IPTC 10607
Maximizing ROP With Real-Time Analysis of Digital Data and MSE
F.E. Dupriest, SPE, ExxonMobil, and J.W. Witt, SPE, and S.M. Remmert, SPE, RasGas Co. Ltd.
Copyright 2005, International Petroleum Technology Conference
This paper was prepared for presentation at the International Petroleum Technology
Conference held in Doha, Qatar, 2123 November 2005.
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Abstract
RasGas Company Ltd Drilling Task Force has instituted a new
work process from ExxonMobil Development Company. This
process is designed to optimize rate of penetration (ROP) in
every foot of hole drilled. ROP limiters are systematically
identified and eliminated during the drilling design, as well as
during real-time well site operations.
A central element in this work process is the real-time
display and analysis of Mechanical Specific Energy (MSE).
MSE is the calculated work that is being performed to destroy
a given volume of rock. When a bit is operating at its peak
efficiency, the ratio of energy to rock volume will remain
relatively constant. This relationship is used operationally by
observing whether the MSE changes while adjusting drilling
parameters such as weight on bit (WOB) or rotary speed
(RPM). If it remains constant while increasing WOB, the bit
is assumed to still be efficient. If the MSE ratio increases
significantly, either while drilling or while adjusting
parameters, the bit has foundered. The driller then determines
the most likely cause of founder and adjusts parameters
accordingly. Adjustments continue to be made until the MSE
value is minimized. The process of adjusting parameters is
referred to as MSE testing. Recorded results of the driller's
MSE tests are also used in post-analysis to guide redesign of
the drilling system when ROP limiters are beyond the driller's
control. In the North Field operations, downhole vibrations
data were coupled with the MSE curves to further enhance the
interpretation of the cause of founder and to manage drilling
parameters.
This paper presents examples from Qatar operations that
demonstrate the manner in which MSE and vibrational data
were used at the rig site to make operational decisions, and in
post-drill analysis to redesign the system. Performance data is
also provided to show the impact on operations. Performance
improvements have varied by hole size, but range from 60 -
380%.
Introduction
The development and pilot testing of a process for displaying
MSE in real time was reported in IADC/SPE 921941. The
success of the pilot test lead to development of the
ExxonMobil Fast Drill Process (FDP) in mid-2004. FDP is a
structured workflow that the operator is implementing globally
to ensure the drilling process is continuously redesigned to
extend drill rates to their maximum economic limit. MSE is a
central element in this workflow. Throughout this paper, the
wells drilled under this program are referred to as "FDP
Wells".
RasGas Company Ltd began working with its vendors
and rig contractors to implement FDP and MSE surveillance
in early 2005. The mud logging service provider developed
the ability to display an MSE curve along with the other
normal drilling parameters. The data was transmitted to the
office in real time for engineering analysis. The LWD service
provider also developed the ability to display MSE along side
real time vibrations curves. When the LWD was in use, this
merged display became the preferred surveillance tool because
vibrational founder has proven to be a major ROP limiter.
Although MSE alone has been used effectively to identify and
mitigate vibrational founder, the simultaneous display of data
from downhole accelerometers has confirmed and enhanced
the MSE analysis.
Just prior to implementation of FDP on each rig,
technical champions provided training to key operator and
contract personnel. The training is designed to achieve
sufficient competency at the rig site so remote engineering
support is not required for MSE interpretation or guidance in
adjustments to operating parameters. The purpose of
transmitting the data offsite is primarily to ensure engineering
personnel are aware of the ROP limiters that are beyond the
control of rig site personnel and these limitations are being
worked as effectively as the real time drilling issues.
Qualitative use of Mechanical Specific Energy
Teale2 derived the Mechanical Specific Energy equation to
show the amount of work that a bit was performing per
volume of rock drilled. He then conducted lab tests that
demonstrated the energy per volume of rock destroyed to be
relatively constant, regardless of changes in ROP, WOB or
RPM.
MSE Input Energy ...(1)
Output ROP
2 IPTC 10607
MSE = 480 x Tor x RPM + 4 x WOB ...(2)
Dia2 x ROP Dia2 x
Teale also observed that the numeric value of MSE was
approximately equal to the compressive strength of the rock.
This was true because the tests were conducted at atmospheric
conditions where the rock failed in a highly efficient, brittle
failure mode. Peak bit efficiencies under field conditions are
usually much lower, often in the 30-40% range3. This
inefficiency results in a MSE measurement that is around three
times the rock strength. For operational reasons, an adjusted
MSE (MSEadj) was created so the value plotted at the rig site
would be closer to the known rock strength. The EFFM that
the operator uses is 0.35.
MSEadj = MSE x EFFM ...(3)
This is a controversial practice because the mechanical
efficiency of a bit may vary greatly from the assumed 35%,
depending on a variety of factors. However, the practice has
generally served its purpose in operations. Drillers often
know the rock strength from bit vendor analysis or geologic
studies. Adjusting the displayed value so it is close to rock
strength when the bit is at peak efficiency provides a tangible
frame of reference to give the driller some sense that the bit is
performing well.
However, the statement that MSEadj should equal rock
strength is not taken too literally. There are additional sources
of error, other than uncertainty in the peak mechanical
efficiency used to adjust the MSE. A major one arises from
the use of surface torque to calculate MSEadj. The value
eventually becomes inflated by torsional friction, and in
directional wells the baseline trend may eventually become
several times the rock strength. However, because MSEadj is
used only as a trending tool in this particular drilling
optimization process, the absolute value is not critical. What
is essential is only that the value be consistent so a baseline
trend can be established. In field tests, the MSEadj has
remained relatively unchanged for an efficient bit during ROP
step tests from 50-600 fph. It is the stability of the MSEadj
value when the bit is operating in its peak efficiency range that
allows MSE to be used effectively as an optimization tool. If
the MSE is close to the apparent baseline trend, the drill team
knows the bit is efficient and that ROP will increase reliably
simply by raising the WOB and RPM. If MSEadj is
significantly above the baseline trend the bit is foundering and
the cause of founder must be diagnosed and addressed by the
drill team before an increase in ROP can be achieved. A
number of examples plots are provided in this paper.
Qatar North Field Drill Wells
The location of the Qatar North Field is shown in Figure 1.
Figure 2 shows the stratigraphy and a typical wellbore
configuration, and Figure 3 shows unconfined rock
compressive strength data for a typical well. The majority of
wells are similar in lithology, hole size, casing configuration,
and casing setting points. They differ primarily in inclination
and throw. About 10% of the wells are vertical, with the
remainder varying from 55 to 60 degrees of inclination to
approximately 10,000 ft TVD. To date, 50,000 ft of hole has
been drilled using the FDP process, including 11, 17-1/2"; 6,
12-1/4"; and 2, 8-1/2" sections on 4 rigs. Training and
surveillance practices are currently being established on the
remaining rigs.
Because of similarity in lithology and design between
wells, any performance improvements that can be achieved are
likely to apply uniformly to most wells and have a significant
financial impact on the total program. A continuous multi-
year program is expected so that increased drilling
performance will significantly accelerate production volumes
during the course of a major capital expansion. The gains in
each interval have been substantial.
Table 1
Relative Enhancement
Average Average
Offset Well FDP Well
17-1/2" Directional 32 fph 71 fph
12-1/4" Vertical 23 fph 65 fph
12-1/4" Directional 21 fph 76 fph
8-1/2" Directional 18 fph 50 fph
Figures 4 and 5 show the previous performance along
with wells drilled in the current FDP program. The gains
shown are notable. Because non-drilling time is included in
the footage per day calculated, the actual increase in
instantaneous ROP has been even greater than indicated.
There was no single dominate ROP limiter identified in the
North Field. The improvements in performance occurred as a
result of continuous analysis and adjustment of WOB and
RPM by field personnel to minimize MSEadj, and through
redesign of numerous well design and equipment related ROP
limiters by the engineering staff. A variety of these are
discussed below.
Bit Structure Cleaning (Bit Balling)
Bit structure cleaning and bit balling are terms used to
describe build up of material on the bit that inhibits transfer of
a portion of the WOB to the cutting structure. The greater the
loss of weight transfer, the lower the depth of cut and the
greater the reduction in ROP. Balling is often associated with
shales, but MSEadj analysis showed that it occurred in many
soft limestones in the North Field. The problem was
significant in Cretaceous limestones in the 17-1/2" hole, and it
was particularly unexpected in Jurassic limestones in the 12-
1/4" and 8-1/2" intervals.
Figure 6 shows an example rig site display from the
12-1/4" interval. The MSEadj is plotted in the left hand track.
The initial MSEadj is around 25ksi. The drilling system is
using the same amount of energy as if this soft rock had a
compressive strength of 25ksi. The team correctly diagnosed
high energy loss due to moderate balling and reduced the
WOB from 25k lbs to 8 k lbs at 5100 ft. The MSEadj showed
an immediate improvement in bit efficiency and the ROP
increased from 80 fph to around 100 fph.
Note that the initial ROP was already acceptable.
Lacking the MSEadj diagnostics, the driller would not have
suspected that a higher ROP might be possible by reducing the
WOB. The example also illustrates how MSEadj is used as a
relative indicator of performance, rather than as an absolute,
IPTC 10607
quantitative value. After the WOB was reduced the MSEadj
value remained around 15 ksi, while the soft limestones are
expected to have comparable or lesser strength. As discussed
above, there are a variety of reasons why the MSE might not
equal rock strength, even when the bit is at its peak efficiency.
The field process for using MSEadj is to adjust parameters and
simply observe whether the MSEadj increases or declines.
Parameters are eventually maintained at the point at which
MSEadj is at its minimum.
Once the driller has optimized parameters within his
control, engineering redesign is required to achieve further
gains. After it was recognized that balling occurred in the soft
limestones, nozzles and flow rates were modified to achieve
the highest hydraulic horsepower per square inch (HSI)
possible with the available rig equipment. The changes were
were sufficient to eliminate the bit structure cleaning problems
that were encountered.
Table 2
Redesigned Hydraulics
Prior Redesigned
HSI (hp/in2) HSI (hp/in2)
17-1/2" Section 0.4-0.6 1.5-2.0
12-1/4" Section 0.7-1.5 2.5-3.5
8-1/2" Section 0.7-1.5 2.5-4.0
Hydraulic horsepower at the bit can be changed by
either increasing the volume of flow through the bit, or
reducing the nozzle size so the pressure drop and velocity for a
given flow are increased. Both consume the available pump
horsepower so the engineer must decide which to give
preference to in the hydraulic design. In general, flow rate is
emphasized in directional wells where hole cleaning is the
priority. Because the pumps were already operating at their
contract horsepower output when bit balling was observed, it
was necessary to reduce flow rate in order to increase the
nozzle pressure drop and HSI. Hole cleaning concerns would
have likely discouraged this without quantitative MSEadj data
to demonstrate the potential value in ROP. To date, there has
been no increase in circulating time or hole cleaning problems
associated with the reduced pump rates, but the team
continues to model cleaning efficiency. With improved
hydraulics, the founder point for balling has now been
elevated to allow consistent application of 25-45k lbs WOB
where cleaning was an issue, rather than 5-25k lbs.
The ROP in the operator's 12-1/4" and 8-1/2" holes is
no longer limited by balling. There may still be some
opportunity in the 17-1/2" hole to further increase HSI. Given
the rig hydraulic limitations, the next step taken to mitigate
balling would normally be to reduce blade count to further
increase the junk slot area. However, experimentation will be
required to determine whether vibrational stability of the bit
can be maintained with reduced blade count in the interval.
Lateral Vibrations (Whirl)
When the bit vibrates it loses cutting efficiency and the MSEadj
clearly shows the resulting increase in energy consumption.
Though the use of the term "founder" has traditionally referred
to bit balling, the operator now applies this term to vibrations,
as well. The MSEadj curve has been used to diagnose
vibrational founder due to both whirl and stick slip.
3
When the bit is not rotating around its precise center it
loses cutting efficiency. This motion across the bottom of the
hole is referred to as whirl and even small levels of whirl may
have a significant impact on ROP. Figure 7 shows and MSEadj
test in which whirl is observed. The display is from a
downhole vibrations monitoring system that has been
modified to show MSEadj along with real time vibrations data.
Initially the MSEadj value is around 50 ksi in rock with a
compressive strength less than 30 ksi. However, this is a
directional well and the high energy consumption may be
largely due to drill string drag. It is necessary to vary drilling
parameters and observe the MSEadj response relative to the
baseline trend in order to know whether the bit was initially
efficient, or not.
At 13:12 hrs the WOB was increased from 12k to 14k
lbs. The MSEadj immediately declined from 50ksi to around
40 ksi. This response suggests the bit was initially foundering
and became more efficient as weight was applied. If the bit
efficiency had not changed, the MSEadj would not have
changed. The ROP did not increase simply because the WOB
was raised, but because the bit became fundamentally more
efficient at the higher load. This is why the ROP increase
(100%) was disproportionate to the increase in WOB (16%).
The improvement in efficiency with increasing WOB is an
expected response of a bit suffering from whirl. The lateral
vibrations display also confirms there was initially a low level
of whirl, which was reduced to the minimum level that could
be detected when the WOB was increased.
The WOB continued to be raised slowly as drilling
progressed from 13:12 to 13:57 hrs and the MSEadj continued
to decline. At 13:57 the WOB was increased further and the
MSEadj and ROP improved again. It is of interest that whirl is
being reduced further, but the downhole vibrations monitoring
tool is not set up to report this. The MSEadj is capable of
displaying the effects of a low level of bit vibration that
common LWD tools do not show in real time. The advantage
that downhole accelerometers have is that they clearly indicate
the type of vibration that is occurring, while some
experimentation is required to determine this from the MSEadj
curve. The advantage of the MSEadj curve is that it clearly
shows the degree to which the vibration is affecting drilling
performance. In this manner, the two tools are
complementary.
Figure 8 shows another example of whirl from the mud
logger's display. The WOB was initially 25k lbs, which is a
reasonable value for an 8-1/2" PDC bit, but the MSEadj is
extraordinarily high at 500ksi. The WOB was raised slowly to
35k lbs and the MSEadj declined to 200 ksi while the ROP
increased from around 25 fph to 75 fph. The WOB is now
near the manufacturer's recommended limit for this
application. In this example, vibrational energy loss still
appears to significant and further optimization efforts will
facilitate even higher WOB to reduce this energy loss. Whirl
is common in harder formations in the North Field wells, such
as the Hith anhydrite, Khail anhydrite and Khuff dolomites
and anhydrites. Steps have been taken in each to redesign the
system to improve bit efficiency. The 1.22 degree motors
have been replaced with 0.78-1.0 degree settings to reduce
rotational imbalance that creates some of the whirling
tendency. In some intervals, the trajectory and target sizes
4 IPTC 10607
have been modified to allow steerable motors to be replaced
by high torque straight motors. Figure 9 shows the MSEadj
curve from an 8-1/2" hole in which a 0.78 AKO motor was
pulled and replaced by a straight motor. The MSEadj declined
from around 80 ksi to 30 ksi. Despite the fact that the WOB
was reduced from 40k to 20 k lbs, the ROP increased from 50
to over 100 fph.
The greatest design change relative to motors was in
the 17-1/2" hole. A low angle, bent housing motor was used
that had a small build tendency while rotating. The natural
build tendency was used to sustain a catenary build rate while
applying high WOB to mitigate whirl. The sliding time for
directional corrections was reduced from 20-30% to 3-7%.
The step change in performance shown in Figure 4 is due to
the combination of reduction in sliding time, reduced
vibrations while rotating the low angle motor, and the ability
to use MSEadj while rotating to mitigate whirl and stick slip.
Other important design changes included extending bit
gauge lengths to improve lateral stability, utilizing near bit
stabilizers that rotating with the bit on straight assemblies
rather than sleeve stabilizers, and utilizing high torque motors
so that the system is not limited by motor differential when the
whirl is effectively mitigated. A measure of the success of
whirl mitigation efforts is that despite the high WOB that is
now being applied, bit grades are often improved. The most
recent record 12-1/4" interval was drilled with one bit that
graded 1-1-CT-S-X-I-NO-TD (10-15 ksi formations).
Torsional Vibrations (Stick Slip)
Stick slip was persistent and occurred in all directional
intervals. Torsional vibration, or stick slip, occurs when the
torque applied at the end of the string reaches a critical level
that tends to excite the given string. Consequently, the
primary mitigation is to reduce the bit torque to a level that
doesn't excite the string. This is accomplished by reducing the
WOB. Increasing the rotary speed also helps to maintain
angular momentum. In Figure 10, the initial MSEadj in this
section of the 12-1/4" hole is in excess of 100ksi. Downhole
vibrations monitoring tools are showing a high level of stick
slip and a moderate level of whirl. As the WOB is reduced
from 45k lbs to 35k lbs the bit becomes significantly more
efficient and the MSEadj declines to less than 10 ksi. The
instantaneous ROP increased from 25 fph to over 200 fph.
Figure 11 shows a series of MSEadj tests during which
stick slip was initiated at a fairly consistent WOB. Each time
WOB approached 40k lbs, MSEadj rose sharply and the ROP
fell. Downhole tools confirmed onset of stick slip and a
moderate amount of whirl during each event. In other cases,
stick slip was mitigated by increasing rotary speed first, then
reducing WOB if this was not effective. The highest
combination of bit speed and WOB that can be achieved
without developing whirl or stick slip will result in the highest
ROP.
In these examples, it was possible for the driller to
manage vibrations effectively with changes in operating
parameters, alone. However, a number of design changes had
been made that had helped to create the low-vibrations
operating window for the driller to work within. The
reduction in angle setting on the motor, discussed above, also
resulted in a reduction in stick slip. Unbalanced mass in the
bent housing motor creates a bending force that would be
expected to result primarily in bit whirl. However, whirl and
stick slip are very often coupled. It is assumed lateral force
associated with whirl increases the drag between BHA and
borehole, which increases the total torque available to generate
stick slip.
Axial Vibrations (Bit Bounce)
Axial vibrations were observed in the hardest dolomite and
anhydrite stringers, though its occurrence was infrequent.
Figure 12 shows the onset of axial vibrations when a stringer
was encountered and the WOB was raised from 10 to 25 k lbs.
The MSEadj climbed to 35 ksi, but this value may be close to
the rock strength in these hard dolomite stringers so the bit
does not appear to have become extremely inefficient. When
WOB was reduced to 15-20 k lbs, axial vibration declined and
ROP increased accordingly. In addition, proper management
of axial vibration preserved bit cutting structure and allowed a
longer, faster bit run with less cumulative cutter damage.
Conclusions
Bit performance is highly dependent on the manner in which
the bit is used. Real time analysis of mechanical specific
energy helps the driller to select WOB, RPM and hydraulics
that achieve the most efficient bit performance. When bit
performance is constrained by factors beyond the driller's
control, the MSEadj curve provides digital documentation the
drilling engineer requires to redesign the system, and to cost-
justify this redesign. The combination of bit efficiency and
vibrations data is particularly useful in illuminating causes of
founder.
The insights MSEadj and vibrations monitoring provide
do not, in themselves, improve drilling performance. An
understanding of the causes of bit founder and appropriate
mitigations is also essential, as well as a work flow that
ensures learnings are captured and that continuous redesign is
occurring. The operator has trained over 180 personnel in
basic bit mechanics and the Fast Drill Process. The majority
of these have been contractor personnel. Though real time
data is provided to the office, the MSEadj analysis and decision
making process is rig-based. Training and rig-based decision
making have been key elements in the effectiveness of the
work process in the North Field.
Acknowledgements
We thank RasGas Company Ltd. for permission to publish this
paper. The performance results reflect the quality of real time
analysis and engineering redesign achieved by each of the rig
teams. Thanks to the many drillers, rig crew, service company
personnel, rig supervisors, and others who have contributed
greatly to this effort.
IPTC 10607 5

Nomenclature
ROP Rate of penetration, ft/hr
RPM Bit rotating speed, revolutions per minute
Tor Torque, ft-lbs
WOB Weight on bit, lbs force
EFFM Mechanical efficiency, ratio
MSE Mechanical specific energy, psi
MSEadj Adjusted mechanical specific energy, psi
Dia Bit diameter, inches

References
1. Dupriest, F. and Keoderizt, W. " Maximizing Drill Rates with
Real-Time Surveillance of Mechanical Specific Energy", SPE
paper No.92194 presented at annual Drilling Conference,
Amsterdam, Netherlands, 23-25 February, 2005
2. Teale, R.: "The Concept of Specific Energy in Rock Drilling,"
Intl. J. Rock Mech. Mining Sci. (1965) 2, 57-73
3. Pessier, R.C. and Fear, M.J., "Quantifying Common Drilling
Problems with Mechanical Specific Energy and Bit-Specific
Coefficient of Sliding Friction", IADC/SPE paper No.24584
presented at 67th Annual Conference and Exhibition
Washington D.C., 4-7 October, 1992
6 IPTC 10607

Figure 1: North Field production and jackup drilling operations

are located 62 miles offshore in the Arabian Gulf.

Figure 3: High compressive strengths and laminations contribute

to vibrational founder.

Figure 4: Steadily increasing performance in 17-1/2 intervals

though continuous redesign to extend ROP limiters. Record
single-day performance, 1450 ft.

Figure 2: Lithology and wellbore configuration.

Figure 5: Step change occurred in vertical wells with vibration
mitigation. Real time MSEadj analysis provided incremental
additional improvement.
IPTC 10607 7

Figure 6: High MSEadj at 5100 ft indicated bit balling. MSEadj

showed bit efficiency improved when WOB was reduced and ROP
increased. Pressure also declined as bit balling cleared. Figure 9: MSEadj declined significantly when bent housing motor
was replaced with straight motor. ROP was doubled with similar
WOB and the same RPM.

Figure 7: Decline in MSEadj reflected immediate improvement in bit Figure 10: Plot showed the significant effect that stick slip and
efficiency when WOB was raised. Downhole tools showed coupled whirl may have on bit efficiency and ROP. Reduction in
reduction in whirl. WOB was effective.

Figure 8: MSEadj indicated that increasing WOB was effective in Figure 11: MSEadj and downhole monitoring tools showed stick
mitigating whirl. ROP increased from 25 fph to 60 fph as WOB slip occurred consistently at the same WOB in the given
was increase from 25 k-lbs to 38 k-lbs. formation. Maximized ROP by drilling ahead with WOB just below
this value.
8 IPTC 10607

Figure 12: WOB was increased as hard stringer was penetrated.

The axial vibrations diminished after the WOB was decreased.