New Methods for Improving Drilling Performance: The Power of Digital Workflows

Aguiar, Romulo; Barreto, Diogo; Tocantins, João Pedro; Barr, A.G.; Lima, Laura; Li, Denis; Hemerly, Adriano; Martins, Guilherme; Lima, Flank Melo De; Sortica, Emanuel; Teixeira, Paulo Roberto

doi:10.2118/208706-ms

IADC/SPE International Drilling Conference and Exhibition 2022

DOI: 10.2118/208706-ms

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New Methods for Improving Drilling Performance: The Power of Digital Workflows

Romulo Aguiar

Diogo Barreto

João Pedro Tocantins

et al.

Abstract: After 10 years of Brazilian presalt exploration and development, the carbonate reservoirs continue to pose drilling challenges, leading to unwanted bottomhole assembly (BHA) trips due to severe shock and vibration, low rates of penetration (ROP), and premature drill-bit cutting structure damage. Today, industry efforts to improve the performance in the Brazilian presalt carbonates are driven by trial and error, which is very costly in the ultradeepwater drilling environment. The adoption of a collaborative min… Show more

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Cited by 4 publications

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Innovative Hyperbolic Cutting Structure Brings Step Change in Drilling Efficiency Onshore Mexico

Rosique,

Anguiano,

Tocantins

et al. 2023

SPE Latin American and Caribbean Petroleum Engineering Conference

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The discovery of field T in Mexico represented the largest such find in a generation. Hence, drilling activity has been focused primarily on economically viable ways to develop these reserves. The reservoir poses several drilling challenges, such as lack of drill bit cutting structure, durability, and aggressiveness leading to unwanted bottomhole assembly trips. These challenges lead to increased well construction costs. Accordingly, an application-specific bit design needed to be developed to optimize drilling efficiency in this section. This complex drilling scenario demanded a comprehensive rock characterization study to accurately diagnose the root causes for the low drilling efficiency. To determine the environmental factors that influence bit performance, a detailed formation mapping analysis was conducted using an engineering program for rock strength identification from offset wells. This information was then used to calibrate the digital formation file inside the integrated dynamic design and analysis software, capable of reproducing actual drilling conditions. The virtual model was used to develop a specific drill bit design equipped with cutting edge 3D-cutter, optimizing performance well beyond conventional fixed and flat cutters.Results from the well D2 indicate that this innovative technology yielded superior overall drilling performance compared to best offsets and has become the new benchmark for this application in Mexico. The comprehensive planning and detailed engineering analysis led to outstanding operational execution, setting new standards for drilling performance, reducing nonproductive time drastically and therefore minimizing CO2 emissions. The customized bit design drilled the longest 10 ⅝-in run in the field. This unprecedent performance led to 29% improvement in rate of penetration when compared to conventional Polycrystalline Diamond Compact (PDC) drill bit models, reducing rig time by 5.7 days exceeding customer expectations. The learning framework was applied using post-well analysis to compare model predictions with drilling data to further refine the model and close the loop on the original calibration, paving the way for further evolution of the bit design.A successful methodology for drill bit development aimed at drilling efficiency improvement was applied using a new cutting element (hyperbolic diamond element) and novel design concepts that replaced the traditional trial-and-error methods. Testing each new design feature virtually and running parameter sensitivity analyses to ensure a wide margin of applicability, the task was made much easier by the development of a calibrated virtual formation model in a fully traceable and replicable process.

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Innovative Hyperbolic Cutting Structure Brings Step Change in Drilling Efficiency Onshore Mexico

Rosique,

Anguiano,

Tocantins

et al. 2023

SPE Latin American and Caribbean Petroleum Engineering Conference

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State-of-the-Art Modeling Eliminates Drilling Dysfunctions in a Challenging Wildcat Ultradeepwater Wildcat Well

Batruny,

Aguiar,

Cruz

et al. 2024

SPE Annual Technical Conference and Exhibition

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Operators have expanded their search for new oil and gas reserves to more complex and challenging environments such as the ultradeepwater, presalt carbonate plays offshore Brazil. The major challenge these wells have faced historically is the well cost overrun from low rate of penetration (ROP) and downhole tool nonproductive time (NPT) related to drilling dysfunctions. To avoid costly trial and error, advanced software was combined with service provider and operator experience to get it right the first time: improving ROP while minimizing damage to the bottomhole assemblies (BHAs), drilling each section on time and on budget. An advanced 4D (spatial 3D + time) finite element transient drillstring dynamics modeling package is used to design the cutting structures, predict the drilling dynamics, evaluate different BHAs and drilling configurations, and optimize drilling parameters. BHAs for riserless, post-salt, salt, and silicified carbonate sections of the well are analyzed and optimized. Simulations are run to determine proposed BHA configurations and the potential for axial, lateral/torsional, and stick-slip vibration for different rock strengths. The BHAs are then optimized by adjusting cutting structure, stabilizer placement, hole enlargement ratio, and drillstring configuration. Once an optimum BHA is selected for each section, a sensitivity analysis is conducted on RPM, weight on bit, and torque to maximize ROP for each BHA. Three criteria are used to evaluate BHA performance: stability, robustness/reliability, and measurement quality. The performance of each optimized BHA is compared to the performance of the base case BHA from offset wells. The accuracy of the model's simulations and the optimum recommended parameters is also examined against field results. Overall, the optimized BHAs delivered up to 50% higher ROP compared to the base case from offset wells drilling similar formations. In most cases, the optimum parameters recommended by the model were also the optimum parameters in the field test. The increased confidence in the model from the field tests enabled its use to optimize the BHA further for future wells. This work presents a digital bit and drillstring design workflow, used to virtually run and analyze different BHA designs prior to running in the field. The work, tested in the field, resulted in multiple learnings shared in this paper, specifically in the realm of drilling mechanics.

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Hybrid Drilling Dynamics Downhole Measurements

Boualleg,

Li,

Johnson

et al. 2024

Adipec

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In the continuous pursuit of enhancing the efficiency and safety of drilling operations, the optimized placement of downhole sensors has emerged as a pivotal area of innovation. This paper presents an optimized configuration for sensor placement, meticulously designed to advance the understanding and control of drilling dynamics. By integrating high-resolution sensors capable of measuring three-axis acceleration, revolutions per minute, weight on bit (WOB), and torque, an optimized approach to monitor and analyze a drilling system's performance can be established. The methodology emphasizes steering efficiency, system integrity, and scenario-specific relevance, catering to a wide range of operational challenges. Several key scenarios are addressed, including high-frequency torsional oscillations (HFTO) detection and mitigation, backward whirl detection indicative of motor failure, motor micro stall conditions, reamer deployment strategies, comprehensive performance optimization, and stick/slip detection for preventing twist-offs. Based on this, the sensors are positioned at the most sensitive spots within the bottom hole assembly (BHA), ensuring a precise characterization of the excitation and distribution of critical stresses. Combined analysis of field data and 4D (3D in time domain) drilling dynamic simulations (Chen et al, [2015]), has affirmed the efficacy of the recommended sensor placement strategy in improving drilling efficiency and reducing operational hazards. The simulations particularly highlighted the capability to infer measurements from sensor data across different BHA components. It was also determined that WOB and torque on bit measurements from elsewhere in the BHA could be confidently inferred at the drill bit through extrapolation. Field data analysis further revealed that capturing burst acceleration data at the drill bit, integrated with a digital solution, effectively identifies HFTOs, facilitating their mitigation. Additionally, positioning a torque sensor just above the steering unit, where significant bending occurs, can prove instrumental in predicting HFTO-related fatigue life with considerable precision. Leveraging field data alongside advanced 3D dynamic simulations has led to the identification of an optimized sensor positioning. This versatility across numerous drilling scenarios, ensures the integrity of the drill bit while seamlessly integrating with the steering mechanism.

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New Methods for Improving Drilling Performance: The Power of Digital Workflows

Cited by 4 publications

References 9 publications

Innovative Hyperbolic Cutting Structure Brings Step Change in Drilling Efficiency Onshore Mexico

Innovative Hyperbolic Cutting Structure Brings Step Change in Drilling Efficiency Onshore Mexico

State-of-the-Art Modeling Eliminates Drilling Dysfunctions in a Challenging Wildcat Ultradeepwater Wildcat Well

Hybrid Drilling Dynamics Downhole Measurements

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