SPE/IADC 139925

Controlling Well Path Trajectory with Rate of Penetration Modulation

S. R. Farley, C. A. Maranuk, SPE, B. J. Hronek, and C. Jasper, Weatherford International

Copyright 2011, SPE/IADC Drilling Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Drilling Conference and Exhibition held in Amsterdam, The Netherlands, 13 March 2011.
This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have
not been reviewed by the Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to correction by the author(s). The material does not
necessarily reflect any position of the Society of Petroleum Engineers or the International Association of Drilling Contractors, its officers, or members. Electronic reproduction, distribution, or
storage of any part of this paper without the written consent of the Society of Petroleum Engineers or the International Association of Drilling Contractors is prohibited. Permission to
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Abstract
The majority of footage drilled directionally is achieved by using bent-housing, positive displacement motors. This
established technology uses oriented drilling intervals to maintain well trajectory. These intervals can be difficult and time
consuming in many drilling environments; however, the economic advantages of this system often preclude the use of more
capable rotary steerable assemblies. Operators have long needed a system that fills the widening gap between the two
technologies.
A new system of wellbore directional control has been developed that uses continuous string rotation above a positive
displacement motor and bent sub. Path deviation is achieved by brief variations in the rate of penetration (ROP) that occur
once during each rotation of the bent sub. Bit advance is increased during each rotation causing the bit to drill faster in the
targeted direction. This directed variation in ROP allows manipulation of hole trajectory while the bent housing and
drillstring are continuously rotating. Steering is accomplished by managing pressure fluctuations within the drillstring,
creating slight oscillations in the flow rate through the mud motor. These controlled fluctuations in flow rate allow variations
in drilling parameters to steer the well in any targeted azimuth.
The goal of this system is to eliminate all oriented drilling in applications up to 3 degree per 100 feet by employing a low
risk, low cost method that maximizes ROP and hole cleaning. At the Gas Technology Institute (GTI) Catoosa Test Facility in
Oklahoma, drilling tests yielded successful well trajectory manipulation, delivering up to 3 degree per 100 feet of controlled
directional performance in both 6 1/8" and 8 1/2" hole diameters. Because a standard bent housing assembly was used, oriented
drilling was always available as needed. This allowed a redundancy in directional control (oriented or rotary), widening the
operational scope and technical capability of the system.
Introduction
The cost reduction of directional drilling has been at the forefront of downhole drilling technology since the ability to steer a
well path was first devised. This is specifically accomplished in two ways. The first is to reduce the cost of whatever
directional drilling tools are used, and the second is to expedite the speed with which they drill to their targets.
Mud Motors
The overwhelming majority of directional footage drilled today makes use of a mud motor. This assembly uses a bent sub
and continuous fluid power to apply some cross-axis pressure to the rotating bit, so that it can drill in any direction at some
rate of change of trajectory. The steering is accomplished by sliding the oriented drillstring while only the bit is turned by the
mud motor. These units have undergone continuous innovation and improvement for some 50 years and, as such, have
become the most reliable means by which directional drilling can be accomplished. A further benefit of their continual use is
that of competitive pricing which naturally accompanies any economy of scale. Taken together, these two strengths have
given drilling motors a significant edge in both reliability and pricing.

SPE/IADC 139925

The speed with which drilling takes place is both a strength and a weakness for the mud motor. While deviation by sliding
the drillstring can be a slow process, the rate of trajectory change per foot can be substantial enough that very few oriented
feet are needed for correcting wellbore trajectory. Once a correction is completed, a straight section can be drilled at higher
ROPs since the motor makes use of both rotary and hydraulic horsepower at the bit face. This clear mechanical advantage
means that any competing products must ultimately make use of a similar hydraulic power section to keep pace with drilling
motors in long tangent sections where borehole trajectory corrections are short or are unnecessary (Warren, 2006).
Mud Motor Problems
While many applications favor the oriented hydraulic drilling motor, others do not. In some applications, making a trajectory
correction with a drilling motor can be a very tedious and costly process. Because the trajectory changes must be made by
sliding long drillstrings through tortuous paths of abrasive rock, this can lead to substantially lower drilling rates over
extended periods of time, and eventually even a complete inability to continue steering. In these applications, drilling motors
are often abandoned for other rotary systems that can deliver wellbore deviation while rotating the drillstring. Although, these
continuously rotating systems are often less reliable, and more expensive, they often become the only means by which
drilling can proceed in a cost-effective manner.
Mud Motor Technologies
The inability of a drilling motor to consistently steer while rotating has become its major drawback. A further drawback is the
inability of a motor to drill straight tangent sections. When the more quickly drilled tangent sections begin to drift off course,
this requires slow and costly sliding corrections. These problems have led to the development of many different motors that
can consistently drill straighter tangent sections than ever before, so that the need for sliding corrections is diminished in
straight sections. The introduction of the adjustable gauge stabilizer (AGS) has likewise proven valuable in many
applications by allowing a means to correct trajectory while rotating a drilling motor. Unfortunately the AGS corrections can
only take place in a 2-dimensional plane, up or down. However, very often the great majority of sliding time can be
completely avoided by their use. Additional benefits of the AGS are reliable operation and lower costs. Both are owed, at
least in part, to the fact they are separate units from the drilling motor, and their failure would not hinder the motor from
continuing to steer the well bore in the proper trajectory by sliding, should that be method be required (Lawrence, 2001).
Mud Motor Control Techniques
Using a drilling motor with bent sub to drill a straight or tangent section is in many ways comparable to the older rotary
assemblies once commonly used for directional drilling. Larger, upper stabilizers placed above the motor will increase drop
rates and forward stabilizers will increase natural build rates (Millheim, 1978). But looking closer at a single rotation of a
bent sub assembly, there is a more complex application of oscillating lateral bit forces, which vary as the drillstring and bent
sub are turned. These periodic forces can have the net effect of drilling straight, dropping, or building boreholes just like their
older rotary counterparts. Unlike their predecessors, the forces applied to the bit are discontinuous, changing significantly
within a single drillstring rotation (Fig. 1 and Fig. 2).
AGS is one common method used to control inclination from a rotating motor assembly. Positioned above the motor, the
AGS appears to work by applying continuous forces to the bit in some given direction, up or down, much like different rotary
assemblies. The advantage of AGS systems is that the stabilizer diameter can be changed without tripping out of the hole.
Any time a bent sub is used near the bit, periodic forces are applied to the bit in every lateral direction during a single
rotation. In this way, rotating a bent housing motor is unlike a pure rotary assembly and acts periodically instead.
The bent sub is pointed down, and the stabilizer above the motor is being used (Fig. 1). When a full string rotation of these
forces are summed and resolved into a resultant direction, they cause net drop. Although the lateral load applied to the bit is
fluctuating, the summation is a drop tendency.
In the retracted AGS position, the collar above the motor lies on the bottom of the hole (the upper stabilizer is removed) and
the weight of the collars must be lifted when the bent sub points the bit upward. In this configuration the bit periodically
builds angle by applying periodic upward lateral loads to the bit (Fig. 2). Here the bent sub is positioned, pointing downward
against the naturally building borehole, distorting the drillstring above. Experience shows that the resultant direction of a full
string rotation is an upward change in hole direction. The lateral loads vary as a function of the bent sub orientation or
toolface. When the collars lay at or near the bottom of the hole, the bit is leveraged to the top. By this description, we see that
a bit below a bent sub typically undergoes periodic variations of lateral force whose net effect (build or drop) is controlled by
the diameter of the stabilizer positioned some distance above the bent sub.

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The need to steer a motor along any given trajectory could likewise be duplicated by varying any other drilling parameters
within a single bent sub rotation, if this variable (a) was powerful enough to influence a change in the motor drilling direction
and (b) could be accurately triggered to occur at any bent housing angular position as the string is rotating. The use of an
AGS is one method of accomplishing this. By applying a periodic lateral load to the bit, the collars work against the pull of
gravity, resulting in an upward force. This only allows steering within a single plane (Rasheed, 2000).
Targeted Bit Speed
Targeted bit speed (TBS) is a periodic steering method, which employs an oscillating flow rate applied to a hydraulic motor
and bent sub to accomplish a continuous trajectory change. Timing these flow rate changes to a specific bent housing
toolface, any 3-dimensional trajectory can be chosen for steering the wellbore. The variations in flow cause slight differences
in the axial drilling rate and combined with a bent sub, the bit drills further toward a specific target. These differences are
continuously applied to the same angular position of the motor housing as it is being rotated such that any 3-dimensional
trajectory can be chosen by the operator. This method is similar, in some ways, to periodic sliding of the drillstring, except
that the motor housing rotation never stops or slows. Instead, it rotates consistently while the bit speed alone varies
depending upon its angular position in the borehole.
This periodic flow is generally accomplished using simple pressure fluctuations within the drillstring generated by a typical
positive pulse telemetry device. These pressure pulses are timed to a motor housing angular position. These pressure changes
effectively manage an oscillating fluid volume entering the motor such that the bit speed can be precisely varied as a function
of toolface. This allows the motor to cut a disproportionally greater volume of rock from a specific arc segment of the
borehole causing the hole trajectory to follow in the direction of higher bit speed.
The motor is bent down by 1.15 degrees at the adjustable bent sub (center) and the hole is curved down toward the right
(Fig. 3). This is the typical hole and motor position if the motor was sliding in a downward trajectory. Here the bit turns
while the bend holds it steadily toward one particular side of the hole or toolface. Likewise, when using TBS, this is the
angular position where the bit speed should be at its maximum if the drillstring were being continuously rotated. The motor
has been rotated 180 degrees out of position from the intended hole trajectory (Fig. 4). In this position, the motor output
speed would be minimized using the TBS drilling method. As the sequence is repeated, a downward change in borehole
trajectory is maintained.
Studying the application of rotary bottomhole assembly (BHA) principles as they are commonly applied to bent housing
motors, we can see that this method of periodically varying a given drilling parameter as a function of toolface is not
necessarily a new technique; however, TBS uses this behavior to control trajectory in three dimensions instead of just two.
As such it meets the criteria for a lower cost drilling technology with all the benefits of a more reliable and proven product.
An additional benefit of this technology is that the motor can still slide to direct the wellbore if a greater build-up rate (BUR)
is needed than TBS and generate.
Laboratory Drilling Data
Testing of the TBS principles initially took place in a full scale directional drilling laboratory. The apparatus (Fig. 5) allows
directional drilling to take place over an 80-foot length through several different simulated formations. This small scale
experimentation allowed pertinent drilling variables to be fully explored before tool design was undertaken. Further
information on this test setup and apparatus can be found in SPE 84449 (Stroud, 2003).
Initial lab testing consisted of drilling nine horizontal holes in simulated formations. Six holes were drilled using 4 3/4"
motors and three holes were drilled using 6 3/4" mud motors.
Two 6 1/8" holes were drilled with 4 3/4" BHAs using standard mud motors. Orientation for the first two holes was done
manually triggering off a 130 degree wedge apparatus (Fig. 6). An inductive proximity switch was installed to pick-up timing
of the modulation and all drilling parameters were monitored within the horizontal drilling machine. The first two holes
proved problematic, but the initial testing showed that sufficiently high rates might be possible using TBS.
For the next three runs, an electronic controller was developed to more accurately trigger the timing of the TBS, with regards
to the mud motor toolface. The mud motor power sections and stabilizer placement were modified to ascertain their
influence.
Another hole was drilled using a 6" roller cone rock bit and a slow speed mud motor. The average ROP was very low and
roller cone bit drilled a hole 3/4" over gauge.

SPE/IADC 139925

Three 8 1/2" holes were drilled using a polycrystalline diamond compact (PDC) bit and a slow speed 6 3/4" mud motor. The
8 1/2" runs demonstrated that TBS could still be used to build the trajectory in larger hole sizes, however, at a lower rate.
Whereas the 4 3/4" tool configuration reached BURs in the 5 to 6 degree range, the 6 3/4" could only reach 2 to 3 degrees per
100 feet.
The nine horizontal lab test results have been summarized (Fig. 7).
The radial plot (Fig. 8) shows ROP vs. toolface for one motor housing revolution where TBS was applied during hole
number three. Here, increasing ROP is shown as a translation of the circle away from the center of the graph. This ROP is
plotted as the bent sub translates one continuous rotation in the borehole. It can be observed from this data that the borehole
is being primarily drilled while the motor housing is pointed at a low and right trajectory. When the bent sub is pointed at this
toolface, the bit is moving axially down the hole at approximately 400 feet per hour, as shown on the vertical scale. When the
bit is pointed away from the target, the ROP has dropped to near zero, as shown at the upper left hand region of the radial
plot.
In the x-y plot (Fig. 9), the bit axial position and ROP are shown for a 3-second period of time in which the bent sub
completed three rotations. Again, the oscillation of the bit position is timed to a specific toolface of the bent sub which steers
the wellbore in the intended direction.
Catoosa Well Testing
In addition to the laboratory testing, a series of wells were drilled at the GTI Catoosa Test Facility in Owasso, Oklahoma
during 2008 and 2009. The wells were drilled to test various aspects of TBS in a real drilling environment. Selective motor
controller software and telemetry enhancements were also tested.
Two 6 1/8" holes and three 8 1/2" holes were drilled using the TBS technology.
The 6 1/8" holes used PDC bits with a 4 3/4" 7:8 lobe, 3.8 stage mud motor to drill S-shaped wells with extended tangent
sections. During initial testing, the tool electronics provided only 2-dimensional directional control. Up/down trajectory
provided directional control capability similar to what an AGS might provide. The first test well was used to verify the
observations seen in the block testing and provide measurable BURs in a more realistic low angle drilling situation. Three bit
runs were made and a total of 1,231 feet of hole were drilled.
Extensive software and hardware enhancements were made to the system before deployment for the second 6 1/8" hole. The
directional controller was modified to provide 360-degree directional control and a pressure-activated downlink was added to
facilitate 2-way communications with the tool controller. Eight bit runs were made during this well test and a total of 1,506
feet were drilled using the system. The test team was able to deliver tight azimuthal control and demonstrate consistent build
rates of about three degrees per 100 feet in the 6 1/8" hole.
The first 8 1/2" test well was drilled using a PDC bit with a 6 3/4" 6:7 lobe, 4.8 stage mud motor. Less aggressive build rates
were observed. Three bit runs were made and 1,415 feet were drilled. This well demonstrated the importance of BHA design,
stabilizer placement, and bit selection.
The second 8 1/2" well was drilled using a PDC bit with a 6 3/4" 7:8 lobe, 5.0 stage motor. The same S-shaped well plan was
followed and the system drilled a total of 1,585 feet in five bit runs. The objective of this test well was to test the impact of
stabilization on the BHA and try to improve 8 1/2" system capacity. An 8 1/2" tri-cone bit was used on the last run of the test
well to ascertain system performance using a non-PDC type bit. Drilling results with the roller cone bit showed the system
was functioning well but not as efficiently as the PDC assembly. A wireline caliper run on this well indicated poor hole
quality where the roller cone bit was run.
The third 8 1/2" well was drilled using a PDC bit with 6 3/4" 7:8 lobe, 5.0 stage motor. A total of 1, 138 feet were drilled in
five bit runs. The objective of this well was to test pulser improvements and additional controller modifications. Both short
and long gauge bits were used in this well and the system demonstrated consistently better build rates for the long gauge bits
than the short gauge bits (Pastusek, 2005).
Results from the Catoosa Drilling tests are provided (Fig. 10).

SPE/IADC 139925

Observations
The primary objective of the TBS drilling method is the repeatability of a modulated drilling speed in a given direction. The
ROP of the drill bit along the axial borehole must be precisely controlled so that each arc segment of string rotation is cut at
the same varying speed throughout repeated drillstring rotations. To accomplish precise and consistent ROP targets, the
highest and lowest bit speeds are likewise targeted at the same toolfaces, with every rotation of the string and bent sub. The
repeatability of this bit speed modulation will equate a precise ROP modulation which, in turn, maximizes the efficiency of
the method. Should these targets begin to vary and become inconsistent, then the resultant trajectory of each string rotation
will change and the effect will be a wandering direction with unpredictable tendencies.
Consistent hole quality is an important factor to consider when optimizing tool performance in any steerable tool.
Inconsistent hole shape and/or hole size can dramatically effect bit loads as rearward control stabilizers enter into
discontinuous sections of borehole. These events will negatively impact the steerability in what would otherwise be a well
controlled environment. This has proven to be especially true when rotating mud motors using drill bits ill suited for the
purpose. Oftentimes this feedback between stabilizer and bit can cause dramatically fluctuating bit loads.
Testing at the GTI Catoosa facility has shown the importance of hole quality when employing the TBS method. Longer
gauge length bits have consistently shown better build rates, better directional control, and better hole quality than short
gauge bits with multiple instances of both helical and hourglass shaped borehole being confirmed from the latter. Testing has
shown that using proper bit stabilization, the rotating motor assembly employed by the TBS method could indeed produce a
high quality borehole free from ledges and other borehole patterns (Pastusek & Bracken, 2003).
Conclusions
1.

Good steerability of up to 3 degrees per 100 feet is achievable using TBS methodology.

2.

Repeatability of bit speeds using TBS is critical to maintaining consistent directional control.

3.

Inconsistent hole quality can dramatically affect bit loads, which can negatively impact steerability.

4.

Bit type is critical to system design.

Acknowledgements
The authors wish to thank Weatherford management for allowing us to pursue the fundamental investigation of drilling
techniques using targeted bit speed.
References
Dupriest, F. E. and Sowers, S. F. Maintaining Desired Steerability While Extending Gauge Length to Manage Whirl
(SPE 119625), presented at SPE/IADC Drilling Conference and Exhibition, Amsterdam, 2009.
Ernst, P. L. Effects of RPM and ROP on PDC Bit Steerability (SPE 105594), Amsterdam, 2007.
Lawrence, S. R. Steerable Motor with Integrated Adjustable Gauge Stabiliser Provides Improved Directional Drilling
Performance in the Middle-East (SPE 68088), Bahrain, 2001.
Lenamond, C.; Marques, L.; Anderson, M.; and Mota, S. Performance gains for rotary steerable through specialised bit
design presented at AADE National Technical Conference and Exhibition, Houston, AADE, 2005.
Mensa-Wilmot, G.; James, B.; Aggarwal, L.; Van Luu, H.; and Reuda, F. Gage Design-Effects of Gage Pad Length,
Geometry and Activity (Side Cutting) on PDC Bit Stability, Steerability, and Borehole Quality in Rotary-Steerable-Drilling
Applications (SPE 98931) presented at SPE/IADC Drilling Conference, Miami, 2006.
Millheim. Directional Drilling (Eight-Part Series) Oil & Gas Journal, 1978.
Minett-Smith, D. J.; Stroud, D. R.; and Pagett, J. M. Real-Time Whirl Detector Aids Drilling Optimization (SPE 135110)
Florence, 2010.
Pastusek, B. L. A Fundamental Model for Prediction of Hole Curvature and Build Rates With Steerable Bottomhole
Assemblies (SPE 95546) Dallas, 2005.
Pastusek, P. and Bracken, V. A Model for Borehole Oscillation (SPE 84448) presented at SPE Annual Technical
Conference and Exhibition, Denver, 2003.
Rasheed, W. Controlling Inclination in Rotary Mode in Tight TVD Corridors using a 2-Dimensional Steerable System
(SPE 65540) Alberta, 2000.
Warren, T. Steerable Motors Hold Out Against Rotary Steerables (SPE 104268) San Antonio, 2006.
Stroud, R. R. Development of the Industrys First Slimhole Point-the-Bit Rotary Steerable System (SPE 84449) Denver,
2003.

SPE/IADC 139925

List of Illustrations
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Bent Sub and Motor Shown Dropping Inclination using Upper Stabilizer
Bent Sub and Motor Shown Building Inclination without using Upper Stabilizer
Rotated Motor Pointed in the Direction of Hole Curvature
Rotating Motor Pointed Against the Direction of Hole Curvature
Horizontal Drilling Simulation Rig
Wedge Assembly Used to Time the Original TBS
Test Block Drilling Results
ROP Plotted as a Function of Toolface using TBS to Steer the Wellbore
Axial Bit Translation as Recorded During TBS Testing
Catoosa Well Testing Results

Fig. 1Bent Sub and Motor Shown Dropping Inclination using Upper Stabilizer

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Fig. 2Bent Sub and Motor Shown Building Inclination without using Upper Stabilizer

Fig. 3Rotated Motor Pointed in the Direction of Hole Curvature

Fig. 4Rotating Motor Pointed Against the Direction of Hole Curvature

SPE/IADC 139925

Fig. 5Horizontal Drilling Simulation Rig

Fig. 6Wedge Assembly Used to Time the Original TBS

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Hole
No.

Bit
Size

Bit Type

Mud Motor Size

Timing

BUR

6 1/8"

PDC

4 3/4" 7:8 lobe, 2.0 stage

Manual

Inconclusive

BHA built angle

6 1/8"

PDC

4 3/4" 7:8 lobe, 2.0 stage

Manual

Inconclusive

BHA built angle

6 1/8"

PDC

4 3/4" 7:8 lobe, 3.8 stage

Electronic

5 to 6 degree

High BUR

6 1/8"

PDC

4 3/4" 7:8 lobe, 3.8 stage

Electronic

5 to 6 degree

High BUR

6 1/8"

PDC

4 3/4" 7:8 lobe, 3.8 stage

Electronic

5 to 6 degree

High BUR

6"

Roller Cone

4 3/4" 7:8 lobe, 3.7 stage

Electronic

1 to 2 degree

Poor hole quality

8 1/2"

PDC

6 3/4" 7:8 lobe, 3.0 stage

Electronic

2 to 3 degree

Good run, showed small BUR

8 1/2"

PDC

6 3/4" 7:8 lobe, 3.0 stage

Electronic

Inconclusive

Drilled into existing boreholes

8 1/2"

PDC

6 3/4" 7:8 lobe, 5.0 stage

Electronic

Inconclusive

Drilled into existing boreholes

Comments

Fig. 7Test Block Drilling Results

Fig. 8ROP Plotted as a Function of Toolface using TBS to Steer the Wellbore

10

SPE/IADC 139925

Fig. 9Axial Bit Translation as Recorded During TBS Testing

Test Well
Number

Bit Size

Mud Motor Type

Number
of Runs

Feet
Drilled

BUR
Achieved

6 1/8"

7:8 lobe, 3.8 stage

1,231

2.3 degrees

Rotated off cement plug

6 1/8"

7:8 lobe, 3.8 stage

1,506

2.6 degrees

Good directional control

8 1/2"

6:7 lobe, 4.8 stage

1,415

2.6 degrees

Poor directional control

8 1/2"

7:8 lobe, 5.0 stage

1,585

2.8 degrees

Used both PDC and roller cone

bits

8 1/2"

7:8 lobe, 5.0 stage

1,138

2.3 degrees

Fig. 10Catoosa Well Testing Results

Comments