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This paper examines the performance of a novel Flanked Non-Planar (FNP) shaped Polycrystalline Diamond Compact (PDC) cutter through laboratory and field testing in challenging applications. Testing results demonstrate significant advantages of the new cutter shape, which are further validated by an extensive field test program in the Middle East. The geometry of the PDC cutter has emerged as a crucial factor in enhancing fixed-cutter drill bit performance industry-wide. Two types of cutters were investigated: a V-shaped FNP and a non-V-shaped FNP cutter. Both cutters had identical non-planar geometry on the face but varied in cutter-rock interaction characteristics. Field evaluations compared these cutters with legacy cylindrical cutters in terms of drilling efficiency, durability, repairability, and cost per foot. Laboratory tests assessed drilling efficiency at single cutter and full-scale drill bit levels. Field testing involved more than 470 runs across the Middle East, using offset runs with legacy cylindrical cutters for comparison. Laboratory tests revealed significant benefits of FNP cutters. The non-V-shaped FNP cutter reduced vertical force by 20% due to its angled flank, which improved cuttings evacuation and decreased frictional losses. The V-shaped FNP cutter showed a 30% reduction in vertical force and enhanced fracture propagation with its tip geometry. Full-scale tests demonstrated a rate of penetration (ROP) improvement of 13 to 38% for the non-V-shaped FNP drill bit across different formations, while the V-shaped FNP drill bit achieved a 29 to 40% ROP improvement. Field trials in the Middle East across various conditions showed ROP improvements of 14 to 112%, with the highest gains in shales and carbonates using the V-shaped FNP cutter. Cutter durability was comparable to conventional round cutters, considering the interval drilled and dull condition. Moreover, a cost analysis considering bit cost, ROP, and rig rates demonstrated significant reductions in cost per foot compared to offset runs. Overall, the novel FNP cutters offer tangible drilling efficiency gains that significantly reduce drilling costs. This paper highlights the significance of exploring innovative shaped PDC cutter designs and their impact on drilling efficiency. It demonstrates that FNP cutters improve efficiency at both micro and macro levels. Field testing confirms that these novel geometries provide tangible ROP performance and drilling cost reduction without compromising durability or repairability.
This paper examines the performance of a novel Flanked Non-Planar (FNP) shaped Polycrystalline Diamond Compact (PDC) cutter through laboratory and field testing in challenging applications. Testing results demonstrate significant advantages of the new cutter shape, which are further validated by an extensive field test program in the Middle East. The geometry of the PDC cutter has emerged as a crucial factor in enhancing fixed-cutter drill bit performance industry-wide. Two types of cutters were investigated: a V-shaped FNP and a non-V-shaped FNP cutter. Both cutters had identical non-planar geometry on the face but varied in cutter-rock interaction characteristics. Field evaluations compared these cutters with legacy cylindrical cutters in terms of drilling efficiency, durability, repairability, and cost per foot. Laboratory tests assessed drilling efficiency at single cutter and full-scale drill bit levels. Field testing involved more than 470 runs across the Middle East, using offset runs with legacy cylindrical cutters for comparison. Laboratory tests revealed significant benefits of FNP cutters. The non-V-shaped FNP cutter reduced vertical force by 20% due to its angled flank, which improved cuttings evacuation and decreased frictional losses. The V-shaped FNP cutter showed a 30% reduction in vertical force and enhanced fracture propagation with its tip geometry. Full-scale tests demonstrated a rate of penetration (ROP) improvement of 13 to 38% for the non-V-shaped FNP drill bit across different formations, while the V-shaped FNP drill bit achieved a 29 to 40% ROP improvement. Field trials in the Middle East across various conditions showed ROP improvements of 14 to 112%, with the highest gains in shales and carbonates using the V-shaped FNP cutter. Cutter durability was comparable to conventional round cutters, considering the interval drilled and dull condition. Moreover, a cost analysis considering bit cost, ROP, and rig rates demonstrated significant reductions in cost per foot compared to offset runs. Overall, the novel FNP cutters offer tangible drilling efficiency gains that significantly reduce drilling costs. This paper highlights the significance of exploring innovative shaped PDC cutter designs and their impact on drilling efficiency. It demonstrates that FNP cutters improve efficiency at both micro and macro levels. Field testing confirms that these novel geometries provide tangible ROP performance and drilling cost reduction without compromising durability or repairability.
Delta Mahakam, located in East Kalimantan has been known as one of the old oil and gas fields in Indonesia which has been developed since 1970. With massive production over more than 50 years, the field has entered the brownfield period. The reservoir pockets get more difficult and challenging to reach. The environment is factory-drilling with a fast operation (up to 200 m/h instantaneous on-bottom penetration rate, multiple offline activities, and fast connections practices) and is considered to be reaching the saturation level. The challenge now is to identify the opportunity for marginal but continuous performance improvement to lower the overall drilling operation cost. Specific to this Delta Mahakam brownfield, there are at least six (6) DD/MWD/LWD-related initiatives that were implemented to optimize the drilling operation: (1) Adaptive and Continuous development of drill bit design; (2) Robust metal-to-metal-based push-the-bit Rotary Steerable System (RSS) utilization to boost up ROP; (3) Downhole steerable motor with high torque performance power section to gain higher horsepower during drilling; (4) High-performance motorized RSS to improve performance in S-type high torque, interbedded high impact formation, and long reach wells; (5) Utilization of LWD tool with single co-located formation evaluation sensors to enhance safety, surface handling efficiency, and geo-stopping; (6) high-resolution real-time data for high-speed drilling and safe BHA pull out of hole (POOH). For the last 5 years, despite the more challenging oil/gas reservoir pockets to be targeted, the directional and logging while drilling performance in Delta Mahakam continuously increased. The drilling statistics show that 19.5% higher on-bottom ROP has been achieved by transitioning the BHA drive system from an elastomer-based to a metal-to-metal-based push-the-bit RSS system. For wells with a steerable motor application (high DLS requirement in wash-out prone zone), the high-torque performance motor helped boost up sliding ROP, improving the total drilling on-bottom ROP by 24%. For the wells with special challenges (S-type high torque, interbedded high impact formation, long reach), the high-performance motorized RSS has proven to achieve 39% higher on-bottom ROP, which potentially saved 175 hours of drilling time from 7 wells drilled compared to the traditional RSS-standalone approach. On the invisible lost time (ILT) reduction side, the utilization of an integrated single-collar LWD tool saved the surface handling time by an average of 34%, and TD determination by 43%. All those performance improvements are achieved without sacrificing the real-time data quality supported by the high-frequency mud telemetry technology which transmits the signal 200% faster than the average technology available in the industry.
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