The Success of Implementing the First 16" Hole Section RCD Job in North Kuwait Development Field for Safe Drilling While Enhancing Production by Keeping Disposal Wells Running

Abstract The project successfully implemented a Rotating Control Device (RCD) to drill the 16-inch hole section in the North Kuwait development field while keeping nearby Tayarat disposal wells in operation and eliminating the risk of H₂S exposure. Several offset wells had experienced simultaneous loss/gain well-control incidents, black-water influx containing 40–60 ppm H₂S, and repeated bull-heading operations that led to stuck pipe, extended NPT, and significant mud losses exceeding 12,000 bbl. Increasing mud weight to 10.0 ppg and installing an 11.0 ppg mud cap did not stabilize these wells due to total-loss conditions and continuous formation influx. The RCD enabled safe, continuous drilling by diverting returns and any sour influx to the flare pit while maintaining a rotating pressure-tight seal at surface. This reduced reliance on reactive well-control methods such as bull-heading and choke circulation, both of which had previously resulted in cuttings settlement and BHA sticking during flow stoppage. This method could be successfully implemented without risking major well control or blow out risk since it is known historically that the influx from the Tayarat disposal wells is a Water influx intermittently associated with H2S and black water. There is no trace of oil or gas which may risk a blow out. The deployment achieved zero NPT in the 16″ section, eliminated bull-heading operations, prevented mud losses, and avoided the typical 2–3 days of downhole NPT observed in comparable conventional wells. A total cost reduction of approximately 74% was realized when compared with conventional drilling responses. The project establishes the first field-proven RCD-only MPD application in Kuwait and demonstrates its value for safe operations, H₂S risk reduction, and improved drilling continuity in complex loss/gain environments.