Varel International

Diamond
Impregnated Bits
DRILLING PERFORMANCE IN HARD
AND ABRASIVE FORMATIONS
IMax™ and IMax+™ bits drill faster and last longer through
hard and abrasive formations. The impregnated diamond
matrix bits are a highly flexible series that allow materials
and designs to be quickly adjusted to the requirements
of a specific application. The result is optimal drilling
performance in very challenging formations.

IMax bit cutting structures feature cylindrical, hot isostatic

pressed (HIP) segments tailored to the formation. IMax+
designs also incorporate PDC cutters for a hybrid bit
ideal for drilling from a softer formation into harder rock
formations where durability is key.

IMax+ PROVIDES HYBRID PERFORMANCE

IMax+ adds premium Vulcan® PDC cutters for a hybrid design with
a dual cutting structure. The bit design is particularly effective in
less-consolidated sandstones or when drilling from a softer formation
into a harder and more abrasive formation. Drilling with the IMax+
optimizes performance and avoids a trip to change bits.

The PDC cutters are placed on the face of the HIP segments for
increased formation shearing. As the formation becomes harder
or more abrasive, the PDC cutters wear down to expose the
HIP cutting structure to the formation.
IMax BIT

HIP Segments Tailored

for Applications

Segment Protrusion for

Drill Out Capabilities

Segment Protrusion
for Better Cooling
and Cleaning

CFD Optimized
Waterways

Reinforced TSP Gauge

Diamond Impregnated
Blades

› T URBINE APPLICATIONS

IMax bits are available
with turbine sleeve and
box up connections
 IMax BIT

DIAMOND SELECTION AND MATRIX DISTRIBUTION

ARE CRUCIAL
High-performance IMax and IMax+ bits are based on the latest in design, material
and manufacturing science. Varel begins with a strict diamond selection process
to ensure each area of the bit utilizes diamonds of similar size and quality.

The diamonds are then pelletized. Pelletization prevents diamond aggregates and
reduces areas of low diamond concentration for a more uniform stone distribution
within the matrix material. This process improves diamond/matrix bonding which
results in a more consistent wear pattern during the bit run.

The same process is followed in manufacturing the HIP segments that form the
bit’s cutting elements. These segments undergo a sintering process to achieve
reduced porosity. The finished HIP segments are then positioned in the bit blades
in specific patterns determined by Varel’s proprietary SPOT™ bit design program.
The high segment standoff improves fluid flow for better bit face cleaning and
cooling action.

A proprietary controlled-atmosphere infiltration process is then applied to the entire

bit. The controlled temperature environment reduces oxidation and graphitization to
improve bit wear characteristics and durability.

Old Diamond New IMax

Impregnated Bit Pelletization Process
Superior hydraulics
For optimum hydraulics, Varel impregnated bit designs
undergo extensive computational fluid dynamics (CFD)
evaluations to ensure a configuration that eliminates
re-grinding and re-circulation of drilled cuttings — a
common occurrence when drilling hard and abrasive
applications. The sophisticated CFD process identifies
and eliminates possible stagnation zones, resulting in a
hydraulics configuration that improves cleaning efficiency,
segment and cutter cooling, and ROP. Segment standoff
also improves fluid flow.
Clear, intelligent nomenclature
The Varel impregnated bit is designated as VI, with
a DGX suffix describing bit features. For example,
the VI1213DGX designates a Varel impregnated bit
with 12 blades and 13 mm diameter HIP segments.
The DGX suffix describes drop-in (D) cutters in the gauge
pad, TSP gauge (G) and tungsten carbide shock studs (X).
IMax+ uses the same convention with the addition of the
plus (+). Thus, a VI+613DGX would be a Varel impregnated
hybrid bit with six blades, 13 mm PDC cutters and the
same DGX features as the first example.

SPOT BIT DESIGN SOFTWARE

IMax bits are designed using advanced analytical
tools. The SPOT bit design program provides a
collaborative environment where bit designers, field
engineers and other stakeholders can fully engineer
a specific bit design for optimal performance and
steerability using particular drilling systems. Using
advanced algorithms, rock mechanics analysis and
extensive field operating and performance data
directly from the rig, the SPOT program manages
large volumes of data and enhances interpretation.

In conjunction with Varel’s proprietary GeoScience™

rock analytics program, SPOT makes it possible
to determine how changes in bit features and
dimensions will affect steerability, bit walk,
DLS capability and vibration control for any
SPOT Graph
well trajectory and BHA.

Because the design process allows the team

to select the most appropriate design elements,
Varel diamond-impregnated bits incorporate a
cutting structure design that is always optimized
for the application.

Cutter Face Layout Options

DELIVERING BEYOND
BENCHMARK PERFORMANCE
IMax DIAMOND-IMPREGNATED BIT NEW 5-5/8" IMax BIT SETS
SETS PERFORMANCE RECORDS PERFORMANCE RECORDS
WITH DEBUT APPLICATION IN IN OMAN
BOLIVIA A 5-5/8" (142.875 mm) IMax VI1213G delivered
In its initial application in Bolivia, where hard and outstanding performance in Oman, drilling 249 m
abrasive formations limit ROP and accelerate bit (817 ft) through an abrasive mixture of sandstone,
wear, a Varel 6" (153.25 mm) diamond-impregnated siltstone, shale, silicilyte and limestone in the
bit VI1213DGX set new performance records in both Mushwar field. This is as much as seven times
footage and ROP to achieve the lowest cost per foot the interval drilled by similar bits in the same
for the slim hole section. well and three times the ROP.

The design of the VI1213DGX impregnated bit was

customized for turbine drilling in the formation’s RECORD: 6" IMax BIT DRILLS
sandstone and naturally fractured quartz. The FARTHER AND FASTER THAN
objective was to drill as much footage as possible
OFFSETS IN ALGERIA
from 5,206 m (17,080 ft) measured depth while
maintaining a competitive ROP. In Algeria’s abrasive Silurian-Gedinian sandstones, a
Varel 6" (153.25 mm) VI1213G drilled 309 m (785 ft)
The bit drilled 430 m (1,410 ft) in a single run,
to exceed the best offset performance, with 7% more
increasing footage drilled by 120% compared
footage and 8% faster ROP. The bit not only exceeded
to the previous-best 6" run. An average ROP
all offset runs, but the dull condition was much better
of 2.43 m/h (8 ft/hr) was 30% faster than the
than average with very even wear across the face.
ROP of the next-longest run.

This single-run performance exceeded all previous

6" (153.25 mm) runs in Bolivia, establishing new
footage and ROP records to deliver the lowest cost
per foot. When the bit was pulled due to MWD
hours, it was dull-graded: 2-2-WT-A-X-I-BT-DTF,
RE-RUNNABLE.

Choose performance-driven excellence that endures.

IMax BIT TURNED AT 800+ RPM
IN BRITISH COLUMBIA, CANADA
Rotating at approximately 880 rpm, an 8-1/2"
(215.9 mm) IMax VI613DG bit drilled 186 m
(472 ft) in 115.5 hours — farther than the next
best offset run and nearly double the footage of the
average offset. ROP was 13% faster than average
offsets in the sandstone and siltstone of the Artex
and Doig formations. When the bit was pulled for a
BHA change, the wear was so low that it could have
continued drilling.

IMax+ BIT ESTABLISHES NEW

STANDARDS IN ALFALFA
COUNTY, OKLAHOMA, USA
In a lateral well drilling the Mississippian’s hard
limestone, sand and chert, a 6-1/8" (155.5 mm)
Varel VI+613DGU run reached 2,238 ft (682 m)
at 44.78 ft/hr (13.65 m/h). The performance
exceeded the combined footage of the bits run
above and below it and far surpassed the typical
660–700 ft (201–213 m) range. The overall ROP
was 71% faster than the most direct offsets.
World Headquarters Varel manufactures drill bits for the global oil and gas industry as well as
Dallas, Texas USA for the blasthole mining, industrial, construction and water well drilling
Tel: 1.800.827.3526 communities. We are committed to delivering ever-increasing value to
Tel: +1.972.242.1160 our customers and other stakeholders by exceeding industry standards
Fax: +1.972.242.8770 for performance, service and innovation.
info@varelintl.com

© VAREL INTERNATIONAL ENERGY SERVICES, INC. 2014