Building on the success of the proven "Lean Casing Profile" technology, Eni plans to further optimize well completion to reduce exploration cost by achieving further reduction of annular clearance between the casing and the borehole wall without losing hole quality. To prove this "Extreme Lean Profile Casing Concept", a new reaming-while-drilling technology was required. The technology development effort was started as a joint industry project in June 2004 between Eni and the service company. This paper describes in detail the operational specifications and technical functionality as well as the complete development process of the industry's first automated vertical reaming system (VRS), from the early concept through the design and laboratory testing to the early field application in a commercial well

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