Wellbore Stability Beyond Mud Weight

Drilling oil and gas wells with stable and good quality wellbores is essential to minimize drilling difficulties, acquire reliable openhole logs data, run completions and ensure well integrity during stimulation. Stress-induced compressive rock failure leading to enlarged wellbore is a common form of wellbore instability especially in tectonic stress regime. For a particular well trajectory, wellbore stability is generally considered a result of an interplay between drilling mud density (i.e., mud weight) and subsurface geomechanical parameters including in-situ earth stresses, formation pore pressure and rock strength properties. While role of mud system and chemistry can also be important for water sensitive formations, mud weight is always a fundamental component of wellbore stability analysis. Hence, when a wellbore is unstable (over-gauge), it is believed that effective mud support was insufficient to counter stress concentration around wellbore wall. Therefore, increasing mud weight based on model validation and calibration using offset wells data is a common approach to keep wellbore stable. However, a limited number of research articles show that wellbore stability is a more complex phenomenon affected not only by geomechanics but also strongly influenced by downhole forces exerted by drillstring vibrations and high mud flow rates. Authors of this paper also observed that some wells drilled with higher mud weight exhibit more unstable wellbore in comparison with offset wells which contradicts the conventional approach of linking wellbore stability to stresses and rock strength properties alone. Therefore, the objective of this paper is to analyze wellbore stability considering both geomechanical and drilling parameters to explain observed anomalous wellbore enlargements in two vertical wells drilled in the same field and reservoir. The analysis showed that the well drilled with 18% higher mud weight compared with its offset well and yet showing more unstable wellbore was, in fact, drilled with more aggressive drilling parameters. The aggressive drilling parameters induce additional mechanical disturbance to the wellbore wall causing more severe wellbore enlargements. We devised a new approach of wellbore stability management using two-pronged strategy. It focuses on designing an optimum weight design using geomechanics to address stress-induced wellbore failure together with specifying safe limits of drilling parameters to minimize wellbore damage due to excessive downhole drillstring vibrations. The findings helped achieve more stable wellbore in subsequent wells with hole condition meeting logging and completion requirements as well as avoiding drilling problems.