Case Study: Intelligent RSS Improving Drilling Performance on Three Mile Laterals in the Appalachian Basin

Abstract

Abstract Longer lateral length in unconventional wells has proven to increase hydrocarbon recovery and lower overall development costs for oil and gas operators in North America. The application of rotary steerable system (RSS) technology aids this effort by improving and sustaining penetration rates to reduce well time and maximize reservoir drainage. A new "intelligent" RSS has been deployed to enhance drilling efficiency with industry-leading operating limits, automated steering controls, and a global lifecycle maintenance system to drive reliability. The new RSS bottomhole assembly (BHA) consists of an advanced downhole motor, a matched bit design, and high-speed geosteering control. An automation process helps operators meet the challenges of drilling time and wellbore placement in long laterals. High rate of penetration (ROP), rotation per minute (RPM) and weight on bit (WOB) limits are controlled by sophisticated sensor technology that enables precise steerability. The RSS platform includes multiple directional sensors and real-time processors capable of reducing hole tortuosity and optimizing reservoir exposure while drilling. It also includes automated inclination and azimuth control features. Furthermore, a structured, pre-job design process evaluates critical engineering risks and mitigates those risks using a systematic methodology. The initial testing of the new RSS on a test beam qualified its ability to operate at high speeds and high loads. Multiple holes were drilled in cement blocks to benchmark performance. Beam testing was followed by full-scale testing at a dedicated drilling rig, where over 40,000 ft was drilled in a variety of configurations, including vertical, curve, and lateral trajectories. After the extensive field testing program, the intelligent RSS was utilized to drill multiple ~14,000-ft, 8.5-in. lateral hole sections in the Utica Shale. A significant reduction of drilling time was achieved in these long laterals, with an average ROP of 245 ft/hr. A record 5,300 ft were drilled in 24 hours, beating previous wells by 600 ft. The activation of inclination and azimuth control delivered a smooth, high-quality wellbore with minimal tortuosity. Inclination was maintained within +/− 0.5° and azimuth +/− 1°. The outstanding performance of the innovative BHA enabled the longest one-run lateral to be drilled with an RSS. The new, intelligent RSS has successfully demonstrated it can decrease well time and drilling costs, while increasing wellbore placement accuracy. The improvement in drilling efficiency and lateral length capability will enhance unconventional asset value across North America, and elsewhere around the world.