Performance Step Change: Optimized PDC Design for Directional Drilling Application Increases ROP by 39% Drilling Difficult Hard/Interbedded Formations in Northern Kuwait

Abstract

Constructing the 12¼" direction hole section through approximately 3000ft of difficult interbedded lithologies (Mutriba-Lower Burgan) in northern Kuwait presents a number of distinct challenges. In the upper portion of the hole section, a PDC bit must penetrate medium to hard carbonate and shale formations with compressive strength ranging between 9-12 kpsi with peaks up to 30kpsi. Next, a challenging abrasive sand with compressive strength between 6-9kpsi requires an RSS/PDC assembly to reach TD. The operator experimented with several different bit designs attempting to efficiently achieve directional objectives and improve borehole quality with limited success. Issues with baseline designs included lack of cutting structure durability and low ROP.To accomplish the operator's objectives, the engineering team analyzed all relevant offset data and concluded an existing 12¼" six-bladed bit with 16-mm cutters would serve as the starting point for an optimization effort. The bit's design data was fed into an FEA-based modeling system. Formation characterization software was then utilized to select the appropriate rock samples to simulate the field formations in the laboratory. Multiple simulations were run to determine the best combination of technologies to achieve the objectives. A new 12¼" directional design (616-type) would include premium cutters that can withstand impact in the interbedded carbonate/shale section and remain sharp while drilling the lower sand formations to TD. The bit also features a torque limiting feature in the blade top and TSP inserts in gauge to ensure hole quality. Next, a series of simulations were preformed to observe how different RPM and WOB values would affect vibration and torque levels. The results were plotted to create a smooth drilling parameter window to maximize the new bit's ROP potential.The new bit design was run on RSS with PDM assist and set a new ROP record of 46 ft/hr, 39% faster than the best offset of 33 ft/hr and 68% higher than the five-well offset average (27.3 ft/hr). The bit met all directional objectives (5-6°DLS) and was pulled in excellent dull condition (0-1-WT). The authors will discuss the bit design and selection process in addition to the HTHP cutter technology which saved the operator 2.5 days of rig-time and associated costs.