Successful Application of Innovative Reaming-While-Drilling Technology in Williston Basin Wells

Presenters Lee M. Smith - Greg Scott Western Energy Products and Services

The Challenge
Challenge eliminate dedicated reamer run in Bakken wells; ream-while-drilling (RWD) application Introduction of 5 7/8 OD PDC reamer for use in 6 lateral section: non-mag and steel body tools Successful installation of multiple swellable packers up to 40 per well Significant savings per well (up to 3 days rig time)

Geology

Williston Basin Bakken

Oil reservoir, dolomite layered between two shales Produces oil, gas and natural gas liquids Depths from 8,000 to 10,000 ft Lower shale, middle sandstone and upper shale Middle sandstone varies in thickness, lithology

Hazards of Bakken
30+ formations from surface to target Potential aquifers Sticking salt, bentonite beds Sloughing shales Known H2S

Williston Basin Well Design

8 -inch vertical hole section to KOP in target formation at 9,000 to 10,000 TVD 8 inch hole builds angle to horizontal in Bakken at around 11,000 TVD Lateral up to 10000 20,000 MD @TD Multiple swell packers to TD

An Innovative Solution
Incorporate PDC Reamer to drill/ream in 6 hole
Eliminates need for dedicated reamer run Delivers high quality wellbore for multiple packer completion

PDC Reamer Tool Delivery to Isolated Rig Location

Introduction to PDC Reamer

Un-aware of PDC Reamer Advantages -Reamer functionality compared to stabilization alone -Reamer reliability proven in multiple applications -Reamer advantages over use of stabilizers alone -Reamer design advantages for added durability - Design features for greater reliability, durability

Not using PDC Reamer

Why

Concerned about PDC Reamer Reliability

- Review PDC Reamer reliability features -Review Run Histories and Customer Testimonials

Thinks PDC Reamer is good but costs more than conventional stabs
Customer

- Discuss PDC Reamer advantages compared to stabs -Explain durability features of PDC Reamer -Show Savings Case Histories

Yes
Using PDC Reamer Experienced Lost Cutters ?

-Review PDC Reamer reliability features -Run Histories and complete re-design

No

-Explain durability features of PDC Reamer -Discuss PDC Reamer application features -Stress Run Histories and Customer Testimonials

Introduction to Drilling Tools

PDC Reaming Tool Customer Approach

A PDC Reamer is fit for any application that is expected to face stuck pipe problems Key words that trigger a need for a PDC Reamer are:
Heavy back reaming Mobile or transient formation Moderate fractured and faulted formation Swelling shales Salt layers and salt domes Unconsolidated formations Tight spots Key seats Poor hole cleaning Inter-bedded formations or hard stringers NPT during POOH

PDC Reamer Tool

Reamer with drilling functionality
Reduce back reaming time Removal of Irregularities for smoother POOH Better hole quality Scraping Cutting (Shearing)

Removes hole irregularities by:

Dual cutting mode ideal for transition drilling

PDC Reamer Features

PDC cutters on leading edges of blades :
Allow re-opening holes to avoid having stuck pipe during POOH Reduce torque and drag in highly irregular holes

Improve hole gauge and shape by removing ledges and irregularities

Allow opening key-seats & ledges Acts as backup hole opener when bit gets under-gauge Cutter design and distribution to match application severity

Design Advantages
Use of stud cutters to introduce in-string drilling Blade design provides proper cutter support to eliminate cutter shear Blade design ensures 360 degree coverage Hydraulic profile optimizes mud flow and resists balling

Impact on Performance
Balanced cutting structure with cutter redundancies ensures optimized cutting and long life Reaming inserts arranged to provide continuous reaming and outstanding hole quality Reamed volume matched to tool life for uniform tool wear
Cutting Elements

Scraping Elements

Drill / Ream Parameters

Multiple RWD BHA designs incorporating both non-mag steel body PDC Reamer tools Test steerability, torque and successful installation swell packers Compare RWD BHA to previous lateral BHA slick and stabilized Results / findings torque increase from 7 to 13 with 20% increase in rotary ROP Optimal RWD BHA 30ft spacing between PDC reamers positioned on top of lower BHA using steel body tools; 30ft spacing between PDC reamers in lower BHA using nonmag tools Able to drill out 7 casing shoe

Introduction to Drilling Tools

PDC Reaming Tool Introduction and Background

Well profiles are becoming more complex and access to reservoir intervals is becoming more challenging New drilling technology and methodology:
Multi-lateral wells Deep horizontal wells Extended reach drilling High Pressure High temperature wells

High Angled J-Profile ; S-Shaped wells

It is critical to optimize drilling efficiency and reduce Non-Productive Time (NPT) A PDC Drilling Tool is a tool that reduces the hazards of having stuck pipe; a feature that significantly reduces NPT

Introduction to Drilling Tools

PDC Reaming Tool Operations Concept
Cutting Elements

A PDC Reaming Tool is a reamer with drilling Scraping functionality Elements The design intent is to:
Reduce back reaming time Removal of Irregularities for smoother POOH Better hole quality Scraping Scraping Cutting (Shearing)

Traditional Reamer removes hole irregularities by:

Tool removes hole irregularities by:

Cutting mode renders this tool unique when dealing with holes with excessive irregularities (transient formations)

Introduction to Drilling Tools

PDC Reaming Tool Main Functions

Blades leading edges doped with PDC cutters to:

Allow re-opening holes to avoid having stuck pipe during POOH

Reduces torque and drag whilst in reaming in highly irregular holes Improve hole gauge and shape by removing ledges and irregularities Allows opening key-seats & ledges Acts as backup hole opener when bit gets under-gauge (Dual action tool) Cutter matrix design and reaming insert distribution can be varied to match application severity

Introduction to Drilling Tools

PDC Reaming Tool Main Functions

Mobile Formations

Moderate Fractured & Faulted Formations

Reactive Formations

Over-Pressured Formations

Hole Cleaning

Unconsolidated Formations

Key Seating

Ledges and Doglegs

Introduction to Drilling Tools

PDC Reaming Tool - Construction

Tool design addresses several design intents and utilizes several features
For drilling:
Tool utilizes the use of stud cutters to introduce in-string drilling Tool blade design solves the problem of stud cutters shear through proper cutter support

Introduction to Drilling Tools

PDC Reaming Tool - Construction

For stability:

Spiral Blade design ensures 360 degree coverage

Mud way profile optimizes mud flow and resists balling
Blade 360 Coverage

For hydraulics:

Introduction to Drilling Tools

PDC Reaming Tools - Construction

For performance:
Balanced cutting structure with cutter redundancies ensures optimized cutting and long life Reaming inserts arranged to provide continuous reaming and outstanding hole quality Reamed volume matched to tool life for uniform tool wear
Cutter Pairs

Backup Gage Cutters

Introduction to Drilling Tools

PDC Reaming Tool - Construction

For productivity:
Design process is automated, this allows for fast customization

For manufacturing:
Stud cutters allow the use of traditional 4 axis milling Tool configurations of same size use same turning profile (for inventory)

Introduction to Drilling Tools

PDC Reaming Tool - Models

Single Action Tool

Fishing side doped with PDC cutters

Dual Action Tool

Fishing side doped with PDC cutters Down-hole side doped with PDC cutters

Down-hole side covered with reaming TCI inserts

Optimized TCI distribution on gauge part

Full coverage spiral

Optimized TCI distribution on gauge part

Introduction to Drilling Tools

PDC Reaming Tool - Models

6 Blade Tool

Larger Mud Way Cross section and more TFA than a 6 Blade

Same reaming capacity as a 6 Blade Tool Same number of cutters as a 6 Blade Tool

Longer tool and longer crown length

Introduction to Drilling Tools

PDC Reaming Tool - Features
Oriented stud cutters for optimum cutting Upper cutter set opens from neck to hole gauge

Chamfered blade for proper PDC cooling and cleaning

360 Blade coverage Omni Axi-symmetric cutter distribution for balanced drilling & reduced vibrations cutter design

Cutters deeply inserted in blade for elimination of shear plane

OMNI mud-ways, optimized to minimize balling potential

OMNI TCI distribution, optimized for uniformity of reamed surface and balanced insert wear

Lower cutter set opens from bit under gauge to hole gauge

Subject Well #1
BHA : PDC reamer above 5 6/7 motor with 1.5 bend; UBHO; 2 x NMDC; PDC reamer Begin reaming lateral 10,500 Flow rate =205 GPM 65 RPM surface rotary +165 RPM at motor for 230 RPM

Well #1 Re-Cap
32 hours reaming, 9000 feet open hole, on bottom drilling at 19,495 depth Average 25 ft/hr in rotary mode and 12 ft/hr sliding mode Rig limited to 4250 psi differential; difficulty with second slide in getting required high side tool face Planned, 10-20 stand short trip Reamed the last 800 to TD at 20,232 BHA POOH and 21 swell packers successfully run

Subject Well #2
BHA : 6-inch PDC bit; 4-3/4 7/8 fixed housing motor with 1.5 bend; 5 7/8-inch NM PDC reamer; UBHO; NMDC; NM PDC reamer Ream lateral hole from 10,500 to 15,552 Ream-while-drilling from 15,552 to TD at 19,576

Well #2 Re-Cap
Run in to ream at 5000 to bottom, holding angle over 4024 feet RWD from 15,552to TD at 19,576 5.14% sliding in 24.5 hrs 94.86% rotating with 49.58 rotary hrs Rotating ROP of 77 ft/hr over 3817 feet Sliding ROP of 9 ft/hr over 207 Eliminated dedicated reamer run 21 swell packers successfully installed

Subject Well #3
BHA : 6-inch PDC bit; 5 4/5 fixed housing motor with 1.5 bend; UBHO; NMDC - 2; XO; steel PDC reamer; HWDP 1; steel PDC reamer Drill out 7 shoe with RWD BHA Ream-while-drilling from 10,320 to TD at 19,820

Well #3 Re-Cap
P/U RWD BHA and drill out 7 casing shoe RWD from 10,320 to TD at 19,820 9.2% sliding in 10 hrs 90.8% rotating with 98 rotary hrs Rotating ROP of 88 ft/hr over 9000 feet Sliding ROP of 35 ft/hr over 350 Eliminated dedicated reamer run 30 swell packers successfully installed

Ream-While-Drilling BHA Design

Optimal RWD BHA
30-foot spacing between PDC reamers positioned on top of the lower BHA using steel body tools 30-foot spacing between PDC reamers in the lower BHA using non-mag tools
RWD BHA concerns: 60-foot spacing between PDC reamers had a dropping tendency in rotary PDC reamers run without any spacing created to stiff an assembly and was difficult to steer/orient while sliding.

Best Practice RWD

Surface handling PDC reamers: Care should be taken in picking up and laying down of reamer tools to insure no surface breaking / chipping of the PDC cutters and TCI When reaming back to bottom with PDC reamers in the lateral drilling BHA, it is recommended to ream at 250-300ft/hr due to the 1.5 degree bend in the motor PDC reamers are only effective while in the rotary mode so it is necessary to ream or back ream each slide interval to insure a smooth well bore.

Conclusions: Use of PDC Reamer

100% successful swellable packer installations No issues with steerability Increase in rotary ROP smooth well bore, greater on bottom WOB Low / manageable torque Versatile RWD BHA using both non-mag and steel body PDC reamer tools Eliminated dedicated reamer run 3 days rig time savings per well

Rockin (reaming) in the Bakken

Innovative solution using PDC Reamer proven in multiple wells Reamed in excess 750,000 of hole / over 50 wells in ND/MT Eliminates need for dedicated reamer run Saves average of 3 days/well $225K savings per well Established best practice for Williston Basin wells

Acknowledgments
This new technology, through the combined efforts of proven North Dakota operations groups, rig and service companies, has eliminated the dedicated reamer run at TD while delivering good wellbore condition that enables multiple swellable packers to be run in a single, fast trip. We have worked with a number of operators , drilling contractors and service contractors we appreciate their support in moving this project forward. Additionally we would like to thank our TERCEL manufacturing plant for their support on this project Omar Ahmed, Duane Shotwell and Michael Byerley . We as also would like to thank our WEPS / AER field service personnel William Collins , Mitchell Fenske and Alicia Kerr.