Innovative PDC Bit Designs with Improved Cutter Technology Deliver Significant Performance Improvements in Arabian Deep Gas Applications

摘要

This paper details the step by step process undertaken by a dedicated focus group established to provide a solution to inconsistent drilling performance with the 16” section in two deep gas fields in the Arabian Peninsula. The paper reviews the analysis undertaken as well as focusing on new design concepts and improved technology introduced. Drilling in these deep gas fields, especially the 16” sections has always been a challenge for Polycrystalline Diamond Compact (PDC) drill bits due to the complex lithology that consists of a variety of carbonates with high interfacial severity, abrasive sandstones and compact shales. Despite improving the ability to consistently drill the 16” sections in a single run over the past few years, the new challenge is further improve consistency and rate of penetration. Having experienced inconsistent performance and a series of premature PDC bit failures in these applications over the last few years the vendor assembled an integrated project team to investigate the issue. This team carried out an in depth analysis of all the available field data and identified several key factors that were responsible for PDC bit damage, such as bit/BHA whirl, poor operating parameters and their associated vibrations, and the limited ability of existing PDC cutters to drill such formations. The findings led to the development of a new PDC bit design solution with high lateral and torsional stability capable of drilling with high drilling efficiency, and the introduction of new cutter technology, along with optimised operating parameters. The successful implementation of the new drill bit and recommended drilling parameters have enabled the operators to more consistently drill these challenging 16”sections in a single run at higher ROPs than previously achieved. This has resulted in significant cost saving for the operator.