Torque and Drag Mitigation in Extend Reach Wells: A Case Study of the SUST-X Well, Sudan

Extended-Reach Drilling (ERD) is a critical technique for enhancing hydrocarbon recovery from remote and complex reservoirs, yet it poses significant mechanical challenges—most notably, managing torque and drag (T&D) forces in long, deviated wellbores. These forces can reduce drilling efficiency, impede weight transfer, and increase the risk of stuck pipe, particularly in the build-up and horizontal sections. This study presents a detailed mechanical analysis of the SUST-X ERD well in Sudan, integrating actual field data with advanced simulations using WellPlan software. The modeling confirmed the well’s ERD profile and identified critical T&D zones. Key findings include sinusoidal and helical buckling thresholds at 98.8 kip and 104.3 kip, respectively; pick-up and slack-off drag values of 35.2 kip and 36.2 kip; and a maximum rotary torque of 13,236.8 ft-lbf during on-bottom drilling. The simulation also predicted a safe overpull margin of 324.0 kip, validating WellPlan’s reliability for pre-drill mechanical risk assessment. By combining real-world data with simulation, this work addresses a key knowledge gap in ERD design and execution—specifically the lack of data-driven, case-specific analysis for quantifying mechanical limits. The findings underscore the importance of simulation-based planning and proactive wellbore design in mitigating T&D challenges and improving both the technical performance and economic outcomes of ERD operations. Future research should extend this approach to dynamic drilling effects for a more comprehensive risk management strategy.