A

SPE 49256

~ Societyof Petroleum Engineers !

Applications and Limitations of Advanced Steel Body PDC Bit Technology

L.M. Smith, Security DBS; V.P. Perrin, Chevron; Petroleum Technology Co.; M. A1-Habsi, ADCO; F. Mody, Baroid Drilling Fluids, Inc.; R. Delwiche, Security DBS; E. Akin, Vortexx Group, Inc.

Copyright

1998, Satiety

of Peboleum

Engineers,

Inc. Conference and

l%is paper was prepared for presenHion al [he T998 SPE Annual Technical Exhibition held m New Orleans. U.S.A., 27-30 September, 1998.

specific applications including high shale content formations drilled with water-based muds.(2) Extensive laboratory testing in combination with an industrysponsored study of underbalanced drilling using water-based drilling fluids, served to identi~ several additional areas for further improvement of steel body bit performance, Specifically, an anti-balling coating and redesigned hydraulics system were found to result in a step improvement in steel body bit performance. Now. with more than 100 steel body bit runs documented worldwide, the application range for the advanced bit designs has been further define4 and limitations have been identified.
Advanced Design Features

Thts paper was seladed for pr-entstion by an SPE Program Committee following review of information contained In an abstract submitted by the aulhar(s). Contents of the psper, as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to .mraction by the author(s). The material, as presented, d&es not necessarily reflect any pasition of the %ciety of Petroleum Engineers, its officers, or members Pap-are pfesented al SPE meetings are subject to publication review by Editorial Committees of the Scciety of Petroleum Engineers. Permission to mpy Is restricted to an abstrscf of not nwre than 300 words. Illustrations nsay not be copied. The abstract shauld ccmtaln conspicucw actmolwedgment of where and by whom the pspar was presented. Write Librarian, SPE, PO. Sox 833838, Richardson, TX 7S083-3836, U.S.A., fax 01-972-952-9436.

Abstract New steel body PDC bit technology is shown to enhance

drilling performance in a range of applications previously limited to matrix body bits. Specific aspects of the technology are &taile& including various proven desigm features, and unique manufacturing and materials treatment. In addition. the paper addresses the impact of increasing energy available at the bit face through utilization of a new hydraulic jet technology in combination with the advanced features of steel body PDC bits. Case histories are included to describe the application range of the new steel body bits, in terms of Mh drilling performance and economic impact.
Introduction A new series of steel body bits, which combines proven

The following design considerations were deemed critical to maintaining the performance advantages demonstrated in laboratory testing: q A high normalized open face volume, which had been &termined to improve penetration rate; q Anti-balling (AB) coating which significantly reduced bit balling under Ml scale laboratory drilling conditions; .
q

Short gage lengJh, which improved stability and steerability; Cutter size, type and numker, with a heavier-set, large PDC cutter style seleeted based on anticipated drilling conditions,

design enhancements of matrix body bits and a completely redesigned hydraulics configuration. has demonstrated enhanced drilling performance in a range of applications previously limited to matrix body bits. Meady widely discussed in the literature. a number of PDC bit design features have been introduced in the past, which have resulted in improved drilling performance of matrix body PDC bits in directional applications.() Limitations to fiuther improvements have been a function of bit design constraints imposed by matrix material science and manufacturing issues. With development of a unique manufacturing process for steel body bits, these design features were able to be incorporated into the new bits. and produced similar drilling performance improvements in

The steel body bits are manufactured with features that enhance directional performance without compromising ROP. Such features include impact arrestors, varied cutter sizes and backrakes, spiraled blades and extremely short profiles that are just half the length of a standard steel body bit. In addition, the steel body bits are force-balanced in a proprietary process that positions cutters to dramatically reduce downhole vibrations that can cause were cutter damage. Furthermore, the new steel body bits incorporate spiral, asymmetric blade layouts which disrupt the harmonic effeets that lead to the onset of bit whirl, as well as tracking

733

SMITH, PERRIN, AL-HABSI, MODY, DELWICHE, AKIN

SPE 4256

cutter layouts which drill a scalloped or ridged bottomhole pattern that has proven more whirl-resistant than the patterns generated by conventional PDC cutter layouts.
Anti-Balling Treatment

fluid across the blades and cutters of the bit. In actual field applicatio~ this has translated into longer cutter life and much improved dull grade condition. Associated with this increase in entrained fluid is a dramatic increase in the localized turbulem at the rock cutter interface, and localized reduction in hydrostatic pressure bearing on the reek face. This peeuliar phenomena has been ( In discussed in a number of prior publications. 4-5) addition, turbulence is increased at least hvofold. An additional feature of the fluted nozzle is that one achieves increased real HSI at the bit without either increasing flow rate or decreasing cross sectional area of the exit orifke. This benefitof the fluted nozzleprovidesa significant advantage when greater-than-normally-possible HSI is desired and when increased HSI is known to be or considered advantageous. The coefficient extraction meth@ described in the literature, and resultant data indicate a range of increased HSI from eighty pereent to well over one hundred percent, depending upon the size of the fluted nozzle used.(s) Briefly, the article describes the differential in HSI when using the new nozzles, and explains how and why a cwfflcient of 2-2.5 should be applied when calculating the adjusted HSI. The actual value to use as a comparison when calculating standard HSI is as follows: Standard circular nozzle HSI = 0.98 X calculated HSI by standard method (The 0.98 correction coefficient is exact and represents the actual HSI when calculating for a standard nozzle.) Then: multiply the corrected calculation by 2.5 to get Vortexx Nozzle HSI value. Example; If HSI calculation is 2, an adjusted value of 2 X 2.5 or 5 is the corrected Vortexx Nozzle HSI value. This explains why Vortexx Nozzles are so effective in those formations that are especially HSI-sensitive: The amount of ener~ available at the bit face ean be increased without increasing flow volumes or decreasing total cross sectional area of the nozzles. Pertlormance increases in ROP are the most obvious consequence; however, longer bit life and lower cost per foot result in all bits using this technology.

Improved PDC bit performance in water-based muds results when bits are treated during manufacture with an anti-balling eating. The AB coating process is shown to reduce PDC bit balling and improve penetration rates in soft shale formations drilled with water-based muds by imparting a permanent electronegative charge to the bit. Because like charges repel, the negative charge of the bit repels negative ions of shale, making them less likely to adhere to the bit, thus preventing balling during drilling. The nitriding process used to apply the AB coating causes the steel, which originally is electrically pxitive relative to the mu~ to become negative. This causes the ions to be repelled from the bit surface, generating a lubricating layer of water and creating an anti-balling effect. Based on this research, a new method was developed to apply a small negative voltage to the bit which causes water molecules to migrate to the charged surface, providing the lubricating film that prevents mud adherence. First tested during an industry-sponsored water-based drilling study, and then in operator-sponsored fieldtests, the ABcoated steel body bits proved to achieve sigtMcant improvements in penetration rates. When run in the simulator using a silicate mud system, the coated bits increased ROP to more than 180 ft/hr. In further lab tests, the steel body bit designs increased ROP from less than 10 fVhr to more than 100 Whr penetration rates that exceed those typical in an oil-based mud system. These performance results have since been eorrotirated by documented field results.
Re-Designed Hydraulics

Fluted nozzles currently used in the new steel body drill bits offer hydraulic features which overcome the typical causes of bit failure and performance limitation. The asymmetric Vortexx nozzle &sign used in the new steel body bits creates a unique flow pattern which essentially increases turbulence at the rockkutter interface, resulting in improved bit performance. Specitlcally, sharply increased fluid entrainment into the prirpary exit flow domain is due to differential fluid exit velocities at the nozzle orifice. The increased entrainment drives fkom four to eight times more re-circulated cooling

734

SPE 43256

APPLICATIONS AND LIMITATIONS OF ADVANCED STEEL BODY PDC BIT TECHNOLOGY

Summary of Global Applications To maximize the benefits of the new technology, steel body

bits are considered in the context of a total systems approach to drilling operations. Application of the bits takes into account the synergies of well design and BEL&fluid properties, drilling equipment, and rig capacities. Limitations have been the result of erosion issues. Both internal and gauge erosion of steel body bits has long been a problem in applications that demand abrasive fluids and enhaneed hydraulics. To date, with engineered application of the new steel body bits only limited erosion problems have been documented. These issues will be investigated further. With more than a dozen field-record runs to date, the steel body bits are initially recommended in drilling applications with more than 40% shale content, and generally are run in the larger diameter, top- and intermediate-hole environments. In directional wells, swelling shales, and a variety of applications requiring use of water-based mud steel body PDC bit performance has produced signitlcant savings for operators through improved drilling performance. Following this summary of global applications, specitlc case histories of several steel body bit applications are detailed in the section, Field Performance Results. AJ%ca. The new steel body PDC bits have achieved outstanding results through diftlcult, interbedded formations in applications in Angola, Egypt and The Congo. (See case history in following section). Alaska. In the 8-1/2 hole section of a Kuparuk Field application, an S424 drilled 3974 feet at 160 ft/hr. When pulled at TD, 10,000 fl depth, it was graded re-runnable. Australia. The steel body bits have been used with success in directional applications through long intervals of mostly limestone with varying marl content, where dolomite stringers are encountered but unpredictable. One S323 drilled 119lm at 37.2 m/hr under controlled drillin~ to successfidly maintain hole angle at 35. It was re-runnable, G@_of Mexico. Initial application of the new steel body bit designs included directional applications using water based mud in the Gulf of Mexico, where the new designs outpetiormed comparable matrix body bits. In one well, an 8-1/2 four-bladed steel body bit drilled 1465 feet in 102 hours, to achieve a weighted average ROP of 14.4 Whr. The S232, with 28 13mm PDC cutlers and four standard nozzles, was run twice; drilling 1154 feet at 15.8

tVhr in the first run, and311 feet in a second run. The bit was pulled green and no bit balling problems were encountered Specific petiormance details are included in Table 1. Norfh Sea. Solid performance results are documented for steal body bit applications in Norway, Holland and Aberdeen, where 12-1/4 and 16 tophole seetions of directional wells have proven to be an ideal application. In one build-and-drop well profile, a 16 S223 drilled 6740 feet at 87 ft/hr through shales and clay. The bit was run on a 9-5/8 motor, successfidly completing all directional objectives and setting a field run record. South America. Offshore Argentina, FS bits have performed well in 8-1/2 sections through sandstone, shale, marl and consolidated sandstones. The bits also have found wide application in Venezuela, as detailed in the ease histories in the following section. Middle East. One of the prime applications identified for the new steel body PDC bits is the 12-1/4 hole section of directional wells through interbedded formations in Abu Dhabi and Yemen fields. In both directional and straight-hole applications, using both top drive and rotary, the steel body bits achieved pmetration rate and fbotage that exdeeded previous performance by all other bits. (Figure 4) The new line of steel body bits currently has achimed the most records of any type of bit run in Abu Dhabi, including records for ROP, most fmtage in 24 hours, fastest interval, most footage and most records. In one project where 50 wells are planned to be drilled using four rigs, application of steel body bits thus far has more than doubled penetration rates from 37 ft/hr to more than 75 fVhr. Already in the course of this project, a 12-1/4 S323 has established two record pefiormances for the field increasing ROP by 32%over the previous six lxst wells drilled with a o PDC bit on a top drive unit; and drilling record footage for a 24-hour period. Run on a slow-shigh-torque motor, the S323 drilled an interval of 3105 feet of interbedded formations at a total average ROP of 76.7 fVhr. This exceeds Wnetration rates of the pr~ious six best runs, which ranged from 70 to 44.6 ft/hr for a cumulative average of 57.2 tVhr. In addition, the steel body bit, used to drill out cement, shoe and float collar, maintained an average ROP of 84.7 tVhr while drilling through 2032 feet of the total footage in a 24-hour period. When pulled at TD at 8795 ft, the bit was graded 3% worn and was re-runnable. The same bit then was re-run and drilled another 2640 feet to within one-tenth of a foot of a new record for ROP in the field

735

SMITH, PERRIN, AL-HABSI, MODY, DELWICHE, AKIN

SF%49256

In the same field in the Middle East, a second steel body PDC bit was run, achieving a field record penetration rate on a kelly rig with an increase in ROP of 35?ZO the previous over three best wells drilled with a PDC bit. All aspects were constant for these runs, including formation tops, fmtage drilled mud weight and system, operating parameters and rig used. This 12-1/4 S323 bit was then rerun and set the new Abu Dhabi 12-1/4 cumulative footage record (for non repair bits) with a total of over 9000 ftxt. Far East. The steel bits have a achieved records in offshore applications 6)and are gaining wide use in tophole sections of wells in Malaysia, Brunei and Borneo, In the Philippines, one FS steel body bit, used in conjunction with the complementary matrix body bit design, achieved pefiormance results that saved the operator an estimated two million dollars.
Field Performance Results

The 12-1/4 steel body bit, designated S123, incorporated the new Vortexx nozzle hydraulics and was run in conjunction with a new PDM with extended power section, which was expected to prove beneficial in the top part of the hole section. The S123 steel body bit initially drilled3311 feet in 32.5 hours, achieving an average ROP of 102 Whr. When ROP then dropped to only 22 tVhr, the bit was pulled and cutting structures were found to be green. However, 6 of the 8 impact arrestors on the bit shoulder were broken. The motor was found to be in good condition. The exact same BHA was then run back in the hole, and the bit drilled an additional 42 fixt in 3.5 hours, for an ROP of 12 Whr. When pulle~ it exhibited severe impact damage at the bit shoulder. Specifically, cutters in this area were broken and chipp@ right down to the body of the blades. However, remaining cutters on either side of the area were in good condition and the bit was in gage. It was determined that there was no manufacturing defects in the bit or motor, but rather, that the drill string experienced some bouncing during the interval, in which traces of dolomite and pyrite were encountered. The bit was dull graded as follows: 2-7-BT-S-X-I-CT-PR. (Figure 1) The S123 achieved the lowest cost per foot of any bit run on motor in this application. However, it was determined that improvements could be achieved by using a slower speed motor (<175 RPM) or minimal top drive speed (100 RPM); and by anticipating and responding to quickly to any sign of vibration or bouncing. The Congo. A six-bladed 16 steel body bit, identified as S123, with 19mm PDC cutters was used to drill a variable formation of clay with thin beds of shaly limestone; through siltstone with sandstone, clay and limestone layers; into interbedded shales, limestone and sandstone. This bit replaced a similar six-bladed steel body bit, but included the following improvements: . .
q q q

Galveston Bay. In a recent Galveston Bay well, one steel body PDC bit replaced an average of three to five PDC and roller cone bits typically used for the 2000-foot interval. The 8-% S323 drilled more than 2046 feet at an average ROP of 16.3 fUhr, achieving penetration rates that averaged twice that of the offset bits. GulJofMexico. In its initial run in the Gul.f.ofMexico, an 8-1/2 S232, a four-bladed design, with four standard nozzles, and a total of 28 %-inch PDC cutters, drilled a total of 1154 fmt in 73 hours to a depth out at 17,392 ft, achieving an average ROP of 15.8 Whr. By compariscq the previous bit run drilled just 520 feet in 56 hours for an ROP of 9.3 R/hr, and was pulled due to bit balling and slow penetration rate. In a second run, the same S232 bit drilled311 additional feet to 17,703 ft in 29 hours, achieving an average ROP of 10.7 fVhr. On the following run, a competing bit chilled 593 feet in 68.5 hours, achieving an ROP of 8.7 ft/hr. Overall in this application the S232 steel body bit drilled two runs for total fmtage of 1465 feet in 102 hours, achieving a weighted average penetration rate of 14.4 Whr. No bit balling problems were encountered. When pullcxl the S232 was still greeq exhibiting less than 20 % wear, and was deemed rerunnable. Alturitas Field, Venezuela. The objective in this well was to drill a straight hole from surface (2115 fket) through La Sierra sands at approximately 9800 feet. This formation is comprised of sand ( 10-800/0),shale (20-30/0) and claystone (10-80%).

Shorter, more stable profile Advanced Ring Claw cutters which incorporate a greater volume of diamond Variable back-rake, as opposed to a 15 back-rake A total of 8 nozzles, as opposed to 6 Anti-balling coating Gage reinforced diamond hardfacing

Using a top drive rotary, the S123 drilled 1476m at an average ROP of 14.5tn/hr. It was pulled in like new condition with no cutter wear and only a single impact arrestor broken on the nose. By comparison, previous steel body bits achieved an average ROP of 11.3 ndhr through a

736

WE 432s6

APPLICATIONS AND LIMITATIONS OF ADVANCED STEEL BODY PDC BIT TECHNOLOGY

similar interval when drilled on rotary, but at times, exceeded 20 m/hr when drilling with a PDM. These bits were not rermmable after being run on rotary. While the S123 did not match penetration rates of the previous steel body designs run on motors, it exceeded ROP for rotary drilling and was pulled in a much Wter dull gra& condition. Specifkally, where early designs experienced spalling and delamination on gage cutters, and were unable to drill the interbedded shales efficiently, the S123 design was dull graded as follows: O/O/NO/A/X/I/NO/TD. (Figure 2) The new S123 bit exhibited greater strength than earlier designs, with ROP expected to improve when motors are used and/or the new redesigned hydraulics nozzles are incorporated. Because no wear was evidenced on the gage cutters, RPM could also be increased from the current 120 to 150/160 RPM on future runs in this application. Venezuela. A 12-1/4 S323 bit incorporating the new Vortexx nozzles was used to drill a shaley formation interbedded with sandstone, achieving an average ROP of 84.2 Whr over 8507 feet. The bit was used to drill out cement, plugs, collar and shoe, starting to drill formation at 7351 feet. Early drilling was controlled to limit ROP, which initially exceeded 200 ft/hr. When pump problems caused a trip at 12,000 feet, the bit was found to be green with only one broken impact arrestor. At 14,000 R it was still onIy slightly worn, and at 15,871 feet, the bit was graded about 40% worn. As documented by a series of photographs of the bit (Figure 2), most of the wear omurred in the final 2000 feet of drillin~ where the formation was quite interbedded by sandstone and encountered coal stringers. It should be noted that during this application, the S323 was modified from Vortexx nozzles to standard nozzles when pulled at 12,000 feet, and yet exhibited no wear tier the next run. However, when ROP slowed and high torque was exhibited at 15,800 ft, (probably due to the coal stringers) the bit was pulled with regular wear, two chipped cutters and three broken impact arrestors. It was dull graded as follows: 2-4-WT-N/T-X-I-BT-TD. (Figure 3) It was determined that, in this application, the impact arrestors were effective in protecting the cutters when harder formation stringers were encountered, Moreover, they add life to the tint cutters without sactilcing penetration rate. In addition, the S323 performed well with both Vortexx and standard nozzles, and exhibited no erosion wear, normally a limitation of steel body designs.
Conclusions

Development of a unique manufacturing process for steel body bits has enabled proven, performance-enhancing bit design f&Uuresto be incorporated into the new steel bits. When applied as part of a total systems approach to drilling operations, the resulting new steel body PDC bit technolo~ is shown to enhance drilling performance in a range of applications previously limited to matrix body bits. The steel body designs are not intended to replace, but rather to complement application of matrix bits as part of an engineered bit program. In additio~ a completely new, asymmetric nozzle design for the steel body bits changes bit hydraulics and increases penetration rates. The Vortexx nozzles are effective in those formations that are especially HSI-sensitive. They effectively increase the amount of energy available at the bit face without increasing flow volumes or decreasing total cross sectional area of the nozzles. Performance increases in ROP are the most obvious consequence; however, longer bit life and lower cost per foot result in all bits using this technology. To date, no signi.tkant problem with internal erosion has been experienced as a result of the redesigned hydraulics used on the steel body PDC bits. The problem of external erosion continues to be investigated. The application limits of these new steel body PDC bits continues to expand as experience is gained. From an initial application of larger-diameter, tophole sections in primarily shalely formations, the bits have now ken proven effective in harder, interbedded formations and greater depths. Performance in these expanding applications require extra consideration of drilling parameters, as well as focus on the total system, to accommodate more diffkult conditions. Application Considerations . Water-Based Mud q Top Hole Section
q q

Larger-diameter,IntermediateHole Section High Shale Content Formations

References

1. D. VrooW R. Munger, A. Rawicki and L. Smith, Applications and Limitations of Composite Cutter Drill Bits in the Gulf Coast Region, SPE 20414, New Orleans, LA., September 1990. 2. Al Habsi and A. Shaman, ADCO, L. Smith, S. Allam, and P. Cortes, Security DBS: New Steel Body PDC Bits Deliver Record Setting Performance, Petroleum Engineer International, February, 1998. 3. S. Roy and G.A. Cooper, Prevention of Bit Balling in Shales: Some Preliminary Results, IADC/SPE 23870, February 1992.

737

SMITH, PERRIN, AL-HABSI, MODY, DELWICHE, AKIN

SPE 492!33

4. Al@ J.E., Smith, S.K., and Dove, N.R.,: The Negative Impingement Pressure Nozzle Phenomenon, Computational Mechanics 95, S.N, Atluri (cd), Springer, Tokyo (1995) 1108-1115. 5. Al@ J.E.: HSI Redefined for Drilling Hydraulics; Journal of Petroleum Technology, 1997. 6. Smiti L.M., et. al., Steel Body PDC Bits Demonstrate Performance Improvements, IADC/SPE paper 47815, Jarkarta, Indonesia, 7-9 September, 1998.

and ADCO for permission to publish this data, and thank the following field and operations personnel: Mike Reese, Terry Dailey, Normal Cooper, Rob Arfele, George Espiritu, Calvin Elmer, Rusty Milam, John Kelety, Dan Symonds, Tommy Hymel, Gary Weaver and Bill King. We also acknowledge the efforts of the drilling contractors and rig crews who supported our efforts during these bit runs. as well as stalT in District offkes in the Fa~East, Malaysia, Africa, Singapore, Jakarta, South America, the Middle East, North Sea, Australia, Alaska and the Gulf of Mexico.

Acknowledgments The authors wish to thank Security DBS, Total, Trans Texas

Comparison: Matrix Body vs. Steel Body PDC Bit Design : Gulf of Mexico First Run Comparable Matrix Body Bit 8-1/2 4-Bladed Steel Body PDC Bit Depth Out 16,238 ft 17,392 ft Footage Drilled 520 ft l154ft Total Hours 56 hrs 73 hrs Average ROP 9.3 ft/hr 15.8 ftlhr Second Run Depth Out 18,296 ft 17,703 ft Footage Drilled 593 ft 311ft Total Hours 68.5 hrs 29 hrs

Table 1. Performance

Figure 1. Venezuela Well: 12-1/4 S123 after 3311 R. in 32.5 hours,

Figure 2. Congo Well: 16 S123 after 1476 meters at 14.5 m/hr.

738

SPE 49256

APPLICATIONS AND LIMITATIONS OF ADVANCED STEEL BODY PDC BIT TECHNOLOGY

Figure 3. Venezuela Well: 12-1/4 S323 progression of wear at 14,000 f&(above) and 15,871 ft (below).

..

..

Figure 4. Comparison of total footage per bit, Abu Dhabi application.

739