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Solving the Salt Challenge: Unique Drill Bit Philosophy Delivers

Breakthrough Performance in the Gulf of Mexico
Steve Barton & Ryan Weeden, NOV Downhole, Graham Mensa-Wilmot & Yoseph Harjadi, Chevron
Copyright 2010, Offshore Technology Conference
This paper was prepared for presentation at the 2010 Offshore Technology Conference held in Houston, Texas, USA, 36 May 2010.
This paper was selected for presentation by an OTC 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 Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference 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 OTC copyright.

Abstract
Salt formations present unique drilling challenges relative to other formation types of comparable compressive strength and
abrasivity. Due to its unique properties, many detrimental issues can occur when employing bit designs which are not
optimized for salt. These issues include severe stick-slip, lateral vibration, and poor directional control. In addition to high
rig rates, Gulf of Mexico (GOM) projects typically use expensive BHA's. Consequently, improved drilling performance is
seen as one of the enablers that can help reduce operational costs. Many considerations must be made relating to the design
techniques employed in the development of Fixed Cutter (FC) bits for drilling salt intervals.
This paper will focus on various design techniques developed for drilling a wide variety of salt sections in the GOM. Aspects
such as load balancing, unique blade geometry and materials, gauge design, and utilization of secondary components will be
covered. In addition, cutting structure design (cutter layout aimed at achieving specific performance objectives), as well as
the analysis and adaptation of bit profile for improved performance will also be discussed. In summary, the paper will focus
on a novel design philosophy that was developed and incorporated into an ultra-large diameter (26") FC drill bit. This
concept was successfully utilized to extend the capability of drilling the 26" salt section with Rotary Steerable Systems (RSS)
in the GOM. This was achieved while significantly improving penetration rates and lowering operating cost.
Case studies are presented from the GOM that demonstrate true solutions to drilling salt in deepwater applications with FC
drill bits.
Introduction
There are three primary forms of salt:
1. Halite, or rock salt Formed in either thin or massive layers. Occurs as a relatively soft white rock, with red or yellow
coloring caused by impurities
2. Anhydrite This occurs extensively in beds associated with halite deposits. It is harder and less soluble than halite, and
harder and denser than gypsum. It often occurs as fibrous, granular, or more compact masses.
3. Gypsum This is basically the hydrated version of anhydrite. It generally occurs in beds associated with layers of halite
and dolomite.
Salt is notably less dense than other sedimentary rocks. As a result, salt deposits tend to flow under pressure, as compared to
either folding or faulting which occurs with lithologies such as sandstones and shales. Salt mobility occurs due to the
difference in density between the salt and any surrounding sedimentary formations. Due to the lower specific gravity of the
salt, it will tend to move upwards, in a similar manner as a lighter fluid would rise through an overlaying denser fluid. The
actual rate of movement is mainly affected by temperature. This plastic flow (or deformation) allows salt to concentrate into
large, domed-shaped masses1, where it can help to form oil traps. Salt deposits are found in a number of locations around the
world, including Colorado and Utah (in the United States), Mexico, Spain, United Kingdom, Russia, Saudi Arabia, India, and
the Gulf Coast region of the U.S. The latter is the focus of this paper.
Extensive subsurface salt structures exist throughout the Lower Tertiary trend2 within the deepwater area of the GOM. These
structures range from 2000 to 12000 in thickness and have trapped considerable amounts of hydrocarbons. The high purity
of the salt in this region, combined with relatively low sub-surface temperatures, has resulted in slow-creeping salt bodies.

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These properties of salt lead to several distinct drilling challenges in the Gulf. These include, but are not limited to;

Hole creep Salt may extrude (or creep) into the wellbore due to its plastic nature. This creep can potentially
cause stuck pipe and fatigue damage to the drill string. The rate of creep will be dependent on the specific properties
of the salt, pressure and temperature. An increase in the last two tends to lead to increased rate of creep.

Washout Salt is soluble. Under certain conditions, salt will dissolve and result in borehole enlargement. This
causes unpredictable directional tendencies, poor BHA performance, and stability issues.

Formation pressure issues During formation of domes, the salt may drag deeply buried formations closer to the
surface as the plastic salt rises, bringing their corresponding formation pressures. These abnormal pressures can
cause unexpected overbalanced or underbalanced drilling conditions, thereby introducing complications to the
drilling program.

Rubble zones/Sutures Commonly associated with salt domes can present several performance problems (e.g.
vibration), especially with drill bits.

Tar Zones - Present a different set of operational problems when encountered in salt drilling.

This paper focuses on the development of an ultra-large diameter (26) FC drill bit to tackle the salt section in deepwater
GOM for a major operator. One of the unique challenges was to provide a bit that could allow the operator to overcome the
vibration and operational issues associated with drilling, which had lead to ROP compromises.
Torsional vibration is a common event when using FC bits in salt. In order to overcome this issue, specific design features,
which typically end up compromising penetration rates, are usually employed. The solution to this problem rested on the
ability to develop a bit that could function effectively. As a primary requirement, the bit had to exhibit good stabilization
characteristics. Such an achievement will negate the need for vibration reducing features that end up compromising ROP.
As a means to further improving operational efficiency and reducing operational costs, the bit had to be operationally
compatible, and directionally effective, with the selected drilling system (BHA/drive system). These benefits, especially for
the hole size under discussion, will reduce operational costs.
In order to deliver a 26 drill bit solution for this specific salt application, all aspects affecting drill bit performance must be
considered and understood. The four characteristics which affect drill bit performance are; steerability, stability, durability,
and aggressivity3. Each of these characteristics is interwoven into a complex system where a mis-applied improvement to
one characteristic can cause detrimental effects to the others. Often, deepwater salt drill bit solutions are the outcome of an
intensive focus on the bits ability to achieve improved stabilization characteristics at the expense of the penetrating ability of
the cutting structure through aggressivity capping features. These salt formations are relatively soft, and in an idealized
laboratory environment could be drilled at ROPs much greater than a deepwater operator using the same bits could ever
hope for. These differences between idealized laboratory environment and the real world suggest that salt drilling efficiency
is not directly related to the bits aggressivity. However, in the quest to improve stabilization, bit solutions routinely fail to
meet their objectives. This is because of the operational issues associated with the aggressivity limiting features which have
been applied to overcome the destructive vibration characteristics of salt drilling. Much higher rates of penetration could be
possible if the underlying factors holding back the bits already available potential for high ROP were addressed through
engineered cutting structure solutions, rather than specific limitations to the bits aggressivity. A successful innovation in salt
drilling bit design would require an understanding of the underlying factors affecting bits performance and then the
application of solutions to minimize these effects in an unconventional way.
The Drill Bit Challenge
Hole quality is the result of the interaction of all components of the drilling system; bit design, BHA, rig capacity, well
trajectory, mud program, etc. Poor hole quality can be caused by deficiencies in the design of any of these components, and
subsequently cascade into costly drilling and completion problems. Because of this, it is imperative that maximum hole
quality be the primary goal for any drill bit solution applied to these intervals. However, due to the economics of deepwater
drilling, it is also extremely important to provide a solution which can drill at the highest ROP. The ultimate goal for any
deepwater operator is to efficiently provide superior hole quality. To achieve maximum hole quality, bit induced vibrations
must be minimized. In addition, the bit must be directionally responsive, so as to minimize BHA and/or formation related
deviation tendencies. These requirements must be achieved without resorting to ROP compromising features or
technologies. While the mechanical properties associated with salt drilling suggests that cutter / formation interaction can
easily result in damaging drilling vibrations than in other formation types, much of this infamy is undeserved.

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Hole Creep
Hole creep, caused by geomechanical stresses plastically deforming the weak salt annulus, can instigate destructive
vibrations and also cause steerability problems. Hole creep can induce torsional and lateral vibrations by creating undesired
friction between the borehole wall and BHA components. Annulus non-concentricity created by hole creep can also cause
steering difficulties for directional tools, thus resulting in poor hole quality. In this application, these issues were adequately
addressed through operational considerations focusing on the drilling fluid system.
Hole Washout
Hole washout, caused by hydraulic erosion or dissolution of the salt, can also cause steerability problems for the
directional tool. Hole washout causes further steerability problems with Push-the-Bit RSS. The majority of hole washout
problems in this application were solved by operational optimization of the drilling fluid system. However, from the bits
perspective, certain features intended to minimize hole washout were incorporated into the design. These features were
analyzed using state of the art predictive fluid dynamics models.
The Drill Bit Considerations
After carefully studying the application, the performance inhibiting issues which would affect hole quality while drilling this
section were individually identified and the four bit performance criteria were addressed through careful consideration of the
positive and negative effects associated with all potential characteristics of the bit design. Stability; issues (from drill bit and
string) will have significant detrimental consequences to the steerability, durability, and aggressivity. Steerability; if the bit
did deviate from the planned trajectory, it would need to be efficiently steered back into place. Durability; ensuring that the
design could complete the interval was reviewed. Aggressivity; as a contributor to improved drilling performance without
the usual initiation and amplification of vibrations, was also evaluated. Drill bit design considerations for each of the
performance criteria are expounded on below.
Stability: Stick-Slip
GOM salt, while generally possessing a relatively low compressive strength, is infamous for inducing damaging
torsional vibrations, especially when drilled with ultra-large diameter FC bits. To help address this issue, downhole motors
(PDM) have had to be used. In addition, extensive BHA design and verification methods have also been incorporated.
However, these strategies were not able to improve ROP, due to the types of bits that had been developed to help address the
vibrations issues. Whereas PDM use usually helps mitigate or dampen vibrations, they do not always improve ROP.
Consequently, the project required an effective resolution to this conflict. A solution that improves ROP without initiating
stick slip vibrations had to be developed, without having to incorporate a PDM in the BHA. To address this issue,
technologies and features that ensure effective WOB transfer were analyzed. In addition, it was also identified that an
efficient torque versus RPM relationship had to be established. Whereas previous industry attempts at solving this issue have
focused on torque reduction, the emphasis this time, focused on torque behavior. To improve ROP, a clear torque elevation
with increasing WOB was also established. These requirements were achieved through the development of a unique cutting
structure arrangement, which focuses on the root causes of torsional vibrations. Through this effort, which did not focus on
bit aggressivity limitations, the usual ROP limitations were removed. Consequently, an effective solution that improves ROP
and limits stick slip events was developed.
Stability: Bit Whirl
Lateral vibrations, as well as whirl vibration tendencies, are common events during salt drilling. Consequently, a
primary requirement is the elimination of lateral movement tendencies. In addition, rotation about points on the bits face,
other than the geometric center of rotation (referred to as whirling), must be minimized. Proprietary design software, which
evaluate and quantify bit properties such as lateral stability index (LSI) and Out-of-Balance Force (OOBF) were used to
evaluate bit dynamics behavior. These processes helped minimize the bits tendencies to go into whirl4. In addition, the bits
effectiveness at dynamically dampening lateral or whirl vibrations, created by external sources (e.g. BHA) was also
enhanced.
Steerability
Steerability can be significantly affected by a wide range of factors including; formation type and hardness,
hydraulics issues, stick-slip and lateral vibrations (hole enlargement), bit design attributes, etc. In addition, unpredictable
inclusions (sutures) in the salt intervals can quickly cause unwanted directional control issues. Developing a steerable
solution requires a careful balance between the bits tendency to easily correct for undesired deviations (under the influence
of the drive system). In addition, the bit must be stable and able to drill effectively without self-initiating or creating
deviation issues. Due to use of a Push-the-Bit RSS, the gauge design for the 26 bit included several well proven steerability
and stability enhancing features. The gauge was designed to have controllable and predictable lateral aggressivity (Figure
1).To fine tune the bits lateral tendencies, this bits side cutting index5 (a proprietary calculation which predicts lateral
aggressivity) was assessed and manipulated to levels deemed acceptable by the development team.

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Durability
Durability in these intervals is typically dictated by the PDC cutters tendency to survive the impact loads caused by
the types of vibrations that are typically associated with salt drilling. However, if stability is optimized (as was the case with
this project), then abrasive wear becomes the dominant issue with regards to bit durability. Considering the low friction
angle of salt, abrasive wear of PDC cutters is fairly benign, consequently, durability from a wear standpoint is of little
concern. Given that the bit had been designed and modeled primarily for stability, and that the risk of abrasive wear in salt is
low, limited attention was paid to cutting structure design for durability.
Aggressivity
After optimizing for stability, steerability, and durability, aggressivity was reviewed. Since the ultimate goal of this
bit design is to produce superior hole quality as efficiently as possible, it was extremely important to balance the aggressivity
characteristics of the bit design without affecting the 3 previous performance criteria (stability, steerability, and durability).
Because of the bits overall ROP dependence on the 3 performance characteristics, any modification to PDC cutter count for
sake of aggressivity was only approved when there was no detrimental effect on those three key characteristics. Also, several
other considerations were made to cutter backrake to increase the ROP response of the design. In each of these cases, when
making improvements to the bits aggressivity, the most important design criteria were not affected negatively. This
aggressivity optimizing method results in the most aggressive design which is highly stable and can steer effectively through
this challenging salt interval.
The Drill Bit Solution
This is not the first attempt at producing a bit design to drill challenging salt intervals in the GOM. Earlier drill bit
development also focused on stability and the appropriate matching of side cutting capability to Push-the-Bit RSS.
Initial Large Diameter RSS Designs
A 17 FC design was designed in 2001 to accompany the initial introduction of a large diameter (11 OD) Pushthe-Bit RSS. The target application was the salt formations within the deepwater GOM, and as such, primary focus was on
the lateral stability of the drill bit. At that time, it was customary for the particular bit supplier to use a ring gauge as a
solution to applications demanding high drill bit stability. The combination of large diameter, salt formations, and a new size
RSS justified the use of this gauge technology within the drill bit. This gauge design features a continuous ring at the gauge
diameter rather than discrete pads as seen on conventional bits. These features are described in more detail by Roberts6. An
example of a fixed-cutter bit with a gauge ring can be seen in Figure 2. Ring bits were designed to improve directional
response by improving the lateral stability of the bit, reducing the propensity of the bit to whirl. By minimizing lateral
vibration, the ring bit reduces torque fluctuations that can occur due to bit whirl. This reduces the potential of the bit to
laterally over engage the formation, which can cause directional issues with the directional tool.
The final design (RS816) created was a steel bodied bit with 8 blades, equipped with a 16mm primary cutting
structure (Figure 3). The cutting structure was force balanced and also featured paired blades that tracked. The ring gauge
was used to enhance lateral stability and also featured a gauge cutting structure, engineered to provide sufficient side cutting
for the RSS.
Initial trials were very successful in terms of both steerability and lateral stability within the salt. The design was
expanded in range from 14 through to 18 and has delivered consistently good performance over the years for several
operators. However, as the salt applications became more refined and the nature of drilling challenges changed, newer
technology was employed for ultra large diameter bits for deepwater salt.
Recent Ultra Large Diameter RSS Designs
The 26 RSR816 (Figure 4) was engineered and manufactured in 2008. This bit was designed to drill a section in
the GOM which consisted of rich clay sediment and also massive salt formations. The main goal of this design was to
achieve optimum drilling performance while drilling in conjunction with a 9 straight hole motor and Push-the-Bit RSS.
This bit was equipped with torque limiting features7 to prevent any over-engagement of the cutting structure which could
result in torsional vibrations. Also, many considerations were made to improve the lateral stability tendencies of the design,
including whirl trigger force prediction (lateral stability indexing), lateral force prediction, and dynamic optimization of the
cutting action of the bit. Also, the partial wheel gauge design implemented with the previous 17 design was carried over
into this new design.
Results of this improvement were incredibly positive. This design set several single run footage records in the
GOM, at times drilling more than 50% further than offset bit runs. However, due to the state of evolution of these
applications at that time, performance was still limited by the fact that downhole motors were still required to overcome the
perceived inability of bit designs to drill these sections stable at lower weights and RPM. Furthermore, drilling fluid system
design at that time still had a long way to go, and typically caused severe hole washout problems which resulted in steering

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and efficiency problems. Only after the operational implementation of DKD fluid system design could these hole washout
issues be conquered.
Learning from the performance of these bits, and the operational improvements to drilling fluid system and BHA
design, allowed progress in understanding the latest challenges and potential solutions for todays salt drilling challenges.
This led to the development of the 26 E1019, which was aimed at making use of state of the art drilling practices.
Latest Ultra-Large Diameter (26) Salt Drilling Bit
The E1019 was derived taking into focus the importance of the four bit characteristics for this specific application.
The final design (Figure 5) is a 10 bladed bit with 19mm cutting elements and 10 nozzles. As discussed earlier, the cutting
structure was specifically adapted to address the limitations of the earlier industry products. In addition, the detailed analysis
and evaluations ensured achievement of the objectives and requirements outlined by the project team members. It is also
worth noting that the bit had specialized gage pads, the length and geometry of which were also adapted to facilitate
achievement of the projects stabilization and steering expectations. The bit has now been employed successfully on 6 wells
for major operators in deepwater applications. The section below highlights the first initial trial of this 26 E1019 design.
Proof of Performance
On its first run in salt (for a major operator in deepwater GOM), the E1019 established a clear and superior advantage over
earlier products used in similar applications. The run, which was deemed highly successful by the operator, met all of the
projects defined performance expectations. It is worth stressing that the BHA designed for the run did not have a PDM.
Once the bit tagged bottom, 25 Klbs weight on bit (WOB) and 120 RPM were applied. Instantly the bit began drilling with
an ROP that was in excess of 40 ft/hr; a significant accomplishment based on legacy designs and products. For this first run,
the bit drilled 968 ft at an average ROP of 53fph. All the performance objectives identified for the project deviation
control, vibration control (with no PDM), durability, etc, were achieved on the run. In comparison to offset performances,
the ROP gain with the E1019 exceeded more than 200% of what earlier and competitive bits had been achieving.
Following this success, the newly engineered E1019 has been used on 6 other projects for other major operators in deepwater
operations. In all instances, the performance has been similar to or better than that achieved on the first run. This strong data
set supports the engineering merits of the new E1019 product.
Conclusions
Drilling salt formations causes a wide range of problems due to its unique characteristics
Well bore deviation and vibrations (typically stick slip and whirl), are common performance limiting factors when it
comes to large diameter drilling in salt
Without understanding the main performance limiting factors, certain bit design features and technologies used to
address the vibrations issues, have compromised ROP
A project was initiated to truly understand the underlying factors affecting performance in salt applications. As a
result, key drill bit performance characteristics were identified and addressed
Proprietary modeling techniques were used to establish a unique cutting structure which allows for high penetration
rates without initiating vibrations, or causing deviation issues
An engineered gauge design was also introduced to match the side cutting requirement of the RSS tool and
trajectory within this ultra large diameter salt section
The initial trial was hugely successful, displaying good steerability, low vibrations, and excellent ROP. This has
changed the game plan on what can be achieved within large diameter salt sections going forward
Similar success with the E1019 was replicated on several other sections within the GOM for major deepwater
operators

References
1) Arndt, S., Gotze, H., Hese, F., Rabbel, W., Schlesinger, A., Theilen, F.,Salt Diapir Evolution in the North Sea, Geophysical
Research Abstracts, Vol. 8, 2006
2)

Langley, D.,Lower Tertiary Trend, Journal Petroleum Technology, March 2002

3) Clegg, J. and Barton, S.: Improved Optimisation of Bit Selection Using Mathematically Modelled Bit Performance Indices paper
IADC/SPE 102287 presented at the 2006 IADC/SPE Asia Pacific Drilling Technology Conference, Bangkok 13-15 November.
4) Johnson, S.: A New Method of Producing Laterally Stable PDC Drill Bits paper IADC/SPE 98986 presented at the 2006 IADC/SPE
Drilling Conference, Miami 21-23 February.

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5) Barton, S.: Development of Stable PDC Bits for Specific Use on Rotary Steerable Systems paper IADC/SPE 62779 presented at the
2000 IADC/SPE Asia Pacific Drilling Conference, Kuala Lumpur, 11-13 September.
6) Roberts, T.: Development of a New Concept of Steerable PDC Bit for Directional Drilling, paper IADC/SPE 39307 presented at the
1998 IADC/SPE Drilling Conference, Dallas, 3-6 March.
7) Barton, S., May, H., Johnson, S.:Gauge, Cutting structure, Torque Control Components What really counts for Optimal Tool Face
Control with FC drill bits paper AADE-07-NTCE-07 presented at the 2007 AADE National Technical Conference and Exhibition,
Houston, April. 10-12 2007

Figures

Figure 1: Gauge Design Utilized by the 26 E1019-A

Figure 2: Ring Gauge Utilized for Improving Lateral Stability

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Figure 3: Face and ISO View of the 17 RSX816S-A, developed for Salt Drilling in 2001

Figure 4: Face and ISO View of 26 RSR816S-A, developed for Salt Drilling in 2008

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Figure 5: Face and ISO View of the newly engineered 26 E1019-A, developed for Salt Drilling