SPE-195062-MS

A Robust Correlation Improves Well Drilling Performance

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Mohammed Murif Al Rubaii, Abdullah Al Yami, and Eno Omini, Saudi Aramco

Copyright 2019, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Middle East Oil and Gas Show and Conference held in Manama, Bahrain, 18-21 March 2019.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Utilization of drilled wells operations’ records is required to perform improvement of performance to
minimize drilling cost of planned drilling of new and re-entry wells (workover – wells). Many operators
are always interested in finding optimum ways to save on drilling cost. Optimization of Rate of Penetration
(ROP) has direct effects on cost reduction. Different Techniques were used to optimize ROP such
as regression technique, multiple linear regression technique, neural network, artificial neural network
methods, and basic reference of Bayesian networks. There are several factors that will limit application of
ROP optimization models in different hole sections with high degree of accuracy. It is the authors’ opinion
that modeling on smaller selected section with controlled parameters will give better optimization and
validation. In this paper an empirical correlation of rate of penetration (ROP) is presented for a particular
hole section. The data selected are from same hole size, formation type and mud type. It is based on
monitoring and controlling simultaneously the applied weight on bit (WOB), drill-string's rotation (RPM),
Torque (TRQ) and rig pump's flow rate (GPM). During this study will demonstrate the use of this empirical
correlation to improve drilling in a hole section by more than 50%. The developed model also has high
potential to be automated in real time operating environment to improve drilling performance.

Introduction
To drill a certain well, there are important factors to be considered together, such as load on bit, rotation
of bit and continuous circulation of drilling fluid within the wellbore. The improvement of ROP has a
major impact on cost effectiveness and minimizing problems of drilled hole section. The controllable
factor of rate of penetration such as (bit wear, bit design, WOB, RPM rig pump's rate, bit-HHP, motor/
turbine geometry and configuration of bit nozzles, sizes and numbers), while the environmental factors
of drilling rate or rate of penetration such as (lithology of drilled hole section and their properties type
of drilling fluid, density of drilling fluid, overbalance/ bottom hole hydrostatic pressure and diameter of
the drill-bit). Techniques that are used to optimize ROP such as multiple regression technique, multiple
linear regression technique, a moving-horizon multiple regression method, development of mathematical
ROP models, numerical solution, comparative drilling optimization method, neural network, artificial
neural network methods, neuro-fuzzy inference systems, a Bayesian inference approach, basic reference of
Bayesian networks, Bayesian decision networks and other artificial intelligent methodologies.
2 SPE-195062-MS

Graham and Muench (1959) tested and evaluated collected drilling data to find proper WOB and
RPM that can ensure cost's reduction. The proposed a mathematical expression of rate of penetration and
expected life of used bit. Maurer (1962) developed ROP of roller-cone bits. He evaluated a mount of
cutters and strength of drilled rock, it assumed that perfect cleaning condition that means, all generated
cutting transported and underneath bit. Maurer's ROP model is a function of WOB, RPM, bit size and
compressive strength of drilled rock. Galle and Woods (1963) studied the influence of WOB, RPM, bit's
dull grading and shape of cutters on rate of penetration. In addition, they evaluated bit wear and life of bit's
bearing. Bingham (1965) suggested or developed a model of drilling rate from laboratory data. Drilling

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rate model is a function WOB and RPM. The exponent factor of WOB can be found experimentally under
certain conditions. Bourgoyne and Youngs (1973 and 1974) did a statistical analysis to explain well drilling
performance enhancement or how to ensure proper or optimized drilling rate. They found relationship
between rate of penetration and common applied overbalance pressure while drilling.
Reza and Alcocer (1986) developed a model of drilling rate or rate of penetration (ROP) by considering
bit's wear and bearings’ wear. They evaluated ROP, wear of bit and bearings influences with drilling
parameters such as (WOB & RPM), size of bit and bearings, mud weight and viscosity, GPM, hydrostatic
and formation pressures, compressive strength, temperature and factor of transfer of heat. The developed
drilling model is a form of non-linear, multivariable equation. Osgouei (2007) developed ROP model by
including mechanical parameters of drilling. He changed PDC and roller-cone cutters of bit. That change of
cutters configuration highly contributed to get optimized drilling rate or proper well drilling performance
in directional wells. The change of inclination with drilling parameters influences was closely evaluated
and monitored. Paiaman et al. (2009) studied influences of drilling fluid weight, plastic viscosity and solid
contents of drilling fluids with ROP.

Correlation of Rate of Penetration and Methodology

The aim of the improvement of accelerating rate of penetration (ROP) by enhancing the drilling parameters
(RPM and WOB). After that, the drilling parameters must be increased by selecting values of drilling
parameters randomly of highest ROP in the field to increase the rate of penetration. The estimated cuttings
volumes in annulus were calculated while drilling with the current rate of penetration. There was noticed
that the generated cuttings volumes is low and below the optimum limit of cuttings volume that means
the holes section was cleaned properly and the hole cleaning efficiency was proper. That means there is
room for optimization of the rate of penetration due to the calculated cuttings volume. The decision was
made to tell the rig's supervisor to increase the rate of penetration until the calculated cuttings volume
was being 4.5%. It is well known that the safest and most opportunity of ability to transport the generated
cuttings volume while drilling is below 5%. Three values of WOB & RPM were selected of the highest
ROP in the field. This is a trial and error method to reach the best WOB & RPM values that will attain
improved ROP that can be achieved without causing any hole problems. The correlation was implemented
in Real Time Operation Center (RTOC) as ROP analyzer that can eventually advise and increase the drilling
rate optimally. One offset well was correlated and analyzed to generate the developed ROP correlation
by generally using valuable statistical parameters. Then the correlation was entered in measurements of
RTOC to estimate the ROP that was higher than the current or measured ROP 50 %, which can give a clear
indication that there is an extra room to maximize the drilling rate. The correlation was implemented on the
same field, formation lithology, mud system and well trajectory. The required data to run the correlation:
WOB, GPM, RPM and torque.
The optimization values for the data application on trial well and the data application on offset well
can be taken simultaneously from measured readings, but the WOB and RPM must be complemented with
selected values of the highest ROP in that certain filed. To find new model of rate of penetration, it very
important to obtain strong relationship amongst the input parameters and the objective output parameters
SPE-195062-MS 3

of main function. It can express the relationship of correlation between the input and output parameters.
Therefore, some methods were used to attain this objective. Some statistical terminologies have been defined
to recognize their importance. Nonlinear regression relationship was applied for developing drilling rate's
correlation. Optimizing of parameters of drilling in order to achieve high levels of ROP is imperative and is
objective for performing research work. The established correlation is used for selecting optimum Drilling
parameters. This correlation contains the drilling parameters that will be boosted (WOB, RPM, GPM and
torque). The optimization was attained by selecting optimum WOB & RPM that can ensure the value of
cuttings concentration in Annulus reach to maximum value of cuttings volume in Annulus (CV) while

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drilling which is 5 %. The CV equation also leads to enhance the ROP by selecting better drilling parameters
(WOB, RPM, Torque, and GPM of bit). Because of that, it is essential to develop a correlation to correlate
the ROP with the drilling parameters. The ROP is a function of several drilling parameters some of which
are manageable by the drilling engineers (controllable), while others are a fact that must be accepted and
dealt with (uncontrollable). In this research only controllable parameters will be treated to develop the
ROP correlation. ROP is a function of WOB, RPM, Torque and flow rate (Q). ROP model also can be
characterized as ROP = f1 + f2 + f3 + f4.
Where the functions f1, f2, f3, f4, for typical and complete set of data, are
(1)

(2)

(3)

(4)
(5)
The coefficients C3, C6, C9 and C12 of the equations can be lumped into one coefficient, C9. The
coefficients (C1, C2, C3, C4, C5, C6, C7 and C8) were estimated using non-linear regression. In order
to estimate the coefficients C1 to C8, nonlinear regression Matlab codes were developed. The followed
methodology that were used to generated or develop the empirical correlation of drilling rate as follows:

Methodology
QA/QC of the Data

• Remove Null values

• Remove Negative values

• Remove outliers

• Check with physical trend

• CConsidered different formations and their ROP trend for removing the outliers.

Analyze the data

• Calculate statistical parameters

• Calculate correlation coefficient of each parameter with ROP

• Apply nonlinear regression to generate coefficients for the ROP correlation for selected wells.
4 SPE-195062-MS

• Calculate R-squared, Root mean square error and average absolute percentage error to estimate
the fitness of curve.
• Plot Cross plot of ROP Calculated VS actual ROP from the data.

• Plot ROP Calculated VS actual ROP as a function of depth.

The results of the ROP correlation developed shows good agreement between the actual and the calculated
ROP. Results that were obtained form correlation of rate of penetration of offset well and trial well of

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optimized rate of penetration have shown good estimation of the ROP with absolute error less than 11%.
The graphs of ROP Calculated VS actual ROP from data and ROP Calculated VS actual ROP as a function
of depth of offset and trial well can be seen in figures-1, 2, 3 and 4.

Figure 1—Measured ROP vs Calculated ROP-Cross Plot for Offset Well

Figure 2—Calculated ROP vs actual ROP as function of depth of Offset Well.

SPE-195062-MS 5

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Figure 3—Measured ROP vs Calculated ROP-Cross Plot for Trial well

Figure 4—Calculated ROP vs actual ROP as function of depth of Trial Well.

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Results of ROP Correlation in Well – A

Offset well

Table 1—Drilling Parameters Statistics for Offset Well

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Table 2—Correlation Coefficient for the drilling parameters for offset well

Results of ROP Correlation in Well – B

TRIAL WELL

Table 3—Drilling Parameters Statistics for Trial Well

SPE-195062-MS 7

Table 4—Correlation Coefficient for the drilling parameters for offset well

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After making deployment with Real time Operating center (RTOC) and including CV of values 4% to 5%
to estimate the calculated ROP as shown in the figure- 5, The final comparative results between two drilling
rate is shown in figure-6.

Figure 5—Deployment of Correlation of ROP in real time operating Center.

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Figure 6—ROP of Offset Well VS ROP of Trial Well.

Therefore, the main advantage of the developed correlation was as ROP advisory system or as ROP
analyzer than can guide and increase the drilling rate to the proposed and optimized ROP as shown in
the figure-7. This is real application of the developed correlation of the drilling rate, which can endorse
that, the calculated ROP was with considering the part of optimization that lead to more than 50% of ROP
improvement, see table-5, which shows that the comparison between the drilling rates of offset well and
trial well were based on using same hole section profile (Vertical hole section), rotary drilling system, bit
type (PDC) with same features such as cutters, jet nozzles sizes and dull grading (new), mud system that
was water based mud (Nacl), drilled footage and same bottom hole assembly (BHA) configuration.

Figure 7—Deployment of ROP Analyzer of Correlation of ROP in real time operating Center.
SPE-195062-MS 9

Table 5—ROP improvement after Deployment.

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Conclusions & Recommendations
• The new ROP correlation with respect of drilling parameters is more realistic than other
correlations. Because the other correlations that have parameters of mud rheology that are
qualitative relationships only.
• If total losses are being encountered, the influence of parameters of mud rheology on hole cleaning
will disappear, however, if the drilling parameters have been applied and are controlled optimally,
the ROP performance can be achieved.
• The new ROP correlation can estimate ROP as a function of mechanical drilling parameters such
as WOB, RPM, GPM and torque with a reasonable accuracy.
• Applying the model in RTOC (Real Time operating Center) so that all monitored wells will ensure
the recommended and improved performance.
• The optimized drilling parameters can be determined by this new ROP correlation easily.

• The eventual aims of optimization are (1) reducing drilling time and (2) saving money. Decreasing
drilling time can be attained by maximizing the ROP through drilling with the best parameters.
The combined methods results display that the best parameters are within the boundaries of the
examine domain. The result showed significantly improved performance.

References
1. Graham, J. W., and N. L. Muench. "Analytical determination of optimum bit weight and rotary
speed combinations." Fall Meeting of the Society of Petroleum Engineers of AIME. Society of
Petroleum Engineers, 1959.
2. Galle, E.M. and Woods, H.B.: "Variable Weight and Rotary Speed for Lowest Drilling Cost",
paper presented at 20th Annual Meeting of AAODC, New Orleans, LA, September 25-27, 1960.
3. Galle, E.M. and Woods, H.B.: "Best Constant Weight and Rotary Speed for Rotary Rock Bits",
API Drilling and Production Practice, 1963.
4. Bingham, Grant. "A new approach to interpreting rock drillability." TECHNICAL Manual
Reprint, Oil And Gas Journal, 1965. 93 P. (1965).
5. Bourgoyne, A.T., Jr. and Young, F.S., Jr.: "A Multiple Regression Approach to Optimal Drilling
and Abnormal Pressure Detectiony', SPE 4238, SPE-AIME Sixth Conference on Drilling and
Rock Mechanics, Austin, TX, January 1973.
6. Reza, M.R and Alcocer, C.F.: "A Unique Computer Simulation Model Well Drilling: Part I - The
Reza Drilling Model", SPE 15108, 56" California Meeting of the Society of Petroleum Engineers,
Oakkand, CA, April 2-4, 1986.
10 SPE-195062-MS

7. Osgouei, Reza Ettehadi, and M. E. Özbayoğlu. "Rate of Penetration Estimation Model for
Directional and Horizontal Wells." 16 th International Petroleum and Natural Gas Congress and
Exhibition of Turkey. 2007.
8. Clark, R.K. and Bickham, K.L. 1994. A Mechanistic Model for Cuttings Transport. Presented
at the SPE Annual Technical Conference and Exhibition, New Orleans, 25-28 September.
SPE-28306-MS. http://dx.doi.org/10.2118/28306-MS

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