SPE/IADC 163472

Design, Development, and Field Testing of a High Dogleg Slim-Hole Rotary

Steerable System
Richard Hawkins, SPE, Steve Jones, SPE, James O'Connor, SPE, and Junichi Sugiura, SPE, Schlumberger

Copyright 2013, SPE/IADC Drilling Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Drilling Conference and Exhibition held in Amsterdam, The Netherlands, 5–7 March 2013.

This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have
not been reviewed by the Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to correction by the author(s). The material does not
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Abstract
High dogleg rotary steerable systems (RSS) were introduced for general industry use in 2011. These systems were developed
for high dogleg shale applications in North American land operations. The initial systems were 6 ¾-in. These tools were
designed to produce up to 15°/100 ft in 8 ½-in. to 8 ¾-in. hole size. High dogleg tools for different borehole sizes followed.
The requirement for high dogleg RSS is now global, and the systems are being used to drill in areas where steerable motors
previously dominated because of their higher dogleg capability. A new 4 ¾-in. RSS has been designed for high dogleg
(15°deg/100 ft) and dogleg assurance applications. Additionally, a new high dogleg RSS for 5 7/8-in. to 6 ¾-in. hole sizes
has been developed and field tested. The new slim-hole high dogleg RSS has proven to perform well and be a cost-effective
solution in specific applications, such as difficult formations and multilateral well construction.

Introduction
High dogleg rotary steerable systems (RSS) have gained acceptance since the introduction of 6 ¾-in. tools in 2011. While the
initial application for these tools was in high dogleg shale wells, the systems are effectively being used in applications that
are more conventional. This paper describes the use of high dogleg RSS to improve performance in difficult formations as
well as increase efficiencies in multilateral well construction.
Conventional slim-hole bottomhole assemblies (BHAs) can be challenging to design and control simply because of the
limber nature of the equipment. With the requirement of stabilization on most slim-hole BHAs to eliminate shock and
vibration, the additional stabilization can bring unwanted effects while sliding, such as hanging up and poor weight transfer
to the bit. A fully rotating high dogleg RSS now provides a responsive control system that can be used for a wide range of
well construction applications worldwide.
The slim-hole high dogleg RSS has a capability in excess of 15°/100 ft, which makes it well suited for North American
shale drilling for curves planned up to 12°/100 ft. In the Middle East and Africa, the system has been used in dogleg
assurance applications in unconsolidated and high formation tendency formations. Horizontal wells that encounter hard and
soft layers can be particularly challenging for standard RSS, especially when geosteering and trying to break through hard
lateral streaks. The high dogleg RSS is very effective at quickly changing course, even in highly variable formation strengths
that can cause BHA tracking.
A properly designed high dogleg RSS BHA, with its single BHA is capable of multiple drilling tasks. The key elements
of the design allow consistent and predictable directional performance when steering for high and low dogleg and provide the
ability to control vertical, tangent, and lateral well paths with the same BHA. The system is capable of kicking off from
vertical on the required azimuth and can be used for efficient openhole sidetracking. Full rotation means there are no
limitations on reaming or backreaming.

Design Specification and Principal of Operation

One of the key design requirements of the high dogleg RSS was to have a fully rotating system. Full rotation is beneficial on
high dogleg wells to eliminate weight transfer problems that are frequently seen. Full rotation also helps with borehole
cleaning, especially at high inclination with fast penetration rates, and reduces the risk of packoffs and stuck pipe. The design
of the system also makes it suitable for reaming, backreaming, drilling out casing shoes, and exiting cased-hole whipstocks.
The steering mechanism for the new high dogleg slim-hole RSS is a hybrid design using aspects of both push-the-bit and
point-the-bit to give a fully rotating system with high dogleg capability. Pads actuated by drilling fluid are used to apply force
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(push) on the inside of the steering sleeve. This results in the steering sleeve pivoting off a universal joint to tilt (point) the bit
in the desired direction. Fig. 1 shows the hybrid steering principle.

Fig. 1—Hybrid steering principle.

The control unit of this slimhole high dogleg RSS is scalable (i.e., the same control unit can be used for the high dogleg
RSS of 4 ¾ in. to 6 ¾ in. and the standard RSS of 4 ¾ in. to 11 in.). This design simplifies the management and servicing of
RSS tools.
The steering unit is a scaled-down version of the 6 ¾-in. high dogleg RSS. Fig. 2 details the main components of the
slim-hole high dogleg RSS.

Control Collar Steering Unit

EM Sleeve Control Strike Steering

Short-Hop Stabilizer Unit Ring Sleeve
Fig. 2—Slim-hole high dogleg RSS.

The system has been designed to produce a maximum dogleg of 15°/100 ft in hole sizes ranging from 5 7/8-in. to 6 ¾-in. The
maximum dogleg can be restricted by changing the size of the “strike ring” on the steering unit. The strike ring limits the
amount of tilt (or point) on the steering sleeve. The full operational specifications are detailed in Table 1.

TABLE 1— SLIM-HOLE HIGH DOGLEG OPERATIONAL

SPECIFICATION
Steering capability 15°/100 ft
Operating flow range 170 to 350 gpm
Maximum operating pressure 20, 000 psi standard
Maximum operating temperature 302°F
Rotary speed 40 to 350 rpm
Maximum weight on bit As per bit specifications
Maximum torque on bit As per bit specifications
Absolute overpull 272,000 lbs
Loss circulation material limit 35 lb/bbl medium nut plug
Sand content 1%
Mud weight range 8.3 to 18 ppg
Hole size range 5 7/8 to 6 ¾ in.
Nominal tool length 14.6 ft
Steering sleeve outside diameter 1/8 in. undergauage
Downhole connection API 3 ½ in. Reg. Box
Uphole connection NC38
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BHA Design
To address different drilling requirements, multiple BHA designs were required, including several high-tier BHA systems for
well placement. The different BHA designs meet the following needs:

1. High-volume shale drilling, with a system capable of 8 to 14°/100 ft

2. High-tier shale drilling, with a system utilizing high-resolution real-time resistivity measurements, borehole
imaging, and logging-while-drilling (LWD) multipole acoustic measurements
3. High-tier basic multilateral well construction including potentially high dogleg severity (DLS) and openhole
sidetracks, with a system capable of real-time azimuthal gamma ray measurements
4. High-tier advanced multilateral well construction, including potentially high DLS with openhole sidetracks, with a
system capable of real-time azimuthal gamma ray, well placement distance-to bed-boundary, apparent neutron
porosity, formation bulk density, and photoelectric factor measurements

To optimize the slim-hole high dogleg RSS performance in the various BHA designs, a system-engineered approach was
required. This involved analysis of bit design, stabilizer placement, and component stiffness utilizing advanced modeling
techniques.
The base-level BHA design, for the high-volume shale drilling, in North America. Whilst well placement within these
shale reservoirs is becoming more important, a simple gamma ray or azimuthal gamma ray measurement is typically
adequate. Fig. 4 shows the base level BHA. The positive mud pulse measurement-while-drilling (MWD) tool provides real-
time data from the RSS control unit via electromagnetic short-hop transmission. The MWD tool is fully retrievable and
replaceable on wireline, which saves rig time and reduces lost-in-hole exposure. The probe design of the MWD system also
allows placement in a collar with adequate flexibility to reduce rotary fatigue accumulation in high DLS applications.

Fig. 4—Base level high-volume slim-hole shale drilling system.

The high-tier BHA was designed for wells with LWD and well placement requirements. The design incorporated a more
advanced MWD system utilizing continuous mud wave telemetry to achieve data transmission rates in the range 6 to 16 bits
per second. With data compression technology, these transmission rates can be increased significantly. Fig. 5 shows the high-
tier slim-hole high dogleg BHA option.

Fig. 5—High-tier high DLS LWD drilling system.

A further progression on these BHA designs allowed a solution to be created for multilateral wells construction. It is
difficult, or even impossible, to perform openhole sidetracks with push-the-bit and standard RSS. The high dogleg RSS. The
high dogleg system allows dual and multilateral wells to be sidetracked laterally so that each leg of the well can be re-entered
later for selective stimulation. Frequently, these multilateral wells have high dogleg requirements to land in the reservoir,
followed by well placement and geosteering with much lower dogleg needs. Fig. 6 shows a typical BHA used in multilateral
well construction.
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Fig. 6. – Multilateral high DLS LWD drilling system.

BHA Modeling
The in-house modeling program was used to simulate directional drilling in a virtual environment. The modeling program
incorporates all components of a drillstring, including top drive, drill pipe, drill collar, stabilizer, MWD/LWD, RSS tool, and
drill bit. Simulation of the downhole working condition included factors such as cutting structure interaction with formation,
drillstring contact with impact on the wellbore, and drilling mud weight. Above the drill bit, a series of beam elements from
finite element method are used to model the drillstring because the whole drillstring is a long and slender structure. The
contact and impact phenomena between drillstring and wellbore are modeled by considering the interaction of beam element
nodes with the wellbore.

Field Test
In the field tests, the systems were tested in multiple drilling environments including water-based and oil-based drilling fluid
types; downhole temperatures up to 300° F; land and offshore rigs; and various formations in multiple geographic areas,
including sandstone, shale and carbonate reservoirs. Several different applications were also field tested, including high
dogleg wells, low dogleg geosteering applications, and dual lateral wells with openhole sidetracks.

High Dogleg North America Shale Development

The slim-hole high dogleg RSS has been tested on projects in the Haynesville Shale and Travis Peak formations in east
Texas. These are challenging drilling environments with a high dogleg requirement. Selecting an area with multiple-rig pad
drilling allowed quick accumulation of hours and footage in a high dogleg environment.
In the Haynesville shale application, up to three wells are drilled from each pad. In the field test, oil-based drilling fluid
was used with an average mud weight of 15.6 ppg, and bottomhole circulating temperatures of up to 300° F were reached.
The wells were designed with curves in 6 ¾-in. hole size planned for up to 12°/100 ft dogleg. The slim-hole high dogleg RSS
was used to drill out 7 5/8-in. casing shoe and then drill several hundred feet of vertical before building the curve to land in
the Haynesville shale. A total of 26 wells were drilled in 1,772 circulating hours accumulating 33,326 ft which was mostly
high dogleg (>12° /100 ft).
Planning for a 12°/100 ft dogleg in the curve resulted in footage of only 750 ft to land. Fig. 7 shows the performance limit
that was reached on the Haynesville curves. By the end of the field test, the curves were being drilled in just over 22 drilling
hours. This was achieved through optimization of bit selection, hydraulics, and drilling practices.

Fig. 7—Slim-hole high DLS curve drilling performance limit.

The Travis Peak formation in east Texas is a challenging formation to drill. Most wells are designed to drill vertically
through the Travis Peak to eliminate the issues that are common in this abrasive and high-shock environment. The slim-hole
high dogleg RSS was deployed on two wells in the Travis Peak. The curves were planned at 11°/100 ft in 6 1/8-in. hole size.
The best well drilled resulted in a rate of penetration (ROP) of over 35 ft/hr. Fig. 8 shows the average curve ROP drilling
with motors and high dogleg RSS.
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Fig. 8—Average curve drilling ROP in Travis Peak, motors (M) and high DLS RSS (A).

Multilateral Well Construction and Dogleg Assurance

In the Middle East and West Africa, the applications for the slim hole high DLS RSS are completely different from the North
America applications.

Middle East Case Study: Dual Lateral Well Construction. One operator in the Middle East wanted to evaluate downsizing
to a slim-hole well architecture to reduce cost. These wells were dual or multilateral horizontal construction in carbonate
reservoirs. The first lateral could be drilled with a standard RSS, but to initiate the lateral openhole sidetrack, a dedicated
steerable motor run was required. The standard RSS was only capable of initiating the openhole sidetrack lowside. However,
the ideal sidetrack exit point was at 120° right or left.
The high dogleg RSS was tested in a dual lateral well utilizing the high-tier advanced LWD BHA incorporating a new
resistivity imaging-while-drilling service and an azimuthal density neutron–while-drilling service. These high-tier LWD
technologies provided 360° high-resolution electrical images, laterolog resistivity measurements, real-time apparent neutron
porosity measurements, formation bulk density measurements, and photoelectric factor data. The measurements were used to
identify fractured zones that needed to be isolated.
The slim-hole high dogleg RSS was configured with a smaller strike ring at surface, which physically limits the
maximum DLS potential of the system. The well was drilled with a planned build rate of 5°/100 ft to land in the reservoir,
which was achieved with a 50% steering ratio setting. Once landed in the reservoir, the well was geosteered utilizing real-
time LWD measurements, and the RSS was controlled using closed-loop inclination hold modes. The high dogleg RSS was
able to maintain the drilling plan despite the formation dips that had previously created problems while drilling the lateral,
and the first lateral was drilled to section total depth.
The assembly was pulled back to sidetrack point, and the high dogleg RSS successfully sidetracked in 12 hr on a 130L
gravity toolface. The second lateral was successfully geosteered through the reservoir to section total depth.
Since this first well, the slim-hole high dogleg RSS has been used on a subsequent dual lateral well. Utilizing the fast
sidetrack procedure, the openhole sidetrack was successfully executed in 2.5 hr, achieving a new record for the field.
This field test resulted in
 Drilling of dual lateral wells in 6 1/8-in. boreholes in a single BHA run with RSS and high tier LWD, which
eliminated two BHA trips
 Saving 10 hours with the fast sidetrack procedure
 Geosteering within the desired layer of the reservoir, even when strong formation effects threatened to throw the
well off plan

Case Study West Africa: DLS Assurance and Well Placement. An operator in West Africa faced significant challenges
when geosteering horizontal wells through loose and unconsolidated formations. Minimizing the attic oil without exiting the
reservoir roof required precision well placement. Previously, standard RSS had insufficient dogleg capability to land in the
reservoir so conventional steerable motors were utilized. Once landed, a trip was required to pick up the RSS BHA to
geosteer through the reservoir. Frequently, the standard RSS struggled to maintain wellbore inclination in the unconsolidated
formations, and this required a further trip for a motor assembly to bring the well path back on track.
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The slim-hole high dogleg RSS was utilized to drill the well in one run. The BHA design incorporated gamma ray and
resistivity tools and azimuthal density-neutron–while-drilling service. The assembly drilled out the shoe, which was set at 82°
inclination and landed the well delivering 7.3°/100 ft. The reservoir section was then drilled using closed-loop inclination-
hold software. The slim-hole high dogleg RSS was able to steer the well to plan and maintain within the narrow target
window.
The field test resulted in:
 Landing the well using slim-hole high dogleg RSS
 Avoiding multiple trips for steerable motors.
 Placement of the wellbore in a narrow total vertical depth (TVD) window, minimizing attic oil and avoiding exiting
the reservoir roof
 Reduced time to deliver the section from 15 days down to 7 days

To date, this operator has drilled two further successful wells using the slim-hole high dogleg RSS.

Conclusions
 The high dogleg slim-hole RSS has been qualified in a wide range of environments worldwide during the field test
 Utilization of the slim-hole high dogleg RSS in high build rate shale wells and in multilateral well construction and
dogleg assurance applications has resulted in significant time and cost savings
 BHA modeling provides a simulation platform for a wide range of drilling environments and rock types

Acknowledgments
The authors would like to thank Schlumberger for their willingness to publish the data obtained during the high dogleg RSS
field test.
[SLD: For SPE, the nomenclature list is for letter symbols and equations. Since abbreviations are defined at the first use in
the text, the nomenclature section is not needed.]

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