SPE/IADC 67769
Determination of Borehole Quality, Diameter and BHA Directional Response: Eccentric
Tool Test Program for Expandable Casing Application North Sea
Robert Jan Lodder, Shell U.K. Exploration and Production; Michael Ruggier, e TECH and Allen Sinor, Douglas Bobrosky
and Steve Radford, Hughes Christensen Company
Copyright 2001, SPE/IADC Drilling Conference
This paper was prepared for presentation at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 27 February–1 March 2001.
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Abstract
A detailed test program was performed with an eccentric tool
at the Baker Hughes Experimental Test Area (BETA) field
research facility to evaluate the feasibility of its use in an
Expandable Tubular Technology application in the North Sea.
The testing used a 9-7/8" Drill Out Steerable Ream While
Drilling (DOSRWD) tool in conjunction with 6-1/2" pilot bits
(both PDC and roller cone). Motor bent housing settings
included 1.0°, 1.5°, 1.75° and 2.0° bends to evaluate
directional and stability response. Surface speeds were varied
from 0, 35, 50 and 75 rpm at each motor housing setting.
Caliper logs including four and six-arm and ultrasonic
borehole imaging (UBI) tools were used to characterize the
borehole under all conditions. The analysis included
directional tendencies, down hole vibration monitoring and
borehole diameter, quality and degradation over time. The test
results show the 9-7/8” DOSRWD system is capable of
providing the high quality wellbore required for expandable
tubular technology, ensuring the casing can be run, expanded
and isolated across the formation.
Introduction
Expandable tubular technology has the potential to
significantly reduce well construction costs. Conventional
well construction results in telescoping of the well size from
the wellhead down to the reservoir. Apart from resulting in
large expensive surface casing, wellheads, trees and operating
equipment, the method can result in an unworkable small hole
size at the required depth. This could then lead to
compromises in well operability or in worst case failure to
reach the final objective.
2
Expandable tubulars can help solve difficult drilling
challenges posed by high-pressure zones, deepwater
environments and troublesome sub-salt plays.1,2,3,4,5 Its
innovative characteristics allow operators to explore in remote
geologic regions and exploit reserves once considered
unprofitable if drilled with conventional technology. Instead
of using progressively smaller diameter pipe as drilling
progresses deeper, Expandable Tubular Technology allows
tubular diameters to be expanded with specially designed
“pigs,” or mandrels. This reduces well tapering while
preserving borehole size. Expandable technology can also
extend the profitable life of mature fields by internally
cladding existing wellbores to isolate troublesome zones.
This developing technology has created a need for improved
understanding of the directional tendencies of eccentric
drilling tools run on steerable assemblies and the wellbore
geometry and quality that can be achieved with these tools.
Consistent wellbore diameter is of particular concern for
expandable tubulars. If the wellbore diameter is too small,
expansion of the pipe with a fixed diameter cone might not
proceed properly across sections of firm formation. Worse
yet, the expansion cone could become stuck requiring
remediation or sidetrack of the well. A wellbore that is too
large could affect the sealing effectiveness depending on the
sealing system used. For example, a closer diameter tolerance
would be required if the seal mechanism is an integral part of
the casing (elastomer bonded to the outside of the casing).
North Sea Application
The challenge to well construction in the Brent field located in
the UK sector of the North Sea, operated by Shell U.K.
Exploration and Production on behalf of Shell U.K. Limited
and Esso Exploration and Production UK Limited, is well
understood. Ongoing depressurization to accelerate gas
production is causing regression of the fracture gradient of the
producing reservoir rock. The fluid density required to tap into
normally or over-pressured reservoir sections will cause
formation breakdown in the depleted sections. As a short-term
measure, while the drilling margin between the fracture
gradient and required mud density is still sufficient, advanced
ECD management has been implemented. However, with the
2 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD
continued depressurization, the Expandable Tubular
Technology should enable the drilling envelope in the Brent
field (in particular in the smaller hole sizes) to be extended.
Benefits of using Expandable Tubulars (from the use of larger
hole sizes) include improved ECD management and mud
weight flexibility as well as the ability to case off zones that
have caused drilling problems while maintaining the planned
hole size.
Shell Expro entered into an Expandable Drilling Liner
Development and Supply agreement with e2TECH to ensure
that Solid Expandable Liners are available for those future
wells when the reservoir pressure will have decreased to such
low levels that they become undrillable with conventional
methods. e2TECH is a Joint Venture between Shell and Baker
Hughes Incorporated.
In order to understand whether the e2TECH concept for
expandable casing is feasible with current eccentric
technologies, Hughes Christensen executed a test plan with
their Drill Out Steerable Ream While Drilling (DOSRWD)
tool for e2TECH and Shell Expro (hereafter "consortium"). The
authors will discuss tests that prove the 9-7/8" DOSRWD met
the "consortium's" narrow diametrical and hole quality
requirements for expandable casing applications in the Brent
field. The DOSRWD tool has since been run in the North Sea
Brent field to calibrate / verify the test results. To confirm
lessons learned and best practices, a final test of the full
Expandable Drilling Liner system is planned at BETA prior to
the Brent field application. The test is planned during the first
quarter of 2001.
BETA Test Facility Background
The testing documented in this report was performed at the
Baker Hughes Experimental Test Area (BETA) field research
facility. The facility is located south of Tulsa, Oklahoma near
the Glenpool field, a major oil field discovery in the early
1900’s. The presence of oil, gas, coals, permeable and hard
and abrasive sands, and unstable shales provides conditions
that are typical of other oil field lithologies. The $2.5 million
investment, located on a 640 acre lease, is unique to the
industry as it allows integration of a wide spectrum of the
corporation's downhole tools and products division's research
efforts. The new facility is used to bridge the gap between
laboratory testing and commercial applications by providing
real world testing and field conditions.
The need to continually improve designs requires the service
companies to conceptualize, design, develop and manufacture
reliable tools as rapidly as possible. Most product and service
suppliers use their customer's wells as testing grounds for their
new products. This helps lower their up-front development
costs. The downside to this approach is the operator assumes
higher risk. This approach also lengthens tool development
time since the priorities of the operator (commercial
production) are often contrasted by service company (tool
SPE/IADC 67769
development and testing) that may require frequent unplanned
trips. In addition, higher risk associated with non-conventional
oilfield products may preclude the option of ever testing on
operator wells until a certain confidence level is attained.
Hence, the development and use of the BETA facility for
product testing and development has been well received
within this corporation.
The yearly footage of new wells drilled at BETA averages
about 30,000 ft/year. Drilling is accomplished with a carrier
based drill rig using a freestanding mast. The rig is mounted
on a skid system to allow easy access over new or existing
surface holes. Directional and horizontal testing dictated the
requirement of a top drive instead of a kelly for pipe rotation.
The rig is equipped with a 150 ton Tesco top drive capable of
rotary speeds up to 310 rpm. A closed loop mud system is
used to minimize surface wastes. The drilling rig is
instrumented to provide high quality data collection and
information access via a webserver throughout the
corporation. In-depth knowledge of the facility’s sedimentary
and petrophysical properties through coring and log analysis
allow tool comparisons and improvements to be quantified.
Test Goals and Objectives
The use of expandable tubulars requires a better understanding
of borehole size and quality. Although eccentric tools are
used on an increasing number of wells, borehole quality and
size is seldom measured. The two-piece ream while drilling
system has been successfully used to cut drilling costs in
various applications worldwide.6,7,8,9,10,11,12,13 The main
objective of this type of technology has been to facilitate
running casing/liner to TD in wells that require a tightly
nested casing string. In many cases, ECD management is not
possible without the use of these tools to provide an enlarged
wellbore, reducing annular pressure losses. Recently, the
RWD tool was modified to allow rotation inside casing in
order to drill out cement and associated float equipment, thus
eliminating a trip to change out the BHA. Still, the measure of
success with these tools has generally been whether there were
problems associated with getting casing to bottom, not the
quality of the wellbore.
The purpose of the project was to determine whether the
"consortium's" concept for expandable casing/liner is feasible
with current RWD technology. The main test objective was to
document actual borehole size and quality drilled by a 9-7/8"
DOSRWD tool using various directional AKO settings. Also
of interest were directional and vibrational tendencies in slide
and rotate mode in addition to borehole degradation over time.
The testing would attempt to simulate drilling conditions in
the Brent field to optimize tool design for the proposed
commercial application of expandable tubulars. From the
detailed geological stratigraphy map that is available for the
test site, the formations that most closely resembled the Brent
situation were identified for the majority of the testing.
 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 3

The test program included the evaluation of the following: The wellbore quality analysis shown in this paper includes
• Hole size and tolerance achievable with various runs three through seven. Run one was omitted from the
directional AKO settings. analysis because of a premature tool failure caused by
• Borehole quality with various directional AKO settings downhole vibration while drilling through a hard stringer. Run
with emphasis on hole ovality, formation of ledges, hole two was a precautionary cleanout run with a drift diameter
spiraling, etc. roller cone bit, drilling only 14 ft. Run 1 was rerun as run
• Hole degradation caused by drilling and tripping through number three.
the drilled interval
• Directional tendencies in slide and rotate mode Histograms were used to compare data sets from the different
• Surface rotary speed effect on hole quality, bit stability caliper logs and hole intervals as illustrated in Figure 3. The
and drill string dynamics. data was collected and separated into “bins." A bin counts all
• Downhole vibration characteristics on tool life and hole diameters within defined ranges, i.e. 9.75" to 9.80", etc. The
quality total number of occurrences in each bin was then plotted vs.
bins to create a histogram. The histogram indicates the
Follow-up work for the Brent project, not part of this paper, distribution of the data set for each set of arms. The histogram
was scheduled to determine the following: shown for a 6-arm caliper for the interval 1246-1267 ft is
broken down into three data pairs. The first pair is for arms 1
and 4, the second is for arms 2 and 5 and the third pair is for
• Correlation of the test results with the Brent field
environment arms 3 and 6, each arm in the pair being 180° opposite from
the other arm. The histogram for this example has peaks at
• BHA optimization for eccentric tools required to achieve
9.95" for arms 1&4; 10.2" for the arms 2&5; and 10.8" for
the desired passthrough and hole properties
arms 3&6.
• Selection of the appropriate logging tool/processing to
confirm the hole is suitable for an expandable liner
The inconsistency between the individual caliper readings
application prior to its deployment.
does not necessarily mean that the wellbore is out of round. In
a deviated hole, the caliper tool is often located off-center
Test Report
from the wellbore centerline. Examination of the raw caliper
The eccentric tool testing fulfilled all planned objectives.
data provides inaccurate borehole characterization unless this
Problems with Run 1 required a re-run and reduced our overall
data is processed to account for misalignment of the tool.
testing program. Table 1 documents the testing sequence
Figures 4a – 4c show how the diameter of a wellbore can
including pilot bit type and size, motor bent housing setting
significantly change based on the orientation of the tool and
(AKO), final section inclination, start and end depth of the
hole deviation.
section and the amount of footage drilled in either the slide or
rotate mode. Cooperation between the "consortium", including
Figures 5 shows a wellbore cross-section measured with 6 arm
daily progress meetings, allowed for test analysis and problem
and acoustic caliper tools during the testing at BETA. The
resolution "on the fly" resulting in an optimal program. The
graph shows the planned diameter, measured diameter and
BHA included a 6.5" pilot bit, 9.875" DOSRWD, 6.75"
processed diameter. The 6 arm tool raw data clearly shows
medium speed directional motor, directional and vibration
the wellbore is oval in shape whereas the processed data
sensing MWD tools, 5" heavyweight and 4.5" standard drill
clearly shows a concentric wellbore. Additionally, the
pipe to surface (Fig. 1). Weight-on-bit varied between 2,000
acoustic UBI tool confirms the concentric shape of the
and 14,000 lb and the flow rate was held constant at 475 gpm.
processed 6 arm data.
Most of the testing occurred in slide mode except for rotary
tests at 35, 50, and 75 rpm at each AKO setting. Penetration
Lastly, considerable discrepancies were noted during the
rates were limited to less than 200 feet per hour in the softer
initial 4 arm logging runs. More detail regarding logging tool
sections. All testing was done with a gel/water drilling mud,
comparisons is included in Appendix 1. Briefly, the 4 arm
weighted from 8.6 to 9.5 ppg.
caliper tools run during the testing were found to be of poor
quality and insufficient for making hole size judgements.
The initial well plan called for the borehole to hold azimuth
while constantly building angle. During the 1.75° AKO run,
Hole Size
well path analysis indicated wellbore inclination would be
Hole size is affected by a number of variables that include
excessively high and would prohibit wireline logging tools
operating parameters, type of mud, bit type, bit and BHA
from accessing the bottom of the hole. To accommodate
dynamics and formations drilled. Comprehensive analysis of
logging tools, the directional plan was altered to perform
these variables was beyond the scope of this project but
azimuth changes with a slight drop to minimize the maximum
attempts were made to evaluate the effect of rpm, bit type and
wellbore angle. The 3D plan and elevation views of the final
bent housing setting.
well are shown in Figure 2.
4 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD
The average hole size measured 10.05”, with a minimum
diameter of 9.69." The standard deviation was 0.20” indicating
a smooth wellbore. For the expandable tubular application
with e2TECH, the required tolerance window is between 9.50”
and 10.50”. Figure 6 shows the processed caliper data as a
function of depth. Runs 1 and 2 and a short section of run 6
were not included in the hole size analysis because of
eccentric tool damage affecting wellbore quality. The effect
of vibration on tool life and wellbore quality is a subject of
more detailed discussion later in the text.
Roller cone and fixed cutter pilots side cut differently because
of the compressive vs. shear failing mechanism while drilling.
Tests were designed to evaluate how the cutting action of the
pilot bit would affect hole diameter with eccentric drilling
tools. An enlarged pilot hole would naturally promote a
decreased reamed hole size since the reamer wing would be
running off center. Two separate tests were performed to
evaluate the effect of pilot bit type, one with a PDC bit, the
other with a roller cone bit. Both assemblies used a motor with
a 1° bent housing. The roller cone pilot promoted a larger
reamed hole in all cases, but by only a small margin of 1.3%
for the worst case (35 rpm). This small variance is
insignificant for oilfield drilling operations. Figure 7A
compares the results of bit type on hole diameter.
Figure 7A also compares the effect of rotary speed on hole
diameter. Hole size was measured in the slide mode and at
rotary speeds of 35, 50 and 75 rpm. At each rpm setting, a
total of 20 ft of new hole was drilled. The hole diameter
produced with the PDC varies by only 0.04” for the three
surface speeds. The hole diameter produced with the roller
cone bit varies by only 0.11” for same speeds. No significant
hole size differences can be inferred from the rotary speed
analysis.
Next, the effect of motor bent housing setting on hole size was
evaluated. For this analysis, a motor setting of 1° was
compared against a motor setting of 1.75° both with PDC pilot
bits. The 2° motor setting data was not used because of the
limited footage drilled. Figure 7B compares the results of the
data generated with the acoustic UBI caliper log. The table
shows no significant hole size differences between the two
motor settings.
Hole Quality
Six arm caliper and ultrasonic caliper tools were used to
evaluate wellbore quality. Output from these tools was
analyzed numerically for statistical analysis and graphically
for visual analysis, the graphical analysis taking the form of
two-dimensional cross-sections and three-dimensional
renderings of the wellbore wall.
One method for describing the quality of the borehole is to use
standard deviation. This measure describes how closely the
data set for selected intervals is grouped. For example, if the
SPE/IADC 67769
average hole size is 10.0” with a standard deviation of 0.20”,
this would imply that 75% of the data points are within two
standard deviations or between 9.60” and 10.40”. With a high
standard deviation, a rough hole with wider variances in
wellbore diameter is predicted. With a small, tighter standard
deviation, a smoother, more consistent wellbore diameter is
predicted. Figure 8 summarizes the standard deviation as a
function of run number, depth and rpm. From the graphic, the
standard deviation is shown to be higher at the highest rotary
speed (75 rpm) and the lowest occurs at 50 rpm, indicating the
wellbore wall is roughest at 75 rpm.
Examination of two-dimensional cross-sections and three-
dimensional renderings of 6-arm and UBI logs show
interesting results. The raw six arm caliper data predicts an
oval hole throughout most of the test interval. The acoustic
UBI tool shows a relatively consistent concentric wellbore
geometry. Figure 9 shows an example of this difference at a
depth of 1,270 ft. The UBI shows a concentric wellbore with
the initial development of a small keyseat. The 6 arm caliper,
both raw and processed data show the wellbore to be oval
based on interpretation of the arm placement inside the
wellbore. This phenomenon was previously described
graphically in Figures 4a – 4c.
Figure 10 shows the development of ledges at connections and
at the transition from slide to rotate mode. These small offset
centerline ledges are typical of directional drilling applications
with standard bits. The six-arm caliper log again appears to
show oval holes as discussed above.
Borehole spiraling was generally not present during the
testing. Figure 11 shows a snapshot where spiraling was
experienced for a short distance. Spiraling is related to surface
rotation of directional assemblies. No correlation was
detected with respect to surface rotary speed and degree of
spiraling. Like ledging, this is typical of any directional
drilling operation and is a function of the distance between the
pilot bit and the bend of the motor.
Hole Degradation
Hole degradation is generally a time related loss of borehole
quality. Causes of borehole degradation include mechanical
abrasion and gouging of the wellbore wall, fluid erosion,
wellbore instability problems caused by formation stresses and
chemical reaction between the drilling mud and formation
fluid. Caliper logs were repeatedly run during the testing to
monitor the degradation of hole quality with time.
The best example of hole degradation is shown by the high
quality UBI logs run first on April 7 and later on April 14
(Fig. 12). The UBI logging runs occurred first after run 4 at a
depth of 1,309 ft. The UBI tool was later rerun at the end of
run 7 to a total depth of 1,993-ft. Total drilling time was only
23 hours. The flat time was spent tripping in and out of the
hole during the additional runs, running additional logs and
 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA
shutting down for the weekend and evenings. The UBI logs
indicate the borehole is larger with UBI Log 2 than it was with
UBI Log 1 (increasing uniformly by an average of 0.27" or
almost 3%). Lithology of the hole enlargement section was
Pennsylvanian shale and sandstone.
The UBI logs also identified key seating, particularly as the
hole deviated from vertical. This can be clearly identified
after examining the cross-sections in Figure 13. The cross-
section on the left of the figure shows a generally concentric
wellbore. The cross-section on the right shows a significant
key seat, extending 0.63” past the originally drilled diameter.
The time interval was 7 days as mentioned above.
Directional Characteristics
The test program used four AKO settings to evaluate
directional tendencies of the DOSRWD tool. The plan was to
drill 240 ft in slide mode and 90 ft in the rotate mode at each
motor bent housing setting. A rotate length of 60 ft was used
instead of 90 ft since the drilling was with 60 ft stands and to
minimize connection effects. The rotate mode would be
equally divided between surface rotary speeds of 35, 50 and
75 rpm. BHA and bit modeling was performed at the end of
each run to compare actual dogleg severity with predicted.
Predicted dogleg severity was calculated using Baker Hughes
INTEQ’s “ECTRAK” software at the end of each run to allow
proper input of the wellbore trajectory.
ECTRAK utilizes a standard three-point geometric equation
but also accounts for bit side-cutting tendencies, BHA material
properties, inner and outer diameters, and BHA/pipe bending.
It is a static analysis, but accounts for the forward-looking 60
feet of hole. The actual dogleg is computed with the standard
formula utilizing the first and last points of the interval. In
some cases the transitional points entering or exiting a rotation
mode are ignored.
Figure 14 compares actual with predicted dogleg severity for
each run. Three separate runs were made with the AKO setting
at 1°. A PDC bit was used on the first two runs and a roller
cone bit was used on the third run. The dogleg severity was
consistent at 5.60° and 5.60° for the PDC bit runs. The dogleg
obtained with the roller cone is less than predicted because of
the PSP (pilot stabilization pad) influence on side cutting
efficiency. The 1.50° AKO setting resulted in a slightly higher
dogleg than predicted due to cutter damage on the reamer
wing. Run 7, with a 2.0° AKO shows a lower dogleg because
of the prior hole geometry. This is surprising to most and
justifies the need for predictive modeling capabilities. The bit-
to- motor bend length was nearly the same for both 2° and
1.75° assemblies (8.91 ft vs. 8.73 ft, respectively). Although
the calculated side force for the 2.0° AKO assembly is
significantly higher than the 1.75° AKO, the 2.0° AKO never
had a chance to reach maximum dogleg because of the short
length drilled.
5
Figure 15 shows dogleg severity and inclination vs. depth.
During rotate mode, wellbore inclination had a hold to slight
dropping tendency with the dogleg measurement near zero.
This is an important observation since other eccentric designs
have been shown to have a strong dropping tendency in the
rotate mode.
Steering with the DOSRWD was easily accomplished and
compared well with standard full hole bits. The measured
azimuth was controlled with all AKO settings in both slide
and rotate modes. The graph in Figure 16 shows the degree of
azimuth change for each AKO setting in slide or rotate mode.
The initial run with a 1° AKO resulted in a 12° azimuth drift.
This drift is a result of the wellbore being near vertical at the
start of this run making azimuth control more difficult. Also,
measured vibrations and stick-slip that occurred when the bit
was damaged made it difficult to maintain toolface. The run
with the 1.5° AKO was intentionally steered as previously
discussed to minimize inclination in an attempt to allow the
logging tools to reach bottom. In all other runs, the azimuth
was controlled within a few degrees as shown in the figure.
Drill String Dynamics
Downhole vibration monitoring was accomplished through the
use of two commercially available tools, VSS and CoPilot.14,15
The VSS (Vibration Stick Slip) monitoring tool is used as a
stand-alone tool to record and transmit downhole vibration
and pressure data to the surface. The CoPilot tool also records
and processes downhole vibrational data and in addition,
provides real-time recommendations to the rig floor. The
CoPilot tool measures stresses, pressures and vibrations
simultaneously at a high data rate (1000 Hz). A downhole
computer processes the information with sophisticated
software that determines the occurrence and severity of
various downhole drilling dysfunctions. The information on
these phenomena (stick-slip, bit bounce, BHA whirl, etc.) is
then transmitted to the rig floor where it is displayed alongside
surface data, giving the driller immediate feedback on drilling
parameter changes. More information on these tools and
dynamics can be found in Appendix 2.
Downhole vibration monitoring showed minimal vibration
throughout most of the testing. During the more representative
runs in rotary and slide mode, with PDC as well as roller cone
bits, the highest lateral vibration magnitudes averaged near 1.0
g with peaks approaching 2 g. The axial vibrations were even
lower, with maximum of 0.3 g with the PDC bit and 0.5 g with
the insert bit, again both very low. Generally, a vibration
measurement below 3 g is considered fairly smooth and below
1 is very smooth drilling. The first run with a 1° AKO showed
the highest vibration magnitude of any run especially towards
the end (Figure 17). Upon recovery of the tool, it appeared to
have had suffered severe damage. Whether the vibrations
caused the damage or the damage caused vibration remains a
question. The lateral (XY) vibrations of 3.3 g’s in stick-slip
could have contributed to the failure of the tool. The bit
6 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD
bounce (Z) vibration on that run averaged below 0.5 g
indicating lack of bit bounce during the run. Figure 18 shows
the repeat run of the 1° AKO without vibration. For this
example, a difference of as little as 1G (XY) indicates the
difference between a damaged and an undamaged tool. The
measured levels of vibration would most likely have been
much higher if the downhole vibration monitoring sub had
been located closer to the bit. Unfortunately, this was not
possible since the steerable testing required a motor next to the
bit.
As it happens, the onset of the increased vibration coincided
with a known hard streak in the drilled formation. Thorough
evaluation of the potential failure mode of the tool resulted in
identifying an opportunity to modify the cutting structure of
the reamer wing and thus improve durability.
Downhole vibrations monitored by the VSS tool showed
acceleration differences between each of the surface rotational
speeds. However, analysis of the data was inconclusive in
showing one rotational speed is smoother at the bit. No
analysis of the data is presented here for discussion. As a side
note, the vibrations observed while testing the eccentric tool
was consistent with other wells drilled at the BETA facility.
Opening an Existing Hole
The damage to the eccentric tool during the first run and
subsequent clean out run with an 8-3/4” roller cone bit
resulted in a short 14 ft section (668 – 682 ft) of undersized
hole. An unplanned test was performed after completing run 6
with the 1.5° motor setting to evaluate the potential for the
DOSRWD to open up the hole.
Figure 19 shows the results of the hole opening exercise.
Although the section was quite short, the two rotary speeds
(32, and 61 rpm) were used to evaluate differences in hole
quality. RPM did not seem to have an effect. Surprisingly to
all, the DOSRWD tool not only opened the hole without tool
damage, but also opened it past the drill diameter of 9-7/8" to
an average 10.91". This may partly be explained by the BHA
side forces at the bit not being constrained by the pilot hole.
Calculations show that side forces at the bit can be in excess
of several thousand pounds depending on the motor setting
and tool length below the motor. More analysis of this result
is pending. Regardless, the hole was opened nicely paving the
road for an unrealized potential use of DOSRWD tools to
open or reopen selected sections.
Conclusions
• The DOSRWD provided a borehole of acceptable size to
meet the "consortium's" tolerance window between 9.5"
and 10.5". The borehole had an overall average diameter
of 10.05 inches, with a minimum of 9.69.
• Hole diameter standard deviation was 0.20, indicating a
smooth hole.
SPE/IADC 67769
• All three of the rotate mode speeds, 35, 50, and 75 rpm,
produced similar larger hole size than the slide mode,
while rotating the directional assembly at 50 rpm
produced the best hole quality.
• Six-arm caliper and UBI caliper log both produce good
geometrical measurements and are judged to be
acceptably accurate for average hole size readings.
• The UBI log is superior in characterizing hole shape and
diameter
• The 4-arm caliper provided poor consistency and
accuracy throughout the three separate logging runs.
• Slight borehole ledging at the initiation of rotate and slide
modes and slight spiraling over a short distance typical of
directional drilling applications with mud motors and
standard bits were identified.
• Key seating up to 0.63" deep developed over a 7-day
period while drilling 900 ft (only 180 ft rotary).
• Although borehole ovality appeared to be shown with the
six-arm caliper the more detailed borehole imaging from
the UBI tool indicated this was not the case and merely a
result of key seats and ledging.
• Slight hole enlargement occurred over the seven day
period increasing by an average 0.27”
• The DOSRWD tool exhibited good steerability and
predictable directional response similar to conventional
directional drilling assemblies.
• In rotate mode, the dogleg severity approached zero
indicating a nearly neutral assembly.
• XY (lateral) vibrational accelerations did not exceed 2.0 g
except where tool damage occurred. Z (axial)
accelerations did not exceed 0.7 g.
• The DOSRWD tool was used to successfully ream an
existing undersize section of hole and produced a slightly
oversize hole (larger than drill diameter)
• The 9 7/8” DOSRWD tool durability has been addressed
by Hughes Christensen
• The improved confidence in the hole size tolerance that
can be achieved with the DOSRWD tool has made it
possible to make decisions on the design and manufacture
of tools to drill the optimal hole sizes for the expandable
liner project
Future Actions
1. Transform learning's to Brent field applications
2. Perform detailed analysis of the high quality data that was
collected during subsequent runs with the DOSRWD in
the Brent field.
3. Perform a full system test of drilling a suitable hole and
expanding an expandable liner at BETA early 2001, prior
to the first field application.
4. DOSRWD directional assemblies should be planned
based on build rates predicted with standard PDC pilots.
5. Downhole vibration measurement MWD tools are capable
of detecting the onset of damaging bit and drillstring
 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA
dysfunctions. These tools should be used to minimize
tool damage and optimize performance.
6. Ultra sonic or 6-arm calipers should be used to accurately
measure the wellbore. The Ultra sonic tools provide the
best image of the borehole.
Acknowledgments
We would like to thank Shell Expro, e2TECH and Hughes
Christensen for supporting this project. We also want to thank
Schlumberger, Baker Atlas, Baker Hughes INTEQ and the
personnel at the BETA test site. Special acknowledgment is
given to Jay Clinkscales, Lester Clark, Chris Charles, Craig
Fleming, Marcelo Fraga, Jim Powers and Mitch Pavlovic for
their individual contributions.
References
1. Stewart, R.B., Gill, D.S., Lohbeck, W.C.M., Baaijens,
M.N.: "An Expandable Slotted Tubing, Fibre-Cement
Wellbore Lining System," SPE Paper No. 36828,
presented at the 1996 European Petroleum Conference,
Milan, Italy, Oct. 22-24.
2. Filippov, A, Mack, R., Cook, L., York, P., Ring, L.,
McCoy, T.: "Expandable Tubular Solutions," SPE Paper
No. 56500, presented at the 1999 SPE Annual Technical
Conference and Exhibition, Houston, Texas, Oct. 3-6.
3. Owoeye, O.O., Aihevba, L., Hartmann, R.A., Ogoke,
V.C.: "Optimisation of Well economics By Application of
Expandable Tubular Technology," IADC/SPE Paper No.
59142, presented at the 2000 IADC/SPE Drilling
Conference, New Orleans, Louisiana, Feb. 23-25.
4. Lohoefer, C.L., Mathis, B., Brisco, D., Waddell, K., Ring,
L., York, P.: "Expandable Liner Hanger provides Cost-
Effective Alternative Solution," IADC/SPE Paper No.
59151, presented at the 2000 IADC/SPE Drilling
Conference, New Orleans, Louisiana, Feb. 23-25.
5. Metcalfe, P., Martyn, K., Aitken, S.: Successful Isolation
of an Overpressured Gas Zone Using an Expandable
Drilling Liner," IADC/SPE Paper No. 62749, presented at
the 2000 IADC/SPE Asia Pacific Drilling Technology,
Kuala Lumpur, Malaysia, Sept. 11-13.
6. Warren, T., Sinor A., Dykstra, M.: "Simultaneous Drilling
and Reaming With Fixed Blade Reamers," SPE Paper No.
30474, presented at SPE Annual Technical Conference
and Exhibition, Dallas, Oct. 22-25, 1995.
7. Csonka, G. Tweedy, M.W. Cornel, S., Anderson, M.:
"Ream While Drilling Technology Applied Successfully
Offshore Australia," SPE Paper No. 36990, presented at
1996 SPE Asia Pacific Oil and Gas Conference, Oct. 28-
31, Adelaide, Australia.
8. Rodriquez, J., Carrè C. L.J., Portillo, R., Leal, M.: "Ream
While Drilling Tool Cuts Costs of Three Venezuelan
Wells," Oil & Gas Journal, Jan. 13, 1997, pp.33-40.
9. Hyatt, P., Little, I., Hanafi, A., Sinor, A., Herran, G.:
"Ream While Drilling Technology Cuts $1 Million in
Nile Delta Well," SPE/IADC Paper No. 39248, presented
at the 1997 SPE/IADC Middle East Drilling Conference,
Bahrain, Nov. 23-25.
7
10. Cook, J., Doster, M., Dykstra, M., McDonald, S.:
"Development of Steerable Ream While Drilling
Technology and Its Application in High Angle Wells in
GOM," IADC/SPE Paper No. 39326, presented at the
1998 IADC/SPE Drilling Conference, Dallas, Texas,
March 3-6.
11. Kinn S., Marshall, G. E., Poerschke W., Froehilch N.:
"The Success of Steerable Ream While Drilling
Technology Applied in Valhall Field-Norway,"
SPE/IADC Paper 52880, presented at the 1999
SPE/IADC Drilling Conference, March 9-11, 1999,
Amsterdam, Holland.
12. Billman, W. J., Brown, L. A., Zaki, M.: "Eccentric Tool
Increases Liner Size Capacity in Challenging Salt Dome
Application Allowing Longest Horizontal Well in Gulf of
Suez", IADC/SPE Paper No. 59238, presented at the 2000
IADC/SPE Drilling Conference, Feb. 23-25 New Orleans,
Louisiana.
13. Kelley, S., Swadi, M., Charles, C.: "Ream While Drilling
Technology Solves Difficult South Texas Drilling
Problem," IADC/SPE Paper No. 59240, prepared for
presentation at the 2000 IADC/SPE Drilling Conference,
Feb. 23-25 New Orleans, Louisiana.
14. Shuttleworth, N.E, Kerkoerle, E.J. and Foekema, N.
“Revised Drilling Practices, VSS-MWD Tool
Successfully Addresses Catastrophic Bit/Drillstring
Vibrations,” IADC SPE paper 39314 presented at the
1998 Drilling Conference, March 3-6, Dallas, Texas.
15. Heisig, G., Sancho, J. and Macpherson, J.D., “Downhole
Diagnosis of Drilling Dynamics Data Provides New Level
Drilling Process Control to Driller,” SPE paper 49206
presented at the 1998 Drilling Conference, September 27-
30, New Orleans, Louisiana.
Appendix 1- Caliper Discussion
It was not the intent of the program to evaluate different
methods of measuring borehole size and quality. However,
after initial review it became apparent certain logging systems
delivered more accurate and detailed information. The authors
determined the 4-arm caliper produced both inaccurate and
inconsistent results and consistently measured gauge
significantly under true diameter. In oilfield applications, the
4-arm tool is used to measuring bedding plane (e.g. dip)
orientation. It’s also used to check for tight / washed out hole
sections prior to running casing and allow the required volume
of cement to be calculated from the average measured hole
diameter to secure the casing in place. The 4-arm caliper
provides accuracy acceptable for those purposes. However,
due to the tight tolerances required on this project, precise
borehole diameter and imaging was required. For this reason,
6-arm and Ultrasonic Borehole Imaging (UBI) caliper tools
were used and consistently delivered superior borehole
measurement data. The 6-arm and UBI tools generally had
good diametrical agreement, although some differences were
noted in cross-sectional images.
8 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD
Figure 20 compares the different logging methods on a typical
hole section between 682-934 ft. The UBI and 6-arm caliper
registered similar results, with the UBI producing slightly
lower values. On average, the 4-arm caliper measured 6-8%
below predicted value while the 6-arm and UBI measured 2%
above.
Log analysts have suggested that the 4-arm log inaccuracy
may be caused by: (1) larger pads not able to distinguish the
finer characteristics of the hole circumference; (2) pads not
being hydraulically pumped to their fullest extent; (3) off-
center running of the caliper tool due to the hole inclination
resulting in the top pad not contacting the hole surface, (4)
incorrect calibration.
Based on these observations, the authors concluded that both
the UBI and 6-arm calipers provided dimensional accuracy,
but the UBI delivered the best borehole image, including hole
ovality and key seating. The 4-arm caliper is unable to
accurately measure borehole size or quality to the tolerances
required.
Appendix 2- Vibrational Analysis
During the course of drilling operations, the movement of the
drill string within the wellbore and the bit's interaction with
the formation generate unwanted and potentially harmful
downhole vibrations. Since drilling is a dynamic process,
vibrations are inevitable. In many instances we can tolerate or
deal with “low level” vibrations. However, severe downhole
vibrations can be destructive.
There is a growing awareness in the industry of the
importance of monitoring vibrations. Real-time monitoring
provides an effective means of reducing the chance of
drillstring failure and general drilling problems. The ability to
monitor and correctly interpret dynamic drilling behavior
depends on background knowledge of vibrational problems
and how they occur. This knowledge provides the framework
used in assessing the dynamic indicators, diagnosing the cause
of the vibrations and recommending corrective action.
Appropriate corrective action can significantly increase MWD
life as well as drillstring, motor and bit life in addition to
having a positive impact on drilling rates and efficiency.
Drillstrings can vibrate in one, or all, of three different modes:
• Axial: Vibrations that travel in a direction parallel to the
length of the drillstring.
• Lateral: Vibrations that travel in a direction perpendicular
to the length of the string.
SPE/IADC 67769
• Torsional: Vibrations that are due to the twisting of the
drillstring.
An example of a downhole axial vibration is bit bounce, which
can sometimes be detected at the surface as "kelly bounce."
An example of a downhole torsional vibration is rotational
stick-slip, which is obvious at the surface as periodic
fluctuations in drilling torque. Downhole lateral vibrations
(also called bending vibrations) are strongly attenuated in the
drillstring and rarely reach the surface, but can be the most
damaging in the least amount of time. All of these vibrational
modes are coupled (they affect one another). Since the drill bit
is fixed to the BHA and the BHA is fixed to the remainder of
the drillstring, it stands to reason any vibration that affects any
one of the components will affect the others.
The MWD vibration tool used during the testing delivers real-
time drilling dynamics and performance information to the rig
floor display. The downhole tool measures stresses, pressures
and vibrations simultaneously at a high data rate (1000 Hz.).
A downhole digital signal processor (DSP) features
sophisticated software algorithms that determine the
occurrence and severity of various downhole drilling
dysfunctions. The information on these phenomena (e.g.,
stick-slip, bit bounce, BHA whirl, etc.) is transmitted to the rig
floor display via mud pulse telemetry. On the rig floor, the
eight downhole diagnostics are displayed alongside surface
data and drilling parameter recommendations in a clear
manner, alerting the driller with immediate feedback of
drilling parameter changes. On this project, the MWD tool
collected downhole diagnostic vibrations: XY (lateral, whirl,
and/or stick-slip) and Z (axial bit bounce) accelerations with
the DOSRWD tool and pulsed processed vibration data to
surface.
The highest stick-slip magnitude (with a reading of 3-7 on a
scale of 0-7), and the highest lateral vibration (3-4) both
occurred on Run 1 when the DOSRWD tool had cutter failure
and badly damaged the body of the tool. It is understandable
stick-slip should be very high while trying to machine off the
blades of the tool and wedge the tapered shape of the damaged
tool into a smaller borehole. The highest bit whirl occurred on
Run 6 with a “2-5” reading, when the second DOSRWD was
damaged. Bit bounce never exceeded a reading of 3 and axial
vibrations never exceeded a reading of 2. MWD accelerations
were somewhat more severe than the VSS/MWD tool because
of its closer proximity to the bit.
 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 9

Table 1
Run Pilot Size Pilot Type AKO Final Inc. Start End Footage
Number (in) (deg) (deg) (ft) (ft) (S) Slide
(R) Rotate
1 6.50 PDC 1.00 12 438 664 S – 226
664 668 R–4
2* 8.75 RC N. A. 12 668 682 R – 14
3 6.50 PDC 1.00 23 682 934 S – 252
934 995 R – 61
4 6.50 RC 1.00 32 995 1247 S – 252
1247 1309 R – 62
5 6.50 PDC 1.75 47 1309 1476 S – 167
1476 1567 R – 91
6 6.50 PDC 1.50 39 1567 1846 S – 279
1846 1907 R – 61
7 6.50 PDC 2.0 40 1907 1993 S - 86
* Cleanout run with drift diameter bit
10 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD SPE/IADC 67769

Figure 1. BHA schematic for eccentric tool testing

 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 11

Figure 2. 3D plan and elevation views of the final well

Histogram 996'-1216', Roller Cone 1deg AKO (Slide Mode)

350

300

250
Count

200

150

100

50

0
9.6 9.65 9.7 9.75 9.8 9.85 9.9 9.95 10 10.05 10.1 10.15 10.2 10.25 10.3 10.35 10.4
Over 10.45

Borehole Diameter

Six-Arm (Pair 1-4) Six-Arm (Pair 2-5) Six-Arm (Pair 3-6)

Figure 3. Histogram of caliper tool output

12 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD SPE/IADC 67769

Figure 4. Effect of logging tool alignment on hole diameter

 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 13

6-arm caliper UBI over same interval

Original
Bore Hole
Shape

Revised
Bore Hole
Shape

Predicted
Bore Hole
Shape

1100-1200 ft MD
Figure 5. Raw and processed 6 arm and acoustic data

11.5
Interval of tool damage
and later reaming
Borehole Diameter (inches)

11

10.5

10

9.5
Interval of tool damage

9
440-667 682-934 954-974 995-1247 1267-1287 1309-1477 1497-1538 1567-1847 1867-1887 1907-1992
(1PDC) (1PDC) (1RC) (1.75PDC) (1.5PDC) (2PDC)

UBI #2 6-Arm Bit Size

Figure 6. Caliper data for runs 1 – 7
14 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD SPE/IADC 67769

UBI Caliper Plot - 1 deg AKO 682'-1309'

10.2

10.15

10.1
Borehole Diameter (inches)

10.05

10

9.95

9.9

9.85

9.8

9.75

9.7
0 rpm 35 rpm 50 rpm 75 rpm

PDC Roller Cone

Figure 7A. Effect of rotary speed and bit type on hole diameter

10.2

10.15

10.1

10.05
Average Borehole Diameter (UBI Log)

10

9.95

9.9

9.85

9.8

9.75

9.7
Slide (0 RPM) 35 RPM 50 RPM 75 RPM
Slide or Rotary RPM

1.00 AKO 1.75 AKO

Figure 7B. Effect of rotary speed and AKO angle on hole diameter
 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 15

S ta n d ar d D e viatio n / H o le Q u a lity

0 .6 0 0

0 .5 0 0
S ta n d a rd D e v ia tion

0 .4 0 0 Reamed Interval

0 .3 0 0

0 .2 0 0

0 .1 0 0

0 .0 0 0
R un 2 -S lid e

R un 3 - 3 5 rp m

R un 3 - 7 5 rp m

R un 4 - 3 5 rp m

R un 4 - 7 5 rp m

R un 5 - 3 5 rp m

R un 5 - 7 5 rp m

R un 6 - 3 5 rp m

R un 6 - 7 5 rp m

R un 7 - 3 5 rp m
1 2 4 7 -1 2 6 7

1 2 8 7 -1 3 0 9

1 4 7 7 -1 4 9 7

1 5 3 8 -1 5 6 7

1 8 4 7 -1 8 6 7

1 8 8 7 -1 9 0 7

1 9 9 2 -1 9 9 3
6 6 7 -6 8 2

9 3 4 -9 5 4

9 7 4 -9 9 5

D e p th In te rv a l

U BI R un 2 6 Arm

Figure 8. Hole size standard deviation

6-Arm
UBI

Figure 9. Ovality comparison between 6 arm and UBI log

16 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD SPE/IADC 67769

Borehole Borehole
Profile Profile
Borehole
Profile
Ledge formed at start of rotate

1477’

Minor Bore Hole spiraling

also present

1567’

Ledge formed at start of slide

Figure 10. Ledges at connections and transition from slide to rotate

 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 17

Borehole Caliper
3-D Image of Borehole
GR (gAPI) 0-200
8 - 2 - 8

Figure 11. Wellbore spiraling

Growth of Borehole between UBI Logs 1 and 2

0.450
0.400
0.350
0.300
Inches

0.250
0.200
0.150
0.100
0.050
0.000
1247-1267

1267-1287
682-934

995-1247
3-35RPM

3-50RPM

3-75RPM

4-35RPM

4-50RPM
934-954

954-974

974-995
3

Figure 12. Borehole degradation with time

18 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD SPE/IADC 67769

Depth 1270 UBI Run 1 Depth 1270 UBI Run 2

Figure 13. Development of a key seat with time

A v e ra g e D o g le g b y R u n

10

9.1
8.9
9

A ctua l D og leg
8
P red icted D ogleg
7.2
A v e ra g e D o g le g (D e g / 1 0 0 ft)

6.7 6.8
7
6.4

6 5.7 5.6 5.6 5.6 5.6

5.2

0
2 deg P DC 1.75 deg P DC 1.5 deg P DC 1 deg P DC (1) 1 deg P DC (2) 1 deg RC

S e g m e n t D rille d

Figure 14. Predicted vs. actual dogleg severity

 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 19

Dogleg Severity and Inclination vs Depth

14 60

J
12 A B C D E F G H I
50
A= Slide 1 degree AKO, PDC Bit
Dogleg Severity (dg/100ft)

B=Repeat of A, new bit, new DOSRWD

10

Inclination (degrees)
40 C= Rotate with B Assembly
D= Slide 1 degree AKO, Insert Bit
8 E= Rotate with D Assembly
30 F=Slide 1.75 degree AKO, PDC Bit
G= Rotate with F Assembly
6
H= Slide 1.5 degree AKO, PDC Bit
20 I= Rotate with H Assembly
4 J= Slide 2 degree AKO, PDC Bit - stopped test
Dogleg Severity
10
2
Inclination

0 0
0 500 1000 1500 2000

Measured Depth (ft)

Figure 15. Dogleg severity and inclination vs. depth

24

21

18
Az im u th C h a n g e (d e g )

15

12

-3
1 P DC S lide 1 P DC S lide 1 P DC 1 RB S lide 1 RB Rotate 1.75 P DC 1.75 P DC 1.5 P DC 1.5 P DC 2 P DC S lide
Rotate S lide Rotate S lide Rotate

R u n D e s c rip tio n

Figure 16. Azimuth change for each test run

20 LODDER, RUGGIER, SINOR, BOBROSKY, RADFORD SPE/IADC 67769

3 .5 90

80
3
70
Lateral (XY)
2 .5 60
Ac c e le r a tio n (g )

50
2

RP M
40

1 .5
30

1 20

Axial (Z)
0 RPM 10
0 .5
0

0 -1 0
400 450 500 550 600 650 700

M e a s u r e d D e p th (ft)

XY Accel Z Accel D o wnho le S tring R P M

Figure 17. Downhole vibration measurement with 1° AKO and PDC pilot

3 .5 90
75
80
3
70

2 .5 60
50
Ac c e le r a tio n (g )

50
2
RP M

Lateral (XY) 35 40
1 .5
30

1 20

Axial (Z) 10
0 .5
0

0 -1 0
650 700 750 800 850 900 950 1000
M e a s u r e d D e p th (ft)

XY Accel Z Accel D o wnho le S tring R P M

Figure 18. Downhole vibration measurement with rerun 1° AKO and PDC pilot
 DETERMINATION OF BOREHOLE QUALITY, DIAMETER AND BHA DIRECTIONAL RESPONSE:
SPE/IADC 67769 ECCENTRIC TOOL TEST PROGRAM FOR EXPANDABLE CASING APPLICATION NORTH SEA 21

4
Borehole Diameter (inches)

Reamed at 61 rpm Reamed at 32 rpm

2

0
660 665 670 675 680 685 690
-2
Tool Size 9.875" Diameter

-4

-6

-8
Depth

Figure 19. Hole opening with DOSRWD tool

Caliper Comparison 682-934

11.5

11

10.5
4 Arm Run 2
10 4 Arm Run 3
6 Arm
9.5
UBI

8.5
Min Max Average Median Mode

Figure 20. Caliper type comparison