From Theory to Field: Validating New PDC Bit Design Leads to 36% Increase in Penetration Rate and Reduces HFTO for Unconventional Reservoir in Argentina

Abstract

Abstract

Abstract HFTO, standing for High-Frequency Torsional Oscillations, is a vibration phenomenon that occurs during challenging drilling environments, especially for Unconventional Operations, affecting tool reliability and operational performance, thus, increasing costs and time. The primary objective is to mitigate these HFTO thru the application of a novel bit design process, tailored to specific drilling environments, precisely for the Vaca Muerta formation in Argentina. The new bit design method leads to increased drilling performance and offers operators opportunities for cost savings. The new methodology combines field data analysis and computational drilling dynamics simulations in a three-dimensional polygonal mesh model software. Simulations of the forces applied to the cutting structure of a PDC bit (Polycrystalline Diamond Compact) are used to align the bit response with requirements to successfully mitigate the excitation of HFTO. The method also includes testing in a full-scale drilling rig that was used to calibrate the computational model. The new bit design increases the operative window (Weight on Bit and RPM) in which the PDC bit operates without triggering HFTO by a factor of three. More energy is applied to rock destruction in a safe manner. This resulted in a positive outcome on its first field deployment of a 36% higher rate-of-penetration compared to the historical average in the field. Improved trajectory stability and reduced reliance on corrective steering were also observed. Beyond the improved PDC bit design, the novel analysis method on identifying the contributing factors behind High Frequency Torsional Oscillations represents a significant advancement in understanding dynamic downhole conditions. This process offers a robust and adaptable solution to reduce HFTO and increase ROP, especially in horizontal sections, where vibrations are most prevalent. The new approach opens new possibilities for improving drilling efficiency and reducing operational costs in similar geological contexts.