Search results for: drilling fluids

Authors: Mubarek Alpkiray, Tan Nguyen, Arild Saasen

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Geothermal drilling operations contain numerous challenges that are encountered to increase the well cost and nonproductive time. Fluid loss is one of the most undesirable troublesome that can cause well abandonment in geothermal drilling. Lost circulation can be seen due to natural fractures, high mud weight, and extremely high formation temperatures. This challenge may cause wellbore stability problems and lead to expensive drilling operations. Wellbore stability is the main domain that should be considered to mitigate or prevent fluid loss into the formation. This paper describes the causes of fluid loss in the Pamukoren geothermal field in Turkey. A geomechanics approach integration and assessment is applied to help the understanding of fluid loss problems. In geothermal drillings, geomechanics is primarily based on rock properties, in-situ stress characterization, the temperature of the rock, determination of stresses around the wellbore, and rock failure criteria. Since a high-temperature difference between the wellbore wall and drilling fluid is presented, temperature distribution through the wellbore is estimated and implemented to the wellbore stability approach. This study reviewed geothermal drilling data to analyze temperature estimation along the wellbore, the cause of fluid loss and stored electric capacity of the reservoir. Our observation demonstrates the geomechanical approach's significant role in understanding safe drilling operations on high-temperature wells. Fluid loss is encountered due to thermal stress effects around the borehole. This paper provides a wellbore stability analysis for a geothermal drilling operation to discuss the causes of lost circulation resulting in nonproductive time and cost.

Keywords: geothermal wells, drilling, wellbore stresses, drilling fluid loss, thermal stress

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Authors: Iftikhar Raza

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Well control is the management of the hazardous effects caused by the unexpected release of formation fluid, such as natural gas and/or crude oil, upon surface equipment of oil or gas drilling rigs and escaping into the atmosphere. Technically, oil well control involves preventing the formation fluid, usually referred to as kick, from entering into the wellbore during drilling. Oil well control is one of the most important aspects of drilling operations. Improper handling of kicks in oil well control can result in blowouts with very grave consequences, including the loss of valuable resources. Even though the cost of a blowout (as a result of improper/no oil well control) can easily reach several millions of US dollars, the monetary loss is not as serious as the other damages that can occur: irreparable damage to the environment, waste of valuable resources, ruined equipment, and most importantly, the safety and lives of personnel on the drilling rig. In this paper, case study of a well is discussed with field data showing the properties of the well. The whole procedure of controlling this well is illustrated in this which may be helpful for professional dealing with such kind of problems.

Keywords: kick control, kill sheet, oil well, gas drilling

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Authors: Lina Ismail Jassim, Robiah Yunus

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To successfully drill oil or gas well, two main characteristics of numerous other tasks of an efficient drilling fluid are required, which are suspended and carrying cuttings from the beneath wellbore to the surface and managed between pore (formation) and hydrostatic pressure (mud pressure). Several factors like mud composition and its rheology, wellbore design, drilled cuttings characteristics and drilling string rotation contribute to drill wellbore successfully. Simulation model can support an appropriate indication on the drilling fluid performance in the real field as Genting Timur field, located in Pahang in Malaysia on 4295 m depth, held the world record in Sempah Muda 1 (Vertical). A detailed 3 dimensional CFD analysis of vertical, concentric annular two phase flow was developed to study and asses Herschel Bulkley drilling fluid. The effect of Hematite, Barite and calcium carbonates types and size of cutting rock particles on such flow is analyzed. The vertical flows are also associated with a good amount of temperature variation along the depth. This causes a good amount of change in viscosity of the fluid, which is non-Newtonian in nature. Good understanding of the nature of such flows is imperative in developing and maintaining successful vertical well systems. A detailed analysis of flow characteristics due to the drill pipe rotation is done in this work. The inner cylinder of the annulus gets different rotational speed, depending upon the operating conditions. This speed induces a good swirl on the particles and primary fluids which interpret in Ester based drilling fluid cleaning well ability, which in turn determines energy loss along the pipe. Energy loss is assessed in this work in terms of wall shear stress and pressure drop along the pipe. The flow is under an adverse pressure gradient condition, which causes chance of reversed flow and transfers the rock cuttings to the surface.

Keywords: concentric annulus, non-Newtonian, two phase, Herschel Bulkley

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

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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

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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

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

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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

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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: Kadir Gök

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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

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Authors: Fabio R. Pires, Paulo R. C. C. Ribeiro, Douglas G. Viana, Robson Bonomo, Fernando B. Egreja Filho, Alberto Cargnelutti Filho, Luiz F. Martins, Leila B. S. Cruz, Mauro C. P. Nascimento

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The use of barite (BaSO₄) as a weighting agent in drilling fluids for oil and gas activities makes barium a potential contaminant in the case of spills onto flooded soils, where barium sulfate solubility is increased due to low redox conditions. In order to select plants able to remove barium in such scenarios, seven plant species were evaluated on barium phytoextraction capacity: Brachiaria arrecta; Cyperus cf. papyrus; Eleocharis acutangula; Eleocharis interstincta; Nephrolepsis cf. rivularis; Paspalum conspersum and Typha domingensis. Plants were grown in pots with 13 kg of soil each, and exposed to six barium concentrations (established with BaCl₂): 0; 2.5; 5.0; 10.0; 30.0; 65.0 mg kg-1. To simulate flooding conditions, every pot was manteined with a thin irrigation water depth over soil surface (~1.0 cm). Treatments were carried out in triplicate, and pots were distributed randomly inside the greenhouse. Biometric and chemical analyses were performed throughout the experiment, including Ba²⁺ accumulation in shoots and roots. The highest amount of barium was observed in T. domingensis biomass, followed by C. cf. papyrus. However, the latter exported most of the barium to shoot, especially in higher BaCl₂ doses, while the former accumulated barium preferentially in roots. Thus, barium removal with C. cf. papyrus could be achieved by simply harvesting aerial biomass. The amount of barium in C. cf. papyrus was a consequence of high biomass production rather than barium concentration in plant tissues, whereas T. domingensis showed high barium concentration in plant tissues and high biomass production as well. These results make T. domingensis and C. cf. papyrus potential candidates to be applied in phytoremediation schemes to remove barium from flooded soils.

Keywords: barium sulfate, cyperus, drilling fluids, phytoextraction, Typha

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Authors: Hasan Al Dabbas

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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

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Authors: Alireza Mehdizadeh, Ghanbarali Sheikhzadeh

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In this paper the pressure loss of drilling fluid flow in the annulus is investigated. On this purpose the domains between two concentric and two eccentric cylinders are considered as computational domains. In this research foam is used as drilling fluid. Firstly simulation results for laminar flow and non Newtonian fluid and different density like 100, 200, 300 kg/m3 and different inner cylinder rotational velocity like 100, 200, 300 RPM is presented. These results are compared and matched with references results. The power law and Herschel Bulkly methods are used for non Newtonian fluid modeling. After that computations are repeated with turbulence flow considering. K- Model is used for turbulence modeling. Results show that in laminar flow Herschel bulkly model has best result in comparison with power law model. And pressure loss in turbulence flow is higher than laminar flow.

Keywords: simulation, concentric cylinders, drilling, non Newtonian

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Authors: C. Njoku Paul

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This paper deals with systems engineering applications design for offshore oil drilling production platform in the Nigerian Marine Environment. Engineering Design model of the distribution and accumulation of petroleum hydrocarbons discharged into marine environment production platform and sources of impact of an offshore is treated.

Keywords: design of offshore oil drilling production platform, marine, environment, petroleum hydrocarbons

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Authors: Sidharth Talan, Sanjay Kumar Sharma, Eoin Joseph Wallace, Nikita Agrawal

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Underground mining is at the core of rapidly evolving metals and minerals sector due to the increasing mineral consumption globally. Even though the surface mines are still more abundant on earth, the scales of industry are slowly tipping towards underground mining due to rising depth and complexities of orebodies. Thus, the efficient and productive functioning of underground operations depends significantly on the synchronized performance of key elements such as operating site, mining equipment, manpower and mine services. Production drilling is the process of conducting long hole drilling for the purpose of charging and blasting these holes for the production of ore in underground metal mines. Thus, production drilling is the crucial segment in the underground metal mining value chain. This paper presents the process mapping tool to evaluate the production drilling process in the underground metal mining operation by dividing the given process into three segments namely Input, Process and Output. The three segments are further segregated into factors and sub-factors. As per the study, the major input factors crucial for the efficient functioning of production drilling process are power, drilling water, geotechnical support of the drilling site, skilled drilling operators, services installation crew, oils and drill accessories for drilling machine, survey markings at drill site, proper housekeeping, regular maintenance of drill machine, suitable transportation for reaching the drilling site and finally proper ventilation. The major outputs for the production drilling process are ore, waste as a result of dilution, timely reporting and investigation of unsafe practices, optimized process time and finally well fragmented blasted material within specifications set by the mining company. The paper also exhibits the drilling loss matrix, which is utilized to appraise the loss in planned production meters per day in a mine on account of availability loss in the machine due to breakdowns, underutilization of the machine and productivity loss in the machine measured in drilling meters per unit of percussion hour with respect to its planned productivity for the day. The given three losses would be essential to detect the bottlenecks in the process map of production drilling operation so as to instigate the action plan to suppress or prevent the causes leading to the operational performance deficiency. The given tool is beneficial to mine management to focus on the critical factors negatively impacting the production drilling operation and design necessary operational and maintenance strategies to mitigate them. 

Keywords: process map, drilling loss matrix, SIPOC, productivity, percussion rate

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Authors: M. A. Moghaddas, M. Short, N. Wiley, A. Y. Yi, K. F. Graff

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The application of ultrasonic vibrations to machining processes has a long history, ranging from slurry-based systems able to drill brittle materials, to more recent developments involving low power ultrasonics for high precision machining, with many of these at the research and laboratory stages. The focus of this development is the application of high levels of ultrasonic power (1,000’s of watts) to standard, heavy duty machine tools – drilling being the immediate focus, with developments in milling in progress – with the objective of dramatically increasing system productivity through faster feed rates, this benefit arising from the thrust force reductions obtained by power ultrasonic vibrations. The presentation will describe development of an advanced drilling system based on a special, acoustically designed, rugged drill module capable of functioning under heavy duty production conditions, and making use of standard tool holder means, and able to obtain thrust force reductions while maintaining or improving surface finish and drilling accuracy. The characterization of the system performance will be described, and results obtained in drilling several materials (Aluminum, Stainless steel, Titanium) presented.

Keywords: dimensional accuracy, machine tool, productivity, surface roughness, thrust force, ultrasonic vibrations, ultrasonic-assisted drilling

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Authors: Sikiru Oluwarotimi Ismail, Hom Nath Dhakal, Anish Roy, Dong Wang, Ivan Popov

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The ultrasonically-assisted drilling (UAD) is a non-traditional technique which involves the superimposition of a high frequency and low amplitude vibration, usually greater than 18kHz and less than 20µm respectively, on a drill bit along the feed direction. UAD has remarkable advantages over the conventional drilling (CD), especially the high drilling-force reduction. Force reduction improves the quality of the drilled holes, reduces power consumption rate and cost of production. Nevertheless, in addition to the setbacks of UAD including expensiveness of set-up, unpredicted results and chipping effects, this paper presents the problems of insignificant force reduction and poor surface quality during UAD of hemp fibre-reinforced composites (HFRCs), a natural composite, with polycaprolactone (PCL) matrix. The experimental results obtained depict that HFRCs/PCL samples have more burnt chip-materials attached on the drilled holes during UAD than CD. This effect produced a very high surface roughness (Ra), up to 13µm. In a bid to reduce these challenges, different drilling parameters (feed rates and cutting speeds, frequencies and amplitudes for UAD), conditions (dry machining and airflow cooling) and diameters of drill bits (3mm and 6mm of high speed steel), as well as HFRCs/PCL samples of various fibre aspect ratios, including 0 (neat), 19, 26, 30 and 38 have been used. However, the setbacks still persisted. Evidently, the benefits of UAD are not obtainable for the drilling of the HFRCs/PCL laminates. These problems occurred due to the 60 °C melting temperature of PCL, quite lower than 56-90.2 °C and 265–290.8 °C composite-tool interface temperature during CD and UAD respectively.

Keywords: force reduction, hemp fibre-reinforced composites, ultrasonically-assisted drilling, surface quality

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Authors: Vishwanath Mali, Hemant Warhatkar, Raju Pawade

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Drilling of bone has been always challenging for surgeons due to the adverse effect it may impart to bone tissues. Force has to be applied manually by the surgeon while performing conventional bone drilling which may lead to permanent death of bone tissues and nerves. During bone drilling the temperature of the bone tissues increases to higher values above 47 ⁰C that causes thermal osteonecrosis resulting into screw loosening and subsequent implant failures. An attempt has been made here to study the input drilling parameters and surgical drill bit geometry affecting bone health during bone drilling. A One Factor At a Time (OFAT) method is used to plan the experiments. Input drilling parameters studied include spindle speed and feed rate. The drill bit geometry parameter studied include point angle and helix angle. The output variables are drilling thrust force and bone temperature. The experiments were conducted on goat femur bone at room temperature 30 ⁰C. For measurement of thrust forces KISTLER cutting force dynamometer Type 9257BA was used. For continuous data acquisition of temperature NI LabVIEW software was used. Fixture was made on RPT machine for holding the bone specimen while performing drilling operation. Bone specimen were preserved in deep freezer (LABTOP make) under -40 ⁰C. In case of drilling parameters, it is observed that at constant feed rate when spindle speed increases, thrust force as well as temperature decreases and at constant spindle speed when feed rate increases thrust force as well as temperature increases. The effect of drill bit geometry shows that at constant helix angle when point angle increases thrust force as well as temperature increases and at constant point angle when helix angle increase thrust force as well as temperature decreases. Hence it is concluded that as the thrust force increases temperature increases. In case of drilling parameter, the lowest thrust force and temperature i.e. 35.55 N and 36.04 ⁰C respectively were recorded at spindle speed 2000 rpm and feed rate 0.04 mm/rev. In case of drill bit geometry parameter, the lowest thrust force and temperature i.e. 40.81 N and 34 ⁰C respectively were recorded at point angle 70⁰ and helix angle 25⁰ Hence to avoid thermal necrosis of bone it is recommended to use higher spindle speed, lower feed rate, low point angle and high helix angle. The hard nature of cortical bone contributes to a greater rise in temperature whereas a considerable drop in temperature is observed during cancellous bone drilling.

Keywords: bone drilling, helix angle, point angle, thrust force, temperature, thermal necrosis

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Authors: Mohammed T. Hayajneh

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Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al₂O₃ particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.

Keywords: composite, fuzzy, tool life, wear

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Authors: Boualem Chetti, Samir Zahaf

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This paper presents the steady-state performance analysis of a four-lobe journal bearing lubricated with a couple stress fluids operating in the turbulent regime, following Constantinescu’s turbulent lubrication theory. The modified Reynolds equation is solved numerically using the finite difference method taking into consideration the effects of the turbulence and the couple stress. In this analysis, the steady-state parameters in terms of the attitude angle, load carrying capacity, side leakage and friction coefficient are determined at various values of eccentricities ratio. The computed results show that the turbulence increases the load carrying capacity, the attitude angle and the friction coefficient for a journal bearing lubricated with a Newtonian or a couple stress fluids. It is found that the turbulence has strongly influence on the steady-state performances of the four-lobe journal bearing lubricated with Newtonian fluids or a couple stress fluids.

Keywords: Four-lobe journal bearings, static characteristics, couple-stress fluids, turbulent flow

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Authors: Ahmed Borg, Elsa Aristodemou, Attia Attia

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Well control involves managing the circulating drilling fluid within the wells and avoiding kicks and blowouts as these can lead to losses in human life and drilling facilities. Current practices for good control incorporate predictions of pressure losses through computational models. Developing a realistic hydraulic model for a good control problem is a very complicated process due to the existence of a complex multiphase region, which usually contains a non-Newtonian drilling fluid and the miscibility of formation gas in drilling fluid. The current approaches assume an inaccurate flow fluid model within the well, which leads to incorrect pressure loss calculations. To overcome this problem, researchers have been considering the more complex two-phase fluid flow models. However, even these more sophisticated two-phase models are unsuitable for applications where pressure dynamics are important, such as in managed pressure drilling. This study aims to develop and implement new fluid flow models that take into consideration the miscibility of fluids as well as their non-Newtonian properties for enabling realistic kick treatment. furthermore, a corresponding numerical solution method is built with an enriched data bank. The research work considers and implements models that take into consideration the effect of two phases in kick treatment for well control in conventional drilling. In this work, a corresponding numerical solution method is built with an enriched data bank. Software STARCCM+ for the computational studies to study the important parameters to describe wellbore multiphase flow, the mass flow rate, volumetric fraction, and velocity of each phase. Results showed that based on the analysis of these simulation studies, a coarser full-scale model of the wellbore, including chemical modeling established. The focus of the investigations was put on the near drill bit section. This inflow area shows certain characteristics that are dominated by the inflow conditions of the gas as well as by the configuration of the mud stream entering the annulus. Without considering the gas solubility effect, the bottom hole pressure could be underestimated by 4.2%, while the bottom hole temperature is overestimated by 3.2%. and without considering the heat transfer effect, the bottom hole pressure could be overestimated by 11.4% under steady flow conditions. Besides, larger reservoir pressure leads to a larger gas fraction in the wellbore. However, reservoir pressure has a minor effect on the steady wellbore temperature. Also as choke pressure increases, less gas will exist in the annulus in the form of free gas.

Keywords: multiphase flow, well- control, STARCCM+, petroleum engineering and gas technology, computational fluid dynamic

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Authors: S. D. El Wakil, M. Pladsen

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Fiber reinforced polymeric (FRP) composites are finding wide-spread industrial applications because of their exceptionally high specific strength and specific modulus of elasticity. Nevertheless, it is very seldom to get ready-for-use components or products made of FRP composites. Secondary processing by machining, particularly drilling, is almost always required to make holes for fastening components together to produce assemblies. That creates problems since the FRP composites are neither homogeneous nor isotropic. Some of the problems that are encountered include the subsequent damage in the region around the drilled hole and the drilling – induced delamination of the layer of ply, that occurs both at the entrance and the exit planes of the work piece. Evidently, the functionality of the work piece would be detrimentally affected. The current work was carried out with the aim of eliminating or at least minimizing the work piece damage associated with drilling of FPR composites. Each test specimen involves a woven reinforced graphite fiber/epoxy composite having a thickness of 12.5 mm (0.5 inch). A large number of test specimens were subjected to drilling operations with different combinations of feed rates and cutting speeds. The drilling induced damage was taken as the absolute value of the difference between the drilled hole diameter and the nominal one taken as a percentage of the nominal diameter. The later was determined for each combination of feed rate and cutting speed, and a matrix comprising those values was established, where the columns indicate varying feed rate while and rows indicate varying cutting speeds. Next, the analysis of variance (ANOVA) approach was employed using Minitab software, in order to obtain the combination that would improve the drilling induced damage. Experimental results show that low feed rates coupled with low cutting speeds yielded the best results.

Keywords: drilling of composites, dimensional accuracy of holes drilled in composites, delamination and charring, graphite-epoxy composites

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Authors: N. K. Thakur

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A major proportion of the formations drilled for the production of hydrocarbons consists of clay containing shales. The petroleum industry has hugely investigated the role of clay minerals and their subsequent effect on wellbore stability during the drilling and production of hydrocarbons. It has been found that when the shale formation comes in contact with water-based drilling fluid, the interaction of clay minerals like montmorillonite with infiltrated water leads to hydration of the clay minerals, which causes shale swelling. When shale swelling proceeds further, it may lead to major drilling complications like caving, pipe sticking, which invariably influences wellbore stability, wellbore diameter, the mechanical strength of shale, stress distribution in the wellbore, etc. These problems ultimately lead to an increase in nonproductive time and additional costs during drilling. Several additives are used to prevent shale instability. Among the popular additives used for shale inhibition in drilling muds, ionic liquids and nanoparticles are emerging to be the best additives. The efficiency of the proposed additives will be studied and compared with conventional clay inhibitors like KCl. The main objective is to develop a highly efficient water-based mud for mitigating shale instability and reducing fluid loss which is environmentally friendly and does not alter the formation permeability. The use of nanoparticles has been exploited to enhance the rheological and fluid loss properties in water-based drilling fluid ionic liquid have attracted significant research interest due to its unique thermal stability. It is referred to as ‘green chemical’. The preliminary experimental studies performed are promising. The application of more effective mud additives is always desirable to make the drilling process techno-economically proficient.

Keywords: ionic liquid, shale inhibitor, wellbore stability, unconventional

Procedia PDF Downloads 157

Authors: Raed Hameed Allawi

Abstract:

Wellbore instability problems are considered the majority challenge for several wells in the Ratawi shale formation. However, it results in non-productive (NPT) time and increased well-drilling expenditures. This work aims to construct an integrated mechanical earth model (MEM) to predict the wellbore failure and design optimum mud weight to improve the drilling efficiency of future wells. The MEM was based on field data, including open-hole wireline logging and measurement data. Several failure criteria were applied in this work, including Modified Lade, Mogi-Coulomb, and Mohr-Coulomb that utilized to calculate the proper mud weight and practical drilling paths and orientations. Results showed that the leading cause of wellbore instability problems was inadequate mud weight. Moreover, some improper drilling practices and heterogeneity of Ratawi formation were additional causes of the increased risk of wellbore instability. Therefore, the suitable mud weight for safe drilling in the Ratawi shale formation should be 11.5-13.5 ppg. Furthermore, the mud weight should be increased as required depending on the trajectory of the planned well. The outcome of this study is as practical tools to reduce non-productive time and well costs and design future neighboring deviated wells to get high drilling efficiency. In addition, the current results serve as a reference for similar fields in that region because of the lacking of published studies regarding wellbore instability problems of the Ratawi Formation in southern Iraqi oilfields.

Keywords: wellbore stability, hole collapse, horizontal stress, MEM, mud window

Procedia PDF Downloads 153

Authors: Chris M. Taylor, Ian Cook, Raul Alegre, Pedro Arrazola, Phil Spiers

Abstract:

Noteworthy results have been obtained in the turning and drilling of hardened high-strength steels using tungsten carbide based cutting tools. In a finish turning process, it was seen that surface roughness and tool flank wear followed very different trends against cutting time. The suggested explanation for this behaviour is that the profile cut into the workpiece surface is determined by the tool’s cutting edge profile. It is shown that the profile appearing on the cut surface changes rapidly over time, so the profile of the tool cutting edge should also be changing rapidly. Workpiece material adhered onto the cutting tool, which is also known as a built-up edge, is a phenomenon which could explain the observations made. In terms of tool damage modes, workpiece material adhesion is believed to have contributed to tool wear in examples provided from finish turning, thread turning and drilling. Additionally, evidence of tool fracture and tool abrasion were recorded.

Keywords: turning, drilling, adhesion, wear, hard steels

Procedia PDF Downloads 308

Authors: B. Chetti, W. A. Crosby

Abstract:

This paper presents a numerical analysis for the dynamic performance of a finite journal bearing lubricated with couple stress fluid taking into account the effect of the deformation of the bearing liner. The modified Reynolds equation has been solved by using finite difference technique. The dynamic characteristics in terms of stiffness coefficients, damping coefficients, critical mass and whirl ratio are evaluated for different values of eccentricity ratio and elastic coefficient for a journal bearing lubricated with a couple stress fluids and a Newtonian fluid. The results show that the dynamic characteristics of journal bearings lubricated with couple stress fluids are improved compared to journal bearings lubricated with Newtonian fluids.

Keywords: journal bearing, elastohydrodynamic, stability, couple stress

Procedia PDF Downloads 336

Authors: V. Morenov, E. Leusheva

Abstract:

Power supplying of well drilling on oil and gas fields at ambient air low temperatures is characterized by increased requirements of electric and heat energy. Power costs for heating of production facilities, technological and living objects may several times exceed drilling equipment electric power consumption. Power supplying of prospecting and exploitation drilling objects is usually done by means of local electric power structures based on diesel power stations. In the meantime, exploitation of oil fields is accompanied by vast quantities of extracted associated petroleum gas, and while developing gas fields there are considerable amounts of natural gas and gas condensate. In this regard implementation of gas-powered self-sufficient power units functioning on produced crude products for power supplying is seen as most potential. For these purposes gas turbines (GT) or gas reciprocating engines (GRE) may be used. In addition gas-powered units are most efficiently used in cogeneration mode - combined heat and power production. Conducted research revealed that GT generate more heat than GRE while producing electricity. One of the latest GT design are microturbines (MT) - devices that may be efficiently exploited in combined heat and power mode. In conditions of ambient air low temperatures and high velocity wind sufficient heat supplying is required for both technological process, specifically for drilling mud heating, and for maintaining comfortable working conditions at the rig. One of the main heat regime parameters are the heat losses. Due to structural peculiarities of the rig most of the heat losses occur at cold air infiltration through the technological apertures and hatchways and heat transition of isolation constructions. Also significant amount of heat is required for working temperature sustaining of the drilling mud. Violation of circulation thermal regime may lead to ice build-up on well surfaces and ice blockages in armature elements. That is why it is important to ensure heating of the drilling mud chamber according to ambient air temperature. Needed heat power will be defined by heat losses of the chamber. Noting heat power required for drilling structure functioning, it is possible to create combined heat and power complex based on MT for satisfying consumer power needs and at the same time lowering power generation costs. As a result, combined power supplying scheme for multiple well drilling utilizing heat of MT flue gases was developed.

Keywords: combined heat, combined power, drilling, electric supply, gas-powered units, heat supply

Procedia PDF Downloads 556

Authors: Rui Huang, Thomas Richard, Masood Mostofi

Abstract:

The lifetime of impregnated diamond bits and their drilling efficiency are in part governed by the bit wear conditions, not only the extent of the diamonds’ wear but also their exposure or protrusion out of the matrix bonding. As much as individual diamonds wear, the bonding matrix does also wear through two-body abrasion (direct matrix-rock contact) and three-body erosion (cuttings trapped in the space between rock and matrix). Although there is some work dedicated to the study of diamond bit wear, there is still a lack of understanding on how matrix erosion and diamond exposure relate to the bit drilling response and drilling efficiency, as well as no literature on the process that governs bit sharpening a procedure commonly implemented by drillers when the extent of diamond polishing yield extremely low rate of penetration. The aim of this research is (i) to derive a correlation between the wear state of the bit and the drilling performance but also (ii) to gain a better understanding of the process associated with tool sharpening. The research effort combines specific drilling experiments and precise mapping of the tool-cutting face (impregnated diamond bits and segments). Bit wear is produced by drilling through a rock sample at a fixed rate of penetration for a given period of time. Before and after each wear test, the bit drilling response and thus efficiency is mapped out using a tailored design experimental protocol. After each drilling test, the bit or segment cutting face is scanned with an optical microscope. The test results show that, under the fixed rate of penetration, diamond exposure increases with drilling distance but at a decreasing rate, up to a threshold exposure that corresponds to the optimum drilling condition for this feed rate. The data further shows that the threshold exposure scale with the rate of penetration up to a point where exposure reaches a maximum beyond which no more matrix can be eroded under normal drilling conditions. The second phase of this research focuses on the wear process referred as bit sharpening. Drillers rely on different approaches (increase feed rate or decrease flow rate) with the aim of tearing worn diamonds away from the bit matrix, wearing out some of the matrix, and thus exposing fresh sharp diamonds and recovering a higher rate of penetration. Although a common procedure, there is no rigorous methodology to sharpen the bit and avoid excessive wear or bit damage. This paper aims to gain some insight into the mechanisms that accompany bit sharpening by carefully tracking diamond fracturing, matrix wear, and erosion and how they relate to drilling parameters recorded while sharpening the tool. The results show that there exist optimal conditions (operating parameters and duration of the procedure) for sharpening that minimize overall bit wear and that the extent of bit sharpening can be monitored in real-time.

Keywords: bit sharpening, diamond exposure, drilling response, impregnated diamond bit, matrix erosion, wear rate

Procedia PDF Downloads 62

Authors: Yongrong Li, Ralf Domroes

Abstract:

Due to significant energy savings, enablement of higher machining speed as well as environmentally friendly features, Minimum Quantity Lubrication (MQL) has been used for many machining processes efficiently. However, in the deep hole drilling field (small tool diameter D < 5 mm) and long tool (length L > 25xD) it is always a bottle neck for a single channel MQL system. The single channel MQL, based on the Venturi principle, faces a lack of enough oil quantity caused by dropped pressure difference during the deep hole drilling process. In this paper, a system concept based on a bypass design has explored its possibility to dynamically reach the required pressure difference between the air inlet and the inside of aerosol generator, so that the deep hole drilling demanded volume of oil can be generated and delivered to tool tips. The system concept has been investigated in static and dynamic laboratory testing. In the static test, the oil volume with and without bypass control were measured. This shows an oil quantity increasing potential up to 1000%. A spray pattern test has demonstrated the differences of aerosol particle size, aerosol distribution and reaction time between single channel and bypass controlled single channel MQL systems. A dynamic trial machining test of deep hole drilling (drill tool D=4.5mm, L= 40xD) has been carried out with the proposed system on a difficult machining material AlSi7Mg. The tool wear along a 100 meter drilling was tracked and analyzed. The result shows that the single channel MQL with a bypass control can overcome the limitation and enhance deep hole drilling with a small tool. The optimized combination of inlet air pressure and bypass control results in a high quality oil delivery to tool tips with a uniform and continuous aerosol flow.

Keywords: deep hole drilling, green production, Minimum Quantity Lubrication (MQL), near dry machining

Procedia PDF Downloads 175