Applying a Downhole Drilling Mechanics Tool to Improve Operational Procedures and Rig Operating Systems in Horizontal Wells

Managing drilling dysfunction is key to safely drilling horizontal wells in harsh environments. However, extended horizontal wells with long open-hole intervals complicate identifying and addressing dynamic drilling problems using surface measurements. The latest generation downhole drilling mechanics tool uses high-frequency measurements to characterize drilling patterns and dysfunctions in turn, is used to improve rig operational practice and drilling system design. This paper describes how to capture and analyze downhole drilling data sets, identify areas for improvement, and address them by improving operational rig processes and the drilling system design. The approach is applied with two different operators using two different rig operating systems with two different contractors in two different basins with varying systems of drilling and muds. The drilling process is characterized in different ways, and energy management is closely evaluated using surface and downhole measurements for a comprehensive system perspective. The authors break down operational activities into processes and apply process improvement concepts to improve drilling outcomes regarding safety, quality, delivery, and cost. The process improvements are sustained by a combination of drilling system design improvement and drilling operation process automation. Examples of the processes improved throughout a well are the repetitive activities completed during drilling a stand of drill pipe (typically about 95’ in length)), an on-bottom transition with the drilling assembly, rotary drilling, and slide drilling operation with conventional steerable systems, and an off-bottom transition. The improvements have saved a trip for two- and three-mile horizontal sections where multiple runs are typical. This paper describes and demonstrates a repeatable approach to using the drilling rig system, downhole drilling system, and body of operational practice to break down the drilling of an interval into processes for improvement. Using a downhole drilling mechanics sub to characterize energy management and qualify operational practice allows a process improvement approach to managing downhole behaviors with drilling rig control systems.