Systematic Drilling Optimization Framework Unlocks Consistent Record-Breaking Performance

Abstract This study presents a drilling system roadmap that incorporates hybrid bit technology to overcome the challenges of drilling the 16-inch interval. The optimization focuses on maximizing the rate of penetration (ROP) and maintaining borehole quality while achieving consistent record performance in challenging interbedded formations. The goal was to exceed an ROP of 35.0 ft/hr in this section. The methodology involved a detailed analysis of offset well data, which included lithology, unconfined compressive strength (UCS) trends, bit logs, bit dull grading, Bottom Hole Assembly (BHA) configurations, and drilling parameters. This analysis was used to develop a drilling parameter roadmap and optimize the BHA configuration, focusing on minimizing shock and vibration while maximizing the weight on bit (WOB) capabilities of the system. Execution was accelerated by leveraging an innovative Cloud-based Ecosystem and platform that utilized real-time data analytics and custom-built applications and dashboards to generate metrics and track standardized Key Performance Indicators (KPIs). A collaborative, multidisciplinary team, including experts in directional drilling, drilling engineering, drilling fluid design, and bit design, worked together to develop the customized hybrid bit solution, iterating on the design based on real-time field feedback. The implementation of the optimized hybrid bit and associated drilling system roadmap resulted in significant performance improvements in the 16-inch section. The hybrid bit combines the crushing action of Tungsten Carbide Inserts (TCI) inserts and the shearing action of Polycrystalline Diamond Compact (PDC) cutters, which proved effective in drilling through hard layers and interbedded formations, even when severe or total loss of circulation events occurred, which are common in this section. The 16-inch section achieved a 66% increase in ROP and a 53% reduction in cost per foot. This efficiency allowed drilling teams to eliminate extra trips for bit changes, with the hybrid bit consistently drilling entire sections in a single run, demonstrating improved durability and achieving excellent dull grading. A new field ROP record was set in the field, achieving 61.0 ft/hr over 2,213 ft, representing a 13% ROP increase over the previous record of 54.1 ft/hr. The optimization strategy also improved directional control and wellbore stability, evidenced by smooth torque response and minimal string stalling. The novelty lies in the integration of the hybrid bit technology with a comprehensive, systematic drilling optimization strategy. This repeatable strategy utilizes a customizable hybrid bit design adapted to specific formation characteristics. Crucially, this integrated optimization strategy was made possible by a Cloud-based Ecosystem and custom application platform which enabled detailed analysis of offset well data, the rapid development of formation-specific drilling parameter roadmaps, and continuous improvement through a collaborative and iterative approach based on real-time insights from the field.