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Abstract One of the main objectives in directional drilling operations is finding ways to optimize the drilling performance and directional work. Drilling and geo-steering through dense and soft Carbonates layers introduces various challenges such as low rate of penetration, high near-bit vibrations and steerability. To overcome these challenges, a shaped edge polycrystalline diamond compact (PDC) cutter technology was introduced. The shaped edge PDC cutter technology employs a point loading chamfer on the diamond tip of the PDC cutter for efficient load distribution on the cutter edge and more weight transfer to smaller portions of the drilled rock. The state- of-the-art cutter technology is developed to increase the bit stability and rock destruction efficiency while drilling through highly interbedded and hard formations. In addition to the new PDC bit design and the in-depth analysis and formation specific parameters roadmap, an optimization process comprising rotary steerable system (RSS) bottom-hole assembly (BHA), enhanced trajectory design, drilling fluids and system hydraulics design and subsurface geomechanics modelling were introduced to optimize the drilling performance and drill the vertical, curve and lateral section in one run. The proposed shaped edge PDC bit design in addition to the optimization roadmap delivered multiple consecutive sections with an exceptional performance without reported steerability challenge. Each section is almost 10,000 ft long, drilled through interbedded carbonate formation capped with dense and soft layer. The average rate of penetration (ROP) improved by 33% compared to the previous PDC technology. With respect to drilling the soft curve interval, the new PDC bit design succeeded to enhance the ROP, overcome the steerability concern and reduce the near-bit vibrations by 33% while eliminating the surface stick-slip vibrations. The implementation of the optimization methodologies helped achieving new performance records in the most challenging drilling environments. The new bit design established greater ROP response over the conventional cylindrical edge PDC cutters while improving the overall stability and steerability of the drilling system. The evolvement of the cutter edge showed substantial outcomes in terms of penetration rates, bit stability, and total cost savings by overcoming the drilling challenges and reducing the number of trips required to drill to total depth (TD), thus reducing the overall well delivery time. The optimization roadmap, job execution, and post well evaluation results that helped to expand the cutter technology in other bit sizes and frames which are presented in this paper including a discussion on the key challenges met during the planning and the execution phases.
Alqarafi et al. (Mon,) studied this question.