SPE-175165-MS

Utilization of an Innovative Tool to Improve Hole Cleaning Efficiency in

Extended Reach Wells in Saudi Arabia
Mike Okot, Marlio Campos, German Muoz, and Alawi G. Alalsayednassir, Saudi Aramco; Matt Weber, Franks
International, LLC; Zahid Muneer, Schlumberger

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Kuwait Oil & Gas Show and Conference held in Mishref, Kuwait, 1114 October 2015.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Saudi Aramco operates one of the largest offshore oilfield developments in the world. This field is made
up of 41 kilometers of causeway, 3 kilometers of bridges, 27 drilling islands, 13 offshore platforms, and
16 onshore drill sites. The magnitude of the field has pushed cutting edge technology and processes to the
forefront of the industry. This new development has driven achievements in multilateral and extended
reach directional wells. One challenge the operator faces is to maintain proper hole cleaning in extended
8 in. tangent sections at a 85-87 inclinations, which are drilled in excess of 10,000 ft.
Historically, drilling very long tangent sections required the use of several tandem sweep pills, wiper
trips, and reaming/back reaming to maintain hole quality and efficiently remove cuttings bed from the
wellbore. The negative effects of poor hole cleaning can lead to tight intervals, increased torque and drag,
and eventually stuck pipe.
In an effort to drill efficiently, utilization of a new technology to increase the cutting removal was trial
tested on well A1 from an onshore location of the field. The ERD well, A1, was drilled to a total depth
of 30,480 ft MD (8,650 ft TVD) into a stratigraphic environment composed of limestone, shale, and
siltstone. The objective of the trial test for the tool was to improve the drilling efficiency. To obtain the
best possible hole cleaning, a simulation was performed by placing the tools every three stands along the
tangent section in the 8 in. hole section.
The goal of the trial test was to achieve the following:

Enhance hole cleaning by removal of cuttings bed.

Reduce the frequency/number of tandem sweep pills.
Reduce the frequency/number of wiper trips.
Reduce torque and drag and compare it with the offset wells.
Reduce drilling cost.

A service company installed a cuttings flow-meter system at the shakers, which was used to evaluate
the hole cleaning efficiency and performance of the hole cleaning tools. This paper will demonstrate the
systematic methodology, which Saudi Aramco and the service company used to approach the utilization
of the hole cleaning tools to achieve a clean hole in well A1.

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Introduction
Hole cleaning in directional wells is one of the main limiting factors in todays extended reach drilling
campaigns. As the industry continues to push the limits of extended reach wells, the much focus is spent
on hole cleaning and cuttings removal. Previous studies have focused around critical mud flow rates and
quantitative models to predict cuttings transport. A previous paper(1) calculated the rheology factor (RF)
and angle factor (AF) and combined them with the mud weight (MW) to form the Transport Index (TI):

The RF can be found from the PV and YP and the AF looks at the effect of the hole angle. At a given
rate of penetration (ROP), increasing this TI will reduce the critical flow rate (CFR) and therefore improve
hole cleaning. Advanced hydraulic programs have now become an industry standard to predict and
optimize mud velocities for optimal hole cleaning. This paper is focused on the mechanical agitation of
cuttings so that they may be reintroduced into the section annulus with critical mud flow to improve the
transport through the long horizontal section.
The analysis presented describes the setup, monitoring, and results of Franks cutting bed impeller
(CBI) tool performance in well A1, and provides a comparison to the well B1 offset.
Well A1 resumed drilling from a pre-set 958 in. casing point in December 2013 in the Manifa field. The
well was drilled from surface to a 30,480 ft measured depth and into a stratigraphic environment
composed of limestone, sandstone, and siltstone (Buwaib, Yamama, Upper, and Lower Ratawi formations-represented in Figure 1). The objective was to hold vertical from surface to 1,535 ft, build-up to 85
from 1,535 ft to 11,659 ft and hold a 85-90 inclination to total depth. The section and plan views can be
seen in Figure 2 and Figure 3, respectively.

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Figure 1Stratigraphic Chart

Figure 2Section View Well A1

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Figure 3Plan View Well A1

The challenges were to hole clean while drilling the long 8 in. tangent section from 11,659 ft to
24,160 ft to address these challenges, Franks recommended the utilization of 47 tools of 5 in. Series
CBIs at a frequency of one tool per three stands on the 5 in. drill pipe with 4 in. IF connections. See
Table 1 for the full bottom-hole assembly (BHA), Figures 4 and 5 for side forces experienced, and Tables
2 and 3 and Figures 6 and 7 for CBI placement information.
End of Run:
The 8 in. tangent section was drilled with 5 bit runs and Schlumberger PowerDrive assemblies. The
interval was drilled smoothly without any hole cleaning issues (no tight hole or stuck pipe). The primary
hole cleaning was achieved during drilling and no secondary hole cleaning was required.
The placement of 47-5 in. Series CBIs in the drill string provided reduction in torque and drag, reduced
the chances of getting stuck due to pack off and ensured cleaner and more stable hole conditions.
Context

Saudi Aramco Saudi Arabia NBR-115 rig well A1

8 in. Section: From 10,828 ft to 24,160 ft
Profile: Tangent section [85-87 inclination]
Driving System: Rotary Steerable System Schlumberger Xceed 675
Franks CBI: 5 in. series

No. of tools used: 47

Connection: 4 in. IF
Placement at TD: 11,828-23,013 ft
Objectives

Install Franks CBIs every three stands to enhance hole cleaning and ensure cleaner and more
stable hole conditions

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Reduce frequency of HI Vis pill or wiper trips to save drilling cost

Reduce torque and drag while in drilling and tripping mode

BHA Description
Table 1BHA Description Well A1

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CBI Placement / Inclination

Start of Run:

Table 2Start of Run

Figure 4 Side Force

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End of Run:

Table 3End of Run

Figure 5Side Force

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At a total depth of 24,160 ft, the Franks CBIs were covering the 8 in. OH tangent section from
11,828 ft to 23,013 ft MD.

CBI Placement/Well Profile

Start of Run:

Figure 6 Start of Run

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End of Run:

Figure 7End of Run

Torque and Drag Analysis

Off Bottom Torque Chart
Figure 8 shows that from 10,828 ft to 14,000 ft, the off-bottom drilling torque progressively increased
from 7,000 ft-lb to 10,000 ft-lb with an open hole friction factor of 0.22. From 14,000 ft to 17,000 ft, the
off-bottom drilling torque remained constant at 10,000 ft-lb, and the open hole friction factor dropped
from 0.22 to 0.14. From 17,000 ft to 19,000 ft, the off-bottom drilling torque increased from 10,000 ft-lb
to 13,000 ft-lb, with an open hole friction factor of 0.16. From 19,000 ft to 24,160 ft, the off-bottom
drilling torque slighly increased from 13,000 ft-lb to 14,000 ft-lb, and the open hole friction factor dropped
from 0.16 to 0.12.

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Figure 8 Off-bottom Torque Chart

The 47 CBIs installed on the 5 in. drill pipe contributed to the low rotational open hole friction factor
experienced while rotating off-bottom. The open hole friction factor decreased from 0.22 at the beginning
of the run to 0.12 at total depth. Non rotating drill pipe protector (NRDPPs) were also installed on the 5
in. drill pipe throughout the cased hole, and contributed to the low rotational friction factor encountered
during this run.
On-bottom Torque Chart
Figure 9 shows that from 10,828 ft to 14,400 ft, the on-bottom drilling torque progressively increased from
11,000 ft-lb to 14,000 ft-lb, and the open hole friction factor was 0.18. From 14,400 ft to 18,800 ft, the
on-bottom drilling torque slightly increased from 14,000 ft-lb to 15,000 ft-lb, and the open hole friction
factor dropped from 0.18 to 0.12. From 18,800 ft to 19,600 ft, the on-bottom drilling torque increased from
15,000 ft-lb to 18,000 ft-lb, and the open hole friction factor increased from 0.12 to 0.16. From 19,600

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ft to TD, the on-bottom drilling torque slightly increased from 18,000 ft-lb to 19,000 ft-lb, and the open
hole friction factor decreased from 0.16 to 0.12.

Figure 9 On-bottom Torque Chart

Utilization of the 47 CBIs showed a great reduction in the rotational friction factors from 0.18 to 0.12
while drilling the 8 in. tangent section. A major reduction in the friction factor was also observed in
the last 5,000 ft of the run, when the majority of CBI tools covered the tangent section.
Tripping Load Chart
The 47 CBIs installed on the 5 in. drill pipe showed a substantial reduction in hook load (Figure 10). In
Table 4, the last trips (#2 and #3) showed a 27.3% increase of slack-off weight and an 11% decrease of
pickup weight, when compared with the simulated hook load with FF 0.15/0.20.

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Figure 10 Tripping Chart Load

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Table 4 Tripping Chart

Hole Cleaning Analysis

SchlumbergerGeoservices installed a cuttings flowmeter (CFM) at the shaker to evaluate hole cleaning
and monitoring the well using their CLEAR service. The CLEAR service monitors hole-cleaning
effectiveness and wellbore stability. The weight of cuttings reaching the surface was continuously
measured and analyzed coming off the shale shakers. By comparing measured and theoretical volumes,
the service provides early detection of inadequate hole cleaning and excess returns caused by wellbore
instability (caving) and/or formation damage. Figure 11 shows the cumulative cuttings recovery for well
A1.

Figure 11Hole Cleaning Chart Showing Recovery % of Cuttings and Dry Volumes

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Summary
A cumulative depth of 13,332 ft was drilled in 8 in. and a final trip at section TD was smooth on
elevators, which indicated an excellent hole cleaning. Table 5 summarizes the hole cleaning status and
recovered volumes as recorded by the cuttings flowmeters.
Table 5Cuttings

Figure 12 shows smooth pull out at TD in open hole section, showed efficient hole cleaning and stable
wellbore conditions.

Figure 12Time Chart Showing the Hook Load and Block Position while Pulling Out in the Open Hole Section

Result

Drilled 13,332 ft in 8 in. section without any hole cleaning issues and no tight hole or stuck pipe
events were recorded.
Drilled 5,490 ft and 3,895 ft in one run (POOH for BOP test and tool failures).
Primary hole cleaning was achieved during drilling no secondary hole cleaning was required.
Excellent hole cleaning efficiency with a CFM recovery of 91.6%.

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All planned short trip/wiper trips were avoided due to optimum hole cleaning, although smooth
tripping to the last casing shoe without pump or rotation was performed four times due to tool
failures and BOP test.
Pill efficiency was monitored and optimized based on CFM data. Only one pill was pumped every
4-5 stands drilled instead off every 45 ft or stand drilled.
With the help of hole cleaning assurance, up to 1,100 ft were drilled without pumping any tandem
pill.
Final trip at TD was smooth, which ensured a better hole cleaning and stable wellbore condition
prior to running 7in. liner.

Offset Well Comparison

Well A1 versus Well B1
Using almost the same drilling parameters, a significantly higher ROP and more consistent footage per
day as noticed in well A1 due to better hole cleaning as compared to well B1 (Figure 13).

Figure 13Comparison between Footage per Day and ROP on Well A1 and B1

Drilling Parameters and Recovery

Well A1 and Well B1 have similar well profiles and architecture. The 8 in. sections for both wells were
a long slant of 85-88 inclination. Identical drilling practices were utilized for both wells (Table 6). Table
7 and Figure 14 show a 91.6% cumulative recovery of well A1 was observed, while a cumulative recovery
of only 82% of well B1 was recorded. An enhancement of 11.7% of cumulative recovery attests to the
great potential of the CBI tools to improve hole cleaning.

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Table 6 Drilling Parameters

Table 7Drilling Parameters - 2

Figure 14 CFM Recovery% as recorded on Well A1 & B1

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Pills Monitoring and Optimization

Pills were monitored with the help of CFM data and based on their efficiency the frequency of pills were
optimized. A major improvement in pills frequency and the total number of pills experienced in well A1,
and a reduction of greater than 50% in pills frequency was achieved (Table 8).

Table 8 Pills Monitoring

Trips/Wiper Trips
All trips in well A1 were due to measurement while drilling (MWD) failure as seen in Table 9. The
primary hole cleaning was achieved while drilling. No wiper trip or back ream was required due to the
excellent hole condition. In well B1, tight spots and high torque were observed, and several wiper trips
were necessary to clean the hole.

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Table 9 Trips monitoring

Desired/Undesired Practices
Most effective drilling practices were followed in well A1, and as a result a significant higher performance
was noticed. Primary hole cleaning was achieved while drilling and therefore planned wiper trips were
avoided. Some undesired drilling practices were noticed in well B1 that affected the overall performance.
Primary hole cleaning was compromised from the start of section and as a result few wiper trips and
secondary circulations were necessary to avoid hole cleaning issues (Table 10).

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Table 10 Desired and Undesired Practices

Well A1 versus Well C1

Tripping Load Comparison Well A1 and well C1 have similar well profiles and architecture. The
slackoff weight of well A1 had a tendency to increase and the pickup weight showed a decreasing trend
in the last 5,000 ft of the run, while the slackoff weight of well C1 had a tendency to decrease and the
pickup weight showed an increasing trend for the 8 in. run, as evidenced in Table 15 and 16. The
positive trend of the drag confirms the CBIs cleaning effect in well A1.

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Figure 15Tripping Load Comparison of Well A1

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Figure 16 Tripping Load Comparison of Well C1

Conclusion

The 8 in. tangent section from 10,828 ft to 24,160 ft was drilled successfully with 5 bit runs. All
bits were POOH in excellent and re-runnable condition. The 47 CBIs installed in the drill string
met and exceeded expectations. The CBIs efficaciously enhanced hole cleaning and ensured a
cleaner and more stable hole condition while drilling the 8 in. tangent section of well A1.
The 8 in. section was successfully drilled without any hole cleaning issues (no tight hole or stuck
pipe events were noticed). Primary hole cleaning was achieved during drilling and no secondary
hole cleaning was required.
The CFM recovery of 91.6% showed excellent hole cleaning. All short/wiper trips were avoided
based on hole cleaning assurance. Pills efficiency was also monitored and their frequency was
optimized. As a result, above 50% of pills volume was saved as compared to drilling plan.
The hole cleaning comparison between well A1 and well B1 revealed the effectiveness of the CBI
tools, with an 11.7% improvement of recovery and a 50% decrease of pills frequency; no wiper
trip was performed.
The 47 CBIs showed a substantial reduction in the rotational friction factor while rotating
off/on-bottom. The open hole friction factor was reduced from 0.22 at the beginning of the run to
0.12 at TD.
The 47 CBIs showed a significant reduction in hook load. The last trips (#2 and #3) showed a
27.3% increase of slack-off weight and an 11% decrease of pickup weight compared with the
simulated hook load with FF 0.15/0.20.
For well A1, the slackoff weight had a tendency to increase and the pickup weight had a decreasing
trend in the last 5,000 ft of the run. Alternatively, the slackoff weight of well C1 had a tendency

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to decrease and the pickup weight showed an increasing trend for the entire 8 in. run. The
positive trend of the drag confirmed the CBIs cleaning effect in well A1.
Nomenclature
ERD
MD
TVD
CBI
TI
RF
AF
MW
CFR
TD
HI Vis
OH
BHA
DP
HWDP
CHFF
OHFF
NRDPP
CFM
POOH
BOP
ROP
RPM
HC

Extended Reach Drilling

Measured Depth
Total Vertical Depth
Cutting Bed Impeller
Transport Index
Rheology Factors
Angle Factors
Mud Weight
Critical Flow Rate
Target Depth
High Viscosity
Open Hole
Bottom-hole Assembly
Drill Pipe
Heavy Weight Drill Pipe
Cased Hole Friction Factor
Open Hole Friction Factor
Non-Rotating Drill Pipe Protectors
Cuttings Flowmeter
Pull Out of Hole
Blowout Preventer
Rate of Penetration
Revolutions Per Minute
Hole Cleaning

Acknowledgments
We would like to thank the management of Saudi Aramco for the permission to publish this work. Thanks
are also due to all the operations personnel of Saudi Aramco, Franks International, and Schlumberger
who have provided considerable support throughout this work.

References:
1. Luo, Y., Bern, P.A., Chambers, B.D., Kellingray, D.S.: Simple Charts to Determine Hole
Cleaning Requirements in Deviated Wells, paper IADC/SPE 27486, presented at the 1994
IADC/SPE Drilling Conference, Dallas, Texas, February 15-18, 1994.