ABSTRACT

The abrasive pre-Khuff sandstones, combined with high

downhole temperatures and the propensity for bottom-hole
assembly (BHA) and bit sticking, present a uniquely hostile
drilling environment. These limit run durations and the ability
to optimize the rate of penetration (ROP) with the use of
conventional rotary assemblies, positive displacement mud
motors (PDMs)/conventional turbodrills and/or rotary
steerable systems. Catastrophic damage or loss of drill strings,
poor hole quality and logging problems are common, even
with the advancements in polycrystalline diamond compact
(PDC) bit technologies.
Of the systems listed above, historically turbodrilling
systems have best addressed the high temperatures and the
abrasive nature of the pre-Khuff formations and held the
potential for drilling economics optimization, but they have
been unsuccessful in addressing bit sticking challenges. The
development of best practices produced only marginal results
because they require surface intervention, and therefore do not
fully address sticking problems (in particular, bit sticking).
The engineering challenge was to develop a downhole
device that automatically engages and imparts sufficient drill
string torque to maintain bit rotation. The turbodrill device
disengages when conditions return to normal and returns the
operation to high productivity drilling without surface
intervention. The turbodrill device, coupled with
advancements in BHA design, stabilizer and jar placement
along with formation characterization and drill bit technology,
is the solution to bit sticking incidents.
Presented with this advancement in turbodrilling
technology, the Operator/Service Company team has
completed trials using this technology and presents data that
supports the use and benefits of anti-sticking technologies.
With this success, the team has regained focus on drilling
optimization and reset the goal for single run-casing point to
casing point.
INTRODUCTION
Saudi Aramco continually seeks ways to improve drilling
efficiencies through the difficult pre-Khuff formations. This
article is about a fortuitous trial of last resort that has
delivered favorable results.
In Saudi Arabia, pre-Khuff formations (Unayzah, Jauf,
Tawil, Sharawra, Qusaiba, Sarah, Qasim and Saq) are
encountered at depths between 13,000 ft and 17,000 ft.
These strata primarily comprise sandstones interbedded with
shales, limestone, dolomite, anhydrite and siltstones.
Sandstones with some siltstone predominate in the top
Unayzah strata downward through the Qusaiba. At the
bottom, the Sarah can also include some interbedded shale.
The Unayzah and Jauf are generally characterized by hard,
abrasive sandstones interbedded with shale and siltstone.
Unconfined compressive strengths can reach 40,000 psi with
internal angles of friction ranging from 25 to 75.
Hardness, abrasiveness, toughness, irregularity in size and
orientation of rock constituents, and problems with sticking
all contribute to a significant challenge and expense
associated with drilling in the pre-Khuff formations
1-3
. High
wear rates on bits and bottom-hole assembly (BHA)
components present a significant potential for premature
equipment failures, limit bottom rotating time, and
necessitate long and frequent trips.
The Upper pre-Khuff (Unayzah to Jauf) strata are the most
difficult of the pre-Khuff formations to drill. These strata
typically consist of very irregular, fine to coarse grained
pebbles and conglomerates that can vary significantly in their
dimensions and hardnesses (both in adjacent wells and at
different depths in a particular well), and the Jauf formation
may also contain pyrite.
Pre-Khuff reservoirs are an important source of present-day
Saudi Arabian nonassociated gas production. Saudi Arabia is
progressively moving toward a significant increase in gas
production. The expected growth is primarily for domestic
fuel and petrochemical feedstock, although Saudi Arabia is
also a large exporter of natural gas liquids (NGLs). To meet
these goals, significant portions of Saudi Aramco drilling
assets have been directed toward pre-Khuff onshore and
offshore gas exploration and development during the past
several years.
Saudi Aramco aggressively seeks drilling solutions that
mitigate inefficiencies. This article describes drilling the pre-
Khuff sections in two offshore trial wells, which will be called
Trial Well 1 and Trial Well 2 in this article. A total of 11
turbodrill with diamond impregnated bit runs, during 661
rotating hours, had four principal goals:
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009 37
Innovative Solution for Drilling Pre-Khuff
Formations in Saudi Arabia Utilizing
Turbodrill and Impregnated Bits
Authors: Gabriel D. Carrillo, Usman Farid, Michael Albrecht, Perry Cook, Nouman Feroze and Kenneth Nevlud
38 FALL 2009 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
wear. This makes long drilling runs a typical and expected
result. The vendor has spent years matching diamond
impregnated bit performance and run life to the turbodrill.
Diamond impregnated bit cutting structures with increased
blade heights enable the incorporation of larger volumes of
diamond material, thus longer bit life, into turbodrill bit
cutting structures
6
. Bit aggressivity can be increased with use
of larger diamonds in the impregnation mix (and vice versa)
and/or modified by changing the number of blades. Cutting
structure geometries also enhance nose and shoulder
durability (and bit run life) without interfering with gauge
protection. Thermally stable polycrystalline (TSP) inserts are
positioned on the gauge and shoulders to ensure the bit has
the capability to drill a gauge hole in hard and abrasive rock,
and increase durability and wear resistance in the shoulders.
Incorporated PDC cutters in the cone area improve ROP.
While a matched bit and turbodrill promised long run life,
bit sticking presented what seemed an insurmountable
problem. If jarring was required to free a stuck bit attached to
a turbodrill, there was a high probability of damage to the
turbodrill requiring a tool replacement trip.
DEVELOPMENT OF MECHANICAL RECOVERY FROM
STICKING
While every effort was made to optimize performance and
durability potentials for all parts of the drilling system, pre-
Khuff turbodrilling could be successful only if bit sticking events
were avoided. Some months prior to the Well 1 problems, the
vendor ran a series of development trials on a new optional tool
feature that allows drillstring torque to be directly applied to a
drill bit mounted on a turbodrill. The purpose of this device is
to prevent the bit sticking, and it had shown solid potential
during the initial prototype tests. This tool feature was disclosed
and Saudi Aramco agreed to a trial.
The device works as follows: If, while drilling ahead in
rotary, the turbodrill drive shaft (attached to the bit) begins to
slow/stall, a locking clutch (LC1) mechanism automatically
(with no intervention from the surface) engages and transmits
string torque via the drive shaft to the bit to prevent the stall.
As most sticking originates during times in which a turbodrill
is stalled, the clutch will prevent most incidents of bit sticking.
Subsequently, as sticking forces are overcome, the need for
string torque decreases, and the LC1 automatically disengages
(again without surface intervention) and returns the system to
high productivity turbodrilling. In turbodrilling conditions in
which the potential for bit sticking is a significant operational
risk, the LC1 showed promise as a very useful innovation, and
a turbodrilling trial commenced using the innovative feature.
At the time of the Saudi Aramco trial, experience with the
LC1 was limited to about 1,800 hours of field testing. Based on
performance data derived from this testing, Saudi Aramco and
the vendor elected to mitigate the risk of a catastrophic bit
sticking event by limiting the operational on-bottom run time to
Decreasing trip frequency.
Decreasing bit and BHA component failures that lead to
fishing.
Increasing productive, on-bottom bit life.
Increasing the rate of penetration (ROP) through use of
high efficiency downhole drives and analytically
engineered BHAs.
Historically, vertical turbodrill runs through the pre-Khuff
formation have been unsuccessful because of their inability to
transmit rotary torque to the bit when sticking events occur
4
.
Still, a turbodrill paired with a specially designed diamond
impregnated drill bit promises a favorable response to all of
the above goals. Although the bit sticking problems clearly
remained in everyones mind, interest in the tool remained as a
result of its potential for durability and productivity in the
event the sticking problems could be prevented
5
. This article
begins with an offshore well, Trial Well 1, at a point where
pre-Khuff problems had become acute. The well has had a
troubled history. At a depth of 16,617 ft in the Unayzah
formation, a twist-off occurred, necessitating a sidetrack. The
sidetrack was started at the top of the Unayzah at a depth of
16,200 ft with a positive displacement mud motor (PDM) and
polycrystalline diamond compact (PDC) bit. Saudi Aramcos
pre-Khuff drilling is typically achieved with PDC bits drilled
with rotary power. Because of the sidetrack, however, PDC
with rotary was not possible in Trial Well 1. The assembly
could not, of course, negotiate the change of direction at the
sidetrack.
The utilization of a down drive system increases the
rotational speed and torque delivered to the drill bit, while
isolating these increased forces from the drillstring. The
drillstring rotary speed and torque required to drill effectively
is reduced. This reduces the stress and tortuosity induced on
BHA components and improves drillstring reliability.
At Unayzah depths in Trial Well 1, temperatures of 340 F
were encountered. These temperatures cast doubt on
reliability expectations for key PDM rubber components.
Turbodrills easily withstand much higher temperatures, and
in spite of past bit-sticking problems, there was little to lose:
It was an opportunity for the evaluation of innovative
turbodrill technology.
TURBODRILL AND MATCHED BIT CHARACTERISTICS
Turbodrills running diamond impregnated drill bits are
normally an excellent combination in hard, abrasive materials.
Diamonds easily cut through all hard rock. Although diamond
exposure in a diamond impregnated drill bit is quite small, the
high rotating speeds of the turbodrill (1,000 rpm to 1,200
rpm or more) produce attractive ROPs because the number of
rotations is so high.
Turbodrills are similar to aircraft engines. Power is
produced by rotating vanes that are subjected to very little
80 hours. This time period was sufficient to provide both
engineering application and fiscal justification for the trial,
which would determine future use of the turbodrilling assembly
equipped with the locking clutch device.
For now, summarizing ahead, it can be mentioned that the
turbodrills equipped with the LC1 produced no drilling
disruptions of any kind, including bit sticking or locking
clutch equipment failure.
TRIAL PROGRAM
Key Saudi Aramco goals for a turbodrilling trial were:
Operational cost reduction, mitigation in the required
number of trips, avoidance of downhole component failures,
increased on-bottom drilling time, and an evaluation of
turbodrilling performance in hard, high temperature pre-
Khuff rock.
On historical turbodrill runs, Saudi Aramco has had a
number of bit sticking problems and almost quit using
turbodrills across the pre-Khuff. The intervening years
brought stabilization engineering and development of matched
diamond impregnated bits designed for drilling efficiency and
for extended run durations.
Turbodrilled hole quality and straightness are greatly
influenced by BHA design. To ensure optimization, the
vendors engineers in Houston used proprietary BHA
simulation software to model critical rpm and stabilizer
placement.
Rig hydraulic equipment and drilling fluid characteristics
are another key factor in turbodrill optimization. Available
pump pressures and flows are optimized to turbodrill
requirements with proprietary software used by on-rig
turbodrill supervisors prior to runs and regularly during
drilling.
Turbodrilling crews are, obviously, the controlling influence
on tool performance. The turbodrilling supervisor is
responsible for training the rig crew on drilling safety and
procedures, and ensures there is no deviation from procedure
during operations. This supervisor also works closely with the
Mud Engineer to be aware of changes to the mud and re-
optimize the tool when changes occur. The crews help prevent
accidents of all types, including bit sticking, and ensure better
optimized drilling performance.
ORIGINAL WELL 1
The original Well 1 is an offshore well. The well targets a
pre-Khuff reservoir drilled with PDC bits and rotary. The
well has had a troubled history. At a depth of 16,617 ft, well
short of the planned total depth (TD), in the Unayzah
Formation, a twist-off occurred that necessitated continuing
the well via a sidetrack that begins at the top of the Unayzah
formation (16,200 ft). This sidetrack was to become
turbodrilling Trial Well 1.
OFFSET WELL
Well 1 could not be used for offset comparison to the Trial
Well 1 sidetrack because it had not reached sufficient depth.
Saudi Aramco, therefore, selected another offshore pre-Khuff
well for comparative evaluation to the Trial Well 1 sidetrack.
In this article, the offset is referred to as Offset Well. In the
Offset Well, the top of the Unayzah begins at 16,416 ft, and
TD 17,970 ft.
The Offset Well was drilled with 17 rotary runs using
PDC bits.
TRIAL WELL 1 SIDETRACK
The Trial Well 1 sidetrack begins at a depth of 16,200 ft and
was competed at 16,394 ft. This portion of the well is not
included in summaries that are shown below.
High bottom-hole temperatures (approximately 350 F) are a
problem at pre-Khuff depths. Because of temperature, PDMs
have unsatisfactory operational life and are not suitable for
drilling in these sections. Moreover, the utilization of a
downhole drive system, which does not allow drillstring torque
to be transmitted to the bit, disqualifies PDMs and con -
ventional turbodrills alike from drilling potential bit sticking
sequences. The wish to avoid the reoccurrence of catastrophic
experiences with rotary drilling on the original well, combined
with the incompatibility of a PDM, resulted in the turbodrill
being the sole remaining alternative. Thus, a 4
3
4 turbodrill
equipped with a locking clutch, and a matched diamond
impregnated bit was selected, subject to the 80 hour drilling
limit described above.
Trial No. 1 goals included: An evaluation of turbodrilling
performance and reliability, operational cost reduction in
hard, high temperature pre-Khuff drilling, mitigation in the
required number of trips, avoidance of downhole component
failures and increased on-bottom drilling time.
The first turbodrill trial run began at a depth of 16,394 ft.
This tool drilled 377 ft in 73 hours. As indicated by surface
torques during the run, bit sticking events did occur and were
overcome by engagement of the locking clutch. There were no
problems disruptive to drilling attributed to the turbodrill. As
a result, Saudi Aramco approved continuation of the trial, on
a run-by-run basis, to a TD of 17,900 ft. A PDC bit on rotary
drilled 127 ft in a formation that was not conducive to
efficient penetration by a diamond impregnated bit.
Trial No. 1 Run Summary
A total of 1,379 ft (six runs total, including five turbodrill
runs and one PDC bit in rotary run) were drilled at an
average ROP of 5.18 ft/hr. All bits were in good condition at
the end of their respective runs. The hole condition was good,
and there was no spiraling. High temperatures had no adverse
effect on the turbodrill durability or performance. No loss of
productive time was attributable to bit sticking or problems
with either the turbodrills with LC1s or the matched diamond
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009 39
40 FALL 2009 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
in the Trial Well 1 sidetrack, and results for both trials are,
accordingly, beneficiaries of added credibility.
CONCLUSIONS
1. During this trial, there were no events in which bit sticking
or BHA problems resulted in lost on-bottom drilling time.
2. The high temperature pre-Khuff environment had no
adverse effect on turbodrill durability or performance.
3. Turbodrills equipped with the LC1 locking clutch and matched
diamond impregnated bits drilled 11 runs. In addition, three
PDC runs are included for a total of 3,863 ft drilled in
comparable pre-Khuff sections in two trial wells, Table 1.
4. During these runs there were no events causing downtime
related to either turbodrills or drill bits.
5. Turbodrills equipped with the LC1 were tripped from
the well after a maximum of 80 on-bottom hours. Based
impregnated drill bits during any of this group of trial runs.
Favorable results were achieved for all trial goals.
TRIAL WELL 2
Based on the favorable results in the Trial Well 1 sidetrack,
Saudi Aramco authorized continuation of the turbodrill with
LC1 trials in the pre-Khuff sections of Trial Well 2. The 80
hour drilling limit was continued.
Primary goals for Trial Well 2 were the same as for the
Trial Well 1 sidetrack. Of additional importance, Saudi
Aramco wanted to determine whether or not the favorable
Trial Well 1 results could be consistently expected, and both
the Offset Well and the Trial Well 1 sidetrack served as
offsets for Trial Well 2.
Trial No. 2 Run Summary
A total of 2,357 ft (eight runs total, including six turbodrill
runs) were drilled at an average ROP of 4.9 ft/hr. Two PDC
bits on rotary, between the first and second turbodrill runs,
drilled 171 ft. A 60 ft core run between the fifth and sixth
turbodrill runs is not included in feet drilled. As with the first
trial, hole condition was good, and no nonproductive time
was attributable to either turbodrills with LC1s or the
matched diamond impregnated drill bits during the runs. Trial
Well 2 results are exceptionally consistent with those produced
Table 1. Summary data
Runs Days Footage Days/ Ft/Day Ave.
1,000 Ft Ft/Run
Offset Well 17 36.8 1781 20.7 48.4 104.8
Trial Well
1 ST 6 22.5 15.6 14.9 67.1 251.0
Trial Well
2 8 35.3 2357 15.0 66.7 294.6
Fig. 1. Typical condition of post-run drill bits.
Fig. 2. Required trips.
0
4
8
12
16
20
R
e
q
u
i
r
e
d

T
r
i
p
s
Offset Trial 1 Trial 2
17
6
8
Fig. 3. Days per 1,000 ft drilled.
0
5
10
15
20
25
D
a
y
s

/

1
,
0
0
0

F
e
e
t
Offset Trial 1 Trial 2
20.7
14.9 15.0
on positive trial results, the limit on drilling time is
correctly established.
6. All diamond impregnated bits were tripped from the well
in excellent condition after a maximum of 80 hours. One
bit was reused with good results. All bits possessed
additional life/value and their respective run lives could
have been extended, Fig. 1.
7. The turbodrill and impregnated bit combination reduced
the tripping required by the offset well by more than 50%.
This is a positive result for the trial goal pertaining to
tripping, Fig. 2.
8. Days per 1,000 ft drilled are 28% lower for the turbodrill
and impregnated bit combination than for the offset well,
Fig. 3. This result contributes positively to trial goals.
9. The impregnated drill bits more than doubled the feet drilled
by PDC bits in the offset well. This contributes to a positive
result for the trial goal of increasing time on-bottom, Fig. 4.
10. Feet drilled per day are 38% higher for the turbodrill,
and impregnated bit combination than for the offset well.
Again, this result is a positive trial result, Fig. 5.
11. Figures 6 and 7 show drilling performance com parison
between offset and Trial Wells with and without
coring runs.
12. It can be concluded from the study of reduction in days
per 1,000 ft drilled, and for the required number of runs
that turbodrilling with the innovative locking clutch and
impregnated bits produced important fiscal benefits.
In conclusion, the turbodrill locking device innovation
had a very positive impact on the vertical pre-Khuff
drilling program through two well trials. Saudi Aramco, in
conjunction with Smith International, continues to seek
and expand the applications for the concept while
significantly increasing value through optimization of the
turbodrilling system.
ACKNOWLEDGMENTS
The authors wish to thank Saudi Aramco management for
their permission to publish this article. Special thanks to W.H.
Wamsley, for his valuable assistance and support in the
preparation of this article.
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009 41
Fig. 4. Average ft drilled per run.
0
50
100
150
200
250
300
350
A
v
e
.

F
e
e
t

/

R
u
n
Offset Trial 1 Trial 2
104.8
251.0
294.6
Fig. 5. Average ft per day.
0
10
20
30
40
50
60
70
80
A
v
e
.

F
e
e
t

/

D
a
y
Offset Trial 1 Trial 2
48.4
67.1 66.7
Fig. 6. Comparative depth vs. days.
Fig. 7. Comparative depth vs. days (including coring).
42 FALL 2009 SAUDI ARAMCO JOURNAL OF TECHNOLOGY
REFERENCES
1. Simpson, M.A., Zhou, S. and Nordquist, D.G.: Drilling
Challenges and Recent Advances of Pre-Khuff Wells, Saudi
Arabia, presented at the SPE Technical Symposium of the
Saudi Arabia Section, Dhahran, Saudi Arabia, June 7-9,
2003.
2. Simpson, M.A., Zhou, S., Treece, M. and Rondon, C.:
Optimal Horizontal Drilling of Hard and Abrasive
Unayzah Sandstones, SPE/IADC paper 85331, 2003.
3. Simpson, M.A., Zhou, S., Treece, M., et al.: Breakthrough
Horizontal Drilling Performance in Pre-Khuff Strata with
Steerable Turbines, SPE paper 90376, 2004.
4. Internal Report, Definition of Bit Sticking Problem with
Turbine in Pre-Khuff Sands, Drilling Technology Unit,
Drilling and Workover Engineering Department, Saudi
Aramco, circa 1998.
5. Nordquist, D. and Zhou, S.: An Interim Report on Bit
Sticking Problem and Recommended Solutions, Internal
Report, Saudi Aramco, October 2001.
6. Simpson, M.A., Roed, A.H., Al-Shammari, H.A. and
Hoekstra, D.: Rotary Application of Low Matrix Strength
Impregnated and TSP Cutter Bits to Unayzah Sandstone
Drilling, SPE/IADC paper 77223, 2002.
SAUDI ARAMCO JOURNAL OF TECHNOLOGY FALL 2009 43
Perry Cook is the Middle East Area
Manager for Smith Drilling &
Evaluation, responsible for the
turbodrill product line. Perry started
his oil field career with Baker Hughes,
working for 7 years in the drilling
fluids sector in the areas of technical
research and field operations. He joined Smith Neyrfor in
2002 and has subsequently held field, technical,
coordination and management positions in the UK, the
U.S., Kazakhstan and Saudi Arabia. Perry is currently
based in Abu Dhabi supporting all aspects of turbodrill
business development throughout the Middle East.
In 1995, he received his B.S. in Biotechnology from the
University of East Anglia, Norwich, UK.
Nouman Feroze is a Petroleum
Geologist working as a Senior Sales
Engineer for Smith Bits, based in Al-
Khobar, Saudi Arabia, where he serves
Saudi Aramcos Exploration Group
and Joint Ventures Operators. He
started his career with Sperry Sun,
Pakistan and worked 2 years as a mud logger, then he
joined Smith Bits and worked in various locations in the
Middle East. Nouman has a total 11 years of oil field
experience.
He received his B.S. degree in Geology in 1994, and in
1996 he received his M.S. degree in Petroleum Geology
(Gold Medalist), both from the University of Karachi,
Karachi, Pakistan.
Nouman is an active Society of Petroleum Engineers
(SPE) member.
Kenneth Nevlud is a Mechanical
Engineer with Smith Neyrfor, where he
is currently the Manager of the
Neyrfor Sustaining Engineering Group.
He started his career with Smith
International in 2000, spending 2 years
with GeoDiamond focusing on bit
design before pursuing turbine design with Smith Neyrfor.
In 2000, Kenny received two B.S. degrees, one in
Mechanical Engineering and the other in Mathematics,
from The University of Texas at Austin, Austin, TX.
BIOGRAPHIES
Gabriel D. Carrillo began working for
Saudi Aramco in 2007. He received his
M.S. degree in Petroleum Engineering
from Texas A&M University, College
Station, TX. Since 1994, he has
worked for ExxonMobil, BP America
around the world, and several small
independent companies in South America, where his jobs
included Field Service Technician, Rig Supervisor and
Drilling Engineer. Currently Gabriel works in the
Exploration Drilling Department where he monitors daily
activities and plans upcoming events in a highly offshore
profile well.
Usman Farid is an Engineering
Supervisor in Saudi Aramcos
Exploration Drilling Department. He
began working with the company in
2002 and over 23 years experience in
rig drilling in the field, as well as in the
office, up to the Drilling
Superintendent level. Usman also worked as a Fishing
Engineer and Sr. Drilling Instructor prior to joining the
company. His job includes covering all engineering aspects
from planning to completion for high profile HPHT
offshore gas exploration wells currently being drilled.
Usman graduated with a double B.S. degree in Math
and Physics and Petroleum Engineering from the
University of Engineering & Technology, Lahore, Pakistan.
He also has an International Trainer certificate from the
Northern Alberta Institute of Technology, Edmonton,
Alberta, Canada.
Michael Albrecht works for Smith
Neyrfor in Saudi Arabia as a Drilling
Product Manager. He started his career
with Norward Energy in 1995,
working in Canada and the USA. In
2000, Mike took an overseas position
in Kazakhstan as a Safety Supervisor
implementing safe work practices with TCO and Parker
Drilling. He joined Smith Neyrfor in 2004 as a Turbodriller
working primarily in Canada, and later took a position as
a Drilling Product Manager for the Middle East in 2006.
Mike has worked in several countries worldwide, including
the Middle East, and has 14 years of oil field experience.
He is currently based in al-Khobar, Saudi Arabia and has
worked closely with the Saudi Aramco Exploration Group
and the Joint Venture Operators on overseeing Turbine
Operations and Sales.