Search results for: drilling fluid loss

Authors: S. J. Addinell, A. F. Grabsch, P. D. Fawell, B. Evans

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The Deep Exploration Technologies Cooperative Research Centre (DET CRC) is researching and developing a new coiled tubing based greenfields mineral exploration drilling system utilising down-hole water-powered percussive drill tooling. This new drilling system is aimed at significantly reducing the costs associated with identifying mineral resource deposits beneath deep, barren cover. This system has shown superior rates of penetration in water-rich, hard rock formations at depths exceeding 500 metres. With fluid flow rates of up to 120 litres per minute at 200 bar operating pressure to energise the bottom hole tooling, excessive quantities of high quality drilling fluid (water) would be required for a prolonged drilling campaign. As a result, drilling fluid recovery and recycling has been identified as a necessary option to minimise costs and logistical effort. While the majority of the cuttings report as coarse particles, a significant fines fraction will typically also be present. To maximise tool life longevity, the percussive bottom hole assembly requires high quality fluid with minimal solids loading and any recycled fluid needs to have a solids cut point below 40 microns and a concentration less than 400 ppm before it can be used to reenergise the system. This paper presents experimental results obtained from the research program during laboratory and field testing of the prototype drilling system. A study of the morphological aspects of the cuttings generated during the percussive drilling process shows a strong power law relationship for particle size distributions. This data is critical in optimising solids control strategies and cuttings dewatering techniques. Optimisation of deployable solids control equipment is discussed and how the required centrate clarity was achieved in the presence of pyrite-rich metasediment cuttings. Key results were the successful pre-aggregation of fines through the selection and use of high molecular weight anionic polyacrylamide flocculants and the techniques developed for optimal dosing prior to scroll decanter centrifugation, thus keeping sub 40 micron solids loading within prescribed limits. Experiments on maximising fines capture in the presence of thixotropic drilling fluid additives (e.g. Xanthan gum and other biopolymers) are also discussed. As no core is produced during the drilling process, it is intended that the particle laden returned drilling fluid is used for top-of-hole geochemical and mineralogical assessment. A discussion is therefore presented on the biasing and latency of cuttings representivity by dewatering techniques, as well as the resulting detrimental effects on depth fidelity and accuracy. Data pertaining to the sample biasing with respect to geochemical signatures due to particle size distributions is presented and shows that, depending on the solids control and dewatering techniques used, it can have unwanted influence on top-of-hole analysis. Strategies are proposed to overcome these effects, improving sample quality. Successful solids control and cuttings dewatering for water-powered percussive drilling is presented, contributing towards the successful advancement of coiled tubing based greenfields mineral exploration.

Keywords: cuttings, dewatering, flocculation, percussive drilling, solids control

Procedia PDF Downloads 248

Authors: Youji Miyake

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In aircraft assembly, a large number of preparatory holes are required for screw and rivet joints. Currently, many holes are drilled manually because it is difficult to machine the holes using conventional computerized numerical control(CNC) machines. The application of industrial robots to drill the hole has been considered as an alternative to the CNC machines. However, the rigidity of robot arms is so low that vibration is likely to occur during drilling. In this study, it is proposed constant-load feed machining as a method to perform high-precision drilling while minimizing the thrust force, which is considered to be the cause of vibration. In this method, the drill feed is realized by a constant load applied onto the tool so that the thrust force is theoretically kept below the applied load. The performance of the proposed method was experimentally examined through the deep hole drilling of plastic and simultaneous drilling of metal/plastic stack plates. It was confirmed that the deep hole drilling and simultaneous drilling could be performed without generating vibration by controlling the tool feed rate in the appropriate range.

Keywords: constant load feed machining, robotic drilling, deep hole, simultaneous drilling

Procedia PDF Downloads 194

Authors: Juan Huang, Hugo Ninanya

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Oil has been used as a source of energy and supply to make materials, such as asphalt or rubber for many years. This is the reason why new technologies have been implemented through time. However, research still needs to continue increasing due to new challenges engineers face every day, just like unconventional reservoirs. Various numerical methodologies have been applied in petroleum engineering as tools in order to optimize the production of reservoirs before drilling a wellbore, although not all of these have the same efficiency when talking about studying fracture propagation. Analytical methods like those based on linear elastic fractures mechanics fail to give a reasonable prediction when simulating fracture propagation in ductile materials whereas numerical methods based on the cohesive zone method (CZM) allow to represent the elastoplastic behavior in a reservoir based on a constitutive model; therefore, predictions in terms of displacements and pressure will be more reliable. In this work, a hydro-geomechanical coupled model of horizontal wells in fractured rock was developed using ABAQUS; both extended element method and cohesive elements were used to represent predefined fractures in a model (2-D). A power law for representing the rheological behavior of fluid (shear-thinning, power index <1) through fractures and leak-off rate permeating to the matrix was considered. Results have been showed in terms of aperture and length of the fracture, pressure within fracture and fluid loss. It was showed a high infiltration rate to the matrix as power index decreases. A sensitivity analysis is conclusively performed to identify the most influential factor of fluid loss.

Keywords: fracture, hydro-geomechanical model, non-Newtonian fluid, numerical analysis, sensitivity analysis

Procedia PDF Downloads 205

Authors: S. Jahangir, S. H. I. Jaffery, M. Khan, Z. Zareef, A. Yar, A. Mubashir, S. Butt, L. Ali

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In this work, drilling responses and behavior of MMC was investigated in Al-Mg2Si composites. For the purpose Al-15% wt. Mg2Si, was selected from the hypereutectic region of Al- Mg2Si phase diagram. Based on hardness and tensile strength, drill bit of appropriate material and morphology was selected. The performance of different drill bits of different morphology and material was studied and analysed using experimental data. For theoretical calculations of axial thrust force and required power calculation, material factor “K” was obtained from different data charts and at the same time cutting forces (drilling forces) were practically obtained using a Peizo electric force dynamometer. These results show the role of reinforcement particles on the machinability of MMCs and provide a useful guide for a better control and optimized drilling parameters for the drilling process. Furthermore, in this work, comparison of MMC with non -reinforced Aluminum Alloy regarding drilling operation was also studied.

Keywords: drilling, metal matrix composite (MMC), cutting forces, thrust force

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Authors: G. H. Li, M. Liu, H. J. Qi, Q. Zhu, W. Z. He

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The drilling and riveting processes are widely used in the assembly of carrier rocket, which makes the efficiency and quality of drilling become the important factor affecting the assembly process. According to the problem existing in the drilling of thick stacked plate (thickness larger than 10mm) of carrier rocket, such as drill break, large noise and burr etc., experimental study of the influence of tool material on the drilling was carried out. The cutting force was measured by a piezoelectric dynamometer, the aperture was measured with an outline projector, and the burr is observed and measured by a digital stereo microscope. Through the measurement, the effects of tool material on the drilling were analyzed from the aspects of drilling force, diameter, and burr. The results show that, compared with carbide drill and coated carbide one, the drilling force of high speed steel is larger. But, the application of high speed steel also has some advantages, e.g. a higher number of hole can be obtained, the height of burr is small, the exit is smooth and the slim burr is less, and the tool experiences wear but not fracture. Therefore, the high speed steel tool is suitable for the drilling of thick stacked plate of 2219 Aluminum alloy.

Keywords: 2219 aluminum alloy, thick stacked plate, drilling, tool material

Procedia PDF Downloads 235

Authors: Vinda B. Manurung, Laila Warkhaida, David Hutabarat, Sentanu Wisnuwardhana, Christovik Simatupang, Dhani Sanjaya, Ashadi, Redha B. Putra, Kiki Yustendi

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The geothermal drilling environment presents many obstacles that have limited the use of directional drilling and logging-while-drilling (LWD) technologies, such as borehole washout, mud losses, severe vibration, and high temperature. The case study presented in this paper demonstrates a practice to enhance data logging in geothermal drilling by deploying advanced telemetry and LWD technologies. This operation is aiming continuous improvement in geothermal drilling operations. The case study covers a 12.25-in. hole section of well XX-05 in Pad XX of the Sorik Marapi Geothermal Field. LWD string consists of electromagnetic (EM) telemetry, pressure while drilling (PWD), vibration (DDSr), and acoustic calliper (ACAL). Through this tool configuration, the operator acquired drilling mechanics and caliper logs in real-time and recorded mode, enabling effective monitoring of wellbore stability. Throughout the real-time acquisition, EM-PPM telemetry had provided a three times faster data rate to the surface unit. With the integration of Caliper data and Drilling mechanics data (vibration and ECD -equivalent circulating density), the borehole conditions were more visible to the directional driller, allowing for better control of drilling parameters to minimize vibration and achieve optimum hole cleaning in washed-out or tight formation sequences. After reaching well TD, the recorded data from the caliper sensor indicated an average of 8.6% washout for the entire 12.25-in. interval. Washout intervals were compared with loss occurrence, showing potential for the caliper to be used as an indirect indicator of fractured intervals and validating fault trend prognosis. This LWD case study has given added value in geothermal borehole characterization for both drilling operation and subsurface. Identified challenges while running LWD in this geothermal environment need to be addressed for future improvements, such as the effect of tool eccentricity and the impact of vibration. A perusal of both real-time and recorded drilling mechanics and caliper data has opened various possibilities for maximizing sensor usage in future wells.

Keywords: geothermal drilling, geothermal formation, geothermal technologies, logging-while-drilling, vibration, caliper, case study

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Authors: İkbal Eski

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This investigation is researched on design of robust neural network predictors for analyzing vibration effects on moving parts of a drilling machine. Moreover, the research is divided two parts; first part is experimental investigation, second part is simulation analysis with neural networks. Therefore, a real time the drilling machine is used to vibrations during working conditions. The measured real vibration parameters are analyzed with proposed neural network. As results: Simulation approaches show that Radial Basis Neural Network has good performance to adapt real time parameters of the drilling machine.

Keywords: artificial neural network, vibration analyses, drilling machine, robust

Procedia PDF Downloads 392

Authors: Mohammadjavad Palimi, D. Y. Li, E. Kuru

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Emulsion-based drilling fluids containing mineral oil are commonly used for drilling operations, which generate a lubricating film to prevent direct contact between moving metal parts, thus reducing friction, wear, and corrosion. For long-lasting lubrication, the thin lubricating film formed on the metal surface should possess good anti-wear and anti-corrosion capabilities. This study aims to investigate the effects of two additives, TERGITOL NP-9 and PEG-10 oleyl phosphate, acting as surfactant and corrosion inhibitor, respectively, on the tribo-corrosion behavior of 1018 carbon steel immersed in 5% KCl solution at room temperature. A pin-on-disc tribometer attached to an electrochemical system was used to investigate the corrosive wear of the steel immersed in emulsion-based fluids containing the surfactant and corrosion inhibitor. The wear track, surface chemistry and composition of the protective film formed on the steel surface were analyzed with an optical profilometer, SEM, and SEM-EDX. Results of the study demonstrate that the performance of the emulsion-based drilling fluids was significantly improved by the corrosion inhibitor by a remarkable reduction in corrosion, coefficient of friction (COF) and wear.

Keywords: corrosion inhibitor, emulsion-based drilling fluid, tribo-corrosion, friction, wear

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Authors: Heqian Zhao, Huaizhong Shi, Zhongwei Huang, Zhengliang Chen, Ziang Gu, Fei Gao

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Hydraulics mechanics is significantly important in the drilling process of oil or gas exploration, especially for the drill bit. The fluid flows through the nozzles on the bit and generates a water jet to remove the cutting at the bottom hole. In this paper, a simplified bottom hole model is established. The Particle Image Velocimetric (PIV) is used to capture the flow field of the single nozzle. Due to the limitation of the bottom and wellbore, the potential core is shorter than that of the free water jet. The velocity magnitude rapidly attenuates when fluid close to the bottom is lower than about 5 mm. Besides, a vortex zone appears near the middle of the bottom beside the water jet zone. A modified exponential function can be used to fit the centerline velocity well. On the one hand, the results of this paper can provide verification for the numerical simulation of the bottom hole flow field. On the other hand, it also can provide an experimental basis for the hydraulic design of the drill bit.

Keywords: oil and gas, hydraulic mechanic of drilling, PIV, bottom hole

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Authors: Vimanyu Chadha, Ranganath M. Singari

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Drilling composite materials is a frequently practiced machining process during assembling in various industries such as automotive and aerospace. However, drilling of glass fiber reinforced plastic (GFRP) composites is significantly affected by damage tendency of these materials under cutting forces such as thrust force and torque. The aim of this paper is to investigate the influence of the various cutting parameters such as cutting speed and feed rate; subsequently also to study the influence of number of layers on delamination produced while drilling a GFRP composite. A plan of experiments, based on Taguchi techniques, was instituted considering drilling with prefixed cutting parameters in a hand lay-up GFRP material. The damage induced associated with drilling GFRP composites were measured. Moreover, Analysis of Variance (ANOVA) was performed to obtain minimization of delamination influenced by drilling parameters and number layers. The optimum drilling factor combination was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that feed rate was the most influential factor on the delamination. The best results of the delamination were obtained with composites with a greater number of layers at lower cutting speeds and feed rates.

Keywords: analysis of variance, delamination, design optimization, drilling, glass fiber reinforced plastic composites, Taguchi method

Procedia PDF Downloads 258

Authors: Anwaar O. Ali, Mahmoud Fathy Mubarak, Mahmoud Ibrahim Abdou, Hector Cano Esteban, Amany A. Aboulrous

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Corrosion resistance and lubrication are crucial characteristics required for geothermal drilling fluids. In this study, a ZnO/Fe₂O₃ nanocomposite was fabricated and incorporated into the structure of Cetyltrimethylammonium bromide (CTAB). Several physicochemical techniques were utilized to analyze and describe the synthesized nanomaterials. The surface morphology of the composite was assessed through scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDAX). The corrosion inhibition capabilities of these materials were explored across various corrosive environments. The weight loss and electrochemical methods were utilized to determine the corrosion inhibition activity of the prepared nanomaterials. The results demonstrate a high level of protection achieved by the composite. Additionally, the lubricant coefficient and extreme pressure properties were evaluated.

Keywords: nanofluid, corrosion, geothermal drilling fluids, ZnO/Fe2O3

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Authors: Rupita Ghosh, Ritwik Sarkar, Sumit K. Pal, Soumitra Paul

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The use of Hydroxyapatite bioceramics as restorative implants is widely known. These materials can be manufactured by pressing and sintering route to a particular shape. However machining processes are still a basic requirement to give a near net shape to those implants for ensuring dimensional and geometrical accuracy. In this context, optimising the machining parameters is an important factor to understand the machinability of the materials and to reduce the production cost. In the present study a method has been optimized to produce true particulate drilled composite of Hydroxyapatite Yttrium Phosphate. The phosphates are used in varying ratio for a comparative study on the effect of flexural strength, hardness, machining (drilling) parameters and bioactivity.. The maximum flexural strength and hardness of the composite that could be attained are 46.07 MPa and 1.02 GPa respectively. Drilling is done with a conventional radial drilling machine aided with dynamometer with high speed steel (HSS) and solid carbide (SC) drills. The effect of variation in drilling parameters (cutting speed and feed), cutting tool, batch composition on torque, thrust force and tool wear are studied. It is observed that the thrust force and torque varies greatly with the increase in the speed, feed and yttrium phosphate content in the composite. Significant differences in the thrust and torque are noticed due to the change of the drills as well. Bioactivity study is done in simulated body fluid (SBF) upto 28 days. The growth of the bone like apatite has become denser with the increase in the number of days for all the composition of the composites and it is comparable to that of the pure hydroxyapatite.

Keywords: Bioactivity, Drilling, Hydroxyapatite, Yttrium Phosphate

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Authors: Abdulaziz F. Ettir, Ghait Bashir, Tarek S. Duzan

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A proper well planning is very vital to achieve any successful drilling program on the basis of preventing, overcome all drilling problems and minimize cost operations. Since the hydraulic system plays an active role during the drilling operations, that will lead to accelerate the drilling effort and lower the overall well cost. Likewise, an improperly designed hydraulic system can slow drill rate, fail to clean the hole of cuttings, and cause kicks. In most cases, common sense and commercially available computer programs are the only elements required to design the hydraulic system. Drilling optimization is the logical process of analyzing effects and interactions of drilling variables through applied drilling and hydraulic equations and mathematical modeling to achieve maximum drilling efficiency with minimize drilling cost. In this paper, practical software adopted in this paper to define drilling optimization models including four different optimum keys, namely Opti-flow, Opti-clean, Opti-slip and Opti-nozzle that can help to achieve high drilling efficiency with lower cost. The used data in this research from vertical and horizontal wells were recently drilled in Waha Oil Company fields. The input data are: Formation type, Geopressures, Hole Geometry, Bottom hole assembly and Mud reghology. Upon data analysis, all the results from wells show that the proposed program provides a high accuracy than that proposed from the company in terms of hole cleaning efficiency, and cost break down if we consider that the actual data as a reference base for all wells. Finally, it is recommended to use the established Optimization calculations software at drilling design to achieve correct drilling parameters that can provide high drilling efficiency, borehole cleaning and all other hydraulic parameters which assist to minimize hole problems and control drilling operation costs.

Keywords: optimum keys, namely opti-flow, opti-clean, opti-slip and opti-nozzle

Procedia PDF Downloads 319

Authors: Navid Zarif Karimi, Giangiacomo Minak, Parnian Kianfar

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Drilling is one of the most frequently used machining process for glass fiber reinforced polymer composites due to the need for structural joining. In drilling of composite laminates, interlaminar cracking, or delamination, has a detrimental effect on the compressive strength of these materials. The delamination can be controlled by adopting proper drilling condition. In this paper, the effect of feed rate, cutting speed and drill point angle on delamination and residual compressive strength of drilled GFRPs is studied. The objective is to find optimal conditions for maximum residual compressive strength.

Keywords: composite material, delamination, drilling, residual compressive strength

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Authors: Shokoufeh Sadeghifard

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This study is a review of the nature of soil arching that develops in the upper layer of soil during drilling processes before pulling product pipe inside the hole. This study is based on the results of some parametric studies which are investigating the behavior of drained sandy soil above HDD borehole using Plaxis finite element solution. The influence of drilling mud injection in these series of analyses has been ignored. However, a suitable drilling mud pressure helps to achieve stable arch when the height of soil cover over the drilling borehole is not enough. In this study, the soil response to the formation of a HDD borehole is compared to arching theory developed by Terzaghi (1943). It is found that Terzaghi’s approach is capable of describing all of the behaviour seen when a stable arch forms. According to the numerical results, a suitable safe depth of 4D, D is borehole diameter, is suggested for typical range of HDD borehole in sandy soil.

Keywords: HDD, Plaxis, finite element, arching, settlement, drilling

Procedia PDF Downloads 355

Authors: Pranjal Srivastava, Piyali Sengupta

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The performance of marine drilling risers is crucial in the offshore oil and gas industry to ensure safe drilling operation with minimum downtime. Experimental investigations on marine drilling risers are limited in the literature owing to the expensive and exhaustive test setup required to replicate the realistic riser model and ocean environment in the laboratory. Therefore, this study presents an analytical model of marine drilling riser for determining its fragility under ocean environmental loading. In this study, the marine drilling riser is idealized as a continuous beam having a concentric circular cross-section. Hydrodynamic loading acting on the marine drilling riser is determined by Morison’s equations. By considering the equilibrium of forces on the marine drilling riser for the connected and normal drilling conditions, the governing partial differential equations in terms of independent variables z (depth) and t (time) are derived. Subsequently, the Runge Kutta method and Finite Difference Method are employed for solving the partial differential equations arising from the analytical model. The proposed analytical approach is successfully validated with respect to the experimental results from the literature. From the dynamic analysis results of the proposed analytical approach, the critical design parameters peak displacements, upper and lower flex joint rotations and von Mises stresses of marine drilling risers are determined. An extensive parametric study is conducted to explore the effects of top tension, drilling depth, ocean current speed and platform drift on the critical design parameters of the marine drilling riser. Thereafter, incremental dynamic analysis is performed to derive the fragility functions of shallow water and deep-water marine drilling risers under ocean environmental loading. The proposed methodology can also be adopted for downtime estimation of marine drilling risers incorporating the ranges of uncertainties associated with the ocean environment, especially at deep and ultra-deepwater.

Keywords: drilling riser, marine, analytical model, fragility

Procedia PDF Downloads 146

Authors: Panagiotis Kyratsis, Konstantinos Kakoulis

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Nowadays, the rapid development of CAD systems’ programming environments results in the creation of multiple downstream applications, which are developed and becoming increasingly available. CAD based manufacturing simulations is gradually following the same trend. Drilling is the most popular hole-making process used in a variety of industries. A specially built piece of software that deals with the drilling kinematics is presented. The cutting forces are calculated based on the tool geometry, the cutting conditions and the tool/work piece materials. The results are verified by experimental work. Finally, the response surface methodology (RSM) is applied and mathematical models of the total thrust force and the thrust force developed because of the main cutting edges are proposed.

Keywords: CAD, application programming interface, response surface methodology, drilling, RSM

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Authors: John Eric C. Bargas, Maria Cecilia M. Marcos

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One of the most common ground improvement techniques is Deep Soil Mixing (DSM). As the technique progresses, there is still lack in the development when it comes to depth control. This was the issue experienced during the installation of DSM in one of the National projects in the Philippines. This study assesses the feasibility of using equipment drilling parameters such as hydraulic pressure, drilling speed and rotational speed in determining the Standard Penetration Test N-value of a specific soil. Hydraulic pressure and drilling speed with a constant rotational speed of 30 rpm have a positive correlation with SPT N-value for cohesive soil and sand. A linear trend was observed for cohesive soil. The correlation of SPT N-value and hydraulic pressure yielded a R²=0.5377 while the correlation of SPT N-value and drilling speed has a R²=0.6355. While the best fitted model for sand is polynomial trend. The correlation of SPT N-value and hydraulic pressure yielded a R²=0.7088 while the correlation of SPT N-value and drilling speed has a R²=0.4354. The low correlation may be attributed to the behavior of sand when the auger penetrates. Sand tends to follow the rotation of the auger rather than resisting which was observed for very loose to medium dense sand. Specific Energy and the product of hydraulic pressure and drilling speed yielded same R² with a positive correlation. Linear trend was observed for cohesive soil while polynomial trend for sand. Cohesive soil yielded a R²=0.7320 which has a strong relationship. Sand also yielded a strong relationship having a coefficient of determination, R²=0.7203. It is feasible to use hydraulic pressure and drilling speed to estimate the SPT N-value of the soil. Also, the product of hydraulic pressure and drilling speed can be a substitute to specific energy when estimating the SPT N-value of a soil. However, additional considerations are necessary to account for other influencing factors like ground water and physical and mechanical properties of soil.

Keywords: ground improvement, equipment drilling parameters, standard penetration test, deep soil mixing

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Authors: Marzieh Zarei

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Well instability is one of the most fundamental challenges faced by the oil and gas industry. Well wall stability analysis is a gap to be filled in the oil industry. The collection of static data such as well logging leads to the construction of a geomechanical numerical model, which will help in assessing the probable risks in future drilling. In this paper, geomechanical model was designed, and mechanical properties of the rock was determined at all points of the model. It was found the safe mud window was determined and the minimum and maximum mud pressures were determined in the ranges of 70-60 MPa and 110-100 MPa, respectively.

Keywords: geomechanics, numerical model, well stability, in-situ stress, underbalanced drilling

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Authors: Abbas Hadj Abbas, Hacini Massaoud, Aiad Lahcen

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In Hassi-Messoud’s oil industry, the systems which are water based (WBM) are generally used for drilling in the first phase. For the rest of the well, the oil mud systems are employed (OBM). In the field of oil exploration, panoply of chemical products is employed in the drilling fluids formulation. These components of different natures and whose toxicity and biodegradability are of ill-defined parameters are; however, thrown into nature. In addition to the hydrocarbon (HC, such as diesel) which is a major constituent of oil based mud, we also can notice spills as well as a variety of other products and additives on the drilling sites. These wastes are usually stored in places called (crud wastes). These may cause major problems to the ecosystem. To treat these wastes, we have considered two methods which are: solidification/ stabilization (chemical) and thermal. So that we can evaluate the techniques of treatment, a series of analyses are performed on dozens of specimens of wastes before treatment. After that, and on the basis of our analyses of wastes, we opted for diagnostic treatments of pollution before and after solidification and stabilization. Finally, we have done some analyses before and after the thermal treatment to check the efficiency of the methods followed in the study.

Keywords: wastes treatment, the oil pollution, the norms, wastes drilling

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Authors: Hamid Rezaei, Xiaotao Bi, C. Jim Lim, Anthony Lau, Shahab Sokhansanj

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A one-dimensional heat transfer model coupled with the kinetic information has been used to predict the overall pyrolysis mass loss of a single wood particle. The kinetic parameters were determined experimentally and the regime and characteristics of the conversion were evaluated in terms of the particle size and reactor temperature. The order of overall mass loss changed from n=1 at temperatures lower than 350 °C to n=0.5 at temperatures higher that 350 °C. Conversion time analysis showed that particles larger than 0.5 mm were controlled by internal thermal resistances. The valid range of particle size to use the simplified lumped model depends on the fluid temperature around the particles. The critical particle size was 0.6-0.7 mm for the fluid temperature of 500 °C and 0.9-1.0 mm for the fluid temperature of 100 °C. Experimental pyrolysis of moist particles did not show distinct drying and pyrolysis stages. The process was divided into two hypothetical drying and pyrolysis dominated zones and empirical correlations are developed to predict the rate of mass loss in each zone.

Keywords: pyrolysis, kinetics, model, single particle

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Authors: Hadi Rezghimaleki, Masatoshi Kubouchi, Yoshihiko Arao

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The use of natural fiber composites (NFCs) is growing at a fast rate regarding industrial applications and principle researches due to their eco-friendly, renewable nature, and low density/costs. Drilling is one of the most important machining operations that are carried out on natural fiber composites. Delamination is a major concern in the drilling process of NFCs that affects the structural integrity and long-term reliability of the machined components. Flax fiber reinforced epoxy composite laminates were prepared by hot press technique. In this research, we evaluated drilling-induced delamination of flax/epoxy composites by X-ray computed tomography (CT), ultrasonic testing (UT), and optical methods and compared the results.

Keywords: natural fiber composites, flax/epoxy, X-ray CT, ultrasonic testing

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Authors: Joao Victor Borges Dos Santos, Thomas Richard, Yevhen Kovalyshen

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Down-the-hole (DTH) percussive drilling is an excavation method that is widely used in the mining industry due to its high efficiency in fragmenting hard rock formations. A DTH hammer system consists of a fluid driven (air or water) piston and a drill bit; the reciprocating movement of the piston transmits its kinetic energy to the drill bit by means of stress waves that propagate through the drill bit towards the rock formation. In the literature of percussive drilling, the existence of an optimum drilling state (Sweet Spot) is reported in some laboratory and field experimental studies. An optimum rate of penetration is achieved for a specific range of axial thrust (or weight-on-bit) beyond which the rate of penetration decreases. Several authors advance different explanations as possible root causes to the occurrence of the Sweet Spot, but a universal explanation or consensus does not exist yet. The experimental investigation in this work was initiated with drilling experiments conducted at a mining site. A full-scale drilling rig (equipped with a DTH hammer system) was instrumented with high precision sensors sampled at a very high sampling rate (kHz). Data was collected while two boreholes were being excavated, an in depth analysis of the recorded data confirmed that an optimum performance can be achieved for specific ranges of input thrust (weight-on-bit). The high sampling rate allowed to identify the bit penetration at each single impact (of the piston on the drill bit) as well as the impact frequency. These measurements provide a direct method to identify when the hammer does not fire, and drilling occurs without percussion, and the bit propagate the borehole by shearing the rock. The second stage of the experimental investigation was conducted in a laboratory environment with a custom-built equipment dubbed Woody. Woody allows the drilling of shallow holes few centimetres deep by successive discrete impacts from a piston. After each individual impact, the bit angular position is incremented by a fixed amount, the piston is moved back to its initial position at the top of the barrel, and the air pressure and thrust are set back to their pre-set values. The goal is to explore whether the observed optimum drilling state stems from the interaction between the drill bit and the rock (during impact) or governed by the overall system dynamics (between impacts). The experiments were conducted on samples of Calca Red, with a drill bit of 74 millimetres (outside diameter) and with weight-on-bit ranging from 0.3 kN to 3.7 kN. Results show that under the same piston impact energy and constant angular displacement of 15 degrees between impact, the average drill bit rate of penetration is independent of the weight-on-bit, which suggests that the sweet spot is not caused by intrinsic properties of the bit-rock interface.

Keywords: optimum drilling state, experimental investigation, field experiments, laboratory experiments, down-the-hole percussive drilling

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Authors: R. Suresh, Pavan Kumar Nimmagadda, Ming Zo Tan, Shane Hart, Sharp Ugwuocha

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Polycrystalline diamond compact (PDC) drill bits are extensively used in the oil and gas industry as well as the mining industry. Industry engineers continually improve upon PDC drill bit designs and hydraulic conditions. Optimized injection nozzles play a key role in improving the drilling performance and efficiency of these ever changing PDC drill bits. In the first part of this study, computational fluid dynamics (CFD) modelling is performed to investigate the hydrodynamic characteristics of drilling fluid flow around the PDC drill bit. An Open-source CFD software – OpenFOAM simulates the flow around the drill bit, based on the field input data. A specifically developed console application integrates the entire CFD process including, domain extraction, meshing, and solving governing equations and post-processing. The results from the OpenFOAM solver are then compared with that of the ANSYS Fluent software. The data from both software programs agree. The second part of the paper describes the parametric study of the PDC drill bit nozzle to determine the effect of parameters such as number of nozzles, nozzle velocity, nozzle radial position and orientations on the flow field characteristics and bit washing patterns. After analyzing a series of nozzle configurations, the best configuration is identified and recommendations are made for modifying the PDC bit design.

Keywords: ANSYS Fluent, computational fluid dynamics, nozzle configuration, OpenFOAM, PDC dill bit

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Authors: Justine Kiiza, Xu Jiafang

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The world’s demand for energy is increasing rapidly due to population growth and a reduction in shallow conventional oil and gas reservoirs, resorting to deeper and mostly unconventional reserves like shale oil and gas. Most shale formations contain a large amount of expansive sodium montmorillonite (Na-Mnt), due to high water adsorption, hydration, and when the drilling fluid filtrate enters the formation with high Mnt content, the wellbore wall can be unstable due to hydration and swelling, resulting to shrinkage, sticking, balling, time wasting etc., and well collapse in extreme cases causing complex downhole accidents and high well costs. Recently, polyamines like 1, 6 – hexane diamine (HEDA) have been used as typical drilling fluid shale inhibitors to minimize and/or cab clay mineral swelling and maintain the wellbore stability. However, their application is limited to shallow drilling due to their sensitivity to elevated temperature and pressure. Inorganic potassium salts i.e., KCl, have long been applied for restriction of shale formation hydration expansion in deep wells, but their use is limited due to toxicity. Understanding the adsorption behaviour of HEDA on Na-Mnt surfaces in present of organo-salts, organic K-salts e.g., HCO₂K - main component of organo-salt drilling fluid, is of great significance in explaining the inhibitory performance of polyamine inhibitors. Molecular dynamic simulations (MD) were applied to investigate the influence of HCO₂K and KCl on the adsorption mechanism of HEDA on the Na-Mnt surface. Simulation results showed that adsorption configurations of HEDA are mainly by terminal amine groups with a flat-lying alkyl hydrophobic chain. Its interaction with the clay surface decreased the H-bond number between H₂O-clay and neutralized the negative charge of the Mnt surface, thus weakening the surface hydration ability of Na-Mnt. The introduction of HCO₂K greatly improved inhibition ability, coordination of interlayer ions with H₂O as they were replaced by K+, and H₂O-HCOO- coordination reduced H₂O-Mnt interactions, mobility and transport capability of H₂O molecules were more decreased. While KCl showed little ability and also caused more hydration with time, HCO₂K can be used as an alternative for offshore drilling instead of toxic KCl, with a maximum concentration noted in this study as 1.65 wt%. This study provides a theoretical elucidation for the inhibition mechanism and adsorption characteristics of HEDA inhibitor on Na-Mnt surfaces in the presence of K+-salts and may provide more insight into the evaluation, selection, and molecular design of new clay-swelling high-performance WBDF systems used in oil and gas complex offshore drilling well sections.

Keywords: shale, hydration, inhibition, polyamines, organo-salts, simulation

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Authors: Eser Yarar, Fahri Vatansever, A. Tamer Erturk, Sedat Karabay

Abstract:

In this study, drilling behavior of multi-layer orthotropic polyester composites reinforced with woven polyester fiber and PTFE particle was investigated. Conventional drilling methods have low cost and ease of use. Therefore, it is one of the most preferred machining methods. The increasing range of use of composite materials in many areas has led to the investigation of the machinability performance of these materials. The drilling capability of the synthetic polymer composite material was investigated by measuring the cutting forces using different tool diameters, feed rate and high cutting speed parameters. Cutting forces were measured using a dynamometer in the experiments. In order to evaluate the results of the experiment, the Taguchi experimental design method was used. According to the results, the optimum cutting parameters were obtained for 0.1 mm/rev, 1070 rpm and 2 mm diameter drill bit. Verification tests were performed for the optimum cutting parameters obtained according to the model. Verification experiments showed the success of the established model.

Keywords: cutting force, drilling, polimer composite, Taguchi

Procedia PDF Downloads 162

Authors: Raed H. Allawi

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Formation pressure is the most critical parameter in hydrocarbon exploration and exploitation. Specifically, predicting abnormal pressures (high formation pressures) and subnormal pressure zones can provide valuable information to minimize uncertainty for anticipated drilling challenges and risks. This study aims to interpret and delineate the pore and fracture pressure of the Mishrif reservoir in the southern Iraq Oilfield. The data required to implement this study included acoustic compression wave, gamma-ray, bulk density, and drilling events. Furthermore, supporting these models needs the pore pressure measurement from the Modular Formation Dynamics Tester (MDT). Many measured values of pore pressure were used to validate the accurate model. Using sonic velocity approaches, the mean absolute percentage error (MAPE) was about 4%. The fracture pressure results were consistent with the measurement data, actual drilling report, and events. The model's results will be a guide for successful drilling in future wells in the same oilfield.

Keywords: pore pressure, fracture pressure, overburden pressure, effective stress, drilling events

Procedia PDF Downloads 83

Authors: Ahmed Z. Mazen, Nejat Rahmanian, Iqbal Mujtaba, Ali Hassanpour

Abstract:

In oil and gas well drilling, the drill bit is an important part of the Bottom Hole Assembly (BHA), which is installed and designed to drill and produce a hole by several mechanisms. The efficiency of the bit depends on many drilling parameters such as weight on bit, rotary speed, and mud properties. When the bit is pulled out of the hole, the evaluation of the bit damage must be recorded very carefully to guide engineers in order to select the bits for further planned wells. Having a worn bit for hole drilling may cause severe damage to bit leading to cutter or cone losses in the bottom of hole, where a fishing job will have to take place, and all of these will increase the operating cost. The main factor to reduce the cost of drilling operation is to maximize the rate of penetration by analyzing real-time data to predict the drill bit wear while drilling. There are numerous models in the literature for prediction of the rate of penetration based on drilling parameters, mostly based on empirical approaches. One of the most commonly used approaches is Bourgoyne and Young model, where the rate of penetration can be estimated by the drilling parameters as well as a wear index using an empirical correlation, provided all the constants and coefficients are accurately determined. This paper introduces a new methodology to estimate the eight coefficients for Bourgoyne and Young model using the gPROMS parameters estimation GPE (Version 4.2.0). Real data collected form similar formations (12 ¼’ sections) in two different fields in Libya are used to estimate the coefficients. The estimated coefficients are then used in the equations and applied to nearby wells in the same field to predict the bit wear.

Keywords: Bourgoyne and Young model, bit wear, gPROMS, rate of penetration

Procedia PDF Downloads 154

Authors: Kadir Gök

Abstract:

In this study, a vacuum system was developed for orthopedic drilling processes, and the most efficient processing parameters were determined using statistical analysis of temperature rise. A reverse engineering technique was used to obtain a 3D model of the chip vacuum system, and the obtained point cloud data was transferred to Solidworks software in STL format. An experimental design method was performed by selecting different parameters and their levels, such as RPM, feed rate, and drill bit diameter, to determine the most efficient processing parameters in temperature rise using ANOVA. Additionally, the bone chip-vacuum device was developed and performed successfully to collect the whole chips and fragments in the bone drilling experimental tests, and the chip-collecting device was found to be useful in removing overheating from the drilling zone. The effects of processing parameters on the temperature levels during the chip-vacuuming were determined, and it was found that bone chips and fractures can be used as autograft and allograft for tissue engineering. Overall, this study provides significant insights into the development of a vacuum system for orthopedic drilling processes and the use of bone chips and fractures in tissue engineering applications.

Keywords: vacuum system, orthopedic drilling, temperature rise, bone chips

Procedia PDF Downloads 98

Authors: Hasan Al Dabbas

Abstract:

In this paper, it is addressed that the mechanical machinery captures a major share of innovation in drilling and milling chucks technology. Users demand higher speeds in milling because they are cutting more aluminum and are relying on higher speeds to eliminate secondary finishing operations. To meet that demand, milling-machine builders have enhanced their machine’s rigidity. Moreover, faster cutting has caught up with boring mills. Cooling these machine’s internal components is a challenge at high speeds. Another trend predicted that it is more use of controlled axes to let the machines do many more operations on 5 sides without having to move or re-fix the work. Advances of technology in mechanical engineering have helped to make high-speed machining equipment. To accompany these changes in milling and drilling machines chucks, the demand of easiest software is increased. An open architecture controller is being sought that would allow flexibility and information exchange.

Keywords: drilling, milling, chucks, cutting edges, tools, machines

Procedia PDF Downloads 572