Fundamentals of Sustainable Drilling Engineering

M.E. Hossain, PhD, is an assistant professor in the department of petroleum engineering at King Fahd University of Petroleum & Minerals. He earned his PhD in petroleum engineering from Dalhousie University in 2008 and is the author of one book and over 40 research on petroleum engineering. A. Al-Majed, PhD, is an associate professor in the department of petroleum engineering at King Fahd University of Petroleum & Minerals, earning his PhD in petroleum engineering in 1988 from the University of Southern California. Dr Al-Majed's industrial experience includes working in the reservoir, production, drilling and workover departments, including over twenty years of experience in teaching drilling engineering.

Foreword xix

Preface xxi

Acknowledgements xxiii

Summary xxv

1 Introduction 1

1.1 Introduction 1

1.2 Introduction of Drilling Engineering 1

1.3 Importance of Drilling Engineering 2

1.4 Application of Drilling Engineering 2

1.5 History of Oil Discovery 3

1.6 An Overview of Drilling Engineering 5

1.7 Organization Chart and Manpower Requirements during Drilling Operations 12

1.8 Aspect of Sustainability in Drilling Operations 13

1.9 Summary 15

References 16

2 Drilling Methods 17

2.1 Introduction 17

2.2 Types of Drilling Methods 18

2.3 Rotary Drilling Rig and its Components 20

2.4 Drilling Process 22

2.5 Types of Rotary Drilling Rigs 50

2.6 Nature and Need for Sustainable Drilling Operations 57

2.7 Current Practice in the Industries 58

2.8 Future Trend in Drilling Methods 61

2.9 Summary 62

2.10 Nomenclature 62

2.11 Exercise 63

Appendix 2A 65

Rig Floor (Conventional Rotary Rig) 65

Rig Floor (Top Drive) 65

Blowout Preventer Stack And Wellhead 66

Drilling Fluid Equipment 66

References 71

3 Drilling Fluids 73

3.1 Introduction 73

3.2 Drilling Fluid Circulating System 74

3.3 Classifi cation of Drilling Fluids 76

3.4 Composition of Drilling Fluids 82

3.5 Mud Additives 84

3.6 Measurement of Drilling Fluids Properties 101

3.7 New Drilling Mud Calculations 124

3.8 Design of Mud Weight 125

3.9 Current Developments in Drilling Fluids 128

3.10 Future Trend on Drilling Fluids 131

3.11 Summary 133

3.12 Nomenclature 133

3.13 Exercises 135

References 136

4 Drilling Hydraulics 141

4.1 Introduction 141

4.2 Types of Fluids 142

4.3 Flow Regimes 156

4.4 Hydrostatic Pressure Calculation 162

4.5 Fluid Flow through Pipes 169

4.6 Fluid Flow through Drill Bits 171

4.7 Pressure Loss Calculation of the Rig System 173

4.8 Current Development on Drilling Hydraulics 183

4.9 Future Trend on Drilling Hydraulics 192

4.10 Summary 195

4.11 Nomenclature 195

4.12 Exercise 197

References 199

5 Well Control and Monitoring Program 205

5.1 Introduction 205

5.2 Well Control System 206

5.3 Warning Signals of Kicks 211

5.4 Control of Infl ux and Kill Mud 214

5.5 BOP Equipment for Well Control System 227

5.6 Well Monitoring System 238

5.7 Current Practice in Well Control and Monitoring 240

5.8 Future Trend on Well Control and Monitoring System 244

5.9 Summary 247

5.10 Nomenclature 247

5.11 Exercise 248

References 249

6 Formation Pore and Fracture Pressure Estimation 251

6.1 Introduction 251

6.2 Geological Aspects of Rock Mechanics in Drilling 252

6.3 Current Development on Formation Pore and Fracture Pressure 312

6.4 Future Trend on Formation Pore and Fracture Pressure 313

6.5 Summary 314

6.6 Nomenclature 314

6.7 Exercise 317

References 318

7 Basics of Drill String Design 321

7.1 Introduction 321

7.2 Drill String Components 322

7.3 Drilling Bit 334

7.4 Drill String Design 344

7.5 Bit Design 364

7.6 Drilling Bit Selection 366

7.7 Drilling Bit Performance 368

7.8 Drilling Optimization Techniques 371

7.9 Factors Aff ecting Rate of Penetration 379

7.10 Rate of Penetration Modelling 392

7.11 Current Development on Drill String and Bottomhole Assembly Design 416

7.12 Future Trend on Drill String and Bottomhole Assembly Design 423

7.13 Summary 424

7.14 Nomenclature 424

7.15 Exercise 427

References 428

8 Casing Design 433

8.1 Introduction 433

8.2 Importance of Casing String 434

8.3 Types of Casing String 435

8.4 Components of Casing String 441

8.5 Classifi cation and Properties of Casing 442

8.6 Manufacturing of Casing 446

8.7 Rig-site Operation 447

8.8 Casing Design and Selection Criteria 451

8.9 Current Development in Casing Technology 477

8.10 Discussions on Some Case Studies 490

8.11 Future Trend on Casing Design Development 497

8.12 Summary 498

8.13 Nomenclature 498

8.14 Exercises 499

References 500

9 Cementing 503

9.1 Introduction 503

9.2 Applications of Oil Well Cements 504

9.3 Cement Production 508

9.4 Classifications of Oil Well Cements 510

9.5 Cement Properties 513

9.6 Types of Cementing 522

9.7 Oil Well Cement Additives 528

9.8 Cementing Design Process 531

9.9 Laboratory Tests on Cements Slurry 534

9.10 Mechanics of Cementing 549

9.11 Cement Job Evaluation 555

9.12 Cement Volume Calculation 557

9.13 Practical Calculations 558

9.14 Recommendations for Successful Cementing 564

9.15 Current Development on Cementing 564

9.16 Future Trend on Cementing 565

9.17 Summary 566

9.18 Nomenclature 567

9.19 Exercises 568

References 570

10 Horizontal and Directional Drilling 571

10.1 Introduction 571

10.2 Functions 572

10.3 Basic Terminologies 576

10.4 Types of Directional Drilling 580

10.5 Well Planning Trajectory 594

10.6 Directional Drilling Tools 599

10.7 Well Survey 616

10.8 Geo-steering 635

10.9 Current Trends in Directional Drilling 636

10.10 Future Trends in Directional Drilling 637

10.11 Summary 639

10.12 Nomenclature 639

10.13 Exercise 640

References 642

11 Well Drilling Cost Analysis 643

11.1 Introduction 643

11.2 Variables Related to Drilling Costs 644

11.3 Types of Well Drilling Costs 645

11.4 Brake Down of Total Well Drilling Cost 647

11.5 Authorisation for Expenditure 647

11.6 Drilling Cost Estimation 649

11.7 Well Drilling Time Estimation 656

11.8 Time Value of Investment 668

11.9 Price Elasticity 669

11.10 Current Trend on Drilling Cost Analysis 670

11.11 Future Trend on Drilling Cost Analysis 672

11.12 Summary 673

11.13 Nomenclature 673

11.14 Exercise 674

References 677

12 Well Completion 679

12.1 Introduction 679

12.2 History of Well Completion 680

12.3 Requirements for Well Completion 680

12.4 Types of Well Completion 683

12.5 Factors Infl uencing Well Completion Design 695

12.6 Completion Equipment and Materials 697

12.7 Sand Control 719

12.8 Remedial Cementing 721

12.9 Corrosion and Corrosion Prevention 724

12.10 Current Development on Well Completion 729

12.11 Future Trend on Well Completion 733

12.12 Summary 735

References 735

Index 737