Effect of Bit Hydraulic Horsepower

on the Drilling Rate of a

Polycrystalline Diamond Compact Bit
Jesse L. Holster, SPE, EXWI pti”.tion Research co

Robert J. KIpp, EWII Prodmio” R~~x~h co.

Summary .._.
A laboratory drilling program was conducted to mcaame on the driiling rate achieved with a jet-nozzled PDC bk
the effect of bit hydmulic horsepower on the drilling rate while three rock types were drilled with both oil- snd
obtained with a polycrystalline diamond compact (PDC) water-based driffing fluids.
bit. Drilling tests were conducted under simulated
downhole condkions with an 8 I%-in. [21.59-cm] diameter PDC Bit Hydrarrtics-Backgrormd
PDC bit fitted with four sets of five equal-sized nom,lea.
Field tests of early PDC bit designs demonstrated that
Mancos shale, P]erre shale, and Berea sandstone were
aftbough the bita could drill ve~ effectively in evapakea,
drilled with both water- and oil-based drilling fluids to
they were very prone to bit bslling in shales when water-
determine the interactions among bit hydraulics, rock
bsaed drilfing fluids were used. 1 In general, retirements
characteristics, and the drifling fluid. For the rsnge of
to these early bits have proved very successful in the North
drilling conditions and rocks examined, the results iZl- Sea where oil-bsae muds sre used. There the bits otlen
dicated that bit hydraulic horsepower hsd a significant in-
have been driven by mud-powered downhole drilling
fluence on the drilfing rate. The degree to which drilling
motors. The Isrge totsl flow areas (TFA) characteristic
rate was affected by bk hydraulic horsepower was depen-
of these bits have kept the pressure drops across the bit
dent on the rock/drilling-fluid combination.
down to an acceptable level for dowrrbole motor opera-
tion, whereas the oil-based muds apparently have been
Introduction inhibiting the balling tendency caused by the active clays
in the shale formations. Failure of these bita to drill shales
Proper hydraulic design for effective cleaning and cool- with water-based mud spurred a series of research pro-
ing of PDC bits bas been recognized as a major factor grams designed to improve bit cleaning. These programs
in their successful application since these bha were in- could be divided into two groups: (1) laboratory tests
troduced. Historically, there have been two approaches aimed at improved cleaning by optimization of cutter
to the hydraulic design of PDC bits: (1) natural dmond- orientation and (2) laboratory and field studies of metlmds
bit flow-distribution systems (water courses with large to enhance cleaning by increasing the flow distribution
total flow areaa) and (2) high-velocity jet nozzles. Both to the cutters.
types have been used with varying degrees of success but Cheatham and Daniels conducted single-cutter ex-
often for unrecognized reaaona. The water-coune-type periments to evsluate the effects of ahsle properties, drii-
hydrati]c designs were characteristic of most early matrix- ing fluid pressures, and cutter configurations on thel
bodled PDC bits. NozzIcd bks evolved from the steel-
drilling of shales. 2 Their work showed that a small
bodkd bka with stud-mounted cutters, aftfrough nzatrix- negative rake angle reduced cutter clogging. Studies by
bodicd bits are now available with jet nozzles. Melaugh and Ssfzer and Iater by Huang and Iveraen tir-
An increasing number of commercial PDC bits are ther examined the effects of side rake m well as+ back
becoming available with interchangeable nozzles, pro- rake. 3,4 They found that the mechanical cleaning action
viding the flexibility of rig-site hydraulics optimization. of the PDC cutter with side rake reduced the tendency
Whh these interchangeable nozzles, the hydraulic energy of formation chips to stick to the cutting surface.
(or power) of the drilling fluid that is dissipated across The other approach to improve the cleaning of PDC
the bit face cm bc adjusted to match that portion of the bits haa involved fluid mechanics more duectly and has
rig’s hydraulic power that is availsble for the bk after other yielded some very interesting concepts. These hydraulic
system losses have been considered. concepts included simple feeder-collector systems, flow
Unfortunately, the benefit in increased drilliig rate that restrictora or baffles, fixed-jet nozzlca, interchangeable
can be expected by an optimization of bk hydraulic jet nozzles, rectangular nozzles, narrow slita for fluid
horsepower has yet to bc adequately defied quantitatively discharge, and even one-on-one correlation of nozzles to
for PDC bits. The objective of our work was to deter- cutters. 5 Baker reported a unique design to enhance the
mine experimentally the effect of bit hyrksufic horae~wer crossflow beneath a PDC bk by using flow reatdctors that
extended more than half the dktance to the hole bottom
as compared to cutter stand-off or exposure. 6 AII im-
0149.2i S6/84/0721 .7 94S$00 .25
copyright 19S4 ScdeW of Pelrdeum Englnem d AIME provement on tlis concept that allegedly reduced erosion

2110 JOURNAL OF PETROLEUM TECHNOLOGY

 TABLE 1—MECHANICAL AND PHYSICAL PROPERTIES

OF ROCKS DRILLED

Confined+

Compressive Bulk Grain

Strength Densi Densi Pornsny Permeability

Y Y
(psi) (g/cm ) (g/cm ) (%) (darcyj

Mancos shale 15,180 2,55 2.72 S.3 <1o-

2.35 3.0 30.0 -,0-9

Pierre shale S90

Berea sandstone 1S,800 2.17 2.67 20.2 0.404

.Cmtining p,.,, ”,, was 2,000 psi

of thesteel-bit body was repnned by Kuhn and Forrest.7 nozzled bits in drifh broken formations because of less
Knowlton and Humzg investigated the perfornrzoce of bits plugging.’2 -
with rectangukwn ozzleflowweas.s Thelongsxczofthe A literature review revezls that very little has been
rectangular fluid ports were aligned tangentially on the published concerning the specific level of bh hydraulic
hit face. In theory, thk nozzle design produced a flow enerw .,, or horsepower that is needed to maximize drifl-
envelope that matched the reverse spiral row nrmngement ing rates. Pzrk ~eports that a hydraulics energy level of
of PDC cutters and simultaneously reduced the potential 2 to 3 hhp/sq in. [1.5 to 2 kW/cm2] provides improved
for nozzle plugging. Perforrmmce data collected with these cleaning and cooling of PDC bhs. 13 Radtke’s analysis of
nozzles showed some positive correlation between bh field data obtzined with water-bsaed muds suggests tit
hydraulic horsepower, which they attributed to better bit there is an optimnl range nf bit hydraulic horsepower thnt
cleaning. is dependent on bit dismeter.’4 Rndtke recommends a
Of all the innovations in hydraulic design features, minimum of 2.7 hhp/sq in. [0.312 kW/cm2] for 6-in.
perhaps the simplest and most versatile concept is the in- [15.24-cm] bits and up to 5.0 hhp/sq in. [0.578 kW/cm2]
terchangcablejet nozzle. The PDCisessentially a drag for 17%-in. [44.45-cm] bits.
bit, failing the rock in shear. Work done by Humble Oil To optimize hydra~lcs with interchrmgeable jet nozzles,
and Refining Co. in the 1940’s demonstrated that jet more definitive knowledge is required of the effects of
nozzIes significantly zffectcd the drilling rstes of drag drilling tloid type, rock type, and bk hydratilc horsepower
bks.9,10 That resenrch discredks my theory that jet on the drilliig response of PDC bks. Interactions between
nozzles enhance oRIy roller-cone bits. By using jet the mechnnica.1 power applied to the bit and the hydratilc
nozzles, high-velocity liquid jets can be made to impact power at the bit also must be accounted for. The results
the rock face nnd create a high level of turbulence, which of our experimental program should heIp bridge that gap

assists in removal of cuttings from beneath the bk. Since in knowledge.

the nozzles in PDC bks are much closer to the rock face
thzn are the nozzles in a rOUer-cOne bit, more nozzles are Experimental Program

used to dktribute tbe flow. An experimental study was designed and conducted to
Glowkz used flow visusliition techniques to study the determine the effect of bit hydraulic horsepower on the
effcctof nozzle pkrcemcnt, nozzle nnmber, and bitrotn- drilling rate obtained with a PDC bit in three rock types
tion on the flow distribution beneatb a sted-bndied bit with and two drilling muds. All &Ning tssts were perfomzed
~t”d.mo”ntedpDCcuaeB.ll He fonndthat thetloiv pat- at the Drilling Research Laboratory in Szlt Lake City, UT.
terns beneath thebit znd cooliig characteristics of the cut- A complete description of the test facility is given in
ters could be zdtered simificantly . by. variations in nozzle Ref. 15.
placement.
The early prototypea of thejet-nozzled bits suffered Bit. A standzrd production model PDC bh with five in-
from severe erosion of the steel body from splash-back terchangeable nozzles wsz purchased for the tests. The
caused bv the close moximitv
. . of the bit face to the rock steel-bodied, 8%-in. [21 .59-cm] diameter bit had 39 stid-
surface. Development of a spray-on, hard-facing surface mountcd PDC crrttwz distributed over the bh face and hsd
materiaJ and improved nozzle retniners have reduced the a relatively flat, shallow-cone proiile. Four sets of noz-
erosion problem. zle sizez were used in the experiment; nozzle sizes tested
Proponents of the jet-nozzed bk use the nrgument that were ~z, ~Z, ~%~, and l%~in. [635, 7.14,7.94, nnd 8.73
the high-velncity jets enhance bit cleaning in shales znd mm] in diameter. Five equal-sized nozzles were used in
consequently expznd the range of formations that can be each test.
drilled with common water-based drilfing fluids. Pro-
ponents of the feeder-collector hydranfic systems point Rocks. Three rock types were used in the program so that
out that the probability for nozzle plugging is increased any effectz of mudhock interactions could be determzimed.
with PDC bhs because of the necessarily smaller diameter The rock samples drilfed were 15% in. [39.37 cm] in
jets in the jet-nozzled bits. (This problem is minimized diameter and 3 ft [0.914 m] long. The rncks drilled were
by the use of drilipipc screens.) One recent study sug- Marzcos shale, Pierre shale, and Berea sandstone. The
gests that the jet-nozzled PDC bits deliver higher rates measured mechanical properties of these rockz are listed
of penetration (ROP) in homogeneous fomzz.tions, while in Table 1. The sandstone was permeabl~ “hence, all
the feeder-collector hydranlic designs are better thzn the samples drilled were presaturated with water, and a pore

DECEMBER 19S4 2111

 TABLE 2–DRILLING FLUID PROPERTIES

Water-Based Oil-Based TABLE 3–DOWNHOLE CONDITIONS SIMULATEO (psi)

Mud Mud

Wellbore Overburden Confining Pore

Weight, Ibm/gal 10,0 * 0.2 10. O*O.I
Pressure Streaa Stress Pressure
Plastic viscosity, cp 15*2 14*1

Yield point, lbf/100 sq ft 7*2 7*1 Mancos shale 2,000 4,400 2,900 0
PH 10.0*1 — Pierre shale 2,000 2,350 2,250 0
API fNtration, cm3 7*0.5 7*1 Berea sandatone 2,000 2,275 2,500 1,700

For each test, the prepared rock sample was Iowercd

MANCOS SHALE into the pressure vessel (wellbore simufator) along with
310 GPM
0 the bit, drillstem, welfhore rotary seal, and pressure vessel
120 RPM
3.4S HSI
0 cap. The cap then was tightened to seul the vessel. The
o
WATER-BASE MUD drifl rig was positioned over the wellbore simulator, and
the drill shaft was. attached to the rotary drive shaft. Then
ROP = 0,0394 W0B0736
hydraulic connections were made, amd contining pressure
o
and overburden streses were applied to the rock.
./’/
Downhole conditions simulated with each rock type are
given in Table 3.
After mud circulation was established, the bit was

1 drilled gently a few inches into the rock to establish a bot-

oo- tomhole pattern before data were recorded. Then mud cir-
14 culation rate was increased to the value desired for the
WOB, 1000 LBF
first series of drilfing conditions. By adjuating a
backpressure choke in the flowline, the borehole pressure
Fig. 1 —Data repeatability.
was maintained at 2,000 psi [13.79 MPa]. Rotary speed
was set at 120 rev/rein [2 rev/s] throughout the tests ex-
cept where noted. Tbe desired WOB then was applied until
pressure 300 psi [2.068 MPa] Iess than the wellbore the drill@ rate appeared to stabilize. Data recorded in-
pressure was maintained during the drilling tests to cluded WOB, rotary speed, flow rate, bit pressure drop,
simuf ate an overbalanced drilliig condition. borehole pressure, torque, mud temperature, and rate of
penetration (ROP).
Drifling Fluids. The drilling fluids used in rhe tests were
Armfysis of Results
a 10-lbm/gal [1 198-kg/m 3] bentonite/lignosulfonate
water-based mud rmd a lCHbm/gaJ [1198-kg/m3] relzxed- The first core of Mmrcos shafe was drilled for the single
tilrrate oil-based mud. The muds were designed such that propose of obtaining an estimate of the repeatability Of

the commonly measured properties (density, plastic the measured drilling rates. After setting the circulation

viscosity, yield point, and filtration) were approximately rate, environment parameters, and rotary speed to 120

equal between the two mud types. These properties were rev/rein [2 rev/s], &ta were collected by alternating the

measured before and after each drilling test by following WOB from about 6,0C0 to 11,000 lbf [26.69 to48.93 kN1.

API recommended practice (API RP 13B). The low- Five data points were coflect.d at each of these WOB

temperature test procedure was used to meaaure the titrat- levels. The resufting scatter in the data is presented in

ion characteristics of both muds, rather than using the Fig. 1. Since the WOB levels were not all exactfy 6,000

higktemperature/high-pressure (HT/HP) test procedure or 11,000 lbf [26.69 to 48.93 kN], the scatter in the data
more commonly reported for oil-based muds. Building was quantified statistically by regression analysis. A lcast-

the muds to produce similar properties provided a com- sqmues tit of the power law model (ROP=a WOBb)

mon basis of comparison. Consequently, the muds were yieldeda better tit than did a linear model. The staodard

not necessarily representative of typical field muds. The error calculated from the residuals of the regression was

propetiies of the muds fluctuated during the tests; the found to be ?i2.05 ft/hr [0. 173 mm/s], or approximately

ranges for each mud’s properties are listed in Table 2. +9% of the calculated mean drifling ROP at 6,000 Ibf
[26.69 kN] and A5.5% at 11,000 Ibf [48.93 kN] WOB.

Test Procedure. Each of the 3 ft [0.914 m] long rock Since drilling in the laboratory was expensive, very few

samples tested waa capped with metaf plates. The top plate repeat points were coUected during the remaining tests

had an opening to allow the bit to pass through and con- and it was assumed .tha.t this computed standard error of

tact the rock. The lower plate had an orifice through which dre ROP data was representative of afl drilling testa con-

the pressure control line for pore pressure maintenance ducted.

was attached. (Pore pressure was maintained at a fixed

Mmrcos Shale. At each measured flow rate, Q, and
level only with the permeable sandstone samples.) The
pressure drop. across the bit, Ap, the bit hydraufic
top and bottom plates were held in contact with the rock
horsepower (PH) was calculated from the equation
by steel rods that extended axially along the perimeter of
QAP
the samples. A rubber sleeve was wrapped tightly around
PH= =4, . . . (1)
the sample to sgal out the confining fluid.

2112 JOURNAL OF PETROLEUM TECHNOLOGY

 MANCOS SHALE

I
120 RPM

70 WATER-BASE MuD

o
60
60 L
16,000 LBf WOB

E D
= ●
9000 LBf wOB

; 50 {;%O
●

$
m
~ 40
A .+

& p
o
3000 LB! WOB
~
~ 30 0

o
~ *

D
A

20

&o
NOZZLE DIAMETER
O 8/32 IN.

‘
10
‘/

Q
O

0
8/32

9/32

10/32
IN.

IN,

IN.
30
L ~
❑

i
9/32

70/32

11/32
IN.

IN,

IN.
.y
Q 11/321N,

oo~ 0
n 7
I
a
I

6
I

8
I
10

BIT HYDRAULIC HORSE POWER, 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) of constant volumetric flow rates with Ql<Q2
was calculated from 4P ff/d2, where d is the bit <Q3<QJ. Over dremiddle range Of WOB levels (or
diameter in inches, Q the volume flow rate in gallons per normal operating conditions) these lines indicate that ROP
minute, and. Ap the bb pressure rhop in psi. is affected more by Q than by hydrafllc power. The order-
The rkiiling re$ponses to HSI at five WOB levels are ing of the curves farther suggests that for this particular
shown in Figs. 2a and 2b for the water-based mud driil- rock and mud combination, the most effective way to rrw.x-
ing of the Mancos shale. Least-squares curve tits of these imize ROPisto maximize Qratber than HSI. (Nosimilac
data were obtained with a power Iaw model and atso are ordering of Iincs of constantQ was Obsemed with the
shown for the five WOB levels. The data show that the water-based mud data.)
bit hydraulic horsepower has a significant effect on the In Fig. 4, the curve fits of the drilling responses toHSI
&Llling rate at all WOB levels. As the blt hydraulic at five WOB levels have been plotted to compare the
horsepower increases above about 5 hhplsq in. [0.578 responses in water and oil muds. The data reveal that the
kW/cm2], the sensitivity to bit hydraulic horsepower oil-based mud is the better drilling fluid (for ROP) at low
decreases, a characteristic also common to roller-cone bithydrardic horsepower levels, while the water-based
bits. 16 mud appears to be the better drilling fluid at higher
Examination of the resrits obtained while this shale was hydraulic horsepower levels. Examination of tie.tit
drilled with the oil-based mud revealed a drilling response following the drilling teats in the water-based mud showed
quite different from that observed in the water-based mud. some balhng of the cutters in the recessed center area of
The effect. of HSI on ROP during the drilling of Mancos the bit. There was essentially no balliig of these cutters
shale with the oil-based mud is shown in Figs. 3a and 3b. when the oil-based mud was used, even at Iow hydraulic
Again, data are presented for five WOB levels. Leaat- power levels.
squares linear fits of these data are shown also. These Further examination of tbe oil- and water-based mud
curves show only a very slight response to bit HSI at all data for Mancos shake showed that the hydradic
five WOR levels. In fact, the data suggest that the HSI horsepower level at which the two mud8 promoted
has a negative influence on the drilling rate at 9,000 lbf equivalent dr~]ng rates was dependent on the WOB (or
[40.03 kN] WOB. The dashed curves represent the locus mechanical power) applied. The dashed curve passes

DECEMBER 1984 2113

 a
80,
I I I I

MfiNCOS SHALE Q, -225 GPM

120 RPM Q> = 290 GPM

r--+---
.1
70 OILBASE MuD Q~ = 358 GPM ‘0
Q = 410 GPM MANCOS SHALE 0, = 225 GPM

120 RPM 02 = 290 GPM

OIL.BASE MUD C!3=3539PM

60
m – Q Q.I - 41OGPM

a t
- ‘-- 16,000 LBf WOB

5
g

$
~ ,0 $t$-~’:~..- -- 9000 LBfwOB

o ‘1-!. . ---
0. -Q
& “0’$ >.,
‘O-Qz

\
8
: 30 —

#?_____ y:’’f”:u

-~Q2 O 81321N,
- Qs
---- ❑ 91321N.
0

I
10
:: .s
0 8/32 IN. 0 10/321N.

❑ NOZZLE ❑ 9/32 IN. A 11(321N.

DIAMETER O ,0{32 IN.

0 I I I
A 111321N.

I
oo~
0 6
B?T HYDRA~LIC HORSEPOWER, H% BIT HYDRAULIC HORSEPOWER, HSI

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

—
through the five’ ‘hydraulic tiesholds, ” which represent
MANCOS
SHALE the hydraulic horsepower levels required to make the drill-
WATER.
BASE
MUD ing rate in the water-based mud equal to that achievable

1
70 -—- 01L-8ASE MUD in the oil-based mud.
-.0-- HYDRAULIC THRESHOLD

80 Pierre Shale. If the hit balling had indeed degraded the

drilling mte in Mancos shale with the water-based mud
at low HSI levels, the effect should be further exaggerated
50 in a gumbo or sticky shale. Mancos shale is a brittle shale,
-?~;z
essentially free of the problem clays such as mont-
-—
morillonite. To examine the effect of bit hydraulic

40 _ horsepower in a more troublesome shale, Pierre shale

“L
, 9~B’%0 B
samples were drilled. Shales are considered troublesome
-6
/
if they contain water-sensitive ckiys (montmorilIonites and

30 — —__—_—- illites) tiat undergo hydration when placed in contact with

, eooOwvtoB water (drilling fluid filtrate). Clay mineralogists and mud
engineers often measure the shale’s hydration chamcter-
1’

20 I
istics in terms of itz specific surface area. Specific sur-
--
face is the total surface area of a known mass (weight)
1! /---
-/- of the dispersed shale (clay platelets included) and
- 13000 LB’ WOB measured in square meters per gram. The magnitude of
10

the specific surface area of a shale has been shown to be

/
a good idcator of its tendency to hydrate and swell. 17
F

oo~ Table 4 presents the relative’ ‘hydratability” of Mancos,

Pierre, and Cook Mountain shales, along with pure
BIT HY:RAULIC4HORSE P:WER, H:l
Wyoming bentonite (sodium montmorillonite)-the
Fig. 4—Bit hydraulic threshold in Mancos shale. ultimate hydratr.ble clay.

2114 JOURNAL OF PETROLEUM TECHNOLOGY

 Im

fi2WIE
SINE FiESRE
WATER4ASE
SNP.LE
MUD
01 L8P.SE MUD 7T
m RPM 0 124 RPM
0 Em la won

❑ NOD.LE WOB !26)

lm -

Y
0
ol.6Mrrrs aw2 WI

W21N. ● 0
OD s/S21N. = .
1!

mo
❑ -
0

0
0

m
m on LB won
~

.
m o
0
~ .0

~y NOZZLE
DW4mM

0 mm.
10
D Smm.
o Iom m.
a Ilnr w

BIT HYDRAULIC HORSEPOWER . HSI

Fig. 6—Response to bit hydraulic power in water-based mud,

pierre shale,

sensitive to bit hydratilc horsepower. This difference can

be partially explained by the relative rock smengths; Pierre
shale has only about one-fifteenth the compressive strength
of Mnncos shale.
The drilling data obtained with thewater-based mud
.~ were very erratic and often unrepeatable. Below about
2 4 6 8
5 hhp/sq in. [0.578 kW/cm2], the bit would hardly drill
BK WDR4UUC HOR2EPOW2!I H24
because of bit baoing. The data indicated that increming
hit hydraulics to greater than5 hhp/sq in. [0.578
Fig. 5-Response to bit hydraulic power in oil-based mud,
kW/cm2] was detlnitely beneficial. Thk improvement
Pierre shale.
should not be viewed as “the solution” to drilling soft,
gumbo-type argillaceous shales with uninhibhive water-
based muds, however. The arrows on the data points in

TABLE 4—RELATIVE HYDRATABILITY

Fig. 6indicate that thedrilliig rates were continually
(SPECIFIC SURFACE) OF SHALES (mZ/g) changing nmdgenemdly decreasing. These ch6nging rates
suggeatedtlmttke bit was beginning to ball up. Onlya
Mancos 69
few inches of rock were drilled to obtain each measure-
Pierre 201

21 i
ment. Hence, if bnlling were happening that fa.s tinthe
Cook Mt. (gulf coast)

Wyoming bentonite Slo laboratory, then surely it would happen in the field where
Iarge footages are drilled.
Fig. 7 shows a direct comparison of tie ROP responses
to HSI in oil- and water-b6sed muds for Pierre shale. The
Drilling &m obtnined from drilling the Pierre shale oil mud was ifilbiting the shale cuttings from sticking
samples in the oil- and water-based muds are shown in tothemseh?am dtothebit, thereby producing drilling
Figs. 5 and 6, respectively. For the oil-based mud, data rates much .sgater than those produced in the water-baaed
areshown at2,000, 4,0QOand 6,0001bf[8.896, 17.79, mud. Urdiie the more stable (less hydratable) Mancos
and 26.69 MYI WOB. For the water-based mud, fewer shale, inthe Pierre shale there does not appear to bea
dntx were collected and Fig. 6 shows the ROP response reIiabIe hydraofic threshoId at which the water-bawd mud
to HSI at 2,000 and 4,LXM lbf [8.896 and 17.79 kNl WOB. drills as effectively aa the oil-based mud. At the very ex-
Examination of Fig. 5 reveals that bit hydratiic treme HSI levels examined, there issome evidence that
horsepower very significantly affects the drilling rats with bit hydraulic horsepower (or energy) was becoming more
theoil-based mud. This isincontraat totheresuksob- effective in cleaning the bit with the water-based mud.
tained in the Mancos shale, where dril~mg was very in- However, theunsteady drilhgrates measurtdsuggcat

2115
DECEMBER 19S4
 PIERRE WMLE
120 RPM
4000 LB WOB

NOG!LE O~~;SE Wkl#3ASE

!MM EIER

VU NL . .“
sr32 w . ❑

1$732 IN, . .
11/32 IN, . .

. .
.

. .
.

.
. . .
. 0

l.: “ .

:L
Fig. 7—Drilling
2
sri

rates
HYDRAUUC

with
4

oil-
HORSWOWES.

and
6

water-bssed
HSI

muds, Pierre Fig.

:,U
9—Effect
2

of
SIT HYDRWLIC

hydraulic
4

power
HORSEPOWER

in
6

water.ixsed
HSI
8

mud, Bcrf

shale. sandstone.

14a that bit cleaning and high drilling rates cordd not bes
SESLh. SANDSTONE Wined. More imports.ntly, a bit hydraulic horsepower le
OIL%ASE MUD of 8 to 10 hhplsq in. [0.925 to 1.156 kW/cm2] is )
120 RPM
practicaI for many field applications
ml -

0 Berea Sandstone. A chemically inert rock (Berea 6an

stone) also was drilled to essentially eliiinatc c1
.
chemistry as a factor. The results sre shown in Figs.
lm - ~o.
and 9. Data are presented for three WOB levels (3,00
6,000, and 9,000 Ibf [13.34, 26.69, and 40.03 kiVl) f
z
t drilling with both the Water- and oil-based muds. The RC
o responses to HSI measured witi bo$r muds 6bow a signi
cant benefit of increused bit hydraulics during tillling
.
this highly permeable sandstone. This increase may rest
from the kinetic energy of the fluid jets being convert
&m into elastic energy in the pore fluid. Since the rock
o
e highly permeable, the fluid in the pore spaces just”belc
:0
: ❑
the bit is pressurized by the impinging jets, thereby redu
% ing the effective overbakmcc and increasing the drillii
rate. A direct comparison between the driing rste in i

oil-based mud smd the water-based mud is shown in FI

10. From these data, it appears that both drilling fluids
affect ciriiing to tie same extent in the sandstone. Tbk
al

1
N00a8::p#rEs similarity might be expected since the fluid propcxlies

❑ 9/32 IN.
(viscosity, densi~, solids content, snd filtrate loss) that
o IW32 IN.
are known to affect drilling rate were approximately equal

~~ with the two muds.

BIF HYDRAULIC HORSWOWER - HSI

Comparison With Field Observations. Overall, the

Fig. 8—Effect of hydraulic power in oil-based mud, B@rea

Laboratory results are in agreement with observations

sandstone. made during field applications of PDC bits. The measured

2116 10URN.4L OF PEIXOLEUM TECHNOLOGY

 140 The water sensitivity of Pierre shale very closely
matches that of Cook Mountain shale encountered along
~EK##WTONE
the Texas gulf coast, as shown in Table 4. Early attempts
ESJI LS WOB
made to drill Cook Mountsin sbule with a PfJC bit b us-
1s0 lo ~
ing a water-based d’ifling fluid were unsuccessful.
the water-bssed mud, the blt balled up immediately snd
0
,0 would not drill. When a PDC bh was rnn later through
*
. the same formation interval with a relaxed-tlltmte, invert
lM - ● .
emulsion oil-based mud, the bit drilled 2,415 ft [736 m]
o .“ ❑ . .
. at 28.9 ft/hr [2.45 mm/s]. Whiie no data were available
g
**””
on the effect of HSI, the field results agree with the

:M laboratory tests as to the influence of the two drilling

0
o fluids. Both the laborato~ snd field dab showed that these
~

very water-sensitive shales (specific surface > 2@3 mz[g)

t .

g . cnuld not be drilled by a PDC bit with water-based muds.

gfo - Also, both the laboratory snd field dsta demonstrated that
~.
oil-based mud was very effective with a PDC bit in these
s ●
soft, sticky formations.
.
40

C0nch3si0na

The most important inference that can be drawn from thk

m -
study is that certain moderately hydratable shales that
No?2LE W-L-DSE WATEIIASE
DIAsWIIS would normalfy require sn oif-based mud for dril~mg with
8/32 IN: . . a PDC bit can be drilled more effectively with a watcr-
91W. [n . .
10/32 IN. . 0 hascd mud by using a higher bit hydraulic horsepower.
It also can be inferred that gumbo-type shales wurnot be
% 2 8
BIT HVD#AULIC HORSEPOWER. HSI drilled by a PDC with an uninfibitive water-based mud,
regardless of the bit hydraufk hocaepower used.
Fig. 10–Drilling rates with oil- and water-based muds, Berea
Analysis of the test data collected with this particuhm
sandstone.
8 M-in. [21 .59-cm] PDC bit configuration and rnck types
driiled has yielded the following more specific conclu-
sions regarding the effects of bit hydraulic horsepower
on drilling rates.
ROP”responses while drilling rhe Mnncos shale nnd Berea 1. Drilling rates were affected positively by increases
sandstone with water-based mud qualkmively match that in bh hydratilc horsepower when the stable Matrcos slwde
reported by Radtke and Pain.’4 Their results for bits in and permeable Bersn sandstone were drilled with water-
tbe 8 IA- to 8%-in. [21 .59 to 22.23-cm] size range and based mud as the drilling fluid.
of the some configuration as the laborato~ test bit sug- 2. The drilling rate showed very little response to bk
gest that the minimum for water-bnscd mud drilling shonld hydraulic horsepower whale the Manms shale was drilled
be 3.3 to 4.0 hhp/sq in. [0.381 to 0.462 kW/cm2]. Their with an oil-based mud.
anal ysis was based on 125 bit runs in the Wilcox, Mid- 3. Drilfing rates were increased significantly by in-
way, Navarro, and Taylor shales and the Ausdn and Sebna creases in bit hydraulic horsepower when the soft,
chalk along the U.S. gulf coast. Their recommended hydratable Plerrc shale and permeable Berea sandstone
minimum HSI levels are equal to or grentcr than the were drilled with oil-based mud as the drilfing fluid. In
hydraulic threshold shown in Fig. 4 and roughly match the sandstone, the ROP sensitivity to HSI decreased above
the HSI levels at which the laboratory-measured water- 5 to 6 hhp/sq in. [0.578 to 0.693 kW/cm2].
based ROP response curves begin to show a decreasing 4. Very h@ levels of bit hydraulic horsepower (> 5
sensitivity to HSI (see Figs. 2 and 10). hhp/sq in. [0.578 kW/cm2]) improved bit cleaning and
The laboratory drilling results obtained in the Mancos the drilfing rate while the soft, hydratable Pierre shnle
shale with oil-bssed mud nlso follow the same trends as was drilled with the water-bawd mud. However, incrcascd
observed in many field PDC bit applications. An amnlysis hit hydraulk horsepower nlone does not appenr to be
of PDC bh runs by Exxon Co. U.S.A. in south Texas capable of keeping a PDC bit clean during the drilliig
and reported by GOIIS I? demonstrated that in the FriO of a gumbo-type shale.
shales and sands, drilliig rate was not positively correlated 5. The inhibitive cbnracteristic nf the oiI-based mud ap-
to bh HSI when m invert emufsion oil-based mud was penrs to account for its better drilling performance com-
used. The absence of a positive correlation between ROP pared with that of water-hazed mud in driiig both sbafe$
and HSI in these field rnns matches that observed in the with relatively low bit hydmdic horsepower. In the clay-
Iaborntory drifhg of the Mancos shale with oil-based mud free (inert) sandstone, the drilling rates achieved with the
(Figs. 3a and 3b) but dries not match that observed in me two fluids were equivalent.
laboratory sandstone drilling (lIig. 10). Other south Texas By conducting a hydraulic study similnr to this one with
operators have also found it rmnecessmy to apply high other shales, a correlation could be made between shsle
levels of bit HSI when drilling the lower Wilcox shafe specific surface area and the bk hydraufic threshold for
with PDC bits and oil-based mud. 19 water-based mud application. This correlation would be

DECEMBER 1984 2117

very valuable to drilling engineers when confronted with 11. Glowka, D.: S‘Optimization of Mt Hydcudic Con figurations,” SOC.

F21. Eng. J. (Feb. 1983) 21-32.

the selection of mud type and the development of a bit
12. van Prooycn, J., l“ergens, R., and Gilbert, H. W.: “Recent Field
hydraulics program for PDC bh application.
Reds with New Bits,>, 3. Pet. Tech., Vol. 34, September 1982,
.. . .
1 Q*L66 .
Acknowledgments 13. Park, A.: ‘&Improvement of Drilling Capabilities of PDC Cutters

i“ Hard Formation,,, Fiml Report DOE/BC/I036&24, U.S. DOE,

We thank R.P, Steiger amd D.M. Rowe of the Drilling
Washingon D.C. (Augmt 1982).
Fluids Section of tke DrilIing and Completions Div., 14. Radrke, R.P. and PaiII, D. D.: ccOpdmizadon of Hydraulics for
Exxon Production Research Co., for tleir assistance in Polycrystalline Diamond Compxite Bits in Gulf Coast Shales with

this prnject by conducting the tests for the specific snr- Water-Based Muds;, J. Pet. Tech, (Oct. 1984) 1697-1702,
15. Black, A.D. a“d Chee”, S.J.: ‘laboratory SimuJatio” of Deep Well
face measurements of the MmJcos mrd Pierre shales. We
Drilling,,, Pm. E.g. Zn?[. (March 1978),
thnnk Exxon Production Research Co. for permission to 16. Tibhins, G. A., et .1.: “The Effects of Bit Hydraulics on Full-8caJe
pnblish thk paper. Laboramw Drilled Shale,” 3. Pet. Tech. (JtdY 1981)’ 1180-88.
17, Steiger, RIP.: “Fu”damerikds and Use of P&.&m/Pilymex DriU-
itg Fluids to Minimize DriJting and Compkdon Pmblerns AsseciWed
References
with Hydratabk Clays,> S J, Pet. Tech. [Aug. 1982), 34, 1661-70,
1. Fecnstra, R., lu.rgens, R., and Walker, B. H.: “New Generation 18. Golis, S, W.: “Analysis of the Inven Em.lsio. Oil Mud-
of Oil Field Bits-Laboratory and Field Test Results,,’ paper SPE Poly.ryskdline Diamond Bit System in Shallow Permeable Forma-
6712 presented at the 1977 SPE Annual Technical Conference and tion,’, paper SPE 11391 presented at the 1983 JADCISPE Drilling
Exhibhion, Drover, Oct. 9-12. Conference, New Orleans, Feb. 20-23.
2. Cheatham, J.B. Jr. and Daniels, W. H.: “A Study of Factors ln- 19. Forrest, S. and Kuhn, K.: .<Near-Perfect Combination Generates
fl.emim the Drillahilitv of Shales Sinele Cutter ExcWimenG with Record Bit Run, ” OiI & Gas J. O&reh 19, 1984), 152-53.
STRAT~PAX Drill Bid%” J. E&y Rewurce; Tech. (Sept. 20. Cowihran, J. L.: “Technology Used to Improve Drilling Perfor-
. . . . 101.1
1979) . .. . . S9-95.
.. . mance and Primary Cementin8 Success in Katy Field,” paper SPE
3. Melaugh, J,R. a“d .%lzer, J, A.: <‘Development of a Predictive 10956 presented at tie 1982 SPE 57th AnnuaJ Technical Conference
Model for Drilling Pressurized Shale with STRATAPAX Blank and Exhibition, New Orleans, Sept. 26-29.
Bits,” paper presented at the 1981 Energy Sources Technolo~ Con-
ference, Houston, Jtdnuaty 9-22.
4, Hum. H.O. and Iversen. R. E.: “The Positive Effec& of Side Rake
in Oi&ld Bits Using Polycr@line Diamond Cnmpact Cutlers,” S1 Metric Conversion Factors
paper SPE 10152 presented at the 1981 SPE Annual TechnicaJ Con-
ference and Eti!bition, San Antonio, Oct. 4-7. “API 141.5/( 131.5 +”API) = g/cm3
5. Allen, J. H.: ‘ .Dimmmd Studded Inser7 Drag Bit with SmxegicaOy-
Cp x 1.0* E-03 = Pas
Lc?wted Hydraulic Passages far Mud Motors,” U.S. Patent No.
ft X 3.048* E-01 = m
4,246,977 (1981).
6. Baker, W.: . Design Considerations for Stud-Type STRATAPAX f@ X 3.785412 E-03 = m3
Bit BJmks;’ pa~r presented at the 19S0 Energy Sources Technology in. X 2.54* E+OO = cm
Conference and Exhibition, New Orleans, March.
lbf X 4.448222 E+OO = N
7. Kuhn, K.0, and Forrest, S.: “Flow Enhancement Characterizes
lbm x 4.535924 E–01 = kg
Design of Polymystalli.. Diamond timer Bits,’. paper SPE 11062
mL x 1.0* E+OO = cm3
P-SMKed at tie 19s2 spE ~m.ar Technical Conference and Ex-
hibition, New Orleans, Sept. 26-29. psi x 6.894757 E+OO = kpa
8. Knowlton, R.H. and Huang, H.: “Polycry$bdline Diamond Com- sq ft x 9.290 304* E-02 = m2
pact Sk Hydraulics,” paper SPE 11063 presented at the 1982 SPE
Annual Technical Conference and E.hibitio”, New Orleans, Sept.
26-29,
9. Nolley, J. P., Cannon, G. E., and Ragland, D.: “The Relation of
NozzJe Fluid Velocity to Rate of Penetmtion with Drag-Ty~ Rotary
E%,, Dri[[. and Prod ,%ac., API, Dallas (1949) 23.
Otigi,,l man”,.hpt remi.sd i.,he S.ac;ely of Petrd.”m En@ers Ofma Oct. s, ,W3.
10. Eckel, J,R. md Nolley, J. P,: ‘tAn Analysis of Hydraulic Factors
P.Per accep!ed f.. p.blkmm J... 27, 19S4 Revised ma..scri$i received Jm. m,,
Affecting the Rate of Penetration of Drag-typ? Rotary Bits, ” Drill. 1984 P,P,, (SPE 11 S4S) firs! P,e,,”Wd d the 1 SS2 SPE Annual Technical Co” fermce

od Prcd. Prac., API, Dallas (1949) 23. and Extibiti.. held in San Francisco Oct. 5-8,

2118 JOURNAL OF PETROLEUM TECHNOLOGY

 o 0

0°
0
o
●

I
f
Sooo=a

8
0

0
o
0

●
o
●
●n o 0

-w-. ❑

o ●

o
0
0
a

y?w
BB?EAIB?EAlws#E BRWABMDHONE
WATERBABE
MUO o
la RPM
120mnl
90WLBWOB
o
o /
●

0 o
0 80WlBWOB ● 0 0
00

0 o
:00 0 0
●
o
0
0

0 8mm
o W32n
o 1W32 n
t 1 I 1

2 8 —
BmHYIH&lc HoA-Hsl B~HYMWUUCHORWOWH1-HBl

m-~ of hylratic powerirroii mud, Eerea sandstone. Fig.9-EffecI of hydraulic power m water-base mud, Berea samMone-
 BEREA SANDSTONE
m RPM
~ LB WOB

0
0
0
●
● ✍

o: ● a
9 o

o 0
%*

0
0

0
0

NOW OILWBASE WATll#ASE

DIAMETER MUD
8/32 IN, ● o
9/32 IN. ~ a
10/32 IN, c o
I 1
2
— 4 6 0
B1l’HYDRiUJLIC HORSEPiJWEB - HSI ~

Fig, 10=-Drilling rates with oil=base and water-base mud, 6erea sandstone,

/19w