PDC Bits PDF

PDC Bit Structure
API Connection
Shank
Breaker Slot
Identification Slot
Weld
Blank
Crown Chamfer
Matrix Bit Body
Gauge Pad
Nozzle
Cutters
Copyright Baker Hughes, Inc.

PDC Face View
Blade
Junk Slot
Nozzle
Cutters

PDC graphite mold assembly
Top
Funnel
Blank
Mid
Funnel
Boat

Diamond Bit Materials
 The Bit Body

 Matrix Body
 Manufactured with a cast, graphite mold
 Bit body made up of tungsten carbide matrix powder
 Bonded together with a copper alloy binder
 Very resistant to erosion and abrasion

PDC Cutter Attachment
 Low temperature braze

 Bonds only to PDC substrate
 Technique is a critical skill

Steel Body
 Two piece design

Diamond Bit Materials
 The Bit Body
 Milled from bar Stock Steel

 Steel body design uses a cast steel body welded to a shank (two
piece design)

Hardfacing
Oxy Acetylene Applied Macro Hardfacing

Shank
 High alloy, heat treated steel

(4140)
 API regular connection
 Breaker slots
 Identification slots

Steel Blank
 Steel “skeleton” of a
matrix body bit
 The tungsten carbide
matrix is cast around
the blank
 Provides for
attachment of the
shank
 Soft, ductile steel
(1018)
Blank
Bit Body - Major Components
Shank
Steel Blank
Matrix Body

Nozzles
 Sintered tungsten carbide
MSP  Standard size is the “SP” (Single

Piece)
SP  Additional size developed for

smaller bits is the “MSP” (Micro
SP)

Diamond Cutting Structures
Natural Diamond
PDC
TSP Impregnated
Polycrystalline Diamond Compact
(PDC)
Man-Made Diamonds • 1976, introduction of first PDC

for drilling in petroleum
and mining
•Stratapax
• A natural diamond is a single

crystal, the term
polycrystalline means
many crystals

PDC Cutter Manufacture
 Pre-made synthetic diamond

 Pre-made tungsten carbide substrate
 High Temperature High Pressure (HTHP) process
Pictures courtesy of US Synthetic

Polycrystalline Diamond Compact (PDC)
Man-Made Diamonds
Diamond Table
0.010 in. 0.016 in.

Tungsten Carbide
Substrate
45º Edge Chamfer

PDC Cutter Properties
 Diamond Table
 Abrasion and impact resistance
 Diamond/Carbide Interface
 Affects impact resistance
 Edge Geometry
 Influences impact resistance

Polished Cutters
 Standard feature
 Low Coefficient of Friction
 Conventional PDC
 Brake pads
 Polished PDC
 Ice on ice
 Hughes Christensen Patent

Cutting Mechanics

Definition - Depth of Cut (DOC)
 The depth the cutter is indented into the rock

 Can be used along with RPM and a units constant to
determine rate of penetration:
 ROP (ft/hr) = DOC (in) x RPM (rev/min) x 5
 ROP (m/hr) = DOC (mm) x RPM (rev/min) x 0.06
Depth of Cut
Example: 0.150” DOC, 100 RPM
ROP (ft/hr) = 0.150” x 100 x 5 = 75 ft/hr

Depth of Cut Questions
 If we speed up the RPM while maintaining the

same depth of cut, what will happen to the ROP?
 ROP will increase
 If we slow down the RPM but maintain the same

ROP, what will happen to the DOC?
 The DOC has to increase

PDC Cutter Size vs. ROP
Max. ROP (ft/hr)

Cutter Size
100 RPM 180 RPM
0.323” (8.2 mm) 81 146
0.529” (13.3 mm) 133 240
0.750” (19.1 mm) 188 338
0.323” (8.2 mm) 0.162” x 100 RPM x 5 = 81 ft/hr
0.529” (13.3 mm) 0.265” x 100 RPM x 5 = 133 ft/hr
0.750” (19 mm) 0.375” x 100 RPM x 5 = 188 ft/hr

Cutter Orientation- Back Rake
15º 20º 30º
 Determines the aggressiveness of the cutter

 The lower the back rake, the more aggressive the cut

Cutting Efficiency - Backrake
 Generally, smaller backrake angles require less weight and

torque
 The magnitude of the effect depends on rock strength

Decreasing Backrake Increases
Efficiency
Medium Shale, Co = 10 kpsi
Specific Energy vs. Penetration Rate

0.016 in. x 45 o , Mancos, 3 kpsi
100,000
15 deg
90,000 20 deg
80,000 30 deg
Specific Energy (psi)
70,000 40 deg
60,000
50,000
40,000
30,000
20,000
10,000 Increasing WOB

0
0 20 40 60 80 100 120 140
Penetration Rate (ft/hr)

Can we just use small chamfers
and 15º BR?
 Based on our current technology,

the answer is NO
 In part, because durability would

suffer
 Also, because low backrakes affect

wearflat development
 For a given wear state, lower
backrakes yield bigger wearflats
25º 15º 10º

PDCWear Predictions: New vs. Worn
Even cooling
Full carbide support Specific Energy vs. Wear
120 RPM 084 G445XL Variants
160,000
15 deg BR
140,000 20 deg BR
Specific Energy (psi)
30 deg BR 30% Worn

120,000
40 deg BR
100,000
80,000
60,000
New
40,000 Condition
20,000
0
0 100 200 300 400 500 600 700
Distance Drilled (ft)
Low backrakes are more efficient in the “new” state

As bits wear they can become less efficient

Introduction to Bit Profiles
 The term “profile” or “crown profile” refers to the

distinctive shape of the bit head when viewed from the
side
 A variety of profile shapes and lengths are used to

optimize bit performance depending on the bit type and
application
 The basic objective of any profile is to optimize bit

stabilization and wear as well as achieve well bore
trajectory objectives

The PDC Bit Profile
 Bit profile and cutter layout

are closely related. Each
Bit Center Line

cutter layout is compromise
between the following:
Gauge 0,0,0 Point  Maximum number of cutters
Length (longer bit life)
 Lowest blade count (better
hydraulics, ROP)
Nose Location
Shoulder Cone Angle

 Shortest possible profile (better
Nose bit stability / cleaning)
Radius
Cone
Nose

PDC Profile Types
Short Parabolic Shallow Cone Long Parabolic

Secondary Stability
BRUTE Inserts
 Acronym for “Backups that are Radially

Unaggressive and Tangentially Efficient”
 A thick diamond table cutter is embedded in

a wear knot and oriented so that it can cut
tangentially, but not radially (sideways)
 Polished diamond provides a “low friction
wear knot”
 Orientation allows BRUTE to do work if
leading cutter is damaged
 Recessed 0.100”

BRUTE Inserts in the Cone
Backups that are Radially Unaggressive and Tangentially Efficient
 Provides a bearing that limits depth of cut for steerability

(Reduced Exposure concept)
 Increased durability
 Repairable Reduced Exposure feature

Dynamics Summary
 Primary Stability  Secondary Stability

 The ability of a bit to drill  The magnitude of vibration when
smoothly unstable
 Inter-related with system  Controlled by chordal drop

stability management (standard)
 Primarily controlled by  Also controlled by external

cutter layout features:
 LMM (standard)
 Wear Knots/Clouds (option)
 BRUTES (option)

Hydraulic Efficiency
 Cuttings Removal (“Cleaning”)

 The effectiveness of each layout is determined through
laboratory tests in sticky shale under fixed conditions
 Maximum ROP without balling
 Cutter Cooling
 Keep the velocity of drilling fluid within an acceptable
range at the face of each cutter along each blade

Computational Fluid Dynamics
Maximize ROP Minimize Erosion

 Minimize Particle  Control Fluid Velocity
Residence Time
 Balanced Flow
 Minimize Re-circulation

Particle Residence Time Simulation
Poor evacuation -- cuttings are forced Good cuttings evacuation

to center of bit

Balanced Flow
Original Nozzle Orientation Optimized Orientation
Flow Comparison Flow Comparison
2.5 1.4
%Flow/%Cuttings
%Flow/%Cuttings
2.0 1.2
1.5 1.0
1.0 0.8
0.5 0.6
0.0 0.4
-0.5 0.2
-1.0 0.0
1 2 3 4 5 6 1 2 3 4 5 6
Junk Slot # Junk Slot #
Reverse Flow

CFD Optimization – Lab Results
8¾” HC406
E0369 E0430
Flow Rate Comparison
3.5
E0369
3.0
E0430
% Flow / % Cuttings
2.5
2.0
1.5
1.0
0.5
0.0
-0.5
1 2 3 4 5 6
Junk Slot No.

Simulator Results: 8¾” HC406
E0369 E0430
Max ROP of 270 ft/hr Max ROP of 290 ft/hr*

Balled and dropped to 200 Field ROP consistent with lab
ft/hr results
*Simulator limit

Gauge
 The stabilizing section of the bit

Matrix Body Gauge
 Round or cube Natural Diamonds

 TCI bricks
 TSP

Steel Body Gauge
PDC In Gauge
TCI Compacts
PDC Cutters
Standard Gauge Premium Gauge

PDC Gauge Option
 In-gauge PDC cutters

 Flush mounted on leading edge
 Extra durability for applications that prematurely wear a conventional TCI/ND
gauge

Spiral Gauge Pads
 Used primarily on low blade count (<5) designs

 Used to manage chordal drop

Updrill Options
Natural Diamond PDC

Genesis Nomenclature
HC R/M X XX S Z X
Product Line Blade Steel Zenith Back Up
Count Body Cutters Cutters
Steerable Type
(R = Rotary Steerable) Cutter Size
(M = Motor Steerable) (eighths of an inch)
 “HC” - Genesis product line

Example: HC607ZX  “6” - ¾” (19mm) cutter size
 “07” - 7 blades
 “Z” - Zenith
 “X” - backup Cutters Copyright Baker Hughes, Inc.
Example: 12 ¼” HCM606

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PDC Bit Structure

Copyright Baker Hughes, Inc.

Copyright Baker Hughes, Inc.

Copyright Baker Hughes, Inc.

 The Bit Body

Copyright Baker Hughes, Inc.

 Low temperature braze

Copyright Baker Hughes, Inc.

 Two piece design

Copyright Baker Hughes, Inc.

 The Bit Body

 Milled from bar Stock Steel

Copyright Baker Hughes, Inc.

Oxy Acetylene Applied Macro Hardfacing

Copyright Baker Hughes, Inc.

 High alloy, heat treated steel

 API regular connection

Copyright Baker Hughes, Inc.

Copyright Baker Hughes, Inc.

 Sintered tungsten carbide

MSP  Standard size is the “SP” (Single

SP  Additional size developed for

Copyright Baker Hughes, Inc.

Man-Made Diamonds • 1976, introduction of first PDC

• A natural diamond is a single

Copyright Baker Hughes, Inc.

 Pre-made synthetic diamond

Pictures courtesy of US Synthetic

0.010 in. 0.016 in.

Copyright Baker Hughes, Inc.

Copyright Baker Hughes, Inc.

 Hughes Christensen Patent

Copyright Baker Hughes, Inc.

Copyright Baker Hughes, Inc.

 The depth the cutter is indented into the rock

 ROP (m/hr) = DOC (mm) x RPM (rev/min) x 0.06

Copyright Baker Hughes, Inc.

 If we speed up the RPM while maintaining the

 If we slow down the RPM but maintain the same

Copyright Baker Hughes, Inc.

Max. ROP (ft/hr)

0.323” (8.2 mm) 0.162” x 100 RPM x 5 = 81 ft/hr

0.529” (13.3 mm) 0.265” x 100 RPM x 5 = 133 ft/hr

0.750” (19 mm) 0.375” x 100 RPM x 5 = 188 ft/hr

15º 20º 30º

 Determines the aggressiveness of the cutter

Copyright Baker Hughes, Inc.

 Generally, smaller backrake angles require less weight and

Copyright Baker Hughes, Inc.

Specific Energy vs. Penetration Rate

10,000 Increasing WOB

Copyright Baker Hughes, Inc.

 Based on our current technology,

 In part, because durability would

 Also, because low backrakes affect

25º 15º 10º

Copyright Baker Hughes, Inc.

30 deg BR 30% Worn

Distance Drilled (ft)

Low backrakes are more efficient in the “new” state

Copyright Baker Hughes, Inc.

 The term “profile” or “crown profile” refers to the

 A variety of profile shapes and lengths are used to