SPE 140459 New Technique to Sidetrack Across Hard Formation in North Oman

Ahmed Al Salmi, Younes Al Haji, Saif Al-Hamhami, and Isehaq Sabhi, Petroleum Development Oman LCC; and Abduallah Al Fadhli, SPE, Halliburton

Copyright 2011, Society of Petroleum Engineers This paper was prepared for presentation at the SPE Middle East Oil and Gas Show and Conference held in Manama, Bahrain, 69 March 2011. 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 In a north Oman field, it is common practice to cement vertical pilot holes up to the kickoff point. A cement plug is then used to initiate the sidetrack through extremely hard formations. Previously, it has taken several attempts to sidetrack these holes and, in some cases, a mechanical whipstock had to be used. There are challenges when trying to initiate the sidetrack because the formation hardness far exceeds that of the kickoff cement plug. As a result, the sidetracking assembly is repeatedly directed back into the relatively softer cement plug (i.e., vertically). Gravity also plays a role to some extent in bringing the sidetracking assembly back into the vertical hole, increasing the challenge. This paper documents successful implementation of modifications to the slurry design and cementing procedure, as well as the successful use of a side-tracking method/technique in North Oman. The compressive strength of cement has been increased from 5,000 to around 9,000 psi for standard, 17-lbm/gal, Class G cement. The effect of oil-based mud (OBM) contamination has been examined and spacer designs have been improved to help ensure good mud displacement while performing cementing operations. The sidetracking method and tools have also been improved with impressive results. This includes proper selection of the kickoff point based on the drill-speed log of the vertical pilot hole, selecting the correct combination and configuration (e.g., outside diameters of components and angle setting) for the bottomhole assembly (BHA), and using the correct application parameters and techniques while initiating the sidetrack, which is also called time-drilling. This paper investigates the new techniques applied in detail and clearly illustrates their development. Some case histories are also presented. Introduction Operators set cement plugs for a variety of reasons (e.g., abandonment, sidetracking, lost-circulation control, or remedial work (Heathman 1996). Achieving a successful kickoff plug on the first attempt is a difficult task because of operational challenges that can occur while placing the cement. Oilfield operators have reported many issues that can negatively influence the performance of cement plugs (Al-Yami et al. 2008), some of which are presented below. Plug slippage Drilling out too soon without waiting for compressive-strength development Inaccurate well data Insufficient slurry volume Poor slurry design Losses while reversing Poor mud removal Neglecting these issues during the job design or execution can have a significant impact on drilling time and cost. To reduce such impact, recommended practices (Babasheikh et al. 2003) have been developed to address certain operational factors, such as planning and laboratory evaluation of prejob conditions, cementing fluids, and placement.

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Many cement guidelines have addressed typical cement-plug properties, such as thickening time, free water, rheology, compressive strength, and fluid loss. However, unless the well has exhibited severe problems, variables, such as fluid loss, gas migration, rheology, solids support, and fallback control, are rarely factored into slurry design for plug cementing (Heathman 1996). Conventional cement formulations are used to prepare cement plugs for sidetrack drilling (Al-Yami et al. 2008). One of the techniques used to help kicking off is to make the compressive strength of the plug greater than that of the formation, or to increase the toughness of the plug. Some of these formulations contain silica sand to help increase the cement compressive strength. Cement compressive strength is a result of the growth of hydrated calcium silicate crystalline structures (Lea 1988). The strength of the cement increases as these structures grow with time. The toughness of the cement plug can also be increased by reinforcing the cement matrix with materials, such as polymer fibers. However, concerns have been raised about potential degradation of some cement properties (i.e., porosity, permeability, and compressive strength) when fibers are added. The compressive strength can be easily affected by contamination from drilling fluids. Therefore, the cement slurry should be kept uncontaminated during the placement because any contamination, such as OBM, can have a detrimental effect on hydration of the cement slurry, increasing thickening times and decreasing the final compressive strength (Diaz et al. 2009). Conditioning the openhole before placing a cement plug is an important task for all operating companies. Several steps are recommended to condition the wellbore to remove as much mud as possible before placing a cement plug. The planned plugged interval should be washed and reciprocated with string several times. Circulation should be performed at a high annular velocity of 240 to 400 ft/min (73 to 122 m/min) if well conditions permit. This is a proven method to help ensure mud removal (Rasheed 2003). After mud gels is broken, annular velocity is used to maintain mud mobility; the highest annular velocity possible usually provides the best displacement efficiency (Heathman 1996). In addition, it is recommended to minimize shutdowns to keep the mud in a fluidized condition (Halliburton Cement Plug Guidelines 2010). Drilling fluid properties play an important role in the success rate of openhole cement plugs. Achieving the proper mud parameters (funnel viscosity, plastic viscosity, yield point, gel strength, and fluid loss) aids efficient mud removal and successful placement of cement plugs. If the filter cake and mud have not been well removed, such contamination can greatly reduce the compressive strength of the cement (Dees and Spradlin 1982). Preventing mud contamination is important and can reduce compressive strength by 70% when using OBM systems (Rasheed 2003). However, the effect of OBM contamination on reducing the compressive strength can be eliminated by proper design of spacers. OBMs are typically removed with spacers containing surfactants, organic solvents, or both. Such surfactants should be able to water wet the surface or casing to create a good cement bond. In addition, the volume of the spacer ahead of the cement should be sufficient enough to provide about 500 to 1,000 ft (~150 to 300 m) of annular fill or a 10-minute contact time to achieve good fluid separation and hole cleaning. This paper summarizes the newly developed slurry design, new placement procedures, and the methodology for sidetracking applied on the candidate wells discussed. Additionally, the reasons for using a cement plug to kickoff instead of using an openhole whipstock are discussed. Slurry Design The initial slurry design used in this field was a standard 17-lbm/gal slurry mixed with Class G cement with friction reducer and retarder. This design had a compressive strength of around 4,300 psi (Fig. 1). Because the formation strength was high (approximately 7,200 psi), it was difficult to initiate a sidetrack and the drilling took an extremely long time. In some cases, sidetracking off the cement plug was not achievable, and the whipstock had to be used. The slurry design was then modified using a standard, 17-lbm/gal, Class G slurry, but with 25% 100-mesh silica sand. The silica sand helped increase the compressive strength and helped the drillability of the cement to enhance sidetracking. This new modification resulted in some improvement and a reduction in drilling-procedure time. The compressive strength of this formulation was 5,300 psi (Fig. 2) and the density after adding the silica sand was 17.3 lbm/gal. The slurry was then modified again by increasing the slurry density to 17.5 lbm/gal with more friction reducer and retarder. After achieving the final density of 17.5 lbm/gal, 15% 100-mesh silica sand was added again to enhance the strength and drillability of the cement. The density increased to 17.8 lbm/gal after adding the silica sand, and the compressive strength increased to 9,000 psi in 24 hours (Fig. 3). Fig. 4 illustrates the thickening time chart for the 17.5-lbm/gal slurry with 15% 100mesh silica sand. To avoid the settlement of silica sand in the mix water for the second and third modification of the slurry, silica sand was added to the batch mixer and final density was achieved. The implementation of this mixing sequence/procedure helped achieve a uniform slurry with the required compressive strength.

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Cement Placement Procedure OBM was used to drill the pilot hole in this field because of some geological challenges. The implementation of the modified placement method led to successful sidetracking in the candidate wells discussed next. OBM was conditioned before performing cementing operations with a deflocculant to disperse and thin the mud. Spacers were pumped ahead of the cement to displace mud and prevent contamination of the cement slurry. The recommended spacer design included the following fluids: A total of 20 bbl of base oil was used to clean the filter cake and dilute the thickened OBM attached to the openhole wellbore. A total of 50 bbl of weighted spacer was used. It contained KCl to increase the weight and condition stable flow behavior. Surfactants were also included to clean and wash the wellbore. A total of 20 bbl of fresh water was used to separate the KCl spacer from cement. It has been observed that displacing the cement at the highest possible rate will help remove the filter cake and help create proper mud displacement. An excess of 100% cement volume was used for the kickoff plug. With this extra volume, the contamination issue was minimized. Methodology for Sidetracking The BHA and formation lithology (kickoff point) are the main factors associated with successful sidetracking. Both were carefully selected based on field experience and conditions of the pilot hole. Although a kickoff point was given in the design proposal, the actual kickoff point was selected based on the drilling parameters observed while drilling the pilot hole. It was decided to select a relatively softer spot in the pilot hole where kickoff might be easier and faster. Fig. 5 is a snapshot showing that shale concentration is greater at a depth of 2860 m. The rate of penetration (ROP) graph (Fig. 6) also supports this information, revealing that a higher ROP was obtained at 2860 m in the pilot hole. This indicated that a relatively softer formation started at 2860 m and kickoff was expected to be relatively easier at this depth. After selecting a proper zone to sidetrack, as mentioned previously, the BHA for sidetracking was selected based on experience. This recommended BHA consisted of the following: a TCI bit, directional motor (with sleeve/no top stabilizer), NMDC, mud while drilling (MWD), a heavyweight drillpipe (HWDP), drilling jar, and drillpipe (DP) to surface. A TCI bit is highly recommended for sidetracking because it achieves a slightly higher buildup rate than PDC bits; therefore, it has a greater tendency to sidetrack. Procedure to Kickoff from Vertical Pilot Hole with CMT Kickoff Plug in the Khuff Formation. Use a 8 3/8-in. TCI bit with directional motor and set motor bend to 1.5. Set the motor sleeve to 8 1/4 in. (under gauge by 1/8 in). Do not RIH with any larger-sized sleeve and do not RIH with top motor stabs. RIH to TOC at the same depth where the excess CMT will be circulated out. Wash down until a slackdown is observed. Then, start dressing cement down to planned sidetrack point. While dressing the CMT, ensure the CMT is hard enough at the sidetrack zone from the drilling parameters (WOB 3 to 5 ton and slightly slow ROP~<10 m/hr). Time Drilling Orient tool face to the required direction and keep pointing the bit while washing at that point for ~0.5 hr (string stationary). Time-drill ~2.5 cm in 6 minutes until cutting returns show 100%. Collect a formation sample at 1 m. while time-drilling. Expect to observe slackdown weight around ~3 ton (when sample shows 30 to 50% formation); it is recommended not to push more weight to avoid damaging the ledge and falling back to the old hole. Drill 2.5 cm in 3 minutes for 3 m with slight increase in WOB ~4 ton (confirm sample 100% during the 2 m). Continue drilling in slide mode for full single (~9.5 m) and maintain WOB ~4 to 6 ton to get enough separation. For the second single, 70% of the single should be drilled in sliding mode. This might produce a higher dogleg than required, but the plan can be corrected later, once enough separation is achieved. After getting enough separation (~30 m), continue drilling BUS as per trajectory plan (or POOH for BHA change if required). However, much precaution must be taken while passing with a BHA through the sidetrack point at any time. While RIH, stop at least 30 m (~1 stand) before KOP and orient tool face to high side. Then, continue RIH slowly through KOP and never pump or rotate until passing KOP at least with ~30 m to avoid damaging the KOP and getting held up in the old hole. Consideration should be taken to ensure smooth entry of the BHA through the KOP just before POOH with the sidetrack BHA.

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Field Trials Field X. The well design for Field X contained a 13 3/8-in. (at 580 m), 9 5/8-in. (at 2500 m), and 8 3/8-in. (at 3450 m) pilot hole to the reservoir. The pilot hole was plugged back and the well was sidetracked to land horizontally with a 7-in. liner. The reservoir section was drilled underbalanced with a 6 1/8-in. barefoot completion, as shown in Fig. 7. The pilot hole was cored and logged to gather reservoir data, and then plugged back with two abandonment plugs and one kickoff plug. After WOC, the 8 3/8-in. directional drilling assembly was RIH and time-drilling was initiated for the sidetrack. The following examples provide details of successful trials of four kickoff plugs using the new cement-plug slurry. Well A. A vertical top hole was drilled in Well A with a 17.5-in. drilling assembly to 750 m and cased with a 13 3/8-in. assembly, then drilled with a 12 1/4-in. assembly to 2534 m and cased using the 9 5/8-in. assembly. The 8 3/8-in. pilot hole was drilled from 2534 to 3351 m and then logged. It was plugged back with cement to 2670 m with two abandonment plugs and one kickoff plug. The kickoff plug was placed from 2920 to 2672 m using a 17-lbm/gal cement slurry with 25% 100-mesh silica sand, where the excess cement was circulated out at 2670 m. After waiting 24 hours on cement, the 8 3/8-in. BHA was RIH and drilling of the cement resumed at 2672 m. While drilling the plug, 1 to 2 kdaN weight was applied on the bit with a flow rate of 1.5 m3/min. The sidetrack was achieved successfully after drilling 188 m of the plug in 61 hours drilling time, and 100% formation cuttings on the shale shaker. Well B. This well had similar design to the previous well; the only difference was that the 13 3/8-in. BHA was set at 568 m and the 9 5/8-in. BHA was set at 2398 m. The pilot hole was drilled with a 8 3/8-in. bit from 2398 to 3322 m and then logging was completed. Three cement plugs (two abandonment plugs and one kickoff plug) were placed separately all the way to 2642 m. The kickoff plug had a density of 17.5-lbm/gal with 15% silica sand and was placed from 2876 to 2642 m. The 8 3/8-in. BHA was RIH to drill the plug after waiting 24 hours for the cement to harden. The cement was dressed with a 8 3/8-in. bit from 2644 to 2790 m. The sidetrack was achieved successfully after 9 m (!2.5 cm every 1 min) of time-drilling and 33 hours of time-drilling (100% formation was observed). Then, only 3 m were drilled in sliding mode to avoid drilling in rotary, which resulted in damaging the ledge and going back into the old hole. A decision was made to drill the cement from 2825 to 2860 m and then attempt another sidetrack with time-drilling using the same parameters that were used in the first attempt. The time-drilling technique was successfully implemented within the same time frame and 100% formation was observed. After that, drilling continued for a full two singles in sliding mode to avoid damaging the leg and a successful sidetrack was achieved. Fig. 8 is a typical pump chart for this job. Well C. The casing design of this well was similar to the previous two wells. The 13 3/8-in. BHA was set at 566 m and the 9 5/8in. BHA was set at 2393 m. The 8 3/8-in. buildup section was drilled from 2393 to 3910 m. After reaching TD, the 7-in. liner was RIH, but because of hole problems, the decision was made to pull it out and go for a check trip. The 8 3/8-in. assembly was run to wash down and the tight spots were reamed; however, because of the slow progress and inability to reach the TD, the decision was made to abandon the hole and sidetrack. Initially, the well was plugged back with an abandonment plug followed by setting an openhole whipstock. The sidetrack could not be achieved and the decision was made to spot the cement plug. The kickoff plug was placed from 2974 to 2724 m using 17.5-lbm/gal and 15% silica sand, where the excess cement was circulated out. After waiting 24 hours on the cement, the 8 3/8-in. slick assembly was RIH to tag hard cement at 2724 m. While drilling the plug, 3 kdaN of weight was applied on the bit with a flow rate of 1.8 m3/min. The sidetrack was achieved successfully after drilling 211 m of the plug in 104 hr drilling time, and 100% formation cuttings on the shale shaker were observed. The longer drill time required in this well was mainly attributed to the slow rate (~2.5 cm every 5 min) compared to the previous well. Comparison of Cement Plug and Openhole Whipstock An openhole whipstock was applied to the kickoff after several unsuccessful trials with a standard 17-lbm/gal slurry. The cement plug is always preferred to sidetracking because of its operational simplicity and for economical aspects. Sometimes, time-drilling operations will cost slightly more (depending on formation hardness) than using an openhole whipstock method; however, the time-drilling method is still preferred because of the risks associated with openhole whipstock operations. According the history of Field X, the whipstock is still not preferable for the following reasons: Sidetracking using a cement plug and time drilling was achieved in an average time of 2 to 3 days, which proved to be less expensive than using an openhole whipstock. In one case in Field X, the drill-time cost was slightly higher than if an openhole whipstock was used, assuming a smooth sidetrack was achieved with the whipstock. However, it was still preferred to continue the practice of time-drilling because of the risks associated with using a whipstock.

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Extra runs were required before and after setting the whipstock, which made it more expensive (including its cost) than using the time-drilling technique. There is difficulty associated with setting the whipstock at deeper depths. There is a risk of dropping the whipstock while RIH. There is a chance of setting the whipstock in the wrong direction. There is risk of spinning the whipstock while drilling through it, or getting stuck on it.

Conclusion The implementation of a new cement-slurry design has lead to an increase in successful sidetracking operations in Field X. Increasing the density of the cement slurry to 17.8 lbm/gal with silica sand has resulted in higher compressive strength of cement. Optimization of the spacers (fluid types and volumes) was carefully examined and implemented in each of the presented case histories. A thorough understanding of the factors that can affect the placement of a cement plug and sidetracking has lead to operational success. The kickoff point at which the cement was placed and drilled through was chosen based on the lithology and drilling performance of a pilot hole. Acknowledgment The authors express gratitude to Petroleum Development Oman (PDO) and the Oman Ministry of Oil and Gas, and to Halliburton for allowing this paper to be published. The authors additionally thank the PDO MAF lab and the Halliburton lab for their technical support conducting required lab tests. Nomenclature BHA = bottomhole assembly DP = drillpipe HWDP = heavyweight drillpipe KOP = kickoff point MWD = measuring while drilling POOH = pull out of hole RIH = run in hole ROP = rate of penetration TOC = top of cement UCA = ultrasonic cement analyzer WOC = wait on cement References
Al-Yami, A., Nasr-Al-Din, H., Jennings, S., Khafaji, A., and Al-Humaidi, A. 2008. New Cement Systems Developed for Sidetrack Drilling. Paper SPE 113092 presented at the Indian Oil and Gas Technical Conference and Exhibition, Mumbai, India, 46 March. doi: 10.2118/113092-MS. Babasheikh, A., Hun, A., Cunningham E., and Helou, A. 2003. New Shock Resistant Cement Reduces the Required Time for Side-Tracking from Kick-Off Cement Plugs. Paper SPE/IADC 119415 presented at the SPE/IADC Drilling Conference, Amsterdam, the Netherlands, 1921 February. doi: 10.2118/79908-MS. Dees, J. and Spradlin, W. 1982. Successful Deep Openhole Cement Plugs for Anadarko Basin. Paper SPE 10957 presented at 57th Annual Fall Technical Conference and Exhbition, New Orleans, Louisiana, 2629 Septemper. doi: 10.2118/10957-MS. Diaz, L., Flores, J., Justus, F., Pasteris, M., Flamant, N., and Milne, A. 2009. Innovative Computer Modle Increase Success Rate Whne Placing Deep Kickoff Plugs in Southern Mexico. Paper SPE/IADC 119415 presented at SPE/IADC Drilling Conference and Exhibition, Amsterdam, the Netherlands 1719 March. doi: 10.2118/119415-MS. Halliburton Cement Plug Guidelines. 2010. HAL.9002.00004.0485. Heathman, J.F. 1996. Advances in Cement-Plug Procedures. JPT. 48 (9): 825831. doi: 10.2118/36351-MS. Lea, F.M. 1988. The Chemistry of Cement and Concrete, Third Edition, New York: Chemical Publishing Co. Inc. p.253. Rasheed, W. 2003. Effective Cement Plug. E & P. November.

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Fig. 1UCA chart for standard 17-lbm/gal slurry.

Fig. 2UCA chart for standard 17-lbm/gal slurry with 25% 100-mesh silica sand.

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Fig. 3UCA chart for 17.5-lbm/gal slurry with 15% 100-mesh silica sand.

Fig. 4T/T chart for 17.5-lbm/gal slurry with 15% 100-mesh silica sand.

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Fig. 5Formation evaluation log for Well A.

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Fig. 6Rate of penetration against depth for Well A.

Fig. 7Well design for Field X.

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Fig. 8Typical job chart for 17.5-lbm/gal with 15% 100-mesh silica sand. Density is not shown as the slurry was batch mixed.