SPE/IADC 85339

Rotary-Steerable Technology Proves to be Economically Successful in Offshore

Arabian Gulf Fields
Dean S. Porter, SPE, Halliburton Sperry-Sun; Hasan Al-Faraj, Saudi Arabian Oil Company
Copyright 2003, SPE/IADC
This paper was prepared for presentation at the SPE/IADC Middle East Drilling Technology
Conference & Exhibition held in Abu Dhabi, UAE, 20-22 October 2003.
This paper was selected for presentation by an SPE/IADC Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the Society of Petroleum Engineers or the
International Association of Drilling Contractors and are subject to correction by the author(s).
The material, as presented, does not necessarily reflect any position of the SPE, IADC, their
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Abstract
In the Arabian Gulf, a rotary-steerable system utilizing pointthe-bit technology decreased the well-construction cost in
two Saudi Arabian offshore oil fields. Drilling offshore, in
many (if not all) parts of the world, is an expensive adventure.
Point-the-bit technology has successfully and consistently
controlled capital expenditures for wells in these offshore
fields and, in head to head comparisons, has cost less money
when compared to the conventional drilling systems that had
previously been used.
When it comes to offshore operational costs, time is a
nemesis. The application of point-the-bit technology as a
way to help solve this problem by permitting the economical
completion of a quality borehole will be discussed in this
paper. A major concern has been that the phenomenon known
as hole-spiraling which has created hole-quality issues.
These issues range from tortuous paths, torque-and-drag
frictional forces, key-seating or sump effects, and poor log
responses to name just a few of the problems. Thus, when the
quality of a borehole and the time it takes to drill it are
considered less than desirable, the drilling process and its
resultant effects increase well costs and reduce
operational efficiencies.
Several case histories within two offshore fields will be
presented in this paper. These case histories will show that
having the capability to make adjustments to downhole
drilling tools on-the-fly makes for better steering control
and creates better hole geometries. Correctly applying pointthe-bit rotary-steerable systems on these wells demonstrates
the value-added potential of this technology.
Introduction
The price and/or cost to do business in the oil-industry for
operations such as exploration, drilling, field-development,
and production has continually increased over time. Even in

the Middle East Region, where the cost to produce a barrel of

oil is one of the lowest in the world (Fig. 1), drilling costs
have naturally increased.1 This phenomena can be attributed
to many factors that are connected to supply and demand
which drive world market conditions. This trend to higher
drilling costs is not expected to change anytime soon and is
especially true when the work being performed is in an
offshore environment.
Because, at times cost seems to be the over-riding factor in
completing a well, the condition of the borehole could suffer
as a result. Operators of wells in areas that present formation,
structural, or integrity related problems would undoubtedly
prefer not to have borehole quality problems to deal with.
Problematic hole conditions, perhaps created unknowingly,
allow situations to occur that makes mechanically drilling the
hole very difficult.
In the past decade, considerable advancements in the
drilling phase from within the drilling services segment of the
industry have contributed to the reduction in operating costs
for operators worldwide. Such advancements in drilling tool
technology become even more important to the customer
when every minute of every day is measured on the
bottom line.
Rotary Steerable (RST) Systems have been part of the
industry for a number of years with the most recent
advancement being a point-the-bit system known
as Geo-Pilot
Value Analysis
Value is measured in many ways and is both quantified and/or
qualified differently between organizations. Value can be
specifically measured with the use of Time and Hole-Quality
as a function of deliverability to the bottom line. However,
even these specific measures, discussed more below, can
affect each other. For example, drilling too fast, or beyond the
capability to keep the wellbore clear of cuttings buildup, may
create a situation where more time to ream and condition the
hole is required or worse yet lead to a stuck BHA problem.
Time Savings.
For an operator, saving time on an offshore rig is very
valuable. As a result, it can be very tempting to drill as fast as
possible to reach TD in order to save time. However, doing so
can lead to conditions that will increase time. Being focused
on increasing ROP to the point of neglecting proper hole
cleaning can lead to major stuck-pipe problems.

Other time consuming problems may also arise, such as

difficulties running pipe or casing, high friction-factors while
drilling, and a wellbore profile that is tortuous. When time is
concerned the old saying: the shortest distance between two
points, is a straight line can easily apply for a tortuous
profile. It will typically require additional time, and money,
to create and work in it or, at the very worst, to fix it or go
around it.
Hole Quality Issues.
The well documented phenomena known as hole-spiraling
creates situations that can compound hole-quality issues.2
Borehole imaging tools have been able to provide a more
detailed look. (Fig. 2) Torque-and-drag frictional forces and
cuttings beds, to name a couple of factors, can be severe
enough that it prevents the hole from being completed to the
planned TD. As a result, precious time is spent fixing the
hole, if possible, in an effort to deliver the well as planned.
Not just in these cases, but within the industry as a whole,
we are seeing the profile of the previous hole section may be
a contributing factor in conditions that affect the performance
in the present wellbore. A wellbore section that is tortuous or
sinuous in nature, even when it has been cased off, could lead
to the inability to slide or rotate. A well studied equation
developed by Woods and Lubinski in 1954 helps explain and
thus resolve crooked-hole issues.3 Hence, the evolvement
of an extended gauge bit design combined with and
incorporated into the RST system for the tool descried in
this paper.
As horizontal wells become more challenging and
extended in reach, this problem will become more
challenging. In offshore environments particularly where
costs are much higher, the scope of field development could
drastically change. By improving borehole quality, potential
reach will increase, dramatically affecting the economics for
the entire field.4
Field Case Histories
At the time of this writing, the subject RST system has been
run in applications other than these case histories with equal
success. The case histories presented in this paper represent
approximately 50 percent of the total runs thus far in Saudi
Arabia. All the wells within the below described field case
histories, with the possible exception of one, could have been
drilled with a conventional assembly.
Table 1 highlights the overall cost to drill the 8 -in. hole
sections in each of the wells using a RST system with pointthe-bit technology. With the exception of one well, as
explained in the case history, all exhibited a reduction in
drilling costs for their respective hole sections. Even with the
one exception, an overall reduction of close to 12 percent was
realized between these two fields. The table also shows that
the ROP used for the conventional systems was based on
actual data from previous wells and then averaged. Table 2
will outline the various Geo-Pilot system designs used in
drilling the case history wells.
Field Case History No 1. The objectives for this field was to
drill and maintain a horizontal section in a production
reservoir know as the Khafji Stringer.

SPE/IADC 85339

First (1223). This was the first run for the subject RST
system with point-the-bit technology in the Kingdom of
Saudi Arabia. The plan was to complete the 8 -in. build to
89.84 degrees at a build rate of 3 degrees/100 feet and
continue drilling to 10,239 feet MD. Since it was not known
how this RST system would respond, it was initially set for
maximum build (high-side tool-face at 100 percent
deflection). This setting was found to give build rates of
approximately 6.5 degrees/100 feet. The deflection was soon
reduced, and the build section was completed with a
combination of zero and 60 percent deflections in order to
achieve the required 3 degree/100 foot build rate.
In the lateral, it was found that zero deflection gave a build
of about 1.3 degrees/100 feet, and that an approximately 25
percent deflection on the low side would hold the angle. To
be sure no hole cleaning issues developed, the ROP was
limited to 120 feet/hour on instructions from the company
representative. It was evident, however, that a much higher
ROP could have been achieved at times.
The build was completed, and the 3,300 foot lateral section
was drilled in one 57-hour run with a PDC bit at an ROP of
69.7-ft/hr while still keeping within two-feet of the
proposed TVD.
Second (2227). This hole section was drilled with oilbased mud and the RST system using the maximum possible
drilling parameters. The angle and direction were controlled
with small deflection changes. After drilling approximately
3,000 feet, a short trip was made to add more drillpipe below
the HWDP and to check hole conditions.
The hole was in good shape, and the remaining 2,000 feet
was drilled to TD without problems. The 5,000 foot build and
lateral section was drilled in 58.5 hours for an average ROP of
85.5-ft/hr. At times, maximum rates as high as 150-ft/hr were
seen while drilling this hole section.
Third (3277). An across-the-board evaluation of this case
history indicates that it could have been a more costly
operation. Given the small target window operations had to
work in, a conventional system would probably have taken
longer to drill due to control problems. The on-the-fly
downlink command capability of the RST system enabled
corrections to be made without too much delay, something a
conventional system would not have been able to provide.
This 8 -in. hole section was drilled with an oil-based
mud. The 6 -in. Geo-Pilot system exhibited excellent
trajectory control and held within the two foot TVD window
requested by Reservoir Management.
This BHA drilled a total of 3,188 feet in 60.5 hours for an
average ROP of 52.6-ft/hr., a little slower than previously
seen. With constant doglegging to keep within a specific
window and being oriented 65 percent of the time, ROP
inevitably suffered. Averages of 80-ft/hr were achieved when
on bottom drilling. Torque was never an issue in this hole
section. Upon reaching TD, no tight spots were noticed when
the BHA was pulled out of the hole.
The 12 -in. hole section leading up to the 8 -in. hole
was also drilled with the subject RST system. The 1,445 feet
was drilled to a >71 degree inclination in 23 hours for an
average ROP of 62.8-ft/hr. Based on previous technical
literature,3 it is plausible to believe the ease with which the 8
-in. hole section was drilled, along with the low frictional

SPE/IADC 85339

forces, could be attributed to the smooth profile that was most

likely created in the 12 -in. section.
Fourth (4276): The 8 -in. hole section in this well
was also drilled using a 6 -in. Geo-Pilot system. The
objective was to precisely drill and land the 8 -in. horizontal
section and reduce doglegs in the lateral. Control proved to be
good, giving 8.1 degrees/100 feet doglegs in the interval from
78 degrees to 90 degrees and around 4.5 degrees/100 feet
when lined out in the lateral.
Unfortunately, this assembly became stuck at the bit after
encountering a zone that appeared to be a coal/carbonaceous
shale with pyrite and petrified resin. Attempts to free the
assembly by various means proved to be unsuccessful, and the
interval was subsequently sidetracked. However, just prior to
hitting the trouble zone, the average ROP for the interval
drilled was 91.5-ft/hr. We again saw ROPs as high as 150ft/hr while drilling the 595 foot interval.
In this well, the 12 -in. hole section was also drilled with
the 8-in. Geo-Pilot system. The 1,860 foot hole section was
drilled in 34.5 hours in a water-base mud system. We believe,
as in the previous case history, the profile of this section
helped in reducing frictional forces while drilling the
8 -in. wellbore.
Fifth (5324). The objective on this well, and for the GeoPilot system assembly, was to drill a +3,900 foot subhorizontal lateral into and within the channel sands of the
main Khafji reservoir.
A 400 foot tangent at 83.5 degrees inclination and 338
degrees azimuth was planned before building and turning at 3
degree/100 foot dogleg rates and passing through an
intermediate target at 86.1 degrees inclination and 335 degrees
azimuth. A further build and turn was then required to land
the well at a final inclination of 88.7 degrees with an azimuth
of 331.4 degrees with minor corrections for a 3,130 foot
tangent as dictated by geology.
Fast ROPs characterized the drilling of this section, and
instantaneous ROPs of up to 200-ft/hr were seen while drilling
the interval. The 3,860 foot section took only 43 hours to drill
for an average ROP of 89.8-ft/hr. Making left turns in the
good portion of the sand required constant attention. In
addition, a couple of shale spots within the section required
attention when pulling out of the hole. Overall, the downlink
was solid as well as constant, and directional control was
maintained without too much difficulty.
Field Case History No 2. The objectives in this field
application were to drill and maintain a horizontal section in a
production reservoir known as the Khafji Main Sand. To date,
only the 8 -in. hole section for the below wells in this field
have been drilled using the subject RST system.
First (1157): As mentioned earlier, this is the well that
could have been very difficult to drill with a conventional
steerable assembly. A diagram of the profile for this section is
displayed in Fig 3.
The objective in this well was for the RST system to
continue to build from the 9 - 5/8-in. shoe at 7,108 feet MD
to the top of the Khafji Main sand at 79.46 degrees. This
angle was to be held for 100 feet to establish the formation
and then continue to build at 4.5 degrees/100 feet to the target
entry point at 7,782 feet MD at an inclination of 90 degrees.

The horizontal interval was to continue, hitting targets two,

three, and four before dropping back to 68 .3 degrees to
intersect and drill 50 feet into the Shuaiba Formation.
This well was geosteered for better wellbore placement,
and the modeling while drilling indicated that the tops were
coming in higher than expected. As a result, the TVD was
changed upward by 10 feet. Commands and instructions were
downlinked to the RST system in real time, allowing on-thefly changes in inclination or direction.
Drilling was fast with ROPs in the 90 to 100-ft/hr range.
Throughout the entire run, corrections were easily achieved
with good responses from the tools. In the horizontal section,
ROPs were in the 90 to 120-ft/hr range with a constant WOB
of 20,000 pounds. Hole-cleaning was also more effective as
RPMs in the 120 range were higher than in previous
conventional systems.
Deflections for correction to
inclination and azimuth were made to hold the well within the
given five foot window as directed. The well was successfully
completed as planned with the Shuaiba appearing on the logs
at a measured depth of 11,850 feet MD. The section was
drilled in 83.5 hours for an average ROP of 56.8-ft/hr.
Second (2159). The 8 -in. hole section in this well was
also created using a geosteering model in conjunction with the
Geo-Pilot assembly. The assembly performed well, making a
soft landing, then, drilling the remaining horizontal section to
a MD of 10,754 feet. The RST system assembly drilled a total
of 3,363 feet in 60.5 drilling hours, averaging 55.6-ft/hr,
including connections.
The build rate required for landing the well was 6
degrees/100 feet. Consequently, a conventional assembly was
run in prior to the Geo-Pilot system, because the Geo-Pilot
system is currently capable of effectively producing buildrates up to and including 5 degrees/100 feet. As a result of
using a conventional assembly for the initial build, and
because the Geo-Pilot system has a much more rigid and fuller
gauged assembly, a short reaming run with a bull-nose stiff
assembly had to be made to "reprofile" the wellbore for the
RST system. During this reaming run, there was one tight
spot that was not adequately drilled with the conventional
assembly. It was eliminated during the reaming run.
Once the Geo-Pilot system began the section, the required
build up rate was 1.5 degrees/100 feet, and tended to average
5 degrees/100 feet with a 100 percent deflection setting. In
rotary, the assembly had a tendency to turn to the right at
about 3 degrees/100 feet. A consistent deflection of 25 to 40
percent at a tool-face of 90L was required to prevent the
assembly from walking right.
The assembly was tripped out of the hole for maintenance
to prevent damaging the internal mechanism of the Geo-Pilot
system after which it was run back in the hole and drilled the
remaining 336 feet to a TD of 11,090 feet MD. The Geo-Pilot
systems performance for this run was satisfactory, even
though hard stringers required that a lot of high deflection be
made to maintain a flat trajectory. The system was easily
steered in the desired orientations. Rapid responses required to
make any corrections were much easier with the on-the-fly
downlink from the surface. Upon completing the section, the
assembly was pulled out of the hole with no indications of
excessive drag, and no tight-spots were encountered.

SPE/IADC 85339

Conclusions
This paper discussed how time and hole cleaning can be
independent measures, but either one can be dependent on the
other. A mechanical issue that was not really addressed was
the reduction of downhole vibration. This concern mostly
affects the bottom line of service companies by reducing the
amount of time, thus affecting wear and tear on drilling and
MWD/LWD tools. This consideration can also have an effect
on time, thus affecting the amount of money spent due to
hole quality.
There were three wells in which the 12 -in hole sections
were drilled with the Geo-Pilot system. They were briefly
mentioned but were not fully described as further analysis is
required to determine the feasibility of future use for this
system in this hole section. Other conclusions concerning
these case histories that involved Geo-Pilot include:
1.
2.

3.
4.

The use of the rotary steerable system in the 8 -in.

hole sections is very cost effective for the operator
versus the use of conventional drilling systems.
No significant forces were required while pulling out
or running in the hole with the drilling assembly or
while running casing. Tight spots were encountered
because of formation characteristics.
The reduction, or possible elimination, of hole
spiraling through improvements in hole-cleaning
plausibly accounts for the ease of drilling.
The length of the section appears to have no effect on
ROP as seen in Fig. 4. High ROPs were achieved in
longer intervals as well as the shorter ones.

Acknowledgements
The authors wish to thank the management of both Saudi
Arabian Oil Company (Saudi Aramco) and Halliburton
Sperry-Sun for permission to publish this paper. We also wish
to thank the personnel on location from both companies who
worked hard to ensure the operations were safely and
successfully completed.

Nomenclature
BHA =
ft/hr
=
MD
=
ROP
=
RST
=
TD
=
TVD
=

bottom hole assembly

feet per hour
measured depth
rate of penetration
rotary-steerable
total depth
total vertical depth

References
1.
2.

3.
4.

Williams, J.L.: "Oil Price History and Analysis." WTRG

Economics (January 1999). Online. Available at http://www
.wtrg.com/opec.html. Retrieved June 2003.
Russell, R.: Improving Borehole Quality and Drilling
Efficiency with a New Suite of Drilling Tools, paper SPE
78497 presented at the 2002 SPE Internation Petroleum
Exhibition and Conference, Abu Dhabi.
Woods, H.B., and Lubinski, A.: How to Determine Best Hole
and Drill-Collar Size, The Oil and Gas Journal, June 7, 1954.
Comeaux, B.C.: Improving Total Well Construction Efficiency
by Addressing Wellbore Quality, paper AADE 01-NC-HO-33
presented at the 2001 National Drilling Conference, Houston,
Mar. 27-29.

SI Metric Conversion Factors

degree x 1.745329 E - 02 = rad
ft x 3.048
E - 01 = m
in x 2.54
E+ 00 = cm
Trademark Recognition
The Geo-Pilot rotary steerable drilling system is a registered
trademark of Sperry-Sun, a product service line
of Halliburton.

SPE/IADC 85339

FIELD CASE 1

Conventional Drilling Assembly

Geo-Pilot Rotary Steerable Drilling System

Wells

Hole Size
(in)

Footage
(ft)

Est ROP
(ft/hr)

Drlg
Days

Est. #Bits

* Cost #1
(000s USD)

Act. ROP
(ft/hr)

Drlg
Days

* Cost #2
(000s USD)

1223

8.500

3992

54.4

3.1

345.5

70.0

2.4

313.9

2227

8.500

5000

54.4

3.8

405.2

85.5

2.4

321.5

3277

8.500

3188

54.4

2.4

298.0

52.7

2.5

327.2

4276

8.500

595

54.4

0.5

145.5

91.5

0.3

132.9

5324

8.500

3860

54.4

3.0

337.7

89.8

1.8

264.0

12.7

1531.9

9.3

1359.5

TOTALS
FIELD CASE 2

Conventional Drilling Assembly

Geo-Pilot Rotary Steerable Drilling System

Wells

Hole Size
(in)

Footage
(ft)

Est ROP
(ft/hr)

Drlg
Days

Est. #Bits

* Cost #1
(000s USD)

Act. ROP
(ft/hr)

Drlg
Days

* Cost #2
(000s USD)

1157

8.500

4740

38.6

5.1

462.1

56.8

3.5

423.4

2159

8.500

3363

38.6

3.6

357.2

55.6

2.5

336.3

6.0

759.7

*Cost
#1:
*Cost
#2:

TOTALS
8.7
2
Includes rig cost, PDC bits, drilling services, and trips in and out of hole

819.3

Includes rig cost, Geo-Pilot system, and trips in and out of hole

Table 1. Cost summary of Geo-Pilot RST system versus the planned conventional summary of drilling data for field case history wells

BHA Designs for Geo-Pilot Rotary Steerable Systems

Wells 1223, 2227,
5324 & 2157
O.D.
Item(s)
(in)

Well 3277

Well 4276

Well 6325

Well 2159 (Run-1)

Well 2159 (Run-2)

Item(s)

O.D.
(in)

Item(s)

O.D.
(in)

Item(s)

O.D.
(in)

Item(s)

O.D.
(in)

Item(s)

O.D.
(in)

Bit

8.500

Bit

8.500

Bit

8.500

Bit

8.500

Bit

8.500

Bit

8.500

Geo-Pilot

6.750

Geo-Pilot

6.750

Geo-Pilot

6.750

Geo-Pilot

6.250

Geo-Pilot

6.750

Geo-Pilot

6.750

FE Stab.

6.800

M/LWD

6.750

M/LWD

6.750

M/LWD

6.750

M/LWD

6.750

M/LWD

6.750

M/LWD

6.750

M/LWD

6.750

M/LWD

6.750

Float Sub

6.750

M/LWD

6.750

M/LWD

6.750

Float Sub

6.500

Float Sub

6.500

FEWD

6.750

Flex DC

6.750

Float Sub

6.500

FEWD

6.750

Stabilizer

8.500

HWDP

5.000

Float Sub

6.500

Spiral DC

6.500

HWDP

5.000

Float Sub

6.500

HWDP

5.000

Drlg Jar

6.300

Stabilizer

8.000

Drlg Jar

5.000

Drlg Jar

6.500

HWDP

5.000

Drlg Jar

6.500

HWDP

5.000

HWDP

5.000

Sub

6.300

HWDP

5.000

Drlg Jar

6.500

HWDP

5.000

DP

5.000

Drlg Jar

6.500

HWDP

5.000

DP

5.000

HWDP

5.000

DP (G)

5.000

HWDP

5.000

HWDP

5.000

HWDP

5.000

DP

5.000

HWDP

5.000

DP

5.000

HWDP

5.000

HWDP

5.000

Table 2. Geo-Pilot system BHA assemblies used in the field case history wells

SPE/IADC 85339

Field

Well

Motor
Run

Hole Size
(in)

Footage
Drilled
(ft)

Inc In
(deg)

Inc Out
(deg)

Azi In
(deg)

Azi Out
(deg)

Drlg
Time
(hrs)

Avg ROP
(ft/hr)

1223

GP-1

8.500

3992

68.7

89.9

348

348

57.0

70.0

2227

GP-1

8.500

5000

89.2

90.0

93

90

58.5

85.5

3277

GP-1

8.500

3188

73.2

91.1

24

20

60.5

52.6

4276

GP-1

8.500

595

80.1

90.9

291

292

6.5

91.5

5324

GP-1

8.500

3860

81.1

89.9

337

329

43.0

89.8

1157

GP 1

8.500

4740

62.5

64.7

104

100

83.5

56.8

2159

GP 1

8.500

3363

84.8

89.9

144

144

60.5

55.6

$4.00

$5.00

Table 3. Summary of drilling data for field case history wells

Lifting Cost by Area

Middle East
FSU & E. Europe
OECD Europe
Foreign
U.S. Domestic
Worldwide
$-

$1.00

$2.00

$3.00

$ / BBL Produced
Direct Lifting Cost
Fig. 1 Lifting cost comparison worldwide

Fig. 2 Image of spiraled borehole obtained from wireline tool

SPE/IADC 85339

Fig. 3 Profile for field case history well #1157

100.0

6000
5000
4000

80.0
60.0

3000
2000
1000
0

40.0
20.0
0.0
1223

2227

3277

4276

5324

1157

Wells
Footage Drilled (ft)
Fig. 4 ROP comparison between wells versus drilled footage

Avg ROP (ft/hr)

2159

ROP (ft/hr)

Drilled Footage
(ft)

ROP vs Footage Drilled for 8.5" Hole-Sections