Deepwater drilling

Bits, and hole enlarging.

Table of contents
DEEPWATER DRILLING.....................................................................................................1
BITS, AND HOLE ENLARGING. ..................................................................................................1
TABLE OF CONTENTS ...............................................................................................................1
BIT TYPE & SELECTION ...........................................................................................................2
Bit type. ..............................................................................................................................2
Bit selection........................................................................................................................2
Bit type & selection: Rules of thumb shallow sections. .....................................................3
DRILLING OPERATING PARAMETERS........................................................................................4
Weight on bit. (WOB).........................................................................................................4
RPM ...................................................................................................................................4
Drillstring vibration. ..........................................................................................................6
Deepwater directional bit hydraulics planning. ................................................................7
Deepwater directional drilling rules of thumb ................................................................11
DEEPWATER HOLE OPENING AND UNDER REAMING ..............................................................12
Optimization.....................................................................................................................12
Bottom hole cleaning/hydraulics optimization ................................................................14
Hydraulics optimization ...................................................................................................15
Operating parameters ......................................................................................................16
DEEPWATER HOLE ENLARGING. ............................................................................................19
Hole open or under-ream?...............................................................................................19
BICENTER BITS AND REA MING WING TOOLS . .........................................................................21
Bicenter bits .....................................................................................................................21
Reaming wing tools. .........................................................................................................21
Near bit reamer................................................................................................................25
The hole enlarging future.................................................................................................26
DEEPWATER BHA COMPONENT AND DESIGN CONSIDERATIONS............................................28
BHA behavior relative to deepwater formations. ............................................................28
Deepwater BHA design Rules of thumb...........................................................................30

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Bit type & selection
Bit type.
Bits selection criteria should be based on a balance of teeth, bearing and gauge
wear, not minimum cost, while maintaining wellbore trajectory to meet section’s
drilling objectives at optimum performance. Balanced wear is when the wear on the bit is
determined by the condition of the teeth, bearings, and gauge wearing out at exactly the same
time. The problems in selecting bits using the minimum cost are;
- Bit selection can only be based on drilling experience.
- Lowest cost is usually interpreted as lowest cost per foot. This is not necessarily true
- Cost comparisons between bits must be made with each bit operating at its optimal
weight, speed and running hours.
- All other factors must be reasonably similar.

Roller cone bit features.

During deep water drilling, roller cone bits/hole openers are used in the shallower
sections. In roller cone selection we must consider, bearings, seals, lubricating
system, design geometry, cutting structure and roller cone feature. Additional
features most common to consider to enhance performance would be, centre, jet, high
flow tubes/extended jets, leg protection, hard facing and enhanced gauge protection

Bit selection
In deepwater shallow formations drilled, optimum drilling performance is normally
achieved using the longest tooth bits, to result in even teeth, bearing and gauge
wear. i.e. IADC code 1-1-1 to 1-3-5 bits, with 2-3 degree cone offset, when operated at
optimal operating and engineered conditions. Bit selection must also consider
formation characteristics, section length to be drilled, directional work required, bit
availability, desired bit features and consideration to offset well data i.e. past performance &
lessons learned.

In the open water section(s), soft-medium formations drilled, teeth wear is however
rarely a problem. “Roller” bearings however are often subject to wear and an IADC
code 5 (sealed bearing) may be preferred especially on hole openers. Centre jets,
extended nozzles and asymmetric flow can also often enhance bit cleaning and
prevent hole washout. Hard banding on bit gauge and/or teeth, sealed bearing (
required for rough drilling or high cutter speeds anticipated) are additionally features that
can improve bit performance, life, bit and bottom hole cleaning, and may be
applicable albeit only in certain circumstances and conditions.

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Bit type & selection: Rules of thumb shallow sections.

1.) Bits selection criteria should be based on a balance of teeth, bearing and gauge
wear, not minimum cost,
2.) A 1-1-1, or 1-1-5 bit is best suited to open water environments.
3.) 1-1-1 and 1-1-5 bits and hole opener components and cutters are not the same.
Selecting best in class can improve performance.
4.) To ensure both bits and hole openers operate efficiently, BHA, bit weight , rotary and
cutter speeds should be optimised to provide a minimum cost per foot environment.
(refer to section on bit operating conditions.)
5.) Centre jet, jet type, and jet optimisation significantly provide optimum drilling
performance and bit/bottom hole cleaning conditions.
6.) Review offset data to review bit, cutter type and bearing selection for best
optimisation.
7.) Bits and hole openers must be combined with proper BHA design and operated
under specific operating and engineered parameters to achieve best results.

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Drilling operating parameters.
Weight on bit. (WOB)
To establish optimal WOB, engineering calculations can be performed to establish
maximum weight on bit before tangency before hole build or drop will occur.

Rules of thumb, WOB

1.) WOB must be controlled until sufficient BHA has penetrated the seabed.
2.) If no build tendency is observed, WOB can be increased accordingly to pre-
determined values to optimise performance
3.) Weight on bit must be maintained below the point of tangency to ensure verticality.
4.) Engineer what WOB is and is not allowable, apply a safety factor and then apply
parameters as required to maintain optimum ROP.
5.) Optimising Bit nozzles for efficient bit/bottom hole cleaning. This will result in desired
ROP at significantly reduced weight , more readily facilitating drilling a straighter
wellbore.
6.) If formation dip is noted in area, do not be surprised if BHA tracks in one preferred
direction.
7.) Control WOB when a negati ve drilling break is observed, i.e. a slowdown in drilling. to
ensure instantaneous undesired hole angle build is avoided.
RPM
Penetration rate increases linearly with increased rotary speed to a threshold limit.
At higher speeds, the response of penetration rate to rotary speed then diminishes.
In larger e.g. 26” and 36” hole sizes, optimum rotary speeds recommended vary depending
on formation types. Table 11 illustrating manufacturers recommendations for bit and
hole opener combinations
Table 1: Recommended bit and hole opening rotary speeds.

Bit & Hole opener Hard Medium Soft

Rotary speed (Rpm)
36” 40 - 80 60 –100 80 –120

26” 60 - 100 80 - 120 100 – 140

17.5” 80 - 120 80 - 140 100 – 180

Cutter speeds.
As the drill string and roller cone bit and/or hole opener rotates in a larger hole size. The bit
cones and peripheral cutter’s speed increase due to increase in circumferential distance
required to be traveled (see table 11 ) Drilling performance, optimization and hole quality can
therefore be effected if cutter speed, hole circumference, bearing and cutter type(s), larger
hole sizes are not properly assessed and accounted for.

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Example 1: Calculating peripheral cutter speeds

The table below illustrates cutter speeds for a drillstring rotating at 100rpm, if a 36”
hole opener has10” cones, a 26” bit, 14” cones and a 12 1/4” bit, 8” cones. (sizes
taken from a drilling equipment handbook.)
Equation 1: Peripheral cutter speeds.

 2π * Hole...radius 
= RPM ×  
 2π × Cutter...radius
Table 2: Bit and hole opener cutter speeds ratio's

Drillstring rotating @ 100rpm.

Bit /Hole size 12 ¼” bit 26” bit 36” hole opener

Cutter/Bit ratio Ratio : 1.5 - 1 Ratio: 1.9 - 1 Ratio : 3.5 - 1
Cutter RPM 150 rpm 190 rpm 350 rpm

Table 12 illustrates cutter speeds vary with cone and hole size. When considering
that the most efficient cutting action is dependant not only on the formation
characteristics and its hardness but also the speed and type of cut of the roller cone
teeth into the formation it is again fundamental to account for cutters, bearing type(s)
and the mechanism required to drill most efficiently. e.g. in soft-medium formations to
scrape, gouge the formation.

Rules of thumb, RPM.

1.) Be aware of cutter velocities in large holes especially hole openers.
2.) Apply rotary speeds as prescribed in table 3.
3.) If rough drilling is noted, change rotary speeds, if no effect is noted, formation
may be the root cause.

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Drillstring vibration.
Severe vibration often occurs during deepwater open water drilling and is generally
considered to be predominantly due to formation characteristics (e.g. while drilling
through boulders, pebble cobble beds.) However drillstring dynamics show that both
severe lateral and longitudinal vibrations are most likely in vertical well bores. Effects
of verticality & limited pipe stretch providing non-dampening conditions where any
energy input can be used to build up amplitude and increase without limits.
Vibrations are therefore often attributable to drillstring conditions and can vary for
weight on bit, rotary speed, drillstring, wellbore size, length and geometry.
Longitudinal, lateral or torsionally related vibrations can occur and could be coupled
with natural frequencies resulting.

Vibrations; Rules of thumb

1. In vertical wells as dampening can be minimal, forced excitation can readily
occur.
2. Design BHA to avoid vibrational speeds for section length & formations drilled
3. Rough drilling is easily noted at surface in open water drilling. Change rotary
speed. If no difference, stop rotating, pick up of bottom and re-establish
parameters. if vibration persists then conclude formation may be the culprit.
4. Plan the BHA length for section to be drilled
Anti vibrational practices: Rota ry BHA
The following times should be addressed to ensure rotary BHA’s are best managed
to avoid unnecessary vibration effects e.g.
1. Bit break in procedures.
2. Reaming guidelines.
3. Making a connection to achieve minimum vibration.
4. Negative drilling Break practices.
5. Actions to be taken when string Stick slip detected.
6. Actions to be taken when string Lateral vibration / whirl detected
7. Actions to be taken when string axial vibrations / bit bounce detected.
8. Drilling Abrasive formations guidelines
9. Drill off test guidelines
o Optimum bit weight
o Optimum rotary speed
o ACTIVE drill off test
o PASSIVE drill off test.

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Deepwater directional bit hydraulics planning.
Primarily, in addition to optimal flow rates and mud properties, inadequate bit &
bottom hole hydraulics in both vertical and high inclination well bores, no matter what
type of well or what kind of drilling fluid is used will cause re-grinding of cuttings. This
will result in the following difficulties :

§ Lower ROPs,
§ Inefficient hole cleaning (fines are very difficult to clean from the wellbore no
matter what the flow rate.)
§ Poor hole condition (excessive solids build up on wellbore wall),
§ Inefficient solids removal, leading to mud deterioration
§ Tight & unnecessary difficult trips,
§ Having to backream, often creating further hole instability, enlargement,
hole deterioration, pack off, stuck pipe, lost circulation and often a
requirement to side-track the section.
§ The use of inadequate and often misunderstood drilling practices.
Bottom hole cleaning / ROP.
Fig 20 illustrates the effect that properly afforded bit hydraulics / bottom hole
cleaning and ROP trend that results in deepwater development build and turn
sections from 20 degrees to horizontal in both 12¼” and 14¾” steerable motor
assemblies that were run with insert bits (IADC 4.1.5 – 4.3.7, 5.1.7.). From fig 1. Bit
bottom hole cleaning hydraulics can be seen to have a clear effect on ROP. It is also
important to note that operational incidences increased i.e. drilling, tripping and casing
difficulties (at a ratio of 4:1) in wells where ill-afforded hydraulics had been applied.

Figure 20; represents 12¼” & one 14 ¾” insert bit runs, directionally drilled sections
from approx. 20-90degrees. (Section lengths 600 – 1200 m)
Figure 1: Bit and bottom hole hydraulics optimisation

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 HSI vs ROP

10.50

9.50

8.50

7.50

6.50
HSI

5.50

4.50

3.50

2.50

1.50
0 5 10 15 20 25 30 35 40

ROP ( m/hr )

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Planning considerations

Soft soft-medium formation directionally drilled sequences, from low angle to

horizontal, with drilling section objectives of:
1.) Design and engineer bit and BHA to drill section in one bit run;
2.) Design for a smooth wellbore geometry with < 3 degree doglegs;
3.) Model hole cleaning for High ROP’s;
4.) Model drilling, mud and directional parameters for adequate hole cleaning;
5.) Manage mud and solids control equipment to ensure high solids control
efficiency, especially at the shale shakers;
6.) Avoid wiper trips with steerable assemblies unless absolutely; necessary;
7.) Apply best practices to ensure a quality hole while achieving the above to run and
cement casing without problems, o r any requirements for additional trips.
8.) Avoid reaming until hole conditions dictate.
9.) Do not backream, Only to be used as a last resort. (study conducted in 2000
demonstrated reaming only serves to reduce overall section performance significantly.)
10.) Drill a hole in the first place that can be readily tripped and cased.
11.) Do not drill a hole faster than it can be cleaned.
12.) Prevent problems rather than trying to compound them. e.g. backream out
of the hole. Note: Prescription without diagnosis being essentially malpractice.

Delivery Results
In wells drilled in phase one of a deepwater drilling project. When applying properly
afforded bit/bottom hole cleaning, results in executing four directional sections, meet
all objectives to suit each well’s needs and requirements as outlined on previous
page. I.e. No reaming or wiper trips were required, casing was run and cemented without
difficulties.. This was achieved by a combination of utilising:
§ Actual well, offset data;
§ Hydraulics / hole cleaning modelling & simulations;
§ Flow rate sacrificed to facilitate optimised drilling and bit/bottom hole
cleaning;
§ Good mud management practices;
§ Fundamental best drilling practices. (no upward rotation applied.)
§ Operator rig floor supervision during open hole trips
The objective of cleaning the bit and the hole at maximum ROP’s was conducted
without experiencing any major drilling, tripping, casing and cementing problems.
A “first” in the field was also achieved by drilling the 12 ¼”section, reaching section
TD in one bit run, tripping out of the hole, and immediately running casing without
difficulty or wiper trip performed. Such success attributed essentially to good oilfield

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practices, sound applied drilling engineering at the rig site, full team participation,
with full awareness and communication maintained with all personnel involved.

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Deepwater directional drilling rules of thumb
1.) Monitor the shakers continuously.
2.) Nozzles to provide: 6-9 HSI, and 350-450 ft/sec Jet velocity.
3.) Use a combined 6 5/8 ” & 5” or a 5½” drillstring.
4.) Model motors and other down hole tools in on bottom hole drilling pressures.
5.) Optimise mud rheology in simulations and aim for these while drilling.
6.) Backream only as a last resort.
7.) Use best practices to manage cuttings and/or fines beds.
8.) Only rotate when moving downwards into the hole.
9.) Wipe the drillstring prior to making connections (without rotation).
10.) If prolonged sliding is required, only ream down, prior to making connections.
11.) When working string for circulating periods, orientate motor to high side and
keep the pipe moving. Consider laying out a stand every hr.
12.) On trips out, pump out if increasing resistance is noted in high angle sections.
13.) Don’t pull faster than you can pump.
14.) Circulate clean when into lower inclination section of wellbore.
15.) Have mud loggers provide a litho-log for trip out of the hole to aid in
recognising increased drag / stuck pipe mechanisms.
16.) Ensure drillers know what to do, where and when.
17.) Wiper trip only if hole conditions dictate.

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Deepwater Hole opening and under reaming
Hole opening and under reaming is required after drilling pilot holes and during
deepwater drilling operations where the demands of multiple casing strings have to
be met. If bits and hole openers are not optimised, penetration rate suffers, tools can
become balled up, and more weight on cutters is required in order to maintain the
desired ROP, often resulting further in:
• Increased torque
• Increasing hole inclination
• Reduced tool life
• Rapid tooth wear generally caused by skidding cones, characterised by localised
flat crested tooth wear.
• Reduced hole quality often resulting in additional drilling problems.

Optimization
In order to optimise bit, hole opener and under reaming, drilling efficiency aspects to
consider are: Component design, nozzle placement, bearing selection and bottom hole
cleaning/hydraulics. These need due attention to fully evaluate a practical, engineered
and technical approach to hole opening.

Hole opener under reamer design

Many different designs of hole opener’s and under reamers exist and they are not all
the same. Many designs do not meet the simplicity of design required to provide the
fundamental drilling requirements of a formation-cutting component.
I.e lubricate and maintain the cutters clean.

The following items should be considered when reviewing requirements for a specific
application.
1. History of the tools, service life, QA records, threads, thread stress relief, connections,
bore back etc.
2. Can the nozzles be replaced?
3. Do the jet nozzles impinge on the cutters, pocket or wing areas of the hole
opener?
4. Are the nozzles adjacent to the cutters or placed behind the cutters?
5. Are sealed and non-sealed bearings available for the tool?
6. Available cutter types, e.g. soft, medium or hard formations
7. Ease of field change out.
8. Price and replacement cost of cutters, in hole, and lost in hole charges.

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Nozzle placement aspects.
In methodology there is little difference between optimising hydraulic horsepower
(HHP) or jet impact force (JIF) when hole opening in shallow and soft formations.
Experience has shown, however, that the optimisation of cutter cleaning and flow
balance between the hole opener and bit should be made relative to the volume of
cuttings generated. In that field data recorded demonstrates that significantly
increased performance can be achieved through such hydraulics optimisation. Note:
Optimisation can only be achieved if the nozzles are correctly aligned and positioned.

Common design faults.

1. Nozzles placed too far from the cutters or hole serving no purpose.
2. Nozzles positioned to jet onto the wellbore, i.e. will wash out hole
3. Nozzles of a fixed size no selection & optimisation can be carried out.
4. Nozzles are inadequate in number.
5. Nozzles cannot be changed, i.e. are welded in.

Velocity profile
Efficient velocity profiles help deliver hydraulic energy where it is needed. This is
especially desirable when flow rates are compromised. In such cases the velocity
profile can greatly assist in keeping the cutters clean.

Extended nozzles
In soft formations extended nozzles should be used as they deliver maximum
hydraulic energy and fluid velocity to the cutting surface. Increased ROP that result
can also improve the bit life as cuttings regrinding, tooth wear and improved
hydraulic efficiency can result. Extended nozzles can aslo provide a velocity profile
that minimises hole erosion, improving hole quality and directional control in both
vertical and deviated wells.

Cutter & Bearing selection

Selection criteria involves balancing teeth, bearing and gauge wear to meet section
objectives at optimum performance. Roller cone cutters generally warrant small pin
angles allowing for larger cones, thinner bit legs and longer gauge length. This
results in one row of teeth driving with the other rows sliding, providing a preferred
scraping tooth action of benefit to drilling performance.

Cutter selection
In open water use the longest tooth cutters, consider formation characteristics,
section length to be drilled, any directional work required, cutter availability, desired
features and o ffset well data. In open water section(s) tooth wear is rarely a problem.

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Bearing selection
“Roller” bearings are often subject to wear and a sealed bearing may be preferred on
hole-openers, especially if a long section length is to be drilled.
If higher rotary speeds are anticipated, cutter peripheral speed needs to be
accounted for in the work being done by each bearing.

Bottom hole cleaning/hydraulics optimization

Methodology
There is little choice between optimising hydraulic horsepower (HHP) or jet impact
force (JIF) in shallow “open water” riser less and often intermediate sections. I.e.
Maximum HHP = 90% max of impact force and visa versa.

In holes > 17 ½“, HHP and JIF criteria are not well defined. Experience has proven
however that both optimised cutter cleaning and flow balance between hole openers
and bit should be applied relative to the volume of cuttings generated. Field data
demonstrating that significant increased performance can be achieved through such
a hydraulics optimisation approach.

Balanced flow
Primarily, design for a balanced flow relative to the quantity of formation cut by each
set of cutters, e.g. From table 13, for a 14 ¾” – 26” two stage hole opener, ratio 2.11
– 1. Design for 1/3 rd flow through the bit and 2/3rds flow through the hole opener.
Table 3 : Bit, Hole opener, under-reamer cutter ratios

Pilot bit ; Size & area cut Hole opener size Area cut Ratio
Size (inches) Area (sq.in) Size (inches) Area (sq.in) Hole O / bit
36” 531 42” 854 1.61 – 1
17 ½” 241 42” 1145 4.76 – 1
26” 531 36” 487 0.92 – 1
17 ½“ 241 36” 777 3.23 – 1
17 ½” 241 26” 290 1.20 – 1
14 ¾” 171 26” 360 2.11 – 1
12 ¼” 118 17 ½” 123 1.04 - 1

Balanced cutter ratios

Select a balanced cutter ratio to share work each set of cutters must deliver.

Jet velocities
The required jet velocity must be applied to the cutter of both bit and hole openers.
This required criteria ensure that cutters are kept clean which is essential for hole
opening (drilling) optimisation. E.g. >26” hole 250-350ft/sec, > 17 ½” hole 350-400 ft/sec,
> 14 ¾” hole 400-450 ft/sec

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Mud pump utilisation
In top and surface hole, to achieve required minimum jet velocities, the available
pump pressure energy is often not fully utilised. Ensuring optimal pump energy
usage by suitably sizing jet velocities to the cutting components of the drillstring is
therefore important.

Pitfalls
Avoid running bits with large nozzles, this does not provide the required flow or jet
velocities to the hole-opener cutters. Cuttings will pack off around the hole opener
cutters resulting in excessive cutter and saddle wear. Similar wear will occur if hole
openers are blanked off or welded over.

Balancing flow
Of course, for different formations, more flow and jetting action may be required
through the pockets than the wings. E.g. In soft sticky gumbo formations, more flow is
generally thought to be required in the pockets to keep the cutters clean. In such cases,
smaller nozzles should be placed in the wing areas so balanced flow & jetting is
provided to the pockets of the tools.

Pilot hole opening

The rule of thumb here is often 25% of flow should go to the pilot bit and 75% to the
hole opener. Dependent upon bit/hole opener sizes and ratios this can, of course, be
fine-tuned as per guidelines provided within this article.

Hydraulics optimization
The examples illustrated present a process of how hole opening or under reaming
hydraulics optimisation can be conducted.

Hydraulics optimisation guidelines

1. Select tool and nozzle design to suit needs and requirements
2. Calculate volume of formation drilled per foot drilled by each set of cutters
3. Determine maximum likely flow that will be available from mud pump output (e.g.
from offset, similar well data, rig equipment .)
4. Consider if required pump can be provided at the bit & tool(s) cutters.
5. Afford jet velocities to keep cutters clean & utilise pump pressure allowed.
6. Calculate required total flow area for each bit and hole opener(s)
7. Select nozzles to suit, evaluation is required for both the wings and pockets of the
tool(s)
8. Drill the section

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9. If drilling with seawater, sweep hole every with suitably sized sweeps
10. Measure and evaluate results, performance, drilling parameters, bit, teeth,
condition and/or correct operational optimisation. Note: When drilling with seawater,
pressures will be approximately 300-500psi higher when pumping high volume viscous
sweeps. Be sure to account for this.
11. Use all pump power (pressure) available.
12. Engineer to provide a balanced a flow relative to amount of formation removed by
each set of cutters ensuring minimum jet velocity (250-350ft/sec) to maintain clean
component’s cutters
13. Review offset wells to establish best performance
14. Vertical wells are easiest to clean, don’t get too hung up on flow rate.
15. Keep the pipe moving to prevent enlarging hole.
16. Reduce pump rate while wiping and reaming.

Operating parameters

RPM
Soft formations do not need high rotary speeds to be drilled efficiently. Higher
speeds may, however be required for directional needs to maintain verticality or to
prevent and mitigate against down-hole vibrations. In these cases, peripheral cutter
speeds must be considered, especially on larger sized tools.
WOB
When efficient cutting occurs, low weight on bit will maintain the required ROP.
Experience has demonstrated that preventing hole loading and keeping the hole clean and
straight has been the constraining factor on wells for this author. Penetration rates and
weight limits on tools have not been a concern.
Flow-rate
Engineers frequently get carried away with flow rate requirements, especially in
vertical holes. E.g. In a recent well, during both 26”/36”/42” hole opening (at 92ft/hr) and
26” hole (controlled drilling at 118ft/hr), flow rates of only 1000gpm and 900gpm were used
without any difficulties. Take note; vertical holes are the easiest to clean. The
important criteria is to ensure that hi-viscous sweeps are pumped frequently so
cutters and hole are flushed clean.
Results
The principles outlined to optimise hole opening and under reaming has provided
improved performance in recent projects. Optimum drilling efficiency resulted by
keeping the cutters clean, balancing the flow and sweeping the hole regularly. Jet
selection was chosen to achieve desired jetting (cutter cleaning) velocities within the
available mud pump (flow and pressure) limits produced increased performance over
offset wells, up to 400% in some cases.

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Benefits viewed.
1. Higher ROP’s (in fact drilling in top hole was controlled due to annular loading, i.e. a Ultra
deepwater well where ECD concerns did prevail.)
2. Low WOB requirements (less wear and tear on components, easier to stay vertical)
3. Low torque (demonstrating efficient cutting action and cutter cleaning.)

4. A perfectly straight wellbore (where wellhead inclination of < 1 deg is critical to prevent BOP,
riser, wear bushing key-seating, wear etc .)

Example calculations attached for

- 17 ½” bit, 26” and 36” hole opening assembly. (Flow rate 1200gpm, Jet velocity
300ft/sec.)
- 14 ¾” bit, 26” hole opening. ( Flow rate 900gpm, Jet velocity 250ft/sec.)
Criteria Used in calculations.
- Flow balance ( Q = Q1 + Q2 + Q3 etc.) based on the volume of formation that
each set of cutters theoretically drills.
- Continuity equation (Q=AV) for a jet velocity (i.e. V > minimum of 250ft/sec.)
- Nozzles selected from the total flow area (TFA) that results through applying
the continuity equation . i.e. A = Q/V

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Example 1 : 3 stage hole opening, Deep Open water drilling from Semi Submersible.

Maximum anticipated flow rate 1200 Gpm Volume of hole / ft drilled

Required jet velocity 300 ft/sec Bit 1.67 ft3
hole opener 1 2.02 ft3
Bit size (inches) 17.50ins hole opener 2 3.38 ft3
Hole opener 1 (inches) 26.00ins Total 7.07 ft3

Hole opener 2, (inches) 36.00ins

Balance for each set of cutters
For one hole opener insert same sizes in 1 & 2 Bit 284 Gpm
hole opener 1 342 Gpm
hole opener 2 574 Gpm
Note: 1.1.1.1.1.1 Total 1200 Gpm

Apply continuity equation for TFA required

Flow area for each set of cutters
Bit * 0.364 sq ins
Hole opener 1* 0.440 sq ins
Hole opener 2* 0.737 sq ins
Total flow area 1.541 sq ins

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Deepwater hole enlarging.
Hole enlarging with non conventional drilling assemblies is often difficult and
problematic. In addition, high down hole and surface torques often accompany
drilling operations, yielding violent, transverse vibration on bottom hole assembly
(BHA) components. Such destructive energy alone is sufficient to fail down-hole tool
components prematurely. For this reason, enlarging well bores was usually
discounted in the well construction activities. As the industry commenced to explore
in greater water depths, with drill string trip time and associated costs to consider,
drilling optimization and minimal trips became an essential priority. e.g. Eliminating
one trip in deepwater, can save in excess of $100,000 for the operator. In simplicity, < BHA
changes and trips results in reduced tripping time, > efficiency and enhanced cost
savings. At present, deepwater drilling is one of the new frontiers for both under-
reaming and hole opening technology application’s e.g. Typical top hole sections may
require 5 days of rig time at a rig costs often in excess of $200,000/day. Hole enlarging to
drill sections in one trip can thus provide significant benefits.

Hole open or under-ream?

The essential difference between hole openers and under reamers are that hole
openers enlarge an existing pilot hole from the surface of the wellbore and contain
fixed cutters of a pre-determined diameter. Conversely, under-reamers enlarge the
hole below a restricted tubular bore allowing annular clearance to be able to run
additional casing strings. The cutters are kept closed during the pass-through and
are activated once the tool reaches the point that requires under-reaming. Turning
the pumps off deactivates the under-reamer cutters with this technology.
Today, therefore under-reaming offers several product options, including:

- bi-center bits,
- reaming wing tools,
- expandable bits,
- under-reamers
- near bit reamers.

Under reaming and drilling & under reaming simultaneously are also regularly
performed with PDC under reamers, with no loss of arms, even in horizontal holes.
These under reamers have no locking devices. For a reaming tool to work in many
situations with operator confidence, improved designs are however needed. E.g
illustrated example from Security DBS, a division of Halliburton Energy Services is a short
fully-stabilized Near Bit Reamer (NBR). Here, these tools can be used to drill oversized
holes, ofte n more efficiently than with some bi-centre bits, reaming-while-drilling
tools, or other types of reamers. Unlike most bi-centre bits and reaming-while -drilling
tools, the NBR has also been used on both conventional mud motor and rotary
steering directional assemblies. Successful runs have been recorded offshore
Norway, e.g. a record run of 2,213 meters of continuous drilling/under-reaming, 20
successful runs offshore Norway and 17runs in the Gulf of Mexico to date.

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Hole enlarging methodology
The accompanying tables in this section, lists the strengths and limitations for under-
reamers, hole openers, bi-centre bit and reaming wing tools application in deep
water drilling operating environments. Essentially under-reaming in deepwater softer
formations can lead to impressive gains in penetration rates. Also under-reaming
often allows both flexibility and contingency to accommodate design for multiple
casing strings that may or may not be required to isolate shallow geo-hazards, e.g.
shallow water flows in the Gulf of Mexico. Problematic areas however can include
cutters becoming “mud packed”, “balled” etc. due to poor hydraulics, cutter cleaning,
inadequate nozzle size and design, reduced rate of penetration, unable to close
cutters etc. making it extremely difficult to pull out of hole. Note: On some designs
PDC under reamers don’t show any balling behind the arms, because there is a nozzle
dedicated to each arm wing to keep it clean. Historically, such factors swayed decision
making in regards to under-reaming and as such under-reamers still have a way to
go in terms of improving mechanical integrity robustness and total reliability.
To improve the mechanical integrity of traditional arm type under-reamers, the
development of bi-center bits, reaming wing tools and polycrystalline diamond
compact under reaming cutters are working towards eliminating the traditional
problems associated with mud packing and arm breakage. E.g. Typical tool life being
extended to 10 runs or more. A further procedural innovation i n under reaming involved
the removal of all cutters from worn roller cones, and replacing with new cutters.
Such cutters being stub -welded in place once fatigue became an issue. Three-cone
under-reamers are also capable of enlarging holes by as much as 50%, and are
typically selected according to formation type so as to optimise performance. The
tools also allowed full volume circulation at all times.

Reamer classification
It is convenient to classify the various reamers as either
• drilling or reaming types.
The reaming type serves only to enlarge an existing hole, involving complete section
re-drill. Conversely, the drilling type allows for the simultaneous reaming of a pilot
hole as it is drilled. It can also be used to under-ream existing holes and its design
allows mudflow to be diverted to the bit or can even be used with guidance system
such as a bull nose for pilot-hole re-entry. The latter has been reported to give good
hold or slight build tendencies, depending on formation and other factors. Thus, its
performance resembles a packed-hole assembly.

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Bicenter bits and reaming wing tools.
Bicenter bits
In the 1990’s, bit manufacturers developed bi-centre bits capable of drilling enlarged
hole sections beneath up to 13 3/8” casing strings. Increased demand and use of for
these bits highlighted certain technological limitations, e.g. poor directional, notably
inclination, drilling performance essentially linked to the lack of a full-gauge stabilizer above
the bi-centre bit, that resulted in bottom hole assembly (BHA) stabilization issues.
It was concluded that without properly afforded stabilization, directional requirements
depend almost entirely on the bent motor housing to steer. Consequently, to make
changes in inclination, drillers spent too much time slide drilling that can be difficult at
the best of times, let alone with the added complication of running a bit that is
geometrically unstable. From this perspective, there was an understandable
apprehension towards running bi-centre bits. As bit/BHA steering issues continued to
hinder directional performance, bi-centre bit manufacturers continued however to
develop more preferred design and operating methods to improve bit & BHA
directional behaviour. E.g. A realization that bi-centre bits could to an extent be steered by
weight and that longer bit profiles helped to stabilize BHA performance.
The success of bi-center bits however does not remove the need for hole openers in
many applications, or eliminate the need to drill the interval twice. E.g. in deep open
water environments, pilot holes are often required to gain valuable data acquisition, to
identify geo hazards, in a hole size where problems can be more readily dealt with. Often
data is required first to make more valued , risked based and cost efficiency savings later.

From the drilling engineers' point of view, a single integral component can however
potentially reduce “while drilling” risks, associated times and costs as compared to
two or three component requirements. All these factors when duly considered
however confirm a place of the bi-center bit in the industry and potential for use in
deep open water applications.

Note: Bi-center bits often produce excitation force required to induce vibrations that are then
detrimental to drillstring and BHA components, It is also felt that they do not drill out shoes
as efficiently as predicted. Finally recent calliper logs run in the GOM illustrated that large
sections of the wellbore had not been enlarge “opened up” at all.

Reaming wing tools.

Finally, a new technology is the reaming wing tools, that feature polycrystalline
diamond compact bit with a ream while drilling capabilities. These tools differ from bi-
center bits in that it they are essentially a two-piece design, allowing for greater
flexibility in pilot bit selection. Directional control would be conducted through a
steerable motor. Again with all factors duly considered reaming wing tools may have
some potential for use in deep open water applications, notably in shallow high angle
wellbore field developments.

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Table 4: Underreaming operating characteristics

Hole enlargement in deep open water drilling

Underreamers
Disadvantages Advantages

Eccentric cutting action leads to hole bellying, Enlarge wellbore size below last set casing string
increasing likeliness of hole instability, tool &
equipment problems.
Can be more costly than Bicenter bits and/or hole Offer some flexibility of operation
openers.
Perception of arm breakage and failure, hence Concentric cutting action means a smoother hole
greater risk
Requires stabilisation of bottom hole assembly. Aids in reducing vibration, delivering better hole stability quality, and
gauging prior to running casing
Risk of mud packing and inability to retract arms Simultaneous drilling and reaming

Fatigue and bending stresses on arms, body and Arms retract when pumps off. Advantageous when pulling out and
connections through casing.
Hydraulics i.e. efficient nozzling and cutter Most tools designed with roller cones, better suited to open water
cleaning often a problem. If not afforded “balling” formations
can occur.
PDC cutters better suited to more consolidated formations

In traditional designs, pivot arms unsuited to Greater certainty of hole gauge. Can be a vital consideration for
deviated wells. In some tools difficult to optimise tripping, logging and casing running/cementing.
nozzle flow.

Table 5: Hole opening characteristics

Hole openers
Disadvantages Advantages
No flexibility of operations. Concentric cutting action means a smoother hole, decreased torque
and lateral vibration.
Robust strong and sturdy tool design.

Hydraulics i.e. efficient cutter cleaning often a Most tools designed with roller cones, better suited to open water
problem formations

Requires stabilisation of bottom hole assembly. Aids in reducing vibration, delivering better hole stability, quality,
and gauging prior to running casing
Hydraulics i.e. efficient nozzling and cutter PDC cutters better suited to more consolidated formations
cleaning often a problem
Need to keep tools moving in deviated wells to Certainty of hole gauge. Can be a vital consideration for tripping,
prevent side-tracking the hole. logging and casing running/cementing.
Two trips often required to drill section. Often advantageous for hole cleaning, getting data acquisition from
pilot hole.

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Table 6: Bi-center characteristics

Hole enlargement in deep open water drilling

Bicenter bits
Disadvantages Advantages
Eccentric cutting action leads to hole bellying, that Enlarge wellbore size below last set casing string
may increase likeliness of wellbore instability, tool
and equipment vibrational problems.
Requires stabilisation of bottom hole assembly. Aids to reduce vibration, delivering better hole stability
quality, and gauging prior to running casing

Diameter of enlarged hole varies between pilot Relatively cheaper than under-reamers
hole and desired gauge.
Increased lateral vibration and torque with larger Integral component with less chance of breakage, failure, lost
OD tools, especially in highly drillable formations. in hole consequence.

Difficult to keep wells vertical, lending to difficulties

running casings.
Risk of mud packing and inability to clean cutters Simultaneous drilling and reaming

Hydraulics i.e. efficient nozzling and PDC cutter PDC cutters generally best suited to more consolidated
cleaning often a problem. If not afforded “balling” formations
can occur

Potential casing damage while tripping, no

flexibility of activation

Tendency for BHA to drop angle in directional

section. Unsuited for soft formations.

Reaming wing tools

Disadvantages Advantages
No flexibility of operations. Concentric cutting action means a smoother hole, decreased
torque and lateral vibration.

PDC cutters only. Hydraulics i.e. efficient cutter Robust strong and sturdy tool design.
cleaning often a problem
Low lost in hole consequence.
Requires stabilisation of bottom hole assembly. Aids in reducing vibration, delivering better hole stability,
quality, and gauging prior to running casing

Hydraulics i.e. efficient nozzling and cutter PDC cutters best suited to more consolidated formations
cleaning often a problem
Need to keep tools moving in deviated wells to Certainty of hole gauge. Can be a vital consideration for
prevent side-tracking the hole. tripping, logging and casing running/cementing.
Two trips often required to drill section Often advantageous for hole cleaning, getting data acquisition
from pilot hole.
Potential for casing damage while running Suited to most formations
in/pulling out Long duration of run in more consolidated formations
Simultaneous reaming while drilling.

Table 7: Reaming wing tools characteristics.

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Deepwater well planning and constructions March 8, 2001
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Near bit reamer
The NBR provides hole enlarging while drilling, can be placed just
above the bit, or higher in the BHA, and was designed for optimum
performance in directional applications where traditional hole
opening techniques have proven difficult. They short in length to be
run below directional drilling assemblies, no additional pressure
drop is created, no vibration induced, safe casing shoes drilling
operation NBR’s are often run in tandem (one cutting one
stabilising). Recent experiences also show that sliding in
directional work is dramatically reduced when using NBR’s. Unlike
bi-centre bits and reaming-while-drilling tools, the NBR is designed
symmetrically with three cutter assemblies to provide balanced
operation for smooth torque and minimal vibration. The tool can be
used with any bit type, fixed cutter, or roller cone, to precisely
match the formation and application for optimum drilling
performance. The tool is hydraulically actuated, eliminating
problems commonly associated with mecha nically actuated tools.

There is no mechanical locking mechanism, thus preventing the

arms from inadvertently sticking in the open position. The tool is
also equipped with shear pins that prevent the cutting structure
from opening while inside casing.
i.e. highly favourable for drilling out float equipment. Once out from
under casing, the shear pins retaining the arms can be sheared,
allowing for opening the hole while drilling.

Applications, benefits
Traditional methods of hole enlargement underneath casing include under-reamers,
bi-centre bits and reaming-while-drilling tools as previously discussed within this
section.

While these tools have proved successful in many applications, use in harsh
environments and difficult directional applications have often proven to be less
reliable and optimal than desired results. However even in the harshest of North Sea
environments, the NBR has been used to successfully open up pilot holes and while
drilling directionally. With the NBR being one of the first reaming-while-drilling tools
to be used in conjunction with a rotary steering system to drill oversized holes.

Also the short, fully stabilized configuration of the NBR provided low impact forces
while steering directional assemblies to result in minimal bottom hole assembly
destructive vibrational energy, efficient bit/BHA operations, longer tools runs and
increased rates of penetration.

Finally the tool in conjunction with a rotary system can thus significantly improve the
economics of hole opening operations and must be viewed as a contender for deep
open water and deepwater directional drilling requirements.

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The hole enlarging future
Three main objectives to best meet deepwater hole enlarging show promise for the
future.

1.) Increased production,

2.) Cost cutting,
3.) Technical innovation in well design

Moreover, strong market drivers in the short, medium, and long term will tend to
encourage conditions apt for growth. Factors worthy of mention are.

1.) Reducing the environmental footprint left by drilling a nd production activities may
soon become an operators strategy or regulatory requirement.
2.) Reduction in hole sizes and volumes go hand in hand with the costs associated
with expensive mud’s, casing strings, and cement.
e.g. such an approach institutionalised by the UK “finder well concept”, seeking to
reduce the average costs of drilling and exploration that will be imposed by demanding
regulatory requirements.
3.) Technical innovation in slender wells will provides a strong mechanism for cost
cutting. Allied to slender wells are two novel technologies.
4.) Expandable casing applications in the short to medium term
5.) Mono bore drilling and completion in the long term.

Such methodology will undoubtedly push the limits of current deepwater under-
reaming technology, inevitably resulting in new "stepping-stone" technologies e.g.
retractable bits and under-reamers, vital to the long-term vision of a viable mono-
diameter wellbore concept. Where the current operational limitations standing
between today's capabilities and the ultimate goal of a mono-diameter well, will likely
be resolved through the development of solid tubular expansion (STE) techniques.
Until then, the adaptation of wellhead design, drill-bit development, and so on, have
no commercial justification until expandable technology fully matures, whereas the
marriage of STE and under-reaming technologies have intermediate applications
throughout the well development cycle.

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Typical Under-reaming Practices
The following practices should be considered when under-reaming.
1. With roller bearing cutters, controlled drilling or weight on bit cannot often be
maintained due to excessive down hole or surface vibrations and “rough
drilling” effects. Consider reducing and/or changing the rotary RPM by 20 or 30 RPM
to avoid premature gauge wear on the cutter cones and arm shirt-tails that can lead to
losing the cones in a very short period of time.
2. If the under-reamer arms will not close e.g. drilled debris blocking the arm
pockets, pump at the highest rate in combination with higher RPM. It may be
possible to “bounce” the drillstring off bottom and dislodge the foreign material
from the arm pockets.
3. When very fast under-reaming is possible, ensure that there is sufficient RPM
to prevent cutting a spiral wellbore. In this case > 100 RPM+ is recommended.
4. When opening the hole, the use of an expandable blade stabiliser behind the
under-reamer may assist in maintaining verticality of the wellbore.
5. Placing a suitably stabilised bit, taper mill, assembly below the under-reamer
may not guarantee vertical hole. It can however prevent any orbiting tendency
of the under-reamer and ensure original hole and/or pilot hole is closely
followed.
6. On making the initial under-reamer cut, rotate for at least 15minutes at a
reduced rate of 30-40 RPM with full pumps prior to drilling ahead. This allows
adequate time for a full gauge initial cut to be made. Note ; The harder the
formation to be under-reamed, the longer the time required before drilling
ahead should commence.
7. After having under-reamed for approximately 3m, stop rotating, pick up the
string with the pumps on, and lower the string in an attempt to tag the ledge
that should have been cut.
- If the formation is firm enough and has not washed out, this will give an indication
that the hole is being cut.
- If the formation is very soft or badly washed out, this procedure will serve no
purpose.

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Deepwater BHA component and design considerations.

BHA behavior relative to deepwater formations.

The ideal and actual response of a bottom hole assembly (BHA) during deepwater
drilling operations varies dependant upon the formation’s type & hardness, hole
enlargement, Bit & BHA design, and drilling parameters used. E.g. In softer deepwater
formations a BHA will not respond to its theoretical behaviour as it would in firmer
formations. The reasons for deviation in behaviour partly attributed to bit features,
side ways cutting action of the drillstring components resulting in the tendency for
hole to be enlarged. This may occur to a greater or lesser degree depending on type
of bit and stabilisers used.

Hole enlargement can also occur in deepwater formations due to improper drilling
practices, inadequate BHA design, or simply hole instability. The net effect is that
attempts to maintain hole angle inclination or prevent build are reduced due to
reduction of wall support at the bit and stabilisers. When one considers that main
wellbore sizes required to be drilled in top and surface holes are the largest in the
well with resulting large hole drilling geometry difference. Correspondingly stiffer
assemblies are required to prevent drillstring components form axial buckling. More
importantly curvature or dogleg can be greater if sufficient forces are applied, further
compounding the forces acting to create hole enlargement.

Rock bit selection, drilling parameters and BHA component selection can thus have
a significant effect on bottom hole assembly, hole quality and formation response.
Cone offset, tooth design length, all influence on how much a bit will cut sideways for
a given force. The speed at which the bit is turned i.e. on a rotary or motor assembly,
will also effect this and should therefore be considered in bottom hole assembly
planning.

Soft formations
Softer formation’s with firmer inter-beds often predominate in top and surface holes
in typical offshore marine environments, deepwater is no exception. The solution to
the side cutting may be achieved several ways in softer formations, including using
proper drilling parameters, practices, bit selection and BHA design.

Another method is drilling a pilot hole with a smaller and more flexible assembly that
does not exert such a large force at the stabilisers. Then following this with an hole
opening assembly. Furthermore, in very soft formations, geological effects such as
dip and strike rarely effect the well bore trajectory as formations are generally
deposited in near almost horizontal layers. Formations bit walk can be however be
anything from a slight ; left right meandering to a stronger left or right hand walk
tendency.

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Medium formations
As the formation firm, in deepwater side cutting, hole enlargement of the wellbore will
decrease and a certain walk tendency is more likely. In deepwater environments
changes in geological depositional periods often result in encountering thin overlying
firmer beds. Here both instantaneous doglegs and wellbore inclination is more likely
to occur especially if BHA design is poor e.g. slick, too stiff or if improper drilling
parameters and practices are used.

Instantaneous angles of two to three degree’s can occur that can lead to difficulties
arising when running the conductor or surface casing strings. Therefore once again
proper BHA design and appreciation that firmer (harder) inter-beds must be drilled
and reamed through with control to ensure that instantaneous hole angles and
unnecessary wellbore inclination does not result.

Drilling a Straight hole.

In summary to drill a straight hole the resultant force at the bit must coincide with the
formation, drillstring, effects and bore hole axis, so that the total deviation force
tending towards vertical. This condition is simply achieved by controlling weight
(force) applied to the formation being drilled to maintain inclination value stable. It
may then be possible to modify the drillstring assembly so that a greater weight on
bit can be applied to improve penetration rate while maintaining a negative deviation
force.

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Deepwater BHA design Rules of thumb.

1. Bottom hole assembly design should take into consideration the conditions
anticipated e.g. formation stratigraphy and bedding, strike and dip obtained from
shallow surveys, local knowledge etc.
2. In soft formations, as inclination increases, the rate of drop becomes
correspondingly higher and it takes a strong building assembly to build angle.
3. In firmer formations instantaneous doglegs are most likely to occur.
4. Low angles of dip. : Formation failure occurs more readily along the bedding
planes resulting in a side force exerted on the bit due to the fact that the bit
follows the easiest path and drills up dip.
5. Walk tendency. The direction of the well with respect to the direction of the dip
may be seen to determine the walk tendency as the side force acting on the
bit also displays a tendency to drop up dip in plan a low angle of dip.
6. Formation stratigraphy often determining the number and type of stabilisers
required, and as discussed previously the desired effect will dictate the
placement of the stabilisers with one or two alternatives to produce best
effect.
7. Prevent or limit inclination increase. Dropping will be time consuming and
not very effective
8. Run heavier collars. If you ever need to drop angle these are preferred. Care
should be taken when hole opening in very soft directionally drilled formations to
avoid side tracking of the original hole. E.g. In long surface hole sections.
9. Bottom hole assembly component selection and placement, can effect the
rate of penetration, performance and resulting forces on the BHA.
10. The position of the first two stabilisers is critical for BHA response.
11. The dimensions of any item run in the BHA are to be recorded (including
lengths, ID's, OD's and fishing necks) on BHA sheets which shall be made up in a
timely manner prior to running tools in the hole.
12. All BHA components should have a bore back box, stress relief pin and cold
rolled threads.
13. The Drilling Contractor and service companies shall maintain records of
equipment usage, inspection and maintenance on the rig e.g. drill collar
rotating hours, jar rotating hours, down hole motor circulating hours.
14. The number of drill collars in the BHA will be determined i.e. utilised on
offset wells, maximum W.O.B. rating for bit type and anticipated mud weight.
15. The minimum number of collars should be run at all times.
16. Drilling jars and crossovers shall not be run in the neutral position.
17. Jar and accelerator placement should be determined from a jar placement
programme assessment.
18. ID's in the BHA shall be larger than the OD of any tools that may be required
to pass through that part of the BHA.

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