Innovative Hyperbolic Cutting Structure Brings Step Change in Drilling Efficiency Onshore Mexico

Abstract

Abstract The discovery of field T in Mexico represented the largest such find in a generation. Hence, drilling activity has been focused primarily on economically viable ways to develop these reserves. The reservoir poses several drilling challenges, such as lack of drill bit cutting structure, durability, and aggressiveness leading to unwanted bottomhole assembly trips. These challenges lead to increased well construction costs. Accordingly, an application-specific bit design needed to be developed to optimize drilling efficiency in this section. This complex drilling scenario demanded a comprehensive rock characterization study to accurately diagnose the root causes for the low drilling efficiency. To determine the environmental factors that influence bit performance, a detailed formation mapping analysis was conducted using an engineering program for rock strength identification from offset wells. This information was then used to calibrate the digital formation file inside the integrated dynamic design and analysis software, capable of reproducing actual drilling conditions. The virtual model was used to develop a specific drill bit design equipped with cutting edge 3D-cutter, optimizing performance well beyond conventional fixed and flat cutters.Results from the well D2 indicate that this innovative technology yielded superior overall drilling performance compared to best offsets and has become the new benchmark for this application in Mexico. The comprehensive planning and detailed engineering analysis led to outstanding operational execution, setting new standards for drilling performance, reducing nonproductive time drastically and therefore minimizing CO2 emissions. The customized bit design drilled the longest 10 ⅝-in run in the field. This unprecedent performance led to 29% improvement in rate of penetration when compared to conventional Polycrystalline Diamond Compact (PDC) drill bit models, reducing rig time by 5.7 days exceeding customer expectations. The learning framework was applied using post-well analysis to compare model predictions with drilling data to further refine the model and close the loop on the original calibration, paving the way for further evolution of the bit design.A successful methodology for drill bit development aimed at drilling efficiency improvement was applied using a new cutting element (hyperbolic diamond element) and novel design concepts that replaced the traditional trial-and-error methods. Testing each new design feature virtually and running parameter sensitivity analyses to ensure a wide margin of applicability, the task was made much easier by the development of a calibrated virtual formation model in a fully traceable and replicable process.