SPE/IADC 163463

Extended Reach Drilling –

new solution with a unique potential

O. Vestavik, Reelwell,

M. Egorenkov, Merlin ERD,

B. Schmalhorst, RWE Dea AG,

J. Falcao, Petrobras,

M. Roedbro, Shell Technology Norway

CONTENT

- BACKGROUND AND TECHNOLOGY

- JOINT INDUSTRY PROJECT ON ERD

- RESULTS

- CONCLUSION

Slide 2

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

BACKGROUND

- Reelwell Drilling Method (RDM)

- Dual channel drill string

- Return flow inside this string.

- 2011: Started a Joint Industry Project on ERD, funded by Shell, Total,

Petrobras, RWE Dea AG and the Research Council of Norway.

- RDM provides:

- Two well barrier MPD system

- Reduced of torque and drag

- Avoid the dynamic ECD gradient

- The following presents a case study on a 16 km ERD well.

Slide 3

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Reelwell Drilling Method

Animation/movie

Slide 4

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

RDM – Basic Drilling Method

Slide 5

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

- RDM is fully compatible with standard bits

- Uses conventional MWD, directional equipment, RCD

Heavy Over Light - Principle

Slide 6

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

- High density fluid in the well annulus

- Low density fluid – inside string and cleaning the hole

Aluminium Dual Drill String

Slide 7

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Dual Drill String parameters Al DDS

Outer string

and tool joint- Pipe outer diameter [mm]

- Tool joint outer diameter [mm]

- Pipe joint length [m]

- Pipe weight [kg/m] in air

- Max tension load [ton]

- Max torque [k ft lbs]

- Yield pressure [bar]

- Collapse pressure [bar]

198 (Al) (7.8”)

209 (steel)

14

28.5

300

67

525

430

Inner string - Pipe inner diameter [mm]

- Pipe weight [kg/m] in air

- Yield pressure [bar]

- Collapse pressure [bar]

90 (Al)

5.8

540

450

- Handled as conventional 6 5/8” drill pipe

- Buckling resistant design

Engineering Model Assumptions

Slide 8

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Hole Size [in] Casing Size [in] Casing shoe depth [m]

24 20 1000

16 13 3/8 5000

13 1/2 10 3/4 14000

9 7/8 7 15800

Casing:

Well path:

Buoyancy Effects on Drag

Slide 9

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

No bouyancy Partly bouyant Full bouyancy

Well annulus

fluid density [sg]

Active fluid

density [sg]

No buoyancy 1.2 1.2

Partly buoyancy 1.56 1.2

Full buoyancy 1.75 1.15

Buoyancy Effects on Torque

Slide 10

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Typical limit

- Buoyancy - Improved operating window on the pipe

- Low torque - Reduced casing wear and hole erosion

0

20

40

60

80

100

120

140

Torq

ue

[kN

m]

Measured Depth [km]

Alu- partly boyant

Alu- full bouyancy

Steel- no bouyancy

Steel- max bouyancy

Alu- no bouyancy

Casing and Liner Installation

Slide 11

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Installation of 10 ¾” casing and 7” liner - feasible by flotation.

Effects of Heavy Over Light

Slide 12

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

• Reduce borehole friction

• Torque & Drag – can be significantly reduced.

• MPD with two well barriers:

• Annular well fluid may be used as a well barrier fluid

• Low density active circulating fluid

• Hole stability

• Optimum well pressure at all times

• Avoids dynamic ECD and flow erosion

MPD with two well barriers

Slide 13

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Effects of Heavy Over Light

Slide 14

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

• Reduce borehole friction

• Torque & Drag – can be significantly reduced.

• MPD with two well barriers:

• Annular well fluid may be used as a well barrier fluid

• Low density active circulating fluid

• Hole stability

• Optimum well pressure at all times

• Avoids dynamic ECD and flow erosion

Avoid Dynamic ECD Limitations

Slide 15

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

- Dynamic ECD gradient in open hole can limit horizontal reach

- RDM – ECD gradient inside the drill pipe is screened from the well annulus

therefore overcomes the dynamic ECD limitation

ERD Comparison

Slide 16

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

Challenge for Conventional ERD Solution by RDM

• High Torque and Drag

- High capacity rigs

- high casing wear and hole erosion

• Low Torque and Drag

- Lower capacity rigs

- Utilize mature asset rigs for ERD

- Low casing wear and hole erosion

• ECD limitations

- Reach limited by ECD margins

- Washouts and hole stability issues

• Avoid ECD limitations

- Dynamic = static gradient

- Washouts avoided, improved stability

• May require additional MPD equipment • Built in MPD

- Two well barriers

• Other:

- Time consuming hole cleaning

- ERD is limited by the above factors

• Other:

- Improved hole cleaning

- ERD is improved by the above factors

Conclusion

Slide 17

SPE 163463 • ERD – New Solution with a Unique Potential • Ola Vestavik

• New solution provides ERD beyond conventional reach,

case example of 16 km long ERD well is considered feasible.

• Unique features:

- MPD with two well barriers

- Low torque & drag

- Avoids dynamic ECD

Acknowledgements / Thank You / Questions

Slide 18

Thanks to Shell

Total

Petrobras

RWE Dea AG

Research Council of Norway

For the support and allowing the study to be presented

Thank you to the many members of these organizations for their

valuable contributions