Professional Documents
Culture Documents
by
2008
A Baseline for Mechanical Specific Energy and
Estimation of Bit Wear Rate
by
Thesis
Presented to the Faculty of the Graduate School of
in Partial Fulfillment
of the Requirements
Approved by
Supervising Committee:
Kenneth E. Gray
Jon Holder
Dedication
To my family
Acknowledgements
I would like to thank all those who helped me complete my Master of Science in
Petroleum Engineering. I would like to thank Dr. Kenneth E. Gray for his support,
guidance and encouragement throughout the project. I would like to thank Dr. Holder for
his guidance. I would like to thank my family for their encouragement and inspiration,
without which this would not have been possible. I specially thank Dr. Ghislaine Kozuh
for her help in editing this thesis. Finally, special thanks to the sponsors for the financial
support provided by the Life-of-Well project, which supported my Master’s degree at the
December 2008
v
Abstract
used to monitor the efficiency of the drilling process and to analyze bit performance.
Mechanical factors that contribute to drilling inefficiency such as bit balling, bit dulling,
torque/drag, drillstring vibrations, etc., are associated with a spike in the Mechanical
Specific Energy (MSE). The Unconfined Compressive Strength (UCS) of the formation
is generally used as a baseline for comparing the operating real time values of MSE.
However, observed MSE values vary significantly from the UCS of the formation. This
thesis details a model to establish a baseline for MSE, based on predicting the rate of
penetration (ROP) of a specific bit in a given formation. The ROP model used is an
Imperfect Hole Cleaning model for a diamond-coated bit. A second model was developed
vi
to estimate the wear rate of bits, which can be monitored in real time using data obtained
from logging tools. Monitoring the MSE and the bit wear rate could potentially improve
the overall efficiency of the drilling process, by helping identify the variables that cause
inefficiency, and offering a quantitative basis for bit change decisions. This provides
quantitative data needed to make design changes and bit change decisions, resulting in a
vii
Table of Contents
Chapter I: Introduction.............................................................................................1
Introduction ....................................................................................................1
Review of Literature ......................................................................................3
References..............................................................................................................22
Vita ......................................................................................................................25
viii
List of Figures
Figure 5: Rectangular cutter profiles - the U profile, L profile and the slab profile
...........................................................................................................16
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Chapter I: Introduction
INTRODUCTION
since drilling performance is related to a number of intangible factors. Most bits are
evaluated based on their performance relative to offset wells. However, drill rates are
limited by factors that the driller does not control, and in ways that cannot be documented
in a bit record. Consequently, drill rates may vary greatly between two wells running
identical bits.
widely used is the "drill rate" test[1], in which various weight on bit (WOB) and RPM
settings are experimented. Weight on bit (WOB) is the total amount of downward force
placed on a bit by the entire weight of the drill stem. The drillers then use the
combination of WOB, RPM and torque settings which provide the best rate of penetration
(ROP). ROP is the measured distance that the drill bit or other drilling tool penetrates
The earliest method was the "drill-off" test wherein the driller applies a high
WOB and locks the brakes. This prevents the top of the string from advancing.
Circulation is continued and the string is rotated. The bit drills ahead and the string
elongates. The weight on bit gradually declines and the rate of penetration (ROP) is
calculated from the increase in the rate of drill string elongation as the WOB decreases.
1
Figure 1[1] shows field data from three drill-off tests using insert bits. As shown in the
plot, the rate of penetration stops responding linearly with increasing weight on bit at a
point. This point is referred to as the "flounder" or "founder" point. The weight on bit at
this point is taken to be the optimum WOB. The drilloff curve is used as a reference to
demonstrate how MSE can be used operationally. By monitoring the MSE in real-time,
one can identify which phase of the drill-curve the bit is currently in.
Several tools have been developed to optimize ROP, which are similar to drill-
rate and drill-off tests. These tools have been used to observe performance trends and
2
seek to identify the founder point. However, the true potential drilling rate for a formation
has not been identified yet. MSE analysis has shown that only 10% of the possible
maximum performance has been achieved in many cases[1]. In many situations, since
offset well performance was used as a baseline, the possibility of a better performance is
overlooked.
MSE monitoring and analysis not only provides the opportunity to identify
performance limiters for optimum drilling, but also a quantitative basis for cost-justifying
Although several investigators have studied the use of MSE as a trending tool, a
baseline for MSE levels to be expected of a formation is still a gray area. This thesis
attempts to establish a predicted value for MSE, which is done by first calculating the
expected rate of penetration. The ROP model used is an Imperfect Hole Cleaning model
for roller cone bits. Since MSE levels are also associated with the condition of the bit, a
model to estimate how much the bit wears out with every depth of cut it makes was
developed. Ngoie’s[2] model for depth of cut per revolution and Dagrain and
Tshibangu’s[3] model for axial and torsional forces acting on a bit was used to derive this
model.
3
REVIEW OF LITERATURE
The concept of using specific energy using Teale’s[4] model has been applied
among several authors who have explored the possibility of optimizing drilling using
Teale’s model. One approach to drill bit selection for a specific formation by applying the
principle of specific energy has been described by Rabia et al.[9] They have shown that
the specific energy approach to bit selection is comparable, if not better than the use of
the traditional cost per meter or average cost per meter approaches for analyzing bit runs.
The rate of penetration in a given formation depends not only on the rock strength of the
formation, but also on how effectively the cuttings are removed. Warren[10] developed a
model to predict the rate of penetration, which takes into consideration the effects of both
the initial chip formation process and the cuttings removal process. Dupriest et al.[11] use
the mechanical specific energy concept developed by Teale in an attempt to optimize the
drilling process and maximize the rate of penetration. In their study, they use the
compare the specific energy levels of the formation. The downside to this approach,
pointed out by Guerrero et al.[12] states that the apparent strength at the rock-bit interface
is higher than the unconfined compressive strength value. This is due to increased
compressive strength of the rock due to the pressure difference between the borehole
pressure and the formation fluid pressure. Consequently, Guerrero et al. have developed a
tool which incorporates the specific energy concept in order to model bit performance
and also predict the rate of penetration for various bit types. They point out that one of
4
the shortcomings of their ROP model is that drilling inefficiency is caused by a variety of
factors, some of which are bit balling, bottomhole balling, hole cleaning, drilling
vibrations and bit wear. Some of these factors are hard to quantify; however, bit wear rate
is measurable. The results and observations from the aforementioned authors have been
used in this study to develop a model that can determine the baseline for mechanical
specific energy levels and a second model that can predict the wear rate of bits.
5
Chapter II: Establishing a Baseline for MSE
INTRODUCTION
The mechanical specific energy concept has been used to optimize the rate of
penetration of bits and although in a limited manner, it has also been used to investigate
monitoring of mechanical specific energy by using downhole data enables the detection
of changes in the efficiency of the system. Optimum operating parameters can thus be
identified and also, design changes that could potentially improve performance may be
evaluated.
Dupriest et al.[6] have shown that specific energy analyses have enabled redesign
in areas as diverse as well-control practices, bit selection, bottom hole assembly design,
As described earlier, the drill-off curve was commonly used to identify the
the linear portion of the drill-off curve is the objective of any drilling optimization
scheme.
Now, the relationship between the specific energy, drilling torque applied, weight
Teale[4]:
MSE =
6
where, MSE stands for the Mechanical Specific Energy, RPM is the bit rotating
speed in rotations per minute, D is the diameter of the borehole and WOB is the weight
All of the above parameters are part of traditionally monitored downhole drilling
data. Figures 2 and 3 show the plot of mechanical specific energy, calculated from the
aforementioned parameters and displayed along with the other downhole parameters such
depends on the compressive strength of the formation. Teale showed through lab
experimental data that this Mechanical Specific Energy was numerically very close to the
compare the MSE levels, and thus determine where the drilling operation stands in terms
of efficiency.
However, field results of MSE are quite different from the actual compressive
strength, since the rock strength is greater at the rock-bit interface. The apparent increase
in rock strength observed results from a pressure differential between the borehole
pressure and the formation fluid pressure. Hence, the observed MSE levels may not be
A better way to compare the MSE levels, as presented in this study, would be to
first determine the optimum MSE levels for a formation. This can be done by first
calculating the maximum possible rate of penetration for a formation, and then using the
7
Figure 2: MSE Plot against Depth
8
Figure 3: MSE Plot against Depth
9
RATE OF PENETRATION MODEL
In addition to formation strength, both the cuttings generation process and the
cuttings removal process limit the rate of penetration of roller cone bits. Warren[10]
developed a model to estimate the rate of penetration of roller cone bits in soft
formations, taking into consideration the effect of cuttings that may impede the drilling
process. The model describes the key parameters that control the rate of penetration.
Warren initially developed a model in which the impact of cuttings removal is not
taken into consideration. Based on laboratory tests in which perfect hole cleaning
situations were assumed led to the development of the following model to estimate the
In the above model, the first term defines the maximum rate at which the rock is
ground by the bit, assuming that the weight on bit is evenly distributed among the cutter
teeth, and independent of the depth of cut. The second term modifies the predictions to
account for the distribution of the weight on bit to additional cutter teeth, when more and
more weight is applied on the bit to penetrate deeper into the rock.
10
Using dimensional analysis techniques, the above model was then extended to
match field experimental data for rates of penetration. Mud properties and modified
impact force were included into this model. The resultant model, called the Imperfect-
The term Fjm modifies the impact force from the drilling fluid, which has been
adjusted for nozzle-size effects and for the influence of the return flow.
11
ESTIMATING BASELINE MSE LEVEL
Now that the model for estimating the rate of penetration has been identified, the
next step is to calculate the baseline MSE level for a particular formation. This is done by
incorporating the calculated ROP into the MSE model and the other parameters are the
MSEest =
where, RPM is the bit rotary speed, WOB is the weight on bit, D is the diameter
of the borehole and ROPest is the estimated rate of penetration, computed using
12
CHAPTER III: ESTIMATING BIT WEAR
INTRODUCTION
The primary use of the specific energy concept has been to serve as a performance
indicator of the drilling program. Teale defined specific energy as the energy required to
remove a unit volume of rock. The ‘energy’ here refers to the sum total of all effort
provided to the bit in order to drill and cut rock. The energy that is dissipated into the
unbroken rock surrounding the borehole, the energy lost in re-grinding the cuttings, the
frictional losses, etc. also come into play. Since the energy associated with removing a
unit volume of rock depends on the type of formation, every bit type has its unique MSE
signature associated with a specific formation. MSE has thus been used successfully as an
associated specific energy could thus serve as a criterion for bit selection. The wear rate
of bits is clearly associated with the specific energy of the formation and this relationship
is used in this study to derive a model that can be applied in real time to monitor the wear
13
ESTIMATING BIT WEAR
The relationship between the forces acting on the drilling cutter and the associated
specific energy has been discussed by Dagrain and Tshibangu[1]. The total force acting on
a cutter can be divided into two groups of components, namely the cutting force Fc and
the contact frictional force Ff. The frictional force acts at the interface of the cutter wear
flat and the rock and is directly proportional to the frictional contact at this interface.
The total cutting force is split into its vertical and horizontal components Fv and
the vertical and horizontal components can be expressed by the following relations:
Fh = ζε (wd + + αtd2)
where,
ε is the intrinsic specific energy and is defined as the energy needed to cut a unit
volume of rock;
ζ is the ratio of the vertical and horizontal components of the cutting force.
Numerically, it is equal to the friction co-efficient on the cutting face. Its value is
given by:
ζ = arctan(θ + ψ);
where θ is the back rake angle and ψ is the inclination of the cutting force to the
15
Figure 5: Rectangular cutter profiles - the U profile, L
profile and the slab profile[2]
The relationship between the horizontal component of the cutting forces and the
The drilling strength S, defined as the vertical component of the drilling force per
16
Figure 6: Theoretical E-S diagram for the 3D model[2]
As defined by Dagrain, the cutting point corresponds to the pure cutting process
and ε is its corresponding specific energy. Cutting point is defined as the intersection of
the cutting line and the friction line. In Figure 4, the cutting line is the line passing
through the cutting point and origin, friction line is the locus which characterizes the
friction process.
In terms of the rate of penetration, Ngoie[3] expressed the relationship between the
17
The above relationship suggests that the drilling rate is dependent on only the bit
speed, specifically after the cutter penetration results from applied weight. This
relationship holds good as long as the bit is new and bit wear is not taken into
consideration.
Now, the relationship between the specific energy, drilling torque applied, weight
Teale[4]:
MSE =
Where MSE stands for the Mechanical Specific Energy, RPM is the bit rotating
speed in rotations per minute, D is the diameter of the borehole, WOB is the weight on
The above equation suggests that for a particular bit operating in a given
formation, the specific energy would remain constant if the formation were the same.
This consistency occurs because any change in the torque, bit speed or weight on bit
would influence the rate of penetration, thus maintaining a balance of the total energy
involved. However, field observations show that the specific energy varies not only as a
function of the compressive strength of the formation but also with the condition of the
bit. Factors such as bit balling, bottom hole balling, drilling hydraulics, etc., significantly
order to rule out the possibility of bit wear as a factor contributing towards high specific
energy levels, an analytical relationship between the condition of the bit and the wear rate
18
should be obtained. This is done by relating the forces acting on the bit and the specific
energy level involved. Therefore, relating the expression for depth of cut, horizontal force
acting on the bit and the specific energy level involved, an expression for bit wear rate is
given below:
The term λ represents the wear flat rate and‘d’ is the depth of cut per revolution.
Thus, the term (λ/d) quantifies the wear rate with every depth of cut that the cutter makes.
19
Chapter III: Discussion and Conclusions
In this study, a model has been presented to estimate a baseline for MSE
levels for specific formations. This baseline can be used to compare the real-time MSE
levels observed in the field during drilling operations, which enables the operators to
gauge the efficiency of the drilling process. In cases where the drilling process is sub-
optimal, deployment of the model enables one to justify potential design changes are to
The second model, which estimates bit wear uses principles of the specific energy
concept to monitor the wear rate of drilling bits in a given formation. Deployment of this
model in real-time enables engineers to identify whether bit wear is a cause of drilling
dysfunction and if so, eliminate one of the factors that contributes to the slump in the
drill-off curve. Additionally, bit failure can be detected, and thus, justifying pull out of
hole for bit change operations. Analysis of several bit types in their corresponding
formations drilled can throw light on identifying which bit is best suited for a given
formation. All of the aforementioned benefits also result in considerably lowering total
drilling time, total down time due to bit related problems and thus, a reduction in total rig
time. This in turn results in significant monetary benefits to the operator, in addition to
All of the data needed in order to implement the above model consists of
traditionally monitored downhole data; consequently, there is no need for any additional
sensors or equipment to deploy this model. This is turn means that without any additional
20
costs, the operators have a tool that to identify the efficiency of the drilling program,
eliminate bit wear as a drilling limiter and also throw light on bit selection principles
The bit wear model, however, focuses only on mechanical specific energy but the
that hole-cleaning and hydraulics would reduce the wear rate of bits, thus bringing down
the estimated value of wear rate. Future work could focus on incorporating the impact of
hydraulics into the model. By comparing the actual wear of bits with the estimated
values, a correlation can be arrived at which factors the effect of hole-cleaning and
hydraulics.
21
References
1. Dupriest, F.E. and W. Koederitz, Maximizing Drill Rates with Real-Time
Surveillance of Mechanical Specific Energy, in SPE/IADC Drilling Conference.
2005, SPE: Amsterdam, The Netherlands.
2. Dagrain, F. and J.P. Tshibangu, Use of the D3 Model for the Estimation of Forces
Acting on a Cutter in Rock Cutting and Drilling, in SPE/ISRM Rock Mechanics
Conference. 2002, Society of Petroleum Engineers: Irving, Texas.
4. Teale, R., The Concept of Specific Energy in Rock Drilling. Int. J. Rock Mech.
Min. Sci., 1965. 2(1965): p. 57-73.
5. Rabia, H., Specific Energy as a Criterion for Drill Performance Prediction. Int. J.
Rock Mech. Min. Sci. & Geomech. Abstr., 1982. 19: p. 39 to 42.
6. Dupriest, F.E., J.W. Witt, and S.M. Remmert, Maximizing ROP With Real-Time
Analysis of Digital Data and MSE, in International Petroleum Technology
Conference. 2005: Doha, Qatar.
8. Waughman, R.J., J.V. Kenner, and R.A. Moore, Real-Time Specific Energy
Monitoring Reveals Drilling Inefficiency and Enhances the Understanding of
When to Pull Worn PDC Bits, in IADC/SPE Drilling Conference. 2002,
SPE/IADC: Dallas, Texas.
9. Rabia, H., M. Farrelly, and M.V. Barr, A New Approach to Drill Bit Selection, in
SPE European Petroleum Conference. 1986: London.
10. Warren, T.M., Penetration-Rate Performance of Roller Cone Bits. SPE Drilling
Engineering, 1987(1987): p. 9-18.
22
12. Guerrero, C.A. and B.J. Kull, Deployment of an SeROP Predictor Tool for Real-
Time Bit Optimization, in SPE/IADC Drilling Conference. 2007, SPE/IADC:
Amsterdam, The Netherlands.
14. Caicedo, H.U., W.M. Calhoun, and R.T. Ewy, Unique ROP Predictor Using Bit-
Specific Coefficient of Sliding Friction and Mechanical Efficiency as a Function
of Compressive Strength Impacts Drilling Performance, in SPE/IADC Drilling
Conference. 2005, SPE/IADC: Amsterdam, The Netherlands.
15. Curry, D., et al., Technical Limit Specific Energy - An Index to Facilitate Drilling
Performance Evaluation, in SPE/IADC Drilling Conference. 2005, SPE/IADC:
Amsterdam, The Netherlands.
16. Farrelly, M. and H. Rabia, Bit Performance and Selection. SPE/IADC Drilling
Conference, 1987: p. 987-996.
17. G.McLaren, et al., Improving the Value of Real-Time Drilling Data to Aid
Collaboration, Drilling Optimization, and Decision Making, in SPE Annual
Technical Conference and Exhibition. 2007, SPE: Anaheim, California.
18. Judzis, A., et al., Optimization of Deep Drilling Performance: Benchmark Testing
Drives ROP Improvements for Bits and Drilling Fluids, in SPE. 2007:
Amsterdam, The Netherlands.
19. Macini, P., et al., How Minimum Interval Concept Can Improve Bit Performance
Evaluation, in IADC/SPE Asia Pacific Drilling Technology Conference and
Exhibition. 2006: Bangkok, Thailand.
20. Perrin, V.P., G. Mensa-Wilmot, and W.L. Alexander, Drilling Index - A New
Approach to Bit Performance Evaluation, in SPE/IADC Drilling Conference.
1997, SPE/IADC: Amsterdam, The Netherlands.
21. Roberts, T.S., A.E. Schen, and J.L. Wise, Optimization of PDC Drill Bit
Performance Utilizing High-Speed, Real-Time Downhole Data Acquired Under a
Cooperative Research and Development Agreement, in SPE/IADC Drilling
Conference. 2005, SPE/IADC: Amsterdam, The Netherlands.
22. Robinson, L.H. and M.S. Ramsey, Are You Drilling Optimized or Are You
Spinning Your Wheels?, in AADE National Drilling Conference, "Drilling
Technology - The Next 100 Years". 2001, AADE: Houston, Texas.
23
23. Rabia, H., Specific Energy as a Criterion for Bit Selection. SPE, 1985.
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Vita
Aravind Suresh Kumar was born on the 14th of September, 1983 in Coimbatore,
India; the son of Suresh Kumar and Renuka Devi. He attended Sri Krishna College of
Engineering and Technology (2001-2005) and the University of Texas at Austin (2007-
2009). He has a Bachelor of Science in the field of Mechanical Engineering and a Master
The author worked with Cognizant Technology Solutions (2005-2006) and with
Ramanathapuram,
Coimbatore – 641045,
25