IADC/SPE 87173

Ultrafast Drilling in the Gulf of Thailand: Putting Science into the Design Process
C.J. Pinto, Unocal Thailand, Ltd., L.E. Pendleton, Consultant, and J.L.Dick, L.A. Sinor, J. Oldham and B. Stauffer, Hughes
Christensen Company

Copyright 2004, IADC/SPE Drilling Conference

This paper was prepared for presentation at the IADC/SPE Drilling Conference held in Dallas,
Texas, U.S.A., 24 March 2004.
This paper was selected for presentation by an IADC/SPE Program Committee following
review of information contained in a proposal submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the International Association of Drilling
Contractors or Society of Petroleum Engineers and are subject to correction by the author(s).
The material, as presented, does not necessarily reflect any position of the International
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members. Papers presented at IADC/SPE meetings are subject to publication review by
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Abstract
A novel PDC bit design, the result of high end numerical
modeling and laboratory testing set the Gulf of Thailand field
record for rate of penetration during its first run by averaging
840 ft/hr over the 5,040 ft section. This was accomplished
while building inclination from 26 up to 56 before dropping
back to 37 at total depth. The bit also made the planned
azimuth turn from 305 to 258. The same design later pushed
the performance record further by averaging 1,023 ft/hr over a
6,144 ft. section. Instantaneous rates in excess of 2,000 ft/hr
were documented over a 1,000 ft section of this hole.
Designing a bit that maximizes rate of penetration while
maintaining a neutral walk tendency in rotate mode is
presented in this paper.
Introduction
The complex and compartmentalized geology in the Gulf of
Thailand requires operators to drill numerous wells at
minimum costs to achieve long term financial success. More
than 1,700 wells have been drilled to date by Unocal in the
Gulf of Thailand, with 253 wells being drilled in 2002 alone
(Figure 1). Unocal, in partnership with PTTEP and MOECO,
has met this challenge by reducing average drilling and
completion costs from $5MM ($10.9MM in todays dollars)
and 68 days in 1980 to completed wells costing less than
$950k and averaging approximately five days (Figure 2). The
dramatic cost reduction has occurred incrementally by
overcoming challenges related to bits, bottom-hole-assemblies
(BHA), casing, downhole tools and wellhead equipment in
addition to completion challenges.1,2,3
Economic success in the intermediate 8-1/2 hole section in
the Gulf of Thailand is overwhelmingly determined by rate of

penetration (ROP). While achieving high ROPs, it is also

required that azimuthal control be maintained while rotary
motor drilling. Unpredictable or uncontrolled rotary motor
drilling tendencies cause the 8-1/2 wellbore not to be
properly aligned with production targets in the subsequent and
final 6-1/8 hole section, where a rotary assembly is utilized.
Unnecessary or corrective slides to meet these directional
requirements thus come at the expense of section ROP. The
8-1/2 hole section ROPs average in excess of 500 ft/hr on
steerable motor assemblies that build-hold-and-drop along the
4,500-5,500 ft average section length. The previous field ROP
record was held by a matrix body PDC bit that averaged 793
ft/hr over 2,380 ft of intermediate hole section.
This paper will discuss how an analytic approach to the bit
selection process demonstrated that even in a highly efficient
operation, significant improvement was possible and that true
economic drivers were masked by perceived success. This
paper will discuss how improvements were made first by
understanding the application, then selecting the appropriate
bit for the application, and finally optimizing the use of the
product to exploit its full potential. It will discuss how
partnering with the bit companys engineering team enabled
technologic breakthroughs improving the steerability and
neutral walk tendency of bits on steerable motor assemblies in
rotating mode. This ability to control walk behavior by
varying surface rotary speed and downhole weight on bit
(WOB) will be discussed. The challenges facing the operator,
historical performance, and the design philosophy required to
achieve high ROP while minimizing unwanted reactive bit
torque will also be discussed. Dynamic stability modeling, a
necessity for aggressive light (set) bladed bits, will be
characterized showing the benefits of primary and secondary
stability. The use of computational fluid dynamics (CFD) to
optimize cuttings transport and minimize re-circulation of
cuttings will be demonstrated. Lastly, results from this project
and the benefits to both the bit company and the operator will
be reported.
Drilling Challenge
The production area lies near the geographic center of the Gulf
of Thailand in approximately 250 ft of water.
The
stratigraphic section in the Gulf of Thailand is intensely
faulted by generally north-south trending graben systems.
These systems create the structural traps exploited in the gas
fields, but also subdivide the already restricted reservoir sands
into small sub units1 (Figure 3). Most reservoirs in these

highly faulted fields are too thin (average 13 ft) to be imaged

by seismic. Each field has literally hundreds of reservoirs and
most reservoirs are penetrated by a single well. The
unconfined compressive strengths range from 3,000 psi to
18,000 psi with abrasive, angular quartz grains present in the
lower intervals.
These unique geologic settings ensure well trajectories are
widely varying in complexity and extremely demanding
technically. The typical well is characterized by a measured
depth (MD) of 15,000 ft and a true vertical depth (TVD) of
10,500 ft. Surface 9-5/8 casing is set approximately 950 ft
below mud line. The intermediate 8-1/2 section builds from
near vertical to between 45 and 60 immediately after leaving
the 9-5/8 surface casing, holds the tangent inclination
throughout the majority of the section, then turns and drops to
properly align the wellbore. Maximum open hole length in the
8-1/2 section is 9,000 ft with maximum inclinations of 60.
Drilling torque is optimized to be less than 15,000 ft-lbs at
total depth in the final 6-1/8 hole section. The wells begin
directional work shallow, with some near 850 ft subsea. The
8-1/2 build section utilizes doglegs of between 6 and 9/100
ft while end of section turns employ doglegs of between 3
and 5 /100. Deeper turns are performed in harder rock, thus
are slower and more expensive.
The 8-1/2 section is drilled with steerable motor systems with
the adjustable bends set between 1.2 - 1.5. The bit speed on
the system is 340 rpm total; 120 rpm from surface and 220
rpm from the motor while pumping 760 800 gpm with
seawater. Returns are taken directly back to the sea. Technical
success in this section is defined by ROP assuming the shoe is
properly aligned and the casing gets to bottom. Proper
alignment is critical as motors are not employed in the final 61/8 section, due to downhole temperatures ranging from 350
to 410F. Sharp doglegs cause the casing to hang up, thus
smooth well trajectories are required.
Bit selection for the 8-1/2 section was historically determined
by the wellbores perceived difficulty. Wells were generically
divided into two categories of either 3D or 2D though no
specific measure determined such definition. Both 2D and 3D
categories had bits that were custom to that application. In
general, 3D bits focused on more tool face control and higher
ROP in sliding mode while 2D bits maximized ROP in the
tangent section with predictable behavior in the rotate mode.
It was believed that due to the aggressive nature of the 2D bits
they would be unable to perform the deep turns that are
required of all wells. 3D bits in 2D applications were known
to be uneconomic due to slower overall ROP.
In Mid 2002, a study by the operator was conducted to define
clearly 2D and 3D well categories. Attempts were made to
find the key characteristics that made wells more difficult.
Measured and vertical depth of the deep turn, measured and
vertical depth of the entire section, changes in inclination, and
others factors were all considered. In the end, and fortunately,
a simpler method was utilized. Any well that had an azimuth
change of greater than 120 would be considered 3D. This
number was arrived at by looking at inflection points for

IADC/SPE 87173

ROPs, but was also somewhat arbitrary based on experience.

Inclination changes were felt to be reasonably consistent.
With the categories now defined and an understanding that no
single product could be expected to possess the unique
requirements for both categories, guidance was given to all bit
vendors on what constituted a successful 2D and 3D bit. There
were many features common to both designs - the ability to
achieve instantaneously ROPs of 1,500 ft/hr in the shallower
sections, to withstand impact damage due to coal and hard
sandstone stringers, and to be durable enough for two
complete runs without rebuild. Bits also needed to possess
excellent tool face control to eliminate time lost reorienting
the motor due to reactive torque. Many of the past bit designs
that were capable of high instantaneous ROP failed the
steerability requirement resulting in poor ROP through the
section. This was the paradox of effective ROP vs. onbottom ROP. Comparing bit performance on instantaneous
ROP or on-bottom time fails to incorporate the negative
impact corrective slides or reactive torque toolface control
problems have on the overall total time. Lastly, the bit needs
to have good azimuthal control while rotating in the tangent
section. This capability is accomplished by varying the applied
bit weight and rotary speed while rotating from surface. Figure
4 shows a typical plan view for the 8-1/2 and subsequent 61/8 section.
Historical Drilling Performance
Performance in the intermediate 8-1/2 hole section was
already strong. Holding and routinely improving field ROP
records in the section demonstrated a high level of field
personnel expertise and a commitment by bit suppliers and
directional drilling companies to implement new technology.
This track record of success and continuous improvement
caused many to believe that a genuine step change was not
possible. A careful look at the data showed otherwise.
Using the newly developed and simplified definition of 2D vs.
3D wells, the operators wells were overwhelmingly 2D. In
fact, more than 70% could be considered in this category. One
would rightly expect a corresponding percentage of 2D bits to
be employed in these wellbores. Surprisingly, this was found
not to be the case in the first half of 2002. While 73% of wells
were considered 2D, 60% of the time the bit selected was 3D
in nature (Figure 5) Assuming only 2D well trajectories in the
first half of 2002, 3D bits drilled at an average ROP of 405
ft/hr, or 17% slower, than 2D bits (Figure 6). Considering
259,787 feet of hole was drilled by 3D bits in 2D applications,
this represented 91 hours or potentially 4 days of lost rig time
in the first half of the year alone. Thus, there was a
tremendous opportunity to improve the performance in this
section by aligning the requirements of the well with the
capabilities of the bit.
This predominant choice of easy steering 3D bits can be
explained in several ways. First, there is tremendous
importance placed on having the well lined up at the casing
point. Failure to do this means costly unplanned corrective
motor runs in the lower rotary hole section. The aggressive
nature of the 2D bits led many to believe that deep turns were

IADC/SPE 87173

not possible and there was significant risk the wells could not
be aligned. Research showed this not to be the case, but the
myth was difficult to dispel. The next obstacle was the
perception that the 2D products would drill the deeper turns
slower than steerable 3D products. This turned out to be true,
however, the amount of time that was made up by 2D products
in the tangent portion of the well more than made up for any
additional time lost due to slower deep turns. In essence, the
section is a race to the finish with time for the whole section
the determinant, not any one components time. The third
problem was that even though the 2D products were faster in
the tangent, they required more attention than a steerable
friendly 3D product. Directional drillers accustomed to
leaving a bit on an azimuth for extended periods of time found
they were constantly having to work to maintain toolface as
desired. They were, however, able to do this and through time
did it much better as familiarity with the bits increased. A final
reason was that the introduction of new bits, away from
known products was difficult. The system was working,
records continued to be broken, thus the system appeared to be
fine. Changing this paradigm had significant risk.
Ultrafast Drilling Bit Design
The bit companies were challenged to provide a bit design that
would allow the highest ROP in the broadest range of 2D
applications. This bit manufacturer used laboratory testing to
bridge the gap and reduce cycle time between modeling and
commercial field results. A unique four bladed PDC bit was
ultimately developed for this field application, commercially
referred to as HC604 or Auger. This product gave the
directional driller the required high ROP while maintaining
azimuthal control in rotary mode.
Designing a bit for ultrafast drilling required the use of high
end numerical modeling and extensive laboratory testing to
achieve the desired bit performance characteristics. Bit face
aggressiveness was maximized while maintaining stability and
steerability. Key design features include:

Face Aggressiveness
Gauge Aggressiveness
Stability
Hydraulics
Cutter size
Steerability
Durability

Face Aggressiveness: The cutter back rake angle used on

most commercial PDC bit designs is 20. Cutter back rake
angle is defined here as the angle the cutter face makes with
respect to the rock. Higher back rake angle generally
improves bit life but reduces the average ROP. Lower back
rake angles would generally cause the bit run to end
prematurely from catastrophic damage to the cutting structure.
It was not until the discovery of bit whirl4,5 and the
introduction of whirl reducing features6 that researchers began
to understand why some of the earlier field results with lower
cutter back rake (aggressive cutter orientation) were poor.
Testing has shown the tendency for bit whirl increases with:

increasing rock strength

increasing rotary speed
decreasing weight-on-bit
increasing profile taper
increasing cutter aggressiveness (less back rake)

Mitigation of bit whirl has allowed bit designers the

opportunity to reevaluate some of the earlier assumptions of
cutter wear and the effect of cutter back rake on performance
under steady state conditions.
Figure 7 shows the laboratory drilling simulator results for
evaluating the effect of different cutter back rake angles. The
tests were performed at a confined pressure of 3,000 psi using
a rotary speed of 120 rpm and a water base mud weight of 9.5
ppg. The confining pressure simulates a down hole depth of
approximately 7,000 ft using seawater as the fluid. Drilling
simulation in two rock types are shown; a Carthage Limestone
and a Mancos Shale. The Carthage has an unconfined
compressive strength of approximately 14,500 psi and the
Mancos Shale has an unconfined compressive strength of
approximately 9,000 psi. Under the simulated pressure of
3,000 psi, the rock strength increases to 22,000 psi for
Carthage Limestone and 18,000 psi for Mancos Shale.
Identical six bladed PDC bits using (13mm) cutters were
evaluated with constant back rake angle of 40, 30, 20 and
15. Included in this curve is the performance of a four blade
ultra-aggressive bit with (19mm) cutters labeled Auger.
The Auger was designed specifically for the ultrafast drilling
application. For the Carthage limestone, a PDC bit with a
standard back rake angle of 20 would require 30,000 lbs
WOB to reach 60 ft/hr whereas the Auger required less than
half the WOB. At the same ROP of 60 ft/hr, the torque for the
standard back rake angle bit is approximately 6,000 ft-lbs
whereas the torque for the Auger bit is reduced by a third. For
the Mancos Shale, the bit with a standard back rake angle
requires 18,000 lbs WOB to drill at an ROP of 100 ft/hr
whereas the Auger requires 5,000 lbs, roughly of the WOB
required for the standard bit. Similarly, the torque reduces
from 5,200 ft-lbs at 20 back rake angle to approximately
2,500 ft-lbs, essentially reducing the torque by a factor of two
in the medium strength shale.
In the Gulf of Thailand field application, torque is ultimately
the limiting factor since the 8-1/2 section is drilled with
motors utilizing adjustable bend sections. The 7 6.5 stage 7:8
lobe motors had a maximum torque limit of 7,200 ft-lbs. The
torque capability was recently increased 11% to 8,000 ft-lbs
by going to an additional stage. Increased power availability
from the motor and decreased torque requirement from the bit
was key for significant ROP increases.
Gauge Aggressiveness:
Drilling fast also requires
understanding and control of the gauge aggressiveness in
addition to the face aggressiveness. High gauge
aggressiveness leads to poor wellbore quality manifesting
itself in high localized doglegs, wellbore spiraling, and ledges.
Laboratory testing has also shown that aggressive gauge bits

are more prone to severe lateral vibration. To mitigate lateral

vibration when it is present, designers have utilized secondary
stability features to reduce the magnitude of the vibrations. A
properly designed gauge reduces the propensity for the bit
to vibrate.
A series of tests were performed at the Baker Hughes
Experimental Test Area (BETA)8 to evaluate the effect of
gauge length on wellbore quality and steerability. Four
identical 8-1/2 six bladed bits were used in the testing. The
only difference in the bits was the gauge length. The shortest
gauge length was 1 followed by 2-1/2, 6 and 12. Figure 8
shows the results of testing these bits at BETA with a motor
setting of 1.2. The test results show a strong correlation
between hole quality and bit gauge length.9 Hole quality
problems due to an overaggressive bit come in the form of
borehole oscillations.
This regular periodic change in
borehole direction has three characteristics; magnitude, shape,
and wavelength. The amplitude of the oscillation may build,
attenuate, or remain in a steady state.
Figure 8 shows a sample of all four bits transitioning from
slide mode to rotate mode, and the oscillation is clearly
visible. Although oscillations in wellbore diameter are present
for both, oscillations in the rotate mode are clearly the worst.
Here, only one arm of a six arm caliper is plotted to show the
oscillation. Normally, readings from opposite pairs of caliper
arms are added together to get a C1, C2, etc. reading.
However, if this is done and the borehole diameter does not
change, then the oscillation in borehole path may not show up.
Therefore, for the purpose of this example, the caliper arm
readings are examined as individual data sets, and are reported
in terms of borehole radius. Converting this oscillation
magnitude into a drift diameter shows why short aggressive
gauge bits tend to cause problems for running logs and casing.
As shown in Figure 9, the 8-1/2 hole drilled by the 1 gauge
bit results in a 7-3/4 drift diameter hole, while the 12 gauge
bit drilled a drift hole only 0.020 under nominal.
The effect of other gauge design variables (width, diameter,
chamfer, etc.) is outside the scope of this section. The gauge
design selected for the Gulf of Thailand application used a
combination of wider and longer gauge pads with a spiral
configuration to maximize wellbore quality.
Primary and Secondary Stability: Bit designers typically
focus on primary stability to minimize the propensity for
lateral vibration. Primary stability is accomplished by
manipulating the cutter placement on the bit into one of three
general design platforms; low imbalance, high imbalance or
tracking/kerfing. In general, stability becomes less of an issue
as ROP increases. Application engineers typically havent
focused on primary stability in high ROP applications like the
Gulf of Thailand which is unfortunate since the firm stringers
and the resulting low ROP cause lateral vibration and bit
damage, ultimately reducing overall ROP.
Figure 10 compares the stability of the Auger to a current
generation PDC while laboratory testing under atmospheric
conditions in Carthage limestone. The vertical axis on the left

IADC/SPE 87173

shows the MU variation (load variation) which is a function of

WOB, Torque and bit diameter. The vertical axis on the right
is the specific energy required for destruction of the rock. The
horizontal axis shows the depth of cut at each selected ROP
set point. From the figure, the Auger is shown to stabilize
quickly at a depth of cut (DOC) of 0.02 which translates into
an effective ROP of 12 ft/hr. The current generation PDC
stabilizes at a DOC of 0.08 or 48 ft/hr, a factor four times
higher than the Auger stability threshold. Getting the primary
stability number this low was quite challenging because of the
aggressive face design.
Recently, designers have turned their attention to secondary
stability as a means of minimizing lateral vibration once it is
initiated.10 It is a matter of fact that most bits can and do
vibrate at some point during a bit run. A major new aspect of
stability testing was documenting the level of load variation
when bits begin to vibrate. We recognized that by taking
certain steps vibration severity could be significantly reduced
while in the unstable state. This improves durability by
protecting the cutters from impact damage. This reduced
vibration is advantageous to the entire BHA.
Hydraulics: Ultrafast drilling requires special attention to
chip management to get the cuttings quickly and efficiently
removed from the bit face to the annulus. Computational fluid
dynamics was used to optimize the nozzle orientation and
placement and junk slot design. The objective of the CFD
analysis is to balance the flow of cuttings from each blade
with the volume of the respective junk slot. This helps to
minimize cuttings recirculation, a primary cause of bit balling.
CFD is also used to minimize erosion by optimizing the fluid
velocity across critical cutter and bit features. A typical 8-1/2
bit design requires a mesh with a quarter of a million cells and
requires 4-5 simulations to optimize a bit. This number has
come down from 15 20 simulations from just over a
year ago.
Single point cutter and full scale laboratory testing has shown
an unimpeded cutting significantly aids ROP. Cuttings which
hit an obstruction quickly accumulate into a massive ball
resulting in global bit balling. Older design PDC bits with
limited exposure between the cutter face and bit body is an
example of the latter which balls quickly. Underreamers
generally have no obstruction above the cutters and do not
experience global bit balling that stops ROP even though they
generally lack nozzles. Removing obstructions for cuttings
evacuation was seen as a requirement for optimizing
hydraulics and ROP.
Figure 11 shows a standard PDC bit blade and junk slot profile
compared to the Auger. The standard junkslot profile
emanates from the center at a constant slope which is
generally flat before the radius. The Auger junk slot profile
begins to taper almost immediately from the bit center
resulting in much higher standoff of the blades from the bit
body. The junk slot volume is thereby increased. But standoff
alone is not the only key. Cuttings that do impinge the Auger
body will contact at a high angle decreasing the tendency for
balling initiation.

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Cutters: Laboratory testing to compare cutter size has shown

minimal ROP advantage for new cutters in firmer rock.
However, there is a ROP advantage with larger cutters at high
rates of penetration.7 Changing the cutter size from (13
mm) to (19 mm) results in a ROP gain of approximately
30% as shown in Figure 12. SPE paper 39306 also
documented the benefit of larger cutters on wear resistance.
During a test to compare cutter size, a bit using (19mm)
PDC cutters showed no cutter wear whereas a bit using 3/8
(8mm) PDC cutters showed wear averaging 10 15% for the
same total depth of testing. Geometry constraints for specific
sizes prevent larger PDC cutters from being used across the
board. For example, you generally wouldnt want to design a
4-3/4 design with (19mm) cutters or a 16 PDC bit with
3/8 (8mm) cutters. For the Gulf of Thailand application,
(19mm) PDC cutters were selected to optimize ROP and wear
resistance. Future plans call for testing a 1 (25mm) cutter
once a suitable cutter design is available for this size.
Steerability: Maximizing ROP in both the rotate and slide
mode is key to pushing the technical limit. As mentioned
earlier, most bits can be designed to drill fast for at least a
short distance. These bits however tend to have erratic walk
and build-up rate resulting in lower penetration rate for the
section. The design for ultrafast drilling would have to
overcome this challenge.
All BHAs create a side force and a resultant tilt at the bit.
These forces cause the bit to build or drop angle or turn left or
right. In general, rollercone bits walk right and PDC bits walk
left. These tendencies are further influenced by whether the
BHA is building angle (left walk tendency) or dropping angle
(right walk tendency). The BHA also creates side forces on the
formation as drilling progresses. A bent housing motor works
on the principle of bit tilt. The forces and displacements for a
given WOB and rotary speed can be determined accurately if
the physical properties of the bit and BHA are known and the
wellbore geometry is accurately modeled. However, we cant
accurately predict wellbore geometry because of bit lateral
aggressiveness and system instability.
Lateral aggressiveness is a function of bit design, RPM and
rock strength. System stability is a function of BHA design,
bit stability and wellbore friction. Figure 13 shows the hole
curvature obtained from a rollercone and two PDC bit designs
during a 100 ft slide section.11 The only variable is bit type.
Note the rapidly changing doglegs with the aggressive gauge
PDC bit compared to the unaggressive gauge PDC or
rollercone bit.
Extensive laboratory and controlled field testing has been
performed to understand and model the effect of bit lateral
aggressiveness and system stability. The models are quite
accurate in predicting dogleg capabilities with bits that are
stable and create a quality wellbore. Focusing on primary and
secondary stability is one step in the process. The other step is
understanding the effect of bit gauge length on wellbore
quality as shown in figures 8, 9, 13.

Walk tendency (left or right) is determined empirically. An

internal study of the Gulf of Thailand confirmed key design
aspects influencing walk behavior. The goal of the authors
was to design a neutral to slight right hand walk PDC bit for
this application. This requires a bit that exhibits efficient
cutting (less torque for a given ROP), stability through the
stringers and quality wellbore through control of gauge and
lateral aggressiveness. Most commercial PDC bits have
erratic walk tendencies because the designers fail to
understand the effect of lateral aggressiveness and system
stability. The wellbore must be smooth and consistent to give
predictable bit and BHA behavior. A bit design that provides
consistent response while drilling can then be manipulated by
varying the drilling parameters (RPM, WOB) to change the
walk tendency.
Field Results
The ability to graphically correlate drill bit performance
versus geological characteristics and drilling parameters, and
then apply the resultant data to optimize bit design has lead to
a significant reduction in operating hours for the company.
The operator has noted consistent and comprehensive ROP
improvements as a result of this systems ability to place the
right bit in the right well type. Collaborative efforts with the
bit manufacturer led to an innovative and specially designed
product that performed extremely well from the first
application. As this bit optimization/selection process gained
acceptance with field crews they began pushing these new
products to the limit. Finally, the resulting procedures and
systems are now an integral part of the bit optimization /
selection system and its continued development ensures that
these gains were not a one-off situation and that continuous
improvement will prevail including future step
change breakthroughs.
The 2002 first half data set is statistically similar to that of the
second half. In the second half of the year, 449,917 feet of
hole was drilled, representing 6% more footage than the first
half (Figure 14).
This footage represents only wells
considered as 2D. This footage was drilled in 11% less than
time that it took in the first half. This represents a time
savings of over 109 hours and 23,800 additional feet drilled.
This was tangible proof the overall bit selection system
was working.
For the second half of 2001, 86% of the wells drilled were
considered 2D according to the new categorization as shown
in Figure 15. Only 12% of the time was a 3D product used
incorrectly in a 2D application. This is compared to an
incorrect choice being made 60% of the time in the first half
of the same year. Predictably, 2D products outperformed 3D
bits by an average 158 ft/ hr, with 2D bits averaging over 546
ft/hr during the second half of 2001. This demonstrated that
the bit selection was matching wellbore categorization with a
high frequency, though some mistakes were still being made.
The attempt to optimize bits specifically for 2D applications
led to the design and introduction of the Auger. The results
were considered impressive. The Auger successively broke 5
Gulf of Thailand field ROP records (840 ft/hr, 933 ft/hr, 947

ft/hr, 997 ft/hr and 1,023 ft/hr) with the initial record coming
on the very first application of the bit. The latest two field
ROP records are held by the same bit and occurred on its first
and second runs without any repair required between the runs.
The most recent, standing record represents a 30% increase
over the previous matrix body record of 793 ft/hr. During
these runs instantaneous ROPs were recorded in excess of
2,000 ft/hr. One of the major keys to this success was the
neutral, non-reactive nature of the bit in rotating mode in the
tangent section. From Figure 16, it is apparent that along the
completed 7,324 ft interval, only 5 slides were required to
maintain inclination and azimuth. Also in the same run was a
continuous interval of 3,161 ft. which required no corrective
slides at all. Considering that some bits require corrective
slides every third stand, this is a measure of the bits design
matching the field requirements. An additional design feature
netted immediate benefits as the Auger produced minimal bit
face reactive torque, thus when corrective slides were
required, they were achieved quickly needing only partial
stands and little time was lost on toolface reorientation.
It should be further noted that during the second half of 2001
relative to the first half, the Augers ROP improved in wells
with similar well trajectories. The Augers average ROP
improved from 475 ft/hr to 548 ft/hr from the first half of the
year to the second with roughly double the amount of footage
drilled. As the field crews gained familiarity and confidence
with the product they became more aggressive with its
application. The predictability of the bit to produce repetitive
results with similar WOB and RPM inputs was a key enabling
feature of the design. The Auger became the standard for the
2D well category.
There were other benefits realized as well. As the field
personnel became more certain of the ability of aggressive 2D
bits to make deep turns that were previously only the realm of
3D products, they wholeheartedly starting pushing to get more
2D products in the hole. It must be noted that the crews are
provided opportunities to receive monetary incentives based
on performance and safety, thus the adoption of the new
technology was swift. As a result, the field requested a review
of what is considered a 2D well. The rule of thumb is now
that wells with an azimuth turn of under 150 are drillable with
a 2D product. The effort to officially change the category is
also underway.
Conclusions
1) Even within highly successful and continuously
improving operations, significant value creating
opportunities can be overlooked due to perceived
success and resistance to change.
2) There is no way to overstate the importance of data to
overcome perception. Fact based conversations
cannot occur until performance benchmarking exists.
Decisions that are based on facts may be proven
wrong by further data, but are always justified.
3) The sharing of benchmarking data and the metrics by
which bit selection occurs proves highly motivational
to bit companies fueling a highly innovative and
competitive environment.

IADC/SPE 87173

4) Step changes in drilling performance require a certain

amount of risk. The environment at Unocal Thailand
proved conducive to risk taking and learning by the
operator and service companies involved.
5) Laboratory and controlled field testing proved
valuable in calibrating the analytical models used to
improve the bit design and to reduce product cycle
time to provide immediate and continuous
improvement in the field
6) The bit optimization / selection system is fully
integrated in the well engineering process and is
recognized as the impetus behind the success. The
nature of the system ensures that these successes
were not a one-off situation and that continuous
improvement will prevail including future step
change breakthroughs.
Summary
A very competitive and open bit environment exists in the
Gulf of Thailand. Benchmarking data and the criteria by
which bits are selected are conscientiously and consistently
provided to bit vendors by the operator. Trust is developed
when the metrics that determine bit selection are
communicated and reflected by actual bit selection. A
systematic trial bit program ensures that a steady diet of new
products is allowed into this challenging environment. The
technology presented in this paper entered the market as a
trial product and has become the standard. When put into the
right application, the Auger performed immediately at a high
level, the result of using science early in the design phase
coupled with teamwork from the local and home office level.
Not only did the bit perform well in classic 2D applications, it
helped to redefine the 2D well category and broadened what is
currently considered 2D.
This work has significantly
impacted the operators bottom line. The approach
documented in this paper that enabled these results is
methodical and repeatable.
Acknowledgements
The authors wish to thank the management of Unocal
Thailand and Hughes Christensen for permission to publish
this paper. Ultrafast drilling required the input and support of
many individuals and teams from both companies. Thanks go
to the Sperry Sun directional representatives who worked out
the steerability and azimuthal control parameters while drilling
at rates in excess of 2,000 ft/hr. Unocal would like to
recognize Steve Southland for his significant and continuing
contributions. Lastly, we want to thank Marty Brown, Unocal
Drilling Manager for his interest and push to evaluate the
novel bit design discussed in this paper.
References
1. Yodinlom, W., Luckanakul, N. and Tanamaitreejitt, P.,
Unocal Thailand Ltd. World Class Drilling in the Gulf of
Thailand: North Pailin Project, SPE/IADC 79896
presented at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 19-21, Feb. 2003.
2. Krueger, P.J., Unocal Thailand Ltd, Leland, A. Smedvig
Asia Ltd., First of Kind Self Erecting Tender Rig
Combines Performance and Safety, SPE 80452

IADC/SPE 87173

presented at the SPE Asia Pacific Oil and Gas Conference

and Exhibition held in Jakarta, Indonesia, 15-17,
April 2003.
3. Meeponsom, A., Unocal Thailand Ltd. Drilling
Innovations: A key to Developing More Reserves in the
Gulf of Thailand, presented at the Thailand Petroleum
Conference 2002.
4. Sinor, L.A. and Warren, T.M., Drag Bit Wear Model,
SPE paper 16699 presented at the 62nd Annual technical
Conference
and
Exhibition,
Dallas,
TX.,
Sep. 27-30, 1987.
5. Brett, J.F., Warren, T.M., and Behr, S.M., Bit Whirl: A
New Theory of PDC Bit Failure, SPE paper 19571
presented at the 64th Annual technical Conference and
Exhibition, San Antonio, TX., Oct. 8-11, 1989.
6. Warren, T.M., Brett, J.F., and Sinor, L.A., Development
of a Whirl-Resistant Bit, SPE paper 19572 presented at
the 64th Annual Technical Conference and Exhibition, San
Antonio, TX., Oct. 8-11, 1989.
7. Sinor, L.A., Powers, J.R., Hughes Christensen Co. and
Warren, T.M., Amoco Production Co. The Effect of
PDC Cutter Density, Back Rake, Size and Speed on
Performance, IADC/SPE 39306 presented at the 1998
IADC/SPE Drilling Conference held in Dallas, Texas 3-6,
March 1998.
8. Sinor, A., Powers, J., Ripp, C., Lovin, S. and McEntire,
M., Hughes Christensen Unique Field Research Facility
Designed to Accelerate New Technology Development
and Enhance Tool Reliability, AADE 01-NC-HO-36
presented at the AADE 2001 National Drilling
Conference held in Houston, Texas, March 27-39, 2001.
9. Pastusek, P, and Brackin, V. A model for Borehole
Oscillations, SPE 84448 presented at the SPE Annual
Technical Conference and Exhibition held in Denver,
Colorado, 5-8, Oct. 5-8, 2003
10. Clark, L., Laing, B., Hughes Christensen Co. and
Robertson, N., Shell Expro New PDC Designs Doubles
ROP on Kingfisher Project Well, Central North Sea,
AADE 01-NC-HO-15 presented at the AADE 2001
National Drilling Conference held in Houston, Texas,
March 27-39, 2001.
11. Norris, J.A., Dykstra, M.W., and Beuershausen, C.C.,
Hughes Christensen Co. and Fincher, R.W. and Ohanian,
M.P., Baker Hughes INTEQ Development and
Successful Application of Unique Steerable PDC Bits,
IADC/SPE 39308 presented at the 1998 IADC/SPE
Drilling
Conference
held
in
Dallas,
Texas,
March 3-6, 1998.

IADC/SPE 87173

300

250

150

100

50

2002

2001

2000

99

98

97

96

95

94

93

92

91

90

89

88

87

86

85

84

YEAR

Figure 1: Historical wells drilled per year by Unocal in the Gulf of Thailand

80

3
40
2

Cost

Days

20

1
0
98
20
00
20
02

96

94

92

90

86
88

82
84

80

Figure 2: Well cost reduction from 1980 2002

$ MM

60
Days

Total Wells

200

IADC/SPE 87173

Figure 3: Extensional graben complexes with vertical and lateral fault seals

Figure 4: Plan view for a typical 8-1/2 and 6-1/8 section with high turn and multiple targets

10

IADC/SPE 87173

1st HALF 2002

DRILL BIT USE DISTRIBUTION IN 2D WELLS

1st HALF 2002

WELL TURN SEVERITY DISTRIBUTION

3D BITS
60%

3D WELLS
27%

2D BITS
40%

2D WELLS
73%

2D BITS

3D BITS

Figure 5: 2D vs. 3D wellbore utilization for first half of 2002

2D WELLS
ONLY

FT.
DRILLED

TOTAL HOURS

AVERAGE
ROP

1ST HALF

259787

641.8

404.8

2ND HALF

81119

209.0

388.1

2002

340906

850.8

400.7

1ST HALF

166307

352.0

472.5

2ND HALF

369474

676.0

546.6

2002

535781

1028.0

521.2

2D BITS
IMPROVE

120.5

Figure 6: 2D vs. 3D wellbore utilization for 2002

IADC/SPE 87173

11

Penetration Rate vs. Weight On Bit

RADX Cutters, Carthage

120

G445XL - 15 BR

G445XL - 15 BR

G445XL - 20 BR (CSE)

100

G445XL - 40 BR (CSE)

80

Auger
60
40

G445XL - 20 BR (CSE)

100

G445XL - 30 BR (CSE)

G445XL - 30 BR (CSE)

Penetration Rate (ft/hr)

Penetration Rate (ft/hr)

Penetration Rate vs. Torque

RADX Cutters, Carthage

120

G445XL - 40 BR (CSE)

80

Auger
60
40

20

20

10,000

20,000

30,000

40,000

50,000

1,000

2,000

Weight On Bit (lbs)

5,000

Penetration Rate vs. Torque

RADX Cutters, Mancos

RADX Cutters, Mancos

160

6,000

7,000

G445XL - 15 BR
G445XL - 20 BR (CSE)
G445XL - 30 BR (CSE)

140

G445XL - 15 BR

120

G445XL - 20 BR (CSE)
G445XL - 30 BR (CSE)

100

G445XL - 40 BR (CSE)
Auger

80
60
40

140
Penetration Rate (ft/hr)

Penetration Rate (ft/hr)

4,000

Torque (ft*lbs)

Penetration Rate vs. Weight On Bit

160

3,000

G445XL - 40 BR (CSE)
Auger

120
100
80
60
40
20

20

0
0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

1,000

2,000

Weight On Bit (lbs)

3,000

4,000

5,000

6,000

Torque (ft*lbs)

Figure 7: Comparison of ROP and Torque vs. WOB in Carthage Limestone and Mancos Shale as a function of cutter back rake angle

Borehole Radius Variation

Versus Gage Length (Arm 1 of 6 Arm Caliper)
4.75

4.65

1"
2.5"

Rotating

6"

4.55

Sliding

12"

Hole Radius (in)

4.45
4.35
4.25
4.15
4.05
3.95
3.85
3.75
0

10

20

30

40

50

60

70

80

90

Depth Drilled

Figure 8: Borehole radius as a function of bit gage length in slide vs. rotate mode with a motor

12

IADC/SPE 87173

Figure 9: Spiral amplitude and drift diameter variance with gage length.

Gulf of Thailand Design

12 ft/hr

Current Generation PDC

Figure 10: MU variation, f(WOB, Torque and Diameter) vs. depth of cut for the Gulf of Thailand design vs. current
generation PDC bit design. A MU variation less than 5% indicates a stable design.

IADC/SPE 87173

13

Auger junk slot

profile

Standard junk slot profile

Blade profile

Figure 11: Auger junk slot profile vs. standard PDC bit design

Figure 12: ROP comparison in Carthage Limestone and Catoosa Shale vs. cutter size

14

IADC/SPE 87173

Hole Curvature Profile

16.0
14.0

Dogleg (deg/100 ft)

Aggressive Gage PDC

Unaggressive Gage PDC

12.0
10.0
8.0
6.0
4.0
Roller Cone

2.0
0.0
0

20

40

60

80

100

Depth Drilled (ft)

ALL BITS

Figure 13: Dogleg severity comparison with bit designs utilizing different lateral aggressiveness

2D WELLS
ONLY

FT.
DRILLED

TOTAL
HOURS

AVERAGE
ROP

1ST HALF

426094

993.8

428.8

2ND HALF

449917

885.0

508.4

2002

876011

1878.8

466.3

TOTALS/AVG.

73001

IMPROVED

79.6

Figure 14: Footage drilled comparison between first half and second half of 2002

IADC/SPE 87173

15

Figure 15: Well type vs. bit selection for second half of 2002

Figure 16: Example well showing azimuthal hold during rotate mode and reduction in ROP during corrective slides. Note
only 5 short corrections were required while drilling the 7,324 ft interval.