DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

PWD Analysis in Deepwater Environments: Campos Basin Case Studies

Authors tila Fernando Lima Arago Gleber Tacio Teixeira Andr Leibsohn Martins Roni Abensur Gandelman Rodrigo Azevedo Silva PETROBRAS S.A.
Av. Hum Quadra 07, Ilha do Fundo, Rio de Janeiro, RJ, Brazil, Zip: 21494-900

1. Abstract The anticipation and remediation of potential hole problems is an ultimate goal of most real time measurement devices installed on drilling rigs. Among the several sensors available, PWD (pressure while drilling) measurements gained popularity due to its potential for problem diagnosis. The complete understanding of the physical phenomena governing downhole pressure is, however, far from being spread among the drilling teams at the rigsite. This article proposes to establish, in a comprehensive way, basic guidelines for PWD interpretation at deepwater environments. Focus concentrate on the most frequent problems detected on drilling operations, such as: hole cleaning and fluid gelation. Based on representative field cases collected from Campos basin operations, offshore Brazil, it was possible to carry on a sensibility analysis of each of this issues at different phases of the well.

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2. Introduction Campos Basin concentrates several fields which constitute the major area of petroleum production in Brazil. The present exploratory scenario leads to ultra deep water environments and complex well trajectories. This scenario presents challenges to be overcome: narrow operational window between pore pressure and frac pressure due to low sediment coverage and low competency formations. Figures 1 and 2 illustrate typical operational windows for shallow and ultra deepwater wells, respectively. Besides, the development of heavy oil fields requires drilling long horizontal section and/or large diameter wells where annular friction losses play an important role.

ECD Gradient (ppg)

8 2100 2200 9 10 11 12 13 14 15 16

Well Depth (m)

2300 2400 2500 2600 2700 2800

Pore pressure Fracture pressure

Figure 1 Typical operational window for shallow water well

ECD Gradient (ppg)

8 2100 2200
Pore pressure Fracture pressure

10

11

12

13

14

15

16

Well Depth (m)

2300 2400 2500 2600 2700 2800

Figure 2 Narrow operational window for an ultradeepwater well

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

In such situations, it is very important to spend all the efforts to guarantee that annular pressures will be inside the operational window during the whole operation. Real time measurement of downhole annular pressures is achieved by the use of PWD tools connected in the BHA section of the drillstring. Additionally, annular temperature and internal pressure data can also be available. PWD data show the ECD (Equivalent Circulation Density) while the pump is on and the ESD (Equivalent Static Density) measurement when the fluid circulation is interrupted. The ECD value is expected to increase gradually with the increase of well depth. However, abrupt increases or pressure peaks can indicate potential operational problems. Among its several applications, the PWD tool, if its data are properly interpreted, may play a capital role in problem detection and prevention. Figure 3 shows a typical plot for the ECD evolution with the increase of well depth. The smooth shape on the curve and its equivalence to hydraulic model predictions suggest that no anomalies are occurring. The colored dots represent minimum, average and maximum pressure during a connection (where circulation and, consequently, data transmission is interrupted) reflect the ESD of the mixture which fills the wellbore annulus. Differences between the average value and the measured fluid density may denote fluid compressibility, temperature effects and solids loading. Mallary et al1 detail field interpretation of PWD data.

Figure 3 Typical ECD profile

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

3. Objective The goal of the present work is to develop a methodology to properly interpret the PWD data and to prevent problems during drilling. This article intends to be a pilot for a longer ongoing project which aims the definition of quantitative relations between annular pressure measurements and operational parameters. Some typical problems, collected from Brazilian offshore fields, will be presented and their PWD data will be analyzed. The abnormal ECD values will be confronted with other operation parameter fluctuations (such as of ROP, drillstring rotation and flow rate) in order to identify their possible causes. The events presented will be gathered by their nature and analyzed. 4. Case studies Three types of events are covered in this article: hole cleaning while drilling, pack offs during connections and fluid gelation when the pump stops . 4.1. Impact of drill string rotation on ECD Several aspects affect hole cleaning in offshore wells, such as: inclination, ROP, drill pipe rotation, fluid properties, water depth, etc. Critical hole cleaning issues occur in high angle wells where there is a tendency of solids accumulation in the lower part of the annulus, forming a cuttings bed, as illustrated by figure 4.

Figure 4 cuttings bed formation in high angle wells.

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

In these cases, rotary drilling helps bed ressuspension due to hydraulic and mechanic aspects: both the tangential component of fluid velocity (Loureiro et al 2) and the orbital motion of the drill sting will play relevant effects on the lifting of deposited particles. Sliding, on the other hand, will tend to coexist with a cuttings bed. The impact of the existence of a cuttings bed on downhole pressure may differ from well to well. Different mechanisms are involved: The solids bed represents a restriction in the annular space, which will result in the increase of annular friction losses. Normally, for conventional well geometries, the annular space is wide enough not to feel such effects. In slim hole drilling and long horizontal section wells this aspect may govern the process. Ressuspended solids will incorporate the fluid-solid mixture and, consequently, transmit hydrostatics and increase downhole pressure. For situations where hole cleaning is poor, or a severe cuttings bed is formed, the start of drill string rotation will immediately increase downhole ECD. Figures 6 and 7 illustrate different impacts of cuttings bed formation and the associated directional drilling mode (sliding/rotating) on ECD. Both situations were collected while drilling a same well, here called well A. Figure 5 describes well path and casing design while table 1 summarizes important well data.

Figure 5 Well A path

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

Table 1 Important well A data Mud Density (ppg) 9.4 Flow rate (GPM) 780 OD (in) Riser Last casing shoe Open hole 20.5 12.615 12.25 Rheolog. Param (Power Law) n 0.40 ID (in) 19.5 13.375 12.25 k (Pa.sn) 1.79 Measured Depth (m) 600 1100 2252.3

Figure 6 clearly illustrates the impact of drill string rotation on the ECD increase. When the rotation is interrupted, ECD reduces again. The abrupt increase of ECD due to solids ressuspension may be critical if frac gradient is reached. Figure 7, on the other hand, shows a minor impact of drilling mode on ECD.

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Figure 6 Impact of cuttings bed ressuspension on ECD

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Figure 7 Minor impact of cuttings bed ressuspension on ECD

The main reason for the different impact of drillpipe rotation on ECD in the situations represented in Figures 6 and 7 is the different hole cleaning conditions. In figure 6, the section was drilled with a higher ROP (21 m/h) than in the section shown in figure 7 (5 m/h). In the first situation there was probably a cuttings bed deposited when the start of drill pipe rotation introduced a large amount of solids in the flow mixture, immediately impacting the hydrostatic term of pressure. On figure 7 due to the low ROP, the solids concentration in the annulus should be much smaller with a small or no cuttings bed deposition. In this case drill pipe rotation had a minor impact on ECD. Table 2 highlights major hole cleaning monitoring variables for both cases, calculated by the hydraulics model proposed by Martins et al3,4. The increase of ECD when rotating drilling starts is normally a sign of inefficient hole cleaning for large diameter wells (12 and greater). Maximizing rotating time, cleaning sweeps and ROP control are possible strategies to avoid near future problems.

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

Table 2 bed heights for both cases

4.2. Pack-off during backreaming operations Backreaming before connections are common practices to reduce the amount of solids deposited in high angle wells. Such trips occur with fluid circulation and drillpipe rotation. Depending on the amount of solids present in the well and on the tripping speed, annular flow restriction may occur. As a consequence, pressure peaks may occur and frequently, frac pressure can be reached. The next figures illustrate several pack-off examples collected from well B. Table 3 summarizes important well data.
Table 3 Important well B data Mud Density (ppg) 9.8 Flow rate (GPM) 800 OD (in) Riser Last casing shoe Open hole 20.5 12.615 12.25 Rheolog. Param (Power Law) n 0.42 ID (in) 19.5 13.375 12.25 k (Pa.sn) 2.17 Measured Depth (m) 1100 1640 2591

During the drilling of the 12 in build up section, systematic ECD peaks were observed during a back reaming trip. The peaks are different in intensity and occur at different operational conditions (trip speeds, previous ROP and inclination). Figure 8 shows an example of two observed peaks. Evident peaks while tripping are noticed at 12:00 and 15:00 hs.

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

Figure 8 example of ECD peaks caused by backreaming trips

The backreaming operations started from different initial conditions and resulted in different peak intensities. The first peak shows a 0.3 ppg step and follows a previous drilling period with average ROP 16.4 m/h. 27.7% of the section was drilled in sliding mode which tends to generate a cuttings bed, as highlighted in the hydraulic calculations detailed on Table 4. Tripping speed was 19.7 ft/min. The second peak presents a smaller intensity (0.1 ppg) and follows a smaller ROP (10.6 m/h) longer sliding period (38,2%) and a high tripping speed. Hydraulic simulation results are also shown on Table 4. These 3 parameters seem to be the driving forces of peak intensity as highlighted in the 20 cases occurred at the same well B compiled in Table 4. Other variables such as wellbore inclination will certainly play a role. High angle, ROP and sliding times contribute to solids accumulation. High tripping speed adds swabbing terms to downhole pressure and may tend to obstruct the annular space if solids are present.

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

Table 4 representative cases of pack-off Well B.

Event A B C D E F G H I J K L M N O P Q R S T

ROP (ppg) (m/h) 0.3 16.4 0.1 10.6 0.1 9.0 0.18 8.6 1.8 14.4 0.12 15.9 0.23 14.5 0 12.5 0.32 16.1 0.2 8.6 0.14 8.8 0 10.5 0 10.3 0 6.3 0 4.8 0 3.8 0 6.0 0 5.2 0.73 8.7 0 5.6

Inclinatio n (degree) 42 42.7 43.8 45.9 50.4 51.4 54.4 57.7 60.8 65.9 68.2 70.7 72.4 74.5 76.2 78 79.2 79.1 79 79

ESD Trip speed (ft/min) 19.7 16.4 6.6 7.0 14.1 24.6 14.1 12.3 5.8 7.0 5.5 2.6 3.1 3.4 2.4 2.2 12.3 8.2 19.7 2.7 (ppg) 10.1 10.1 10.1 10.1 10.2 10.1 10.15 10.1 10.15 10.2 10.2 10.2 10.2 10.2 10.15 10.2 10.15 10.2 10.3 10.25

Mud Dens. (ppg) 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8

Sliding time percent. (%) 27.3 38.2 75.0 81.0 60.8 37.2 77.4 54.2 69.6 53.8 56.4 60.5 56.6 56.8 70.0 79.9 0.0 0.0 0.0 0.0

Predic. bed Height (%) 0 0 0 0 15 11 6 4 10 0 0 0 0 0 0 0 0 0 0 0

Results from table 4 show no direct correlation between inclination and peak intensity. The smaller peaks are observed at the higher inclinations. A comparison between events E and F highlights the impact of sliding time on peak intensity (). The sliding time previous to event E is much higher than the time previous to event F, resulting in a severe solids accumulation explaining the higher intensity peak. ROP is similar in both cases and tripping speed higher in event F. Events E and F are shown in figure 9.

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

Figure 9 comparison between E and F events.

Cases Q, S and T illustrate an interesting example of the effect of the tripping speed. In all cases ROP was controlled and sliding time previous to a connection was minimized. The low tripping velocities on cases Q, and T generated no peaks while the higher trip speed on case S was probably the responsible for the pressure peak observed. The cases are in sequence. Cases Q and S are illustrated in Figures 10 and 11. All the cases represent situations where the amount of solids in the well was smaller than in cases E and F previously discussed.

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DOT - Deep Offshore Technology XVII November 8 10th Vitria - Brazil

Figure 10 event Q

Figure 11 event S

Pressure peaks while tripping are clear signs of solids accumulation. Backreaming before connections are effective ways to resuspend a solids bed but, especially in cases where the solids accumulation is severe, tripping speeds should be monitored in order to avoid excessive peaks which can overcome frac

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pressures. It is important to notice that the resuspended cuttings may settle again if hydraulic conditions are not sufficient to keep them in the stream. 4.3. Resuming circulation after a pump stop Gelation phenomena occur when pump stops and are desirable aspects of a drilling fluid since it would help keeping drilled solids in suspension. Gelation tendencies are normally higher at low temperatures typical of deepwater risers. Severe gelation can, however, induce pressure peaks when the pump starts again. Such peaks may have detrimental effects when frac pressure is reached. Important parameters governing gelation are temperature, pumps off time, drillpipe rotation and start up flow rate. The smaller the pump off time, smaller will be the time available for heat exchange and to form a gelled structure. Once a gelled structure is formed, the energy required to break it and restart movement will be greater (Bjrkevoll at all5) and consequently, a pressure peak will be generated. Rotating the pipe before starting the pump may help breaking the gelled structures. Starting the pump with increasing steps of flow rate can also help gradual breaking of gelled structures and minimize the risks of pressure peaks. Table 5 shows three representative examples of pressure peaks due to gelation in the same well B.
Table 5 pressure peaks after pump start up

Event A B C

(ppg) 0.15 0.35 0.1

Flow rate (GPM) 400 700 250

Speed rotation (RPM) 130 0 120-140

Pump off time (min) 40 430 200

In event A, shown in figure 12, the pump was turned on (400 GPM) and off several times to help gel breaking. Pipe rotation was 130 RPM. Similar peaks were obtained. Finally, a similar peak was also obtained when the pump was started at 800 GPM to resume drilling. Even with the adopted procedure, 0.15 ppg pressure peaks were observed. Possibly higher peaks would be experimented if no rotation was adopted and the pump was started directly at 800 GPM.

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Figure 12 event A

Event B resulted in the largest pressure peak among the considered database. Figure 13 illustrates the values, besides no rotation speed and the less careful process adopted on the pump start up: in this case the pump was started and turned off immediately and then restarted at 700 GPM. ECD values decrease continuously with time reflecting gel breaking and fluid thinning due to heat exchange processes.

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Figure 13 event B

Event C (figure 14) illustrates a very detailed gel breaking procedure adopted which resulted in the lower pressure peak among the cases detailed in table 2. In this case, drillstring rotation was turned on and off (at 120 and 140 RPM) several times. Besides, the string was also reciprocated. Pump was turned on and off at 250 GPM for several times before the resume of circulation at 700 GPM. A 0.1 ppg peak was observed.

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Figure 14 event C

Gelling properties of drilling fluids are desirable for solids suspension while pumps are off. On the other hand, they can generate dangerous pressure peaks when the pump is restarted, especially in the low temperatures typical of deepwater scenarios. 5. Final Remarks The main contribution of the present article is to propose a comprehensive methodology to analyze the correlation of PWD data with relevant events which may occur while drilling a well. The correct interpretation of such data may result in important contributions for problem detection and anticipation. The analysis of the proposed events (hole cleaning, gel formation, etc) certainly involves more parameters than the ones highlighted in the examples here described. The global comprehension of such processes requires a more complete parameter sensibility evaluation. A broader analysis should enable, in a near future, the definition of algorithms to describe the relation between the parameters which impact downhole pressure in different operations which compose the drilling of a well phase. Such algorithms should be the basis for a decision support tool for real time PWD data interpretation.

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6. References 1. Mallary, C.R., Varco, M., Quinn, D., Pressure-While-Drilling Measurements to Solve Extended-Reach Drilling Problems on Alaskass North Slope, SPE 78288, June 2002. 2. Loureiro, B.V., Nieckele, A.O., Mendes, P.R.S., Helical Flow of a Viscoplastic Material Through the Developing Region of Annular Spaces, Proceedings of International Mechanical Engineering Congress & Exposition , November 17-22, 2002, New Orleans, Louisiana, USA. 3. Martins, A.L., de S, C.H.M. e Frydman, M., O Simulador Computacional SIMCARR e Suas Aplicaes na Perfurao e Circulao de Poos de Alta Inclinao, I Seminrio de Engenharia de Poo , Rio de Janeiro, RJ, Brasil, nov. 1996. 4. Martins, A.L. e Santana, C.C., Evaluation of Cutting Transport in Horizontal and Near Horizontal Wells A Dimensionless Approach. SPE 23643, Second Latin American Petroleum Engineering Conference, II LAPEC, Caracas, Venezuela, mar. 1992. 5. Bjrkevoll, K.S., Rommetveit, R., Aas, B., Gjeraldstveit, H., Merlo, A., Transient gel breaking model for critical wells applications with field data verification. SPE/IADC 79843, The Netherlands, 19-21 February 2003.

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