Improving the Directional Behavior of PDC Bits Affected by Stick-Slip: A Statistical Approach

Abstract

AbstractTorsional vibrations are a very common phenomenon affecting drilling operations by limiting efficiency, increasing the risk of downhole equipment failure and generating additional costs, particularly when their most severe form is encountered, the stick-slip. It is less known that torsional vibrations also strongly affect directional drilling operations reducing directional stability and tool face control. In this paper, the highly variable solicitation induced by torsional vibrations is addressed with a statistical approach. This approach, used successfully in Kuwait applications, resulted in an operational savings of 30% of the cost per foot over a panel of more than 15 runs analyzed.Steerability and directional stability is critical on directional wells, especially when using push-the-bit systems with PDC bit due to side force distributed unevenly over one bit revolution. Most of today bit design comparisons are made with an average steerability factor computed over one full revolution of the bit. The method described in this paper is going further in details and looks at the evolution of directional performance indicators within one bit revolution. With the help of a state-of-the-art 3D bit-rock interaction model, which simulates the drilling environment considering the drive system mechanism and both the drill bit and the hole being drilled as a set of 3D meshed surfaces, an accurate picture of the directional stability of the bit design is available. This approach is complemented by a statistical analysis which allows to simulate a multitude of input parameters combinations and to map the directional response of a bit design in a more robust way.Based on the results of the statistical analysis, an optimized design was selected and manufactured for a 12 ¼’-in. rotary steerable system (RSS) directional application known for having torsional vibration limitations. As revealed by the simulation results, this design was expected to exhibit a better directional stability than previous bit design iterations. This optimized design was run on RSS and positive displacement motor (PDM) assemblies and successfully drilled several wells in different fields of Kuwait operations ground. It experienced smooth and stable directional control while reducing the risk for torsional vibrations and resulted in tremendous reduction of the overall cost per foot.PDC bit selection and design process have considerably evolved in the last decade with the use of increasingly accurate simulations models. This paper presents the next step of evolution dedicated to delivering the best adapted solution to any given scenario by examining in greater detail the directional response of a drill bit.