XR Reamer

Introducing a New and Flexible Solution For eXtRa Challenging Drilling Operations.

Presented by: Svein Ravndal, DHT Technology Manager, Europe & Eurasia

Challenges to Hole Enlargement

Typical XR Reamer applications are to Enlarge a hole due to:

ECD concerns. Intermediate casings. Swelling formations. Casing Cement job issues. Ease the casing running. Casing drilling Expandable casing / Mono diameter well bores

Operating Efficiency & FlexibilityOvercoming Activation Limitation

Dormant Mode

The flow inside the tool is unrestricted the arms are mechanically locked by a shear pin

Using 150 bar shear pins there is normally no limitation on the drilling parameters used to drill out the shoe and reach the reaming point

Operating Efficiency & FlexibilityOvercoming Activation Limitation

Drop Ball Activation Mode

The pump rate is reduced and activation ball dropped

When the ball lands, a peak and subsequent reduction in SPP reveals that the tool is activated and unlocked

Once unlocked the flow is diverted around the ball for full flow operation

StandpipePressure

FlowRate

3490 psi

315 psi

Ball Dropped

Low Flow Rate

Ball Lands

The XR reamer can also be activated hydraulically

Operating Efficiency & FlexibilityOvercoming Activation Limitation

Drop Ball Activation Advantages

The tool is activated at a low flow rateMinimal hole wash-out at bit or reamer while activating Ball activation method utilizes pressure inside the tool rather

than differential pressure below the tool The increase and subsequent drop in pressure, which is a

positive indication of ball seating, can be easily seen by the rig personnel (provided that the correct procedure is used)

Operating Efficiency & FlexibilityDeactivation Feature

Drop Ball Deactivation

The pump rate is reduced anddeactivation ball dropped

When the ball lands, a pressure surge inside the tool shears the deactivation pins, reversing the force on the drive rod and closing the arms

A subsequent reduction in SPP indicates that the tool is hydraulically deactivated

StandpipePressure

FlowRate

Ball Dropped

Ball Lands

Pressure Spikes

Operating Efficiency & FlexibilityDeactivation: Why Should the Customer Use it?

Advantages of Hydraulically Deactivation Function

Ability to drill and log a pilot hole after enlarging the hole Ability to circulate and rotate while tripping out of the hole

without deploying cutting structure Cleaning while in the casing Minimize formation destabilization in open hole

Operating Efficiency & FlexibilityEnsure Opening at Low Flow Rate

Cutter Arms Autoblocking FeatureThe geometric position of cutter arms where the opening forces become greater than the closing forces.

12-1/4 13-1/2 14-3/4 16 17-1/2

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Benefits of Autoblocking

During the entire arms opening process the surfaces rather than the hinge pins are loaded.

The flow rate can be reduced if necessary

Eliminates the reamer cutting structure engagement fluctuation due to hydraulics, thus minimizing torsionalvibration and assures enlarged hole diameter.

Operating Efficiency & FlexibilityEnsure Opening at Low Flow Rate

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Self-Body Stabilization

ReliabilityLimiting Reamer Vibration Sources

Lateral vibration reduced due to tight tolerance body to hole

Torsional vibration reduced due to stiffness resisting bending and tilting

The XR reamer body helpsminimizes BHA vibration and macro-doglegs at formation transitions interfaces

ReliabilityMinimize BHA Component Failure

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Articulated Deployment Lateral Deployment

Collaring Effect

Articulated deployment utilizes PDC cutters more efficiently to collar the reaming window

When autoblocking occurs and arms in full extension, the stabilization pad is non-aggressive

ReliabilityLimiting Reamer Vibration Sources

REAMINGFORCESREAMINGFORCES

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XR Layout Competitors Layout

Cutting Action Efficiency

Higher percentage of PDC utilized for reaming the hole

Profile of reaming cutting structure is conical which adds stability to the reaming cutting action

Dedicated and optional back reaming cutting structure

True Non-aggressive gage pad design minimize the tendency to initiate whirlfrom BHA side forces

Dedicated Arm Sets Per Opening Size

Autoblocking is a prerequisite Cutters are spaced to full homogeneous spacing and density

Other Key Discussion PointsCutting Structure

High-Density Robust Cutting Structure and Gage Protection

Other Key Discussion PointsCutting Structure

Other Key Discussion PointsHinge Pin

Drilling loads are distributed at hinge intersections and back wall of pocket

Hinge is protected by PDC cutting structure and gage hardfacing and dome inserts

Simplified Hydraulic Design

XR effectively cleans within the cutter arm housing by diverting 6-8% of the flow (XR 1200)

No external nozzles required that typically wash out borehole wall in soft formations

Experience with both NBR and XR demonstrate that nozzles are not required to clean cutter arms

Other Key Discussion PointsNozzles

World record single BHA run for length and hours in hole for a hole enlargement tool 4661 meters enlarged, 170 hours at 80 hole angle. No reamer effect on Bit ROP and directional drilling performance.

Successfully drilled the worlds first 12- x 17- and 8 x 12 section with an RSS system and hole enlargement device.

Case Studies and Accomplishments

XR 1200 has done the longest runs with all RSS;Geopilot: (2906 m on Statoil Vigdis, March 2007) Autotrak: (3486 m on Exxon Ringhorne, May 2007)Powerdrive: (4661 m on Statoil Gullfaks Gulltopp, October 2005)

Statoil Norway, Well 34/10-A-32 CT2 GulltoppSecurity DBS Drill Bits delivers technical limit performances

Challenge- Activate the tool at the shoe- Drill 12-1/4 and open 13-1/2 4661m at 80 inclination in one run- Deactivate the tool at TD

SolutionXR 1200 reamer set up with 13-1/2 PDC cutter arms with shear pin activation and drop ball deactivation system

ResultThe XR1200 was activated after the BHA had drilled 71m below the casing shoe. Clear indication of the cutter release was seen on the surface.

Drilling proceeded for another 4660m to TD. Total of 160 hours drilling, 332 hours circulation.

While drilling the section, no negative impact on the BHA performance was observed. None of the drilling parameters (rpm, flow rate or WOB) were limited due to the XR 1200 tool. The ROP was not significantly reduced and no increase in vibration was seen with the XR1200 tool in the BHA.

When entering stringers, drilling break procedures were followed in order to drill through. The assembly drilled the 4706m of new formation and opened 4661m from 12-1/4 to 13-1/2. The XR1200 tool was deactivated before circulating and rotating out of hole using a drop ball. Clear pressure indication was seen during deactivation.

29.3Overall ROP (m/hr)

159.1Hours Drilling Formation

4661Meters Reamed

4661Formation Drilled (m)

7964Depth Out (m)

3303Depth In (m)

XR1200

Case History #1

Hydro Norway, Well 30/9-F29Security DBS Drill Bits and Sperry Drilling Services delivers technical limit performances

Challenge- Drill 700 meters in hard chalk, Shetland formation- Drill 12-1/4 X 17-1/2, reaming and RSS BHA

SolutionXR 1200 reamer matched to a 9600 Geo-Pilot rotary steerable system.

ResultThe drilling exceeded expectations and the reamer tool was activated using the drop ball system. Clear indication of the cutter release was seen on surface.

While drilling the section no negative impact on the BHA performance was observed. The ROP was not significantly reduced and no increase in vibration was seen compared to the previous runs with other type reamers where the hole was opened from 12-1/4 to 13-1/2

Steerability of the Geo-Pilot system in conjunction with the Geo-Span downlink system gives the ability to change settings on-the-fly with no interruption to the drilling process or loss of LWD data.

The section was drilled using a Security DBS Drill Bits FMF3643ZSC bit designed specifically for the application. The assembly drilled the 681 meters of new formation and opened the hole from 12-1/4 to 17-1/2. The tool was deactivated before circulating and rotating out of the hole. At surface, the XR1200 was confirmed deactivated.

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2987

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Overall ROP (m/hr)

Hours Drilling Formation

Meters Reamed

Formation Drilled (m)

Depth Out (m)

Depth In (m)

XR1200

Case History #2

Statoil Norway, Well 34/10-B-20ASecurity DBS Drill Bits and Sperry Drilling Services delivers technical limit performancesChallenge- Activate the tool at 10 meters below the 8-1/2 window placed at

2531 meters.- Drill 8-1/2 and open 9-1/2 1700 meters in two planned runs due

to RSS and MWD requirement.- Deactivate the tool at TD.SolutionXR 800 reamer set up with 9-1/2 arms with drop ball activation and drop ball deactivation system.ResultThe XR800 tool was activated by drop ball after the BHA had drilled 64 meters below the whipstock. Clear indication of the cutter release was seen on surface.Drilling proceeded for another 944 meters to TD of run #1 at 3480 meters MD in 50 hours drilling, 82 hours circulation. Constant turn and build leaded to dogleg up to 7 degrees/30 meters including reaching 95 degrees inclination.Tool #1 was deactivated at 3480 meters and 5 hours were circulated on bottom to clean the hole. BHA was POOH without any problem and low wear on the reamer.XR800 tool #2 was run in the second BHA and activated at 3480 meters drilling proceed to TD at 3900 meters and tool was deactivated after 34 hours drilling. 8 hours were circulated on bottom to clean the hole with the XR800 tool in closed position.BHA #2 was pulled without any issue and the XR800 tool was graded with low wear. The liner was then run successfully to TD at 3900 meters MD.

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Run #1

Overall ROP (m/hr)

Hours Drilling Formation

Circulation Hours

Meters Reamed

Depth Out (m)

Depth In (m)

XR800

Case History #3

Performed runs in Norway per 13.03.2008:XR 800: 18 runsXR 1200: 56 runsXR 1600: 14 runs

Case Studies and Accomplishments

Tool fleet in Europe / Eurasia per 13.03.2008 :XR 800: 13 tools (+ 6 more within 01.04.2008)XR 1000: 2 toolsXR 1200: 12 tools (+ 6 more within 15.04.2008)XR 1600: 8 tools (+ 4 more within 01.08.2008)

Future requirement - Development

XR wired: XR reamer wired allows to place the reamer closer to the bit

(between the Geopilot and the MWD) Will be developed for all tool sizes, with first priority to XR1200 and

XR800 Prototype testing performed with ConocoPhillips and Sperry in three

operations in the North Sea with very good results