SPE 93856

Cutting-Edge Materials Technology Elevates Drilling Performance in

Soft-Formation Applications
D. Caraway, SPE, and K. Card, SPE, ReedHycalog, and S. Pullen, SPE, Mayne & Mertz Inc.

Copyright 2005, Society of Petroleum Engineers Inc.

This paper was prepared for presentation at the 2005 Asia Pacific Oil & Gas Conference and
Exhibition held in Jakarta, Indonesia, 5 7 April 2005.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in a proposal submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum Engineers is
prohibited. Permission to reproduce in print is restricted to a proposal of not more than 300
words; illustrations may not be copied. The proposal must contain conspicuous
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Abstract
Drill bits manufactured using the powder forge (PF) process
rather than conventional welded hard metal are setting new
standards for soft formation drilling. The PF process provides
unique advantages in hardmetal placement and metallurgical
design thus allowing cutting structures capable of drilling a
variety of formations from IADC 11 to 41 and fixed cutter
type applications with superior performance. This paper will:

Explain the PF manufacturing process, highlighting

lessons learned in the development learning curve.
Review the benefits of producing bits using this process.
Examine actual field results showing the cost savings
available through application of cutting edge
technologies.
Discuss the improved wear characteristics of PF bits that
has led to changes in operational variables such as weight
on bit, rpm, hydraulic horsepower and monitoring drilling
progress based on changes in rate of penetration.

Introduction
In 1984, ReedHycalog began to explore a distinctly new
manufacturing process that led to PF cutter technology.
Experiments with an advanced forging method that formed
and densified cutters allowed the creation of cutting
structures that were unachievable with conventional closed-die
forging and machining.
Full-scale tests were conducted in 1991 with prototype bits
that duplicated the cutting structure and materials used in
standard IADC 11 type cutters. The following year a unique
manufacturing facility was built and in 1993 testing began
with 9 7/8-in experimental bits featuring advanced profile
designs.

Two key observations were made following these runs: the

bits showed a significant improvement in durability over
conventional bits and wear was also very consistent between
bits. The similarity of dull conditions was attributed to the
inherent consistency of the manufacturing process. These
observations are discussed in SPE 26344.
R&D efforts slowed in the late 1990s but after 2000, as the
business climate improved, these early successes led to a
renewed emphasis on commercialization of the technology.
Since then, significant advances have been made in the PF
process, including geometric control and process automation.
The resulting product consistency led to development of an
IADC 117 product line with 7 7/8-in (200 mm), 8 -in. (216
mm) and 8 -in. (222 mm) sizes, and plans were made for
production of 9 7/8-in. (251 mm) and 12 -in. (311 mm) bits
featuring PF cutter technology.
In field applications around the world the unique
characteristics afforded by the PF process have improved bit
performance compared to offset wells drilled with
conventionally manufactured bits. These improvements
include footage, ROP and bearing life.
For instance, directional and vertical footage compared to
offsets nearly doubled with the use of PF bits in Louisiana. In
West Texas, an average cost per foot savings of 16% has been
achieved while increasing footage and setting a new field ROP
record. In Russia, bearing failures that occurred in 80% or
more of conventional bits were eliminated, while footage
improved 25.6% and ROP was 15.9% faster.
PF Manufacturing Process
The PF manufacturing process begins with creation of a solid
cutter structure or form referred to as a pattern. Its shape,
which only remotely resembles the final form the cutter design
will take, is determined by a mathematical model that
anticipates the high degree of asymmetric compression which
occurs later during densification. This pattern is used to create
a flexible mold. (See Figure 1)
In a separate step, hardmetal tooth coatings or caps are
formed by an injection molding process. The hardmetal to be
injected is prepared as a pliable material consisting of
precisely mixed metals such as tungsten carbide pellets, steel
powder and binders.

www.petroman.ir

SPE 93856

These prefabricated hardmetal caps are positioned in the mold,

which is then filled with steel powder. The prepared mold is
isostatically compressed to partially densify the powder into
an elongated structure called a preform.
This preform is heated and rapidly consolidated to 100%
density and the desired net shape by non-isostatic forging. The
process begins with heating the preform to approximately
2000F (1093C). Simultaneously a pressure transfer medium
(PTM) of granular graphite is heated to a similar temperature.
When the preform has reached temperature, it is robotically
placed in the center of a thick-walled die cylinder. While the
preform is held suspended, the hot PTM is poured to fully
surround it.
In the final compaction cycle, a 2500-ton (2268 metric ton)
hydraulic press compacts the bed of PTM around the preform.
Contained within the die cylinder, the resulting pressure field
acts on all surfaces of the preform to fully densify and shape it
to its final forged form.
The resulting forged cutters are then cleaned and the bearing
cavity is conventionally machined, hardened and precision
ground.
Advantages of the PF Process
The powder forge process yields many advantages over
conventional closed-die forging and machining methods. With
injection-molded hardmetal caps, the carbide volume fraction
and matrix microstructure are essentially identical in every
tooth on every cutter. Eliminating welding procedures, a
manual step, also contributes significantly to this hardmetal
consistency. For instance:
Hardmetal thickness and location are routinely controlled
with much closer tolerances than possible with welding.
Higher hardmetal thicknesses up to 0.22 in. (5.6 mm) and
the ability to vary hardmetal formulas allows for
optimization of tooth hardmetal for strength and abrasion
resistance.
With no welding, heat degradation that causes material
breakdown is eliminated. The maximum temperature
reached in the PF process is at least 1000F (538C)
below welding temperatures. These lower temperatures
also eliminate dilution due to melting of substrate.
Tooth integrity and durability is improved by eliminating
welding-related issues of heat-affected zones, porosity
and abrupt metallurgical transitions between hardmetal
and substrate.
Over 90% of the gage surface can be covered with
tungsten carbide, maximizing gage wear resistance for
better seal protection and longer bit life.
While hardmetal consistency and enhanced durability yield
many benefits, the greatest long-term advantage of the PF
process is in cutter design. Because the process is not
constrained by the inherent limitations of conventional closeddie forging and machining, design considerations are based on
operational objectives not manufacturing issues. For instance,

more aggressive tooth shapes can be designed using tooth

locations and orientations that are not otherwise possible.
The ability to precisely and repeatably place hardmetal means
the wear mode can be determined during the design phase,
allowing the bit to be tailored for the application with
enhancements for high penetration, high durability and
resistance to gage wear.
Furthering this purpose-built capability is the ability of the PF
process to accommodate many hardmetal materials, allowing:
Alternative materials to tungsten carbide,
Optimization of hard particle type, size, shape and
distribution,
Application of composite materials, and
Creation of gradient tooth structures.
Hydraulics
Bit hydraulics have benefited from the ability to create more
efficient tooth geometries and more effective hardmetal
placement. Tooth configuration has evolved from replicating
the original welded-tooth geometry to a more sculpted tooth
shape that helps fluid flow around and between the teeth This
also reduces the areas where stagnant flow can allow cuttings
to collect and start a balling condition.
The ability to fully cover the cutter with hardmetal has
improved bit life by reducing erosion. Erosion in the seal area,
which can be aggravated by aggressive hydraulics, has been
reduced with extended coverage of gage hardmetal. This
smooth hardmetal also extends seal life by creating a close fit
to the borehole that reduces fluid and cuttings flow to the seal
area.
Computer Technology
Computer tools are more integral to the development of PF
products than with conventional bits. The complex geometry
required in the deformation process can only be defined by 3D
solid modeling. Research in the late 1980s led to the 3D solid
modeling capabilities that are now being applied across the PF
bit product lines.
Computer tools also enabled rapid tooling capabilities that are
central to fully optimizing bit geometry (see discussion
below). The complex geometry of PF cutters and the
development of rapid prototyping equipment through the
1990s are closely related. Rapid prototyping works directly
from the 3D solid model without the translation and
interpretation of traditional drawings. This allows the design
intent to be captured exactly in the manufactured product.
Finite element analysis (FEA) is used in optimizing tooth
strength and protrusion, and cutter shell thickness (See Figure
2). While it is a common design tool, FEA modeling of the
welded hardmetal on a conventional tooth bit is difficult and
time consuming. But the PF process yields consistently
quantifiable materials properties that work well with current
FEA software and as a result, this analysis of PF cutters is a
standard part of our design process.

www.petroman.ir

SPE 93856

Computational fluid dynamics (CFD) is used to maximize

hydraulic energy available at the bit. (See Figure 3) CFD is
similar to FEA but instead of computing the behavior of
materials, the program computes the flow of fluids. It is used
to analyze the direction and magnitude of the mud flow, which
identifies areas of stagnant flow that can initiate balling, as
well as high velocity turbulence that can cause erosion.
This is of particular value in addressing the unique hydraulic
circumstances presented by various rigs. Many rigs have
pumps capable of outputs that can erode a bit to the point of
destruction in hours. Conversely, there are rigs that barely
have the pump capacity to flush the cuttings away from the
bit. CFD allows optimization of the bit design to deal with
both circumstances.
Bit drilling models are also used to minimize tracking
tendencies of the bit before any tooling or manufacturing.
Proprietary software is used to analyze the motion of the bit as
it drills (See Figure 4). This indicates where each tooth
contacts the formation. The goal is to minimize the occurrence
of teeth contacting the formation at the same point or radius.
This ensures more uncut formation is contacted, leading to
more efficient drilling and longer bit life. (See Figure 5)
Bit Optimization
The inherent capabilities of the PF process combined with the
flexibility of computer design provide a unique capacity for
fully optimizing the bit. For instance, rapid tooling has
shortened new design lead times to the field, providing much
greater flexibility in developing new concepts.
Rapid prototype tooling can be produced in as little as four
weeks after the design is complete. It takes approximately four
months for tooling using conventional machining. (See
Figures 6a, b and c) Proprietary advances in molding
methods are a direct result of innovations in computer design
and manufacturing capabilities.

Increased resistance to erosion results from the integral full

coverage of the cutter shell with hardmetal. Because it is part
of the forging, the hardmetal has superior impact resistance
compared to traditional flame-sprayed bits, which yields better
cutter shell, tooth and seal protection.
Bearing systems have also benefited from improvements in
hardmetal performance. The life of existing bearings systems
has been extended due to the improved erosion resistance of
the gage hardmetal. In comparing a conventional welded tooth
bit with a PF bit using the same bearing in the same
application, a 40% improvement in bearing life has been
documented (See Figure 7).
Improvement is also seen by keeping the teeth sharper longer
which gives the bit more consistent dynamic behavior
throughout its application. Cleaning is enhanced and erosion is
minimized due to optimization of hydraulics in the design
stage using CFD. (See Figure 8)
Operational Changes
The improved wear characteristics of PF bits have led to
changes in operational variables. These include WOB, RPM
and hydraulic horsepower as well as ROP-based monitoring of
drilling progress
Higher abrasion resistance has extended PF bit life past
traditional welded-tooth bit intervals. As a result, the faster
ROP PF bits stay in the hole longer. Conversely, with insert
bits increases in ROP are commonly traded for shorter
intervals.
The hydraulics configuration must also consider the
operational characteristics of PF bits with nozzle sizes
adjusted for longer run length and deeper depth. To ensure a
longer run length, nozzles sizes must keep mud velocity and
HHSI below critical levels. Greater depth also requires that the
nozzles be sized to allow proper flow to be maintained
throughout the run.

Tailored and fully-optimized blended hardmetal is a

significant PF process advantage. Discrete injection molding
of hardmetal caps allows precisely mixed metals and binders,
including tungsten carbide pellets and steel powder. Optional
hardmetals are available for high-abrasion or high-impact
applications. Methods are being tested to improve these
characteristics concurrently instead of separately as
conventional industry technology has traditionally required.

Case History Examples

SW Louisiana. In a directional application in Calcasieu
Parish, Louisiana, an 8 -in (216 mm) PF bit on a 3/4 benthousing motor nearly doubled footage compared to offset
performance by competitive bits in both directional and
vertical drilling.

Automation has significantly advanced the precision of cap

placement and finished geometry. In early development bits
the caps were handmade. The production machines now used
are more precise and much faster than the manual method.

Lithology of the formation consisted primarily of moderately

abrasive sandstone and shale to about 8800 ft (268 m)TVD. In
the PF bit run, the objective was to drill from the kick off
point at 6190 ft (1887 m), building 2/100 ft (2/30 m) to
reach 22 by 7414 ft (2260 m) MD and continue to a TD of
10,023 ft (3055 m) MD.

This process allows hardmetal types to be more easily and

cost-effectively applied with greater variations on the same
bit. Hardmetals can be developed for specific applications
using existing designs and tooling. It is also possible to have
different hardmetals on different teeth.

The PF bit drilled 2142 ft (653 m) with a 30.2 ft/hr (9.2 m/hr)
ROP compared to a directional offset drilled with a competitor
bit (1) that made 1356 ft (413 m) of hole at 27.7. ft/hr (8.4
m/hr) ROP. In a nearby vertical well, a different competitor bit
(2) drilled 1388 ft (423 m) at a rate of 33.5 ft/hr (10.2 m/hr).

www.petroman.ir

SPE 93856

A performance summary comparing PF bit performance and

economics to two offsets is provided in Figure 9a and b. Dull
grades reflect the differences in performance. (See Figure 9c)
Texas Panhandle. Drilling with PF bits in western Texas
has resulted in significant gains in footage and ROP. With
over 50 years of drilling history, the Panhandle area provides
numerous offset wells for performance comparison. These are
San Andres formation wells with a lithology that includes
sand, shale, lime anhydrate, dolomite and chert sections.
Tooth bits are used on almost every well with a 7 7/8-in (200
mm) size typically used to drill out from casing at about 400
500 ft (122 152 m).
In Yoakum County, the 7 7/8-in. (200 mm) tooth bits (IADC
116-117) used in the West Brahaney field typically drill from
400500 ft (122152 m) to an average 2765 ft (843 m) based
on a study of 36 competitor bit runs. At this depth the tooth bit
is pulled and an insert bit is used to drill harder rock to TD.
In 26 runs using PF bits, footage drilled increased about 406 ft
(124 m) to an average 3171 ft. (966 m) In addition, the
incremental footage was drilled at a higher ROP than achieved
with the insert bits.
A new field record for ROP was established when one of these
wells was drilled in 101.5 rotating hours4 hours faster than
the previous best well. In this application, the surface 12 -in.
interval was drilled to 390 ft (119 m) in 3.25 hours, which is
typical for the area. The interval was followed by a 7 7/8-in.
(200 mm) PF bit with a more aggressive cutting structure. This
bit significantly extended the interval typically drilled with
welded tooth bits.
The PF bit drilled 3626 ft (1107 m) in 38.25 hr at 94.8 ft/hr
(28.9 m/hr) compared to the offset tooth-bit average of 2737 ft
(834 m) in 33 hr at 92.6 ft/hr. (28.2 m/hr) Total depth was
reached with an IADC 537 insert drilling 1299 ft (396 m) at
21.7 ft/hr (6.6 m/hr). Even though this was a low cost per foot
application, the PF bit resulted in a 16% savings at an average
$4.56/ft (14.96 USD/m) versus $5.37/ft (17.62 USD/m). (See
performance comparisons in Figures 10a, b and c)
Russia. Drilling difficult S profile wells in western
Siberias Samatlor field using PF bits resulted in significant
improvements in intervals and ROP compared to typicallyused Western- and Russian-designed welded tooth and insert
bits.
The improvements were noted in an operator study comparing
historical bit performance and the new bit technology.
Twenty-five western bits and 8 Russian bits were included in
the study. The study formation consists primarily of soft clay,
shale and sandstone. Build rates in the study group vary
between wells in the field, WOB typically ranges from 410
tons (3.69.1 metric tons), and RPM varies from 150220
revolutions.

undergauge and failed seals were reported on all dulls. Dull

condition of the western 1-1-7 milled tooth and 4-1-7 insert
bits were similar with undergauge wear, and broken and
chipped cutters. Seal failure occurred in 81% of the bits.
On average, the Russian bits drilled a 771 ft (235 m) interval
in 11.6 hr for a ROP of 66.5 ft/hr (20.2 m/hr). With a slightly
higher ROP of 67.7 ft/hr (20.6 m/hr), the western bits drilled a
much greater interval of 2346 ft (715 m) in 38 hr.
The first two 8 -in (216 mm) PF bits tested in the study
showed a remarkable improvement in durability, yielding a
288% improvement in total footage over the Russian bits.
Compared to the western-manufactured bits, the PF bits
yielded an average 27% footage improvement at a 11% faster
ROP. After drilling 2894 ft (882 m) in 35.7 hr at a rate of 81.0
ft/hr (24.7 m/hour), one bit had a dull grade of 1-2-CT-G-E-1NO-TD. The second bit drilled 911 m in 39.8 hours at 75.1
ft/hr (22.9 m/hr) (a field record) and was graded 3-6-BT-G-E1-CT-BHA. Both had effective seals.
After the study was completed, continued use of the PF bits
resulted in another field drilling record with 3071 ft (936 m)
drilled in 37 hr at an average ROP of 83.3 ft/hr (25.4 m/hr.)
Dull grade was 1-2-WT-M-E-2-BT-TD. A comparison of
average performance in the field is shown in Figures 11a, b
and c. Photos of three PF dulls are shown in Figures 12a, b
and c.
Conclusion
Advantages in hardmetal placement and metallurgical design
afforded by the PF manufacturing process are resulting in
significant advances in bit performance in a range of soft
formations.
An IADC 117 product line of 7 7/8-in (200 mm), 8 -in. (216
mm) and 8 -in. (222 mm) sizes is being successfully applied
and 9 7/8-in. (251 mm) and 12 -in. (311 mm) models are
planned.
In field applications around the world, footage, ROP and
bearing life has been improved compared to offset wells
drilled with conventionally manufactured bits.
For instance:
Directional and vertical footage compared to offsets
nearly doubled with the use of PF bits in Louisiana.
An average cost per foot savings of 16% has been
achieved in West Texas while increasing footage and
setting a new field ROP record.
In Russia, bearing failures that occurred in 80% or
more of conventional bits were eliminated, while
footage improved 25.6% and ROP was 15.9% faster.

Typical dull grade of the Russian 1-1-7 milled-tooth bits in the

study was 2-2-BT-G; gauge was 1/16-in (1.59 mm)

www.petroman.ir

SPE 93856

Figure 1 (PF Process Flow)

Figure 2 (FEA image)

www.petroman.ir

SPE 93856

Figure 3 (CFD image)

Figure 4 (bit motion)

Figure 5 (bit tracking)

www.petroman.ir

SPE 93856

Figure 6a (computer models of cap tooling)

Figure 6b (rapid prototype tooling with injected cap)

Figure 6c (computer model of cutter pattern

and isostatic press tooling)

www.petroman.ir

SPE 93856

8 1/2" & 8 3/4" PFC vs. Conventional Bits

Bearing/Seal Reliability Curve

120%

PFC Bit Data

100%

2003 Welded Tooth Data

Reliability

80%
Number of Bits - 60
Effective Seal Ratio - 77%
80% Reliability- 523 Krevs

60%

Number of Bits - 56
Effective Seal Ratio - 71%
80% Reliability- 423 Krevs

40%

20%

0%

100

200

300

400

500

600

700

800

900

Krevs

Figure 7 (bearing life)

Figure 8 (CFD image)

Bit Comparison
SW Louisiana
PFC Bit

Offset 1

Offset 2

Bit type
Depth Out ft (m)
Footage Drilled ft (m)

*PFC Bit
8332 (2540)
2142 (653)

*Competitor 1
8245 (2513)
1386 (422)

Competitor 2
8300 (2530)
1388 (423)

ROP ft (m)/hr
Inclination In/Out
(degrees)
WOB (TONS?)/t

30.2 (9.2)
0.750/220

27.7 (8.4)
11.9/16.0

33.5 (10.2)
1.30/1.30

15/25

20/25

10/20

RPM Min/Max

50/160

50/114

90/130

Offset
Avg.

1387 (423)
30.6 (9.3)

* Directional application on motor

Figure 9a

www.petroman.ir

SPE 93856

Average Cost Per Foot (USD/Foot)

Calcasieu Parish, Louisiana USA

25

23

21

19

17

15
PFC Bit

Competitor 1

Competitor 2

Figure 9b

Cutting Structure
IADC Dull Grade

Inner Outer
1
2
3

PFC Bit
Competitor 1
Competitor 2

Location
Dull
Characteristics

1
2
3

WT
WT
WT

A
A
A

Bearings/
Gauge
Seals
E
E
E

Figure 9c

Average Cost Per Foot (USD/Foot)

Yoakum County, Texas USA

$5.50

$5.25

$5.00

$4.75

$4.50

$4.25

$4.00
PFC Bit

Competitor

Figure 10a

www.petroman.ir

I
I
I

Other Dull
Characteristics

Reason
Pulled

NO
NO
NO

HR
TD
TD

10

SPE 93856

Average ROP (Ft/Hr)

Yoakum County, Texas USA

100

95

90

85

80
PFC Bit

Competitor

Figure 10b

Average Footage
Yoakum County, Texas USA

3800

3600

3400

3200

3000

2800

2600

2400

2200

2000
PFC Bit

Competitor

Figure 10c

Samatlor field Run Comparison

PF bits

Welded milled tooth bits and 4-1-7 insert bits

Bit type
Interval ft (m)
Hours
ROP ft /hr (m/hr)

PF bit avg.
TC11
2989 (911)
39.8
75.1 (22.9)

Western built avg.

1-1-7 & 4-1-7
2346 (715)
38.0
67.7 (18.8)

Russian-built avg.
1-1-7
771 (235)
11.6
66.5 (20.3)

Seal failure rate

0%

81%

100%

Figure 11a

www.petroman.ir

SPE 93856

11

Footage

3000

2500

2000

1500

1000

500

0
PFC Bit Average

Western Competitor Bit

Russian Competitor Bit

Figure 11b

ROP (Ft/Hr)

80.0

76.0

72.0

68.0

64.0

60.0
PFC Bit

Western Competitor Bit

Russian Competitor Bit

Figure 11c

www.petroman.ir

12

SPE 93856

3,071 ft (936 m) 37 hr, 1-2-WT M-E-2-BT-TD

2,894 ft (882 m) 35.7 hr, 1-2-CT-G-E-1-NO-TD

2,999 ft (914 m) 3-6-BT-G-E-1-CT-BHA

Figures 12 a, b and c.

www.petroman.ir