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Since the introduction of PDC bits, there have been many The three main types of drill bits for these applications are
significant advances in the properties and design of the PDC PDC, diamond impregnated, and roller cone bits. PDC bits
cutting elements (cutters).3,4,5 In addition to the development traditionally exhibit good ROP through the shale sections, but
of the cutters themselves, drill bit manufacturers have made quickly dull out in abrasive sands. Roller cone bits also
large strides in understanding the drilling mechanisms exhibit good ROP in these sections, but cannot drill for the
involved in the shearing action of this type of drill bit. This extended times typical of fixed cutter diamond bits. The main
improved understanding has led directly to new advanced bit problem with using roller cone or PDC bits is the cost induced
designs that are greatly increasing the application envelope of by tripping out of the hole frequently to change out dull bits.
PDC bits.6,7,8 In many cases, this increased application On the opposite end of the spectrum lies traditional diamond
envelope has taken away a large portion of the “softer end” of impregnated bits. This type of drill bit is ideally suited for
the surface set diamond bit market. drilling in abrasive / sandy applications, but does not drill
efficiently through sections with a high percentage of shale.
The circle of diamond bit development was completed with The limited exposure of the diamond cutting structure,
the fairly recent re-introduction of impregnated type diamond coupled with the limited amount of space available for the
bits. With the proliferation of turbines and high-speed motors, ejection of cuttings, equates to very slow rates of penetration.
capable of higher rotary speeds than previously possible, Therefore, while traditional diamond impregnated bits can
diamond bit manufacturers were able to produce diamond bit drill through these formations for fairly long times, their
designs with smaller diamonds without sacrificing ROP corresponding rates of penetration tend to be very low.
potential. Further, as a result of advances in the design,
materials and manufacturing processes involved in producing This paper will present a novel diamond bit design that
diamond impregnated bits, drill bit manufacturers are able to bridges the gap between diamond impregnated and PDC bit
deliver diamond impregnated bits which can drill as fast as, applications. This new type of diamond bit combines the
and longer than, surface set diamond bits in hard and abrasive advantages of PDC and diamond impregnated cutting
applications. The combination of high rotary speeds and structures, and introduces a unique concept in diamond bit
improved diamond impregnated materials has allowed cutting elements.
diamond impregnated bits to nearly displace surface set
diamond bits in the “harder end” of that market. Background:
The Palo Marcado field in Tarija, Bolivia contains a very hard,
The challenge that remains to the diamond bit industry is to variable formation. The current drilling campaign on this
expand the existing market in order to continue to reduce field, located in Southern Bolivia, just north of the
operators’ drilling costs. Significant strides have been made Argentinean border, began early in 1997.
in this area through a more thorough understanding of the
formations being drilled. The tools that are available and in The formation in question is called the Huamampampa. In
common use today for formation evaluation are a major reason this field, the formation top comes in just below the Los
for the increase in the application envelope of diamond bits.9 Monos at a depth of ~ 4100 meters, and continues down to
Nonetheless, in spite of the excellent work that has been finish just above the Icla at a depth of ~ 4800 meters. This
completed in the development of both PDC bits and diamond formation is of Devonian age, and contains mostly sandstone
impregnated bits, there are still many applications that fall and shale. The compressive strength of the Huamampampa
between the two. The industry has seen, and continues to see, averages around 18,000 psi, with a high of 30,000 psi. The
significant technological developments in PDC bits which difficulty in drilling this hard formation is evident through
enable these bits to perform economically in harder and more investigation of the lithology. In this area, the shale content of
abrasive applications than ever before, yet there are still many the Huamampampa is highly variable and can range from 10%
applications that are either too hard or too abrasive for PDC to 90%.
bits. Conversely, while traditional diamond impregnated bits
drill effectively in hard and abrasive applications, bit balling Much effort has been devoted to determining the most
and ineffective cutting action are common in non-abrasive economical method of drilling this challenging interval. As
formations. with many other applications of this nature, the three main
types of drill bits discussed above have been utilized. Roller
There are many hard rock drilling applications around the cone bits have proven to perform with respectable ROP (1 – 2
world where certain hole intervals have very mixed m/hr), but have historically drilled short sections (20 – 30 m).
lithologies. For example, many intervals contain wide-ranging PDC bits have displayed even better ROP (up to 2.5 m/hr), but
percentages of sandstone and shale. In these applications, the have similarly been dulled quickly (~ 60 m). The bit type that
costs associated with drilling are very high. The traditional has historically exhibited the best performance in this
options available for drilling these intervals are to either run a formation is the diamond impregnated style. However,
drill bit that will produce a fairly high rate of penetration although they have been able to drill fairly long sections (135
(ROP) for a short period of time, or to run a bit which will – 170 m), the rate of penetration of these bits still remains
drill for a fairly long period of time at a slow ROP. relatively low (0.5 – 1.75 m/hr).
IADC/SPE 59113 NEW TECHNOLOGY IN DIAMOND DRILL BITS IMPROVES PERFORMANCE IN VARIABLE FORMATIONS 3
It became obvious that a different type of drill bit was required challenge, too, was overcome with the inclusion of PDC
to effectively drill a variable formation such as this one. cutters. In addition to traditional matrix gage protection,
Based on the performance of the drill bit types that had been which consists of natural diamonds, tungsten carbide, and
used to date, the decision was made to use a diamond thermally stable polycrystalline diamond (TSP), this new bit
impregnated bit as the platform upon which to develop this type incorporates PDC gage trimmers. These PDC cutters are
new bit style. pre-ground to produce a large flat area that maximizes the
diamond available for maintaining gage diameter.
New Technology:
In order for a new bit type to achieve optimum performance in Diamond Impregnated Blades:
variable formations, it was necessary to implement features As previously mentioned, the traditional diamond impregnated
from both PDC and diamond impregnated bits. As mentioned bit is the basis for this new type of diamond bit. The entire
previously, the basis of the design is a diamond impregnated structure of the blades on this novel drill bit is constructed
cutting structure. However, in order to maximize the from diamond impregnated material. Therefore, in the
performance of the bit in shale sections, PDC cutters have absence of the other two components of this new diamond bit
been added in crucial locations. In addition to these two (PDC cutters and hot-pressed inserts), there remains a
cutting structures, a third, novel, diamond impregnated cutting complete cutting structure comprised of diamond impregnated
structure has been developed. This new cutting structure material.
consists of hot-pressed diamond impregnated inserts
strategically placed over the surface of the bit. These inserts The advanced materials used in the diamond impregnated
have proven to provide three times greater wear resistance blades have been designed to maximize diamond quality and
than traditional diamond impregnated material. diamond retention. In order to manufacture a diamond
impregnated bit, it is necessary to suspend the diamonds in a
PDC Cutters: tungsten carbide matrix and then infiltrate the matrix in a
One of the greatest challenges in impregnated bit design furnace operation. Thus, the quality of the diamond cutting
concerns the center of the bit. A frequent failure mode of structure is dependent on the temperature of the infiltration
impregnated bit designs is coring. This is a result of many process and the cycle time required to complete the
factors, including the fact that it is difficult to incorporate infiltration. The advanced materials and manufacturing
sufficient diamond density for long-lasting and efficient processes used to create the diamond impregnated blade
drilling while maintaining sufficient void volume for the structure of this unique diamond bit were specifically
proper ejection of cuttings. To overcome this challenge, PDC developed to minimize the infiltration temperature and total
cutters have been employed in the center of this new type of time at temperature.
drill bit. As a result of the relatively high diamond density of
a PDC cutter as compared to a traditional diamond In order to quantify the improvement realized in diamond
impregnated cutting structure, the void volume in the center of quality, an extensive set of laboratory tests was undertaken.
the bit can be greatly increased without sacrificing durability. The tests were based on the industry standard, granite log test
Also, due to the fact that the surface speed of the formation that is utilized to test the abrasion resistance of PDC cutters.
with respect to the PDC cutters is low, as a result of the small This represents a unique application of the granite log test to
distance from the axis of rotation, the PDC cutters experience the quantification of the performance of a diamond
very long life. Thus, there is no decrease in durability, yet a impregnated matrix. In the tests, a cylindrical sample is
greatly decreased chance of balling in the center of the bit. produced to mimic the materials and processes of the matrix
This reduces the possibility of failure due to coring. blade structure. Next, a wear ratio value is calculated based
on the volume of rock that is removed by the sample and the
Another positive effect of the use of PDC cutters in the center volume of sample that is worn away during testing (Fig. 1).
of the bit is increased ROP potential. Again, due to the large As shown in Figure 2, the new advanced matrix used to form
void volume that is produced by the relatively enormous the diamond impregnated blades is nearly one and one half
exposure of the PDC cutters, as compared to the diamonds in times more wear resistant than traditional materials.
the diamond impregnated cutting structure, the center of the
bit is much more aggressive than the remainder of the bit’s Hot-Pressed Diamond Impregnated Inserts:
profile. Therefore, the ROP is governed by the cutting action The hot-pressed diamond impregnated inserts utilized in this
of the diamond impregnated cutting structure located further new diamond bit represent the highest quality diamond
along the profile of the bit where surface speeds are impregnated cutting structure. As mentioned above, the
significantly higher than in the center. quality of the diamonds in an impregnated cutting structure is
entirely dependent upon the temperature to which they are
A further challenge in the design of diamond impregnated bits exposed and the time for which the exposure occurs. Through
is the retention of gage diameter. The challenge stems from the use of the hot-pressing operation, the time that the
the fact that these bit types commonly drill in very abrasive diamonds are exposed to elevated temperatures has been
applications at very high rotary speeds (1000+ RPM). This
4 T. BEATON, K. JOHNSON IADC/SPE 59113
reduced by 85%, and the temperature to which they are speed of 363-378 revolutions per minute (RPM), with a
exposed has been reduced by 35%. weight-on-bit range of 4,000-15,000 lbs. These and other run
parameters, including ROP, torque, flow rate, and standpipe
In a unique application, the inserts are attached to the diamond pressure, can be found in Figure 4. The shale content recorded
impregnated blade structure in a brazing operation, during this run ranged from 10% to 90%, as shown in Figure
simultaneously with the PDC cutters. This novel process 5. Figure 5 also displays the ROP curve alongside the
eliminates the need to subject the diamond in these inserts to lithology, demonstrating the bit performance throughout the
the elevated temperatures and long cycle times required during run.
the infiltration of the matrix body.
The new diamond bit drilled 182 meters of the Huamampampa
In an extension of the testing program from above, these new in 62 hours, for an average ROP of 2.93 m/hr. Figure 6
hot-pressed inserts were compared against the diamond reveals photographs of the dull bit. The fastest offset in this
impregnated cutting structure used in the blade structure. As area of the Huamampampa was a PDC bit that recorded an
seen in Figure 3, these new inserts are nearly twice as wear average of 2.40 m/hr, but drilled only 63 meters. The longest
resistant as the advanced materials used in the blade structure, offset in this area was achieved with a traditional diamond
and nearly three times as wear resistant as traditional diamond impregnated bit which drilled 172 meters at an average ROP
impregnated materials. of 1.70 m/hr (Fig.6). Penetration depths and ROP’s for these
offset bit runs and the new diamond bit are shown graphically
In addition to the improved properties of these inserts, insert in Figure 7.
placement has been engineered similar to that of the cutters in
PDC bits. Thus, this new diamond bit type has two complete This novel diamond bit achieved the desired result of drilling
cutting structures. In the absence of the PDC cutters or hot- at faster penetration rates for longer times than previously
pressed inserts, the diamond impregnated blade structure possible with traditional bits. By drilling this variable
constitutes a complete bottom hole pattern. Additionally, in formation faster than offsets, this single run through the
the absence of the diamond impregnated blade structure, the Huamampampa saved the operator over $100,000.
PDC cutters and hot-pressed inserts comprise a full bottom
hole pattern. Therefore, there is redundancy in diamond Conclusions:
coverage yielding maximum durability. Also, because the 1. Advances in the design of PDC cutters and PDC bits are
new inserts are several times more wear resistant than a expanding the envelope of drilling efficiency into harder
traditional infiltrated diamond impregnated cutting structure, and more abrasive applications.
the void volume on the bit face can be correspondingly 2. Advances in the materials and design of diamond
increased, improving performance in shale sections. impregnated bits, along with the proliferation of turbines
Consequently, this new type of diamond bit can have fewer and high speed motors, are expanding the envelope of the
blades, or thinner blades, than traditional diamond drilling efficiency of diamond impregnated bits into
impregnated bits, increasing the cleaning efficiency of the “softer” and less abrasive applications.
design while concurrently increasing overall durability. 3. In spite of the excellent improvements in diamond bit
technology, there remain many applications where
Finally, another major advantage of this new type of diamond diamond bit performance is poor.
bit is the ability to customize each drill bit according to the 4. For formations in which diamond bit performance is poor,
formation to be drilled. The primary cutting structure of this a new type of diamond bit has been developed that
new design is comprised of PDC cutters and hot-pressed combines the features of diamond impregnated and PDC
inserts, and, similar to PDC cutters, the hot-pressed inserts are bits.
available in different compositions. Therefore, the inserts 5. New materials have been developed which increase the
used in each drill bit can be specially selected to match the life of diamond impregnated blades by over 40%.
formations being drilled. 6. A novel diamond impregnated insert has been developed
which has nearly three times greater wear resistance than
Performance Summary: traditional diamond impregnated materials.
The next step in the development of this new type of diamond 7. The use of PDC cutters in the center and gage sections of
bit was to test it in the field. An ideal opportunity was the new bit allows a much more open design, decreasing
presented in the Palo Marcado field in Tarija, Bolivia. The 8 balling tendency without sacrificing durability.
½” hole section of the Palo Marcado-X5 well included a 8. Due to a very open faced design, the new diamond bit
significant section of the Huamampampa. discussed herein displayed unsurpassed ROP in a long
hole interval where the percentage of shale ranged from
An 8 ½” diameter drill bit incorporating the advanced features 10% to 90%.
described in this article was designed, produced, and used for
drilling through the Huamampampa. The run was performed
in oil-based mud with a high speed motor, for an overall rotary
IADC/SPE 59113 NEW TECHNOLOGY IN DIAMOND DRILL BITS IMPROVES PERFORMANCE IN VARIABLE FORMATIONS 5
Acknowledgements:
6000
The authors wish to thank Tom Oldham, David Truax, Duane
Van Waes, and Jorge Vargas of GeoDiamond for their insight 5000 Wear Ratio = Volume Rock Removed
and efforts towards the completion of this project. Special Volume Sample Removed
4000
Wear Ratio
thanks also go to Paul Redfield and Christy Martin of Smith
Bits for their support and assistance. 3000
References: 2000
1. Selim, A.A. et. al.: “The Effect of Additives on
1000
Impregnated Diamond Bit Performance,” paper SPE 2387
presented at the Fourth Annual Drilling & Rock 0
Mechanics Conference, Austin, Texas Jan. 14-15, 1969. Standard Advanced
2. Garner, N.E., “Cutting Action of a Single Diamond Under Matrix Matrix
Simulated Borehole Conditions,” paper 1701 presented at
SPE Third Conference on Drilling and Rock Mechanics,
Fig. 2 - Bar graph of the wear ratio of diamond
Austin, Texas, Jan. 25-26, 1967.
impregnated samples consisting of standard and advanced
3. Mensa-Wilmot, G., “New PDC cutters improve drilling
matrix materials.
efficiency,” Oil & Gas Jornal, October 1997.
4. Mensa-Wilmot, G., et. al. “Twin Edge Cutter (TEC) –
Enhancing PDC Bit Development and Performance,”
SPE/IADC 37637, Amsterdam 1997.
5. Mensa-Wilmot, G., et. al. “Unique Polycrystalline
6000 Wear Ratio = Volume Rock Removed
Diamond Compact (PDC) Cutter Improves Drilling
Efficiency,” SPE 53954, Caracas, Venezuela, April 1999. 5000 Volume Sample Removed
Wear Ratio
4500 4508
4505 4513
4510 4518
4515 4523
4520 4528
4525 4533
4530 4538
4535 4543
4540 4548
4545 4553
DEPTH (m)
4550 4558
HUAMAMPAMPA
DEPTH (m)
4555 4563
4560 4568
4565 4573
4570 4578
4575 4583
4580 4588
4585 4593
4590 4598
4595
4603
4600
4608
4605
4613
4610
4618
4615
4623
4620
4628
4625
4633
4630
4638
4635
4643
4640
4648
4645
4650
200 3.50
PMO-X5 WELL
SAL-X10 WELL
180
3.00
160
140 2.50
Drilled
(m) 120
2.00 ROP
(m/hr)
100
1.50
80
SAL-X10 WELL SAL-X10 WELL
60 1.00
40 MGT-X1 WELL
0.50
20
0 0.00
PDC BIT TSP BIT IMPREGNATED BIT BICENTER BIT NEW DIAMOND BIT
(PDC)