SPE/IADC 125516

New Generation PDC Bits Successfully Replace Impregnated Bits Resulting

in Significant Performance Improvements and Savings for the Operator
Yaqdhan Nabhani, SPE, Henry Obame-Ondo, Mahmoud Kindi, SPE, Ahmed Saidi and Moosa Al-Sheriyani,
Petroleum Development Oman LLC; Edwin Reek, Chaitanya Vempati, and Marco Cruz, Baker Hughes

Copyright 2009, SPE/IADC Middle East Drilling Technology Conference & Exhibition
This paper was prepared for presentation at the SPE/IADC Middle East Drilling Technology Conference & Exhibition held in Manama, Bahrain, 26-28 October 2009.
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
A rigorous engineering and research effort combined with targeted field testing has delivered a new generation of PDC
technology. This technology is intended to be used for the most technically challenging drilling applications across the
globe.
During the development of this technology, several new design features were successfully tested in Sultanate of Oman in
traditional PDC applications. Once the new technologies were fully developed, an effort was made to test these PDC bits in
historically non-PDC drillable applications.
One of the first applications identified for the new technology was in Field-A, Sultanate of Oman. The 8 3/8-in. section at
Field-A consists of abrasive sands and hard shales of the Haushi and Haima formation groups and is typically drilled using
turbines and impregnated bits.
Successful application of PDC bits in Field-A prompted a second application: Field-B. This application is drilled with the
turbine/impregnated bit combination through the same formation groups. Penetration rates in Field-B are typically higher and
run lengths longer.
In both applications, testing started with the first bit out-of-the-shoe using a rotary assembly. The objective was to understand
the capabilities of the new technology, then apply key learnings to the next design iterations.
The authors will describe the technologies developed for the new PDC bits. These new technologies have been able to extend
the typical PDC application range into harder abrasive rocks. Improvements in penetration rate of 25% to over 200% have
been realized with run lengths competitive to impregnated bits resulting in substantial reduction in drilling cost. Additional
cost reduction is achieved by replacing turbine with rotary. Thus far, savings of up to almost 200% have been realized in a
single section compared with offsets and 11-day time savings compared to plan.
Introduction
This paper is focusing on two specific areas in Sultanate of Oman, refered to as Field-A and Field-B in this paper. These
wells are typically drilled vertically to a depth of approximately 4500 to 5400 m, with the final section of approximately 1500
to 2200 m drilled in 8 3/8-in. The lithology of the 8 3/8-in. section comprises nine different formations. Al Khlata, Safiq,
Ghudun, Barakat, Mabrouk, Barik, Al Bashair, Miqrat, and Amin (Fig. 1). Rock types include sandstone, shale, claystones,
and siltstones and are considered hard and abrasive. Figs. 2 and 3 show a calculation of the rock properties. Unconfined
compressive strength (UCS) ranges from 10,000 to 40,000 psi for Field-A and 5,000 to 28,000 psi for Field-B. The friction
angle (FA) gives an indication of the abrasiveness of the formation; 42 and up is considered as abrasive rock. FA ranges
from 35 to 55 in Field-A and 32 to 54 in Field-B field. Field-A is considered to be one of the toughest applications in
Sultanate of Oman.

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Historically, the 8 3/8-in sections have been drilled with diamond impregnated bits on a turbine assembly providing the best
longevity and acceptable pentration rates. In Field-A this would require on average five bit runs to reach TD at penetration
rates averaging 2.5 to 4.5 m/hr. Field-B typically requires the same number of bits with penetration rates between 4 and 7
m/hr. The operator showed a desire to drill these intervals more efficiently and reduce the high cost per meter (CPM) related
to the utilization of diamond impregnated bits and turbines. It was decided to explore the possibilities of using new PDC
technology on a simple rotary bottom hole assembly (BHA).
Background
Design principles and material technology for PDC bits have improved significantly over the last 10 years. However, there
continues to be a need for improved product performance as applications become more challenging. Drill bit service
companies are encouraged to invest in research and development efforts to deliver improved performance with their
technology.
One of the main demands for the local Sultanate of Oman drilling environment is to improve performance in the deeper,
harder rocks. As part of abovementioned research and development efforts, new PDC bit concepts have been evaluated in
Sultanate of Oman targeting hard rock applications. Initially, these concepts focused on bit durability through diamond
volume management (DVM). As development efforts progressed, advanced cutter technologies were introduced to take
performance to the next level. At a later stage, new concepts were introduced to further enhance durability and to improve
stability and drilling efficiency.
Close cooperation with the operator allowed the bit company to go through a fast learning curve. Applying learnings from the
initial trial PDC bit runs in the targeted applications, new PDC bit frames were introduced, tested and evaluated successfully,
and again leading to new concepts for further improvement.
Challenges
With these sections being typically drilled with impregnated bits on turbine, one of the first challenges was to break the
paradigm that the rocks are non-PDC drillable. Early attempts with PDC bits were unsuccessfull and there was basically no
benchmark to work against.
PDC bits have a much more efficient cutting action than diamond impregnated bits and therefore it was expected that ROP of
the PDC bit would be superior. However, to be economical the PDC bit needed to deliver substantiallyb improved durability
compared to standard PDC offerings to be competitive with impregnated bit technology in overall CPM.
During the R & D stage some new concepts were used successfully in typical PDC bit applications already. Improvements in
durability, run length, and ROP were realized. With the introduction of advanced PDC cutter technology, the operator and the
bit company felt confident to try this new technology in one of the target applications. Field-A was selected as the first
application for a PDC bit trial.
Objectives/General Solution
It was decided to use one of the latest generations of PDC bit technology to set a benchmark for future development. The bit
would be run on a packed rotary BHA eliminating the operational cost of the turbine and controlling rpm to lower levels to
reduce abrasive wear to the PDC bit.
Technology (How it Addressed the Challenges)
The hardness and abrasivity of the sandstones in Field-A and Field-B coupled with high confined compressive strengths
(CCS) generated by overburden pressure poses a significant challenge for PDC bit technology. To achieve successes, an
overall systems approach was taken to develop application-specific PDC bit technology using considerable research, design,
modeling and analysis, and laboratory testing. The key technologies that were identified and deployed in Field-A and Field-B
are elaborated in the following sections.
Next-Generation PDC Cutters
The unique environment in these fields warrants a cutter that is resistant to abrasive wear to achieve increased footage at a
higher average ROP. Additionally, the extreme abrasivity necessitates a cutter that would resist fracture when wearflat starts
to develop and hence maintain cutting efficiency longer throughout the run.
These next-generation PDC cutters address this challenge from both the material and design perspectives. Optimized
diamond tables and interfaces were developed to address the abrasion and fracture-resistant requirements.
By modifying the diamond feedstock used in the PDC manufacturing process and optimizing sintering conditions,
researchers obtained cutter prototypes that substantially increased abrasive wear resistance. By augmenting the particle size

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distribution of the diamond feed, researchers effectively increased the abrasive wear resistance of the diamond table as
indicated by rock lathe testing 1. Fig. 4 illustrates a step change in abrasive wear resistance over the previous generation PDC
cutter.
Upgrading the next-generation PDC cutter design with a thinner diamond table and improved interface design further
enhanced the performance over the previous generation. A thinner diamond table maintains drilling efficiency through the
life of the PDC cutter by reducing the diamond surface area exposed to the formation in the worn state, decreasing the weight
on bit required to drill in that state. Interface design is another critical component of PDC cutter design. Due to the
mismatched coefficients of thermal expansion of the polycrystalline diamond and cemented tungsten carbide substrate,
internal residual stresses are inherent to the manufacturing process of cutters. The next-generation interface was designed to
reduce the presence of stress risers previously identified and optimized using finite element analysis to minimize residual
stresses and manage the applied loads from the drilling environment in both the new and worn condition. The result is a
cutter with improved resistance to fracture and premature failure in the drilling environment, providing more reliable
performance run to run. Fig. 5 presents a finite element analysis highlighting the hoop stresses of the optimized diamond
table substrate interface. The blue coloring shows minimal stress regions of the diamond table and the progression to higher
stress regions is shown by the yellow and red colors. The reader should note the minimal high-level stress regions and the
setback from the diamond table edge. The lower stress region on the edge of the cutter improves diamond durability.
(Mohammed Al-Saeedi et al., 2009)
Enhanced Stability Features
Stability is a key component in the design of PDC bits in any hard rock application. Due to the high abrasivity of the rock, it
is imperative that the bit is inherently stable and resists the BHA vibrations to maintain drilling efficiency and minimize the
possibility of cutter chipping. Application-specific PDC bits were designed with primary stability in mind. Primary stability
methodology is a philosophy of generating inherent stability in PDC bits using proprietary knowledge of blade profiles, cutter
layout schemes, variable cutter rakes, etc. The newer PDC bits were designed using updated cutter profiles that were
engineered for stability and efficiency. The inherent stability of the PDC bits was further augumented using an enhanced
lateral movement mitigation feature on PDC bits. The lateral movement mitigation feature is illustrated in Fig. 6. Essentially,
it is the buildup of blade matrix behind and around the upper shoulder cutters and gauge cutters. This additional material
around the cutters absorbs lateral impact loads and limits the lateral travel distance when the bit is vibrating. This helps
protect these cutters from impact damage should the bit see periods of instability.
Advanced Bit Modeling and Cutter Force Distribution
The stability of new PDC designs and the cutter forces have, for quite some time, been modeled using advanced dynamics
software that has been validated with laboratory drilling simulator results. Using these modeling techniques and laboratory
testing, it was found that managing the net imbalance force on the bit and distribution of cutter forces over the entire bit has a
tremendous impact on stability and durabilityl of the bit. An updated bit design process using design optimization through
cluster computing and bit dynamics modeling helped achieve a dynamicn signature that is far superior to any previousgeneration PDC bits. Furthermore, the new design process runs thousands of computer-generated iterative modifications
through the proprietary dynamic modeling software to yield an optimized cutting structure layout. This process helps to
deliver designs that are field-ready faster without iterative field trials and to identify the best suited bit for the application
mitigating potential risks in new bit testing.
Diamond Volume Management to Reduce Wear
While drilling abrasive rock, cutter wear is detrimental to PDC bits. As the cutters wear and generate a wearflat, they become
more and more inefficient thereby requiring more energy to drill the same volume of rock. Diamond volume management
(DVM) has been employed to address the areas where typical PDC bits exhibit the greatest wear. Diamond volume
management is the idea of increasing cutter density using both primary and secondary cutting elements where the bit is likely
to wear the most. The new PDC bit designs insert secondary cutting elements into the blade, which extends the reach of PDC
bit applications by improving drilling in a typical dull state. The back-up cutter locations were optimized using wear
simulation as well as dull analysis ini the field. The back-up cutters were placed so that they augment and protect the primary
cutters as the primary cutters wear. Managing wear on the new bit designs enabled the operator to drill farther at higher rates
of penetrations.
Other Notable Design Features
The new generation of bits has a superior hydraulic configuration, which is specially optimized using state-of-the-art
computational fluid dynamics (CFD) modeling for providing optimum cutter cooling and managing erosion. These bits also
have enhanced thermally stable polycrystalline diamond (TSP) gauge protection to ensure the bit maintains gauge in the

Rock lathe testing is a standard process used for measuring relative abrasive wear resistance of synthetic diamond materials.

SPE/IADC 125516

abrasive applications. Furthermore, the bits have heavy-duty shanks thereby allowing them to withstand very high torque and
allowing the operator to apply high weight on bit.
Case Studies
The following case studies illustrate the success of the new PDC bit technology and how performance improvements and cost
savings were realized. By working closely together with the operator, the bit company was able to go through a steep learning
curve. New bit designs, new technology and new concepts have been introduced to the field with consecutive successes.
After drilling six succesful 8 3/8-in. sections, the new PDC bit technology has proven to be a more cost effective solution to
drill intervals previously considered as non-PDC drillable.
Case Study 1 Field-A (Figs. 7, 8, and 9)
Well-1The first bit tested was a seven-bladed PDC bit design with 16-mm primary cutters and 13-mm back-up cutters. The
bit incorporates DVM and the new highly abrasion-resistant cutter technology. This bit was selected to set a benchmark for
the latest PDC bit technology in an application unknown to PDC bits. The 8 3/8-in. bit was run on a packed rotary BHA in
well-1, drilled out the shoe, and continued to drill 266 m through Al Khalata, Safiq, and Ghudun at an ROP of 4.1 m/hr. The
BHA used comprised the following: Bit / NB Stab / DC / Stab / 2xDC / Stab / 19xDC / XO / Jar / XO / 3xDC / 12xHWDP.
Compared to the impregnated bit and turbine combination the run length of the new PDC bit was considered short; however,
the ROP was 17% faster and CPM was 10% lower than the impregnated bit used on the previous well. The PDC bit was
exchanged for the proven impregnated bit/turbine combination, which also did not meet the distances typically drilled in
Field-A. Two impregnated bits were run to drill 250 m and 205 m, respectively, with an ROP of 3.7 m/hr and 2.9 m/hr,, about
half the distance normally drilled by an impregnated bit. With this in mind, it could be concluded that there was potential for
the new PDC bit technology and it was agreed upon to make improvements to the design based on the dull condition of the
used bit.
Well-2After close examination of the dull of the seven-bladed PDC bit, a new design was created with the objective to
improve run length and ROP. This time a six-bladed frame was selected, which would allow for a higher cutter density in the
areas of the bit that needed improved durability. Cutter exposure was altered and cutters were changed to the most wearresistant type available.
The new 8 3/8-in. bit design was run on a packed rotary BHA in Well-2, and drilled out the shoe and a total of 384 m at an
ROP of 6.1 m/hr. The bit drilled 118 m (44%) further compared to the previous trial reaching deeper into the Ghudun
formation. This run of almost 400 m is competitive with impregnated bits while the ROP of 6.1 m/hr is about 50% faster than
the best runs with impregnated bits on turbine.
Well-3While the first two trials were ongoing, efforts were made to design a complete new bit. The primary objective was
to increase bit durability without losing too much efficiency. It was decided to create a bit with increased diamond volume on
those locations that show most wear. In addition, the bit was designed as a high-imbalance bit to improve primary stability,
which would reduce impact loading on the cutters and increase efficiency for better ROP. Back-up cutters are typically one
size smaller than the primary cutters; however, for this new design the 13-mm back-up cutters were replaced by 16-mm
cutters since the larger size cutters have shown better durability. Furthermore, the back-up cutter positions were optimized
through software modeling. Instead of positioning the back-up cutters at a fixed radial position and exposure relative to the
primary cutters, the optimum radial position and amount of exposure for each individual back-up cutter was computed based
on wear expectation. This resulted in an eight-bladed bit with 16-mm primary and 16-mm back-up cutters.
Like the previous two bits, the new eight-bladed design was again run on a packed rotary BHA. In Well-3, it drilled out the
shoe to drill through Al Khalata and Safiq and reaching to the bottom of the Ghudun formation. This resulted in the longest
PDC run thus far with 493 m drilled in total, a 28% improvement over the six-bladed bit, and 85% greater than the sevenbladed bit.
Case Study 2 Field-B (Figs. 10 and 11)
Well-1Field-B is considered to be a faster drilling application than Field-A, and it was decided to use the same six-bladed
bit as used in Field-A, Well-2 trial. Again, the objective was to learn more about the performance of the new PDC technology
in typical impregnated bit applications.
In the offset well an impregnated bit drilled 482 m at 6.69 m/hr. Based on this performance, the objective for the PDC bit was
set at drilling 650 m at 7 m/hr. If ROP was still okay, the run would continue.

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The initial objective was achieved after drilling 673 m at an ROP of 14.5 m/hr more than double the target ROP and more
than double the ROP of the impregnated bit/turbine combination. The bit continued to drill totaling 1332 m at 7.8 m/hr
through Al Khalalta, Saih Nihayda (Safiq), Ghudun, and into the Barakat formation.
Compared to the offset well, this run with the new PDC bit technology replaced two impregnated bits, eliminated a bit trip,
drilled at 25% faster ROP, with a 100% reduction in CPM.Compared to the most recent well in Field-B, the new bit replaced
three impregnated bits, eliminated two bit trips, drilled 100% faster at 196% less CPM. Finally, compared to the well plan,
the new technology saved 11 days.
Well-2A competitor-A PDC bit was selected to start the 8 3/8-in. section, drilling out the shoe and 157 m of Al Khlata
formation at 7.7 m/hr before being pulled out of hole for penetration rate. This performance did not match the performance of
the new PDC technology introduced on SR-291 and it was decided to change out the competitor product for the same sixbladed design used successfully on the previous well already. The bit repeated its performance and drilled a total of 1226 m
at an average ROP of 7.25 m/hr making it through Barakat and into the Mabrouk formation. Instead of changing to the
default impregnated bit option this time, the operator decided to test another PDC bit. A competitor-B bit was selected. This
PDC bit managed to drill 108 m at 4.11 m/hr through the Mabrouk and Barik formations. In total, 1491 m were drilled with
three different PDC bits at an average of 6.9 m/hr, and 1226 m of those were drilled by the six-bladed bit using the new PDC
bit technology.
Well-3The same six-bladed design used in Field-B, Well-1 trial was selected to start the 8 3/8-in. interval. Again, the bit
repeated its successful performance. This time the operator decided to pull the bit out of hole earlier, achieving a higher gross
ROP. A total of 1153 m was drilled at 11.6 m/hr reaching into the bottom Ghudun. A fresh bit of the same type was run to
continue the 8 3/8-in. section for another 450 m at 3.4 m/hr; drilling deeper than ever before with a PDC bit through Barakat,
Mabrouk, Barik and into the Al Bashair formation. In total, 1603 m were drilled with two PDC bits of the same style and the
same new technology at an average of 6.9 m/hr.
Conclusion
Advanced PDC technologies targeted at improving durability, stability, and cutting efficiency have been introduced in
applications previously considered as non-PDC drillable. These applications used to be drilled primarily with diamond
impregnated bits on a turbine assembly. The development efforts for two specific areas in Sultanate of Oman, Field-A and
Field-B have resulted in a new generation of PDC bits with the capability to outperform diamond impregnated bits in ROP
and in run length. In addition, the new technology has proven to be superior to other PDC bit technology that is currently
available. The combination of the elimination of the operational cost of turbines and the favorable performance of the new
PDC bits has resulted in significant savings for the operator.
Reference
Mohammed Al-Saeedi, Meshal Al-Khaldy, V.S. Mahesh, Ali Jaffar, Anthony Brown, and Maneesh Sharma, 2009. Breaking Records
in North Kuwait Deep Gas Fields Drilling 16-in. Hole Sections at Greater Depths. Paper SPE 119517 presented at the SPE/IADC
Drilling Conference and Exhibition, Amsterdam, The Netherlands, 17-19 March.

Acknowledgments
The authors wish to thank Petroleum Development Sultanate of Oman LLC and Baker Hughes for permission to publish and present
this paper. Special thanks also go to Erica Tucci of Baker Hughes for her invaluable help in editing this manuscript.

Fig. 1: Lithology column for 8 3/8-in. section

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Fig. 2: Field-A rock strength analyses

Fig. 3: Field-B rock strength analyses

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Cutter Wear Resistance Overview

Relative Abrasion Resistance

10

0
Previous Generation

Next Generation

Fig. 4: Lab performance of next-generation PDC bit in abrasion test

Fig. 5: Finite element analysis of hoop stresses with the next-generation PDC cutter

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Standard PDC

Previous Generation

Advanced Technology

Fig. 6: Comparison of the lateral movement mitigation feature on standard PDC bit, on the first generation of product
that included the feature, and the feature on the new advanced technology PDC bit

Fig. 7: Field-A comparison meters drilled

Fig. 8: Field-A bit development

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11

Depth In/Depth Out vs ROP

Field-A
2800

well-1

well-3

Depth (ft)

well-2
3300

New PDC Technology

3800

4300

4800

Impregnated bits on turbine

2

2.5

3.5

ROP (ft/hr)

Fig. 9: Field-A comparison run length and ROP

Fig. 10: Field-B comparisonmeters drilled

4.5

5.5

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Depth In/Depth Out vs ROP

Field-B
2800

well-3

Depth (ft)

w ell-2 "competitor A"

3300

3800

4300
w ell-2 "competitor B"

well-1

Legend:
New PDC Technology
Impregnated bits on turbine
Other PDC Technology

well-2
well-3

4800

ROP (m/hr)

Fig. 11: Field-B comparison run length and ROP

10

11

12