Hole Opening Guidelines

Hole Opening Guidance
Document
INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE

© 2009 BP p.l.c. All rights reserved.
This document contains confidential information, which is the exclusive and proprietary
property of BP p.l.c. and affiliates. In whole or part, this document or its attachments MAY
NOT be reproduced by any means, disclosed or used for any purpose without the express
written permission of BP p.l.c. or affiliates.
Exploration & Production BP Confidential, © 2009 BP p.l.c.

Technology
E&P Segment Guide
for Hole Opening
SG No. 4.1-0001
This guide will be subject to periodic review.
Issue Date September 2009
Revision Date September 2009
Next Review Date September 2011
Technical Authority Nicholas Robertson, Drilling Modelling Specialist, EPT
Content Approval Tom Christopher, Standardization Project Manager, D&C
Authorization for Issue Scott Sigurdson, VP Drilling and Completion Engineering
Document Administrator Drilling and Completions
INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE
© 2009 BP p.l.c. All rights reserved.
This document contains confidential information, which is the exclusive and proprietary
property of BP p.l.c. and affiliates. In whole or part, this document or its attachments MAY
NOT be reproduced by any means, disclosed or used for any purpose without the express
written permission of BP p.l.c. or affiliates.
HOLE OPENING GUIDANCE DOCUMENT
CONTENTS
Contents
FOREWARD ........................................................................................................................7
1. INTRODUCTION .........................................................................................................9
1.1. Underreaming Challenges ...............................................................................................10
2. WHY UNDERREAM? ................................................................................................13
3. OPTIONS FOR HOLE OPENING ..............................................................................15

3.1. Bi-centre Bits...................................................................................................................16
3.2. Eccentric Reamers ..........................................................................................................17
3.3. Concentric Underreamers ...............................................................................................18
4. PLANNING ...............................................................................................................19
4.1. Hole Cleaning ..................................................................................................................19
4.2. Underreaming Hydraulics................................................................................................20
4.3. BHA Design ....................................................................................................................22
4.4. Bit Selection ....................................................................................................................24
4.5. Stabilization .....................................................................................................................27
4.6. Underreaming Dynamics, Vibration Modelling and Drilling Mechanics Measurements.29
4.6.1. Underreaming Dynamics .....................................................................................29
4.6.2. Vibration Modelling..............................................................................................30
4.6.3. Drilling Mechanics Measurements .....................................................................31
4.7. Anti Stall Technology (AST) ..............................................................................................34
5. EXECUTION ..............................................................................................................37
5.1. Shallow Hole Testing .......................................................................................................37
5.2. Tripping in and Drilling Cement .......................................................................................37
5.3. Activating and Opening the Underreamer.......................................................................38
5.4. Establishing the Ledge....................................................................................................40
5.5. Drilling and Underreaming Ahead ...................................................................................41
5.6. Interpretation of Real Time Data .....................................................................................43
5.7. Connection Practices ......................................................................................................49
5.8. Interbedded Formations..................................................................................................52
5.9. Confirmation of Hole Size ...............................................................................................55
5.10.Reaming off Bottom ........................................................................................................56
5.11. Reaming in Salt ...............................................................................................................59
5.12.Ratholes ..........................................................................................................................60
5.13.Hole Conditioning and Tripping Out.................................................................................62
6. CONTACTS AND REFERENCES...............................................................................63

6.1. Contacts..........................................................................................................................63
6.2. References ......................................................................................................................63
Exploration & Production BP Confidential, © 2009 BP p.l.c.

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7. APPENDICES ............................................................................................................65
7.1. Data Analysis...................................................................................................................65
7.2. Trinidad (Cashima) ...........................................................................................................66
7.3. Trinidad (Mango)..............................................................................................................68
7.4. Azerbaijan (Shah Deniz)...................................................................................................70
7.5. North Sea (Foinaven) .......................................................................................................72
7.6. Gulf of Mexico (Mad Dog)...............................................................................................78
7.7. Gulf of Mexico (Atlantis)..................................................................................................85
7.8. Angola (Urano-1) .............................................................................................................88
7.9. Vibration Mitigation Flowcharts .......................................................................................91
7.10. Symbols and Abbreviations .............................................................................................95
BP Confidential, © 2009 BP p.l.c. Exploration & Production

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FOREWORD
is one of the worlds biggest operators—in 2008 we drilled over 8 million feet of hole
BP in more than 1000 wells. These wells penetrated some of the most extreme
subsurface environments experienced anywhere, and not all were as trouble-free as we
would wish them to be. It is also worth noting that non-productive time (NPT), as a
percentage of overall drilling time, is consistently greater for wells involving hole opening
operations. There is a significant prize if we were to reduce NPT on these types of wells.
This guide is designed to convey the best guidance available in designing and executing
trouble-free hole opening operations. Its targeted audience are those who are involved in
both the planning and the execution phases of wells that require hole opening.
This Hole Opening Guide was compiled by Nicholas Robertson, Drilling Modelling Specialist,
in BP’s Exploration & Production Technology Group. Members of the Drilling Engineering
Excellence Network Leadership Team have reviewed the content to ensure SPU applicability.
I trust you will find this Guide useful in your work, as we strive to make BP the industry
leader in delivering wells that enable maximum economic recovery of BP’s world class
resource base.
Scott Sigurdson
VP Drilling and Completion Engineering
Exploration & Production Page 7 BP Confidential, © 2009 BP p.l.c.

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1. INTRODUCTION
1. Introduction
The terms “hole opening” and “underreaming” are commonly used interchangeably in
drilling and completions; however, a distinction does exist. Hole opening is the process of
enlarging the diameter of an existing borehole.
There are a number of methods by which hole opening can be achieved, underreaming being
one of these methods.
An underreamer is a particular type of tool which can be used to open a hole. They are
designed to pass through the diameter of the previous casing shoe in the closed mode.
When they reach the open hole, arms incorporating cutting structure are deployed to open
the hole to the required diameter. A concentric underreamer in the closed and open position
is shown below in Figure 1.1.
Upper Stab.
Pads
Cutter Block
Sliding
Track
Nozzle
Lower Stab.
Pads
Underreamer Arms Closed Underreamer Arms Open
Figure 1.1: Concentric Underreamer
Other tools used to open holes include bi-centre bits and eccentric reamers. Examples are
shown in Figure 1.2.
Bi-Centre Bit Eccentric Reamer
Figure 1.2: Bi-centre Bit and Eccentric Reamer

Technology
1. INTRODUCTION
There are a number of reasons why it may be desirable to open the hole to a diameter greater
than the previous casing internal diameter using such tools. In deepwater applications, the
need for multiple close tolerance casing strings drives the requirement for larger hole sizes.
A larger hole reduces annular frictional pressure drop while drilling which can consequently
reduce ECD (Equivalent Circulating Density). Surge pressures while running casing and ECD
while cementing are also reduced. In other applications, mobile or troublesome formations
such as salt or swelling shales are opened in order to reduce the potential for problems in
these formations. A more extensive list of reasons why hole opening is desirable can be
found in Section 2.
Today, the industry is trending towards using concentric underreamer tools to open the hole
as opposed to bi-centre bits or eccentric reamers. With concentric underreamers, the hole
can be opened simultaneously while drilling or on a separate run after drilling a pilot hole.
With high rig rates, the industry is trending towards simultaneous drilling and underreaming
in order to eliminate additional runs and rig time. Generally speaking, simultaneous
underreaming while drilling proves to be the most reliable way of opening a hole.
For these reasons, this guidance document focuses on simultaneous underreaming while
drilling using concentric underreamer tools. There are many technical issues associated with
simultaneous underreaming while drilling using concentric underreamer tools which must
be addressed in order to realise trouble-free operations. This is reflected in the analysis of
NPT (Non Productive Time) associated with hole opening operations, as detailed in Section
1.2.
1.1. Underreaming Challenges
One of the main complexities associated with simultaneous underreaming while drilling is
predicting and controlling where the weight applied from surface acts and the impact on
BHA dynamics. With two different cutting structures (bit and underreamer) each taking some
of the surface weight, the distribution of weight between the bit and underreamer is not
always obvious. The underreamer and the bit can be over 30m apart and drilling different
formations. Excessive weight on the underreamer can leave the pilot BHA in tension and
essentially un-stabilized at the bit, therefore free to vibrate. These vibrations can result in
reduced ROP, steering problems, reduction in hole quality or bit/underreamer/downhole tool
damage or failure. Vibrations while reaming off bottom have been found to be particularly
problematic and destructive. The complex dynamics related to simultaneous underreaming
while drilling are discussed in more detail in Section 4.6.1.
Other key issues with simultaneous underreaming while drilling are as follows:
• Hole cleaning challenges (drilling oversized hole).

• Confirmation that the underreamer has been activated.
• Confirmation that hole has been successfully opened.
• Stabilization (cannot fully stabilize above the underreamer).
• Dealing with ratholes.
BP Confidential, © 2009 BP p.l.c. Page 10 Exploration & Production

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1. INTRODUCTION
The purpose of this document is to promote best practices which have been shown to
improve the chances of trouble-free simultaneous underreaming while drilling operations.
The recommendations inherent in the document have been taken from a number of sources
including the following:
• An extensive analysis of various BP underreaming while drilling data sets (see

Section 7.1).
• Industry publications.
• Service sector documentation.
• Conversations and input with BP Drilling Engineers.

Technology
1. INTRODUCTION

Technology
2. WHY UNDERREAM?
2. Why Underream?
There are a multitude of reasons why it can be advantageous to underream a hole section;
however, it is important to realise that for the reasons described in Section 1.1, underreaming
is a more technically challenging operation. Before planning to drill and underream a hole
section, it is useful to consider 2 key questions:
1. Why do I need to underream this hole section?

2. Are there any simpler alternatives to underreaming which achieve the same
objective?
For example, you may be planning to underream a hole section in order to reduce ECD. A
potentially simpler way of reducing ECD may be to refine the mud properties (reduce mud
weight and/or viscosity). Alternatively, it may be possible to use smaller drillpipe or control
the ROP to reduce ECD to acceptable levels. Should an alternative solution which is less
technically challenging and expensive be identified then this should be progressed in
preference to underreaming. If possible, always plan a well so that it can reach its objectives
using conventional bits and BHAs and do not introduce the complexities of underreaming
unless absolutely necessary.
The following is a non-exhaustive list of reasons to underream a hole section. These can be
broadly categorized as proactive or reactive:
Proactive underreaming
• To reduce drilling ECD.
• To run close tolerance casing.
• To run expandable tubulars.
• To reduce surge pressure while running casing or liner.
• To reduce cementing ECD.
• Increased hole size for improved production.
• To combat mobile or troublesome formations such as salt or swelling shales.
• To reduce drag while tripping drilling BHAs or running casing1.
Reactive Underreaming
• To remove formation damage.
• To aid installation of contingency liners.
1
It has been shown that in some regions, casing running friction is consistently less in underreamed hole (See SPE
108427-MS)

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2. WHY UNDERREAM?

Technology
3. OPTIONS FOR HOLE OPENING
3. Options for Hole Opening

Having considered the 2 key questions in Section 2, if it is still deemed necessary to open
the hole beyond the ID of the previous casing, different options are available to achieve this.
Simultaneous underreaming while drilling using a concentric underreamer tool should be
considered the primary option. This eliminates the need for a separate hole opening run and
is generally a more reliable way of opening the hole as the pilot BHA is stabilized at the bit
resulting in less severe vibrations. This is shown below in Figure 3.1. A number of back-off
failures have been reported when opening pre-drilled pilot holes on a separate run with a
stubby pilot BHA. The mechanism for this is described in more detail in Section 5.10 which
relates to reaming off bottom.
Simultaneous
underreaming Separate run
while drilling hole opening
Pilot BHA Pilot BHA

Stabilized Un-stabilized
(on bottom) (off bottom)
Tension Compression
Figure 3.1: Simultaneous Underreaming while Drilling versus Separate Run Hole Opening
Drilling teams may choose to consider alternatives to simultaneous underreaming while

drilling if past experience supports this. As such, it is appropriate to consider the pros and
cons associated with the alternative options.
The main considerations for deciding how to open the hole are the amount of hole
enlargement required, assurance that the selected method and tools will deliver a borehole
of the required diameter, the length of rathole hole that is acceptable, the steerability of the
BHA, and the levels of vibration tolerable during operations.

Technology
3.1. Bi-centre Bits
A Bi-centre bit is shown in Figure 3.2.
Reamer
Section
Pilot
Bit
Figure 3.2: Bi-centre Bit
Advantages
Unlike concentric reamer tools, bi-centre bits benefit from having no moving parts, and do
not need to be activated. Since the pilot bit and reamer cutting structures are in close
proximity, bi-centres are less susceptible to weight stacking phenomena (see 4.6.1) than
concentric underreamers and no rathole is required beyond the casing point. Generally bi-
centre bits are a cheaper alternative to concentric reamer tools.
Disadvantages
Bi-centre bits can suffer from many issues including severe vibration due to their out of
balance geometry, and unpredictable directional response and control. They can also drill
under-gauge hole, especially in soft formations where the pilot bit is not sufficiently stabilized.
Other issues associated with bi-centre bits are poorer hole quality, lower ROP, less durability
than conventional PDC bits, restricted reaming parameters and limitations to the maximum
amount of hole enlargement possible. The maximum hole enlargement possible is
determined by the pilot bit size and the upset diameter of the eccentric blade; which in turn
is restricted by the ID of the previous casing string. BHA stiffness considerations also mean
there are limitations on the size of tools which can be run in the BHA. Any LWD tools run
behind a bi-centre bit will be logging in the enlarged hole size, potentially reducing the log
quality. With RSS (Rotary Steerable Systems), bi-centre bits may only be used with point the
bit systems and are not suitable for use with push the bit systems.

Technology
3. OPTIONS FOR HOLE CLEANING
3.2. Eccentric Reamers
An eccentric reamer with a mill tooth pilot bit is shown in Figure 3.3.
Figure 3.3: Eccentric Reamer with Mill Tooth Pilot Bit
Advantages
Eccentric reamers run close to the bit have the same advantages over concentric
underreamers as detailed for bi-centre bits (see Section 3.1). When compared with bi-centre
bits, eccentric reamers have the added advantage of flexibility of choice for the pilot bit.
When eccentric reamers are run back from the bit, this can allow the use of both point or
push the bit RSS; however, it is more common to use an eccentric reamer or bi-centre bit if
using a motor. In hard formations bi-centre bits and eccentric reamers are more likely to
deliver their designed full hole diameter than in soft formations. Depending upon the well
path (build and turn rate requirements) the steerability of bi-centre bits and eccentric
underreamers may be acceptable. Eccentric reamers are more appropriate for soft
formations than bi-centre bits because the hole-opening mechanics can be moved back from
the bit. Hard formations are challenging for both eccentric reamers and bi-centre bits due
to limited space to accommodate sufficient cutting structure at the gauge.
Disadvantages
Similarly, when compared with concentric underreamers, eccentric reamers are subject to
the same disadvantages as bi-centre bits (see Section 3.1).

Technology
3.3. Concentric Underreamers
There are a number of concentric underreamers available in the service sector for various
hole size configurations and applications. Data sets using as many different tools as possible
were analysed in order to provide recommendations for this document. Based on the data
analysis and BP experience, choosing a concentric underreamer is not a straightforward
choice. It is not simply a case of asserting that one underreamer is better than the others.
BP have had positive and negative experiences with all the major underreamer providers.
Sections 4 and 5 cover the most important aspects of trouble-free underreaming in the
planning and execution phases respectively. Paying close attention to these is more
important than choosing which type of underreamer.
Having said that, it is still important to be aware of the latest underreamer tool developments,
performance data and operational issues. For the latest specification and key features of
concentric underreamer tools, please visit the vendor websites.

Technology
4. PLANNING
4. Planning
This section deals with subjects that require close attention to detail during the planning
phase of wells which will be simultaneously underreamed while drilling.
4.1. Hole Cleaning
It is extremely important to recognize impact of the larger underreamed hole size on the
ability to clean the hole. As an example, when increasing the hole size from 12-¼” to 12-¼”
x 13-½” or from 8-½” to 8-½” x 9-½”, the amount of cuttings volume increases by 21 and
25% respectively. Additional measures to assist with hole cleaning will be required. Such
measures may be an increased flowrate, adjustment of mud properties, controlled ROP, or
changes to drilling practices.
WellPlan software should be used to predict the flowrate required for effective hole cleaning
for underreamed hole sections. An output from WellPlan showing the contrast between the
flowrates required to clean 12-¼” hole (conventionally drilled) versus 12-¼” x 13-½” hole
(underreamed) is shown below in Figure 4.1 for a deviated well. It can be seen that the larger
hole size means that for an ROP of 30 m/hr, an additional 150 GPM is required to clean the
hole.
Additional 150 GPM required

@ ROP = 30 m/hr
Figure 4.1: WellPlan Hole Cleaning Prediction
In the event that the ability to clean the hole is a limitation, ROP should be controlled to
ensure adequate hole cleaning. The maximum ROP should be explicitly stated in the Drilling
Program. This maximum ROP should be kept in mind when selecting the bit to run with the

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4. PLANNING
underreamer. The bit should always be selected to drill slower than the underreamer so that
the bit does not out-drill the underreamer, thus drilling off its WOB and causing vibration.
Wherever possible, the section should be planned such that the well is cleaned as it is drilled
without the requirement for backreaming and reaming at connections or other remedial hole
cleaning practices (See Section 5.7). With underreaming BHAs, any reaming off bottom
introduces additional risks (See Section 5.10), so it is advantageous to clean the hole while
the bit is on bottom, even if this means controlling ROP.
WellPlan should also be used to predict the ECD while drilling the section. Real time ECD
and ESD (Equivalent Static Density) data can then be compared with the predicted modelling
to assess whether the hole is being cleaned effectively. It is best to do this in real time, but
if this is not possible, post-well analysis will be valuable for future planning.
Further information about optimising hole cleaning can be obtained from the BP Hole
Cleaning Guidelines which are available on the Drilling Mechanics and Well Design Site:
https://epti.bpglobal.com/sites/DRG-Drilling_Mechanics/default.aspx
If opening a hole on a separate trip, WellPlan can be used to predict hole cleaning flowrates.
To do this, the underreamed hole size should be modelled and the ROP should be adjusted
to reflect the reduced amount of cuttings when compared with drilling a full sized hole in a
single pass.
For deviated wells, it is recommended that drag plots are produced and sent to the rig
beforehand. These can be used to monitor the effectiveness of hole cleaning.
4.2. Underreaming Hydraulics
Underreaming while drilling hydraulics are complicated by the fact that underreamers may
have nozzles to clean and cool their cutting structure. This results in a reduced flowrate
through the pilot BHA and bit when compared with a conventional drilling scenario.
When performing the hydraulics analysis, it is important not to consider underreamer

hydraulics in isolation. In addition to the pressure drop required below the underreamer,
attention must also be paid to the following:
• What flowrate is required for hole cleaning? (see Section 4.1)

• What flowrate is required to power downhole tools?
• What is the maximum allowable standpipe pressure?
• What is the maximum allowable ECD?
WellPlan 2003.16.1.17 can be used to model simultaneously underreaming while drilling

hydraulics. Note that in previous versions of WellPlan, underreaming hydraulics were not

Technology
4. PLANNING
correctly calculated and underreamers could only be modelled directly behind the bit. It is
crucial that hydraulics modelling is calibrated against field data. Training documentation
relating to hydraulics modelling using WellPlan is available on the Drilling Mechanics and Well
Design Site:
When designing the hydraulics program, the bit and underreamer nozzles should be selected
such that an appropriate percentage of the total flow (typically between 10% and 25%) is
diverted through the underreamer nozzles, with the remainder of the flow passing through
the bit. Care should be taken when performing hydraulics analysis that the nozzle setup
allows sufficient flow through the pilot BHA to power downhole tools.
The hydraulics analysis should be performed for a range of sensitivities:
• Minimum and maximum anticipated mud weights

• Range of measure depths (previous shoe to TD)
• Range of flowrates
An example of a hydraulics analysis for an XR reamer is shown below in Figure 4.2
Figure 4.2: Example Hydraulics Analysis [24]
Consideration should also be given to what happens in the event of the underreamer or bit
nozzles becoming blocked. Hydraulics programs allow users to model this situation in order
to re-calculate the flowrate at which underreamer arms deploy in the event of a blocked
nozzle. It is useful to provide this information in results of the hydraulics analysis to assist
with troubleshooting.

Technology
4. PLANNING
Higher ECD in the pilot hole, and higher levels of BHA vibrations result whenever the nozzles
of an underreamer become obstructed. Larger underreamer nozzles are less likely to become
obstructed and facilitate better cleaning of the underreamer cutting structures. These are
preferred if there is sufficient hydraulic horsepower for the bit and tools in the pilot hole
assembly.
If high ECD and the potential for pack offs is a concern, then the flow by area of the different
underreamer tools will become a consideration. Each vendor will be able to provide data on
the flow-by areas of their tools. Improving the flow by area associated with large tools such
as underreamers and stabilizers will reduce the likelihood of pack offs.
4.3. BHA Design
One of the keys to designing a BHA for simultaneous underreaming while drilling is to
understand the force distribution in the BHA. It is important to keep the reamer in
compression and avoid the undesirable result of two neutral points in the drillstring with the
reamer in the transition zone, as shown in Figure 4.3. This can lead to the rapid onset of
fatigue in the underreamer and the components close by.
Compression Tension Compression Tension
Neutral Neutral
Point 2 neutral points Point
Reamer in
transition zone
Neutral
Point
Tension Compression
Figure 4.3: Neutral Points in an Underreaming BHA

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4. PLANNING
MWD / LWD
MWD and LWD tools are best located in the pilot BHA. LWD tools produce better quality
logs in the smaller hole where the BHA stand-off is less. Drilling mechanics measurements
(vibration, downhole weight on bit, downhole torque) are more insightful when located in
the pilot BHA (this is detailed in Section 4.6.3). Placing the MWD tools in the pilot hole where
it is stabilised also reduces the bending and vibration levels to which these tools are
subjected, and thus improves the tool’s reliability.
BHA Modelling
It is important to get directional providers to model the BHA to ensure that there is sufficient
weight in the upper and pilot BHA to provide weight for both cutting structures whilst not
inducing buckling.
Modelling should also identify critical speeds, mode shapes and the distribution of bending
moments. This will assist in optimizing the BHA and identifying the best location for the
drilling dynamics measurements in the pilot BHA. BHA modelling is NOT a substitute for
real time drilling mechanics data while drilling and underreaming.
Reamer Placement
Ideally, the reamer should be placed high enough in the BHA to prevent the likelihood of the
pilot BHA being inadvertently pulled from the pilot hole. If possible design the pilot BHA so
that the lowermost stabilizer stays in the pilot hole. This is especially important if you plan to
back-ream after drilling each stand (see Section 5.7). It may also be critical to choose the
distance between bit and reamer such that other sensitive BHA components always stay
within the pilot hole (for example the steering module on an RSS tool). The downside is that
increasing the length of the pilot BHA means that the bit and underreamer can spend more
time drilling different formations, and a longer rathole is produced.
If a section is drilled and underreamed in more than one run, and a BHA change is introduced
between runs, the impact of this must be carefully considered in order to ensure the entire
section is underreamed to the required diameter. If the length of the pilot BHA is shortened,
then some off-bottom reaming will be required. Note that if the underreamer requires weight
to be activated, the pilot BHA should not be shortened between runs in order to ensure the
entire hole section can be opened.
Stabilization
Stabilization of the BHA is discussed in detail in Section 4.5.

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4. PLANNING
4.4. Bit Selection
Appropriate bit selection is fundamental to planning trouble free simultaneous

underreaming while drilling operations. The most important thing to remember is that the
bit should not out-drill the underreamer. This can lead to severe vibration in the pilot BHA,
as depicted in Figure 4.4.
Stable Underreamer while Drilling Bit Out-drilling the Underreamer
SWOB = WOB + WOR SWOB = WOB
SWOB = 20 klbs SWOB = 20 klbs
WOR = 5 klbs WOR = 20 klbs
Vibration
(Unstabilised at bit)
WOB = 15 klbs WOB = 0 klbs
SWOB = Surface indicated weight; WOR = Actual weight on reamer; WOB = Actual weight on bit
Tension Compression
Figure 4.4: Bit Out-drilling the Underreamer
In most cases, the concentric underreamer has been chosen and the engineer must choose
a compatible bit. When it comes to bits, there is a much wider choice of features / designs
and configurations compared to underreamers. It is worth checking with underreamer
providers to discern how much flexibility there is with the underreamer cutter structure. For
example, can the cutter density and cutter back rakes be altered on the underreamer to suit
the application?
It is strongly advised that you involve all stakeholders (bit supplier, underreamer and
directional providers) in the bit selection process to select a bit which is compatible with the
rest of the system. Note however there may be conflicts of interest!

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4. PLANNING
Bit Size
It is recommended to use the maximum size of bit possible according to the drift of the
previous casing. This will minimize the amount of work the underreamer is required to do
and the torque it generates, giving it the best chance of keeping pace with the bit. In general
terms, the maximum amount of enlargement recommended is of the order 25-30%.
Gauge Length
It is desirable to select a bit with a long (>3½”), non-aggressive gauge (PDC bits) in order to
provide better lateral stability to the bit. Shorter gauges should only be used if this is required
for dogleg capability or if experience has shown shorter gauges to be effective.
Bit Aggressiveness
It is recommended that the bit cutting structure is always slightly less aggressive than that
of the underreamer to ensure the bit is always drilling on bottom. If the desired ROP and
hours/footage can be achieved using a roller cone bit, then this is likely to reduce the level
of vibrations. Roller cone bits are less susceptible to torsional and lateral vibrations than PDC
bits. When choosing how aggressive the bit should be, remember there is no point selecting
a bit that can drill at 50 m/hr if hole cleaning can only be achieved at 30 m/hr.
Historically, when selecting a bit to be compatible with an underreamer, it has been deemed
sufficient to simply match the cutter sizes. Unfortunately it is not as simple as this. For PDC
bits, there are a number of bit characteristics which determine how aggressive a bit is. Many
subtle design features exist, and they can effect performance substantially, but some key
visible characteristics are as follows:
• Cutter backrake (Lower back rake = More aggressive)

• Cutter size (Larger cutters = More aggressive)
• Cutter count (Greater number of cutters = Less aggressive)
• Blade count (Fewer blades = More aggressive)2
As such, matching the bit and underreamer aggressiveness is not as simple as selecting a
bit with the same size of cutters. Bit aggressiveness can be calculated using the following
formula:
36T
m=
DW
Where m = Bit Aggressiveness
T = Bit Torque (ft. lbs)
D = Bit Diameter (in)
W = WOB (lbs)
Figure 4.5: Bit Aggressiveness
2
Note that cutter size, cutter count and blade count are all directly related, e.g. a 6 bladed bit can accommodate a
certain number of large cutters or a greater number of small cutters.

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4. PLANNING
If the aggressiveness of the reamer is known (ask the Manufacturer), then a bit with a similar
value (slightly less) of aggressiveness which meets all other section objectives can be
selected. If the underreamer manufacturer is unable to supply data for the underreamer
aggressiveness, then it can be calculated using field data. It is also possible to calculate bit
and underreamer aggressiveness from real time data using downhole WOB and downhole
torque data. Contact the EPT Subject Matter Expert for details on how to do this.
The underreamer is drilling formations which have already been drilled with the bit and as
such, the internal stresses in the rock will have been “relieved”, i.e., reduced. This usually
means that the underreamer should find the rock easier to drill that the bit did.
In some cases, the aggressiveness of the bit has been reduced by grinding wear flats onto
the cutters before shipping the bit to the rig. This is not recommended as a good solution to
matching the aggressiveness of the bit and reamer cutting structures. Always allow enough
time to work with the bit supplier and underreamer / directional provider to select or design
a bit with appropriate aggressiveness.
One bit feature which has been shown to work well with underreaming BHAs is DOC (Depth
of Cut) Control. DOC control basically makes the bit less aggressive for higher levels of
applied WOB. As the weight on bit is increased, the body of the bit (bit face) absorbs the
additional load, rather than the cutters themselves. This effectively makes the bit less
aggressive. This is illustrated in Figure 4.6.
Drilling Torque vs. Weight-on-Bit

Various 8.500 Bits
3.0
Reactive Torque (kft-lb)
2.5
2.0
1.5
Aggressiveness (slope) changes
from PDC to roller cone when
1.0 bearing contacts borehole
0.5
0
0 4 8 12 16 20 24 28
Weight-on-Bit (klb)
Figure 4.6: Bit Aggressiveness with DOC Control [25]
An example of a feature designed to control DOC is where the PDC blade tops are raised to
heights close to the cutter tip, reducing the cutter exposure. This is shown in Figure 4.7.

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Reduced
cutter
exposure
Figure 4.7: Depth of Cut Control [25]
The intention with using a bit which has DOC control in an underreaming application is that
if excessive surface weight is applied, rather than this causing the bit to out-drill the
underreamer, some of the excessive weight is absorbed by the bit body. The bit face rubs
on the bottom hole, distributing load across a large bit surface area, thus controlling the bits
aggressiveness to a narrow range, which then results in consistent ROP and bit torque.
It should be recognised that matching the aggressiveness of the bit to that of the
underreamer is one aspect bit selection. Further information about the factors which affect
how aggressive a bit is and other factors for considerations may be found in the BP Bit
Selection Guidelines. This document is available on the Global D&C Document Library:
https://epti.bpglobal.com/C17/C4/GlobalDocLib/default.aspx
4.5. Stabilization
BHA Stabilization is another fundamental reason why simultaneous underreaming while

drilling is more complex than conventional drilling. The lack of stabilization in the opened
portion of the hole means underreamer BHAs are more prone to vibration related failures.
Some of the key considerations related to the stabilization of underreaming BHAs are as
follows:
1. Directional requirements (Build, hold or drop section?)

2. Adequate buckling resistance for maximum expected WOB
3. Bending moment control
4. Torsional response of stabilizer (potential to introduce stick-slip)
5. Gauge of stabilizer, number of blades and blade type e.g. spiral or straight blade.
Directional providers should provide modelling to optimize the BHA stabilization to ensure a
predictable directional response, minimize bending moments / side load and prevent

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buckling. Information on various stabilizer configurations for different directional objectives

can be found in the BP BHA Design Guidelines. This document is available on the Global
D&C Document Library:
https://epti.bpglobal.com/C17/C4/GlobalDocLib/default.aspx
Pilot Hole Stabilization
It is highly recommended to run a slightly under-gauge (⅛” or ¼”) stabilizer directly below
the underreamer to centralize the underreamer in the pilot hole. This is still the case when
running an underreamer which has in built stabilization as this stabilizer is often under-gauge
to make the underreamer versatile across a range of hole sizes.
Other stabilizers in the pilot BHA should be placed to meet the considerations listed above.
If stick-slip from the stabilizers is known to be an issue, consider replacing with premium
sealed-bearing roller reamers.
Reamed Hole Stabilization
Placing a stabiliser of the same diameter as the pilot hole in the BHA above the underreamer
can help reduce vibration and whirling of the upper BHA. The stabilizer above the
underreamer will obviously be under-gauge according to the difference in diameter between
the pilot and underreamed hole sizes; however, it will still provide a degree of stabilization.
Expandable Stabilizers
One way to increase the stabilization in the underreamed hole section is through the use of
an expandable stabilizer. Expandable stabilizers are essentially concentric underreamers
where the blocks are configured as stabilization pads rather than with cutting structure.
Smith Rhino Reamer, Andergauge Anderreamer and Security DBS NBR have all successfully
been used by BP as expandable stabilizers to provide stabilisation in the underreamed
section of a hole.
For example, in GoM a second underreamer (expandable stabilizer, i.e. no cutting structure)
which is typically ¼" - ½" less than the gauge of the lead underreamer is used. If opening to
22" with the primary underreamer, the stabilizer underreamer is usually 21-½" - 21-¾" with
no cutting structure. GoM have learned that while drilling salt, it helps to have some PDC
cutters on the trailing edge of the stabilizer underreamer in the event you have to backream
out of a tight spot. Refer to the Well Engineering & Performance Forum (WEPF) for the latest
experience using expandable stabilizers.
Usually the introduction of the second underreamer as a stabilizer will not impact the system
hydraulics as it will not have nozzles; however, you should check this with the manufacturer.

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Eccentric Stabilizers
Reed Hycalog markets the V-Stab which is an eccentric stabilizer with 2 blades in a “V”
arrangement for use to provide stabilization behind bi-centre bits or concentric underreamers
where conventional full gauge stabilization is not possible.
4.6. Underreaming Dynamics, Vibration Modelling and Drilling

Mechanics Measurements
Downhole dynamics are the single most important aspect to understand, plan for and
control with underreaming BHAs. These “events” happen quickly and can cause tool
failures, twist-offs, and back-offs.
With conventional mud pulse telemetry, there is a limit to the MWD bandwidth available to
send Real Time (RT) data to surface while drilling. Hence, a balance must be struck between
the amount of RT FE (Formation Evaluation) data versus the amount of RT drilling dynamics
data.
Historically, more importance has been placed on FE data, with drilling mechanics
measurements sent to surface less frequently. Simultaneous underreaming while drilling is
one application where additional importance should be put on drilling mechanics data
because of the dynamic complexities introduced by the underreamer. Remember the real
time FE data won’t be available if the MWD tool fails as a result of excessive vibration! For
each underreamed hole section, consider how important it is it to have frequent FE
measurements sent to the surface. If these are not being used proactively to identify
formations and casing points, then consider sacrificing some of the bandwidth for more
detailed drilling mechanics updates. Remember, all being well, detailed FE data will be
recovered from the tool memory after the run.
Most MWD systems can be configured so that downlinks can be sent to the tool to control
what data they send. For example, you may want to configure the MWD to send detailed
drilling mechanics data while drilling and underreaming in salt, then downlink to the tool to
provide more FE data after the salt exit.
4.6.1. Underreaming Dynamics
As previously mentioned, simultaneous underreaming while drilling is dynamically a lot more

complex than conventional drilling. With two different cutting structures (on the bit and on
the underreamer) which are potentially over 30m apart and drilling different formation types,
the distribution of weight between the underreamer and the bit is not always obvious.
Excessive weight on the underreamer can leave the pilot BHA in tension and essentially un-
stabilized at the bit face, therefore free to vibrate. These vibrations can result in reduced
ROP, steering problems, reduction in hole quality or bit / underreamer / downhole tool
damage or failure. Vibrations while reaming off bottom have been found to be particularly

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problematic and destructive. Underreaming dynamics are further complicated by the fact
that the upper BHA above the underreamer cannot be fully stabilized, leaving it prone to
vibration. Some possible BHA states are depicted below in Figure 4.8.
Stable Underreamer Weight stacking Extreme weight
while Drilling on reamer stacking on reamer
SWOB = WOB + WOR SWOB = WOR SWOB = WOR
SWOB = 20 klbs SWOB = 20 klbs SWOB = 25 klbs
Buckling!
WOR = 5 klbs WOR = 20 klbs WOR = 25 klbs
WOB = 15 klbs WOB = 0 klbs WOB = 0 klbs
Tension Compression
Figure 4.8: Underreaming Weight Distribution
On the left, the applied surface weight is distributed appropriately between the bit and
underreamer. In the centre, weight begins to stack on the underreamer. This typically occurs
when the underreamer is in a harder formation than the bit. The result is that the neutral
point moves upwards, and the pilot BHA goes into tension because the bit has drilled off all
its weight. Because the pilot BHA no longer has WOB to stabilize it, it is prone to vibration.
In addition, the lack of bit torque makes the connections in the pilot BHA more susceptible
to backing off if torsional vibrations are present. The right hand diagram shows a more
extreme case where as more weight is stacked on the underreamer, the upper BHA starts
to buckle. In this situation, not only is the pilot BHA still prone to vibration, the upper BHA is
now at risk of fatigue failure.
4.6.2. Vibration Modelling
It is recommended that the directional provider carries out modelling to optimize the BHA
design and predict critical speeds. The results of modelling should be used as a guide
only and are not a substitute for real time monitoring of dynamics data while drilling
and underreaming.

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4. PLANNING
Sophisticated modelling packages such as Smith i-DRILL have proven useful to help plan
hole opening operations. It is believed that results from such modelling software can
provide useful qualitative results e.g. the predicted impact on vibration levels from moving
an underreamer closer or further form the bit. Figure 4.9 depicts i-DRILL results showing
the impact on torque and side force resulting from moving the underreamer back 24 ft in
the BHA.
Figure 4.9: i- DRILL Modelling (28)
i- DRILL can also be used to assess the impact of different bit or BHA designs, drillstrings,
and drilling/underreaming parameters on performance.
4.6.3. Drilling Mechanics Measurements
Real time drilling mechanics measurements are only useful if the personnel are trained to
understand and respond to the drilling mechanics data in real time. Interpretation of the data
is covered in Section 5.6. It is recommended that an optimization engineer who is skilled
and experienced in the interpretation of drilling mechanics and downhole pressure data be
on the rig for all critical underreaming operations.
Shock and Vibration Measurements
As a minimum, all critical underreaming while drilling BHAs should be configured to send
the following dynamics information to the surface in real time:
• RMS (Root Mean Square) Axial Acceleration

• RMS Lateral Accelerations

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4. PLANNING
• Instantaneous RPM
• Maximum RPM
• Minimum RPM
These measurements have been shown to be infinitely more useful than threshold shock
count measurements. Additional measurements such as bending moment and vibration
mode diagnostics including forward and backward whirl indicators are also extremely useful
to help identify and react to dysfunctions. Decision trees, such as those shown in the
appendix (Section 7.9) must be agreed and understood before they are sent to the rig.
Location of Dynamics Measurement Sub
Whichever drilling dynamics tool is deployed, the best location for this is in the pilot BHA.
Shock and vibration measurements from above the underreamer have been found to be less
informative than those from the pilot BHA.
Downhole WOB and Downhole Torque
It is highly recommended to run a downhole WOB and downhole torque sub in the pilot BHA
of an underreaming assembly. Such measurements are invaluable in determining the force
distribution in the BHA and where the weight and torque applied at surface is acting (see
Figure 4.3, Figure 4.4, Figure 4.8, and Figure 5.16). Schlumberger and Baker Hughes both
offer this service. Some tools downhole WOB and downhole torque measurements are
known to be very sensitive to the drilling environment and require frequent calibration. As
such, it is important that you check that the MWD operators are calibrating these
measurements as and when required.
Annular, Bore and Differential Pressure
It is highly recommended to run a downhole pressure sub for real time annular pressure
data. As explained in Section 4.1, effective hole cleaning is one of the biggest challenges
during simultaneous underreaming while drilling operations due to the larger volume of
cuttings which must be removed from the annulus. The annular pressure measurement can
be used with good effect to determine how effectively the hole is being cleaned.
If available, differential pressure across the pressure sub can provide useful data. When the
underreamer arms are deployed, some of the flow is diverted through nozzles which can be
identified by a reduced differential pressure. Hence annular and bore pressure or differential
pressure can be used in combination with hydraulics modelling to determine if the
underreamer arms are opened.
Caliper
It can be useful to have a caliper measurement (density or ultrasonic) in the pilot hole and
log the underreamed hole afterwards if time permits in order to confirm that the hole has

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4. PLANNING
been opened to the required diameter. Note that these measurements may have limits
associated with the level of standoff over which they can produce accurate results.
Data Displays
Real time drilling mechanics data and surface data should be displayed on the rig floor, in
the MWD unit and in the Wellsite Leader’s office to ensure it gets attention from all quarters.
Each service company have their own preferred displays which are usually customisable.
Some programs allow the data to be visualized alongside a representation of the BHA, as
shown in Figure 4.10. These data displays can be configured so that the drilling team in town
can access them over internet connections.
Figure 4.10: Perform Toolkit for Data Visualization [27]
This type of visualization is very helpful to help determine the location of the bit, underreamer
and stabilizers relative to formation changes while drilling and to the pilot / reamed hole while
off bottom.

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Recorded Mode Only Tools
Recently, several service companies have developed memory only dynamics subs which
can be used to record dynamics wherever they are placed in the BHA or drillstring. These
tools are designed to be non-intrusive (they come in a short carrier sub or can be installed in
a recess milled somewhere in the BHA). They are best suited to help optimize drilling
performance over the course of a program of wells or to investigate dynamics at a particular
point of interest in a BHA. A summary of the capabilities of some of the main memory only
tools can be found on the Drilling Mechanics and Well Design site:
4.7. Anti Stall Technology (AST)
As the name suggests, the AST started life as a tool designed to reduce the likelihood of
motors stalling and hence improve steering capability, predominately in coiled tubing drilling.
As RSS uptake has increased, the AST is now marketed as a solution to reduce stick-slip. It
has application anywhere stick-slip and torsional vibration is an issue, including drilling, coring
and underreaming.
The AST is very simple. Run above the BHA, a spring controls the tool length based on the
level of torque seen below. When the torque increases above a threshold, the AST retracts,
reducing the WOB and therefore torque and stick-slip. As torque reduces, the AST extends
to its original length. A schematic of the AST is shown in Figure 4.11.
Figure 4.11: AST [20]

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4. PLANNING
Tool Supply and Specification
In Norway, the tool is supplied through Halliburton but in all other areas it is supplied directly
by Tomax. The tool does not require a rig site operative, it is shipped with an electronic user
manual. The specification of the various tool sizes is as below in Figure 4.12:
Tool size Max Bit Size ID Length Connection Max Bit Torque UTS Max DLS
(in) (in) (in) (ft) (ft.lbs) (lbs) (º/30ft)
1-1/16 3 0.62 4.9 1"AMMT 200 49,000 24
2-1/8 4 0.71 4.6 1-½"AMMT 400 54,400 24
2-7/8 5 0.78 4.3 2-3/8" PAC 1,000 124,000 24
3-½ 6 0.98 4.3 2-7/8" REG 1,315 207,900 24
5 7 1.38 4.5 NC38 10,000 474,000 24
6-¾ 10 2.40 13.1 NC50 27,500 726,000 24
9-½ 17-½ 3.00 10.7 6-5/8" REG 35,000 1,024,000 15
Figure 4.12: AST Specification [20]
Underreaming Applications
Many of the AST applications (non-BP) to date have been above an underreamer. Effectively
the AST manages the amount of weight being applied to the underreamer which is one of
the keys to reducing vibration while underreaming.
Using an AST tool above the underreamer may be an effective way of controlling the weight
on the reamer and the torque it generates (see Figure 4.8). It is recommended you contact
EPT Subject Matter Experts if you plan to use this tool in an underreaming application.

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5. Execution
This section deals with areas which require close attention to detail during the execution
phase of well sections which are simultaneously underreamed while drilling.
5.1. Shallow Hole Testing
As with all MWD operations, a shallow hole test should be performed in casing in order to
ensure that the MWD tools are operating correctly, and that the underreamer arm locking
pins do not release prematurely while either circulating or drilling cement. This is best
conducted just below the rotary table at the flowrate at which it is planned to drill cement.
Pump at this flowrate long enough to confirm that the shear pins do not fail prematurely.
If an un-pinned underreamer is being run (e.g. to finish drilling a section after a trip out of
hole), then the shallow hole test should be performed at the drilling flowrate. With the
underreamer nozzles just below the mud surface, it should be possible to visually check that
the underreamer arms open at the expected flowrate. In this situation, it is useful to
incrementally increase the flowrate and record the exact flowrate at which the arms fully
open.
5.2. Tripping in and Drilling Cement
Care must be taken when tripping in and drilling cement not to prematurely open the
underreamer by setting down too much weight on a mechanically activated underreamer, or
pumping with too high a flow rate that might open hydraulically activated underreamers.
In one case, an underreamer was damaged because the driller forgot it was present in the
BHA, and the flowrate caused the tool to open inside casing which damaged the
underreamer and probably the casing. It is recommended that the underreamer operator is
always present on the rig floor when the reamer is being rotated inside casing and that a
driller awareness sign is always mounted on the drillers console with some key information
about the underreamer:
!UNDERREAMER IN HOLE!
Previous Casing Size and Depth: 16-1/2 @ 17,000 ft

Bit Size: 14-3/4
Underreamer Size: 16-1/2
Bit to Underreamer Distance: 105 ft
Flowrate to open Underreamer Arms: 800 GPM
MWD Flow Range: 800-1000GPM
Figure 5.1: Example Driller Awareness Sign for Underreamer BHA

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It is also important to be aware of the diameter and length of rat hole left by the previous
hole section BHA. It can be helpful to visualize the BHA relative to the casing shoe and
previous rathole as in the example below in Figure 5.2.
Position A:
16½ x 20 drilling BHA with bit at bottom
of rathole of previous 18-1/8 x 22
section. 9281 csg s-op
Position B: 9294 22

First stabilizer of 16½ x 20 drilling BHA
entered in gage hole after drilling 14 ft 9308 20
of new hole. 78 feet
Position C:
Second stabilizer of 16½ x 20 drilling 9332 26
BHA entered in gage hole after drilling

38 ft of new hole.
9372 18.175
35 feet 9386 16.5

Lateral vibrations (red curve) in
g_RMS (scale 0 to 10 g_RMS)
measured in BHA at point D
9401 16.5
Figure 5.2: Drilling out Previous Rathole [3]
In the example in Figure 5.2, vibrations were high until the first stabilizer entered the newly
cut gauge hole. Light weight should be applied while opening the existing rathole as the
weight on the underreamer will all be taken by the outermost cutters and the pilot BHA is
not stabilized.
5.3. Activating and Opening the Underreamer
Activating the underreamer refers to the process of shearing the pins so that hydraulic
pressure may act to open the underreamer. Opening the underreamer refers to pumping
with sufficient flowrate such that the underreamer arms are opened after activation.
Activating the Underreamer.
The most common way to activate underreamers is to drop a ball and apply pressure to
shear pins. This opens up ports to allow hydraulic pressure to act to deploy the arms. The
number of pump strokes to pump the ball should be calculated and the pressure response
should be clearly seen on surface. In the event that no indication of the pins shearing is seen
on surface, consider whether the underreamer may have been activated prematurely inside
the casing which may result in damage.
For ball activated tools in high angle wells, be aware that the ball can get hung up in larger
ID portions of the string. One way to prevent this is to use light weight balls (1.25 SG) which
move more easily with the flowing fluid.

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5. EXECUTION
Opening the Underreamer
After activation, it is important to get as much evidence as possible to confirm the

underreamer arms are opening. The evidence depends upon the type of tool, but there are
a few common signs to look out for.
Surface Pressure and Downhole Pressure

Hydraulics modelling will have identified the flowrate at which the underreamer should open.
If the underreamer has nozzles to bypass some of the flow to clean and cool the cutting
structure, the reduced flow through the BHA will result in a change in the pressure drop and
reduced differential pressure. This can be seen on surface.
If real time differential pressure information is available, this can give a very clear indication
that the underreamer has opened. Turbine RPM can also be used as an indicator - this will
be reduced when some of the flow is bypassed through the underreamer nozzles.
It is good practice to stage up the pumps and record the exact flowrate at which the
underreamer arms are opening. The hydraulics modelling carried out in the planning stage
will have provided a guide as to the flowrate required to open the underreamer; but this way,
a more exact flowrate can be obtained. This flowrate should be annotated on the driller
awareness sign (See Figure 5.1). Ensure that the flowrate does not drop below this threshold
at any time while underreaming and drilling.
An example showing how surface and differential pressure can be monitored to confirm
successful opening of the underreamer is shown in Figure 5.3.
DEPTH WEIGHT TORQUE ROTATION BENDING FLOW PRESSURE

Surface
0 rpm 400
Bit Depth Surface BHA Minimum Bending
## ft ## 0 klbf 40 0 rpm 400 0 40
ROP Downhole Surface BHA Maximum C/P Lateral gs Standpipe
0 ft/hr 200 0 klbf 40 0 klbf 30 0 rpm 400 8 0 0 psi 6000
Gamma Ray Axial gs Downhole Whirl BB Lateral gs Flow In CoPilot Differential
0 API 100 1 0 0 klbf 30 0 rpm 400 8 0 0 gpm 1500 800 psi 1400
10700 16:40
05 Jan
Reduction in SPP
17:00
10700
05 Jan
Reduction
in Delta P
10700 17:20
05 Jan
10700 17:40
05 Jan
18:00
10700
05 Jan
Figure 5.3: Activating and Opening a Hydraulically Activated Underreamer

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At 16:40, the drill string is being rotated 60rpm while pumping the ball down to the
underreamer at the desired depth to start the underreaming. As the ball approaches the
underreamer, the flow is reduced until a standpipe pressure increase indicates that the ball
is has seated in the underreamer (at 17:10). The flow is then increased to shear the pins and
open the underreamer arms. The reduction in standpipe and differential pressure are evident
now that some of the flow is bypassing the pilot BHA.
Downhole WOB and Downhole Torque

If correctly calibrated, the separation will increase between surface WOB and downhole
WOB when the underreamer is activated. Increasing SWOB and DWOB separation indicates
that the reamer is taking some of the weight applied on surface. The same is true of torque.
Note that particularly in soft formations, the reamer may not generate a lot of torque making
this response difficult to see.
Figure 5.4: Confirmation of Underreamer Activation using

Downhole WOB and Torque Data [3]
5.4. Establishing the Ledge
After successful activation and opening of the underreamer as described in Section 5.3, the
ledge can be established. Establishing the ledge is an operation that poses a high risk of
backing off pilot assembly connections. When the underreamer is first opened it can either
be in the rat hole from the previous well section (see Figure 5.2), or in the new hole section
where it immediately establishes a ledge. Usually the pilot bit will not be bearing any
weight, so the rotary speed must be kept at around 60 RPM to avoid the risk of
torsional shocks backing off the pilot BHA connections (see Section 5.10). Downhole
vibration, whirl and stick-slip should be closely monitored to ensure that they remain
at acceptable levels.
When the ledge has been established, this should be confirmed by either setting down
weight or applying a modest overpull (generally 10-20 klbs used). After stopping the pumps

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(to close the underreamer arms) verify that the underreamer can move freely up and down
past the ledge.
After cutting the ledge, pull back through the casing shoe to establish that the underreamer
arms are retracting when the pumps are shut down.
5.5. Drilling and Underreaming Ahead
General
Five key operational recommendations while simultaneously underreaming while drilling are:
1. Keep the surface weight below the upper BHA bending limit (Use WellPlan to
model buckling)
2. Drill off the weight and reduce the rotary speed each time before lifting off bottom
(See Section 5.7)
3. Maintain weight-on-bit when drilling with a high rotary speed (increase surface
weight gradually)
4. Ensure stick-slip and vibration do not exceed acceptable limits both when on and
off bottom
5. Avoid whirl and carefully lower stabilisers past the ledge when reaming into the
pilot hole
Drilling and Underreaming Optimization
Soon after the ledge has been established and underreaming while drilling is progressing, it
is recommended to carry out finger-print tests to determine optimum parameters for surface
WOB and RPM values. Finger-print tests essentially involve drilling with different
combinations of surface WOB and RPM whilst closely observing the ROP, downhole vibration
and stick-slip responses. The combination of drilling parameters that maintains acceptable
levels stick-slip and vibration with optimal ROP should be used. Note that the ROP should
not exceed the maximum ROP at which hole cleaning can be achieved (See Section 4.1)
Drilling Ahead - Maintaining constant WOB
Drilling should proceed with an appropriate surface weight for the bit and underreamer
cutting structures in the particular formation(s) being drilled. Care must be taken at all times
to ensure that not too much weight is stacked on the underreamer such that the upper BHA
section bends and whirls, resulting in undesirable levels of stick-slip and vibration (See
Section 4.6.1). If rig heave is excessive and the compensators cannot properly compensate
for the rig movement, it can be difficult to maintain constant WOB and there is an elevated
risk of vibration and connection back-off. Additional attention should be paid to dynamics,
and in extreme cases, drilling should be stopped until conditions improve.

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Picking Up Off Bottom
If, for any reason while drilling and underreaming, it is necessary to pick up off bottom, the
weight and torque on the bit and underreamer should first be drilled off. To do this, drill and
underream with the string in a fixed position until the surface hookload and torque return to
their free-rotating values. RPM can then gradually be reduced to 60 before coming off bottom
to the required depth.
The example in Figure 5.5 highlights the importance of drilling off the bit weight and torque
before coming off bottom. The sudden change in BHA torque while coming off bottom induced
large axial, and lateral vibrations, as well as torsional oscillations in excess of 7kft-lbf at surface.
This resulted in a connection back-off in the pilot BHA. More details on the incident can be
found in Section 7.3. If picking up off bottom should initiate observable large fluctuations in
the surface torque, drill string rotation should be gradually (not abruptly) stopped entirely.
DEPTH WEIGHT TORQUE ROTATION FLOW PRESSURE

Whirl Axial gs Lateral gs Reverse Maximum
100 rpm 300 1 g 0 10 g 0 1 00 rpm 300
Bit Depth Downhole Bending Downhole Minimum
## ft ## 0 klbf 25 0 kftlbf 50 0 kftlbf 25 0 rpm 300
Block Height Surface Tangential gs Surface RPM Flow In Standpipe Pressure
120 ft 0 0 klbf 25 300 g 0 0 kftlbf 25 0 rpm 300 0 gpm 1500 0 psi 5000
20:10
8810 15Feb
20:21
8830
15Feb
20:38
8820 15Feb
20:40
8820 15Feb
20:50
8840
15Feb
21:00
Connection
8830 15Feb Back-off
Figure 5.5: Back-off Event
Remedial Action when Drilling
The drilling process has a transient nature, with many intermittent torque shocks, vibration,
whirl and pressure spike events. The frequency with which various downhole parameters
are transmitted to surface depends upon the type of MWD tool used and the configuration.
Ideally the downhole stick-slip, whirl, vibration or pressure measurements should be
transmitted to surface at least every 30 seconds or less. In this case, the driller should wait
for confirmation that an excessive downhole condition was not just a transient that mitigates
itself before taking remedial action. If the transmission interval to surface of the drilling

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related parameters is more that 30 seconds, then the driller may not have the luxury of
waiting on confirmation of transients and should take remedial action immediately if any
excessive downhole condition is observed.
Vibration Mitigation flowcharts are available in Section 7.9. These have been developed to
minimize the impact of BHA and drillstring vibrations whilst avoiding running downhole
equipment out of specification and the charges that are associated with that.
5.6. Interpretation of Real Time Data
A key point to remember is that real time data is only useful if personnel who are
skilled in its interpretation are analyzing the data and taking actions based on what
the data is telling them.
Annular Pressure
During simultaneous underreaming while drilling, the enlarged hole size means that there is
a greater volume of cuttings to remove compared with drilling conventional hole sizes. Real
time annulus pressure data (in conjunction with other surface measurements) can be
extremely valuable to help evaluate the effectiveness of hole cleaning. The interpretation of
annular pressure data is a subject itself, too extensive to be covered in this document.
Training material on the interpretation of annular pressure data is available the Drilling
Mechanics and Well Design Site:
Differential Pressure (Bore - Annulus)
If available, differential pressure data can be used to indicate whether the underreamer is
opening successfully. As the underreamer arms are opened, flow is diverted through the
underreamer nozzles, therefore reducing the flow through the BHA and the differential
pressure across the downhole pressure sub located in the pilot BHA. Similarly a reduction
will be evident on the standpipe pressure; but this is more difficult to see as the % reduction
will be less than the % reduction in differential pressure.
If the differential pressure while opening the underreamer is less than expected (normal
flowrates) it could mean that the underreamer arms have not fully opened. If you suspect
that an interval has been drilled but not fully underreamed, the interval should be re-reamed
at low RPM (see Section 5.10)
An increase in differential pressure (without change in flowrate) while drilling and

underreaming could mean that the nozzles in the underreamer or bit may have become
plugged. This should have been modelled during the planning stage (see Section 4.2). Note
that a plugged nozzle will change the flowrate at which the underreamer arms are opened.

Technology
5. EXECUTION
Surface and Downhole WOB and Torque
Downhole WOB and downhole torque are perhaps the most useful measurements to help
diagnose downhole dynamics issues during underreaming while drilling (see Section 4.6.1).
When these tools are located in the pilot BHA close to the bit, they effectively read the
amount of WOB being transmitted to the bit and the amount of torque being generated by
the bit. The difference between the surface and downhole WOB can be assumed to act at
the reamer, as shown in Figure 5.6. Note that in order to infer what the reamer torque is,
the free rotating torque must be known:
Reamer Torque ≈ Surface Torque - Downhole Torque - Free Rotating Torque
If you assume the reamer torque to be constant, you can expect to see the separation
between surface and downhole torque grow with depth as the free rotating torque increases.
Weight on Reamer Torque =

Reamer Free Rotating Torque
Figure 5.6: Interpretation of Downhole WOB and Torque Data [3]

Technology
5. EXECUTION
Figure 5.6 shows a typical downhole WOB response as the bit drills through a hard layer,
and then the underreamer reams through the same layer.
At point 1, the bit and underreamer are drilling in a stable manner. Surface WOB is
approximately 15 tonnes, and approximately 10 tonnes of this is acting on the bit and 5
tonnes on the reamer. At point 2, the bit has encountered a hard formation, hence it can be
seen that all the applied surface weight goes to the bit. (See also Figure 5.13). At point 3,
the bit has drilled through the hard formation and the weight on the reamer is restored. It
can be seen that at this point the ROP increases. At point 4, the underreamer has reached
the same hard formation. It can be seen that at this point surface and downhole WOB
diverge, indicating that the underreamer is taking more weight. At point 5, the reamer has
drilled through the hard formation, and the weight acting on it is reduced.
Downhole WOB trends can also be used to identify cutter wear on the bit and the
underreamer. If the separation between the surface and downhole WOB gradually decreases,
this can indicate that the underreamer cutting action is becoming less efficient. In the
example shown below in Figure 5.7, this was confirmed when the underreamer was pulled
out of hole revealing worn cutters.
Figure 5.7: Wear on Underreamer Cutters
Further insights into the cutting efficiency of the bit and underreamer may be obtained by
calculating and plotting the Mechanical Specific Energy (MSE) at the bit and at the
underreamer. MSE is calculated using the following relationship:

Technology
5. EXECUTION
Energy Expended
MSE = [Units psi]
Volume of Rock Removed
WOB 120p * Torque * RPM

MSE = +
A A * ROP
MSE = Mechanical Specific Energy (psi)

WOB = Weight on Bit or Reamer (lb)
Torque = Torque at Bit or Reamer (ft.lb)
RPM = Bit RPM
ROP = ROP (ft/hr)
A = Area of hole drilled by Bit or Reamer (in2)
Figure 5.8: MSE Calculation
For details on the calculation and interpretation of MSE trends, contact the EPT Subject
Matter Expert.
It is important to be aware that downhole WOB (and to a lesser extent downhole

torque) measurements require careful and frequent calibration. One tell-tale sign that
the calibration has not been carried out properly or frequently enough is if downhole weight
on bit or downhole torque read higher than their respective surface measurements.
One issue with the accuracy of downhole weight on bit measurements is their response in
deepwater environments. An example of this is shown below in Figure 5.9 for the Baker
Hughes CoPilot tool.

Bit Depth Surface Weight Surface RPM
17300 ft 17400 0 klbf 40 0 rpm 400
ROP Downhole Weight BHA Minimum C/P Lateral gs
0 ft/hr 200 0 klbf 40 0 rpm 400 8 g 0
Bit Depth Hookload Surface Torque BHA Maximum Bending Standpipe
## ft ## 300 klbf 500 0 klbf 30 0 rpm 400 0 40 0 psi 6000
Block Speed Axial gs Downhole Torque Bending RPM BB Lateral gs Flow In CoPilot Differential
-10 ft/min 10 1 0 0 klbf 30 0 rpm 400 8 g 0 0 gpm 1500 800 psi 1400
12:00
14400
08 Jan
13:00
14400
08 Jan
14:00
14500
08 Jan
Figure 5.9: CoPilot Deepwater Response

Technology
5. EXECUTION
It can be seen from Figure 5.9 that after each connection there is a large drift in the downhole
WOB measurement. During a connection the column of mud in the riser cools considerably.
As the cooler mud circulates through the CoPilot tool, the temperature gradient across the
body of the tool increases. It takes time for the temperature to stabilize and for the cooler
mud to pass through the tool. It is important that this response is not mistakenly interpreted
as inefficient weight transfer to the bit. Note that the downhole torque response is not
subject to such effects.
In applications where changing conditions (temperature, pressure, flowrate etc) make it

difficult to maintain a good calibration on the downhole WOB tool, the qualitative response
can still be useful to help determine the proportions of weight and torque generated by the
bit and underreamer.
Rotational Stick-Slip
The various MWD service companies, and even the same MWD service company with
different tool designs, compute real-time downhole stick-slip measurements and severity
levels differently. In order to make correct use of the data, the stick-slip measurements which
are being transmitted to the surface in real-time must be fully understood.
Stick-slip measurements are all related to the variation in the speed of BHA rotation when
the surface rotation is held constant. A large variation in the speed of BHA rotation is
generally caused by insufficient drill string inertia (surface RPM) to overcome torsional
friction, bit torque, underreamer torque and torque resulting from any other downhole drilling
dysfunction (e.g. drill string whirl or poor hole cleaning).
Large variations in the rotational speed of the BHA while underreaming can result in the drill
sting connections over-torquing (downhole make-up) and/or drill string connections backing-
off – especially the connections within the pilot BHA (See Section 5.10). The minimum
downhole rotation speed should be kept as close to the surface rotary speed as possible
and not permitted to fall below a minimum limit. Any time the minimum downhole rotation
speed is zero or even negative, the amount of stick-slip is excessive. Backward rotation is
extremely damaging to PDC cutters so should never be tolerated.
As discussed previously, stacking too much weight on the underreamer can cause the upper
BHA to bend and/or whirl and induce large amounts of stick-slip. Similarly too great a depth
of cut of either the bit or underreamer cutting structures can result in an increase in torque
and also induce large amounts of stick-slip. In both cases the weight-on-bit and penetration
rate (or block speed if off bottom) should be decreased.
In the event that there is excessive stick-slip without any indication of whirl or excessive
lateral vibrations, it may be appropriate to increase the surface rotary speed in order to
overcome the cumulative torsional drill string forces.

Technology
5. EXECUTION
An example of severe stick-slip resulting from excessive weight is show in Figure 5.10.
Increased WOB Stick-Slip
Figure 5.10: Extreme Stick-slip
Lateral Vibration
The various MWD service companies, and even the same MWD service company with
different tool designs, compute real-time downhole vibration measurements, shock and
severity levels differently. Some vibration tools count “shocks” or the number of instances
of axial accelerations above a fixed threshold (Schlumberger commonly uses a 50G threshold).
Some tools make linear averages, where as some tools transmit maximum values, and other
tools RMS averages. In order to make correct use of the data it must be known and
understood which measurements are being transmitted to the surface in real-time.
How a vibration sensor is mounted within its MWD tool and where the MWD tool is located
in the BHA both have a significant effect on the levels of vibration that are detected. In
general, shock sensors detect large acceleration events, but do not measure the duration or
severity of the accelerations. Downhole tools often fail when greater amounts of energy are
dissipated over a longer duration, but frequently with little indication of “shocks” from the
MWD tool because the shock accelerations are below the MWD sensor threshold. The
averaged lateral vibration style sensors provide the most consistent overall indication of the
severity of the downhole drilling environment.
Whirl, chaotic shocks and resonant vibration can each create high vibration levels. Drillers
should establish an acceptable and normal vibration level for a particular BHA design, hole
inclination, operational mode (e.g. drilling of backreaming) and formation type. It is common
for transient vibration events to occur, but drillers should ensure that severe vibration levels

Technology
5. EXECUTION
are not permitted to persist for more than two sequential real-time values (depending on
data transmission rates). In the event that severe downhole vibrations should persist for two
sequential real-time values, immediate remedial action should be initiated (See Section 7.9).
An example of severe whirl and lateral vibration while rotating of bottom is shown in Figure
5.11.
Lateral
Vibrations
Figure 5.11: Severe Whirl and Lateral Vibration
5.7. Connection Practices
Connection practices differ between one rig and the next within BP. Generally speaking,
connection practices are based on what has delivered success in the past (in terms of
successful drilling, tripping and casing installation). The main differences between connection
practices relate to whether to wipe or ream stands or joints after drilling each stand and the
parameters used while wiping or reaming. These differences are essentially driven by hole
conditioning requirements.
The Ideal Connection Procedure
Ideally, the combination of parameters while drilling and underreaming (flowrate and RPM)
will be sufficient to clean the hole. In this ideal case, no remedial hole conditioning measures
should be required after drilling each stand. In this case, the trip out of hole at section TD
will be trouble-free, and casing will be successfully installed at the required depth.

Technology
5. EXECUTION
For this ideal situation, the connection practice would be as follows:
1. Drill off the last 10 ft of the stand at drilling RPM until hookload and torque return
to their free rotating values. Monitor DWOB (Downhole Weight on Bit) and DTOR
(Downhole Torque) if available to confirm the bit weight and torque have been
drilled off1.
a. Record rotating weight and torque
2. Stop rotation gradually, keep pumps on.
3. Pick up for one single, (no RPM) with drilling pump rate, watching for drag.
a. Record pick up weight and compare with modelled predictions2
4. Run back in (no RPM) with drilling pump rate, watching for drag
a. Record slack off weight and compare with modelled predictions2
5. Take the survey and make the connection
6. Gradually build up rotation to 90 RPM to break gels. Bring up pumps. tag bottom
and gradually build up to drilling RPM and WOB
7. Drill ahead
Remedial Hole Conditioning Measures
In reality, drilling parameters are often insufficient to provide favourable hole conditions for
tripping and subsequent casing running. Drilling flowrate may be limited by factors such as
surface pressure limitations or pump capacity where as RPM may be limited by downhole
tool limitations or casing wear concerns. In such situations, remedial hole conditioning
measures need to be figured into connection practices.
The following connection procedure was developed in collaboration with BP Trinidad, and is
designed to challenge backreaming and reaming down every stand as a standard practice
minimizing the amount of off-bottom reaming. Often such practices are carried out for historic
reasons, without robust technical justification.
The risks associated with backreaming and reaming with underreaming BHAs are discussed
in detail in Section 5.10. Note that the backreaming and reaming RPMs quoted in the
procedure may not necessarily be applicable to all operations. Actual backreaming and
reaming RPMs will depend upon downhole tool limitations, connection specification,
reactive torque generated, hole cleaning requirements etc.
1
If drilling off weight and torque results in excessive vibration, pick slowly off bottom before weight has completely
drilled off.
2
It is important that the process of taking pick up and slack off weights is performed in a consistent manner. The
string should be picked up or slacked off at a constant speed over one joint or until a steady drag reading is achieved.
When picking up, ensure that the pipe stretch has been taken out of the string. For consistency, pick up and slack
off weights should be taken at the same depth.

Technology
5. EXECUTION
Connection Procedure with remedial hole conditioning:
1. Drill off the last 10 ft of the stand at drilling RPM until hookload and torque return
to their free rotating values. Monitor DWOB (Downhole Weight on Bit) and DTOR
(Downhole Torque) if available to confirm the bit weight and torque have been
drilled off.1
a. Record off bottom rotating weight and torque
2. Stop rotation gradually, keep pumps on
3. Pick up for one single, (no RPM) with drilling pump rate, watching for drag.
a. Record pick up weight and compare with modelled predictions2
4. Run back in (no RPM) with drilling pump rate, watching for drag
a. Record slack off weight and compare with modelled predictions2
5. If no overpulls have been experienced3
a. Take survey and make connection
6. If overpulls are experienced
a. Return to bottom and gradually increase to 120 RPM. Backream the stand to
move cuttings away from the BHA. Backream at 120 RPM, whilst monitoring
real time vibration, stick-slip and ECD data closely. Backreaming speed should
be controlled such that ECD does not become excessive.
b. At the top of stand, reduce the RPM to zero prior to changing direction for
washing back down.
c. Wash back down to bottom.
d. If while washing down, drag or ledges are encountered, it may be necessary
to lightly ream past these at low RPM. Ream back down at 60 RPM whilst
monitoring real time vibration and stick-slip (change RPM if vibration or stick-
slip are experienced). It is important that the driller is aware of the location of
large diameter components such as stabilizers if reaming back to bottom, and
their location with respect to the pilot hole ledge (See Section 5.10). There
should be no need to tag bottom.
7. Take survey and make connection
8. Gradually build up rotation to 90 RPM to break gels. Bring up pumps, tag bottom
and gradually build up to drilling RPM and WOB
9. Drill ahead
Figure 5.12 below illustrates poor connection practices. In this case, the RPM was reduced
while backreaming and increased while reaming down. This resulted in significant backward
whirl (Bending RPM, orange in track five) as well as significant axial and lateral vibrations
(red in tracks two and six).
3
Note that drilling ECD and ESD may also be used as well as observing overpull to assess whether backreaming
and reaming of stands is necessary.

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5. EXECUTION

Surface Torque Surface RPM
0 kftlbf 25 0 rpm 400
Block Height Surface Weight Downhole Torque BHA Maximum

120 ft 0 0 klbf 25 0 kftlbf 25 0 rpm 400
Rate of Penetration Downhole Weight Maximum Surface Torque BHA Minimum Lateral gs Standpipe Pressure
0 200 0 klbf 25 25 klbf.ft 50 0 rpm 400 10 g 0 0 psi 5000
Depth Axial gs Minimum Surface Torque Bending RPM Bending Flow In Differential Pressure
## ft ## 1 g 0 25 klbf.ft 50 0 rpm 400 0 klbf.ft 50 0 gpm 1500 500 psi 1500
16:50
8540 15Feb
17:00
8470
15Feb
17:10
8540 15Feb
Figure 5.12 : Poor Connection Practice
5.8. Interbedded Formations
There is a greater likelihood of vibration when drilling non-homogeneous formations,

particularly when the bit and underreamer are in different formations. It is critical that the
driller records the measured depths of all stringers and is aware of the position of the
underreamer and stabilizers relative to these. The dynamics associated with drilling and
underreaming interbedded formations is illustrated in Figure 5.13 below.

Technology
5. EXECUTION
Stable Underreamer while Drilling Stable underreaming while drilling Weight stacking on reamer
(bit in hard formation) (bit and UR in same formation) (UR in hard formation)
SWOB = WOB + WOR SWOB = WOR SWOB = WOR
SWOB = 20 klbs WOB = 15 klbs

SWOB = 15 klbs
WOR = 0 klbs
WOB = 15 klbs
WOR = 5 klbs WOB = 15 klbs
Vibration
(unstabilised at bit)
WOB = 15 klbs WOB = 0 klbs
Tension Compression
Figure 5.13: Drilling and Underreaming Interbedded Formations
Bit in Hard Stringer, Underreamer in Soft Formation
On the left side of Figure 5.13, the bit encounters a hard formation. In this instance, WOB
should be reduced to prevent stick-slip or the BHA being kicked off. It is also advisable to
decrease RPM to ensure that the underreamer does not drill an over-gauge hole. The driller
should note the start and end depths depth of the stringer and calculate the depth at which
the underreamer will reach the stringer and ream through the stringer.
Bit and Underreamer in Same Formation (Underreamer Approaching Stringer)
The centre of Figure 5.13 shows stable underreaming with the bit and underreamer in the
same formation. The underreamer is approaching the stringer. By controlling the ROP as the
underreamer approaches the stringer (drop RPM and WOB), sudden vibration spikes of
stalling can be avoided.
Stringers can be reamed a second time for assurance that they have been opened to full
gauge if past experience suggests this is necessary.
Bit in Soft Formation, Underreamer in Hard Formation
On the right hand side of Figure 5.13, the underreamer encounters the hard layer, and the
applied surface weight stacks on it. The bit drills off, leaving the pilot BHA in tension, free to
vibrate. Whirl vibration is particularly likely in this situation, as such, RPM should be reduced

Technology
5. EXECUTION
to a level that does not induce any whirl. The amount of WOB applied from surface should
also be reduced to prevent the underreamer inducing stick-slip.
The example in Figure 5.14 illustrates this type of behaviour. It can be seen that when the
reamer reaches the sand, lateral vibrations become excessive and stick-slip is also
experienced. These vibrations terminate when the reamer exits the sand.
Reamer
Bit
Reamer
Bit
Figure 5.14: Drilling and Underreaming Interbedded Formations

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5. EXECUTION
5.9. Confirmation of Hole Size
Section 5.4 describes the recommended procedure for establishing the ledge having
activated the underreamer and opened the arms. This does not in itself, however guarantee
that the entire section has been underreamed to the required hole size as per the plan. If
the underreamer arms have not been fully opened or if the underreamer cutters become
damaged or worn, then this can result in under-gauge intervals of hole.
LWD calipers
One way to determine whether or not the hole has been opened successfully is to run an
LWD caliper. You must first check with the specifications that the caliper can accurately
determine the required hole size. Ultrasonic or density calipers usually have a maximum
standoff at which they can give reliable results. Since the LWD caliper is most likely to be in
the pilot BHA, logging the underreamed hole size needs to be performed off bottom.
Figure 5.15 shows a reaming pass from an LWD caliper in 8-½” x 9-⅞” hole, confirming
successful opening of the hole. Note that this application used wired drill pipe, so high real
time data transmission rates were possible.
All calipers showing shoulder

Ultrasonic (brown) and density and good hole where bit drilled
caliper (blue) showing in gauge hole is entered with LWD tool
drilled hole
Reamed interval with

caliper sensor (18m
behind bit)
~ 3647-3676 m
3659 - depth to which

underreamer cut
Figure 5.15: LWD Caliper Measurements from a Reaming Trip

Technology
5.. EXECUTION
Fluid Calipers
Circulating lag time/volume can provide a general idea of the overall hole size, but is not
accurate enough to pinpoint short intervals where the hole may be under-gauge.
Wireline Calipers
If it is absolutely critical to confirm the underreamed hole size, for example if the bit and
underreamer have come out under-gauge, then a wireline caliper is the best way to ascertain
the actual hole size.
5.10. Reaming off Bottom
As per the recommended connection practices detailed in Section 5.7, backreaming and
reaming off bottom after connections should only be performed if deemed absolutely
necessary. In some situations, it may be necessary to ream off bottom. In this case, the
recommendations in this section are designed to minimize the risks.
Consider what is happening when the BHA is being rotated off bottom, e.g. if backreaming
/ reaming down is performed after drilling each stand. This is shown below in Figure 5.16.
Stable Underreamer while Drilling Backreaming Reaming Down

(stab. taking weight)
SWOB = WOB + WOR
SWOB = 20 klbs
Vibration
(unstabilised)
Vibration
(unstabilised)
SWOB = 5 klbs Torsional
Stabiliser takes
weight on ledge
Vibration
SWOB = 15 klbs
Tension Compression
Figure 5.16: Reaming off Bottom
Stable underreaming while drilling is shown on the left hand side of Figure 5.16. The centre
diagram shows the BHA while backreaming which is completely in tension. With the pilot

Technology
5. EXECUTION
BHA now in the enlarged hole, it is no longer fully stabilized and free to vibrate, especially
whirl.
The right hand diagram shows what can happen while reaming down. If weight is taken by
one of the large diameter components such as the underreamer biting into the borehole wall
or a stabilizer hanging up on the ledge, this can cause a rapid reduction in the downhole
RPM at that point (note that this downhole reduction may not be visible on surface). The
resulting lateral and torsional shock can cause connections below the component taking
weight to back-off, as there is no bit torque to counteract the torsional shock.
Reaming down is a more risky operation with an underreaming BHA than backreaming;
hence, reaming down should be performed at reduced RPM. With the string in tension
(backreaming), the BHA is less distorted and less likely to come to a halt. While reaming
down, if one of the large diameter components such as the underreamer takes weight, the
compression can result in increased wall contact which further suppresses the rotation and
increases the chance of lateral shock, reactive torque & back-off / connection damage.
The example in Figure 5.17 from Immortelle in Trinidad shows the block position at which a
stabilizer is entering and re-entering the pilot hole, and the correlation with high lateral
vibration and stick-slip:
Figure 5.17: Reaming off Bottom - Stabilizer Entering and Re-entering Pilot Hole

Technology
5. EXECUTION
For these reasons, while reaming down, the driller must be aware of locations of stabilizers
and other large OD components in the pilot BHA and take extreme care (slow the block
speed) as these are moved into and out of the pilot hole. Exercise the same care as large
OD components pass any hard stringers which may have been encountered.
Underreamer manufacturers can provide charts which show the reactive torque (y-axis)
generated as the underreamer rotating at a certain RPM (x-axis) stalls. An example is shown
for a 14-¾” Anderreamer tool in Figure 5.18.
Figure 5.18: Anderreamer Reactive Torque Chart
This can be compared with the torque which the connections in the pilot BHA are made up
to. Making up the pilot BHA connections (including modular connections on MWD and LWD
tools) to higher make up torques will mitigate against back-offs. Strap welding connections
below the underreamer to prevent back-offs is NOT recommended because this can have
an adverse effect on the properties of heat treated carbon steel.

Technology
5. EXECUTION
As a general rule of thumb to minimize the chances of connections backing off, the BHA
should not be reamed down at RPM greater than 60.
Backreaming can be done at higher RPM because with the BHA and string in tension, there
is less chance of the BHA stalling out.
Because of the likelihood of damaging BHA dynamics while backreaming and reaming with
underreamer BHAs, it is critical to pump at a flowrate sufficient to power the MWD tool to
send real time data while backreaming connections. Vibration and stick-slip data should be
monitored closely at all times while reaming off bottom.
5.11. Reaming in Salt
Salt can be a troublesome formation to due to its plastic and mobile nature. As such, it is
often underreamed, the larger hole size helping to mitigate the problems. Salt is known to
have UCS (Unconfined Compressive Strength) in range of 3,000 to 3,500psi however,
significantly higher weight on bit (WOB) and torque are required when drilling salt (compared
to other formations of similar UCS) due to the plastic nature of the salt. As such, vibration
and stick-slip are likely to be at their highest levels in salt. An example of lateral vibration
data while drilling and underreaming salt is shown in Figure 5.19.
9 90
CoPilot Average Lateral Acceleration - 1 Second RMS
8 CoPilot Gamma Ray - Apparent 80
WOB
7 70
Lateral Acceleration (gRMS)
6 60
GR (API)/WOB (klbs)
5 50
4 Salt
40
3 30
2 20
1 10
0 0
6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
Depth (ft)
Figure 5.19: Underreaming while Drilling in Salt (29)

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5. EXECUTION
It is good practice to maximize the amount of real time vibration data while drilling the salt
section. Downlinks may be sent to change the MWD setup after salt exit. It is common
practice to downlink to modify the MWD setup to send more information to help determine
pore pressure (e.g. sonic) after exiting the salt.
The top and base salt can clearly be seen on the gamma ray trace; however, there are other
early indicators. At the top of the salt section, an increase in torque and reduction in ROP is
experienced. The depth of the top salt should be noted and ROP should be controlled until
the entire BHA including the underreamer has been buried in the salt. During this time it is
critical to closely monitor drilling parameters, vibration and stick-slip.
If inclusions are present in the salt, then the advice related to interbedded formations applies
(Section 5.8).
On approaching the prognosed base of salt, the ROP should be reduced, and the drilling
parameters, vibration and stick-slip closely monitored. Usually the first indication of the base
of the salt is a reduction in torque and an increase in ROP. As with top salt, the depth of the
base of the salt should be noted and ROP should be controlled until the entire BHA including
the underreamer has been buried in the new formation. Again, during this time it is critical
to closely monitor drilling parameters, vibration and stick-slip. This is especially important if
there is a chance of encountering tar or rubble zones at the salt exit.
After exiting the salt, special procedures to flow check and mitigate against high sub-salt
pore pressure may be implemented.
5.12. Ratholes
After simultaneous underreaming while drilling operations, a rathole with the diameter of
the pilot bit and length of pilot BHA will remain. Generally, the rathole is left, and the casing
or liner is set in the underreamed hole, i.e. off bottom. This saves the cost of the additional
run and enables the casing to be run soonest, should time-dependent wellbore instability
be an issue.
In this case, it is good practice to spot a high weight, high viscosity pill in the rathole before
tripping out to run the casing or liner. The weight of the pill must be greater than that of the
cement to ensure the pill is not displaced during the cement job. This practice is proven to
improve the quality of the cement job.
Note that if the rathole is left, the impact on drilling out in the next section must be
considered. The issues associated with this are discussed in Section 5.2.
It may be a requirement that the casing is run as close to TD of the section as possible, e.g.
if the additional shoe strength is required for the next hole section. If this is the case, 2
different options exist:

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5. EXECUTION
1. Separate Hole Opening Trip with Stubby BHA
A new stubby BHA with the underreamer directly behind a pilot bit or bull nose can be used
to open the rathole, as shown in Figure 5.20. This operation carries all the risks associated
with reaming off bottom, as detailed in Section 5.10 and should be avoided if at all possible.
Baker-locking connections is recommended if opening a rathole using a stubby BHA. There
have been instances of bull noses backing off downhole, despite the connections being
Baker-locked.
Opening
Rathole
Figure 5.20: Opening Rathole
2. Drill the Casing into the Rathole
A second option to consider if it is critical to get the liner to TD of the section is to run a
casing or liner drilling bit like the one shown in Figure 5.21.

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5. EXECUTION
Figure 5.21: Casing Drilling Bit
To progress this option, the liner running operation needs to be modelled and engineered
such that the torque on surface and in the connections are within design limitations.
5.13. Hole Conditioning and Tripping Out
The BP Hole Cleaning Guidelines contain recommendations relating to the number of times
to circulate bottoms up at TD of the section based on the hole size, inclination and measured
depth. The Hole Cleaning Guidelines are available on the Drilling Mechanics and Well Design
Site:
If the underreamer permits, de-activate it before beginning to condition the hole. This means
that full circulation rates are available with rotation while conditioning the hole. This is of
particular advantage where there is a potential for cuttings accumulation in the casing where
rotating with the reamer arms open could result in damage to the tool and/or casing.
While conditioning the hole off bottom, all the issues associated with reaming off bottom
exist (See Section 5.10). Note that the stabilizer directly below the underreamer will be in
the enlarged hole. It is recommended that the RPM does not exceed 60 and while
reciprocating, that the bit and lowest stabilizer are kept in the pilot hole and the bit is not
allowed to accidentally tag bottom.
Annular pressure, cuttings returns, vibration and stick-slip should be closely monitored while
circulating to assess the effectiveness of hole cleaning and ensure that the rotation and
reciprocation do not induce any damaging BHA dysfunctions. In the event of any vibration,
changing block speed and RPM can help to tune this out.
Drag levels during tripping out can be used as key indicator as to whether the hole is clean
enough to run casing or if further hole cleaning measures are required. Actual trends should
be compared with the expected trends from modelling.

Technology
6. CONTACTS AND REFERENCES
6. Contacts and References
6.1. Contacts
Nicholas Robertson
Drilling Modelling Specialist
EPT Sunbury
Tel: +44 1932 739523
nicholas.robertson@uk.bp.com
6.2. References
1. SPE 108427-MS Supersize Hole Creates Drilling Opportunity
2. SPE 112647-MS A Systematic Approach to a Better Understanding of the Concentric

Hole-Opening Process Utilizing Drilling Mechanics and Drilling
Dynamics Measurements Recorded Above and Below the Reamer
3. SPE 105578-MS Achieving Shoe to Shoe Drilling Performance in Hole Opening

Applications with Rotary Steerable Systems
4. SPE 92623-MS Reducing Risk and Cost in Diverse Well Construction Applications:
Eccentric Device Drills Concentric Hole and Offers a Viable Alternative
to Underreamers
5. SPE 112670-MS Concurrent Rotary-Steerable Directional Drilling and Hole Enlargement

Applied Successfully: Case Studies in North Sea, Mediterranean Sea,
and Nile Delta
6. SPE 87153-MS Wellbore Enlargement for a Deepwater Casing Program: Case Study
and Developments
7. SPE 112669-MS Challenges of Directional Drilling Through Salt in Deepwater Gulf of

Mexico
8. SPE 84247-MS Innovative Concentric Reamer Enhances Deepwater Drilling

Operations
9. SPE 99124-MS Ringhorne Development-Technologies Applied in Extended-Reach

Drilling: Successes, Failures, and Communicating Risks
10. SPE 67767-MS Reducing Drilling Costs in Deep-Water Gulf of Mexico Utilizing Two
Piece Drill Out Reaming Technology

Technology
6. CONTACTS AND REFERENCES
11. SPE 80476-MS Steerable Hole Enlargement Technology in Complex 3D Directional

Wells.
12. SPE 112702-MS The Utilization of the Massive Amount of Real Time Data Acquired in
Wired-Drillpipe Operations
13. SPE 79810-MS Challenges of Drilling an Ultra-Deep Well in Deepwater - Spa Prospect
14. SPE 67760-MS First Simultaneous Application of Rotary Steerable/Ream-While-Drill

on Ursa Horizontal Well
15. Rhino Reamer Brochure
16. Security DBS XR Reamer Brochure
17. Andergauge Anderreamer Brochure
18. http://www.andergauge.com
19. Hughes Christensen XPR Reamer Presentation
20. Anti Stall Technology Presentation
21. Reed Hycalog V-Stab Presentation
22. Security DBS Near Bit Reamer Brochure
23. www.aps-tech.com
24. Security DBS Satis-1 Hydraulics Analysis
25. Hughes Christensen Bit Steerability Poster
26. Bit Technology for Steerable Systems, DEA(e) Meeting (Wytch Farm) 29.09.2005
27. www.worldoil.com
28. Smith i-Drill Presentation
29 T. H. Hill DS-1

Technology
7. APPENDICES
7. Appendices
7.1. Data Analysis
A number of data sets were selected for an in-depth analysis in order to evaluate tools /
technologies and practices relating to the subject of simultaneous underreaming while
drilling. The data sets discussed in this document are as follows.
• Trinidad (Mango and Cashima)

• Azerbaijan (Shah Deniz)
• North Sea (Clair and Foinaven)
• Gulf of Mexico (Mad Dog, Atlantis)
• Angola (Urano)
What follows is a summary of the key findings from each analysis. Full details of each analysis
are available on request.

Technology
7. APPENDICES
7.2. Trinidad (Cashima)
Summary of Analysis
Data from a 12-¼” x 13-½” underreaming operation with an Anderreamer on Cashima well
A2 has been analysed. During this run, the BHA connections backed-off. The data analysis
was aimed at evaluating the root cause of the back-off event and what could be done to
prevent re-occurrence on future wells.
Key Findings
Figure 7.1 shows data from Cashima well A02 leading up to the last successful MWD
downlink at 16:35 on August 27th. This is followed by some time backreaming and reaming
down as shown by the reciprocating block height in track one.
Of most significance are the large tangential accelerations (orange), axial and lateral vibration
levels (red), and severe stick-slip events shown by the spread between minimum and
maximum BHA RPM. Minimum RPM values approach zero and maximum values
occasionally reach 300RPM. Various reverse rotation (red) events also are shown on the right
in the torque track.
Although extreme lateral and axial vibrations are most undesirable and often cause tool
failures, these alone would not cause the BHA to back off. The severe tangential accelerations
however are indicative of severe torsional forces, but their magnitude and effect are not
obvious. A more direct indication of torsional forces is the spread between minimum and
maximum BHA rotation speeds. There were various events during the time interval between
17:10 and 17:50 when the BHA accelerates up to as much as 300 RPM then decelerates to
approximately 50 RPM.
The most likely cause of the BHA backing off in Cashima A02 is shown in Figure 7.2 where
there was a single and severe stick-slip event at 18:47 after an extra 10klb WOB was stacked
on the BHA. The downhole rotation first of all stopped, and then accelerated back up to
around 320 RPM. It is most likely that this event resulted in the greatest negative torsional
BHA forces and backed off the BHA. Reverse BHA rotation was also recorded during this
event.

Technology
7. APPENDICES
Cashima A2 Run #5
Axial gs Lateral gs Reverse Maximum
1 g 0 10 g 0 1 0 0 rpm 300
16:20
11600
27Aug
11600 16:40
27Aug
17:00
11600
27Aug
17:20
11600
27Aug
17:40
11500
27Aug
18:00
11500 27Aug
18:20
11600
27Aug
18:40
11600
27Aug
Figure 7.1: Data Leading to Cashima A2 Back-off
Likely back-off
event
Figure 7.2: Cashima A2 - Most Likely Back-off Event

Technology
7. APPENDICES
Finally, Figure 7.3 illustrates how high RPM alone does not necessarily result in stick-slip or
severe vibrations. The BHA was rotated at 140 RPM while both backreaming and reaming.
Of note is the very small value of downhole torque and slight variation in both the surface
and downhole torque values. This reinforces that it is torsional transients that appear most
hazardous and not simply high RPM.
Cashima A2 Run #5
Axial gs Lateral gs Reverse Maximum
1 g 0 10 g 0 1 0 0 rpm 300
11900 09:00
28Aug
09:30
11900 28Aug
10:00
11800
28Aug
10:30
11900
28Aug
11:00
11900
28Aug
11:30
11900
28Aug
Figure 7.3: Cashima A2 - Vibration Data at High RPM
Conclusions
The Cashima A02 BHA backed-off most likely as a result of a single torsional event induced
by the application of an additional 10klbs WOB while on-bottom and underreaming. There
were other severe torsional events that may also have caused the BHA to back-off while
reaming down at 120 RPM with high vibration and stick-slip levels that were sustained for
six minutes immediately following time intervals with no flow.
7.3. Trinidad (Mango)
Summary of Analysis
Data from a 12-¼” x 13-½” underreaming operation with an Anderreamer on Mango well
A05 has been analysed. During this run, the BHA connections backed-off. The data analysis
was aimed at evaluating the route cause of the back-off event and what could be done to
prevent re-occurrence on future wells.

Technology
7. APPENDICES
Key Findings
Figure 7.4 shows the time period leading up to the BHA backing-off on Mango A05. The back-
off incident occurred at 20:57 on February 15th.
Having just finished drilling a stand at 20:19 the driller reduced the rotary speed from around
140 RPM to 90 RPM. The stand was then backreamed with 90 RPM and reamed with 110
RPM. Drilling then proceeded normally until 20:55 when by contrast the driller picked up off
bottom with approximately 6kft-lbf of BHA torque still remaining, and maintained the surface
rotation speed at 140 RPM. The sudden change in BHA torque induced large downhole axial,
lateral and torsional vibrations, as well as torsional oscillations in excess of 7kft-lbf at the
surface.
The surface torque oscillations dissipated as soon as the driller reduced the surface rotary
speed to 90 RPM, but the BHA had already backed-off – as can be inferred by the abrupt
termination of the downhole axial and lateral vibration data. It is even possible that the timing
in reduction of the surface rotary speed may have actually exaggerated the transient
downhole BHA forces. In any event it would have been prudent to drill off the downhole bit
torque and reduce the rotary speed, before picking up off bottom and thus reduce the
torsional transients.
Mango A05 Run #4
Whirl Axial gs Lateral gs Reverse Maximum
100 rpm 300 1 g 0 10 g 0 1 00 rpm 300
20:10
8810 15Feb
20:21
8830
15Feb
20:38
8820 15Feb
20:40
8820 15Feb
20:50
8840
15Feb
21:00
8830 15Feb
Figure 7.4: Mango A05 Back-off Event

Technology
7. APPENDICES
Conclusions
The Mango A05 BHA backed-off as a result of picking up off bottom without first reducing
the rotary speed. The sudden reduction in BHA torque (6klb) induced severe torsional
oscillations (observable at surface), and the high off-bottom RPM (140 RPM) was maintained
for two minutes before being reduced to 80 RPM.
The study of the Mango data set highlighted the importance of not coming off bottom with
high RPM before the bit torque has been drilled off.
An independent study carried out by Baker Hughes in Trinidad proved that it is possible for
the connections on BHA modular components to have been subjected to reactive torque
greater than make up if the BHA were to suddenly stop while rotating off bottom. This means
that a stuck reamer or stabilizer may have caused the connection to back-off. The other main
conclusion from this work was that depending upon the position of the CoPilot relative to
the stuck point, it may not see the extent of the torque shock.
The Mango and Cashima analysis gave rise to extensive discussion around optimum
connection practices for Trinidad that are also applicable in other BP locations. The final
connection practices are documented in Section 5.7.
7.4. Azerbaijan (Shah Deniz)
Summary of Analysis
Several runs and BHA / bit designs were required to drill the 8-½” x 9-½” hole section on
Shah Deniz well SD-X4. On the first run, the Reed Hycalog V-Stab was run in conjunction
with a Rhino Reamer. Two further Rhino Reamer and V-Stab assemblies were run after coring
runs, both resulting in the Rhino Reamer failing to open.
Key Findings
On the first underreamer run, the bit was pulled ‘as-new’, however, the underreamer was
severely damaged. Blackbox data showed the cause of this damage to be severe torsional
vibration in the Balakhany VIII formation. On subsequent runs after coring, the reamer was
found to be unworn, confirming that it had not opened. During the runs where the reamer
failed to open, less stick-slip was evident confirming the reamer as one of the main
contributors to stick-slip. This is shown in Figure 7.5.

Technology
7. APPENDICES
Figure 7.5: Shah Deniz 8-½" x 9-½" Drilling and Underreaming Data
ROP data from the 8-½” x 9-½” underreaming run on SDX-4 was compared with the ROP
from 8-½” sections (no underreaming) on offset Shah Deniz wells. This showed a clear
reduction in ROP in the different formations due to the introduction of the underreamer.
Figure 7.6: Shah Deniz ROP Data
Conclusion
It should be recognised that the addition of an underreamer will reduce the achievable ROP
when compared with geological offsets.

Technology
7. APPENDICES
When using an underreamer, always cut a ledge to pull back against (or set down on) to
confirm the tool has opened. Pressure drops across tools measured either at surface or with
the MWD can be unreliable should not be used in isolation to confirm the tool is open and
working.
The data from Shah Deniz clearly indicated that the worst case for stick-slip was when the
bit was in a sand formation and the reamer is in mudstone. It is extremely important to
record depths of stringers and take appropriate action when the reamer encounters these
stringers.
The drilling data from the V-Stab runs yielded no conclusive evidence that the V-Stab is
effective in reducing shock and vibration. On the other hand, the data did not show that the
V-Stab contributed to torsional vibration.
7.5. North Sea (Foinaven)
Summary of Analysis
The Foinaven team in North Sea deployed an AST tool (see Section 4.7) in the 12-¼” section
of well P212. Note that this was not in an underreaming application, however it was believed
that any conclusions would be applicable to underreaming applications. The main objective
of using the AST on P212 was to aid ROP through stringers. Prior to the deployment, Key
Performance Indicators (KPI’s) were developed to assess the benefit of the AST. This was
done by benchmarking drilling performance on 12-¼” sections on offset wells in West of
Shetland. These KPI's are available on request (email to nicholas.robertson@uk.bp.com).
After the P212 AST run, the surface and downhole (CoPilot) data were analysed in order to
evaluate the impact of AST tool and its applicability to underreaming applications.
Key Findings
ROP Performance
For P212 Run 4 with AST, average on bottom ROP was the highest of all the 12-¼"
runs considered (42.2 m/hr)
For P212 Run 4 with AST, ROP in stringers was highest of all the 12-¼" runs
considered where stringer details were available (34.3 m/hr)

Technology
7. APPENDICES
Foinaven 12-1/4 Section ROP Performance

45
Average ROP Overall

40 Average ROP in Stringers
Average ROP not in Stringers
35
30
ROP (m/hr)
25
20
15
10
0
W16 WW16 P110 P211 P212 Run 4 P212 Run 5 P212 Run 6
(with AST)
Well
Figure 7.7: Foinaven ROP Comparison
Stick-slip
Note stick-slip calculated as follows: Stick-slip % = (Max RPM-Min RPM)/Average
RPM.
For P212 Run 4 with AST, average level of stick-slip was 28%. This is greater than
on P212 Run 5 (16%) and Run 6 (24%) which did not have the AST.
For P212 Run 4 with AST, average level of in the stringers stick-slip was 71%. This
was the highest of all the 12-¼" runs considered where stringer details were
available.
It is also worth pointing out that during this well, the surface RPM data is suspicious, as it
does not correlate with average downhole RPM which correlates well between runs. The
implication of this is that the rig may have been using a lower value of RPM that they had
planned during drilling.

Technology
7. APPENDICES
Foinaven 12-1/4 Section Stick Slip Performance

80%
Average Stick-Slip % Overall

70% Average Stick-Slip % in Stringers
Average Stick-Slip % not in Stringers
60% Stick Slip % = (Max RPM-Min RPM/Avg RPM
50%
Stick Slip (%)
40%
30%
20%
10%
0%
(with AST)
Well
Figure 7.8: Foinaven Stick-Slip Comparison

Lateral Vibration
For P212 Run 4 with AST, average level of lateral vibration was 1.01 gRMS. This is
less than on P212 Run 5 (1.38 gRMS) and Run 6 (1.74 gRMS) which did not have
the AST. This reduction is primarily achieved whilst drilling the stringers.
For P212 Run 4 with AST, the largest difference between lateral vibrations while
drilling stringers and non-stringers is present of all the wells considered.
For P212 Run 4 with AST, average level of lateral vibration was the lowest of all
offsets considered.
Foinaven 12-1/4 Section Lateral Vibration Performance

2.00
1.80 Average Lateral Vibration (gRMS) Overall

Average Lateral Vibration (gRMS) in Stringers
Average Lateral Vibration (gRMS) not in Stringers
1.60
1.40
Lateral Vibration (gRMS)
1.20
1.00
0.80
0.60
0.40
0.20
0.00
(with AST)
Well
Figure 7.9: Foinaven Lateral Vibration Comparison

Technology
7. APPENDICES
Axial Vibration
For P212 Run 4 with AST, average level of axial vibration was 0.02 gRMS. This is
less than on P212 Run 5 (0.06 gRMS) and Run 6 (0.08 gRMS) which did not have
the AST.
For P212 Run 4 with AST, average level of axial vibration was the lowest of all
offsets considered.
Foinaven 12-1/4 Section Axial Vibration Performance

0.20
0.18 Average Axial Vibration (gRMS) Overall

Average Axial Vibration (gRMS) in Stringers
Average Lateral Vibration (gRMS) not in Stringers
0.16
0.14
Axial Vibration (gRMS)
0.12
0.10
0.08
0.06
0.04
0.02
0.00
(with AST)
Well
Figure 7.10: Foinaven Axial Vibration Comparison
WOB Applied
For P212 Run 4 with AST, average level of surface WOB applied was 22.1 klbs. This
is greater than on P212 Run 5 (17.0 klbs) and Run 6 (19.4 klbs) which did not have
the AST. It is expected that this is also contributing to the greater ROP in run 4 (as
explained in the summary)

Technology
7. APPENDICES
Foinaven 12-1/4 Section Drilling Parameters - WOB

50
Average WOB (klbs) Overall

Average WOB (klbs) in Stringers
Average WOB (klbs) not in Stringers
40
30
WOB (klbs)
20
10
0
(with AST)
Well
Figure 7.11: Foinaven WOB Comparison
Mechanical Specific Energy (MSE)

In its most basic terms, MSE is a measure of the efficiently of the drilling process.
Lower values of MSE mean that the drilling process is more efficient (assuming
same formation strength)
For P212 Run 4 with AST, average level of MSE was approximately 490,000 psi.
This is less than on P212 Run 5 (838,000 psi) and Run 6 (1,094,000 psi) which did
not have the AST.
For P212 Run 4 with AST, average level of MSE was lowest apart from well WW16
(344,000 psi) of all the offsets considered.
Foinaven 12-1/4 Section Drilling Parameters - Mechanical Specific Energy (MSE)
3,000,000
Average MSE (psi) Overall

Average MSE (psi) in Stringers
Average MSE (psi) not in Stringers
2,000,000
MSE (psi)
1,000,000
0
(with AST)
Well
Figure 7.12: Foinaven MSE Comparison

Technology
7. APPENDICES
MSE is The energy used to remove a unit volume of rock
Energy Expended
MSE = [Units psi]
Volume of Rock Removed
Can be used to determine when there are drilling inefficiencies e.g. vibrations
WOB 120p * Torque * RPM

MSE = +
A A * ROP
MSE = Mechanical Specific Energy (psi)

WOB = Weight on Bit lb)
Torque = Torque at Bit (ft.lb)
RPM = Bit RPM
ROP = ROP (ft/hr)
A = Area of hole (in2)
Cost
For P212 Run 4 with AST, overall run time (bit below RT to bit above RT) = 189
hours
For P212 Run 4 with AST, cost of rig time = £2.47 M
Actual invoiced cost of AST = £107 k
For P212 Run 4 with AST, overall cost = £2.47 M + £107 k = £2.577 M
If you do a "What if we hadn't used the AST on run 4?" analysis (basing the ROP
performance on P212 Run 5 which had no AST)
For P212 Run 4 without AST, overall run time (bit below RT to bit above RT) = 199
hours
For P212 Run 4 without AST, overall cost = £2.608 M
Hence based on these assumptions, the AST has saved £27,000.
Conclusion
In summary, it seems the use of the AST tool could have contributed to cost savings of
£27,000 on Foinaven well P212. Of all the offsets considered, P212 run 4 with the AST had
the best ROP performance. It should be noted that the small cost saving / increased ROP
may not be entirely due to the influence of the AST as this run also used the highest WOB.
On P212 run 4 with the AST, stick-slip was the highest of all the offset wells considered
which counteracts the main reason for deploying such technology. This may also be down to
the fact that higher levels of WOB were applied which is generally associated with increased
risk of stick-slip. Lateral and axial vibrations are however reduced compared with the offsets.
The analysis on Foinaven P212 has proved inconclusive. Whilst the AST is believed to have
improved the ROP performance on Foinaven, cost savings have proved to be minimal. For
the run utilizing the AST tool, lateral and axial vibrations were reduced when compared with

Technology
7. APPENDICES
offsets, however stick-slip is increased when compared with offsets. This may be due to the
suspicious surface RPM data and/or the higher level of WOB being applied for the run with
the AST. With the relatively high cost of the AST, cost savings were minimal even with the
high West of Shetland rig rate.
7.6. Gulf of Mexico (Mad Dog)
Summary of Analysis
In Mad Dog well OCS-G 15610 /GC 782/#8, a Reed Hycalog Blackbox drilling dynamics
memory only tool was utilized in conjunction with a Baker Hughes CoPilot tool in an
underreaming application (14-½” x 16-½” Section). The Blackbox was located above the
Smith Rhino Reamer and the CoPilot tool was located below the reamer. The BHA is shown
below in Figure 7.13:
Description OD ID Gauge OD Length Accum.
Length
14 1/2 PDC HC 507Z 9.5 3.00 14 1/2 1.60 1.60
AutoTrak Steering Unit 9.5 3.00 14 1/2 8.20 9.80
14 3/8 Mod Flex Stab 9.5 3.00 14 3/8 11.73 21.53
OnTrak LWD/MWD 9.5 3.00 17.88 39.41 64

14 OnTrak Modular Stabilizer 9.5 3.00 14 5.93 45.34
OnTrak BCPM 9.5 3.00 11.74 57.08
Copilot 9.5 3.00 7.30 54.38
Closure Sub 9.5 3.00 1.98 66.36
14 3/8 IB AutoTrak Style Stab. 9.5 3.00 14 3/8 5.35 71.72 28
NM Downhole filter sub 9.5 3.00 5.22 76.94
Concentric Reamer Smith 14.25 2.50 16 1/2 16.63 92.57
8 1/4 Steel Drill Collar 8.25 2.81 29.95 122.52
14 3/8 IB AutoTrak Style Stab. 8.25 2.81 14 3/8 7.67 130.19 40
BlackBox Sub 8.25 2.81 1.67 131.86
8 1/4 Steel Drill Collars 9.25 2.81 149.65 281.51
Crossover Sub 8.00 3.00 4.04 295.55
5 7/8 HWDP 5.88 4.00 185.30 470.85
7 Jar 7.25 2.75 32.15 503.00
5 7/8 HWDP 5.88 4.00 525.12 1029.12
5 7/8 Drill Pipe 5.88 5.15
Figure 7.13: Mad Dog 14-½” x 16-½” BHA
The purpose of running the Blackbox was to collect drilling dynamics data from above and
below the reamer tool in order to compare and contrast the magnitudes of dynamics effects
under different conditions.

Technology
7. APPENDICES
Vibration measurements between the Blackbox and CoPilot tools correlated well. Key
observations are discussed below.
Key Observations
Circulating off bottom

While circulating and rotating off bottom to clean the hole after drilling out the
cement, (Rhino Reamer Closed), the RMS value of lateral vibration is higher at
CoPilot tool than at the Blackbox, implying that off bottom the lateral vibrations
originate from closer to the CoPilot tool (see Figure 7.14)
Max Lateral overlay well

during the circulating,
RMS is higher at the
Copilot tool. Torsional
vibration is low, with
some small spikes in
RPM, most likely related
to working the string.
Figure 7.14: Mad Dog 14-½” x 16-½” - Circulating off Bottom
Opening Reamer Arms

It was seen that when opening the reamer arms, severe torsional vibrations were
recorded with Blackbox downhole RPM varying between 20 and 150. The reamer
arms opening can also be clearly seen on the torque trace.

Technology
7. APPENDICES
Torque signature
while reamer arms
open Drop Ball and seal
Reamer opening
giving some high
vibrations
Figure 7.15: Mad Dog 14-½” x 16-½” – Opening Reamer
Initial Drilling and Underreaming

While initially drilling and underreaming with the reamer still in the previously drilled
rathole, severe torsional vibration was encountered, with downhole RPM varying
between 0 and 205 (i.e. full stick-slip). Data indicated that the stick-slip was reamer
induced as vibration at the CoPilot was less severe than recorded by Blackbox.
CoPilot DWOB Response in Deepwater & Associated Temperature Effects

During this analysis it was discovered that the CoPilot DWOB measurement can
produce erroneous readings in deepwater environments. During a connection the
column of mud in the riser cools considerably. As the cold mud is circulated
through the CoPilot tool, the temperature gradient across the body of the tool
increases. It takes time for the temperature difference to equalize and for the cold
mud to pass through the tool. This took approximately 10 to 12 minutes in the Mad
Dog examples, and then the DWOB becomes steady again.

Technology
7. APPENDICES
CoPilot WOB
response after
making connections
Figure 7.16: Mad Dog 14-½” x 16-½” – CoPilot Deepwater DWOB Response
It is important that this response is not mistakenly interpreted as inefficient weight transfer
to the bit and reamer.
Weight Transfer
Figure 7.17 corresponds to a period of drilling where the DWOB response is not
being affected by the temperature effects described above (i.e. mud has been
circulating for > 12 minutes). Points 1, 3 and 5 annotated on Figure 7.17 show
where SWOB and DWOB are diverging. This corresponds to the situation where
the weight applied on surface is stacking on the reamer and not being effectively
transferred to the bit. The result is higher lateral and RMS vibration levels at the
CoPilot and the underreamer.

Technology
7. APPENDICES
Figure 7.17: Mad Dog 14-½” x 16-½” – Weight Transfer DWOB
RPM Effects
The data analysis indicated that minor changes in RPM could have a significant
impact on torsional vibrations. This is indicated in Figure 7.18 below which shows
the reduction in torsional vibration when moving from 140 to 150 RPM.

Technology
7. APPENDICES
Figure 7.18: Mad Dog 14-½” x 16-½” – RPM Effect
Salt Exit
Interesting trends are noted when the BHA exits the salt interval which is
illustrated in Figure 7.19. In this case, the base of the salt is clearly marked by a
BHA stall as the bit enters the new formation. As the bit exits the salt, there is a
marked decrease in lateral vibration recorded by CoPilot. Conversely, the lateral
vibration recorded by the Blackbox increases.
When the reamer cutters exit the salt, a distinct decrease in the level of stick-slip
recorded by the Blackbox and CoPilot is witnessed.
Further reductions in the vibration levels are seen by the Blackbox as the top
stabilizer exits the salt section.

Technology
7. APPENDICES
BHA stalls
Figure 7.19: Mad Dog 14-½” x 16-½” – Salt Exit
Conclusion
The analysis of the Mad Dog data has highlighted a number of key learning’s:
Underreaming assemblies are highly sensitive to RPM effects. It is important to perform

finger-printing in order to determine the least damaging drilling RPM in terms of stick-slip
and lateral vibration.
CoPilot is an extremely useful tool to deploy in order to determine the effectiveness of weight
transfer. It is important to be aware of the effects of circulating cold mud through the CoPilot
tool on the DWOB measurement. This effect could masquerade as poor weight transfer to
the bit if engineers are not aware of it.
When drilling and simultaneously underreaming in salt, it is important to be aware of the

salt exit. Vibration levels do not reduce to background levels until the top stabilizer exits the
salt section. It is important to calculate the bit depth at which the entire BHA will have exited
the salt section.

Technology
7. APPENDICES
7.7. Gulf of Mexico (Atlantis)
Summary of Analysis
Three consecutive tool failures with drilling and underreaming BHA’s on Atlantis in GoM were
studied. The failure details are as per the table in Figure 7.20.
Well BHA Hole Size Drilled Interval Failed Component
DC143 G5 #5 14¾ x 17½ (Rhino Reamer) 10,275 13,785 RSS Impeller Bearings
DC113 C4 #4 14¾ x 16½ (Rhino Reamer) 10,263 13,047 Not Reported
DC123 E4 #5 14½ x 16½ (Anderreamer) 10,540 11,919 RSS Impeller Bearings
Figure 7.20: Atlantis Failures
Key Findings
Torsional oscillations and BHA whirl were the failure mechanisms for all three RSS tool
failures. The root cause of each failure was predominantly mid-ranging rotary speed
combined usually with insufficient weight-on-bit. Excessive vibration problems occurred
when reaming down after a bit trip, drilling new formation, and while conditioning the
borehole prior to connections and prior to tripping.
Lateral vibrations
when RPM and
SWOB are reduced
Figure 7.21: Atlantis RSS Failure 1

Technology
7. APPENDICES
Whirl vibration Note

RPM changed, but
never stopped
Stick slip when RPM

reduced, WOB
increased
Stick slip while back-

reaming
Large lateral vibration

spike Drilling 0 SWOB,
100 RPM RSS failure

Technology
7. APPENDICES
Conclusions
• Destructive BHA motions occurred while reaming down, conditioning the borehole
both at connections and before tripping, as well as while drilling
• The most damaging BHA phenomena were stick-slip and backward whirl
• BHA’s were more prone to whirl when drilling (sandier) intervals with less dogleg
severity
• Mid-ranging rotational speed combined with low weight-on-bit produced the most
destructive BHA torsional forces, shocks, vibrations and whirling motion, as shown
below in Figure 7.24.
Stick-Slip (rpm)
Hole Cleaning
# Lateral gs
1.7 0.8 80
2.1
30
2.0 -Infinity
180
2.6 2.2 0.5
Stick-Slip 120 2.8 1.3 1.5
(rpm) 1.4 0.9
1.4
60
1.5 1.6
0.2 200
0 Mid range
0.6 0.3 RPM worst160
for stick slip
0.3 0.2 120
0
Block Velocity 0.2 80 RPM
(ft/s) (rpm)
-0.3 40
-0.6 0
Figure 7.24: Atlantis Vibration Analysis
• Opening and closing the under-reamer when stick-slip was present and while on-
bottom drilling induced transitional high severity shocks
• The Powerdrive system in BHA #5 of the DC143 G5 well failed as a result of
cumulative extreme BHA motions caused by mid-ranging rotational speed when
drilling through a hole section with low dogleg severity
• The Powerdrive system in BHA #4 of the DC113 C4 well failed as a result of
cumulative extreme BHA motions caused by middle-ranging rotational speed when
drilling through a hole section with low dogleg severity
• The Powerdrive system in BHA #5 of the DC123 E4 well failed as a result of
cumulative extreme torsional and lateral forces caused by mid-ranging rotational
speed when drilling formations with low dogleg severity
• Other BHA’s also experienced destructive vibrations, but over shorter time intervals
that did not result in tool failures
• Failures related to the modes of vibration described above were experienced with
Rhino Reamer BHA’s (wells DC143 G5 and DC113 C4) and also with an Anderreamer
BHA (well DC123 E4). This suggests that it is not one particular type of underreamer
that is resulting in failure. The failures are closely related to how a particular BHA is
operated rather than the specific tools making up that BHA

Technology
7. APPENDICES
7.8. Angola (Urano-1)
Summary of Analysis
The 17” x 20” (through salt) section on the Urano-1 exploration well in Angola was planned
as a single run using an AutoTrak BHA with 20” Smith Rhino Reamer. High lateral vibrations
were recorded by the MWD tool when the underreamer was activated which subsequently
led to the failure of the MWD tool at 2,489m. In this case, the data analysis was performed
by Baker Hughes.
Key Findings
While drilling and underreaming the 17” x 20” section, repeated instances of high lateral
vibrations were encountered. These ultimately lead to the MWD failure. The repeated
instances of the vibration events are annotated in Figure 7.25.
Figure 7.25: Urano 17" x 20" Underreamed Section – Repeated Instances of Lateral Vibration

Technology
7. APPENDICES
Figure 7.26 details one of the instances of high lateral vibration. The scaled BHA shows that
the high level of lateral vibration coincides with the reamer encountering a formation change.
Upon analysis of the other instances, it was clear that these all corresponded to either the
underreamer or a stabilizer hanging up on a ledge at a formation change.
Figure 7.26: Urano 17" x 20" Underreamed Section – Example Instance of Lateral Vibration
Conclusion
All 17 incidents of high lateral vibrations can be related to either the underreamer
encountering a change in formation or stabilisers exiting sections of hole drilled with high
laterals (hanging up on a ledge). High lateral vibrations were caused by the weight reaching
the bit being reduced or the bit “drilling off” and reducing the depth of cut. This reduced the
stability of the bit and BHA which moved into a laterally unstable condition.

Technology
7. APPENDICES
BHA Design
The lack of stabilization around the Rhino Reamer was believed to have contributed to the
excessive vibration and MWD failure. The old and new BHA designs are depicted in Figure
7.27.
Figure 7.27: Urano-1 BHA Design
Bit Design
The 17” bit used was a Smith MGR619HPX (relatively light set, six bladed design with 19mm
PDC cutters and a 2.75” gauge). As a rule of thumb for AutoTrak BHAs:
High DLS (> 5deg/100ft) Gauge length = 2.5” - 3”

Low DLS/Tangent (<4deg/100ft) Gauge length = 3.5” – 4”
It is believed that the aggressive nature of the bit contributed to the excessive vibration. A
less aggressive bit compatible with the underreamer would have helped to avoid the bit
“drilling off” and becoming unstable. An increased gauge length would reduce the side
cutting action and minimise the creation of ledges.
Finally, depth of cut limitation features on the bit such as Hughes Christensen Eze-Steer
would help to match the bit aggressiveness with that of the hole opening device. This feature
is illustrated in Figure 7.28. Here, the matrix forming the blades is built up close to the cutter
tip, reducing the cutter exposure.
Reduced
cutter
exposure
Figure 7.28: Hughes Christensen Eze-Steer Depth of Cut Limitation

Technology
7. APPENDICES
7.9. Vibration Mitigation Flowcharts
Out Of Specification - Communication Guideline

Drilling Ahead, Reaming, Hole Opening
Well Placement Supplier and crew to monitor the available parameters for indications
of surface and drilling problems in particular the onset of vibration: torque increases,
vibration, stick-slip, lost MWD detection.
On-site crew (Driller, Onshore support (ACE

Mud Logger, WSL) personnel, DE, office
witness Out of staff) witness Out of On-site Well
Specification event. Specification event. Placement Supplier
(DD, M/LWD
Engineer, Drilling
Optimisation
Engineer) witness
Out of Specification
Inform On-site Well Placement Supplier (DD, M/LWD event.
Engineer, Drilling Optimisation Engineer) of Out of
Specification event at earliest opportunity.
Well Placement Supplier to confirm specifications being compromised. Monitor,

establish mode & severity.
Are operating limits close to being or have been exceeded?
Trends indicate that tool reliability

Tools immediately operating out of will be affected over time yet the
design specification. risk for failure is not imminent.
Immediately inform Well Site Leader Monitor trends over time and
and Drill Floor of situation, implement mitigations with Drill Crew
recommendations to mitigate, the time (interruption to the drilling process must
within which to resolve (nominally a be minimal) to eradicate or reverse
minimum 30 minutes cumulative per trend. Inform Well Site Leader at the
run) before tools are compromised or next available opportunity of
commercial penalties are incurred. The compromising trend and
clock starts once BP is adequately recommendations.
informed.
Vibration Modes
Axial Torsional Lateral
What is an event?
Real-time event (not Memory) where the following specifications are potentially compromised:
Shock (lateral, torsional, axial, stick-slip, BHA whirl, backward Surface RPM and Weight on Bit combination
rotation), Bottom hole static and circulating temperature
Flow rate, Bottom hole pressure
Dog-leg Severity (bending force) Drilling events jarring, rotation without flow,
Mud (sand and solids content, LCM, corrosive elements (eg. excessive tripping speeds.
Chlorides))

Technology
7. APPENDICES
Axial
(Bit Bounce)
Axial Vibration-Commonly caused by lithology changes or fractures in the rock as

the bit begins a new cutting pattern. Large weight-on-bit fluctuations causing the
bit to repeatedly lift off and impact the formation. This mechanism, which often
occurs when drilling with tricone bits in hard formations, can cause axial bit vibration
with a frequency range of 1-10 Hz. The resulting increase in impact loading can
be damaging to the bit and the BHA.
Symptoms
Surface Downhole
Shaking of surface equipment, particularly Axial vibration sensor readings.
at shallow depths. Total vibration sensor if no directional
Large Weight on Bit fluctuations. detail provided (axial, lateral, torsional).
Possible SPP fluctuations. Loss of communication from MWD.
Loss of Tool Face, poor directional control.
Reduced or erratic ROP.
Axial
Step 1
Stay on bottom. Increase WOB 4-10 klb(2-
5 tonne). Decrease rotary speed by a similar
Repeat incremental percentage (approx 5-10 RPM)
adjustments without
exceeding WOB limits
YES Vibration NO
Continues
YES
Step 2
Pick up off bottom and allow string torque to unwind. Set
RPM to between 40% 50% of original. Increase WOB
by 10% - 20% over original. Return to original RPM after
WOB is established. Correlate Stabilisers to formation.
Vibration NO
Continues
YES
The Suppliers clock
is always ticking Step 3:
Pick up off bottom & stop rotation, work string. Set RPM
to between 40% 50% of original & increase WOB by
10% - 15% over original WOB. Increase to 25% less than
original RPM once WOB has been established.
YES Vibration NO
Continues
TRIP or DRILL AHEAD DRILL AHEAD

Well Site Leader to decide Well Placement Supplier to document

Technology
7. APPENDICES
Lateral
(Bit or BHA Whirl)
Lateral Vibration - Very destructive & needs immediate attention and is a chaotic
behaviour of the BHA and drill string. This state is reached when the vibration
mechanisms of bit bounce, BHA whirl or modal coupling become sufficiently
extreme. It is associated with whirl & bending of the drillstring and with resonance
often occurring at a BHA critical rotary speed.
Symptoms
Surface Downhole
An increase in average torque. Lateral vibration readings increase.
Loss of Tool Face, poor directional control. Increased average downhole torque and
Reduced ROP. torsional vibration readings.
Possible associated torsional shocks, Total vibration sensor if no directional
and cyclic RPM. detail provided (axial, lateral, torsional)
Loss of communication from MWD.
Lateral
Step 1: Step 1:
Low-angle holes: High-angle holes:
Decrease RPM by 10%, Increase WOB Stay on bottom. Decrease rotary
by 10% by 10-50 RPM.
Repeat incremental
adjustments without
exceeding WOB limits
YES Vibration NO
Continues
YES
Step 2:
Pick up off bottom, stop rotation and work pipe to allow
string torque to unwind . Restart rotary with 40-70 RPM.
Return to bottom & slowly increase WOB to target value,
avoiding Stick-Slip & buckling. Increase RPM to maximize
ROP.
Vibration NO
Continues
YES
The Suppliers clock
string torque to unwind . Restart rotary with 40-70 RPM.
Return to bottom & slowly increase WOB to target value,
avoiding Stick-Slip & buckling. Increase RPM to 25%
below previous.
YES Vibration NO
Continues


Technology
7. APPENDICES
Torsional
(Stick-Slip)
Torsional Vibration - Non-uniform bit rotation in which the bit stops rotating
momentarily at regular intervals causing the string to periodically torque up and
then spin free, accelerating the bit to high speeds. This mechanism sets up the
primary torsional vibrations in the string with a frequency below 1 Hz (i .e . one
vibration cycle per second) and can cause severe impact damage to PDC bits.
Symptoms
Surface Downhole
Cyclic surface torque and rotary Drive Increased downhole delta RPM stick-slip
stalling. readings.
Loss of Tool Face, poor directional control. Increased differential in downhole torque
Reduced or erratic ROP. and torsional vibration readings.
Interference with mud pulse MWD
telemetry.
Torsional
Step 1:
Increase rotary by 10% (approx 10-20
RPM). Hold WOB or decrease by 5%
Repeat incremental (2-5 klb).
adjustments without
exceeding WOB or RPM limits
YES Vibration NO
Continues
YES
Step 2:
Ensure top drive has high gear selected. If Soft Torque
Rotary System installed ensure fully operational and
configured. Come off bottom & wipe hole section. Restart
with less 15%-20% reduction in WOB and a 10% increase
in RPM.
Vibration NO
Continues
YES
The Suppliers clock
string torque to unwind . Restart rotary with 60 RPM.
Increase WOB to 25% below original value. Increase
RPM to 20% above original
YES Vibration NO
Continues


Technology
7. APPENDICES
7.10 Symbols and Abbreviations
Symbol/ Symbol/
Definition Definition
Abbreviation Abbreviation
AST Anti Stall Technology MWD Measurement While Drilling
BHA Bottom Hole Assembly NPT Non-productive Time
D&C Drilling & Completions OD Outer diameter
DoC Depth of Cut PDC Polycrystalline Diamond Compact
DIMS Drilling Information Management RMS Root Mean Square

System
ROP Rate of Penetration
DP Drill Pipe
RPM Revolutions per Minute
DTOR Downhole Torque
RSS Rotary Steerable Systems
DWOB Downhole Weight on Bit
RT Real Time
ECD Equivalent Circulating Density
SME Subject Matter Expert
EPT Exploration Production Technology
SWOB Surface Weight on Bit
ESD Equivalent Static Density
TD Total Depth
FE Formation Evaluation
UCS Unconfined Compressive
GoM Gulf of Mexico Strength
ID Internal diameter WOB Weight on Bit
KPI Key Performance Indicator WOR Weight on Reamer
LWD Logging While Drilling WSL Well Site Leader
MSE Mechanical Specific Energy

Technology
7. APPENDICES

Technology

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INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE

Exploration & Production BP Confidential, © 2009 BP p.l.c.

Issue Date September 2009

Revision Date September 2009

Next Review Date September 2011

Technical Authority Nicholas Robertson, Drilling Modelling Specialist, EPT

Content Approval Tom Christopher, Standardization Project Manager, D&C

Authorization for Issue Scott Sigurdson, VP Drilling and Completion Engineering

Document Administrator Drilling and Completions

INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE

© 2009 BP p.l.c. All rights reserved.

2. WHY UNDERREAM? ................................................................................................13

3. OPTIONS FOR HOLE OPENING ..............................................................................15

6. CONTACTS AND REFERENCES...............................................................................63

Exploration & Production BP Confidential, © 2009 BP p.l.c.

BP Confidential, © 2009 BP p.l.c. Exploration & Production

Exploration & Production Page 7 BP Confidential, © 2009 BP p.l.c.

Underreamer Arms Closed Underreamer Arms Open

Figure 1.1: Concentric Underreamer

Bi-Centre Bit Eccentric Reamer

Figure 1.2: Bi-centre Bit and Eccentric Reamer

Exploration & Production Page 9 BP Confidential, © 2009 BP p.l.c.

1.1. Underreaming Challenges

• Hole cleaning challenges (drilling oversized hole).

BP Confidential, © 2009 BP p.l.c. Page 10 Exploration & Production

• An extensive analysis of various BP underreaming while drilling data sets (see

Exploration & Production Page 11 BP Confidential, © 2009 BP p.l.c.

BP Confidential, © 2009 BP p.l.c. Page 12 Exploration & Production

1. Why do I need to underream this hole section?

Exploration & Production Page 13 BP Confidential, © 2009 BP p.l.c.

BP Confidential, © 2009 BP p.l.c. Page 14 Exploration & Production

3. Options for Hole Opening

Pilot BHA Pilot BHA

Drilling teams may choose to consider alternatives to simultaneous underreaming while

Exploration & Production Page 15 BP Confidential, © 2009 BP p.l.c.

3.1. Bi-centre Bits

A Bi-centre bit is shown in Figure 3.2.

Figure 3.2: Bi-centre Bit

BP Confidential, © 2009 BP p.l.c. Page 16 Exploration & Production

3.2. Eccentric Reamers

Figure 3.3: Eccentric Reamer with Mill Tooth Pilot Bit

Exploration & Production Page 17 BP Confidential, © 2009 BP p.l.c.

3.3. Concentric Underreamers

BP Confidential, © 2009 BP p.l.c. Page 18 Exploration & Production

4.1. Hole Cleaning

Additional 150 GPM required

Figure 4.1: WellPlan Hole Cleaning Prediction

Exploration & Production Page 19 BP Confidential, © 2009 BP p.l.c.

4.2. Underreaming Hydraulics

When performing the hydraulics analysis, it is important not to consider underreamer

• What flowrate is required for hole cleaning? (see Section 4.1)

WellPlan 2003.16.1.17 can be used to model simultaneously underreaming while drilling

BP Confidential, © 2009 BP p.l.c. Page 20 Exploration & Production

The hydraulics analysis should be performed for a range of sensitivities:

• Minimum and maximum anticipated mud weights

An example of a hydraulics analysis for an XR reamer is shown below in Figure 4.2

Figure 4.2: Example Hydraulics Analysis [24]

Exploration & Production Page 21 BP Confidential, © 2009 BP p.l.c.

Previous Casing Size and Depth: 16-1/2 @ 17,000 ft

Position B: 9294 22