1st National Iranian Drilling Industry Congress.

Experience with Rotary Steerable System for 8 Section Drilling in Iranian Offshore Oilfield
Amirhossein Molayee Iranian Offshore Oilfield Company, SPE

Abstract: The majority of the wells which have been drilled in Iranian offshore oilfield in Persian golf include a build and tangent section in 8 hole section, landing the well at same section and drill a 6 horizontal section through reservoir. Most of these wells have been drilled by the conventional steerable mud motor assemblies. In Foroozan oilfield in Persian golf due to presence of famous Ahmadi and Nahr Umr formation which has unstable shale lithology, steerable motor is relatively inefficient process with associated problem. To provide directional control in build and tangent section, considerable oriented drilling has been required. Oriented drilling has proved to be time consuming and would often result in poor borehole quality. On top of this, slow ROP and bit hanging up during sliding are other factor which impact drilling performance. In order to minimize the effect of these issues, rotary steerable system has been deployed in one well in Foroozan oilfield in Persian golf for 8 section drilling by Iranian Offshore Oil Co. over the past year. This paper looks at a range of specific applications where the change from steerable motor to rotary steerable system has been both technically and commercially successful in offshore Foroozan oilfield. Through the case history, this paper will demonstrate both tangible and intangible benefits resulting from the use of rotary steerable systems that have led to a step change in overall drilling performance. Introduction : The benefits of a directional drilling system capable of steering while rotating are immense. Rotary steerable system replaced conventional steerable motor technology and eliminates oriented drilling or sliding, an inefficient and time-consuming process in which the drillstring was pointed from surface and pushed in the desired direction with no rotation. Rotary steerable system offers the potential to drill longer horizontal sections faster and more safely. Sliding ROPs during directional drilling are generally 50% lower than those achieved during rotary drilling. Consequently, a rotary steering system delivers substantially higher overall rates of penetration. This, combined with the fact that no time is wasted orienting the toolface prior to drilling, increases overall ROP when compared to conventional steerable systems, especially in extended reach and horizontal applications where orienting is particularly difficult. Precise TVD control and wellbore positioning in lateral section whilst horizontal drilling in reservoir are the main concerns of clients. In most cases, drilling with bent motor assembly in horizontal sections result in tortuous and spiral well path

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which will impair productivity especially when the thickness of reservoir is small and any uncontrolled deviation causes the well will not meet the predetermined production. Eliminating the need to steer by orienting and sliding by rotary steerable system reduces unwanted deviation from the planned well trajectory and as a consequence, enhances accuracy and precision in TVD control, allows easier completion installation and improves production in comparison with traditionally drilled horizontal well. Also, Studies show that drillstring rotation helps keep cuttings suspended which improves hole cleaning and minimizes drillpipe-to-borehole friction. The results are fewer wiper trips and circulating operations, fewer stuck pipe incidents, fewer washout conditions and a lower, more constant ECD. Rotary steerable systems of various designs are now commercially available. One class of system that has been utilized in Iran involves a technique known as push the bit whereby deflection relies on exerting side forces on the wellbore to cause the bit to drill in the opposite direction. Working Principles : Currently, the industry classifies rotary steerable system to two groups; push the bit and point the bit system which the first one has been used in Iranian offshore oilfields. Push the bit system consists of two principle components: The Bias Unit, which applies a lateral force to the bit while it constantly rotates at bit speed. The Bias Unit is normally connected directly to the drill bit. Three exterior pads are kept in constant contact with the formation by internal, mud powered actuators. The Control Unit, which is a roll-stabilized platform located within a nonmagnetic collar. It contains self-powered electronics and sensors which set the direction and magnitude of the force vector applied to the bit by the Bias Unit. When deviation is required, each actuator is extended in sequence, once each revolution of the bit, against the side of the hole opposite the intended bias direction (Fig.1). The Control Unit is mechanically linked to the Bias Unit and sets direction and deviation. It contains sensors and control electronics inside a cylindrical pressure case which is mounted on bearings within the drill collar. The bearings allow the control unit to rotate, or remain stationary, independent of drill string rotation. Power is generated through two turbine impellers, which support the Control Unit sensors and electronics. The push the bit system settings can be altered from the surface while drilling using a sequence of mud pulses. The on-the-fly downlink command capability of RSS enables corrections to be made without too much delay, something a conventional system would not have been able to provide. This paper will describe some of the successes that have been realized while using Push the bit system in comparison with conventional system. Field case study :

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Scenario. Iranian Offshore Oil Company (IOOC) is a National Iranian Oil Company branch formed 1980. IOOC has started to improve the production from Foroozan oilfield in Persian golf since 2007. This production enhancement project include drilling of several re-entry wells with typical profile of re-entering from 9 casing and drill about 800 m of 6 horizontal drain after landing the well in 8 section. A typical re-entry well takes about 55 days from start of re- entry till completion with about 67% of time spent in drilling, casing running and cementing (31 days for 8 and 6 days for 6 section) with the conventional Mud Motor Steerable BHA. From previous experience, the biggest challenge is the poor steerability of the conventional BHA (especially with PDC bit) that demands significant BHA Sliding time (min. 40% of drilling time at 50% of rotary ROP) and frequent BHA trips (to change to Tri-Cone Bit or to change out Mud Motor). In the Persian golf the 8 hole section is typically used to drill the sequence from Tayarat to Burgan formation. This sequence is a mixture of limestone and shales including the famous Ahmadi and Nahr Umr shale. Drilling directional wells through these shaly formations using a steerable motor is frequently problematical with larger bends and long slides needed to counter a dropping tendency while rotating. The Ahmadi and Nahr Umr are highly laminated shale exhibiting both mechanical instability and a need for inhibition. The average daily ROP in 8 section with mud motor is around 80-100 m. Being enthusiastic and visionary in new technology to improve efficiency, it has been decided to adopt PowerDrive 675 rotary steerable system in 8 section to evaluate achievable benefits. Detailed plan was carried out to ensure that all aspects of the job that including well trajectory, BHA design, hydraulics, rig capacity and bit selection were covered in depth. Based on the offset wells data, rotary steerable system with 6 size tool was expected to achieve at the minimum of 50% increase in daily drilling ROP i.e. 150 m/day while achieving the required well trajectory. Also it should be able to meet the challenges; Improved hole cleaning Reduced tortuosity Improved hole gauge Being cost effective Run Summary : To kick off well from 9 5/8 casing, a whipstock assembly has picked up and window has opened in same casing with 27 inclination and 67 azimuth at 1606 m. A PD675 with five blade PDC bit (125X616M) was then picked up and used to drill 8 hole section. A 66 pcf OBM was used. Inclination angle was built from 27 at 1606 m to 63 at 2075 m with max build rate 3.3 per 30 m. A 400 m tangent section was then drilled before angle was again built to 72 at 2590 m. In addition the hole azimuth was turned to right from 67 at window to 16 at 2590 m. Eventually after 97 hrs drilling time due to insufficient build rate by PD675, the tool has pulled out of the well at 2590 m. It has been found one of the Pad (No.2) in Bias

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1st National Iranian Drilling Industry Congress.

unit has jammed. So to avoid same risk and due to short distance till 7 liner point, the mud motor has picked up to finish section. Value Assessment : Rotary steerable system has proven extremely adept at meeting the drilling requirements for this section. In all, PD675 has drilled 984 m from 1606 m to 2590 m in totally 97 hrs drilling time including connection and survey time with the maximum daily ROP record of 301 m. So, the resultant average ROP hit the 10.13 m/hr value. Of particular note was the excellent instantaneous ROP of 30 m/hr through the Ahmadi and Nahr Umr laminated shale from 2018 m to 2565 m. At this time, the inclination has built from 60 to 69 and azimuth has turned to left from 30 to 17. This formation sequence is perhaps a classic for responding to the benefits of a rotary BHA. In this field, where oil based mud is used to control the Nahr Umr and Ahmadi shale, high penetration rates are achieved through maximizing drilling parameters. Using a five bladed PDC bit with 16mm cutters, on a fully rotating system such as the PowerDrive 675 with weight on bit equal to 20000- 25000 lb. Rotary speed should be as high as possible to limit stick slip vibration and, of particular importance; bit HSI should be run in the range of 3 to 4. These parameters are very difficult to achieve using a steerable motor explaining why the rotary steerable systems drill the section so much faster. Table 1 shows data comparison between previous records with bent housing assembly and PD675 for same section in same field. Followings are the key achievements delivered by rotary steerable system: I. To kick off, build angle to 71 degrees during 1000 m drilling using a steerable motor would normally take a minimum of two bit runs with an average penetration rate in the region of 5 meter per hour. Rotary steerable system drilled same section with total ROP of 10.13 m/hr which means more than 200 % of bent housing assembly ROP (Fig.2). II. The well trajectory was kept under excellent control. Economic Evaluation : A cost analysis is of obvious importance when assessing the value which a rotary steerable system can bring. The value of each project is determined with respect to the cost and time saving. As it is mentioned, PD675 drilled 984 m and after that tool has pulled out of the well due to insufficient build rate. The plan of this section proposed total of 237 hrs to drill this much length including drilling time by bent housing assembly and two trip time to change the bit, based on offset well data which have been shown in table 1. Eventually, PD675 Rotary Steerable System drilled 984 m in 97 hrs which means 140 hrs equal to 5.8 days ahead of plan. Fig.3 shows drilling time comparison between this well and previous ones which have been drilled by conventional system.

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1st National Iranian Drilling Industry Congress.

As it is shown in table 1, the total drilling cost of 984 m of 8 hole section by rotary steerable system in total operating and standing by time (8 days) was 969217 US $ which means 985 US $/m, including rental and shipping expense of tool and daily rate of rig. Due to the offset well data, the average cost/meter of this section in same field and same rig daily rate with conventional system was 1208 US $ per meter. So, compared to conventional system, deployment of RSS has led to 223 US $/meter cost saving. It means more than 215000 US $ has been saved in drilling of 8 section by RSS (Fig.4). IOOC regards the application of PowerDrive Rotary steerable system as an Evolutionary Step Change in drilling efficiency has decided to expand the use of PowerDrive in different hole sizes in different fields to optimize the benefits of the system in all possible dimensions. Conclusion : This paper discussed how change of mud motor assembly to Rotary Steerable System for drilling of 8 build and tangent section being cost effective in Iranian offshore oilfields. While benefits are achieved in terms of pure drilling economics, the benefits drived from improved hole placement and reduced tortuousity should be given high importance and will likely in longer term become key drivers for use of rotary steerable system. Performance today supports the following conclusions: 1. The benefits of the ability rotate every part of the drilling assembly from surface to bit whilst controlling the direction of the hole include higher rates of penetration (ROP), improved transfer of weight on bit (WOB) and ease of holding toolface in the presence of drilling parameter and formation changes. 2. Over the past year, IOOC has utilized rotary steerable systems to drill 8 hole section. This result in enhanced accuracy and precision in trajectory control in comparison with traditionally downhole motor. The reduction, or possible elimination, of hole spiraling through improvements in hole cleaning plausibly accounts for the ease of drilling. 3. The RSS has proven to be cost effective for drilling of 8 hole section. The 984 m was drilled with 10.13 m/hr which means 200% of conventional system average ROP. Also this length was finished 5.8 days ahead of plan.

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1st National Iranian Drilling Industry Congress.

Nomenclatures : BHA Bottom Hole Assembly ECD Equivalent Circulating Density HSI Horsepower per Square Inch TD Total Depth TVD True Vertical Depth ROP Rate of Penetration RSS Rotary Steerable System WOB Weight on Bit

Acknowledgement : The author would like to thank IOOC for permission to publish this paper. References : 1. Hartmut Gruenhagen, Ulrich Hahne, Graham Alvord, Application of New Generation Rotary Steerable system for Reservoir Drilling in Remote Areas, IADC/SPE paper presented at the 2002 IADC/SPE Drilling Conference, Dallas, Texas, 2628 February. 2. I.R. Tribe and L. Burns, D. Howell. and R. Dickson, Precise Well Placement using Rotary Steerable systems and LWD Measurements SPE paper presented at the 2001 SPE Annual Technical Conference and Exhibition held in New Orleans, Louisiana, 30 September3 October. 3. John Edmondson and Chris Abbott, Clive Dalton and John Johnstone, The Application of Rotary Closed-Loop Drilling Technology to Meet the Challenges of Complex Wellbore Trajectories in the Janice Field IADC/SPE paper presented at the Drilling Conference 2000, New Orleans, Louisiana, 2325 February. 4. Adam T. Bourgoyne Jr., Martin E. Chenevert, Keith K.Milheim, F.S. Young Jr., Applied Drilling Engineering, SPE Text Book Series. Vol 2. 5. Colebrook, S.R. Peach, F.M. Allen, BP Exploration and G. Conran, Application of Steerable Rotary Drilling Technology to Drill Extended Reach Wells Paper SPE presented at the 1998 SPE conference, Dallas, 36 March. 6. Molayee, A.H., Iranian Offshore Oil Company, Teymoori, Ali, Petroiran Development Co., Experience with Rotary Steerable System for Reservoir Drilling in Iranian Offshore Oilfields Paper SPE presented at the 2006 SPE conference, Adelaide, Australia, 11-13 September .

Table.1. Summary of drilling data for field case history No.1

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1st National Iranian Drilling Industry Congress.

W ell

Ty pe of Motor

D ay

M eter

R OP

T rip

Dr illing Time (Hrs)

T rip Time

Tota l Cost

Cost/Me ter

F -161H F -161H

No rmal Motor RS S, PD675

9 .8

92 0

19 7

4 0

1,111 ,360

1208

4 .8

98 4

1 0.13

97

2 0

969,2 17

984

Fig.1. Generating side force by applying pressure to three string pads

Fig.2. 8 hole drilling ROP for field case history

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1st National Iranian Drilling Industry Congress.

Foroozan Field 8 1/2" Hole Drilling ROP (Average On-Bottom Drilling) 25 20

Meters/Hour

15 10
7.00 5.16 5.54 10.13

5 0 F14-1H F14-0H F17-1H

4.82

4.90

F13-3H

F3-1H

F16-1H

Fig.3. 8 hole progress chart comparison for field case history

Foroozan Field 8 1/2" Hole Progress Chart Total Days

Days 16 14 12 10 8 6 4 2 0 F14-1H 9.57

14.25

14.75

14.46

8.74

4.80

F14-0H

F17-1H

F13-3H

F3-1H

F16-1H

Fig.4. Cost saving due to use of RSS for field case history

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