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Abstract
Extended Reach (ER) wells have usually been proven
the world over to provide an exceptionally cost effective
means of field development.
For example, in one
particular instance, adoption of ER drilling resulted in +/50% savings compared with a sub-sea completed well.
Additionally, intervention costs were dramatically reduced
since the substantial cost associated with mobilizing a
floater into the relatively remote area was averted (1).
Frictional losses due to torque/drag (T/D) are a primary
limitation in extending the reach of many high angle wells.
This paper specifically considers T/D problems associated
with current well designs and presents roller-based tool
technology as a solution for reducing mechanical friction
losses.
Also considered are some of the other merits of roller
type technology that are not immediately apparent. They
include decreased likelihood of differential sticking; an
important consideration given the significant 4D seismic
created interest in in-fill drilling. The drilling tools can also
have an impact on drilling performance by helping to
reduce axial and rotational stick/slip, thus prolonging bit
life, increasing rate of penetration (ROP), and potentially
avoiding a trip to replace the bit.
Field trial results, case studies and laboratory tests
will demonstrate that roller-based tools are an effective
solution to combating mechanical frictional losses.
An important point is that since roller-based tools
function almost independently of drilling fluid type, they
should enable operators to use lower-cost drilling fluids,
such as water based muds that comply more easily with
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Fundamentals
In order to achieve low friction coefficients,
conventional downhole tools require that a fluid film be
maintained between contact surfaces. In general terms, it
follows that the downhole fluids that exhibit the highest
film strength will produce the lowest friction factors.
Aside from fluid film strength, the relative speed
between two contacting surfaces may also affect friction,
viz: a drill string that is rotated at say 10 rpm (boundary
lubrication regime) will normally generate higher surface
torque than the same string rotated at 150 rpm (partial
hydrodynamic or viscous lubrication).
Conversely, roller tools provide a very low friction
coefficient between axle and roller, almost irrespective of
fluid type. In open hole however, the performance of a
roller is a function of its diameter versus the in-situ
compressive strength of the formation and load. Again,
this is all but independent of fluid type.
An important consideration is the spacing of tools. If
placed too far apart, the tubular will contact the wall of the
hole and a portion of the friction reducing benefit will be
lost. If too close, it may be that the added stiffness of the
string will result in high bending induced normal forces
and correspondingly higher friction.
The independence that a roller tool gives from fluid type
has very important considerations for the industry in that
drilling and completion fluids may be selected for other
than their friction reducing properties.
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Centralization Equipment
(i) Wear Performance
On a number of occasions roller centralization
equipment has been run into extended reach wells and
retrieved, thus providing an accurate measure of the
effectiveness of a roller in combating blade wear and
resultant loss of stand-off.
In a special application on two ER wells in California,
9-5/8 casing was selected for use as a landing string due
to its weight and resistance to buckling. To further
improve running weights, roller centralization was added to
the string.
On retrieval of the running string, the (normally
consumable type) roller tools were cleaned, repainted and
used on the following well. On a BP Amoco Harding ER
well in the UK, 9-5/8 roller centralizers were also used,
retrieved and refurbished for re-use.
Fig 11 shows a 9-5/8 roller centralizer prior to it being
refurbished.
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Hewitt B-11
Phillips Petroleum constructed an extended reach well
in the UK Sector of the Southern North Sea. This well
was drilled through the depleted and under-pressured
Bunter formation (a former gas reservoir) to access the
underlying Hewitt formation.
Whilst drilling the 12-1/4 hole section, total losses
were experienced and the drilling assembly had to be
reamed out of the hole. The thief zone is thought to have
been the Bunter formation.
In view of the poor hole conditions, prior to running the
9-5/8 casing, confidence on the rig was low with respect
to landing it. This feeling was exacerbated by the fact
that mud losses continued while running in hole. To add
insult to injury, 2/3 of the way through the run, it became
necessary to cut and slip line on the travelling block.
Despite the 9-5/8 casing lying for 3 hours at an
inclination of 80 across a formation that was taking fluid,
the running forces chart (Fig. 12) shows that the drop in
slack-off weight was relatively small (indicated by a *) and
quickly recovered.
It is thought that despite having the classic conditions
for differential sticking resulting in an intermediate casing
string that would not have been landed, the very small
contact area of the rollers prevented the creation of any
significant suction, thus leading to the excellent
performance. Fig. 13 refers.
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Harding PN1y
The BP Amoco Harding field is developed from a
platform in 350ft water depth. Prior to PN1 the majority of
wells drilled have been relatively short with 1,000ft to
2,000ft horizontal sections and are completed with prepacked screens or open hole gravel packs. The reservoir
is relatively shallow and ranges from 5,300 to 5,800ft TVD.
Harding PN1 was planned as the first ER well to
access reserves from a satellite location in the North East
of the field. Based on experience from shorter offset wells
it was clear that running the 10-3/4 x 9-5/8 to a planned
MD of 15,300ft would be a particular challenge. This
would be, by and far, the longest casing string run in this
field to date. The profile was of build and hold type,
comprising a kick off point at 500ft and a 11,000ft tangent
section at an inclination greater than 78. Cased / open
hole friction factors from offset wells were calculated to be
0.30 / 0.40 on average and application of these values to
the PN1 casing run predicted zero available weight at TD.
Assessment of drag reducing centralizer products
highlighted the lack of factual information on downhole
product performance. However roller centralizers had
previously been used in the Gyda field to run a 22,300ft
casing string (3). Here it was found that significant drag
reduction occurred in cased hole, but was more difficult to
detect in open hole. On this basis it was decided to run
drag reducing roller centralizers in cased hole only for
PN1y. Since the 13-3/8 casing shoe was relative deep at
7,500ft, roller centralizers were installed at one per joint
from 2,000ft to 7,000ft with the casing shoe at TD
(15,300ft). Operational experience on the Harding field
had also shown that laying a pill of lubricating beads at
the end of the section being cased prior to running casing,
had a beneficial effect. Whilst it was not possible to
quantify this effect, it was decided to spread stickless
beads along the final 3,000ft of open hole as additional
insurance.
The combined effect of these drag reduction
techniques was dramatic, see Fig 14 below.
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WOB control.
Reduced casing and DP tool joint wear.
Reduced key seating and DP heat checking.
Resistance to differential sticking.
Improved hole cleaning.
Has very low lost-in-hole risk compared to say
rotary steerable tools.
Tools may be used for drilling, logging, running
completions, perforating etc.
,
Fig. 23, Joanne M-6, Torque Reducing Performance
Conclusions
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Acknowledgments
The authors thank BP Amoco, Phillips Petroleum,
Norsk Hydro ASA, Weatherford International and Austoil
Technology for permission to publish this paper.
References
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