Case History: Coring in ERD Well with Collision Risk Challenge and Optimization of Coring Parameters Based on Previous Coring Jobs in Carbonate Formation Alleviated Core Recovery
Authors: Kamble Rahul , Kassem Youssef Ali , Indulkar Kshudiram , Price Kieran , Mohammed A. Majid , Abid Kashif , Ahmed Mostafa 
Published: March 2021

Coring during the development phase of an oil and gas field is very costly; however, the subsurface insights are indispensable for a Field Development Team to study reservoir characterization and well placement strategy in Carbonate formations (Dolomite and limestone with Anhydrite layers). The objective of this case study is to capture the successful coring operation in high angle ERD wells, drilled from the fixed well location on a well pad of an artificial island located offshore in the United Arab Emirates. The well was planned and drilled at the midpoint of the development drilling campaign, which presented a major challenge of wellbore collision risk whilst coring in an already congested area. The final agreed pilot hole profile was designed to pass through two adjacent oil producer wells separated by a geological barrier, however, the actual separation ratio was &lt; 1.6 (acceptable SF to drill the well safely), which could have compromised the planned core interval against the Field Development Team's requirement. To mitigate the collision risks with offset wells during the coring operation, a low flow rate MWD tool was incorporated in the coring BHA to monitor the well path while cutting the core. After taking surveys, IFR and MSA corrections were applied to MWD surveys, which demonstrated an acceptable increase in well separation factor as per company Anti-Collision Risk Policy to continue coring operations without shutting down adjacent wells. A total of 3 runs incorporating the MWD tool in the coring BHA were performed out of a total of 16 runs. The maximum inclination through the coring interval was 73° with medium well departure criteria.

The main objective of the pilot hole was data gathering, which included a full suite of open hole logging, seismic and core cut across the target reservoir. A total of 1295 ft of core was recovered in a high angle well across the carbonate formation's different layers, with an average of 99% recovery in each run. These carbonate formations contain between 2-4% H2S and exhibit some fractured layers of rock. To limit and validate the high cost of coring operations in addition to core quality in the development phase, it was necessary to avoid early core jamming in the dolomite, limestone and anhydrite layers, based on previous coring runs in the field. Core jamming leads to early termination of the coring run and results in the loss of a valuable source of information from the cut core column in the barrel. Furthermore, it would have a major impact on coring KPIs, consequently compromising coring and well objectives. Premature core jamming and less-than-planned core recovery from previous cored wells challenged and a motivated the team to review complete field data and lessons learned from cored offset wells. Several coring systems were evaluated and finally, one coring system was accepted based on core quality as being the primary KPI. These lessons learned were used for optimizing certain coring tools technical improvements and procedures, such as core barrel, core head, core handling and surface core processing in addition to the design of drilling fluids and well path. The selection of a 4" core barrel and the improved core head design with optimized blade profile and hold on sharp polished cutters with optimized hydraulic efficiency, in addition to the close monitoring of coring parameters, played a significant role in improving core cutting in fractured carbonate formation layers. This optimization helped the team to successfully complete the 1st high angle coring operation offshore in the United Arab Emirates.

This case study shares the value of offset wells data for coring jobs to reduce the risk of core jamming, optimize core recovery and reduce wellbore collision risks. It also details BHA design decisions(4"core barrel, core head, low flow rate MWD tool and appropriate coring parameters), all of which led to a new record of cutting 1295 ft core in a carbonate formation with almost 100% recovery on surface.