Solving 16" Deep Harsh Drilling Environment Challenges in South East Kuwait

Abstract

The 16′ Vertical Performance Motor Section is the most challenging section in Exploration Deep Drilling in Burgan Field & All South East Kuwait. The section comprises drilling hard and abrasive Zubair formation followed by reactive Ratawi Shale formation. Several technologies were introduced during the last ten years in search of an economic solution to deliver this section safer and faster with limited success. The objective of this paper is to present the process and technology implemented to drill Zubair and Ratawi Shale formations in two different wells with the same bit at record rates of penetration. Bit durability is generally the main driver in the 16′ section performance. Historically, one to two polycrystalline diamond compact (PDC) bits were utilized in this section and were pulled out for low penetration rates. The new solution required a thorough offset data analysis, including formation porosity, rock strength and abrasiveness analysis, applied drilling parameters and Mechanical Specific Energy (MSE) analysis using software. A customized PDC bit design was then developed using a state of the art bit/formation interaction model combined with an advanced cutter technology and hydraulics pairing for ultimate cutter cooling. The new PDC bit design and the implementation of the softwares used to analyse offset wells drilling parameters and rock mechanics had a significant effect on the bit durability and Rate of Penetration (ROP). The optimized drilling parameters applied as per the former set roadmap aided in managing the bit cutting structure through Zubair and Ratawi Shale formations and the bit was pulled out in re-runnable condition with a new field ROP record. The same bit was then used again in different well and drilled Zubair and Ratawi Shale formations and pulled out with 1, 3 dull condition. Over the two wells drilled, the optimized drilling plan saved National Oil Company over US $200,000, reducing the cost per foot (CPF) drilled by 38% over the field average CPF, increasing the ROP by 55% over the field average and drilling 69% footage more than the previous section benchmark footage. With the engineering evaluation of the offset data and the utilization of the new bit design, National Oil Company managed to drill Zubair and Ratawi Shale section in two different wells with the same bit for the first time and was able to improve drilling efficiency and cutting the drilling cost by eliminating bit trips and cost of new PDC bits.