SPE 128562

Latest PDC Technology and Optimization Process Enable Replacement of

Multiple Impregnated and Roller Cone Bits with One PDC Bit Run
Hubert Foucault and Raul Malagon, JV Gas; Enis Aliko, Reina Teelken, and Ross Hitchman, Baker Hughes

Copyright 2010, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE North Africa Technical Conference and Exhibition held in Cairo, Egypt, 14–17 February 2010.

This paper was selected for presentation by an SPE 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 and are subject to correction by the author(s). The material does not n ecessarily reflect any position of the Society of Petroleum Engineers, its officers, or
members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Socie ty of Petroleum Engineers 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 copyright.

Abstract
The Cambro-Ordovician formation in onshore Algeria consists of hard and abrasive sandstones that have proven challenging to
drill. Up until now, no bit has completed the section in one run, and these formations have been considered beyond the limit of
what is drillable by PDC cutters. Previous sections have used impregnated diamond and roller cone bits that achieved low
penetration rates and required multiple bit runs. The impregnated runs require the additional cost of turbo drills or high-speed
motors to deliver the rotation speeds necessary to achieve acceptable rates of penetration, while a bearing seal failure of a roller
cone bit increases the risk of losing bit pieces in hole.

The operator conducted an optimization process based on rock mechanics including an analysis of prior performances to conclude
that the formation could be drilled more economically applying the recent advances in PDC bit technology. Collaboration between
the bit manufacturer and the operator facilitated the implementation and development of the latest bit technology, including
enhanced bit stability, improved cutter layout and more resistant cutters. After an initial, partially successful run, new bit
improvements were implemented. The two subsequent runs completed their sections, enabling the operator to drill with one bit
through what was previously a multiple-bit section. Rates of penetration were improved significantly over previous impregnated
and roller cone runs. Requirements for down hole drive tools and bit trips were eliminated as was the risk of bit junk being left in
hole.

This paper outlines the process that led to improved understanding of the formation drill ability, the research and development
behind this new bit technology, the continuous optimization of the specific bit, its field performance, and the resulting cost saving
for the operator.

Introduction
The Cambro-Ordovician reservoir in east Algeria consists of hard and abrasive sandstone that has been challenging to drill. Each
of the operator’s nearly thirty wells experienced low penetration rates in the reservoir section. In a typical well, the final casing
shoe is set at the base of Silurian mudstones, and the reservoir formations are drilled with either 8 1/2-inch bits in vertical wells or
6-inch bits in deviated or horizontal wells down into basement rock. Prior to 2008, these sections were drilled exclusively with
multiple impregnated bits and/or roller cone bits. Impregnated bits have been able to drill acceptable run lengths; however
improvement of performances has been limited. Further, drilling economics were negatively impacted by the additional cost of the
downhole drive system required to deliver high-speed rotation. Roller cone bits on the other hand do not require expensive
downhole drive tools, but were not able to achieve runs that sufficiently long to be economic.

Stuck in hole was seen as a potential drilling risk with the impregnated bits, while roller cone bits have the potential for a bearing
failure and resulting in junk in hole that could require expensive milling and fishing operations. The operator’s objective was to
reduce drilling costs for the section by using rotary drilling assemblies together with fixed cutter bits to deliver better penetration
rates and longer runs.
2 SPE 128562

A drillability study conducted by the operator indicated that the formations could potentially be drilled using the latest PDC bit
technology. In concert with the operator, the drill bit provider initiated a process to design a new PDC bit and optimization process
that targeted these formations using the latest design concepts. The process required the collaborative input of research and
development, design, and application engineering resources. The result of this process was the first PDC bit to successfully drill
the section in one run.

Optimization Process
Following a general review of the drilling performances in the Cambro-Ordovician, in late 2007 the operator implemented a new
technical approach for delivering timely continuous improvement. This approach employs fewer design iterations to meet
performance objectives that best fit the application. It requires a rapid, closed loop cooperation between operator’s drilling
engineers, petrophysicists, rock mechanics experts and drilling bits research and development teams.

Initially, a detailed rock strength analysis of the Cambro-Ordovician formation was performed using cores from the offset wells.
Then a bit performance analysis was conducted that evaluated each bit run in terms of bit specifications, drilling parameters and
conditions, geological lithofacies, mechanical properties and well deviations.

Offset rock mechanics and performance analyses

The reservoir section normally comprises four distinct formations: base of Silurian (S10), top Cambro-Ordovician (MS2), bottom
Cambro-Ordovician (MS1) and finally Basement (Fig. 1). The Silurian (S10) consists of mudstones that are relatively soft with
unconfined compressive strength (UCS) values ranging from 10 to 15 kpsi. The MS2 and MS1 formations consist of hard and
abrasive sandstones with UCS values ranging from 18 to 28 kpsi. In some areas, either MS2 or MS1 formation would not be
present. The Basement formation comprises a very hard meta-granite lithology with very high UCS values ranging from 25 to 35
kpsi). The UCS values were interpreted from acoustic wireline logs using standard algorithms (J. Spaar et al., 1995) (Fig. 2).
Accurate lithology verification was inferred from mud logs.

Offset drill bit records from twenty-six wells in the same field were evaluated against benchmark performance in the Cambro-
Ordovician formations. The drilling performances of more than one hundred bit runs were divided into four categories and
averaged based on size and type. These were: 6-inch impregnated bits, 8 1/2-inch impregnated bits, 6-inch tungsten carbide insert
(TCI) bits and 8 1/2-inch TCI bits. The majority of the bit runs were in vertical wells, but some were from deviated wells.

Bit performance analysis indicated that 6-inch roller cones (IADC codes 617-637) drilled on average 42 m per bit at 2.7 m/hr,
while the 8 1/2-inch roller cones (IADC codes 547-637) achieved 75 m per bit at 2.9 m/hr. The 6-inch impregnated bits averaged
142 m per bit at 1.7 m/hr, while the 8 1/2-inch impregnated bits achieved 171 m per bit at 2.2 m/hr (Fig. 3). On average, these
sections would require more than four bits to be completed to TD. Typical offset well bit performance is shown in Table 1.

Based on the field synthesis of rock mechanics properties and on the correlation with drilling performances, the operator felt
confident the reservoir sections could be drilled more economically by innovating and using PDC technology and the latest in PDC
cutters instead of previous roller cone and impregnated bits.

The operator, then, approached several leading bit manufacturers, before choosing to collaborate with one on the basis of a history
of demonstrated technology innovation, R&D capacity, credibility and experience in hard rock PDC drilling. It was then agreed
that the operator and bit manufacturer would focus on the next five vertical applications. Deviated and horizontal sections were set
as secondary priorities. For each application, the operator built a detailed well prognosis including pseudo rock strength derived
from the different petrophysical scenarios predicted. Each run would have to be analyzed by closely comparing expectations for
rock strength, recommended parameters and predicted performances versus actual rock strengths and actual drilling performances.
Major improvements and faster learning were anticipated using this comprehensive approach.

Bit Research and Development

The bit manufacturer had embarked on a sizable research and development program focused on a new PDC product line to enable
drilling of increasingly harder and more abrasive rocks. The program involved 12 teams working on distinct aspects of bit
technology, that includes: hydraulics improvement, diamond volume management, dynamic stability, cutter enhancement, rock
cutting modeling, new matrix materials, bit design optimization, and other areas. The research and development of this new PDC
product line, which is discussed below, involved more than 2,500 tests run on both surface and bottomhole drilling simulators,
with more than 2000 m drilled through 21 different rock types.
SPE 128562 3

Numerous technologies were developed during this program and were eventually incorporated into the bit selected to drill the
subject formation. Only the most significant will be addressed in this paper.

Depth-of-cut control (C. Lenamond et al., 2005) is a feature that limits penetration of the cutters into the rock to a calculated and
customizable distance per each revolution of the bit. If drilling conditions change, (such as sudden formation change, weight on bit
(WOB) increase, or bit instability), the depth-of-cut control feature causes a portion of the blade surface to rub on the rock and
generate forces that mediate the harmful effects of the changes (e.g., cutter load variation or bit instability). Depth-of-cut control,
therefore, can be used to increase bit stability, which is distinct from its original use for steerability control. The area of the
rubbing surface of the blade varies with cutter penetration. This area is often reinforced with abrasion-resistant materials such as
thermally stable polycrystalline diamonds (TSPs) or flush set PDC cutters (Fig. 4).

Diamond volume management (M. Al-Saeedi et al., 2009 and Y. Nabhani et al., 2009) is the strategic placement of diamond
material where it is needed through the use of various bit profiles, cutter layouts, and multiple rows of backup cutters. Using this
method the designer provides the maximum diamond material precisely where it is needed without sacrificing bit efficiency. The
diamond placement is determined by examination of dull bits and through sophisticated bit wear simulation software to identify
areas on the bit that require more protection to prevent premature wear. Backup cutters are also strategically engineered to be
exposed to the rock surface only when needed, to maximize diamond coverage when the bit becomes unstable, or when primary
cutters start to wear. Using these techniques the bit becomes more durable and can drill farther at higher ROP.

One research teams was focused on the development of simulation software (J. Gent et al., 2009 and Y. Nabhani et al., 2009) that
would calculate bit dynamic stability, i.e., bit stability under simulated drilling conditions. This effort resulted in software, using
bit design files, simulated drilling conditions, prescribed drilling parameters and rock types predicts the stability of the design
before actually building the bit. PDC bit stability is a critical component of a bit’s performance. Further, once manufactured the bit
is tested for stability on a block of natural rock under controlled laboratory conditions. Finally, the analytical model is analyzed
with the lab results and then field runs to continually improve the design. Using these methods the stability of the new product line
was improved (in the low RPM range where it is generally most prevalent) by more than 50% compared over the previous designs
enabling operators to drill significantly longer sections.

The hydraulics of the new design was optimized using the well established methods employed by the bit manufacturer. First, the
general flow regime beneath the bit was optimized using state-of-the-art computational fluid dynamics (CFD) techniques described
in (M. Wells et. al. 2006). These methods focus on hydraulically increasing cuttings transport while systematically reducing bit
erosion. In addition to the general hydraulics optimization, the blade geometry of the bit was optimized using the so called “pinch
point” and “cuttings trajectory” analyses (M. Wells et. al. 2008). The pinch point analysis prescribes a minimum distance between
adjacent blades on a PDC bit to alleviate the entrapment of cuttings. Typically, the primary junk slots on PDC bits are partially
restricted by the near proximity of the opposing secondary blade. The pinch point analysis ensures that sufficient space is allotted
between these two blades at the restriction to allow the passage of cuttings cenerated upstream of the restriction. The cuttings
trajectory analysis provides design guidelines to ensure that the rock cuttings generated along a blade migrate out of the junk slot,
rather than back towards the center of the bit to cause bit balling (Fig. 5). Overall, these improvements provide better, more
effective cleaning in the junk slots and thus less bit balling and improved rates of penetration.

Finally, the development of new PDC cutters (J. Gent et al., 2009; M. Al-Saeedi et al., 2009; and Y. Nabhani et al., 2009) had a
substantial effect on the performance of the new bit design. These newly developed cutters, which feature improved diamond feeds
with optimized particle size distribution, an optimized sintering process and treated diamond surfaces for improved abrasion
resistance. These enhancements make these cutters more abrasion resistant compared to previous cutters produced by the
manufacturer (Fig. 6). The new cutters also retaina novel interface engineered to reduce stresses between the diamond table and
the carbide backing (Fig. 7). A finite element analysis was performed to identify stress concentraions, and develop suitable
interfaces to mitigate their effects. An optimum interface was identified, that provides the maximum stress relief, maintaining a
sharper cutting edge during drilling and, as a result, enables the bit to drill faster and farther.

Bit Design
Based on the well prognosis and predicted rock strengths, the initial bit needed to be sufficiently aggressive to assure competitive
ROP in the early stages of the run, yet durable enough for the lower part of the section characterized by high rock strength
formations. The latest PDC bit technologies, discussed above, were adopted as the starting point for the new design. The ability to
dynamically simulate bit stability (Fig. 8) before committing to building the bit, together with the ability to run full-scale surface
stability tests played a key role in rapid design optimization. The final bit design was a seven-bladed PDC bit with highly abrasion-
resistant, 16-mm diameter primary cutters, and 13-mm secondary cutters (Fig. 9). The bit featured a hard rock profile and
improved gauge protection. The stability of the bit was verified using the dynamic bit stability simulator.
4 SPE 128562

First Run
Anticipated rock gamma ray, acoustic values, and rock strength were generated by the operator’s petrophysicists. The bit
manufacturer’s engineers used these properties to prepare recommended drilling parameters and best drilling practice guidelines
for each forecast lithology. This enabled the rig site engineers to optimize parameters during the run to maximize performance, and
protect the cutting structure of the bit against damaging vibrations while drilling.

The objective of the first run was to drill the 8.1/2-in section on a packed rotary assembly through the MS2 formation and reach
the MS1 formation. The bit was fitted with 7x15/32-in. nozzles for a calculated horsepower per square inch (HSI) of ~2.0 hp/in2.

The bit drilled out the 9.625-in. casing shoe, through the initial Silurian mudstone, and the entirety of the MS2 formation.
Frequently penetration was accompanied by severe torsional vibrations that could not be eliminated through changes in drilling
parameters. On entering the MS1 formation, the ROP had decreased and the bit continued drilling ahead slowly until no further
progress was possible and the bit was pulled. In total, 160 m were drilled at an average ROP of 1.9 m/hr (Table 1). The section was
completed with a roller cone bit.

On surface the bit graded 8-5-CR-C-X-1-WT-PR (Fig. 10). The bit was cored out in the cone, and missing cutters and blades in
that area. The bit gauge was 1/16-inch under gauge.

Post-well examination of wireline logs revealed a severe over-gauge hole for the initial 35 m of the run. Rock strength analysis
showed that the MS2 was hardest at the top. The over-gauge hole, coupled with the lack of thick wall drill collars resulted in poor
bit and BHA stability. With the bit deriving little stability from the assembly, severe drilling vibrations occurred while drilling the
hard sandstone. The drilling parameters were analyzed and the specific energy (R.C. Pessier and M.J. Fear, 1992) was calculated
to measure drilling efficiency. The efficiency calculations showed a steady decrease in efficiency starting from early in the run
which suggests the bit damage occurred then. The bit damage compromised the stability of the bit and escalated to the observed
dull condition. The stabilizers were heavily worn and were found 1-inch under gauge. The quality of stabilizer blade protection
was poor and evidently not resistant enough to handle these abrasive formations.

The first run was considered successful since this was the first PDC bit ever run in such hard and abrasive sandstones and it met
the average performance of previously run impregnated bits. The main lesson learned was that the formation did appear to be PDC
drillable, although it would require some BHA adjustments to minimize the drilling vibrations that had been encountered. Another
key learning was that drilling efficiency increased when relatively higher WOB and lower RPM were applied to the bit.

Second Run
The objective of the second run was to drill the section to TD in one bit run. Lessons learned from the first run were used to
modify the BHA and the bit design. Stabilizers with higher quality blade protection were picked up and more drill collars were
placed in the BHA to enable higher WOB.

The following bit design modifications were made based on the observations from the first run (Fig. 11):
• Additional diamond inserts to protect the depth-of-cut control surface in the cone of the bit
• Decrease cone aggressiveness by increasing cone backrake
• Increased cutter density in nose and cone areas
• Increased gauge diamond density by changing from round to hexagonal diamond inserts (Fig. 12)
• Lengthened gauge to 3 in. to improve bit stability

The bit was equipped again with 7x15/32-in. nozzles for a calculated HSI of ~2.0.

The bit drilled the 9.625-inch casing shoe and Silurian mudstone, then MS2 to Basement. The MS1 formation was not encountered
in this well. The bit drilled the entire section, a total of 166 m at an average ROP of 4.1 m/hr (Table 1). No adverse drilling
vibrations were encountered. The bit was dull graded 2-4-BT-A-X-I-WT-TD, showing even wear across the profile and with some
chippage (Fig. 13). The bit and stabilizers were found in gauge.

The rock strength of the MS2 formation was inferred from wireline logs to be lower than in the first run. The massive hole over-
gauge was not present. These factors unquestionably contributed to the bits ability to drill the section in one run from shoe-to-shoe.
SPE 128562 5

This was the first time the operator was able to accomplish this feat in nearly thirty wells drilled in the field.

Third Run
Inspired by the success of the second run, the operator elected to run the same bit again without further modification, except to
nozzle down jets to 7x14/32-in. to improve bit hydraulics to ~3.5 HSI. The higher HIS, thus higher jet velocity, is believed to
increase cooling of the cutters and provide added cleaning of the bit to improve performance.

The objective was again to drill the entire section in one bit run. This was a somewhat more challenging target than achieved
previously since the planned section for the third well was about one third longer than had been drilled todate.

The bit drilled the 9.625-in. casing shoe and Silurian mudstone, then MS2 and MS1 to Basement, a total of 214 m at an average
2.4 m/hr (Table 1). The drilling parameters during the run were again fully optimized to reduce drilling vibrations.

At surface the bit was graded 3-6-BT-A-X-I-WT-TD (Fig. 14). The cutting structure was evenly worn with some broken cutters in
the cone.

Post-well analysis of wireline logs indicated the MS2 was harder than had been drilled in either of the two previous runs.
Additionally the third run showed the highest quality wellbore. Observations while drilling suggested less drilling vibrations were
encountered.

Conclusions
Although geological lithofacies of these three wells were different, including rock abrasiveness, they were drilled with PDC bits.
The most important conclusion is that the hard and abrasive Cambro-Ordovican reservoir can be drilled using PDC bits. Their
application enables higher ROP to be achieved, eliminates the need (and the associated cost) of a high speed motor/turbine, and
lowers operational costs compared to previous bits.

Collaboration between the operator and bit manufacturer facilitated the development and implementation of new PDC bit
technology that delivered performance improvements, faster learning and lowered the operator’s drilling costs. A key factor was
the preparation of a prognosed lithology plot including prognosed Gamma Ray and acoustic values as well as estimated rock
strength for each section to be drilled, which helped the team anticipate problem areas and plan corrective measures.

Todate, after three completed wells, the optimization process described herein has saved an estimated US$ 700,000 in drilling the
reservoir section (Fig. 15). The new PDC technology is appropriate to drill hard and abrasive formations that were until now
drillable only using impregnated and TCI bits. A section that previously required several impregnated and hard rock roller cone
bits has been drilled shoe-to-shoe on several occasions using a single bit run, and at increased rates of penetration.

BHA improvement and continuous monitoring and optimization of drilling parameters can prolong bit life and improve hole
quality in this difficult application.

More wells have been drilled since the preparation of this manuscript, which have enabled further savings. Moreover, the bit
continues to be improved for increased penetration rates.
6 SPE 128562

Acknowledgements
The authors would like to thank management at JVGas and Baker Hughes for permission to publish this paper. Special thanks go
to Erica Tucci for final preparation of the manuscript.

References
Al-Saeedi, M., Al-Khaldy, M., Mahesh, V.S., Jaffar, A., Brown, A. and Sharma, M. 2009. Breaking Records in North Kuwait Deep Gas Fields
Drilling 16-in Hole. Paper SPE/IADC 119517 presented at the SPE/IADC Drilling Conference and Exhibition, Amsterdam, The
Netherlands, 17-19 March.
Gent, J., Isenhour, J., Freeman, M., Hale, M., and Lyons, N. 2009. Advanced PDC Technologies Deliver Significant Performance Improvements
in the Pinedale Anticline Production Interval. Paper SPE/IADC 119423 presented at the SPE/IADC Drilling Conference and Exhibition,
Amsterdam, The Netherlands, 17-19 March.
Lenamond, C., Marques, L., Anderson, M. and Mota, S. 2005. Performance Gains for Rotary Steerable Through Specialized Bit Design. Paper
AADE-05-NTCE-46 presented at the AADE National Technical Conference and Exhibition, Houston, Texas, US, 5-7April.
Nabhani, Y., Obame-Ondo, H., Kindi, M., Saidi, A., Al-Sheriyani, M., Reek, E., Vempati, C., and Cruz, M. 2009. New Generation PDC Bits
Successfully Replace Impregnated Bits Resulting in Significant Performance Improvements and Savings for the Operator. Paper SPE/IADC
125516 presented at the SPE/IADC Middle East Drilling Technology Conference & Exhibition, Manama, Bahrain, 26-28 October.
Pessier, R.C, and Fear, M.J. 1992. Quantifying Common Drilling Problems With Mechanical Specific Energy and a Bit-Specific Coefficient of
Sliding Friction. Paper SPE/IADC 24584 presented at the SPE Annual Technical Conference and Exhibition, Washington, US, 4-7 October.
Spaar, J., Ledgerwood, L.W., Goodman, H., Graf, R.L. and Moo, T.J. 1995. Formation Compressive Strength Estimates for Predicting
Drillability and PDC Bit Selection. Paper SPE/IADC 29397 presented at the SPE/IADC Drilling Conference / Exhibition, Amsterdam, The
Netherlands, 28 Feburary-2 March.
Wells, Dr. M., Marvel, T., and Beuershausen, C. 2008. Bit Balling Mitigation in PDC Bit Design. Paper IADC/SPE 114673 presented at the
IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition, Jakarta, Indonesia, 25-27 August.
Wells, M. R., 2006. The Use of Computational Fluid Dynamics in Oil Field Applicatons; Invited lecturer, International Oil and Gas CFD
Conference London, UK, 30 November – 1 December
SPE 128562 7

Fig. 1: Lithology column

Fig. 2: Typical UCS, friction angle, and rattiness log

8 SPE 128562

Metres Drilled per Bit Type

Rate of Penetration per Bit Type
200 4

150 3
DISTANCE (m)

ROP (m/hr)
100 2

50 1

0 0
8.5" Imp 6" Imp 8.5" TCI 6" TCI

Fig. 3: Average bit performance by type

Fig. 4: depth-of-cut control rubbing area protection Fig. 5: Lab verification of cuttings trajectory theory

Cutter Wear Resistance Overview

10
Relative Abrasion Resistance

0
Previous Generation Next Generation
Fig. 6: PDC cutter improvements Fig. 7: Stress reduction through FEA interface
SPE 128562 9

Fig. 8: Dynamic stability simulation output

Fig. 9: Original PDC bit design

Fig. 10: Dull bit from Run 1

10 SPE 128562

Fig. 11: Bit improvement

Fig. 12: Gauge type improvement

Fig. 13: Dull bit from Run 2 Fig. 14: Dull bit from Run 3
SPE 128562 11

Fig.14: Section cost/meter comparison

Well Bit Drive In Out Drilled Hours ROP Formations Dull Grade
New PDC Rotary 2085 2245 160 84.4 1.9 Silurian - MS2- MS1 8-5-CR-C-X-1-CT-PR
Well-1
TCI Rotary 2245 2300 55 34.9 1.6 MS1- Basement 1-2-WT-A-E-I-NO-TD
Well-2 New PDC Rotary 1950 2116 166 40.7 4.1 Silurian - MS2 - Basement 2-4-BT-A-X-I-WT-TD
Silurian - MS2 - MS1 - 7-7-WT-A-X-1-BT-TD
Well-3 New PDC Rotary 2188 2402 214 90.3 2.4
Basement
Impregnated HS Motor 2308 2384 76 34.0 2.2 MS2 6-8-RO-N-X-I-WT-DMF
Offset
Impregnated HS Motor 2384 2432 48 21.0 2.3 MS2 2-2-WT-A-X-I-BT-DMF
well
PDC Rotary 2432 2448 16 16.4 1.0 MS2 - MS1 4-4-WT-A-X-I-CT-PR
Table 1: Details of runs