Redefining Technical Limit – Managed Pressure Directional Drilling Solution in Mexico Zaap Field

Based on input from key operators in the Middle East region, a new rotary steerable system (RSS) was launched after a compressed development schedule. This paper describes the development and introduction of the larger tool sizes needed for both onshore and offshore hole sections, including hole sizes from 12 in. and up, in the Middle East. It also outlines the deliberate design of the tool for local assembly and repair. Large diameter (9-1/2 and 11 in.) RSS designs used an existing, smaller design for Middle East applications in both offshore and onshore wells as a basis. When designing these new sizes, engineers took note of lessons learned with smaller sizes of the tool and incorporated design elements for local manufacturing, assembly, and repair. The resulting simple, modular construction enables increased levels of local content and provides for significant reductions in transportation, and therefore associated emissions. Of course, although local content and sustainability are highly desirable, performance is essential, and this paper describes case histories demonstrating how well the new tool worked in real-world Middle East applications. In one notable example, the newly introduced 9 1/2-in. diameter RSS was used to drill an offshore section in the Gulf of Arabia. The tool was mobilized after two older generation RSS had become stuck for days. Consisting primarily of argillaceous limestone, the formation had a history of stuck-pipe events. The new RSS was recommended for this application because of a slicker construction, with a fully rotational bias unit, minimal bottom hole assembly (BHA) stabilization, and an optimized junk slot area, which together help to reduce stuck-pipe risks. The tool drilled to the target depth in a single run, thereby achieving all directional requirements. Notably, after reaching the target depth, the assembly was tripped out of the hole without any requirement for backreaming. This seamless exit, in turn, indicated achieving a smooth wellbore. Other case histories demonstrate results with both new sizes of this tool. The paper also discusses in detail the ability to repair locally and engage the local supply chain. Specifically with Middle East applications in mind, a new, simple RSS design in large diameter versions has demonstrated success in offshore and onshore applications across the region. The design has also proven capabilities for manufacturing and repair local to operations, which enables maximizing in-country value, optimizing use of the tools, and energizing local supply chains.

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Simple but Effective: A Case History Demonstrating Enhanced Performance and Simplified Logistics from New Rotary Steerable

Perez

Yadav

Farley

2021

Day 5 Fri, March 12, 2021

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Offset Data Analysis and Seam Less Execution Through Real Time Monitoring Results in Step Change in Drilling Performance

Yadav

Chohan

2021

Day 4 Thu, October 21, 2021

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In oil and gas drilling, consistency of performance delivery heavily depends upon rig capability and its ability to maintain performance assurance through its execution cycle. It's not an uncommon occurrence that a rig is found with an underperforming top drive, one such scenario was observed in an in-fill oil well drilling project. This project was essentially drilling horizontal wells with bottom hole assemblies which had primary drive mechanism as a top drive. The rig in question was struggling to provide not only the requisite RPM but also not been able to deliver consistent torque needed to drill the well. This study analyzes how severe rig limitations were overcome through an optimization plan in which most optimal BHA was designed and drilling practices were customized for safe and successful execution of wells. In order to understand root cause of the challenge, an offset well analysis was conducted, it identified that high torque was mostly generated while drilling through inter-bedded formations which typically caused top drive to stall. In addition, multiple tool failures were encountered due to the high stick slip which rig couldn't mitigate due to the low RPM yield of the top drive. To manage the rpm and torque limitations, a motorized RSS BHA was designed as a solution. Further, based on micro-stall events of motor only BHA's across the inter-bedded formations in the field, a stick slip management tool was placed below the motor so that a potential twist-off and/or motor damages can be avoided. Also, different bottom hole assembly's drilling dynamics response were analyzed to come up with optimal stabilization and connection practices to avoid back reaming while trip outs. This paper would showcase actual results which highlight improvements achieved in stagnant drilling performance of the project. The analysis would demonstrate how multiple wells were drilled in one run following the risk assessment developed from the optimization study and subsequent real time monitoring of mitigating actions while execution. The comprehensive bottoms-up drilling optimization approach helped save 4 planned days for each well, this really paves way to pursue applied-engineering solutions to achieve step change in drilling performances, especially on rigs which are severely limited either due to capacity or malperformance issues. The bottoms up approach taken to understand the drilling challenges followed by a methodical approach to address each of the challenges demonstrate importance of effective pre-job planning. Learnings from this study can be adopted as a template to mitigate similar drilling challenges.

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Redefining Technical Limit – Managed Pressure Directional Drilling Solution in Mexico Zaap Field

Cited by 2 publications

References 3 publications

Simple but Effective: A Case History Demonstrating Enhanced Performance and Simplified Logistics from New Rotary Steerable

Simple but Effective: A Case History Demonstrating Enhanced Performance and Simplified Logistics from New Rotary Steerable

Offset Data Analysis and Seam Less Execution Through Real Time Monitoring Results in Step Change in Drilling Performance

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