Enhancing Drilling Efficiency with Integrated Agitator, PDC with 3D Cutter, Non-Rotating Protector, and Rotary Steerable System: An Innovative Industry Practice

Abstract Drilling horizontal section in Saudi Arabia is associated with significant challenges, including high torque, severe losses, and trajectory control difficulties caused by up-dipping formations. The study is aimed to mitigate torque, improve weight transfer, and increase ROP by improving the BHA design to achieve efficient drilling and meet target objectives. To address these issues, the BHA was optimized through offset well analysis and evaluation of multiple bit and string configurations. The final solution incorporated reconfigured heavy weight drill pipe (HWDP) to manage the torque, advanced polycrystalline diamond compact (PDC) bit with 3D cutter technology, and the addition of non-rotating drill pipe protectors (NRP) and Drilling Agitator System (DAS) combined with a rotary steerable system (RSS). Detailed simulation defined the optimal operating window, and the revised BHA was implemented with close collaboration between the client and service provider. Field results demonstrated a 35-40% reduction in surface torque, lowering the rig strain and minimizing equipment failure risk. This translated into six drilling days saved in a 5,000-ft lateral section while maintaining the trajectory and meeting operational objectives. The integration of NRPs, DAS, and advanced 3D cutter PDC technology established an effective field-proven solution for drilling in up-dipping formations, offering a validated approach to improve efficiency and providing operational insights for future applications under similar conditions