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Energize your mind. www.halliburton.

com December 2005



In a "systems solutions" approach that integrates Halliburton
technologies and product service lines, new reamer technology
from Security DBS Drill Bits has been combined with Sperry
Drilling Services' FullDrift system in a drilling package that
successfully challenges the technical limits of conventional hole
enlargement operations.
Planned Hole Enlargement covers a range of operations that
result in an "oversized" hole below a conventional-size borehole
or restriction. Driven in part by continuing advances in well
design and casing technology, hole enlargement is an expanding
market, expected to comprise an estimated 16 percent of total
worldwide footage drilled by 2007.
Whether dictated by formation, use of expandable tubulars
and/or mono-diameter technology, hole enlargement operations
optimize hole size in the completion zone and allow the largest
possible casing string to be set while maintaining a quality
cement job. The process is accomplished with specifically-
designed tools which can pass through a restriction, usually a
cased hole, in order to enlarge the area below, either in one pass
while drilling (simultaneously), or after a pilot hole has been
drilled.
In a growing number of hole enlargement applications, including
extended-reach, high-angle wells and hard formation drilling,
simultaneous hole opening technology is required that can
withstand downhole vibration to reliably perform when extreme
wellbore geometry requires BHA steerability.
New Concentric Ultra-reaming Drilling Apparatus (CUDA
Reamer) technology from Security DBS was designed to meet
these growing technical demands, providing simultaneous hole
enlargement drilling in both rotary and rotary steerable
applications.
With "on demand" activation and deactivation, CUDA and CUDA-
XR reamer tools can be positioned in the string or in a near-bit
configuration, and are capable of enlarging a hole 10 - 50% over
pilot hole or "drift" diameter.
Advanced Drilling Package Incorporates New
Reamer Technology to Redefine Technical
Limits for Hole Enlargement Applications







Stein Erik Moi

Product manager DHT


Once the desired hole interval is enlarged, the tool is deactivated
and locked in the closed position to allow effective drilling ahead
with the original pilot hole size and/or full flow circulation with no
risk of cutter arm deployment.


Tool reliability already is proven in successful field applications
that include a world record for the longest 12-1/4" x 13-1/2" hole
opening run, in which a CUDA-XR 1200 drilled 4645 meters in a
Norwegian offshore well while simultaneously opening the 12-
1/4" hole to 13-1/2".
The Drilling Package
When run on a FullDrift system combining the Geo-Pilot system
and extended gauge bit, the CUDA-XR Reamer provides a
versatile new option in hole enlargement operations, redefining
the technical limits for these applications.
The system allows a wellbore to be steered in any desired
direction while rotating the drillstring. Delivering maximum
wellbore drift, the system uses point-the-bit technology to
achieve directional control by deflecting a one-piece rotating
driveshaft off-center between two bearings. This deflection
"points" the FullDrift bit, which has an extended gauge design
that acts as a stabilizer or centralizer to keep the bit on true
center, eliminating hole spiraling and improving directional
control.
Using real-time data from the Geo-Span downlink
communication system, the system is pointed and
controlled by the directional driller while in manual
steering mode, and is self-guiding along a pre-
programmed trajectory in automated mode.
With the Geo-Span downlink providing "on-the-fly"
two-way communication between the directional
driller at surface and the drilling system downhole,
wellbore trajectory can be controlled with extreme
precision. In one North Sea application, a CUDA 800
Reamer was matched with a Geo-Pilot 7600 rotary
steerable system to simultaneously drill and open
horizontal wellbores that were steered precisely






within reservoir targets just 3 to 15 feet thick.
Clearly, this advanced drilling package combines technologies
that are redefining the technical limits of hole enlargement
applications.
Case History: Norsk Hydro, Well 30/9 F29
In this offshore Norwegian application through hard chalk in the
Shetland formation, extreme vibration plagued previous reamer
runs to open the 12-1/4" hole to 13-1/2".
In this well, plans called for rotary steerable drilling through 700
meters of the Shetland's Cretaceous chalk while opening the hole
from 12-1/4" to 17-1/2".
Combining hole enlargement drilling with steering
capability, a CUDA-XR1200 reamer was matched with a
Geo-Pilot 9600 rotary steerable system using an
FMF3643ZSC bit. Incorporating highly abrasion-
resistant Z3 PDC cutters, the extended gauge
FullDrift bit design from Security DBS is based on
advanced FM3000 Series technology proven to
improve directional drilling performance and deliver
higher rates of penetration without compromising the
life of the bit.
With this BHA run in hole to 2987m depth, the CUDA-
XR reamer was activated by drop ball after drilling 43
meters of 12-1/4" hole, with a clear indication of cutter
release at surface. The Geo-Span downlink enabled the
driller to change tool settings "on-the-fly" to steer the
GeoPilot system without interrupting drilling or
compromising logging-while-drilling (LWD) data.
With the Geo-Span downlink monitoring Geo-Pilot
progress, the CUDA-XR then drilled 615 meters while
simultaneously opening the hole to 17-1/2", with a
drilling vibration log confirming no excessive vibration
was experienced. The drilling package was pulled out
of hole at 3634m depth after 63.5 hours, having
delivered 655 meters of enlarged hole in the
Cretaceous chalk at an average penetration rate of
10.3m/hr.
Case History: BP Norway, Well 2/11-S-03T4
This Valhall Flank well required drilling 900 meters of
open hole sidetrack in a single run from an existing 8-
1/2" wellbore, enlarging the hole while reaming and backreaming
to deliver 1125 meters of 9.20" hole for running a 7-5/8" liner. In
addition, a full LWD suite would be run, and full rotation and flow
inside the casing was required during the trip out.







Using the Geo-Span downlink for uninterrupted steerability
without loss of LWD data, a Geo-Pilot 7600 rotary steerable
system was matched with a FullDrift FMF3731 PDC bit design
based on the proven FM3000 Series technology from Security
DBS, and run with a CUDA 800 reamer. The BHA also
incorporated at-bit inclination and gamma sensors as well as a
full suite of LWD sensors for vibration, gamma, resistivity,
azimuthal lithodensity, and compensated thermal neutron, with
the CUDA positioned above these sensors in the drillstring.
In a single run, this advanced drilling package drilled 900 meters
of new formation in an open hole sidetrack, with the CUDA
opening the 8-1/2" hole to 9.20" before TD at 4805m, then
backreaming to the shoe to deliver a total of 1166 meters of 9.2"
hole suitable for running a 7-5/8" liner.
The successful run achieved all objectives, with the CUDA drilling
and opening the sidetrack in 44.5 hours at an average ROP of
25.8, then backreaming 264 meters in 22 hours for an overall
ROP of 12 m/hr. Real-time data from the ALD azimuthal
lithodensity tool, ABI at-bit inclination and ABG at-bit gamma
sensors assisted in efficient geosteering during drilling
operations, while the InSite system allowed real-time remote
monitoring by the client.
These outstanding performances reflect a "systems solution"
approach to increasingly complex hole enlargement applications.
Integrating rotary steerable drilling and LWD technology from
Sperry Drilling Services with advanced bit and reamer technology
from Security DBS, the resulting drilling package combines
Halliburton technologies and product service lines to successfully
challenge the technical limits of planned hole enlargement.







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