Slimhole Drilling: The Story So Far. Reducing the diameter of a borehol ing costs. A slimhole rig weighs about one fifth of a can significantly cut at open new frontiers by making economic exploration in environmentally sensitive or remote areas. If slimhole drilling could be safely applied offshore whore well costs multiply, savings are likely to be huge. Nevertheless, Scott Randolph Jacques Bosio Bill Boyington At the end of the 1950s, the oil exploration ‘Amoco Production Co. Ef Aquitaine Conoco (UK) Ltd industry began to investigate the practicabil Tulsa, Oklahoma, USA axis, France London, England ity of a novel and specialized form of drilling, ls proponents argued that conquer ing the technical challenges would be rewarded by significant cost savings. At the lime, these challenges proved too difficult, and few believed this novel drilling tech- hique would ever materialize. Twenty-five years later, most of the obstacles were sur mounted and horizontal drilling came of age. Wil slimholedilling similarly confound the skeptics? Slimhole dailling means different things 10 dliflewent people. Some companies use the Be Oltiold Reviewig and its small size can expression when they design production wells with a reduced number of casing strings. This eliminates the need for a sec- ‘ond set of blowout preventers, reduces the volume of rack drilled and requires less mud and cement. In its North Sea Forth field, British Petroleum (BP) Exploration Co. eliminated the 20-inch {508-millimeter (onm)} casing sting, resulting in cost savings (of 30 to 40 percent over the 15-well pro- gram. These wells were drilled and com- pleted using conventional equipment. Other definitions of a slim hole include small diameter boreholes drilled at the end ‘of conventional wells. This occurs either as a result of problems which necessitate set July 1991 spread acceptance of small diameter wellbores remains in doubt. This article summariz. ling an extra sting of casing or after a well has been reentered and an adlitional slim- hole iled, often horizontally Alternatively, a slim hole can he defined asa well in which 90 percent or more of the length has an openhole diameter of 7 inches For lpn preparation of his atl hans to at Moca Mix A to, Swede, Ly Cama Schlieren Servicer Moning, race and Dave White, Seco Forex, Montage, Hance, 1. Fox "sinfae Dail Cas Stings aed Ces,” ‘sve engineer ce 900171 2. ult 1D, tard, Souyer FO an Farmer WR Sin Hale Oring n Harsh Enon paper LDCS 19549, rsa at he ADCS Dall Corterence Howton, Tess, USA February 27 ct 10, the current state of play. a7[180 mm) oF less (below, right)» His this kind of slim hole and the variations within this definition that will be discussed here Slimhole drilling has been fueled by oil ‘companies seeking to exploit a number of potential advantages, preclominantly cost savings. In 1957, Carter Oil Co. recorded 3 to 25 percent savings in 108 slim holes in Utah, Arkansas, Louisiana, Mississippi, Oklahoma, Illinois and Wyoming, USA Supporters of slimhole drilling today expect to yield savings of 40 to 60 percent in exploration dilling, In 1970, the Canadian company Heath nd Sherwood Drilling Ltd. drilled an 11,600-foot [3535-meter] well with a diam- eter of 31/2 inches (69 mm for Gulf Canada ‘Moving onto location. Tis slimhole hhalrig used by Conoco indonesia wras canted onto location in about 100 its. Aporeacho fxocton and Extlaton Ds he Sino hc ding Sen,” paper 4. lat "sin Hole Dili Decreases Caters Muir 980 19 5. Sal Dime fps Hele My Get Me 6, Dah Ssh Ceoup Sl Hele halo Ding fev Cuts Conta” Oe aun 48 a less than half the cost of a conventional \well dilled nearby. Subsequently, in 197 to 1981, the Swedish exploration group Oli- jeprospektering AB dlilled 93 slim holes at Gatland Island, Sweden, These hacl a diam: eter of approximately 2¥/ inches [63 mm) and recorded a 75-percent saving over con- ventional drilling methods. These savings accrue from many sources: loss site preparation, easier equipment ‘mobilization, a reduction in the amount of consumables, less cuttings to dispose of and smaller equipment. In 1986, in a six-well evaluation program on its onshore Plungar field, England, BP recorded savings of 70, percent in site preparation and estimated that the time spent rigging up and down the taper ADCS 1900, resend he ADCP Billing Conkeence, Hosta leas, USA, Feary neck 100 vole ig Fonts Over indore Swamp” (i nC a 6, ey 8 196396 10. Macfadyen Mt toton KA and Byingion WH sna Exploration Dring Prous ran be, Irenres,” paper St 14733, ert tthe TADSPE Ding Contre, Dal, Tas, USA, For thor Sine Helnig Operon ran ayo Feveun Ascot Cventon. vo 2a smaller equipment reduced transportation costs by 60 to 70 percent? Savings that result from a reduction in consumables such as rock bits, muds, cement and fuel oil can also be significant The annular volume of a slimbole well can be as little as 6 barrels (ob) per 1000 feet (3 litersmeter) compared with conventional volumes generally an order of magnitude greater. In one application, a sixfold decrease in formation cuttings volume was recorded, with a concomitant reduction in disposal cost There are advantages besides cost savings. The scaled-down equipment makes opera tions particularly sullable for sits demand ing a low impact on the environment. The Contrasting well profles—conventional cand slimhole. Oilfield Reviewcompactness of slimhole drilling rigs signi cantly reduces the drillsite area, in some ceases to less than 7,500 squate feet 700 square metets|—a conventional rig capable of drilling to 18,000 feet {5500 meters) requires at least four times the area (see Comparison of Typical Rigs With 5000-Foot 11500-Metes! Dailling Capability,” righ. This is particularly advantageous when hilling near residential areas. Noise is also Jess than from conventional rigs. Société Nationale Flf Aquitaine has employed two slimhole dilling rigs in the densely populated Paris basin, By the endl of 1989, the two rigs had drilled about 60 ver- tical and directional slim holes—a total of 400,000 fect (120,000 meters. Slimhole drilling rigs are ideal for remote areas. In 1964, Standard Oil Company (Indi ana) afiite Pan American Indonesia drilled four wells with a slimhole rig mounted on nine skids 27 feot long, 6 fect wide and 3 feet decp [8 meters, 2 meters and 1 meter respectively]. These were capable of maneuvering across a swampy 13,500: squate-mile [35,000-square kilometer] con. ‘cession in central Sumatra, Indonesia.? Portability also played a key role in a 12 well dailling program in 1985 by Conoco Indonesia and Westburne Drilling Co in the difficult Irian Jaya area, Indonesia. The wells were located over a wide area and ‘often in swamps. Its purpose-built slimbole sig was designed to be carried tothe dillsite by a Sikorsky $587 helicopter in 4,000-1b [1,800-kilogram (kx)) sections and assem- bled without assistance from a crane, bull- dozer or fork ruck (previous page, fe About 100 airlifs were required to move the rig, excluding consumables and person- nl. By comparison, moving a conventional 18,000-fo0t helirig requires 330 airlits (plus a further 220 to move the rig camp and tubulars), To minimize transportation costs, Conoco employed shallow-drait tugs and cargo barges (measuring only 40 feet by 75 feet [12 meters by 23 meters) to transport the rig as close as possible to the drilling site. The plan envisaged moving the stimhole rig in 4 t0 7 days and drilling each well in 7 to 10 days. By the end of the program, Conoco Indonesia had achieved signifi cantly quicker times. For atleast thee of the wells the rig was moved and the well drilled to about 2700 feet [820 meters} in only 7 days (righ) july 1991 Cae | Mud mp power=HW Conventional | _stimhole Tite diameter—in aA 204 (mm) (216) {75 to 102} Dilsting weiht—metictons | 40 |b to7 Rig weight—metric tons 65 Diets ava ES Tsaled power—KW 350 Mud tank capacity bbl m9 v5) aE s Ae®® boo. gs oe cu 7 Penne 7 Beating the sched. ule. In Conoco’s cling program at Idan Jaya, Indone- Sia, twelve wells ‘were dilled In less than five months, {our months faster ‘an planned. 49 | | |50 ‘Smati scale ollokd hardware: Microdis tiny MD-5 Britta dling rig. Slimhole Deiling Slimhole Coring ‘Stirahole ailing options. limhole dulting can be car- Hed out either using: scaled-down oll- field harciware, or Today, slimhole dling falls into two dis tinct categories each requiring its own thilling hardware. First there are wells that are diilled using small bits. These tend 10 have diameters 6 inches 152 rml to 4¥7 inches [114 mm} and can be both explo: ration ane! prodaction wells. The rigs fr this are scaled-down versions of conventional ‘equipment evolved frorn the oilfield “Then there is a continuous coring system borrowed from the mining industry. Wells diilled in this way are almost exclusively for ‘exploration and have a diameter of as litle as 3 inches [76 mm] (below, lef, ‘Typical of the scaled-down, purpose. designed equipment is Microdrll ABS MD: 5 Brita rig that celled BP's Plangar field and ‘more than 250 wells in Turkey, Tunisia and Europe (left. t has a 36-foot [11-meter} ‘mast compared with around 130 feet [40 meters} for a conventional land rig (next page). Maximum diilling depth is 4900 fect 11500 meters. Instead of a conventional kelly bushing, the system uses a hydraulic rotating torque head mounted on the mast. This allows simultaneous rotation and tripping of diillpipe. Mud is pumped into the sting via a swivel above the torque head. ‘Ata connection, as with normal eiiling, the diillstring is raised until the pipe joint he table, and the reaches the level o hydraulic slips are engaged. The rotating head then breaks the connection, The next joint of pipe, just 10 feet [3 meters} long, is then positioned by hand and screwed into the top of the deilsting. Torque is applied sing the rotating head, the hydraulic slips ate released and duiling continues, Slimhole dillpipe comes in 3.3- to 197. foot [1- to G-meter}lengths—rather than the 30-foot [9-meter} joints of conventional deillpipe—and has externally flush connec: tions, which reduce drag particularly in deviated wells, To allow sufficient torque 10 bbe applie to the string, reduce leaks at con rections and limit fluid fection losses in the annulus, upsets are placed internally (as ‘opposed to internally flush/extesnal upsets of normal drillpipe). Outside diameter ranges from 1 inch (25 mm] to 5 inches (127 mm The reduced weight of slimhole drillpipe may reduce wall abrasion, but may also Oilfield Review‘make the drilstring mechanically weaker than its conventional equivalent. Buckling, fof the smaller diameter pipe is partially ameliorated by support from the hole wall, which typically may have an annular clear. ance of only fs inch [13 mm Bottomhole assemblies (BHAS) are very sensitive to weight on bit (WOB)-too ‘much and the bit can be damaged. This isa particular problem when drilling from a floating rig where heave can vary WOB. Because of this, the rig's motion compen: sators and the shock absorbers in the BHA require careful attention. Thin tubulars may also be more suscepti bie to twist of, particularly in deep, aonver: tical wells. This can be obviated by keeping, the wells as near vertical as possible and by using mul motors, These mud motors must be designed to take into aecount the high bottamhole temperatures caused by the depth, the speed of rotation and the small volume of mud cooling the BHA, Downhole motors with a diameter as small as 27/4 inches [72 mm] have been used. A typical dailing assembly fora direc tional well consiss of a side-cutting, hig speed bit, a downhole motor, a fixed/move- able bent motor guidance system, wireline steering tools and nonmagnetic and regular ail collas. In slimhole drilling, fixed-cutter bits are enerally preferred because they can withstand high rotational speeds (up 10 1,000 rpm compared to 2 maximum of 200 rm in conventional dlling)."? While poly ceystalline diamond compact (POC) and thermally stable polycrystalline (TSP) tech nology has been successfully used, tradi tional diamond bits often produce smaller cuttings that are easier to remove.!? The second slimhole drilling technique, continuous coring, offers the potential 10 extract large quantities of geologic informa: tion from core samples Inthe mining indus- ity the technique is employed! to verity that «an ore body discovery contains a suifictent mineralogical grade to jusiy full-scale min- ing. This commonly envails coring of up 10 40 percent of a well In the late 1950s, this technique began to be adapted tothe cil industry, Using a string consisting of two concentric tubes welded together, Strato Dall Inc, recovered 100 per= cent of the core from a 1400-fo0t [430- meter] well in Texas, USA. During coring, fluid was pumped down the tubular annulus and reverse-circulated to the surface carry- 1-H Ws -Hoscotl Dang Aplin Sin ole,” eto Eine inartial 39)0.2 Selection” On are Gas loumal 86 no. 3 (October foc iss Pot 2” Apphestone” humstot Peon Teco 0 (980) 017.021 Environmental Impact, This conventional rig dling in Lincolnshire, England, was able to get permit to drill—something environ- ‘mental concerns make harder each year. Siimhole dling reduces the environmental footprint. July 1991 51ing core in 6-inch [152-mm) inerements (below, right. But today cores are retrieved by pulling through the drillstring by wireline. A good example of a modern coring rig is the Longyear Co. rig PM 603. Last year it suc: cessiully cored to 9800 feet [3000 meters} in the Mallorquin field, Paraguay, for Texaco Inc. The well was drilled asa stratigraphic test. At total depth the hole diameter was 3 Yar inches [77 ram} (next page, lef). Like ios! such rigs the PM 603 has a topdrive and can pull down on the dillsing in the samme way as subbing unit “The Mallorquin well was cored through a mixture of sedimentary and igneous foxna- tions but until recently, litle research had been performed on continuous coring of sedimentary rock. In 1987, Amoco Produc- Cie ene tion Co. started its statigraphic high-speed advanced drilling system project (SHADS). This resulted in the continuous coring of ‘more than 70,000 feet [21,335 meters} of sediments. More recently, Amoco and Elf conducted the Soit Rock Project to gain experience in continuous coring and drilling of soft foxnations. Four wells were drilled onshore through sedimentary lithologies in the Texas Gulf Coast, USA, (next page, middie). A total of 1670 feet 1510 meters} of continuous core was extracted from Tertiary sediments Continuous coring differs from conven- tional oilfield coring. The core passes through the throat of the core bit into an inner barrel up to 90 feet [27 meters} long, ‘Once the core barrel is fll, a wireline over. shot is lowered from the surface through the Hole size nm | 3% | 3% i007 | fe | 16 | 065 198 | 065 2aa | it 498] 0.09 138 | 065 076 128 | 085 244 | a 198 | 0.85 244 Formation MicroScamer | it 52 ‘Specialized coring technique, Using a duai-concontri sting, {uid is pumped down the tubular annulus and reverse-circux lated to the surface canrying coro in é-inch (152-mm] increments. liillstring, The overshot connects with the inner barrel, which is then pulled through the tubulars to surface. Another inner barrel is then lowered downhole, Core recovery rates of up to 100 percent are common in metasediments and volcanic lithologies. Although good recovery rates have been reported by Amoco, for younget coastal sediments recovery is often consi ‘erably less—typically around 40 percent, To maximize core recovery in soft sediments, @ split sloove may be used, This is a two-piece stainless steel cylinder inserted inside the inner barrel. The smooth stainless steel reduces friction experienced by the core as it enters the barrel, The split barre! protects the core when itis removed from the barrel al the surlace because the exisusion force is applied to the tube and not the core islf Oilfield Review+= 9%/¢.in casing 12 hole Zincasing, })8ilsinhole 1 ayjcinnole -——3irinhole <— seit \Wol plan for the Mallorquin well, cored last year in Paraguay for shatigraphic exploration. 15, Gunn KE: “Wel Cn 9,000 Pea,” Cd AP: Sink Contncs 17. Mel RH ae Sayer DO: "Appin of Cal Tata Shin He Long ool Quant Fow mation Elton vite SPA eh anal ogre Sranarn aston, es USA, July 1991 These improved techniques yield more than 0-percent cove recovery In hard competent, uniform lithologies, the mining industry finds diamond-impreg. hated bits the most economical, These typi cally consist of small diamonds of 310 to 525 panicles per carat embedded within a tungsten-carbicle mats. In adapting such ‘mining techniques tothe oil and gas duiling industry, different bit designs have been employed that are more suitable to the solter heterogencous sedimentary lithologies (bottom) Following a drilling program by Amoco (on ils Catoosa, Oklahoma, USA, exper’ mental field, 30 bits were evaluated for bit life and penetration rates unler caring con ditions, By experimenting, with bit profile, diamond concentration and placement and Diamond! impregnated bit for slimhole coring. also with PDCs, Amoco was able to double the diling rate Handling all the core from a whole well presents logistical problems. These been pattally solved by Amoco, usin onsite automated core processing system to and slore core sections, lean, label, analy Despite having extensive availability of core, the deste for wireline logging is litle Although the small diameter wellbores tend to restrict the logging suite that can be used, tools developed for the mining industry as well as oilfield logging ‘equipment are available for slimhole ser vice. The table ("Wireline Logging Too! Clearances” previous page, lei) shows the Schlumberger equipment that can be run in slim holes. Two key services yet to be aval able are a dual induction tool and a forma. ‘The slimhole drilling rig usod in Bt and Amoco's Soft Rock Project in the Texas Gull Coast, USA,tion testing tool. A 3¥/-inch (89-mm) testing tool is under development. The small diameter holes also restrict use ‘of measurement-while-diling (MWD) tech- nology. However, directional MWD tools ‘with external diameters of 2 inches [51 mm) ‘and, more recently, 13/4 nches [44 mm, are ow available. These are witeline retiev ‘able and sit inside 4°/«inch dill collars and ‘ean be used with a bt as small as 6 inches (Cight).8 There are plans to further reduce the size of MWD equipment. ‘A key development area in slimhole dilling is mud, Slim holes generally have an annular clearance of about ¥2 inch [13 mm], compared t0 11/2 to 9 inches [38 10 230 mm! in conventional wells. Because of small annuli, high annular velocities are generated at low pump rates which obviates the need for viscosity-building additives. ‘Another consideration is the deillsting rotation speed. When small diameter pipe is rotated at 500 to 1,000 rpm, it can act as a Ccontrifuge causing mud solids to adhere to the intemal surface of the dissing. These solids graclally build up and impede fluid flow and prevent wireline retrieval of a core barrel. A solution is to use a brine-oil emul sion with weighting material or a gel-water system. A recent approach is to use highly inhibitive catfonic polymer systems. Restricting solids raises a challenge to slimhole dillers—attaining sufficient mud weight to prevent kicks. Amoco calculates that a 2-barrel [320-Iter] kick taken at 8000 feet 12440-meters] by a conventional well would occupy 40 feet [12 meters) of the annulus and reduce bottomhole hydrost pressure by 15 psi. A 2-bartel kickin a con- tinuous-coring slimhole annulus would ‘occupy 375 feet [114 meters] and reduce hydrostatic pressure by 120 psi. Not only does the small fluid increase make kick dotection dificult to detect conventionally, but reaction time is reduced with conventional methods, a kick is detected by observing an increase in mud volume in the return pit or an increase in ‘out. In slim holes, the pit gain could be {0 smal for even the most sensitive float 50 new technology is required to provide Improved accuracy. For instance, sensitive electromagnetic flowmeters have been ‘employed by Amoco to measure mud inflow and outflow"! An acoustic outflow measure ment has been developed by Anadrill! Another technique developed by Anadrill tects the presence of a gas influx by mon toring the round-trip travel time of mud pump pressure waves. Because these waves travel more slowly through gas than through ‘mud, a sharp inerease in travel time indi- cates a gas influx Cn floating rigs, slimhole kick detection will be even more difficult because mud cutflow varies as the rig moves. Variations can be as much as 300 gal/min {1,135 litesdminute} compared to a pump rate of as little as 40 gal/min {150 liters/min|. Shell UK Exploration and Production Co. esti ‘mates that at least two more years of devel ‘opment is required to enable the first slim- hole high-pressure exploration well to be diiled from a semisubmersible. However, the calculated savings from this would be upto $1 milion per well ‘Once detected, a kick must be killed. This requites a precise knowledge of downhole pressures which is not calculated in the usual way. When mud circulates inside a wellbore, the hydrostatic head increases because of frictional forces caused by the ‘mud moving in the annulus. This increases the apparent density of the mud, called the equivalent circulating density (ECD). This is enerally not an important factor in conven: tional drilling because standard hole sizes and velocities are small. But in slim holes, particularly the very slim ones, ECD becomes significant, Controlling ECD by varying pump rale—having taken into consideration hole diameter, depth, pipe size, mud rheolony and pump performance—can help control a {The SLIM} direc: tonal MWD tool. ‘This can hang inside 43/4inch ddl collars ant ‘can be used with géinch bit kick in what is called the dynamic kill Because no weighting up of mud is needed to increase downhole pressure, response time can be very rapid. However, use of Annular pressure loss to control downhole pressure can inadvertently cause lost circu lation. This in turn can exacerbate the well control problem, Although slimhole drilling activity is clearly increasing, it is concem about safety that is inhibiting a more rapid spread of slimhole projects. Amoco estimates that with no previous experience, an operator could assemble the equipment within three to six months to drill onshore slim holes safely 10 6000 feet [1829 meters). Tous applications, like deeper holes or offshore drilling, will not be so easily achieved. Futhermore, widespread use of slimhole dilling for new appraisal andl development \wells—as opposed to pure exploration wells and recompletions—will depend on how successully the technique is applied over the next few yeas, 1H 16, Hendon 8 ar Clubey MO: New aD Ap "con Using iin uly Renee a Ic paper SPLIADC 1600, essed the SFEADC Dring Coneence, Ne Oren, tulsa USA arch 1-18 167 19, ier, Dorough DS an Sehnidh DO: TheDeelpme of an ihive Catone ling Fl fo Sine tee Coring Aptos pe TADCSPE 1908, peered the ADCP anya ach 2,10. 2 ee , Noh Ran Nika “Wel Can trol Methods ne acces n Sl Dante Wel ores" paper SC 19526 pseme trey SP al fechnkalConfetrice an Eon, St 21. Haber K Powe Man Wie Dew Teco er Saving ven Oe Reve 40 22, Ks rl re Mh Pest Wel Deen fore SPC 20800 pres otro 4, The tg, the Nett Oct 3294, 1990 Oilfield Review