New and Advanced PDC Bit Design with Innovative Backup Layout Cutters Helps Extend Bit Life without Sacrificing Rate of Penetration During a Heterogeneous Application, Northwest Kuwait
- Hocine Boussahaba (Halliburton) | Jayaram Sugumar (Halliburton) | Kyle Vrnak (Halliburton) | Lyes Benyoucef (Halliburton) | Ashish Fadtare (Kuwait Oil Company) | Altaf Al-Shammari (Kuwait Oil Company) | Khaled Al-Failakawi (Kuwait Oil Company) | Abhjeet Dutta (Kuwait Oil Company) | Meshal Al-Khaldy (Kuwait Oil Company)
- Document ID
- International Petroleum Technology Conference
- International Petroleum Technology Conference, 13-15 January, Dhahran, Kingdom of Saudi Arabia
- Publication Date
- Document Type
- Conference Paper
- 2020. International Petroleum Technology Conference
- Backup cutters layout, UCS Variation, New Innovative PDC design, Drilling, Controlled Depth of cut
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- 77 since 2007
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The 9 1/4-in. polycrystalline diamond compact (PDC) bit is a unique size necessary for long-interval deep-drilling casing programs in Kuwait. Drilling the section is a major challenge because the long interval consists of nonuniform lithology with variations in compressive strengths, and it contains an abrasive ultra-hard sandstone, a compact hard shale with a low rate of penetration (ROP) performance, and carbonates with shale, oolite, and sand traces. The interval is commonly drilled using either two or three new PDC bits, and extra trips are expected.
Efforts were made to substitute the numerous PDC bit runs with one customized and reliable design that can overcome formation hardness and variations in compressive strength and maintain the same ROP to total depth (TD) with limited success, even though the idea of backup cutters has existed for decades. A new, durable PDC design was implemented with the objective of helping improve the ROPs across all intervals. The innovative backup cutter placement design and minimal critical depth of cut for each primary and backup cutter in the same radial position are the most desirable solutions.
The new and innovative PDC cutters’ distribution structure using the new bit design software coupled with an innovative backup cutter placement minimized the calculated bit wear and maintained the cutters’ sharpness along the entire section without needing an extra trip or a new second bit, which produced the best performance achieved in the northwestern Kuwait fields.
The new bit design achieved the longest footage drilled in Kuwait for a single bit of 9 1/4-in. size with a competitive ROP compared to previous cases. The used bit came out of the well in excellent condition with minimal normal wear.
A case study of an innovative PDC cutting structure layout using the new PDC bit design with efficient backup cutter placement, bit formation interaction modeled to help predict cutting structure wear, and advanced rock mechanics analysis are discussed. The new backup cutters’ layout procedure extended bit life without sacrificing ROP.
|File Size||1 MB||Number of Pages||12|