SPE/IADC 163436

A Breakthrough Performance for an Inland Application with a Hybrid Bit

Technology
M. Di Pasquale, E. Calvaresi, Baker Hughes; S. Pecantet, NV Turske Perenco

Copyright 2013, SPE/IADC Drilling Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Drilling Conference and Exhibition held in Amsterdam, The Netherlands, 57 March 2013

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

This paper describes the field experience of a new hybrid bit based on proven polycrystalline diamond
compact (PDC) bit designs with rolling cutters on the bit periphery. A hybrid bit can drill shale and other
plastically behaving formations up to three or four times faster than a roller-cone bit by being more
aggressive and efficient.
The penetration rate of a hybrid bit responds linearly to revolutions per minute (RPM) unlike roller-cone
bits, which have an exponential response with an exponent of less than one. In other words, the hybrid
bit drills significantly faster than a comparable roller-cone bit in motor applications. Another benefit is
the effect of the rolling cutters on the bit dynamics.
Compared to conventional polycrystalline diamond cutter bits, torsional oscillations are as much as
50% lower; stick/slip is reduced at low RPM, and whirl at high RPM. This gives the hybrid bit a wider
operating window and greatly improves toolface control in directional drilling.
The hybrid drill bit technology combines roller-cone and PDC bits into a single patented design,
employing the best attributes of each bit type to improve reliability and efficiency, while ensuring
performance consistency in the most problematic applications. This revolutionary technology has a
large spectrum of applications, excelling in typically troublesome formations for PDC and roller-cone
bits, such as interbedded hard and soft stringers or hard nodular inclusions.
The results of a field test in an inland application will be presented, comparing the performance of
hybrid bits with conventional PDC and roller-cone bits used on offset wells.
A planning and engineering process was applied, ensuring high-quality support to the operator in the
office and at the rigsite. The client saved multiple conventional tungsten carbide insert bit runs and
drilled 100% farther, ultimately achieving a rate of penetration (ROP) two times faster than the best
tungsten carbide insert (TCI) bit run in the same well.
2 SPE/IADC 163436

Project Background

In January 1996, the operator acquired oil fields in the vicinity of Diyarbakir, in southeast Turkey (see
Fig. 1). With a daily production of 10,000 bopd (net share), the site represents the largest foreign oil
producer in Turkey.

Fig. 1 - Perenco concessions in Turkey

The operator currently manages 200 wells and seven production-gathering stations within a 100 km
zone. The export facility is located at the Pirinclik terminal, which exports crude oil to Mediterranean
seaports.
Production levels have been sustained through recompletions, reactivations, secondary recovery by
water injection, deepening, sidetracking, and development and exploration drilling activities. Two
workover rigs are dedicated solely to well maintenance.
The operator is also actively involved in oil exploration activities in Turkey and committed to increasing
reserves through new field discoveries. The operator is one of the biggest investors in exploration
activities in Turkey and plans to increase investment in exploration projects, especially in southeast
Turkey.

Their operations in Turkey were conducted in line with the internal community development policy. One
of the operators most valuable projects is the Sahaban Bridge over the River Tigris.
The new well, Terdoken-2, is in the Hazro North field near Terdoken and northeast of Diyarbakir, in the
Diyarbakir region of Turkey.
Terdoken-2 will be a vertical well drilled into southeast Turkeys Foldbelt Basin, down to the Mardin
formation (Fig. 2).
The most challenging part of the well included drilling the Karadut formation, where little or no offset
data is available. The Devonian section of the well, to be drilled in 12.25 in., has many shale interbeds
that serve as cap rocks for the lower section's reservoir levels (Mardin Group).
SPE/IADC 163436 3

Fig. 2 - Terdoken-2 well, prognosis and casing sketch

4 SPE/IADC 163436

Hybrid Bit Design

Early concepts of hybrid drill bits (Fig. 3) date back to the 1930s, but the development of a viable
drilling tool has only become feasible with the recent advances in polycrystalline diamond compact
(PDC) cutter technology.

Fig. 3 - The first hybrid bit

The modern hybrid bit design (Fig. 4) is based on two proven (up to six bladed) PDC bit designs in
which the secondary blades have been replaced with truncated rolling cones. As a result, the central
portion of the borehole is cut solely by PDC cutters on the primary blades. The most demanding outer
portion is disintegrated by the combined crushing and shearing actions of the cutting elements from the
rolling cones and fixed blades.
The rolling cones are partial toward the backside of the blades to open up a space or junk slot in front
of the blades for the return of cuttings and placement of nozzles.
A modern hybrid bit can drill shale and other plastically behaving formations up to four times faster than
a roller-cone bit while also being more aggressive and efficient.

Fig. 4 - The modern concept of the Hybrid bit

SPE/IADC 163436 5

Drilling Mechanics and Dynamics

In a hybrid bit, the intermittent crushing of a roller-cone bit is combined with the continuous shearing
and scraping of a fixed blade bit. The characteristic drilling mechanics of a hybrid bit can be best
illustrated in a direct comparison to a roller-cone and fixed blade bit in laboratory tests under controlled,
simulated downhole conditions (Ledgerwood, L.W., Kelly, J.L. Jr. 1991). The drilling mechanics of the
different bit types and their performances are highly dependent on formation or rock type, structure and
strength.
The hybrid bit closes the ROP performance gap between roller-cone and PDC bits without sacrificing
durability. It is uniquely suited for heterogeneous formations with hard, abrasive streaks by achieving a
faster ROP than a roller-cone bit, and being more stable and durable than a PDC bit. Fig. 5 shows the
lower differential torque (T) response of the hybrid bit vs. the PDC, and the lapse of ROP gaps
between the PDC and hybrid bits.

In directional drilling, a hybrid bit has the toolface control of a roller-cone bit and the ROP potential of a
PDC bit. As a result of the lower aggressiveness of the hybrid bit, it is less likely to whirl, and the lower
torque oscillations (T) make it more resistant to stick slip (Fig. 5).

Torque vs. Depth

(Segmented Core, 4000 psi BHP, 120 RPM)

Hybrid RC PDC
8000

7000

6000 T=1800
5000 T=3800
Torque

4000

3000

2000

1000

0
0 5 10 15 20 25 30 35 40
Depth

Fig. 5 - Torque vs. Depth for bit type

Laboratory and field tests show that hybrid technology can be used to improve the drillstring mechanics
and the drill bits dynamic stability. Hybrid bits are highly application-specific and should not
necessarily be considered as a direct replacement for either PDC or roller-cone bits. Hybrid bits have
the potential to greatly enhance the performance of roller-cone bits in shale and other formations that
behave plastically and are subject to bottom balling under high-confining pressure.

The performance of roller-cone bits can be further enhanced in motor drilling where the inherently poor
response to RPM limits their potential. Hybrid bits are well suited for drilling heterogeneous and
interbedded formations where roller-cone bits are too slow and PDC bits are subject to premature
impact damage from harmful vibrations. In directional application, the hybrid bit can provide the strong
tool face control of a roller-cone bit at ROPs typical of PDC bits.
The favorable hybrid bit dynamics are most beneficial in large-diameter roller-cone and PDC bits that
are run at weight on bit (WOB) and torque limits for most rigs, drillstrings and bottomhole assemblies
(BHAs).
The smoother running characteristics, lower torque oscillations and generally lower vibrations of the
hybrid bit not only improves drilling performance, but also the reliability and service life of todays
complex and expensive BHAs.
6 SPE/IADC 163436

Engineering Optimization Process and Field Experience

During the planning phase, a thorough offset analysis was conducted using an engineered optimization
approach that enabled the root causes of downhole tool failures to be identified while mapping the main
drilling hazards.
In the only available offset well, most of the drilling problems were associated with borehole instability,
which induced significant vibration in the BHA and premature cutting structure damage despite the use
of TCI bits.
The implementation of a multi-discipline, total-system approach to select the ideal combination of an
application-specific motor steerable system, downhole drilling dynamics tool and new technology hybrid
bit, in combination with appropriate planning, recommendations, drilling procedures, and best practices,
were crucial to delivering significant performance improvement.
The optimization process had been used successfully for decades in various applications worldwide
and is based on a continuous improvement cycle. In this application, the process involved teamwork
and close cooperation between the operator and the drilling service companies.

Fig. 6 - 12.25-in. target section

The first element of a successful project is proper and effective communication among the service
company team members (both onshore and offshore), and between the team and the operator
representatives. Peer review meetings were conducted to discuss each step of the action plan. This
ensured all team members were aware of the problems encountered on the original well and the
solutions proposed to overcome them on the target well. Those meetings provided a powerful platform
to discuss the tools and equipment being used during the project, and to confirm the best drilling
practices to be applied at the rigsite.
SPE/IADC 163436 7

Data Provided

The meticulous analysis of the 12.25-in. section previously drilled identified areas for improvement
in the future section to be drilled.

BIT NUMBER 3 4 4RR 5 6 6RR 6RR 3RR 8

DIAMETER 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4 12 1/4
IADC CODE PDC - 8b, 13mm 447 447 447 447 447 447 PDC - 8b, 13mm 447
SERIAL NUMBER - 5179054 5179054 5179062 5179052 5179052 5179052 - 5179326
NOZZLES (1/32) 8x14 2x18, 1x16 2x18, 1x16 2x18, 1x16 2x18, 1x16 3x16 3x16 6x14+2x12 3x16
DEPTH IN (ft) 1667 1893 2384 3104 3704 4128 4443 4909 4950
DEPTH OUT (ft) 1893 2384 3104 4411 4128 4443 4909 4950 5789
TOTAL DRILLED (ft) 226 491 720 1307 424 315 466 41 839
DRILL. TIME (Hrs) 33.5 37.5 62 84.25 59.25 30.5 47.75 10.5 114
ROP (ft/Hr) 6.7 13.1 11.6 15.5 7.2 10.3 9.8 3.9 7.4
DRIVING MODE Motor Motor Motor Motor Motor Rotary Rotary Motor Rotary

WOB (klb) 15 - 25 25 - 40 25 - 40 20 - 35 20-40 25 - 35 35 - 45 45 - 55 40 - 45

RPM 84 - 114 84 - 140 98 - 140 150 96 90 90 - 100 150 110 - 130
FLOW RATE (lpm) 2000 - 2200 2000 - 2400 2300 - 2400 2400 2300 2200 2400 2200 2400 - 2500
PRES. (psi) 950 - 1150 1050 - 1250 1200 - 1600 2000 - 2500 1900 - 2600 2650 3100 3000 3200
Gercus / Kayakoy Evaporites / Kastel Marl /
FORMATION Gercus Evaporites Kayakoy Evaporites Kastel Marl Kastel Marl Kastel Marl Kastel Marl
Kayakoy Kastel Marl Kastel limy (40ft)
1-2-WT-A-X-I-BT- 1-1-WT-A-E-I--NO- 3-8-BT-G/M-E-I-WT- 8-8-BT/CC-A-F-N-LT-
DULL GRADING LIH 1-1-WT-A-E-I-NO-PR 1-1-WT-A-E-I-NO-PR 1-1-WT-A-E-I-NO-HR 1-2-BT-G-X-I-WT-PR
BHA BHA PR PN-TD

Fig. 7 - Offset well bit record

For example, the following key areas were identified and should to be strongly re-marked for a
customized bit and BHA technology actualization:
- Seven TCI IADC 447 bit runs for four bits;
- Two eight- bladed, 13-mm bit runs for one PDC bit were deployed on a motor BHA;
- A lost in hole produced relevant non-productive time (NPT), delaying the entire 12.25-in. section
(bit #5);
- The average 12 -in. section ROP was lower than expectations - 2.89 m/hr;
- The number of days to complete the 12 -in. section has been 20-30 days.

All the above points lead to five bits for nine runs on 1,246 meters of footage drilled in 389.5 hours.
This led to more than 20% NPT because of additional cleaning trips, an insufficient DHM torque
response and capability associated with premature bit wear; there was neither a satisfactory nor
smooth drilling process for the entire 12.25-in. section.

Unfortunately, no other examples can be added because of the lack of wireline log data, which
prevented the performance of an effective rock strength analysis.
On a side note, the TCI bits provided acceptable performance; however, the use of PDC bits led to
poor performance with high costs per meter.
8 SPE/IADC 163436

Application Review

Probability Impact Risk Root Cause

Hazard/ Event
(Frequency) (e.g. Cost) (PxI) of event
12 phase

3 3: ILT 9 Hard formation, bit selection, weight

Low ROP [5/9 bit runs] transfer

Many bits to drill the 3 3: extra trips, bit cost 9 PR, HRs, PP, DTF, BHA unable to
section (> 5 bits) deliver DLS
Vertical

Pull bit early (with low 3 3: trips 9 DTF, unable to achieve DLS, change
wear) [5/9 bit runs] BHA, PR

3 3: NPT, sidetrack 9 -
Stuck pipe [6/9 bit runs]

Reaming (more than 2 3: NPT, damage hole 6 -

reasonably expected) [5/9 bit runs]

Hole quality (weight 2 3: ILT as low ROP, 6 -

transfer, stuck pipe) [3/9 bit runs] vibrations, poor logs

Poor Directional Control 2 3: ILT for correction run 6 DTF, bit selection, weight transfer
(w/ PDC bits) [2/9 bit runs]

1 3: low ROP 3 Interbedded in formation / vibrations,

Bit damage [2/9 bit runs] chert, sliding on motor

1 2: NPT, cement costs 2 Flowrate, mud weight, formation

Losses
[1/9 bit runs]
1 1: NPT, extra trip 1 Mud System, Bit Damage, Vibrations
Motor Failure
[1/9 bit runs]

Vibrations ? ? ? ?

Table 1 - Risk hazards analysis

PROBABILITY
1 2 3
One run <= Half run Every run
Level / Seldom / Sometimes / Every Time or
Often
IMPACT

3 1 0 4

2 1 3 0

1 1 1 0
Table 2 - Hazards probability and mitigation plan
SPE/IADC 163436 9

12.25-in. Section Objectives

The final action plan consisted of a tailored BHA design in line with the well trajectory to maximize the
bit performance. These actions led to a drastic cost reduction by reducing and mitigating NPT and risk
hazards. This minimized the bit run cost per meter while maximizing the distance drilled and associated
drilling hours (Fig. 8 and Fig. 9).

250000 1400

1200
200000

1000

150000
800

Feet
USD

Costofthesectiondrilled
600
100000 TOTALDRILLED(ft)

400

50000
200

0 0
PDC 447 447 447 447 PDC 447
121/4 121/4 121/4 121/4 121/4 121/4 121/4

Fig. 8 - Cost analysis for bit run

1400 120

1200
100

1000
80

800
Hours
Feet

60 TOTALDRILLED(ft)
600 DRILL.TIME(Hrs)
TripTime(Hrs)
40
400

20
200

0 0
PDC 447 447 447 447 PDC 447
121/4 121/4 121/4 121/4 121/4 121/4 121/4

Fig. 9 - Footage and time analysis for bit run

The final action plan, the operators objective and extensive engineering modeling, was the result of
intensive brainstorming and discussions within the team, which ultimately defined the best practices
and procedures. The contingency plan and risk analysis provided a course of action to minimize or
avoid unexpected problems.
10 SPE/IADC 163436

Action Plan
The solution was a bit combination of two standard bits to improve drilling at tough formations.
The special drilling characteristics of the hybrid bit enable it to drill various problematic formations better
than PDC bits (less torque fluctuations) and faster than TCI bits.

Fig. 10 - 12.25-in. hybrid bit

The chosen hybrid bit with three cones and 16-mm/13-mm PDC cutters, customized for the application
(Fig. 10) was approved through an action plan discussed and agreed to at the rigsite, and finalized
with the drilling superintendent to properly plan for premature bit pull out of the hole (during the run).

During the pre-run phase, the risk analysis was linked to the bearing life of the roller-cone part of the
hybrid bit to define the best time to POOH with least risk (Fig. 11). Karadut and Kastel Marl were the
key formations throughout the run (Fig. 12).

Fig. 11 Roller-cone Krevs limit and POOH decision table

SPE/IADC 163436 11

Fig. 12 - Key Formations

Fig. 13 shows the results of the optimized BHA design and hydraulics approved by the operators
representatives at the rigsite.

Fig. 13 - Motor BHA with the 12.25-in. hybrid bit

12 SPE/IADC 163436

The use of a bit-sensing module installed in the bit shank was also agreed upon by the operator. The
advantage of this bit-sensing module enables the BHA to be closer (into) the bit. This module can help
the operator identify, once out of the hole, the root cause of the vibrations.

Fig. 14 Bit-sensing module

Run Execution
During execution, a drilloff test was conducted to identify the optimal parameters based on the actual
drilling environment. The base WOB used was higher than a standard PDC, but lower than a tungsten
carbide insert bit. The RPM used was significantly lower compared to a standard PDC; the crushing
action of the roller-cone part of the hybrid bit mitigates potential vibration, while a lower RPM extends
the bit bearing life.
The first three 12.25-in. runs began in a medium/soft formation with hard dolomite and chert inclusions.
There was an inconsistent overall performance of the TCI bit and premature motor failure (power
limitation, poor reliability).
Meanwhile, the borehole incline progressed to 8 over the last run, leading to very poor vertical control.

Bit Run Type ROP Footage BHA Formation Reason Pull

# [m/hr] [m] Type
GX-03 3.81 523 NS Shale, Gravel
11 IADC 417 Motor and Dolomite PR
(Kayakoy) (7-7-BT)
GX-18 5.28 219 NS Shale, Gravel
12 IADC 447 Motor and Dolomite PR
with Cherts (5-7-BT)
(Kayakoy)
Comp-1 3.25 78 NS Marl, Shale,
13 IADC 517 Motor Dolomite and DTF
Limestone (1-1-WT)
(Kayakoy-
Karadut)
Table 3 - Bit runs prior the hybrid bit run

The time arrived to use the hybrid bit: while approaching the Kastel Marl and into the Karadut formation.
SPE/IADC 163436 13

Performance Summary

Although a low-speed motor deployment was recommended as a result of the planning phase, the
operator had to use a normal-speed motor (max 175 RPM total) with an AKO set to 0.8-in. to spot the
well profile back to the verticality.
During the run, some problems were encountered while trying to keep the inclination as low as possible
because of the highly interbedded nature of the formation (limestone and shale with radiolarite
nodules). Despite the adverse drilling environment, the hybrid bit helped reduce the borehole inclination
from 8 to 2.8 before POOH.
The overall average ROP was 9 m/hr until the mud pumps failed at approximately 2,100 m. This event
caused 10 hours NPT once the ROP did not rise up and the formation changed again over last 20m
(shale/marl stringers).

In 78.5 hours 328 meters were drilled, as summarized in Table 4. The bit was POOH for hours having
achieved more than 800 Krevs on a PDM BHA (red tag in the risk analysis) with the cutting structure in
good condition; there was more wear in the PDC shoulder and gage areas with a failed cone (Fig.
15). Overall, the hybrid bit drilled 100% more than the offset, and almost three times faster than the
offset TCI runs despite the presence of radiolarites.

Bit Run # Type ROP Footage BHA Formation Reason Pull

[m/hr] [m] Type
Limestone, Marl,
14 HP533X 4.2 328 NS Shale, Cherts HR
Motor and Calcite
(Karadut /
Kastel)
Table 4 - Hybrid bit run record
14 SPE/IADC 163436

Fig. 15 - Hybrid bit dull grading pictures

To complete the section, the operator needed two additional tungsten carbide bits (IADC 417-517)
because of the massive presence of hard nodules in the shaly drilling environment before entering the
top of the reservoir.
Both roller-cone bits came out heavily damaged and did not perform as expected in terms of cost per
meter and overall drilling performance (Fig. 16).

Fig. 16 - 12.25-in. IADC 417 (bit run #14)

SPE/IADC 163436 15

Conclusions

The deployment of the 12.25-in. hybrid bit in the Terdoken-2 well delivered an outstanding
performance, and demonstrated strong potential for this revolutionary bit technology versus standard
roller-cone bits or previously deployed PDC bit technology.
This applies to interbedded lithology (marl, shale and dolomitic stringers with chert nodules, i.e. Kastel
Marl formation) drilled in Terdoken.
The tungsten carbide insert bit IADC code 417 failed to drill through chert/radiolarites inclusions.
Harder roller-cone bits (IADC 447/517) resisted damage better but they delivered slower ROP when
compared to the hybrid bit.
A PDC bit used in the offset well failed to drill through the Kastel Marl formation, and the ROP was
lower in comparison to the roller-cone bit IADC 447. The use of vertical PDM assembly has contributed
to the ROP improvement of the hybrid bit performance when compared to the same BHA with a TCI bit.
The total system approach and proper pre-well planning were vital to success. Overall, the hybrid
drilled farther than any TCI used in the Terdoken-2 well, saving at least two bits and further bit runs.
The hybrid design was the bit of choice when bit consumption was high, performances poor, and in the
presence of highly interbedded formations.
The hybrid bit produced the lowest cost per meter value (Fig. 17) for the last four 12.25-in. sections,
saving the operator more than USD 100k.

Fig. 17 - Cost per meter chart

16 SPE/IADC 163436

Acknowledgments
The authors wish to thank the operator and Serges Pecantet for their collaboration while editing this
paper, trusting this new technology and giving us the chance to run the first hybrid bit in our continental
Europe geomarket in a challenging environment. Their involvement in proposing changes and
improvements on BHA configuration and rigsite follow-up gave the spark to everyone in the
organization to progress with this new bit technology introduction, improvement, deployment and
development.

Nomenclature
BHA bottomhole assembly
BOPD barrels oil per day
RSS rotary steering system
DART design application review team
DOCC depth of cut control
ECD equivalent circulation density
LMM lateral movement mitigator
LWD logging while drilling
MD measured depth (m)
MTBF mean time between failures
MWD measurement while drilling
PDC polycrystalline diamond compact
PDM positive displacement motor
RCLS rotary closed-loop system
RNS reservoir navigation system
RSS rotary steerable system
ROP rate of penetration (m/hr or ft/hr)
ST sidetrack
TVD true vertical depth
TCI tungsten carbide inserts bits
WOB weight on bit
WT worn teeth
SPE/IADC 163436 17

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