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SPE 38615
Rotary Drilling System Optimizes BHA Performance in Horizontal Austin Chalk Wells
B.M. Wisenbaker, SPE, and T.L Moser, Sonat Exploration; M.L. Edwards", SPE. NALCO/Exxon Energy Chemical, LP;
and W.H. Eggleston, SPE, Halliburton Energy Services
reviewed, and the additional benefits offered by the new BHA To build angle with this steerable BHA, the tool face is
configuration that was developed will be discussed. These oriented toward the high side of the hole. Weight is applied to
benefits include reduction of trips, extension of horizontal the bit without rotation of the drillstring. The drillstring slides
sections (accessing additional reserves), reduction of mud along the low side of the hole, allowing the BHA to build
additives, and increased life of the measurement-while-drilling angle. To drop angle, the same procedure is followed, except
(MWD) assembly and motor while drilling in deep, high- that the tool face is oriented toward the low side of the hole.
temperature wells. In addition, software simulation prior to Sliding a siesrable BHA to control wellbore inclination in
field testing provided an accurate BHA for implementation, the 15- to 30-ft target window of the Austin Chalk is very time
further reducing the cost of trial field testing. In conclusion, a consuming. Sliding becomes even more difficult as mud
comparison of earlier field data will be given to help quantify weights approach 12 lb/gal and lateral displacements approach
benefits of running rotary steerable systems as well as prejob 3.000 ft. Under these conditions, wellbore torque and drag
planning with software simulation programs. make sliding a steerable BHA slow and ultimately impossible,
even with the use of expensive lubricants. Penetration rates
Introduction during sliding are usually less than 15% of the penetration
The Austin Chalk is a naturally fractured carbonate reservoir rates while rotating (Fig. 4). Thus, the key factor in
that is productive over a region spanning 650 miles, extending maximizing the overall rate of penetration (ROP) in horizontal
wells in the Austin Chalk is minimizing sliding time.
PDM With Adjustable Stabilizer Behind Motor. A few of the previous generation. This increased strength allows the
years ago, several operators ran an adjustable stabilizer behind assembly to safely pass through a 28°/100-ft dogleg, whereas
a sieerabie motor in an attempt to control we 11 bore inclination the previous design was limited to 15V100 ft. Furthermore, the
while rotating the drillstring. The intent of this configuration drivetrain is capable of withstanding inenial torque peaks
was to allow inclination to be controlled with the adjustable caused by the bit and adjustable stabilizer of up to 11.000
stabilizer or with the bent-housing motor. However, with the Ib-ft.
limber 474-in. motors typically used in the Austin Chalk, the To meet the special demands that would be required of the
adjustable stabilizer was too far behind the bit to effectively BHA in horizontal Austin Chalk wells, several refinements to
control inclination with an acceptable response time. Because the stabilizer design and construction were necessary. First, the
this BHA configuration provided little advantage over running design of the components that generate the pressure signal
a PDM alone, its use was discontinued. indicating tool position was changed to ensure that the
magnitude of the signal was recognizable at the surface. The
New BHA Configuration signal magnitude and total pressure losses across the tool are
To increase wellbore control while rotating the drillstring, a optimized for different mud weights by changing the diameter
new BHA configuration has been developed in which an of the venturi.
adjustable stabilizer is placed ahead of a straight PDM and just Next, several areas were addressed to mitigate potential
behind the bit. Three points of stabilization are critical in such damage and wear that could be caused from the extreme
a BHA configuration. These points are provided by the sideloads and rpms to which the stabilizer would be subjectc%
adjustable stabilizer, a stabilizer placed over the housing of the Because die stabilizer would be placed below the motor, u
motor bearing, and a stabilizer over the crossover between die would operate at double to triple the designed rpms.
motor stators. Accordingly, the internal mandrel was shot peened to improve
Computer modeling, using an in-house program.1 fatigue life, pistons were strengthened, and piston cylinders
determined the stabilizer ODs and locations needed to were outfitted with liners that could be replaced when worn.
maintain the ideal borehole offsets for maximizing build and These modifications increased stabilizer reliability and life,
drop tendencies. The computer model was used to select the thereby reducing running costs.
diameters of the bearing-housing stabilizer and crossover Initial runs were made with medium-speed motors, but in
stabilizer. Fig. 5 shows the effect that the diameter of the an attempt to reduce repair costs, a switch was made to low-
bearing-housing stabilizer has on the BHA's rotary-mode speed motors. This change in motors has reduced repair costs
build-drop rate with the adjustable stabilizer in the open and on the adjustable stabilizers by 73% and. as an added benefit,
closed positions. The final BHA used a 5 V2-in.-OD bearing- has increased ROP. With the slow-speed motors, torque is only
housing stabilizer placed about 11 ft behind the bit and 5 '/•*- slightly reduced compared to the high-speed motors, but there
in.-OD crossover stabilizer located at about 24 ft behind the is a significant reduction in horsepower, thus allowing the
bit. BHA to maintain better contact with the bottom of the hole
Adjusting the downhole stabilizer between the open and and give the improved ROP. Specifications for both motors are
closed positions moves the BHA fulcrum point and changes summarized in Tables 1 and 2.
the sideloading on the bit (Fig. 6). In particular, closing the
adjustable stabilizer to the minimum position moves the Case Studies
fulcrum point away from the bit to the 5 '/2-in. bearing-housing The geographic location of runs made with the new n
stabilizer on the motor. Tnis fulcrum position gives an II-ft configuration are highlighted in Fig. 1. Wells from two of the
pendulum assembly that creates negative sideloading on the fields shown in the figure are discussed here. The first well
bit. causing the BHA to drop angle. Opening the adjustable was drilled in a 14.5-lb/gal-mud environmeni. where the new
stabilizer to the maximum position creates a near-bit fulcrum BHA design was critical in maximizing ROP and minimizing
point a few feet from the bit face. This results in positive tool failures. The second well was drilled with 9-lb/gal mud to
sideloading on the bit. causing the BHA to build angle." a horizontal displacement of 8,018 ft. a record that could not
The rotary-mode build/drop rates predicted by the have been attained economically without the new BHA design.
computer model for the new BHA configurations were in
agreement with actual drilling results as seen in Fig. 7. With Scobee 34 #1. This well was drilled in the Master's Creek
the adjustable stabilizer in the maximum gauge position, this Field in the Austin Chalk in Vernon Parish, Louisiana. Drilling
BHA can achieve BURs of approximately 1.75°/IOO ft. With activities proceeded as follows:
the adjustable stabilizer in the minimum gauge position, the 1. Spudded on December 25. 1996.
BHA can provide drop rates of approximately 2.507100 ft. 2. Drilled 13 '/2-in. hole to 3.200 ft and set 10 3/4-in. surface
Fig. 8 shows the new BRA. configuration. A dual power casing.
section with sealed, oil-lubricated bearing pack is used. The 3. Drilled 978-in. hole to intermediate casing point at 13,760
sealed-bearing-pack driveshaft has 21/: times the bending ft. and set 7 3/8-in. casing.
strength and twice the torque capacity compared to the design 4. Drilled 6 V:-in. pilot hole to 14.293 ft.
'E 38615 ROTARY DRILLING SYSTEM OPTIMIZES 8HA PERFORMANCE IN HORIZONTAL AUSTIN CHALK WELLS
5. Set cement plus in pilot hole and drilled out cement plus 8. Drilled wiih same assembly to 3.785 ft vertical section.
to 13.825 ft. Average sliding ROP was 6 ft/hr. and average rotating
6. Picked up insert bit. adjustable bent housing motor, and ROP was -6 ft/hr. Sliding percentage was 30%.
MWD assembly; built angle to 90.5° at azimuth of 357° 9. Tripped for motor failure with 81 hours on BHA.
with BUR of 227100 ft. At this point, well was 18 ft 10. Picked 6'/s-in. PDC bit. 55/8-in. x 6-in. adjustable
below the target centerline. stabilizer, and 47.»-in. motor with 5'/2-in. bearing-housing
7. Picked up 6'/:-in. PDC bit and 2.12° adjustable bent stabilizer and 5'/j-in. crossover stabilizer between the two
housing motor, drilled to 2.138 ft vertical section. power sections. Average ROP was 34 ft/hr to a vertical
Average sliding ROP was 10 fi/hr. and average rotating section of 8.018 ft. This BHA had 128.5 rotating hours.
ROP was 37 ft/hr. Sliding percentage was 18%. 11. Stopped drilling on April 24. 1997, because of land
8. Tripped for motor failure. restrictions.
9. Picked up 6'/s-in. PDC bit. 55/8-in. x 6-in. adjustable
stabilizer, and 43/4-in. motor with S'/z-in. bearing-housing Total footage drilled was 18.899 ft. TVD was 9,160 ft. and the
stabilizer and 5'At-in. crossover stabilizer between the two maximum circulating bottomhole temperature was 246°F.
power sections. Average ROP was 38 ft/hr to a vertical
section of 3.911 ft. Reduction in Drilling Costs
10. Pulled out of the hole and laid down BHA. Picked up More than 30 runs have been made with an adjustable
(finsen bit. adjustable bent housing motor, and MWD stabilizer in front of a straight PDM. Application of the new
assembly to sidetrack for downdip lateral. Built angle to BHA configuration has resulted in substantial savings in
90° at azimuth of 166° with BUR of 177100 ft. At this drilling costs. In environments where mud weight has been
point, well was 6 ft below the target centerline. high (greater than 14 Ib/gal), savings have exceeded S200.000
11. Picked up 6*/8-in. bit. 5s/8-in. x 6-in. adjustable stabilizer, per well. These savings have accrued from reduction in tool
43/4-in. motor with 5'/2-in. bearing-housing stabilizer, and failures, reduction in the use of slide lubricants, and reduction
5'/4-in. crossover stabilizer between the two power in the number of wells needed to drain the reservoir.
sections. Average ROP was 40 ft/hr to a vertical section of
3,332 ft. Reduction in Tool Failures. Downhole tool failures are a
12. Slopped drilling on February 27, 1997, because of federal major problem in high-temperature and high-mud-weight
unit constraints. environments. The high solids content of heavyweight muds
causes difficulties in tripping pipe. Because rotating in and out
Total footage drilled was 21.999 ft. true vertical depth (TVD) of the hole in such situations is necessary, round-trip times can
was 14.100 ft, and the maximum circulating bottomhole be in excess of 30 hours.
temperature was 275 6F. Drilling with the new BHA design has resulted in increased
ROP and. thus, reduced drilling time. The increased ROP, in
Snyder Minerals 14 #1. This well was drilled in the turn, means that more footage can be made between mean-run
Brookeland Field in the Austin Chalk in Sabine Parish, time failures of the motor and MWD tools. Because Austin
Louisiana. Drilling activities proceeded as follows: Chalk wells are drilled underbalanced, heavy muds must be
ifjpudded on March 23.1997. pumped down the backside of the drillpipe to kill the well
2. Drilled 13 V:-in. hole to 2,065 ft and set 10 3A-in. surface during tripping to change out motors and MWD tools.
casing. Therefore, reducing the number of trips for downhole failures
3. Drilled 97/g-in. hole to intermediate casing point at not only reduces rig-time costs, but also decreases the cost of
8.828 ft and set 7 5/8-in. casing. mud needed to kill the well.
4. Picked up insert bit, adjustable bent housing motor, and A simplified equation for determining the cost per foot of
MWD assembly. Built angle to 92° at azimuth of 348° drilling a horizontal section can be found in the appendix of
with BUR of 257100 ft. At this point, well was 1 ft below this paper. The equation involves sliding and rotating ROPs,
the target centerline. various hourly charges (rigs, rentals, and services), and footage
5. Picked up 6'/s-in. PDC bit, 55/8-in. x 6-in. adjustable charges for adjustable stabilizers and slide lubricants.
Reduction in the Number of Wells. A major part of any than 30 runs have been made with the new design in which an
operator's field development plan is maximizing well spacing adjustable stabilizer is placed ahead of a straight PDM. These
and horizontal lateral lengths. With the development of the runs have quantified cost reductions accruing from reduction
adjustable stabilizer technology, lateral lengths are being in tool failures, reduction in the use of slide lubricants, and
extended. Where 4,000-fi dual opposing laterals have been reduction in the number of wells needed to drain the reservoir.
standard (giving 8.000 ft of horizontal displacement, as shown In environments where mud weights have been greater than
in Fig. 10), 5.000-ft laterals should be possible (giving 10.000 14 lb/gal. savings have exceeded S200.000 per well.
ft of horizontal displacement). This 25% potential increase in
horizontal displacement from a single vertical wellbore Nomenclature
translates into 25% fewer wells needed to drain the reservoir. AS = adjustable stabilizer costs, per foot
Reduced well count is the most significant savings attributable BHA = bottomhole assembly
to the new BHA configuration. BUR = build-up rate
CPF = drilling costs in horizontal section, per foot
Well-Selection Criteria DC = drilling costs in horizontal section, per hour
The new BHA design is not applicable to all wells in the LUB = lubricant costs, per foot
Austin Chalk. Response time, dogleg seventy, and wellbore MWD = measurement while drilling
inclination must be considered. PDC = polycrystalline diamond compact
PDM = positive displacement motor m^
Response Time. The operator must determine whether a rpm = revolutions per minute
maximum BUR of 2.5 "/100 ft provides adequate response time ROP = rate of penetration, ft/hr
for course corrections. In areas of severe faulting, better RROP = rotating rate of penetration, ft/hr
response time may be needed to maximize footage drilled in SP = sliding percentage
the target window. SROP = sliding rate of penetration, ft/hr
TD = total depth
Dogleg Severity. To date, the maximum dogleg through which TVD = true vertical depth
the new BHA has passed has been 27°/100 ft. In more severe
doglegs, the bending stress is too high on the motor driveshaft Acknowledgments
and on the connection between the motor and adjustable The authors wish to thank Sonat Exploration, Halliburton
stabilizer. To enable passage through more severe doglegs up Energy Services, and Andergauge USA for their support of the
to 407100 ft. work is underway to design and develop a BHA preparation of this paper. The authors also thank Brent
with flexible subs to be placed in the motor and between the Murphy. Mark Cox, and Mark Deal of Sonat Exploration for
motor and the adjustable stabilizer. their valuable discussions and Mike Hooper of Haliibunon
Energy Services for his computer modeling efforts in
Wellbore Inclination. The new BHA should not be run unless determining optimum stabilizer sizes and locations.
the wellbore inclination is within 2s to 3° of formation dip. If References
1. Williamson. J.S., "Predicting Borehole Assembly Performance,"
the wellbore is not within 2° to 3° of formation dip, a build or
SPE Drilling Engineering. March 1987.37-46. ^
drop trend may develop that is hard to break and that makes it
2. Bourgoyne, A.T.. Jr., et al.: Applied Drilling Engineering, SI >
difficult to bring the wellbore back into the original target zone Richardson. Texas. (1986) 437-443
and dipping plane.
Appendix—Cost-Per-Foot Economics
Operational Notes Three key variables in calculating economics for an adjustable
The motor driveshaft is the most vulnerable pan in the BHA stabilizer below the motor are rotary ROP (RROP). sliding
and care should be taken when running it in the hole. While ROP (SROP). and slide percentage (SP). SP is the slide time
this assembly is being run through the build section of the divided by the total drilling time. These three variables can be
well, the drillstring should not be rotated and the pumps should used in a simple equation for determining the cost per foot
not be turned on: otherwise, the motor driveshaft could be (CPF) for drilling the horizontal section of a well:
damaged or broken to the extent that premature failure of this
DC
assembly could occur. If the new BHA is being run into the CPF = - ■+LUB + AS (A-l)
RROP(1-SP) + SROP«SP
hole to finish the curve and continue drilling ahead, then the
entire BHA should be out of the curve and landed in the target where drillins costs (DC) include all hourly charges for the rig,
before drillstring rotation is started. rentals, directional drilling. MWD services, and liquid mud.
LUB is the footage cost for lubricant, and AS is the footage
cost for the adjustable stabilizer. If an adjustable stabilizer is
Conclusions
A new BHA configuration has been developed to help reduce not used, then AS = 0. If an adjustable stabilizer is used, then
horizontal drillins costs in the Ausun Chalk formation. More SP = 0 and LUB = 0.
SPE 38615 ROTARY DRILLING SYSTEM OPTIMIZES BHA PERFORMANCE IN HORIZONTAL AUSTIN CHALK WEUS
ML£S
J
Fig. 1—Geographic extent of the Austin Chalk formation
B.M. WISENBAKER. T.L. MOSER. M.L EDWARDS. W.H. EGGLESTON SPE 38615
7"**
I J«
Austin Chalk
Ash Marker,
• •■••
kTarget Window
■
1000
1500
2000
2500
3000
500
Dual-Power-Section Motor
7/
PDC Bit Crossover X/O FT FT X/O 30'Non-mag X/O 30'Non-mag Drtllpipe
Stabilizer Stabilizer Sub Sub Sub Sub Drill Collar Sub Drill Collar
Fig. 3—Conventional BHA used for drilling in the Austin Chalk without an adjustable stabilizer
Bent Adjustable
Motor Stabilizer
BHA Design
Fig. A—Comparison of drilling penetration rates for 10 wells in the Brookeland Field at greater than 2,500 ft vertical section
E 38615 ROTARY DRILLING SYSTEM OPTIMIZES BHA PERFORMANCE IN HORIZONTAL AUSTIN CHALK WELLS
W/AdjStab- 6'
W/AdiStafi- 5.625'
5.(00
Fig. 5—Relationship between the diameter of the bearing-housing stabilizer and the range of the rotary-mode build/drop rate when the
adjustable stabilizer is in the open and closed positions.
i
Adjustable Stabilizer
in Open Position
26$ Ibf
772 !bl
BH 968 Ibl
■ Adjustable Stabilizer
in Closed Position
Olfll
152 Ibl
641 Ibf
916 Ibf
Fig. 6—Sideloading on the BHA when the adjustable stabilizer is in the open and closed positions
B.M. WISENBAKER. T.L. MOSER. M.L. EDWARDS. W.H. EGGLESTON SPE 38615
2.S
1.5
2 o.s
•§
"■^ 0
o
w
a 6* Adjustable Stabilizer 5-5/8- Adjustabli
§ -0.5 Stabile
-1.5
•2
•2.5
Fig. 7—Comparison of rotary-mode build/drop rates predicted by the computer model with rates achieved during actual drilling of five wells
PDCBit Adjustable X/O Crossover X/O FT FT X/O 30' Non-mag X/O 30' Non-mag X/O DfiUpipe
Stabilizer Sub Stabilizer Stabilizer SuD Sub Sub Sub Drill Collar Sub Drill Collar Sub
120.000
Jan Feb Mar Apr May Jun Jul Aug Sap Oct Nov Dec
Fig. 9—Decrease in 1996 slide-lubricant costs when using new BHA configuration
J.I
8.000'
10.000'
Fig. 10—Potential increase in horizontal displacement when using new BHA configuration