Finding a safe and efficient approach to drilling in challenging applications is a difficult task for drillers because each field is unique. The industry's common ambition is to use various technologies to increase the mechanical penetration rate and reduce overall drilling time. Most recent studies show that drilling bits play an important role in drilling optimization and help to overcome most of the challenges connected with the rock destruction process and tool lifecycle. In recent years, 3D PDC cutters such as ridge diamond elements (RDE), rolling PDC cutters (RC), and conical diamond elements (CDE) have helped to further improve the drilling efficiency in a majority of applications worldwide. The PDC bit brazed with unique 3D cutters moved the industry set benchmark performance standards to the next level by improving cutter durability and efficiency in drilling. These cutters, depending on the shape, can improve ROP, durability, and can improve overall cutting efficiency. Field tests were conducted in multiple applications with multiple customers in RCA and the authors will present several case studies that will document performance improvement in challenging drilling applications. The results clearly show that the combination of this unique 3D cutter has helped operators to bring a step change in performance by improving ROP and footage drilled. In some cases, operators were able to drill the entire section with the bits equipped with 3D cutter combinations where traditionally more than one bit was used to complete the section. Customization of 3D cutters in the appropriate location of the bit is key to this success.
Designing and developing competitive tools for use in the oil and gas industry to meet the high-demand market requires years of experience and a high-level knowledge base. In today’s drilling environment, innovations in bit technologies play an increasingly important role to improve overall drilling performance and reduce drilling time. Cylindrical cutters had their own limitations and restricted the drilling industry from advancing the operations performance to the next level. 3D-shaped cutters were developed to provide maximum drilling efficiency in the most challenging applications by mitigating cutting structure damage and improving its technical limits. The invention of the 3D polycrystalline diamond cutter (PDC) is helping operators to drill wells faster by improving rate of penetration (ROP) and reducing in-out trips. The combination of ridged diamond element (RDE) and conical diamond element (CDE) on bits is a new method for drilling formations. These bits improve drilling ROP by maximizing the shape of the PDC cutters. This combination also improves cutter durability, which in turn, enhances bit performance and drilling efficiency. Bits equipped with these 3D cutters require less mechanical specific energy during drilling compared with bits having conventional cylindrical cutters, which helps to reduce shock and vibrations and weight on bit required to drill hard formations. Field data have proved, beyond any doubt, the benefits from using the combination of 3D PDC cutters in drilling hard formations. These cutters, depending on the shape, are able to improve ROP and durability, and by placing them in the right position on the bit, can improve the overall durability of the bit. Multiple field tests were conducted in various applications with customers in Russia. The results clearly showed that the combination of these unique 3D cutters helped operators achieve a step change in performance by improving ROP and depth drilled. In some cases, operators were able to drill an entire section using bits equipped with 3D cutter combinations, whereas traditionally more than one bit was used to complete the section. This paper will present the advantages provided by 3D cutters and by implementing a combination of CDE and RDE 3D elements in challenging applications in Russia, in addition to performance benchmarks achieved using this unique combination of 3D cutter combinations.
Terrigenous intervals usually consist of interbedded sandstone, siltstone, clay and claystone. These intervals can be also difficult to drill even though rocks have low strength. Sticky and plastic rocks are the cause of rate of penetration (ROP) decreasing without drill bit cutting structure wear. A new hyperbolic diamond element (HDE) bit has been developed to improve drilling efficiency in such conditions. HDE has a standard cylindrical carbide substrate as conventional PDC cutter. The main difference is shape of diamond layer, it has hyperbolic profile. HDE has positive rake which helps to improve performance in soft formations: the cutter penetrates deeper in rock under the same loadings. Hyperbolic diamond element also helps to avoid ribbons generation while drilling in soft and plastic formations. HDE technology was implemented on different oilfields in Russia. Naulskoe oilfield is one of them. It is in the Timano-Pechora oil basin. Development section interval consists of terrigenous rocks: sandstone, clay and claystone. New bit design with HDE cutters was specially developed for oilfield geology. The same well profile, bottom hole assembly (BHA) and drilling parameters (flow rate, weight on bit and drill pipe rotation) were used in bit tests. HDE bits set a new field ROP record which is 70% higher than average result on the drilling pad and 17% higher than the best previous result. This achievement proved HDE technology efficient. HDE bits were used also on another oilfield which is located in the South part of Russia. Low rate of penetration is observed while drilling soft and plastic clay there even with no bit dull. There were several different tries to optimize drilling process with no success. It was decided to test hyperbolic elements technology on the oilfield. Average ROP increased in 90% as a result after HDE bit implementation. It allowed to reduce well construction time.
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