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Abstract
Drill bits manufactured using the powder forge (PF) process
rather than conventional welded hard metal are setting new
standards for soft formation drilling. The PF process provides
unique advantages in hardmetal placement and metallurgical
design thus allowing cutting structures capable of drilling a
variety of formations from IADC 11 to 41 and fixed cutter
type applications with superior performance. This paper will:
Introduction
In 1984, ReedHycalog began to explore a distinctly new
manufacturing process that led to PF cutter technology.
Experiments with an advanced forging method that formed
and densified cutters allowed the creation of cutting
structures that were unachievable with conventional closed-die
forging and machining.
Full-scale tests were conducted in 1991 with prototype bits
that duplicated the cutting structure and materials used in
standard IADC 11 type cutters. The following year a unique
manufacturing facility was built and in 1993 testing began
with 9 7/8-in experimental bits featuring advanced profile
designs.
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SPE 93856
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SPE 93856
The PF bit drilled 2142 ft (653 m) with a 30.2 ft/hr (9.2 m/hr)
ROP compared to a directional offset drilled with a competitor
bit (1) that made 1356 ft (413 m) of hole at 27.7. ft/hr (8.4
m/hr) ROP. In a nearby vertical well, a different competitor bit
(2) drilled 1388 ft (423 m) at a rate of 33.5 ft/hr (10.2 m/hr).
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SPE 93856
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SPE 93856
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SPE 93856
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SPE 93856
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SPE 93856
120%
Reliability
80%
Number of Bits - 60
Effective Seal Ratio - 77%
80% Reliability- 523 Krevs
60%
Number of Bits - 56
Effective Seal Ratio - 71%
80% Reliability- 423 Krevs
40%
20%
0%
100
200
300
400
500
600
700
800
900
Krevs
Bit Comparison
SW Louisiana
PFC Bit
Offset 1
Offset 2
Bit type
Depth Out ft (m)
Footage Drilled ft (m)
*PFC Bit
8332 (2540)
2142 (653)
*Competitor 1
8245 (2513)
1386 (422)
Competitor 2
8300 (2530)
1388 (423)
ROP ft (m)/hr
Inclination In/Out
(degrees)
WOB (TONS?)/t
30.2 (9.2)
0.750/220
27.7 (8.4)
11.9/16.0
33.5 (10.2)
1.30/1.30
15/25
20/25
10/20
RPM Min/Max
50/160
50/114
90/130
Offset
Avg.
1387 (423)
30.6 (9.3)
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SPE 93856
25
23
21
19
17
15
PFC Bit
Competitor 1
Competitor 2
Figure 9b
Cutting Structure
IADC Dull Grade
Inner Outer
1
2
3
PFC Bit
Competitor 1
Competitor 2
Location
Dull
Characteristics
1
2
3
WT
WT
WT
A
A
A
Bearings/
Gauge
Seals
E
E
E
Figure 9c
$5.50
$5.25
$5.00
$4.75
$4.50
$4.25
$4.00
PFC Bit
Competitor
Figure 10a
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I
I
I
Other Dull
Characteristics
Reason
Pulled
NO
NO
NO
HR
TD
TD
10
SPE 93856
100
95
90
85
80
PFC Bit
Competitor
Figure 10b
Average Footage
Yoakum County, Texas USA
3800
3600
3400
3200
3000
2800
2600
2400
2200
2000
PFC Bit
Competitor
Figure 10c
Bit type
Interval ft (m)
Hours
ROP ft /hr (m/hr)
PF bit avg.
TC11
2989 (911)
39.8
75.1 (22.9)
Russian-built avg.
1-1-7
771 (235)
11.6
66.5 (20.3)
0%
81%
100%
Figure 11a
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SPE 93856
11
Footage
3000
2500
2000
1500
1000
500
0
PFC Bit Average
Figure 11b
ROP (Ft/Hr)
80.0
76.0
72.0
68.0
64.0
60.0
PFC Bit
Figure 11c
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12
SPE 93856
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