Society of Petroleum Engineers
IADCISPE 47815
Steel Body PDC Bit Technology Demonstrates Performance Improvements
L.M. Smith/Security DBS; V.P. Perrin/Chevron Petroleum Technology Co.; R. Delwiche/Security
tip~ght 1998, Sooiety of Petroleum Engineers, Inc
~s pep.9r was prepared for p~ntstion at the IADUSPE Asia Pacific Driig Technolcg~
’98 held in Jaketi, Indonesia, 74 September, Im,
This paper was seleoted for presentation by an SPE program Cornmiw follting ti~
information mnteined in an abstracf submitted by the author(s). Contente of the pa~r, as
presented, have nti been revi~ by the %Iety of Petroleum Engineers and are subject to
mrrection by the author(s). The material, as presented, does not necessarily reflect any
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words. Illu%tions may not be mpied, The absireot should contain wnspicuous
acknolwedgment of where and by whom the paper was pr-nted. Wrii Librarian, SPE, P.0,
h _ Richardson, TX 7=3030, U.S.A., fax 01-972-952-S435.
Abstract
New bit technolog was used to create a series of steel body
bits which incorporate proven PDC bit design features for
improved ~rformance. The bits have achieved field records
in filly one-third of the applications in which they were
introduced. The teehnolo~ deseribed includes all aspeets of
bit application, including new manufacturing processes,
advanced design engineering, a unique nozzle configuration
and use of a computerized rock compressive strength analysis
program to refine application.
Field performance of steel body PDC bits is detailed and
Compared to mnventional matrix body bits to illustrate the
resulting performance improvements possible with propr
stwl body PDC bit application.
Introduction
Steel body PDC bits, while not a totally new concept within
the industry, have provided the neeessary material design and
quality properties for dramatically improved performance in
specific drilling applications.
Because stwl has significantly greater thermal expansion and
is more ductile than matrix material, steel body bits are far
less likely to fail due to breakage or shearing. Taking full
advantage of this fact, a new manufacturing process was
developed which allows one line of st~l body bits to
incorporate more complex geometries than previously
possible.
In particular, the new steel body bits can feature significantly
higher blade standoff than matrix bits. Higher blade standoff
DBS
translates into greater face volume, which, with more effieient
wttings removal, contributes to better penetration rates,
Of
Normalized open face volume is a measure the total volume
of the junk slots on the bit, measuring from the bit renter to
at the first point of gauge mntact. A larger normalized open
d
face volume contributes to hydradic efficiency, as well as
diwuraging cuttings from sticking to the bit body in what is
known as “bit balling.”
In addition, being made of steel, the new bits ean be treated
with an anti-balling (AB) surfacing technolo~ that
discourages cuttings from adhering to the bit face and musing
bit balling.
Manufacturing Process
An innovative manufacturing technique was developed for
use in production of the steel body bits. The process makes it
possible to create a new bit design with the exact performance
features required for a given drilling application, and have it
built and delivered to the rig in as little as four weeks. This
compares to the 15 weeks or more typically required by
conventional techniques.
The rapid prototyping that is possible with the manufacturing
technique also improves the economics of “one-off bit
designq unique bit configurations including bi-center casts
can be produced for a ~ific application more cost-
effectively than with conventional hard die and sand casting
techniques.
In addition to the significant efficiencies of production, the
process affords greatly expanded design flexibility, enabling
the steel body bits to incorporate improvements on traditional
steel body bit configurations as well as performance-
enhancing f~tures previously available only in matrix body
bit designs.
Anti-Balling Coating
The steel body PDC bits are treated during manufacture with
a patented anti-balling (AB) surfacing technology that
discourages cuttings from adhering to the bit face and causing
balling. The unique anti-balling treatment imparts an eleetro-
271
2 SMITH, PERRIN, AND DELWICHE
negative charge to the steel body bit which effectively repels
the negative ions in the drilling mud. The result is a lubricant
barrier of highly wnmntrated water that prevents the bit from
balling. ‘1)
Performance-Enhancing Design Features
The new steel body PDC bits can be manufactured with
fmtures that enhanm directional performance without
eomprornising ROP. Such features include impact arrestors,
varied cutter sizes and backrakes, spiraled blade layouts and
extremely short profiles that are just half the length of a
Wndard steel body bit. ‘2)
The impact arrestors, which provide stabilization to both
axial and lateral modes of vibration, effectively dampen
chaotic downhole vibrations. Typically positioned in the nose
and gauge area of the bit, the small round insets are aligned
directly behind PDC cutters to intentionally control depth of
eut ~) of the PDC cutter at the nose, where reek strength
may exti cutter strength and cause premature failure.
The steel body bits are also force-balanced in a proprietary
prwss that positions cutters to dramatically reduce downhole
vibrations that ean cause severe cutter damage. In addition,
the new steel body bits incorporate spiral, asymmetric blade
layouts which disrupt the harmonic effects that lead to the
onset of bit whirl, The bits also have tracking cutter layouts
which drill a *loped or ridged bottomhole pattern. Such
“ridged” patterns have proven more whirl-resistant than those
generated by conventional PDC cutter layouts.
SumsWly used in a number of sidetrack operations, the
steel body bits retain steerability while posting solid increases
in penetration rates. For example, during one North Sea
@onal projeet, a 17” steel body bit on a 11-1/4” motor
drilled more than 2800 feet per day in an application where
2000 f~t per day was typical.
Advanced Nozzle Technology
Available hydraulic ener~ is a tiction of date equipment
eapaeity, drill pipe size, motor requirements, directional tool
requirements, lithology wnsiderations, drilling fluid
rheology, and ofien, specKlc paradigms Partitiar to a given
area.
New nozzle technology has shown si~lcant drilling
bentits horn employing non-eitiar jets with speeialked
interior shapes to produw less than hydrostatic pressures at
the rock faw. These jets are ofien referred to as “negative
pressure jets”, or “fluted jets.”
Ol&r matrix body PDC bit designs had been used for fluted
jet application &veIopment, and the need for increased face
volume and other refinements beearne increasingly apparent
272
lADC/SPE 47815
over time. Refinement of the matrix ~ PDC drill bits and
global application with the fluted nozzles has clearly
demonstrated the viability of this technology, and fil step
improvements in penetration rate have resulted. ‘3)
Available as an option on the steel ~ bit designs, a new
“Vortexx” fluted nozzle has been develowd which features a
uniquely shaped orifice that effectively increases HSI without
increasing flow rate or decreasing cross sectional area of the
exit orifice. ‘4)
Unlike conventional circular jets, the asymmetric orifice of a
Vortexx nozzle creates a negative impingement pressure at
the formation interfaee. This in turn creates an underbalance
situation and increased turbulence under the bit, resulting in a
more productive pressure for more efficient cleaning and
cuttings removal.
Application Determination
Formation analysis is an important area of research that may
offer new performance benefits. The ability to interpret well
log data or other sources of information to predict when bit
balling may occur is extremely usefil.
The GeoMechanics computerized drilling analysis program
can be used at any point during a drilling program, from
initial plannin~ including directional plans, through post-
well analysis, Reek Compressive Strength analysis can be
conducted for a s~ified depth interval of interest, with the
system taking into account the effeets of relative dip angle
and temperature gradient.
The Bit Mechanical Efficiency analysis incorporates a Bit
\Vear Model that allows for accurate estimation of bit life
based on cmmdative work pe~ormed. The model establishes
bit work ratings to optimize bit selection by matching the
ratings to work requirements of the interval to be drilled. Bit
design changes also can be evaluated based on resutting
changes in bit mechanical efficiency.
In a real-time application, the Penetration Rate Model can
determine the optimal working range of weight-on-bit/RPM
for a given rock strength, bit wear condition and power Imel,
allowing penetration rate to be maximized without unduly
compromising bit life through exposure to severe wear,
It is important, howmer, that bit application be viewed as part
of a total “systems approach” to engineered drilling. Bit
selection and operating parameters are determined based on a
number of variables such as rig and pump capacities, mud
~stem, operational constraints, and well objectives. Use of a
computerized drilling analysis program such as
GeoMechanics is intended to enhance the bit seleetion
process within the wntext of a total system,
lADC/SPE 47015 STEEL BODY PDC BIT TECHNOLOGY
Performance Results
Drill bit performance improvement is typically defined as
either longer bit runs with fewer costly trips to replace worn
bits, increased rate of penetration, or more commonly, both.
The use of new steel body PDC bit designs in combination
with fluted hydraulic jets provides a clear advantage to the
operator in terms of improved bit performance.
This new series of steel body PDC bits is initially
recommended in drilling applications with more than 40°/0
shale content; generally, the bits are run in the larger
diameter, top- and intermediate-hole environments. In
direetioti wells, swelling shales, and a variety of
applications requiring use of water-based mu~ steel body
PDC bit performance has produced significant savings for
operators through improved drilling performance.
The following data represents actual field results in various
areas of the world where this technolo~ has kn employed.
One major operator has found successful application of the
bits in Venezuela, Argentina, Jakarta, the North S= and the
Middle East.
Offshore Indonesia A number of successful steel bit
applications are documented in Indonesian wells. Initial
results from one re~nt offshore directional application
indicate a 12-1/4” AB-coated steel body bit drilled more than
9000 feet at an average ROP 36*. This performance in the
S-sha@ directional well set a record for the fastest ROP and
longest run to date in that field, (Figure 1)
The steel body bit, which fmtured a spiral six-bladed design
with 3# PDC cutters, was run from 1139m depth in to TD the
well at 3780m, a total run of 273 lm in 74.4 hrs. The bit
averaged 36.7 m/hr compared to the previous best run of
2400m at 29 m/hr, and experienced none of the bit balling
problems characteristic of this application. (Figure 2)
Another 12-1/4” FS2663 steel body bit drilled 8960 feet in an
offshore Indonesian well. The bit averaged penetration rates
of 90 ft/hr, drilling to a depth of 12,402 ft to achieve a field
run reeord.
In Brunei, a 12-1/4” FS2663 drilled 2687 feet at an ROP of
203 ft/hr to achieve a field run record. When pulledat4019
feet, the bit was ddl graded 1-1 -W-A-X-I-NO-TD. The bit
was run again to drill another 1014 fmt at 56 W, and was
@led due a problem with the BHA.
In one East Malaysia well, a 12-/4” FS2743 drilled a total of
6931 feet at an average ROP of 95 ft/hr in two runs. Another
was run on a 9-5/8 motor using oil-based mu~ drilling 3005
fmt at an ROP of 88 W for a field record. When pulled at
6625 ft, the bit was ddl-graded: l-1-LT-N-X-I-BT/CT-TD.
DEMONSTRATES PERFORMANCE IMPROVEMENTS 3
In vertical exploration wells in West Malaysia, the steel body
PDC bits have performed well in the 12-1/4” tophole section.
One 12-1/4” FS2463 drilled2514 meters at an average ROP
of 35 m/hr. Another drilled 869m in two runs, achieving an
average ROP of 33.8 rn/hr, and was dull graded re-runnable.
Philippines One steel body bit application in the tophole
section of a directional well set a field run performance record
when used in conjunction with the complementary matrix
body PDC bit design. The 8-1/2” FS2565 drilled 3115 feet at
an ROP of 37.4 ft/hr, and was followed by a 6“ FM2463
which drilled 774 feet to TD, The time savings that resdted
from the performance of these bits under directional drilling
constraints produced economic savings of an estimated two
million dollars.
Australia In a number of offshore Australia applications,
the steel body PDC bits have demonstrated pefiorrnance
improvements over offsets. They have &n used successfully
in directional applications through long intervals of limestone
with varying marl content. In one well, wrheredolomite
stringers were encounter~ a 9-7/8” FS2563 drilled 1191m at
an ROP of 37.2 m/hr, and was graded repairable. (Figure 3)
The bit was used for controlled drilling to hole inclination at
35° through the section.
Middle East The new line of steel ~ bits currently has
achieved the most records of any type of bit run in Abu
Dhabi, including records for ROP, most footage in 24 hours,
fastest interval, most footage – and most records.
In one project where 50 wells are planned to be drilled using
four rigs, application of steel body bits thus far has more than
doubled penetration rates from 37 f?/hr to more than 75 fUhr.
Already in the course of this project, a 12-1/4” FS2663 has
established two record performances for the field: increasing
ROP by 32% over the previous six best wells drilled with a
PDC bit on a top drive unit; and drilling record footage for a
24-hour period.
Run on a slow-speed high-torque motor, the FS2663 drilled
an intewal of 3105 feet of interbedded formations at a total
average ROP of 76.7 W. This exceeds penetration rates of
the previous six best runs, which ranged from 70 to 44.6 ~r
for a cumulative average of 57.2 ft/hr. In addition, the steel
body bit, used to drill out cement, shoe and float collar,
maintained an average ROP of 84.7 ft/hr while drilling
through 2032 feet of the total footage in a 24-hour period.
When pulled at TD at 8795 h, the bit was graded 3% worn
and was re-runnable. The same bit then was re-run and
drilled another 2640 feet - to within one-tenth of a foot of a
new record for footage in the field.
273
4 SMITH, PERRIN, AND DELWICHE lADC/SPE 47815

~rsonnel to adjust drilling parameters accordingly to

In the same field in the Middle East, a second steel body PDC
bit was run, achieving a field record penetration rate on a
kelly rig with an increase in ROP of 35% over the previous
three best wells drilled with a PDC bit.
All aspects were mnstant for these runs, including formation
tops, fmtage drilled mud weight and system, operating
parameters and rig used. When pulled at TD at 8680 fret, the
steel bit was graded 5% worn and was re-runnable.
This 12-1/4” FS2663 bit was then re-run and set the new Abu
Dhabi 12-1/4” cumdative footage record (for “non repair”
bits) with a total 6047 feet. Mer the seeond run, the bit was
graded just 10% worn and still re-runnable.
As shown in the tables klow, steel body bit performance in
this application consistently exceeds that of offsets, in both
kelly and top drive application, and well as for total footage
per bit.
optimize performance through ~lcdt or changing
conditions. Employing a compressive strength analysis
program which incorporates CEC values also has proven
useti in predicting bit balling problems, and may help to
define the success of new technology in combating this
problem.
Acknowledgments
The authors wish to thank Security DBS, Chevron, Trans
Texas and ADCO for prmission to publish this data, and
thank the following field and operations personnel: Mike
R&se, Terry Dailey, Normal Cooper, Rob Arfele, George
Espiritu, Calvin Elmer, Rusty Milam, John Kelety, Dan
Symonds, Tommy Hymel, Gary Weaver and Bill Wng. We
also acknowledge the efforts of the drilling contractors and
rig crews who supported our efforts during these bit runs, as
well as staff in District offices in the Far East, Malaysia,
Aftica, Singapore, Jakarta, South America, the Middle East,
North Sea, Australia, Alaska and the Gulf of Mexico.

Conclusions
In directional wells, swelling shales, and a variety of
applications requiring use of water-based mud steel body
PDC bit performance has produced si~lcant savings for
operators through improved drilling pefiormance.
The use of new steel body PDC bit designs in combination
with fluted hydradic jets provides a clear advantage to the
operator in terms of improved bit performance. SpecKlcally,
longer bit runs and improved dull grade conditions are a
fiction of better heat transfer and bit cleaning as well as
anti-balling coating of the bit and aggressive design features.
Bit selection remains part of a “total systems” approach.
Using a computerized drilling analysis program, specific
operating parameters can be employed at the rig to limit PDC
cutter damage in the new steel body bits. In addition,
anticipation of harder, interbedded formations enables
References
‘ Hale, A., Romslo, N., et. al.,: “Successful Field Application
of an Electro-Negative ‘Coating’ to Reduce Bit Balling
Tendencies in Water Based Mu*” paper IADC/SPE
35110 presented at the 1996 IADC/SPE Drilling
Conference, New Orleans, La., March 1996,
2Dahlem, J.S., Dresser Seeurity, et,al.,: “The Application of
Advanced PDC Concepts Proves Effective in South
Texas”, paper IADC/SPE 27472, presented at the 1994
IADC/SPE Drilling Conference, Dallas, Tx., February
1994.
3 Akin, J.E., Smith, S.K., and Dove, N.R.,: “The Negative
Impingement Pressure Nozzle Phenomenon,”
Computational Mechanics ’95, S.N. Athu-i (cd.),
Springer, To@o (1995) 1108-1115.
4 Akin, J.E.,: “HSI Redefined for Drilling Hydraulics,”
Journal of Petroleum Technolo~, 1997.

ROP Comparison: Kelly Runs

40.9
38.0 I
45.3
63.3

Tables: Comparison of Steel Body PDC Bit vs. Offset Performance

Onshore Middle East application. Formation tops, mud system and
weight, parametem and rig are constant. The only identifiable variable is
bit type. Steel body bit performance indicated in bold.

274
IADCISPE 4~15 STEEL BODY PDC BIT TECHNOLOGY DEMONSTRATES PERFORMANCE IMPROVEMENTS 5

3821: 9.5fl SHOE, 2599mN0

42W TOP TMG~,3317mlV

W69: 7“S~E, 4117mlV0

1
5169: 4.l@ SWL 4217mlVU

4=+ , I 11111111 Ill T

Figure 1. Directional wellplan offshore Indonesia application. Figure 2. Steel@ PDC bit afier drilling more than 9000 feet,

i,
m
Fi~ 3. Before (Iefi) and Mer (right) drilling 1191 metres, offshore Australia.

275