Professional Documents
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INTRODUCTION
Problems are what drilling personnel are about! As a junior engineer, it didn't take me long to
recognize that if I could eliminate the drilling problems peculiar to a given area, I could reduce
the cost. Pursuant to that logic, I would draw the anticipated performance curves without
consideration for potential problems. To my dismay, it became apparent that in most cases the
problems could not be eliminated! However, it was equally apparent that the effect of the
problems could be minimized by properly describing the problem, understanding fundamental
causes and determining the most expeditious and economical solution.
Some of the most common problems associated with rotary drilling operations are as follows:
1. Lost Circulation
3. Key Seating
4. Boulders
5. Salt
6. Hole Instability
7. Deviation
8. Pressure Control
9. Hole Cleaning
This chapter will discuss the first six as the latter are covered by complete chapters later in the
book.
LOST CIRCULATION
Lost circulation occurs when the effective hydrostatic becomes greater than the formation pore
pressure plus the resistance to flow of the fluid through the formation. The effective hydrostatic
(also known as the equivalent circulating density or ECD) is the hydrostatic added to the
frictional pressure loss in the annulus plus the effect of cuttings accumulation.
Mathematically:
Fr = Pφ + f (φ, kh ) + f (M )
Equation 3-2
Figure 3-1. Unit Cells and Groups of Uniform Spheres for Cubic Rhombohedral Packing
Permeability is a measure of the resistance to flow of a fluid thru a rock. The units of
permeability are darcys (D) or millidarcys (md = D/1,000). Permeability may also be thought of
as a measure of the degree to which the pore spaces are interconnected. Values of
permeability in productive reservoirs range from 0.1 md in deep, hard rocks to as high as 10
darcys in prolific reservoirs. Other examples are given in Table 3-1.
φ k
Cement 0.01-0.1 md
Lost circulation will be divided into surface hole and intervals with high matrix porosity and
permeability, deeper zones with low primary and high secondary porosity, and lost circulation in
the presence of potential hydrocarbon production.
LOST CIRCULATION IN THE SURFACE HOLE OR INTERVALS WITH HIGH PRIMARY POROSITY AND
PERMEABILITY
The surface hole interval is characterized by high productive capacity (combination of porosity
and permeability). Only in this geologic environment is it possible to lose whole mud into
primary porosity. In more normal environments, the mud solids which range in size from 2-200
microns are too large to pass into the matrix porosity and are deposited on the formation face
forming an impermeable filter cake and preventing further losses. Any solution to lost circulation
problems must be in response to Equations 3-1 and 3-2.
Under these circumstances, whether shallow or deep, lost circulation is most often combated by
thickening the mud in order to reduce its ability to pass thru the matrix porosity. Thickening is
most commonly accomplished by adding lime (Ca(OH)2) to mixtures of benetonite (gel) and
water. It must be remembered that the Ca++ ion is a contaminant which reduces the yield of
bentonite. Commonly, sodium bicarbonate (NaHCO3) is added to fresh water prior to the
addition of bentonite to remove any excess calcium in the make up water and maximize the
bentonite yield. Therefore, if an intentionally contaminated system is to be used, it is imperative
that the bentonite be premixed in fresh water and then contaminated and flocculated with lime.
Remember, water plus bentonite plus lime yields thick mud; whereas water plus lime and
bentonite yields only contaminated water.
If the thick mud fails to solve the lost circulation problem, the most common alternative is to drill
without returns to the surface which is commonly referred to as "dry drilling." Dry drilling should
only be considered when hydrocarbon production is not anticipated. Many operators are
reluctant to drill without returns to the surface due to potential stuck pipe problems. Such
problems are caused by insufficient annular velocities or sloughing of the formations above the
lost circulation zone. To combat sloughing conditions, experienced operators use a "mud cap"
which involves pumping viscous and sometimes weighted mud down the annulus while drilling
with water accompanied by viscous sweeps as dictated by torque and drag. The most common
mistake is insufficient annular velocities. Some field personnel feel obligated to reduce the
pump strokes and conserve drilling fluids. It must be remembered that the same annular
velocities are needed to carry the cuttings to the zone of lost circulation as to carry them to the
surface. Don't slow down the pump! In reality, if water is substituted for mud, higher pump
rates may be required to compensate for the reduction of viscosity.
Further, in soft formations, high penetration rates can contribute to mud weight while frictional
pressure losses in large holes are generally negligible. Consider the following example.
Example 3-1
Given: Hole Size 17½ inches (444 mm)
Pfa = Negligible
Phe = Ph + Pca
⎛ π / 4(17.5 )2 ⎞
=⎜ ⎟(15 )(2.5)(62.4 ) = 3,909 lbs/min
⎜ 144 ⎟
⎝ ⎠
Weight of Cuttings
Volume of Cuttings =
Density of Cuttings
3,909 lbs/min
Volume of Cuttings =
(2.5 )(8.33 lbs/gal )
Volume of Cuttings = 188 gpm
Total Weight
Phe =
Total Volume
3,600 + 3,909
Phe = = 12.81 lbs/gal
400 + 188
Therefore, the equivalent circulating density ( Phe ) is 12.8 ppg or an increase of 3.8 ppg due to
the accumulation of cuttings in the annulus. Since the frictional pressure losses are negligible,
the equivalent hydrostatic could be reduced by increasing the pump rate. If the pump rate is
increased to 1,000 gpm in the same example, the equivalent circulating density is reduced as
follows:
9,000 + 3,909
Phe = = 10.9 ppg
1,000 + 188
Pfa = Negligible
Phe = Ph + Pca
Weight of Cuttings
Volume of Cuttings =
Density of Cuttings
1,815 kgs/min
Volume of Cuttings =
(
(2.5) 998 kgs/m 3 )
Volume of Cuttings = 0.7275 m 3 /min
Total Weight
Phe =
Total Volume
1,620 + 1,815
Phe = = 1542 kgs/m 3
1.5 + 0.7275
Therefore, the equivalent circulating density ( Phe ) is 1542 kgs/m3 or an increase of 462 kg/m3
due to the accumulation of cuttings in the annulus. Since the frictional pressure losses are
negligible, the equivalent hydrostatic could be reduced by increasing the pump rate. If the pump
rate is increased to 4.0 cu m/min in the same example, the equivalent circulating density is
reduced as follows:
4312 + 1,815
Phe = = 1296 kg/m 3
4.0 + 0.7275
As drilling people, we must respond according to the existing conditions. In the previous
examples, the problem may be solved be thickening the mud or increasing pump rate. As we
shall see, in a 6½ inch (165 mm) hole at 23,000 feet (7000 m), the solution would be to thin the
mud and slow the pump rate.
In the event dry drilling is unacceptable, lost circulation material (LCM) is generally the next
alternative. A brief look at lost circulation material is appropriate. Lost circulation material
should be the cheapest, most readily available bulk material. It may be cottonseed hulls in
farming areas, sawdust in mountainous or wooded areas, ground sea shells in coastal areas or
some manufacturing residue in industrial areas. There is no definitive work which suggests that
one lost circulation material or any combination of lost circulation materials is more effective
than another. Lost circulation material is a shallow additive. The best information suggests that
a lost circulation bridge can increase the formation strength by approximately 300 psi (2,070
kpa). Consider the following example.
Example 3-2
Given: Fracture Gradient = 0.5 psi/ft (11.3 kPa/m).
Determine: The permissible mud weight at 1,000, 5,000, 10,000 and 20,000 feet (or
300, 1500, 3050, & 6100 meters) if lost circulation material is added.
Solution:
TOTAL
FRAC FRAC EQUIVALENT
DEPTH PRESSURE ΔP PRESSURE MUD WEIGHT
Solution(SI):
TOTAL
FRAC FRAC EQUIVALENT
DEPTH PRESSURE ΔP PRESSURE MUD WEIGHT
3
(meters) (kPa) (kPa) (kPa) (kg/m )
It can be clearly seen from Example 3-2 that lost circulation material may improve the fracture
pressure from 9.6 ppg. (1150kg/m3) to 15.4 ppg (1850kg/m3) at 1,000 feet (300 meters) yielding
a 60% increase. However, at 10,000 feet (3050 meters), the improvement is only 0.6 ppg (70
kg/m3) or an increase of less than 10% in the available mud weight. Further, as will be seen in
deep, small holes frictional pressure losses may be responsible for the lost circulation problems.
Mud rheology is measured only after lost circulation material has been removed. Limited
research indicates conclusively that LCM contributes to viscosity and increases frictional
pressure losses. Further, due to its low specific gravity, the use of LCM should be discouraged
in weighted mud systems. (The use of fine mica to prevent seepage of weighted muds is an
exception.) Plainly, LCM is not a reasonable alternative in a 23,000 foot (7000 meter) well with
a 6 inch (152.4 mm) hole, 2⅞ inch (73.0 mm) drill pipe and 16.8 ppg (2010 kg/m3) pore pressure
combined with 17.0 ppg (2040 kg/m3) fracture gradient.
If LCM is to be used, it is common practice to pull a few stands off bottom to avoid the pipe
sticking problems while mixing LCM in the suction pit. LCM concentrations to 30 lbs/bbl (85
kg/m3) are not unusual and can be pumped thru nozzles in the bit provided the LCM is properly
dispersed throughout the system. Once the suction pit is ready, drilling can be resumed without
returns until returns are regained, the fractured zone is penetrated or until the mud losses
preclude further drilling. It is imperative that the lost circulation zone be completely penetrated
prior to attempting more drastic alternatives since sealing only half of the interval will cease to
be effective once additional interval is penetrated. If this technique is not successful, the drill
pipe may be run open ended to utilize larger concentrations of LCM.
In examining Equations 3-1 and 3-2, it is apparent that hydrostatic reductions using air, foam or
air assist are a reasonable alternative. These procedures are discussed in more detail in the
chapter on "Air Drilling."
The alternative, most commonly following the failure of LCM, involve the use of solids squeezes
such as "gunk", thixotropic cements, diacel and plastics. For many years, the "gunk" squeeze
was the most popular procedure to control lost circulation. "Gunk" was first made by adding
250-300 lbs. (113-136 kgs) bentonite to one barrel (0.16 m3) of diesel oil and was called diesel
oil-bentonite (DOB). Later, cement was added to the bentonite (50:50 by weight) and the
mixture was called "gunk." "Gunk" was very successful and popular as a treatment for lost
circulation primarily because water activates the slurry and most lost circulation zones are
aquifers.
By the late 1970's, the price of diesel had made the "gunk" squeeze very expensive. In
addition, in some countries such as Canada, it had become a violation of regulations to use a
valuable resource in this manner. As a result, the thixotropic or high calcium cements replaced
the "gunk" in popularity and, with experience, in success. The thixotropic cements have been
very successful under the most adverse circumstances. In one case history involving
cavernous conditions, more than ten thousand sacks of cement was being considered, which
would have limited the project. Abandonment of the project was considered. The zone was
squeezed with 300 sacks (13 tons) of thixotropic cement and full returns were obtained for
several months. At regular intervals of 2-3 months thereafter, returns would be lost and the
procedure successfully repeated until the project was completed. In another instance, a hole in
the surface pipe with only soft shallow zones exposed could not be repaired by ordinary means.
Again, the thixotropic cement solved the problem and the project was finished without incident.
Diacel or diatameous earth is a clay having extremely high initial gel strengths. Diacel is
successfully used around the world for lost circulation into both primary and secondary porosity.
Diacel plugs are temperature sensitive and may deteriorate with time necessitating additional
applications.
Plastics and resins were popular during the mid 1960's. However, they were not very
successful. They were expensive and, therefore, used in small quantities. To further
complicate matters, the activator had to be pumped separately, and in many instances, the two
never made contact in the wellbore.
Cross linked polymers are also popular for controlling lost circulation. A delayed cross linking
polymer is pumped down the drill string and spotted across the lost circulation zone. Hopefully,
the polymer will cross link at the lost circulation zone. If the polymer cross links before it gets
out of the drill pipe, the pipe will plug. If the polymer cross links to late, it may be washed away
in the lost circulation zone.
In long sections of open hole, locating the zone of loss can be the most difficult problem in
determining where to spot the plugging material. Temperature surveys and radioactive tracer
surveys are the most common and reliable methods. The temperature survey is more reliable
and involves locating a cool anomaly. The normal geothermal gradient in sedimentary rocks is
illustrated in Figure 3-2 (A) and varies from 1 to 3°F/100 feet (1.8-5.5°C/100 meters). Routine
drilling operations shift the gradient as further illustrated in Figure 3-2 (A). A loss of significant
quantities of drilling mud will cool the entire wellbore. However, only that portion of the hole
containing the larger volumes of lost mud will remain cool for long periods of time. The
temperature in the remainder of the hole will move toward the geothermal gradient leaving a
"bulge" at the zone of loss (Figure 3-2 B). Temperature surveys are generally run at two hour
intervals in an attempt to expedite the process.
The radioactive surveys are faster, but generally, not as reliable. Modern tools consist of an
emitter and two detectors as illustrated in Figure 3-3. Weak radioactive materials with a short
half life are used to avoid formation contamination which would effect the Gamma-Ray
correlation log. Depending on the service company, more than a dozen individual "pills" can be
emitted with one trip in the hole. A pump rate is established that will provide an identifiable
velocity. Then, the tracer tool is set at positions in the hole and the detector response is noted
as the passing or failure to pass of the "pill." The tracer tool is simply moved around until the
zone of loss is located by the failure of the "pill" to go up or down, but out into the lost circulation
zone.
Figure 3-2. (A) Temperature Survey while Drilling Figure 3-3. Radioactive Survey Tool
(B) Temperature Surveys with Lost Circulation
Casing seat testing should always be performed when hydrocarbon production is anticipated.
Testing procedures vary with need and geologic environment. The most common procedure is
to drill a minimal distance (20 feet or 6 meters) below the shoe and test. In some areas, the first
sand below the shoe is drilled prior to testing. In overthrust areas, sedimentary rocks below
hundreds or even thousands of feet of granite are penetrated and tested. The purpose of the
test is to determine the maximum permissible mud weight, to insure the integrity of the cement
job or to insure that the required mud weight will not exceed the fracture gradient at the casing
shoe. A typical casing seat test is illustrated in Figure 3-4. In this figure, part (A) illustrates the
normal test for sandstone. Point "A" in the figure represents the mud weight required for known
reservoirs. Point "B" represents the deviation from linearity and is defined as "leak off." Point
"C" is defined as "break down" and point "D" is defined as "pump in." If sufficient data are
available to determine that the equivalent mud gradient represented by point "A" is adequate for
drilling below the shoe, it is pointless to test beyond point "A". For example, if it is known in a
Figure 3-4 (B) and (C) represent typical tests for shales
and older limestones, respectively. Most shales do not
break down, but merely balloon while older limestones
may fracture suddenly. When the formation ruputures,
some tests in shale and sand can also look like those
shown in the figure.
Example 3-3
Given: Well depth = 10,000 feet (3050 Figure 3-4. Plot of Typical Casing Seat
meters) Tests for (A) Sandstone, (B) Shales,
(C) Limestones
Mud weight = 9.6 ppg (1150 kg/m3)
Determine: The surface pressure required to test the shoe at 10,000 feet (3050
meters) to 15 ppg (1800 kg/m3).
Example 3-4 shows how the pressures within the wellbore react when the well is again tested to
an equivalent mud of 15 ppg (1800 kg/m3) after being drilled to 15,000 feet (4570 m).
Example 3-4
Given: The data are similar those given in Example 3-3
2. Hydrostatic at 10,000 ft
9,200 psi
ρ em10,000 = = 17.7 ppg
(10,000ft )(0.052 )
Solution:(SI) 1. Hydrostatic at 4,570 meters
2. Hydrostatic at 3,050 m
65,540kPa
ρ em3, 050 = = 2190kg / m 3
(3,050m )(0.0098)
As illustrated in Example 3-3 and Example 3-4, when the zone at 15,000 feet (4570 meters) is
tested to 15 ppg (1800 kg/m3), the casing shoe is tested to 17.7 ppg (2120 kg/m3). The
remainder of the open hole interval between 10,000 ft and 15,000 ft (3050 m and 4570 m) is
tested to equivalents above 15 ppg (1800 kg.m3) and below 17.7 ppg (2120 kg.m3). Therefore,
should leak off or break down occur at or below 4,200 psi, a 15 ppg Equivalent (29,000 kPa, a
1800 kg/m3), the break down could have occurred at any point in the open hole section and the
test results are inconclusive.
Pressure control expertise becomes of the utmost importance when lost circulation occurs in the
presence of hydrocarbon production. Every consideration must be given to the possibility of a
sudden, uncontrollable flow. This particular problem is discussed in the chapter on Pressure
Control.
Pipe getting stuck in a wellbore is a huge menace in drilling. Several operators around the
world have reported the perils of stuck pipe. It is considered one of the costliest unscheduled
events during drilling operations. 1 In the Netherlands, the stuck equipment incidents resulted in
5% of the drilling capital expenditure in 1993. 2 Shell reported stuck pipe in 70% of its wells
causing 80% of the lost time while drilling in Nigeria. 3 Stuck pipe incidents cost over one billion
dollars per year through losses in rig time, production and drilling operations, tools and
equipment, and through expenses for fishing or side-tracking operations. The cost is ever
increasing as more and more deviated and horizontal wells are drilled.
Though drilling has been done for over 100 years, stuck pipe problems are not inevitable. 4 The
problem can’t go away completely, but can be made to stay away more frequently. It is believed
to be more cost-effective to prevent stuck pipe incidents than to develop new tools for freeing
stuck pipe. 5 More than 65% of stuck pipe occurrences can be avoided with better planning and
drilling crew training. There is a need for better awareness of the problem and continued
emphasis on prevention measures to achieve minimal stuck pipe incidents. There is also a
need to develop better detection systems to forewarn against stuck pipe problems. The warning
can prepare the crew to take corrective actions and prevent serious sticking incidents. These
measures have helped to reduce the stuck pipe costs by over 70% at several locations.3,4
The mechanics of differential pressure sticking are well known to the industry. Annis 6 and
others reported that the sticking force is described by the following equation:
fAf ΔP
Fs = Equation 3-6
98
Af
Filter Cake
Af
Filter Cake
Annis wrote extensively concerning the sticking coefficient. Two observations are particularly
significant to field operations. It was observed that ordinary emulsified crude oil reduced the
sticking coefficient to minimal values. Commonly used surfactants were helpful with certain oils,
but ineffective with others, the maximum reduction being about 30%. Common additives such
as CMC and lignosulfonate had no effect on the sticking coefficient. Bentonite solids resulted in
the lowest coefficients for any solids. Of perhaps more significance was the behavior of the
sticking coefficient with time. The sticking coefficient increased by a factor of four in 20 minutes
and by a factor of six in 2 hours. The significance is that efforts to pull the pipe free are more
likely to be successful early.
Efforts to free the pipe must be within the concept of the aforementioned equation. The first
effort should be to pull to the rated capacity of the weakest link of the hoisting system thereby
taking advantage of the low values of the sticking coefficient. The often used practice of pulling
only some small amount over the string weight should be abandoned in this instance.
Depending upon depth, it may be possible to apply more weight to the stuck point while
applying torque. Do not apply torque and pull to the maximum tensile load of the pipe. If the
pipe remains stuck after the initial effort to pull free, it is pointless to continue to work the pipe or
otherwise "rodeo" the rig. In fact, other remedial efforts should be commenced as soon as
possible. Otherwise, hole conditions might deteriorate.
The most common method of freeing differentially stuck pipe has been to spot oil. This
technique reduces the sticking coefficient and also thins the filter cake thereby reducing the
contact area. In some areas it may be environmentally unacceptable to spot oil and
environmentally acceptable products may be used. The technique is generally successful within
6 hours. If no success is experienced within 24 hours, an alternate is usually considered.
Working on the "ΔP" component of the sticking force has become more popular in recent years.
The availability of nitrogen within the continental United States has made pumping nitrogen
bubbles very popular as well as successful. In some areas the hydrostatic is lowered by merely
pumping a lighter fluid into either the drill pipe or the annulus. The well is then permitted to back
flow reducing the effective hydrostatic and "ΔP". Lowering the mud weight or spotting a pill of
lighter mud has been effective in reducing the hydrostatic enough to free the pipe. In the past,
drill stem test packers have been successfully used to free pipe. Any effort affecting the "ΔP"
component should be done with caution as some famous blowouts have resulted from these
circumstances.
Spiral drill collars reduce the contact area; however, they are not always successful in
eliminating differential pressure sticking. Shorter drill collar strings and more heavy weight drill
pipe have reduced the problem. Fewer native solids and more fresh bentonite have reduced
instances of stuck pipe. Oil muds reduce, but
do not always eliminate differential sticking.
KEY SEATING
Keyseating occurs when the combination of
dogleg severity and string tension causes the
pipe to drill into the side of the hole. As
illustrated in Figure 3-6, the rotation of the drill
pipe causes the pipe to drill into the side of the
hole producing the illustrated hole condition.
Depending on geometry, it is clear that the drill
pipe can pass thru the key seating interval;
however, the drill collars are too large to enter
the smaller hole and may become lodged.
Note that the tool joints of the drill pipe actually
cut the keyseat. If the collars are larger than
the drill pipe tool joints, they can become
lodged in the keyseat.
In the higher portion of the hole where keyseats most often occur, rig loads are minimal and trip
speeds are at their highest. Therefore, the sudden encounter of a keyseat can cause the string
to become stuck in the keyseat. The most common solution is to drive the string down using the
full weight of the pipe or surface drivers (at depths of generally less than 4,000 feet or 1,220 m).
Failing these efforts, the pipe is backed off and fishing jars run to drive the stuck pipe down out
of the keyseat. Extreme caution should be used in backing off keyseated pipe. If the back off
point is in the keyseated interval, it is often impossible to screw into or otherwise get over the
top of the fish. A careful study of an offset caliper log should be made and an interval of gauge
hole chosen for the back off. Failing all else, wash pipe will free the fish provided the fish can
be located. If wash pipe is to be used, it is not uncommon to back off inside the casing string
and use the free pipe as a guide for the wash pipe. In instances where the top of the fish
cannot be located, an attempt to merely drill past the fish is often successful. In many
instances, the fish is successfully passed and the hole entered below the fish. The fear that the
fish will later fall in and stick the string or otherwise cause problems, is unsupported by
experience.
BOULDERS
"Boulders" are the presence of pieces of formation too large to be removed by the carrying
capacity of the mud. Boulders are caused by extraordinary feature and stress patterns within
the formations or the presence of glacial till. This author has witnessed two extraordinary
instances of the presence of boulders. One occurred in the Cody shale in the Bighorn Basin of
north central Wyoming. An overshot was run to retrieve 6" (152.4 mm) collars inside a 7⅞"
(200.0 mm) hole. After several unsuccessful attempts to get over the fish, the overshot was
pulled. Lodged inside the overshot was a piece of Cody shale approximately 6½” (165 mm) in
diameter. The other instance occurred in central Colorado. A reverse circulating junk basket
recovered three large pieces of limestone with the largest measuring approximately 6 by 8
inches (152 mm by 203 mm).
1. Severe torque while drilling. Sometimes the table is stopped and the string stuck.
3. No difficulty in circulating.
5. The tight spot is not in the same place, but rather moves around.
Boulder problems seldom result in fishing jobs. The problems almost always end after the
troublesome formation has been penetrated and the stresses are relieved. Therefore, in many
instances, time and a gentle hand on the brake are the only solutions. Most often a good driller
can gently work by the boulders without getting stuck. Viscous sweeps can be successful,
provided the boulders are not too large. In one operation, viscous sweeps were pumped every
time the erratic behavior of the torque gauge indicated the accumulation of boulders. The
boulders would pass over the shale shaker and the symptoms would disappear for 8-10 hours.
In the event the pipe does become stuck and cannot be freed, caution should be observed in
backing off the collars to insure that the fish can be screwed into. It is usually a simple matter to
jar the fish loose.
SALT
Salt is most often a problem after the well has been completed. The salt will begin to flow and
subject the casing to geostatic overburden pressures of 1 psi/ft. Sodium chloride is not the
culprit. It is rather the mixed salts that cause the problems. When the salts are present in long
intervals, the problems are inevitable.
The solution is simple, but any deviation can be catastrophic. The salts should be drilled with
saturated brine to prevent hole enlargement. The casing in the salt interval should be designed
to withstand at least 1 psi/ft (23 kPa/m) in collapse. Finally, the salt interval should be cemented
with salt saturated cement. There are few reported instances of failure when this procedure is
followed. However, there are still a few reported instances of failure.
Salt creeping into the wellbore can be a problem while drilling. In some cases, the salt will
restrict the diameter of the hole making it difficult to pull the bottomhole assembly or causing the
well to become tight while drilling. The easiest way to alleviate this problem is to pump fresh
water and spot it across the salt water zone. The fresh water will dissolve some of the salt and
enlarge the hole.
SLOUGHING SHALE
Troublesome shales are perhaps the most universal problem in all of drilling. The biggest
problem is that operators tend to over react to the slightest problem and to respond with the
typical oil field philosophy that money will solve any problem. The common denominator to all
shale problems is the presence of a liquid. Other contributing factors to problematic shales are:
2. Abnormal pressures.
3. Tectonic stresses.
It is generally true that shales cause problems because they get "wet." However, it must be
understood that API Water Loss is not related to shale stability! In more than 60 years of drilling
experience, the industry has not produced any evidence linking shale stability to API Fluid Loss.
There is not one major oil company research facility or one major mud company that even
suggests that a relationship exists between the API Fluid Loss and Shale Stability.
The Gumbo shales common to geologically young environments in coastal areas around the
world are an excellent example of water sensitive shales. Gumbo is merely young shale
containing high percentages of sodium montmorillinite commonly known as bentonite or gel.
The name describes the physical state of the clay when the affinity for water is not completely
satisfied. The State of Wyoming is a source of bentonite. This author has experienced such an
accumulation of bentonite after a rain on auto tires that the tires would no longer turn. The
same thing happens in the hole while drilling. If the affinity of the clay for water is unsatisfied,
the clay will accumulate or "gum up" on the drilling assembly hence, the name "Gumbo."
Sometimes strong dispersants such as SAPP are used. However, the most common solution is
an abundance of water in order to satisfy the clay's affinity for water. Gumbo shales are more
problematic when weighted muds are required because the shales contribute to viscosity. The
decanting centrifuge is very cost effective under such circumstances. Some operators use
highly dispersed lignosulfonate muds while others prefer potassium inhibited polymer muds. In
some instances, oil muds are used. Under some circumstances, the highly dispersed fresh
water mud combined with good solids control offers the most economical solution.
In the truly water sensitive environment, cost must be the final measure of success. The
inhibited systems have experienced limited success in controlling hole size while an inverted oil
mud may be even more successful in controlling hole size. However, all costs considered the
water system usually is more economical.
PRESSURED SHALES
The term "pressured shale" has been overworked in
recent years. Certainly, pressured shales do exist and are
almost always accompanied by abnormally pressured
production. Since the shales are the source beds for the
hydrocarbon accumulation, it is basically geologically
impossible to encounter abnormally pressured shales on
either side of a normally pressured hydrocarbon reservoir
unless the reservoir has been depleted.
TECTONIC STRESSES
Tectonic stresses are the forces associated with the
movement of the earth's crust. These stresses are the
Figure 3-9. Elliptical Hole Due to Stress most common contributor to hole instability in shale
Related Sloughing
sloughing. Most often these shales are located in or around mountains or mountain fronts. Or
they are associated with complex subsurface geology. They are generally geologically older
and almost never water sensitive. Some shales are in more subtle geologic environments.
However, when hundreds to thousands of feet (meters) of shale are present with intervals to
gauge and intervals enlarged, stress is the obvious culprit.
If the shale sloughs due to tectonic stresses, the hole will generally have an elliptical shape as
illustrated in Figure 3-9. The term is often called “wellbore breakout.” Sloughing is related to
the large differences between the minimum and maximum horizontal stress. When the stresses
are sufficiently different, breakout occurs perpendicular to the maximum stress. Fortunately,
sloughing will stop when the hole achieves a predetermined shape. If the formations are also
water sensitive, hole enlargement may not stop and hole cleaning becomes a problem.
Stress related sloughing can be reduced by increasing the mud weight. If the value of the
minimum and maximum horizontal stress is known, the mud weight required to prevent
sloughing can be calculated. The minimum stress can be calculated by inducing a hydraulic
fracture, but the maximum stress can not be measured directly. The maximum stress can be
interpreted from logs and from core testing. Increasing the mud weight will also slow down
penetration rate and increase mud costs.
The solution to the problem is simple and was pioneered by the operators of Western Canada in
the early 1950's -"Clean the Hole." The Canadians increased the carrying capacity by
flocculating the mud (which causes the API water-loss to be high) and cleaning the hole. Other
operators pump viscous sweeps at regular intervals while in the most serious cases, weighted
viscous sweeps are used. Remember! Clean the hole!
A good example is the Waltman shale of central Wyoming. The Waltman was diagnosed by a
major service company as being abnormally pressured and water sensitive. The mud density
was routinely increased to 14.9 ppg (1780 kg/m3) and API water loss was reduced to below 6
cc's/30 minutes. Trip time could be from a day to a week. The Waltman was successfully
drilled with a 9.0 ppg (1080 kg/m3) flocculated system with a 35 cc's fluid loss. The mud costs
were less than 10% of that for the weighted muds while penetration rates were so improved that
total cost for the interval excluding the savings in mud was 30% of the best previous effort.
Caliper logs indicated that the hole was essentially in gauge.
In summary, be very critical of shale problems. The worn out "Raise the weight and lower the
water loss" should be abandoned forever as should the routine use of KCl or oil systems. Study
the shale problem and attack the problem. Let science and technology conquer fear and
superstition!
NOMENCLATURE
o Sticking coefficient
f
Fs = Sticking force, kgf
Reference
1
Watson, B. and Smith, R.; “Training Reduces Stuck Pipe Costs and Incidents,” Oil and Gas
Journal, (19 September 1994) 44-47.
2
Hopkins, C.J. and Leicksenring, R.A.; “Reducing the Risk of Stuck Pipe in the Netherlands,”
paper SPE/IADC 29422 presented at the 1995 SPE/IADC Drilling Conference, Amsterdam, 28
February-2 March 1995.
3
Magaji, M.A., Amoo, O.A., and Owoeye, O.O.; “An Innovative Approach to Stuck Pipe
Reduction in the Niger Delta,” paper IADC/SPE 74523 presented at the IADC/SPE Drilling
Conference, Dallas, TX, 26-28 February 2002.
4
Bradley, W.B., Jarman, D., Auflick, R.A., Plott, R.S., Wood, R.D., Schofield, T.R., and Cocking,
D.; “Task Force Reduces Stuck-pipe Costs,” Oil and Gas Journal, (27 May 1991) 84-89.
5
Bradley, W.B., Jarman, D., Plott, R.S., Wood, R.D., Schofield, T.R., Auflick, R.A., and Cocking,
D.; “A Task Force Approach to Reducing Stuck Pipe Costs,” paper SPE 21999 presented at
the 1991 SPE/IADC Drilling Conference, Amsterdam, 11-14 March 1991.
6
Annis, M. R. and Monaghan, P. H.; "Differential Pressure Sticking-Laboratory Studies of
Friction Between Steel and Mud Filter Cake," SPE 151, May, 1962.