Real-Time Development of New Technology Saves Operator $5.1 Million Drilling Deep Exploration Well, Colombia
Authors: Frazelle Andrew , Vargas Reynaldo , Krasuk Raul , Price MacLean 
Published: December 2007

Due to the challenging topography, lack of suitable surface locations and reinterpreted seismic data after construction work had commenced on a chosen location, the operator modified the wellbore directional profile from being the preferred "natural drift" to near vertical. The drilling of vertical wells, utilizing conventional equipment and procedures, had never been successful in Colombia. Based on the success in Argentina of this type of well, the operator requested the technical assistance of a drilling optimization service. The operator and service company developed a flexible, yet detailed strategy to address the anticipated challenges. The plan had the following main components: (1) the application of a straight hole drilling device used in combination with PDC and roller cone bits; (2) implementation of a teamwork philosophy to ensure all personnel felt committed to delivering significant performance improvement.

Because of slower than prognosed penetration rates using conventional bit technology and the corresponding negative impact on the 14 3/4" hole section performance curve, the operator and service company elected to build a new-style diamond impregnated bit that had been discussed during the planning phase. A prototype was designed using a multidisciplinary team comprised of operator and service company personnel. Members of the team who determined that the relatively short run length and excessive wear on the nose of the bit could be designed out of subsequent bits analyzed the initial run in the field. The changes that could be built into the next prototype within a short "turn around time" would be a different matrix type that would optimize diamond grit exposure, increased diamond volume and maximization of the cutting structure's contact area on the bottom of the hole. They also recommended a more aggressive anti-sticking gauge configuration to allow the bit to efficiently drill-out of a tight hole. The engineers returned to Houston and the optimized bit solution was manufactured and shipped back to Colombia in one week.

Due to the optimized design, the 14-3/4" impregnated bit IADC M842 set a new world single run footage record drilling 499 ft at 3.9 ft/hr. To capitalize on the new design's success, the engineers designed a 10-5/8" and 8-1/2" versions of the IADC M842 bit with the 10-5/8" version achieving another world single run footage record drilling 585 ft at 3.3 ft/hr. To measure the effectiveness of the plan flexibility and the service company's ability to solve unexpected challenges, the authors will document cost savings relative to offset wells. The typical Colombian foothills exploration well takes an average of 188 days per 10,000 feet to complete. However, because of the service company's ability to develop and deliver new technology to the well site in real-time, the operator was able to cut the time required to drill the exploration well by 86 days saving BP $5.1 million versus utilizing conventional technology and procedures.

The authors will review each section outlining success and areas for improvement. They will also discuss the development of the innovative technology and give examples on how to best apply it to achieve maximum performance.