Numerical Simulation of Nonlinear Processes in the “Thruster—Downhole Motor—Bit” System While Extended Reach Well Drilling

Kunshin, Andrey; Buslaev, George V.; Reich, M.; Ulyanov, Dmitriy S.; Sidorkin, Dmitriy I.

doi:10.3390/en16093759

Cited by 2 publications

(2 citation statements)

References 32 publications

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“…In this study, the focus lies on investigating the rock-breaking performance of the cutter under various schemes and parameter combinations. In order to enhance computational efficiency, it becomes necessary to exclude secondary factors and make the following assumptions [16,23]: (1) Due to the difference in hardness between the PDC cutter and the rock material, the wear of the cutter during rock breaking is ignored and considered a rigid body. (2) The rock is removed immediately upon breaking, and repeated PDC drill bit performance, PDC cutters of three different shapes, namely cylindrical, axe, and triangular prism, were designed using SOLIDWORKS 2021 software.…”

Section: Finite Element Model Assumptions and Evaluation Guidelinesmentioning

confidence: 99%

“…The axe PDC cutter demonstrates a high rate of penetration (ROP) in rock breaking, facilitating easier penetration of hard rocks. This, in turn, helps prevent bit sticking and sliding [16], maintains stable weight on the bit (WOB) during drilling, and enables the bit to maintain a high ROP. Additionally, its simple structure, ease of processing, and relatively mature technology make it an advantageous choice for drilling into hard rock formations.…”

Section: Introductionmentioning

confidence: 99%

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Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Yuan

Zhang

et al. 2023

Applied Sciences

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As the depth of petroleum drilling increases, the strata environment becomes more complex. The efficiency and lifespan of Polycrystalline Diamond Compact (PDC) drill bits fail to meet current drilling demands. However, the structure and arrangement of PDC cutters are valuable determinants of drilling efficiency, although related research still has gaps and deficiencies. This study focuses on PDC cutters in axe, triangular prism, and circular forms. It establishes an inhomogeneous granite model based on the actual measurements of granite and verifies the accuracy of this model through uniaxial compression simulation. Finite element models of three types of cutters in various combination schemes are constructed to examine rock-breaking effects, with the best scheme optimized using Box-Behnken response surface methodology. The rock-breaking process of the optimal PDC drill bit layout has been compared to that of a single cutter bit. Field drilling has demonstrated the effectiveness of a mixed cutter arrangement. The results show that the inhomogeneous granite model can be trusted. The optimal arrangement involves axe cutters in the front row and an alternate arrangement of triangular prism cutters and axe cutters in the back row. The optimal lateral and longitudinal distances for the triangular cutters from the front row of axe cutters are 10 mm and 7 mm, respectively, while those for the back row of axe cutters from the front row are 10.06 mm and 7 mm, respectively. The ROP standard deviation in the drilling process of mixed cutter bits decreases by 53.06% and 43.08% compared to axe and triangular prism cutter bits, respectively. The drilling efficiency increases by 16.8% and 16.6%, respectively, demonstrating higher efficiency and stability. Field drilling results indicate that a mixed cutter bit increases efficiency by 23.5% compared to a bit with only triangular prism cutters. This study posits that research on the combination schemes and parameters of PDC cutters can significantly enhance drilling efficiency, thereby reducing the drilling cycle and costs.

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Section: Finite Element Model Assumptions and Evaluation Guidelinesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Yuan

Zhang

et al. 2023

Applied Sciences

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Numerical Simulation and Field Test of PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Wu¹,

Yuan²,

Zhang³

et al. 2023

Preprint

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The cutter structure and layout scheme of PDC (Polycrystalline Diamond Compact) bits are important factors in improving efficiency. To further improve the drilling efficiency of PDC bits, axe, triangular prism, and cylindrical PDC cutters were used as research objects. Based on the measured granite data, a finite element model of non-homogeneous granite was established and verified by uniaxial compression simulation. The rock-breaking process of different cutter combination schemes was compared using the finite element method, and the parameters in the best scheme were optimized using the Box-Behnken response surface method. The results show that the constructed model of non-homogeneous granite is consistent with the stress-strain relationship of real granite and is reliable. The axe PDC cutter is more aggressive than the other two cutters and is more suitable for the front row of the bit blade tooth arrangement, while the triangular prism cutter is the second most aggressive and is suitable for the rear row of tooth arrangement, and the best combination scheme is the front row of axe cutter and the rear row of triangular prism cutter arranged alternately with the axe cutter. The optimal transverse and longitudinal distances of the optimized triangular prism cutter from the front axe cutter are 10mm and 7mm, and the optimal transverse and longitudinal distances of the rear axe cutter from the front cutter are 10.06mm and 7mm. The drilling speed is more stable during drilling and the PDC bit with mixed tooth arrangement has 16.8% and 16.6% higher rate of penetration(ROP) compared with the bit with single axe cutter and triangular prism cutter, and the drilling speed is more stable during working, which can effectively improve the rock breaking efficiency of the PDC bit. The field application proves that the bit with mixed cutter arrangement is easier to break the complex formations, with more stable ROP and better efficiency. The study can provide theoretical support for the cutter layout of the PDC bit.

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Numerical Simulation of Nonlinear Processes in the “Thruster—Downhole Motor—Bit” System While Extended Reach Well Drilling

Cited by 2 publications

References 32 publications

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Numerical Simulation and Field Test of PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

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