D12 - D22 - D32) 0.097

cap (cuft/100 ft) = (D12 - D22 - D32) 0.545

32
 Where: D1 = ID of outer string of pipe, inches
D2 = OD of inner string of pipe, inches
D3 = OD of second inner string of pipe, inches

Example: What is the annular capacity per 100 feet if the outside casing is 7, 29 lb/ft (ID =
6.184) and inner strings are - 2.375 inches OD?

cap (bbl/100 ft) = (6.1842 - 2.3752 - 2.3752) 0.097= 2.62

cap (cuft/100 ft) = (6.1842 - 2.3752 - 2.3752) 0.545= 14.70

VII: HYDRAULICS

Optimization in the drilling business is often defined as "collapsing the learning curve which
leans you post appraise data from one or two wells and then drill the 3rd and remaining wells
much cheaper. Optimization could, therefore, be defined as cutting cost. The order of
optimization with reference to cutting cost is: 1) optimize mud; 2) optimize hydraulics; 3)
optimize bit selection; and 4) optimize weight on bit and RPM. Mud and hydraulic
optimization, however, make the big money difference.

A. Optimum hydraulics is the proper balance of the hydraulic elements that will adequately
clean the hole below the bit, clean the bit and clean the bore hole above the bit with
minimum horsepower. The balance of the hydraulic elements is influenced by: 1) lost
circulation (ECD effect); 2) hole stability (turbulent erosion); 3) bit cleaning (cross flow); 4)
cleaning hole below bit (jet velocity) and cleaning the bore hole above bit (Ann. Velocity-
Flow rate-yield value-and flow profile).

Rule: Balance flow rate between 24 gpm and 75 gpm (for optimum bit weight between
25-50 gpm/inch) per inch of bit size. Jet velocity is influenced by formation
drillability and mud overbalance chip hold down. The greater the overbalance the
higher the jet velocity has to be to help free up the chip that is being differentially
held down below the bit. The jet velocity range is usually between 250 and 450
ft/sec.

Formula(s)

G/B = 4B + 5

G = 4B2 + 5B

Gmin = 12.72 (B)1~~7

J = ROP
v 0.01 + 0.002 (ROP)

33
 Where: G/B = GPM/inch bit diameter
G - GPM (flow rate), gpm
G min - For flow rate sensitive bits (PDC, etc)
B : Bit diameter, inches

J = Jet velocity, ft/sec

.
ROP =Penetration rate, ft/hr

Example: What is the gpm/inch range; the flow rate recommended; and recommended
jet velocity, to minimize chip hold down, bit balling and give adequate hole
cleaning? Given: 12-1/4" bit; ROP 40 ft/hr.

G/B = 4(12.25) + 5= 54 gpm/inch

G= 4(12.25)2 + 5(12.25) = 662gpm

J = 40 = 444 ft/sec
v 0.01 + 0.002(40)

B. Hydraulic Guidelines

Hydraulics can be optimized by concentrating on four main guidelines. The four are:
flow rate; jet horsepower; percent of horsepower at bit; and jet velocity.

Rules: The following guidelines are based on running optimum bit weight.

Rule 1: Maintain flow rate 30-50 gpm/in of bit diameter. The following ROP
ranges are general guidelines for flow rates required.

ROP Ranges

Range1 - over 50 ft/hr 50 gpm/in

Range2 - 25 to 50 ft/hr 40 to 50 gpm/in
Range3 - 15 to 25 ft/hr 38 to 45 gpm/in
Range4 - 10 to 15 ft/hr 35 to 40 gpm/in
Range5 - 5 to 10 ft/hr 30 to 39 gpm/in

Rule 2: Maintain jet horsepower 2.5 to 5 HHP/in2 (hydraulic horsepower per sqin
of bit area). The rule is based on the square root of the rate of penetration.
In big hole (12-1/4 and greater size) the HHP/in2 could be allowed to go
slightly above 5.0 (up to 6.5) if drill ability is good (above 25 ft/hr).

34
 Rule3: Design hydraulics so that 50 to 65% of available
pump pressure is across the bit jet nozzles.
If optimized at midrange (55 to 60) the driller
has lore flexibility with flow rate as influenced
by formation drill ability ECD, and other
drilling operational factors.

Rule 4: Maintain jet velocity between 350 and 450

ft/sec. Do not drop below 250 ft/sec. ROP and
chip hold down influence optimum jet velocity
as discussed in Section VII A.

Formulas:

Flow rate (Q) = (gpm/in range) x Bit OD

HHP/in2 = square root(R.0.P) (no higher than 6.5)

plan

HHP/in2 = (Q) (Pbit)

1346(Bit OD)2

press drop= Pbit x 100

bit bit +Psurf

P surf =P bit +P system

P system = System pressure losses

(surface connections, drill string and

annulus - from book/slide rule/etc.)

P - 1346(Bit 0D)2 - ROP

bit Q

(156.482)(Q)2MW
P bit actual (J12 + J22 + J2 + etc.)2

35
 (418.3) (Q)
Jet velocity actua1 = (J12 + J22 + J32 + etc.)

Where:

Q = Flow rate (gpm)

HHP/in2 = Hydraulic horsepower per sqin of bit area
R.0.P. = Rate of penetration
P bit = Pressure loss through bit nozzles
P surf = Pressure required at surface
J1, J2, etc. = Numerator only (i.e., 15/32 = 15, 12/32 = 12)
MW = Mud weight (lb/gal)
P bit plan = Pressure on bit calculated when planning, psi

P bit actual = Pressure at bit calculated after selecting bit nozzles.

L = Length (ft)
P ID = Pipe inside diameter (in)
D h = Diameter of hole (in)

D = Outside diameter of pipe (in)

Example: Plan and evaluate the basic four hydraulic elements. Given: bit size = 12-1/4";
ROP = 25 ft/hr; MW = 10 ppg; no. of jets = 3.

Q = 45 gpm/in x 12-1/4"=551 gpm

HHP/in2 = square root of 25= 5.0

P= 1152 psi (from hydraulic book tables system for drill string and hole configuration)

P bit = 1346(12.25)2-25 = 1832 psi

551 planed

36
Jet Size = 3.536 (551 (1832)e~S)C~S

13.02 (13) use 3 size 13/32 jets

P bit = (156.482)(551)2(10)
(132 + 132 + 132 )2

= 1848 psi (actual pressure a bit after sizing nozzles)

Psurf = 1152(system) + 1848(bit)

= 3000 psi

press drop= 1848 x 100= 61.6%

bit 3000

HHP/in = (551)(1848) = 5.04

actual 1346(12.25)2

Jet Vel = (418.3)(551) = 454 ft/sec

(132 + 132 + 132 )

Optimization Checks:

1.Flow rate = 551/12.25 = 45 gpm/in

(30 - 50) opt. range

2. HHP/in2 = 5.0 (OK)

(2.5 - 5) opt. range

3. %P bit = 61.6% (OK)

(50 - 65%) opt. range

4. Jet Vel = 454 ft/sec (OK)

(350 - 450) opt. range

C. Horsepower at Surface and Bit

Optimum horsepower requirements are based on hole size and rate of penetration.

Rule: For input horsepower at surface, multiply 10 times the square of hole size (ten "D"
rule). For hydraulic horsepower at bit, take the square root of the rate of
penetration.

37
 Formula(s):

HHP surf = 10(Bit Size)2

HHP/in2 = square root R.O.P.

Example: Calculate the required surface horsepower the rig should have available
(influencing rig selection). Calculate hydraulic horsepower needed a bit if ROP
is 20 ft/hr:

HHP surf = 10(12.25)2= 1500

HHP/in2 = square root20= 4.5

D. Rough Neck Formula

The number one drilling parameter trend to monitor and evaluate potential hole stability
problems with is the pressure and pump stroke relationship.

Rule: When pump strokes are doubled the pump pressure will quadruple. This is
because pressure loss inside a drill string increases as an exponential function of
the pumping rate.

Formula:

P2 = P1 (SPM2/SPM1)2

Where:

P2 = Pump pressure after changing pump stokes to new

level (SPM2 - either up or down).

P1 = Pump pressure that is associated with SPM1 (original

pump pressure and strokes).

SPM1 = Stroke per minute original (P1 assoc. with SPM1) SPM2 = New pump
strokes (P2 assoc. with 5PM2)

38
 Example 1: The pump pressure (P1) was 2500 psi with 80 strokes
per minute (SPM1). What would the pressure be if
the pump strokes are raised to 85 (SPM2)?

P2 = 2500 (85/80) 2= 2822 psi

Example 2: In the same example if the hole loaded up with

formation cuttings and SPM2 dropped to 78 and the
pressure remained at 2500 psi, how many psi can be
attributed to the cuttings?

P2 = 2500 (78/80) 2= 2377 psi

Therefore:

AP = 2500 - 2377 psi

= 123 psi due to cuttings

E. Effect of Pipe Size on Hydraulics

Because pressure loss inside a drilling string increases as an exponential function of the
pumping rate, it is very important to choose drill string equipment with large bores. If
this guideline is violated the hydraulic horsepower will be mostly lost before it reaches the
bit nozzles.

Rule: The pressure loss in drill pipe and drill collars changes inversely proportional to
the change of bore diameter raised to the 4.82 power.

Formula:

P2 = P1 (ID 2/ ID 1) 4.82

Where:

P2 = Pressure loss with small pipe (psi)

P1 = Pressure loss with large pipe (psi)
D1 = Large diameter pipe (inch)
D2 = Small diameter pipe (inch)

Examnle: How much greater pressure loss does 4-1/2, 16.6 (ID-3.826) have compared to 5,
19.5 (ID-4.276)? Pressure loss with 5" dp = 25 psi/1000 ft.
= (4.276 /3.826) 4.82 = 1.71

39
 (The 4-1/2 drill pipe would lose 1.71 times more pressure loss than the
5 inch drill pipe.)

P2 = 25 *1.71 = 43 Psi

F. Effect of Mud Weight and Plastic Viscosity on Hydraulics

Pressure losses increase as the mud weight and plastic viscosity go up. Consequently it is
important to maintain the mud weight and plastic viscosity at operationally safe low levels.

Rule: The pressure loss is directly proportional to the mud weight. Divide new mud
weight by old mud weight and multiply this number by the pressure loss measured
(or calculated) with old mud weight.

Formula(s):

Pressure Loss MW = (P loss 1-MW2 ppg)

corr MW1 ppg

Where:

Pressure.Loss = Pressure loss corrected for mud

MW
corr weight change

Pressure Loss PV = Pressure loss corrected for plastic

corr viscosity (usually done in weighted muds)

MW1 = Mud weight (original) corresponding to pressure loss

either all measured or calculated.

MW2 New mud weight. The pressure loss MW will

correspond to this mud wt. corr

Exainle:Correct the pressure loss in the system for Mud weight changes and plastic
viscosity. Given: Pressure loss with MW1 = 1000 psi; MW1 = 13 ppg; PV (with MW1) =
25 cps; new MW (MW2) = 14 ppg.

Pressure Loss MW = (1000 psi)-141077 nsi

corr 13

G. Equivalent Circulating Density (ECD)

40
 The equivalent circulating density (ECD) is the effective mud weight on the formation due
to the total effect of the mud weight plus the friction loss in the annular space between the
pipe and the hole while circulating.

Rule: The simplified version of the Binghei plastic equation gives a quick ECD estimate.
Multiply yield value times 0.1 and divide by the hydraulic diameter (hole size
minus pipe size). Add the results to the mud weight (lb/gal).

Formula(s):

ECD = MW + 0.1 x YV
Dh -D

L xYV
P loss ann = 225(Dh- D )
P loss ann d/p L xYV +L x PV X ANN vel d/p
225(Dh- D ) l500(Dh - D )2

ECD equivalent = MW +P loss ann

(0.052 x Depth)

Where'
ECD = Equivalent circulating density
PLAnn = Pressure loss in annulus
MW = Mud weight (ppg)
Y,V, = Yield value (on Yield Point) lb/100 ft2
Dh = Diameter of hole
PV = Plastic Viscosity
D = Diameter of pipe
L = Length (feet)
v = Annular velocity, feet per sec
Example: Compare the estimated ECD with the formulas given.
Given: MW = 16.0 ppg; PV = 45; YV = 25; Flow rate = 330 gpm; Ann. Vel d/p = 2.85
ft/sec; Ann. Vel d/c 4.5 ft/sec; DP Length= 12,000 ft; DC Length = 70 ft; DC OD
= 6-1/2 inches; DP OD = 5 inches.

ECD = 16 + 0.1 x 25 = 16.7 ppg

(8.5 - 5)

P loss ann = 12,700 x 25 = 403 psi

225(8-1/2 - 5)

41
 ECD = 16 + 403 = 16.6
equiv 12,700 x .052

PL - 12,000 x 25 + 12,000 x 45 x 2.85 = 465

Ann 225(8-1/2 - 5) 1500(8.5 - 5)2
dp

PL = 700 x 25 700 x 45 x 4.5

Ann 225(8-1/2 - 6.5) + 1500(8.5 - 6.5)1 63
dp

Total P Loss Ann = 528 psi

ECD = 16 + 528 = 16.8 ppg

equiv 12,700 x .052

H. Optimum Annular Velocity (From Fullerton)

Optimum annular velocity is influenced by mud weight and hole size.

Rule: Divide the product of mud weight times hole diameter into 11,800 to get annular
velocity in feet per minute.

Formula:

Ann. Vel. = 11,800 (ft/min)

(MW x Dh)
Where:

Ann Vel = Optimum annular velocity in ft/min (by Fullerton)

MW = Mud weight (lb/gal)

Dh = Diameter of hole, inches

Example: What would the recommended annular velocity be for the

12-1/4 inch hole section with the following mud weights:
Case1 : 9.5 ppg/12-1/4 hole;
Case 2 = 11.5 ppg'12-1/4 hole;

42
 11,800
Ann Vel (Case 1) = (12.25 x 9.5) = 101 ft/min

Ann Vel (Case 2)= 11,800 = 84 ft/min

(12.25x11.5)

VIII: ESTIMATING HYDROSTATIC HEAD (PRESSURE)

The basic hydrostatic formula to calculate pressure is used constantly in the drilling
business. The formula is rearranged to also calculate mud weight and even depth.
Before introducing the rule a few concepts will make the formula clear.

Concepts' Two concepts will be introduced:

97.24lbs Weight of a column of fluid and;

Pressure in a column of fluid and pressure gradient.

Consider a 13 ppg mud. How much does 1 ft3 of this mud weigh?

MDI = 13 ppg = (13) (7.48) p cf

= 97.24 p cf = 97.24 1b'cu ft

Note' 1 Cu ft = 7.48 gal

1 bbl = 42 gal
1 cu It = 144 sq in

Now consider 5000 such blocks stacked vertically.

Total weight = (97.24) (5000) =

486,200 lbs

Now, what is the pressure, in psi, at the bottom of a 5000 ft stack of 1 cu ft cubes?

Total weight = 486,200 lb

Base area = 12 x 12 sq ins = 144 sq in

So:

P (psi) = 486,200 lb = 3376 psi

43
 144 in2

Now, how much does 1 in3 of 13 ppg mud weigh?

MW = 97.24 = 0.05627 lb/cu in

How many 1 inch cubes stacked up make 5000 ft?

Number = (5000) (12) = 60,000 cubes

Total weight = (60,000)(0.05627) = 3376 lbs.

Now, what is the pressure in psi at the bottom of this mud column?
Base area = 1 sq in and weighted above = 3376 lbs

So:

P = 3376 lb = 3376 psi

1 sq in

From this we see that, although the cross-sectional area of the mud columns are different,
the pressure at the bottom of the columns is the same! The pressure at any point in a
mud column depends only on the true vertical depth (~ID), not on the area or the shape
of the column.

It turns out that we have a simple formula that will predict the pressure at any depth. It is'

PSI = 0.052 (MW) (ft.)

0.052 gal x lb x ft - lb
The units are = - = psi
ft sqin gal sqin

Example:

PSI = (0.052) (13 ppg) (3000 ft) = 2028 psi

Know this formula! You will use it all the time. With the above formula we can find the
pressure at any depth with:

44
 PSI = (0.052) (13 ppg) (ft) valid for 13 ppg mud constant term

You need only to compute the constant term once. It is:

(0.052) (13) = 0.676 psi/ft

This number is special and is called the pressure gradient for

13 ppg mud. It tells us how much the mud pressure changes for each foot of depth, so:

1f 0.676 psi
2ft 1.352 psi
3 ft 2.028 psi
4ft 2.704 psi
5ft 3.38 psi

5000 ft M}3376 psi

Rule: To help remember the basic formula to calculate

pressure multiply the number of weeks in a year by
the mud weight in pounds per gallon. Multiply this
product by true vertical depth in thousands of feet.

Formula:

PSI = MW x (No. of weeks in a year) x TVD

Where:

PSI = Pressure at some depth

MW = Mud weight in pounds per gallon

TVD = True vertical depth, in thousands of feet

No. of weeks in year = 52

Note' The 0.052 units are arrived at this way:

7.48gal/cu ft - 7.48 gal sg ft

144 sq in/sq ft cu ft 144 sq in

= 0.052 ft/sq in

Example: What is the hydrostatic head (pressure) at 5000 feet if the hole contains 13 ppg
mud?

45
 PSI = 13 x 52 x 5

= 3380 psi

IX: ESTIMATING STRENGTh OF STEEL CABLE2

The approximate strength of steel cable can be estimated in tons by the following rule.

Rule: 1. Change line diameter to eights.

2. Square the numerator.
3. Divide by the denominator.
4. Read the answer in tons.

Example' What is the approximate strength of 3/4 inch steel cable?

1. Diameter = 3 *8 inch = 6 inch

4
2. 6*6=36

3. 36 /8= 4.5

4. Answer = 4.5 tons

Ref. 2: Production Rules of Thumb Notebook, World Oil, Gulf Publishing Co. - 1967.

X: ESTIMATING STRENGTh OF RQPE

The approximate strength of manila rope can be stimated in pounds by the following
rule.

Rule: The working strength of manila rope is approximately equal to 900 times the
diameter squared. If rope diameter is greater than 2 inches, a factor lower than 900
should be used. In working with heavier rigging, accepted hand hooks should be used
to find safe working strength.

Formula:

Working Strength = 900 x D2

Where:

D = Diameter of rope, inches

46
 Exaaple: What is the estimated working strength of 1/2 inch manila rope?

Working strength = 900 x (0.5)2 = 225 lbs

Ref. 3: Production Rules of Thumb Notebook, World Oil, Gulf Publishing Co. - 1967.

XI: MAKE UP LOSS IN LINE PIPE WITH STANDARD 8 ROUND THREAD4

When line pipe is made up (screwed together), there is a loss in length at each joint. This
make-up loss can be calculated by the following rule.

Rule: For pipe sizes 3-inches in diameter and larger, which have standard 8-threads per
inch, the following formulas may be used to determine pipe make-up loss.

Formula(s):

Correction in percentage = 0.57 + (0.04) D

Correction in feet per mile = 30.1 + (2.11) D

Correction in inches per 1000 feet = 68.4 + (4.80) D

Where: D = Nominal diameter in inches

Note: These rules (estimates) are adequate for standard weight pipe. However, there
is some variation in

larger sizes of pipe and for extra heavy and very light weight tubes.

Example: How much extra pipe should be ordered to make up for screw loss in a 5
inch rig water line.

= 0.57 + 0.04 x 5 = 0.77% ft/mile = 30.1 + 2.11 x 5 = 40.65 ft/mile

inches/1000 ft = 68.4 + 4.8 x 5 = 92.4 ins/1000 ft

Ref. 4: Production Rules of Thumb Notebook, World Oil, Gulf Publishing Co. - 1967.

XII: CENTRIFUGAL PUMPS

The main factors influencing rating of centrifugal pumps are impeller diameter and
operating RPM. These two variables influence head (in feet), output capacity (in GPM) and
horsepower. Some of the rules are listed below.

47
Rules:

A. Head in feet varies in proportion to the square of the speed (RPM). The higher the
speed, the higher the head. Head in feet varies in proportion to the square of impeller
diameter. The bigger the diameter, the higher the head in feet.

B. Capacity (GPM) varies in direct proportion to the speed. The higher the speed, the
higher the capacity. Capacity varies in direct proportion to impeller diameter.

C. Horsepower varies in proportion to the cube of impeller diameter. Horsepower varies

in proportion to the cube of the speed.

Formulas:
Head2 (ft) = Head1 (RPM1/RPM2 ) 2
Head2 (ft) = Head1 (D2/D1)2
GPM2 = GPM1 (RPM2/RPM1)
GPM2 = GPM1 (D2/D1)
HP2 = HP1 (D2/D1)3
HP2=HP1(RPM2/RPM1)3
Ref. 5: Production Rules-of-Thumb Notebook, World Oil, Gulf Publishing Co. - 1967.

'
HP = 75 ft x 0.052 x MW (ppg)

Where:

Head2= Calculate new feet of head wi either RPM or impeller diameter changed

GPM2 = Calculate new capacity (GPM) with change in RPM or impeller diameter change

HP2 = Calculate new HP with change in RPM's or impeller diameter change

P hdl - The pressure on the hydrocyclone manifold if the hydrocyclone head is kept
constant at 75 feet

Example 1:Calculate: the change in Head (Head2); change in

capacity (GPM,); change in horsepower (HP2). Given:
HP1 = 25; GPM1 = 400; Head1 = 170 feet; D1 = 7 inch;
RPM1 = 1450. Changes: D2 = 8 in.; RPM, = 1750.

Head2 = 170 (1750/1450) 2= 248 ft (if only RPM' are changed)

Head,= 170 (87)2= 222 ft (if only impeller diameter is changed)

GPM,= 400 (1750/1450) =483gpm (if only RPM' are changed)

48
GPM,= 400 (8/7) =457gpm (if only impeller diameter is changed)

HP,= 25 (8/7)3=37.3 (if only impeller diameter is changed)

HP, = 25(1750/1455) 3= 44 (if only RPM's are changed)

Example 2: How much pressure should you have on the hydrocyclone if 9.5 ppg mud is being
used?

P = 75 ft x 0.052 x 9.5= 37 psi

XIII: BOP ACCUMULATORS

Usable hydraulic fluid, to operate the blow out preventor equipment, is affected by
accumulator pressure and nitrogen pre charge. The following rules apply to sizing
accumulator (volume required for nitrogen and hydraulic fluid) and for running a quick check
on average nitrogen

precharge of system (without having to drain hydraulic fluid back into accumulator storage
reservoir and individually check each bottle, which is time consuming).

Rule 1: If the nitrogen precharge is at the correct (recommended) pre charge multiply the sizing
factor (see below) times the fluid required to operate a specified number of BOP
functions to arrive at required total accumulator volume.

Accumulator Recommended Minimum Accumulator

Operating Pre charge Useable Size
Pressure Pressure Fluid Factor

1500 750 1/8 8

2000 1000 1/3 3
3000 1000 1/2 2

Based on minimum discharge pressure of 1200 psi.

Bottle Bottle Bottle
at Pre charge at Minimum Fully Pressured
Discharge
1000 1200 3000

Rule 2:A quick check can be made on the average nitrogen pre charge of the complete BOP
accumulator system with the following steps:

Note: Pipe out of the hole and blind ram closed and locked.

1. Read accumulator pressure (i.e., 3000 psi).

2. Close off hydraulic line going to air and electric accumulator pumps.

49
 3. Pick up test joint and position in BOP's. Operate one or more of BOP functions (i.e.,
closed hydril and opened Type F valve).
4. Read new manifold pressure (now drawdown because of operating BOPE, i.e., 1800
psi.
5. Calculate fluid required to operate BOP functions (i.e., 29.94 gal).
6. Calculate average nitrogen pre charge of accumulator system.

Formula(s):

VT =Vd x(Starting Accum. Press.)(Final Accum. Press.)

(Starting - Final Accum. Pressure)

VT =Vd x 2

P = (Vol. Removed)(Starting Accum. Press.)(Final Accum. Press.)

a (psi) (V )(Starting - Final Accum. Pressure)
T

Where:

VT = Total hydraulic fluid and nitrogen to base accumulator volume sizing on

Vd = Volume required to operate BOP that accumulator sizing will be based on

Accum. Press. =Pressure rating of accumulator system (or operating pressure)

Nitrogen Pre charge = Should be 1000 psi for 2000 and 3000 psi
system. It should be 750 psi for a 1500 psi accumulator system

Minimum Discharge
Pressure = This is the recommended minimum discharge pressure to base design on
(200 psi above nitrogen pre charge)

Pa= The average nitrogen pre charge in system (calculated after operating BOP and measuring
drawdown)

Example 1:Calculate the required accumulator system if the design was based on operating the
following BOPE and having 50% SF; 3000 psi accumulator.

BOP’s Close Open

1, Hydril, GK, 13-5/8, 10,000 psi (bag) 29.35 20.96

2, CIW, Type "U", 13-5/8, 10,000 psi (ram) 11.6 10.90

1, CIW, Type "F", 4", 10,000 psi (hydv.) 0.59 0.59

50
 50% Reserve 37
Total (Hydraulic Fluid) 111 gal

V = (111)(3000 )(1200) = (111 gal) x (2)=222 gal(N2+hyd fluid)

T (1000 )(3000 – 1200)

Note: The sizing factor comes from the pressure side of the above equation.

Example 2: Using the above accumulator system (222 gal~ 3000 psi). Calculate the average
nitrogen precharge in the system after the system had been in use several days.
Given: (from steps in Rule 2): drawdown pressure = 1800 psi after removing
29.94 gal of hydraulic fluid (operated hydril and Type F choke valve).

Pa = (29.94)(3000 )(1800)
(222 )(3000 – 1800)

=607 psi (average nitrogen pre charge in accumulator system)

Note: This system should have 1000 psi nitrogen pre charge, and this lower pre charge
pressure lowers the amount of usable fluid that is available to operate the BOPE. To
find out which bottle(s) are low in nitrogen pre charge the hydraulic fluid has to be
drained back into accumulator storage reservoir and each bottle checked with a
pressure gauge. Use clean nitrogen to pressure the bottles back to 1000 psi.

XIV: KICK TOLERANCE

By utilizing known rig data and a series of formulas (in which part are rules-of-thumb) kick
tolerance can be calculated for several "what-if" situations. A leak off test sometimes leads to
false security unless the size kick is considered. Kick size greatly affects control capability and
in fact it is the number one limitation to control capability. The

size kick a drilling crew allows is a direct reflection of motivation and well control awareness
of rig personnel and places a high priority on rig-selection. When kick tolerance, based on a
realistic kick size, is calculated to be below one pound per gallon (1 ppg) an operator may
consider running casing to prevent lost circulation (the greatest associated problem to well
control).

Rule: To evaluate kick tolerance choose two or three hypothetical (realistic) pit gains and:
calculate DC annular volume (formulas); evaluate whether the kick is large enough to
cover the drill collars and part of the drill pipe or not -- after
making this determination use either formula 7 or formula 6 to calculate length of
influx; calculate estimated shut in casing pressure (formula S); calculate maximum
allowable pressure (formula 1); calculate bottom hole pressure maximum allowable
(formula 2); calculate bottom hole pressure maximum mud weight equivalent (formula
3); and calculate kick tolerance (formula 4). Make decision about the safety of drilling

51
 operation related to well control (taking a kick that would break the formation down
somewhere in open hole).

Formula(s):

1. Max Allo Press = (L.O.T. - MW) .052 x Shoe TVD

2.BHP Max = (TVD - Length Influx)(.052)(MW) + (Max Allo P) + (Length Influx x 0.1)

3. BHP MWE = BHP Max

(TWI) x .052

4. Kick Tolerance = BHP MWE - MW

5. DC Ann Vol. = (Bit Size' – d/c OD2) DC Lengh

1000
6. Lengh Influx= (Pit Gain - Ann (dc) Vol) 1000
d/p Ann (Bit Size' – d/p OD') + DC Lengh

7. Len Inflx Ann = (Pit Gain) 1000

d/c (Bit Size' – d/c OD2)

8. SICP = SIDPP + Lengh Influx (Mud gradient - Influx gradient)

9.Equiv MW Shoe = Hole MW + SICP

0.052x Shoe TVD

10. Shoe Pressure = Form Press - (Hydrostatic Pressure below Shoe)

Note: Hyd. Pressure is made up of Orig. Mud, Influx Fluid, and sometimes kill weight mud.
Influx Gradient assumed to be 0.1 psi/ft (gas).

Where:
L.O.T. = Leak off test mud weight
MW = Mud weight (ppg) in hole
Shoe WI) = True vertical depth of shoe

BHP Max = Bottom hole pressure maximum (a partial

step in kick tolerance calculation)
WI) = True vertical depth (TD)
Max Allo P = Maximum allowable pressure based on leak off test at shoe

BHP MWE = Bottom hole pressure mud weight equivalent

(partial calculation in kick tolerance
program)

52
Kick Tolerance = The maximum kick intensity (kill wt.) that can be taken for the size (pit
gain) kick and the L.0.T. calculated

Equiv. MW Shoe = Equivalent mud weight at shoe based on shut in casing pressure

Shoe Pressure = Pressure applied to a casing shoe

Form Press = Formation pressure (hydrostatic pressure + SIDPP)

Example 1: Calculate the kick tolerance for a 26 barrel kick.

Given: Bit OD - S.5 inches

DC OD - 6.5 inches
DP OD - 5.0 inches
DC Len - 720 feet
Pit Gain - 26 barrels
TVD Shoe - 8,000 feet
TVD TD - 12,500 feet
MW Hole - 14 ppg
MW L.O.T. - 16.7 ppg
SIDPP - 650 psi

DC Ann Vol = (8.52 - 6.52)(720) = 21.60 bbl

1000

Size Kick = 26 bbl; therefore part of the kick is above drill collars

Len Inflx - (26 - 21.6) 1000 = 813 feet

(8.52 - 5.02) + 720
dp Ann

SICP = 650 psi + 813 (14x0.052 -0.1) = 1161 psi

Equiv. MW Shoe = 14 +1161 psi= 16.8 ppg

(0.052 x 8000)

Max Allo Press = (16.7 - 14) .052 x 8000 ft= 1123 psi

53
BHP Max = (12'500813)(O.O5)(MW)+(1123)+(813x0.1) = 9713 psi

BHP MWE = 9713 = 14.9 ppg

12,500 x .052

Kick Tolerance = 14.9 - 14= O.9ppg

Comparing a 10 bbl kick with the above 26 bbl kick.

Size Length Maximum BHP BHP Kick

Kick Influx SICD SIDPP Allowable Max. MWE Tolerance

10 333 826 650 1123 10,014 15.4 1.4

26 813 1161 650 1123 9,713 14.9 0.9

Note: A 10 bbl kick could be taken but a 26 bbl would probably break the shoe down.
Max Allo Press = (16.7 - 14) .052 x 8000 ft= 1123 psi

XV: WATR HAMMER EFFECT

A well that is flowing with great intensity (high flow rate) can cause high hammer force which
may damage BOPE or wellhead. However, most kicks, that are detected early and that are not
too much under balanced (<1.5 ppg kick intensity) will have only minimum hammer effect on
equipment. The once recommended soft closure to minimize the water hammer effect, has lost
some of its popularity and many operators are recommending hard closures to minimize kick
size. Kick size has the greatest effect on kick control capability. The maximum rate of closure
to prevent most of the hammer effect depends on how fast the closure pressure wave travels
through the mud and the well depth. If the speed of sound in mud is taken to be 1000 ft/sec
then the round trip time for the closure pressure wave is:

Time (sec) = 2 x Measured Depth = 20 sec in the example below 1000

If the well is closed in (less than 20 seconds) then the chance for a severe hammer is high. For
shallow kicks this time is greatly reduced.

Rule: Calculate the hammer pressure utilizing the annular velocity and mud weight and
multiply this times the cross-sectional area of pressure exposure.

Formulas:
AP hammer = ~2?72 )(Annular Velocity)(VMW)

54
 AF hammer = (AP hammer )(BOP Size2 – d/p OD2)(0.7854)

Where:

AP hammer & AF hammer =Pressure and force created from rapid closure in a water base mud.

(Note: oil muds are more compressible and therefore have less hammer effect.)

Ann. Vel = Annular velocity in feet per minute

MW = Mud weight (PPG)
BOP Size = ID of BOP’s (inches)
d/p OD = Drill pipe outside diameter (inches)
Example:
Bring Kick to a "Halt" Gradually to Prevent Shocking Formation and BOP‘s

Given:

BOPE Diameter - 13-5/8

Hole Size - 8-1/2" below 9-5/8 casing 47 lb/ft
Drill pipe Diameter = 5"
Ann Cap Around d/p = .049 bbl/ft
MW - 13 ppg
Flow Rate = 20 bbl/minute
Well Depth - 10,000 feet
Annular Velocity = 20 bbl/min = 408.2 fpm
0.049
So:

Hammer = 0.102 (408.2) (13) = 541 psi

or
Hammer = 541 (13.6252-52) (0.7854)= 68,256 Ibs

This hammer force will be exerted on the wellhead for a few seconds.

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