Breakthrough in Large-Hole Drilling Reliability: Record ROP and Overcoming BHA Failures with Real-Time Downhole Intelligence in Challenging Deep Gas Wells in Kuwait

Abstract Large-hole drilling in Kuwait Oil Company's (KOC) deep gas wells continues to be one of the most technically demanding operations in the region. The 22-inch sections in the Jurassic sequence have historically exhibited severe drilling dysfunctions, including bit bounce, torsional oscillations, lateral vibrations, chaotic whirl, and pressure-driven instability, leading to premature BHA failures, non- productive time (NPT), and operational inefficiencies. Previous wells commonly experienced PDM motor twist-offs, elastomer chunking, and cracked shafts with failures often occurring before completing the section. This paper presents an integrated drilling dynamics evaluation across two deep gas wells using Drilling Dynamics Tool (DDT); a high-resolution real-time drilling dynamics service with 19 downhole sensors sampling up to 10,000 Hz. The combined analysis provides a unique dual-well perspective. Well A demonstrated that maintaining stable parameter envelopes, particularly WOB, RPM, and motor differential pressure can suppress severe dynamics and prevent the failure modes seen in offsets. First well illustrates how system sensitivity, reduced flow due to losses, and motor differential spikes can trigger chaotic dynamics, stall events, and unavoidable failure risks. The study establishes formation-specific dynamic signatures, identifies optimal parameter ranges, and recommends transitioning to hybrid bits, redesigning BHAs for stiffness and balance, and implementing hydraulic damping strategies. The integrated insights provide a field-wide blueprint for optimizing large-hole drilling in Kuwait's deep gas wells, improving BHA reliability, reducing NPT, and enabling safer, faster, and more consistent well delivery.