Integrated FEA Modeling Offers System Approach to Drillstring Optimization

Aslaksen, H.; Annand, M.; Duncan, R.; Fjaere, A.; Paez, L.; Tran, U.

doi:10.2523/99018

Cited by 12 publications

(9 citation statements)

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“…To accomplish the operator's objective, a comprehensive FEA-based engineering program was used to model the total drilling system. [7][8][9][10][11][12][13][14] The design tool accurately predicted the drill bit's performance and behavior as an integral part of the total downhole system. The first step was to select a PDC design based on the operator's application requirements and analysis of offset performance.…”

Section: Fea Modeling/pdc Design Iterationsmentioning

confidence: 99%

Solving Deep, Hard/Abrasive 16" Application Challenges with New PDC Technology Saves Operator 13 Days Rig Time, Kuwait

et al. 2011

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Drilling the deep vertical 16" hole (starting at 9,300ft) in northern Kuwait is challenging due to the complex stratigraphic section that contains abrasive Zubair sand (with pyrite), reactive Ratawi shale, hard Ratawi, Minagish, Makhul limestones and Hith anhydrite (UCS 10-30kpsi). Completing the 16" section typically requires around 45 days of rig-time and four polycrystalline diamond compact (PDC) bits on a positive displace motor (PDM) driven bottom hole assembly (BHA). However, inconsistent PDC bit performance/durability and lack of downhole stability was causing premature bit/motor failure. The operator required new PDC technology that could efficiently drill the abrasive, Zubair and continue as far as possible into the Ratawi without premature cutter failure at acceptable rates of penetration (ROP). The PDC bit would also need to possess improved stability characteristics to reduce PDM failures/trip hours.An engineering team was assembled to analyze the latest drilling/PDC technologies, optimize BHA design, and determine the best practices to enable reaching section TD with two PDC bits/runs. A finite element analysis (FEA) based engineering system was utilized to predict the dynamic behavior of each BHA component. The resulting information led to greater bit stability when drilling in lithologies comparable to the specific field application. The development of a new abrasion resistant cutter was considered important to improving durability and maintaining cutting efficiency.The in-depth study and PDC design changes/advanced cutter technology produced a new nine-bladed PDC bit. The new bit was run on a performance motor in Raudhatain field and set new PDC footage and ROP records for drilling through Zubair (1,200ft) in northern Kuwait (Figure 1). Historically, the Zubair alone required three/four TCIs or two/three PDCs to complete the formation interval. Next an eight-bladed PDC, fitted with the new cutter technology, drilled 2,508ft from Ratawi to section TD for the first time in Kuwait. The improved performance reduced rig hours by an average of 13 days for a total savings of approximately $390,000USD compared to the closest two PDC offset runs. SPE 139873Conclusions KOC's Deep Drilling Team 1, working in conjunction with the service provider, set a new performance benchmark drilling the deep 16" vertical hole section utilizing teamwork and new PDC bit/cutter technology. The new HPHT PDC cutters have reduced accelerated cutter wear and diamond table loss enhancing penetration rates and bit durability. Using the advanced dynamic FEA engineering software systems helped prevent BHA and formation induced vibrations, associated failures and trips by providing dynamically stable BHA and PDC bit combinations. The application specific bit design was tested and certified according to the operator's requirements through the use of dynamic simulations and rock laboratory tests. The result saved the operator rig time and reduced drilling costs by eliminating the traditional trial and error improvement/optimization...

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Section: Fea Modeling/pdc Design Iterationsmentioning

confidence: 99%

Solving Deep, Hard/Abrasive 16" Application Challenges with New PDC Technology Saves Operator 13 Days Rig Time, Kuwait

et al. 2011

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“…The system improves the design method by modeling the bit as part of the total drilling system. [7][8][9][10][11][12][13][14] The software program helped engineers design a dynamically stable bit optimized for specific Middle East carbonate formations, well profile, BHA and operating parameters. The sophisticated program is based on laboratory-derived drilling mechanics data that accurately characterize the cutting structure's interactive mechanics during fundamental crushing action.…”

Section: Modeling Systemmentioning

confidence: 99%

Performance Step Change: New 16" TCI Design Solves Multiple Middle East Carbonate Drilling Challenges

Al-Baghli

Al-Khaldy

Al-Mutawa

et al. 2011

SPE/IADC Middle East Drilling Technology Conference and Exhibition

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Drilling the 16" hole section through mostly carbonates in southern Kuwait presents several distinctive challenges. Interbedded formations with vastly different compressive strengths that vary between 5-30 Kpsi and a significant amount of blind drilling can result in twist-off and lost-in-hole situations. The most common tungsten carbide insert (TCI) rollercone bit failures mechanisms are impact induced cutting structure damage, hydraulic inefficiency issues and bearing failure caused by high weight-on-bit (WOB) through the hard Dammam to Ahmadi carbonate sections.To solve the challenges the operator's drilling team, working in conjunction with the bit supplier, launched a performance improvement initiative. The carbonate application was analyzed using finite element analysis (FEA) based dynamic simulation program to fully understand how to stabilize the bit in different downhole conditions and improve hydraulic efficiency. Based on the computer analysis and field run data, engineers conceived a new stable bit design. The technology platform includes improved hydraulics and a specialized cutter structure configuration with tougher insert carbide grades to mitigate impact damage. A high-aspect ratio seal employs two dynamic sealing surfaces (ID, OD) that reduces frictional heat and minimizes wear to improve bearing reliability.The new rollercone bit was run with an optimized drilling plan with outstanding results establishing a performance step change in southern Kuwait's carbonate applications. The bit recently set a new 16" world cumulative TCI footage record of 12,656ft drilling three wells shoe to total depth (TD) and 531ft of a fourth well. The bit amassed a total 446 hours of onbottom drilling time turning 2.4 million revolutions without a seal failure. The bit saved the operator 4.5 days of rig time plus bit spend. The new technology has enabled the operator to drill long footage intervals or multiple wells using a single bit with good penetration rates (ROP). The authors will discuss the formation challenges, application analysis and resulting performance improvement.

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“…The process utilized a sophisticated simulation modeling software ( Figure 5) to "test drill" various BHA configurations and resulting component performance through the different formation types and hole sections. [3][4][5][6][7][8][9][10][11][12] To satisfy precursor modeling requirements, engineers captured all relevant offset drilling/geological data and well planning scenarios to create an extensive data archive. The analysis included expert drill bit selection, rock mechanics analysis, drilling shock analysis, drilling fluids, hydraulics optimization and directional drilling planning.…”

Section: Holistic Optimization Approachmentioning

confidence: 99%

Holistic Optimization Approach Improves Economic Viability of Bakken Shale Play

et al. 2011

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The Bakken Shale is one of the largest, unconventional crude oil plays in the United States covering as much as 25,000 sq miles in the Williston Basin. The formation underlies portions North Dakota and Montana and is found at depths ranging from 9000ft to 10,500ft. Reserve estimates vary but the United States Geological Survey (USGS) has calculated risked undiscovered resources of up to 4.3 billion barrels of recoverable oil and bbl/cu ft equivalent using current technology. At this time the field is being developed with single, dual and triple-leg horizontal wells with laterals extending 4500ft to 9500ft into the formation.However, drilling activity in the area has fluctuated as a result of changing oil prices. Accordingly, reducing overall operation costs is essential to the economic feasibility of each drilling project. Because of the significant impact on drilling costs, the correct selection and utilization of drilling equipment including bits, drilling fluids, hydraulics and downhole tools is paramount. To optimize operations, a holistic approach was adopted to create a drilling "road map" utilizing several application software systems. These software tools enable engineers to envision the specific drilling environment and tool/BHA interaction before the bit goes in the hole.A recent Bakken project included expert drill bit selection, rock mechanics analysis, shock studies, drilling fluids and hydraulics optimization. The directional well plan was optimized with wellbore simulation software. In order to circumvent deficient options prior to and during actual drilling operations, multiple scenarios are simulated using a collection of detailed geological and offset drilling information. These results were studied, analyzed and assessed as the optimum drilling solution prior to submitting them to the operator. Finally, the service provider monitored and implemented the recommended engineered solutions.The initial results were encouraging: Drilling days on Well 1 were reduced by 30% which represents a cost savings of $572,000USD while achieving the drilling target and delivering a high-quality wellbore. Building on this initial success, second and third wells confirmed the value of holistic optimization saving the operator 13 days ($676,000USD) and 16 days ($832,000USD) of rig time respectively.

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Integrated FEA Modeling Offers System Approach to Drillstring Optimization

Cited by 12 publications

References 0 publications

Solving Deep, Hard/Abrasive 16" Application Challenges with New PDC Technology Saves Operator 13 Days Rig Time, Kuwait

Solving Deep, Hard/Abrasive 16" Application Challenges with New PDC Technology Saves Operator 13 Days Rig Time, Kuwait

Performance Step Change: New 16" TCI Design Solves Multiple Middle East Carbonate Drilling Challenges

Holistic Optimization Approach Improves Economic Viability of Bakken Shale Play

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