SPE/IADC 148312

Development and Optimization of PDC bits for Rotary Steerable Systems

through Unstable Formations
Oscar Portillo and Salah Bahlany, Petroleum Development Oman; Gloria Agudelo, Octavio Alvarez and Ali Al-
Marzooqi, Halliburton

Copyright 2011, SPE/IADC Middle East Drilling Technology Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Middle East Drilling Technology Conference and Exhibition held in Muscat, Oman, 24–26 October 2011.

This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not
been reviewed by the Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to correction by the author(s). The material does not necessarily
reflect any position of the Society of Petroleum Engineers or the International Association of Drilling Contractors, its officers, or members. Electronic reproduction, distribution, or storage of any
part of this paper without the written consent of the Society of Petroleum Engineers or the International Association of Drilling Contractors is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE/IADC copyright.

Abstract
Directional drilling in the build up section at North Oman Field in the Sultanate of Oman is challenging because of highly
intercalated and unstable formations. The formation consists primarily of soft to medium hard limestones, dolomites inter-
bedded with anhydrite, and a thick layer of unstable shale that forms the cap-rock of the targeted reservoir. The field
development plan (FDP) specifies drilling long horizontal wells with two casing strings and a liner, and requires the reservoir
section to be placed within the top meter of reservoir rock. Consequently, it is critical to land inside the top meter of the
reservoir. The lack of directional control throughout the soft intervals, high dip angles in some of the formations, and the
short vertical section from surface to landing point requiring BUR of 5 to 6 degrees/30mts created complications in drilling
the build section. With these elements, optimum directional tools steerability is necessary to achieve the well objectives.
To overcome these challenges, the operator and drill Bit Company developed an optimization process to design a
polycrystalline diamond compact (PDC) bit to use with point-the-bit rotary steerable systems (RSS). The optimization
process included increasing the bit steerability and stability to increase the rate of penetration (ROP). This challenge required
the development of a new PDC technology with optimized drilling practices and a reliable drive system. Specific bit design
algorithms were incorporated with a new bit gage configuration, and drilling simulation software was used to optimize bit
cutting structure design in the directional drilling environment. Significant bit design improvements were achieved. Going
through field testing, drilling parameter evaluation and optimization, an 8½-in PDC bit design was created that established
benchmark performances in the North Oman Field field.
The successful development of the PDC bit with the RSS system enabled record bit runs in the build sections, which were
drilled in accordance with the FDP with significant ROP improvements compared to conventional motor. This paper reviews
the bit design and optimization process that helped to improve the drilling performance and hole geometry, reduce rig days,
and enable early delivery of the wells in the challenging Sultanate of Oman drilling environment.

Introduction
The Aptian stage Shuaiba Formation in the Gulf region contains large amounts of hydrocarbons in a number of oil fields and
many regional and local studies haven been carried out (e.g. Murris, 1980, van Buchem et al., 2002, Warrlich et al., 2009). In
PDO’s concessions in the Sultanate of Oman, a number of fields with relatively flat structures are found in the interior of the
Shuaiba platform. Low-energy conditions in these protected platform interior led to deposition of fine-grained sediments.
These were transformed through diagenesis into reservoir rocks (mud-, wacky- and pack stones) with high porosities, but
retained small pore throats, resulting in low permeabilities. Long, continuous depositional bodies are also typical for platform
interior depositional environments. To increase the oil production and ultimately the oil recovery without disregard of the
complexity posed by the well surface location driven by the existing facilities, a strategy of horizontal oil producers and
injectors have been engineered. The challenges faced are diverse starting with a very unstable overburden section comprised
by the formations: Fiqa-Shargi Shale, Natih and Nahr Umr Shale. In addition to this the dog leg requirements are high from
4-7 degrees per 30 mts, negative sections are targeted to tackle the required vertical section at landing point and hole
geometry is a must in order to enhance an easy casing running operation. This paper will exploit the improvements in well
construction mainly in the overburden section of the North Oman Oil Field.
The field was discovered in 1971 and is one of the three carbonate pancake oil reservoirs in the Qarn Alam area (North
Oman). The reservoir is formed by a relatively flat, thin and continuous carbonate structure in the Shuaiba formation with a
2 SPE/IADC 148312

10-15 m thick oil column capillary confined to the uppermost reservoir unit. The oil column (Light API gravity) is overlying
an aquifer of considerable thickness. The field has been developed in stages since 1991. Initially, Vertical wells were drilled
but not very successful, followed by multi-lateral and more recently long single horizontal wells.
Rotary Steerable system (RSS) tools were introduced in the North Oman drilling operations in June 2007 as an attempt to
reduce drilling problems, diminish the time exposure in the Shargi and Narh Umr shales, improve hole quality and ROP,
nevertheless in order to enable optimum steerability, stability, ROP, and bit life it was necessary to develop a PDC bit to
match the system.
After several bit optimization cycles and optimum drilling practices levered by the experience built, the latest interaction
of the 12 ¼” and 8 ½ “ PDC bit designed to work with RSS achieved multiple drilling records in the three different zones of the
field. Today, it is possible to drill the entire section in one run with a very fast ROP in the order of 30 to 40 meters per hour
without compromising hole geometry or hole cleaning.

North Oman
Field

Fig. 1—North Oman Field Localization.

The field has been in production for over 20 years from 1 to 2 km long horizontal wells, barefoot completed and placed
within the top 1-2 m of the reservoir with a spacing of about 100 m. The operations undertaken in this are mainly comprise an
array between horizontal oil producers and water injector located in the waterleg, about 20-30m below the producers, at
double the spacing. The field has three crestal areas (termed Area 1, 2 and 3 – Fig. 2) which have been developed with
multilateral wells of up to 8 legs in the 1990s. Since 2006 an extensive drilling program to develop the flanks is underway as
part of a field development project with 102 wells completed and 60 more planned. Wells are drilled in a Producer-Producer-
Injector (P-P-I) pattern.
SPE/IADC 148312 3

Area 3
Area 2

Area1

Area 4

Fig. 2—Areas Subject to Drilling Activity in North Oman Field.

For the field development, various development options have been assessed and field proven thorough diverse drilling
campaigns, the challenges faced are broad in nature such:
1. The well orientation is dictated largely by existing well placements or the need to place wellpath parallel to faults (if
within 500m) so as not to exit the reservoir at seismic or sub-seismic faults.
2. Surface constrains in regard to production facilities and roads have led to a difficult surface location pick process, as
such most of the recent wells drilled underwent negative section profiles in the intermediate hole which posses a
challenge in terms of Build up Rate, Torque and Drag Analysis and Hole Geometry.
3. Long Horizontal Section targeted as part of the recent Field Development Plan going beyond 2200 mts of horizontal
open hole.

Geology of the Overburden 12 ¼” or 8 ½ in Section

The geology of the 12 ¼” or 8 ½” hole section, shown in Fig. 3, includes the following formations.

Arada. Is an argillaceous limestone (may be hydrocarbon bearing) several leak off test have shown leak off values in the
order of 16.5 to 17 Kpa/m. The estimated formation pore pressure is 10 Kpa/m since no over pressures zones have been
observed during the field development and it is drilled with a mud weight of 11.5 to 12.3 Kpa/m. The typical mud weight is
12 Kpa/m.

Natih’s. Low permeability limestone with thin layers of shale interbedded which a hydrocarbon is bearing zone; several leak
off test have shown leak off values in the order of 16 to 16.3 Kpa/m. The estimated formation pore pressure for the entire
overburden section including the Natih’s is estimated to the in the order of 10 Kpa/m since no over pressures zones have been
observed during the field development. Since Natih’s are a continuation of the 12 ¼” or 8 ½” overburden section depending
on which well type is being drilled the mud window for this section is the same as mention before for the Arada formation
nevertheless, towards the end of Natih close to Nahr Umr one can increase further the mud weight to a maximum of 12.3
Kpa/m.

Nahr Umr. Very unstable and reactive shale which represents the most troublesome interval in this section if insufficient
mud weight is use and shale inhibition is not achieved, possess a challenge to achieve and maintain BUR over 5 degrees per
30 mts constantly. Due to the nature of this formation, conventional directional assemblies fail to generate the require build
4 SPE/IADC 148312

up rates due to formation washouts, that eliminate the necessary pivot point the tools needs to build angle. Formation
swelling adds an additional challenge while tripping in and out.

Fig. 3—Stratigraphic column; formations drilled directionally.

Well Profile – Well Design

The initial drilling campaigns of this North Oman drilling operations were carried out on a performance motor with a
combination of insert and PDC bits in some wells. The concept is to drill a vertical section to a kick off point at +/- 1000 mts
into the Natih C formation to then kick of the well to end up in the Nahr Umr formation if drilling hybrid oil producers or to
end up into the Shuaiba reservoir in one build for water injector wells. What was observe in most of wells drilled with
conventional Bottom Hole Assembly (BHA) is the requirement for two trips in order to change the bit; several hole
instability problems were observed due to hole geometry and insufficient mud weight, and casing operations required much
more attention and time. The average ROP in the 8 ½” section with motor was averaged in 21.4 m/hr. Figs. 4 and 5 shows
the wells profile.
In a typical well design, 13 3/8” or 9 5/8” casing is set 5 m into the Top of Arada Formation. A typical well profile
requires vertical drilling of approximately 550 mts with a performance motor and/or Rotary Steerable Systems and a potential
combination of insert and PDC bits. The curve section is planned with a Build Up Rate (BUR) of approximately 4- to 7 deg
per 30 m. The 9 5/8-in. casing is planned to be set into Nahr Umr formation +/- 12-15 m AHD (Along the Hole Depth) for
hybrid oil producers and 10-15 mts TVD into Shuaiba formation for the water injector wells (building section in 8 ½” hole
size) Fig 6. It required an average of two trips to drill the curve section with mud motors. The formations encountered while
drilling the buildup section are soft and interbedded (limestone and shale sequence) and typically maintaining azimuth while
building introduced a challenge for the directional drillers because of the number of hours on the tools, tool face orientation
incidents and low ROP.
The objectives with the implementation of PDC bits on a Rotary Steerable Systems were listed as follows: to drill both
vertical and build up sections in one run whilst maximizing the ROP, increase the footage drilled per bit run while meeting
directional requirements, improve hole cleaning capacity as the BHA spins at the same rotary speed among other benefits.
SPE/IADC 148312 5

The following graph sketches the two main well designs long used in the field development up to date. The main
difference is the casing scheme is driven by completion surveillance requirements (Y-Tool). The oil producers are drilled
across the overburden section in two hole sections whereas the water injectors achieve the same objective in one vertical-
build up section to landing into Shuaiba reservoir.

Fig. 4—Well Designs Currently Implemented.

Fig. 5―Well Plan.

6 SPE/IADC 148312

ABI inclination

Building the inclination to 91 to get a control

point.

RT& Offset Porosity/Density Porosity

RT& Offset Density

The Separation indicate close approach RT& Offset Res

from the roof. The SH Phase cross all

RT, Offset GR & ROP/Oil Sat

Nahr Umr Shale

1-1.5m of Target zone
Bit position
Shuaiba Well plan
Actual trajectory

Fig. 6—Vertical section view of well design & Evaluation

Bit Performance with Steerable Motor

This section shows the bit performance with a steerable motor in an 8 ½” section of the North Oman field where the bit
optimization process occurred. The rock hardness, transition zones, shale reactivity, differs slightly between zones, which
represents various bit design challenges. In the overburden or intermediate hole a group of troublesome shaly formations are
crossed, problems of different nature had rose such: stuck pipe, losses in the Natih’s, and high torque, erratic dog leg outputs
and casing held ups among other problems, are issues that affects the overall drilling performance; an average of two runs are
required to drill a 12 ¼” or 8 ½” directional sections with steerable motors. The first BHA is used to drill vertically with
performance motors to the kickoff point, and then it is pulled out to pick up the directional tools. The average ROP for the
section is 21.4 m/hr. Fig. 7 shows the motor drilling performance in comparison with the runs with RSS and the designed
PDC bits.

ROP ‐ 8 1/2" Section North Oman Field

mph
35 mph
32.76
mph 32.15
30.73
mph
30 28.82
mph mph
26.03 26.10

25

mph
mph 24.00
22.88
20
mph ROP Well drilled with PDM (Two trips average)

mph ROP Well drilled with RSS (Shoe to shoe runs)

mph
15
16.95

Fig. 7—RSS vs. MOTOR performance in the 8 ½” building section.

SPE/IADC 148312 7

Fig. 8—Typical Doglegs severity achieved while drilling the 8 ½” directional section (RSS Vs Motor).

Rotary Steerable System

Rotary steerable systems (RSS) have gained ground rapidly because they have revolutionized the way that directional wells
are drilled. RSS tools can be categorized by the mode of operation; there are two steering concepts for these systems: point-
the-bit and push-the-bit. The RSS tool used during this bit optimization exercise is a point-the-bit system (Figs. 9 and 10),
which operates by offsetting the bit and creating a bend that changes the course of the well in the desired direction. The bit
and the internal tool body rotate at the same speed, and the magnitude of the bit tilting effect is controlled electronically from
surface. By eliminating the need to slide to follow the well plan and the use of highly stable bits with integrated long gage
sleeves, the system creates high-quality wellbores that improve almost every aspect of drilling by lowering vibration,
extending bit life, minimizing downhole tool failures, and increasing ROP like the case in the 8 ½” section where the ROP
was improved by 47% compared with the performance with conventional directional assemblies (Fig. 7).
8 SPE/IADC 148312

Fig. 9—Point-the-bit RSS Tool.

Fig. 10—GeoPilot RSS configuration.

In general terms, the RSS point-the-bit tool operates by placing a relative bit offset bend in the system, much like a
standard motor assembly. This bend is held geostationary with respect to the formation. To understand the point-the-bit
principle, one can make comparisons to conventional drilling systems that use motors or turbines. In a conventional system, a
SPE/IADC 148312 9

bent housing and stabilizer on the bearing section enables the motor to drill in either an oriented (sliding) mode or a rotary
mode. In the rotary mode, the bit and the drillstring both rotate. The rotation of the drillstring negates the effect of the bent
housing, and the bit drills an overgauge straight path parallel to the axis of the drillstring above the bent housing. In the
sliding mode, only the bit rotates. The motor changes the well course in the direction of the bent housing, and the drillstring
slides down the hole behind the bit. In the point-the-bit system, the bent housing is contained within the collar of the tool.
The bent housing direction is controlled by eccentric rings that rotate at different speeds aligning or pointing the bit to the
direction of and at the same velocity as the drillstring. This control enables the outer housing to remain geostationary
(nonrotating) while the collar is rotating. The RSS tool used during this optimization process is called commercially
GeoPilotTM system (Fig. 10) and in order to change the hole inclination, the system requires a bit with an integral sleeve
which allows having the pivot point further from the bit face letting the extended gage be in contact with the borehole which
improve significantly the hole quality. Besides the ROP gained by not sliding the well, the RSS with the long gage bit
reduces stick/slip and other damaging vibration modes common to conventional rotary drilling. The long gage bit increase the
hole quality by reducing hole tortuosity creating a smooth hole transition. Fig. 8 shows compares the erratic dogleg severity
achieved by the motor assemblies in comparison with a smoother hole pattern when the RSS point-the-bit system is used
along with the long bit sleeve in the North Oman Field field. All available energy is used to drill the hole optimally; casing
wear and drill string fatigue is reduced as a result of slower drillstring rotation, which minimizes the possibility of drillstring
or casing failure (Al-Yami et al. 2008). All external parts rotate at drillstring speed, which reduces drag. The rotation also
helps to clean and condition the hole by stirring up the cuttings from the low side of the hole for the drilling mud to bring it to
surface, reducing the risk of differential or mechanical sticking.

Bit Design Tools

To obtain the maximum potential from the GeoPilotTM RSS tool, a bit design optimization process was put in place in order
develop an 8 ½”-in. PDC bit to match the system. The new bits required proper system geometry (long gage integral sleeve)
with specific length, diameter and spiraling, adequate bit face and sleeve cleaning, and sufficient wellbore contact to limit
over-engagement and undercutting of the formation. In addition to the gage configuration, which must match the RSS
geometry for maximum tool steerability, the process of designing a bit to drill directionally through this complex interval,
provided a series of challenges that were addressed during the bit optimization process. The ultimate goal was to develop a
bit with the right profile and optimum cutting structure that allow the bit to be steerable, stable, durable and with a neutral
walk tendency. To meet these challenges, the several bit design analytical tools, including IBitSTM, Direction by Design ™,
and computational fluid dynamics (CFD) software, were used, emphasizing bit steerability and stability.

IBitS™. IBitS software is the bit designing tool platform that enables the bit designer to generate the cutter layout and to
simulate the forces to which the bit will be exposed under specific drilling parameters. Depending on the cutter geometry and
space position on the bit face, this tool can be used to calculate the torsional, axial, and lateral forces of each cutting element
showing the total bit force imbalance as output. Force imbalance provides a good measure of the bit stability which is critical
in rotary steerable applications due to the complexity of the electronics mounted on the tools that require low vibrations level
to increase its reliability. The bit force imbalance (stability) can be improved by manipulating the cutter layout (cutter size,
back rakes, blade spiraling, etc) that enables increased bit energy levels (RPM and WOB) by evenly distributing cutter forces.
IBitS also is set with a transition drilling model, which helps to identify possible areas of impact damage when the bit moves
from soft to more competent formations.

Direction by Design™. Direction by Design (DxD) software is a high-technology analytical tool that provides advanced bit
design engineering to optimize directional performance. It provides a powerful means of optimizing the matched bit design
for the specific directional application and drive system. The software eliminates lengthy and expensive trial-and-error bit
design, making it possible to define the relationship between specific bit design changes and their full effect on the
directional deliverables. This tool enables the bit designer to compare the performance of various bit designs before they are
run. The new DxD tool is based on a mathematical model described by Chen et al. (2007). The deployment of the DXD tool
in the North Oman Field field was a key factor in reducing the learning curve during the bit optimization process of the 8 ½”
PDC bit used with the GeoPilotTM rotary steerable system. When the tool is performing a simulation, it takes in consideration
not only the whole bit geometry but also the geometry of the drive system that in this particular case was the RSS point-the-
bit. In order to simulate the drilling conditions as close as possible to the real scenario, the hole geometry and main formation
characteristics are taking in consideration: hole inclination, formation hardness and abrasiveness, dip angle and other
variables are input in the system. The software performs the analysis reading the bit cutter layout and sleeve configuration,
calculating the three main dimensions of a bit aimed to do directional work: Bit steerability, Bit Stability and Bit Walk
tendency. For first time in the oil industry there is a tool capable to predict the bit directional behavior in comparison with
other bit designs.

Computational Fluid Dynamics. CFD analyses were also performed during the bit optimization process to ensure that the
new bits had the correct hydraulic configuration. Proper bit face cleaning is critical through the Nahr Umr formation because
of the reactive shale that can cause bit balling situations. The GeoPilot RSS uses bits with extended gage that requires
10 SPE/IADC 148312

optimum cleaning as well, not only to keep the mud channels free but also to avoid recirculation of cutting around the
surfaces that eventually reduce the bit performance.

8 ½” PDC Bit Design and Optimization

During the last two years, different bit designs were tested in the field obtaining mix results; all of them showed improved
cutter life and rate of penetration due to the nature of the rotary steerable system but in some cases the steerability or the rate
of penetration was below the expectations. In other cases while drilling the North Oman Field field, the bits showed high
vibrations levels increasing the risk of a failure due to the excessive stress on the tools. High vibration levels forced the
directional driller to reduce the drilling parameters in an effort to break the harmonics caused during the slip-stick or whirl
incidents, reducing considerably the system optimum performance and ultimately increasing the drilling time. Several bit
design iterations were performed during the bit optimization process but only the utilization of the new analytical tool
allowed having an optimum bit design for the RSS tool and application that brought reduction in drilling time, optimum
steerability and stability, and neutral walk tendency.
In the following sections Bit A represents the previous bit iteration before the DXD tool was deployed and Bit B
Represents the latest bit design implemented in the field that proved to have the right balance between directional capabilities
and rate of penetration.

Bit A Design. This bit was set with 6 blades and 16mm cutters (Fig. 11) and offered a good balance between ROP and bit life
but the directional drillers time to time complained about not be able to control the bit in some intervals of the section. From
the directional point of view, the formations drilled through the 8 ½” interval have different reactions; Arada is soft but firm
enough to allow a solid pivot point of the tools so building through this formation does not offer a major challenge but, since
high penetration rates can be achieve, the Bit A and the bits used before this point tended to generate vibrations which
affected the RSS tool and PDC cutters life. Natih formations are harder and difficult to drill since the formation in some of
the wells tends to offer great resistance to be drilled directionally hence its dip angles ended up causing a strong building or
dropping tendency. Bit A had good performance through this area most of the time but the RSS required full deflection
anyway to achieve the required build up rates. Bit A performance through Nahr Umr showed mixed results since in some
runs the steerability was good but the ROP poor while in other wells it was difficult to follow the well plan but the rate of
penetration was above the average.

Wellbore contact Integral Sleeve

Fig. 11―Bit A Design. Integral sleeve.

The Bit A did not have enough stability for the application; it was not clear what was causing the bit vibrations tendency
and even more difficult was to quantify the amount of such a tendency. The GeoPilot tool is run almost all the times with a
sensor called DDS (Drill String Dynamic Sensor) that records the bottom hole vibrations the BHA is exposed to. The DDS
tool counts with three accelerometers that can measure and record the magnitude of the three modes of vibrations: Axial,
Torsional and Lateral. Bit A recorded several vibration incidents, with slip-stick observed at the surface and high frequency
SPE/IADC 148312 11

lateral motion detected by the DDS tool. One more sensor set directly on the Geopilot body is the TEM (Torsional Efficieny
Monitor) that measure the difference in rotational speed between the drive shaft that rotates at the string speed and the outer
housing that tends to be stationary; the difference in speed determines if the rotation of the drive shaft is smooth, abrupt or
oscillating and to what degree. TEM gives a clear indication of the Slip-Stick events that most of the times is related to the
bit since the sensor is connected directly to the shaft mechanism that transmit the rotational energy to the bit. Fig. 12 shows a
Slip-Stick incident during one of the Bit A runs in North Oman Field field; when the curve approach the red zone in the
Torsional Efficiency column, it indicates the tool is detecting Slip-Stick vibrations, high values in the DDSR Avg X curve in
comparison with the DDSR Avg Y trace, corroborates the Slip-Stick vibration mechanism at this point . Once the bits were
pulled out of the hole after finishing the section, most of the times the PDC cutters exhibited medium wear, and several
chipped cutters indicating a need for improvements in the cutting structure.

Fig. 12―Bit A Design. Vibration log North Oman Field Field.

Bit B Design. For the new design, the basic bit design geometry of six blades and 16mm cutters remained the same since
cutter life was not an issue for the application and the 16mm cutters offers a good balance between aggressiveness and
durability. Besides that, many other variable were altered based on the utilization of the new analytical tools. The application
of the DXD tool allowed the bit design engineer to change several bit features and simulate the effects of such features on the
bit directional response. The new bit (Fig.13) was designed with a flatter profile, 13mm cutters in the cone, shorter gage
length and a different bit sleeve configuration called MEG (Modify Extended Gage). During the designing phase also, the
back rakes of the cutters and blade spiraling were adjusted to reduce the bit aggressiveness and to improve the ability of the
bit to mitigate vibrations. The utilization of the MEG sleeve allowed having a four blade sleeve design instead of six blades
as the Bit A, which increased the cutting evacuation area through the sleeve facilitating the bit face cleaning. With the
previous sleeve design the bit designer had to match the number of blades in the bit head with the sleeve, resulting in
reduction of the hydraulic flow area and more contact points with e wellbore. With the four blade sleeve design on Bit B it
was possible to have fewer interruptions and a more passive fulcrum point to smooth torque transition. The spiraling of the
sleeve blades was increased to have full borehole coverage.
12 SPE/IADC 148312

Fig. 13―Bit B Design. Modified Extended Gage sleeve design.

On the design phase, by changing the cutter layout, gage configuration, bit profile and sleeve geometry, the steerability
was improved by far as compared with Bit A. Fig. 14 illustrates the results generated by DxD. The simulations shows that to
generate a building rate of 5 degrees per 30m, Bit A will require a side force of 1,317 pounds while Bit B will require only
532 pound to do the same work. The DXD is a comparative tool and in this case the results are interpreted as the new Bit B
will be more steerable than Bit A by more than 100%. Improving the bit steerability means that the bit B will require less side
force than bit A to generate the planned doglegs under the same drilling conditions; in challenging drilling environments
through intercalated formations, the RSS tool output will be optimum in terms of doglegs. In soft and medium formations, the
deflection on the RSS shaft will be less, minimizing the stress on the tool and increasing its reliability.
Bit walk tendency is another comparative analytical tool incorporated in the DxD software. To calculate the bit walk
tendency, the program calculates the forces in the bit cone area vs. the forces on the shoulder and bit gage. Fundamental
studies on which the DxD is based demonstrates that the bit walk tendency also depends on the drilling mode; if the bit is
building or dropping, the bit walk tendency will change. With the point-the-bit system, the gage pad and gage cutters
generate a large walk force, which drives bit walk to the left (Chen et al. 2007). Fig. 15 shows that both bits have a slight bit
walk tendency to the left, as expected. Bit B tends to be more neutral, which reflects improvements of the bit design.

Fig. 14—Bit Steerability.

SPE/IADC 148312 13

Fig. 15—Bit Walk Tendency.

As shown in Figs.7 and 8, the field results of Bit B were optimum; the system steerability was improved, the bit cutter
life extended, and the high vibration seem with the previous design was reduced to minimum values. In addition, the ROP
was improved by 22% average, as compared with the previous RSS bit design.
One month after the last Bit A bit was run in the North Oman Field field, the Bit B was tested under similar conditions
and the difference in performance was evident; the improvement in ROP compared with the last Bit A run was 17%, the bit
showed optimum steerability making possible to follow the well plan with minimum values in tool deflection. After this run
the bit was graded 1/1/WT which means the cutting structure was in perfect condition making possible to run the same bit
again. The fact the cutting structure did not show any broken or chipped cutter gives a clear indication of the bit stability.
Once the recorded vibration logs were analyzed, it was evident there were not major vibration events during the entire run.
Fig. 16 is a snapshoot taken from the actual logs after the first run with Bit B; the DDS curves registered very low
acceleration values of the vectors (Axial, lateral, torsional) that reflects the bottom hole vibration mechanisms.

Fig. 16―Bit B Design. Vibration log North Oman Field Field.

14 SPE/IADC 148312

Conclusions
As part of the drilling optimization in the North Oman development field an 8 ½” directional PDC bit was successfully
designed fulfilling the specific RSS tool requirements and more over intended to reduce the total drilling and trip time by
significant ROP increase as well as minimize the down hole vibration to be reflected in both directional drilling efficiency
(smoother DLS trends) and hole geometry. Once the bit was in the ground the results are clearly showed by counting figures:
- 47% of ROP increase versus Motor runs
- 22% of ROP increase compared with the previous RSS’s PDC design (A).
- One single run shoe to shoe to complete the Build Up section.
- Improved bit dull condition to ensure multiple runs resulting in CPM reduction for the field
- Bottom Hole vibrations measured by TFM tool were clearly reduced to half reaching minimum values of less than
one unit
- Smoother DLS trend up to the landing point (Fig. 7) ensuing in hole geometry improvement.
- All above resulted in lower open hole exposure, faster drilling an easier building in Nahr Umr shales and earlier well
delivery for production.
- Improved hole geometry which enhance NPT free casing run operations, it has enabled the option to drill the entire
overburden section (Vertical – Build Up – Tangent) in one go, finally landing the well into the reservoir at 90 degrees
inclination.

PDC bit steerability and stability were clearly improved in the new bit design (B) as per single DSL readings and bottom
hole vibration reduction redounding in ROP increase. The main bit changes related to these two features were, higher &
optimized force balance, shorter & flatter bit face profile, shorter bit gage pad, MEG™ sleeve configuration, higher sleeve’s
blade spiraling
The software used to design the steerable-RSS pdc bit B, certainly proved that the required side force to build a given
punctual angle was much lower over previous A bit designed with the program were these figures could not be managed and
predicted with such accuracy.
Hydraulic configuration of the bit face and sleeve certainly contributed on the ROP improvement; one of the easy
countable features was the increase of the sleeve junk slot area in 33% by removing 2 blades over the previous design in
addition to the optimized fluid motion suggested by the CFD.

References
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Step Change in Drilling Performance. Paper SPE 115491-MS presented at the SPE Asia Pacific Oil and Gas Conference and
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