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Summary
This paper discusses a successful initiative begun 6 years ago to
eliminate differential sticking across global operations. In the 5year period from 2004 through 2008, there were only three differential-sticking events in 3,476 wells drilled with the recommended
practices. There were an additional 17 sticking events with designs
that did not conform to recommended practices, and 14 of these
were freed. The drilling environment was diverse. Overbalances
in excess of 1,000 to 2,000 psi were common in multidarcy rock
and at high angle, and depleted reservoirs have been drilled with
overbalance as high as 7,800 psi in vertical wells.
The early focus of the stuck-pipe-avoidance practices was the
elimination of differential sticking. However, some level of sticking occurs routinely in drilling operations, and these events become
problematic only if the force required to initiate pipe movement
exceeds what can be delivered to the stuck point. It is now accepted
that sticking cannot be prevented and that elimination of sticking is
not a proper design objective. The philosophical objective has now
shifted from elimination of sticking to maintaining conditions that
allow the pipe to be pulled free, assuming that it will become differentially stuck. The desire to maintain this ability to move the
pipe has required the implementation of a range of practices, some
of which were not common in the industry.
Changes were made in bottomhole assembly (BHA) design,
fluid design, real-time cake-shear-strength recognition, and realtime cake-remediation practices. A finite-element (FE) model was
also applied to redesign new systems or applications that lie outside
the operators previous experience. The stochastic model predicts
cake growth and sticking force and the probability that it will be
possible to deliver a force that can free the pipe for any given
still-pipe time. The model inputs were calibrated through pullout
tests with a variety of fluids to determine mechanical cake-strength
properties, the rate at which those properties develop, changes in
the pressure transient through the cake as it matures, and the cake
contact areas and geometry at any point in time.
Engineering and operations training also contributed greatly
and allowed relatively uniform implementation to be achieved
across a large, globally diverse operation in less than 1 year.
A small number of noncompliant designs continued to be used,
and these contributed greatly to the incidence of stuck pipe in the
first 3 years. Last year, there was only one incident of stuck pipe
with a noncompliant design.
The paper describes the underlying sticking concepts, the engineering design and field practices used, the modeling capability,
and the field results.
Introduction
Differential sticking occurs when the drillstring, wireline, or
other surfaces are held against the borehole wall by forces that
develop in an area of contact with permeable formations. The
dominant force is usually associated with the pressure differential
between the borehole and formation in the contact area, though
adhesion and cohesion may also contribute some resistance to
pipe movement (Helmick and Longley 1957). Many of the most
Cake Pressure vs
vs.Time
Time
Pullout Force
Differential
Differential
P
x Area
Pressure
Pressure
CakePressure
Pressure
Pressure
(psi)
(PSI)
(PSI)
Shear
Pcake
600
600
Stationary
Stationary
Pressure
declining,
Differential
technically
stuck
increasing
500
500
400
400
Embedment
Pullout and
repeat
Pull
300
300
200
200
100
100
00
0
20
20
40
40
60
60
80
80
Time(minutes)
(Minutes)
Time
Time
(Minutes)
100
100
120
120
SPE 105560
Fig. 1Internal pressure of cake after pipe motion stops as measured at the borehole wall. Pipe can be pulled free at any point in
time until the decline in cake pressure creates sufficient effective stress that cake shear strength exceeds the axial and torsional
pullout force that can be delivered to the stuck point.
across the pipe is transferred to the solids in the cake. The stress
between the solids is referred to as the effective stress. In very low
permeability, some of the pressure drop may occur in internal cake
within the formation itself so that less stress develops within the
cake (Courteille and Zurdo 1985). However, in higher permeability
where differential sticking is more problematic, virtually all of the
pressure drop and stress may occur across the cake (Isambourg
et al. 1999). The increase in effective stress results in the development of (1) shear strength within the cake and (2) increased contact
force between the cake solids and pipe (Outmans 1958). In order
to move the pipe, it is necessary to apply sufficient force to overcome the shear strength of the cake so that the cake itself fails or
to overcome the frictional resistance between the steel and cake so
that the pipe slides across the surface of the cake.
Whether one believes that the cake shears or that the pipe slides
on the cake is of some operational interest because the techniques
used to reduce these resistances may vary. Despite published
data showing that sliding is possible, the failures that have been
observed in the operators laboratory tests have consistently been
shear failures within the cake. Consequently, the authors believe
shear within the cake to be the dominant mechanism in the field.
If the pullout force is dependent on cake shear strength, the
sticking tendency can be reduced by practices that reduce this
strength. It is useful to apply traditional soil-mechanics concepts
to describe the increase in effective stress, as Outmans did in
1958. However, the conclusion drawn at that time was that this
increased stress acted at the pipes surface, and methods were
studied to reduce the sliding friction (Annis and Monaghan 1962).
Because pullout failure is seen to occur most often within the cake
(Courteille and Zurdo 1985), it is the shear strength of the cake
that is being overcome and the sliding resistance must typically be
a higher value. The Mohr-Coulomb view of cake strength would
suggest that it is dependent on the effective stress acting between
the filter-cake solids and the angle of friction of the solids. It is
interesting to note that when papers are examined that have been
written on factors that effect pullout force, it is seen that the proposed practices to alter the sliding friction would also be expected
to change the internal shear strength by altering the angle of friction (i.e., lubricants, emulsified oil, surface-active agents). Unfortunately, experiments that focused on friction reduction have not
generally reported the point of failure, only the change in pullout
force. When assessing field data and practices, the authors assume
that the angle of friction is the factor that is being modified rather
than sliding friction.
Another significant observation is that the pullout force is time
dependent. The reason for this can be seen in Fig. 1. Because the
pressure decline is time dependent, the effective stress and the
shear strength that develops from this must also be time dependent.
One operational implication is that it is impossible to develop a
very high sticking force (shear strength) the instant the pipe stops
moving. Although some sticking force develops immediately, time
116
14 in.
24 in.
25 in.
Fig. 2Comparison of the upset contact areas in conventional drillpipe (upper) and HWDP (lower).
Stuck-Pipe-Avoidance Practices
Practices That Minimize Contact Area. The earliest publications
recognized the importance of contact area in differential sticking.
For example, operators understood the value of stabilizing drill
collars (DCs) in the 1950s, even before the first differential-sticking concepts were published. As each technique for minimizing
contact area was developed, opposing arguments were made
that it compromised other drilling priorities. Generally speaking,
when the BHA is changed, we have to change something else to
address the risk that the new configuration creates. This has been
a recurring theme over the last 50 years, and it is true of many of
the practices presented in this paper. Consequently, in addition to
describing the practices, some discussion of the concerns is provided as well as the mitigations for those concerns.
Use Heavyweight Drillpipe (HWDP) To Apply Weight on Bit
(WOB). Stiff, large-diameter DCs have traditionally been used to
apply weight to the bit. Their stiffness is desired because it prevents
buckling. In addition, because they are thick-walled, their weight
per foot is high, and very little length must be put into compression
to achieve the desired WOB. Unfortunately, conventional collars
exposed significant contact area to differential sticking. This has
been recognized from the earliest research, so much so that studies
of the phenomena have uniformly focused on this area of the BHA
(as will be discussed later, new practices have moved the concern
to a new area). The collars are prone to sticking for two reasons:
(1) The ratio of the curvature of their outside diameter (OD) may
be close to the curvature of the borehole wall so that as cake thickness increases, the cake contact area goes up rapidly; and (2) they
make contact along their entire length (30 ft) because their OD is
uniform and flush with the borehole.
An option that greatly reduces the contact area is the use of
HWDP in compression to apply WOB. Typical joints of conventional and HWDP are shown in Fig. 2. The wellbore contact area
is reduced from 30 ft with drill collars to approximately 6 ft per
joint with HWDP. The wear pad section in the middle of the tube
also helps to prevent contact along the tube body. By convention,
the tube OD of HWDP is the same as that of conventional drillpipe,
but the inside diameter is reduced so the tube body is thick walled.
This increases the weight per foot and the buckling resistance so
that it can be used in high compression to apply WOB. It is not as
stiff as a DC but may be adequate for most applications.
The use of HWDP in compression to provide WOB became
common in directional wells in the 1980s, and by the mid-1990s
operators had eliminated the majority of the collars above the top
stabilizer. However, directional drillers often continued to request
that a small number of unsupported DCs be run between the top
stabilizers and the HWDP (usually three to four). It was also felt
that transition members were required above the top stabilizer.
This design persisted to the time when the stuck-pipe-avoidance
practices were implemented in 2003 and the operator prohibited
the use of any unsupported DCs in directional wells. The reason
March 2011 SPE Drilling & Completion
was that the contact area in only one of these unsupported DCs
may easily be sufficient to prevent the pipe from being pulled free
in many situations. Because a collar has five times the contact area
of a joint of HWDP, the sticking event that would require only
40,000 lbf of pullout force per joint might require 200,000 lbf per
DC. In directional wells, and especially high-angle wells, it may
not be possible to deliver the required force to the stuck point if
even a small amount of DC contact is allowed, regardless of the
tensile pull capability at the surface.
In addition, there was no particular value found in having
the unsupported collars in the assembly for directional steering,
vibrational stability, or stress-fatigue reduction. The current practice in directional wells with low-to-intermediate angles is to run
sufficient HWDP above the stabilized BHA to provide the required
WOB, and to make the HWDP up directly to the top stabilizer so
there are no unsupported DCs. At higher angles, there are new
issues that have been identified with even the contact area in the
HWDP, which is discussed in a separate section.
The industry did not move as quickly to replace DCs with HWDP
in vertical wells as it did in directional wells. The operator began this
practice in the mid-1990s and achieved a major, immediate reduction
in stuck-pipe events. The pipe manufacturers provide guidelines for
the use of HWDP in vertical wells in various combinations of pipe
and hole sizes. Sinusoidal buckling will occur, but field experience
suggests that the associated stress levels are acceptable. The guidelines
do not explicitly account for operating conditions, actual vibrational
fatigue, or the level of buckling stress over the life of the pipe. And
yet, over the last decade, the failure of HWDP used in compression
in vertical wells based on these guidelines has been rare. From field
experience, the notional guidelines appear to be conservative.
Another factor that has probably affected the failure rate of
HWDP in compression is that polycrystalline-diamond bits are
often run at low WOB. A typical BHA used by the operator has
90120 ft of stabilized DCs, with HWDP above. As the driller lowers the string to apply WOB, the first 15,000 to 25,000 lbf of WOB
would come from placing the DCs, LWD tool, or other stabilized
members in compression before further slackoff would place the
HWDP into compression. Bit weights in soft formations tend to
range from 5,000 to 20,000 lbm, in which case the HWDP is never
actually compressed. While some teams have been running HWDP
far into compression in vertical wells with 35,000- to 40,000-lbf
WOB, the majority of the operators statistical experience is at
lighter weight with low levels of sinusoidal buckling in the HWDP.
On the basis of the low historical failure rate and large impact on
differential sticking, the design practice for both low-angle and
vertical wells is to use a minimal number of stabilized DCs and run
compression in the HWDP up to the point of helical buckling.
Use Stabilized BHAs. Slick assemblies are not recommended
for any application. All BHAs are fully stabilized, meaning that
stabilizers are used and their number and spacing ensure that there
is no wall contact between the DCs and the formation. The initial
117
The current recommended practice for intermediate and highangle wells is to use only one to three joints of HWDP above the
top stabilizer. If a jar is used above this, the stiff HWDP allows the
jarring force to be transmitted to the BHA should it become stuck.
This stiffness could also be achieved by putting the jars within the
collars, but the presence of the HWDP provides tool joints below
the jars with lower makeup torque, should it become necessary to
back off with a string shot charge to retrieve and replace the jar.
Wear Groove
guidelines allowed only one to two DCs above the top stabilizer for
vertical holes. It was assumed that the flex would be limited to the
point that there is no significant wall contact in the first 60 ft above
the top stabilizers. However, sticking events still occurred, and in
recent years, this allowance has been reduced to zero to one DC.
In directional wells, it is recommended that the HWDP be made up
directly to the top stabilizer so there are no unsupported DCs.
Slick assemblies are common in the industry, particularly in
hard formations drilled with bent-housing motors. There are various reasons why directional drillers prefer slick assemblies: (1)
They believe the stabilizers hang up and reduce the ability to slide
the motor when steering, and (2) the build rate (bit tilt) with a slick
assembly can be adjusted by changing the WOB. The build rate
of any steering system is determined by the geometry of the first
three contact points because the three points define the radius of
curvature. In a stabilized assembly, these three points are the bit,
sleeve stabilizers at the bottom of the motor, and the top stabilizer
above the motor. In a slick assembly, these points are the bit, the
sleeve stabilizer, and the first contact point between the BHA and
borehole. By adjusting WOB, the directional driller can flex the
slick BHA and move the contact point in the collars downward or
upward. This provides them some flexibility if needed to catch up
with the planned trajectory if they get behind the desired build rate,
or to slow down if the build rate is greater than desired.
Unfortunately, this variability also translates to rougher holes
with larger doglegs and increased bit whirl because of variability
in WOB. The slick assembly then slides more easily in this rough
hole with vibrationally induced trajectory patterns. In some sense,
the slick assembly becomes essential only because of the patterns
it creates in the borehole in the first place. In each field area where
slick assemblies have been replaced by stabilized assemblies, steering objectives have been achieved and overall borehole quality
has been improved. The most significant gains are that it becomes
possible to run low-clearance casing through high build rates, the
certainty of any casing being run to bottom is improved, and differential sticking has been reduced.
Eliminate HWDP at Higher Angles and Extended-Reach Sections. Though HWDP has significantly less contact area than a
DC, a further reduction can be achieved in higher-angle wells by
using conventional drillpipe with shorter tool joints. Conventional
drillpipe can be used at low angles but only to a limited extent
because of the low force at which it buckles helically. However, at
intermediate and higher angles, buckling is suppressed and a significantly greater compression can be put into the thinner tube body
of the conventional pipe, as documented by Dawson and Paslay
(1984). The use of conventional drillpipe with shorter tool joints
reduces the contact length with the borehole from approximately
6 ft with HWDP to less than 3 ft per joint, as illustrated in Fig. 2.
This results in a significant reduction in pullout force required to
overcome the shear strength in the contact area. This further reduction becomes important at high angle because the measured depth
required to traverse even thin sands becomes large at high angles.
Wells are now being drilled routinely with tool joints lying on 300
to 3000 m of sand with more than 2,000 psi of overbalance.
118
Use Standoff Subs With Jars. In terms of its differential-sticking potential, a drilling jar poses the same risk as an unsupported
DC. A single jar has been found to be the root cause in several
sticking events. Consequently, standoff subs are recommended on
all jars to prevent wall contact. The design of these subs varies
with vendor.
Manage Risks Associated With the Groove in High-Angle
Boreholes. During fishing operations to free differentially stuck
pipe at high angle, the stuck point is occasionally found to be in
the drillpipe above the BHA. It is often assumed this is caused by
the progressive sticking of the tool joints during the extensive time
in which the pipe has not been moved. However, the speed with
which some sticking events have occurred, and the fact that the
contact area in the fully stabilized BHA should not have provided
the resistance observed, has led to continued study of the fundamental mechanism. There are two issues that may be contributing
to sticking in the tool joints, one of which has not been discussed
previously.
The high-resolution, 3D borehole images that are now available
show the development of a groove in the bottom of high-angle
wells. An example image is shown in Fig. 3. The groove is created by the rotation of the tool joints or tube body against the
bottom of the hole, and some level of this feature appears to be
present in most high-angle wells. The severity would presumably
depend on the rock hardness, normal force, string rotations, and
roughness of hardbanding on the tool joints. It is unlikely that it
can be prevented entirely. (This bears similarities to key seating,
but that term already has another common use in the oil industry
and refers to a mechanical wedging process in doglegs or ledges).
The groove persists for thousands of feet and offers no mechanical
resistance that has been noted. However, it creates a significant
differential-sticking risk because its curvature will be very close
to that of the tool joints that created it, and the increase in contact
area dramatically increases the pullout force. A 5-in. tool joint
with a common 7-in. OD might normally have a contact arc of
1 to 2 in. If the tool joint is lying in the groove and has 60 of
contact, which might be the situation in Fig. 3, the arc increases
to more than 6 in.
Differential sticking may also occur more quickly, and the shear
strength of the cake may be higher. It has been demonstrated that,
all other things being equal, thinner cakes develop shear strength
more quickly because they require less time to lose their filtrate, so
that the effective stress and shear strength increase more quickly.
Also, thinner cakes have been shown to achieve higher levels of
shear strength, presumably because the angle of friction exhibited
by the solids is not reduced by high fluid content within the cake
(Annis and Monaghan 1962). If pipe is rotated without axial movement, the tool joint may wear the cake down so that it is thin, or
even so that it does not exist at all. It is also common to ream
each stand of new hole, which may allow the tool joints above the
BHA to wear down the cake within the groove just before stopping
pipe movement to make a connection. This is certainly speculation
and unproved, but it is one model that may explain (1) the speed
at which sticking shear strength has been observed to develop in
the field (cakes should not lose filtrate that quickly) and (2) the
high pullout force seen from calculated contact areas that should
be quite small.
Another potential contributing factor is suggested by research
conducted by Haden and Welch (1961). They found that the pullout
force for DCs having upset bands to prevent wall contact exceeded
the theoretical resistance of the contact area. They also found that
the force required to move the pipe exceeded the force required to
March 2011 SPE Drilling & Completion
Centralizer at Midpoint
100
90
90
80
80
Probability of Success %
Probability of Success %
Centralizer at Coupling
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(ppg)
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13.0
ppg WBM
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- WBM
Modeled
Modeled
pullout
pullout
13.0
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13.0
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ppg
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5050
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0.8
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Fig. 6Pullout force predicted by FE modeling vs. laboratory measurements, and an example triaxial test showing the elastoplastic behavior of a filter cake.
Compliant BHAs
Number of
Events
Stuck But
Freed
Stuck Not
Freed
Stuck But
Freed
Stuck Not
Freed
14
events where it was possible to free the pipe with spotting fluids
or reduction in MW are distinguished from those where the pipe
and BHA were not recovered successfully.
Altogether, there were only three stuck-pipe events in wells with
BHA designs that complied with the stuck-pipe-avoidance practices. Many practices, such as D&S, are critical to success but are
applied only when appropriate for the specific situation. In contrast,
recommendations for the allowed length of unsupported DCs apply
to all wells because this is believed to be the dominant risk factor.
Consequently, wells were classified as noncompliant only on the
basis of whether they contained more than the allowed length of
10
9
Compliant BHAs
Noncompliant BHAs
8
7
6
5
4
3
2
1
0
2004
2005
2006
2007
Year
Fig. 7Differential-sticking events by year.
122
Noncompliant BHAs
2008
Use HWDP in compression for bit weight in vertical and lowangle wells within the limits specified by the manufacturer.
Use conventional drillpipe in compression in intermediate and
high-angle wells within its helical-buckling limits.
Use standoff subs on drilling jars run above the stabilized BHA.
Conduct progressive pipe-sticking tests before making connections in wells with high sticking potential.
Do not use API FL or API HT/HP tests as an indicator of cake
quality except in very-low-permeability formations.
Conduct API PPTs and use appropriate blocking solids to
improve cake quality.
Conduct D&S treatments to enhance cake quality in intervals of
high differential pressure or chronic cake growth.
Model the differential-sticking risk quantitatively when planning operations that lie outside of previous experience.
When planning mitigations, consider the sticking risk associated
with a wear groove in high-angle wells. Additional mitigations
may be required, even when NAF is used and all DCs are supported.
When the design and practices comply with the stuck-pipeavoidance recommendations, the likelihood of differential sticking
is statistically very low. However, some sticking events (three in 5
years) continue to occur in the drillpipe above the BHA. The most
common cause is believed to be the high contact area between tool
joints and a wear groove that exists in most high-angle wells. Also,
the increasing length of high-angle penetrations in the operators
well mix is resulting in a greater number of tool joints in contact
with permeable formations.
References
Annis, M.R. and Monaghan, P.H. 1962. Differential Pressure Sticking
Laboratory Studies of Friction Between Steel and Mud Filter Cake.
J Pet Technol 14 (5): 537543. SPE-151-PA. doi: 10.2118/151-PA.
Bushnell-Watson, M. and Panesar, S.S. 1991. Differential Sticking Laboratory Tests Can Improve Mud Design. Paper SPE 22549 presented at
SPE Annual Technical Conference and Exhibition, Dallas, 69 October.
doi: 10.2118/22549-MS.
Courteille, J.M. and Zurdo, C.A. 1985. New Approach to Differential
Sticking. Paper SPE 14244 Presented at SPE Annual Technical Conference and Exhibition, Las Vegas, Nevada, USA, 2226 September. doi:
10.2118/14244-MS.
Dawson, R. and Paslay, P.R. 1984. Drill Pipe Buckling in Inclined Holes. J Pet
Technol 36 (10): 17341738. SPE-11167-PA. doi: 10.2118/11167-PA.
Desai, C.S. 2001. Mechanics of Materials and Interfaces: The Disturbed
State Concept. Boca Raton, Florida: CRC Press.
Dupriest, F.E., Smith, M.V., and Zielinger, S.C. 2008. Method to Eliminate
Lost Returns and Build Integrity Continuously with High-FiltrationRate Fluid. Paper SPE 112656 presented at IADC/SPE Drilling Conference, Orlando, Florida, USA, 46 March. doi: 10.2118/112656-MS.
Fisk, J.V., Shaffer, S.S., and Helmy, S. 1990. The Use of Filtration Theory
in Developing a Mechanism for Filter-Cake Deposition by Drilling
Fluids in Laminar Flow. Paper SPE 20438 presented at the SPE Annual
Technical Conference and Exhibition, New Orleans, 2326 September.
doi: 10.2118/20438-PA.
Haden, E.L. and Welch, G.R. 1961. Techniques for Preventing DifferentialPressure Sticking of Drillpipe, A Laboratory Study. Oil & Gas Journal
(April 3, 1961) 59 (14): 24.
Helmick, W.E. and Longley, A.J. 1957. Pressure-Differential Sticking of
Drillpipe and How It Can Be Avoided or Relieved. Oil & Gas Journal
55 (17 June): 132.
Hunter, D. and Adams, N. 1978. Laboratory and Field Data Indicate Water
Based Drilling Fluids That Resist Differential-Pressure Pipe Sticking.
Paper OTC 3239 presented at the Offshore Technology Conference,
Houston, 811 May.
Isambourg, P., Ottesen, S., Benaissa, S., and Marti, J. 1999. Down-Hole
Simulation Cell for Measurement of Lubricity and Differential Pressure
Sticking. Paper SPE 52816 presented at the SPE/IADC Drilling Conference, Amsterdam, 911 March. doi: 10.2118/52816-MS.
Monaghan, P.H. and Annis, M.R. 1962. Differential-Pressure Sticking
Laboratory Studies of Friction Between Steel and Mud Filter Cake.
J Pet Technol 14 (5): 537-543: SPE-151-PA.
Outmans, H.D. 1958. Mechanics of Differential-Pressure Sticking of Drill
Collars. SPE-963-G. Trans., AIME, 213: 265274.
Reid, P.I., Meeten, G.H., Way, P.W., Clark, P., Chambers, B.D., and Glimour, A. 1996. Mechanisms Of Differential Sticking And A Simple Well
Site Test For Monitoring And Optimizing Drilling Mud Properties.
Paper SPE 35100 presented at the SPE/IADC Drilling Conference,
New Orleans, 1215 March. doi: 10.2118/35100-MS.
Simpson, J.P. 1962. The Role of Oil Mud In Controlling DifferentialPressure Sticking of Drill Pipe. Paper SPE 361 presented at the SPE
Drilling and Production Practices Conference, Beaumont, Texas, USA,
56 April. doi: 10.2118/361-MS.
Fred Dupriest is currently Chief Drilling Engineer at ExxonMobil.
He graduated from Texas A&M in 1977 with a BS in mechanical
engineering. Dupriest provides global support in the implementation of programmatic initiatives to enhance well design, drilling
performance, and new technology development. William Elks
is currently a technical advisor in Drilling Technical Operations
Support at ExxonMobil. He graduated with a BS in chemical
engineering from the University of South Carolina in 1978. Elks is
the companys lead subject matter expert and provides global
support in directional drilling operations, extended reach practices, drillstring design, and well path surveying. Steinar Ottesen
is currently a technical advisor in Drilling Technical Operations
Support at ExxonMobil. He graduated from the University of
Aston, Birmingham in 1981 with a BS in chemical engineering.
Ottesen is the companys lead subject matter expert and provides global support in wellbore stability, hydraulic modeling,
hole cleaning, and quantitative risk assessment.
123