SPE/IADC 163491

Innovative Hybrid Bit Mitigates Geological Uncertainties, Improves Drilling

Performance in Brazilian Pre-Salt Formations
Slim Hbaieb, Michael Azar, Smith Bits, a Schlumberger Company

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
An innovative hybrid bit design has been successfully applied offshore Brazil to mitigate geological/formation uncertainties
in pre-salt formations and eliminate several trips for new bits. In the application, PDC bits can drill these carbonates
effectively until the cutters are damaged by problematic chert inclusions. The hybrid bit is capable of similar ROP and run
lengths as standard PDC and allows the operator to achieve a long run at high ROP when no silicate inclusions are present.
However, the hybrid bit also provides the added benefit of continued drilling at reasonable ROP when a nodule is
encountered with its secondary and tertiary cutting elements.

The unique hybrid design utilizes grit hot-pressed inserts combined with alternating PDC shearing elements and wedge
shaped TSPs all set in an impregnated post-on-blade design. Extended bit life is achieved when the cutting mechanism
changes from shearing to grinding as the PDC/TSP elements are worn away. When the PDC cutting structure is worn down
to 50%, the bit still has 75% of life remaining.

The paper will focus on case studies where pre-salt carbonate lithology is non-uniform with a high occurrence of silicate
inclusions. The authors will discuss drive system and drilling parameters selection that were critical to achieving the desired
performance. When used with the appropriate BHA and drilling parameters, the hybrid bit displayed good ROP performance
and total footage capabilities. Lower cost/meter was achieved because the hybrid bit had faster initial ROP compared to PDC
and stayed on bottom drilling longer due to improved durability with TSP then impregnated cutting structures. Cuttings size
and resulting lithology analysis will also be discussed. Engineers are currently working on a real-time surface/downhole data
processing system to detect when the impregnated cutting structure engages formation in order to make changes in operating
parameters to maximize drilling efficiency and penetration rates.

Introduction
With continuing advances in synthetic diamond cutter technology and improved bit stability, PDC bits have become a
dominate force in the worldwide drilling scheme. In 2004, total footage drilled by PDC bits (54%) surpassed that of roller
cone bits (46%) and the trend has continued. In spite of the gains, service providers are continually working to expand the
application range of PDC/diamond bits into harder, more abrasive formations and interbedded hole sections. Recent studies
have indicated PDC cutting elements are susceptible to thermal damage when drilling highly abrasive formations and to
impact damage in non-homogeneous formations and inclusions of chert or pyrite (Figure 1). Once the PDC cutting elements
are worn or damaged, ROP drops and ring-out of the bit body may occur. Historically, PDC bits have performed best in
relatively homogeneous and non-abrasive applications.

Conversely, impregnated bits (Figure 2) have been mostly restricted to deep intervals that contain mainly hard and abrasive
sands. The synthetic and/or natural diamonds used in impregnated bits have good thermal stability and abrasion resistance
improving bit life and footage drilled compared to conventional PDC. Diamond size, concentration, distribution, and
surrounding matrix (bond) can be varied to improve ROP and durability when drilling through difficult chert/pyrite
inclusions or conglomerates with minimal bit vibration. The major drawback to standard impregnated designs is they
generally have much slower ROP than PDC bits in soft/medium formations. Impregs also have issues with cleaning the
cutting structure in soft formations leading to bit balling.
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Figure 1 Thermal damage on worn PDC cutter (left) leading to low ROP and bit ring-out (right)

Figure 2 - Impregnated diamond material (left), and top view of a diamond impregnated drill bit (left)

This left a very common sequence of formations, abrasive sandstone interbedded with soft shale, to be drilled with either
roller cone or PDC. Neither of the two choices has delivered satisfactory penetration rates or bit life. Working with several
operators, the service provider has conducted extensive laboratory and field development tests that have resulted in a new and
aggressive hybrid bit technology that incorporates the advantages of both PDC and impregnated bits.1 The new style bit
(Figure 3) offers unique advantages for drilling hard/abrasive and interbedded formations more economically than either
roller cone or PDC. The hybrid bit has been successfully run in various applications in Algeria, Gulf of Mexico, Brazil,
United Kingdom, on-shore USA, Angola and Russia.

Figure 3 Innovative hybrid bit design with multiple cutting structures

SPE/IADC 163491 3

Although the new hybrid style bit was initially developed for applications that have a non to medium abrasive top hole
section followed by a very abrasive formation, engineers wanted to test the bit in the heterogeneous pre-salt carbonates
encountered offshore Brazil to solve the random occurrence of hard silicate inclusions. In some instances a PDC bit can drill
these carbonates (with inclusions) effectively for extended footage until the cutting elements are damaged by inclusions
requiring a trip for a new bit. The new style hybrid bit would allow for similar performance when inclusions are absent but
with the added benefit of continued drilling with its secondary and tertiary cutting mechanisms after hitting a series of
nodules potentially saving multiple trips and expense of additional bit buy.

The authors will describe the new bit concept and how it functions in a downhole environment. They will also outline
specific case studies in the offshore pre-salt carbonates where heterogeneous carbonates have random silicate layers and
nodules. Because the bit combines various cutting mechanism, the selection of the drive system and drilling parameters is
critical to achieve the desired performances. Next the paper will explore the various lessons learned using the hybrid bit in
various scenarios to achieve maximum performance.

Hybrid Bit Concept and Key Features

The hybrid bit (KH) possesses multiple cutting mechanisms combined in a single cutting structure (Figure 4) including:

1. A PDC cutting structure

2. An alternating wedge shaped thermally stable polycrystalline (TSP)
3. Multiple blades with diamond impregnated material

In addition, the bit incorporates high density diamond impregnated cylinders on gauge to prevent the bit from suffering
reduced OD size. Extended bit life is achieved through transformation of the cutting mechanism from shearing to grinding as
the PDC/TSP elements are worn away. When the primary PDC cutting structure is worn down to 50%, the bit still has 75%
of life remaining.

Figure 4 Explanation of hybrid bit cutting mechanisms (left) and schematic of fully impregnated blades

The goal is to attain similar ROP to PDC bits in the initial formation. The TSP elements engage the formation after the
PDC cutters wear to a certain level. When the PDC and TSP are worn flush to the blade, the cutting mechanism transforms
from shearing to a grinding action as shown in Figure 5. This triple stacked cutting structure results in a fast initial ROP with
premium PDC cutting elements and much improved durability with TSP and diamond impregnated portions.
4 SPE/IADC 163491

Figure 5 Hybrid bit wear patterns showing different levels of cutting structure exposure

The new hybrid bit has an improved ROP in hard/abrasive formations through an innovative shearing cutting mechanism.
Indeed, the PDC cutters provide complete bottom hole coverage while the TSP elements track the PDC cutters at
predetermined lower exposure. The PDC/TSP cutting structure of the new-style hybrid bits is analyzed through a FEA-based
integrated dynamic modeling system to optimize bit behavior and reduce damaging vibrations (Figure 6). Further
information on the modeling system and its capabilities can be found in references papers 2-13.

Figure 6 FEA-based modeling system optimized the PDC/TSP cutting structure for dynamically stable drilling

The hybrid bits hydraulics consists of nozzles instead of fixed ports adding flexibility in adjusting the total flow area.
Computational fluid dynamics (CFD) optimized hydraulics was utilized to optimize the bits cleaning characteristics ensuring
efficient cleaning and cooling of the cutting structure (Figure 7).
SPE/IADC 163491 5

Figure 7 CFD analysis ensures efficient cleaning and cooling of the cutting structure
Flow path (left) and bottom velocity (right)

The new hybrid bit is equipped with high abrasion resistant premium PDC cutter technology for extend bit life.14-20 These
new cutters have been extensively tested in the laboratory and show significant improvement to resist abrasive wear
compared to standard premium shearing elements (Figure 8).

Figure 8 - New type cutter displays superior resistance to abrasive wear in laboratory tests

The new type hybrid bit is dull graded in a similar manner to an impregnated bit but since the entire blade has usable
diamond, initial blade heights are recorded and final blade heights are measured after the bit run (Figure 9). Using the
amount of worn blade/PDC, a 0 to 8 scaling ratio is used to calculate its appropriate dull grade. Grading is based entirely on
blade/PDC height. Post run measurement should be taken on the same profile section of the bit as first measurement. For
example, if the initial blade/PDC height is measured at 4.0 cm and after running the bit the final blade/PDC height is 2.0 cm,
a final dull grade of 4 is given.
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Figure 9 Precise measurement required to accurately determine hybrid bit wear and assess dull condition

Application Challenge (Pre-Salt Carbonates)

Pre-salt carbonate reservoirs offshore Brazil represents one of the most important recent oil discoveries. One technological
challenge yet to be solved to make these reservoirs commercially viable is the unpredictable nature of bit durability and very
slow ROP. When exiting the evaporate layer, the formation encountered is heterogeneous with varying thickness. Some
intervals are PDC drillable with ROP up to 6m/hr with bit runs over 250m long. Other intervals contain hard and abrasive
carbonates (Figure 10) unpredictable occurrence of stromatolitic limestone, microbial laminitis, volcanics, and sporadic
silicates inter-layers and nodules.21 These difficult formations have caused multiple trips to change out the bit due to heavily
damaged and worn cutting structures in less than 30m of drilling.

Courtesy of Repsol
From Peixoto Filho and De Souza Neto (SPE 139195)

Figure 10 Problematic silicate inclusions imbedded in pre-salt carbonate formation

Laboratory sample (left) and core section (right)

The heterogeneity and unpredictability of these formations has affected drillability, in particular the sporadic occurrence of
silicate make the bit-drive selection challenging. Historically, various bit types were tried:

Roller cone averaging 100 to 250m/run at 1-3 m/hr resulting in cost/meter higher than $30,000
Impregnated averaging 400 to 500m/run at 1-3 m/hr resulting in cost/meter of $15,000-$20,000
PDC runs varying from 20 to 250m at 0.5 to 6 m/hr. Although cost/meter for a long PDC run can be lower than
$10,000, it can exceed $50,000 for the short PDC runs.

The justification for trialing the new hybrid bit offshore Brazil is the presence of silicate. The bit offers the potential of high
ROP achieved with the primary PDC cutters. When hard and abrasive inclusions or layers (Carbonate with silica content or
SPE/IADC 163491 7

volcanic formation) are encountered, the TSP s offer superior abrasion resistance. After these cutting elements are worn, the
bit transforms into an impregnated bit and will continue to drill avoiding premature POOH.

Several operators have used the hybrid bit to drill total footage over 1800m in 12-in and 1100 meters in 8-1/2in hole size.
From a cost per meter (CPM) perspective, it was shown that when used properly the hybrid bit offers an average CPM below
20k$, with best runs below 15k$ when the carbonates encountered were more PDC drillable and the worst runs cost
approximately $25,000USD when the PDC structures quickly degraded. Therefore, when planned properly and mainly for
exploratory wells where carbonates are very unpredictable and prior knowledge of the formation is reduced, the hybrid
solution can lead to fewer trips/NPT, reduced bit spend and ultimately lower cost per meter.

Drilling System and Parameter Considerations

The new hybrid bit was used with various drive systems and parameters to drill pre-salt carbonates including:

Rotary BHA with 140-180 RPM

Standard speed motors with or without a rotary steerable system at 200-250 RPM
High speed motors with 600-900 RPM
Turbines at over 1000 RPM

While most runs showed improvement in performances and have led an operator to adopt this hybrid bit systematically in
their pre-salt drilling campaign, few bit runs did not show performance improvement due to inappropriate drive system and
drilling parameters selection. The different runs offered an interesting dataset to analyze the performances obtained with the
various BHAs and operating parameters applied. This exercise led to a better understanding on how to use this technology
in different formations to maximize performance. Various recommended drilling practices and conclusions will be listed in
the subsequent section.

Results of Hybrid Bit Runs (Various Drive Systems)

The hybrid bit was run twice on a high speed turbine in the 8-in hole section. Figure 11 shows the drilling parameters
used in one of the hybrid/turbine runs. Bit RPM ranged from 1200 to 1250. In this case, bit RPM could not be lowered at the
start of the run by reducing flow rate because it would have shut down MWD telemetry. Also, WOB could not be increased
above 15klbs as the torque generated would stall the turbine. Due to these limiting factors, the PDC/TSP structure did not
generate any considerable added value and performance was comparable to offsets drilled with impregnated bits in terms of
ROP and total footage.

ExampleofHybridrunwithTurbine
DownholeRPM(rpm)

WOB(klbs)/ROP(m/hr)
rpm ROP WOB

1300.00 20.00

1280.00 18.00

1260.00 16.00

1240.00 14.00

1220.00 12.00

1200.00 10.00

1180.00 8.00

1160.00 6.00

1140.00 4.00

1120.00 2.00

1100.00 0.00
5050.00 5100.00 5150.00 5200.00 5250.00 5300.00 5350.00 5400.00 5450.00
Depth(m)

Figure 11 - Drilling parameters used on hybrid bit run on a turbine BHA on a pre-salt well

The next hybrid/turbine run drilled 400m of section and came out of the hole in good condition and was dull graded 4-4
(Figure 12). Similar results were also obtained when using a hybrid on a high speed motor rotating the bit at 700-900 RPM.
Looking at several worldwide applications, PDC cutting structures have delivered good performance on a turbine BHA when
drilling homogeneous and non abrasive formations. However, a PDC bits shearing elements suffer low depth-of-cut when
run on a high-speed turbine and encountering an abrasive layer would lead to premature failure of the cutting structure.
Drilling heterogeneous formations with PDC, such as conglomerate or inclusions, could lead to catastrophic cutter chipping.
8 SPE/IADC 163491

Figure 12 - Hybrid bit with 50% cutting structure remaining after over 400m of pre-salt turbine drilling

Main lesson learned is that rotating the PDC structure at high RPM is detrimental in these lithologies. Therefore, it would be
best to avoid running the hybrid bit on turbine or high speed motor in the pre-salt drilling application.

Hybrid on Rotary BHA

Two 8-in hybrid bits were run on a rotary BHA. One bit drilled over 400m while the other was POOH after only 70m. An
analysis of the drilling data from the 400m bit run shows 5 m/hr was achieved for 200m using 120-140 RPM with 20 klbs at
375gpm. When the PDC elements were worn away and the impregnated structure engaged, a maximum of 160-180 RPM at
25 klbs at could be applied due to top drive limitations. Penetration rate was controlled at an average of 2 m/hr for 200m.
The flow rate was limited to 355 gpm due to static fluid losses. The bit was dull graded 8-5.

An analysis of drilling data from the 70m run shows that WOB started at 25-35 klbs with average RPM of 160-180 with a
surface RPM peak of 250 due to stick/slip. The drilling dysfunction exposed the PDC cutting structure to a higher load than
on the first run. Flow rate was kept at 355gpm due to static fluid losses. The bit was pulled out of hole due to partial losses
and was dull graded 8-8 with ring-out marks (Figure 13).

Figure 13 - Bit was dull graded 8-8 after a rotary run at 180 RPM 35 klbs WOB
SPE/IADC 163491 9

Lessons Learned (Rotary)

In an 8--in hole section the impregnated structure could be cleaned with a relatively low flow rate of approximately
355gpm confirming the good hydraulic design. When using a top drive, an RPM range of 160-180 is sufficient to achieve a
reasonable 2m/hr ROP when drilling with the impregnated structure. However, high levels of stick/slip were experienced
when drilling with a rotary BHA which proved detrimental to the PDC/TSP cutting structure. Reducing the WOB in this case
will preserve the cutting structure but could compromise ROP. Although BHA design guidelines can help attenuate
damaging downhole dynamics, it is recommended to avoid rotary BHA drilling in this scenario.

Hybrid Runs on PDM/RSS

A total of 11 hybrid bit runs were drilled with a downhole power section:

Eight 12-in runs on an RSS with a 9 5/8-in power section

Two 12-in runs with a 9 5/8-in positive displacement motor
One 8 -in run with a 7-in positive displacement motor

All bits run exceeded 150m with four bit runs above 250m. Penetration rates achieved depended on formations encountered.
One run reached 9.4 m/hr where the operator encountered a PDC drillable layer at the top of the a hole section. Similar to
what was learned from the rotary BHA run, the impregnated structure could achieve good ROP with an RPM range not
exceeding 220-250 RPM. The positive displacement motor had an advantage compared to a rotary BHA because it could
achieve higher RPM than the top drive could deliver. If total pressure drop and other well considerations allow, the driller
could maximize surface RPM and flow rate once the impregnated portion of the hybrid bit engages.

Engineers observed when drilling with the impregnated structure, higher WOB was required compared to a standard
turbine/impregnated BHA application. The drilling team surmised this situation is caused by the worn PDC and TSP cutters
acting as a bearing surface. However, excessive WOB will lead to a faster impregnated blade wear rate. Therefore, it is
recommended to do frequent tests to maximize the bit life in this case.

Unlike turbines, a PDM can efficiently drill with high torque and therefore ROP can be enhanced when drilling with the PDC
portion of the hybrid bits cutting structure. Also, a lower level of stick/slip occurred compared to rotary drilling preserving
the PDC structure. To reduce RPM when drilling with the PDC structure, the driller could reduce surface RPM and
eventually the flow rate.

The hybrid design proved valuable when cutting samples were collected at the surface to enhance geology/geophysics (G&G)
interpretation and analysis. Even in instances when the impregnated blades were exposed, several PDC cutters remained
intact at the bit center and kept producing large drill cuttings. From a G&G perspective, this added significant value
comparing to the turbine applications in cases when high-quality formation samples were required.

As expected, the hybrid bits multiple cutting structures proved extremely valuable in the pre-salt application. The
combination of PDC/TSP in diamond impregnated material virtually eliminated lithological uncertainties. In one of the wells
the hybrid bit was run after an eight-bladed 13mm cutter PDC (M813) was pulled after drilled just 60m as follows: 20m at
7m/hr; 40m at 2 -3m/hr. The bit came out dull graded 4-8. The hybrid bit (KH813) drilled: 20m at 9m/hr; 90m at 3 m/hr;
and then 200m at 2 m/hr. The KH bit was pulled after drilling 300m and was dull graded 8-8.

A subsequent run with an identical hybrid design encountered an unexpected soft formation and was able to drill 138m at a
fast ROP of 9 m/hr and was pulled at section TD in good dull condition (2-3). On another well, a six-bladed 16mm PDC bit
(Mi616) drilled just 18m of formation at 3m/hr and then was POOH after completing an additional 10m at 1-2 m/hr. It was
pulled for low ROP and was graded 8-8 after less than 30m. The KH813 hybrid was RIH and made 23m at an ROP of 2-
4m/hr and then 227m at 1.5-2 m/hr (DG 7-8). A second hybrid run drilled 315m at 4m/hr and was pulled 7-8 at section TD.

Conclusions
The hybrid bit offers an innovative new solution to solve geological uncertainties associated with the Brazilian pre-salt
play. Using this combination of cutting technologies allows the operator to achieve long bit runs at high ROP when no
silicate inclusion are encountered and the opportunity to keep drilling ahead at reasonable ROP when/if the nodules are
encountered. Lower cost/meter can be therefore be achieved with the hybrid bit with faster initial ROP using PDC and more
on-bottom drilling hours with TSP then impregnated.

Analysis has shown that good and consistent performances were obtained when properly planning and running the hybrid bit
in a combination with the appropriate downhole power section. Cuttings were also collected for lithology analysis even
when drilling with the impregnated body as result of the remaining inner cutting structure. Drilling parameters should be
constantly adjusted to maximize bit life and run performance.
10 SPE/IADC 163491

Going forward, efforts will be made to acquire real time surface and downhole data processing to detect when the
impregnated structure is exposed to appropriately adjust drilling parameters to maximize ROP. Engineers will also strive to
improve existing KH hybrid bit designs by continually evolving PDC and impregnated guidelines for the pre-salt
application to increase drilling efficiency and bit durability.

Acknowledgements
The authors would like to thank management at Schlumberger for permission to publish the bit technologies and run results
outlined in this paper. Also, thanks to Craig Fleming, Smith Bits, for his technical writing and editorial contributions.

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