IPM Stuck Pipe Manual Volume

STUCK PIPE MANUAL
VOLUME 2
Schlumberger Private
PREVENTION IN THE PLANNING & EXECUTION
PHASES.
1
TABLE OF CONTENT
1. PLANNING PHASE........................................................................ 5
1.1. Well Engineering Management System (WEMS) ........................................... 6
1.2. Risk identification offset well analysis. .......................................................... 7
1.2.1. Stuck Pipe Triggers how can you recognise the hazards?.............................. 8
1.2.2. Chance of getting stuck?.......................................................................................12
1.3. Casing Design/Hole configuration: ............................................................... 14
1.3.1. Casing Design Examples .........................................................................................14
1.3.2. Expandable Tubulars. ..............................................................................................17
1.3.3. Hole Size: ....................................................................................................................18
1.4. Hole Cleaning:.................................................................................................. 21
1.4.1. Hole cleaning in vertical wells (<35deg)..............................................................22
1.4.2. Hole Cleaning In Deviated Wells (>35deg).........................................................24
1.4.3. How do we achieve good hole cleaning in a directional well? ....................28
1.4.4. Pipe Rotation.............................................................................................................28
1.4.5. Flow Rate....................................................................................................................31
1.4.6. Equilibrium Bed Height.............................................................................................34
1.5. Directional Planning ........................................................................................ 38
1.5.1. Trajectories.................................................................................................................38
1.5.2. Directional Strategies...............................................................................................42
1.6. Directional Assemblies. ................................................................................... 45
1.6.1. Conventional Steerable Assemblies: ....................................................................45
1.6.2. Rotary Steerable Systems (RSS)..............................................................................48
1.6.3. Drilling tools and Equipment...................................................................................49
1.7. Drilling Fluid Selection. ..................................................................................... 55
1.7.1. Vertical wells - Hole cleaning................................................................................55
1.7.2. Deviated & High Angle wells..................................................................................55
1.7.3. Differential Sticking...................................................................................................59
1.7.4. Reactive/time dependent shales. ........................................................................59
1.8. Rig sizing and capability. ................................................................................ 62
1.8.1. Hydraulic capability:................................................................................................62
1.8.2. Rotary capability: .....................................................................................................64
1.8.3. Power Capability:.....................................................................................................68
1.8.4. Hoisting capability....................................................................................................68
1.8.5. Solids Control Equipment: .......................................................................................68
1.9. Software & Modeling Tools. ............................................................................ 79
1.9.1. Osprey Risk .................................................................................................................80
1.9.2. Drilling Office. ............................................................................................................82
1.9.3. Modeling Hydraulics ................................................................................................82
1.9.4. Modeling Swab and Surge.....................................................................................84
1.9.5. Drill Viz: - 3D Visualization. .......................................................................................86
1.9.6. Rocksolid Wellbore Instability Analysis ...............................................................87
1.9.7. Stuck Pipe Analysis and Interactive Diagnostic tool SPAID...........................88
1.9.8. Sticking Risk Assessor for wireline jobs? .................................................................89
2. REAL TIME ANALYSIS HOW TO MONITOR THE PLAN? ........... 91
2.1. Introduction ...................................................................................................... 92
2.2. Surface measurements - Rig Floor measurements...................................... 93
2.2.1. Drilling Parameters....................................................................................................93
2.2.2. Torque & Drag Analysis............................................................................................97
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2.3. Downhole Measurements Indicators and Signals ..................................... 102
2.3.1. Downhole Weight on Bit. ......................................................................................102
2.3.2. Annular Pressure while drilling (APWD). ..............................................................102
2.4. Real Time Software Packages...................................................................... 106
2.4.1. PERFORM ..................................................................................................................106
2.4.2. Stuck pipe Indicator SPIN...................................................................................110
3. BEST PRACTICES....................................................................... 113
3.1. Communication............................................................................................. 114
3.1.1. Introduction: ............................................................................................................114
3.1.2. Pre-Spud Meeting...................................................................................................114
3.1.3. Pre-Section meeting ..............................................................................................115
3.1.4. Pre-Job Meeting .....................................................................................................115
3.1.5. Pre-Tour Meeting ....................................................................................................115
3.1.6. Handover on the Drill Floor ...................................................................................115
3.2. Drilling in the box............................................................................................ 116
3.3. Hole Cleaning................................................................................................. 118
3.3.1. Introduction .............................................................................................................118
3.3.2. Drilling........................................................................................................................118
3.3.3. Hole Cleaning pills..................................................................................................122
3.3.4. Circulating Prior to Tripping ..................................................................................123
3.4. Connections & Surveying ............................................................................. 126
3.4.1. Connection Practices:...........................................................................................126
3.4.2. Surveying - Stuck Pipe Avoidance While Surveying ........................................127
3.5. Tripping ............................................................................................................ 129
3.5.1. Considerations Prior To Tripping ...........................................................................129
3.5.2. Considerations During Tripping ............................................................................129
3.5.3. Reaming and back reaming. ..............................................................................130
3.6. Differential Sticking ........................................................................................ 135
3.7. Problematic Shales ........................................................................................ 138
3.7.1. Swelling Shales. .......................................................................................................138
3.7.2. Cavings....................................................................... Error! Bookmark not defined.
4. IDENTIFYING & FREEING STUCK PIPE ...................................... 148
4.1. Stuck Pipe Identification ............................................................................... 149
4.1.1. Stuck Pipe mechanism Identification Worksheet.............................................149
4.1.2. Stuck Pipe Summary Tables:.................................................................................151
4.1.3. Stuck Pipe Identification Trees .............................................................................153
4.2. First Actions to free......................................................................................... 161
4.2.1. Solids Induced - First Actions ................................................................................161
4.2.2. Differential Sticking.................................................................................................164
4.2.3. Mechanical & Well Bore Geometry....................................................................170
4.3. Jars & Accelerators........................................................................................ 171
4.3.1. Jars ............................................................................................................................171
4.3.2. Accelerator Description........................................................................................174
4.3.3. Jar and Accelerator Positioning..........................................................................175
5. STUCK POINT OF NO RETURN. .............................................. 177
5.1. Free point Indicator & Backing-off .............................................................. 178
5.1.1. Free point Indicator................................................................................................178
5.1.2. Backing-off...............................................................................................................181
5.2. Fishing Economics .......................................................................................... 183
5.2.1. Fishing Economic Calculator ...............................................................................183
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5.2.2. Decision trees. .........................................................................................................184
5.3. Sidetracking .................................................................................................... 187
5.3.1. General ....................................................................................................................187
5.3.2. Kick-off methods.....................................................................................................187
5.3.3. Kick-off plugs ...........................................................................................................188
5.3.4. Kicking-off with a motor. .......................................................................................195
5.4. Reporting......................................................................................................... 197
6. Acknowledgements............................................................... 199
7. Appendix................................................................................. 200
7.1. Unconsolidated Formations ......................................................................... 201
7.2. Mobile Formations ......................................................................................... 202
7.3. Faulted & Fractured Formations .................................................................. 203
7.4. Naturally over pressured shale collapse..................................................... 204
7.5. Appendix 4: Induced Over-pressured shale collapse. ............................. 205
7.6. Reactive Formations...................................................................................... 206
7.7. Hole Cleaning................................................................................................. 207
7.8. Tectonically Stressed Formations ................................................................. 208
7.9. Differential Sticking ........................................................................................ 209
7.10. Key Seating ................................................................................................. 210
7.11. Undergauge Hole ...................................................................................... 211
7.12. Doglegs & Ledges ...................................................................................... 212
7.13. Junk .............................................................................................................. 213
7.14. Cement Blocks............................................................................................ 214
7.15. Green Cement ........................................................................................... 215
7.16. Stuck Pipe HARC Analysis.......................................................................... 216
7.17. PowerPak Motors with Adjustable Bends Drill String RPMs: Curved
sections....................................................................................................................... 219
7.18. PowerPak Motors with Adjustable Bends Drill String RPMs:
Tangent/Straight Sections........................................................................................ 220
4
5
1. PLANNING PHASE.
1.1. Well Engineering Management System (WEMS)
The WEMS is the heart & soul of stuck pipe avoidance. This process combined
with the correct technical expertise should:
1. Determine stuck pipe hazards & risks from the offset data: offset reviews
EOWR, rig limitations etc. Compile the risks in a risk register.
2. Mitigate the hazards in the design phase: casing design, trajectory
planning, HARC analysis, mud selection, rig modifications etc.
3. Review remaining risks. Provide specific procedures in the well operations
program to minimise the severity of these remaining risks.
4. Execute the plan: implement the procedures & monitor (real-time
analysis).
5. Review the operations and plans. Highlight the lessons learned and
feedback into the planning cycle: EOWR, Drill DB, Intouch.
Figure-1: IPM WEMS flow diagram
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1.2. Risk identification offset well analysis.
An offset well review is a fundamental piece of the well engineering design
process and is the first opportunity to identify stuck pipe hazards.
There are many sources of information (see list below), but the best by far are the
day drilling reports.
List of documentation that can aid stuck pipe identification.
Daily Drilling/Operations summary report

End of Well Reports
Time/depth graphs.
Directional drilling slide sheets and report.
Pore pressure and fracture gradient profile
Seismic Cross section and structural maps
Drilling log.
Surface and down hole drilling parameter
Studies rock mechanics, stress regimes.
Once the stuck pipe hazards have been identified they should be compiled in
the risk register. This is used to evaluate the economic risk of the well and to
mitigate/minimize these risks in the planning and/or execution phase. A typical
risk register is shown below.
Risk Consequence/Exposure Mitigation Probability Days Cost Risked Risked

K Days Cost.
Depleted reservoirs in Losses with high MW. Steer around 5% 60 1000 3 50
the overburden. SSH- Have to set contingency them.
17 is at 62bar. expandable liner.
Borehole instability in Hole collapse. Sidetrack Maintain 10% 10 400 1 40
intermediate section. correct MW
Borehole instability in Hole collapse. Set Maintain 2% 60 1000 1.2 10
intermediate section. contingency expandable correct MW
Depleted reservoir + Differential sticking. Drilling practice 20% 10 250 2 50
high perms. Sidetrack. + mud
properties.
Borehole instability in Hole collapse. Sidetrack. Maintain 10% 10 250 1 25
reservoir section. correct MW.
Rig rate increases for Increase in well cost Long term 5% 0 1100 0 55
2nd phase by 20% contract
Fixed costs increasing Increase in well cost Fix contracts for 20% 0 370 0 74
by 20%. field
development
TOTAL 7.2 304
Table 1: Shows an example risk register.
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1.2.1. Stuck Pipe Triggers how can you recognise the hazards?
1.2.1.1. Time-depth graphs:

These provide an excellent high level stuck pipe identification tool and are great
for highlighting major events.
Well-XX
Time Versus Depth
NAFE
500 Actual
1,000
1,500 Sidetracks are

unmistakeable on
2,000
time/depth graphs
2,500
3,000
3,500
4,000
4,500
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0 75.0
tim e in days
Figure 2: Example of a time depth graph.
1.2.1.2. Daily drilling reports:

These provide the bulk of the data and are invaluable in identifying potential
stuck pipe hazards in the area. Typical triggers are:
a. O/Ps recorded on trips out.
b. Reaming required on trips.
c. Cavings reported during drilling and circulating.
d. Sticking tendency during connections.
e. Bit balling packed off BHA on surface (see figure 4)
f. Trip times.
g. Large volume of cuttings/caving's coming over the shakers
h. Actual stuck pipe events.
Once the triggers have been identified they have to be linked together to
determine the root cause of the problem. In most cases you need to read
between the lines to come out with the correct root cause.
Quality.
Daily drilling reports can only be used as a source of information if they have
been filled out correctly and the right data has been recorded. Typical
information that needs to be captured to aid stuck pipe identification should
include:
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Over pulls: record depth and weight.
Cavings: shape, size, and percentage (compared to cuttings).
Reaming: record reaming parameters.
Drilling parameters: flow rate (do not record spm unless liner
volume is given), rpm, torque, circulating pressure, WOB etc.
Circulating parameters prior to tripping: flow rate, rpm, pressure,
and amount of cuttings coming over the shakers.
Sweeps: volume, type, % increase in cuttings.
Drill string & BHA: size of tubulars, bend setting of motor, type of
stabs etc.
Without quality data the reports become useless.
1.2.1.3. Surface and down hole drilling parameters
A picture paints a thousand words.
The drilling data provided by real time monitoring systems such as PASON can be
extremely effective at highlighting problems, especial whilst tripping.
Figure 3: Trip data from a real time rig drilling data system.
The left hand chart shows the hook load for a trip out through a salt sequence.
The spikes in the hook load easily identify the problems areas. The chart in the
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centre shows the trip back to bottom and the right hand chart shows the final
trip out of hole. It can clearly be seen in this case that the check trip really
helped in reducing the amount of tight spots in the section. This can now be
used in planning stage to help mitigate the hazard in future wells.
1.2.1.4. End Of Well Report:

The end of well report is a very valuable document if compiled correctly, but
there is a tendency within the industry just to repeat what is in the daily drilling
reports. To be of real use to the drilling engineer in the planning stage it must
highlight the lessons learnt, discuss the planned versus the actual, and give clear
and concise explanations on why certain operations were performed. Pictures
and real-time graphs should be included and its just as important to highlight
the things that worked as the things that didnt.
Figure 4: The pictures show a balled up BHA after drilling surface hole. This type of
information can help the engineer build-up an accurate picture of the drilling problems
and is a great aide in communicating the hazards to the rig. Pictures like these should be
included in the end of well report.
Figure 5: Photograph of cavings with a scale, are much better than a written
explanation in an EOWR.
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1.2.1.5. Studies:
In order to quantify & then mitigate a hazard it is sometimes necessary to look at

a specific problem/hole section in more detail. Rock mechanics studies are a
good example of this, but it doesnt have to be as complex. It can be as simple
as plotting some basic trends (see Figure 6).
Length of 12 1/4" BUS vs time
600
500
400
hours & meters
300
Hours to drill section
Hrs to check trip & POOH
Length of BUS (m)
Total hrs for 12 1/4" section
200
100
0
MLM-18 MLM-17 H3 MLM-16 MLM-15 MLM-14 MLM-13 MLM-12 MLM-11 MLM-10
Well number
Figure 6: The graph opposite is a simple plot to show how slight changes in design can
have a massive impact on the timings and risk. This examples shows the timings to drill
8deg/30m build-up sections from vertical too horizontal in 12 hole in the same field,
using the same well design. The first 4 wells (MLM 10-14) are straight builds, but after that
short tangent sections at 65deg inclinations are included in the trajectory. Initially (MLM-
15) the tangents are 80m in length, but by the time of MLM-17 they have crept up to
150m. On MLM-18 the tangent length was reduced back to 70m.
The graph clearly shows that the inclusion of a tangent had a massive impact on the
timings. Analysis concluded that the root cause was poor hole cleaning, which was a
direct result of the design of the trajectory & sub optimum hydraulic capacity.
No management of change process was applied when the tangents were added and
as a result, the rig and trajectory limitations were not anticipated.
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upper limit = Fracture Gradient @ 18.14 kPa/m Borehole Azimuth
17.8
SW1 @ 1.35 sg
16.8 H2 @ 1.29 sg
100
15.8
110 and 90 deg
Increasing Optimum Mudweight
120 and 80 deg

14.8
SW1 130 and 70 deg

[Kpa/m]
13.8 40 and 160 deg
30 and 170 deg

12.8
10
11.8 0 and 20 deg

H2 & SO1
10.8
lower limit = Pore Pressure Gradient @ 9.8 kPa/m

9.8
0 30 60 90
Borehole Inclination [deg]
Figure 7: The graph shows the optimum mud weight vs. inclination through a shale
sequence that is situated in a tectonically stressed area (maximum stress in this case is
horizontal). Unfortunately the study was commissioned after a series of stuck pipe events.
1.2.1.6. Directional drilling slide sheets:
These should be kept as part of the well file/end of well report. They can provide
valuable information on the hole condition and provide the drilling data for
torque and drag analysis (see section 2.2).
1.2.1.7. Logs
Calliper logs can help analyse well bore stability and can identify potential
problem areas.
1.2.2. Risk of getting stuck?
How easy is it to determine our chances of getting stuck?
There are four main methods:
1.2.2.1. Experience:
This is the most common method and is based on a persons, or group of
persons previous experience & knowledge. The results of the assessment vary
widely, and are influenced by specific problems they have encountered and/or
their pet hates. However, if combined with a formal HARC analysis the subjective
nature of the exercise can be minimised.
1.2.2.2. Field/area risk sheets:
12
This method is excellent if you have plenty of relevant offset data and/or you are
involved in a drilling campaign. It takes out the subjectivity that is associated
with method one, and can help with identifying trends, especially when changes
are made (management of change). Two examples of this are:
a. The trend graph in figure- (BUS section graph) is one example.
b. Compiling a differential sticking index for an area. This requires a
wide offset review focusing on wells that got differential stuck
and looking for a consistent trend e.g. wells with inclinations of
over 30deg with overbalances of 1400psi or more have a 60%
chance of getting stuck.
1.2.2.3. Historical data for different well types (Osprey Risk):
Osprey risk has a number of generic risk categories that can be used to highlight
areas of high risk in a well design. Osprey risk is described in more detail in section
1.9.1.
1.2.2.4. HARC Analysis.
HARC analysis provides an excellent format for assessing risk and identifying
control measures. A generic stuck pipe HARC analysis is in InTouch at the
following link:
http://intouchsupport.com/intouch/methodinvokerpage.cfm?method=ITEVIEW&
caseid=3858822&outype=3 - File Attachments
HARC - Stuck Pipe Final Rev 001.doc
HARC analysis does not have to be performed on such a high level. It can be
easily used to analysis specific stuck pipe mechanisms in a certain well type e.g.
differential sticking when drilling through depleted reservoirs.
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1.3. Casing Design/Hole configuration:
Stuck pipe hazards have a major affect on casing design and in some cases
drives the design process as much as the well control requirements. Unstable
shales, hole cleaning and differential sticking are probably the most likely stuck
pipe mechanisms to influence and change a design.
The next three examples highlight this point, and show how the casing scheme
can be changed to mitigate the stuck pipe risk. In some cases an additional
string might not be an option, and in these situation the drilling practices and
mud selection becomes of paramount importance.
1.3.1. Casing Design Examples
1.3.1.1. Example 1
LIMESTONE
SHALE
SANDSTONE
INTERBEDDED
SANDSTONE
The schematic shows a fictitious geological column with a simple build and hold
trajectory. The surface casing is set at the top of the shale to ensure BOP
protection for the potential hydrocarbons in the intermediate section.
The plan is to drill the intermediate section with Oil Based Mud, and from offset
data we know the shales are stable with a mud weight of between 1.3-1.35sg.
In this situation the main stuck pipe risk is hole cleaning in the intermediate
14
section and as such the drilling procedures should be planned to minimise this risk
(see section 1.4 & 3.3).
1.3.1.2. Example 2
LIMESTONE
SHALE
(Time dependent shale)
SANDSTONE
INTERBEDDED
SANDSTONE
In this next case the shale is time dependent and from offset data the exposure
time is estimated at 7days. If a 2-string scheme is used, then the estimated drilling
time for the intermediate section is 6 days. Oil based mud is prohibited in this
area so the decision has to be made whether to attempt to drill the section with
two strings, or go for the safe option and add an additional string to case of the
shale after it has been drilled. In this case the 3-string option has been chosen
because:
o Running casing takes 2 days
o 50% of the intermediate sections require TD logging.
If the well is the first one of a 20 well campaign then the ultimate aim would be
to reduce drilling, logging, & casing times in the intermediate section to below 7
days. This would allow us to revert back to the original 2-string design.
15
1.3.1.3. Example 3
LIMESTONE
SHALE
(Unstable shale. MW required = 1.5sg)
SANDSTONE
(High Permeable Sand. Estimated overbalance = 10000kPa)
1
INTERBEDDED
(Unstable shale. MW required = 1.5sg)
SANDSTONE
In this third example the maximum stress (1) is horizontal and the shallowest
sandstone has a high porosity and permeability. Rock mechanic studies indicate
that a safe MW to stabilize the main shale and the shale layers in the inter-
bedded section is a mud weight of 1.5sg.
To mitigate the shale stability risk it has been decided to use oil based mud and
drill with the recommended mud weight. This decision has greatly increased the
differential sticking risk from a low to high potential across the sandstone. This is
considered unacceptable and it has been decided to drill the sandstone with a
minimum overbalance and to introduce a 4th string in to the design.
In many cases a 4th string is unrealistic and expensive option and in many cases
may not be feasible. An alternative option would be to change the trajectory
(see section 1.5.1).
16
1.3.2. Expandable Tubulars.
Adding an additional casing to a conventional well design can be costly and in
many cases will have a massive impact on the project economics.
To incorporate the string in to the design we either have to:
Keep the top-hole size the same, and size down the final
hole size through the reservoir.
Or, keep the final hole size the same and size up from the
surface.
The first option impacts the productivity of the well and the second impacts the
cost.
Expandable tubulars can provide a solution to this problem and are becoming
more common within the industry. They can also be used as a contingency if the
casing is stuck off bottom.
1.3.2.1. Example:
In example 2 an additional casing string is required to case of the time
dependent shale. If production requires the reservoir hole size to remain the
same, we have to up size the well to incorporate the additional string. In this
case we have a light rig and upsizing is not possible. An expandable liner
provides the solution (see below).
LIMESTONE
13 3/8
SHALE
(Time dependent shale)
Trajectories
SANDSTONE
Expandable liner
3
OD 11 /4 12.238
ID expanded 11.385
INTERBEDDED
Next Section: 2 options.
Under ream to 12 or,
Drill 11 or 10 5/8 hole.
Next Casing/Hole:
SANDSTONE
9 5/8 casing / 7 hole or,
8 5/8 casing / 6 5/8 hole.
17
1.3.3. Hole Size:
In the drilling industry we tend to drill with conventional hole and casing sizes i.e.
17 / 13 3/8, 12 / 9 5/8, & 7 / 6 1/8. In most cases this is acceptable, but
with respect to stuck pipe avoidance this is not always the case.
The table below is the Hughes Christensen tri-cone product line. It clearly shows
that there are many different bit sizes available and it is not always necessary to
drill conventional sizes.
Table 2: Shows the tri-cone bit types available for different hole sizes.
Hole size optimization with respect to stuck pipe avoidance, is mainly applicable
for the following:
Hole cleaning: 12 hole is the hardest to clean and in many cases the rig is
working at 100% of its capacity and is drilling outside the box (see section
3.2). In order to move back inside the box, 11, 10 5/8 & 9 7/8 hole instead
of 12 can be a solution. Of course this has to be balanced against the
reduction in hole size through the reservoir, but in cases where this is not a
major issue, drilling these sizes can be a real advantage (see section 1.4 for
flow rate improvement).
Sticky / reactive formations: This application is mainly used in top-hole drilling
where larger hole sizes are drilled to give more annular clearance for running
casing. An example of this comes from a major operator in the Middle East.
During an in fill drilling campaign, it was decided to slim down the well design
18
from 17 hole / 13 3/8 casing top hole, to a 12 hole / 9 5/8 casing. The
bottom third of the top-hole section contained reactive/sticky shales and it
was common to have tight hole/ packed BHAs when POOH. An offset
review of the early wells was made, and they noticed that one other well had
been drilled in the slim design. Coincidentally this had the most difficulty in
getting the casing to TD and they were close to losing the top-hole section.
To mitigate the increased sticking risk with the slim design, they decided to
drill a larger hole size to increase the annular clearance e.g. 14 hole
instead of 12 . The difference this made to the reduction in the stuck pipe
risk and the improvement in the section timings can clearly be seen on the
graph.
Figure 8: Offset analysis showing improved tophole performance on the last three wells
(XXX-28 to 30). The performance can be attributed to drilling with a large hole sizes to
minimize the impact of sticky shales/clays.
Factors to consider when changing the hole size:

1. Management of change process.
2. Reduction in hole size impact on ECD?
3. Increase in hole size impact on hole cleaning.
4. BHA components stabs, subs etc.
5. Bits.
6. Fishing tools size, availability?
Bi-centered bits & hole opening tools
Bi-centered bits & hole opening tools are now widely used within the industry to
increase the annular clearance in a hole section. Their main advantage is that
19
the casing scheme does not need to be upsized to incorporate the larger hole
OD, and this is off particular advantage in deeper hole sections. Typically they
can enlarge the borehole up to 20% of the bit OD.
20
1.4. Hole Cleaning:
The facts speak for themselves. A third of all stuck pipe events in non-deviated
wells and 80% events in high angle wells are hole cleaning related. The ramp up
in percentage is a direct result of the increasing difficulty in achieving good hole
cleaning with increasing hole angle (see figure 9).
Hole - Cleaning: Difficulty vs. Angle
Difficult
Relative
Difficulty I II III IV
Easy
0 30 Inclination 60 90
Figure 9: Graph shows the hole cleaning relative difficulty vs. inclination.
Many of the events, especially in deviated wells, are failure by design/poor

planning and could have been prevented if the proper measures had been
implemented in the planning stage.
In this section we will discuss the main components that control the effectiveness
of hole cleaning in the well.
For a more detailed discussion on the theory of hole cleaning and cuttings
transportation then please go to Chapter 7: Trouble Free Drilling Manual.
21
1.4.1. Hole cleaning in vertical wells (<35deg).
Hole cleaning in vertical wells is often overlooked and considered unimportant.

However, it is amazing the number of stuck pipe incidents in vertical wells that
can be attributed to poor hole cleaning.
1.4.1.1. Main factors that influence hole cleaning in vertical wells?
High
Cuttings Mud ROP
density weight
Flow
Cuttings Rate
Influence size LSYP
on cuttings PV
transport YP
RPM
Low
Low Ability to control High
Figure 10: Shows the main factors that influence hole cleaning in a vertical well vs. the
ability for us to control.
1.4.1.2. How can we evaluate hole-cleaning efficiency in vertical wells?
One method is the volumetric cuttings concentration in the annulus and the
other is the transport ratio. The equations are shown below:
Transport Velocity Volume of cuttings in

Transport Ratio = FT = the annulus.
Annular Velocity
Vol cuttings conc. =
V Vslip Total annular volume
FT = T = 1
Va Va
Both equations are described in detail in Page 46, Chapter 7: Trouble Free Drilling
Manual.
Anything that increases the transport ratio increases the hole cleaning efficiency
in vertical wells. A reduction in slip velocity is one way that the transport ratio can
22
be increased. The slip velocity is influenced by the density and size of the cutting,
and by the viscosity and density of the fluid. Much of what we do to improve
hole-cleaning efficiency in vertical wells is aimed at reducing the slip velocity or
increasing the average annular velocity.
The volume of cuttings concentration in the annulus is influenced by the rate of
penetration and the annular velocity. To improve cuttings concentration in the
annulus we can either reduce the ROP or increase the annular velocity.
1.4.1.3. What can be done in the planning stage?
Less planning is required to ensure good hole cleaning in vertical wells

compared to deviated wells. In the end it comes down to the implementation
of good drilling practices and keeping the mud in shape.
Factors That Influence Measures that should be taken in the Planning Phase.
Hole Cleaning
Mud weight The higher the weight the better the cleaning.
Mud rheology Ensure that the correct mud parameters are in the program
and these have been communicated effectively to the
wellsite. See next section for guidelines on correct rheology.
Annular Velocity Calculate the annular velocity for the planned flow rate.
Check that there is effective cuttings removal.
Limited on flow rate?

1. Reduce ROP
2. Drill pilot hole & open up with hole opener. Good
option for hole sizes >17 .
ROP Calculate the maximum ROP for the planned flow rate in the
section. Set maximum ROP limits to ensure the annulus is not
overloaded. Communicate these limits to the rig and ensure
they stick to them.
Scenario Planning What ifs? IPM have had a number of stuck pipe incidents in
vertical wells where the shakers or flowline has been
overloaded and the pumps have been stopped to clear the
cuttings. On resumption of circulation the hole has packed off.
Discuss contingency planning with the well site for these types
of situation.
Solids Control Equipment Do you have enough shakers? What screen sizes are required?
Is the flowline & cuttings shoot large enough?
Table 3: Lists the factors that influence hole cleaning in a vertical well.
23
1.4.2. Hole Cleaning In Deviated Wells (>35deg)
1.4.2.1. Introduction
Figure 11 sums it up. The drilling practices and fluids that work to clean the hole
in a vertical well will not work in a deviated wellbore. This combined with a lack
of understanding of hole cleaning within the industry makes for a recipe for
disaster. Hopefully, this section and Chapter 7 of the Trouble Free Drilling Manual
will change this.
WHAT WORKS HERE

2
MIGHT WORK HERE
3 WILL NOT WORK HERE
4
0 35 65 90
Hole Inclination
Figure 11: Highlights the fact that what works in a vertical section will probably not work in
the deviated portion.
1.4.2.2. Recap: The differences between vertical & directional wells.
1. Gravity works against us.
During drilling, the velocity of the drilling fluid must exert a force high enough to
counteract the effects of gravity, which will tend to make the cutting drop to the
bottom of the well. Usually, enough velocity is achieved by the drilling fluid to
perform this task efficiently in vertical wells.
On the other hand, directional wells pose a more difficult problem. Influenced
by gravity, the cutting will still try to drop, but due to the inclination of the well it
does not have to travel too far before it reaches the lower side of the wellbore.
In this situation, the velocity of the drilling fluid has to be higher in order to keep
the cutting moving up towards the surface.
24
Particle Velocity
Particle Velocity
Mud Velocity
Mud Velocity
Vertical Well Directional Well

Figure 12: Shows particle (cutting) and mud velocity direction in a vertical & deviated
wellbore.
2. Pipe is eccentric.
25
The drill pipe sits where the cuttings accumulate,
on the low side of the hole
What are the Effects?

- Non-uniform hole shape
- Adhesion of the cuttings in the bed
- Increased torque & drag
How does Mud Respond? DRILL PIPE

- The mud on the low side is overloaded with
cuttings and they drop out. Mud rheology at
low shear rates is critical for good hole
cleaning.
- Forms a new boundary layer of no flow
between the cuttings bed and the mud. Figure 13: Diagram showing pipe
eccentricity in the well bore.
26
3. Flow profile changes.
The pipe eccentricity changes the flow profile in the hole. Unfortunately with the
pipe stationary e.g. not rotating, it does not work in our favor!
Figure 14: Shows the difference in the flow profile (red arrows) between a vertical &
directional well. No cuttings are present in this example.
10 ft/min
150 ft/min
100 ft/min
100 ft/min
50 ft/min
50 ft/min
0-3 ft/min DP 0-3 ft/min
27
Figures 15: shows the flow profile in a directional well with the DP lying on the low side.
The top section of the wellbore has a high-energy flow zone and the bottom has a low-
energy flow zone. This creates a top part with fast moving thin mud and a bottom zone
with high solids, slow moving mud. This slow moving high cuttings concentration mud is
unable to carry the solids up the wellbore and they fall out creating cuttings beds on
the low side of the hole.
1.4.3. How do we achieve good hole cleaning in a directional well?
There are three main factors that affect the hole cleaning capability and they
are all interdependent on each other. They are:
1. Pipe Rotation.
2. Flow rate.
3. Low-end mud rheology (discussed in section 1.7)
To achieve good hole cleaning the correct rpms, flow rates & mud parameters
must be chosen for the given hole size. K &M technology group likens the process
to that of a conveyor belt. If the correct parameters are chosen, the cuttings
are thrown up from the low side of the well bore, on to the conveyor belt and
transported out of the hole.
Figure 16: Visualisation of K & Ms hole cleaning conveyor belt.
1.4.4. Pipe Rotation.
Pipe rotation is critical in cleaning the hole. There are some differences in
opinion on the mechanism that causes the improvement in hole cleaning, but
there is no doubt that it has a huge impact.
The different theories are:
28
1. Mechanical agitation: at low rpms the drill pipe rolls up the walls and
slides back down. At a certain threshold rpm, the pipe breaks out of the
cutting bed and will rattle around the wellbore and mechanically agitates
the cuttings. Chapter 7 of the Trouble Free Drilling Manual promotes this
theory, and suggest that a typical threshold rpm for 12 & 8 hole,
occurs around 50 & 75rpm.
2. Hydraulic action: The pipe rotation creates fluid movement in the bed
and the whirl moves pipe around the wall creating additional velocity at
the sides. This velocity causes frictional drag and lifts the cuttings to where
the mud is moving. K & M explain it as the viscous coupling?
In reality it is probably a combination of the two and experimental data has

supported this.
1.4.4.1. How fast do we need to rotate the pipe?

There are different rules of thumb out there in the industry. K & M promote that
in 12 & 9 7/8 hole sizes, step improvements in cuttings returns are seen at 100-
120rpm and at 150-180rpm. The thresholds are not based on a theoretical model,
but rather on actual operational experience in high angle well bores.
150 - 180 RPM
100 120 RPM

Relative Cuttings Return
Volume
Fine-tuning of pipe RPM

from 60-80 RPM is generally
not meaningful
Pipe RPM
Figure 17: Graph showing relative cuttings return vs. drill string surface RPM for 12 hole.
Note the step changes at 120 & 180rpm.
29
Table 4 is K & Ms recommended drillstring rpm for different hole sizes. This table is
supposedly based on field observations, but it has been difficult to validate. We feel the
minimum rpms are a more realistic target and if the string is rotated faster e.g. to the
desirable rpms, then other problems are created e.g. more equipment failures etc.
Hole Size Desirable Minimum

RPM RPM
17 120-180rpm 120 rpm
12 120-180rpm 120 rpm
9 7/8 120-150rpm 100 rpm
8 70-100rpm 60 rpm
Table 4: Recommended drill string RPM for different hole sizes.
Chapter 7 of the Trouble Free Drilling Manual sets the thresholds much lower, at 50 75rpm
for 12 & 8 . This is based on field experience with pressure while drilling tools in
deviated well bores.
In reality the effect of drill pipe rotation is dependent on a number of interrelated factors.
These are covered comprehensively on Page 84, Chapter 7: Trouble Free Drilling Manual.
SPE 56406 is a good research paper on the affect of DP rotation on hole cleaning and is a
recommended read.
Rotary Cuttings Mobilization in

PWD
12-1/4 Horizontal Section g/cc ECD
3000 1.68 14.02
MD/RPM/Flow In/Cuttings
1.67
2500 Cuttings agitated 1.66 13.88
Drill by pipe rpm 1.65
2000 Steer Steer Drill
Steer 1.64 13.67
1500 1.63
ECD
Increase in ECD 1.62 13.52
1000
1.61
1.6 13.35
500
1.59
0 1.58 13.19
12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 0:00
MD,m RPMx10 Cuttings flux, kgx10 PWD EMW
Figure 18. The graph shows the increase in ECD and cuttings returns at surface (blue line) when the
drill string is rotated after a period of sliding. The increase can be attributed to pipe rotation
agitating cuttings off the low side of the well into the mud stream.
30
In general we should be aiming to rotate the pipe as fast as possible within the limits of our
downhole tools and surface equipment. For larger hole sizes e.g. > 9 7/8, this should be
higher than 100rpm.
1.4.4.2. Planning Rotation.
Pipe rotation must be planned in advanced. It is no good wishing you could rotate at
120rpm when you have a directional assembly in the hole with a 1.5deg bend.
The best way of ensuring that you can rotate at the required rpm is to build the well
trajectory and directional plan around this condition. This means working closely with the
directional company to come up with the optimum solution.
In many cases the design will already be fixed, and you will not have a free hand. In these
situations the risks in the design need to be highlighted and comprehensive
procedures/control measures put in place to mitigate these risks (see section 3.3.2.2).
Factors affecting pipe rotation:
1. Dogleg severity requirement & tortuosity of the wellbore

2. Bottom hole assembly.
3. Topdrive or rotary table torque rating.
4. Connection rating mainly constrained to ERD wells.
1.4.5. Flow Rate
Turbulent flow rules in hole cleaning. Unfortunately for us we very rarely achieve it, and we
have to face the fact that we have to clean the hole in a laminar flow environment.
The good news is that the industry is fully aware of the importance of pumping at high
enough flow rate in a laminar flow regime to clean the hole. However, there is a problem.
What is that optimum flow rate for the particular conditions?
31
50
50 fpm
fpm
Static
Static
150
150 fpm
fpm
100
100 fpm
fpm
Figure 19: Shows an MI flow tube. The test shows the changes in flow regime with increasing flow
rate all other parameters have been held constant. The results clearly show a cuttings bed at 50
fpm (feet per min) to turbulent flow and no cuttings bed at 150fpm.
1.4.5.1. Experimental Research

Experimental data has also confirmed the importance of flow rate in improving the hole
cleaning efficiency in deviated wells. Figure 21 is an example of the research.
32
Figure 20: The chart shows experimental results of cutting bed erosion rates with varying flow rates.
The experiments were conducted on a 30ft 8 flow loop with 4 DP. In this case the flow loop was
set at 87deg and there was no pipe rotation. Initially cuttings were injected into the annulus until
they built up to an equilibrium height. Injection was stopped and the bed erosion rate was
measured. The results clearly show the impact of increasing flow rate, and in this example there is a
significant step change between 250gpm to 300gpm. It is interesting to note that at the lower flow
rates it is virtually impossible to clean the hole. The chart is taken from SPE63050.
1.4.5.2. How fast do we need to pump?
The industry is a wash with tables & rules of thumb for optimum flow rates/annular velocities
in different hole sizes. Whilst these can give you an idea of what to pump they dont take
into account the other factors that affect the hole cleaning efficiency i.e. rpm, rheology,
inclination etc. The next two tables give optimum flow rates for different hole sizes and
inclinations.
Hole Size Desirable Flow rate Minimum Workable Flow rate
17 900 1200 gpm 800 gpm with ROP at 20m/hr

650 gpm with ROP at 10-15m/hr
12 800 1100 gpm
9 7/8 700 900 gpm 500 gpm with ROP at 10-20m/hr
8 450 600 gpm 350-400 gpm with ROP at 10-20m/hr

lpm= 3.785 x gpm
33
Table 5: Shows K & Ms recommended flow rates for different hole sizes.
OPTIMUM FLOW RATES

Hole Size 26 17-1/2 16 12-1/4 8-1/2 6-1/8
Flow rate 1200 1300 900 1200 800 1100 450 600 350 500
(GPM)
MINIMUM FLOW RATE (GPM) VERSUS HOLE SIZE AND HOLE INCLINATION
0 to 35 degree 700 GPM 700 GPM 650 GPM 400 GPM 250 GPM
35 to 55 1250 GPM 850 GPM 700 GPM 450 GPM 300 GPM
degree
55+ degree 1100 GPM 750 GPM 500 GPM 400 GPM
Table 6: Shows the PERFORM manuals recommended flow rates for different hole sizes and
inclinations. ECD & hole erosion (unconsolidated sands) need be considered for the smaller hole
sizes (8 & 6 1/8) before the optimum flow rates are used. Typically smaller hole sizes will clean
effectively at the minimum flow rates.
The optimum flow rates in both tables concur, and these rates should be used as a good
rule of thumb.
1.4.6. Equilibrium Bed Height
This next section is discussed in Chapter 7 of the Trouble Free Drilling Manual, but its off
critical importance in understanding the term a clean hole that we will recap the topic
here.
If you asked most drilling engineers in the industry how do you get a clean hole they will tell
you that by circulating for a time x, at a flow rate of y and pipe rotation of z you will
affectively clean the hole. If either y or z is reduced, then an increase in x is required to
get back to a clean hole. In the industry 4 x bottoms-up is seen as a good rule of thumb
on how much circulation time is required to achieve good hole cleaning in a directional
well. However, experimental data indicates (ref SPE56406) that the cuttings bed height is
reduced during hole cleaning circulation prior to tripping, but under many conditions will
not disappear completely (see figures 21 & 23)
Figures 21 & 23 show two tests that have been carried out in the cuttings transport simulator
at Tulsa University (Ref SPE56406). Stage 1 represents the accumulation process, where the
cuttings concentration in the annulus increases from zero until it reaches a constant value.
In stage 2, the cuttings injection rate is equal to the cuttings collection rate and the
cuttings mass in the annulus remains constant (equilibrium). Pipe rotation starts in stage 3
and continues until the end of the test. Erosion of the bed begins and continues until a new
steady state (equilibrium). This is the beginning of stage 4 in which the cuttings mass in the
test section remains constant. At the end of stage 4, the cuttings injection rate is stopped,
resulting in further bed erosion. The erosion is shown in stage 5 where the cuttings
concentration decreases to its lowest value. Figure 21 shows that under the given
conditions, not all the cuttings are removed from the annulus. However, Figure 22 shows
that under the same conditions, rotary speed of 90 rpm does clean the hole.
34
Experimental Hole Cleaning Graphs.
Bed height reduces, but

does not disappear
completely. On the rig the
shakers would indicate the
hole is clean!
Figure 21: Test graph for 50rpm. Taken from SPE56406. After cuttings injection is stopped, the bed
height reduces, but does not disappear completely.
Bed height reduces to zero

with an additional 40rpm.
35
Figure 22: Test graph for 90rpm. Taken from SPE56406. The additional rpm reduces the bed height
during cutting injection and cleans the hole completely once injection is stopped.
Significant cuttings bed

remains after injection is
stopped.
Figure 23: Is taken from the same SPE paper and shows the affect of a reduction in flow rate has on
the cuttings bed height. In this case a significant bed height remains after cutting injection is
stopped.
What does it mean if we cant get the hole completely clean when circulating prior to a
trip? Well its simple, the risk of stuck pipe increases. The amount of risk depends on a
number of factors. These are:
- The height of residual cuttings bed.

- Clearance between downhole drilling equipment and wellbore.
- Tripping practices i.e. pulling speed, circulations etc
The bed height is dependent on the three main factors: rpm, flow rate and low-end
rheology and these have been discussed already.
36
The amount of clearance between the BHA and wellbore is extremely important because
in most cases we leave cuttings beds in the hole. The trick is to have enough annular
clearance around the BHA to allow the cuttings bed to pass by without increasing the
height of the bed e.g. a steady state situation. However, if the bed height is increases,
cuttings build up around the BHA and the risk of pack-off increases and stuck pipe
incidents will occur. In this scenario the BHA needs to be designed to maximum annular
clearance and this will be discussed in more detail in section 1.6
Acceptable cuttings bed the hole is not 100% clean, but the bed height is low enough
to allow easy passage of the assembly without pumps or rotation.
Unacceptable cuttings bed the hole is not 100% clean, but the bed height is too high to
allow passage of the assembly. The cuttings build up around the x-over between the BHA
and DP, and the stabilizers. If pulling out continues the hole will pack-off. In this example
the remedial action is to go back down two stands and circulate the hole clean.
Figure 24: Schematic a BHA tripping through open hole.
Lastly good tripping practices are required to stop cuttings building up to a height that can
cause the BHA to pack-off. A major factor is the speed at which the BHA is pulled out of
hole and the ability to recognise a build-up before it is too late. Recommend tripping
practices will be discussed in section 3.5
37
1.5. Directional Planning
1.5.1. Trajectories.
The well trajectory plays a major role in stuck pipe prevention and many root causes of
stuck pipe incidents can be attributed to poor trajectory design. Sadly in many cases the
rig is blamed for most stuck pipe incidents, but in reality it was set up for failure even before
it started drilling.
The good news is that a well planned trajectory and directional philosophy can
mitigate/reduce the stuck pipe risks in the well, and allow the rig plenty of margin for error
before a stuck pipe incident occurs.
1.5.1.2. Different types of trajectory.
The main types of directional profiles are shown on the schematic below.
Derrick.ico
LIMESTONE
SHALE 1
SANDSTONE 1
d c a b
INTERBEDDED
SANDSTONE 2
Figure 25: Shows the different types of trajectory profile.
38
J Type (a)
A constant build rate is used to kick the well off from vertical, building to a tangent angle
that is held constant all the way to the target. J profiles minimize the total depth and
required directional work and are the most common profiles in the industry.
Points to note:
Kick-off depth & step out determines tangent angle.
Shortest total depth
Care needs to be taken if tangent angle is between 45-60deg in the cuttings
avalanche zone.
Minimises directional work.
S Type (b)
The S profile is similar to the J profile, but instead of continuing on a tangent, it drops off
back to vertical or near vertical to penetrate the objective. This can be used for the
following applications:
Exploration drilling when the well is deviated it. The geological & TVD uncertainty
is reduced at the top of the reservoir.
Differential sticking risk. The reduction in inclination and directional work can
reduce the differential sticking risk. This would be applicable if sandstone 2 in
Figure 25 if it had a high differential sticking risk
Pay zone cementing may be more reliable.
ECDs through the pay zone may be reduced.
Points to note:
Higher torque and drag compared to the J profile.
Higher tangent inclination compared to the J profile.
Continuous build (c)

This is based on the natural profile that the drill string would take between two points. The
profile is characterised by low build rates of 0.5/1 / 100ft. This profile is not widely used
within the industry, but can be applied in certain situations. These are:
When building from vertical to horizontal. Reducing the build rates in the build
allows you to run with a low bend setting on the motor and allows an increase in
the string rpm.
Instability in upper zones. This would be an advantage if Shale 1 in figure 25 were
unstable. The continuous build profile would allow you to minimise the inclination
through the shale, and then increase the build rate after the shale has been
drilled (pseudo-continuous).
Points to note:
Additional total depth
Low torque, but in many cases higher drag.
May need additional hydraulic capability.
39
Double build (d)
This is a variation on the J profile, but instead of building once it builds twice. Like the
continuous build profile it is not widely used within the industry, but can be applied in
certain situations. These are:
Borehole instability in the upper sections. The double build profile allows you to
minimise the inclination through these unstable formations i.e. if shale 1 is
unstable in figure 25.
Slower ROP in the upper formations. The double build minimise the along hole
depth through these formations.
Depleted zones in the overburden formations. The double build profile allows you
to minimise the inclination through these formations i.e. if sandstone1 in figure 25
has a significant differential sticking risk.
Complex builds (3-D).

3-D wells have both azimuthal & inclinational components. They are used in the industry to:
Avoid collision with other wells.

Steer around geological hazards.
Drill in a preferred direction to minimise the affect of certain geological
hazards e.g. dipping formations, stress orientation.
It is important to remember that the rates of build and turn for any given assembly are not
the same. Typically a directional assembly will achieve higher doglegs building then it will
turning.
1.5.1.3. Horizontal Wells

Horizontal profiles are used in development drilling to increase reservoir exposure.
Figure 26: Shows a horizontal profile for a shallow oil producer. The profile has been designed to
incorporate an ESP pump positioned in the tangent section. The blue circle indicates the critical
hole cleaning section in the well.
40
The trajectories are typical constrained by production requirements and they have a
significant stuck pipe risk. To add to the problems many horizontal wells are drilled in cheap
operating environments, in to shallow oil reservoirs. Typical these wells are drilled with light
underpowered rigs (many cases with a kelly) and inexperienced crews.
Hole cleaning and its associated problems is the main stuck pipe risk in a horizontal well
and the trajectory can be key in minimising the stuck pipe risks. The main areas of concern
are:
Build-up section:
Typically this section has more hole cleaning problems than its horizontal counterpart. The
explanation for this is pretty simple, the build-up sections are drilled in larger hole sizes,
typically 12 , and they require higher flow rates and rpms to clean the hole efficiently.
The build rate has a huge influence on the directional philosophy in the build-up section
and as a general rule should be minimised at much as practically possible.
The trajectory in figure 26 is a case in point, and is an actual well in the Middle East. In this
particular scenario the final dogleg severity from the end of the tangent at 45 inclinations
to horizontal was 7.5/30m. To achieve this dogleg a minimum motor bend setting of 1.5
was required. This setting restricted the string rotation to a maximum of 60rpm whilst drilling
and circulating. This restriction reduced the hole cleaning efficiency and the affect was
compounded when the well was drilled with an underpowered rig, which could only
circulate at a maximum flow rate at section TD of 2.6m3/min. The section experienced
numerous hole cleaning related problems, and one catastrophic stuck pipe incident
occurred (sidetrack required) during tripping. Even on the sidetrack it took 3days to trip out
of hole. The investigation concluded that the main root cause of the stuck pipe incident
was the underpowered rig combined with high dogleg severity requirement in the final
build section.
How do we reduce the build rate?

Move the surface location away from the sub-surface target & kick-off
higher. This is subject to the surface restrictions in the area that you are
drilling in and only applies to land drilling.
Move the subsurface target further away from the surface location & kick-off
higher. This needs to be discussed with the production guys, but sometimes a
solution can be found.
Tangent sections within the build:

The key to the tangent section is to try and keep the inclination below 45deg. If the
tangent is required for the placement of an ESP (doglegs < 2deg/30m to avoid pump
failures) then you must ensure that the tangent length is kept to an absolute minimum.
Experience has shown that the inclusion of a tangent section for an ESP into a straight build
profile can tip the balance and severely increase the drilling times and the stuck pipe risk.
This is highlighted by the graph in section 1.2 figure 6
41
Horizontal Section:
Typically this section tends to be less critical then the build section. The reasons are quite
simple:
Smaller hole sizes. Typically 8 or smaller.
Straight section with minimal direction work. BHAs can be setup for higher
string rpms e.g. typically bend settings of 0.75deg.
Smaller hole sizes mean cuttings are agitated with less string rpm. Typically
70rpm in 8 hole.
Lower flow rates are required to achieve efficient hole cleaning.
1.5.2. Directional Strategies
The recent trend within the industry has been to aim for a one run philosophy from shoe to
TD. This has evolved due to an increased reliability in downhole equipment, the
advancement in PDC technology and the drilling the limit culture.
The problem with this philosophy in directional wells is that the best BHA for the build section
is not necessarily the best BHA for the tangent section. A good analogy is formula one
motor racing. Ferrari does not try and go the hole race without pitting. Instead, he and his
team meticulously form a pit stop strategy that over the hole race is much faster than if he
didnt stop at all.
A well-planned strategy will not only be faster from shoe to TD, but will minimize the stuck
pipe risks.
1.5.2.1. Example
Figure 27 includes a build-up section and a tangent section.
There are several different ways to drill this section:
1. One run with a conventional motor assembly.

The assembly will be set up to achieve the dogleg requirement in the build-up section. The
bit will be selected to last for the whole run, typically a PDC that is not too aggressive to
allow for directional control. The planned dogleg will dictate the bend setting of the motor,
and this impacts the build tendency of the assembly in rotary mode e.g. typically the
higher the bend setting = greater the rotary build. This impacts the amount of corrections
required in the tangent section and can cause a tortuous well path and poor
performance. The bend setting can also impact the amount of string rpm for hole cleaning
in the tangent section.
2. One run with a rotor steerable assembly.

If the dogleg severity is < 8 deg/30m then a rotary steerable assembly can be used. The
merits of rotary steerable tools will be discussed later in this section, but as a general rule if
the economics can be justified then this is the optimum solution. A two run strategy can still
be used with a rotary steerable tool; the difference between the two runs would be the bit
selection.
42
3. Two runs with a conventional motor assembly.
The first BHA would be set-up to drill the build section. The bit selection would focus on
directional control and maximizing ROP. To maximize steer ability i.e. reduce reactive
torque and help the directional driller, a roller cone bit would be a good option for the
build section. It also has the advantage of making you pull the assembly for bit hours,
ensuring that you are not tempted too continue drilling with the build assembly in the
tangent section.
The second BHA would be used to drill the tangent section. It would be set-up to maximize
string rotation and ROP. A bend setting of 0.78deg could be used and an aggressive PDC
run to improve ROP.
Out of the two conventional strategies it is extremely likely that option 3 would be the
fastest from shoe to TD.
It is the role of the drilling/well engineer to work closely with, and steer the directional
drilling company, typically D & M, to develop this strategy. The worst mistake an engineer
can make is to give the directional planner two points, the surface and sub-surface target
and tell him to get on with it.
Derrick.ico
LIMESTONE
SHALE 1
Build-up section
SANDSTONE 1
INTERBEDDED
Target
Tangent
SANDSTONE 2
Figure 27: Schematic showing a standard J profile.
43
1.5.2.2. Drilling the plan
The directional plan is a guideline for the WSS & directional driller. It is not meant to be
stuck to religiously and a bit of common sense and local knowledge needs to be
incorporated.
A good directional driller should factor the following into the plan:
Build/drop tendency of the directional assembly in rotary mode. If the

assembly is known to drop at 0.3deg/30m a good directional driller will aim
to be above the line (J type) when he comes out of the build. This way he
can allow the assembly to natural drop back to the line in rotary mode.
The effect of the formation on the build/drop tendency (see figure 28). This
allows the directional driller to anticipate changes and keeps him or her in
control of the situation.
When the directional drilling and/or WSS decide to drill on the line with a motor assembly
they:
Increases the amount of sliding.

Increases the tortuosity of the wellbore
Increases the torque and drag.
Reduce the hole cleaning efficiency.
Figure 28: Shows build tendencies in a 12 build up section. Recording the dogleg severities in
different formations allows the directional driller to plan ahead and stay in control of the drilling.
44
1.6. Directional Assemblies.
1.6.1. Conventional Steerable Assemblies:
The majority of directional wells around the world are still drilled with conventional steerable
assemblies. The main issues with respect to hole cleaning/stuck pipe are:
1. No rotation when sliding. Cuttings are not thrown on to the conveyor belt. Figure
18 clearly shows this.
2. RPM restrictions are imposed with increasing bend setting. This is to avoid fatigue
failure of the bearing housing. The limit might not be high enough to clean the
hole.
3. Annular clearance between the wellbore and the sleeve or integral stabiliser.
80 models from 2 1/8 in. to 11 1/4 in.
PDM
Bend Setting
Sleeve or integral
stab.
Figure 29: Shows a typical motor assembly.
1.6.1.1. No String Rotation When Sliding
As discussed in the hole cleaning section pipe rotation has a huge impact on the hole
cleaning efficiency. Unfortunately for us conventional steerable assemblies cannot be
rotated whilst steering and the result of this is a cuttings build-up in the annulus during this
period. This disadvantage has been one of the main drives behind the development of
rotary steerable systems.
1.6.1.2. Bend Setting & the affect on string RPM.
Conventional steerable design is driven by the dogleg requirements of the trajectory. This
translates simply to:
Higher dogleg = higher the bend setting = greater the restriction in RPM.
45
This is important to remember when designing the trajectory. If for example a 12 section
has been designed with a build-up rate of 8deg/30m its likely that the motor bend setting
will have to be either 1.5deg or 1.83deg. The D & M Powerpak Motor Uniform Operating
Procedures show that the maximum string RPM that can be applied to the string during
drilling of this build-up section is 40rpm well below what is required for cuttings agitation.
To compensate for the lack of rotation you can:
1. Increase the flow rate. In most cases we wont be able to increase the flow rate to
a sufficient rate that would make up for the lack of rotation.
2. Ensure rotation of sufficient speed is achieved in the tangent section after the build-
up section. This only applies if there is a tangent section after the build.
3. Change the trajectory. This means reducing the build rates so that a lower bend
setting can be used. In order to do this the surface location might have to be
moved.
4. Putting in dedicated hole cleaning procedures. This could involve clean-up trips
during the build-up section and having dedicated assemblies for different parts of
the section i.e. one assembly for the build-up and a different assembly for the
tangent section.
In wells with inclinations over 50deg it is very unlikely to get stuck whilst drilling. In nearly 95%
of the cases we get stuck pulling out of hole and it is important to maximise circulation prior
to tripping. This means maximizing the RPM & flow rate even if you have been restricted
whilst drilling the build section. See appendix 7.17 & 7.18 for the RPM tables.
Intouch Content ID: 3016498: PowerPak Motors Uniform Operating Procedures (v 1.4).
1.6.1.3. Junk Slot Area.
Field experience and research has shown that it is very difficult to get a deviated hole 100%
clean. Therefore we have to assume that there is a cuttings bed lying on the low side of the
hole when we trip. The height of this bed will depend on how efficient our hole cleaning
has been.
In order to successfully trip out of the hole the cuttings must pass around the BHA without
increasing the bed height e.g. a steady state situation. However, if the bed height
increases, cuttings will build up around the BHA and the risk of pack-off and stuck pipe
incidents increase.
The three main factors that influence this are:
- The height of residual cuttings bed.

- Clearance between downhole drilling equipment and wellbore.
- Pulling speed.
The bed height is governed by the equilibrium conditions of our rig and well design.
Tripping speed is in the hands of the driller and he must be made aware that the hole is
probably not 100% clean prior to the trip (even though the proper practices have been
followed), and that any resistance is the build-up of cuttings around the BHA this is an
46
extremely important message to get across. Junk slot area needs to be planned in
advanced, and is especially important when the well is being drilled with a sub-optimum
flow rate & rpm. In this situation the junk slot area needs to be maximized.
Where is the least amount of annular clearance?
Typically this is between the sleeve stabilizer on the mud motor and the wellbore. Figure 32
shows the difference between a 12 FG, 9 5/8 motor sleeve stab & a 12 FG, 8
motor sleeve stab. It can clearly be seen that there is a significant reduction in clearance
between the two.
How to increase the clearance?
Note: We will focus on 12 hole because it tends to be the critical hole size.
1. Run an 8 mud motor assembly instead of 9 5/8 mud motor assembly. This will
increase the annular clearance, but it may reduce the performance. Another
problem is that 8 assemblies tend to build more angle than a 9 5/8 assembly
when rotating in a tangent section. To compromise a two assembly approach could
be used i.e. 8 for the build-up & a 9 5/8 for the tangent.
2. Manufacture some 9 5/8 integral blade stabilizer bodies to increase the clearance
e.g. 9 5/8 instead of an 11 diameter. At the moment D & M do not supply these,
but they can be easily manufactured with enough lead-time.
3. Run a slick assembly. The main issue is a strong drop tendency in rotary mode?
Sleeve
stabilizer
Figure 30: Shows the different stabilizer options for a mud motor. Integral blades are normal used on
small motors e.g. <6
47
9 5/8 MM sleeve stab. 8 MM sleeve stab.
Clearance
11 dia.
9 3/8 dia.
12 1/8 Sleeve stabilizer

in 12 hole.
Figure 31: Scale drawing of a 9 5/8 & 8 motor sleeve stabilizer for 12 hole. The diagram shows
a significant increase in junk slot for the 8 motor sleeve stabilizer. This increase could be important
if we are trying to trip out of a dirty hole (see figure26).
To find the optimum solution it is important to discuss the requirements & options with the
directional drilling company in the planning phase.
Other Factors
The amount and type of stabilizers run has an impact. The philosophy should be to always
minimize the number of stabilizers in the BHA and run straight bladed stabs instead of spiral
stabilizers. If spiral stabs are used ensure the wrap is not more than 270deg.
If a clean out trip is planned before running casing it is always better to lay down the
directional assembly and run back in with a dedicated clean out BHA.
1.6.2. Rotary Steerable Systems (RSS).
The single most important advantage that a rotary steerable system has over a
conventional motor system is continuous rotation of the string at speeds over 120 rpm. As
mentioned previously, continuous rotation at high rpm is one of the key factors for
achieving good hole cleaning and rotary steerable systems are the solution. However, it is
important to stress that a rotary steerable system alone wont solve your hole cleaning
problems unless the other key parameters are optimized.
The main advantages with the use of rotary steerable systems are:
1. Continuous rotation maximizes hole cleaning efficiency and ROP.

2. Full inclination and azimuth control with a broad range of dogleg capability.
3. Not limited by weight stacking and buckling issues, as are motors.
48
4. Minimize tortuosity in the wellbore smooth wellbore aids further torque and drag
reduction.
So why arent these tools used for all wells in all applications? There are currently two main
limitations:
1. Cost: initially the costs of the tools were expensive, and because of this were rarely
used in land operations. This is changing; the cost of the tools is coming down as
new systems enter the market, and operators are becoming aware of the additional
advantages and indirect savings that a RSS can bring to their operations.
If the economics are cost neutral or slight negative then a RSS should always be run.
One point to note is that Lost In Hole charges tend to be fairly high.
2. Reliability: RSSs have not had a good reputation in this area. However, in the last 2
years tool reliability has increased dramatically as the service companies define and
fix problems with the tools. D & M are leading the way in reliability compared to the
competition and the mean time between failures for PowerDrive in 2003 was 13000ft
between failure, or 350 circulating hours.
1.6.2.1. What to consider when running RSS?
1. Pressure drop required at the bit and by the tool is significantly higher than a mud
motor.
2. Planned dogleg severity. Maximum dogleg is 7-8 deg/30m, but can be less in softer
formations.
3. Junk slot area same discussion as in section 1.6.13
4. Can I ream & back ream with the tool?
5. Does the whole system rotate? Some types of system have non-rotating parts that
can cause problems when POOH and reaming.
6. Will there be an increase in ROP? If so, is the flow rate sufficient to still clean the
hole?
1.6.3. Drilling tools and Equipment.
The intention of this section is to discuss the downhole drilling tools that can help us mitigate
stuck pipe hazards and improve our hole cleaning efficiency. Jars and accelerators will be
discussed in section 4.3
1.6.3.1. Tools to improve the hole cleaning efficiency.
When trying to improve any system it makes sense to try and concentrate on the factors
that have the biggest influence. In the case of hole cleaning it is flow rate, string rotation
and low-end mud rheology.
If we assume that the mud type and solids control equipment control the rheology, then
the only things we can influence with downhole equipment is the flow rate and string
rotation/improved cuttings agitation.
49
1.6.3.2. Drill Pipe.
Drill pipe accounts for 60% of the pressure losses in the circulating system and the
maximum flow rate, is governed by the circulating pressure loss in the system and the
pressure rating of our mud pump liners.
When the circulating pressure (system pressure drop) reaches the maximum pressure rating
of the liner we have to do something if we want to continue drilling deeper in the same
hole size. The normal procedure is to gradually reduce the flow rate to keep the circulating
pressure just below the pressure rating of our liners. Obviously this has a negative impact on
our hole cleaning efficiency, especially in critical sections of our well.
To enable us to pump more flow rate for a given pressure we have to change one of the
parameters that contribute to the circulating pressure loss in the system. If we assume the
mud rheology, hole geometry and BHA configuration is fixed then the only option open to
us is to increase the ID of the drill pipe. This means using larger drill pipe (see Figure 32).
Many engineers believe the main reason to pick-up larger to drill pipe is it reduces the
annular x-sectional area and thus increase the annular velocity for the same flow rate.
Figure 34 shows that while this is the case, it is negligible compared to the increase in
annular velocity provide by the increase in flow rate caused by the reduction in the drill
pipe pressure loss.
Figure 32: This graph illustrates the advantage of using larger DP by comparing the standpipe
pressure for an example well. Two hole sizes are considered, in each hole size three sizes of DP are
used. For this example a maximum stand pipe pressure is assumed to be 3800 psi. The depth of the
17.5" hole is 6000' and the depth of the 12.25" hole is 10000'.
50
Annular Velocities for 800gpm flow rate & varying hole sizes
& 6 5/8"
600
An
nul 500
ar
Vel
oci 400
ty
(ft/ 300 5" DP
mi 6 5/8" DP
n)
200
In the small hole sizes ECD issues
100 could start coming into play.
0
17.5 16.5 15.5 14.5 13.5 12.5 11.5 10.5 9.5 8.5
Hole Size (in)
Figure 33: This chart illustrates the difference in annular velocity when pumping at a constant flow
rate of 800gpm and using different drill pipe sizes e.g. 5 & 6 5/8 and a variable hole size.
Other factors to consider when up sizing DP:
a) Derrick set back area and size of the monkey board. Can they accommodate
the larger pipe?
b) Higher ECDs, torque & hook load, especially in small hole sizes.
c) Time required to lay down & pick-up new pipe e.g. laying down 6 5/8 DP &
picking up 5 DP to drill 8 hole. The additional time required should not be an
argument against switching to bigger DP if it reduces the chances of getting
stuck and enables the rig to drill within the box.
d) Well control equipment for new size of DP.
e) Lifting equipment e.g. elevators, lifting subs etc.
f) Fishing tools. Do you have them available? Are they conventional sizes? etc.
Further documentation on the advantages of using different DP sizes can be found in:
InTouch Content ID 2021253: ERD Drill Pipe Feasibility Study: Technical report which analyses
the interaction between different OD/ID combinations of 5", 5 1/2" & 5 7/8" plus tapered
drill strings. It is used to identify the best drill pipe for future wells. Criteria being lowest
surface torque, lowest ECD & lowest Standpipe pressure.
1.6.3.3. BHA components:
BHA components e.g. directional drilling tools require large pressure drops to power the
tools. The table below gives some representative figures.
51
Tool Pressure drop across tool
Powernap A962XP, 9 5/8 OD, 3:4 lobes, 305psi
4.5stg
Powernap A962XP, 9 5/8 OD, 3:4 lobes, 580psi
6stg
Power Pulse - 8 Normal Flow 506psi
Power Drive X5 100psi tool, 600-800psi back pressure from
bit
Turbine 1500psi
Table 7: Pressure drops across different BHA components.
It is impossible to eliminate these pressure drops whilst drilling, but if additional flow rate is
required at TD, prior to tripping, a multi opening & closing circulating sub (PBL) can be
placed on top of the BHA to bypass the flow straight into the annulus.
For further information on this tool go to: http://www.dsi-pbl.com
A performance report on the use of a PBL sub for Shell Gabon between '97 and '98 is in
Touch Content ID 3316624.
Bit:
Bit nozzle area does have an associated pressure loss, but the nozzles are normal sized to
provide the required backpressure for the directional drilling tools and optimisation is
limited.
1.6.3.4. Bladed Hole Cleaning Drill Pipe:
Bladed drill pipe has been developed by different manufactures to improve the hole
cleaning efficiency. The different types available are fairly similar in design and all promote
the same advantages:
Disturbs Cuttings beds to produce a clean hole

Reduces Wall Contact
Reduces Drilling Torque and Vibration
Reduces Drag
Reduces Casing Wear
Prevents Differential sticking
Prevents Buckling
Figure 34 shows two companies products: Hydro-clean from Smith & E.P.D.P from Stable
Services Ltd.
52
Figure 34: Shows two different types of bladed hole cleaning DP that are available on the market.
http://www.smf-international.com/hydroclean/
http://www.stable-services.co.uk/
The following text is taken from Smiths website and is a brief explanation on how hydro-
clean works?
Compared to a conventional profile, which only agitates cuttings, the patented hydro-
clean profile is a combination of angles that work in harmony to provide a number of
effects resulting in the cuttings being re-introduced into the flow stream.
It works by creating a differential pressure that moves the particles from high pressure to an
area of low pressure where they are held in place in the vortex created by the rotation.
K & Ms experience on these tools (from their ERD manual):

K & Ms experience with these tools has shown no obvious benefit to the string if good
hole cleaning practices were already in place.
Industry
Research has shown that under test conditions these products do improve the hole
cleaning efficiency.
SPE 59143 Improved Hole Cleaning and Reduced Rotary Torque by New External Profile on
Drilling Equipment
53
However, the general industry response is mixed. Some operators have had great success
using these products, while others have not seen the improvements that they wanted. In
practice it really is dependent on the specific conditions.
The general rule is that if you do decided to run this pipe then you should follow the
companies placement guidelines even if it means picking up a lot of additional pipe. In all
cases the results should be compared with standard DP and the learnings and results
cascaded to the WE community.
Schlumberger does have some experience with this type of drill pipe and the reports can
be found at the following Intouch content pages:
Content ID: 3278829 Multi drillstring ID changes attenuate signal: MWD signal attenuation
when hydro clean DP pipe was alternated with standard HWDP.
Content ID: 4060205 Use of Enhanced Drill Pipe and Torque reducing devices in KE5-01,
AGIP KCO: Discusses the impact of the drill pipe in reducing torque and the reduction of
the risk of differential sticking.
54
1.7. Drilling Fluid Selection.
1.7.1. Vertical wells - Hole cleaning
In large diameter low angle holes, and environments with reduced drilling margins and
high fracturing/ lost circulation risks, WBM systems are the preferred mud systems for drilling
and hole cleaning. Care should be taken to prevent high annular cuttings loading
(resulting in high ECD, packoff, aggravated BHA balling, etc) due to a combination of high
ROP, insufficient flow rates, and insufficient rheology (especially low 6 & 3 rpms and YP).
High-vis sweeps may need to be programmed to clean the hole properly.
1.7.2. Deviated & High Angle wells
1.7.2.1. Mud Selection
Critical technical issues that need to be considered in drilling fluids selection process are
detailed in the following table:
Issue Impact on Drilling Fluid Selection

Hole cleaning The mud property design, and rheology, must take into account the flow rate
Capability capability of the rig. Rheology will be heavily dependent upon the actual fluid
used. In general, hole-cleaning capability can be attributed to a well-
maintained 6-rpm reading. Target 6 rpm readings should be 1.0 1.2 x hole
size in inches.
Hole cleaning An inhibitive mud will require better hole cleaning conditions than a dispersive
requirements system. Dispersive systems allow long, large high angle surface holes to be
And lithology successfully drilled, despite relatively poor hole cleaning parameters, because
the cuttings are predominately dissolved into the mud. Note: that the lithology
must be appropriate if dispersion is to be relied upon as an effective hole
cleaning tool.
Wellbore Required minimum mud weight and inhibitive performance of a drilling fluid are
stability closely related. In most cases, with improved inhibition the well will require
less mud weight for stability purposes. Therefore, the chemical interaction
between the rock and drilling fluid has been minimized (or taken out of the
equation) and the mud weight is now only required to maintain the mechanical
strength of the rock.
Time Hole sections are generally open much longer and must be tripped through
Dependency of more often than on conventional wells. Therefore, it is very important that the
Formation wellbore is either maintained in good gauge condition or is allowed to disperse
in a mud making system. Shale hydration is a common problem in the industry
that is amplified in ERD wells. It is important to be able to run with a minimum
mud weight to slow down the hydration process and/or to minimize the
chemical interaction with the wellbore. An invert emulsion (e.g. OBM or SBM)
system keeps the water away from the rock and virtually eliminates the
hydration process if the fluids water activity (Aw) level is designed properly for
the formations being drilled.
55
Well control This is not only a mud weight issue. Factors such as gel strength properties
(that affect likelihood of swabbing or surging if the mud gels up when static),
solubility of gas into the mud, barite sag and ability to use high flow rates with
increased mud weights must be considered.
Lubricity In an ERD well, lubricity is an important factor in the total picture of hole
cleaning. If a drilling fluid is providing better inhibition and keeping the hole
gauge, then hole cleaning is greatly improved. This will lead to fewer cuttings
in the hole (i.e. Cuttings beds), which will produce lower coefficient of friction
(cof) factors. WBM lubricants are available and have proven effective at
obtaining OBM-like cof. These systems are not as inhibitive as the OBM
systems, and require continuous additions.
Differential Differential sticking performance of a mud system will be a key consideration
sticking when drilling through permeable formations. Generally, the increasing angles
associated with high angle wells lead to increased mud weight, while the
reservoir section is generally much longer due to the high angle of the wellbore.
Further, high angle wells are shallow by their nature, and are commonly under-
pressured. This is critical, given that there is less capability to accommodate
further increases in torque and drag, and there is less available jarring
capability to deal with stuck pipe. Differential sticking can act on bhas in
degrees. Namely, just because an assembly is not differentially stuck, does not
mean that there is not a degree of differential sticking acting on the assembly.
These forces act to drive the cof in the well up and often play a role in the
viability of the hole section. Selecting the proper fluid and/or fluid
additives/lubricants to minimize the effects of the differential sticking is a key
issue in high angle wells.
Accretion This affects both drilling and tripping. The mud systems anti-accretion
(Bit Balling) performance has a dramatic effect on the bit and BHA selection, bit hydraulics,
rig flow rate capabilities, tripping capability, well control (swabbing), and hole
cleaning risks. New HPWBM, Glycol and Silicate WBM systems have been
successfully used for the prevention and mitigation of accretion. These
products preferentially attach/coat themselves to steel and have eliminated
accretion tendencies in many wells. OBM is the most effective way to deal with
accretion problems.
Accretion is an important issue in high angle wells, because bit hydraulics is

often compromised due to limited rig capabilities. Accretion should not only be
thought of as the commonly viewed global balling, but also the micro-balling
that occurs at the cutters.
Ecd Ecds are often greatly magnified on high angle wells, both while drilling and
And while running and circulating casing. As high angle wells have grown longer
Mud losses and shallower ecds have begun to play a limiting factor in many programs.
The shallower the vertical depth of an high angle well, the more effect the
pressure drop in the annulus will have on ECD. For example, in a 25,000
(7,600.) Vertical well, a 1,000 psi annular pressure drop would only add a
matter of 0.8 ppg to the ECD. In comparison, a 25,000 MD high angle well at
6,000 TVD (2,440m TVD) will experience a 3.3 ppg emw increase for the
same annular pressure drop.
56
In hindsight, the industry has many wells where ecds have exceeded 10 ppg
emw while running casing, which explain the frequent lost circulation problems
that are associated with some hole size/casing combinations.
Typical ecd fluctuations in shallow 8 high angle wells will run up to 5.0 ppg
emw, unless the well has been specifically designed to limit ecds. The selected
drilling fluids play an important role in managing ecds.
Table 8: Technical issues that need to be considered in drilling fluids selection for deviated wells.
However, many of the issues are equally valid for vertical holes.
Main mud selection criteria for drilling high angle holes are: hole-making ability (i.e.
prevention of bit-balling), wellbore stability in shales, friction coefficient and fluid loss
control (i.e. prevention of differential sticking). In most cases, these criteria strongly favor
the use of SBMs (exceptions are areas with very high fracturing/ lost circulation risks).
For hole cleaning, it is recommended to formulate the mud with appropriate low-end
rheology (i.e. 6-rpm reading preferably at 1 - 1.2 x hole size), provided other system
limitations (e.g. restrictions on viscosity due to ECD limitations) are met as well. Note that it
is difficult to modify low-end rheology independent from high-end rheology (i.e. 600-rpm &
300-rpm readings that affect PV and YP).
Barite Sag is an important detrimental phenomenon that must be taken into account in the
selection and design of a mud system for high angle wells. Barite Sag may adversely affect
ECD and surge pressures, wellbore stability, packoff and lost circulation, and well control.
Minimizing barite sag tendency requires dedicated formulation of the mud for sag control
(using sag control agents such as organophilic clays), proactive monitoring (using special
sag screening techniques such as the VST test), and maintenance at the rig-site (especially
maintaining adequate ultra low-end rheology, i.e. < 3-rpm readings).
For deepwater applications, mud rheology should be considered explicitly as a function of

temperature and pressure. Hole cleaning and ECD modeling should be conducted using
parameter input from Fann 70 (or equivalent) viscometer measurements. Mud checks at
the rig-site should be conducted at downhole circulating temperature, mud line
temperature, and flow line temperature.
1.7.2.2. Mud Properties
The mud weight required for both wellbore stability (as determined by off-set data) and
well control should be maintained prior to drilling into formations. Field experience shows
that it is usually possible to maintain a mud weight of 0.2 0.3 ppg below the calculated
mud weight (e.g. to accommodate high ECDs in small drilling margin environments),
without suffering excessive hole problems. However, maintaining even lower mud weights
(e.g. > 0.5 ppg below calculated recommended mud weight) will inevitably lead to
wellbore enlargement (with cavings and reduced annular velocities complicating hole
cleaning), packoff problems (with associated fracturing & lost circulation risks), hole
collapse, and stuck pipe.
57
The effect of mud compressibility (more pronounced for SBMs than for WBMs) always needs
to be taken into account when selecting and maintaining an optimum downhole mud
weight.
The use of a pressurized mud balance is recommended to accurately measure surface

mud weights.
Mud rheology should be optimized in accordance with hole cleaning simulations (e.g.
Virtual Hydraulics*). Simulations need to be carried out using mud properties as a function
of temperature and pressure, as determined by Fann 70 (or equivalent) viscometer. It is
recommended to obtain Fann 70 measurements of the mud sent out from the plant, and
occasionally test mud samples from the rig.
Use cuttings size (i.e. monitor shakers, consult with bit experts) to update hole-cleaning
predictions.
It is recommended to maintain the mud with appropriate low-end rheology (i.e. 6 rpm
reading preferably at 1 1.2 x hole size), provided other system limitations (e.g. restrictions
on viscosity due to ECD) are met as well. Note that it is difficult to modify low-end rheology
independent from high-end rheology (i.e. 600-rpm & 300-rpm reading that affect PV and
YP).
Thixotropy (i.e. gelation) allows for cuttings to remain suspended in the mud while static.
Gel strengths should be non-progressive (i.e. little difference between 10 min. and 30 min.
gels) but adequate to suspend cuttings (e.g. 10 sec. gel: 10 18 lbs/100ft2; 10 min. & 30
min. gels: 16 28 lb/100ft2).
Good solids control, preventing cuttings/ solids breaking down to colloidal size in the mud,
is crucial to minimize PV (thereby minimizing pump pressure/ maximizing flow rates), keep
YP in check (thereby controlling ECDs), and prevent gels from becoming progressive
(thereby preventing excessive swab & surge pressures). LGS should preferably be < 5%, API
SP (measuring solids control efficiency) should preferably be > 90% (note that high dilution
rates to maintain optimum properties will inflate drilling fluid costs).
Running SBMs with higher synthetic-to-water ratio (SWR) will help to thin the fluid, minimizing
pump pressures and maximizing flow rates for hole cleaning. Note that higher SWRs will
increase the cost of the mud system.
Maintaining good shale inhibition and chemical wellbore stabilization is an important

requirement for drilling and cleaning high-deviation well bores, strongly favouring the use
of SBMs. Poor inhibition and chemical stability will complicate hole cleaning by causing
wellbore enlargement, higher annular loading, and cuttings beds that are more difficult to
remove (due to mutual sticking of cuttings). Note that good shale inhibition may
complicate hole cleaning in large diameter vertical holes, as all cuttings are kept intact
(i.e. no dispersion occurs) and must be removed from the hole.
58
Sweeps in high angle holes should be avoided, as they tend to be ineffective, make
controlling mud properties more difficult, and may increase the chance of pack-offs.
Barite sag is aggregated by low shear operations (e.g. slow pump rates and slow pipe
rotation, tripping, logging, small wellbore influx, slow fracture breathing etc.), which should
be minimized if at all possible. Mud treatment recommendations (e.g. maintenance
requirements on sag control agents such as organophilic clays in the correct ratios) should
be strictly adhered to. Pro-active sag monitoring using representative tests (e.g. VST)
should be practiced. PWD information on static mud weight while tripping yields valuable
information on sag tendency and should be used to optimize pump staging and mud
circulation during trips.
1.7.3. Differential Sticking
Prevention of differentially stuck pipe is primarily established by selecting optimum mud

properties (density and plastering properties), to control the pressure differential between
mud column pressure and formation pore pressure and the composition and thickness of
the filter cake. Good filter cakes can be obtained with any of the water-based muds;
hence no obvious preference exists for any of the water-based muds.
IOEM provides superior mud cakes with regard to thickness and lubricity. This mud type
could, therefore, be considered in holes with an increased risk of differential sticking, e.g.
deviated hole sections over pressure depleted reservoirs.
1.7.4. Reactive/time dependent shales.
Borehole instability in shales is a major source of drilling trouble time, and is thought to be
the cause of approximately one-third of all stuck pipe cases. Stability problems generally
build up in time, starting with shale failure at the borehole wall, followed by transfer of shale
fragments into the hole. Then, if hole cleaning is insufficient, problems such as "sticky" hole,
packing off, and hole fill and stuck pipe will occur. Eventually this may result in losing the
hole and having to sidetrack. Other negative consequences include high torque and
drag, and poor cementations. The fundamental reasons behind shale failure are covered
in Chapter 8 of the Trouble Free Drilling Manual.
This section will summarize the best drilling fluids to use to minimize the impact of unstable
shale formations.
1.7.4.1. Non water based fluids
OBM
Historically OBM has shown to be the best shale drilling fluid. The main reason for this is
capillary effects, which prevent pore pressure invasion (See figure 35 & the Drilling Fluid
Filtrate section, in Chapter 8 of the Trouble Free Drilling Manual).
59
Figure 35: Non-water based systems are effective in preventing pore pressure penetration in shales
due to capillary effects.
OBM also has very good lubricating properties and high temperature stability, making it
very suitable for deep and long reach wells. However, due to environmental constraints it
will not be possible to use OBM without cuttings re-injection in the near future and thus
alternative muds have to be considered.
Pseudo OBM
Pseudo OBMs behave similarly to conventional OBM, preventing pore pressure
penetration in shales through capillary action at the pores. The systems are based on non-
toxic biodegradable material such as esters or ethers. The main drawbacks to Pseudo
OBM are the high costs and limited temperature stability of ester based muds such as
Petrofree (140-150C).
1.7.4.2. Water Based Fluids
The effectiveness of water-based shale drilling fluids is dependent on the inhibiting principle
(pore pressure penetration or hydration stress) and on the amount of chemicals used
(cost). A mud that eliminates pore pressure penetration also prevents the effects of
hydration stress since no fluid is allowed into the pores. A mud designed to prevent
hydration stress by inhibition automatically implies a (de-stabilising) pore pressure invasion!!
Examples of water-based shale drilling fluids are KCl/Polymer muds, viscous brines and Poly-
glycol systems (Aquacol, SSL-5).
Brine systems
All salts reduce hydration stress in shales, but certain salts are more effective than others.
However, salts are not capable of reducing hydration stress to zero.
The strongest inhibitive effect is seen from Potassium Chloride (KCl) mud, which is why KCl is
used frequently as a basis for shale drilling fluids. Field trials with high concentration KCl
60
mud indicate this mud to be less effective than Polyglycol muds.
The drawback to most salt systems is that they do not reduce pore pressure penetration.
Salt ions are simply too small to plug a shale pore system. Also, brine filtrate viscosity at
saturation is generally equal to that of water, which is not enough to hamper pressure
invasion.
Exceptions to the above are Saturated CaCl2 brine and high-density formates, which both
have a high filtrate viscosity causing a strong reduction of pore pressure penetration in
shales. It should be noted that reduction of pore pressure penetration is dependent on
filtrate viscosity and not "bulk" fluid viscosity. A high viscosity drilling fluid can have a low
filtrate viscosity that will not affect pore pressure invasion.
Polyglycol muds
A number of systems advertised as shale drilling fluids are based on glycol and glycerol
polymers. Examples of polyglycol muds are thermally activated mud emulsions like BW's
SSL-5 and Milpark's Aquacol.
An advantage of both mud systems is the environmentally friendly principle on which they
are based. The muds contain low molecular weight polygylcols that will cloud out and
form an emulsion above a certain temperature (cloud point). This emulsion creates a film
on the shale surface that acts as a filter cake and thus reduces pore pressure penetration.
61
1.8. Rig sizing and capability.
The rig can play an import role in stuck pipe prevention and in many cases is a major
contributing factor in getting us stuck.
In most situations we do not have the luxury of drilling with the ideal rig with unlimited
hydraulic capacity and the perfect solids control system. In reality we have to make some
compromises and it is important to know the rigs limitations before we drill a well that it is
out of the operating envelope of our rig.
The rig capacity is a major factor in determining the size of the drilling box that we can
safely operate in and the main components are:
Hydraulic capability
Rotary capability.
Power capability.
Solids control equipment.
For additional information on this topic see:
Intouch Reference Page Content ID 3956915: Rig Selection, Inspection and Operations
Intouch MCA GFE Content ID: 3956721: Project - Rig Selection
1.8.1. Hydraulic capability:
In general the 12 section on deviated wells will determine the rigs pumping
requirements, but this is not always the case. It is therefore important to determine where
the maximum pressures and flow rates will occur and then determine whether the rig can
meet these requirements. Modelling the hydraulics and using the relevant offset data to
calibrate the model allows us to do this.
What determines the maximum flow rates and pressures of our system & how can we
improve it?
1.8.1.1. Rig pumps (triplex).
Bigger pumps can provide more flow rate for the same pump pressure than smaller pumps.
The table below is taken from the National Oilwell website and it shows the range of triplex
pumps they offer.
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Max.
Model Input Power Discharge Length Width Height Weight
Pressure
HP (kW) PSI (kg/cm2) GPM (LPM) ft in (mm) ft in (mm) ft in (mm) lbs (kg)
7-P-50 500 (372) 4830 (340) 160 (605) 11 10" (3614) 6 7" (2069) 4 6" (1384) 16750 (7600)
26970
8-P-80 800 (597) 5000 (352) 222 (840) 13 6" (4105) 7 10" (2385) 5 0" (1524)
(12235)
33200
9-P-100 1000 (746) 5000 (352) 287 (1085) 14 8" (4477) 8 6" (2572) 5 4" (1626)
(15060)
42550
10-P-130 1300 (969) 5000 (352) 357 (1351) 15 7" (4740) 8 11" (2727) 5 7" (1702)
(19300)
54700
12-P-160 1600 (1193) 5000 (352) 444 (1682) 17 5" (5309) 9 6" (2890) 6 3" (1905)
(24810)
82000
14-P-220 2200 (1640) 7500 (527) 375 (1419) 18 2" (5544) 10 6" (3194) 7 1" (2139)
(37195)
40950
A-1400-PT 1400 (1044) 5000 (352) 382 (1446) 16 0" (4877) 7 11" (2407) 7 5" (2267)
(18575)
41350
A-1700-PT 1700 (1268) 5000 (352) 459 (1728) 16 0" (4877) 7 11" (2407) 7 5" (2267)
(18756)
47780
HD-1400-PT 1400 (1044) 5000 (352) 367 (1389) 16 0" (4877) 7 11" (2407) 7 5" (2267)
(21673)
49030
HD-1700-PT 1700 (1268) 5000 (352) 444 (1682) 16 0" (4877) 7 11" (2407) 7 5" (2267)
(22240)
Table 9: Shows the different triplex mud pumps available from National Oilwell
Different pump liner sizes determine the working pressure and maximum flow rate of the
pump and the amount of flow is inversely proportional to the pressure. The table below is
taken from the National Oilwell website and its shows the different liner sizes for their 10-P-
130 Mud Pump. The industry rule is that the pumps can be run at 90% of maximum for
continuous operations e.g. 120 spm. However, the condition of the pumps and the
climate does play a role and a realistic figure for planning is 100spm. It is important to
factor this limit into any sizing calculations because you will have overestimated your rigs
pumping capability if you use the 140spm values.
Liner size,
6-3/4 6-1/2 6-1/4 6 5-1/2 5 4-1/2 4 Pump Max.
inches Hydraulic*
(171.5) (165.1) (158.8) (152.4) (139.7) (127.0) (114.3) (101.6) Speed Input
(mm)**
Max. Discharge
3085 3325 3595 3900 4645 5000 5000 5000
Pressure, psi
(216.9) (233.8) (252.8) (274.2) (326.6) (351.5) (351.5) (351.5)
(kg/cm)
GPM* GPM GPM GPM GPM GPM GPM

GPM (LPM) spm HP HP
(LPM)* (LPM) (LPM) (LPM) (LPM) (LPM) (LPM)
651 603 558 514 432 357 228 140 1300
289 (1093) 1170 hp
(2463) (2284) (2111) (1946) (1635) (1351) (863) spm hp
558 517 478 441 370 306 196 120 1114
248 (939) 1003 hp
(2111) (1958) (1810) (1668) (1401) (1158) (742) spm hp
465 431 398 367 309 255 163 100 929
207(784) 836 hp
(1759) (1631) (1508) (1390) (1168) (965) (617) spm hp
372 345 319 294 247 204 131
165 (625) 80 spm 743 hp 669 hp
(1407) (1305) (1207) (1112) (934) (772) (496)
279 259 239 220 185 153
124 (469) 98 (371) 60 spm 557 hp 501 hp
(1056) (979) (905) (834) (701) (579)
Vol./stroke, 4.647 4.309 3.984 3.671 3.085 2.549 2.065 1.632
gal. (Liters) (17.592) (16.313) (15.082) (13.9) (11.679) (9.652) (7.816) (6.177)
* Based on 90% mechanical efficiency and 100% volumetric efficiency
Table 10: Shows the liner sizes for National Oilwells 10-P-130 Mud Pump. The 120 & 100spm rows have
been highlighted, as these are the realistic maximum continuous pumping rates.
63
The rig contractor will probably not be contracted to carry all the liner sizes. Check what is
available, and if a different size is required then get the drilling contractor to order it.
Additional pumps.
An additional pump enables you to pump at a higher flow rate for a given pressure rating
and can provide redundancy.
The additional flow rate advantage is shown below:
Pumping at 100spm with 6 liners (values taken form the table above)
2 pumps: maximum flow rate = 734gpm at 3900psi
3 pumps: maximum flow rate = 1101gpm at 3900psi
There are some significant issues with adding an additional pump to the rig. These are:
Additional cost.
Power capability of the rig normal needs upgrading.
The additional flow rate might not give a significant advantage.
1.8.1.2. Surface Lines & Standpipe manifold.
The surface lines & standpipe manifolds are normally rated to 3000psi, 5000psi or 7500psi.
The important aspect is to check that the maximum pump pressure does not exceed the
rating of the surface lines. This is unlikely, but can happen for example when you have a
3000psi system and > 1000HP pumps.
1.8.2. Rotary capability:
To achieve effective hole cleaning the drill string should be rotating at a continuous rpm
sufficient to clean the hole (see section 1.4).
Torque calculations at the planned rpm should be made for each hole section and then
compared with the rigs rotary system torque rating for that rpm. This is important as the
maximum quoted torque normally drops off as the rpm is increased (see Figure 37).
Different types and sizes of rotary tables are available i.e. series or shunt, gears or no gears,
and they normally have a lower torque rating then there top drive cousins. It is important in
the planning phase to get the amp vs. torque graph (see below) for your specific rotary
table to determine the rigs torque capability especially when drilling a deviated/horizontal
well.
64
Figure 36: The charts are taken from the Transocean SedcoForex drilling practices manual and shows
the evolution of pumping & torque capabilities with time.
65
Figure 37: Shows the torque output curves vs. rpm for the 3 different TDSs. The graph clearly shows
that the maximum torque output changes with RPM. The message here is to check your torque
rating at the required rpm for your topdrive or rotary table.
Example:
Figure 38 shows an amps vs. motor torque graph for a 37 table on a kelly drilling rig. The
torque output of the table in the figure is extremely low, and in this specific example the rig
had problems drilling deviated wells. In this case the original rig was designed for a 27
table. The rig was then refurbished and a 37 table installed. However no modifications
were made to the substructure below the rig floor. As a result no room was available for a
gearbox and the table was permanently in high gear. This meant when medium to high
torque was experienced the table just died!
66
Figure 38: Shows an amps vs. motor torque graph for a 37 table. To establish the string torque,
take the amp reading from the gauge on the rotary table. Project up from the x-axis until the line
intersects the torque vs. amp line. Project across to the y-axis until the line intersects the motor shaft
torque. Multiply this value by 3.6. This gives you the string torque. For the example shown the amp
reading is 750. Following the red line it intersects the motor shaft torque axis at 3200 ft.lbs. This value
multiplied by 3.6 equals a string torque value of 11520 ft.lbs.
67
1.8.3. Power Capability:
Rig power is one of the most important issues to consider in rig design specifications and
they are many stuck pipe events that can be attributed to operating outside of the rigs
power capabilities.
The maximum power requirements for the well should be calculated and compared to the
rigs capability. Older rigs may have a certain capability on paper, but in reality this is not
the case. It is important to confirm actual versus theoretical before drilling commences
especially when the rig is close to its limits. This can be achieved by performing a load test
on the power system & this should be part of any rig acceptance criteria.
1.8.4. Hoisting capability.
Every engineer should be able to calculate the maximum hook loads in the well and
compare them with the maximum loads for the hoisting equipment, drill pipe and
derrick/mast. It can get a little more complicated in deviated wells where the drag comes
into play, and friction factors have to be estimated. In this case its better to come up with
a range of values by varying the friction factor in the model.
Maximum over pull limits need to be calculated and based on the weakest component in
the system. In most cases this will be the DP, but on light rigs the derrick rating can be the
limiting factor.
The minimum margin O/P should be at least 100,00lbs during drilling operations.
1.8.5. Solids Control Equipment:
It is important that we have a basic understanding of the solids control equipment on the
rig because the mud condition plays an important role in preventing stuck pipe incidents.
This next section we give an overview of the solids control equipment on the rig and will
give some operating guidelines.
Figure 39 shows a schematic diagram of the surface mud system
1.8.5.1. Shale Shakers:
Shale shakers are probably the most important device in the solids control system in terms
of the amount of low gravity solids (LGS) removal. When one views the piles of discarded
LGS accumulating beneath various pieces of solids control devices, the pile beneath the
shale shakers is usually significantly larger than under any other group of devices. In fact,
the pile is usually larger than all other devices combined.
Shale shakers are vibrating screening devices that process returning drilling fluid laden with
drilled cuttings or low gravity solids. The LGS returning in the fluid vibrate across the screen
and are discarded from the end of the shaker deck. The fluid flows through the screen,
along with fine LGS and is recovered for further processing and re-use. In general, when
finer screens are used (screens with smaller holes in them), greater amounts of drilled solids
are removed. However, when finer screens are used, less fluid will flow through the
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openings in the screens and less fluid can be processed. This relationship between fluid
processing capacity and particle size removal must be understood in order to understand
shale shaker operations.
Tank/Mixing Capacity
Is the tank volume sufficient?
What reserve volumes are
required?
What is the mixing
capability of the system?
Shakers
Does the rig have
enough?
Do you have the
correct sized screens?
What is the plan when
they get overloaded?
Cuttings Shoot
Dimensions is it
large enough?
Access Points in case
Flowline. of blockage?
Dimensions is it
large enough?
Access Points in case
of blockage?
Figure 39: Schematic of the mud system on the rig.
Table 11 shows the relationship between the amounts of fluid that can be processed by
one shale shaker dressed with certain sized screens and the separation potential for that
screen. This figure is an approximation compiled from a number of different sources and
should not be used too literally, but is excellent for demonstrating the concept. Coarser
screens, such as the API 40, can process a large volume of fluid (850 gallons per minute),
but only remove particles larger than 410 microns. If the drilled solids coming to the surface
to be processed contain particles smaller than 410 microns, the shakers will not remove
them. The only way to remove finer particles with the shakers is to use finer screens;
however, by using finer screens, the maximum flow over one shaker must be reduced or
the screens will blind and fluid will be lost over the end of the shaker.
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Figure 40: Picture of a typical shale shaker.
Separation
API Maximum Flow
Potential
Number (GPM)
(microns)
40 850 410
60 620 250
84 390 180
110 350 140
140 300 110
160 275 100
175 250 80
210 200 70
Table 11: Relationship between flow capacity and separation potential.
Fluid flow to the shale shakers is fixed by the circulating rate of the drilling fluid. The
circulating rate of the drilling fluid, after considering hole cleaning and hydraulic
horsepower at the bit, will generally be between 35 and 50 gallons per minute per inch of
bit diameter. This was an old rule-of-thumb prior to computer hydraulic calculations. This
means that the desired circulating rate for 17-1/2 hole might be 900 gallons per minute.
At that circulating rate, two shakers screened with API 60 screens could probably process
the entire flow, but two shakers with API 84 screens would probably blind. If three shakers
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were available, then API 110 screens or API 140 screens might be able to process the flow.
Since the separation potential with increasing API number is much better, the finer screens
would make a more efficient removal of low gravity solids (LGS).
In the past, most drilling rigs only had two shale shakers. Recognition of the increased
separation potential with finer screens and the general trend towards drilling larger hole
sizes (deeper drilling requirements) have caused many rigs, especially offshore rigs, to have
as many as six or more shale shakers.
One additional factor must be considered in the flow capacity equation. The amount of
solids loading on the shale shaker screen can affect the amount of flow that can go
through the holes in the screen. Thus, an adjustment to the maximum flow for solids loading
must be made. Table 12 shows the adjustments for mud weight that should be made to
the maximum flow rate. This table indicates that if drilling with a 12 pound per gallon (ppg)
drilling fluid, and the maximum flow capacity of a shaker and screen was 500 gallons per
minute, then the actual flow capacity (reduced due to high solids loading) would be 450
gallons per minute.
Mud Weight Reduction

Range (ppg) in Flow
8.34 - 11.0 1.00
11.1 - 13.0 0.90
13.1 - 15.0 0.80
15.1 - 17.0 0.70
> 17.1 0.65
Table 12: Reduction in maximum flow capacity for high gravity solids loading
What screens should be run?
Example 1
What screens could be run in 26 hole with a 10.5 ppg maximum mud weight if only two
shakers were available?
The flow rate desired for this hole size is likely to be 1,300 gpm (50 x 26). Since two shakers
are available, each would have to handle half of the flow or 650 gpm. From table 11, the
capacity of an API 60 screen seems just slightly too low, while the capacity of an API 40
screen is sufficient. Since the mud weight is low, no correction factor is needed.
Example 2
What screens could be run in 14-3/4 hole (maximum size drilled with bi-center bit) with a
13.5 ppg maximum mud weight if four shakers were available?
71
The flow rate desired for this hole size is likely to be 750 gpm (15 x 50). If this flow were
divided between four shakers evenly, then each shaker would need to handle slightly less
than 200 gpm. But with the solids loading likely to be fairly severe, a reduction from the
maximum flow would indicate each shaker would have to handle about 20% more fluid in
order to process the desired amount of fluid and solids. This means that each shaker would
have to handle 235 gpm (750 / 4 / 0.80). From table 11, API 175 screens could be run.
Example 3
How many shakers would be needed on a rig intending to drill the following hole sections?
Section 1 is 26 hole with maximum 10 ppg mud (API 140 screens desired) and section 5 is
8-1/2 hole with 17.5 ppg mud (at least API 210 screens are desired).
For section 1, the anticipated circulating rate would be 1,300 gpm (26 x 50). No solids
correction is needed, so the flow per shaker is obtained from table 11. API 140 screens can
tolerate 300 gpm per shaker. This means that the total number of shakers required would
be 5 (1300 / 300). Note that four shakers could only process 1,200 gpm.
For section 5, the anticipated circulating rate would be 425 gpm (8.5 x 50). Since the mud
weight is very high the maximum flow needs to be adjusted for solids plugging on the
screens. In this case the adjustment is 0.65. This means that the overall flow is increased to
654 gpm (425 / 0.65). From table 11 the flow per shaker is 200 gpm; therefore the number
of shakers required would be 4 (654 / 200).
The answer to example 3 is that the rig would need five shale shakers to carry out the
envisioned program (given these two sections alone).
This provides an easy way to quickly estimate screens that can be run on a shale shaker
without having field data available. Naturally, this estimation technique is not completely
accurate. Many factors, including shaker type, screen type, fluid properties, etc, could
drastically alter screen performance.
1.8.5.2. Hydrocyclones and Mudcleaners
Hydrocyclones are accelerated gravitational separation devices. The accelerated gravity

comes from centrifugal force caused by the fluid spinning inside the hydrocyclone.
Hydraulic head being supplied by the feed pump causes this spin. Since an artificial
gravitational force is being applied to the hydrocyclone, solid particles tend to settle. In
this case settling means movement toward the shell of the hydrocyclone. Solids laden fluid
near the shell of the hydrocyclone is expelled from the hydrocyclone through a nozzle at
the bottom. The bulk of the fluid gets sucked into a vortex spiralling upward in the cone
and is removed at the top of the cone.
Hydrocyclones come in a variety of sizes. The largest common hydrocyclone is 12 inches in

diameter. Another common large size is 10 inches. These large hydrocyclones are
commonly called de-sanders. Another very common size is 4 inches. Four-inch
hydrocyclones are referred to as de-silters. There are also hydrocyclones in the 2 inch and
3 inch range. The amount of fluid that is processed through the hydrocyclone cone is
72
dependent on the size. Table 13 shows the processing rates of some common
hydrocyclone cone sizes.
Cone Diameter Flow Rate Through

(inches) One Cone (gpm)
2 25
4 50
10 500
12 500
Figure 13: Hydrocyclone cone processing rates.
The particle size separated by the hydrocyclones is also dependent on the cone diameter.
Larger cones (de-sanders) will typically remove particles above 80 microns. The smaller de-
silters will remove particles above about 40 microns. With these removal targets, de-
sanders are operating on about the same range particle as finer shale shaker screens. De-
silters may remove slightly finer particles.
Hydrocyclone discharges are characterized by high fluid to solid particle content.

Whereas shale shakers usually remove about equal volumes of solid and liquid,
hydrocyclones may remove 3 parts liquid to every part solid (sometimes as high as 5 times).
Typically, the removal amount, volumetrically, by a hydrocyclone is about 10% of the feed
stream, but this is highly variable based on operating conditions.
On drilling rigs, a bank of de-sander cones is usually two or three 10 or 12 cones. A bank
of de-silters is usually eight, twelve, or sixteen 4 cones. A bank of eight 4 cones will
process about 400 gallons per minute and discharge a volume of concentrated solids at
about 40 gallons per minute.
Hydrocyclones are intended for operation when un-weighted, water-based mud is used.
Barite and polymers will be concentrated in the discharge stream. Thus, there will be an
economic consideration about when to stop using the hydrocyclones when mud weight is
increased or expensive polymers are added.
A mud cleaner is a bank of hydrocyclones mounted above a shale shaker equipped with
fine screens4. Obviously, the screens on the shaker deck must be able to handle the fluid
and solids being discarded by the hydrocyclone bank. One of the weaknesses in mud
cleaner design is the inability of the screen to process the full discard. A typical response to
this is to either pinch back the hydrocyclones to operate inefficiently or to choose a screen
with larger screen openings to allow full processing.
The original concept of the mud cleaner was to remove particles in the range between API
200 screens (74 micron) and API 80 (170 micron) screens. The mud cleaner was equipped
with API 200 screens because barite is removed with finer screens. At the time of their
development API 80 screens were the finest practical screens that could be run on shale
shakers. This remains one of the primary reasons for using a mud cleaner; however, since
shale shakers have improved so much, the use of mud cleaners is declining.
73
A second purpose of a mud cleaner is to recover expensive base fluid in un-weighted
mud. If, for example, expensive potassium chloride fluid is being used, an extremely fine
screen could be run on the shaker deck and fluid (along with very fine particles) could be
recovered. The particles removed by the hydrocyclones (including barite) would be
discarded. This is obviously an economic decision.
1.8.5.3. Centrifuges
Decanting centrifuges act to separate solids from liquid by imparting high centrifugal force
on the slurry5. The bowl spinning at high rotational speed causes the high centrifugal force.
The feed slurry enters through the center of an internal auger and is released into the bowl
through the feed ports. Since the centrifugal force acts to push solids to the outside of the
bowl, a conveyor (auger) pushes them towards the solids discharge end of the centrifuge.
Liquid drains (decants) from the opposite end. Figure 41 shows a drawing of a centrifuge
operation.
Figure 41: Centrifuge operation drawing.
Centrifuges are not intended to operate on the entire flow stream or circulating rate as
other pieces of solids control equipment are. Instead, a high-speed centrifuge will operate
at about a maximum of 150 gallons per minute (gpm) with un-weighted (9 ppg) mud. As
mud weight is increased to the 16 ppg range, throughput capacity decreases rapidly to
the 20 gpm range.
There are some relationships that should be understood in centrifuge operations.

Increasing G-force improves separation of solids from the liquid feed slurry. In one series of
tests, 90 pounds per minute of cake (solids) were removed at 900 G, while 75 pounds per
minute of cake were removed at half the G-force. Cake removal is adversely affected by
increased viscosity. Under the same conditions of 900 G described above, increasing the
74
yield value from 8 to 24 decreased the cake formation from 90 pounds per minute to 75
pounds per minute.
Maximum flow capacity is obtained with minimum pond depth, but maximum separation
occurs with maximum pond depth. The best combination of separation and flow capacity
is dependent on the size of the particles to be removed. For fine particle size removal,
deeper ponds are more efficient than shallow ponds. In one set of tests, 50 pounds per
minute of cake were generated with about 130 gpm flow rate and a two inch pond, while
the same rate of cake generation required 160 gpm flow rate with a one inch pond. For
coarse particle size removal, shallower pond depths are preferred. The higher flow
capacity associated with shallower pond depths allows more cake removal.
One use for centrifuges is to process un-weighted mud. This is the only device that can
remove fine particles that other solids control devices cannot remove. It also does this with
a minimum of liquid carryover in the discard. The lower limit of particle size that can be
removed with a centrifuge is said to be two microns, but a more practical field limit (unless
extreme care is taken) is probably 8 microns.
Another use for centrifuges is to process hydrocyclone underflow. In this use, hydrocyclone
discharge is diverted to a small feed tank for the centrifuge. The centrifuge is used to
recover liquid from this feed. Of course, the centrifuge will also recover ultra-fine or sub-
micron particles. Equalizers will be needed to match the processing rates of the
hydrocyclones and centrifuge. This process is especially economic when high value liquid
phase is being used, as with potassium chloride fluid.
The centrifuge can also be reversed to recover solids and discard liquid phase. In this
mode, coarse solids are recovered and fine solids are discarded with the liquid. This mode
is used because colloid sized particles are especially damaging to drilling properties and
can cause differential sticking, slow penetration rates, and high fluid treatment costs. This
process is also called barite recovery because barite is a sized material with most of the
particles above 2 microns. The recovery of the barite can sometimes be justified on an
economic basis.
Two-stage centrifuging can also be used, but is controversial. In the first stage, solids are
recovered. In the second stage, the fluid and fine particles (discarded from the first stage)
are processed and some small amounts of solids are discarded. Fluid and colloid sized
particles are recovered. With current screening technology, two-stage centrifuging is
generally less desirable than running fine screens on the shakers and using a tolerance
mud system.
1.8.5.4. Solids Control Operating Principles Overview
Shale Shaker
Perforated plate screens usually exhibit longer screen life than other hookstrip screens.
They provide the most support and are repairable.
75
Screen life is inversely proportional to plate opening size. If premature wear is apparent
in the pool region, install panels with smaller perforated plate sizes at the feed end of
the shaker where loading and wear is greatest.
Reduce deck angles to improve solids conveyance, reduce loading and eliminate
solids grinding at the feed end.
If premature backing plate failure is experienced, check that all deck rubbers are in
place and in good condition. Check for a buildup of solids between the screen and
the support areas on the shaker deck.
When possible, run the same screen mesh over the entire deck of a single deck shaker.
When running different mesh cannot be avoided, the coarser mesh should be run at
the discharge end. Do not vary the mesh size by more than one increment from feed
to discharge.
Select the finest screens, which will give 70-80% fluid coverage on the shaker.
Use sufficient shakers to achieve a separation target of at least API 140 (100 microns).
Always run the coarser screens on the top deck of a tandem deck shaker or on the
upstream shaker. The upper deck screen should be at least two API sizes coarser than
the bottom deck. It has been observed that running screens, which are too fine on the
top deck can actually impede cuttings conveyance on the lower deck.
Select screens for which the new API designations are known to ensure predictable
performance.
In order to improve cuttings dryness, try the following:
Increase deck angle. This is the simplest solution. Fluid loss along the hookstrips is
reduced. Solids conveyance will decrease with steeper deck inclinations, which
increases the contact time to remove excess moisture. Protection against whole mud
losses due to flowline surges is also improved.
Change to coarser screens. This has two effects. First, the fluid endpoint on the shaker
will recede. Second, the average discharged cuttings size will increase; however, this
action will result in poorer separation efficiency and higher costs. Try running a coarser
screen at the discharge end before converting the entire deck to coarser screens.
In order to combat sticky solids (Gumbo), try the following:
Use scalping shakers ahead of fine screen shakers. Circular or unbalanced elliptical
motion shakers or shakers with short basket lengths are recommended as the scalping
shakers. If space is limited, tandem deck linear motion shakers may be used.
Use downhill or flat deck angles. Gumbo will not convey well uphill.
Gumbo will not stick as persistently to wet screens. When spray bars are necessary to
keep the screens wet, use low flow rate nozzles, which produce a fine mist with an
umbrella or fan-shaped discharge. These nozzles operate at less than 0.5 gpm. No
more than two are normally required. Do not use high volume or high-pressure sprays
on a continuous basis. This will degrade the gumbo patties and drive the solids through
the screens.
76
For polymer mud systems try the following:
Pre-hydrate and pre-shear the polymer before adding into the active mud system to
eliminate fish-eyes and blinding at the shaker.
Select high efficiency screens to maximize the flow capacity of the shakers.
Expect an overall reduction in shaker flow capacity of as much as 40%.
Hydrocyclone
Operate enough hydrocyclones to process over 100% of the circulation rate or to

handle the maximum solids loading rate.
The hydrocyclone overflow should be discharged to a compartment downstream from
the feed compartment. Use bottom equalization between compartments.
Mechanically stir all hydrocyclone removal and discharge compartments to ensure
uniform feed. Mud guns should not be used because they can reduce hydrocyclone
efficiency by bypassing a portion of the mud.
Do not allow cones to operate with plugged apexes or inlets.
Spray discharge at the cone underflow is desired. Rope flow will cause premature wear
and is less efficient. Rope flow indicates that either more hydrocyclones or finer shaker
screens are required or that the underflow apex size is too small.
Because 2-in, cones are extremely susceptible to plugging, consider using the 3-in,
cone instead. It has twice the capacity and equivalent performance.
Do not bypass the shale shaker or operate with torn screens.
The hydrocyclone manifold should be located above the mud level in the active
system to prevent accidental loss of mud by siphoning when the cones are not
operating.
Replace flanged-type hydrocyclones with the quick-connect type to improve servicing
time.
Replace worn, malfunctioning cones immediately. If no spares are available, remove
the cone and blank off the feed and outlet lines.
Have a working pressure or head gauge on the manifold feed inlet.
Install a siphon breaker on the overflow manifold exit.
Size suction and discharge piping to provide flow velocities in the range of 5-10 ft/sec.
Use one centrifugal pump per hydrocyclone manifold.
Centrifuge (processing un-weighted fluids)
When processing the active system, the centrifuge feed should be taken from the
desilter discharge compartment or downstream. The concentrate should be returned to
next downstream compartment.
Provide enough centrifuges to process at least 25% of the circulation rate. Large, high-G
units are usually required.
Run at maximum bowl RPM to achieve highest G-force and best separation.
Operate the centrifuge just below the flood-out point.
The best-feed rate and pond depth will depend on the size distribution of the drilled
solids. Use shallow ponds and high feed rates when coarse solids predominate.
Conversely, deeper ponds and lower feed rates are more efficient when fine-drilled
77
solids are to be removed. Field experimentation is necessary to optimize centrifuge
setup.
Always wash out the centrifuge on shutdown.
If the centrifuge is to be used on both un-weighted and weighted fluids, rig up to allow
either option. Both the concentrate and solids streams should be rigged up to allow
each to be discarded or returned to the active system.
The solids discharge chute should be angled at greater than 45 to prevent solids
buildup. If this is not possible, a wash line may be necessary to assist in moving the
solids. On land-based operations, use the reserve pit as a source for wash fluid. Do not
create unnecessary reserve pit volume by using rig water.
78
1.9. Software & Modeling Tools.
Software packages and modeling tools can help identify, analyze and mitigate stuck pipe
risks in both the planning and execution phase.
This section will list the tools available and give a brief description of each. The real time
monitoring programs will be discussed in the real time trend analysis section.
It is the engineers job to select the applicable package and use it correctly.
Remember:
GARBAGE IN = GARBAGE OUT
The table below gives a brief summary of the software available:
OFFSET WELL ANALYSIS SOFTWARE

Identify relevant offset wells RiskTRAK
Offset well data gathering RIG STATE can take, LAS and ASCII files
Define objective for data Analysis SPAID Looking at events
Offset well data presentation PETREL Borehole visualization, Osprey Risk
MODELING SOFTWARE
Software Components Remarks
Drilling Office DrillSAFE Tripping Load Analysis
Drill string buckling Analysis
Drilling Torque Loss computation
Rotating Axial plot with torque
Side Forces Analysis
Friction factor Calibration
BHA tendency / Vibration analysis
Hydraulic Cuttings load analysis & ECD modeling
RockSolid Well bore Stability Analysis
PPW Pore pressure modeling
Sticking Risk Assessor Wireline MDT stickiness analysis
Osprey Risk Risk Identification.
Stickance Differential sticking
Prespro RT Real time MI Hydraulics
PERFORM Toolkit
MONITORING AND ANALYSIS SOFTWARE
Sticking Pipe Indicator (SPIN) IDEAL Software
Stuck Pipe Analysis (SPAID) Stickance
Pore Pressure Window (PPW) Drilling Office Software
Real time Hydraulics - PERFORM Toolkit
Real time Torque and Drag PERFORM Toolkit
DrillSAFE Drilling Office Software
Drilling History Drill Viz
Super Smart Alarms PERFORM Toolkit
Table 14: Lists the available Well Engineering software tools.
79
1.9.1. Osprey Risk
Osprey Risk is a software for rapid creation of detailed drilling operational plan that
provides economics and risk analysis. The User inputs trajectory and earth properties
parameters along the borehole path (Pore Pressure, Fracture Gradient and Rock Strength)
Figure 42: An example of an Osprey Risk Output Page
The software uses an automated, integrated, comprehensive well planning system to

provide
A technical well design, including hole geometry, casing and tubing design,
bit, hydraulics, drillstring, etc.
A risk analysis including the risk of Stuck Pipe and Wellbore instability
A detailed operational activity plan
A probabilistic time and cost estimate for the project
This enables a quick decision support to evaluate different well construction scenarios and
high volume prospect screening in a time frame unimaginable using other tools. The major
workflow components are:
Input Data: Provides the data the system uses to generate a well design.
Wellbore Geometry: Computes such outputs as mud weights, casing points,
and Wellbore sizes, and provides casing and cement design. If you have the
advanced workflow, this set of tasks also provides a Wellbore Stability
interface.
80
Drilling Parameters: Defines actual drilling activities and their requirements.
Results: Provides outputs of Osprey Risk task flow in a variety of formats.
System tasks are arranged in a single workflow in which the output of one task is included
as input to the next. The user can modify each output, which permits fine-tuning of the
input values for the next task. An example of Osprey Risk output is illustrated in figure 43.
The table below shows the different Osprey risk categories and how they relate to the
different stuck pipe mechanisms. The main problem faced with the Osprey Risk analysis is
that the different risks types tend to cloud each other out. It then makes it difficult to
evaluate the risk of the individual stuck pipe mechanisms such as hole cleaning.
Risk Category High Criteria Explanation of risk Weighting Stuck Pipe

Mechanism
Hydrates > = 3000ft Based on water 1 Only applicable for
depth. deep water and
gas influxes.
DLS >= Trajectory has a 3 Hole cleaning
6deg/100ft doglegs greater than Mechanical sticking
6deg/100ft.
Tortuosity > = 90 Summation of the 3 Hole cleaning
doglegs severities in Mechanical sticking
the well
Inclination > = 65deg Inclination 2 Hole cleaning
Differential sticking
Horizontal > = 1.0 Ratio of displacement 3 Hole cleaning
Displacement / TVD
DDI > = 6.8 Directional drilling 3 Hole cleaning??
index?? Mechanical
sticking??
PP low < 8.33ppg Low pore pressure 5 Differential
sticking??
Rock soft < 2 kpsi Soft clays have low 4 Gumbo/sticky
UCS values. shales
MW Frac < = 0.2ppg MW is close to the 5 Not really a stuck
fracture gradient pipe driver.
MWW < = 0.5ppg Frac & pore pressure 4
close together
WBSW < = 0.4ppg Advanced model. 4 Caving's pack-off.
Shale stability Hole cleaning.
Shear Failure MW <= PP <= Advanced model. 4 Cavings pack-off.
SF or SF <= Shale stability Hole cleaning.
MW <= PP or
MW <= SF <=
PP
HS length > = 8000ft Long hole section 2 Hole cleaning
length Borehole stability
with WBM
Hole Big > = 24 Large OH diameters 1 Hole cleaning
81
Hole Small < = 4.75 (on) Small OH diameters 3 Mechanical sticking
< = 6.5 (off)
Hole csg < = 1.1 Ratio of area of OH / 4 Annular clearance
area of casing size for running casing.
(OD)
Csg Csg < = 1.005 Casing ID / Next 3 Mechanical sticking
maximum casing size
Csg Bit < = 1.05 Ration of casing ID / 3 Mechanical sticking
next bit size
Csg MOP < = 50 Margin of over pull on 2 Chances of getting
casing free
DS MOP < = 50 kips Margin of over pull on 3 Chances of getting
casing free
Kick Tol < = 50 bbls Kick tolerance is < 50 1 Not applicable to
bbl stuck pipe.
Q crit < = 1.0 Flowrate/critical 2 Hole cleaning
flowrate
ECD Frac < 0.0ppg Upper bound limit 5 Losses
ECD
Cuttings 45 65 deg Avalanche area for 2 Hole cleaning
hole cleaning
Table 15: Shows the different Osprey Risk categories. The rows highlighted in yellow are directly
related to stuck pipe.
1.9.2. Drilling Office.
The Drilling Office software is an integrated well planning and execution package which
comprises of a number of fully integrated modules that allows the drilling team to plan,
execute and evaluate Wellbore construction activities. The software components useful for
Stuck Pipe prevention planning include:
Trajectory design
Torque and Drag analysis
BHA design/tendency prediction
Casing design
Circulation Pressure losses
ECD prediction & Hole cleaning Analysis
Wellbore Stability analysis
Pore Pressure analysis
RiskTRAK/DrillMap/Drill Viz
1.9.3. Modeling Hydraulics
Hydraulic design plays a very important rule in the prevention of Stuck Pipe. The available
model usually involves a comprehensive set of algorithms that assist in analyzing planned or
actual well trajectory.
82
It gives an overview of the various component pressure losses and equivalent circulating
densities (ECDs) calculations. The design calculates pressure losses over a range of
available pump flow rates, and output includes Hole cleaning analysis. Critical pump rate
needed to completely remove cuttings are also calculated. An example of Hydraulics
design output is shown below.
VIRTUAL HYDRAULICS MD: 9300 ft Operator: CTOC
SnapShot
Drilling 8.5" to TD
TVD: 6355 ft Well Name: Cakerawala
ROP 220 ft/hr
Bit Size: 8.5 in. Location: Offshore Kelantan
Flow 668 gal/min
1996-98 M-I L.L.C. - All Rights Reserved Date: 23.01.2002 Country: Malaysia
Casing Program Angle Density (lb/gal) PV, YP, LSYP Temp (F) AV (ft/min) Hole Clean Ind Pressure Loss (%)
Depth
Depth Csg/H Dia (ft) 0 30 60 90 10.5 11.0 11.5 12.0 12.5 0 25 50 75 0 200 400 0 250 500 750 0VG0.25G0.50 F0.75 P
1.00 0 25 50 75 100
307' 8.835" 309

Drill String
1000
Bit
Annulus
2000
DRILLING FLUID
PV
NOVADRIL
3000 ECD Ann
Mud Weight 11 lb/gal
Test Temp 120 F
3831' 9-5/8" SYSTEM DATA

3135.3' 4000 Flow Rate 668 gal/min
347
8.835" ID Riser Pump 0 gal/min
ROP 220 ft/hr
RPM 150 rpm
5000 YP WOB 10 K lb
Nozzles 12-12-12-12-14
ESD DS Nozzles 14-32
6000 PRESSURE LOSS (psi)
Modified Power Law (@R6/R3)
Drill String 2496
MWD 310
7000
Bit 191
Bit On/Off 100
LSYP Annulus 465
8000 Surface Equip 78
U-Tube Press 51
Total System 3690
ESD ECD +Cut
9000
Csg Shoe 10.78 11.64 11.80
9300' 8.5"
TD 10.78 12.19 12.35
6355'
VRDH - Version 2.5
File - CAK_3_1!.MDB
10000
Figure 43: Example of M-I Virtual Hydraulics output
The Drilling Office Hydraulics application provides the tools to estimate pressure losses
throughout the entire circulatory system, optimize motor performance and bit nozzles, and
give an indication of hole cleaning capabilities. It also computes swab and surge pressures
and takes into account the effect of pressure and temperature on mud density and
rheology.
The model outputs in both tabular and graphical form the Critical Transport Rate (CTR): the
pump flow rate necessary to completely suspend cuttings in the annular flow. Also
displayed are the measured depth and inclination of the most critical section. The model
also allows the sensitivity of the CTR to the ROP to be explored.
83
Figure 44: Example of Drilling Office Hydraulics Input
1.9.4. Modeling Swab and Surge
Swab and Surge effects during drilling can impact the stability of the wellbore, which could
result in stuck pipe incidents. It is therefore important that the drillstring tripping speed is
modeled during the planning phase.
Swab and Surge modeling exist in the Drilling Office software. Here modeling can be done
for Closed-Ended Pipe and, if Open-Ended Pipe, with Pumps On or Pumps Off. Note that
with Open-Ended Pipe and Pumps Off selected, the Acceleration/Deceleration field is
disabled. This field corresponds to the time necessary to get to the tripping speed from rest
and vice versa in a linear approximation (e.g., if it takes 5 sec to reach a tripping speed of
3 feet/sec, then the acceleration is 0.6 feet/sec^2). The same value is used to calculate
additional Swab / Surge pressures resulting from acceleration to the tripping speed when
RIH or from deceleration from the tripping speed when POOH.
84
Figure 45: Snapshot of Swab and Surge panel in Drilling Office
The Stand Length is the length of pipe tripped in between connections, whether 90 feet
when tripping a stand of drill pipe or 30 feet when tripping a single joint at a time or 40 feet
when running casing. The Connection Time is used to calculate the Total Tripping Time,
whether for a User-Defined Tripping Schedule or an optimized Margin-Based Tripping
Schedule, and corresponds to the time necessary to make up every connection.
The Swab/Surge module Office yields its own reports and plots. These reports and plots
consists of Swab/Surge pressures calculated for each tripping section and the
corresponding Equivalent Mud Weights versus Bit Depth at the bit, at the casing shoe and,
if applicable, at a Formation Marker and Sensor Location.
Figure 46 is an example of Actual Swab versus Drilling Office Model. The plot below shows a
combination of actual swab measurement with Drilling office model. It indicates that when
the wellbore is in good condition (free from cuttings) the Drilling Office Swab and Surge
Model can be used to accurately predict the swab pressures recorded during tripping out
of the hole.
85
Figure 46: An example of Actual Swab versus Drilling Office Model. The red line is the real-time data
from the APWD and the dashed line is the modeled.
1.9.5. Drill Viz: - 3D Visualization.
DrillViz, a Drilling office software component, is a three-dimension visualization and earth

model-building tool. This tool is used to assist in planning, visualizing, and simulating drilling
projects. DrillViz can show surfaces, volumes, well trajectories, drilling targets, and well
markers in 3D view as well as ellipse of uncertainty, log curves and 3D image data along
the well trajectory.
It enables you to integrate and visualize your drilling data; it is a PC based application for
the drilling engineer.
With Drill Viz you:

Important surface/faults to view, move or reshape
View, edit and interact with drilling targets and drilling risks
Gain a greater insight into the spatial relationship of the downhole condition
View drilling problems captured in RiskTRAK.
The snapshot below shows example of 3D visualization of wells on a particular field with
depths of encountered drilling problems marked along the trajectory
86
Figure 47: An example of 3D visualization of wells on a particular field with depths of encountered
drilling problems marked along the trajectory.
1.9.6. Rocksolid Wellbore Instability Analysis
RockSolid provides various models/correlations for user to compute the mechanical

properties from the basic inputs (dipole sonic and density logs and Elan interpretation). The
module implements the Schlumberger Geomechanics methodology on a single well basis
and allows specifically DCS engineers to compute and visualize stability of the wellbore at
the planning stage
The wellbore stability output is displayed as a function of well deviation and azimuth; mud
weight window along the planned trajectory and mud weight. The software allows the
user:
To construct one-dimensional Mechanical Earth Model (1D-MEM) for an existing well
To calibrate the 1D-MEM based on core and field data of the existing well
To analyze the sensitivity of borehole stability vs. orientation and/or mechanical properties
at a given depth for well planning and 1D-MEM study
To analyze planned well stability using a 1D-MEM propagated from an offset well
To predict in real-time the drilling well stability for wellbore stability monitoring and control
87
A wellbore stability sensitivity module also provides a powerful function for users to
diagnose wellbore stability problems; identify the risks; optimize borehole trajectory and
visualize borehole failures.
A good understanding of the output will be most useful in minimizing drilling surprises such
as Stuck Pipe.
Outputs should be reviewed with the WSS prior to any job. This should be included in Well
Program to prompt WSS when to take necessary preventive actions
An example of RockSolid output is shown below.
Figure 48: An example of RockSolid output.
This example shows the mechanical properties, mud weight window, zones and types of
breakouts and possible borehole size due to the anticipated breakouts.
1.9.7. Stuck Pipe Analysis and Interactive Diagnostic tool SPAID
SPAID is an application package designed to help determining the likely cause of a Stuck
Pipe. It takes the user through a sequence of questions, each one dependant on the last
one answered and shows an estimate of the likelihood of the different possible causes of
Stuck Pipe. Once the cause is determined, the software generates a report and provides a
directed access to appropriate practices and procedures This knowledge in turn helps to
make a better-informed decision about the nature of the Stuck Pipe problem and the
appropriate actions to be taken
88
The SPAID display has three main panels. On the left questions are displayed and responses
can be entered. On the right, a set of indicators shows the current estimates of the
likelihoods of different possible causes.
Figure 49: An example of a dialogue and estimate of possible causes is shown below
1.9.8. Sticking Risk Assessor for wireline jobs?
The Risk Assessor is a simulation program to predict in advance the possibility of differential
sticking of tool, differential sticking of cable and cable key seating. It was developed by
SCR and accomplished by calibrating an experimentally verified theory to the Gulf of
Mexico database of 10 years of MDT and RFT job. It can compute the sensitivity to drilling
parameters overbalance, WBM, and mud solids
Objective of the Sticking Risk Assessor

Without Risk Assessment
On Wireline, you dont know your risk of getting stuck and lost time
On TLC, you dont know if you might have saved TIME and MONEY by running on Wireline
With Risk Assessment
Make better decisions (Wireline when risk of getting stuck is Low. TLC when Risk is High
Reduce adverse consequences (Getting stuck on wireline and Running TLC needlessly
Inputs to the Sticking Risk Assessor include:

Tool/Cable: Length, Weight, Stationary Time, run number.
89
Borehole: Openhole Interval, Diameter, Temperature, Deviation, Maximum Dogleg
Mud: Type, Density, Fluid Losses, Lubricants, Low Gravity Solids, and Stickance Factor
Formation: Differential Pressure, Compressive Strength etc.
Input and Output should be reviewed with the WSS prior to any job. This should be included
in Well Program to prompt WSS.
An example of a Sticking Risk Advisor menu is shown below:
Figure 50: An example of a Sticking Risk Advisor menu
90
2. REAL TIME ANALYSIS HOW TO MONITOR
THE PLAN?
91
2.1. Introduction
In this section we will focus on drilling trend analysis during the execution phase and we will
show how this plays an important role in minimizing stuck pipe incidents. The analysis
performed also provides vital data for future well planning, and should be a continuous
process.
Figure 51 below shows a graphical representation of the process:
SURFACE MEASUREMENTS
Stuck Pipe Identification
WOB
Torque
Rig team Pump Pressure
RPM
DRILLING PROBLEMS. ROP
Cuttings/Cavings
Poor Hole Cleaning. Mud Properties
Hole Pack-off. PERSONNEL
Cavings
Mud Losses WSS
WSDE SURFACE SYSTEMS
Poor weight transfer.
High torque.
Risk Analysis Dir Driller PLANNING PHASE
Toolpusher Drillers Console
Output High OP/Drag.
Driller Data Gathering MWD logging unit Modeling of trends
Overpressure. Real time Mud Engr Mud logging unit Risk assessments
Enlarged Wellbore
Shocks/ Vibrations Interpretation Mud Logger Mud Engineer unit
Drillstring/Failure Perform Engr.
DOWNHOLE
Excessive/Backreaming
MEASUREMENTS
WOB
Torque
Office Team APWD
Real time logs.
Figure 51: Shows a schematic of the real time analysis process.
The level of analysis performed will depend on the stuck pipe risks identified and the overall
economics. However, there is one common thing, all analysis starts with looking at the
basic drilling trends form the surface parameters.
92
2.2. Surface measurements - Rig Floor measurements
2.2.1. Drilling Parameters
Critical decisions in the drilling of a well are made on the basis of what the wellsite
determines is happening downhole. Usually this judgment is based upon the interpretation
of the surface information that is available. With the advent of real time monitoring systems
such as PASON, this is no longer the sole responsibility of the driller. Theses days the WSS &
other rig staff should play a major role in analyzing the drilling trends. The main sources of
information and the changes, which they are most likely to represent, are shown in the
table below.
Wellsite Information and the possible causes of trend change.
Sources of Information Trend Changes
A reduced differential pressure indicates one or more of the following:

Differential Pressure Reduced flow rate
Washout in the pipe
Extreme erosion of the bit (rare)
Reduced weight on bit
An increase in differential pressure indicates one or more of the
following:
Increased flow rate
Cutters have worn to the point that the bit face is in
contact with the hole bottom
Excessive weight-on-bit
Large depth of cut - formation softer than expected
Hole Cleaning
Increased Circulating Pressure could be due to one or more of the
Circulating Pressure following:
Heavier mud weight or poor mud properties
Plugged or partially plugged bit
Increased flow rate
Annular restriction
Internal restriction
Inadequate hole cleaning
Decrease in Circulating pressure would result from one or more of the
following:
Lighter mud weight or better mud properties
Washout
Reduced flow rate
Air in the mud
Pump malfunction
Kick and Influx into wellbore
Varying hole cleaning
Increasing Torque can be caused by one or more of the following:
Surface Torque Hole angle changing
Washout
Formation change
Poor mud properties
Increased weight-on-bit
93
Decreasing Torque caused by one or more of:
Formation change
Rotary speed change
Decreased weight-on-bit
Better mud properties
Bit wearing out
Addition of lubricants
Hole angle straightening out
Varying or irregular Torque caused by one or more of:
Reaming with stabilizer
Dry drilling
Bit balled up
Sand formation
Junk in hole
Washout
Excessive Weight-on-bit
Rotary speed
Drilling Break (changing formation, sand/shale
sequence, stingers
While the pump stroke rheostat remains at same setting,
Pump Stroke
An increase in strokes indicates the same things as a decrease in
circulating or differential pressure
While the pump stroke rheostat remains at same setting,
A decrease in strokes indicates the same things as an increase in

circulating or differential pressure
An increase in penetration rate may indicate:
Penetration Rate Formation change
Drilling close to balance, i.e. mud weight does not
substantially exceed borehole pressure.
A decrease in penetration rate may result from one or more of the
following:
Worn bit
Weight, rotary speed or hydraulics no longer
optimized
Formation change
Crooked hole
Washout
Mud weight too high relative to formation borehole
pressure
Poor mud properties thus effecting cuttings removal at
the bit face and hole cleaning
Varying penetration rate indicates one or more of the following:
Formation layers
Bit wearing out
Bit balled up
Wash out
Inconsistent application of Weight-on-bit
Table 16: Table showing possible reasons for changes in surface drilling parameters.
94
2.2.1.1. Surface Trend Example:
As the table shows there can be many different reasons for a change in a drilling
parameter.
This example shows that in many cases a change in trend can be an early warning sign for
the onset of a future problem, in this case stuck pipe. If these early warning signs are
picked-up, then remedial actions can be put in place to mitigate the risk.
The first warning sign of the onset of Stuck Pipe occurred between 474m and 483m where
the surface torque showed a continuous increase (for about 8mins) to a max of 1800 amps.
Standpipe pressure also increased by 120psi (to 2280psi) with ROP of 52m/hr (172ft/hr) at
550gpm. Over pull off slips at connections showed 6klbs after the first connection at 454m,
and 8klbs at 474m.
Over pull off slips at

connections showed 5klbs
after the first connection at
454m, and 8klbs at 474m
Increase in surface torque

could be an indication of
poor hole cleaning
Figure 52: Drilling chart
These warning signs were ignored and the next chart shows the result. As drilling continued,
a stuck pipe incident occurred at 531m. Prior to this, there was an instantaneous torque
spike up to 1800amps at around 515m, this later dropped to an av. torque value of
1400amps (normal trend 1200 amps) and maintained for 10 mins (between 515 and 523m)
before dropping to 1100amps. The last warning before the stuck pipe incident was the
overpull value, which had increased to 20Klbs.
95
Torque spike followed
by a reduction.
Stuck after connect.

Hole packed-off
No circulation. Pump
off, but still pressure
holding on standpipe.
Hole packed-off.
Figure 53: Drilling chart
What the example also shows is that it is not easy to identify changes in the drilling trend
from the time plot. In order to make it easy for ourselves we need to plot the actual data
against the expected or model trend. The main application for this is torque and drag
analysis to monitor the hole cleaning efficiency and this leads us nicely onto the next
section.
96
2.2.2. Torque & Drag Analysis
Torque and drag analysis is a very powerful tool to help identify the onset of hole cleaning
problems in the wellbore, especially in deviated wells. To highlight this fact, K & M
technology group promote torque and drag analysis as their major tool to predict poor
hole cleaning.
The steps in the process are
1. Model the theoretical torque and drags for the section using Drilling Office or other
suitable software. Depending on the area the torques and drags can be calculated
using single friction factors or a range of friction factors.
2. Produce torque & drag plots for drilling and tripping, and send them to the wellsite.
3. Take real time torque and drag readings at the wellsite and plot against the
modeled data.
4. Monitor deviations from the modeled trends.
5. Implement remedial actions if poor hole cleaning is diagnosed.
There are some extremely good examples of this type of analysis in Intouch, and a good
example is summarized below:
Intouch Content ID 3265546: Detection of hole cleaning problems using plot of Driller's P/U,
S/O and rotating weights
Reason for Best Practice:

We have seen problems POOH on high angle wells due to "dirty" hole conditions in which
APWD did not indicate a hole cleaning issue. We believe that very large caving's caused
by wellbore instability was the problem but needed another method for detection.
Best Practice Details:

PowerPlan's DrillSafe application is used to calculate theoretical rotating off-bottom;
Pickup and slack-off hook loads in each hole section. This data is imported in a MS Excel
Spreadsheet (see attached) and while drilling the Driller's actual hook loads are entered
and plotted versus the theoretical data. The attached example demonstrates that
increases of 10% to pickup weights while drilling can indicate "significant" hole cleaning
issues. In this example, the APWD data did not indicate a hole cleaning issue, the mud was
in good shape and this was the third well that we had drilled with all drilling / engineering
services. The shifts and trend changes seen on the P/U weights were identified as hole
cleaning issues (wellbore stability related) and recommends for mechanical cleaning of
the hole were made as various mud sweep programs appeared to have little effect in the
high angle 12 1/4" hole. It should also be noted that Gamma Ray was added to the chart
while drilling to check for formation changes.
Other Intouch Submission on Torque and Drag Analysis:

Content ID: 3951195: High Torques due to Hole Cleaning in Russia Novo 83 6545
Content ID: 4061655: Torque and Drag Analysis plot
Content ID: 3881395: Brazil Petrobras EOWR Standard
97
SLP (Self Learning Package) Torque & Drag: Explains the theory of torque & drag.
http://intouchsupport.com/intouch/MethodInvokerpage.cfm?caseid=3978035
The next two figures show examples of torque and drag monitoring and are taken from the
Intouch submissions above:
Actual deviates away

from theoretical trend
indicating hole -
cleaning problems.
Figure 54: Drag chart from Intouch Content ID: 3265546. The deviation of the pick-up weight away
from the theoretical was interpreted as poor hole cleaning
Actual T&D on KE 5-01, 16" section

100
120
140
160
180
200
Pick Up Weight, ton

60
80
800 Rot Weight, ton

900 Slack-off Weight, ton
1000
DO Pick Up
1100
DO Rot. weight
1200
1300
DO Slack off
1400
1500 #4 MRS89 + vorteX
Bit Depth, meters
1600 to 2357m
1700
BRT
1800
1900
2000
2100
2200
2300
#5 HCM606Z to 2414m
2400 #6 MAX22 to 2440m
2500
#7 MRS89
2600 to 2695m
2700
#7RR MRS89
2800 to 2952m
2900
3000
#8 MKS76SRO to 2977m
#9 to 3008m
3100 #10 MRS89 to 3156 m
3200 #10RR MRS89 to 3302 m
3300
#11 MGR84BVP to 3436 m
3400
3500 #11RR MGR84BVP to 3567 m
3600
3700
Weight indicator readout, ton
Figure 55: Intouch Content ID: 4061655 drag chart. What is interesting is that the theoretical and
actual up & down weights do not match. However, the trends are similar. This is probably the result
98
of using the wrong friction factor and highlights the need in some cases to produce a range of plots
for different friction factors e.g. a broom plot.
3500
4
3600 4
5
6
3700 5
6
6
3800 7
9
10
3900 9 #12RR MGR84BVP from 3575 to 4266 meters
9 ( 50 TVR )
10
4000 9
8
9
10
4100 10
10
10
4200 10
10
10
WOB ( TONS )
10
4300
8 #15 MGR89TVPX from 4266 meters
8 ( 204 WWT
4400 6
Measured Depth (m)
&
9
10 30 TVR )
4500 12
10
4600 5
15
6
4700
4800 Legend:
Silty Claystone
4900
Poorly cemented Sandstone
5000 Interbeds of silty Claystone and SDSTa/a
5100 Argillaceous Limestone TOP DRIVE TORQUE LIMIT

Calcareous Claystone
5200 Siltstone Off bottom-Driller's data

DO - off bottom
5300 DO- TQ while drilling
On bottom - Driller's Data
5400 Series8
Weight on bit k ftlbs
5500 Series9
0 5 10 15 20 25 30 35
Torque Klbs.ft
Figure 56: shows a torque graph from Intouch Content ID 4061655.
A Drag chart is as useful for running Casing as it is for tripping a drill string (see figure 57).
Close monitoring of the down weight and by occasional pull tests, the up weight will result
in an early identification of additional resistance and a timely decision to start washing
down.
99
Deviation from the trend
could indicate a hole -
cleaning problem
Figure 57: This example shows hook load chart for running a 9 5/8 casing string. Here, the actual
hook load trend is plotted against multiple theoretical hook loads trends, which correspond to
various friction factors as shown by the coloured lines. Ideally, this type of multi-friction factor plot
should be used when monitoring torque and drags in the drilling phase
Taking Pick Up, Slack off and Rotating weights.
T&D readings should be recorded at regular intervals and to be more effective in

indicating trends, it should be carried during the following operations (see figure 59):
At every connection while drilling ahead
Before, during and after wiper trips,
After circulating bottoms up and after pumping sweeps,
With bit inside casing/liner, prior to drilling out/going back into open hole
As soon as practicable after a mud weight increase; mud type change,
major rheology changes.
At TD after hole has been cleaned,
Before and after additions of torque reducers, such as lubricants and non-
rotating drillpipe protectors (NRDPP), etc,
Monitor while tripping out/in, especially in open hole,
In order to have accurate T&D plots there is need to get good quality T&D readings while
drilling:
The following are steps that would enhance the quality of T&D readings.
100
1. After drilling down each connection, work the stand once to ensure good hole
cleaning and any cuttings are clear of the BHA and to determine if the hole is free
(situation may be different for different rigs/company procedures).
2. At the bottom of the first full stroke, a few meters off bottom, get rotating weight
and torque at drilling RPM and flow rate.
3. Stop rotary and get pick up (P/U) weight on up stroke, 5-6 meters, at point of zero
Drag,
4. Get the Slack off (S/O) weight on the down stroke at point of zero Drag, while
returning the 5-6 meters to bottom (length of stroke to get proper P/U and S/O
weights will vary depending on hole size, BHA, angle, etc).
5. If necessary get pumps off P/U and S/O weights, stop the pumps and repeat Steps 2
and 3 above, before the connection.
6. Working the drill string at the same speed every time will make the readings more
consistent.
7. Do not take the average readings at connections take the least affected, steady
weight indicator reading in all circumstances lowest on P/U and highest on S/O.
8. Also, take the circulating readings at the same flow rate (for each hole section) to
avoid the potential influence/interference of hydraulic lift.
9. Actually, pumps off readings at connections are preferred as they give a truer
representation of the FF and the expected readings while tripping.
10. While tripping out, just get the pick-up weights while pulling, and for tripping in, get
the slack-off weights while running. Document depths and amounts of any S/O
changes and over pulls monitor for tight spots, formation changes, etc.
11. For running casing/liner, get the Slack-off weights while running, and to get the P/U
weights, ensure the driller picks up sufficient length to get a good reading.
Figure 58: Example Torque and Drag Collection Sheet.
101
2.3. Downhole Measurements Indicators and Signals
Technological advances over the last decade have allowed us to record the actual
downhole drilling parameters. The main measurements used to monitor the downhole hole
condition are downhole weight on bit, and annular pressure while drilling.
2.3.1. Downhole Weight on Bit.
Downhole Weight on bit provides a real time measurements of down hole weight (DWOB)
and Downhole Torque (DTOR) and it can provide valuable information about what is really
happening at the bit.
It has been found that it is a good tool for monitoring hole cleaning. When hole cleaning is
deteriorating, the downhole data deviates away from the surface values e.g. the Martin
Decker shows the WOB is 15T, but the downhole data indicates that the downhole WOB is
only 5T.
2.3.2. Annular Pressure while drilling (APWD).
Annular Pressure While Drilling (APWD) provides real time measurements of equivalent
circulating density (ECD), equivalent static density (ESD) and Annular temperature which,
complemented with surface parameters, allows the wellsite to improve drilling practices for
hole cleaning, borehole stability and well control
In wells that have that have potential borehole instability or small margins between the
fracture gradient and pore pressure, it is important to monitor the ECD and maintain it at
tight limits both while drilling and while tripping.
It is fair to say that operators have had mixed results using APWD to monitor hole cleaning
efficiency. The main problem is the tool picks up changes in ECD caused by the amount of
cuttings suspended in the mud. However, in deviated wells the cuttings are lying on the low
side of the hole and not in the mud stream, and as such will not be detected by the tool
until the equilibrium state changes see section 1.4.6. In many cases this is the point of no
return and your BHA has packed-off - it basically acts as the final warning sign.
If an APWD is run then the following should be done:
1. The ECD should be plotted against the theoretical.

2. It should be used in conjunction with surface trend analysis e.g. torque & drag.
3. The wellsite should be aware of its limitations and should not rely on it 100%.
4. An experienced operator is on site to analysis the data.
2.3.2.1. Example 1: Using APWD

The figure 60 overleaf shows part of the drilling mechanics log for the 9-MLS-102-RJS well. It
shows the ECD running with a background of +/- 10.25 ppg for the given drilling
parameters. At 2843.4 m the connection was made and the stand was back reamed. It
102
appears that the speed at which they came back down with was too fast and the well
was surged to a maximum pressure of +/- 11.5 ppg. This event appeared to have triggered
a stability problem since the ECD no longer remained at it background of +/- 10.25 ppg but
fluctuated between this background and 10.75 ppg. This was possibly due to cavings
falling in the hole after being destabilized buy the surge event, which took place earlier.
Figure 61 shows that the destabilization of the formation continued until +/- 2858.8 m before
the ECD stabilized again at +/- 10.4ppg after the pipe was reamed and the hole was
circulated a bit. Drilling continued to TD at +/- 2868.2 m and the ECD continued to
increase to 10.5 ppg before the hole became packed off when the pumps were turned
off. The maximum ECD at this time was > 11.5 ppg which may have exceeded the tensile
strength of the weakest point in the open hole, creating a fracture and lost circulation.
From the log it can clearly be seen that two major avalanche event took place: one
before the formation was fractured, and the other after with a maximum ECD of 11.25 ppg.
103
9-MLS-102-RJS 9-MLS-102-RJS
Wellbore stability
Drilling ahead problem continued
normally with a until +/- 2858.8 m.
background ECD
of +/- 10.25 ppg.
ECD now
maintained a
Backreaming at
background of +/-
connection and
10.4 ppg and
moving down too
increased to +/-
fast, creating a
10.5 ppg just
huge surge
before the section
pressure of +/-
TD.
11.5 ppg. This
was the start of the Pumps turned off
WBS issue. and 2 major
avalanching event
Well bore stability occurred. The
issue materialized first event
on the ECD. fractured the
Should be able to formation and
see on the shakers created a lost
as well. circulation event.
Figure 59: Shows the APWD response of the example.
104
2.3.2.2. Example 2:
The APWD (red & blue lines in the right hand column) does not give an early
warning sign before pack occurs.
It interesting to note that once packed-off the tool does not show the sudden
increase in standpipe pressure (black line, right hand column). This suggests that
the pack-off was below the APWD sensor.
Little drag at connection:

Hole OK
Pump pressure increases
But little change in Annular
Pressure (compatible scale)
Figure 60: This example shows little change in the APWD prior to pack-off.
In vertical wells the ECD change does directly relate to the hole cleaning
efficiency and it has been used with great success to prevent the formation of
clay rings in vertical wells see Intouch content IDs 2021251 & 3945116.
105
2.4. Real Time Software Packages
2.4.1. PERFORM
PERFORM Toolkit is the combination of three real-time enabled applications:

Drilling History, Real-Time Hydraulics and Torque & Drag (HTD)
Drilling History (DH) is an application for viewing and analyzing time and depth
based data both in real-time or through importing historical data. The HTD was
developed for use at the well site to compute Hydraulics and Torque & Drag in
real-time
2.4.1.1. Drilling History Monitor, Analysis & Playback
Drilling History is both monitoring and analysis tool supporting drilling relevant real
time decisions. The BHA position on a lithology and/or Image at any given time is
displayed side by side along with the traditional time log display.
The components include a playback (DVD alike) controls in addition to time and
date, Numeric display, Rig status, Statistics and Cross-plots. Data flow to this
module is either seamless through InterACT or via a static file upload. All rig
drilling activity and selected measurements are recorded and saved as media
linked to the software module.
Figure 61: Drilling history analysis screen.
106
The user can playback any missed activity over the past few minutes or days in
relevant real time. The numeric controls allows the user to change the depth
scale, the time scrolling speed and/or any relevant surface / down hole
measurements among some other functionalities. This module can be extremely
useful in a stuck pipe situation, drilling problems or even loss of circulation.
Reviewing these events in a quick and easy to use interface has a direct impact
on real time decisions. Displaying the last twelve hours activity in twelve minutes
or picking up a single stand of drilling and analyzing it in details is like telling a
story. This module provides the user with a tool to set their own preferences for
the story they are interested in.
2.4.1.2. Real Time Hydraulics and Torque & Drag Analysis
This module is a semi-automated real time application. It requires initial setup by

an operator and minimum maintenance that doesnt interfere with the data
stream. Data streams from the surface and downhole sensors through the
acquisition system and computed channels can be streamed out to InterACT.
For the end user on the clients side, this is an informative answer product. The
only interaction expected from the client end user is monitoring and/or replaying
jobs. The main screen (user interface) on the application operator machine
consists of real-time channels, parameters and computed channels.
The operator has the ability to format the display independently of the way the
end user setup. The module is based on automated interpretation algorithms fed
with the right drilling measurements data in real time and the necessary
parameters. The answer accuracy highly depends on the availability and quality
of the input measurement sensors. Bit, Motor, Rotary steerable systems efficiency
and performance indicators are the main outputs of this application.
When downhole WOB and torque measurements are available, the Sticking Pipe
Indicator (SPIN) answer products; Rotating friction and Drag coefficient will be
computed by module and results similar to IDEAL SPIN+ can be plotted with early
analysis of the onset of Stuck Pipe incident. In addition, ECD analysis and hole-
cleaning indicators can also be plotted once the measurements are available.
107
Figure 62: Real time torque and drag screen.
2.4.1.3. Rig State detection
The drilling process can be impeded by a wide variety of problems. Accurate

measurements of downhole conditions, rock properties and surface equipment
allow many drilling risks to be minimized, but they are also crucial for detecting
that a problem has occurred. At present, most problem detection is the result of
human vigilance, but detection probability is often degraded by fatigue, high
workload or lack of experience.
Rig state detection is a component of PERFORM Toolkit which provides a way of

computing the activity a rig is performing at any time, based on data from the
surface sensors: Torque, Pump pressure, Hook load and Depth. An integer
channel in the time data is created to store the computed Rig state events. The
calculation can be performed either in offline mode (on previously loaded data)
or in real time as new data is received. Figure 63 below illustrates the Rig
detection.
108
Pooh
Pump
Rih
Pump
InSlips
Figure 63: illustrates the Rig detection.
Automatic interpretation of the Rig state should assist the following tasks:
Event detection: A change in the Rig state will cause changes in some of the
surface and downhole measurements. Without knowledge of these change
points, a problem detection algorithm is forced to make the erroneous
assumption that the input data has been at steady state for some time. Drilling
problems that may be detected:
Stuck pipe
Lost circulation
Poor hole cleaning
Washout detection
Accidental sidetracking
POOH/RIH too fast - swab/surge
Over-/under-torque pipes
Improved manual interpretation: Plotting the most probable rig state alongside
other data channels should help focus the attention of an engineer looking at
the logs.
Data interrogation: Historical data could be extracted according to rig state,

e.g. all data while drilling in sliding mode.
Non-productive time: Automatic calculation of NPT. Correlation between NPT

and earlier problems may be derived, e.g. time setting tool face angle
correlated to earlier poor hole cleaning problems.
109
2.4.2. Stuck pipe Indicator SPIN
Most Stuck Pipe incident occurs during tripping or connections when the pipe is
stationary. However, there are often indications of an approaching problem in
abnormal values of hook load or rotary torque prior to the Stuck Pipe incident.
Abnormal values of hook load and torque can be difficult to diagnose just from
comparison with offset wells. This is because hook load and torque are
dependent upon the borehole trajectory and BHA configuration. However real
time information systems can track hook load and torque throughout all drilling
operations and use mathematical models to remove the effects of borehole
trajectory and BHA configuration.
Schlumberger IDEAL Wellsite information system includes a Sticking Pipe Indicator

(SPIN+) model which combines surface and downhole weight and torque
measurements with the BHA design and wellbore surveys to calculate expected
Torque and Drag values
These computations can be made continuously while on-bottom or off-bottom.

The difference between the weight slacked off at surface and the downhole
weight-on-bit can be used to compute the average axial friction factor, axial
(DRAG)
2.4.2.1. What SPIN+ can do?

Detects conditions that could result in Stuck Pipe
Evaluates BHA performance
Optimizes ROP
Evaluate Hole Cleaning practices
2.4.2.2. What SPIN+ computes

Rotating Friction Factor - FRIC
Sliding Drag Coefficient DRAG on a foot by foot basis
Computation starts 500-ft below rotary
Minimum wellbore inclination of 20-degrees
Automatic computation of hook load
Automatic friction vs. depth profiles for:
Over pull Sliding and Reaming
Slack-off Sliding and Reaming
Torque loss Rotating
2.4.2.3. What SPIN+ requires to work

Surface Weight on Bit (Using a Clamp line Tension meter)
Surface Torque
Downhole Weight on Bit (DWOB)
Downhole Torque (DTOR)
Surveys all the way to surface (Inc & Az)
Drillstring description
110
Mud Weight for Buoyancy Factor
2.4.2.4. Interpretation of SPIN+ model

Results from the SPIN+ model are normalized data expressed in terms of friction
factors. These friction factors are dimensionless in character and in principle are
independent of hole size and depth. They are mainly a function of the friction
between the rock and the drillstring so they are dependent upon mud type.
Experience shows that
During normal tripping without rotation, or sliding operations with mud motors
axial friction (DRAG) = 0.1 to 0.3
During normal reaming or rotary drilling operation:
axial (DRAG) = 0.0 to 0.05
rotary (FRIC) = 0.1 to 0.3
During rotation in a clean borehole
axial is close to zero because the rotation dissipates most of the axial friction
unless the drillstring components become hung up on ledges.
Drillers Action:
Under normal drilling operations the friction factors do not change (or only
change very slowly) with depth, BHA or trajectory. Abnormal values in Hook load
or torque clearly appear as increases in axial (DRAG) or rotary (FRIC)
respectively.
As soon as this increase are detected, the driller can be alerted to take
appropriate remedial action such as a wiper trip, mud circulation or avoid
leaving the pipe stationary.
Also the driller can measure the benefit of remedial action by comparing the
reduction in the friction factor after the operation with the value before it. In this
way it is possible to determine which actions are beneficial and avoid
performing unnecessary procedures if they do not bring about a significant
reduction in friction.
2.4.2.5. Examples of Using the SPIN
The example shown below is from a well in the Gulf of Mexico. The data come
from a tangent section of a directional well in fairly homogenous shale. The
rotary friction factor, Urotary (FRIC) was 0.2 and appeared to be normal.
However, the surface weight on bit of 20klbs only resulted in 10klbs of downhole
weight on bit. This corresponds to an axial friction factor, Uaxial (DRAG) of
between 0.05 0.09, with increased with depth between X800 and X020. Thee
result was a drop in penetration rate (ROP) from 50ft/hr to 40ft/hr.
Without the downhole weight-on-bit measurement (DWOB), the decline in ROP

would probably have been attributed to a harder shale formation or a worn bit.
The axial friction (DRAG) was probably increasing either as a result of swelling
shale, or cuttings build up. The diagnosis of increasing axial friction led the drilling
111
crew to perform an 11 stand short trip. After the short trip, the ROP increased to
its original 50ft/hr achieved with a SWOB of only 10klbs, which was half the
previous value. The DRAG was reduced significantly to a value less than 0.05,
resulting in less chance of Stuck Pipe.
Using SPIN to quantify the effects of hole conditioning technique
Figure 64: Output screen from SPIN.
112
3. BEST PRACTICES
113
3.1. Communication.
3.1.1. Introduction:
The importance of effective communication in preventing stuck pipe cannot be
overemphasized. Preventing fishing, like any non-productive rig time, is a team
responsibility. Everyone has a role too play. Effective communication ensures that
these roles are understood and performed in a way that gets better results than
with the most competent individuals working by themselves.
The process begins well before drilling, continues through every step of the rig-
site operations, and continues afterwards as lessons learned and experience
gained are documented for use next time around The following are the kind of
meeting that can be help.
3.1.2. Pre-Spud Meeting

The pre-spud meeting on the rig is a basic requirement and an essential
communication tool before any well is drilled. The objective is to make sure that
details of the well are understood by all concerned, and that required resources
are available to carry out operations safely and professionally. This includes
planning to prevent stuck pipe, but also to react promptly and effectively to
Stuck pipe incidents if they occur.
Participants should include key representatives of the operator, drilling

contractor (including the Rig manager) and service companies. The drilling
program should be received by the drilling team well in advance of the
anticipated spud date.
The main subject of the pre-spud meeting is usually a step-by-step review of the
drilling program. This focuses on experience on offset wells, anticipated problem
sections, and the steps to be taken to deal with them.
Issues apparently unrelated to the drilling program must also be considered.

Logistical support, major equipment maintenance, personnel issues and other
factors can indirectly affect drilling performance and the ability to respond to a
stuck pipe situation.
Most importantly, the pre-spud meeting must not be allowed to become a

routine, meaningless exercise. Properly conducted with prepared and active
participants, it is one of our most powerful tools in foreseeing and preventing
Stuck Pipe incidents.
For pre-spud meetings as with meetings generally, the following checklist can be
applied:
Are the objectives of the meeting clear?
Have the right participants been identified and invited?
Has everyone been given sufficient notice of the meeting and
anything they should prepare?
114
Is there a clear agenda?
Is the meeting room set-up satisfactory?
Is there enough time?
Are the minutes of the meeting being recorded?
Are follow-up actions identified and communicated to the
relevant team members?
3.1.3. Pre-Section meeting

Before drilling a well section or formation with a particular risk of Stuck Pipe, a
brief additional meeting should be held. Here drilling parameters, anticipated
problems and remedial actions will be discussed, and the role of each
crewmember in applying these actions clearly re-stated. In many cases this pre-
section/formation meeting can be integrated with the pre-tour meeting.
3.1.4. Pre-Job Meeting

Before any non-routine drilling operation, a short meeting should be called on
the rig floor to brief members on the operations and risks involved. Most
important for a pre-job meeting is to highlight the safety aspects of the job but
anticipated stuck pipe problems can be discussed as well.
3.1.5. Pre-Tour Meeting

Before going on tour the drill crew will meet to be briefed by the Rig
Superintendent or Asst Rig Superintendent on the ongoing operations, plans for
the coming 12 hours, and any points to watch. The Driller coming onto tour must
familiarize himself with standing instructions for drilling, written by the Rig
Superintendent, and discussed at this meeting.
3.1.6. Handover on the Drill Floor

Most Stuck pipe incidents occur within two hours of Drillers shift change.
Communication between the drillers and crews at handover is therefore crucial
The incoming Driller must look at the IADC report, chart recorder and downhole
measurements if available at the rig floor for information on drilling parameters
and developing trends. But most importantly he must listen to the Driller going off
tour. Any abnormalities observed e.g. over pulls, tight spots should be discussed,
and the relief Driller should take time to observe and understand the drilling
parameters before re-commencing his tour.
The Driller must pass any relevant information to the rest of his crew, particularly
the Assistant Driller and Derrick man, who will have their own handovers as well.
115
3.2. Drilling in the box
A Drilling in the box technique is suited for sticking mechanisms that involves
hole cleaning. It is simply applying the systems approach used in the planning
stages to the execution phase. It is a technique whereby drilling performance
(i.e. ROP) is optimized to match the hole cleaning ability of the entire drilling
system. Given the BHA that is in the hole, the directional requirements
associated with this BHA, and the well path objectives, the ROP is effectively
matched to the best drilling parameters that the rig can sustain. Real time
monitoring and analysis of all available drilling data combined with close
observation of cuttings return is used as a tool for ensuring that drilling is not
progressing in a way that will result in drilling surprises for the systems capability.
When referring to the system, the following parameters are included. Note that
these parameters are constantly changing, and therefore the system is
changing, as well. No single aspect can be treated as independent, as any
changes to one aspect will no doubt affect others.
ROP
Drilling Parameters (Flow rate, pipe RPM)
Mud type and rheology
Nature of cuttings (volume, size, shape and stickiness) will affect
how they move up the wellbore)
Hole size and angle of tangent section both of which may vary
with time as the well progresses
T&D
BHA and drill bit design.
Figure 65: Visualisation of the Drilling In the Box Concept
116
For successful implementation of this concept, it is important that all aspects of
the system are considered. The schematic above helps to visualize this
technique where each parameter and circumstance forms the walls of the box.
Drilling in the box is a closed loop feedback approach, for mitigating stuck
pipe hazards for a given situation.
117
3.3. Hole Cleaning.
3.3.1. Introduction
Hole cleaning has been discussed in detail in Volume 1 and in the planning
section of this manual. This section will concentrate on the implementation of the
plan and what to do if we have to drill with sub-optimum drilling parameters.
3.3.2. Drilling
When establishing hole-cleaning guidelines, it is important to review relationships

among the parameters and to recognize that some can be both independent
and dependent variables. Often, one parameter, such as formation type, will
determine how to approach hole cleaning. For example, a typical horizontal
well drilled through a very competent Austin Chalk formation might use a brine
reservoir drill-in fluid. It follows that these parameters would be appropriate
turbulent flow, high annular velocity, low fluid viscosity and gels, with minimal
effects from pipe eccentricity and rotation. On the other hand, an
unconsolidated-sandstone, horizontal interval would dictate tight filtration
control and laminar flow. Elevated low-shear rheology and flat gels would be
suitable, especially if the eccentric pipe can be rotated.
Listed below are practical hole-cleaning guidelines aimed at field use. They are
grouped according to general (all wells), vertical/near-vertical wells and
directional wells (including horizontal).
3.3.2.1. General
1. Use the highest possible annular velocity to maintain good hole cleaning,
regardless of the flow regime. Annular velocity provides the upward
impact force necessary for good cuttings transport, even in directional
and horizontal wells.
2. Rely on mud rheology and gel strengths for suspension and transport
capabilities.
3. Control drill to manage difficult hole cleaning situations only as a last
resort. Penetration rate determines the annular cuttings load. The
negative implications of limiting drill rate are self-evident.
4. Take advantage of top drives, if available on the rig, to rotate and
circulate (back ream) when tripping out.
5. Continually monitor parameters affecting hole cleaning, and react
accordingly. Always consider the consequences of changes on other
operations.
6. Measure mud rheology under downhole conditions, especially in
deepwater and High-Temperature, High-Pressure (HTHP) applications.
7. For deepwater wells with a large diameter riser, add a riser pump to
increase riser annular velocity.
8. Avoid using highly dispersive muds that might help cleaning, but can
create a mud solids problem.
118
3.3.2.2. Vertical and near-vertical wells
1. Keep cuttings concentration less than 5% (by volume) in order to minimize

drilling problems.
2. For efficiency and cost considerations, use a mud viscosity selected
based on hole size and slip velocity calculations. Further increase yield
point and LSYP only when hole-cleaning problems have been
encountered or are imminent.
3. Maintain LSYP between 0.4 and 0.8 times the hole diameter in inches
unless hole conditions dictate otherwise. Yield point and LSYP for highly
dispersed muds typically are low, so higher annular velocities may be
required.
4. Use periodic high viscosity & high-density/high viscosity sweeps to correct
cleaning problems. Do not run sweeps unless hole conditions warrant.
5. Monitor the hole for symptoms of cuttings accumulation, fill and bridges.
6. Do not expect pipe rotation to help hole cleaning, especially in larger-
diameter holes.
3.3.2.3. Directional wells
1. Hole-cleaning techniques to minimize cuttings-bed formation and

subsequent slumping, which can occur in 30 to 60 hole sections.
2. Pump at optimum flow rates:
Hole Size Desirable Flow rate Minimum Workable Flow rate
17 900 1200 gpm 800 gpm with ROP at 20m/hr

12 800 1100 gpm
9 7/8 700 900 gpm 500 gpm with ROP at 10-20m/hr
8 450 600 gpm 350-400 gpm with ROP at 10-20m/hr

Table 17: K & M recommend flow rates.
3. Utilize elevated-viscosity fluids from the start, because cuttings beds are
easy to deposit, but difficult to remove. As the inclination increases the
effectiveness of the viscosity decreases.
4. Maintain LSYP between 1.0 and 1.2 times the hole diameter in inches
when in laminar flow.
5. Treat mud to obtain elevated, flat gels for suspension during static and
low-flow-rates periods.
6. For optimum performance from FLO-PRO* fluids, maintain Brookfield
viscosity above 40,000 cP.
7. Schedule periodic wiper trips and pipe rotation intervals for situations
where sliding operations are extensive and bed formation is expected.
119
8. Rotate pipe at recommended RPMs for the given hole size to prevent
bed formation and to help remove pre-existing beds. Fully eccentric pipe
combined with proper LSYP values can provide best results.
9. Increase mud weight to correct wellbore stresses problems causing hole-
cleaning problems.
10. Recognize that turbulent flow across the annulus may be difficult to
achieve and maintain.
11. Consider drilling small-diameter, competent, horizontal intervals using
turbulent flow. Low-viscosity fluids enter a state of turbulence at lower flow
rates than viscous ones. Any beds which form can be eroded by the high
flow rates required for turbulent flow.
12. Expect little help from viscous sweeps, unless they are accompanied by
high flow rates and pipe rotation and/or reciprocation.
3.3.2.4. Drilling with optimum parameters.
When drilling with optimum parameters we have to make sure that we do not
drill ourselves outside of the box. This means drilling at the correct rate of
penetration for our system, and monitoring the hole cleaning efficiency e.g. real
time trend analysis.
The following rules should be followed:
1. Drill with the correct parameters in the program:

a. Flow rate
b. Mud rheology
c. RPM
2. Monitor the hole cleaning efficiency:
a. Torque and drag
b. Surface drilling trends e.g. circulating pressure
c. Mud trends
d. Cutting return over the shakers
e. Downhole drilling parameters (if available).
3. Drilling at an ROP that keeps us within in the box. This is not an exact
science and does not mean sticking at a constant ROP; some common
sense has to be used. For example if a drilling break occurs and the ROP
doubles, then ensure that the drilling system can cope. If not reduce the
ROP and drill at a controlled rate.
4. If you stop drilling with the optimum parameters implement procedures to
cope with the reduction in the hole cleaning efficiency. If this is not
possible, stop drilling until optimum parameters can be returned e.g. if one
pump is down.
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Operational Practice: Hole Cleaning.
Situation: General good hole cleaning.
Use maximumRPM.
Howto establish good hole cleaning:
High RPMis needed to keep the
cuttings in suspension.
Use maximumRPMand flowrate as
specified in the program. When the cuttings are in
suspension, the flowrate will catch
If you are not able to continue to themup and move the cuttings to
proceed with recommended good hole surface.
cleaning parameters, be prepared to
check the hole conditions before
continue drilling.
Continous rotation helps keeping
Drag trends are usually the best indicator
the cuttings in suspension.
of hole cleaning. Torque, cuttings return,
Continous rotation is best for good
pump pressure, and ECD are good
hole cleaning.
secondary indicators of hole cleaning.
If you use motor, reduce sliding to
In challenging sections (high inclination,
an absolute minimum.
long open hole sections etc.), the
standard observation parameters might
not be sufficient.
Use maximumavailable flowrate.

Control ROP up to maximumfor
good hole cleaning. High flowrate is required in order to
move the cuttings out of the well.
If the ROP is too high, neither high
RPMnor high flowrate will be
sufficient to bring the cuttings to
surface at a steady high rate. The
cuttings will accumulate in the
annulus.
Figure 66: Schematic showing the operational practice for good hole cleaning.
3.3.2.5. Sub optimum parameters.
In some IPM operations we are restricted by the well design and/or rig and we
cannot drill with the optimum parameters e.g. flow rate &RPM. In these cases the
following guidelines should be followed:
1. Keep the mud in good shape and as per program.

2. Monitor trends for excessive build up of cuttings.
3. Reduce ROP. This may reduce the height of the cuttings bed.
4. Minimise the amount of directional work e.g. steering.
5. Opt for the conservative directional philosophy e.g. two runs instead of
one.
6. Stop drilling and circulate the hole clean at maximum possible RPM and
flow rate at different stages during the section.
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7. Short wiper trips to clean the hole and disturb the cuttings bed.
8. Raise awareness with the rig team that sub optimum drilling parameters
are being used and hole cleaning related problems could occur.
Operational Practice: Hole Cleaning.

Situation:Sub Optimum Parameters
Do not reduce the flowrateor RPM

What happens if you reduce the flowrate
below recommended setting!
and/or RPM are below recommended
parameters:
1.) It is not sufficient flow or energy to

remove the cuttings to surface.
2.) The cuttings will settle at the downside
of the wellbore.
3.) Even if you have sufficient RPM or
flowrate, the cuttings will settle.
4.) Be aware of the rathole or other types
of washout. A lot of cuttings will
accumulate in over gauged hole.
Remember:
It can be difficult to remove a cuttings
bed that has been settling over a long
period!
Figure 67: Schematic showing sub optimum hole cleaning.
3.3.3. Hole Cleaning pills
Proper use of mud pills may improve hole cleaning in vertical and deviated wells.
High viscosity (preferably weighted) pills are often effective in hole sizes larger
than 8 whilst low viscosity pills are beneficial in smaller holes. When using a low
viscosity pill, it is important to maintain the normal high flow rate and minimise
non-circulation time. Also it is often necessary for a low viscosity pill be followed
by a high viscosity (weighted) pill in order to ensure adequate hole cleaning in
the larger diameter vertical hole section. The specific pill volumes should be
determined based on the hole size and the calculated effect on hydrostatic
head. Typical volumes used are:
Table18: Sweep volumes for per hole size.
122
Note:
The use of low viscosity, turbulent flow pills are not recommended in
weakly consolidated formations as washout or hole collapse may occur.
Pumping pills can have a serious impact on the mud rheology and are
sometimes counter productive.
There are several types of hole cleaning pills that are in common use. The
function of each of these pills is described below.
3.3.3.1. High Viscosity Pill

Viscosifying additives are added to the base fluid of the mud and pumped
around the well, the usual volume being 25 to 50 barrels. A highly viscous pill will
be effective at sweeping cuttings out of a vertical hole. Studies observing
circulation of viscous pills over cuttings beds at high angles have shown that the
pill deforms over the bed without disturbing the bed. Therefore the use of a
viscous pill to clean deviated wells is not recommended.
3.3.3.2. Low Viscosity Pill

The base fluid with no additives is often used for this pill. The base fluid usually has
a low viscosity and will therefore become turbulent at lower flow rates. A low
viscosity pill will help to lift and remove a cuttings bed. Use of a low viscosity pill
alone may not be successful. It will not be able to carry the cuttings up a vertical
section of the hole or suspend the cuttings when the pumps are stopped.
3.3.3.3. Weighted Pill

A weighted pill comprises base fluid with additional weighting material to create
a pill weight 2 to 3 ppg heavier than the mud. This type of pill will aid hole
cleaning by increasing the buoyancy of cuttings slightly. Heavier mud also tends
to be more viscous. This type of pill is usually used as part of a tandem pill.
3.3.3.4. Tandem Pill (also called Combination pill)

This consists of two pills, a low viscosity pill followed by a weighted pill. The
concept is that the low viscosity pill stirs up the cuttings from the low side of the
hole and the weighted pill sweeps them out of the hole. The weighted pill is
sometimes substituted for a viscous pill. Tandem pills can be very effective at
stirring up cuttings and should be used as a preventative measure for hole
cleaning problems. If the hole is full of cuttings and a tandem pill is pumped,
there is a chance the amount of cuttings stirred up can cause a pack-off. If hole-
cleaning problems are being encountered, initially use high circulation rate, drill
pipe rotation and reciprocation to clean the hole. After the hole has apparently
been cleaned up, then use a tandem pill for further cleaning.
3.3.4. Circulating Prior to Tripping
Circulating the hole prior to tripping is crucial in getting the hole clean enough to
trip out. In most operations people and impatient and see circulating on bottom
as lost time. They are too eager to POOH and stop circulating to soon. In most
123
cases this is false economy as they then encounter stuck pipe problems during
tripping that far out weigh the time saved on not circulating.
3.3.4.1. Rules of thumb:
Table 19 gives rules of thumb for the minimum bottoms up circulations required
for different hole sizes and angles. The figures assume that the circulation is
taking place at the optimum parameters for hole cleaning. If this is not the case
than the rules of thumb are not appropriate and additional methods will be
required to get then hole clean for tripping.
Hole Size Inclination Circulation

17 to 12 > 45 deg At least 3-4 btm-up circulations at optimum
parameters.
17 to 12 < 45 deg At least 2 btm-up circulations at optimum

parameters.
8 to 6 > 45 deg At least 2 btm-up circulations at optimum
parameters.
8 to 6 < 45 deg At least 1.5 btm-up circulations at optimum
parameters
Table 19: Table showing the rules of thumb for circulating on bottom at optimum
parameters prior to POOH.
124
Effective Circulation Volume vs. Angle
20,000' (6000m) tangent length, shallow KOP
6 This gives some feel for how much

circulation is necessary for different angles
5
Note only convey or belt circulation counts !
Min. Circulation Volume
0
0 10 20 30 40 50 60 70 80 90
Angle
Figure 68: Shows the number of minimum bottom up circulations required for a 6000m
tangent section at different tangent inclinations. The graph is qualitative, and it does not
consider hole size. It should be used as a guideline only.
The convey belt i.e. circulating at optimum flow rate and rpm, must be turned on
thorough out the circulation period. Circulating 4 x btms-up at sub-optimum parameters
= 0 btms-up for hole cleaning purposes.
3.3.4.2. Operational Guidelines
1. Bring pumps up slowly to the maximum flow rate. Observe pump pressure
(fluctuating) for signs of pack-off see section 4.2.1.
2. Circulate at the maximum flow rate and rpms.
3. Keep reciprocating the string at all times to avoid creating a ledge.
4. Trip a stand every bottoms up to avoid circulating in the same spot for too
long.
5. Monitor the shakers.
6. Be patient.
Please note the term circulating the hole clean is a misnomer. In many cases
you will never get the hole 100% clean, see section 1.4.6. What you are hoping is
that you can get it clean enough to be able to trip through and run casing
without problems.
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3.4. Connections & Surveying
3.4.1. Connection Practices:
Sticking problems can occur when making connections. These have occurred in
all hole sizes and have resulted in expensive Side tracking operations. The
following guidelines should be used to minimize potential problems during
connections. These guidelines assume top drive drilling
1. All Drillers should be familiar with these connection procedures.

2. Wipe the last joint prior to making a connection. If erratic or high torque is
experienced prior to the connection, take time to ensure the cuttings are
well above the BHA.
3. After making a connection break circulation slowly, checking for returns
at the shakers.
4. Avoid starting and stopping the mud pumps suddenly. This may disturb the
well bore downhole (shock loading effect).
5. Minimize the period without circulation during a connection.
6. If differential sticking is expected to be a risk;
Maximize pipe motion.
Consider rotation of string with slips set, whilst picking up the next
stand. Beware of inducing slip cuts and, if you do, lay out that joint
of pipe for inspection. Perform a risk assessment before attempting
this procedure.
7. Connections should only be made if hole condition is good. Never make
a connection with any over pull onto the slips.
8. Set slips high enough to allow downward movement. If hole conditions
are sticky, extra stick up may be required. Take care not to bend the pipe.
3.4.1.1. Highly deviated wells
Connection practices on highly deviated and ERD wells should be different than
those on a vertical or low angle well. The recommended baseline connection
procedure is as follows:
1. Drill down the stand with the current rpm and flow rate
2. Pick-up off-bottom and increases flow rate and rpm to their maximum
3. Ream one stand out and back in (repeat if the hole is tight)
4. Get Off-bottom Torque and String Weight
5. Shut down the rotary
6. Reciprocate the pipe and obtain Pick-up (PU) and Slack-off (SO) weights
7. Shut down the pumps and make connection
The aims of the above connection procedure are to:
Move cuttings away from the BHA to ensure a trouble free

connection
126
Condition the new section of hole that has been drilled
Collect Torque & Drag data in a consistent manner
3.4.2. Surveying - Stuck Pipe Avoidance While Surveying
3.4.2.1. Planning
1. Make sure the MWD or survey engineer is ready to survey before you stop
drilling. Ensure the time taken to survey is not going to be excessive. Find out
the maximum time required to go through the entire survey cycle and ensure
this is both reasonable and is not exceeded. The average MWD survey takes
from 3 to 5 minutes. It should be up to the person in charge on the rig floor to
determine whether or not the pipe must be moved between surveys, or if
another survey can be attempted. To cut down the survey time in a high risk
area consider using power pulse instead of slim pulse.
2. Look at the survey requirements and discuss modified survey program
through the high-risk zone i.e. are surveys required, can we use different
tools?
3. Never allow the MWD operator to continue surveying without the Driller's,
Directional Driller's or Tool pushers permission.
4. The depth or position on the Kelly of the next survey, the last survey result and
the amount of reaming or circulating before and during the surveys should
be written up on the rig floor.
5. To cut down the survey time in a high risk area consider using power pulse
instead of slim pulse.
3.4.2.2. General/Operation
1. The pipe should be worked, reamed or circulated before taking a survey. The
amount of pre-survey working, reaming, or circulating should be discussed
with the Tool pusher and Wellsite Supervisor before drilling the hole section.
2. It is possible to rotate some MWD tools one or two minutes into the survey
time. Ask the MWD operator for all of his options, especially if the hole is tight.
3. If the survey is required at a set depth, the Wellsite Supervisor may
recommend more circulating before surveying. He may also recommend
drilling a few more feet and then picking back up to that survey depth. All of
these actions should be discussed at the pre-section meetings.
4. The position of the Kelly is of particular importance in preventing stuck pipe.
The survey should never be taken with the Kelly completely down or
immediately after the connection is made. There will not be enough room
available to cock the jars and work the pipe should the hole become tight. A
joint can be added or removed, but this wastes valuable time and may result
in stuck pipe.
5. A good position to survey is the first or second tool joint of the stand. This
position avoids taking a survey near the Kelly down position. The theory is to
compensate for the stretch and compression of the drill string in order to
operate the jars properly.
127
6. Some wells require drill pipe screens to be placed in the box of the Kelly stand
before the connection is made. The lower screen will then be removed from
the box connection that is in the slips. The Wellsite Supervisor will decide if a
screen will be run before tripping in the hole with an MWD tool. It is the
responsibility of the crews to remove and install these screens and keep track
of them at all times. The two-screen system works for most rigs. One screen
remains on the drill floor while drilling and two while tripping, except when
surveying whilst making a trip. During tripping the screen is installed only for
the survey and is removed afterwards.
7. The risk of using screens should be carefully considered. Handling screens
when drilling in stands with top drive presents a significant safety hazard.
Some assets have stopped using them for this reason. The floor hands must
clean out the screens after connections and report any washouts and
abnormal amounts of junk that may plug up the screen or the MWD
downhole. A plugging of either could reduce the ability to have full flow and
increase the chance of stuck pipe. Screen in the standpipe/mud line can
eliminate the possibility of misplaced drill pipe screens.
8. Ensure all screens are removed after circulating for a survey. If a screen is left
in the string by accident it could prevent any wireline work that may be
needed for a free point or back off.
9. Consider the effect hole condition may have on survey interval times when
surveys are dropped before tripping. If hole conditions are poor the Kelly may
need to be picked up to circulate or back ream during the trip out through
open hole. The additional time this may take should be added when setting
survey time intervals.
10. The effect of mud additives on the survey tools should also be considered.
Some additives can increase the chance of packing-off inside the survey
tool. This is especially true if the mud contains Lost Circulation Materials (LCM).
128
3.5. Tripping
The majority of stuck pipe events occur while tripping, especially in deviated
wells where hole cleaning is an issue. It is therefore imperative that trips should be
carefully planned and executed.
3.5.1. Considerations Prior To Tripping
Planning the trip out of hole is extremely important in deviated wells. Things to
consider in the plan are:
1. The hole will never be 100% clean even circulating at optimum parameters.
2. Identify trouble spots from offset data and previous trips and plan for them.
o Where will we encounter a build up of cuttings? Do I need to
circulate at different inclinations to mitigate hole pack-off e.g. 75,
60 & 45deg inclinations?
o Troublesome formations e.g. tight formations, ledges. Will I need to
ream through these areas?
3. WHAT IF questions, e.g.
What if I dont move the string for 2 minutes
What if I get stuck pulling out?
What if I get stuck running in?
4. The preparedness and appropriate response by Drillers and Assistant Drillers
when they encounter:
Swab and surges and the effect on hole stability
Excessive over pull or resistance and the decision to pick up the
Kelly or top drive
Tendency of the hole to pack-off during circulation or when
breaking circulation
Likelihood of key seats developing over intervals with severe
doglegs
Decision to ream or back ream.
5. What is the maximum initial over pull limit over normal drag before the driller
stops and goes back down? Normally it is the 30Klbs rule.
6. Optimising the mud system to facilitate tripping i.e. adding lubricates,
condition mud for casing and cementing
7. Communicate the plan to the rig team. Hold a pre-trip meeting during the
last part of the circulation.
3.5.2. Considerations During Tripping
1. Pull slowly and at constant speed. This allows the cuttings to flow around the
BHA junk slot area and stops the cuttings building up around the top of the
BHA and/or top stab.
2. Monitor drag.
3. Record the depth of the top of the BHA while circulating bottoms up prior to
tripping. Take extreme care when the top stabilizer reaches this depth and for
129
the following two stands, as this is the likely place the BHA will be pulled in to
a cuttings bed if one exists.
4. Apply the 30Klbs over pull rule. This is a rule to used for initial over pulls over
normal drag while tripping out of the hole. Do not initially pull more than 30k
lbs. If over pull exceeds 30klbs consider all resistance in a deviated well as
hole cleaning related. The first action should always be to go down 1-2 stands
and circulate btms-up. If the resistance is still there after circulation then other
measures such as reaming can be started.
5. Always bring the pumps up slowly and watch for pack-offs. The best way is to
raise the flow rate is in pre-determined steps once the circulating pressure has
stabilised for that step.
6. Pumping out and back reaming in a dirty hole increases the chance of pack-
off and stuck pipe. The initial response is:
a. Circulate the hole clean to remove the cuttings.
b. Pull dry until resistance is encountered 30Klbs rule
c. Run in 1-2 stands and circulate hole clean.
d. Pull dry past initial resistance and continue out of hole. If resistance
is still encountered consider back reaming as an option.
3.5.3. Reaming and back reaming.
Reaming is a high-risk operation, which accounts for a large proportion of stuck

pipe incidents. If reaming operations are conducted too fast solids from
washouts and cavings are introduced into the circulating system at a faster rate
than the hole is being cleaned. This results in a pack-off. Do not assume that any
resistance is always at the bit; stabilisers and drill collar contact may be
indicative of a build up of loose material in the hole and a potential pack-off
situation. The following guidelines are offered as a general list.
3.5.3.1. Planning
1. Have a contingency plan for all possible problems. E.g., what to do in case of
a leaking wash pipe or leaking saver sub.
2. Always pre-plan a trip. Have an up-to-date mud log/PASON data on the rig
floor. Know where high doglegs exist and note troublesome areas from past
trips.
3. Have singles in the V-door in case downward motion is required to free the
pipe after a connection.
3.5.3.2. Organisation
1. The shakers must be monitored continuously and the volume of solids being
removed from the well bore should be recorded.
2. While drilling or reaming in problem formations have two people at the
console: one man on the brake and the other on the pumps (spm dials). The
man on the pump is there to react to the signs of hole pack-off (sudden
increases in pressure).
130
3. Ensure that the driller knows what actions to take in the event of problems.
Are over pull limits, freeing procedures and reaming practices understood?
Are written instructions for the driller prepared and updated regularly?
4. Mud loggers will record all parameters. Significant changes in trends should
be reported immediately to the driller and well site supervisor, and then
investigated.
3.5.3.3. Parameters
1. Use optimums parameters for reaming operations. This assists in identification

of changes in torque and pressure trends. Ensure that the flow rate is sufficient
to clean the hole.
2. Any indication of changes in parameters should be addressed immediately.
Most drag problems can be reduced by time spent circulating the hole
clean.
3. An increase in drag, torque or pressure may indicate that the annulus is
loaded up, and a pack-off may be forming. Circulate and clean the well
bore before continuing reaming.
4. If indications of a pack-off occur, immediately reduce the pump strokes (e.g.
by half) to reduce the pistoning effect. If, after several minutes the hole does
not pack-off, return to the original parameters and be prepared to circulate
the hole clean.
5. Reaming speed and circulation time should be adjusted if the returning
cuttings' volume rate is excessive.
6. If torque becomes erratic or any of the following occurs:
a. The rotary is stalling out.
b. The cave-in rate increases.
c. Torque and pressure readings are increasing; be prepared to stop,
circulate and clean up the hole.
7. Prior to heavy reaming, slow rotation (<80 rpm) should be used in an attempt
to "walk the pipe past ledges.
8. Reaming operations should be conducted with the same flow rate as drilling.
Be aware of formation washout risk in unconsolidated formations.
9. Reaming weight and speed should be kept low (< 10 - 15k lbs either up or
down). This reduces the chance of sidetracking the well and is less damaging
to the drill string. Torque and weight on bit should also be less than the same
drilling parameters through that section.
10. Control the speed of reaming operations (4 stands an hour can be used as a
rule of thumb for the maximum speed). This should also reduce the
mechanical damage the drill string does to the well bore.
11. Large volumes of settled cuttings or new carvings can be introduced to the
hole when reaming. It is critical that this material is circulated out of the hole.
3.5.3.4. General/Operation
1. If the hole packs-off, immediately shut down the pumps and slowly bleed the
pressure under the pack-off down to less than 500 psi.
131
2. While reaming in problem formations the hole may need to be wiped at
regular intervals, if conditions require it.
3. Do not use the Soft Torque (torque feedback system used to reduce torsional
vibrations) while reaming as it may disguise torque trends.
4. Make sure the pipe is free before setting the slips.
5. After drilling or reaming down, the cuttings should be circulated above the
BHA prior to picking up.
6. The preferred practice is to always try to work the string past a tight spot as a
first option. However, over pull limits must be known and used. Work up to the
over pull limit in stages ensuring free movement in the other direction at each
stage.
7. If the top drive stalls out during reaming operations there is a great deal of
stored energy in the drill string, always release this torque slowly.
8. When back reaming do not over pull the pipe into the slips to connect the
top drive.
9. When washing in, with a motor in the BHA, rotate the whole drill string at low
rpm.
10. Back reaming is extremely hard on equipment, especially motors e.g. shocks
and vibrations.
3.5.3.5. Example of excessive back reaming
Circulation for 7 hrs

Hole condition deteriorates
with time
High Shocks appeared.
Large cuttings/cavings on
surface.
132
Figure 69: Downhole and surface drilling data chart. The peaks in the resistivity have
been interpreted as washouts caused by excessive back reaming.
This example illustrates the downside of excessive back reaming. Here the
formations were relatively unconsolidated with a well inclination of 60deg. The
rule of thumb again is to circulate after every 500ft. Back reaming was carried
out for several hours due to the fact that the shakers were heavy loaded during
the back reaming operation. While the driller thought the circulation and back
reaming operation was actually cleaning the hole, the downhole measurement
showed otherwise. ECD showed that the cuttings were being generated
downhole from the back reaming operation across the unconsolidated
formation.
Resistivity measurements also started showing divergent signals indicating that
the hole size was undergoing enlargement due to washout of the formation.
3.5.3.6. Example of effect on ECD of pumping out of hole.
ECD trend as
pumping out
was initiated
Figure 70: Downhole and surface drilling data chart.
133
Figure 70 shows the evidence of high and unsteady ECD trends while pumping
out of hole. The ECD value prior to POOH was 10ppg. But as operation
progressed, ECD increased to a maximum of 11.5ppg. This indicates that the
hole condition with respect to cuttings was not in good shape. The result was a
tight spot and over pull while tripping out of hole.
134
3.6. Differential Sticking
The theory of differential sticking has been discussed in the Trouble Free Drilling
Manual Volume 1, Chapter 9. This section will concentrate on prevention during
the execution phase.
To prevent differential sticking we need to minimise following conditions:
1. Permeable formations out of our control.

2. Filter Cake dependent on mud properties.
3. Overbalance
4. Wall Contact
5. Static Pipe
6. Time
7. Side loads
THICK WALL CAKE

MW
PIPE PIPE
Figure 71: Schematic showing differential sticking.
3.6.1.1. Permeable formations

There is a higher risk of getting differentially stuck in a permeable formation then
there is in a tight shale formation. If permeable formations are present, and the
pore throat sizes are known (from core data) then plugging material can be
added to the mud system to block the pore throat and reduce the permeability
around the wellbore.
135
In reservoir sections the plugging material must be removable to reduce the
impact on production.
3.6.1.2. Filter Cake

The filter cake should be thin, hard and impermeable. It is determined by the
mud type and its properties.
Focus during drilling should be on maintaining the mud rheology at its
recommended values and this is highly dependent on the competence of the
mud engineer and the type and condition of solids control equipment.
Both laboratory studies and field use suggest that cellulosic lost circulation
materials (LCMs or Seepage Control Materials, SCMs), lubricants and fluid loss
reducing agents incorporated into the mud system can mitigate differential
sticking potential (DSP).
Product Supplier Concentration Chemical

(Vol. %) Description
BXR-L Baroid 3.00 Blend of asphalt and
sulfonated asphalt in
glycol carrier
DL-100 Chemrich 3.00 Sulfurized paraffinic
material
DRIL-KLEEN M-I 0.17 Surfactant blend
HF-100N Hydra Fluids 10.00 Neutralized polyglycerol
IDLUBE XL M-I 3.00 Organic acids/alcohols/

esters blend in glycol
Lubrizol 1000 Lubrizol 3.00 Calcium sulfonate
SCMs Various 2 to 16 lb/bbl Cellulosic fibers

Suppliers
Table 20: Various materials studied in POLYNOX, bentonite, and low-solids non-dispersed
muds that can help mitigate DSP.
3.6.1.3. Overbalance
Minimise the overbalance as much as possible. Do not allow the mud weight to
slowly build up density whilst drilling and limit the amount of cuttings in the mud
system.
3.6.1.4. Wall Contact

The golden rule here is to minimise the wall contact as much as practically
possible. Measures can include:
136
1. Drill with small tubulars in large hole sizes e.g. small drill collars. Buckling & hole
cleaning could be an issue in some circumstances.
2. Minimise the amount of drill collars in the BHA. Use HWDP for weight and drill
with a downhole mud motor.
3. Use spiral drill collars and HWDP.
4. Stabilise the BHA to keep the tubulars away from the wall.
3.6.1.5. Static Pipe

Differential sticking does not occur until the pipe remains motionless long enough
for the lubricating layer to drain into the filter cake. Motionless pipe is
unavoidable, as connections and surveys must be made. We must try to avoid
any unnecessary static pipe and plan surveys carefully.
1. Follow the connection and survey guidelines in this chapter. Ensure that the
survey is taken at least a joint off bottom to ensure the jar can be fired
downwards.
2. Is directional control required? Do we need surveys through this formation?
Challenge the program to minimise the amount of stationary time.
3. For unscheduled repairs continuously reciprocate the pipe and continue
circulation (if possible).
3.6.1.6. Time
It takes time to develop the differential sticking pressure necessary to cause a

sticking force.
The crews need to be aware of the first signs of the onset of differential sticking
(increasing drag) and they need to know how to react e.g. re-establish pipe
movement as quickly as possible.
3.6.1.7. Side loads

Doglegs through permeable formations should be avoided, especially high in the
open hole section. Long, heavy BHAs in high inclinations will cause drag and
impart a large side load on the low side of the hole. Good tripping practice calls
for the pipe motion to be downward prior to setting the slips. This is partly to
remove the excessive tension in the string that leads to higher side loads.
137
3.7. Problematic Shales
The theory of Shale stability and failure is covered in detail in the Trouble Free
Drilling Manual, Volume 1: Stuck Pipe Prevention, Chapter 8.
3.7.1. Swelling Shales.
Mud inhibition is the best way to combat swelling shales. Unfortunately, the fluids
that provide this e.g. OBM, are normally prohibited in the shallower sections
where they occur. Instead, we have to use partly inhibitive water based mud
systems and good drilling practices to minimise the risk.
An extremely good best practice on minimising the NPT caused by swelling

shales is documented in Intouch Content ID: 3945116 - Clay Rings.
Figure 72: Picture from Intouch Content ID 3945116 of a clay ring at surface.
3.7.1.1. General guidelines
1. Minimise exposure time of the formation.

2. Minimise the number of stabilisers in the BHA.
138
3. Drill with a high flow rate. The idea is to try and stop the cuttings joining
together and forming a clay ring.
4. Good bit hydraulics. If drilling with a rock bit, use one with a centre jet.
5. Maintain the desired mud properties.
6. Good solids control equipment.
7. Stop drilling and circulate the hole clean at regular intervals.
3.7.2. Cavings
3.7.2.1. What are Cavings?

Cavings are rock fragments produced by wellbore instability and transported to
surface in the drilling mud. Typical carvings are centimetre sized fragments, but
can range from 1mm to more than 10 cm. Small carvings, called coffee-
ground carvings can form from disaggregating of larger water-sensitive shale
carvings. Larger cavings are typically produced from naturally fractured
formations. Natural fracture planes bound such cavings.
3.7.2.2. Cavings Analysis
Interpretation of cavings morphology:
Helps determine cause of wellbore failure

Helps determine optimal remedial action
Angular
Splinter
Platy
Figure 73: Photographs of the three main types of cavings.
139
Monitoring the volume of cavings versus time:
Provides an early warning of wellbore instability

Signals need to improve hole cleaning
Indicates which drilling practices destabilize the wellbore
Figure 74: Cavings vs. time graph
3.7.2.3. Angular Cavings
These multifaceted rock fragments result from shear failure of the wellbore.
Newly Created Fracture Surfaces
Wellbore Surface
Figure 75: Shows typical angular cavings.
Key Characteristics
Facets are newly created fracture surface
Facets may be curviplanar
140
Facets are nonparallel
Failure-two regions on the wellbore separated by 180
Indicates compressive failure of rock
Scanline
Fig. 17
A B A C B
Wellbore Surface
Figure 76: Borehole Images illustrating sections of wellbore that have suffered shear failure
(dark bands A and B) which are the sources of angular cavings. RAB* (Resistivity At Bit)
images allow diagnosis of wellbore failure while drilling.
Remedial Action
If mud weight close to Pp: raise mud weight
If mud weight close to fracture pressure
Maintain mud weight
Decrease fluid loss
Manage hole cleaning
3.7.2.4. Platy/Tabular Cavings
These cavings are rock fragments bounded by pre-existing planes of weakness.
141
Bedding planes
Natural Fractures
Figure 77: Shows various examples of blocky/platy cavings.
Key Characteristics
Majority of caving surfaces represent pre-existing planes of
weakness
One or more parallel surfaces are common
Surfaces tend to be relatively smooth and planar
Failure initiates on high side of wellbore when well is nearly parallel
to a plane of weakness
142
Figure 78: Schematic diagram of a well intersecting pre-existing planes of weakness
(bedding, fractures). Platy-blocky cavings originated on the high side of the hole due to
gravitational instability.
W e l l De v i a t i o n
A z im ut h
Bedding planes
Natural Fractures
Figure 79: Schematic borehole cross-section (looking down hole) showing locus UBI
image (right) high side damage is oriented 330. Note: High side damage is well
developed when wells are deviated along bedding or fracture dip direction.
Remedial Action
Maintain mud weight
Minimize fluid loss coefficient of drilling mud
Use crack blocking additives
Avoid back reaming
Manage hole cleaning
Avoid excessive rpm and drillstring vibrations
143
Employ gentle drilling practices
3.7.2.5. Splintered Cavings
These elongated platy rock fragments result from tensile failure of the wellbore.
Splintered cavings are believed to form as a poroelastic response to drilling too
fast through low-permeability shale or drilling underbalanced.
Plume Structure
Figure 80: Plume structures in splintered cavings.
Key Features
Typical lithology: low-permeability shale fragments
Caving surfaces show plume structure indicative of tensile failure
e.g. drilling underbalanced
Entire circumference of wellbore may be damaged
144
Figure 81: Surface structures commonly associated with extension (mode 1) fractures
(after Kulander and Dean, 1985).
Remedial Action
Raise mud weight
Reduce rate of penetration
3.7.2.6. Geo-mechanics
Wellbore stability studies are key in mitigating the risk of unstable formations.
There define the stable wellbore pressure window (optimum mud weights) and
optimum well trajectory, and identify and locate geological hazards. They can
be constantly refined & updated throughout the drilling process (PERFORM) and
are essential in high-risk areas (see section 1.2.1.5 & figure 82).
145
Figure 82: Shows an output screen from a wellbore stability study.
3.7.2.7. Drilling Guidelines
1. Minimise Open hole time: Mud types that allow a certain degree of pore
pressure penetration, will with time, cause formation pressures to gradually
equalise with the mud pressure. Thus net effective rock stresses will increase
around the borehole, bringing the shale either to or close to failure.
Minimising open hole time will therefore reduce the chance of borehole
stability problems.
2. Pressure fluctuations: Pressure fluctuations in the well can cause cavings to

be pulled into the hole or they can directly cause shale failure. At all times
pressure fluctuations should therefore be minimised and care should be taken
when tripping in/out or breaking circulation. Proper mud conditioning i.e.
keeping the gels and the plastic viscosity within specified limits will help to
decrease pressure fluctuations when circulating or pulling or running pipe.
3. Hole cleaning: Hole cleaning is very important to prevent sticking problems

after shale failure has occurred. However, proper hole cleaning can also
help to prevent shale instability! Insufficient hole cleaning will lead to large
amounts of solids in the hole. This effectively increases mud pressures exerted
146
on shale formations, which in turn causes an increase in pore pressure
penetration and de-stabilisation of the shales.
4. Mud weight increase: Ideally, shales should be drilled with a mud system,
which totally prevents pore pressure penetration, and if correct initial mud
weights are used shale failure will be prevented. However, most WBM systems
do allow a certain degree of pore pressure invasion and in those cases, the
de-stabilising effect of pore pressure penetration can somewhat be reduced
by increasing the mud weight gradually in small steps. Every weight increase
provides a small increase in effective mud support, which stabilises the hole.
However, this increased mud support is only effective for a limited time since
the new mud pressure and formation pressure will equalise. Increasing the
mud weight in small steps over a long time period is thought to be more
effective in providing sustained mud pressure support than a single large
increase.
5. Do not decrease the mud weight: When the mud weight is lowered in an
open hole section which has previously been drilled with a higher mud
weight, shales will be exposed to increased rock stresses and may fail,
especially when pore pressure penetration has decreased the required mud
pressure at which shale failure will occur. Lowering the mud weight before a
hole is cased off increases the chance of borehole instability in shales! It
should be realised that decreasing the mud weight after a hole is cased off
can still cause shale instability in the pocket below the casing. These stability
problems will only become apparent when drilling out the casing shoe and
pocket. Thus, lowering the mud weight should be prevented whenever
possible.
6. Drill string vibrations: The mechanical action of the rotating drill string against
the borehole wall can cause shale fragments to be pulled into the hole and
in some cases can initiate failure in brittle shales. Thus is it important to
minimise vibrations in the drill string. Back-reaming i.e. rotating the drill string
whilst pulling out of hole can also cause shale fragments to be pulled/pushed
into the wellbore. It is therefore important to use back reaming only when
necessary i.e. in tight whole situations.
7. Monitoring: More than one type of caving (mode of instability) can be

produced in a single openhole section. The rig team must determine which
mode of failure is most problematic and take the appropriate remedial
action. It is important to respond to sudden changes in cavings rate. A small
constant volume of cavings production is worth monitoring but may not
require immediate remedial action. The use of cavings morphology to
diagnose wellbore failure cavings is relatively new. When interpretation of
cavings is problematic, e-mail a digital image of the cavings to a
geomechanics specialist. Include a coin or ruler for scale and, if possible,
locate the source on a (RAB, UBI, FMI*[Fullbore Formation Micro Imager])
borehole image or on an oriented 4-arm or 6-arm calliper.
147
4. IDENTIFYING & FREEING STUCK PIPE
The first three chapters of this manual have concentrated on stuck pipe
prevention. In an ideal world we would not need this next section, which focuses
on remedial action once we have got stuck. Unfortunately the world is not
perfect.
The flowchart below shows the stuck pipe process.
FREEING STUCK PIPE

Stuck Pipe
Identify SP
Mechanism
Estimate
Stuck Point
Start Working Pipe
Calculate Optimum
Fishing Time
Switch Freeing Continue
Method Working
Cut Pipe
Pipe
& Fish
End Time Give up trying
to free pipe Pipe Freed
Sidetrack or P&A Remedial Action
Figure 83: Flow diagram detailing the stuck pipe process.
148
4.1. Stuck Pipe Identification
Once a stuck pipe incident has occurred, an understanding of the mechanism is
very important.
The correct remedy, beginning with the first action to be employed depends on
knowing the cause of the sticking event. Wrong or improper understanding of
sticking mechanism and/or wrong application of first actions worsens many stick
pipe incidents.
In the event of a stuck pipe incident, the following steps should be considered.
Evaluate the sticking mechanism and employ the most appropriate first action
without delay. If this could not help free the pipe, employ a secondary freeing
action (e.g. pumping pills etc), followed by series of jarring operations. A backoff
operation is then considered and an attempt to fish carried out. How long the
freeing operation takes is dependent on the economics of Fishing. Below is a
detailed explanation of these steps
4.1.1. Stuck Pipe mechanism Identification Worksheet
The Stuck Pipe mechanism Identification worksheet below will be helpful in

determining the Stuck Pipe mechanism. Although the worksheet does not always
provide a conclusive indication of the Stuck Pipe mechanism, it helps to
eliminate mechanisms that are not contributing to the stuck pipe incident. When
the stuck pipe mechanism is determined, attempt to free the string will follow a
more focused approach.
149
STUCK PIPE MECHANISM IDENTIFICATION WORKSHEET
PIPE MOTION PACK-OFF / WELLBORE

PRIOR TO STICKING? BRIDGE DIFFERENTIAL GEOMEETRY
Moving Up 2 0 2
Rotating Up 0 0 2
Moving Down 1 0 2
Rotating Down 0 0 2
Static 2 2 0
PIPE MOTION AFTER
STICKING?
Down Free 0 0 2
Down Restricted 1 0 2
Down Impossible 0 0 0
PIPE ROTATION AFTER
STICKING?
Rotate Free 0 0 2
Rotate Restricted 2 0 2
Rotate Impossible 0 0 0
CIRCULATING PRESSURE
AFTER STICKING?
Circulation Free 0 2 2
Circulation Restricted 2 0 0
Circulation Impossible 2 0 0
TOTALS
INSTRUCTIONS: Answer the shaded questions by circling all the numbers in the row with the correct
answer. Add the columns, the column with the highest number indicates the sticking mechanism.
INSTRUCTIONS: Answer the shaded questions by circling all the numbers in the
row with the correct answer. Add the columns, the column with the highest
number indicates the sticking mechanism.
150
4.1.2. Stuck Pipe Summary Tables:
4.1.2.1. Table 21: Hole Pack-off.
Problem Settled Cuttings Shale Instability Unconsolidated, Cement Junk in Hole

Fractured Formation (Blocks or Soft)
Causes - Drilling too fast - Drilling reactive shale - Drilling uncemented - Cement blocks fall - Accidental junk falling
- Inadequate annular with non-inhibitive mud formations from around casing in hole
velocity or rheology - Drilling pressured - Little or no filter cake shoe, squeeze plugs or - Downhole equipment
- Cuttings accumulation shale with insufficient - Drilling naturally sidetrack plugs failure
(washouts) mud weight fractured formation - Attempt to circulate
- Not enough circulating while the drillstring is
time immersed in soft cement
- Drilling blind without (flash set)
sweeps
- Drilling without
circulating
Warning signs - High ROP with poor - Increase in FV, PV, YP, - Solids-control equipment - Excessive casing rathole - May occur any time
and indications cuttings return gels, and CEC loaded with sand - Increase in torque - Metal parts at the
- Increase in torque, drag - Increase in torque, and cuttings and drag shakers
and pump pressure drag and pump - Seepage losses - Circulation restricted - Partial motion is
- Overpull on connection pressure - Fill on connections and - Restricted pipe movement possible
and when tripping - Overpull on after tripping
- Fill on bottom after connection - Sudden increase in torque
connection and trips and when tripping and drag
- Circulation restricted - Bit & BHA balling - Circulation restricted
- Increase in LGS and - Pore pressure increase - Large cavings at shakers
mud weight - Fill on connection and
after trips
- Large cavings at shaker
- Circulation restricted
Prevention - Proper mud rheology - Use inhibited mud - Provide good filter- - Limit casing rathole - Use good practices
- Use maximum GPM - Increase mud weight cake quality - Allow sufficient time - Keep hole covered
for hole size - Minimize open hole - Use appropriate for cement to set - Check downhole tools
- Control ROP if needed exposure time bridging materials - Reduce tripping speed on regular basis
- Pump sweeps to clean - Use sweeps to clean - Avoid excessive opposite cement section
the hole the hole circulating time - Calculate top of cement
- Wiper trip after motor - Increase mud rheology - Use sweeps to keep the and start circulation two
run hole clean stands above
- Increase drillstring - Increase mud rheology - Control drilling in
rotation soft cement
- Circulate longer
151
4.1.2.2. Table 22: Well Geometry
Problem Key Seating Undergauge Hole Stiff Assembly Mobile Formation Doglegs & Ledges Collapsed Casing
Causes - Drill pipe wears a key- - RIH with a full- - BHA change from - Drilling plastic salt - Drilling hard/soft - External formation
seat in the formation gauge limber to stiff cannot or shale formation interbedded pressure (often
- Often associated with bit and BHA in an tolerate changes in formation opposite plastic
doglegs undergauge hole angle & direction - Frequent change in formation) exceeds
- Drill collars jam into hole angle/direction casing strength
the narrow groove of - Drilling fractured/ - Failed cement
keyseat faulted formation
- High dip angles
Warning signs - Severe dogleg section - Undergauge bit - New BHA is run - Increase in torque - Overpull on connec- - Drilling plastic
and indications - Pipe rotating at the pulled in hole and drag tions & trips formation
same spot for - Tight hole - Presence of doglegs - Overpull when - Increase in torque - Cement chucks
extended period - Sudden loss of - Sudden loss of tripping out of hole and drag - Lost circulation
of time string weight string weight - Tight hole
- Tight hole inside casing
Prevention - Minimize - Gauge old & new - Minimize BHA changes - Maintain sufficient - Minimize sharp and - Use proper casing
dogleg severity bits - Limit dogleg severity mud weight frequent wellbore strength opposite
- Wiper trip/ream - Ream last three joints - Plan a reaming trip - Select the proper course changes plastic formation
dogleg sections at least to bottom if a stiff BHA will mud system - Avoid prolonged
- Use keyseat wiper - Never force bit be used - Frequent reaming/ circulation opposite
or reamer through tight spot, tripping soft formation
ream - Use eccentric bit - Minimize BHA changes
- Minimize open hole
exposure time
4.1.2.3. Table 23: Differential Sticking
Problem Differential Sticking

Causes - The hydrostatic pressure exceeds - Porous permeable formation - Thick, poor quality filter cake
formation pressure - High fluid loss - Pipe stationary too long
Warning signs - Circulation is not restricted when stuck - Drilling with high overbalance - Overpull opposite porous formation
and indications - Increase in torque & drag - Poor filtration properties - Hole sticky on connection
Prevention - Minimize overbalance - Minimize area of contact by using - Improve filter-cake quality
- Control downhole filtration heavy-weight drillpipe & spiral collars - Minimize coefficient of friction, use lubricant
- Minimize time pipe is stationary - Maintain optimum hydraulics - Use proper bridging agents
- Proper casing design - Minimize drill solids content
152
4.1.3. Stuck Pipe Identification Trees
4.1.3.1. Figure 84: Stuck Pipe incident when ROTARY DRILLING
Rotary Drilling
Increased Torque
Is there a formation Change?
Increase in Torque
Are bit hours N Y Related to formation
Excessive?
Change
Are hole Drags If Tri-cone bit

Excessive?
N Y
bearings worn
Have abrasive
Formations been Can drag be related
N Y to dogleg ?
Drilled ?
Wellbore Is Circulation
N Y Geometry Y N restricted?
Have formations of Undergauge hole

Varying hardness causing stabilizers N Y Are Drags reduced
been drilled? to hang up? when pumping?
Can hole problem

be related to a Inadequate Have problem formations
formation change?
Y N Already been exposed?
N Y Hole cleaning
N Y Y N
Bit failure Stabilizers
String Component Hanging up
Cement Blocks
On formation Fractured/Faulted Slow moving mobile Newly drilled
failure Junk
Ledges Formations Formations reactive Geopressured forms
Casing Keyseat
formations Unconsolidated forms
Fractured/Faulted forms
Fast moving mobile forms
153
4.1.3.2. Figure 85: Stuck pipe incident when MAKING CONNECTION
Moving pipe from static after

making/breaking connections
during drilling, tripping and
reaming or after surveys
Drag trend increasing

when moving string
from static
Is circulation restricted?
Are known problem Are permeable

formation exposed? Y N formations exposed?
Y N Y N
Reactive formations
Junk
Fractured/faulted formations Is drag reduced Can drill string Cement blocks
Mobile formations when pumping? be moved? String component failure
Unconsolidated formations
Stabilisers hanging up on ledges
Geopressured formations
Y N
Y N
Reactive formations
Fractured/faulted formations Junk
Inadequate hole
Mobile formations Cement blocks Differential sticking
cleaning
Unconsolidated formations Stabilisers hanging
Geopressured formations up on ledges
154
4.1.3.3. Figure 86: Stuck Pipe incident when CIRCULATING
155
4.1.3.4. Figure 87: Stuck Pipe incident when RUNNING CASING
Running Casing
Increase in downwards
resistance while running
casing or after connection
Can pipe be
worked upwards?
Is circulation Is circulation
restricted?
N Y restricted?
Hole packing off
Hole packing off Reactive formations
Are permeable Are dog-legs
Reactive formation Y N formations exposed? excessive? N Y Mobile formations
Unconsolidated formation Unconsolidated formations
Wellbore
Surface load limitation with N Y geometry
respect to larger drag
(especially directional well) Differential
N Y sticking
(Cuttings beds)
Centralisers broken/bunching
Formation ledges
Fractured/faulted formation
Centralisers broken/bunching
Casing too light
(Has not been filled)
Junk in hole
156
4.1.3.5. Figure 88: Stuck Pipe incident when TRIPPING IN
Tripping In
Increase in downward resistance
Is increase
Smooth smooth or Erratic
erratic?
Is there excessive
Is there excessive
upward drag?
upward drag?
Inadequate Hole bridged

Was previous
hole cleaning N Y Is circulation restricted?
Can this be related N Y bit undergauge?
(Cuttings beds) to problem formations?
Y N N Y
N Y
Is drag reduced Was previous Formation ledges

when pumping? Reactive formations Undergauge hole
bit undergauge? Wellbore geometry Mobile formations Are dog-legs
Cement blocks Fractured/faulted formations excessive?
Junk Unconsolidated formations
N Y N Y
N Y
Reactive formation Inadequate Wellbore geometry
Mobile formation Undergauge hole
hole cleaning Formation ledges Has there been a BHA
Can resistance and drag
change on this trip?
be related to formations?
Formation Wellbore
Ledges N Y Geometry
N Y
Cement blocks
Junk string Fractured/faulted
Component failure formations
157
4.1.3.6. Figure 89: Stuck Pipe incident when TRIPPING OUT
Tripping out
Increased drag or overpull
Is overpull
Smooth smooth or Erratic
erratic?
Is overpull in Is overpull in
new hole section? new hole section?
Are known problem Are known problem
Are known problem Are known problem
formations exposed in formations exposed in
formations exposed Y N hole section drilled hole section drilled N Y formations exposed
in new hole section? in new hole section?
by previous bits? by previous bits?
Y N N Y Y N Y N
Unconsolidated- Unconsolidated formation

Is downward Is downward
Is circulation Is circulation Is circulation Is circulation or Fractured/ Fractured/faulted and
motion possible? motion possible?
restricted? restricted? restricted? restricted? Faulted formations Geopressuredformation
Y N Is circulation N Y
Y N Y N N Y Y N restricted?
Wellbore geometry Can BHA be Cement

Wellbore geometry Inadequate Can BHA be N Y
Formation ledges rotated free? blocks
Formation ledges hole cleaning rotated free?
Reactive formations Junk
(Bit/stabiliser balling)
Mobile formations Cement blocks Fractured/faulted
Unconsolidated formations Inadequate Junk formations
hole cleaning Reactive formations
(Bit/stabiliser balling)
Mobile formations N Y N Y
Unconsolidated formations
Wellbore geometry
Formation ledges Formation ledges Key seating
Fractured/faulted Key seating
Wellbore geometry Wellbore geometry
formation
158
4.1.3.7. Figure 90: Stuck Pipe incident when REAMING IN
Reamingin
Increasedtorque
Increasedreaming
weight required
Is
increase
Smooth Erratic
smoothor
erratic?
Is circulation Iscirculation
restricted? restricted?
Areholedrags Was previous bit Are updrags Waspreviousbit

excessive? Y N undergauge? excessive? Y N undergauge?
Inadequatehole
Inadequatehole Y N Y N
Y N Y N cleaning
cleaning (Cuttingbeds)
Dodrags Wellbore geometry

increasewhen Wellboregeometry Formationledges
Undergaugehole Undergaugehole
not pumping? (Side-trackinghole?) Junk
Cement blocks
Aredrags Bit failure
Mobileformations
Y N Reactiveformations increasedwhen
Unconsolidatedformations not pumping?
Inadequate
holecleaning
Inadequate Unconsolidatedformations
holecleaning
Y N Fractured/faultedformations
159
4.1.3.8. Figure 91: Stuck Pipe incident when REAMING OUT
ReamingOut
Increasedtorque
&Drag
Is
increase Erratic
Smooth
smoothor
erratic?
Iscirculation Iscirculation
restricted? restricted?
Areholedrags
reducedwhen Isdownward
pumping? Y N motionrestricted?
Y N
Y N Y N Junk
Unconsolidatedformations Cement Blocks
Fractured/faulted Stringcomponent
formations failure
Inadequate MobileFormations
Holecleaning ReactiveFormations Wellboregeometry KeySeating
FormationLedges
StringComponent failure
160
4.2. First Actions to free
4.2.1. Solids Induced - First Actions
The stuck pipe mechanisms listed below (in order of occurrence) are solids related
mechanisms and the same first actions apply. They are covered in detail in Volume
1 and the appendix of this manual.
Hole Cleaning
Unconsolidated Formations
Reactive Shales
Naturally Over-Pressured Shales
Fracture and Faulted Formations
Induced Over-Pressured Shales
Tectonically Stressed Formations
Overburden Stress
Junk in the Hole
Green Cement and LCM Treatment
Cement Blocks
4.2.1.1. Excessive Over pull
This is the most important first action. It is the stage when you are not completely
stuck and you still have movement in the opposite direction. If the driller reacts
correctly you can still retrieve the situation.
The golden rule when excessive over pull is observed when tripping in deviated
wells is to assume that it is hole cleaning related e.g. there is a build-up of cuttings
(could be cavings) around the BHA which is stopping you from coming out of
hole.
The first action tripping out:
1. Run back in hole at least 1 stand, but preferably 2.

2. Switch on pumps and bring flow rate up in stages to maximum rate. Rotate
drill string at maximum rpm.
3. Circulate for at least one bottoms-up at maximum flow rate and rpm.
4. Monitor shakers. If large amounts of cuttings are coming over the shakers
then circulate until the shakers are clean consider pumping sweeps.
5. Stop pumping.
6. Pull past original stuck point.
a. If no over pull then it was hole cleaning related.
b. If the same over pull is observed then it is probably a mechanical or
geometry related problem and the appropriate actions taken e.g.
back reaming.
161
What normally happens. The
flow rate is brought up too
quickly which increase the risk
of pack-off.
SPM
Pump strokes should be

brought up to maximum flow
rate in planned steps. The next
step increase should only occur
once the pressure has
stabilised.
Time
Figure 92: Graph showing how the SPM should be brought up in steps.
4.2.1.2. Packing Off - First Actions
1. At the first signs of the drill string torquing up and trying to pack-off, the
pump strokes should be reduced by half. This will minimise pressure trapped
should the hole pack-off. Excessive pressure applied to a pack-off will
aggravate the situation. If the hole cleans up, return flow to the normal rate.
2. If the string packs off, immediately stop the pumps and bleed down the
standpipe pressure [NB not possible with a non-ported float valve]. When
bleeding pressure down from under a pack-off, control the rate so as not to
"U" tube solids into the drill string in case they plug the string.
3. Leave low pressure (<500 psi) trapped below the pack-off. This will act as an
indicator that the situation is improving should the pressure bleed off.
4. Holding a maximum of 500 psi on the standpipe and with the string hanging
at its free rotating weight, start cycling the drill string up to maximum make-
up torque. At this stage do not work the string up or down.
5. Continue cycling the torque, watching for pressure bleed off and returns at
the shakers. If bleed off or partial circulation occurs, slowly increase pump
strokes to maintain a maximum of 500 psi standpipe pressure. If circulation
improves continue to increase the pump strokes.
6. If circulation cannot be regained, work the pipe between free up and free
down weight. DO NOT APPLY EXCESSIVE PULLS AND SET DOWN WEIGHTS AS
THIS WILL AGGRAVATE THE SITUATION (50k lb max). Whilst working the string
continue to cycle the torque to stall out and maintain a maximum of 500 psi
standpipe pressure.
7. DO NOT ATTEMPT TO FIRE THE JARS IN EITHER DIRECTION.
162
8. If circulation cannot be established increase the standpipe pressure in
stages up to 1500 psi and continue to work the pipe and apply torque.
9. If the pipe is not free once full circulation is established, commence jarring
operations in the opposite direction to the last pipe movement. Once the
pipe is free rotate and clean the hole prior to continuing the trip.
HANG STRING AT FREE POINT WEIGHT
APPLY RIGHT HAND TORQUE
APPLY LOW PRESSURE TO STRING
APPLY LOW UP/DOWN WORKING FORCES TO STRING
CONTINUE WORKING STRING
NO
IS THERE EVIDENCE OF MOVEMENT YES
OR CIRCULATION?
INCREASE TORQUE IN STEPS & CONTINUE EFFORTS BY GRADUALLY

CONTINUE TO WORK STRING AT INCREASING PULL & PRESSURE UNTIL
SAME LEVEL FULL CIRCULATION GAINED
NO
IS THERE EVIDENCE OF YES
SUCCESS?
CONTINUE EFFORTS BY GRADUALLY INCREASE PUMP PRESSURE &

INCREASING PULL & PRESSURE UNTIL
CONTINUE WORKING PIPE
FULL CIRCULATION ESTABLISHED
IS THERE EVIDENCE OF
NO YES
SUCCESS?
INCREASE PULL & SET DOWN CONTINUE EFFORTS BY GRADUALLY

WEIGHTS INCREASING PULL & PRESSURE UNTIL
CONTINUE WORKING STRING
IS THERE EVIDENCE OF CONTINUE EFFORTS BY GRADUALLY

CONTINUE EFFORTS NO YES
SUCCESS? INCREASING PULL & PRESSURE UNTIL
UNTIL FREE
Figure 93: Decision tree showing the first actions when packed-off.
163
4.2.2. Differential Sticking
4.2.2.1. First Actions
First Actions in the event of Differential Sticking.
1. Establish that Differential Sticking is the mechanism, i.e. stuck after a

connection or survey with full unrestricted circulation across a permeable
formation (Sand, Dolomite and possibly Limestone).
2. Initially circulate at the maximum allowable rate. This is to attempt to erode
the filter cake.
3. Slump the string while holding 50% of make-up torque of surface pipe
(unless mixed string of pipe is being used). Use an action similar to what
would be used with a bumper sub - see note below.
4. Pick up to just above the up weight and perform step 2 again.
5. Repeat 2. & 3. Increasing to 100% make-up torque until string is freed or until
preparations have been made to spot a releasing pill
Freeing Differentially Stuck Pipe

Differentially Work/ Yes
Work Free ?
Stuck Jar Pipe
No
Select alternate Is U Tubing
Spotting method Possible?
No
fluid at rig?
Yes
Yes Is over balance
Prepare U Tube
Yes needed for No
Mix Spot & Spacer
Well control/
U Tube
stability
Pump Spot & Spacer
No
U Tube second Time Pipe Free??
Yes
Pipe Free??
Yes
No
Cut pipe/Fish/ No Yes

Pipe Free?? Cond Mud
Sidetrack/P&A & Drill Ahead
Figure 94: Decision tree for freeing differentially stuck pipe.
164
4.2.2.2. Freeing stuck pipe with pipe release agents
Once it is determined that the drill-string is differentially stuck, the annulus should
be displaced with a spotting fluid from the bit to the free point. Surveys can
determine the free point accurately, but running such surveys often takes a
significant amount of time.
A pipe-stretch method is a quick way to estimate the depth of the stuck zone. To
increase the likelihood of success, the spotting fluid should be applied as soon as
possible. Plans should be made to mix and spot a soak solution as soon as possible
after differential sticking occurs. Jarring should continue while this is being done.
The soak solution to be used depends on several factors. When drilling with water-
based muds, oil-base spotting fluids are preferred. If oil-base fluids present a
contamination or disposal problem, alternative environmental spotting fluids must
be used. Often, oils, oil-base mud, saturated saltwater, acids or surfactants can be
used to spot and free stuck pipe, depending upon the situation. The line of M-I
PIPE-LAX products is specially formulated for this purpose. PIPE-LAX can be mixed
with diesel oil, crude oil or kerosene to make unweighted spotting fluids. For
weighted muds, PIPE-LAX can be mixed with VERSADRIL or VERSACLEAN muds
corresponding to the weight of the mud in the hole.
Well control must be one of the primary considerations when using pills of different
density. Note that the use of pipe release agents involves unique procedures and
technical/environmental considerations therefore it is essential that the drilling fluid
/ acid supplier(s) be involved early in the planning stage. Unlike U-tubing, there are
no hydrostatic pressure restrictions on using pipe release agents (PRAs). Any PRA
pill should be spotted within 4 hours of sticking for best results. After 16 hours there is
little chance of the pill working so the method should not be considered. The
graph below (figure 95) shows the probability of the pipe coming free against
soaking time in hours. This can be used to calculate the time a pill should be left to
soak before circulating out and backing off.
As a rule of thumb, soak for a minimum of 20 hours and a maximum of 40 hours.
Figure 95: Shows the probability of the pipe coming free against soaking time in hours.
165
Pipe release agents and formulations (Examples are from MI, but other products
can be used.)
The paragraphs below describe the MI PIPE LAX product range.
PIPE-LAX SPOTTING FLUID

1. Determine volume needed. (Annular volume opposite drill collars plus 100 to 150
%).
2. Add 1 gal. of PIPE-LAX per barrel of oil in the spot. Mix thoroughly.
3. Periodically, pump 1-2 bbl of soak solution to collars covered while working pipe.
Note: If premixed oil-based or invert oil muds are available and mud weight is
needed PIPE-LAX can be added to these carriers and spotted. Advantage of using
this type of solution is that the spotting fluid will not migrate while soaking.
PIPE-LAX W SPOTTING FLUIDS

PIPE-LAX W may be mixed as a weighted spotting fluid. Formulations using mineral
oil with either M-I BAR or FER-OX are found in the tables below. These tables are
designed to produce the minimum viscosity required to support weight material.
Viscosity can be increase if needed by increasing the concentration of PIPE-LAX W
from 4.36 to 4.8 gal/bbl.
Note: If diesel oil in used decrease the concentration of PIPE-LAX W from 4.36
gal/bbl to 3.5 4.0 gal/bbl. Diesel oil provides higher viscosities, therefore, if it is
necessary to reduce the viscosity of this solution, dilute with oil and add 0.25 to 0.5
lb/bbl VERSAWET.
Mixing order for PIPE-LAX W is as follows:
1. Mineral Oil
2. PIPE-LAX W
3. Water
4. M-I BAR or FER-OX
Table 24: PIPE-LAX FORMULATION USING MINERAL OIL AND M-I BAR (1 Final Barrel)
166
Table 25: PIPE-LAX FORMULATION USING MINERAL OIL AND FER-OX (1 Final Barrel)
PIPE-LAX ENV SPOTTING FLUIDS
PIPE-LAX ENV spotting fluid is a low-toxic, non-petroleum solution for use in areas
where oil or oil-base fluids are not permitted. It is a premixed solution, and needs to
be weighted to the desired density. The solution should not be contaminated with
water or mud, as it will result in excessive viscosity.
Note: Water and/or mud contamination causes a significant increase in viscosity in

PIPE-LAX ENV; therefore, ensure that all mixing pump and mud lines are drained
the then filled with PIPE-LAX ENV prior to weighting up.
Densities above 15.0 lb/gal (1.8 SG) require the addition of LUBE 167 prior to
weighting up to reduce final viscosity (see mixing table below).
Table 26: PIPE-LAX ENV / Weighting Material Formulations (1 Final Barrel)
167
Table 27 *Suggested dilution concentrations with LUBE 167 prior to weighting up are as
follows:
4.2.2.3. Spotting HCl acid to free stuck pipe in carbonate
Spot 20 50 bbl of 15% HCl acid around the suspected stuck area. It is suggested
that downward weight be applied just prior to the HCl leaving the drill pipe. This will
give you an indication as to when the pipe is free. Use enough HCl to allow for a
second soaking if needed. A 10-bbl to 30-bbl spacer (water or diesel) should be
used in front and behind the HCl acid solution.
Note: Due to possible corrosion of the drill pipe an appropriate acid inhibitor should
be used if this procedure is attempted.
After the pipe is freed the HCl solution may be displaced, it can be incorporated
into mud if the HCl has been completely depleted and the pH can then be
adjusted. If the HCl is not depleted it is suggested that the solution be disposed of if
possible and the pH adjusted as quickly as possible to reduce contamination.
Adjust the pH with lime, or caustic soda.
Precautions when using HCl acid:
1. Dilute concentrated HCl by adding the HCl to water. NEVER ADD WATER TO
ACID!
2. Circulate HCl solution out through the choke at a slow pump rate, since
CO2 gas may be present after the acid has reacted with the carbonate
formations.
3. Use proper safety equipment when handling HCl.
4. Maintain enough caustic soda and lime on location to neutralize the
solution when it is circulated out of the hole.
4.2.2.4. The U-Tube Method to be used only after an exemption has been
obtained.
Another method is to reduce the height of the mud column in the annulus to
below the bell nipple. This procedure is referred to as the U-Tube Technique. In
this procedure, mud is displaced from the annulus by pumping a light fluid (such as
diesel oil, water or nitrogen) down the drill string. After pumping the required
volume of low-density fluid, the pressure (and some liquid) is bled off the
standpipe. The heavier mud in the annulus is then allowed to U-Tube back into
the drill string, resulting in a reduction in the height of the mud in the annulus.
Caution should always be exercised when reducing the differential pressure. In this
case, precise calculations should be made to determine the volume of light fluid
to pump before allowing the annulus to U-Tube. This procedure should not be
attempted with a small-nozzle bit in the hole due to the possibility of plugging the
bit.
168
Special considerations
Factors that should be considered before employing this technique include

The amount of open hole and likely effects of sharp reduction in hydrostatic
pressure on stability of all exposed formations.
Is there geological closure at the depth of the permeable formations? Is it
likely to contain gas or oil?
Are there any other permeable zones exposed? What effect will the
reduction in mud have on them?
How much confidence is there in the accuracy of formation pressure
estimates
The true vertical height of the permeable zone and the drawdown imposed
on the top of the interval when the bottom is balanced. This could be
considerable and result in a seriously underbalanced formation.
Well control implications HARC & Exemption will be required.
Procedure
Below is a U Tube freeing technique for differential sticking mechanism. (Procedure
assumes no float valve is installed).
1. Calculations.
a. Calculate the heads of base oil or water and mud which when
combined, balance the formation pressure at the bottom of the
permeable zone
b. Calculate volume in the choke line and drill pipe/casing annulus to give
the head of base oil or water calculated in Step 1
c. Calculate the head(s) of mud that balances the formation pressure at
the bottom of the permeable zone
d. Calculate the volume of air in the drill pipe above the mud head after U-
tubing
e. Calculate the total volume of base oil or water required i.e. the sum of
volumes from step 2 and step 4
f. Calculate the maximum draw down that will be imposed on any other
permeable formation (i.e. the uppermost permeable zone) after U
tubing (See Appendix)
g. Calculate the backpressure held on the choke after displacing base oil
or water to the annulus.
2. Close the annular preventer (with minimum closing pressure) and reverse
circulate (with minimum pump pressure) the volume of base oil or water
calculated in step 5 down the choke line. Check the backpressure.
3. With down weight, assuming the pipe is off bottom, and right hand torque
applied, vent the drill pipe above a full opening valve. Bleed of the
backpressure rapidly through the choke, allowing the mud level in the drill string
to fall. Monitor drill pipe to determine whether it is sucking or blowing. Monitor
the weight indicator and rotary torque for signs of release and attempt to work
downwards and achieve rotation.
4. If the pipe is freed, continuously move and fill the drill string with mud. Circulate
out the base oil or water from the annulus and continue to circulate bottoms
up (through the choke if there is a chance of gas being produced).
169
5. If the pipe remains stuck (note that release might not be instantaneous draw
down should be applied for at least 2 hours before the attempt is considered to
have failed) the mud should be reconditioned and one more attempt made
with a bigger reduction in hydrostatic say to 50psi below formation pressure.
6. If this second attempt fails it is suggested that the pipe is severed immediately
above the stuck point and the well sidetracked. The decision to abandon or
continue fishing attempts will be dependent on fishing economics evaluation.
For more information on drilling high over balance depleted zones see MIs best
practices document MI00724.
4.2.3. Mechanical & Well Bore Geometry
Guidelines for freeing stuck pipe other than Pack-offs and differential sticking.
1. Ensure circulation is maintained.
2. If the string became stuck while moving up, (apply torque) jar down.
3. If the string became stuck while moving down, do not apply torque and Jar up.
4. Jarring operations should start with light loading (50k lbs) and then
systematically increased to maximum load over a one-hour period. Stop or
reduce circulation when: a) cocking the jars to fire up and b) jarring down.
Pump pressure will increase jar blow when jarring up, so full circulation is
beneficial.
5. If jarring is unsuccessful consider acid pills, if conditions permit.
170
4.3. Jars & Accelerators
4.3.1. Jars
There are two basic types of jar, mechanical and hydraulic. Hydraulic jars use a
hydraulic fluid to delay the firing of the jar until the driller can apply the
appropriate load to the string to give a high impact. The time delay is provided by
hydraulic fluid being forced through a small port or series of jets. Hydraulic jar firing
delay is dependent upon the combination of load and time. Mechanical jars have
a preset load that causes the jar to trip. They are thus sensitive to load and not to
time. It can be seen from these descriptions that the terms mechanical and
hydraulic jar refers to the method of tripping the jar.
4.3.1.1. General Comments on the Successful Use of Jars.
Jars are frequently returned to the workshops marked failed and subsequently
test successfully. The main reason for this appears to be the inability to fire the jars,
often in the down direction. Estimating the force required to fire jars, when the user
is under pressure due to the stuck pipe situation, is not always performed correctly.
This chapter gives some insight into how jars operate and how to choose the
correct surface forces to fire the jars. There are a number of reasons a jar might fail
to fire:
Incorrect weight applied to fire jar - one or more assumptions in

calculation incorrect.
Pump open force exceeds compression force at jar (no down jar
action).
Stuck above the jar.
Jar mechanism failed.
Jar not cocked.
Drag too high to allow sufficient force to be applied at the jar to fire it
(usually mechanical jars).
Well path is such that compression cannot be applied to the jar (no
down jar action).
Jar is firing but cannot be felt at surface.
Right hand torque is trapped in torque setable mechanical jars.
Not waiting long enough for the jar to fire.
Correct use of jars and the correct application of jarring is critical to freeing stuck
pipe. Applying the most appropriate jarring action is key to aiding or worsening the
stuck situation. If while pulling out of the hole, the string becomes stuck the natural
instinct of a driller is to jar up. This is, after all, the direction he is trying to move his
BHA, i.e. out of the hole. However, if the string is packed off above a stabiliser, a
likely cause of stuck pipe while pulling out of the hole, the act of jarring up may
make the situation worse by compacting the pack-off.
Jarring should start in the opposite direction to that which got the string stuck
Another reason for the frequent inability to fire jars is the miscalculation of the
forces required at surface in order to get the jar to fire. Although the calculations
are relatively uncomplicated, in the heat of the problem on the drill floor small
171
calculations can appear quite complex. It is often this type of situation that leads
to the jars not firing.
4.3.1.2. Forces Required to Fire Jars
All jars have a firing force envelope for each direction they fire in. A dual acting jar
(one that can fire up and down) will have both an up jar force envelope and a
down jar force envelope.
The firing force envelope consists of two forces, one to cock the jar in preparation
for firing, the second to fire the jar. A dual acting jar will therefore have two force
envelopes, one for up jarring and one for down jarring.
The jar envelope forces can be considered at the jar or at the surface. The jar firing
force envelope at the jar is known.
Jar Firing Force Envelope
It is the job of the rig team to estimate / observe the surface instruments in order to
choose the surface firing force envelopes.
The forces that must be applied to the jar to cock and fire it when it is lying on a
test bench are described by the jar force envelops i.e. forces at the Jar.
In the example above: To cock the jar to fire up, a compression force of
approximately 5k lbs is required. This is to overcome internal friction. Once cocked
the jar will fire once the force at the jar reaches 90k lbs.
Figure 96: Jarring envelope
172
To cock the jar to fire down, a tension of 5k lbs is required to overcome internal
friction, once cocked the jar will fire down once 20k lbs compression is reached.
The fixed limits of 90k lbs and 20k lbs are typical of mechanical jars. When using a
hydraulic jar, it will fire as long as the jars internal friction is exceeded. The time
taken to fire is inversely proportional to the force applied: the greater the force the
shorter the waiting time.
We have only considered the forces at the jar so far. The driller only knows the
force at surface and must estimate the force at the jars.
It is sometimes easy to see from the measured weight indicator when the jars are
opening or closing. The measured weight indicator needle will stop moving for a
few seconds while the string is still being moved up or down. It is a very good
indicator that the axial neutral point is at the jar. It is often observed whilst drilling
vertical wells but can be very difficult to observe in highly deviated, extended
reach or horizontal wells.
If this neutral weight indicator is observed, it is relatively easy to set surface jarring
forces. The measured weight at which the neutral point is observed is recorded.
The up trip force (mechanical only) is added to this value, together with any up
Drag.
Note: When stuck, any pull on the string results in an increase in drag over and above the
normal up drag. The full amount of overpull applied at surface will
not reach the jar. In deviated wells this must be compensated for by additional overpull.
If the pumps are running then the pump open force must also be subtracted from
the firing force and added to the set down weight used to cock the jars.
Note: The pump open force charts will be found in the manual for the jar being used. A
copy of the current pump open force charts for the types of jars
covered by this text is included after the description of each jar type.
Similarly the down trip force (mechanical only), the down drag and the pump
open force are subtracted from the neutral point reading.
If the neutral point at the jars cannot be observed then the calculated neutral
weight at the jars must be used.
4.3.1.3. Pump Open Force
The jar pump open force (also called jar extension force) is the effect of the
difference in surface areas of the jar exposed to pressures on the out side and
inside the jar. When a differential pressure exists between the inside of the jar and
the outside of the jar it causes a force that opens the jar. Depending on the jar
type the force acts on the cross-sectional area of the washpipe, or the washpipe
and any floating pressure equalising piston exposed to the internal fluid of the jar.
The effect on jarring can be considerable if for example 2000 psi is trapped inside
the jar when the string is packed off below the jar. The pump open force chart for
each type of jar discussed is included in these guidelines.
The pump open force acts to:
173
Assist firing the jar up
Assists cocking the jar after firing down
Opposes firing the jar down

Opposes cocking the jar after firing up
As an example we can look at an actual situation that happened recently in the

North Sea.
Having struggled out of the hole pumping and with indications of pack offs the
string finally packed off. Jarring commenced in a downward direction. There was
2000 psi trapped in the string and the pack-off was below the dual acting
hydraulic jar. The parameters are shown in the table below:
Figure 97: Jarring example from the North Sea.
As can be seen with 2000 psi trapped in the string a 34 klbs pump open force
resulted. Down jarring was attempted six times, each time the measured weight
reading of 60k lbs was held for 30 seconds without any indication of the jar firing.
Down jarring was aborted and up jarring commenced until the well was
sidetracked.
The three main problems this team had were:

Trapped pressure inside the string while trying to jar down.
Insufficient weight to allow down jarring (even without the pump
open force opposing this action)
Insufficient time allowed for the jar to meter through its stroke.
4.3.2. Accelerator Description
The functions of a drilling accelerator can be summarised as follows:
To compensate for the lack of stretch in a short string.

To compensate for slow contraction of the drill string due to high
hole drag.
174
Act as a reflector to the shock wave travelling up the string from the
jar blow.
Intensify the jar blow.
Drilling and fishing accelerators (also called jar intensifiers) are basically the same
design. The Drilling equipment has an up-rated spline drive mechanism to enable
the tool to withstand 300-500 rotating hours.
The accelerator consists of an outer barrel and an inner mandrel. The inner
mandrel slides in / out of the outer barrel. The two are connected by an
interference fit between a piston chamber on the outer barrel and piston on the
inner mandrel. The piston chamber contains a solid or fluid or gas that acts as a
spring. When a force is applied to the accelerator the tool opens. The extension is
dependent upon the applied force. When the extending force is released, the tool
closes under the spring force of the fluid inside the piston chamber. Dual acting
accelerators work in similarly with both the up jar and down jar.
4.3.3. Jar and Accelerator Positioning
Jar positioning programs do exist but all are configured to position the jars for
maximum up jarring effect, which is not always the desired direction for jarring. To
make a full analysis of optimum jar position many factors must be taken into
account. However, this is not normally done for drilling operations. Usually the jars
are run in a position determined by field / personal experience or company policy.
There are a number of issues that should be considered when positioning jars in a
drill string.
Likely places for sticking to occur.

Most likely jarring direction required.
Well bore contact / differential sticking risk.
Position of the axial neutral point when drilling with maximum WOB.
Depth of hole section.
Drag in hole section.
Minimum allowable measured weight for plastic buckling when not
rotating.
4.3.3.1. Guidelines for Use of Jars in Vertical Wells
In vertical wells the jar should be placed such that:
1. They are above the buckling neutral point even when maximum WOB is
applied.
2. They are at least two Drill Collars above the jars.
3. They have differential sticking prevention subs fitted, if differential sticking is
a risk.
4. No stabilisers should be placed above the jars.
5. Use Accelerators in shallow hole section. (Check that it will be possible to
cock and fire the jar before running them)
175
4.3.3.2. Guidelines for Use of Jars in Deviated & Horizontal Wells
1. Do not run the jars if they are buckled. (This is easily said, but complicated to
work out. Jars should not be run below the buckling neutral point in 45 wells. In
horizontal wells the jars can be run in the 90 degree section without much
chance of them ever being buckled). The area in the string to avoid placing
jars is the pressure area neutral point. This is the point in the string where the
tension in the steel is zero and is always above the buckling neutral point.
2. If using two jars or two jars and an accelerator ensure the driller is fully aware of
how to use this system.
3. Use jars with differential sticking prevention subs if differential sticking is a risk.
4. It is important to calculate the measured weight readings at which the jar will
cock and fire. The drag in the hole may prevent the driller from seeing the jars
open and close on his weight indicator gauge.
5. In horizontal well drilling, a common problem is the inability to get sufficient
force to a horizontally placed jar to fire it down.
176
5. STUCK POINT OF NO RETURN.
177
5.1. Free point Indicator & Backing-off
5.1.1. Free point Indicator
Most pipe freeing efforts are dependent upon knowledge of where the pipe is
stuck. One method of estimating the depth at which a string is stuck is the Free
Point Indicating tool.
5.1.1.1. General
Generally, the FPI tool consists of series of strain gauges which have the capability
to sense changes in torque and tension. The tool is run through the drillpipe using
regular logging cable.
If the jars are still operating, minimize the number of stretch and torque readings
above the jars to necessary calibration runs only. Attempt to establish the free
point using FPI stretch measurements first. Attempting stretch and torque together
early is time consuming and could result in trapped torque affecting stretch and
torque readings. Once a preliminary free point is established from stretch
measurements, verify that torque can be worked down to that point or lower for
determination of deepest back-off point.
1. If the drilling jars are not firing, a rough free point depth can be estimated from
drill pipe stretch calculations prior to wireline unit arriving on location. This rough
depth is of limited value in deviated holes or holes with relatively shallow
doglegs. It is accurate to only 200 to 300 ft in deeper holes, but can give useful
starting depths for the FPI tool runs.
Straight hole stretch values:

o 3.5 inches stretch per 1000ft of free 5", 19.5ppf drill pipe with 50k Ibs over
pull.
o 5.0 inches stretch per 1000ft of free 6 5/8", 27.7 ppf drill pipe with 100k Ibs
over pull.
2. If drilling jars are not stuck, fire up and un-cock jars prior to RIH with wireline
tools. For remainder of free point determination and back-of, do not go below
slack-off weight required to re-cock jar.
3. Run in hole with FPI tool to maximum depth possible within the drill string if the
jars are operational or to 500ft below estimated free point from stretch calculations
if the jars not operational. Run CCL correlation log to minimum 500ft above the
suspected stuck point and correlate BHA/formation depths using a paper BHA
model
4. After CCL correlation, begin running FPI stretch tests. Minimize intervals tested if
good indication of stuck pipe point is known (e.g. jars firing). Stretch readings
should be taken at mid-joint and the same amount of over pull should be taken
each time (50k lbs recommended). The initial stretch test reading should be in a
section known to be free, for use as baseline reading.
5.1.1.2. Stretch test procedure
1. Ensure pipe is in tension by pulling the up weight plus 10k lbs.
178
2. Open the tool anchors.
3. Slack off cable according to Wireline company recommendations, typically 2
inches per 1000ft.
4. Pull 50k lbs tension in 10k lb increments and record percentage free on free
point data readings and on pull and torque chart.
5. Repeat stretch test at each point to check that FPI reading is consistent.
6. Return to anchor setting point (up weight plus 10k lbs).
7. Pick up cable slack and close anchors.
8. Slack off to pre-stuck down weight then pick up to pull 10k lbs over up weight in
preparation for the next check depth.
9. Move to next FPI point and repeat this sequence until the stuck point is
identified. Establishing down to 30% free is sufficient.
Once a preliminary free point is determined from stretch, commence torque FPI
tests beginning at deepest 100% free stretch interval if believed stuck in drill pipe.
Take a reading in the bottom of the drill pipe, the bottom of the HWDP and the top
drill collar if a BHA free point indication is observed from stretch test.
5.1.1.3. The torque test procedure.
1. Ensure pipe is in tension by pulling the up weight plus 10k lbs.

2. Open the tool anchors.
3. Slack off cable according to Wireline company recommendations, typically 2
inches per 1000ft.
4. Apply RH torque (0.75 to 1 turn per 1000ft depth) to maximum of 80% of drill
pipe make-up torque. Work torque down the string by pulling maximum 50k lbs
over up weight and slacking down to the pre-stuck down weight. Current
(Amps) to top drive, rotary or line puII on tongs used to hold RH torque will
decrease as torque is transferred down the hole. When sustained working of
pipe fails to reduce the amperage or the tong line pull, record the percentage
free.
5. Release torque slowly, work pipe, and count turns returned to ensure that no
trapped torque remains. Failure to work out all the trapped torque will give
erratic torque readings subsequently.
6. Return to the FPI tool anchor setting point (up weight plus 10k Ibs).
7. Pick up cable slack and close anchors.
8. Move to next FPI point and repeat this sequence until the stuck point is
determined. Establishing down to 50% free is sufficient.
Note:
If you are unable to work torque down to the stretch free point depth, it is unlikely
that a successful back off can be made at that depth. Alternatives such as pipe
cutter tool should be considered. Normally, an 80% free reading in both torque
and stretch is recommended for best chance of successful back off.
Upon completion of FPI tool torque measurements, review the BHA

component depth vs. Lithology log [Paper BHA Model] to determine the
best back-off depth. If possible the back-off point should be selected in
an interval, which improves the chance of getting back onto the fish or
as deep as possible if an immediate sidetrack option is selected.
Potential washed out intervals and under gauge section are the worst
back-off points to choose.
179
Utilize the FPI tool to accurately determine the neutral point weight at
proposed back-off depth prior to POH with the FPI tool to apply the
required Left Hand torque for the back-off attempt.
5.1.1.4. Pipe Stretch formulas
180
5.1.1.5. Allowable Simultaneous Torque and Pull On Drill Pipe.
5.1.2. Backing-off.
Once the free point has been established then the next operation is to back off
the drill string above the stuck point.
Backing off is a tricky operation especially in deviated wells and can be the cause
of large amounts of NPT. This section will highlight some of the salient points, but for
more details see the Intouch Content ID: 3314294 - Schlumberger SIT Back Off
Manual.
5.1.2.1. Basic Procedure
Drillpipe or collars can be unscrewed downhole by exploding a charge known as

a string-shot (prima-cord folded up inside a piece of tubular plastic) inside a
selected tool joint connection, just above the stuck point. A connection should be
selected which has been broken during the round trip prior to the pipe becoming
stuck.
A successful back off depends upon having the following:
Zero or slightly positive tension at the joint

Sufficient left-hand, or reverse torque at the joint - 50% to 75% of
make-up torque is suggested
181
A sufficiently large explosive charge, accurately located at the joint.
Particular care should always be taken when applying torque or releasing it from
the string. Keep the forces involved fully under control and keep men out of the
potentially dangerous area.
Torque should be worked down the string before the string shot is fired, this may
take some time. If the string fails to back off after firing the charge, continue to
work the torque down the string before trying another string shot.
182
5.2. Fishing Economics
The decision to cut our losses and sidetrack should be a purely economic one
unless there are extenuating circumstances e.g. there is a radioactive source in the
hole. Unfortunately most engineers find it hard to give up and they continue to
attempt to retrieve the situation when it was already lost many days before.
After a certain effort has been put into freeing the pipe, the decision has to be
made whether to back off or not. There are likely to be four options:
- Continue attempts to free the pipe

- Back off above the free point and run in with a fishing assembly
- Back off above the free point, plug and sidetrack
- Back off above the free point prior to abandoning the well.
The decision to back off and run in with a fishing string will be made if it is
considered to offer an increased chance of success. As a general rule if the
sticking mechanisms are: Solids induced packed off, unstable, time dependent
formations and Differential Sticking, there is little point in trying to run in with a
fishing assembly. Normally, the best option in these cases is to plug back and
sidetrack.
5.2.1. Fishing Economic Calculator
IPMs Fishing Economic Calculator (Intouch Content ID: 3318778) is the emotion
free way of deciding when to cut your losses. It is based on historical data from the
Gulf of Mexico and the North Sea and looks at the reducing probability of
retrieving a fish over time. The basic formula is shown below:
Economic fishing time = Cost of sidetrack * Probability of fishing success

Daily costs while fishing
Two output sheets from the calculator are shown below & opposite.
Figure 98: Fishing economics calculator output sheet.
183
Figure 99: Fishing economics calculator output sheet. The red line is the optimum fishing
time.
The optimum fishing time starts at the moment you get stuck, and includes working
the string and/or spotting pills in an attempt to get free. It also includes the time to
back off and run in with fishing tools.
The common mistake with the calculator is that people start the clock running from
when they have backed-off and are ready to run in with fishing tools, and not from
the moment they get stuck.
Engineers have also challenged the accuracy of the tool especially in cases where
an expensive BHA is stuck with high lost in hole charges e.g. Powerdrive with LWD.
Typically in these cases the optimum fishing time is around 3 days, which many
engineers believe is too low. However, the historical data shows the probability of
recovering from a stuck pipe event decreases exponential with time and as such
the economical solution is to sidetrack.
5.2.2. Decision trees.
Decision trees can be used to evaluate the best economic course of action during
fishing operations. They allow the team to define the probability of success or
failure and can be tailored to the specific well conditions and stuck pipe
mechanism, rather than using the general rules used by the calculator.
The most important thing to remember is that the probability of success or failure is
an entirely qualitative number when making decisions trees, and this number has a
massive impact on the results. It is therefore extremely important to compare the
decision tree results with the results from the fishing calculator. Any differences
need to be explained and quantified.
184
5.2.2.1. Decision Tree Example.
The decision trees are from a differential sticking stuck pipe event.
RECOVERY: PROB. OF SUCCESS 50%

FISHING COST FOR: 3 Days
108.2 K
FISHING
= % SUCCES + % FAILURE
= 54.1 K + 214.0 K
Risked fishing cost. = 268.1 K
STUCK PIPE
ACUMM COST NOT RECOVERY: PROB. OF SUCCESS 50%
= COSTO OF FISHING + SIDETRACK COST
22.9 K
= FISHING COST + SIDETRACK COST
428.0 K
SIDETRACK
= COSTO OF FISH + SIDETRACK PLUG AND TIME
319.9 K
CONCLUSION: CONTINUE FISHING
Figure 100: Decision tree to continue fishing for a differential stuck pipe event.
The first branch is the stuck pipe event itself and the accumulated cost. The tree
then splits into two branches: fishing and sidetracking. The former has a further two
branches: recovery and no recovery.
The cost of sidetracking, recovery and no recovery is calculated. The probability of
success is estimated and then the risked fishing cost calculated.
Risk fishing cost = (cost of recovery x %success) + (cost of no recovery x %success).
This is compared to the cost of sidetracking and if the figure is lower then it is
economic to continue fishing. As you can see the success factor has a major
influence on the outcome. In this case it was economic to continue fishing.
The second decision tree is from the same event, but the fishing operations would
take 5 days and the probability of success has been reduced to 10%. In this case
best economic course of action is to sidetrack the well.
185
RECOVERY: PROB. OF SUCCESS 10%
116.3 K
FISHING
= % SUCCES + % FAILURE
= 11.6 K + 308.8 K
=
320.4 K
STUCK PIPE
ACUMM COST
NOT RECOVERY: PROB. OF SUCCESS 90%
69.8 K = COSTO OF FISHING + SIDETRACK COST
= FISHING COST + SIDETRACK COST
343.1 K
SIDETRACK
= COSTO OF FISH + SIDETRACK PLUG AND TIME
226.9 K
CONCLUSION: SIDE TRACK
Figure 101: Decision tree to continue fishing for a differential stuck pipe event.
186
5.3. Sidetracking
5.3.1. General
Once the decision has been made to re-drill the section the decision has to be
made on the depth of the kick point. This decision will depend on the trajectory,
exposure time of formations above the stuck point, and hardness of the
formations.
It is also extremely important to abandon the original hole section in accordance

with IPM standards. This is critical in situations where hydrocarbons or over-
pressured formations are present.
In highly deviated wells the kick-off can be initiated by time drilling with a
directional assembly (PDM or rotary steerable).
For more information on this subject see Intouch Find: Open hole sidetracks.
5.3.2. Kick-off methods.
Igneous &
Sedimentary
Metamorphic
1 4 5 6 7 8
Motor
Jetting Whipstock
Figure 102: Kick-off methods by rock type.
Here we can see a table of the primary codes of the IADC Code Chart. Codes 2 &
3 have been omitted, as there is little demand any longer for these products.
The codes range from the softest formations on the left (code 1) to the hardest on
the right (code 8). Against this scale we can place a line representing the
formation hardness most suitable for jetting. These are the formations that are
poorly consolidated and can be removed by hydraulic action alone.
At the other end of the scale are the hardest of the sedimentary rocks along with
the Igneous and Metamorphic rocks that are the hardest to deflect into especially
when coming off a cement plug, which is much softer than the formation that we
wish to drill into. It is here that the open hole Whipstock is most effective.
Overlapping these two deflection methods is the most popular deflection method
of all, the Motor combine with a kick-off plug. The thing that makes the motor so
popular is its flexibility, though it may be noted that it is not as effective at the
extremes as the alternative methods.
187
5.3.3. Kick-off plugs
The objective of the kick-off plug is to establish a hard basis to allow the bit to
sidetrack from the original well bore.
The main problems associated with setting a kick-off plug are:
1. Too soft cement with respect to formation, unable to sidetrack

a. Incorrect slurry design.
b. Contamination of the cement with mud.
c. Unstable base. See figure 104.
d. Formations too hard.
e. Not weighting the required time for the cement to set (see Table 28)
2. Incorrect cement top
a. Poor displacement practices
Soft
Abandon the
original hole in
accordance with
IPM standards.
Figure 103: Shows schematic of kick-off and sidetrack.
188
Figure 104: Schematic of the stability (left) and instability (right) of a dense cement placed
above a lighter fluid.
5.3.3.2. Summary of important guidelines
For successfully kicking-off, the cement must be harder to drill than the adjacent
formation. Hence:
1. The plug must be placed in a soft formation rather than a harder formation.
Consult drilling speed logs to determine the softest formation. This can be
combined with UCS data from an offset well. Do not be afraid to kick off
higher than planned.
2. The plug top must be as the designed depth: take special care to correctly
design cement volume: Calliper log, enough excess volume (50 to 100%)
3. Plan the top cement +/-50m above preferred kick-off point. This will allow for
the expected contamination at the top of the plug.
4. The cement length must be sufficient to allow successful kick-off: 150 meters
minimum, to account for contamination at plug ends
5. The cement must have a high enough strength:
a. Design a high CS slurry, i.e. reduced water or CemCRETE formulation
b. Design the minimum safe thickening time, based on good BHCT
value.
c. Minimize eventual contamination, by proper placement.
d. Allow ample time for cement to set (24 hours)
Note: The OH section needs to be abandon in accordance with the IPM-WCI

Standards
5.3.3.3. Where to place a kick-off plug
189
The kick-off plug should NOT be positioned opposite an excessively hard formation.
The plug should extend from a soft shale down to a hard formation where the bit
can easily be kicked out in a new direction and not drift back into the original
hole. Highly permeable zones and thief zones should be avoided to prevent fluid
loss (and subsequent changes to the slurry properties) and complete slurry loss,
respectively. The logs and drilling rate record should be consulted when selecting
the plug interval.
The kick-off plug should be long enough to:
Account for mud contamination

Provide a gradual deviation of the bit
Ensure sufficient distance between the bit and the old hole when
the bit has traversed the length of the plug.
5.3.3.4. Slurry volume
Typical plug lengths range from 150 to 250m.
When possible, utilize an open hole calliper to determine cement volumes. It is

recommended to use calliper volume plus 10% to ensure sufficient plug volume.
When a calliper is not available, the following guidelines are proposed:
Hole size (in) % Excess (WBM) % Excess (OBM)
20-24 100%
17 -14 50% 20%
12 - 10 5/8 30% 15%
9 7/8 - 6 30% 10%
Plan for the top of the cement to be 30-50m above the required kick-off point. This
will allow for contamination and the top of the plug.
5.3.3.5. Slurries for kickoff plugs.
High compressive strength slurries are required for kick-off plugs. A minimum of 3000
to 5000 psi is required, while a 7000 psi compressive strength is recommended, but
not always achievable. If 5000psi cannot be achieved then the compressive
strength should always be harder than the surrounding formation. Cement
compressive strength should be tested at a temperature half way between
circulating temperature and estimated bottom hole static.
Thickening time should be set for between 1-2 hrs over actual job time. The
temperature should be based upon MWD circulating temperature if available.
Fluid loss can retard cement and lower overall compressive strength and is not
recommended unless cementing in less than an 8 hole across a permeable
formation. If BHST is above 230 deg F, then silica is necessary to prevent strength
retrogression, which can occur relatively quickly especially at 300 deg F and
above
190
API Class G Cement Mixed at 15.8 lb/gal
Depth 10,000 ft, BHST 228OF, BHCT 180OF

Retarder COMPRESSIVE STRENGTH (psi)
THICKENING TIME
gal/sk (hrs:min) 8hrs 16hrs 24hrs
None 1:20 3050 3500 4100
0.04 2:25 2500 3000 3700
0.08 3:40 1200 2200 3600
Table 28: Slurry Thickening Time and Compressive Strength Table for API Class G Cement.
Class H Cement 16.5 lb/gal Effect of Mud Contamination*

Mud Compressive Strength Mud Normal Slurry Reduced Water
Contamination (psi at 170F) Contamination 15.6 lb/gal Slurry** 17.5 lb/gal
(%) 8 hr 16 hr (%) (psi) (psi)
0 4,647 5,862 0 4,082 8,600

5 3,512 5,300 10 2,950 8,237
10 2,619 4,538 40 2,426 3,850
20 2,378 2,331 60 593 2,967
50 245 471
Table 29: Mud Contamination vs. Compressive Strength.
* Compressive strength is 18hr at 230F
** Contains dispersant
High-density slurries
Dispersants (normally TIC D065 or Liquid TIC D080) allow the water/solids ratio to be
reduced while maintaining the slurry pumpable, thereby allowing the slurry to be
mixed at densities up to 17.0 lbm/gal using Class A or C cements and 18.0 lbm/gal
using Class G or Class H cements.
Compared to standard-weight systems, reduced water slurries exhibit higher
compressive strength and improved set-cement properties. The higher
compressive-strength development is achieved at low temperatures in a shorter
time period and can reduce WOC times. Reducing the water/solids ratio lowers
the water loss and results in a set cement that is more dense, has less permeability,
exhibits less shrinkage and has more resistance to contamination by well fluids.
191
CemCRETE slurries.
CemCRETE technology allows the design of lightweight slurries, which will develop
very high compressive strength in a short period of time. The main advantage of
these systems is that the interface between the lightweight CemCRETE slurry and
the mud is much more stable because the density differential between the two
fluids is significantly reduced. Such systems are much less prone to contamination
and will not tend to channel through the viscous pill or the mud.
5.3.3.6. Viscous Pills
To act as a solid base for the cement a 300 ft long Hi-Vis pill (or a viscous reactive
pill) should be placed just below the cement plug setting depth. The viscous
reactive pill is favoured when the hole angle is between 20 to 70 degrees, the
critical angle for cement slump and the main cause of failure.
Viscous pills rarely have a sufficiently high yield point to stop cement sinking
through. This adverse condition can be minimised by keeping the density of the
slurry no higher than 2 ppg above that of the viscous pill.
Standard Viscous Pill (Hi-Vis Pill)

A minimum volume equal to 300 ft in the open hole section is required.
Water Based Mud (including Silicate Based Mud): To avoid contact with retarders,
which could contaminate the cement and prevent it from setting, the viscous pill
should be made up fresh in the pill pit using a simple gel slurry at 25 to 50 ppb. The
pill should be as thick as possible, with a yield point of at least 70 lb/100 ft^2 at 120
F. The density should be 45 pptf above the mud weight in use.
Oil/Synthetic Based Mud: Transfer active mud to a pill pit and viscosify with
organophylic clay (e.g. TRUVIS, CARBO-GEL) at 2-2.5 ppb to obtain a yield point of
at least 70 lb/100 ft^2 at 120 F. Increase the density by 45 pptf above mud weight
in use.
Note: Achievement of increased YP at surface may require prolonged shear.
Note: Composition, density, rheology and volume of Viscous Pill must be stated on
drilling and CC service report.
Reactive Viscous Pill

Clean out the slug pit and drain the lines.
Ensure that the mix water and any fluid remaining in the lines have a calcium level
below 400 ppm with chlorides below 2000 ppm. Treat the mix water (drill water)
with 0.37 ppb soda ash (ppm calcium x 0.00093) to remove the hardness and
adjust the pH to 9 by the addition of 0.5 ppb caustic soda.
Prehydrate the bentonite (20-30 ppb) for at least an hour prior to the addition of
D75 (5gal/bbl). If the bentonite fails to yield the drill water is likely to be
contaminated. After D75 is added, the density should be raised to 45 pptf above
the mud weight. Properties can be adjusted by the addition of bentonite or fresh
water, with D75 added to maintain concentration.
A 20 bbl pill is required for 12 1/4 holes and smaller. For larger hole sizes use 50 bbl.
In hole sizes of 12 1/4 or less, a 20 bbl spacer ahead of the reactive pill is sufficient,
with sufficient spacer behind to balance.
192
5.3.3.7. Equipment.
Utilize a 2 7/8 or 3 cement stinger for all hole sizes 17 or smaller. The 2 7/8 is
recommended in most cases except for higher angles wells where the hole size is
12 or bigger, where 3 is recommended. It is also recommended to use a
stinger 1.5 times the expected plug length. The stinger should be blanked off at the
bottom and slots cut in the sides of the bottom joint.
Plug placement using open-ended pipe results in considerable disturbance to the

fluids interface by the slurry changing its flow direction and is a major contributor to
plug failure. Plug placement using a flow diverter tool at the end of the pipe
minimizes this disturbance effect because the flow pattern of the pumped fluids
exiting the pipe is a lateral and upward movement.
8 holes phased at 450
Bull Plug
Figure 105: Schematic of plug diverter tool.
An alternative to the steel cement stinger, and one that is becoming more
common is fiberglass tubing. The main difference between the two is that the
fiberglass tubing is disconnected from the DP after the cement has been
displaced and left to set in the cement. This avoids mud contamination when the
stinger is pulled through the cement.
5.3.3.8. Plug Setting Guidelines.
1. Ensure the pit (for mixing the spacer) and the batch tank are thoroughly
cleaned out and all the lines are flushed. Check the chloride content of the
fresh water to be <1000 ppm.
2. Make up the pre-flush (wash and/or spacer) in mud pits as per recipe.
3. Prepare the cement mix water in the batch tank. Add the cementing
chemicals to the batch tank as per the slurry recipe. Add the chemicals in
the order they appear in the recipe. Add the retarder last just before batch
193
mixing the slurry. Take samples of the mix water, at least one gal, so that
tests can be carried out if problems occur.
4. Circulate at least bottoms up until the well fluid is balanced. Reciprocate
and rotate the pipe while circulating if possible.
5. Hold pre job meeting to discuss job procedures and safety aspects.
6. Flush lines with water and pressure test surface lines to 3000 psi for 5 min.
7. Batch mix the slurry as per the slurry recipe. Switch off the circulating pump
when the correct density is reached to avoid the possibility of over shearing
the slurry and thereby shortening the thickening time. Take two samples of
the cement slurry.
8. Pump ____ bbl of Pre-flush (Wash and/or Spacer) (from mud pit) with the
cement unit at ____ bpm.
9. Pump ____ bbl of cement slurry from the batch tank with the cement unit at
___ bpm. (Volume depending on depth/length of plug)
10. Pump _____ bbl of spacer behind to balance the cement plug with the
cement unit at ____ bpm.
11. Displace with mud with the cement unit to ensure the displacement
volumes are accurate. Under displace by volume given in the table below.
Table 30: Under-displacement volumes for different DP sizes.
12. Pull out of plug as slowly as practical and do not rotate while pipe is in the
plug, place stinger at 50 ft above top of cement. Watch for indicators such
as drag or sticking while on the slips. Pulling too quickly and/or rotation will
destabilize and/or contaminate the plug.
13. Drop drill pipe wiper dart (if run) and circulate the well clean (150% annulus
volume minimum). As a general rule, it is NOT recommended to reverse out
on top of the cement plug. The risks of losing returns, plugging off and
contaminating the cement plug are thought to outweigh the time
advantage that it affords.
5.3.3.9. Evaluation
194
The success of kick-off plugs is evaluated by actually trying to kick-off: there is no
way to question the validity of this test!
If the kick-off plug is also acting as an isolation plug then it needs to be tested in
accordance with IPM WCI 006 Setting and Verification of cement plugs.
5.3.3.10. Additional Material
Intouch has a dedicated cement plug reference page.
Intouch Content ID: 3318658 - Cement Plug Reference Page
5.3.4. Kicking-off with a motor.
Motors are the predominate method of kicking off a well for the following reasons:
Plentiful Supply, usually already on location

Cost effective for most applications
Tenacious
Able to meet objectives after the Kick-off is completed
Highly flexible in controlling DLS.
When the success of a sidetrack is not a foregone conclusion (most cases) you
must be aware of:
1. The Sidetrack is the objective of the current operation. Bit selection should
be for the short term and not long term e.g. to kick-off from the cement
plug.
2. Discuss the operation with the DD and the office.
3. Commitment to success.
The Time drilling program. Be patient. Give the DD the time to
kick-off successfully. The cost of setting a new plug is higher
than drilling slower
The likely outcome of our actions. Discuss all outcomes with
the DD.
The factors that have limited our success previously.
4. The contingency plan.
5.3.4.1. OH Whipstock.
Whip stocks are highly effective tools designed to provide lateral displacement
from the well bore. They do not give very large changes in dogleg but due to the
fact that what is provided is done in a very small change in MD. They generate
high DLS values. Though whip stocks are a niche market tool their range and
diversity is on the increase. They are normally run in the following cases:
1. When hard formations are present and the soft formations suitable for
sidetracking in are too shallow.
2. Where exact depth control is required.
3. No requirement to abandon to original hole
195
Whipstock face.
New hole section.
Original hole section.
Whipstock anchored
with ECP.
Figure 106: Shows schematic representation of OH whipstock.
196
5.4. Reporting
It is important to investigate stuck pipe incidents, especially catastrophic events.
The investigation must get to the root cause of the problem and the lessons learnt
must be distributed within the well engineering community.
An example of the format of a typical stuck pipe report is detailed below.
STUCK PIPE INCIDENT REPORT
Reporting Guidelines
Drilling Unit: state name of rig

Type of Rig: state semi, jack-up, drill ship, land.
Drilling Contractor: state name
Well name: DOE well number after spud
Well Type: state EXP, APP, DEV, Re entry, Sidetrack
Directional profile: Vertical, Directional with max angle, S Shape,
Horizontal.
Well total depth: state depth in metres
Hole drilled: Total length of hole drilled
Spud date: start of drilling
Dry hole days

Exp/App wells: Spud to start of anchor handling or start of rig down less
time for testing E/A wells
Dev wells: Spud to last operation prior to running production
casing/liner or pre-wipe trip.
Test/comp days
Exp/App wells: From running production casing/liner or pre casing

wiper trip to final lay down of test tools.
Dev wells: From running production casing/liner or pre casing
wiper trip, to suspend prior to skid.
Well completion date: Record date well operations completed i.e. rig release.
Sticking incident
Date/time: Record details.

Depth: Depth stuck in metres or feet.
Hole size: Record details.
Hole Angle: Record details where stuck.
Mud weight: Weight in SG or ppg of mud in hole at time of sticking.
Overbalance: Record overbalance in psi.
Mud type: State mud systems in use in hole.
Full Details of Incident and Action Taken

Complete detailed summary of events and actions taken throughout including
recording the following points where relevant:
Time string free after becoming stuck
197
Amount of over pull to free
If pill pumped, type volume, density, spacers, displacement rate and
time after pipe stuck etc.,
Time attempts to free were aborted i.e. sidetrack start time
Fish left in hole
Amount of hole lost.
Interpretation of Cause and Lessons Learnt

This should be completed following a review of what happened to identify the
mechanism and cause of the incident i.e. Mechanism: Differential sticking, Cause:
BHA poor design, mud weight too high, etc. Consider any human factors relating
to the time of the incident i.e. Crew change, New Rep etc.
In addition the actions taken following the incident should be reviewed to establish
what other problems occurred if any and state lessons learnt to be applied to
future wells.
Planned Action / Recommendation

Consider what action needs to be taken to improve awareness and avoid such an
occurrence i.e. Incorporate within stuck pipe course/workshops, review of BHA
design needed, more training in specific areas.
Lost Time
State lost time in total to recommence operations from where stuck pipe incident
occurred. This will include all time associated in performing a sidetrack and re-
drilling relevant hole section to original depth. Record time spent to free pipe or
until attempts aborted i.e. where decision taken to sidetrack.
Cost
Record: Total cost in US dollars
Total cost of fish in US dollars
198
6. Acknowledgements
IPM
Philip Church Author
Gokhan Yarim Reviewer

Alejandro Trejo Reviewer
Graham Ritchie Reviewer
D&M
Tony Pink
Maximo Herdandez
199
7. Appendix
200
7.1. Unconsolidated Formations
201
7.2. Mobile Formations
202
7.3. Faulted & Fractured Formations
203
7.4. Naturally over pressured shale collapse
204
7.5. Appendix 4: Induced Over-pressured shale
collapse.
205
7.6. Reactive Formations
206
7.7. Hole Cleaning
207
7.8. Tectonically Stressed Formations
208
7.9. Differential Sticking
209
7.10. Key Seating
210
7.11. Undergauge Hole
211
7.12.Doglegs & Ledges
212
7.13.Junk
213
7.14.Cement Blocks
214
7.15.Green Cement
215
7.16.Stuck Pipe HARC Analysis. Comment:
Comment: Taking into account all
Hazard Analysis and Risk Control Record Contributing and Escalating Factors,
describe all Controls applicable to
each Hazard, both Prevention and
Revision: Final Rev 001 Task/Process Assessed: Stuck Pipe Drilling/Workover/Intervention Mitigation Controls. If PPE is a
Control, it must be described.
Date: 13 Oct 2003 Location: All IPM managed projects
Comment: Choose the Loss
Operation: Assessment Team: Ritchie/Struthers/McEwan/Bourque/Cuvillier/ Categories from the HARC Risk
Toolbar
HAZARD INITIAL RISK CONTROL MEASURES Comment: From instructions in App
4, identify Likelihood of an undesired
Hazard Description List all Current and Planned Control Measures, ta event with no Prevention Controls in
and Worst Case Loss Contributing and Escalating Fact place for each Hazard. Use the
Likelihood
Risk Level
Consequences with no Category/ HARC Risk Toolbar to insert the

Severity
Prevention or Likelihood.
Mitigation Measures in Population Current and Planned Prevention Current an
Activity Steps Affected Comment: From instructions in App
Place Measures to reduce Likelihood Measure 4, identify Likelihood of an undesired
event with all current and planned
Drilling/ Natural Phenomenon, Non productive Identify stuck pipe incidents in offset well Consider L Controls in place for each Hazard.
Tripping Gravitational Potential time, operating analysis BHA (e.g. Use the HARC Risk Toolbar to
Energy (mechanical sticking) cost, lost in hole Consider potential for stuck pipe in well Consider L insert the Likelihood.
& Pressure (Differential charges, cost of design and directional planning e.g. Ensure fis
sticking) redrill and cost inclination of tangent section for hole Comment: Classify the Initial Risk
all tools R
of deferred cleaning, casing seat selection, etc. Level from the OFS Risk Assessment
... [1]
Confirm fis
Stuck pipe leading to fishing production on Minimize open hole exposure time (WBS) Comment: Classify the Residual
Ensure fis
operations and/or sidetracks development Consider geomechanics study & No Risk Level from the OFS Risk ... [2]
wells. down hole
to redrill hole Drilling Surprise services
Intolerable (-12)
Catastrophic (-4)
Design dri Comment: From instructions in App

Possible (3)
Consider Perform engineers for critical adequate 4, identify potential Severity of an... [3]
wells Run jar pla
Run RPM to identify specific risks the jar pos Comment: From instructions in App
Consider rig suitability for well design 4, identify potential Severity with ...
all[4]
Have stuc
Highlight risk at pre-spud meeting and available f Comment:
hole section reviews Consider e
Highlight stuck pipe risks in the Drilling stuck pipe Comment: Separate the job into
program individual tasks, or the process into
... [5]
Comment: Choose the Hazard
Categories from the HARC Risk
... [6]
Comment: If Personnel: Name all
types of personnel at risk. Remember
... [7]
216
Drilling/ Natural Phenomenon, Non productive Design mud program to minimize the risk Have back
Tripping Gravitational Potential time, operating (optimize overbalance, minimize fluid loss, available
Energy (mechanical sticking) cost, lost in hole consider adding CACO3 for permeable Plan conti
(continued) & Pressure (Differential charges, cost of sections) radioactive
sticking) redrill and cost Run Drilling Office hydraulics & hole If stuck, ru
of deferred cleaning while drilling to determine sticking m
Stuck pipe leading to fishing production on minimum flow rates and ECD Evaluate r
operations and/or sidetracks development Implement engineered hole cleaning pipe hand
to redrill hole wells. practices to avoid pack offs Run IPM f
Highlight risk of cuttings beds (45 70 spreadshe
deg) and include procedures for dealing fishing tim
with cuttings beds Implemen
Perform torque & drag analysis to assess corrosion
the impact of the drillstring selection and environme
BHA design on sticking potential. If stuck, co
Catastrophic (-4)
Intolerable (-12)
Conduct stuck pipe training with the rig experience

Possible (3)
team
Ensure rig team have access to the Stuck Note: These m
Pipe handbook Industry pract
Consider using a top drive, spiral drill ALARP
collars, rotary steerable, bi-center bits.
Issue drilling procedures and written
instructions to the driller (e.g. max
overpull on trips)
Keep pipe moving while across
porous/permeable formations
Monitor trends (drag, reaming)
Implement drag charts for tripping
Implement Trip charts highlighting tight
hole
Ensure stuck pipe risks highlighted in
Drillers handover
Assess Driller competency in stuck pipe
avoidance
217
Comment:
Hazard Analysis and Risk Control Record
Comment: Taking into account all
Revision: Final Rev 001 Task/Process Assessed: Stuck Pipe Drilling/Workover/Intervention Contributing and Escalating Factors,
describe all Controls applicable to
each Hazard, both Prevention and
Date: 13 Oct 2003 Location: All IPM managed projects Mitigation Controls. If PPE is a
Control, it must be described.
Operation: Running Casing. Assessment Team: Ritchie/Struthers/McEwan/Bourque/Cuvillier/
Comment: Choose the Loss
HAZARD INITIAL RISK CONTROL MEASURES Categories from the HARC Risk
Toolbar
Hazard Description List all Current and Planned Control Measures, ta
Comment: From instructions in App
and Worst Case Loss Contributing and Escalating Fact 4, identify Likelihood of an undesired
Likelihood
Risk Level
Consequences with no Category/ event with no Prevention Controls in

Severity
Prevention or place for each Hazard. Use the

Mitigation Measures in Population Current and Planned Prevention Current an HARC Risk Toolbar to insert the
Activity Steps Place Affected Measures to reduce Likelihood Measure Likelihood.
Running Natural Phenomenon, Non productive Limit maximum dog leg severity Applicable meas 4, identify Likelihood of an undesired
Casing Gravitational Potential time, operating Design casings (including landing strings) Casing pa event with all current and planned
Energy (mechanical sticking) cost, lost in hole to maintain adequate overpull hanger Controls in place for each Hazard.
& Pressure (Differential charges, cost of Ensure sufficient clearance with previous Run expan Use the HARC Risk Toolbar to
sticking) redrill and cost casing and open hole extension insert the Likelihood.
of deferred
Consider bi-center bits, special clearance Consider c
Stuck casing potentially production on
well desig Comment: Classify the Initial Risk
couplings
leading to additional casing development Level from the OFS Risk Assessment
... [8]
wells. Run casing centralization software to
string or redrill of section
determine maximum drag Comment: Classify the Residual
Intolerable (-12)
Catastrophic (-4)
Ensure adequate centralization across Risk Level from the OFS Risk ... [9]
Possible (3)
potential differential sticking zones

Consider running reaming shoe and being 4, identify potential Severity of an
able to rotate casing in the event of ... [10]
bridges Comment: From instructions in App
Consider using casing fill up tool to 4, identify potential Severity with
...all
[11]
minimize stationary time and allow casing
Comment:
to be washed to bottom
Ensure hole and mud in good condition Comment: Separate the job into
prior to running casing individual tasks, or the process ...
into
[12]
Implement drag charts for running casing
Comment: Choose the Hazard
Keep pipe moving while across Categories from the HARC Risk
... [13]
porous/permeable formations !
Comment: If Personnel: Name all
types of personnel at risk. Remember
... [14]
218
7.17.PowerPak Motors with Adjustable Bends Drill String RPMs: Curve
219
7.18.PowerPak Motors with Adjustable Bends Drill String RPMs: Tange
220
Page 216: [1] Comment Note
Classify the Initial Risk Level from the OFS Risk Assessment Matrix for each Hazard. Use the HARC Risk Toolbar to
insert the Initial Risk Rating.

Classify the Residual Risk Level from the OFS Risk Assessment Matrix for each Hazard. Use the HARC Risk Toolbar
to insert the Residual Risk Level.

From instructions in App 4, identify potential Severity of an undesired event with no Controls in place for each Hazard.
Use the HARC Risk Toolbar to insert the potential Severity.

From instructions in App 4, identify potential Severity with all current and planned controls in place for each Hazard. Use
the HARC Risk Toolbar to insert the potential Severity.

Separate the job into individual tasks, or the process into phases, and record in sequence.

Choose the Hazard Categories from the HARC Risk Toolbar Describe all Hazards identified and their effects for each
task (from Hazard Catalogue in App 2 and experience).

If Personnel: Name all types of personnel at risk. Remember to include people outside the work party who may be
affected.

Classify the Initial Risk Level from the OFS Risk Assessment Matrix for each Hazard. Use the HARC Risk Toolbar to
insert the Initial Risk Rating.

Classify the Residual Risk Level from the OFS Risk Assessment Matrix for each Hazard. Use the HARC Risk Toolbar
to insert the Residual Risk Level.

From instructions in App 4, identify potential Severity of an undesired event with no Controls in place for each Hazard.
Use the HARC Risk Toolbar to insert the potential Severity.

From instructions in App 4, identify potential Severity with all current and planned controls in place for each Hazard. Use
the HARC Risk Toolbar to insert the potential Severity.

Separate the job into individual tasks, or the process into phases, and record in sequence.

Choose the Hazard Categories from the HARC Risk Toolbar Describe all Hazards identified and their effects for each
task (from Hazard Catalogue in App 2 and experience).

If Personnel: Name all types of personnel at risk. Remember to include people outside the work party who may be
affected.

IPM Stuck Pipe Manual Volume

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STUCK PIPE MANUAL

Figure-1: IPM WEMS flow diagram

List of documentation that can aid stuck pipe identification.

Daily Drilling/Operations summary report

Risk Consequence/Exposure Mitigation Probability Days Cost Risked Risked

Table 1: Shows an example risk register.

1.2.1.1. Time-depth graphs:

1,500 Sidetracks are

Figure 2: Example of a time depth graph.

1.2.1.2. Daily drilling reports:

Without quality data the reports become useless.

1.2.1.3. Surface and down hole drilling parameters

A picture paints a thousand words.

1.2.1.4. End Of Well Report:

In order to quantify & then mitigate a hazard it is sometimes necessary to look at

Length of 12 1/4" BUS vs time

120 and 80 deg

SW1 130 and 70 deg

13.8 40 and 160 deg

30 and 170 deg

11.8 0 and 20 deg

lower limit = Pore Pressure Gradient @ 9.8 kPa/m

Borehole Inclination [deg]

1.2.2. Risk of getting stuck?

How easy is it to determine our chances of getting stuck?

There are four main methods:

1.2.2.2. Field/area risk sheets:

1.2.2.3. Historical data for different well types (Osprey Risk):

1.2.2.4. HARC Analysis.

HARC - Stuck Pipe Final Rev 001.doc

1.3.1. Casing Design Examples

Factors to consider when changing the hole size:

Bi-centered bits & hole opening tools

Hole - Cleaning: Difficulty vs. Angle

Many of the events, especially in deviated wells, are failure by design/poor

Hole cleaning in vertical wells is often overlooked and considered unimportant.

1.4.1.1. Main factors that influence hole cleaning in vertical wells?

1.4.1.2. How can we evaluate hole-cleaning efficiency in vertical wells?

Transport Velocity Volume of cuttings in

1.4.1.3. What can be done in the planning stage?

Less planning is required to ensure good hole cleaning in vertical wells

Limited on flow rate?

WHAT WORKS HERE

3 WILL NOT WORK HERE

1.4.2.2. Recap: The differences between vertical & directional wells.

1. Gravity works against us.

Vertical Well Directional Well

What are the Effects?

- Adhesion of the cuttings in the bed

- Increased torque & drag

How does Mud Respond? DRILL PIPE

0-3 ft/min DP 0-3 ft/min

1.4.3. How do we achieve good hole cleaning in a directional well?

Figure 16: Visualisation of K & Ms hole cleaning conveyor belt.

1.4.4. Pipe Rotation.

The different theories are:

In reality it is probably a combination of the two and experimental data has

1.4.4.1. How fast do we need to rotate the pipe?

100 120 RPM

Fine-tuning of pipe RPM

Hole Size Desirable Minimum

17 120-180rpm 120 rpm

12 120-180rpm 120 rpm

9 7/8 120-150rpm 100 rpm