SPE/IADC 79797

New, Stable PDC Technology Significantly Reduces Hard Rock Cost Per Foot
Edward J. Schell, SPE, and Duane Phillippi, SPE, Anadarko Petroleum; and Robert T. Fabian, SPE, Reed-Hycalog
Copyright 2003, SPE/IADC Drilling Conference
This paper was prepared for presentation at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 1921 February 2003.
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paper, as presented, have not been reviewed by the Society of Petroleum Engineers or the
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Abstract
Historically, the hardest and most abrasive rock formations,
such as the Travis Peak, Hosston, and Bossier Sands areas of
East Texas and North Louisiana, were drilled almost
exclusively by roller-cone insert bits. With some exceptions,
the only polycrystalline diamond compact (PDC) runs were
small-diameter holes where the formation was predominantly
comprised of shale and limestone. Significant advances in
design and cutter technology in PDC bits during the past 510
years have made it possible for PDC to be used more
frequently on the fringes of these hard rock intervals.
Combining advanced PDC bit designs with state-of-the-art
cutter technology has opened up many new applications for
PDC bits that were once only appropriate for IADC Series 6,
7, and 8 insert drill bits. Because of this new technology, PDC
has become a practical alternative for drilling hard rock,
providing a significant reduction in cost per foot. Combining
new, highly abrasion-resistant PDC cutters with competent
stable bit designs that provide both low torque and
dynamically stable characteristics was the key to this
development.
Several case histories of hard rock drilling using PDC bits will
be discussed in this paper, illustrating the reduction in costs.
These case histories demonstrate, through descriptions of trial
and error, the problems associated with these new PDC
applications and how they were overcome.
Background
Until recently, insert bits were mandatory when drilling hard
rock intervals in areas of East Texas and North Louisiana that
have significant sandstone sections. This paper will discuss
trial applications of PDC bits designed for drilling such hard
and abrasive formations as the Travis Peak, Hosston, Cotton
Valley, and Bossier in this area. The areas and intervals

discussed in this paper have historically been drilled best with

insert bits; however, because of advancements in cutter
technology and drill bit design, operators have recently been
testing PDC bits. In some cases, the PDC bit option offers
considerable savings.
In the past 10 years, PDC bits were widely used in these areas
for drilling the softer and less abrasive shallow sections to
depths of 6,0009,000 ft. These formations were found to be
very PDC drillable, being composed of shale, limestone, and
anhydrite, with minor amounts of sand. Upon reaching the
hard and abrasive sandstone sections, however, insert bits
became necessary in most areas. This interval may extend to
3,000 ft or more, as in the Travis Peak and Cotton Valley.
This section alone may represent 6080% of the drilling costs
for an entire well.
The use of PDC bits has consistently and significantly reduced
drilling costs, but this was usually in softer formations.
Occasional attempts to drill with a PDC bit in the hard rock
intervals typically resulted in poor rate of penetration (ROP)
and footage results, with dulls exhibiting extensive bit wear.
However, in some areas, such as the first 700 ft of the Travis
Peak in Panola County, PDC has been used successfully.1
These areas tend to have formations composed more of shale,
with sands being less consolidated in nature. Another
successful example is the use of PDC for intervals with
slimhole size. Because of the smaller radial diameter of
slimhole size bits, less bit wear is a direct result of the slower
rotational velocities, which tend to wear less on the cutting
structure. The decreased wear is typically reduced in the outer
diameter radius area only, where abrasive wear is lessened in
the small hole versus the same formation being drilled in a
significantly larger hole size.
Impact damage to the PDC cutting structure caused by bit
vibration is a common problem associated with drilling hard
rock with PDC. In heterogeneous lithologies, cutting structure
failure can result from vibration forces generated when the bit
is subjected to variations in acceleration. Because of the
cutting mechanism involved, PDC bits are more likely to be
affected by these forces than roller-cone bits. (There is much
literature available on the subject of vibration, which includes
bit whirl and slip stick. These phenomena are collectively
referred to as bit and drillstring vibrations. They include
lateral, torsion, and axial vibrations of the bit and
drillstring.) 2,3

The genesis of these vibrations may be the bit, drilling

parameters, bottomhole assembly (BHA), mud properties, rig
mast, or more likely, a combination of some of these factors.
Vibration can occur when drilling with PDC bits through
multilayered hard and soft formations.ibid Typically, the
practice of running high weight on bit (WOB) with slow
rotary speed through such formations creates prime conditions
for the generation of downhole vibrations in hard rock.3 The
ideal parameters to drill with PDC bits are 6080 rpm with
high bit weights, which will greatly prolong bit life. In hard
formations, high bit weights (20,00030,000 lb) are often
needed to drill the 7 7/8-in. through 9 7/8-in. hole sizes. PDC
bits are especially at risk in this method of drilling because
they use shear mode against the rock, compared with a rollercone bits, which use compression mode. Therefore, a PDC
bits relationship of ROP, RPM, and torque generated makes it
especially sensitive to vibrations that can affect performance.
As these forces increased, it was not unusual for a PDC bit to
fail almost immediately in an encounter with the Travis Peak,
often after drilling only a few feet.
In order to reduce the effect of vibration damage to the bit,
stabilization features in the bit design are necessary.
Additionally, the PDC bits cutters must be resistant to very
high formation abrasiveness, and the cutters must have
sufficient impact resistance. In theory, even if bit and
drillstring vibrations are somehow controlled, the transition
from soft to hard rocks will create cutter impact damage
because of changes in momentum.
This paper will discuss the unique style of PDC bits developed
for such East Texas and North Louisiana hard rock
formations. Until recently, these areas and formations were
not known to be PDC drillable, or at least capable of being
drilled to sufficient interval length to achieve improved
economics over conventional technologies.
Recent
advancements in cutter technology, design, and application
technique have broadened the capacity of PDC bits to drill
hard rock. This paper will discuss these advancements, the
drilling technique needed, the limits of the technology, and
several case histories. It is very probable that similar
applications exist worldwide; therefore, a brief review of the
applications geology and application scenario is included.
Geology
This paper will discuss the drilling applications of the East
Texas Travis Peak, Cotton Valley, and Bossier formations.
Also included is North Louisianas Hosston formation. The
geologic age of these formations is Lower Cretaceous. A study
area map and a stratigraphy table for the areas are shown in
Figs. 1 and 2.
The Travis Peak comprises thick sequences of interbedded
sandstone, mudstone, and shale. They are composed primarily
of 6080% very-fine to fine-grained sandstone, with
subangular grain shapes, commonly bonded with siliceous
cement. The sands are interbedded with shale and mudstone.
The upper sections often have more shale, with sand
thickening occurring toward the base.
Unconfined

SPE/IADC 79797

compressive strength (UCS) values for these formations

average 10,00020,000 psi.
Following the Travis Peak is the Cotton Valley formation.
This is Lower Cretaceous in age, and is typically more hard
and compacted. It is composed of 80100% very-fine to finegrained sandstone interbedded with shale, mudstone, and
limestone, with the average UCS in the range of 15,000
25,000 psi.
The Bossier Sand of East Texas was also tested. This is also
Lower Cretaceous in age. Its sandstone properties are similar
to the formations discussed above. This section is the deepest,
and is typically drilled with slimhole bits. The UCS values for
these formations average 10,00025,000 psi.
In North Louisiana, the area of application testing was the
Hosston formation in the Vernon Field of Jackson Parish.
This formation is the stratigraphic equivalent of the Travis
Peak. Its interval thickness and sandstone properties are
similar to that of Travis Peak; however, in this area, the
Hosston contains thicker beds of shale, limestone, and
mudstone. The UCS for these formations averages 10,000
20,000 psi, with occasional peaks as high as 25,000 psi.
In most areas, the stratigraphic dip of the Lower Cretaceous is
between 3 and 6. Natural fractures are common. Pyrite is
found regularly in trace amounts and at times in significant
amounts.
Drilling History
Tests in East Texas were conducted primarily in the Travis
Peak section of Freestone County.
Paralleling the
development of a hard-rock PDC bit, tests were also made in
Smith, Anderson, Nacogdoches, and Harrison counties. As
most work occurred in Freestone, this paper will focus
on the development of Freestones Travis Peak and Cotton
Valley interval.
The Travis Peak section of Freestone County is usually drilled
as the intermediate hole size, typically 8 3/4-in. PDC bits are
normally used to drill the Upper Cretaceous formations prior
to reaching the top of the Peak. Drilling with insert bits
normally begins there, at approximately 9,000 ft. Insert bits
(IADC Series 537647) are run 7001,000 ft from the top of
the Travis Peak, followed by six to eight more insert bits
(IADC Series 817 837), drilling to the base of Cotton Valley
at 12,70013,000 ft, where casing is set. The production hole
interval is through the Bossier sand and shale. This interval is
commonly 6 1/8-in. It is variable, and may require one to
three IADC Series 537617 insert bits to drill to a total depth
of approximately 13,50014,000 ft. In the Freestone test area,
slick BHA assemblies are typically used with conventional
roller bits (and the test PDC bits). This is because the abrasive
formation properties cause rapid wear to the stabilizers. The
hard rock section in Freestone is drilled with minimal
deviation problems, hence roller reamer stabilizers are seldom
employed. The formations are so severely abrasive that often
insert bits use diamond-enhanced gauge and heel rows to
enhance durability. In Smith and Harrison counties, several

SPE/IADC 79797

operators have made observable improvement in PDC

performance by using specialized undergauge string stabilizers
for hard rock drilling PDC bits. Three undergauged (1/8-in.)
stabilizers are run in a semipacked hole configuration.
The second regional area for bit development is the Vernon
Field of Jackson Parish, North Louisiana. The intermediate
hole size is typically 9 7/8-in. The hard rock section begins at
the top of the Hosston, which tops at around 7,200 ft.
Standard heavy-set PDC bits drilled up to 1,300 ft into the
Hosston formation, followed by five to six IADC Series 617
647 insert bits to drill to casing depth, just above the top of the
Cotton Valley Massive Sand. Intermediate casing is set at
approximately 10,700 ft, and mud weights are increased. The
production interval is drilled with three to four 6 3/4-in. to 8
1/2-in. IADC Series 617747 bits through the massive Cotton
Valley to 12,000 ft. Depending on the mud weights and
properties, this is followed by one or two natural diamond bits
to drill the Lower Cotton Valley members of interbedded
sandstone, limestone and shale.
In the Vernon field,
pendulum BHA assemblies are typically used with
conventional roller bits and the test PDC bits. Common well
design programs for Freestone County and North Louisianas
Jackson Parish are shown in Figs. 3 and 4.
Fixed Cutter Bit Testing
The use of fixed cutter bits to improve drilling economics in
these areas had been attempted before. Surface-set natural
diamond bits, impregnated diamond bits, and PDC bits have
had disappointing results for more than one bit company or
operator. Because this application is highly abrasive, and
widely variable in rock strength, most attempts to drill the
hard rock sandstone using standard fixed-cutter bits were not
economical, and typically suffered catastrophic cutting
structure failure.
In recent times new technologies have evolved and operators
have periodically tested them on these challenging formations.
But until recently, PDC bit design stability, drilling
techniques, and cutter technology had not been improved
enough to permit drilling of the hard rock strata prevalent
throughout East Texas and into North Louisiana.
Bit Design History
In 1997, an evolutionary bit design was developed to provide
smooth torque response for steerable motor systems. (See Fig.
5.) The design was unique in that it incorporated a 360 fullcontact gauge ring, referred to as a ring. This ring prevents
outer cutters from overbiting into the hole wall at the gauge,
thus providing a restriction to lateral movements, which then
reduces bit whirl and improves cutter life.4 The resulting
ability to drill faster and longer, with better directional control,
was a significant improvement. This design continues to be a
popular directional PDC bit.
A full ring bit and a non-ring version were laboratory tested by
drilling a series of pilot holes into the Torrey Buff sandstone
(UCS 11,100 psi). ibid Results showed conclusively that the
full ring was more stable. Enclosing the bits junk slot
significantly reduced bit vibrations and gave much smoother

torque response. ibid (See Figs. 5 and 6.) It was also observed
that because of the lack of lateral bit movement, the full ring
design drilled a smooth-walled borehole, showing no bit whirl,
by drilling on center. The non-ring bit version showed clear
evidence of whirling, as the hole walls showed an obvious
spiral with a bottomhole pattern indicative of bit whirl. ibid
(See Fig. 7.)
This approach to creating a more steerable directional bit led
to the development of a full size range, with many variant
designs, for the drilling industry. However, until recently, the
inherently stable ring bit was applied primarily for its
directional responsiveness.
A breakthrough in cutter
technology has now paved the way for the stabilizing effect of
the ring bit to be tested in severe hard rock applications.
Advancements in Cutter Technology
Polycrystalline diamond has historically been manufactured in
various grades of hardness and impact resistance. This was
primarily achieved by varying the size of the diamond grit. In
the mid-1990s, PDC cutters gained improved impact and
abrasion resistance when nonplanar interface (NPI) carbide
substrates were attached to the PCD layer (polycrystalline
compact diamond). The various designs relieved the in-situ
stresses born into the diamond during manufacture. Wear life
was simultaneously improved in these designs by the
increased thickness of the diamond table. NPI cutters
continue to be very popular for general PDC applications. In
this papers topic application, such an improvement in
abrasion resistance was necessary.
Polycrystalline diamond has impact and abrasion properties
that bear an inverse relationship to each other, dependent upon
the size of the diamond grit particles that constitute the PDC
wafer. Since its entry to the market in the 1970s, there have
been a few notable improvements in these properties, such as
processing a mixture of grit sizes (multimodal) to enhance
abrasive properties, and the NPI between the diamond layer
and its tungsten carbide carrier substrate.
Recently, a new hybrid of NPI PDC cutter was synthesized
and tested in the laboratory. Test results showed that this
material possessed unusually high abrasion resistance
properties compared to industry standards for premium quality
materials. The standard and enhanced cutters were tested for
abrasion resistance using the granite log test, in which a single
cutter is ground against a log of granite turned on a lathe to
establish wear rate. The enhanced cutter material was found
to have four times the abrasion-resistant properties of default
premium materials, but with no reduction of impact properties.
Field tests confirmed the laboratory results, with increases in
section length drilled and rate of penetration. Typically, this
was without significant additional wear to the cutters. The
increase in ROP was a direct function of the cutters staying
sharp as they wear, thereby cutting the rock to optimum
efficiency. The high abrasion-resistant property of PDC
greatly improved the cutters ability to stay sharp, thus
protecting the substrate and bit body from wear. A photo of a
partially worn enhanced PDC is shown in Fig. 8. A graph
showing worldwide run data, where performance data of new

NPI cutters shows a significant percentage improvement over

offset benchmark PDC runs, is shown in Fig. 9.
As was learned through lab tests, the impact resistance of the
enhanced cutter was virtually the same as standard cutters;
thus, applying them in hard rock required a low-vibrationimpact situation. Field testing of enhanced cutters in hard
rock applications began in late 2001. It was found that select
use of bits in applications with inherently low impact potential
permitted the cutters to perform to their fullest potential, since
the impact properties remain unchanged. Ideal applications
were homogeneous formations with consistent rock strength
signatures. The use of motors, where drillstring vibrations
were reduced, also contributed to excellent cutter
performance. In hard rock, where rotary drilling parameters
use a combination of reduced RPM (4070) and higher WOB,
conventional PDC design bits using the enhanced cutter
showed improved performance.
In the Vernon field of North Louisiana, the top 1,000 ft of the
Hosston is PDC drillable by using the slow rotary technique
and applying standard heavy-set PDC bits. Operators further
improved performance in this interval by running the same
heavy-set PDC equipped with the new PDC cutter technology.
Complete intervals of the Hosston in several areas were drilled
using two PDC bits equipped with this new cutter technology.
These runs resulted in spectacular savings (up to $100,000).
The same bit style using the new PDC cutter replaced three to
five IADC Series 617647 insert bits, often doubling the rate
of penetration. Previously, PDC bits seldom drilled beyond
8,300 ft. To 8,300 ft, the primary lithology is shale, mudstone,
and limestone, with minor sands; beyond that level, the first
major hard sand horizon occurs. These are low porosity
sands, having unconfined rock compressive strengths of
15,00020,000 psi. Standard cutter PDC bits reaching these
depths typically ring out. The use of the new PDC cutter
technology improved drill rate and footage interval, allowing
extension of the interval to 10,300 ft in several cases. This
successful experience was a result of very low RPM (3060)
and controlled WOB of 20,00030,000 lb for 9 7/8-in. to 12
1/4-in. drill bits. Run interval average economics of the new
PDC cutter technology bits compared with offset standard
cutter PDC bits and all insert bits are shown in Fig. 10.
Savings were significant, with an average reduction of
$150,000 in the Hosston to Cotton Valley interval.
Many of the techniques of using slow rotary speeds and high
bit weights were developed through operator and rig
experience. Refinement in technique often was specific to the
particular rig and area. Control of torque fluctuations to
reduce bit and string vibration was key in the application of
PDC in hard rock. In the Vernon Field, more specialized
drilling techniques were developed. Through experience, each
rig fine-tuned the running techniques to control torque,
thereby extending bit life, often with improved penetration
rates. Such techniques included torque control by setting low
limits to the rotary table; using high gear versus low gear;
gaining sensitivity in the control and use of the auto driller;
fully computerized drill parameter observation; and clear
communication with each member of the drilling team.

SPE/IADC 79797

The cost per foot savings of running PDC in the Hosston

formation more than justified the risk of relatively higher bit
cost owing to premature bit damage. Even using the enhanced
cutters, catastrophic failure causing bit ring-out and core-out
continued; however, these failures occurred with less
frequency and therefore achieved substantial savings
compared to running insert bits. Enhanced cutter testing
continued with the stable ring bit design and has further
increased the PDC savings benchmark for this field. The selfstabilizing properties of this design allow application of higher
RPM resulting in improved penetration rates, with longer
intervals drilled.
The first 9 7/8-in. ring bit including the new PDC cutter
technology was tested in the summer of 2002. The bit drilled
3,316 ft, from 6,567 to 9,733 ft, at 19.5 ft/hr. The cost savings
over using standard PDC and insert bits was $105,000.
Interestingly, there was only one chipped cutter, with the
remaining cutters showing little or no wear. This run
demonstrated that the ring provides the bit with superior
stability, which minimized mechanical cutter damage and
allowed the new cutters to succeed. The combination of the
ring technology and the new cutter technology are being
tested further.
East Texas Hard Rock Testing in the Travis Peak
Economically drilling the Travis Peak and Cotton Valley
formations with PDC bits in Freestone County, Texas, was
considerably more challenging than adapting PDC bits to
North Louisianas Hosston formation.
This area is
considerably harder and more abrasive throughout the entire
interval from approximately 9,000 to 12,500 ft. When using
conventional insert bits, six to eight bits were needed to drill
the interval. By using the new cutter technology, it was
possible to reduce the number of insert bits, on average by two
and to a maximum of four, with improved ROP. Several test
runs were made using the new cutter technology in both ring
and non-ring designs.
The tests included a range of
parameters, drive types, BHA, locations, and depths in the
Travis Peak/Cotton Valley.
To determine PDC drillability, several attempts were made to
drill the hard 7 7/8-in. intervals of the Travis Peak and Cotton
Valley areas. Using the new cutter technology with standard
heavy-set PDC bit designs produced moderate savings in
Smith and Harrison Counties. These bits were run with the
same technique of using a slow rotary rate (5060 RPM) with
higher weight on bit of 20,00030,000 lb. Although bits with
this new cutter technology showed the ability to drill
economically, they were prone to vibration damage. Bit whirl
and slip stick damage were apparent in the dull bits.
Numerous broken and chipped cutters were observed,
consistent with impact damage. The first test runs were on
slick BHA assemblies, which lacked stabilization, and were
more prone to bit and drillstring vibration impact damage.
Interestingly, when a set of specially made 1/8-in.
undergauge stabilizers was tested using the same standard
PDC bit, the bits displayed minimal vibration impact damage.

SPE/IADC 79797

A developmental bit program to test the combined

technologies of the new cutter technology and the stable ring
feature was created for the harder, more abrasive Freestone
County, Travis Peak/Cotton Valley interval. Several test runs
were made, some showing good footage and ROP, with
marginal to good economics compared to running insert bits.
Running techniques were applied similar to those used in
drilling the Hosston: relatively slow rotary rate of 6070
RPM, and ample bit weights (25,00030,000 lb). A rock
strength log of the 8 3/4-in. interval drilled using two ring bits
and three IADC Series 837 insert bits is shown in Fig. 11.
Also shown are offsets for insert bits normally run in sequence
through the tested zones of the Travis Peak and Cotton Valley.
The ring bit tests show the Travis Peak and Cotton Valley to
be PDC drillable; however, several test runs also showed that
major portions of the Cotton Valley were not economically
viable for the use of PDC bits when compared to using insert
bits. Interestingly, as shown in Fig. 9, the hardest portion of
the section was drilled with a ring PDC design, which made
570 ft at 13 ft/hr. This was equivalent to one IADC Series 837
insert bit, at a 3 ft/hr decrease in rate of penetration. Future
testing of enhanced designs may someday prove this interval
to be economically viable. However, based on UCS averages
of 25,000 psi, this is regarded as the current technical limit for
present ring bit designs using the new cutter technology.
In the Travis Peak, the initial test run of the ring bit used
WOB ranging from 30,00040,000 lb. It was quickly learned
that weight loading at this level resulted in cone and nose
failure. After several tests, the best run resulted from applying
the minimal weights needed to drill aggressively. The practice
of continual adjustment of WOB and rotary rate prolonged bit
life. This practice gave acceptable rates of penetration, and
resulted in economical runs. Refer to Table 1, for ring bit
economics and parameter data for the Freestone test area.
Average ring bit savings during the test period was $10,379.
With present designs, the economic window of opportunity
lies in drilling the Travis Peak from the formation top at 9,000
ft to approximately 10,500 ft, which nears the top of the
Cotton Valley formation. The most economical runs have the
lighter weights. The best run drilled 1,561 ft but with a
sacrifice of penetration rate. When extra WOB (30,000
40,000 lb) was used, these runs proved to drill the fastest, but
at a sacrifice of interval. The ability to repair and rerun the bit
was an important factor in meeting the economic target.
Running very high WOB tended to reduce the opportunity for
bit repairability and rerun. Extra weight typically led to
premature cutting structure failure in the bit cone or nose.
A 9 7/8-in. ring bit was designed for the Travis Peak and
Cotton Valley formation in Anderson County, Texas. This
was the same design as the bit used successfully in the
discussed Hosston run in the Vernon Field. In Anderson
County the 9 7/8-in. design failed to provide improved
economics over insert bits. Two ring bits were run, each
drilling slightly less or equal to one insert bit, before coring
out with catastrophic cutter damage in the cone. A post-run
bit study indicated that an improvement was needed in the
cone area. Using larger hole size PDC bits to drill hard and

abrasive formations successfully remains a challenge. The

interval lengths and the rates of penetration as compared to
insert bits were not economical.
As drilling performance often improves with smaller bit sizes,
a 6 1/8-in. ring bit was designed to drill the Bossier Sand and
shale sequence for the Freestone production interval. Three
IADC Series 537 insert bits, or one to two insert bits and a
standard PDC bit, traditionally drilled this interval. Until
applying the new cutter technology, the PDC bit could not be
used until the insert bits drilled out the harder sands. The
enhanced cutter was first applied to a standard design PDC bit,
using slow rotary techniques. The first test bit drilled all but
the first insert bit interval. Without repair, the bit was rerun,
and again drilled the same interval. Later, a ring bit using the
same grade of cutters was also tested and it also drilled a two
well interval without repair. Savings were considerablean
average savings of $20,000 was achieved applying the new
cutter on standard and ring bits. A rock strength log, detailing
the formation compressive strength and formations drilled in
the Freestone 6 1/8-in. production hole, is shown in Fig. 12.
In addition, an interval economic performance comparison of
insert bits and new cutter equipped PDC is shown in Table 2.
Later tests of the ring bit included three Lower Cotton Valley
tests in Freestone and Anderson counties. With respect to
insert bits, the interval drilled and ROP of the ring design
proved that the current design is not yet economical to run.
Although logs showed potential for PDC drillability, the ring
PDC bits did not perform as expected through the Lower
Cotton Valley, where UCS averaged 25,000 psi with peaks to
30,000 psi. Such high strength and severely abrasive
formations present a technical limit for operating ring designs.
A second generation of ring bit designs was created in the fall
of 2002, the first of which was in 7 7/8-in. Improvements were
made based on the results of early ring hard rock tests, and
focused on the cone and nose areathe areas of the bit
typically subject to core-out and ring-out whenever higher bit
weights were used to drill the hardest sand sections. Major
design changes included bit profile, cutter size and count in
the cone, and increased cutter coverage in the nose area. A
photo of the second-generation ring bit is shown in Fig. 13.
Testing of the new design continues in East Texas, but in runs
completed in the Nacogdoches, Smith, and Harrison Travis
Peak intervals, three out of four runs provided significant
savings. The test results for these are in Table 3.
Continued improvements in PDC cutter and design technology
may eventually make it economically feasible to drill the
hardest and most abrasive formations with PDC. The creation
of competent stable bit designs, employing highly abrasionresistant cutters, has provided access to previously non-PDCdrillable formations. The East Texas-North Louisiana area
provides an excellent benchmark for measuring hard rock bit
performance and therefore illustrates the potential to
significantly reduce drilling costs for operators in areas having
similar applications.

SPE/IADC 79797

Conclusions
1. The use of PDC in some hard rock applications is now
economically practical because of improvements in cutter
technology. New, highly abrasion-resistant cutters can make
significant cost-per-foot savings as long as proper drilling
techniques are used to control impact damage caused by bit
and drillstring vibrations.
2. Damaging bit vibrations can be reduced by using slower
rotary speeds and controlling WOB to reduce torque, thereby
reducing the effects of slip stick and bit whirl, even without
special running techniques.
3. The ring bit design, incorporating a 360 ring about its junk
slot, has proven to be stable in reducing the lateral forces of bit
whirl. It was bit whirl that prevented standard designs from
successfully drilling the hardest and most variable formations.
A ring bit with the new, highly abrasion-resistant nonplanar
cutters is a specialized breed of PDC that can drill the East
Texas-North Louisiana hard rock, sandstone bearing
formations.
4. Factors such as hole size and formation compressive
strength limit the application of this technology.
5. Because of the variability of these formations, each well
should be carefully screened, making use of offset logs when
calculating interval rock strengths.
6. Offset bit CPF economics should be predetermined,
creating realistic interval goals.
Acknowledgements
The authors wish to thank Reed-Hycalog and Anadarko
Petroleum for permission to present this paper. Special thanks
also to Southwest Energy and Samson Resources who helped
share the risk in testing. Lastly, we express thanks to the
drilling contractors, Nabors Drilling, Patterson Drilling, Scan
Drilling, H & P Drilling, and Unit Drilling, who through their
keen observations, patience, and innovative techniques, helped
push the envelope of the new PDC applications.
References
1.

Martin, Donnie; Jacobson, Jim: New Hard Rock Roller

Cone Bit Technology/Operational Excellence Improves
Economics in Mature East Texas Gas Fields, 2002,
IADC/SPE 74527, presented at the IADC/SPE Drilling
Conference, Dallas, TX, February 2628.

2.

Fear, M.J.; Abbassian, F.; Parfitt, S.H.L: The Destruction

of PDC Bits by Severe
Slip-Stick Vibration, 1997,
SPE/IADC 37639, presented at the SPE/IADC Drilling
Conference, Amsterdam, The Netherlands, March 46.

3.

Dufeyte, M.P.; Henneuse, H.: Detection and Monitoring

of the Slip-Stick Motion: Field Experiments, 1991,
SPE/IADC 21945, presented at the SPE/IADC Drilling
Conference, Amsterdam, The Netherlands, March 1114.

4.

Roberts, T.S.: Development of a New Concept of

Steerable PDC Bit for Directional Drilling, 1998,
IADC/SPE 39307, presented at the IADC/SPE Drilling
Conference, Dallas, TX, March 36.

SI Metric Conversion Table

in.

2.54* E+00
ft

3.048* E-01
psi

6.894757 E+00
*Conversion factor is exact.

= cm
=m
= kPa

SPE/IADC 79797

System

East
Texas

North
Louisiana

Lower Cretaceous

Travis Peak

Hosston

Prob. Lower Cretaceous

Mesozoic

Era

Fig. 1 - East Texas-North Louisiana study area. Stars indicate test run locations.

Cotton Valley

Cotton Valley

Bossier Group

Fig. 2 - Stratigraphy of study area.

SPE/IADC 79797

Bit Dia:
14.75"
Casing Dia. 10.75"
MD:
2900'

Bit Dia:
12.25"
Casing Dia. 9.625"
MD:
5,000'

Approximately 7500' - 8000'

Top of Hosston Formation

Approximately 9000'
Top of Travis Peak Formation

Approximately 10,500'
Top of Cotton Valley Group

Bit Dia:
8.75"
Casing Dia. 7.00"
MD:
12,500'

Bit Dia:
MD:

Bit Dia:
9.875"
Casing Dia. 7.625"
MD:
11,000'

Approximately 11,300'
Top of Cotton Valley Group

Approximately 12,500'
Top of Bossier Group

Bit Dia:
MD:

6.125"
13,500'

Fig. 3 - Freestone Area Well Design.

6.75"
14,000'

Fig. 4 - Jackson Area Well Design.

Fig. 5 - Photo of ring PDC bit design.

SPE/IADC 79797

140

140

120

120

100
80

Standard bit

100

60

Lateral
acceleration
60
(m/s2)
80

40
20
0

40
20

bit
ring test
t
c
a
t
n
o
180
c
Full
140 160
120
80 100
RPM

Fig. 6 - Laboratory test comparing vibration level of ring bit versus non-ring bit.

Standard bladed test bit

Bottom hole pattern showing

evidence of bit whirl

With full contact gauge ring

Much smoother bottom hole pattern

due to full contact gauge ring

Fig. 7 - Bottomhole pattern comparison of standard versus ring bit design.

Fig. 8 - Worn enhanced NPI cutter.

10

SPE/IADC 79797

New PDC Cutter vs. Standard Cutter and Benchmark Runs

ROP
FT

N
or
w

ay

Be
N
nc
or
hm
w
ay
ar
k
St
U
an
K
Be dar
d
nc
h
m
U
Au
K
ar
st
k
S
ra
ta
lia
nd
ar
Au Be
nc d
st
hm
ra
M
lia
ar
al
St
k
ay
a
si
nd
In
a
ar
do
B
d
ne en
ch
si
m
a
In
ar
Be
do
k
n
c
ne
hm
si
ar
a
S
k
U
SA tan
Be dar
d
nc
U
h
m
S
Th A S ark
ta
ai
nd
la
nd
a
St rd
an
da
rd

% Improvemen

100
90
80
70
60
50
40
30
20
10
0
-10

Fig. 9 - Worldwide data showing percent improvement of enhanced NPI cutter versus benchmark offset
data.

Cost Per Foot Comparisons Drilling the Hosston

Formation Interval
Jackson Parish, Louisiana
Inserts Avg.

100.00

NPI PDC Avg.

New NPI Cutters

CPF [USD/ft

80.00
60.00
40.00
20.00
0.00

Inserts Avg.

NPI PDC Avg.

New NPI Cutters

Fig. 10 - Economic analysis of insert bits and standard NPI cutters vs. new NPI PDC cutters.

SPE/IADC 79797

11

Offset Performance

IADC 747

9060 - 9697 @22.8 FPH

IADC 837

9697-10037 @20 FPH

IADC 837 10037 -10584 @18.5 FPH

(PDC)
IADC 837 10584 -11046 @17.2 FPH

IADC 837 11046 -11297 @16.2 FPH

IADC 837 11297 - 11735 @17.5 FPH

IADC 837 11735 - 12265 @17.5 FPH

IADC 837 12265 -12478 @17 FPH

Fig. 11 - Freestone 8 3/4-in. Travis Peak-Cotton Valley UCS log with drilling parameters, including ring PDC
and insert bit runs, with offset insert bit performance.

Fig. 12 - UCS log of Freestone 6 1/8-in. interval.

12

SPE/IADC 79797

Fig.13 - Second-generation ring bit.

Bit Runs
Depth Depth Footage Hours ROP
Travis Peak
In
Out
FPH
Ring Bit #1
8806 9832
1026 31.0 33.1
Ring Bit #2
9096 10657
1561 85.0 18.4
Ring Bit #3
9100 10036
936 47.0 19.9
Ring Bit #4
9125 9995
870 40.5 21.5
21 Insert Bit Avg.
9050 9805
755 57.7 13.1
4 Ring Bit Avg.
9032 10130
1098 50.9 21.6

$CPF CPF
Inserts
40.37 $52.93
45.05 $56.35
49.70 $52.93
54.88 $52.93
52.93 $52.93
44.16 $53.61

Run
Savings
$12,890.18
$17,633.85
$3,024.48
-$1,698.40

RPM
60-75
60-65
60-70
60-70
55-60

WOB
KLB
20-40
22-33
20-32
25-35
60-80

$10,379.08
(Average Run Savings)

Table 1 - Economic and run parameter comparison of ring PDC bit and offset insert bit runs in
Freestone study area.

Bossier Formation
6-1/8" Interval
Interval Cost [USD]
Interval CPF [USD/ft]
Interval Savings

Offset
Inserts Only (3)
76,993.05
109.68

Well 1
Insert+NonRing PDC
48,003.35
71.12
28,989.70

Well 2
Well 3
Insert+NonRing PDC Insert+Ring PDC
63,677.25
51,550.30
86.99
69.66
13,315.80
25,442.75

Table 2 - Interval savings in Freestone Area 6 1/8-in. interval.

Bit run Area

Travis Peak Formation
Smith County
Nacogdoches County
Nacogdoches
Harrison

Depth Depth Footage Hours ROP

In
Out
FPH
8686 9588
902 56.0 16.1
9150 10180
1030 64.0 16.1
8944 9950
1006 62.0 16.2
7006 8180
1206 75.5 16.0

Table 3 - Bit performance data of second-generation ring bit.

$CPF CPF
Inserts
52.99 $51.95
55.43 $93.24
53.65 $91.24
44.64 $47.27

Run
Savings
-$935.10
$38,947.20
$37,812.44
$3,167.62

RPM WOB
KLB
60-75 20-32
60-65 18-30
60-70 18-30
55-60 20-25