SPE-169249-MS

Mitigating Vibration with Roller Reamer Technology Improves Drilling

Efficiency in Hard/Abrasive Formation, Sao Francisco Basin, Brazil
Mario Breton, Julio Mayol, Martin Gerlero, Oscar Rojas, Gerardo Leon, and Joao Pedro Tocantins, Schlumberger

Copyright 2014, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Latin American and Caribbean Petroleum Engineering Conference held in Maracaibo, Venezuela, 21–23 May
2014.

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
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Abstract
When drilling operations commenced in Sao Francisco basin, the operator knew the exploratory well
campaign would present a major investment. However, as operations progressed the well costs and time
exceeded assessments mainly drilling the 8½⬙ production hole section through two hard and abrasive
formations. Due to the unconventional nature of the reservoir, well costs must be held to a minimum in
the exploration phase to ensure each project is economically viable. To accomplish the objective, several
tool technologies were analyzed and proposed with the aim of reducing down-time and tool failures. One
of the main issues identified was the high level of shock and vibration (S&V) observed while drilling the
Macaubas and Paranoa formations. The environment had a negative impact on drilling efficiency and
contributed to tool failures and excessive wear on BHA components leading to additional trips and
preventing the operator from achieving higher ROP and run lengths.
After an engineering analysis, the drilling team determined the root cause was BHA/bit whirl while
along with several other contributing factors related to the challenging hard and abrasive formations.
Based on this information, the provider recommended using a roller reamer in the bottom hole assembly
(BHA), to mitigate shock and vibration and improve drilling efficiency. Results were positive and the
roller reamer reduced NPT and overall well costs in this economically sensitive play. Roller reamers are
currently part of standard packed BHA and are being used as a reference for operators experiencing the
same type drilling dysfunctions.

Introduction
As the operator prepared for its first exploratory campaign for unconventional resources in Sao Francisco
basin (Figure 1), their engineering team had a basic understanding of the drilling challenges they would
encounter. However after drilling the first well in June 2011, the operator reassessed the major drilling
challenges they would have to overcome to efficiently gain access to the reservoir.
The hard and abrasive Macaubas and Paranoa formations1 have an extremely high compressive
strength (UCS) measured between 20 – 40 kpsi (Figure 2). The difficult drilling environment led to high
bit consumption/excessive tripping, extremely low ROP and short bit runs. On several occasions tools
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were damage beyond repair and fishing operations

Figure 1—General location map Sao Francisco basin, Brazil
were required to retrieve lost reamer parts. All of
these factors were contributing to an increase in
operational time inflating overall project costs.
The drilling team considered several options to
solve the drilling inefficiency issues and elected to
launch an analysis to determine the root cause of
high shock and vibration. The goals were to im-
prove ROP and run lengths by mitigating S&V
levels by introducing new drilling technologies and
optimizing operating parameters. The team also
wanted to determine the exact type of vibration that
was leading to tool damage especially in the 8½⬙
hole section that must penetrate the Macaubas and
Paranoa formations.

Engineered Problem Solving Technique

In the 17½⬙ hole section, axial shocks were experienced but were solved by drilling offline with a
roto-pneumatic rig. This allowed the drilling rigs to spud in the 12¼⬙ section with more available weight
to place on the BHA to drill the hard surface formations. In the 8½⬙ hole section vibration problems were
mitigated by introducing a roller reamer after an engineering study that included the following steps:
➢ Problem identification
➢ Proposed solution
➢ Field implementation
➢ Results evaluation and continuous improvement proposal

Problem Identification
During drilling operations, lateral shocks are predominant however vibrations occur along three axes and
circumferentially around the BHA equipment. The MWD tools that were used in the initial Sao Francisco
basin wells could only measure vibrations that were perpendicular to the vertical axis of the tool (lateral
vibrations). Although the information was useful, the lack of comprehensive vibration analysis was an
issue to optimizing drilling efficiency. In addition to the low rate of penetration in the Macaubas and
Paranoa formations, vibrations were leading to excessive wear on BHA components further increasing
drilling costs by shortening bit runs and increasing the number of damaged tools and resulting fishing jobs.
Initially, BHA imbalance was considered as the possible root cause of the high vibration levels. But
after experimenting with several different BHA configurations and drilling parameters adjustments, the
problem persisted. Besides BHA configuration issues, additional hypotheses were generated and inves-
tigated as outlined below:
➢ Turbine and impregnated bits: high levels of lateral vibration were registered when drilling with
turbine BHAs (even though experience indicates that turbines don’t induce a high level of vibration)
through Macaubas and Paranoa formations. Suspecting that a rubber element and bend housing
could be a possible cause, the rubber was replaced with metal components and bend housing
reduced from 0.5 to 0 degrees. However, problems persisted even after these changes. Vibration
occurred with or without a turbine in the BHA.
➢ Drill string: suspected imbalance force being generated after fishing operations on the first well. In
an attempt to solve the perceived imbalance, all drill pipe was replaced with inspected tubulars.
SPE-169249-MS 3

Figure 2—Rock strength identification program pegged UCS of Macaubas and Paranoa at 30 – 40 kpsi
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After change out, drill pipe was eliminated from consideration because lateral vibrations were not
as high when drilling outside the Macaubas and Paranoa formations. Therefore, it was determined
that drill pipe was not the root cause.
➢ BHA tools: bits, drill collars, heavy weight drill pipe, jars, shock subs, dog subs and motors were
all investigated as potential cause of vibrations (even though experience indicates that shock subs
and motors act as shock dampeners) however no reason for vibrations generation was found for any
of these tools. It is important to note that when using different rigs with different BHA types to drill
Macaubas/Paranoa formations in 8½⬙ hole section (packed BHA with and without motor, turbine
BHA and coring BHA) were experiencing a similar high level of vibrations along with its
devastating effect on BHA components.
After an in-depth investigation, engineers identified the root cause for vibrations were related to BHA
whirl. The effect was mainly due to the BHA contact points’ interaction with hard and abrasive formations
(Macaubas and Paranoa) and friction factor contrast. This conclusion is based on the following facts:
Using MWD data, the same experience was observed in all wells with a consistent behavior of low
lateral vibration levels prior Macaubas and Paranoa formations. When drilling outside these two forma-
tions with similar lithology composition (sandstone), vibrations were below 100cps. But when drilling
through Macaubas and Paranoa, readings were 300 –500cps. A more detailed analysis helped identify the
lateral vibrations were experienced regardless of having the bit on or off bottom (whilst circulating).
Damage on elements pulled, especially on the stabilizers, indicated BHA whirl.

Sao Francisco Basin Formations (Contributing Factors)

The following three contributing factors inherent to Sao Francisco basin formations were identified as
related to BHA whirl phenomenon:
Coefficient of friction – BHA whirl has two major formations’ physical factors contributing to its
generation, which are the coefficient of friction and coefficient of restitution explained below (Fahim,
Harmer, Harkness).2

“Coefficient of friction: acts to start the preferential forces in the BHA, which direct a non-stabilized portion in a resulting
direction due to the collar’s inertia. Essentially, the point of contact where friction is highest becomes the center of
rotation. Coefficient of restitution: is the dampening of energy based upon the hardness of the formation. Sandstones tend
to have a higher coefficient of friction and restitution, whereas shales are lower. Once the frictional forces are overcome
by surface generated torque, then the assembly accelerates and whips until it hits the opposite side of the borehole. The
process repeats itself based on the amount of energy absorbed by the borehole wall and the tool”.

During friction factor calibration performed on the operator’s wells, it was realized that friction factors
are higher in the Macaubas and Paranoa, exacerbating BHA whirl generation.
Borehole enlargement – Hole enlargement lead to a higher probability of severe lateral shocks, due to
increased room for the BHA to move and slap against the borehole wall since lower resistance to buckling
exists in this condition as a result of lost support of the borehole wall for stabilization. Borehole
enlargement also exacerbates the BHA whirl effect. Some formations drilled in the 8½⬙ hole section have
preexisting micro-fractures that tend to cave in and create caverns. In addition to bit whirl, other BHA
components will also contribute to an over-gauge wellbore because of impact with the borehole wall
(mainly stabilizers).
Formation abrasiveness – Macaubas and Paranoa formations are both very abrasive and contribute to
accelerated tool wear while drilling. Once a severe shock and vibration environment has been established,
high frequency BHA impact against the borehole wall occurred leading to a premature wear on stabilizers
blades exacerbating lateral vibrations. When the stabilizers are significantly under-gauge the occurrence
of BHA whirl increases.
SPE-169249-MS 5

Figure 3—Drilling scenario leading to S&V environments

Proposed Solution
BHA whirl is characterized by lateral vibrations creating a significant side force in contact with the
borehole wall. This side forces leads to frictional drag causing high levels of torque at contact points
which can result in stick and slip, better known as “coupled stick and slip” because it is produced by whirl
at the stabilizers.3
Based on the identified drilling scenario, it was recommended to replace the 8-3/8⬙ stabilizers with an
8½⬙ roller reamer to reduce torque-generation at the contact points (Figure 3) induced by the interaction
with Macaubas and Paranoa formations.
The use of a roller reamer (Figure 4) in the 8½⬙ hole section was expected to solve the issues due to
its:
➢ Track record of reliable performance4
➢ Variety of cutter structures with improved sealing capacity
➢ Wear resistant cutter blocks with back-reaming profile with TCI reaming inserts and extended full
gauge cutting section for superior gauge maintenance
Roller reamer application also increases drilling efficiency by:
➢ Reducing drilling torque, BHA stick slip and resultant vibration allowing the use of higher drilling
parameters
➢ Extended meantime between failures of other BHA elements
➢ Reduces tools damage related to fatigue
➢ Smooth/high quality in-gauge borehole optimizes tripping, logging, casing running
➢ Longer bit runs and improved ROP by increasing energy available at the bit (Figure 5)
A summary of the advantages related to using a BHA equipped with a roller reamer rather than an
integral blade stabilizer to drill the Macaubas and Paranoa formations (Figure 6).
Field Implementation
Drill strings used in the 8½⬙ hole sections initially included a packed BHA, a near bit stabilizer (NBS) and
two spiral integral blade stabilizer (IBS) at 7m and 25m respectively. All stabilizers were 1/8⬙ under
gauge. The packed BHA was used to maintain vertical trajectory when drilling with the high WOB
(45–50klbs) required in the hard and abrasive Macaubas and Paranoa formations (Figures 7, 8).
Shock subs were also placed in the BHAs in an attempt to mitigate axial shock that was contributing
to the extreme S&V environment (Figure 9). However, the BHA still produced high lateral vibration
levels in spite of shock sub utilization and benefits could not be measured because the sub has no sensor
to measure axial acceleration. More robust PDC bit designs were also run with downhole motors on a
packed BHA but had little affect mitigating vibration levels.
6 SPE-169249-MS

Figure 4 —Advanced sealed bearing roller reamer; three cutter assemblies enable tool optimization for specific formations

Figure 5—Drilling efficiency diagram for low and high shock and vibration environments

When drilling through Macaubas and Paranoa formations with the packed BHAs, the operator used
high drilling parameters (45–50klb, 60 – 85rpm) and vibrations values registered were above the tools
specifications of 300 –500cps (500cps maximum detection limit), however ROP performance was low at
an average of 1–1.2m/h with short runs generally less than 30m.
SPE-169249-MS 7

Figure 6 —Comparison of benefits/limitations roller reamer versus IBS

Figure 7—Two types of BHAs used to drill Macaubas and Paranoa

Figure 8 —ROP and run length comparison showing ROP and footage gains with BHA #2

On the initial wells the operator’s drilling team did not ascertain how these excessive vibration levels
negatively impacted the BHA, drill string and bits. Despite attempts to mitigate vibration levels by
changing drilling parameters, the operator left parameters in a relatively high range. Finally, after several
damage incidents that included failed, broken, washed out and parted tools, an effort to alter parameters
and evaluate results related to ROP and vibration levels. Despite achieving vibration reduction when
adjusting parameters (45rpm), vibrations values still remained above tools specifications. Vibration values
could only be reduced below 300cps with 40 rpm, but with a dramatic drop of in ROP of 50% down to
0.5– 0.6 m/h. The reduction in ROP was unacceptable and the operator continued drilling with higher
parameters despite the high vibrations levels.
After an engineering analysis that clearly defined the relationship between high vibrations and
frequency of damage incidents, the operator agreed to test a BHA with a roller reamer in the same position
8 SPE-169249-MS

Figure 9 —Parted shock sub (left) and excessive wear on the integral blade stabilizers (right)

as the IBS to reduce lateral vibration readings to specification levels. Drilling parameters would also be
adjusted to reduce vibration levels.
One of the critical factors when elected to run a roller reamer was related to tool reliability when facing
harsh scenarios. To mitigate risk, the drilling team elected to take a conservative approach with regards
to roller change-out time. This factor is validated in function of krevs at the rollers as well as durability
of the seal components. Additionally, shorting change-out time significantly increases the benefits of the
roller reamer tools. Considering the formations high UCS and abrasive nature, engineers decided to
establish a change-out time of 150 hrs. This would serve as a benchmark to build a learning curve to
determine when change-out time could be increase without compromising tool integrity.
Results Evaluation/Improvements
The introduction of 8½⬙ roller reamers into BHAs used to drill Macaubas and Paranoa formations proved
to reduce lateral vibrations from out of specification levels of 300 –500cps to levels below 100cps (Figure
10). Along with a reduction in vibration and unplanned trips, drilling efficiency improved with increases
in ROP, run lengths/BHA/bit and roller reamer life.
As a results of the positive results, the operator has adopted the roller reamer as a standard element in
the packed BHA for drilling the 8½⬙ hole section. Several of the roller reamer’s key technologies
contributed to improved performance including:
➢ Strategically placed tungsten carbide inserts (TCI) that improved the reamer’s durability by
providing extra wear protection on the upper and lower ends of the tool body
➢ Improved reaming structure retention mechanism with three sources: 1) Primary – interference
geometry; 2) Secondary – high yield cap screws (four units per roller) with controlled torque; 3)
Tertiary – retainer rings (four units per roller).
➢ Improved sealing mechanism with primary and secondary seals that provided inboard and outboard
protection
➢ Roller reamer is equipped with dual sealing technology that provides a high wear and abrasion
resistance (these are the same seals used in the provider’s premium roller cone bits)
➢ High flow body design for increased annular TFA and improved hole cleaning

Lessons Learned
The decision to replace the worn rolling reamers at the provider’s service shops proved beneficial because
it enabled a comprehensive inspection on each tool before it was delivered to the field and run. It is
common practice to have rollers replaced on location but this can lower quality standards compared to
what is achieved when the tool is properly serviced in a repair facility. Another type roller reamer was
repaired at the rig site and lost a roller in the hole which led to 6.8 days fishing NPT.
SPE-169249-MS 9

Figure 10 —Roller reamer reduce lateral vibrations below 100 cps

The use of the service provider’s extensive run records database enabled field engineers to accurately
track hours, roller krevs, seal effectiveness and wear on TCI components to achieve high tool reliability.
Gradually increasing running time up from the starting point of 150hrs/900 krevs increased hours
downhole. The increased change-out time was confirmed successful by the amount of wear observed after
the run during tool dull grading.
Conclusions
The objective to reduce shock and vibration was successful which ultimately reduced well construction
time and drilling costs. Before the introduction of the roller reamer, average run lengths were between
114ft–164ft at an average ROP of 3.0 – 4.2 ft/hr per run. Using the roller reamer along with optimized
operating parameters significantly increased average run lengths up to 246ft–295ft at an ROP of 4.9 – 6.5
ft/hr drilling the difficult Macaubas/Paranoa formations.
The gains were a result of an engineered problem solving approach that quantitatively defined the
interaction between the BHA components that were causing bit/BHA whirl leading to the severe shock
and vibration levels in the hard/abrasive formations. The engineering study identified that additional
factors (coefficient of friction, borehole enlargement and formation abrasiveness) were directly related to
the unique characteristics of the formations drilled during the shock and vibration reduction initiative.
The operator accepted the recommendations to mitigate lateral vibrations by adjusting drilling param-
eters to achieve a stable drilling condition. However, this practice alone was not enough to keep vibrations
within tool specification levels (100 –300cps) and led to dramatic ROP reductions.
The use of an 8½⬙ rollers reamer in a packed BHA reduced vibration levels from 300 –500cps to a low
level below 100cps. This reduced the number of unplanned trips related to tool failures whilst drilling
through the Macaubas and Paranoa formations. Drilling efficiency was improved as less energy was
consumed by high vibrations resulting in higher ROP and run lengths.
Running elements with moving parts in BHA components is not always welcomed nor well perceived
due to the inherent risks caused by objects left in the hole. In spite of these considerations, the roller
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reamer proved robust, durable and reliable over long runs in the challenging drilling environment. The
operator did not experience a lost-in-hole event or a fishing operations related to the roller reamer use.
Plans Going Forward
The successfully introduction of roller reamers in Sao Francisco basin has established a platform to build
a local database and capture lessons learned for transfer knowledge to other South American applications.
For future operations in Sao Francisco basin, the next recommendations are being considered:
If turbines runs are attempted, the BHA must include a roller reamer to mitigate S&V. Run a down hole
vibration analysis tool to get a better understand S&V severity as current interpretations are based on a
single axis sensor that only measure lateral vibration.

Acknowledgements
The authors would like to thank management at Petra Energia Company and Schlumberger for their
support in the publication of this paper. Also thanks to Craig Fleming, Schlumberger for his technical
writing and editorial contributions.

References
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Performance in Wells Limited by Bit and Bottomhole Assembly Vibrations” paper SPE 119375
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