SPE-174838-MS

Solving Pre-Salt Underream While Drilling Challenge: Dynamic Simulations

Optimize BHA/Cutter Block Configuration Offshore Brazil
Mario Andres Breton, Miguel Barreto, Fyaed Hosein, Dario A. Palomino R, Julio Mayol, and Michael Stewart,
Schlumberger

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Annual Technical Conference and Exhibition held in Houston, Texas, USA, 28 –30 September 2015.

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 have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Challenges while drilling pre-salt wells offshore Brazil have led to planed hole enlargement operations as
part of the drilling solution of this type of imviroments in vertical sections from 18-1/8⬙ x 22-in. However,
this application proved to be challenging for the hydraulic underreamer cutting structures as high vibration
levels together with increased cutter block matrix exposure to the formation led to premature wear on the
hydraulic hole enlarger cutter blocks.
Formation to be enlarged is composed of 40% disaggregated sandstone, 40% shale and 20% mud-
stones, the objective was to enlarge intervals that ranged from 850 mts to 1000 mts in one run. The BHA
was experiencing high levels of shocks and vibrations that forced the operator to make additional trips to
finish enlarging the section. These additional trips proved to be costly high with rig rates between
$750,000-$1million USD.
Efficiently undereaming while drilling the entire section depth in one trip as planned would be
challenging and present a significant risk because of high daily rig-rates. To achieve objectives, a Finite
Element Analysis (FEA)-based simulation was performed aimed at improving BHA design and to
evaluate a new desing of underreamer cutter block with the objective of improving cutter durability as well
as reducing stresses experienced while enlarging the wellbore.
The study used a well records database and numerous offsets runs with a hydraulic expandable
underreamer used in offshore applications. A rock-strength identification program, that uses log data
including GR and sonic, was applied to determine formation type and foot-by-foot UCS. A hydraulic
analysis was also performed to determine efficient hole cleaning as well as ensuring adequate flow
distribution to ensure correct functionality of different BHA components, finally a FEA-based modeling
system identified the following key points:
The BHA used in previous application had room for improvement by modifying the size of DCs used
and by using a concentric expandable stabilizer to improve drilling efficiency and reduce vibration. A new
cutter block re- arrangement was designed for the application with changes including: 1) introduction of
a three row cutter-block with increased PDC density and optimized stresses distribution; 2) adjusted cutter
block nose design for more efficient hole coverage; 3) reduced depth-of-cut without compromising ROP
2 SPE-174838-MS

potential; 4) define an optimal operating parameters window with conclusions drawn from results of the
FEA-simulations aimed at improving ROP and reduce levels of stresses at the hole enlargement tool.
The new-style BHA was run and underreamed while drilling 734 mts without requiring an additional
trip to finish enlarging the section. The BHA also improved ROP during the UWD run. This new system
saved the operator between 96-120 hrs of rig time and met the objectives set when compared to offset
wells for similar applications.
Introduction
Underreaming while drilling operations attempted to be done in one trip in pre-salt wells presented
significant challenges associated to high levels of vibration resulting in severe wear on hydraulic
underreamer cutter blocks (figure 1), Sections ranged in length from 850 mts to 1000 mts from 18-1/8⬙
to 22⬙ through a lithological column that showed interbbeded intervals composed of 40% disaggregated
sandstone, 40% shale and 20% mudstones.

Figure 1—Dull Grade.

To overcome and evaluate the challenges presented, a dynamic finite element analysis program was
utilized that facilitates accurate simulation of multiple drilling scenarios in a virtual environment that
helps to improve drilling system for specific applications such pre salt wells.
The scope of these analysis was to evaluate different BHAs designs and support the assessment in terms
of performance improvement of a fit for purpose cutter block that presented innovative features.
Drilling Dynamics Model
Modelling was done through an engineering service that specializes in predictive modeling to solve
problems and deliver solutions using a highly sophisticated, proprietary Finite Element Analysis (FEA)
SPE-174838-MS 3

programs, these simulators are capable of predicting the dynamic behavior of the entire drill string from
the bit to surface due being supported by laboratory testing of rock samples for different cutting elements
creating as a result “Rock Files” that are used in the simulators to predict drilling dynamics under different
confinement pressures in order to replicate down hole conditions.
The program simulates transient performance for the entire drill-string and is able to predict bit – rock
interaction, rate of penetration, directional tendency, stick and slip, torque, moments, forces and displace-
ments at any point along the string. The model accounts for proprietary cutting structures, formation
effects, hole size, wellbore trajectory, tortuosity, BHA, drive type, parameters, eccentricity of components
and fixed cutter cutting structure wear.
Some other factors in the analysis to be considered are hole cleaning, poor bit hydraulics, wellbore
stability (Any non-cylindrical shape of the wellbore will sacrifice accuracy of vibration predictions),
hydraulics forces and stuck pipe scenarios
The dynamic behavior of bit and hydraulic underreamers for a specific bottom hole assembly
configuration and drilling parameters is critical when planning underreaming while drilling applications
in order to select a combination that produces a more stable system (See figure 2), this behavior is
determined based on the cutter-rock interaction model. Extensive cutter indentation and scrape tests are
conducted in different formation types under controlled pressures, Resulting cutting forces are correlated
to the rock failure mode and rock removal rate. These forces form the basis in the model for determine
dynamics and rate of penetration of a cutting structure in the given formation, as there are no assumptions
made towards the source and magnitude of cutting structures forces and vibrations, modelling results
closely replicate field performance, this time based 4-D modelling tool accurately predicts a drilling
system’s performance using FEA.

Figure 2—Dynamic behavior comparison

4 SPE-174838-MS

Methodology Implemented
The computer modelling was done following a methodology aimed at clarified the root caused for the
premature wear experience on the hydraulic underreamer cutter blocks and to improve previous BHA
design in order to achieve the objectives set for this application (See Figure 3).

Figure 3—Analysis Work Flow.

Post- Job Investigation Findings

Analysis of post job data supported by FEA led to raise the following findings:
● Compatibility between the PDC bit and the hydraulic underreamer was found as a good match
showing a stable and compatible pattern when engaging the formation.
● Bending of the BHA against the borehole was increasing the exposure between the formation and
the cutter block matrix, this is believed to have contributed to matrix wear. (See figure 4), this
scenario led to pursue the need for stiffer BHA’s.
SPE-174838-MS 5

Figure 4 —Engagement of PDC inserts against formation.

● A new desing of cutter block was to be evaluated for better distribution of loads through the cutters
as well as higher matrix protection by reducing the cutter depth of cut.
● Levels of lateral stresses experienced at the hydraulic expandable reamer proved to have room for
improvement, therefore it was decided to model several BHA’s that were aimed at reducing
stresses experienced at the cutting structures.
It was found that bending of the BHA against the borehole wall, was translated into higher penetration
of the PDC cutters into the formation leading as a consequence to higher contact of the cutter matrix
against the abrasive formation being enlarged while drilling, this behavior could have contributed to steep
matrix wear leading as a consequence to PDC inserts debonding.
Validation of modified cutter block layout The design process of a fit for purpose cutter block to
enlarge while drilling from 18-1/8⬙ x 22⬙ was set with the purpose of improving stresses distribution
through the reamer as well as limiting the depth of cut of the cutter block without compromising ROP.
Improvement of cutter loading against baseline product Hydraulic underreamer cutter blocks are
designed to enlarge a pilot hole to a predetermined, larger diameter. Often, the underreamer can be
assembled with the same cutter blocks, and the tool can be adjusted to different opening sizes, depending
upon client needs. For this specific application, the underreamer cutter block was designed to open the
borehole from a pilot hole of 18-1/8⬙ to a maximum diameter of 22⬙. For this fit-for-purpose cutter block,
the cutters were distributed over the available area such that the individual loads on each cutter, static and
dynamic, were minimized, and the loading dynamics imparted to each cutter were favorable. In contrast,
the original design was not suitable for this application, having multiple cutters which were well within
the pilot hole size, and therefore would not engage the formation for this application. (See Figure 5)
6 SPE-174838-MS

Figure 5—new cutter block design. PDC inserts re- arrangements.

This was done by maximizing the cutters under load that the cutter block carried. This cutting structure
was then iteratively optimized by simulating the BHA and analyzing the cutter and rock fracture
interaction. The results of this analysis yielded the rock reaction forces directed to the cutters, as well as
dynamic results on cutting structure stability. The results were used to drive the placement of cutters on
the next iteration to achieve lower loads and increased drilling stability. The resulting cutter loads were
reduced by 38% in critical reaming areas. (See figure 6).

Figure 6 —Cutter Loads of new design (red) relative to baseline design (blue)

Improvement of borehole quality Reaming stability is beneficial, because increased instability rep-
resents a portion of the energy imparted to the drilling system is not being used to drill the hole, and
instead is putting the cutters under increased dynamic load. The cutting structure was also analyzed for
dynamic behavior, to ensure there would be increased stability over baseline products, To verify stability,
the hydraulic underreamer was analyzed by simulating the BHA and investigating its stability, which can
be envisioned by plotting the theoretical center of the reamer as it drills. The new cutting structure was
SPE-174838-MS 7

shown to be more stable (See figure 7), with less absolute lateral motion, less eccentricity and less lateral
acceleration than the baseline standard cutting structure. This translates into more efficient cutting and a
better hole quality, with less energy being lost to lateral vibration, which will improve integrity of the
cutting structure.

Figure 7—Reamer theoretical center of baseline design (left) and new design (right)

Figure 8 —Simulated borehole quality of baseline design (left) and new design (right)

Modified BHAs Modified BHAs were designed taking into consideration post job findings previously
mentioned on this documents, leading to simulate four BHA configurations (See picture 9) to determine
stability and drilling behavior of each configuration, these simulations were done considering BHA# 1 as
a baseline.
8 SPE-174838-MS

Figure 9 —Modified BHA designs.

(BHA#1), which was the standard configuration for this type of applications with a previously used
standard cutter block and had the hydraulic underreamer stabilized with two integral 18⬙ blade stabilizers,
having the upper Stabilizer place 30 ft above the underreamer,
Main purpose of the upper stabilizer is to reduce the lateral loads that are experienced at the hydraulic
underreamer cutter blocks, the clearance between the upper stabilizer and the enlarged pilot hole was 4⬙
this due to casing diameter restrictions.
BHA#2 was modelled with a new cutter block re- arrangements and with the utilization of 9.5⬙ drill
collars, seeking to have a more stable system.
BHA#3 & BHA#4, were modeled considering the newly design cutter block and the implementation
of a hydraulic expandable stabilizer, the only difference between these BHA’s was the space out between
the hydraulic expandable stabilizer and the hydraulic hole enlargement tool.
Key findings obtained through these finite element analysis after simulating a wide range of parameters
through all four BHA’s can be summarized as:
● The implementation of the concentric expandable stabilizer delivered a more stable BHA, dynamic
finite element analysis showed a significant decrease in the level of contact forces experienced at
the hydraulic underreamer by changing the pattern on stresses distribution, where most of the
contact forces were absorbed by the hydraulic expandable stabilizer. (See figure 10).
SPE-174838-MS 9

Figure 10 —FEM simulations results – Expandable / Underreamer load distribution

● The newly cutter block desing led to significantly reduced levels of Stick and Slip experienced
with different combinations of drilling parameters proposed.
● Level of vibrations in BHA # 4, were higher while BHA# 3 displayed a significant reduction of
vibration when placing the adjustable stabilizer 30ft above the hydraulic underreamer.
● Comparison of drilling parameters showed improved drilling dynamics for BHA#3 when com-
pared to the baseline BHA, leading for safe utilization of a wider range of drilling parameters. (See
figure 11).
10 SPE-174838-MS

Figure 11—FEM simulations results –Drilling parameters proposed

● Implementation of results obtained from the FEA, led to successfully deliver an 18-1/8” x 22”
section without generating excesivewear in the hydraulic underreamer cutting structures. (See
figure 12)

Figure 12—Dull grade – New designed cutter block

Conclusions
● Finite Element Analysis simulations helped to truly understand the dynamics of the
baseline BHA, helping to understand and improved the BHA design required to
meet the challenged of the application.
● Use of the FEA simulation enableto operators reduce non-productive time saving
drilling costs by optimizing BHA and cutting structures. .
● The re- arrangements of the PDC inserts within the cutter block geometry provided
a greater coverage of the matrix becoming more uniform distribution of loads
SPE-174838-MS 11

resulting in better protection of the block matrix exposure to the abrasive formation
reducing the probability of loss inserts and consequently compromising the effi-
ciency of the cutter block.
● Several design considerations for Underreamer cutter blocks were identified by
using the FEA software. All this modeling allowed the deployment of more stable
cutting structure configuration and when paired with the appropied hydraulic
stabilization system reductions in vibration can be notice while maintaining cutting
structure integrity.
● Combination of a stiffer BHA with a managed depth of cut presented significant
benefits when controlling exposure of the cutter matrix to the abrasive formations
being drilled.
● Using the FEA in order to evaluate drilling dynamics and to draw a road map of
parameters, has proved to be a successful strategy in order to deliver an enlarged
hole from shoe to shoe.
References
1. Radford, S., Li, T., Jenkins, M.: “Novel Concentric Expandable Stabilizer Results in Increased
Penetration Rates and Drilling Efficiency with Reduced Vibration” paper SPE/IADC 119534
presented at the SPE/IADC Drilling Conference and Exhibition, Amsterdam, The Netherlands,
17-19 March 2009
2. Torvestad, B. T., Ray, t., Hu, J., Gjertsen, O. J., Muir, M.: “Development of a New Advanced
Multiple Activation System for Concentric Underreamers” paper IADC/SPE 151337 presented at
the 2012 IADC/SPE Drilling Conference and Exhibition, San Diego, California, USA, 6 – 8
March 2012
3. Torvestad, B. T., Bjoerneli, H. M., Toerge, K., Andreassen, L., Haavardstein, S., Blikra, H.:
“Industry’s First Hydro-Mechanical Surface Controlled System for Multiple Reamer Activation/
Deactivation Increases Drilling Efficiency” paper SPE/IADC 163537 presented at the SPE/IADC
Drilling Conference and Exhibition, Amsterdam, The Netherlands, 5–7 March 2013
4. Lirette, N., Aubin, M., Davis, J., Duvvuru, H., Nagaraj, M.: “Ream-On-Demand System Elimi-
nates Dedicated Trip to Enlarge Rathole in Deepwater Gulf of Mexico Operation” paper SPE
166127 presented at the SPE Annual Technical Conference and Exhibition, New Orleans,
Louisiana, USA, 30 September–2 October 2013
5. Breton M, Lima A, Oliveira D: “Efficiently Delivering Difficult Tortuous Well Profile Deepwater
Brazil Ream-on-Demand System Saves Operator Trip for Tool Change-Out,” presented at SPE
Latin American and Caribbean Petroleum Engineering Conference 21-23 May 2014, Maracaibo,
Venezuela
6. Barret M, Compton M, Agnihotri M, Verano F, Mitchel S, Fitzmorris D: “Dyanmic BHA
modelling enlargement while drilling leads to ROP improvement in gulf of mexico”.
7. Courville D, Childers R, Miller G: “Wellbore enlargement for a deepwater casing program: Case
stud and developments” IADC/SPE paper 87153 presented at the 2004 IADC/SPE drilling
conference, Dallas, Texas, Mar 2-4