SPE 131357

Rotary Steerable System Enhances Drilling Performance on Horizontal

Shale Wells
Junichi Sugiura, SPE, and Steve Jones, SPE, PathFinder Energy Services

Copyright 2010, Society of Petroleum Engineers

This paper was prepared for presentation at the CPS/SPE International Oil & Gas Conference and Exhibition in China held in Beijing, China, 810 June 2010.
This paper was selected for presentation by a CPS/SPE 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 and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, 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 is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
In North America, shale gas wells are typically drilled with build rates of 10-14/100ft to land, followed by 3000-5000 ft
horizontal sections. As more shale plays open up, horizontal sections have been extended to seek more shale exposure. Today, the
majority of shale gas wells are drilled using conventional steerable motors, but as horizontal sections get longer, Rotary Steerable
Systems (RSS) become a more viable option to reach the target depth.
Standard RSS currently on the market cannot provide sufficient build rates to drill the curve on shale gas well designs. However,
as wells step out further, it has become more common to drill the curve with steerable motors and to drill the lateral with RSS. On
shale wells where the curve and the lateral are drilled in the same hole size, it would be more efficient to drill the entire well with
RSS. Hence, there is a necessity for higher-dogleg RSS for these applications.
This paper describes the development and testing phase of a new 6 -in. RSS that can produce higher build rates than the standard
RSS on the market. During testing, the 6 -in. RSS proved to be capable of producing 12-15/100 ft in 8 -in.- and 8 -in.-holesize sections. The system was tested under controlled conditions through variable rock strengths to ensure consistent and
predictable build rates, as well as fine dogleg control for horizontal sections.
When sufficient test data had been gathered to prove the RSS was fit for purpose, it was then released for initial field testing on
shale gas wells in North America.
Introduction
In the 90s, the introduction of the first commercial RSS revolutionized directional drilling. Since then, RSS technology has made
remarkable improvements in reliability and has become a standard drilling tool in a number of markets worldwide. Their use is not
only limited to high-cost offshore markets but is now becoming more common in lower cost land markets, especially shale gas
drilling.
With economics in mind, there is a requirement in shale gas applications for RSS to drill vertical, kick off, build at planned
10/100ft and drill the lateral to lengths of up to 10,000ft. To date there is not a conventional assembly or RSS that can effectively
and reliably execute all these tasks.
Using conventional drilling techniques, shale gas wells are typically drilled with multiple assemblies as shown in Figure 1. It is
becoming more common for RSS to be used on the lateral section, especially when the lateral is long and weight transfer while
sliding using steerable motor assemblies is difficult.

SPE 131357

Figure 1: BHA options for North America Shale applications

The development of a reliable RSS that can fulfill all of the tasks to drill from vertical to lateral TD would allow shale wells to be
drilled more economically. Also, the improved borehole quality produced by RSS over conventional steerable assemblies allows
for faster ROP, less torque and drag and better wellbore positioning. This can ultimately lead to laterals being drilled more
efficiently towards TD and even pushing the limit further.
Reducing build rates on the curve from 12/100ft to 10/100ft has the negative effect of losing some of the reservoir at land point
(approximately 100ft). However, if an RSS could drill the well more efficiently, then the 100-ft loss of reservoir exposure at land
point may be overcome by providing more efficient and faster drilling towards the end of the lateral. If lease lines allowed the
lateral could be pushed even further.
Rotary Steerable System
There are currently only a limited number of high-dogleg RSS on the market that could be used for drilling shale well applications
from vertical to lateral TD. These tools are not based on the current lower dogleg technology but have been specifically engineered
for high dogleg applications.
During the conceptual design evaluation stage for a higher dogleg 6 -in. RSS, a number of questions had to be answered.
Question
Answer

- Is it mechanically possible to produce an RSS that could drill wells at more than 10/100ft planned dogleg?
- Yes, but in general the system would become unstable while drilling vertical and lateral sections where fine control
is required. If a system could be produced to drill planned 10/100ft in water based mud where hole wash-out is a
factor, then the system could be used commercially for the majority of shale applications in North America. Oilbased mud applications would then fit the design also.

Question

- Given that a high percentage of the build sections are drilled with water-based mud, what build rate output would be
acceptable to overcome the effects of hole wash-out and still achieve the planned 10/100ft build rates?
- If the RSS had a capability of 12-14/100ft in gauge hole, a certain amount of borehole wash-out would still allow
the system to pull 10/100ft. The deign criteria was set at 12-14/100ft in water-based mud.

Answer

SPE 131357

Question
Answer

- Could the current 6 -in. RSS be upgraded to give the required results or is a completely new RSS design required?
- The current system could be upgraded with modifications to the touch point spacing and some mechanical strength
changes. This would allow major components in current RSS to be used and reduce the overall development time.

With the major questions answered, the decision was made to embark on an upgrade of existing equipment. The current 6 -in.
RSS has been commercial for several years and had been proven for reliability and directional consistency in a number of different
applications worldwide1. Also, with the majority of reliability improvements already in place, the existing 6 -in. RSS would
provide an excellent foundation to develop a higher-dogleg product.
The existing RSS works on the principal of three independent hydraulic pads mounted 120 apart in a non-rotating steering unit 2, 3,
. Each pad is driven by hydraulic oil stored in an accumulator and is compensated to wellbore pressure. Hydraulic oil to and
from each pad (for pad extension and retraction) is controlled using direct operating solenoid valves. The extension of each pad is
acquired using an accurate position measurement device to provide feedback to the controller.

4, 5, 6

Figure 2 shows the principal of control system operation. The system is well suited to overgauge borehole situations since each
pad has one inch of travel. This allows the control unit to maintain contact in hole-sizes up to 9.7 in. for the 8 -in.-hole-size
option and 9.9 in. for the 8 -in.-hole-size option.

Figure 2: Principal of RSS control system

Design Upgrade Specification for Higher-Dogleg RSS

To develop an RSS to be reliable and practically functional for shale gas applications the following operational specification was
laid out.

Nominal Tool Size:

Hole Size:
Planned Dogleg Capability:
Maximum Dogleg Capability:
Maximum Tool Diameter:
Flow Rate:
Maximum Hydrostatic Pressure:
Maximum Temperature:

6 in.
8 in. and 8 in.
Planned up to 10/100 ft
12-14/100ft capability in gauge hole
7 in. at Steering Unit
250 to 700 GPM
22,000 psi
150C (302F)

SPE 131357

Maximum Rotary Speed:

Maximum WOB:
Maximum Torque:
Downhole Life:
Bit Pressure Drop:
PDM Power:
Onboard Measurements:
Drilling Functions:

250 RPM
45,000 lbs
20,000 ft-lbs
250 hours operating
No restriction
PDM Powered option with real-time short-hop for underpowered rigs
Caliper7, Inclination and Gamma
Drill out, kick off, sidetrack from cement and open-hole

The current RSS already fitted the majority of the operational specification. Now the main challenge was to upgrade the system to
produce 12-14/100ft build rates and mechanically withstand rotating through 10/100ft curves for long periods. To produce the
higher build rates the system 3-point geometry was evaluated using in-house prediction software. This software had been
developed, verified and enhanced based on several years of data gathered while running the existing 6 -in. RSS commercially.
The upgrade design for predictable dogleg essentially required optimizing the spacing between bit-to-steering unit and steering
unit-to-3rd touch stabilizer. Also, the mechanical integrity and stiffness of the system was critical to produce a balanced system.
Figure 3 shows the critical areas that required upgrade.

Figure 3: Upgrades required for High-Dogleg RSS

To optimize spacing between the 3 touch points a modified driveshaft was required. This made the bit box integral to the
driveshaft and also allowed for an overall tool length reduction. The upper sleeve stabilizer was designed to be integral to the
upper end sub which reduced the distance to the 3rd touch point. Some minor changes to the systems lube oil location was required
but fortunately the original design had room to accommodate this.
Laboratory Testing for Mechanical Strength and Fatigue Limits
Overall mechanical strength and fatigue life had to be evaluated under controlled conditions to ensure the system could withstand
the higher dogleg applications. The system underwent 6 months of fatigue testing using a machine specifically designed for this
purpose. Figure 4 shows the fatigue test machine set-up used to test the mechanical limits of the new system.

SPE 131357

Figure 4: The RSS in the rotary fatigue test machine

Major components under test were driveshaft, bearings and rotary seals. The system was tested at various rotation speeds and
bending moments to evaluate the limits. Multiple bending moment sensors and distributed temperature sensors were installed to
measure the tool condition and to detect any mechanical anomalies in real time. Changes were made during testing to prolong life
on bearings and rotary seals. The shaft was run to failure repeatedly to generate accurate fatigue life calculations. This testing
proved invaluable for benchmarking the life of components in the system prior to commencement of full-scale drilling tests.

Drilling Test Facilities & Results

Full-scale drilling tests were conducted at the Catoosa Test Faculty near Tulsa, Oklahoma where the RSS was run in 5,000
25,000 PSI compressive strength formations with a water-gel mud system. Drilling tests were carried out in both 8 -in. and 8-
in. hole sizes to compare directional results. Various PDC bit designs were evaluated to assess the effect of gauge length and
structure with borehole quality, dogleg capability and consistency. The majority of wellbores drilled were sidetracked from cement
plugs close to vertical.
Throughout 2008 and 2009, the high-dogleg RSS was extensively tested. The system was tested for vertical drilling, high dogleg
curve and laterals. Changes were made as required during the drilling test phase to optimize the system for dogleg performance,
consistency and fine directional control. Various bit types were run to assess borehole quality for the various directional aspects of
drilling operations encountered during shale gas development.
As well as Catoosa testing, the tool was also run on selected customer wells to evaluate performance under a trial basis. Some of
the data presented in the paper is taken while drilling trial wells for customers in North America.
Test results for vertical drilling are shown in Figure 5. The tests were carried out with the RSS set in Automated Vertical Mode8
through interbedded sand and shale sequences with a Smith MDi616 (2-in. passive gauge). As can be seen from the surveys, the
inclination was quickly dropped from 0.44 to 0.09 and maintained below 0.1.

SPE 131357

Figure 5: Survey data and RSS settings with 8 -in. Smith MDi616 (2-in. passive gauge) - Vertical Section

The most critical area of the drilling tests was to achieve high and consistent doglegs through the curve. A variety of bits were used
but ultimately the focus was on having a system that could produce good results with a passive gauge bit for improved hole quality
and stability. Figure 6 show the survey data and RSS settings with 8 -in. Smith MDi616 (2-in. passive gauge) from kick off,
gradually staging up the offset to 75% of maximum. Once the build direction was established, the tool exhibited excellent
toolface control with the effective toolface (TF) on target.

Figure 6: Survey data and RSS settings with 8 -in. Smith MDi616 (2-in. passive gauge) - Kick Off and Build Rate Tests

Figure 7 shows the survey data using the same bit at higher inclination with 75% of maximum offset and finer dogleg control on
lower offsets. In addition to proving the system could produce more than 10/100ft, it was essential that the high build rates could
be reduced and become controllable for a soft landing and/or landing point adjustment on approach.

SPE 131357

Figure 7: Survey data and RSS settings with 8 -in. Smith MDi616 - 75% of Maximum Offset and Fine Control

The results indicated that the RSS is capable of producing more than 10/100ft build rate when on highside toolface/0.30-in. offset
setting. This is 75% of maximum offset capability in 8 -in. hole size which leaves the system with good potential for overgauge
borehole situations. Effective toolface back-calculated from the surveys were within 10 or less from the set toolface. This was
very good control and essential for high-dogleg applications.
The results also highlight that the system reduced build rate on highside toolface/0.05-in. offset to provide a controlled approach
for soft landing. The toolface was then set lowside to test the system could overcome the build trend. The surveys indicate that on
lowside toolface/0.05-in. offset the system responded well dropping inclination. The offset was then increased to 0.35 in. to assess
higher drop rate. At 87% of maximum offset, the RSS produced 12/100ft drop rate.
While using the same bit that drilled the curve, it was critical that the system was well balanced and controllable while drilling the
lateral. There was no gain in having a system that was very effective at drilling the curve but was difficult to control in the lateral.
This particular RSS has a very neutral tendency when the steering unit is central in the hole. This tendency makes the system very
efficient in the lateral requiring very little work to maintain inclination or move up and down on True Vertical Depth (TVD).
Figure 8 shows test results obtained while drilling a lateral on a North American Shale well.

SPE 131357

Figure 8: Survey data and RSS settings with 8 -in. Smith MDi616 (2-in. passive gauge) Lateral Control

In the above lateral section of the Shale well, the RSS was set in automated steering mode (Hold Mode), where Target Inclination
can be changed quickly and accurately using a non-intrusive Flow/RPM downlink method 9,10,11. A number of changes in Target
Inclination may be required while drilling the lateral to keep the well in the sweet spot as per geologists instructions. Downlinks
to trim the Target Inclination can be done while drilling if required, thus reducing non-productive time.
As shown in Figure 8, the TVD was controlled within 0.05 ft (0.6 in.) to the target (6185.1 ft TVD) in the 2340-ft (from 7543 ft
to 9883 ft MD) horizontal section. The system proved to have enough finesse to produce minimal doglegs along the lateral section.
Even though the well was drilled very close to the upper transition zone, it still managed to maintain predictable control. This
tendency is attributed to the neutral behavior of the assembly when on zero offset.
With some other RSS designs on the market, the control system has to work very hard just to maintain inclination. This is
operationally inefficient due to the system continually using energy just to maintain inclination or perform very small directional
changes. This particular RSS has the benefit of good stability and no strong directional tendencies when the steering unit is
centralized in the hole. This neutral characteristic ultimately leads to higher-quality hole as the system is only making very small
steering unit changes to build and drop at low-dogleg values.

SPE 131357

A summary of the results obtained is compiled in a plot of build rate versus offset shown in Figure 9. The results produced a close
to linear relationship which is perfect for high, medium and low dogleg applications. The 6 -in. high-dogleg RSS is capable of
producing up to 0.5-in. offset in 8 -in. hole, however in the test, 100% maximum offset was not attempted since 0.4-in. (80%)
offset yielded 14/100ft build rate with a 2-in. passive gauge PDC bit. This build rate was considered more than enough to support
a planed maximum build rate, even in overgauged, low-quality hole conditions. Overall test results were very positive. The
decision was made to start embarking on the customer trial phase to drill wells at planned 8-10/100ft initially. At the time of
writing, data is not available and will be presented in a future paper.

* MDi616 (2-in. Passive Gauge PDC bit) was used

Figure 9: The pure build-up test result with high-dogleg RSS in 8 -in. hole

Conclusions
Selection of the optimum bit gauge structure for a higher-dogleg RSS to produce effective and predictable results on high,
medium and low dogleg applications is critical. The bit has to be designed to be stable yet directionally aggressive when
required.
An RSS designed to drill planned 10/100ft curves may not be suitable for all shale applications, however it can provide
economic gains in areas where the lateral reach can be extended to increase pay zone exposure.
Drilling vertical and then a smooth curve to land with RSS has the benefit of producing high-quality borehole, hence reduced
torque and drag which allows the well to be drilled more efficiently in the lateral section.
Producing high dogleg with water-based mud where the formation is prone to wash-out can be a challenge. The real-time pad
contact caliper measurement on this RSS provides early warning of the onset of borehole wash-out. Drilling and surface
parameters can be optimized promptly to bring the borehole back into gauge for optimal directional performance.
Systematic testing from a drilling test facility proved that the RSS was capable of achieving all the directional objectives before
embarking on the customer trial phase of the project.
Higher-dogleg RSS will start challenging the efficiency of methodology currently used to drill wells for shale gas.
Acknowledgments
The authors would like to thank PathFinder Energy Services for their willingness to publish the data obtained with the 8 -holesize and 8 -hole-size PathMaker RSS. We are grateful to Smith International, Inc. for permitting the publication of this work.

10

Nomenclature
BHA
=
DLS
=
FE
=
GPM
=
LWD
=
MD
=
MWD
=
PDC
=
PDM
=
PRSS
=
ROP
=
RPM
=
RS
=
RSS
=
TD
=
TVD
=
VS
=
WOB
=

SPE 131357

Bottom Hole Assembly

Dogleg Severity (degrees per 100 feet)
Formation Evaluation
Gallons Per Minute
Logging While Drilling
Measured Depth
Measurement While Drilling
Polycrystalline Diamond Compact
Positive Displacement Motor
Powered Rotary Steerable System
Drilling Rate Of Penetration
Revolutions Per Minute
Rotary Steerable
Rotary Steerable System
Target Depth
True Vertical Depth
Vertical Section
Weight On Bit

References
1.

Sugiura, J.: The Use of the Near-bit Vibration Sensor While Drilling Leads to Optimized Rotary-Steerable Drilling in Push- and Point-theBit Configurations, SPE 115572 presented at the 2008 Asia Pacific Oil & Gas Conference and Exhibition, Perth, Australia, 20-22 October
2008.
2. Sugiura, J., and Jones, S.: Integrated Approach to Rotary-Steerable Drilling Optimization Using Concurrent Real-time Measurement of
Near-bit Borehole Caliper and Near-bit Vibration, SPE 112163 presented at the 2008 SPE Intelligent Energy Conference and Exhibition,
Amsterdam, The Netherlands, 25-27 February 2008.
3. Jones, S., Sugiura, J., and Barton, S.: Results from Systematic Rotary-Steerable Testing with PDC Drill-Bits Depicts the Optimal Balance
between Stability, Steerability and Borehole Quality, SPE 112579 presented at the 2008 IADC/SPE Drilling Conference, Orlando, Florida,
4-6 March 2008.
4. Jones, S., and Sugiura, J.: Concurrent Rotary-Steerable Directional Drilling and Hole Enlargement Applied Successfully: Case Studies in
North Sea, Mediterranean Sea and Nile Delta, SPE 112670 presented at the 2008 IADC/SPE Drilling Conference, Orlando, Florida,
U.S.A., 4-6 March 2008.
5. Sugiura, J., and Jones, S.: The Use of the Industrys First 3-D Mechanical Caliper Image While Drilling Leads to Optimized RotarySteerable Assemblies in Push- and Point-the-Bit Configurations, SPE 115395 presented at the 2008 Annual Technical Conference and
Exhibition, Denver, Colorado, 21-24 September 2008.
6.
Sugiura, J.: Improving Rotary-Steerable Borehole Quality Using Innovative Imaging Techniques, OTC 19991 presented at the 2009
Offshore Technology Conference, Houston, Texas, U.S.A., 4-7 May 2009.
7. Sugiura, J. and Jones, S.: Closed-Loop Physical Caliper Measurements and Directional Drilling Method, US Patent Application No.
20090090554, PathFinder Energy Services, 11 December 2008.
8. Baron, E. and Jones, S.: Control Method for Downhole Steering Tool, US Patent 7243719, PathFinder Energy Services, 17 July 2007.
9.
Baron, E. and Jones, S.: Drillstring Rotation Encoding, US Patent 7245229, PathFinder Energy Services, 17 July 2007.
10. Jones, S. and Sugiura, J.: Programming Method for Controlling a Downhole Steering Tool, US Patent 7222681, PathFinder Energy
Services, 29 May 2007.
11. Sugiura, J.: Rotary-Steerable Tool Including Drill String Rotation Measurement Apparatus, US Patent 7426967, PathFinder Energy
Services, 23 September 2008.