SPE-171852-MS

Innovative and Cost-Effective Coring Technique Extended Coring for Long

Intervals of Multiple Zones with World Record Case Histories from the
UAE
M.Hegazy Gehad, ADCO, SPE, UAE; Adel M. Salem, American University in Cairo (AUC), Egypt;
Shedid A. Shedid, Consultant & Professor; Muhammad N. Aftab, Ali Muhammad, and Reyami Mazin Al, ADCO;
Wahab Hazem and Farouk Mohamed, Baker Huges, UAE

Copyright 2014, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition and Conference held in Abu Dhabi, UAE, 10 13 November 2014.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Continuous core acquisition across formations of interest to perform quantitative and qualitative analysis
is extremely important for exploration geologists and reservoir engineers. Measurements performed on
cores are typically calibrated against well logging data for accurate and better reservoir interpretations.
However, the coring cost is directly proportional to coring technique, core length and a significant part of
coring cost is associated with rig time. In deep formations, the coring cost becomes extensively high due
to multiple trip times required after each conventional coring run (90 ft). The best way to minimize the
coring cost is to reduce the rig time efficiently achieved by reducing the number of trips required to
acquire core.
Abu Dhabi Oil Company for Offshore Oil Operations (ADCO) has recently investigated different
coring scenarios and technologies to optimize the coring operation time. An innovative and cost effective
solution was developed and applied as a result of this investigation by Extended Coring (Long Barrel)
which meets ADCOs objective of continuous coring across formations of interest. This procedure
reduced number of trips, rig time and eventually drilling cost. The extended coring (Long Barrel) can be
run in lengths from 120 ft to 810 ft with proper timing and planning for the jobs.
This paper describes ADCOs new strategy of extended coring (long barrel) acquisition based on
formations geological description. The case histories of extended coring in different formations in 8
and 6 hole size sections, the core handling procedures applied and lessons learned in a continuous
iterative process to optimize drilling cost in future operations are presented and analyzed.

Introduction and Literature Review

As global energy demand continues to rise and production of unconventional oil declines, further
development of low permeability oil recovery processes and technologies is needed to meet future energy
demands. The value of core samples to enhance reservoir evaluation and completion strategies has long
been recognized. Coring has early been recognized as very desirable to provide both qualitative and

SPE-171852-MS

quantitative geological and mechanical data necessary for reservoir characterization and management,
completion decisions, drilling, and other applications. The difficulty has been identified in justifying the
coring cost. The solution to the cost problem of core quality and ensuring that the core is representative
of the reservoir is to obtain more and sometimes longer cores in the minimum possible time.
Core analysis has been widely divided into Routine Core Analysis (RCAL) and Special Core Analysis
(SCAL), as shown by Shedid (2013). When the drilled formation become more complex of low and very
low permeability, special core analysis has become necessary for better evaluation of the formation
underdevelopment (Aboud et al., 2008).
It is important to have a comprehensive understanding of heterogeneity and structural complexity of the
reservoir under development. The main sources for better description of complex heterogeneous reservoirs
involve special core analysis, well logging, and well testing (Shedid, 2014). Coring goal is to obtain core
representative of the formation of interest while minimizing the physical and chemical alteration of the
rock during coring process. Earlier the target was to core a low Invasion core samples to minimize the
physical and chemical alteration of the rock but recently with the demand to core long interval it was also
required to save rig time without affecting the core quality.
The main applications of coring tight gas/oil reservoir can be summarized as: (1) definition of
unconventional gas/oil reservoirs, (2) Identification of cost-effective coring and core characterization
programs for basin-scale model development and sampling strategies, and (3) Understanding the challenges and defining progressive drilling and completion strategies, (Shedid, 2014).
The cost effective cutting of large intervals of continuous core in dolomitic formations requires
optimization of existing coring practices (Bretches et al., 1993). This study indicated that coring costs can
be reduced as much as 38% when innovative techniques are applied to the coring operation with regard
to core barrel spacing, core barrel modification, and proper bit selection to include the use of suitable
coring bits. Another major problem of coring is Health, Safety, and Environment concerns. Briner et al
(2010) succeed in coring sour ones in the South Rub Al-Khali. They considered the HSE aspects, the mud
system and core barrel vibrations by close monitoring to guarantee good core recovery with a maximum
of H2S scavenged. Special attention was also given to the cores after recovery to ensure no poisonous gas
is released in an uncontrolled manner. Moran et al (1989) cored samples in 1.0 meter length. These
samples were collected from Shelf in the south to Baffin Bay in Canada. Coring long core to be more
representative is another difficult task in coring process.
Some studies indicate that the overall cost of coring is influenced more by higher rig costs, due to
additional trip time and slower penetration rates, than by charges made by the penetration rates, than by
charges made by the coring companies for their tools and services. Filshtinsky and Quinn (1983) presented
three coring tools to reduce coring cost and make it economically feasible, including (1) non-jamming
core barrel, (2) downhole motor coring system, and (3) wireline downhole motor coring system. Today,
several advanced technologies have been developed and used in this study to reduce the coring cost.
Conventional core barrels collect and containerize a column of core material in an inner barrel that can
be made of non-disposable steel or disposable materials such as aluminum, fiberglass, or thin-walled steel.
In 2008, Hall et al (2008) presented a new tool as a one-piece aluminum inner barrel liner system to
protect and containerize core material during coring operations with conventional and wireline core
barrels.
Commonly exploration and appraisal objectives are different than the development objectives where
the cores are one of the main targets to measure the rock properties of very low permeability. Geomechanical measurements become one of the goals to design the well completion for future fracturing
where studding the layers above and below the main reservoir become very important to insure the
isolation. An example of conventional coring technique is shown in Figure 1, below. Comparison of
conventional and extended coring is listed in Table 1.

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Figure 1Examples of Conventional Coring Technique.

Table 1Extended Coring Summery

ADCO Exploration and development teams request to have many cores for early studies and also to
overcome the conventional way of higher rig time and consequentially higher required cost. These two
reasons of attaining representative very log core at minimum costs were the main incentives of the authors
to undertake this study.

Problem Statement
This study was important to achieve the required cores meanwhile not affecting the ongoing planning.
Many techniques were reviewed and evaluated such as extended coring, wire line coring and side wall

SPE-171852-MS

core to achieve the objective. Considering the risk, rock size and quality are the main targets followed by
the operation cost. Based on the above comparison of coring operations, which shown more complex
process due to the following reasons:

Limited technology.
Limited Core Size.
Less Core Quality.
Higher Operation risk due to high H2S.
More Operation cost.

The General Coring Goals

Major and general goals of coring process of a formation under development are summarized to be as
below:

Obtaining representative core of the formation to be developed while minimizing the physical and
chemical alteration of the rock during coring process.
Providing great care and concern to reduce time associated with high cost.

Current ADCO Coring Technique

Cut cores with maximum 90 120 ft length
The average core trips were ranged from 2 to 3 days based on the core depth and

H2S % value.
Considering three different examples for the existing core objectives.
ADCO New Goals
Unconventional reservoirs high uncertainties and long intervals: to minimize the

uncertainties it was recommended to cut long core intervals 800 ft to 1200 ft.
Conventional reservoirs: it was recommended to cut the dense between the layers
for frac geo-mechanical studies within same cost and time effective program.
Getting the long coring without affecting the company budget and business plan
(number of wells/year)
Coring Techniques and Study Outcomes
This study was important to extract the required cores and not affecting the ongoing planning. Many
techniques were reviewed such as extended coring, wire line coring and side wall core to achieve the
objective. It was important to minimize the risk, keep rock size and quality, and also reduce the operation
cost. The main current coring techniques involve:

Extended coring: Applied in areas where the core length is more than 120 ft
Wire Line coring: Used when coring, drilling operation are in sequence.
Side wall core : In exploration wells where hydrocarbon indication after drilling

New System Selection

Baker Hughes Extended Coring System (Long Barrel) is designed to be able to core longer interval above
90 ft where the system is consisting of the followings:
Core Barrel (HT Series) core barrel, which is 30 ft in length of each joint incorporated with 4 ft
stabilizer, the assembly can be made up till 840 ft. in one run, Figure 2.

SPE-171852-MS

Low Invasion bits were recommended, Figure 3.

The core barrel is incorporated with Long
Distance Adjustable (LDA) system, Figure
4, for the following:
A) Adjusting the thermal expansion of the
inner barrels without lifting the assembly
after picking up.
B) Swivel assembly which has the ball seat
for the flow diversion.
C) Pressure relief plug to allow releasing any
trapped gas while pulling out of the hole.
Inner parts
The System can be made up with Aluminum
inner barrel with different lengths, Figure 5.
Aluminum tube might be vented or normal
depending on the reservoir conditions.
LaserCut Liner (Core Quick View) and / or
Jambuster Liner can be made up easily on the
system.
Minimum ID Gage, Figure 6
Reduced Disturbance
Reduced Core Fluidization
Improved Protection
Force Balance Technology
Wear Knots reduce depth of cut, limits
aggressiveness

Figure 2Core Barrel Design

Lateral Movement Mitigate (LMM),

building up of blade behind & around the
gauge cutters, limits lateral motion, reducing bit whirl
Increased Stability
Extended coring systems can be used in vertical
& deviated hole with interbedded formations as well
as the system can be used a combined Jambuster
system which is used for highly interbedded formations:

Figure 3Low Invasion Bits

Protecting the Core for Enhanced Reservoir Data

The JamBuster anti-jam coring system incorporates telescoping inner core barrel sleeves into the proven
Baker Hughes HT- Series heavy duty core barrels to eliminate the effects of core jamming. With the
JamBuster system, two concentric inner core barrel sleeves automatically telescope if a core becomes
jammed in the core barrel. Coring continues without interruption.

SPE-171852-MS

Figure 4 LDA assembly

Figure 5Integration of Aluminum Inner barrel with PRCV helps in releasing trapped gas and pressure while POOH with the core barrel in high
gas wells/high H2S %.

Applications
JamBuster is especially effective in difficult coring applications:

Coring fractured formations

Coring through a slanted formation fault
Coring interbedded shales and expanded clays
Extended coring system.

Proven Results and Analysis

System effectiveness has been demonstrated repeatedly:
Core barrel efficiencies (percent of barrel filled) of 70% to 100% can be obtained

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Figure 6 BHC-406C Core Bit

Three-jam capacity reduces coring trips by at least two-thirds, core sample milling is eliminated
Offset comparisons with conventional systems show twice the length of core recovered with
JamBuster.
JamBuster can be run with new generation core bits and Core-Guard low invasion coring systems, and can
be combined with the Baker Hughes Gel Coring technology. Core diameters of 2 1/8 to 4 1/2 can be
obtained with the various barrel configurations.
Baker Hughes JamBuster anti-jam system, Figure 7, can reduce the costs associated with coring and
produce quality core samples.

SPE-171852-MS

ADCO and Baker Hughes Achievements in the UAE

Case 1, Well X-71, Top Drive Rig

Plan:
Conventional:
Extended Coring Outcome:

Was to cut 480 core across conventional formations 8 vertical hole

90 ft barrel, 6 runs and rig time planned was 15 days
482 ft core was cut in two runs with 100% recovery, excellent core condition
First run was 180 ft. and second run was 300 ft core length
5 days for coring operation
Longest core run in conventional formations with 34% H2S.
Saved 10 days of rig time with 400,000 USD
Many lessons were learned in the first coring runs in ADCO.
Case 2, Well X-71, Top Drive Rig

Plan:
Conventional:
Extended Coring Outcome:

Was to cut 540 ft. Core across deep and tight formations, 6vertical hole.
90 ft barrel, 6 runs and rig time planned was 21 days
350 ft core was cut in two runs with 65% recovery, excellent core condition
First run was 270 ft and run was 80 ft core length
11 days for coring operation
Saved 10 days of rig time with 500,000 USD
Many lessons were learned in this first 6 coring runs in ADCO
World record pf longest core run 270 ft in 6.0 inch hole
Case 3, Well X-30, Top Drive Rig

Plan:
Conventional:
Extended Coring Outcome:

Was to cut 420 ft. Core across three layers with 20 deg. Inclination.
90 ft barrel, 5 runs and Rig Time planned was 13 days
422 ft core was taken with 101% recovery, excellent core condition
Achieved in one run
6 days actual coring operation
Saved 7 days of rig time with 450,000 USD
Longest core run in 20 degree deviated hole
World record of longest core run 422 ft in 20 deg deviated hole
Case 4, Well X-30, Top Drive Rig

Plan:
Conventional:
Extended Coring Outcome:

Was to cut 780 ft core across five formations

90 ft barrel, 9 runs and rig time planned was 27 days
780 ft core was taken in two runs with 100% recovery
Excellent core condition
Achieved in 2 runs (390 ft each)
8 days actual coring operation
Saved 19 days of rig time with 900,000 USD
Case 5, Well X-64, Kelly Rig

Plan:
Conventional:
Extended Coring Outcome:

Was to cut 1150 ft core across tight formations

90 ft barrel, 13 runs and Rig Time planned was 26 days
100% recovery and excellent core condition
Achieved in 5 multiple coring runs from 156 to 287 ft core length
16 days actual coring and drilling operations
Saved 10 days of rig time with 400,000 USD
World record of longest Core run 287 ft with Kelly Rigs

Conclusions
Based on the executed field coring jobs and the developed analysis, the following conclusions are drawn
as follows:

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Figure 7JamBuster System (Anti-Jamming System) used with Extended System

1. A new technology has been proven as the first time in the UAE tight/inclined reservoirs. In
addition, an innovative coring strategy based on the requirements has been developed and applied
successfully.
2. Remarkable cost and time saving were achieved with zero operation Non-Productive Time (NPT)
and/or no safety concerns.
3. The first longest core through 8.5 wellbore slanted hole, the first longest core through 6 hole, and
the first longest core through Kelly rig are carried out successfully as the worldwide records.
4. Extended coring has proven its ability to core with long barrel to reduce rig time and to reduce the
overall time of the reservoir exposure to the drilling fluid. This allows better quality of wire line
data to be obtained especially when sampling and pressure record runs are required.
5. Extended coring reduces the overall time of the core sample exposure to the drilling fluids which
also lead to a reliable routine and special core analyses.
6. Extended core reduces the number of trips required for coring, which effectively reduces and even
eliminates negative Health, Safety and Environment (HSE) concerns and consequently removes
expected risk involved. This method also reduces the overall cost of the rig which allows wells to
put on production faster and allows calibrating the drilling plan.

Recommendation
The following recommendations are important to be considered in the future coring jobs:
1. Extended Coring services need to be planned prior to the jobs to ensure Maximum benefit of the
tools.
2. Extended Coring Services need to be selected as per Core Analysis Program, i.e. Extended Coring
assembly with LaserCut System allows repaid access to the core sample to be able to do all the
core analysis services at well Site.
3. Extended Coring System can be assembled with JamBuster System to be able to core inter-bedded
formation without pullout of hole incase jam occurs / or Suspected.
4. When coring in formation with High H2S and CO Gas, Extended Coring Can be used with vented

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SPE-171852-MS

inner barrel to allow the gas to escape while pulling out of hole.

Acknowlegements
The authors would like to thank ADCO, ADNOC Management and Baker Hughes for their support and
the permission to publish.
Nomenclature
LDA Long Distance Adjustable system
LMM Lateral Movement Mitigate
RCAL Routine Core Analysis
NPT Non Productive Time
SCAL Special Core Analysis

References
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