Thermal Investigation on Coated and Uncoated HSS Twist Drill using ANSYS Software

In drilling, a cylindrical hole is produced in workpiece, removing the material inside the workpiece. The cutting tool used in drilling operation is called ‘Twist Drill’; it rotates and allows the material to be removed from the workpiece in the form of chips and thus drill the hole. Cutting fluids or coolants are used to perform this operation smoothly. The coating on the drill bits helps to reduce friction in the cut and the heat buildup in the drill bit. Coating also helps in protecting against corrosion. The present work focuses on the features of uncoated High Speed Steel (HSS) Twist Drill bit and Titanium Nitride (TiN) and Titanium Aluminium Nitride (TiAlN) coated on HSS Drills. The workpiece material was Mild Steel and the drilling operation was done using normal machining condition i.e. in presence of coolant. The cutting parameters used are cutting speed (35.5 m / min), spindle speed (1500 rpm), feed rate (0.2 mm / rev.), depth of cut (10 mm). These parameters were kept constant. Temperatures were measured with the help of thermal imaging camera and with the help of ANSYS software thermal analysis were done. Experimental results showed that the average rise in temperature of uncoated HSS tool was higher as compared to TiN coated and TiAlN coated HSS tools. TiAlN coated drills showed the least average rise in temperature. Keywords: High Speed Steel (HSS) Drill, TiN and TiAlN Coated HSS Twist Drill, Mild Steel (MS), Thermal Analysis, ANSYS Software.

OPTIMIZATION USING RESPONSE SURFACE METHODOLOGY AND ARTIFICIAL NEURAL NETWORK IN GEARED DRILLING

Drill on different layered composite causes to force the layers ahead of it, creating unacceptable delamination on the leaving side. The current work describes the influence of different process parameters like spindle speed, feed, diameter of drill bit and addition of filler material on delamination damage on carbon and jute hybrid fiber composites during drilling operation. The experimental output for delamination is optimized by RSM-Response Surface Methodology and ANN-Artificial Neural Network Model. The experimental prediction model was established by considering DOE (design of experiments) of three levels performed with drilling operation by varying above said process parameters The optimum values for minimized delamination damage conditions found to be at (J-C-C-J) +5g of filler (fly-ash) composite. This is drilled with 8.5mm diameter drill bit with a feed of 0.08mm/rev at 875rpm speed. From the theoretical results it is recognized that cutting-speed and filler-material have much influencing factors on responses (delamination), and their individual contribution in an order of 47.25% and 47.32% respectively. By using Box-Behnken design RSM model is developed, with a feed-forward back-propagation method to develop the predictive ANN model which consists of 15 neurons in its hidden layer along with ANN Model. Here ANN Results (R2=0.99and RMSE=1.99) showed that the developed model is performing better to predict content of delamination when compare to RSM results (R2=0.97and RMSE=2.24).

High-Performance-Low-Invasion Fluids Technology Enhances, Optimizes Drilling Efficiency in the Gulf of Suez - Egypt

High Performance Low-Invasion Fluids Technology Enhances, Optimizes Drilling Efficiency in the Gulf of Suez – Egypt Objectives / Scope: The main objective of this paper is to characterize the drilled shale formation in order to select and propose a "tailored" High Performance Low Invasion Fluids (HPLIF) system aided by Bridging Particles Optimization Tool (BPOT)(5),(6)(9)(11), capable of maximize hole stability in pressure depleted sands, allowing optimized well design through reactive and dispersible shale formations(7)(8) that eliminated one casing section, and to replace Oil Base Mud (OBM) and avoid its HSE issues related to use it, consequently, reduce formation damage, eliminate waste management cost, minimizing Non Productive Time (NPT) and finally enhances Drilling performance. Methods, Procedures, Process: This paper explain the reactivity information about Shale Samples recovered from different wells drilled in the-GOS-Egypt followed by extensive laboratory testing done(1) in order to characterize the main clay minerals presented in the samples using X-Ray Diffraction-(XRD) technology and their meso-and micro-structure by Scanning-Electron-Microscope-(SEM) and their reactivity to compare the inhibition efficiency of the proposed-(HPLIF)-System with Blank and Conventional Water-Base-Fluid-System. The reactivity of the cuttings was assessed by Dispersion, Swelling and Hardness tests. Field application experienced (HPLIF) System combined with Well-Bore Strengthening Materials (WSM) gives the required protection against induced losses and reducing the risk of differential sticking problems when mud overbalance is above 2500 psi(5), (6)(9)(11). Results, Observations, Conclusions: Compared with the use of conventional fluid systems, Field data demonstrated the successful application of (HPLIF) System combined with (WSM) and shows a great success during drilling through reactive clays, dispersive shale, naturally micro fractured(8), and depleted sand formations in many wells drilled in the GOS(2), (3), (4). Drilling operations reported no differential sticking, or wellbore instability issues even at highly mud overbalance or at highly deviated wells. The first challenged well R1-63 was drilled about 2391 ft, through 8.5" hole using 9.8-10.01 ppg using (HPLIF) system, penetrating through Thebes, Esna Shale, Sudr, Brown Lime Stone, Matulla, Nubia"A" Sand and Nubia "B" without any down-hole losses. Additionally, there was no sticking tendency experienced during drilling or while recording pressure points. The Non Productive Time NPT showed a reduction by about 19.2%. Finally, it ran and was cemented the "7" Liner in open hole successfully without problem. For the second challenged case well # 2, the Open hole was exposed to (HPLIF) water based mud system for a long period of time while rig repairing, rig switching, and during drilling operation. The well had 6" hole from 12,752 To/14,945 (2193.0ft) through Red bed, Thebes Esna, Sudr, Matulla and Nubia Sand formations with max inclination 68.6° and bottom hole temperature 325°F using 10.0-10.5 ppg (HPLIF) system, the 4.5"liner successfully was ran, cemented without any problems. The-HPLIF-System has also been shown to give excellent wellbore stability in brittle shales Fm where bedding planes or micro-fractures can become pressurized with mud, leading to wellbore instability. This innovation avoids induced lost circulation and differential sticking when the mud overbalance is expected to be greater than ±2500 psi. Additionally, the proposed solution enhances the drilling operation, reduces the waste management costs, eliminates a possible additional casing string, and finally minimizes the (NPT) which reflects on the overall cost of drilling these challenged wells.

Understanding the Impact of Monsoon Season in Malaysia Water Based on Data Analytics for Planning and Executing Drilling Operation

Drilling operation in Malaysia are typically from offshore, thus offshore weather condition does contributed to the success or delay of a drilling operation. Wait on Weather (WOW) especially during monsoon season in Malaysia has impacted Operator's drilling operation, thus incurring additional cost to Operator. Monsoon season in Malaysia is typically from November to February every year. This paper will discuss and share the statistics of actual WOW happening from 2008 to 2019 in Malaysia water especially for jack-up rig (JUR) and tender assisted drilling rig (TADR) which are two common rigs in Malaysia water. The data was collected from one of the drilling operator in Malaysia. These data will be of assistance to Operator in better planning and executing drilling operation with the actual statistics as the risk factor. WOW is considered as non-productive time (NPT), thus NPT data gathering from Operators in Malaysia water were conducted. Data was then filtered to achieve the WOW data. WOW data was segregated between region in Malaysia which are Peninsular Malaysia (PM), Sabah (SB) and Sarawak (SK) as well as rig type, which are JUR and TADR. Distribution analysis were made to calculate the average and observe the maximum numbers of actual WOW occurrence. Further analysis was made to zoom into monsoon season in Malaysia which typically in November to February. 11 years data is generally good coverage for the analysis since it covers the up and down of oil and gas industry. Analysis was also done for both mob/demob and operation stage where it can be observed that WOW for mob/demob stage during monsoon season is significantly higher compared to operation stage. At the end of the analysis, the average or maximum numbers of WOW will be shared, and it will be used as recommendation for future projects to consider these figures as WOW risk factor and embed in the planning stage. This paper will help not only Operators in Malaysia water but the host authority on understanding the WOW risk factor during monsoon season. As WOW is not something that can be predicted, utilizing the standard results from actual statistic data for the past 11 years will assist engineers to incorporate the WOW risk factor during planning and execution stage. Rig and project sequencing can be optimized with understanding of WOW impact thus reducing the value leakage during operation due to WOW.

Drilling Efficiently, Durably and Consistently Through Cherts and Conglomerates with PDC Bits is Possible

Drilling into harsh environment with heterogeneous formations including chert or conglomerate is usually a boundary that can't be crossed with standard PDC bit technology. This paper will show how an innovative PDC cutter shape combined with a novel 3D approach of cutting structure design have withstood this challenge and successfully replaced 16-in. traditional roller cone application in United Arab Emirates by the latest PDC technology delivering an average 35% improvement on Rate Of Penetration (ROP) while continuously drilling to Total Depth (TD) on each section. When drilling chert or conglomerate type of formation with a PDC drill bit, uneven load per cutters is detrimental to their integrity and results in short runs or brutal stop in the drilling operation triggering a trip for drill bit change. The new technology shown in this paper includes a unique hybrid combination of cutter shapes with a design arrangement of the cutting structure to allow for the pre-fracturing of any hard formation heterogeneity by 3D shaped cutters while standard cutters ensure a high level of cutting efficiency through their shearing action. This innovative concept has been intensively tested in the lab through single cutter and full bit scale drilling testing. In addition, in-house 3D bit simulation software has been used to optimize the cutting structure and assure performance within a wide range of drilling scenarios. Based on these simulations, an optimized design was manufactured for 16-in. directional applications usually tackled by roller cone drill bits and known for having heterogeneous cherty formations to drill throughout the end of the 5,000 ft section. Simulation results helped to validate the unique shaped cutters placement on the cutting structure to maximize the pre-fracturing effect. This design was run on Rotary Steerable System (RSS) and Positive Displacement Motor (PDM) assemblies and successfully drilled 5 wells in a challenging field of the United Arab Emirates offshore operations. 100% successful rate to reach TD in one run was achieved while increasing drastically the average ROP of the section by at least 35%. Moreover, the unique design configuration allowed to better control the directional behavior of the drill string, which resulted in a significant reduction in the overall cost per foot. A new boundary has been breached in several wells of a complex 16-in. chert and conglomerate application in the United Arab Emirates thanks to a years-long effort combining an innovative cutter technology, an optimized bit design process including a state-of-the-art 3D simulation software with lab and field experimental testing campaigns. By looking at the micro level structure of the rock destruction mechanism, a huge improvement has been obtained at the macro level of drilling operation economics.

Prediction and analysis of penetration rate in drilling operation using deterministic and metaheuristic optimization methods

The rate of penetration (ROP) optimization is one of the most important factors in improving drilling efficiency, especially in the downturn time of oil prices. This process is crucial in the well planning and exploration phases, where the selection of the drilling bits and parameters has a significant impact on the total cost and time of the drilling operation. Thus, the optimization and best selection of the drilling parameters are critical. Optimization of ROP is difficult due to the complexity of the relationship between the drilling variables and the ROP. For this reason, the development of high-performance computer systems, predictive models, and algorithms will be the best solution. In this study, a new investigation approach for ROP optimization has been done regarding different ROP models (Maurer, Bingham, Bourgoyne and Young models), algorithms (Multiple regression, ant colony optimization (ACO), fminunc, fminsearch, fsolve, lsqcurvefit, lsqnonlin), and different objective functions. The well-known data from the Louisiana field in an offshore well have been used to compare the used parameter estimation approach with other techniques. Indeed, datasets from an onshore well in the Hassi Messaoud Algerian field are explored. The results confirmed the superiority and the effectiveness of B&Y models compared to Bingham and Maurer models. Fminsearch, lsqcurvefit, ACO, and Excel (GRG) algorithms give the best results in ROP prediction while the application of the MNLR approach. Using the mean squared error (MSE) and the determination coefficient (R$$^{2}$$ 2 ) as objective functions significantly increases the accuracy prediction where the results given are ($$R=0.9522$$ R = 0.9522 , $$RMSE=2.85$$ R M S E = 2.85 ) and ($$R= 0.9811$$ R = 0.9811 , $$RMSE=4.08$$ R M S E = 4.08 ) for Wells 1 and 2, respectively. This study validates the application of B&Y model in both onshore and offshore wells. The findings reveal to deal with data limitation problems in ROP prediction. Simple and effective optimization techniques that require less memory space and computational time have been provided.

NanoTags for Improved Cuttings Depth Correlation

During a drilling operation, rock cuttings are often sampled off a shale shaker for lithology and petrophysical characterization. These analyses play an important role in describing the subsurface, and it is important that the depth origin of the cuttings be accurately determined. Traditionally, mud loggers determine the depth origin of the sampled cuttings by calculating the lag time required for the cuttings to travel from the bit to the surface. These calculations, however, can contain inaccuracies in the depth correlation due to the shuffling and settling of cuttings as they travel with drilling fluid to the surface, due to unplanned conditions like drilling an overgauge hole, and due to other unforeseen drilling events, especially critical in horizontal sections. We, therefore, aimed to remedy these inaccuracies by developing a series of styrene-based nanoparticles that tagged the cuttings as they were generated at the drill bit. These “NanoTags” were tested while drilling in Q4 2019, and the results indicated that the NanoTags did, in fact, have the potential to identify some systematic errors compared with traditional mud-logging calculations.

Managing the Salvage, Removal, Preservation and Re-Installation of Tilted Wellhead Platform

This paper describes the planning, offshore execution and technology involved in the intact salvage, removal, preservation and relocation of a Wellhead Drilling Platform (WHP) which was tilted during drilling operation in the "X" field. The field development plan consists of a WHP tied-back to a Floating, Production, Storage & Offloading (FPSO), anchored at 700 m away from the WHP. The oil field is located 110 km from shore and at water depth of 57 m. The Project Management Team (PMT) had completed the installation of the WHP, unfortunately mishap was happened when the WHP experienced tilting during drilling operation. The platform tilted/leaned two (2) degrees towards the drilling rig. The strategy adopted by the PMT was to rig-down and move out the affected rig; immediately salvage the newly installed 1,300MT WHP's topside. The work was executed under the crisis management envelop with the aim to save the rig and platform from total loss i.e., to avoid the platform topples into the sea and subsequently hits the rig. The salvage operation employed unique processes, procedures, and technology to safe hold the tilted platform by Anchor Handling Tugs (AHTs) and pipelay barge; rig-down and move out the drilling rig, reinstatement of lifting lug/pad eyes which had previously removed after completion of topside installation and finally removal of topside from the tilted jacket. The topside then transported to the fabrication yard, where there the topside had been preserved on the transportation barge for a period of five (5) months while waiting for the new jacket to be fabricated and installed. The re-development of the affected offshore facilities from the incident involved installation of new jacket at 150 m away from the tilted jacket location, re-installation of the topside to the new installed four (4) legged jacket, re-routing the previous installed infield pipelines (8" Liquid, 16" Wet Gas and 12’ Export Gas pipeline from FPSO) and tied-in to the new platform. The planning, innovation and execution has resulted in a significant cost containment and managed to avoid major disaster; subsequently safeguard Company's reputation. The salvage of the topside and rejuvenation of the pipelines have managed to avoid the reconstruction of the topside module which potentially could lead to non-cost recovery of huge amount of additional cost (in USD millions) and managed to avoid any Loss of Primary Containment (LOPC) by taken all the necessary precautions.