Effect of Bit Hydraulic Horsepower
on the Drilling Rate of a
Polycrystalline Diamond Compact Bit
Jesse L. Holster, SPE, Exxon Production Research Co.
Robert J. Kipp, Exxon Production Research Co.
Summary
A laboratory drilling program was conducted to measure
the effect of bit hydraulic horsepower on the drilling rate
obtained with a polycrystalline diamond compact (PDC)
bit. Drilling tests were conducted under simulated
downhole conditions with an 8 1/2-in. [21.59-cm] diameter
PDC bit fitted with four sets of five equal-sized nozzles.
Mancos shale, Pierre shale, and Berea sandstone were
drilled with both water- and oil-based drilling fluids to
determine the interactions among bit hydraulics, rock
characteristics, and the drilling fluid. For the range of
drilling conditions and rocks examined, the results in-
dicated that bit hydraulic horsepower had a significant in-
fluence on the drilling rate. The degree to which drilling
rate was affected by bit hydraulic horsepower was depen-
dent on the rock/drilling-fluid combination.
Introduction
Proper hydraulic design for effective cleaning and cool-
ing of PDC bits has been recognized as a major factor
in their successful application since these bits were in-
troduced. Historically, there have been two approaches
to the hydraulic design ofPDC bits: (1) natural diamond-
bit flow-distribution systems (water courses with large
total flow areas) and (2) high-velocity jet nozzles. Both
types have been used with varying degrees of success but
often for unrecognized reasons. The water-course-type
hydraulic designs were characteristic of most early matrix-
bodied PDC bits. Nozzled bits evolved from the steel-
bodied bits with stud-mounted cutters, although matrix-
bodied bits are now available with jet nozzles.
An increasing number of commercial PDC bits are
becoming available with interchangeable nozzles, pro-
viding the flexibility of rig-site hydraulics optimization.
With these interchangeable nozzles, the hydraulic energy
(or power) of the drilling fluid that is dissipated across
the bit face can be adjusted to match that portion of the
rig's hydraulic power that is available for the bit after other
system losses have been considered.
Unfortunately, the benefit in increased drilling rate that
can be expected by an optimization of bit hydraulic
horsepower has yet to be adequately defined quantitatively
for PDC bits. The objective of our work was to deter-
mine experimentally the effect of bit hydraulic horsepower
01492136/84/01211949$00.25
Copyright 1984 Society of Petroleum Engineers of AIME
2110
on the drilling rate achieved with a jet-nozzled PDC bit
while three rock types were drilled with both oil- and
water-based drilling fluids.
PDC Bit Hydraulics-Background
Field tests of early PDC bit designs demonstrated that
although the bits could drill very effectively in evaporites,
they were very prone to bit balling in shales when water-
based drilling fluids were used. I In general, refinements
to these early bits have proved very successful in the North
Sea where oil-base muds are used. There the bits often
have been driven by mud-powered downhole drilling
motors. The large total flow areas (TFA) characteristic
of these bits have kept the pressure drops across the bit
down to an acceptable level for downhole motor opera-
tion, whereas the oil-based muds apparently have been
inhibiting the balling tendency caused by the active clays
in the shale formations. Failure of these bits to drill shales
with water-based mud spurred a series of research pro-
grams designed to improve bit cleaning. These programs
could be divided into two groups: (1) laboratory tests
aimed at improved cleaning by optimization of cutter
orientation and (2) laboratory and field studies of methods
to enhance cleaning by increasing the flow distribution
to the cutters.
Cheatham and Daniels conducted single-cutter ex-
periments to evaluate the effects of shale properties, drill-
ing fluid pressures, and cutter configurations on the'
drilling of shales. 2 Their work showed that a small
negative rake angle reduced cutter clogging. Studies by
Melaugh and Salzer and later by Huang and Iversen fur-
ther examined the effects of side rake as well as back
rake. 3,4 They found that the mechanical cleaning action
of the PDC cutter with side rake reduced the tendency
of formation chips to stick to the cutting surface.
The other approach to improve the cleaning of PDC
bits has involved fluid mechanics more directly and has
yielded some very interesting concepts. These hydraulic
concepts included simple feeder-collector systems, flow
restrictors or baffles, fixed-jet nozzles, interchangeable
jet nozzles, rectangular nozzles, narrow slits for fluid
discharge, and even one-on-one correlation of nozzles to
cutters. 5 Baker reported a unique design to enhance the
crossflow beneath a PDC bit by using flow restrictors that
extended more than half the distance to the hole bottom
as compared to cutter stand-off or exposure. 6 A n im- .
provement on this concept that allegedly reduced erosion
JOURNAL OF PETROLEUM TECHNOLOGY
 TABLE 1-MECHANICAL AND PHYSICAL PROPERTIES
OF ROCKS DRILLED
Confined'
Compressive
Strength
(psi)
Mancos shale 15,180
Pierre shale 890
Berea sandstone 18,800
'Confining pressure was 2,000 psi.
of the steel-bit body was reported by Kuhn and Forrest. 7
Knowlton and Huang investigated the performance of bits
with rectangular nozzle flow areas. 8 The long axes of the
rectangular fluid ports were aligned tangentially on the
bit face. In theory, this nozzle design produced a flow
envelope that matched the reverse spiral row arrangement
of PDC cutters and simultaneously reduced the potential
for nozzle plugging. Performance data collected with these
nozzles showed some positive correlation between bit
hydraulic horsepower, which they attributed to better bit
cleaning.
Of all the innovations in hydraulic design features,
perhaps the simplest and most versatile concept is the in-
terchangeable jet nozzle. The PDC is essentially a drag
bit, failing the rock in shear. Work done by Humble Oil
and Refining Co. in the 1940's demonstrated that jet
nozzles significantly affected the drilling rates of drag
bits. 9 ,10 That research discredits any theory that jet
nozzles enhance only roller-cone bits. By using jet
nozzles, high-velocity liquid jets can be made to impact
the rock face and create a high level of turbulence, which
assists in removal of cuttings from beneath the bit. Since
the nozzles in PDC bits are much closer to the rock face
than are the nozzles in a roller-cone bit, more nozzles are
used to distribute the flow.
Glowka used flow visualization techniques to study the
effect of nozzle placement, nozzle number, and bit rota-
tion on the flow distribution beneath a steel-bodied bit with
stud-mounted PDC cutters. 11 He found that the flow pat-
terns beneath the bit and cooling characteristics of the cut-
ters could be altered significantly by variations in nozzle
placement.
The early prototypes of the jet-nozzled bits suffered
from severe erosion of the steel body from splash-back
caused by the close proximity of the bit face to the rock
surface. Development of a spray-on, hard-facing surface
material and improved nozzle retainers have reduced the
erosion problem.
Proponents of the jet-nozzed bit use the argument that
the high-velocity jets enhance bit cleaning in shales and
consequently expand the range of formations that can be
drilled with common water-based drilling fluids. Pro-
ponents of the feeder-collector hydraulic systems point
out that the probability for nozzle plugging is increased
with PDC bits because of the necessarily smaller diameter
jets in the jet-nozzled bits. (This problem is minimized
by the use of drillpipe screens.) One recent study sug-
gests that the jet-nozzled PDC bits deliver higher rates
of penetration (RaP) in homogeneous formations, while
the feeder-collector hydraulic designs are better than the
DECEMBER 1984
Bulk Grain
Densi1X Density Porosity Permeability
(g/cm ) (g/cm 3 ) (%) (darcy)
2.55 2.72 8.3 <10 -6
2.35 3.0 30.0 -10 -9
2.17 2.67 20.2 0.404
nozzled bits in drilling broken formations because of less
plugging. 12
A literature review reveals that very little has been
published concerning the specific level of bit hydraulic
energy or horsepower that is needed to maximize drill-
ing rates. Park reports that a hydraulics energy level of
2 to 3 hhp/sq in. [1.5 to 2 kW/cm2] provides improved
cleaning and cooling of PDC bits. 13 Radtke's analysis of
field data obtained with water-based muds suggests that
there is an optimal range of bit hldraulic horsepower that
is dependent on bit diameter. 1 Radtke recommends a
minimum of 2.7 hhp/sq in. [0.312 kW/cm2] for 6-in.
[15.24-cm] bits and up to 5.0 hhp/sq in. [0.578 kW/cm2]
for 17 1/2-in. [44.45-cm] bits.
To optimize hydraulics with interchangeable jet nozzles,
more definitive knowledge is required of the effects of
drilling fluid type, rock type, and bit hydraulic horsepower
on the drilling response of PDC bits. Interactions between
the mechanical power applied to the bit and the hydraulic
power at the bit also must be accounted for. The results
of our experimental program should help bridge that gap
in knowledge.
Experimental Program
An experimental study was designed and conducted to
determine the effect of bit hydraulic horsepower on the
drilling rate obtained with a PDC bit in three rock types
and two drilling muds. All drilling tests were performed
at the Drilling Research Laboratory in Salt Lake City, UT.
A complete description of the test facility is given in
Ref. 15.
Bit. A standard production model PDC bit with five in-
terchangeable nozzles was purchased for the tests. The
steel-bodied, 8 1/2-in. [21.59-cm] diameter bit had 39 stud-
mounted PDC cutters distributed over the bit face and had
a relatively flat, shallow-cone profile. Four sets of noz-
zle sizes were used in the experiment; nozzle sizes tested
were 5b ?b 1%2, and 1~2 in. [6.35,7.14,7.94, and 8.73
mm] in diameter. Five equal-sized nozzles were used in
each test.
Rocks. Three rock types were used in the program so that
any effects of mud/rock interactions could be determined.
The rock samples drilled were 15 1h in. [39.37 cm] in
diameter and 3 ft [0.914 m] long. The rocks drilled were
Mancos shale, Pierre shale, and Berea sandstone. The
measured mechanical properties of these rocks are listed
in Table 1. The sandstone was permeable; hence, all
samples drilled were pre saturated with water, and a pore
2111
 TABLE 2-DRILLING FLUID PROPERTIES

Water-Based Oil-Based TABLE 3-DOWNHOLE CONDITIONS SIMULATED (psi)

Mud Mud
Weight, Ibm/gal 10.00.2 10.00.1 Well bore Overburden Confining Pore
Plastic viscosity, cp 152 14 1 Pressure Stress Stress Pressure
Yield point, Ibf/100 sq ft 72 71 Mancos shale 2,000 4,400 2,900 0
pH 10.0 1 Pierre shale 2,000 2,350 2,250 0
API filtration, cm 3 70.5 Berea sandstone 2,000 2,275 2,500 1,700

50 For each test, the prepared rock sample was lowered

cr: MANCOS SHALE
~ 310 GPM
I- 40
120 RPM
Ii.
3.48 HSI
z
g WATERBASE MUD
I- 30
cr:
I-
w
z 20
w
a..
u.
0 given in Table 3.
w
I-
10
cr:
0 tomhole pattern before data were recorded. Then mud cir-
0 12
WOB. TOOO LBI
Fig. 1-Data repeatability.
pressure 300 psi [2.068 MPa] less than the wellbore
pressure was maintained during the drilling tests to
simulate an overbalanced drilling condition.
Drilling Fluids. The drilling fluids used in the tests were
a lO-lbm/gal [1198-kg/m3] bentonitellignosulfonate
water-based mud and a lO-lbm/gal [1198-kg/m3] relaxed-
filtrate oil-based mud. The muds were designed such that
the commonly measured properties (density, plastic
viscosity, yield point, and filtration) were approximately
equal between the two mud types. These properties were
measured before and after each drilling test by following
API recommended practice (API RP 13B). The low-
temperature test procedure was used to measure the filtra-
tion characteristics of both muds, rather than using the
high-temperature/high-pressure (HT /HP) test procedure
more commonly reported for oil-based muds. Building
the muds to produce similar properties provided a com-
mon basis of comparison. Consequently, the muds were
not necessarily representative of typical field muds. The
properties of the muds fluctuated during the tests; the
ranges for each mud's properties are listed in Table 2.
Test Procedure. Each of the 3 ft [0.914 m] long rock
samples tested was capped with metal plates. The top plate
had an opening to allow the bit to pass through and con-
tact the rock. The lower plate had an orifice through which
the pressure control line for pore pressure maintenance
was attached. (Pore pressure was maintained at a fixed
level only with the permeable sandstone samples.) The
top and bottom plates were held in contact with the rock
by steel rods that extended axially along the perimeter of
the samples. A rubber sleeve was wrapped tightly around
the sample to seal out the confining fluid.
2112
into the pressure vessel (wellbore simulator) along with
the bit, drillstem, wellbore rotary seal, and pressure vessel
cap. The cap then was tightened to seal the vessel. The
drill rig was positioned over the well bore simulator, and
the drill shaft was attached to the rotary drive shaft. Then
hydraulic connections were made, and confining pressure
and overburden streses were applied to the rock.
Downhole conditions simulated with each rock type are
After mud circulation was established, the bit was
drilled gently a few inches into the rock to establish a bot-
14 culation rate was increased to the value desired for the
first series of drilling conditions. By adjusting a
backpressure choke in the flowline, the borehole pressure
was maintained at 2,000 psi [13.79 MPa]. Rotary speed
was set at 120 rev/min [2 rev/s] throughout the tests ex-
cept where noted. The desired WOB then was applied until
the drilling rate appeared to stabilize. Data recorded in-
cluded WOB, rotary speed, flow rate, bit pressure drop,
borehole pressure, torque, mud temperature, and rate of
penetration (ROP).
Analysis of Results
The first core of Mancos shale was drilled for the single
purpose of obtaining an estimate of the repeatability of
the measured drilling rates. After setting the circulation
rate, environmental parameters, and rotary speed to 120
rev/min [2 rev/s], data were collected by alternating the
WOB from about 6,000 to 11,000 Ibf[26.69 to 48.93 kN].
Five data points were collected at each of these WOB
levels. The resulting scatter in the data is presented in
Fig. 1. Since the WOB levels were not all exactly 6,000
or 11,000 lbf [26.69 to 48.93 kN], the scatter in the data
was quantified statistically by regression analysis. A least-
squares fit of the power law model (ROP=a WOB b )
yielded a better fit than did a linear model. The standard
error calculated from the residuals of the regression was
found to be 2.05 ft/hr [0.173 mm/s], or approximately
9% of the calculated mean drilling ROP at 6,000 lbf
[26.69 kN] and 5.5% at 11,000 lbf [48.93 kN] WOB.
Since drilling in the laboratory was expensive, very few
repeat points were collected during the remaining tests
and it was assumed that this computed standard error of
the ROP data was representative of all drilling tests con-
ducted.
Mancos Shale. At each measured flow rate, Q, and
pressure drop across the bit, ~p, the bit hydraulic
horsepower (PH) was calculated from the equation
Q~p
PH =-, ............................. (1)
1,714
JOURNAL OF PETROLEUM TECHNOLOGY
 a b
80,------,-------,------,-------,-------, 80r-----~-------r------,-------~----~

MANCOS SHALE MANCOS SHALE

120 RPM 120 RPM
WATER-BASE MUD 70 WATER-BASE MUD
70

o
60 60

a: a:

I I

t;: 50
9000 LBf WOB j::: 50
LL

z z-
6000 LBf WOB
o Q 0
f-
<l:
~ 40
UJ
f-
<l:
~ 40
UJ
0
0
Z Z
UJ UJ
"- "-
LL
LL 3000 LBi WOB
o 0
UJ 30 o UJ
f-
30
f-
<l: <l:
a: a:

20 20
NOZZLE DIAMETER
NOZZLE DIAMETER 0 8/32 IN.
o 8/32IN_ 0 9/32 IN.
10 o 9/32 IN. 10
0 10/32 IN.
o 10/32 IN. 6 11/32 IN.
6 11/32IN.

0
o~----~~----~------~------~----~.
o 10 0 2 4 6 8 10
BIT HYDRAULIC HORSEPOWER, HSI BIT HYDRAULIC HORSEPOWER, HSI

Fig. 2-Response to bit hydraulic power in water-based mud, Mancos shale.

and the bit hydraulic horsepower per square inch (HSI)
was calculated from 4P Hf7rd 2 , where d is the bit
diameter in inches, Q the volume flow rate in gallons per
minute, and t:.p the bit pressure drop in psi.
The drilling responses to HSI at five WOB levels are
shown in Figs. 2a and 2b for the water-based mud drill-
ing of the Mancos shale. Least-squares curve fits of these
data were obtained with a power law model and also are
shown for the five WOB levels. The data show that the
bit hydraulic horsepower has a significant effect on the
drilling rate at all WOB levels. As the bit hydraulic
horsepower increases above about 5 hhp/sq in. [0.578
kW/cm2], the sensitivity to bit hydraulic horsepower
decreases, a characteristic also common to roller-cone
bits. 16
Examination of the results obtained while this shale was
drilled with the oil-based mud revealed a drilling response
quite different from that observed in the water-based mud.
The effect. of HSI on ROP during the drilling of Mancos
shale with the oil-based mud is shown in Figs. 3a and 3b.
Again, data are presented for five WOB levels. Least-
squares linear fits of these data are shown also. These
curves show only a very slight response to bit HSI at all
five WOB levels. In fact, the data suggest that the HSI
has a negative influence on the drilling rate at 9,000 lbf
[40.03 kN] WOB. The dashed curves represent the locus
DECEMBER 1984
of constant volumetric flow rates with Q 1 < Q2
< Q3 < Q4' Over the middle range of WOB levels (or
normal operating conditions) these lines indicate that ROP
is affected more by Q than by hydraulic power. The order-
ing of the curves further suggests that for this particular
rock and mud combination, the most effective way to max-
imize ROP is to maximize Q rather than HSI. (No similar
ordering of lines of constant Q was observed with the
water-based mud data.)
In Fig. 4, the curve fits of the drilling responses to HSI
at five WOB levels have been plotted to compare the
responses in water and oil muds. The data reveal that the
oil-based mud is the better drilling fluid (for ROP) at low
bit hydraulic horsepower levels, while the water-based
mud appears to be the better drilling fluid at higher
hydraulic horsepower levels. Examination of the bit
following the drilling tests in the water-based mud showed
some balling of the cutters in the recessed center area of
the bit. There was essentially no balling of these cutters
when the oil-based mud was used, even at low hydraulic
power levels.
Further examination of the oil- and water-based mud
data for Mancos shale showed that the hydraulic
horsepower level at which the two muds promoted
equivalent drilling rates was dependent on the WOB (or
mechanical power) applied. The dashed curve passes
2113
 a
80.------,------,------r-----,r-----,

MANCOS SHALE 01 c 225 GPM b

120 RPM 02 ~ 290 GPM 70.-----~-------.------,_------._----_,
70 OIL-BASE MUD 03 ~ 358 GPM
04 ~ 410 GPM MANCOS SHALE 01 ~ 225 GPM
120 RPM 02 ~ 290 GPM
60 OIL-BASE MUD 03 ~ 358 yPM
60 04= 410GPM

cr:
;r.: 50
t;: 50 cr:
I
z l-
o lL

z
'? 40
I-
0:{
cr:
I-
w
Z

20
is _ Q _ _ _ _ _ 3000 LBf WOB
NOZZLE DIAMETER
60 1..n..O_-0 2 _0 o 8132 IN.
r<\ /_'-<r _ - - 3
~- --- 0 o 9132 IN.

10
c:, 08132 IN. 10 o 10/32 IN.
o NOZZLE 9132 IN. o c:, 11/321N.
DIAMETER 010132 IN.
c:, 111321N. O~ ____ ~ ______ ~ ____ ~ ______ ~ ____ ~

o~ ____ ~ ______ ~ ____ ~~ ____ ~ ____ ~

o 2 4 6 8 10
o 10
BIT HYDRAULIC HORSEPOWER. HSI BIT HYDRAU LlC HORSEPOWER. HSI

Fig. 3-Response to bit hydraulic power in oil-based mud, Mancos shale.

80.-----.------r-----,~----.-------,
through the five "hydraulic thresholds," which represent
MANCOS SHALE the hydraulic horsepower levels required to make the drill-
WATER8ASE MUD ing rate in the water-based mud equal to that achievable
70 OILBASE MUD in the oil-based mud.
--0-- HYDRAULIC THRESHOLD

60 Pierre Shale. If the bit balling had indeed degraded the

cr: drilling rate in Mancos shale with the water-based mud
I
l-
at low HSI levels, the effect should be further exaggerated
lL
in a gumbo or sticky shale. Mancos shale is a brittle shale,
z
'? essentially free' of the problem clays such as mont-
I-
0:{
morillonite. To examine the effect of bit hydraulic
cr: horsepower in a more troublesome shale, Pierre shale
I-
w samples were drilled. Shales are considered troublesome
Z
w if they contain water-sensitive clays (montmorillonites and
a.
u. illites) that undergo hydration when placed in contact with
0
1JJ water (drilling fluid filtrate). Clay mineralogists and mud
I-
0:{ engineers often measure the shale's hydration character-
a:
istics in terms of its specific surface area. Specific sur-
face is the total surface area of a known mass (weight)
of the dispersed shale (clay platelets included) and
measured in square meters per gram. The magnitude of
the specific surface area of a shale has been shown to be
a good indicator of its tendency to hydrate and swell. 17
Table 4 presents the relative "hydratability" of Mancos,
10 Pierre, and Cook Mountain shales, along with pure
Wyoming bentonite (sodium montmorillonite)-the
Fig. 4-Bit hydraulic threshold in Mancos shale. ultimate hydratable clay.
2114 JOURNAL OF PETROLEUM TECHNOLOGY
 1111 120
PIERRE SHALE PIERRE SHALE
DJL.lIASE MUD WATER-8ASE MUD

10
120 RPM 120 RPM
NOlllE WOB lBI
t
0 100 DIAMETER 2000 4000
8/32 IN. 0
9/32 IN. 0
; t
10
~80
t::
z
Si!
t
411 ~

1111 ~Il t
0
...if! ~0 ;1
...
I:)

II:

~
10 <
=48

t
I...
iI!
II
20 f
0

CI
NomE DIAMETER 0

~
0
0
o
II: 411
0
0
1!32 IN.
1!32 IN.
0 0

0 10/32 IN.
6 11/32 IN. 00 Z 4 6 8 10
BIT HYDRAULIC HORSEPOWER . HSI
20
10
Fig. 6-Response to bit hydraulic power in water-based mud,
Pierre shale.

sensitive to bit hydraulic horsepower. This difference can

BIT HYDRAULIC HORSEPOWER HSI
Fig. 5-Response to bit hydraulic power in oil-based mud,
Pierre shale.
TABLE 4-RELATIVE HYDRATABILITY
(SPECIFIC SURFACE) OF SHALES (m 2 /g)
Mancos
Pierre
Cook Mt. (gulf coast)
Wyoming bentonite
Drilling data obtained from drilling the Pierre shale
samples in the oil- and water-based muds are shown in
Figs. 5 and 6, respectively. For the oil-based mud, data
are shown at 2,000,4,000 and 6,000 Ibf [8.896, 17.79,
and 26.69 kN] WOB. For the water-based mud, fewer
data were collected and Fig. 6 shows the ROP response
to HSI at 2,000 and 4,000 Ibf[8.896 and 17.79 kN] WOB.
Examination of Fig. 5 reveals that bit hydraulic
horsepower very significantly affects the drilling rate with
the oil-based mud. This is in contrast to the results ob-
tained in the Mancos shale, where drilling was very in-
DECEMBER 1984
be partially explained by the relative rock strengths; Pierre
shale has only about one-fifteenth the compressive strength
of Mancos shale.
The drilling data obtained with the water-based mud
were very erratic and often unrepeatable. Below about
5 hhp/sq in. [0.578 kW/cm2], the bit would hardly drill
because of bit balling. The data indicated that increasing
bit hydraulics to greater than 5 hhp/sq in. [0.578
kW/cm2] was definitely beneficial. This improvement
should not be viewed as "the solution" to drilling soft,
gumbo-type argillaceous shales with un inhibitive water-
based muds, however. The arrows on the data points in
Fig. 6 indicate that the drilling rates were continually
changing and generally decreasing. These changing rates
suggested that the bit was beginning to ball up. Only a
69 few inches of rock were drilled to obtain each measure-
201
211 ment. Hence, if balling were happening that fast in the
810 laboratory, then surely it would happen in the field where
large footages are drilled.
Fig. 7 shows a direct comparison of the ROP responses
to HSI in oil- and water-based muds for Pierre shale. The
oil mud was inhibiting the shale cuttings from sticking
to themselves and to the bit, thereby producing drilling
rates much greater than those produced in the water-based
mud. Unlike the more stable (less hydratable) Mancos
shale, in the Pierre shale there does not appear to be a
reliable hydraulic threshold at which the water-based mud
drills as effectively as the oil-based mud. At the very ex-
treme HSI levels examined, there is some evidence that
bit hydraulic horsepower (or energy) was becoming more
effective in cleaning the bit with the water-based mud.
However, the unsteady drilling rates measured suggest
2115
 140 140
PIERRE SHALE
120 RPM BEREA SANDSTONE
4000 LB WDB WATER-8ASE MUD 0

120 RPM
NOZZLE DIL-8ASE WATER-8ASE 120 9000 LB WDB
120 DIAMETER MUD MUD

0
0
8/32 IN. 0
9/32 IN.
10/32 IN.
0
c
0

11/32 IN.
tOO 100

a::
~
0
(
16: 16:
! 80
0
~ 80
~
III III
I! !
~60 ~60
0
$a:: $

D

... : D
0
a:: 0
0

0
40 0
40
0
0

0
0

20 20
NOZZLE DIAM ETER
D
0 0 8/32 IN.
o
0
0 0 a 9/32 IN.
0
0 10/32 IN.
00 2 4 6 8 10 00 2 4 6 10
BIT HYDRAULIC HORSEPOWER - HSI BIT HYDRAULIC HORSEPOWER - HSI

Fig. 7-Drilling rates with oil- and water-based muds, Pierre Fig. 9-Effect of hydraulic power in water-b&sed mud, Berea
shale. sandstone.

140 that bit cleaning and high drilling rates could not be sus-
BEREA SANDSTONE tained. More importantly, a bit hydraulic horsepower level
OIL-8ASE MUD of 8 to 10 hhp/sq in. [0.925 to 1.156 kW/cm2] is not
1211 RPM
practical for many field applications.
1211
0 Berea Sandstone. A chemically inert rock (Berea sand-
stone) also was drilled to essentially eliminate clay
100
chemistry as a factor. The results are shown in Figs. 8
and 9. Data are presented for three WOB levels (3,000,
a:: 6,000, and 9,000 Ibf [13.34, 26.69, and 40.03 kND for
i!E
16: drilling with both the water- and oil-based muds. The ROP
z BO responses to HSI measured with both muds show a signifi-

iI! cant benefit of increased bit hydraulics during drilling of

this highly permeable sandstone. This increase may result
from the kinetic energy of the fluid jets being converted
"-
= &0 into elastic energy in the pore fluid. Since the rock is
highly permeable, the fluid in the pore spaces just below
i
0

the bit is pressurized by the impinging jets, thereby reduc-

D ing the effective overbalance and increasing the drilling
40 0 rate. A direct comparison between the drilling rate in the
oil-based mud and the water-based mud is shown in Fig.
10. From these data, it appears that both drilling fluids
affect drilling to the same extent in the sandstone. This
20
NOZZLE DIAMETER similarity might be expected since the fluid properties
o 8/32IN.
a 9/32 IN. (viscosity, density, solids content, and filtrate loss) that
o 10/32 IN. are known to affect drilling rate were approximately equal
with the two muds.
~ 2 4 6 8 to
BIT HYDRAULIC HORSEPOWER - HSI
Comparison With Field Observations. Overall, the
Fig. a-Effect of hydraulic power in oil-based mud, Berea laboratory results are in agreement with observations
sandstone. made during field applications of PDC bits. The measured

2116 JOURNAL OF PETROLEUM TECHNOLOGY

 140 The water sensitivity of Pierre shale very closely
matches that of Cook Mountain shale encountered along
BEREA SANDSTONE
120 RPM the Texas gulf coast, as shown in Table 4. Early attempts
1lOIII LB WOB made to drill Cook Mountain shale with a PDC bit b~ us-
120
ing a water-based drilling fluid were unsuccessful. 0 In
the water-based mud, the bit balled up immediately and
0
0
would not drill. When a PDC bit was run later through
D
100 the same formation interval with a relaxed-filtrate, invert
emulsion oil-based mud, the bit drilled 2,415 ft [736 m]

a:
~
z 80
...
o
0
0
D at 28.9 ft/hr [2.45 mm/s]. While no data were available
on the effect of HSI, the field results agree with the
laboratory tests as to the influence of the two drilling

~
0
D fluids. Both the laboratory and field data showed that these
0
~ D
!!;1iII
...
lie
a:
40
20
NOZZLE OILBASE
DIAMETER . MUD
8/32 IN.
9/32 IN.
10/32 IN.
00 2 4 6 8
BIT HYDRAULIC HORSEPOWER HSI
Fig. 10-Drilling rates with oil- and water-based muds, Berea
sandstone.
ROP responses while drilling the Mancos shale and Berea
sandstone with water-based mud qualitatively match that
reported by Radtke and Pain. 14 Their results for bits in
the 81;2- to 8%-in. [21.59 to 22.23-cm] size range and
of the same configuration as the laboratory test bit sug-
gest that the minimum for water-based mud drilling should
be 3.3 to 4.0 hhp/sq in. [0.381 to 0.462 kW/cm2]. Their
analysis was based on 125 bit runs in the Wilcox, Mid-
way, Navarro, and Taylor shales and the Austin and Selma
chalk along the U.S. gulf coast. Their recommended
minimum HSI levels are equal to or greater than the
hydraulic threshold shown in Fig. 4 and roughly match
the HSI levels at which the laboratory-measured water-
based ROP response curves begin to show a decreasing
sensitivity to HSI (see Figs. 2 and 10).
The laboratory drilling results obtained in the Mancos
shale with oil-based mud also follow the same trends as
observed in many field PDC bit applications. An analysis
of PDC bit runs by Exxon Co. U.S.A. in south Texas
and reported by Golis 18 demonstrated that in the Frio
shales and sands, drilling rate was not positively correlated
to bit HSI when an invert emulsion oil-based mud was
used. The absence of a positive correlation between ROP
and HSI in these field runs matches that observed in the
laboratory drilling of the Mancos shale with oil-based mud
(Figs. 3a and 3b) but does not match that observed in the
laboratory sandstone drilling (Fig. 10). Other south Texas
operators have also found it unnecessary to apply high
levels of bit HSI when drilling the lower Wilcox shale
with PDC bits and oil-based mud. 19
DECEMBER 1984
very water-sensitive shales (specific surface> 200 m 2 /g)
could not be drilled by a PDC bit with water-based muds.
Also, both the laboratory and field data demonstrated that
oil-based mud was very effective with a PDC bit in these
soft, sticky formations.
Conclusions
The most important inference that can be drawn from this
study is that certain moderately hydratable shales that
WATER-8ASE
MUD would normally require an oil-based mud for drilling with
0 a PDC bit can be drilled more effectively with a water-
0
0 based mud by using a higher bit hydraulic horsepower.
10 It also can be inferred that gumbo-type shales cannot be
drilled by a PDC with an uninhibitive water-based mud,
regardless of the bit hydraulic horsepower used.
Analysis of the test data collected with this particular
8V2-in. [21.59-cm] PDC bit configuration and rock types
drilled has yielded the following more specific conclu-
sions regarding the effects of bit hydraulic horsepower
on drilling rates.
1. Drilling rates were affected positively by increases
in bit hydraulic horsepower when the stable Mancos shale
and permeable Berea sandstone were drilled with water-
based mud as the drilling fluid.
2. The drilling rate showed very little response to bit
hydraulic horsepower while the Mancos shale was drilled
with an oil-based mud.
3. Drilling rates were increased significantly by in-
creases in bit hydraulic horsepower when the soft,
hydratable Pierre shale and permeable Berea sandstone
were drilled with oil-based mud as the drilling fluid. In
the sandstone, the ROP sensitivity to HSI decreased above
5 to 6 hhp/sq in. [0.578 to 0.693 kW/cm 2].
4. Very high levels of bit hydraulic horsepower (> 5
hhp/sq in. [0.578 kW/cm2]) improved bit cleaning and
the drilling rate while the soft, hydratable Pierre shale
was drilled with the water-based mud. However, increased
bit hydraulic horsepower alone does not appear to be
capable of keeping a PDC bit clean during the drilling
of a gumbo-type shale.
5. The inhibitive characteristic of the oil-based mud ap-
pears to account for its better drilling performance com-
pared with that of water-based mud in drilling both shales
with relatively low bit hydraulic horsepower. In the clay-
free (inert) sandstone, the drilling rates achieved with the
two fluids were equivalent.
By conducting a hydraulic study similar to this one with
other shales, a correlation could be made between shale
specific surface area and the bit hydraulic threshold for
water-based mud application. This correlation would be
2117
very valuable to drilling engineers when confronted with II. Glowka, D.: "Optimization of Bit Hydraulic Configurations," Soc.
the selection of mud type and the development of a bit Pet. Eng. 1. (Feb. 1983) 21-32.
12. Van Prooyen, J., Juergens, R., and Gilbert, H.W.: "Recent Field
hydraulics program for PDC bit application. Results with New Bits," 1. Pet. Tech., Vol. 34, September 1982,
1938-46.
Acknowledgments 13. Park, A.: "Improvement of Drilling Capabilities of PDC Cutters
in Hard Formation," Final Report DOE/BC/10364-24, U.S. DOE,
We thank R.P. Steiger and D.M. Rowe of the Drilling Washington D.C. (August 1982).
Fluids Section of the Drilling and Completions Div., 14. Radtke, R.P. and Pain, D.D.: "Optimization of Hydraulics for
Exxon Production Research Co., for their assistance in Polycrystalline Diamond Composite Bits in Gulf Coast Shales with
this project by conducting the tests for the specific sur- Water-Based Muds," 1. Pet. Tech. (Oct. 1984) 1697-1702.
15. Black, A.D. and Green, S.1.: "Laboratory Simulation of Deep Well
face measurements of the Mancos and Pierre shales. We Drilling," Pet. Eng. IntI. (March 1978).
thank Exxon Production Research Co. for permission to 16. Tibbitts, G.A., et al.: "The Effects of Bit Hydraulics on Full-Scale
publish this paper. Laboratory Drilled Shale," 1. Pet. Tech. (July 1981) 1180-88.
17. Steiger, R.P.: "Fundamentals and Use of Potassium/Polymer Drill-
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2118 JOURNAL OF PETROLEUM TECHNOLOGY