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Abstract
Horizontal wells are proven to be better producers because they can be extended for a long distance in the pay zone.
Engineers have the technical means to forecast the well productivity for a given horizontal length. However, experiences
have shown that the actual production rate is often significantly less than that of forecasted. There are a number of reasons
for the discrepancy of predicted to actual production rates in horizontal wells. However, it is a difficult task, if not
impossible, to identify the real reason why a horizontal well is not producing what was forecasted. Often, the source of
problem lies in the drilling of horizontal section such as permeability reduction in the pay zone due to mud invasion or snaky
well patterns created during drilling. Although drillers aim to drill a constant inclination hole once in the pay zone, the more
frequent outcome is a sinusoidal wellbore trajectory.
Logging while drilling (LWD) and real time measurement of resistivity at bit help drill in the pay zone by constant
monitoring of borehole trajectory and formation boundaries. Rotary steerable tools (RTS) allow spontaneous intervention to
drilling direction and inclination if run with LWD tools. Nevertheless, there are still many cases where LWD cannot be
deployed due to technical difficulties. One such case was noticed in the Middle East where LWD sensors were worn out
completely during 1 h run time due to extreme formation abrasiveness. In the absence of LWD and RTS, it becomes a
challenging task to drill a constant inclination borehole which will be addressed in this paper.
The two factors, which play an important role in wellbore tortuosity, are the inclination and side force at bit. A constant
inclination horizontal well can only be drilled if the bit face is maintained perpendicular to the longitudinal axis of bottom
hole assembly (BHA) while keeping the side force nil at the bit. This approach assumes that there exists no formation force
at bit. Hence, an appropriate BHA can be designed if bit side force and bit tilt are determined accurately.
Finite element method (FEM) used in this study determines the bit side force and bit tilt simultaneously. The FEM is
superior to existing analytical techniques because it can accommodate many more independent parameters which otherwise
cannot be taken into account. As a matter of fact, it is believed that oversimplification of actual physical phenomena with
unacceptable assumptions is the major source of error with existing BHA designs.
This paper presents an FEM technique in assessing the bit tilt and side forces and compares the results with the existing
techniques.
D 2004 Elsevier B.V. All rights reserved.
1. Introduction
0920-4105/$ - see front matter D 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.petrol.2003.12.005
122 F. Akgun / Journal of Petroleum Science and Engineering 42 (2004) 121–132
force is the controlling factor for hard formations 2. Estimation of the bit side force based on existing
(i.e., drilling rates 1 to 10 ft/h). For formations that analytical techniques
are soft to medium hard, the side force is not the
only component that will influence the inclination A set of equations has been derived and published
and direction of the bit; the bit tilt becomes influ- (Jiazhi, 1986; Adam et al., 1991; Agawani et al.,
ential as well. Because of the curvature of the BHA 1994) to determine the bit side force based on ‘‘three
near the bit, the bit is canted or tilted in some moment equation’’. These equations are derived
resultant direction and inclination, somewhat like depending on how many stabilizers are attached such
the bent housing and bent sub (Adam et al., 1991). as slick BHA, single-stabilizer BHA and two-stabi-
Side force becomes a controlling factor once again lizer BHA. In all three cases, the essence of this
for very soft formations (i.e., drilling rates in excess technique is to determine the point of contact be-
of 100 ft/h). tween the pipe and wall of the hole called ‘tangency
For a given BHA, the bit side force and tilt point’.
depends on a number of parameters. These param-
eters are hole, drill collar and stabilizer sizes, BHA Slick BHA
material properties, mud weight, stabilizer locations,
borehole inclination, direction, contact length and Slick BHA has no stabilizers attached to it. The
location between pipe and hole and, finally, weight tangency point in this case is the first point where pipe
on bit. Unfortunately, analytical techniques derived departs from the borehole wall above the bit. The bit
to estimate bit side force ignores some of these side force, FB, is determined from
parameters for the sake of simplicity. For example,
the analytical method developed based on ‘‘three
FB ¼ 0:5Wc LT Bc sin/
moment equation’’ ignores the effect of pipe to
wall contact as well as hole curvature (Timoshenko, ðWOB 0:5Wc Bc LT cos/ÞS 3
1936; Jiazhi, 1986). Other techniques have been þ ð1Þ
LT
developed to handle the wellbore curvature, vari-
able gauge holds and combination BHA compo-
LT in the equation is the first point tangency and is
nents, and situations in which pipe/wall contact
measured from the bit. It has to be estimated before
occurs between the bit and stabilizers, as well as
substituting in Eq. (1). LT is determined by trial and
the cases in which increases in weight on bit force
error as following.
the creation of additional points of contact (Walker,
1977; Milheim and Apostal, 1981; Agawani et al.,
1994, 1996).
Table 1
Finite element method (FEM) has a long history Slick BHA bit side forces
of being successfully used to model solid structure Analytical method FEM
deformations and stresses. It has been used exten-
WOB (lbf) LT (ft) FB (lbf) LT (ft) FB (lbf)
sively to model oil field tubulars for a number of
reasons such as to model casing deformations 0 52.32 151.8a 49.2 150.4
10,000 50.83 133.2 48.3 132.0
(Akgun et al., 1992) and to predict drill pipe 20,000 49.38 113.9 46.7 112.8
stability (Akgun et al., 1996). It is an ideal tool in 30,000 47.98 93.9 45.0 92.9
analyzing BHA as well. The FEM designed for this 40,000 46.63 73.1 44.2 72.4
study helps assess bit side forces without accepting 50,000 45.33 51.6 42.5 51.1
many dangerous assumptions as in the analytical 60,000 44.08 29.2 41.7 29.0
70,000 42.89 6.1 40.8 6.1
case. It helps estimate the bit tilt simultaneously 80,000 41.75 + 17.8 39.2 17.7
which cannot be done practically with existing
db = 8 3/4 in; ODDC = 7 in; IDDC = 2 3/16 in; MW = 9.2 lb/gal;
analytical techniques. Furthermore, it can easily be / = 3.2j.
used to study the effects of stabilizers on the side a
‘ ’ sign indicates dropping tendency, whereas ‘ + ’ sign
force and bit tilt (Akgun, 1999). indicates building tendency.
F. Akgun / Journal of Petroleum Science and Engineering 42 (2004) 121–132 123
db ds2
S 1 ¼ 0:5ðdb ds1 Þ ð15Þ S 2 ¼ 0:5 ð19Þ
12
S 3 ¼ 0:5ðdb d2 Þ ð16Þ db d2
S 3 ¼ 0:5 ð20Þ
12
qi ¼ Wc Bc sin/ ð24Þ
3. Limitations of estimating bit side force based on
rffiffiffiffiffiffiffi rffiffiffiffiffiffiffirffiffiffiffiffiffiffi ‘‘three moment equation’’
Li pci Li pci pci
3 tan
2 EIi 2 EIi EIi The bit side force calculations based on ‘‘three
Xi ¼ rffiffiffiffiffiffiffi3 ð25Þ
Li pci moment equations’’ for two stabilizers or less are
2 EIi relatively easy. However, this technique becomes te-
dious for BHAs installed with more stabilizers. More-
2 3 over, this technique is limited to straight hole
3 6 1 1 7 conditions and is not applicable for curved boreholes
Wi ¼ rffiffiffiffiffiffiffi 6 7
6 rffiffiffiffiffiffiffi rffiffiffiffiffiffiffi 7 ð26Þ such as dropping and building wells. If more contact
Li pci 4 pci pci 5
sin Li Li points develop due to increased WOB or borehole
2 EIi EIi EIi
conditions, again, this method will not be applicable.
2 3
Finally, the deflection of BHA to the side of borehole
cannot be determined practically with this method.
3 6 1 1 7 However, the bit tilt can only be determined depending
6 7
Vi ¼ rffiffiffiffiffiffiffi 6 rffiffiffiffiffiffiffi rffiffiffiffiffiffiffi 7 ð27Þ
pci 4 pci pci 5 on near-bit BHA deflection.
Li Li tan Li
EIi EIi EIi
The borehole is modeled with a special gap ele- to displace in global ‘z’ direction, as this model is
ment which is capable of supporting compression in only a two-dimensional one. It does not predict
the direction normal to the surface. The element is displacements in the azimuthal plane. The two
made up of three nodes. Two nodes will represent a nodes of each gap elements, which are located to
surface and cannot be penetrated by the third node. represent the borehole wall, are restricted to move
The two nodes of each gap element is placed, such from all directions to simulate rigid borehole con-
that it represents the wall of the hole, and the third ditions. The top element on the global ‘y’ direction
node is placed on the BHA (Fig. 1). The element may representing BHA is restricted from bending (rota-
be straight to model straight holes or circular to model tion along x-axis), as this portion of BHA will lie on
building and dropping holes. the low side of the hole and take the shape of hole.
Fig. 1 indicates global x, y and z directions. The This restriction is needed to prevent rigid body
node 1 represents the bit. Therefore, it is restricted motion.
to displace in global ‘y’ direction. It is also restrict- Stabilizers are modeled simply by restricting x
ed to displace in global ‘x’ direction to simulate direction displacement of nodes where stabilizers are
matching bit and hole size. All nodes are restricted considered.
Fig. 1. The finite element model and the nodal displacement constraints.
F. Akgun / Journal of Petroleum Science and Engineering 42 (2004) 121–132 127
Table 5
Single-stabilizer BHA in a 3.2j hole
Shade area indicates pipes are in contact with the wall of the hole at corresponding distance from bit.
128 F. Akgun / Journal of Petroleum Science and Engineering 42 (2004) 121–132
similar results. However, a somewhat significant de- – In the absence of LWD and RTS tools, borehole
viation has been noticed for two-stabilizer BHA at inclination can be held constant by keeping bit
60,000 lbf weight on bit. There is a deviation simply side force nil (in the case of no formation force)
because, at 60,000 lbf weight on bit, there is an while keeping the bit face (tilt) perpendicular to
additional pipe-hole contact below the first stabilizer the BHA longitudinal axis (in the case of no
(Fig. 3), and Jiazhi’s (1986) technique does not BHA sag).
consider such a case. – Available analytical method of Jiazhi predicts the
At hole inclinations near 90j, it was noticed that bit side force for a number of drilling parameters
the bit side force does not change much with changing for an inclined and straight wellbore but is short of
weight on bit. For this particular case, both methods delivering BHA alignment and bit tilt which are
give similar values of tangency length and the bit side considered to be major players in determining well
force (Table 1). inclination.
Tables 1 and 5, and Figs. 2 and 3 present the – The proposed FEM technique can be used to
deflection of the BHA axis from the centerline of estimate the bit side force as well as bit tilt not only
borehole for slick, single- and two-stabilizer assem- for straight wellbores but also for inclined and
blies. For example, Table 1 illustrates the deflection curved boreholes for different weight on bit, hole
vs. ‘distance from the bit’ for a slick BHA in a and BHA combinations.
horizontal well at zero weight on bit. Fig. 2 illus- – By estimating bit tilt and bit side force accurately,
trates the deflection vs. distance for a slick BHA in a practicing engineers can design better stabilizer
3.2j inclination hole and at zero and 80,000 lbf. As locations and select more appropriate BHA –WOB
expected, near-bit inclination of BHA axis increases combinations to minimize wellbore tortuosity.‘
with increasing WOB. Table 5 presents the deflec-
tions of BHA axis for a single-stabilizer BHA in a
10j hole inclination and at varying WOBs. As Nomenclature
expected, there is a changing BHA inclination and Bc Buoyancy factor
increasing bit tilt with increasing WOB. Fig. 3 db Bit diameter
illustrates the change in a two-stabilizer BHA axis d2 Drill collar diameter
at five different WOBs in a hole with 10j inclina- ds1 1st stabilizer diameter
tion. For this particular case, it was noticed that there ds2 2nd stabilizer diameter
is an additional hole-pipe contact between the bit and E Young’s modulus
the first stabilizer. FB Bit side force
Finally, no pipe stability problem was noticed for G Shear modulus
WOB values at and below 80,000 lbf. However, it Ii Axial moment of inertia (i = 1, 2 and 3)
can be expected to see pipe instability for higher J Polar moment of inertia of drill collars
values of WOB. In such a case, the critical buckling LT Tangency length (ft)
load of BHA can be determined with this technique L1 Distance between the bit and first stabilizer
depending on the stabilizers location (Walker, L2 Distance between the 1st and the 2nd
1977). stabilizer
S1 Hole clearance around 1st stabilizer
S2 Hole clearance around 2nd stabilizer
6. Conclusions S3 Hole clearance around drill collars
pci Compressive load on the collars (i = 1, 2
– Drilling of a constant inclination path in a and 3)
horizontal well becomes a difficult task if rotary m Bending moment
steerable tools (RTS) cannot be employed with Wc Unit weight of drill collars
logging while drilling (LWD) due to severe Wc1 Unit weight of 1st stabilizer
formation abrasiveness where LWD tools wear WOB Weight on bit
out rapidly. u Hole inclination at bit
130 F. Akgun / Journal of Petroleum Science and Engineering 42 (2004) 121–132
The stress – strain relationship can be written as The shear moduli Gxy , Gyz and Gxz are as follows:
frg ¼ ½D feel g ðA 1Þ Ex E
Gxy ¼ ðA 10Þ
Ex þ Ey þ 2txy Ex
where{r}: stress vector;[D]: elasticity matrix;{eel}:
total strain vector; Gyz ¼ Gxy ðA 11Þ
where ex: direct strain in the x direction; ey: direct where Aw: pipe wall cross-sectional area = p/4(D02
strain in the y direction; ez: direct strain in the z D i2); E: Young’s modulus; L: element length; G: shear
direction; Eq. (A-1) may be inverted into modulus; J: polar moment of inertia = p/32(D04 Di4).