Using In-Bit Data Capturing Sensors to Identify and Reduce Dysfunctions Using a Higher Drilling Efficiency Shaped Cutter Solution

Abstract

Abstract Drilling oil wells with long laterals in extended reach reservoirs present one of the hardest challenges for drilling companies in the demanding environment especially given their propensity to high downhole vibrations causing many premature tool failures. Managing to attenuate these sources of vibrations can lead to reduced drilling risks and lower section times with less exposure to reservoir hazards. Through a downhole vibrations study using in-bit sensor captured data along with a force simulations model between the drill bit and the formation, lower vibrations are expected with improved drilling efficiency. Understanding the drilling vibrations using a high frequency reading sensor placed in the bit is the key to differentiate the types and excitation sources of dysfunctions downhole in order to quickly and effectively address and reduce them through parameter optimization and drill bit design modification. The 6 1/8" lateral section drilled with a standalone push the bit Rotary Steerable System (RSS) was studied deeply to understand the types of vibrations coming from the bit to attenuate any identified dysfunctions. The high frequency readings in this drilling application demonstrated high stick and slip vibrations typically excited from the increased engagement of Polycrystalline cutters into the formation which led to increased BHA vibrations and lower rates of penetration (ROP) increasing well time and cost. Mitigating this destructive dysfunction caused in part by certain drilling limitations of the conventional round PDC cutter was found to be the key to a higher drilling efficiency with lower vibrations and improved stability extending the life of the bits and the downhole tools. This led to an overall decrease in section drill time and an increase in the consistency of well delivery. Point loading shaped cutters with an adapted drill bit design profile were used in several lateral wells in MENA. The new bit attenuated the overall torsional related dysfunctions in the section by 15% and producing more efficient drilling which resulted in an improved average ROP of the lateral section by 34% as well as a reduction in the rate of downhole tool failures from 11% to less than 7%. Using image recognition technology to assess, analyze and digitize the bit dulls, each cutter on the bit was evaluated, and the new bit design illustrated a 9% improvement in the average dull with a lower requirement for bit repair. The digitally enhanced drill bit design with the point loaded shaped cutters enabled a pre-fracturing of the formation while also benefitting from the shearing mechanism of the shaped PDC cutters enhancing the overall drilling efficiency of the bit. These shaped cutters also added stability to the bit which resulted in reduced overall drilling dysfunctions and extending the BHA life along with an improved section ROP.