The Disruptive Concept of 3D Cutters and Hybrid Bits in Polycrystalline Diamond Compact Drill- Bit Design
- Sara Negm (Smith Bits, a Schlumberger company) | Karim Aguib (Smith Bits, a Schlumberger company) | Venki Karuppiah (Smith Bits, a Schlumberger company) | Mamdouh ElOufy (Smith Bits, a Schlumberger company) | Mostafa Remah (Smith Bits, a Schlumberger company) | Mohammad Zayyan (Smith Bits, a Schlumberger company) | Omar El Sheikh (Smith Bits, a Schlumberger company)
- Document ID
- Society of Petroleum Engineers
- Abu Dhabi International Petroleum Exhibition & Conference, 7-10 November, Abu Dhabi, UAE
- Publication Date
- Document Type
- Conference Paper
- 2016. Society of Petroleum Engineers
- 1.10 Drilling Equipment, 1.6.9 Coring, Fishing, 7.2.1 Risk, Uncertainty and Risk Assessment, 7.7.1 New Technology Deployment, 5 Reservoir Desciption & Dynamics, 7 Management and Information, 5.3 Reservoir Fluid Dynamics, 1.5 drill Bits, 1.5.1 Bit Design, 1.5 drill Bits, 5.3.4 Integration of geomechanics in models, 7.2 Risk Management and Decision-Making, 1.6 Drilling Operations
- Disruptive PDC technology, 3D PDC Cutters, Hybrid PDC bits
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The innovation used in polycrystalline diamond compact (PDC) bit design has historically focused on two main elements—cutting structure (CS) stability, whether statically or dynamically, and the grade and quality of the PDC cutting element, which mainly involves the diamond microstructure and interface design. Since the onset of PDC bit development, there existed a limitation on PDC cutter element construction, and that is they had to be cylindrical diamond tables. This geometric PDC constraint derived everything else relating to PDC bit design. This constraint has finally been overcome. With the advent of new manufacturing techniques, PDC geometry flexibility has now been unlocked. Three-dimensional (3D) cutters add two new degrees of freedom to PDC bit design—cutter geometry and cutter placement on the bit face.
The first wave of 3D cutters included a conical diamond element (CDE), ridged diamond element (RDE), and rolling PDC cutter (RPC). This paper will present the fundamentals of such technology and their effect on field performance. The process by which these elements are applied to a PDC bit is by thorough review of bit-face anatomy versus the drilled application challenge. With such in-depth analysis, these new cutters are separately or concurrently utilized in a "hybrid" bit design, which eliminates traditional PDC bit failures, such as ringout, cored dulls, and impact in extreme applications, including fully drilling conglomerates.
The hybrid bit solution is a disruptive concept that is application-specific and significantly increases drilling efficiency through the selection of the proper technology mix. Moreover, embedded in the development of 3D cutters are the latest diamond microstructures that were traditionally the focus of PDC manufacturers. This paper highlights field deployment results to prove the concept of the technology mix per application in addition to some of the perceived risks.
Chronic deficiencies affecting PDC bit life have been resolved with new, innovative cutter geometries and their placement on the bit face depending on failure modes and load distribution. In addition, the proper selection of the applications suitable for each technology deployment is a key factor in the success of the trials and preserving the bits' cutting structure throughout the bit run. Consequently, the new method improved the bits' lifetime, drilled footage, and rate of penetration compared with the PDC bits using conventional cutters. The effectiveness of the newly introduced 3D cutter technologies and hybrid bits on lowering the cost per foot shows the success of such an approach in harsh economic climates and that the development of new technology is more important than ever in times of pricing pressure.
|File Size||1 MB||Number of Pages||10|