SPE

SPE 23027
The Uses of Buoyancy in Completing High-Drag Horizontal WeIIbores
J.L. Hood III and M.D. Mueller, Unocal Corp., and M.G. Mims, K&M Enterprises
SPE Members
Copyright 1991, Society of Petroleum Engineers, Inc.
This paper was prepared for presentation at the SPE Asia-Pacific Conference held in Perth, Western Australia, 4-7 November 1991.
This paper was selected for presentation by an SPE Program Committee following review of Information contained in an abstract submitted by the author(s). Contents of the paper,
as presented, have not been reviewed by the Society of Petroleum Engineers and are SUbject to correction by the author(s). The material, as presented, does not necessarily reflect
any position 01 the Society of Petroleum Engineers, its officers, or members. Papers presented at SPE meetings are subject to publication review by Committees 01 the Society
of Petroleum Engineers. Permission to copy is restricted to an abstract 01 not more than 300 words. Illustrations may not be copied. The abstract should contain conspicuous acknowledgment
of where and by whom the paper is presented. Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836 U.S.A. Telex, 730989 SPEDAL.
ABSTRACT
Unocal has been actively developing
horizontal well drilling and completion
technology. This technology has been
used to drill and complete wells with
horizontal displacement to true vertical
depth ratios (HD/TVD) of up to 2.92.
This technology has also has been used to
drill and install casing in the world's
two longest horizontal wells, each
containing approximately 1.1 miles of
producing formation. This paper presents
. the techniques used to analyze torque and
drag forces, and the buoyancy assistance
technology used to overcome those forces.
INTRODUCTION
The' improved hydrocarbon recoveries of
horizontal wells and the distinct
economic advantages of drilling extended
reach wells have pushed the limits of
drilling and completion further and
further. Many wells are being drilled at
such high average angles that normal
frictional drag prevents pipe strings
from reaching bottom under their own
weight. These wells are known as
"negative weight wells".
One measure of a well's difficulty is its
horizontal displacement to true vertical
depth ratio (HD/TVD). The higher the
ratio, the more difficult the well. The
world's two furthest reaching wells
drilled by Statoil in the North Sea and
Woodside Petroleum offshore Australia,
References and figures at end of paper
757
have HD/TVD ratios of 2.25 and 2.06,
respectively. Generally, for wells
drilled with water based muds, pipe
strings stop sliding freely into the hole
when the HD/TVD ratio approaches 2.2 to
2.4. This is highly dependent on the
drilling fluid lubricity as well as the
open hole condition. When the pipe string
stops sliding freely due to excessive
drag, something must be done to reduce the
drag forces. Available options include
lubricants, glass beads, rotation,
buoyancy assistance, and increasing pipe
weight in the low angle hole. Buoyancy
assistance and/or rotation have been used
successfully on eight wells with HD/TVD
ratios of 2.20 to 2.92. These wells were
drilled offshore California and in the
Gulf of Mexico. Table 1 summarizes the
statistics. and Figures lA, lB, and lC
display each well's vertical section.
DRAG-RISK ANALYSIS
Drag-risk analysis refers to a method of
predicting and evaluating a given drilling
plan's probable torque and drag forces.
The method utilizes an in-house computer
program to calculate tripping-in,
tripping-out, and torque values. The
computer program is based on a simple
three dimensional mathematical model. The
model assumes that the pipe string loads
are a result of gravity and frictional
drag. The frictional drag is dependent
solely on the normal force between the
pipe string and hole wall, and the
friction factor. The normal force is a
result of gravity on the pipe and the
effects of tension or compression in the
2 THE USES OF BUOYANCY IN COMPLETING HIGH DRAG HORIZONTAL WELLBORES SPE 023027
pipe curvatures. Pipe bending moments
are assumed negligible. The program
calculates values based on 100 foot pipe
increments, starting at the bottom of the
string and summing values to the surface.
The computer program is used to generate
drag-risk plots. A drag-risk plot is
simply a graph of surface tripping-in or
tripping-out hook loads versus measured
depth for several friction factors. The
risk plots are made by assuming one
friction factor inside casing and several
friction factors in open hole. Surface
loads are then calculated for each open
hole friction factor at 100 foot
intervals while tripping-in and out. The
hook load block weight is represented by
a vertical line on the risk plot. All
values to the right of that line
represent tensile surface loads in the
pipe string, and all values to the left
are compressive surface pipe string
loads. The same type of plot can be
generated for surface torque loads.
Drag-risk plots are very useful in
determining . potential problems with
getting pipe to bottom. They can also be
used during drilling to identify and
correct deteriorating hole conditions.
Drag-risk plots are also used to design
buoyancy assisted casing runs. In order
to generate a buoyancy assisted risk
plot, the computer program must be
"fooled" with an equivalent air weight
value for the section of casing that is
run dry. This is accomplished by
calculating the buoyed weight of the
empty casing and dividing by the buoyancy
factor. The result is an equivalent air
weight value which the computer program
can use to accurately calculate drag
forces on empty casing.
BUOYANCY ASSISTED CASING (AIR CAVITY)
Buoyancy assistance has enabled the
succussful completion of six wells with
high average angles over long intervals.
Buoyancy assistance is achieved by
running a specified amount of empty
casing ahead of mud filled casing
separated with an inflatable casing
packer (Figure 2). The air filled casing
provides a significant reduction in
effective weight, which allows it to be
"pushed" through the high angle/open hole
portion of the well path by the heavier
mud filled casing, which for the most
part remains in the lower angle cased
hole portion of the well path. A typical
hookload curve illustrates a buoyancy
assisted casing run (Figure 3).
Drag risk analysis is the first step in
designing a buoyancy assisted casing run.
758
Once a wellplan is optimized for torque
and drag and proximity to existing
wellbores, a drag risk plot is generated
for the surface casing string to establish
the maximum amount of casing that can
feasibly be run in the well. Before
desiging a buoyancy assisted casing run,
a check must be made to assure that the
collapse resistance for the planned casing
string will not be exceeded, since the
lower portion of casing will be run dry.
A drag risk plot is then generated for the
buoyancy assisted casing string to
determine the optimum amounts of empty and
mud filled casing lengths needed to assure
that the casing can be safely run to the
desired setting depth. Depending on the
geometry of the wellbore, a large "window"
of safe mud/air filled casing length
combinations may exist. If this is the
case, the amount of redundant surface
casing can be reduced as a cost saving
measure.
The successful implementation of a
buoyancy assisted casing run consists of
both pre-job and on-site checks and
measures. The pre-job checks include
proper equipment selection and drag
monitoring. Equipment checks include
selection and testing of float equipment
and inflatable packers capable of handling
the differential pressures they will be
expected to withstand. The highest
expected mud weight at casing point should
be used to calculate the differential
pressure at the true vertical depths of
the packer and float equipment. A prudent
safety factor should be incorporated along
with the selection and testing of quality
equipment, since the failure of anyone
piece could prevent the desi.red casing
point from being reached. Furthermore,
redundancy of float equipment is highly
recommended since its failure could lead
to well control problems. Undersized
positive standoff centralizers, spaced
properly for the desired stand-off, are
recommended to avoid the increased drag
associated with bow spring centralizers.
Hole conditions, as indicated by drag
information, should be monitored as the
hole is being drilled and during the
clean-out run before running casing. If
hole conditions while drilling indicate
drag values higher than those factored
into the casing job design, measures
should be taken to bring the values back
into the anticipated range. If subsequent
measures are unsuccessful at achieving
this, contingency planning will become
necessary, which may call for are-design
of the casing job. Once casing point is
reached, the hole must be adequately
prepared to run the casing. This would
include reaming of ledges,
SPB 023027 J. HOOD, M. MUELLER, M. MIMS 3
addition of lubricants, and proper hole
cleaning. Hole cleaning is most
effective in high angle holes when
mechanical agitation of cuttings is
combined with high flow rates and
alternating high/low viscosity sweeps.
The surface casing should also be swept
clean both at the shoe and at the end of
any build sections exceeding 35
inclination. Drag data checks should be
made to assure values are within the
expected ranges.
Once the hole has been prepared for
running casing, the job procedure is
straightforward. Before running the
buoyancy assisted casing string, the
equipment should be checked for any
transportation damage. The float
equipment valves should be checked to
make sure their valves are properly
seated and the packer element pressure
should be checked for proper inflation
pressure. As the dry casing is run into
the hole, drag data is monitored to check
against expected values. Before the
buoyancy assisted casing string exits the
shoe of the surface casing, a final data
point is established which is used to
determine an inside casing friction
factor. This friction factor is assumed
constant throughout the remainder of the
run so that open hole friction factors
can be determined from subsequent drag
data. Once the optimum amount of empty
casing has been run, the packer joint is
installed and a joint of casing is run
above it and filled to check the packer.
The job continues, filling the casing
above the packer as needed to supply
ample weight to push the casing in the
hole. Occasional stops are made to
completly fill the pipe to assure that
the packer is still holding. Once the
casing is successfully run to the desired
setting depth, the packer bypass valve is
opened which allows the mud above the
packer to fall into the air filled
casing. The packer is then unset and the
casing is filled with mud. At this point
the packer is retrieved and the casing is
ready for cementing.
The hookload curves for the six wells
completed to date are shown in Figures 4A
thru 4F. Deviations from expected values
are noticeable in both the cased and open
hole sections of the curves.
Discrepancies in values while running
inside casing are created by cuttings
buildup on the low side of the surface
casing. Variations from expected values
while running in the open hole can be
attributed to cuttings buildup and/or
other restrictions such as swelling
formations or ledges. Usually, slack-off
weight can be regained by reciprocating
759
the casing to smooth out any cuttings beds
that might be inhibiting the run. If this
does not allow sufficient weight to be
regained, other contingency plans may be
used to help push the casing to bottom.
The flat lines on Figures X and X are
examples where a contingency method was
used to get the casing on bottom.
AIR ANNULUS WITH CASING
One of the negative aspects to buoyancy
assisted casing is the inability to
circulate during the running phases of
casing placement.
A system has been developed which affords
the benefits of buoyancy assistance but
still allows for circulation during the
running of the casing string. This system
utilizes an air annulus between concentric
strings of pipe where the inner string is
"packed off" at or near the bottom of the
outer string of pipe. Figure 5 is a
schematic of this air annulus system.
Although the effect of buoyancy assistance
is cut nearly in half due to the added
weight of the inner string and the weight
of the fluid in the inner string, the
ability to circulate and to keep the hole
clean around the pipe will act to lower
the effective friction factor. The air
annulus system utilizes a modified version
of the standard retrievable Selective
Flotation Device (SFD.). The required
amount of "dry" casing is picked up and
run in the hole. Special techniques are
often employed in order to get an adequate
amount of "dry" pipe into the hole (1. e. ,
drag risk analysis).
Once an adequate amount of "dry" pipe has
been rup in the hole, the inner stinger
assembly is run and stabbed into its seal
assembly at the bottom of the dry casing.
The SFD system is then attached to both
strings of pipe and the subsequent casing
is run and filled as required. Circu-
lation is now possible throughout the
remainder of the running process.
Once the casing is in place the SFD system
and stinger assembly can be removed prior
to cementing, or cementing can take place
through the stinger to allow reciproca-
tion. A standard cement job can then
commence. This "Air Annulus" system has
been employed in a field test environment
in Argentina. Actual use of the Air
Annulus SFD in an extended reach
application is planned for late 1991.
4 THE USES OF BUOYANCY IN COMPLETING BIGB DRAG BORI ZOHTAL WELLBORBS SPE 023027
GENERAL REFERENCES
SI METRIC CONVERSION FACTORS
Johancsik, C.A., Friesen, D.B., and Dawson,R.: "Torque
and Drag in DirectionaL WeLLs--Prediction and
Measurements," JPT (June 1984) 987-92.
"Limitations of DirectionaL DrilLing--Phase 1," Report
No. DDL86-1-1, Maurer Engineering Inc., Houston
(March 1986) Sec.3.
developed to
enable the
of wells

= em'
E-01 = m'
E+OO =mPa.S
E-OO =m
E-02 = m'
E-03 '" m'
E+OO = cm
E+OO =N
E-01 =Pa
E-01 =kg
E+OO = km
GAPI 141.5/(131.5+
o
API)
bbL x 1.589 873
cp x 1.0*
ft x 3.048*
ft' x 9.290 304*
gaL x 3.785 412
in. x 2.54*
Lbf x 4.448 222
Lbf/100 ft' x 4.788 026
Lbm x 4.535 924
miLes x 1.609 344
ACKNOWLEDGEMENTS
4. Equipment that has been
utilize buoyancy will
successful completion
previously thought to be
MueLLer, M.D., Quintana, J.M., and Bunyak, M.J.: "Extended
Reach DrilLing from PLatform Irene," SPE DrilLing
Engineering (June 1991), Presented at the 1990 AnnuaL
Offshore TechnoLogy Conference, Houston, May 7-10
The authors would like to acknowledge
Donna Phillips for her effort in preparing
this document.
*Conversion factor is exact
AIR ANNULUS WITH LINER AND BRT
Like in the casing air annulus system,
the liner must be run in the hole "dry".
Again, special techniques will likely be
necessary to get all of the liner through
the rotary table so that the inner string
can be run inside. Once the last joint
of liner has been run, the stinger
assembly is run in and stabbed into the
pack-off assembly near the bottom of the
liner. Now, the air annulus between the
two strings of pipe will make the liner
lighter and thus reduce the torsional
drag acting on it.
The air annulus system has also been
looked at for long liner applications.
Very long extended reach wells often have
liners in excess of 5,000 feet. Torque
can quickly become unmanageable for these
wells and the liner air annulus system,
in theory, can reduce torque values by
over 25%. Plot A shows the slack-off
(S/O), rotating off bottom (ROB) and
torque values for Unocal's well #A-2l on
Platform Irene. This 7" liner was
rotated into the hole without the air
annulus system. Surface torque values
with the liner on bottom were in excess
of 33,000 ft-lbs. Theoretical values
generated by the Unocal Torque and Drag
Model predicted liner air annulus torque
values of around 25,000 ft-lbs. Figure 6
is a schematic diagram of the liner air
annulus system.
Once the liner is on bottom, a standard
cement job is commenced. A single wiper
plug wipes the drill pipe and the
stinger. When the plug bumps up on
bottom, hydraUlic pressure releases the
Hydraulic Releasing Tool (HRT) from the
liner. Cement can be reverse circulated
through the HRT setting assembly to clean
up the liner top. The system can then be
pulled from the hole.
CONCLUSIONS
1. Drag risk analysis has been used to
design buoyancy assisted casing
strings and to examine the
effectiveness of various uses of
buoyancy.
2. Buoyancy assistance has allowed the
successful completion of six highly
deviated wells in both the Gulf Coast
and offshore California.
3. An "air annulus" system for casing and
liners has been developed to obtain
the benefits of buoyancy in highly
deviated wells, while still allowing
circulation for hole cleaning.
760
TABLE 1
EXTENDED REACH WELLS
HORIZONTAL HDITVD
WELL DISPLACEMENT RATIO
OFFSHORE CAUFORNIA
UNOCALJPLATFORM IRENE
UNQCALJPLATFORM IRENE
UNOCAl/PLATFORM IRENE
UNOCALJPLATFORMIRENE
UNOCALJPLATFORMIRENE
UNOCALJPLATFORM IRENE
A-14
A-16
A-17
A-19
A-20
A-21
9,060
12,740
11,362
8,216
10,897
14,871
1.7
2.9
2.5
2.2
2.2
2.9
OFFSHORE GULF OF MEXICO
FOREST OIL.JE1-326
NERCO/E1-37O
A-6
8011
6,091'
7,3fY'
2.7
2.4
Ii: 0 r------------;::====:::::;-i
. I FIGURE 1AJ

o 2,000

ffi 4,000
>
UJ
::::l
IE 6,000 ........
o 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000
HORIZONTAL DISPLACEMENT, FT
UNOCAWPLATFORMIRENE
Ii: 0
IFIGURE 181

ffi2,000
>
UJ
::::l
IE
1,000 2,000 3,000 4,000 5,000 6,000 7,000
HORIZONTAL DISPLACEMENT, FT
FOREST OIWEI-328 #A-6
0.-----------------------,
IFIGURE 1cI
1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000
HORIZONTAL DISPLACEMENT, FT
NERCO/EI370 #8-11
Ii:
1,000
UJ
o
;i 2,000
9
Ii:
3,000
UJ
::::l
II:
I- 4,000
o
761
BUOYANCYASSISTING 9-5/8" CASING
TYPICAL HOOK LOAD CURVE
I
FIGURE 3
./
9-5/8" 47# CSG (.B FF)
13-3/8 @ 5000' (.3 FF)
20 40 60 80 100 120 140
INDICATOR WEIGHT (LBS)
Thousands
o
A. AIH W/AlR AUEDCSG IN LCNI ANGLE
PORTION OF HOLE
B. AlA ALLED CSG ENTERS HIGH ANGLE
PORTION OF HOLE
C. AlR ALLED CSG ENTERS OPEN HOLE
(PICKUP PACKER)
D. MUD AUBl PIPE PUSHES AlR ALLED
PIPE 1HRU HOLE
E. MUD ALLED PIPE ENTERS HIGH
AJNGLE PORTION OF HOLE
BLOCKWEIGHT
....................

0
2
I;
4
j!: ..
Go 'a
W C
C =:
6
c ::I
W 0
f=

8
:::E
10
12
(2Oj
FIGURE 2
MUD = 9.34 PPG
CASING = 9-5/S" 47# AIR WEIGHT
BUOYED WEIGHT OF FULL CASING = 40.4 #/FT
BUOYED WEIGHT OF EMPTY CASING =11.6 #/FT
(13.5 #/FT AIR WEIGHT EQUIVALENT)

o I K I
PLATFORM IRENE WEll #A-16
9-5/11' CASING: HOOK LOAD CURVE
AClUAL
THEORETICAL
..'
... j
..............)
......
..
PLATFORM IRENE WELL #A-17
9-5/11' CASING: HOOK LOAD CURVE
0

2,000
4,000

UJ
0
6,000

:!
8,000
10,000
AClUAL
THEORETICAL
.....\
....
.......
.................
13-318"CSG@5042'
INSIDE CSG FF =0.33
OPEN HOLE FF =0.60
2,000

4,000
UJ
0

6,000
8,000
10,000 I I I I I I
50,000 60,000 70,000 60,000 90,000 100,000 110,000 120,000 130,000
SlACK.QFF WEIGHT
F1GURE4A
12,000 I I I ! I I : I
50,000 60,000 70,000 80,000 90,000 100,000 110,000 120,000
SLACK.oFF WEIGHT
F1GURE4B
ACTUAl
THEORETICAL
.......
................
..::::. ....
PLATFORM IRENE WELL #A20
9-5/11' CASING: HOOKLOAD CURVE
o I iZ;;;;:;:: I
2,000
BLOCKWEIGHT
4,000
:I:
t
w
0
0
6,000 w
a:
:::J

:;;
8,000
".
ACTUAL
THEORETICAL
.......
BLOCKWEIGHT
PLATFORM IRENE WELL #A19
9-5/11' CASING: HOOK LOAD CURVE
6,000
o , iZ:;;;;:;: I
2,000

0.. 4,000
w
o
fa
a:
:::J

:;;
8,000
10,000
120,000 110,000 80,000 90,000 100,000
SLACK-OFF WEIGHT
F1GURE4D
70,000
12,000 I I I I
60,000 120,000 110,000 80,000 90,000 100,000
SLACK-OFF WEIGHT
F1GURE4C
70,000
10,000 I ! I
60,000
ACTUAL
THEORETICAL
.::'
..

6,000
7,000 LI----'----'---'-----'----'-------'-----'----'-----'
o 10,000 20,000 30,000 40,000
SLACKOFF WEIGHT
F1GURE4F
o I Ie;;;:::: I
5,000
1,000
2,000
FOREST OIL CORP. WELL #A-6
9-5/8" CASING: HOOK LOAD CURVE
t
3,000
o
w
a:
:::J
4,000
:;;
120,000
.")
ACTUAL
THEORETICAL
110,000
.......
...............
:/..:'>
.........
.,::: .
0

2,000
4,000
:I:
t
w
0
0
ll! 6,000
:::J
en

:;;
8,000
10,000
12,000
60,000 70,000
PLATFORM IRENE WELL #A21
9-5/11' CASING: HOOK LOAD CURVE
80,000 90,000 100,000
SLACK-OFF WEIGHT
F1GURE4E

- Mud" to ppg
- Casing" 9 5/8" 47ppf Air Equtv. Wt.
- Air Equlv. Wt. of Empty Casing" to.8t ppf
- Air Equlv. Wt. of 23/8" x 95/8" Air Annulus" t9.96 ppf
Ported Nipple
Pack-off Bushing
Hydraulic Releasing Tool
HRT Running Head
Stinger
High Torque Safety Joint
Inflatable Packer
Stab- in/Pack- off Ass'Y
Sub /Seal Sub
SCHEMATIC
LINER AIR- ANNULUS
SYSTEM
Air AnnctkIs
Mud Annulus
FIGURE 6
FIGURE 5
- - - - HAT RIlftfActual D_tat
---Air AJIftUlu, Run
CONCEPT
AIR ANNULUS SFD
----......
... "
",
\ "
I "
I ,
/ \
'" \
., " ROB WEIGHT \ ROB WEIGHT
\
\
\
\
\
,
,
,
,
,
,
,
, "
, \

Liner , cMpth ftS,712'
-m 0 m M
String Weight - Lb.. X 1000
Plot A
POINT PEDERNALES FIELD
Well A-21
HRT VI. Air Annulul

'"
'"
'"
'"
'"
'"
'"
'"
'"
'"
'"
'"
"---
SAMPLE BUOYANCY EFFECT
CI 5/8- Shoe

Friction Factor
.5
0
I
2
3

S
0
0
S!
><
8
..
..
S 10

"
Q
! 12
J
13
U
"
I.
17
18
I.
I
-SO
i!
I ! --,---- I 1
o 10 20 30 40
Torque Lbs./Ft. X 1000