Drilling System Optimization Leads to Expedited Wells Delivery

Abstract On a Deep Gas Project in the Middle East, it is required to drill 3500 ft of 8-3/8" deviated section and land the well across highly interbedded and abrasive sandstone formations with compressive strength of 15 - 35 kpsi. While drilling this section, the drill string was constantly stalling and as such could not optimize drilling parameters. Due to the resulting low ROP, it was necessary to optimize the Drill string in order to enhance performance. Performed dynamic BHA modelling which showed current drill string was not optimized for drilling long curved sections. Simulation showed high buckling levels across the 4" drill pipe and not all the weight applied on surface was transmitted to the bit. The drilling torque, flowrate and standpipe pressures were limited by the 4" drill pipe. This impacted the ROP and overall drilling performance. Proposed to replace the 4" drill pipe with 5-1/2" drill pipe. Ran the simulations and the model predicted improved drill string stability, better transmission of weights to the bit and increased ROP. One well was assigned for the implementation. Ran the optimized BHA solution, able to apply the maximum surface weight on bit recommended by the bit manufacturer, while drilling did not observe string stalling or erratic torque. There was also low levels of shocks and vibrations and stick-slip. Doubled the on-bottom ROP while drilling this section with the same bit. Unlike wells drilled with the previous BHA, on this run, observed high BHA stability while drilling, hole was in great shape while POOH to the shoe after drilling the section, there were no tight spots recorded while tripping and this resulted in the elimination of the planned wiper trip. Decision taken to perform open hole logging operation on cable and subsequently run 7-in liner without performing a reaming trip. This BHA has been adopted on the Project and subsequent wells drilled with this single string showed similar performance. This solution has led to average savings of approximately 120 hours per well drilled subsequently on this field. This consist of 80 hours due to improved ROP, 10 hrs due to the elimination of wiper trip and a further 30 hrs from optimized logging operation on cable. In addition, wells are now delivered earlier due to this innovative solution. This paper will show how simple changes in drill string design can lead to huge savings in this current climate where there is a constant push for reduction in well times, well costs and improved well delivery. It will explain the step-by-step process that was followed prior to implementing this innovative solution.