Improving drilling performance through optimizing controllable drilling parameters

Ahmed Bani Mustafa,Ahmed K Abbas,Mortadha Alsaba,Mamoon Alameen

doi:10.1007/s13202-021-01116-2

Ahmed Bani Mustafa, Ahmed K Abbas + Show 2 more

Open Access

https://doi.org/10.1007/s13202-021-01116-2

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Abstract

The prediction of the drilling rate of penetration (ROP) is one of the key aspects of drilling optimization due to its significant role in reducing expensive drilling costs. Many variables could affect ROP, which can be classified into two general categories; controllable operational variables and uncontrollable or environmental variables. Minimizing the drilling cost can be achieved through optimizing the controllable drilling parameters. As a direct result, the drilling speed will be increased while maintaining safe practices. The primary purpose of this study is to address the simultaneous impact of controllable parameters such as weight on bit (WOB), revolutions per minute, and flow rate (FR) on the rate of penetration (ROP). Response surface methodology was applied to develop a mathematical relation between operational controllable drilling parameters and ROP. To accomplish this, actual field datasets from several wells drilled in Southern Iraq in different fields were used. The second purpose of this study was to identify all prospective optimal ranges of these controllable parameters to obtain superior drilling performance with an optimum ROP. The obtained results showed that the developed model offers a cost-effective tool for determining the maximum ROP as a function of controllable parameters with reasonable accuracy. In addition, the proposed model was used to estimate optimal combinations of controllable drilling parameters for various depths. The results have shown that FR has the most significant effect on ROP variation with a sum of squares values of 23.47. Applying high WOB does not permanently improve ROP but could result in reducing ROP for some cases. The developed mechanical specific energy model for polycrystalline diamond compact (PDC) bit with vertical and deviated wells can estimate combinations of controllable drilling parameters. The developed model can be successfully applied to predict and optimize the drilling rate when using PDC bits, hence reducing the drilling time and the associated drilling cost for future wells.

Highlights

Drilling operation is one of the most critical parts of any exploration and developmental project
The data show that 67% of the time, flow rate (FR) is above the recommended maximum value
The variance and regression analysis indicates that the FR has the most significant effect on rate of penetration (ROP) variation with the sum of squares values of 23.47, among the other controllable drilling parameters

Summary

Introduction

Drilling operation is one of the most critical parts of any exploration and developmental project. Operational costs related to drilling processes have increased substantially in the last ten years (Amer et al 2017). A number of related actions have been stimulated by the high costs, which involve more than half of the budget of any field development plans (Lashari et al 2019). Drilling engineers and operations teams are often motivated to reduce the well drilling duration and associated costs. Drilling optimization has an important role in improving drilling performance and reducing unnecessary drilling costs. These issues influence drilling time, the drilling rig’s productivity, and, increase the profitability of oil and gas projects (Mohammed et al 2018)

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