Beruflich Dokumente
Kultur Dokumente
SUMMER TRAINING AT
IDT,Dehradun
TOPIC: STUDY OF DRILL BITS
Submitted by:
Akshat kumar singh
Bachelor of technology mechanical engineering
Indian Institute of Technology (ISM)
Dhanbad
Submitted to:
Mr. Prafull Kumar Gupta
Deputy Suptdg. Engineer (Drilling)
ONGC, Dehradun
ACKNOWLEDGEMENT
I owe many thanks to great people who helped me during my summer
training project.
I would also like to thank training centre IDT, ONGC Dehradun for providing
an opportunity to undergo training. It was indeed an opportunity for me to
visit the different sections of IDT, ONGC Dehradun. During my visit for the
training program to the company, I learnt interesting things about company.
I express thanks to my mentor Mr. Prafull Kumar Gupta for extending his
support and providing his valuable time and knowledge for guiding and
correcting me in different sections with attention and care. He also provided
me necessary information as and when needed.
I would also like to thanks ONGC and their employees without whom this
project would have been a distant reality.
CONTENTS PAGE NO.
CHAPTER 1: ABOUT IDT 1
CHAPTER 2: BIT TYPES 2
2.1 Roller cone bits 2
2.2 Polycrystalline Diamond Bits 12
2.3 Diamond and TSP Bits 18
CHAPTER 3: BIT SELECTION 20
3.1 Introduction 20
3.2 Through assessment and Comparison of Offset data 20
3.3 Bit run cost equation 20
3.4 Drill off tests 21
3.5 Variable Information Analysis 21
CHAPTER 4: BIT DULLING CAUSES AND REMEDIES 24
4.1 Wear mechanism for Roller Cone Bits 24
4.2 Wear mechanism for PDC Bits 25
4.3 Precautions for Roller Cone Bits 26
4.4 Precautions for Fixed cutter Bits 27
CHAPTER 5: REFERNCES 33
CHAPTER 1: ABOUT IDT
The Institute of Drilling Technology (IDT) was set up in 1978 at Dehradun.
Located in the picturesque valley of Doon between the green Shivaliks and
the lower Himalayas, it is engaged in relentless effort in R&D and has
rendered excellent services in the area of oil and gas well drilling technology.
Over the years, the Institute has emerged as a premier R&D centre in South
East Asia, capable of providing advance technical knowledge through
training and offering plausible solution to field problems. Institute of Drilling
Technology (IDT) provides its techno-economic expertise & solutions to
various field problems faced by various services of ONGC with the ultimate
objective to promote cost effective E&P activities of the company. Besides
R&D, the institute also imparts training & disseminates the knowledge
required for developing a qualified and efficient workforce capable of
delivering, through the ONGC Training Academy.
The Institute with highly qualified and experienced scientists and engineers,
carries out applied research in all facets of drilling related activities to
achieve technical excellence in R&D efforts and assimilation of emerging
technologies.
The integrated HRD division imparts training to participants from both
national and international oil companies in various aspects of oil well
drilling technologies. The renowned Well Control School at IDT has been
accredited by International Well Control Forum, The
Netherlands, International Alliance for Well Control, the Netherlands, and
also from International Association of Drilling Contractors, USA.
IDT is one such drilling institute in India which has infrastructure for
applied R&D has been developed with the state-of-the-art equipment and
machines to achieve qualitative experimental results. Focus of R&D is
directed towards drilling technology, drilling fluid engineering and
cementation and cementing materials to meet challenges of drilling industry.
The technologists and scientists provide solutions to the down hole drilling
problems, improving design of the systems and thereby contributing towards
the development of excellent, efficient and cost effective operations.
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CHAPTER 2: BIT TYPES AND THEIR
DESIGN PAREAMTERS
2.1 Roller Cone bits:
2.1.1 Basic Features
As the name implies roller cone bits are made up of equal sized cones
(generally 3 cones) and identical legs which are attached together with a pin
connection. Each cone is mounted on bearings which run on a pin that forms
an integral part of bit leg. The legs are welded together and form the cylindrical
section which is threaded to make a pin connection. The pin connection
provides a means of attachment to drill string. Each leg is provided with an
opening for fluid circulation. The size of this opening can be reduced by adding
nozzles of different sizes. Nozzles are used to provide constriction in order to
obtain high jetting velocities necessary for efficient bit and hole cleaning. Mud
pumped through the drill string passes through the bit pin bore and through
the nozzles.
There are two type of roller cone bits:
Milled tooth bits: Here the cutting structure is milled from the steel
making up the cone.
Insert bits: The cutting structure is a series of inserts pressed into the
cones.
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The capacity to accept hard facing without damage
Machineability
Physical properties for bit components are contingent on the raw material
from which a component is constructed, the way the material has been
processed, and the type of heat treatment that has been applied. Steels used
in roller-cone bit components are all melted to exacting chemistries,
cleanliness, and interior properties. All are wrought because of grain
structure refinements obtained by the rolling process. Most manufacturers
begin with forged blanks for both cones and legs, because of further
refinement and orientation of microstructure that result from the forging
process.
Structural requirements and the need for abrasion and erosion resistance
are different for roller-cone bit legs and cones. Predictably, the materials
from which these components are constructed are normally matched to the
special needs of the component. Furthermore, different sections of a
component often require different physical properties. Leg journal sections,
for example, require high hardenabilities that resist wear from bearing
loads, whereas the upper portion of legs are configured to provide high
tensile strengths that can support large structural loads.
Roller-cone bit legs and cones are manufactured from low-alloy steels. Legs
are made of a material that is easily machinable before heat treatment, is
weldable, has high tensile strength, and can be hardened to a relatively high
degree. Cones are made from materials that can be easily machined when
soft, are weldable when soft, and can be case hardened to provide higher
resistance to abrasion and erosion.
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2.1.4.2 Cone offset
The “offset” specifies to a certain degree a drilling action of the roller cone bit.
Figure 3 illustrates cone offset. Shift of the cone‟s axis to the centerline of the
bit is defined as “offset”. The roller cone bit with no offset has the intersection
point of cones axis in the centre of the bit. The size of offset depends on the
type of rock to be drilled. Its values range from 40 for soft formations to 00 for
hard formations. Angular measure of the offset is called skew angle.
The cone offset results in interim stops in rotation and brake the hole like a
drag bit. With increasing the offset the bit wear increases proportionally.
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in soft formations and in the case when foam, air or gas are used as a drilling
mud.
Nowadays the vast majority of drilling bits are equipped with sealed and
lubricated bearings. As a result their resistance has been increased to provide
longer suitability in demanding conditions. In case of the sealed roller
bearings the detrimental effect of drilling mud has been eliminated as long as
the seal is working properly. However, component wear still exists. The major
cause of bearing breakage is journal spalling, which results, in the long run,
in permanent failure. At present sealed roller bearings are used mainly on
milled tooth bits and their resistance often exceeds that of the cutters. The
most efficient solution currently used is journal bearing. The bearing consists
of no moving parts, but is just a journal pin fitted to the inside coated surface
of the cone. The main advantage is much bigger contact area at the critical,
improved distribution of the load. Therefore it can better withstand high
rotary speeds and weights. As a result lifetime has been extended, allowing
their use in carbide cutters. To ensure proper seal between the cone and the
journal metal seals have been incorporated.
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pushes the grease towards bearings. Some leakage of the grease may take
place due to sudden pressure variations.
Figure 6A and 6B
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The long teeth are designed to drill soft formations
with low compressive strength where the rock is
more yielding and easily penetrated. Penetration is
achieved by applying weight on bit (WOB) which
forces the teeth into the rock by overcoming the
rock compressive strength. Rotation of the bit helps
to remove the broken chips.
Harder rocks have field WOB values. Hard rock bits therefore have much
shorter and more teeth with a larger bearing are, therefore the short teeth will
be less likely to break when they are subjected to drilling loads. The teeth
apply load over a much larger area and break the rock by crushing, creation
of fractures and chipping. The teeth are not intended to penetrate rock, but
simply to fracture it by application of high compressive loads.
Tooth Shape
Viewed from the side most teeth appear like an a without crosspeice. There
are other design such as L, T, U which are more durable and are usually
found at gauge area.
Tooth hardfacing
To increase the life of the cutting tooth, hard metal facing (usually tungsten
carbide) was initially applied to one side of tooth to encourage preferential
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wear. As the bit drills away, the tooth wears on one side thereby always
leaving a sharp cutting edge on metal faced side.
Inserts with large protrusions are suitable for soft rocks as would be seen on
a 4-3 type cutting structure and to a limited protrusion as on the insert as
on an 8-3 cutting structure.
Gauge Retention
The majority of the drillbit work is spent around the heel and gauge area
and therefore this partsuffers the greatest amount of wear.
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Trimmers are used to maintain bit gauge (diameter). this achieved by the
use of T-shaped teeth on milled tooth bits and very short inserts in the
gauge row. The gauge inserts may be diamond coated.
Shirttail Protection
All drill bits may have tungsten carbide inserts placed in the heel area of the
bit. A worn shirttail I (Figure 9.12) may expose the seal, leading to seal wear
and bearing failure. Various devices may be used to limit or delay shirttail
wear. Tungsten Carbide Inserts may be placed in the shirttail itself. Lug
pads may be added to the upper part of the shirttail. A band of hardmetal
can be added to the margin of the shirttail.
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2.2 Polycrystalline diamond bits
2.2.1 Design Factors
A polycrystalline diamond compact (PDC) bit employs no moving parts (i.e.
there are no bearings) and is designed to break the rock in shear and not in
compression as is done with roller cone bits. Rock breakage by shear
requires significantly less energy than in compression, hence less weight on
bit can be used resulting in less tear and wear on the rig
and drillstring.
A PDC bit employs a large number of cutting elements, each called a PDC
cutter. The PDC cutter is made by bonding a layer of polycrystalline man-
made diamond to a cemented tungsten carbide subtrate in a high pressure,
high temperature process. The diamond layer is composed of many tiny
diamonds which are grown together at random orientation for maximum
strength and wear resistance.
Cutters
Size of Cutters
Back Rake
Side Rake
3. Geometry of Bit
Number of Blades
Blade Depth
4. Diamond table
Substrate interface
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Composition
Shape
Bit Body
The bit body may be forged or milled from steel (steel-bodied bits) or
constructed in a cast from tungsten carbide (matrix bit).
From a practical standpoint, steel bodies bit are preferable as they can be
easily repaired but suffer from erosion. Matrix bits are more resistant to
erosion but are prone to bit balling in soft clay formations due to their low
blade height compared with steel bodied bits.
Cutter Geometry
Cutter geometry depends on:
1. Number Of cutters
Soft rocks can be penetrated easily and hence fewer cutters are used on soft
PDC bits as each cutter removes a greater depth of cut. More cutters must
be added to hard PDC bits for harder formation to compensate for the
smaller depth of cut.
2. Cutter Size
Large cutters are used on softer formation bits and smaller cutters on the
harder formation bits. Usually a range of sizes is used, from 8mm to 19mm
is used on any one bit.
3. Back Rake
Cutter orientation is described by back rake and side rake angles .Back rake
is the angle presented by the face of the cutter to the formation and is
measured from the vertical, see Figure 12
The magnitude of rake angle affects penetration rate and cutter resistance to
wear. As the rake angle increase, ROP decreases but
the resistance to wear increases as the applied load is now spread over a
much larger area.
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Figure 12 back rake= A side rake = B
PDC cutters with small back rakes take large depths of cut and arc therefore
more aggressive, generate high torque, and arc subjected to accelerated
wear and greater risk of impact damage. Cutters with high back rake have
the reverse of the above.
Back rake angles vary between, typically, 15° to 45°. They are not constant
across the bit, nor from bit to bit.
4. Side Rake
Side rake is an equivalent measure of the orientation of the cutter from left
to right. Side rake angles are usually small. The side rake angle assists hole
cleaning by mechanically directing cuttings toward the annulus.
5. Cutter Shape
The edge of the cutters may be bevelled or chamfered to reduce the damage
caused by impacts.
Bit Geometry
The factors affecting bit geometry include:
1.Number of Blades
Using the same analogy for roller cone bits, a PDC bit designed for soft rocks
has a fewer blades (and cutters) than one designed for hard rocks.
The soft formation PDC bit will therefore have a large junk slot area to
remove the large volume of cut rock and to reduce bit balling in clay
formations, Figure 13 a.
A hard PDC bit with many blades requires many small cutters, each cutter
removing a small amount of rock, Figure 13 b.
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Figure 13 a and 13 b respectively
2.Blade Height
A soft formation PDC bit will have a lager blade height than a hard PDC bit
with a consequent increase in junk slot area. Higher blades can be made in
steel bodied- bits than matrix bits, because of the greater strength of steel
over that of matrix.
3.Blade Geometry
PDC bits can be manufactured with a variety of blade shapes ranging from
straight to complex curve shapes. Experience has shown that curved blades
provide a greater stability to the bit especially when the bit first contacts the
rock.
4.Bit Profile
Bit profile affects both cleaning and stability of the bit. The two most widely
used profiles are: double cone and shallow cone, Figure14.
The double cone profile allows more cutters to be placed near the gauge
giving better gauge protection and allowing better directional control. The
shallow cone profile gives faster penetration but has less area for cleaning.
In general a bit with a deep cone will tend to be more stable than a shallow
cone.
5.Bit Length
This is important for steerability. Shorter bits are more steerable.
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6. Gauge Protection
As discussed before, the greatest amount of work is done on the heel and
gauge of the drillbit. A PDC bit that wears more on the gauge area will leave
an undergauge hole which will require reaming from the next bit. Reaming is
time consuming and costly and in some cases can actually destroy an entire
bit without a single foot being drilled.
Hence maintaining gauge is very important. One or more PDC cutters may
be positioned at the gauge area. Pre-flatted cutters are used to place more
diamond table against gauge. Tungsten carbide inserts, some with natural
or synthetic diamonds embedded in them, maybe placed on the flank of the
bit.
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5 When drilling mobile, plastic formations such as salt sections the use of
eccentric PDC bits should be considered. These bits have proved successful
in preventing incidence of stuck pipe in many areas where salt flow
problems are experienced.
6 When planning the use of mud motors or turbines, the use of long tapered
profile bits should be considered. In addition, radial jetting bits reduce the
potential for friction inducedhigh cutting temperature when run on a motor
or turbine which reduces temperature degradation of cutter.
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applied weight. If considerable reaming is needed in medium hard and
abrasive formations, the bit should be pulled and a tricone bit used for
reaming purposes.
(d) Do not apply more than 5000 pounds WOB when reaming. The rotary
speed should not be more than 50 to 60 rpm.
(e)It is recommended to ream the last joint to bottom in order to avoid nozzle
plugging from any down hole fill.
(f)Use the lightest bit weight possible to locate the bottom of the hole and
then pull one or two feet off the bottom. Circulate at full rate for 10-15
minutes.
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Diamond bits comprise: natural diamond bits, TSP bits and impregnated
bits. They share several features:
similar profiles
The central design elements for diamond hits are the diamond size,
diamond quality. the hydraulics pattern and the bit profile. The hydraulic
energy (HSI) at the hit should be optimised to keep the face of the hit cool
(to save the diamonds) and to provide efficient hole Cleaning.
As the formations get harder the diamond size gets smaller. Soft formations
(ROP >10 ft\hr) require 1-1 1/2 carat diamonds, while very hard drilling (ROP
2<ft\hr) may require 6-8 stones/carat.
A bit with a turbine sleeve type body with a long tapered profile
should be considered for turbine applications.
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CHAPTER 3: Bit selection
3.1 Introduction
Even though our goal is to make the best preparation at the well planning
stage, in industrial practice, the final bit selection is conducted in the field.
The drilling engineer should be able to select properly, operate and evaluate
the drill bit. It is not an easy task, considering diversification of drilled rocks
and wide range of available tools.
There is no particular rule that ensure adequate bit choice. However, using
several practical methods the right bit can be chosen with a fair degree of
certainty. Ultimately, the personal experience is invaluable as well as an
opportunity to compare the offset data in the area.
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uncertain factor. Finally bit selection is typically supported largely by offset
data.
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analysis of cuttings to produce a geocolumn. This display serves as an
excellent indicator of what will be drilled. In addition, the penetration rate
log can be of use in determining the drillability of the proposed formation
interval. Inferences to formation properties can be made, affecting the final
bit selection and proposed operational parameters. With all this information
correlated to depth, an assessment can be made of which formation
intervals in the proposed well are diamond bit applicable.
If the previously mentioned data is unavailable, an offset bit record should
be consulted. Otherwise, the risk of poor performance will be greatly
increased. When selecting a bit, it naturally follows that an estimation of
potential footage, penetration rate, and cost savings should be given. The
following guidelines are recommended for selecting bit records:
1) The most recent bit record will normally be the best indicator of the type
of performance to be expected in a proposed drilling interval.
2) Probability is highest when the drilling technology used is most similar to
what will be available.
3) The nearest offset records Increase the chance that the formations
encountered in the proposed well will be the same and exhibit similar drill
ability. In faulted areas, an attempt should be made to verify that the offset
data is on the same side of the fault as the proposed well. If not, a
comparison of bit runs in the same formations is recommended, although
they may be at different true vertical depths.
4) Bit sizes and casing programmes should be similar. Different bit sizes
affects the ultimate penetration rate, even when all other variables are
equal. Cost comparisons can also be affected.
5) Comprehensive dull grades should be available. They will provide a
qualitative gauge of the formation abrasiveness. Furthermore, they can give
insight to the required type and density of cutters needed to drill.
6) Similar mud type and mud weights are also important, in that different
bits will perform differently depending on mud types and properties. An
example of this is that PDC bits perform significantly better in oil based
mud.
7) Finally, the total depth should be at least equal to or greater than the
proposed well. If formation tops change radically, then a conformation
should be made that the offset bits drilled the same formation to be drilled.
Methods have been proposed for selecting rock bits using offset well logs
such as sonic and gamma-ray logs (Somerton and El-hadidi, 1970, Mason,
1984). These methods appear to work but involves substantial time in the
analysis of the logs and in the interpretation of the results.
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The international association of drilling contractors IADC bit code offers a
method of bit selection based on bit type. If approximate formation
properties are known, the table can be used to choose the appropriate bit
type. Its drawback is that the geological description contained in the table,
on which the bit type is selected, is rather limited. Even if this description
was improved, the available geological knowledge from a prospective field
would probably be inadequate for use with such a table to select bits.
The geophysical data analysis and the general geological considerations
methods tend to be used in new fields where previous drilling is limited or
non-existent. Seismic exploration data can be used to predict drillability and
formation types. With a knowledge of the expected formation hardness and
abrasivity the lADC coding or manufacturers' guides can be used to select
bits.
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CHAPTER 4: Bit Dulling causes and
remedies
4.1 Wear mechanisms of Roller cone bits
Wear of drill bits is defined as macroscopic or microscopic removal or
fracture of material, particularly at the cutter surface, or more general as,
any degradation that reduces bit life. Mouritz and Hutchings (1991)
investigated the wear rates of the materials used in the teeth of the rotary
drill bits and the abrasive wear mechanisms of these materials. The teeth of
the rotary drill bits contain three layers. The external layer consists of a WC-
Co hardfacing layer, the second layer is made from high-carbon martensitic
steel and the third layer is the core of the tooth that consists of low-carbon
martensitic steel. Small cylindrical specimens manufactured from materials
similar to those used in the teeth of rotary drill bits were used in the
investigation by Mouritz and Hutchings (1991). The abrasive rocks like
sandstones and non-abrasive rocks such as limestone, representing the
most common rock formations encountered in oil drilling were used in the
tests.
When the specimens of low and high carbon steel were scratched with a
diamond stylus, the wear damage caused by the process of micro-ploughing
and micro-cutting as shown in Figures 16.1 and 16.2 respectively. In micro-
ploughing, the material is displaced to the sides of the wear groove and the
material is not removed from the surface, while in cutting a chip is formed
at the end of the groove and the material is removed from the surface
(Kopeliovich ,2015).
16.1 16.
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Osburn (1969) and Perrott (1979) illustrated the strong influence of rock
hardness on the wear of the rotary drill bit tools made of tungsten-carbide
with cobalt as a binder. Abrasion was found to be worse under high
temperatures (hot abrasion) causing thermal fatigue. Osburn (1969) also
added that the WC grains during the manufacturing of the roller-cone insert
bits must be structured perfectly to gain maximum fracture resistance.
Larsen-Basse (1973) explained that the main modes of failure for roller-cone
insert drill bits are as the follows:
1- impact fracturing, 2- thermal fatigue, 3- abrasive wear and 4- mechanical
fatigue due to overloads.
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(9) distribution of cutters on the bit and (10) thermal failure. The
improvements of synthesising manufacture methods of PDC bits to
withstand both failure and impact have been investigated by many
researchers. However, an important step for the improvement is to
understand the failure mechanisms and modes of PDC bits. Fang et al.
(2001) illustrated the main failure modes of PDC cutters are due to frictional
heat and the high abrasiveness of the rock, as shown in Figure 17.
Figure 17 Typical failure modes of PDC inserts for rock drill bit
It is worth mentioning that, other kinds of wear such as adhesive wear has
minor effect on oil drill bits, while impact wear affect the drill bits, especially
when applying excessive loads on the bits as mentioned by Wirojanupatump
and Shipway (1999). In drill bits, when fluids are present, the influence of
corrosion is considered negligible when compared to the wear where the
material forming the drill bit is being physically removed. The corroding
effect is neglected since the abrasive wear take action on the surface of the
material forming the drill bit before oxidization.
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Excessive Broken Teeth: Improper break in procedure for a new bit can
result in excessive breaking of teeth. Excessive WOB can also cause
breaking of teeth.
Hence to control the breakage of tooth we must use proper break in
procedure for new bit and low WOB.
In some cases we may use harder formation bit type with more teeth.
Fluid cut cones and teeth: Excessive fluid circulation rate or excessive
sand in circulating system often results in wear and tear of cones and teeth.
So proper fluid circulation rate and removal of sand from circulating system
should be done.
Cones skidded due to balling up: May be caused by high WOB, improper
bit type or improper fluid circulation rate.
To avoid skidding of cones we must use soft formation type bits and low
WOB. Fluid circulation must be proper
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—second, wear of peripheral teeth conditions rated diameter of a drill bit;
—third, replacement of damaged teeth is the most expensive part of repair;
—fourth, evaluation of drilling characteristics of a drill bit consumes much
time as it is necessary to examine individual teeth and, then, their
ensemble, and to count the damaged teeth.
To assume a drill bit unworkable, it is required that more than 60% of teeth
are damaged. When many teeth are worn-out, drilling performance drops
while rate of wear of other members of a drill bit grows until complete
failure.
From practice of drilling with drill bits, sides of a drill bit are subjected to
major wear. Teeth arranged at different spacing along the radius from the
drill bit axis deteriorate utterly unevenly. Peripheral teeth are in the most
unfavourable conditions.
Wear of peripheral teeth is most often represented by chippage, galling, wear
of underlayer with the concomitant symptom of thermal overload. Wear of
drilling teeth after cutting in variable hardness rocks is of the mixed
abrasive and impact-abrasive nature. Cyclical heating and cooling of surface
during operation and, consequently, alternate expansion and contraction of
surface layers causes the so-called fatigue grooves.
It is known that downhole fluid motors are also sources of vibration due to
disbalance of rotating rotor, clearings of radial supports and distortion of
rotor shaft and housing. Amplitude of transverse vibrations may reach 10
mm and above, and frequency is equal to one vibration per revolution. High-
rate wear of peripheral teeth is an aftereffect of this factor, too.
2. Wear of teeth holders. Replaceability of a tooth depends not on the
depreciation of the tooth but on the integrity of the tooth holder
characterized by percentage of damaged surface of the holder. Accordingly,
when the surface of a holder is completely covered by the tooth body,
housing and alloying material, the holder is assumed unworn (Figure 18a 3).
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Figure 18. Schematic representation of surface of teeth holders: (a) unworn holder; (b) and
(c) repairable holder (surface wear from 10 to 50%); (d) unrepairable holder (surface wear
more than 50%); 1—diamond plate; 2—tungsten–carbide under layer; 3—surface of tooth
holder; 4—PDC bit body; 5—hard-alloy welding.
If the damage of a tooth holder makes 1/10 (i.e. visible) to 1/2 of the overall
surface area, the holder is assumed repairable as it is yet possible to fix a
new tooth in it.
Figures 2b and 2c illustrate typical partial damage of surface of a tooth
holder with the lost portion of the tooth body or failed alloying material that
protects the holder. Exposure and damage of surface of a holder usually
take place simultaneously.
When more than a half of the holder surface is damaged (see Figure 2d), the
holder is assumed unrepairable as it fails to preserve initial guiding base to
orient a tooth.
3. Wear of jet nozzles. During operation of a dill bit, it is necessary to
control jet nozzles and the absence of erosion. Under erosion or when any jet
nozzle is lost, pressure difference in the bit reduces, washing fluid flow rate
slows down and quality of cleaning of the dill bit and the well bottom
deteriorates. Erosion of bit housing is understood as generation of holes in
the housing, aside from drilling-bit fluid discharge ports.
The loss of a jet nozzle is sufficient to assume the jet nozzle unit is in want
of repair. When a jet nozzle is come down, or initial diameter of the jet nozzle
hole is eroded by 4 mm and more, the jet nozzle unit is unrepairable.
4. Reduction in bit diameter. This factor is an aftereffect of wear of
peripheral teeth, which results in the gage loss of a drill well, and is to be
controlled using a set of two specially manufactured gage rings with the
diameters smaller than the rated diameter of a drill bit. Diameters of the
first and second gage rings are selected based on geological features of the
drill log, rigidity of the bottom of the drill-stem assembly and process steps
scheduled for implementation in the course of drilling.
If a drill bit does not get through gage ring 1, the drill bit is assumed
unreduced in diameter.
Passage through gage ring 1 and nonpassage through gage ring 2 defines
the range of repairable drill bits. In this case, the operation of a drill bit is
stopped, wear of other elements of the drill bit is evaluated and, based on
this, a decision on the drill bit repair or disposal is made.
If a drill bit passes through gage ring 2, the drill bit gage loss is assumed
and the drill bit is unrepairable.
5. Wear of thread connection. Any damage of thread, preventing from
screwing a drill bit, is a sufficient condition for assuming the thread
connection inappropriate for further operation of the drill bit.
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6. Vibration. Vibration complicates the control over technical data of
drilling, optimal drilling mode is failed and power consumed to rotate the
drilling assembly sharply grows.
Among possible approaches to combating vibration, the most promising way
seems to be installation of vibration dampers at the bottom of the drill stem
assembly. It is highly important to stabilize a drill assembly during
operation of drill bits, as this governs the drilling efficiency in variable
hardness rocks and stabilization can ensure even loading of all teeth.
Currently, bottomhole bumpers enjoy no wide application, and no studies
have been carried out to examine PDC bit operation under conditions of
vibration damping. In the East Siberia, bottomhole vibration dampers are
the mandatory requirement for operation of drill bits. This method of
damping vibrations is a promising technique to be used in drilling and
construction of oil and gas wells in other regions of Russia.
Also, it is possible to suppress vibration of a drill stem assembly and to
enhance efficiency of drilling in variable hardness rocks though installation
of a hydraulic pulsator in the drill bit body.
The hydraulic pulsator placed in a counterbore in the drill bit body
periodically catches drilling fluid in the drill bit cavity, pressure in the drill
bit cavity grows, and opening of the cavity initiates an impulse in the drilling
fluid flow. This allows transmission of impulses of axial dynamic loads
directly to the drill bit with avoiding absorbing effect of intermediate units,
including a downhole drilling motor. When a damper is installed between a
drill bit and a downhole drilling motor, the impact exerted by the axial
dynamic loads on the drilling motor is considerably reduced, which extends
the motor service life. At the same time, transmission of high axial dynamic
forces to a drill bit at the seam rpm enhances the cutting force of the drill
bit, especially the vertical force component. Thus and so, with the increased
cutting force, the rate of penetration grows.
7. Packing. This obstacle appears in PDC drilling in argillaceous deposits.
As a consequence of adhesion of clay to metal surface of a drill bit, packing
can coat entire drill bit, which totally blocks drilling (refer to Figure 19).
Packing is mostly prevented by modification of drilling mode (reduction in
axial load on drill bit, increase in flow rate) or design of drilling tool. Also, it
is possible to use drilling fluids with the improved anti adhesion
characteristics.
In case of sticking of a drill bit, a borer has to try to remove a ball from a
drill bit in the hole, or to move up an untreated drill bit.
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Figure 3. General view of a PDC bit with clay packing.
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It is known that drilling temperature at the cutting tool and rock contact
may reach 1000°С, and inefficient cooling can cause critical wear of
diamond-bearing cutting layer and underlayer, and can induce fall of teeth
from holders.
Efficient cooling of cutting tools requires that a mud system ensures
required and sufficient washing fluid flow rate and high flow rate along
active faces of blades.
Polished Diamonds: rotating in hard formations without making a hole
may polish diamonds.
To prevent polishing of diamonds we must use higher WOB or choose a bit
with small cutters.
Shattered Diamonds: Improper stabilization of bit and improper handling
can cause serious damage to diamonds on bit.
In some cases some abnormal vibrations may occur and diamonds may
shatter
So to prevent shattering of diamonds we must handle and stabilize the bit
properly. If abnormal vibrations occur me must try to reduce RPM.
Sheared Diamonds: may be caused due to improper break in and broken
nose stone.
So we must clean bottom hole properly and use correct break in procedures
Diamonds: Inadequate cooling of PDC bits may result in burning of
diamonds
To ensure proper cooling we must give proper fluid circulation.
Worn throat: fragments of hard formations rolling in throat may result in
wear of throat area.
If such a problem is encountered we must check the hydraulics.
Loss of gauge: If we ream for long intervals with insufficient cooling due to
clogged junk slots then gauge may be damaged.So while reaming we should
minimize RPM and WOB.
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CHAPTER 5: REFERENCES
[1] Chulkova VV 2012 Experience of drilling with PDC drill bits in variable
hardness rocks in the Ural–Volga region Bulletin of Association of Drilling
Contractors (in Russian)
[2] Chulkova VV 2012 Resource-saving drilling with PDC drill bits under
conditions of variable hardness rock mass Burenie Neft, pp 56–57.
[3] Myasnikov YaV, Ionenko AV, Gadzhiev SG et al. 2014 Guide on PDC drill
bit wear evaluation in field conditions Burenie Neft No 3, pp 14–18.
[4] http://www.buroviki.com/yaf/forum.aspx?g=posts&m=584
[5] Multi-Set PDC Drill Bit and Method Inventors: Drews SW, Maurstad C.
Assignee: Varel International, Ind., L.P. 2012
[6] Timonin VV and Kharlamov YuP 2014 Mathematical modeling of mud-
circulating system of an air drill hammer with a central mud removal line
using SolidWorks Flow Simulation, Vestn. KuzGTU, 6 (106), pp. 61–65. 6
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