Breaking Barriers in Extended Reach Drilling: Integrated Drill String Design and Drilling Parameter Optimization for Enhancing Lateral Reach

Abstract

This study addresses the critical Torque and Drag (T&D) and Vibration challenges encountered during drilling operations at the GJN-23 Extended Reach Drilling (ERD) well, specifically identifying a significant failure in pipe torque ratings and Top Drive System (TDS) limitations, alongside drill pipe buckling risks during tripping in under worst-case parameters. To mitigate these issues, a comprehensive drill string remodeling was implemented, involving changes in drill pipe grade and weight (from 19.5# E NC-50 to 25.6# G-105 5-1/2 FH) and adjusting the length and grade of the Heavy Weight Drill Pipe (HWDP) in the vertical section. This remodeling substantially increased the drill pipe's torsional limit and improved axial drag resistance. Furthermore, by optimizing drilling parameters such as Friction Factor Open Hole (FFOH) to 0.25 (Water Based Mud), maintaining Weight on Bit (WOB) at 30-35 Klbs, Torque on Bit (TOB) at 2500-3000 ft-lbf, and Tripping Speed RPM between 70-80 RPM, optimal safety values were achieved while avoiding critical vibration frequencies (85-92 RPM and 130-138 RPM). Consequently, these optimizations enabled the GJN-23 ERD well to successfully extend its lateral reach to 28534.3 ftMD, representing a ~10% increase from the previous target, thereby significantly enhancing the absorption length for unconventional well objectives.