Editor’s note: Offshore’s directory of rotary steerable drilling equipment and services includes new and updated product specifications and descriptions provided by the participating companies. It is organized alphabetically by company, service line, and associated equipment. Although every effort has been made to include all rotary steerable providers, Offshore does not guarantee that the directory is an exhaustive list of rotary steerable equipment and services. To participate in future rotary steerable system directories, contact Frank Hartley, Drilling/Production Editor, at[email protected].
Rotary steerable drilling systems have become a mainstream service with advantages in several applications. They can drill directionally and continuously without slowing or stopping to change direction, allowing uninterrupted drilling with continuous weight on the bit, while at the same time providing real-time log data.
These systems have been on the market for over six years with great success and reliability. With the proper drilling parameter and bit selections, rotary steerable systems (RSS) produce accurate results with less downtime, and produce faster, cleaner and smoother wellbores.
Manufacturers of the systems describe a number of new tools and technology in this year’s equipment directory.
Andergauge Drilling Systems
The “DART” rotary steerable tool from Andergauge Drilling Systems is purely a mechanical tool developed for wells where it would be economically prohibitive to use “state of the art” RSS technology and where applications do not require high DL capability.
The tool is 100% mechanical, and uses push-the-bit and three-point (stabilization) geometry to generate a constant 3°/100 ft (30 m) DL in its standard set up. The tool may be workshop configured for greater or lesser degrees of dogleg capability.
Steering is achieved by orienting a non-rotating offset stabilizer less than 1 m (3 ft) behind the bit, to generate a side force at the bit, thus pushing it in the desired direction. Toolface setting from surface consistently has proven reliable at depths of more than 7,010 m (23,000 ft). In terms of accuracy, the DART has been used to drill lateral sections of over 2,438 m (8,000 ft) maintaining TVD and azimuth to less than +/- 1 m (3 ft) of the proposed.
It is limited to applications where variable DL capability is not required and steering requires no more than the tools set DL capability of which the standard tool set up is 3°/100 ft (30 m).
The tool’s low pressure drop allows maximum utilization of available rig pressure. It is compatible with all vendor measuring-and logging-while-drilling (MWD/LWD) systems and can be used with both PDC and roller cone bits. The tool is viable economically for use even in land wells and in applications where high-end RSS capabilities would be excessive for the well objectives.
Baker Hughes Inteq
Developed jointly by Eni (Agip) and Inteq, the first-generation AutoTrak Rotary Closed Loop System (RCLS) was introduced in 1997. Since then, the system has been used globally on several thousand jobs.
The systems are proven to deliver precise and consistent steerability in formation types ranging from unconsolidated in deepwater West Africa to hard rock onshore Italy. Well types have varied from “straightforward” to > 11 km (7 mi) extended reach wells in Sakhalin Island to the world’s most complex 3D trajectories in the North Sea.
The product is now in its third generation form, designed for increased reliability, durability and capable of integrating advanced formation evaluation LWD and drilling performance improvement systems as close to the drill bit as possible.
It is a fully integrated, closed-loop steering and advanced LWD system. The system integration reduces bit-to-sensor spacing, reduces the number of bottomhole assembly (BHA) components and shortens the overall BHA length.
It incorporates a precise, automated directional control system. This closed-loop deviation control allows precise wellbore placement automatically for consistent target interception. The steering control has been used to intersect challenging geological targets including several relief wells. Combining the short BHA length and precise directional control with advanced geosteering allows maximum reservoir exposure in each well, resulting in increased production at reduced drilling costs.
For one offshore Norway field, the operator has attributed over $6 billion of incremental asset value to the contributions of the system.
In 2004, Inteq achieved the first successful commercial application of a 79.4-mm (3 1/8-in.) RSS. The 79.4-mm (3 1/8-in.) system was run through 139.7-mm (5 1/2-in.) casing to re-enter and drill a 114.3-mm (4 1/2-in.) hole.
The operator selected the slim hole to extend the horizontal sections while improving hole quality and placement accuracy. The system was custom-engineered to meet the pass-through restrictions in through tubing re-entry applications.
The AutoTrak X-treme system integrates the steering capabilities of the RCLS with the power of X-treme technology precontoured drilling motors. By combining the high rotary speed capabilities of the RCLS (to 400 RPM) with the high torque of X-treme technology motors, increased horsepower is delivered directly to the drill bit for maximum performance without compromising hole cleaning benefits of string rotation. Using hard-wired communication through the motor section, the system maintains two-way communications with the steering unit, assuring precise steering control from real time near bit inclination and steering system diagnostics.
Applications include drilling performance improvement, harsh environment drilling, drilling envelope extension and casing/drillpipe wear reduction. In addition to breaking local drilling performance records, AutoTrak X-treme is being applied in mature field re-entry programs to access stranded reserves economically; to extend the reach of ERD wells past prior limits, to reduce the risk of rotary steerable drilling in smaller hole sizes, and to improve field recovery while reducing drillstring wear in complex multi-lateral wells offshore India.
Gyrodata
Well-Guide is a third-generation RSS using point-the-bit technology. The system can drill highly accurate trajectories using pre-programmed courses with full downhole closed-loop control.
The system has proven itself in over 150 commercial bit runs in a wide range of conditions - from the softer formations in the North Sea, Gulf of Mexico and offshore California, to the hard and difficult formations onshore Italy and offshore The Netherlands. Applications have included holding vertical, kicking off from vertical, near horizontal drilling and complex 3D trajectories. Run durations are averaging 150 bit hours.
The company currently has two RSS tools: the 10-300 series with a dogleg capability of 3°/100 ft (30 m) for hole sizes of 311.15 mm (12 1⁄4-in.) to 444.5-mm (17 1/2-in.) (and up to 660.4-mm (26-in.) with a hole opener); and the 7-100 series with a dogleg capability of 7°/100 ft (30 m) for hole sizes of 212.7-mm (8 3/8-in.) to 250.8-mm (9 7/8-in.)
The system consists of a non-rotating outer collar, which houses a rotating transmission shaft that drives the bit. Steering is achieved by bending the rotating shaft with hydraulic actuators to point the bit in the target direction. According to the company, key features include:
- Fully automated closed-loop downhole control
- Near bit sensors for continuous 3D azimuth and inclination updates
- Pre-programmable multiple trajectories
- Trim control from surface while drilling
- Closed loop control for tangent holding and vertical drilling
- Kick-off from vertical or in a deviated section
- Steering to highside gravity toolface in magnetic environments
- Two full-gauge rotating stabilizers for optimum hole cleaning and for backreaming
- Full thru-bore for low pressure loss with no flow rate limitations
- No restrictions on formation type, fluid characteristics or media.
Halliburton - Sperry Drilling Services
Sperry Drilling Services’ Pilot launches its 2007 product fleet of automated drilling systems consisting of:
- Geo-Pilot XL rotary steerable system
- Geo-Pilot GXT rotary steerable system with integrated GeoForce motor
- EZ-Pilot rotary steerable system for cost-sensitive environments
- V-Pilot vertical drilling system.
The Geo-Pilot XL rotary steerable system builds on the established point-the-bit Geo-Pilot series. The XL Series includes the Torsional Efficiency Monitor (TEM), which alerts drillers to the onset of stick-slip so that drilling parameters can be modified and maximum drilling efficiency maintained, resulting in increased bit and LWD life. This system has long-life seal technology and other improvements to extend downhole running time in harsh conditions.
The Geo-Pilot GXT rotary steerable system incorporates all the XL Series improvements and adds a GeoForce enhanced performance range power section to deliver 50% more torque and more horsepower to the bit than conventional performance motors. The GeoForce motor is the next generation Sperry Drill motor, with the lobe profile machined directly into the steel stator housing. This yields better temperature capability and eliminates microstalling, resulting in higher overall rates of penetration and longer life in hostile conditions. The system is for extreme extended-reach drilling, providing high bit speed and torque while maintaining a lower rotary speed to reduce drill string fatigue and casing wear.
The EZ-Pilot rotary steerable system has 3D directional control with continuous drillstring rotation. The EZ-Pilot system targets cost-sensitive operating environments, which demand a straightforward, efficient solution. The system has few parts and can be serviced on location for in a more economical rotary steerable solution suitable for remote operations. This system is equipped with a real-time MWD communications link for monitoring near-bit inclination and tool status. The system has the point-the-bit concept and bit gauge extension, yielding consistently high hole quality and reducing the need for conditioning runs. It is capable of producing 8°/100 ft (30 m) dogleg in directional applications and also can be configured for vertical control.
The V-Pilot vertical drilling system is a complete departure from existing automatic steering technologies. This hydro-mechanical system automatically corrects back to vertical when inclination exceeds 0.2°. With no electronics, the system is inherently more reliable and suited to drilling in hard rock and high temperature environments. The V-Pilot is driven by either a GeoForce or Sperry Drill Performance power section depending on the rig capabilities. The rigid body and FullDrift bit stabilization design allows drilling with high weight on bit without inducing ledging, which results in increased ROP.
Noble Downhole Technology
A state of the art 3D rotary steerable drilling tool, Well Director, meets the demand for advanced directional drilling technology. This step-changing technology provides directional drilling control, increased rates of penetration and a smoother, less tortuous well bore. The tool’s near-bit sensors make continuous adjustments in the azimuth and inclination headings to steer the well accurately to the desired targets.
This technology enables operators to accurately and efficiently drill long horizontal and directional wells which previously were not cost effective. In addition, the use of this tool for vertical control improves the efficiency of drilling deep vertical wells in heavily faulted formations.
Noble has significantly upgraded the tool since its acquisition in 2002, including new high temperature (175° C/347° F) sensors and electronics. It can operate in conjunction with other service companies’ MWD/LWD and formation evaluation tools, providing increased flexibility in choosing suppliers.
Pathfinder Energy Services
Introduced in August 2004, the 311.2-mm (12 1⁄4-in.) PathMaker RSS has been deployed successfully on directional and vertical wells in the Gulf of Mexico, US onshore, North Sea and Middle East. The 215.9-mm (8 1⁄2-in.) version was commercialized during 1Q 2006.
The system consists of a non-rotating housing with three pads that maintain constant pressure contact with the wellbore. Steering is achieved by positioning the pads to offset the tool center from the hole centerline. Therefore, the system drills a continuous curve and does not rely on on/off biasing. Standard drilling practices such as drilling out shoe tracks, back-reaming, kicking-off from vertical, sidetracking off cement plugs and exiting casing whipstocks, are performed efficiently with this system.
Using point-the-bit and push-the-bit configurations, the system is the only RSS available that provides a real-time pad contact calliper measurement while drilling.
The calliper measurement, taken a few feet behind the bit, allows the driller to react to borehole enlargement changes by optimizing surface parameters. Typically, hole enlargement will reduce directional control and lower the expected dogleg output. Reaction to these wellbore changes results in a smooth and consistent well profile with lower torque and drag values to eliminate casing problems.
The push-the-bit configuration has proven effective in washed-out borehole environments. Since each steering pad has 25.4 mm (1 in.) of travel, the 311.15 mm (12 1⁄4 in.) RSS can steer in boreholes up to 330.2 mm (13 in.) diameter and can produce build rates up to 6°/100 ft (30 m). This system can be used in unconsolidated or washed out formations typically found on shallow water based wells.
Down-link commands are sent to the tool via drill string rotation while drilling ahead, making the system efficient and reducing the time to drill to the next casing point. A backup (redundant) programming method is for reliable communication in harsh drilling environments and underpowered rigs.
Recently implemented automated inclination and azimuth hold control improves drilling efficiency on long tangent sections and horizontals.
Real-time stick-slip and vibration detection allows monitoring of harmful near-bit vibrations at the RSS. This increases drilling efficiency and survivability of the RSS and MWD/LWD tools. The option of a RSS motor-assist assembly is used on underpowered rigs or simply for performance drilling to increase ROP beyond offset records.
With maximum dogleg capability of 10°/100 ft (30 m) in 212.7-mm (8 3⁄8-in.) to 222.3-mm (8 3⁄4-in.) holes and 6°/100 ft (30 m) in 311.15-mm (12 1⁄4-in.) holes, the RSS reduces overall drilling time in directional, horizontal and extended reach wells.
Integrated with LWD tools, the system can thread tight reservoir targets. It also is run stand-alone without MWD and may be used as a vertical drilling system maintaining verticality below 0.5° inclination. One pre-programming at the surface before the run is all that is needed to maintain vertical control. The system can be used with an underreamer and has drilled directional wells successfully while simultaneously enlarging the hole up to 444.5 mm (17 1⁄2 in.) The unique “floating pad” arrangement on the steering unit helps dampen unwanted vibrations typically generated with hole opening devices.
Schlumberger
The PowerDrive RSS offers improved ROP and efficient hole cleaning in demanding applications; kickoff from vertical, open hole sidetracks, tangent sections, slimhole extended-reach drilling, long lateral sections and drilling under harsh conditions at elevated temperatures.
All PowerDrive systems parts rotate at drillstring RPM. This enhances hole cleaning efficiency, wellbore quality, and reduces lost in hole potential due to mechanical or differential sticking can drill hole sizes ranging from 146.1 mm (5 3⁄4 in.) to 26 in. In 2006, a 165.1-mm (6 1/2-in.) hole size variant was added to address the needs of the US market.
PowerDrive Xceed is for harsh, rugged environments, and is suited for openhole sidetracking, and steering in overgauge hole and in soft-formations. Minimal wellbore dependence also allows Xceed to be run with bi-center bits. In 2006, Xceed 900 was added to the range and covers 311.15 mm (12 1⁄4 in.) to 374.7 mm (14 3⁄4 in.) hole sizes.
PowerDrive vorteX integrates a high torque power section with rotary steerable technology for performance in hard-rock. The system also prevents downhole vibration damage, and lowers the risk of drillstring fatigue and excess casing wear in hole sections with high doglegs. It is suitable for rigs with lower power specifications.
PowerV is a new fully rotating vertical drilling system that automatically drills an optimized vertical well. It senses if hole inclination is building and automatically steers to vertical. Once vertical, any deviation is corrected automatically. Therefore, little to no directional interaction or supervision is needed to operate the system. It requires no MWD system to function, although such systems or simple inclination only devices can be used to provide directional information.
The system also can run below a motor power section. It permits bit selection and weight on bit to be optimized for specific formations rather than be compromised through the need to slide with a conventional motor or to avoid deviating from vertical. Cost savings are realized through increased ROP and elimination of potential correction runs. Drilling operations are simplified because dedicated rig site supervision needs largely are eliminated. This adds to the system’s cost efficiency and reduces HSE exposure to personnel.
Target Energy Inc.
The smart drilling rotary steerable system (RSS) is a new generation of downhole closed loop push-the-bit RSS technology for 155.6-mm (6 1/8-in.) and smaller wellbores. The system improves ROP, and provides better hole cleaning, smoother wellbores and more accurate well placement, with an overall cost reduction. The system is based on steering physics and uses four hydraulic pistons combined with a downhole electrical and hydraulic power generation system and state-of-the-art magnetometer and accelerometer attitude measurement technology. It is designed to steer the bit from the current measured point to the desired position along a trajectory at a predefined build rate.
Another rotary steerable system, RockSTar, cost effectively incorporates the benefits of the more complex point-the-bit rotary steerable systems. Cost constrained projects can benefit from rotary steerable technology that incorporates:
- No sliding while drilling
- Rotational deviation eliminates need to alter drilling parameters for control of tool face
- Drilling parameters can be maintained to maximize ROP
- No hole spirals or fractional orientation ledging
- Continuous rotation minimizes torque and drag
- Continuous rotation improves hole cleaning
- Better hole cleaning reduces ECD
- Rotation reduces friction-increasing ROP
- Constant drill pipe movement reduces potential for differential sticking
- Ability to perform directional control at greater reach
- Allows more complex well profiles with lower risk
- Elimination of torque effect on toolface for slimmer drill strings at greater depths.
Weatherford International
Weatherford International (formerly Precision Energy Services) says it developed the Revolution service in 2003 as the first slimhole 120.7-mm (4 3⁄4-in.) RSS to use point-the-bit technology. Since then, its RSS has expanded to include 171.5-mm (6 3⁄4-in.) and 209.6-mm (8 1⁄4-in.) collar sizes, covering a range of hole sizes from 152.4 mm to 444.5 mm (6 in. to 17 1⁄2 in.).
Laboratory drilling tests, BHA software modeling and field experience show point-the-bit mode provides better hole quality, longer bit life and more efficient rock cutting than push-the-bit mode. Point-the-bit mode uses a pivot stabilizer between the bit and rotary steering tool to orient the drill bit axis with that of the hole. This improves wellbore quality by reducing ledging, spiraling, tortuosity and gauge problems associated with push-the-bit systems.
Simulation and field experience has been used to optimize BHA designs that achieve efficient face cutting of the bit in point-the-bit mode. These designs help the RSS maximize penetration rates and eliminate inefficient side-cutting forces, improving bit life and stability, while reducing harmful vibration that can damage other BHA components such as LWD tools.
The company says point-the-bit systems drill a smoother wellbore that is more nearly gauge than push-the-bit systems. A smooth wellbore allows the RSS to steer the bit consistently to the exact target, extending well sections and improving completions and reservoir optimization.
The system’s compact design reduces BHA complexity while placing critical LWD formation evaluation components close to the bit. The result is higher than average ROP and fewer DLs than in wells drilled with conventional motors.
Click here to view 2007 Annual Rotary Steerable Systems Directory
