Successful Introduction of a Novel, High Dogleg Rotary Steerable System

Rotary Steerable Systems (RSS's) have proven beneficial over conventional steerable motor systems, which has driven significant market uptake over the last several decades. Consequently, applications for RSS's have expanded and encouraged RSS technology developers to meet these ever-changing market demands. Modifications to the basic proven RSS methods, attempted independent reproductions of those methods, and other novel methods have emerged to fulfill these market demands. The initial RSS method and technique were invented and proven in the late 1990s, and common ways of creating wellbore deflection emerged, allowing the industry to attempt the classification of these methods. These classifications were an attempt to gain a better understanding of the advantages and disadvantages of each and help understand where and what version of technology to apply for an ever-increasing expansion of applications. This paper describes the attempts at classification of RSS's, then addresses the drivers, development, and field trial results of a new method for placing wells using a high dogleg automated rotary steering system (SwR; Steering-while-Rotating). The SwR was targeted to meet market changes identified in 2016 and projected out ten (10) years by the SwR technical team. Simplicity, fostering reliability and value were major design tenets. A high dogleg curve (20°/100’) design, enabling "one-run, Vertical, Curve, and Lateral" bottom hole assemblies, two-way (uplink-downlink) downhole communications along with autonomous self-steering capability, also drove the SwR development. The initial SwR prototype system for 8-3/8"-9-7/8" hole sizes was built, and field trials began in Q3 of 2019. The SwR team weathered the global Covid-19 pandemic of 2020-21 with the rest of the world and deployed systems to the Middle East, while also securing and executing trial and commercial runs within North America in 2021 and 2022. Conclusions are based upon, and data is presented from thirty-seven (37) bit runs and the first 50,000 feet drilled with the SwR. The SwR team has delivered a unique steering method to the industry and presents the early run data demonstrating the SwR technology capability to drill challenging well profiles, in challenging environments. The SwR technology was designed for the RSS market of today and for several years to come improving the value proposition for modern RSS well placement technology.