Distributed Data Acquisition Using Drilling Microchips in Horizontal Wells

Abstract Acquiring downhole data during the drilling of long horizontal wells is essential for monitoring drilling performance and ensuring operational safety. This study presents the first successful implementation and recovery of drilling microchips in a horizontal well. Two tests were conducted to evaluate the effectiveness of drilling microchips in acquiring downhole temperature and pressure data under realistic drilling conditions. In each test, 20 microchips were deployed in two batches, and the circulation parameters, such as pump rate and pipe rotation speed, were monitored. In Test 1, the microchips experienced multiple pump-off events and variations in operating conditions, leading to temporary trapping at different depths. In Test 2, the circulation was maintained more consistently, reducing pump-off events to improve data quality. The recorded times of drilling microchips were converted into a depth scale to create pressure and temperature profiles along the wellbore trajectory. The analysis of circulating pressure and temperature profiles reveals key insights into movement of drilling microchips in the annular space. The study also identifies critical periods where microchips became temporarily stagnant, due to change of operating conditions, effect of pipe eccentricity, and borehole geometry. It is recommended to maintain consistent pump rates and pipe rotation speeds to mitigate trapping and optimize microchip recovery. This case study highlights the potential of drilling microchips for distributed downhole data acquisition in horizontal and extended-reach wells. Lessons learned from the field tests provide valuable guidelines for improving recovery rates and data quality, paving the way for broader application of this technology in complex wellbores.