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Applied Drilling Circulation Systems - Hydraulics, Calculations, and Models PDF

307 Pages·2011·4.985 MB·English
by  GuoBoyunLiuGefei
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APPLIED DRILLING CIRCULATION SYSTEMS , , HYDRAULICS CALCULATIONS AND MODELS BOYUN GUO, Ph.D. University of Louisiana at Lafayette GEFEI LIU Pegasus Vertex, Inc. Amsterdam•Boston•Heidelberg•London NewYork•Oxford•Paris•SanDiego SanFrancisco•Singapore•Sydney•Tokyo GulfProfessionalPublishingisanimprintofElsevier GulfProfessionalPublishingisanimprintofElsevier 30CorporateDrive,Suite400,Burlington,MA01803,USA TheBoulevard,LangfordLane,Kidlington,Oxford,OX51GB,UK Copyright©2011ElsevierInc.Allrightsreserved. Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans,electronicor mechanical,includingphotocopying,recording,oranyinformationstorageandretrievalsystem,without permissioninwritingfromthepublisher.Detailsonhowtoseekpermission,furtherinformationaboutthe Publisher’spermissionspoliciesandourarrangementswithorganizationssuchastheCopyrightClearance CenterandtheCopyrightLicensingAgency,canbefoundatourwebsite:www.elsevier.com/permissions. Thisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythe Publisher(otherthanasmaybenotedherein). Notices Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperiencebroaden ourunderstanding,changesinresearchmethods,professionalpractices,ormedicaltreatmentmaybecome necessary. Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluatingand usinganyinformation,methods,compounds,orexperimentsdescribedherein.Inusingsuchinformationor methodstheyshouldbemindfuloftheirownsafetyandthesafetyofothers,includingpartiesforwhomthey haveaprofessionalresponsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assume anyliabilityforanyinjuryand/ordamagetopersonsorpropertyasamatterofproductsliability,negligence orotherwise,orfromanyuseoroperationofanymethods,products,instructions,orideascontainedinthe materialherein. LibraryofCongressCataloging-in-PublicationData Guo,Boyun. Applieddrillingcirculationsystems:hydraulics,calculations,andmodels/BoyunGuo,GefeiLiu. p.cm. Includesbibliographicalreferencesandindex. ISBN978-0-12-381957-4(hardback) 1.Mudpumps.2.Oil-welldrilling.3.Gaswelldrilling.I.Liu,Gefei.II.Title. TN871.27.G862011 622’.3381–dc22 2010043249 BritishLibraryCataloguing-in-PublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary. ForinformationonallGulfProfessionalPublishingpublicationsvisitour Websiteatwww.elsevierdirect.com PrintedintheUnitedStates 11 12 13 1415 10 9 8 7 6 5 4 3 2 1 . PREFACE Drilling circulation systems in the oil and gas industry have advanced significantlyinthelastdecade.Themajorchangesresultedfromthemerging of air and gas drilling and underbalanced drilling with traditional liquid drilling systems. During the several years of teaching drilling engineering courses in both academia and industry, the authors realized the need for a book that covers modern drilling practices. The books that are currently availablefailtoprovideadequateinformationabouthowengineeringprinci- ples are applied to solving problems that are frequently encountered in drillingcirculationsystems.Thisfactmotivatedtheauthorstowritethisbook. This book is written primarily for well drilling engineers and college students of both senior and graduate levels. It is not the authors’ intention to simply duplicate general information that can be found in other books. This book gathers the authors’ experiences gained through years of teach- ing courses on drilling hydraulics, air and gas drilling, and underbalanced drilling engineering in the oil and gas industry and in universities. The mission of this book is to provide drilling engineers with handy guide- lines for designing, analyzing, and operating drilling circulation systems. This book covers the full scope of drilling circulation systems. Follow- ing the sequence of technology development, it contains ten chapters presented in three parts. PartI contains fourchaptersthatcoverliquiddrilling fundamentalsas the first course for entry-level drilling engineers and undergraduate students. Chapter 1 presents an introduction to the equipment used in mud drilling systems.Chapter2documentsmudhydraulicsfundamentalsthatareessential for selecting and optimizing mud pumps and mud hydraulics programs. Chapter3coversindetailtheprocedureforselectingmudpumps.Chapter4 presentstechniquesusedtooptimizemudhydraulicsprograms. Part II includes three chapters that present the principles and rules of designing and operating gas drilling systems. Chapter 5 introduces the equipment used in gas drilling systems. Chapter 6 covers in detail the procedure for selecting gas compressors. Chapter 7 provides guidelines for operating gas drilling systems. Part III consists of three chapters that cover underbalanced drilling systems. Chapter 8 presents an introduction to the equipment used in underbalanced drilling systems. Chapter 9 describes the procedure for ix x Preface selecting gas and liquid flow rates. Chapter 10 provides guidelines for underbalanced drilling operations. Since the substance of this book is virtually boundless in depth, knowing what to omit was the greatest challenge. The authors believe that it requires many books to describe the foundation of knowledge in drilling circulation systems. To counter any deficiency that might arise from space limitations, this book provides a reference list of books and papers at the end of each chapter so readers can consult other sources of information about the topics discussed. As for presentation, this book focuses on providing and illustrating engineering principles used for designing and optimizing drilling circula- tion systems, rather than on discussion of in-depth theories. Derivation of mathematical models is beyond the scope of this book. Applications of the principles are illustrated by solving example problems. While the solutions to some simple problems that do not involve iterative procedures are demonstrated with stepwise calculations, complicated problems are solved with computer spreadsheet programs, some of which can be downloaded from the publisher’s website. The combination of the book and the computer programs creates the perfect tool kit for drilling engineers for performance of their daily work in the most efficient manner. All of the computer programs were written in the form of spreadsheets in MS Excel that are available in most computer platforms in the oil and gas industry. These spreadsheets are accurate and very easy to use. While both U.S. field units and SI units are used in the book, the option of using U.S. field units or SI units is provided in the spreadsheet programs. This book is based on numerous documents, including reports and papers accumulated through years of work at the University of Louisiana at Lafayette and at Pegasus Vertex, Inc. The authors are grateful to the university and the company for permission to use these materials. Special thanks go to Chevron USA for providing professorships in petroleum engineering throughout the editing of this book. Our thanks also go to Mr. Guoqiang Yin of Shell USA, who contributed a thorough review and edit of this book. On the basis of the collective experiences of the authors and of reviewers, we expect this book to be of great value to drilling engineers in the oil and gas industry. Dr. Boyun Guo Chevron Endowed Professor in Petroleum Engineering University of Louisiana at Lafayette CONTENTS Preface ix Part One Liquid Drilling Systems 1 1. Equipment in Mud Circulating Systems 3 1.1 Introduction 3 1.2 MudPumps 3 1.3 Drill Strings 6 1.4 Contaminant-Removal Equipment 11 Summary 18 2. Mud Hydraulics Fundamentals 19 2.1 Introduction 19 2.2 Characterization ofDrillingMud 19 2.3 Hydraulics Models 26 Summary 57 3. Mud Pumps 61 3.1 Introduction 61 3.2 MudFlow RateRequirements 61 3.3 Pressure Requirements 66 3.4 Horsepower Requirements 72 3.5 Capacities ofMudPumps 74 Summary 78 4. Mud Hydraulics Optimization 81 4.1 Introduction 81 4.2 TheCriteria ofHydraulics Optimization 81 4.3 TheOptimumDesign ofa Hydraulics Program 86 Summary 104 Part Two Gas Drilling Systems 107 5. Equipment in Gas Drilling Systems 109 5.1 Introduction 109 5.2 SurfaceEquipment 109 5.3 DownholeEquipment 114 Summary 117 vii viii Contents 6. Gas Compressors 119 6.1 Introduction 119 6.2 Gas Flow Mechanics 119 6.3 Gas InjectionRateRequirements 128 6.4 Gas InjectionPressure Requirements 138 6.5 Horsepower Requirements 142 Summary 144 7. Gas Drilling Operations 147 7.1 Introduction 147 7.2 Gas DrillingProcedures 147 7.3 Problems andSolutions 150 Summary 163 Part Three Underbalanced Drilling Systems 165 8. Equipment in Underbalanced Drilling Systems 167 8.1 Introduction 167 8.2 Surface Equipment 167 8.3 Downhole Equipment 170 Summary 171 9. Gas and Liquid Injection Rates 173 9.1 Introduction 173 9.2 Multiphase Flowsin UBD Systems 173 9.3 TheGas-Liquid Flow RateWindow 194 Summary 209 10.Underbalanced Drilling Operations 213 10.1 Introduction 213 10.2 AeratedLiquid Drilling 213 10.3 FoamDrilling 223 Summary 230 Appendix A UnitConversion Factors 231 Appendix B Minimum GasFlow Rates Required forLifting Solids andWater inAirDrilling 233 Appendix C APIDrillCollar Weight(lb/ft) 241 Appendix D APIDrill PipeDimensional Data 243 Appendix E APICasing DimensionalData 245 Index 255 PART ONE Liquid Drilling Systems Liquid is widely used as a circulating fluid to drill oil and gas wells, water wells, geotechnical boreholes, and mining boreholes. This type of drilling fluid is most commonly suspensions of clay and other materials in water and is thus called drilling mud. Since it usually has a density ranging from 8.33 to 18.33 ppg (1.0–2.2 S.G.), drilling mud is used for drilling rock formations with normal to abnormal fluid pressure gradients (>0.433 psi/ft or 0.01 MPa/m). Because the bottomhole pressure is greater than the for- mation pore pressure, mud drilling is an overbalanced drilling operation. Compared to gas drilling and two-phase drilling (see Parts II and III), mud can be used to drill various types of formation rocks with better control of formation fluids and borehole stability. PartIprovidesdrillingengineerswithbasicknowledgeaboutmudcircu- lating systems and techniques that are usedfor optimizing drilling hydraulics to achieve the maximum drilling rate. Materials are presented in the first fourchapters: Chapter 1: Equipment in Mud Circulating Systems Chapter 2: Mud Hydraulics Fundamentals Chapter 3: Mud Pumps Chapter 4: Mud Hydraulics Optimization 1 CHAPTER ONE Equipment in Mud Circulating Systems Contents 1.1 Introduction 3 1.2 MudPumps 3 1.3 Drill Strings 6 1.4 Contaminant-Removal Equipment 11 Summary 18 1.1 INTRODUCTION Figure 1.1 shows a typical mud circulating system (Lyons et al., 2009). The drilling mud travels (1) from the steel tanks to the mud pump; (2) from the pump through the standpipe and the kelly to the drill string, which consists of drill pipes and the bottomhole assembly (BHA), with a major length of drill collars; (3) through the drill string to the bit; (4) through the nozzles of the bit and up the annular space between the drill string and the borehole (open hole and cased hole sec- tions) to the surface; and (5) through the contaminant-removal equip- ment back to the suction tank. The contaminant-removal equipment can include shale shakers, degassers, hydrocyclones (desanders and desilters), and centrifuges. An integrated unit of desanders and desilters is called a mud cleaner. This chapter provides a brief introduction to the equipment that controls the circulating pressure of the system. 1.2 MUD PUMPS Mud pumps serve as the heart of the mud circulating system. Reciprocating piston pumps (also called slush pumps or power pumps) are widely used for drilling oil and gas wells. The advantages of the reciprocat- ing positive-displacement pump include the ability to move high-solids- content fluids laden with abrasives, the ability to pump large particles, ease AppliedDrillingCirculationSystems.DOI:10.1016/B978-0-12-381957-4.00001-2 ©2011ElsevierInc.Allrightsreserved. 3 4 PartI LiquidDrillingSystems Rotary Hose Standpipe Swivel Mud Pump Kelly Mud Line Mud Tanks Drill Pipe Shale Shaker Drill Collar (BHA) Drill Bit Figure1.1 Atypical mudcirculating system. Figure1.2 Aduplex pump.(Courtesy ofGreat American.) of operation and maintenance, reliability, and the ability to operate over a wide range of pressures and flow rates by changing the diameters of the compression cylinders (pump liners) and pistons. The two types of piston strokes are the single-action piston stroke and the double-action piston stroke. A pump that has double-action strokes in two cylinders is called a duplex pump (Figure 1.2). A pump that has single- action strokes in three cylinders is called a triplex pump (Figure 1.3). Triplex pumps are lighter and more compact than duplex pumps, their output EquipmentinMudCirculatingSystems 5 Figure 1.3 Atriplex pump.(Courtesy of TSC.) Figure 1.4 Pumpliners. (Courtesyof TSC.) pressure pulsations are not as great, and they are cheaper to operate. For these reasons, the majority of new pumps being placed into operation are of the triplex design. Normally, duplex pumps can handle higher flow rates, and triplex pumps can provide higher working pressure. However, for a given pump of fixed horsepower, the flow rate and working pressure can be adjusted by changing the sizes of the liners inside the pump. Some types of pump liners are shown in Figure 1.4. Changing the speed of the prime mover can also affect the mud flow rate in a certain range.

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