Baker Hughes INTEQ

A Guide to Understanding Rotary Steerable Technology

By Jon Ruszka

ince their introduction in 1997, rotary steerable drilling systems have delivered significant gains
in drilling efficiency. In addition to this fundamental benefit, these systems have enabled ever
more challenging wells to be drilled with a wide range of other benefits ranging from reduced
HS&E exposure to improved hydrocarbon recovery. These benefits are accepted by the industry.
However, once the decision has been made to use a rotary steerable system on a particular well or
well section, there are several technical aspects that must be considered when determining the
best rotary steerable system for the job.
Does the system deliver precise, automated closed-loop deviation control for the most accurate
wellbore positioning possible? Is the steering vector adjustable to ensure a smooth curvature and
does the system deliver truly continuous steering to eliminate hidden tortuosity? Is the system
reliable? Is it an integrated drilling and evaluation system with near-bit measurements for
improved geosteering? Another area of concern among many involves theoretical operating
principles of the various systems.

12

L2

L1

Constant
Steer Vector
S

Bit pointing in
direction of steer

L2
3

Operating Principle
To Push or to Point?
When discussing the operating principle of
various rotary steerable systems, reference
to point the bit and push the bit is frequently made. Each of these theoretical
operating principles has its own relative
strengths and weaknesses. However, what
truly matters is consistent steerability in a
wide range of drilling environments providing a precisely placed wellpath with the
highest possible hole quality and drilling
efficiency.
The Push the Bit Operating Principle
A pure Push the Bit rotary steerable system steers simply by applying a side load to
the bit. This forces the bits outer cutting
structure and gauge to cut sideways into
the formation to drill a curved hole in that
direction. Systems employing this principle
are restricted to very short gauge bits
(typically less than 2-in. gauge length)
where the gauge is set with an active
highly cutting structure. While these
systems are agile, permitting a quick and
precise response to any required changes
in wellbore deviation, the short gauge bits
used by these systems may drill a spiralled
hole when high side-loading is applied.

L1

BHA bent into curved hole

by steering vector

The Point the Bit Operating Principle

A pure Point the Bit rotary steerable system steers by precisely pointing (tilting) the
bit in exactly the direction the wellpath
needs to be steered. In doing so, the drill
bits face is pointing perfectly in the direction to be drilled and there is no side loading on the bit. The advantage of this
operating principle is that longer gauge
bits can be used to avoid hole spiraling.
Unfortunately, these systems are slower
to respond to required trajectory changes
and the overall dogleg severity capability
is typically lower than that of a push the
bit system.

Figure 1

The AutoTrak system operates using a

hybrid of operating principles, simultaneously delivering the best of both established
systems - consistent, reliable steerability and
superior hole quality.

The Hybrid Operating Principle

INTEQs AutoTrak Rotary Closed Loop
System (RCLS) design incorporates parts of
both operating principles permitting the
system to switch between modes depending on the wellbores immediate requirements (Figure 1). When initiating a change
to wellbore trajectory (e.g., ending a tangent, starting a 3-D turn, etc.), the bit is
immediately pushed to the side. Once a
few feet of the new curvature is drilled,
the steering mechanism is then used to
bend the bottom hole assembly into the
new curvature and effectively point the bit
in the direction to be steered.

13

Baker Hughes INTEQ

A Guide to Understanding Rotary Steerable Technology

Because they employ a hybrid operating principle, AutoTrak systems are more
agile than pure point systems while
delivering higher borehole quality than
push systems. In addition, AutoTrak
systems steer more consistently in a
wider range of formation types than
other systems.
Ultimately, the push the bit vs.
point the bit is beside the point. What
really matters is whether the rotary steerable system consistently steers precisely
and reliably to target while simultaneously
delivering a high-quality wellbore.

Closed Loop Deviation Control for

Precise Wellbore Placement

Figure 2

AutoTrak RCLS closed loop control uses near bit inclination data (input) fed continuously to the steering control logic (controller). This automatically adjusts the steering mechanism (process) to maintain
the wellpath precisely on track as programmed. Deflection of the wellbore from formation influences
(random events) is therefore continuously countered for the most precise wellbore positioning control
possible (optimized output).

Available Steering
Vectors

8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
Highly Agile

Figure 3

14

Low Agility

Very Low Agility

The AutoTrak system has approximately 7,500 different steering vectors constantly available. Systems
having fewer steering vectors compromise on both wellbore quality and positioning control.

The AutoTrak steering system incorporates

an automated drilling mode in which
the precise inclination is measured
continually (at 5-second intervals) by a
near-bit sensor. These measurements are
fed into the tools downhole logic system,
which compares the near-bit inclination
trends to the target inclination programmed into the systems downhole
memory within a small fraction of a
degree. If the inclination trends are of
greater value than the target inclination,
the tool automatically steers down to drop
inclination and visa versa. When required
by the wellplan, the target inclination
value is reset easily by downlinking to
the tool from surface. The value of this
automated closed loop control is that the
wellbore trajectory is continuously maintained precisely on track automatically
(Figure 2).
Rotary steerable systems without
precise, adjustable closed-loop-control
steering must allow the wellpath to
deviate from the planned trajectory and
then manually steer back to plan
typically overshooting the plan and
then manually steering back the other
way. This adds significant tortuosity to
the wellbore and can cause operational
difficulties in drilling, evaluating or completing the well. In horizontal wells, this
tortuosity can cause premature coning of
undesired fluids and increased pressure
drawdown when multi-phase production
flow from the wellbore exists. Using
automated closed-loop-steering control,
AutoTrak systems consistently position

wellbores more precisely than any other

drilling systems, benefiting both operational efficiency and the production profile.
Highly Adjustable Steering Vector
Most rotary steerable systems that define
their steering settings in terms of vectors (a
certain steering response in a certain direction) have less than 100 steering vectors to
choose from, and some have significantly
less than that. The fewer steering vectors a
system has to select from, the more tortuous the wellpath and the less precisely the
wellbore can be positioned (Figure 3).
Some systems have just a single fixed bit
tilt setting. These systems not only compromise steerability, they degrade overall hole
gauge quality. In contrast to other systems,
the AutoTrak system has approximately
7,500 steering vectors continuously
available. As a result, the precise steering
response can be achieved without compromise to tortuosity or hole gauge quality.
Truly Continuous Steering
Many rotary steerable systems do not truly
steer continuously. To achieve steering
responses at intermediate intervals

Figure 5

between the available steering vectors,

some systems steer to a high dogleg
severity followed by steering with minimal
dogleg severity (sometimes referred to as
the tools duty cycle). Steering in this
manner hides a highly tortuous trajectory
between survey points which may cause
operational problems during the well
construction process (Figure 4).
Because the AutoTrak system possesses
such a wide selection of steering vectors
and an automated closed loop drilling
mode, it truly steers continuously
delivering smooth curvatures.
Integrated Drilling and Evaluation Concept
Most rotary steerable systems are not integrated with either MWD or LWD systems.
This moves LWD sensors farther away from
the bit and requires a longer, more complex BHA containing more components and
connections. INTEQ engineers designed
AutoTrak RCLS as an integrated drilling
and formation evaluation system (Figure
5). Because of this design, the entire
AutoTrak BHA is significantly shorter with
LWD sensors positioned closer to the bit
than other systems. The shorter BHA

S
DL
ge
era
v
A

Steering
Off
Steering
On

Figure 4

Rotary steerables systems which do not

steer continuously hide a more tortuous
wellpath. AutoTrak systems steer
continuously to give the smoothest
possible curvature.

Being an integrated BHA design, LWD and other sensors on the AutoTrak BHA are all close to the bit and overall BHA length reduced.

15

Baker Hughes INTEQ

A Guide to Understanding Rotary Steerable Technology

improves geosteering efficiency and minimizes surface handling, to enhance rig

floor safety and reduce risk of stuck pipe.

Instantaneous RPM
250
200
150
100
50
0

Figure 6

2
4
Elapsed Time, seconds

During drilling operations, stick-slip can cause rapid changes in downhole rotary speed. Rotary steerable
systems that do not reference steering direction via a non-rotating sleeve can lose steering control
when stick-slip is present.

Steering Response Independent of

Bit Hydraulics
Some rotary steerable systems require a
very specific bit pressure drop to operate
(Figure 7). This is highly limiting because
any changes in flow rate or mud properties
will detrimentally affect steering capability. Similarly, a lost or plugged bit nozzle
will affect steering response. Setting the
bit hydraulics up in this specific manner
also results in less than optimal drillbit
hydraulics increasing the risk of
washouts in weak formations, poor
steering control and other hole problems.
In contrast, the AutoTrak systems steering
capability is completely independent of
bit hydraulics to ensure optimal drilling
performance.

Maintaining 90% of Maximum HHP

100
90
Maximum HHP (%)

80
70
60
50
40
30
0.65

20

Effect of Stick-Slip on Steering Response

Stick-slip effects result in large and rapid
fluctuations in bit rotary speed (Figure 6).
While more severe instances of stick-slip
should always be avoided due to their very
damaging nature, lower levels of stick-slip
must often be accepted. Rotary steerable
systems that do not incorporate a nonrotating sleeve are exceptionally sensitive
to stick-slip. These systems cannot maintain
steering vector orientation when stick-slip
occurs and steering capability is lost. As a
result, operators often are forced to select
less aggressive drill bits or restrict drilling
parameters to maintain steerability.
The AutoTrak system uses a non-rotating sleeve to reference steering vector orientation within the wellbore. By using a
non-rotating sleeve, the steering direction
reference is decoupled from the stick-slip
effects, enabling continuous and precise
steering even when stick-slip occurs.

10
0
0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Fraction of Surface Pressure across Bit

Figure 7

16

To optimize drilling performance it is necessary to optimize bit hydraulics. Rotary steerable systems that
require a specific pressure drop at the bit do not allow this performance optimization. AutoTrak system
operation is completely independent of bit hydraulics.

Downlinking
Some rotary steerable systems require 20
minutes or more to send a command from
the surface to the downhole BHA. In addition, these commands often are limited to
simply altering steering parameters via
direct manipulation of rig controls (pumps
or rotary table). During this lengthy and
inconvenient downlinking process, some

tools stop steering. This can result in an

unacceptable drop in inclination. Because
of this delay, operators of some rotary
steerable tools frequently take the tool
off-bottom to downlink wasting significant drilling time.
In contrast to other rotary steerable
systems, communication between the surface and the AutoTrak system is fast, reliable and automated. A wide range of
commands (ranging from steering parameter control to multiple LWD functions) can
be sent. Sending a downlink to the
AutoTrak system is an automated process
(controlled from computers in the LWD
cabin) and only takes a few minutes. To
ensure full confidence in the process, and
allow drilling to proceed unhindered, the
AutoTrak system immediately responds to
the new command by sending a complete
analysis of new settings to surface. In addition, during the downlinking process, the
AutoTrak tool continues steering to plan.

3 independent
hydraulic units &
control systems

No rotating
mud:oil seals

Highest rotary
speed
specification of
any rotary
steerable

Figure 8

AutoTrak system eliminates rotating mud:oil seals

Figure 9

Most rotary steerable systems have one single steering mechanism with no back-up. Utilizing three independent hydraulic and control systems, AutoTrak operations normally can continue in the event of a single system failure.

Rotating Seals
Most rotary steerable systems, with or
without a non-rotating sleeve, must incorporate rotating mud:oil seals to protect
fragile internal components from mud
ingress (Figure 8). The seals represent a
life-limiting component in the downhole
tool. They also can be sensitive to sudden
spikes in pressure as a result of a partially
blocked bit nozzle or annulus pack-off.
Sudden failure can result. Rotating mud:oil
seals in the downhole tool also limit the
tools maximum rotary speed.
The 634-in. and 912-in. sizes of the latestgeneration AutoTrak systems have been
specifically engineered to eliminate rotating mud:oil seals. As a result, the systems
reliability and durability are increased
along with the tools rotary speed limit
(400 RPM).
Redundancy in Steering Mechanism
Most rotary steerable tools have one centrally functioning mechanism (either
mechanical or hydraulic) to produce the
steering response. If any component in this
single system fails, steering control is completely lost.
INTEQ engineers built redundancy into
the steering systems in the latest-generation 634-in. and 912-in. AutoTrak systems

17

Baker Hughes INTEQ

A Guide to Understanding Rotary Steerable Technology

integrated BHA design, and the resulting

good physical hole properties reduce the
risk of hole problems and stuck pipe incidents. The lost in hole (LIH) incident rate
for AutoTrak systems is believed to be the
lowest in the industry (Figure 10).

(Figure 9). Instead

of a single unit, the
system possesses
three independent
hydraulic and associated control systems
(one for each steering rib). If one of
the systems fails,
AutoTrak RCLS, in
most instances, can
maintain the desired
wellpath by steering
with the two remaining systems.

LIH Incident Rate (LIH Incident per 100,000 ft drilled)

1.6
1.4
1.2
1
0.8
0.6
0.4

Conclusion:
Rotary steerable drilling is now firmly
established as a mainstream technology.
It has proven to deliver value through
drilling efficiency improvements, HSE
benefits, production enhancements, and
lower overall cost per barrel produced
(Figure 11). The operating principles and
design features of the latest generation
AutoTrak system help operators reliably
achieve these benefits.

0.2

Reduced Risk of
Stuck Pipe
The AutoTrak systems increased
operational
efficiency, short

0
Steerable Motors

Figure 10

AutoTrak RCLS

Reduced risk of stuck pipe through use of AutoTrak systems is a result

of a number of design and operational features unique to the AutoTrak
system. This excellent LIH history is believed to be industry Best in Class.

About the Author:

East (m)
-800 -600 -400 -200

200 400

600

1500 1000

500

North (m)
0

-500

-1000

-1500

-2000

400

-2500

600

TVD (m)

Jon P. Ruszka is the Advanced Drilling & Evaluation

Market Analyst for Baker Hughes INTEQ in
Aberdeen. Mr. Ruszka obtained his BSc (Hons)
degree in Aeronautical Engineering from Bristol
University and postgraduate diploma in Offshore
Engineering from RGIT in Aberdeen. He began
his oilfield career with Dresser Atlas in 1985 as a
wireline logging engineer and joined Eastman
Christensen in 1987 as a Directional Surveyor.
After Eastman Christensen became a part of
Baker Hughes, Mr. Ruszka specialized in directional
drilling and is participating in the continuing
development of the AutoTrak drilling and
evaluation system.

800
1000
1200
1400
1600

1500
1000
500
0

The AutoTrak system was jointly developed by

Baker Hughes INTEQ and ENI S.p.A.

-500

No

rth

TD @ 6510m Md

-1000

(m

)
-1500
-2000
-2500
-800

Figure 11

18

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600

Utilizing the unique advantages of AutoTrak systems, complex extended reach lateral production holes
are geosteered precisely through multiple targets to increase recoverable reserves.

Further Reading
For more information on AutoTrak RCLS and the benefits of rotary steerable technology, the following technical papers are available. Please contact your local Baker
Hughes INTEQ representative to obtain a copy.

SPE Abstracts:
SPE/IADC 77205: Innovative Multidiscipline Approach and Use of New Technology Reduces Costs and Opens New Opportunities in a Mature Field in the South China Sea:
Z. Djerfi, Baker Hughes INTEQ, G.A McNair, CACT Operators Group.
SPE 74457: Application of New Generation Rotary Steerable System for Reservoir Drilling in Remote Areas:
Hartmut Gruenhagen; Baker Hughes INTEQ, Ulrich Hahne; SPE, Baker Hughes INTEQ, Graham Alvord; SPE, Phillips Alaska Inc.
SPE/IADC 67721: The Value of Rotary Closed-Loop Drilling Technology on Chevron Albas North Sea Horizontal Field Development:
A. Johnstone, Baker Hughes INTEQ, Philippa Stevenson, Chevron UK Ltd.
SPE 71398: Field Development Utilizing Rotary Steering Technology
Morten Grini, SPE, Esso Norway, and Bill Rice, SPE, Esso Canada, and Svein Stromberg, SPE, Baker Hughes INTEQ
SPE 71840: Using Rotary Closed-Loop Drilling to Increase Operational Efficiency and Reduce Operational Risk
John A Johnstone; Baker Hughes INTEQ, Hartmut Gruenhagen; Baker Hughes INTEQ
SPE 67760: First Simultaneous Application of Rotary Steerable/Ream-While-Drill on Ursa Horizontal Well
L. F. Eaton, Shell Offshore Inc.; Scott McDonald, Hughes Christensen; Edgar M. Rodriguez, Baker Hughes INTEQ
SPE 67715: Drilling with Rotary Steerable System Reduces Wellbore Tortuosity
P.Weijermans, J. Ruszka, SPE, Baker Hughes INTEQ, H.Jamshidian, M.Matheson, Shell U.K. Expro
SPE 65526: The Benefits of Truly Horizontal Wells
D. Georgi, V. Krger, J. Wang (INTEQ)
SPE 59218: The Application of Rotary Closed-Loop Drilling Technology to Meet the Challenges of Complex Wellbore Trajectories in the Janice Field
John Johnstone, Clive Dalton (INTEQ) and John Edmonson and Criss Abbot (Kerr-McGee)
SPE 59110: Application of Rotary Steerable System/PDC Bits in Hard Interbedded Formations: A Multidisciplinary Team Approach to Performance Improvement
Harald Fiksdal, Clive Rayton (OASIS), Zvonimir Djerfi (INTEQ)
SPE 56958: Realizing True Value from Rotary Steerable Drilling Systems
Johnstone, John A and Allan, Derek
SPE 56932: Increased Oil Recovery by Economical Pilot Hole Delineation of Reservoirs Using 3D Rotary Drilling Technology
George J. Gaskin, SPE, Baker Hughes INTEQ ; Harald Laastad, SPE, Statoil Petroleum Technology (PETEK); Ina Garvik, SPE, Statoil Drilling Technology
SPE/IADC 52839: The True Value of Automated Rotary Directional Drilling Technology is Demonstrated on a Well Offshore Brunei
Jon Ruszka, Baker Hughes INTEQ; Anton Vos, SPE, Brunei Shell Petroleum Co. SDN. BHD; Bert Otter, SPE, Brunei Shell Petroleum Co. SDN. BHD; Osmera Bin Hj Othman, SPE,
Brunei Shell Petroleum Co. SDN. BHD
SPE 50379: Automated Steering Systems Applied to Complex Horizontal Well in South Italy
A. Calderoni, SPE, ENI AGIP; J. Oppelt, SPE, Baker Hughes INTEQ; A. Ligrone, SPE, ENI AGIP; A. Trampini, ENI AGIP; and S. Gauld, Baker Hughes INTEQ
SPE 50378: Improving Wellbore Position Accuracy of Horizontal Wells by Using A Continuous Inclination Measurement From A Near Bit Inclination MWD Sensor
P. E. Berger, SPE, Baker Hughes INTEQ, and R. Sele, Baker Hughes INTEQ
SPE/IADC 52788: The Lean Profile - A Step Change in Drilling Performance
A. Calderoni, SPE, A. Ligrone, SPE, C. Molaschi, ENI S.p.A./AGIP Division
SPE/IADC 39329: Rotary Steerable System Improves Reservoir Drilling Efficiency and Wellbore Placement in the Statfjord Field
E. Andreassen, H. Blikra, A. Hjelle, S.A. Kvamme , Statoil and J. Haugen Baker Hughes INTEQ
Article in SPE News Australasia 4/2000, Issue 45: Cutting Edge Technology for Extended Reach Drilling Applications in the Asia Pacific
Alan Good and Zvonimir Djerfi (Baker Hughes INTEQ)

Journal Articles:
Oil and Gas Journal - February 15, 1999: Closed-loop Steerable Drilling System Tackles Multiple Targets.
Tom Claus, Greg Hull, Nelson Emery and Dennis Romero (Baker Hughes INTEQ) and Tony Lilburn (Spirit Energy 76)
German Scientific Association for Oil, Gas and Coal April 1998: A Technological Leap through Automated Directional Drilling in the Rotary Mode - Examining the
Advantages of a New Directional Drilling System with Integrated MWD. Hartmut Gruenhagen(Baker Hughes INTEQ)
Petroleum Engineer International - February 1999: Statoil Applies Rotary Steerable Technology for 3-D Reservoir Drilling.
Johnny Haugen and Zvonimir Djerfi (Baker Hughes INTEQ), Statoil
SPE Drilling & Completion - June 1998: Advanced Tools for Advanced Wells: Rotary Closed-Loop Drilling System Results of Prototype Field Testing.
Joachim Oppelt and Detlef Ragnitz (Baker Hughes INTEQ), Sandro Poli and Franco Donati, (Agip)
American Oil & Gas Reporter January 2003: Rapid Advances in Drilling Technology Enable Complex Well Designs
Ray A. Ballantyne and Jon Ruszka (Baker Hughes INTEQ)

19