Optimizing Drill Bit Design Iteration with a New Sensor System Developed for Large-Scale Deployment and Automated Analysis of Drilling Dysfunctions

Schen, Aaron; Graham, Ryan; Engel, Braden

doi:10.2118/210170-ms

SPE Annual Technical Conference and Exhibition 2022

DOI: 10.2118/210170-ms

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Optimizing Drill Bit Design Iteration with a New Sensor System Developed for Large-Scale Deployment and Automated Analysis of Drilling Dysfunctions

Aaron Schen¹,

Ryan Graham²,

Braden Engel³

Abstract: A drill bit dynamics sensor system has been developed with a new approach that enables economical, widespread use of downhole data to improve bit design. The system emphasizes ease of deployment and minimal manpower requirements for data interpretation. The goal was to develop a system appropriate for deployment on a new scale to the bit industry. The system consists of a small in-bit sensor coupled with an automated software system that provides direct design guidance targeted at drill bit specialists. This p… Show more

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2023

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Cited by 2 publications

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Deployment of an Eccentric Borehole Conditioning Tool Yields Significant Drilling Efficiency Improvements

Bailey

Roberts

Suleiman

et al. 2023

Middle East Oil, Gas and Geosciences Show

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Wellbore conditioning has become prominent in recent years as operators strive to reduce flat time costs. This paper examines how an eccentric wellbore conditioning tool (WCT) improves drilling performance and reduces flat time in challenging sections. Torque and drag are common challenges in extended laterals, with micro-doglegs and ledges being major culprits, especially in hard carbonate formations. The performance of the WCT is benchmarked in terms of flat time components: trip speed, system torque, rate of penetration (ROP), casing operations, and on-bottom performance. The paper also scrutinizes the allowable parameter envelope for wells drilled with and without the WCT. Laboratory testing was conducted to observe the behavior and effects of the eccentric WCT when confronted by the major wellbore conditioning challenges. Following these initial laboratory tests, a proprietary software program was created to determine the WCT's ideal bottom hole assembly (BHA) placement for field trials. Several field trials were conducted to validate the placement software's accuracy as well as the key benefits achieved by the WCT. Development testing has proven that the WCT's capabilities reliably improve wellbore quality and reduce overall torque and drag. Also, a proprietary software program confirmed the most effective WCT placement. Overall, there was a net flat time reduction and a marked improvement in ROP—up to 35% when directly compared with and without the WCT. Reduced system torque and less stress on downhole tools enable a wider and, more importantly, higher drilling parameter window. A new generation of eccentric WCTs has been introduced to solve a legacy drilling pain. Poor wellbore conditioning contributes to significant flat time costs for operators worldwide. A proven, effective solution has been long overdue; however, the WCT has shown to be a cost-effective tool, improving flat time and drilling performance. The benchmarking and exploration of drilling performance and reduced flat time provided by wellbore conditioning tools will allow others to exploit lessons learned and recapture drilling efficiency.

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Deployment of an Eccentric Borehole Conditioning Tool Yields Significant Drilling Efficiency Improvements

Bailey

Roberts

Suleiman

et al. 2023

Middle East Oil, Gas and Geosciences Show

View full text Add to dashboard Cite

show abstract

Breaking New Ground. Enhancing Polycrystalline Diamond Compact (PDC) Bit Performance in Chert Formations through Use of Shaped Cutter Technology

Abdelrazik¹,

Ahmed²,

Suleiman

et al. 2023

Day 2 Tue, March 14, 2023

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Cherty formations are notoriously challenging for fixed cutter drill bits and present a costly challenge for operators who routinely experience short intervals and numerous trips. The predominant limitation is short bit life due to mechanical failure of the cutters. This paper details how an inter-company collaboration led to the development of a design philosophy and a novel shaped cutter technology that resulted in a step change in drilling efficiency and drilling consistency in chert formations. A collaboration between companies was initiated that commenced with a comprehensive study into the cutter-rock interaction to identify the failure mechanism of chert. The results of the research were then used to determine the critical design levers required to overcome these challenges, extended bit life and maximize drilling efficiency. Two fixed cutter drill bits in the 6-in. and 8.5-in. hole sizes that incorporated the new design philosophy and shaped cutter technology were designed. These bits were then field tested in the Egypt Gulf of Suez interbedded carbonates application characterized with the presence of dark brown chert. The new 6-in. and 8.5-in. designs were tested twelve times across four different fields. The runs were then evaluated against durability, rate of penetration (ROP) and cost per foot (CPF) compared to field offsets. In the 6 in. section, the new design drilled the entire section of 3,369-ft that includes 381-ft cherty formation with one bit compared to three bits previously required to drill the same interval. For the same offsets, an improvement of between 50-85% in ROP was achieved. The CPF assessment demonstrated drilling cost reduction between 24-75% across the fields tested. In the 8½ in. section, the new design drilled the entire section of 6,141 ft that includes 296-ft cherty formation with one bit compared to four bits previously required to drill the same interval. ROP wise, an improvement between 59-178% was achieved which corresponded to a CPF reduction of between 41-69% across the fields tested. These field tests demonstrate ground-breaking results in the durability, ROP and CPF performance metrics measured. Furthermore, the number of runs and diverse nature of the fields tested demonstrate the consistency of this new approach to drill cherty formations with full directional control and mitigating downhole vibration severity. A re-examination of the failure mechanism of chert drilling and the root cause behind drilling deficiencies in cherty applications conducted in a collaborative environment has paved the way for a step change in drilling performance. Novel design philosophies were created, laboratory tested, and field validated for consistency of the trials. As the drilling industry continues to explore unchartered applications to ensures cost efficient solutions is paramount to success

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Optimizing Drill Bit Design Iteration with a New Sensor System Developed for Large-Scale Deployment and Automated Analysis of Drilling Dysfunctions

Cited by 2 publications

References 5 publications

Deployment of an Eccentric Borehole Conditioning Tool Yields Significant Drilling Efficiency Improvements

Deployment of an Eccentric Borehole Conditioning Tool Yields Significant Drilling Efficiency Improvements

Breaking New Ground. Enhancing Polycrystalline Diamond Compact (PDC) Bit Performance in Chert Formations through Use of Shaped Cutter Technology

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