A New Method of Backup Cutter Layout to Extend Bit Life Without Sacrificing Rate of Penetration

Chen, Shilin; Khlefat, Yazan; Cleboski, Chris; Anderle, Seth; Maouche, Zakaria

doi:10.2118/187644-ms

Cited by 4 publications

(4 citation statements)

References 9 publications

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“…where u c represents the angle between plane M and plane ORH and is named the circumferential angle. Then, the lateral force F l can be represented by equation (9)…”

Section: Lateral Force Model Of Pdc Bitmentioning

confidence: 99%

“…To make the PDC bit reach the global force-balanced state in all drilling moments, the optimal objective function is set to minimize the mean value of the ratio of the lateral force to the WOB and the ratio of the bending moment to the TOB throughout the drilling process, as shown in equation 20Min : where R F is the ratio of the lateral force F l to the WOB F w ; R M is the ratio of the bending moment M b to the TOB M t ; t represents a moment in the drilling process; and T is the total drilling time. In equation (20), the wear condition of PDC cutters at each drilling time t is updated by numerical iteration of the ZPT method; then, the PDC forces and moments can be obtained according to equation (9), equation (18) and the wear condition at each drilling time t.…”

Section: Construction Of the Optimization Modelmentioning

confidence: 99%

“…In the optimal design for a global force-balanced PDC bit, the ZPT method is employed to calculate the cutting area A and cutting arc length L of each cutter. Combined with the single cutter force model equation 4, WOB and TOB model equation 7, lateral force model equation (9), bending moment model equation (18) and cutter wear model equation (19), R F and R M can be calculated. The Kriging surrogate model is used to build the function relationship between the ratio (R F , R M ) and the design variables (b, u c ).…”

Section: Optimization Approachmentioning

confidence: 99%

“…8 A general approach of backup cutter layout to extend bit life without sacrificing rate of penetration was discussed. 9 The aforementioned studies have greatly improved the drilling performance of PDC bits. However, in those studies, the wear of a PDC bit is not considered in the process of cutter layout design, and the specific computing methods for reducing M b are not mentioned.…”

Section: Introductionmentioning

confidence: 99%

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Optimal design of a global force-balanced polycrystalline diamond compact bit considering wear condition

Lian

Huang

et al. 2019

Advances in Mechanical Engineering

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Polycrystalline diamond compact bits are one of the most widely used oil and gas drilling tools in the world. With wear, a large unbalanced lateral force and bending moment exist. These force and moment contribute not only to bit lateral vibration and whirl but also to wellbore tilt and enlargement, which will then cause early bit failure and low drilling efficiency. In this article, considering wear condition, a single cutter force model is proposed. Lateral force and bending moment models are constructed based on space-force theory. An optimal cutter layout model considering cutter wear is established. The matching approach for the optimal model is discussed based on Kriging surrogate model and genetic algorithm. Then, an optimization case is presented. The results show that the bit force models are in line with the actual drilling condition. The optimal approach is efficient. After optimization, the lateral force to weight on bit ratio is reduced by 10.99%, and the bending moment to torque on bit ratio is reduced by 30.43%. This result is a significant improvement in the force condition and stability of the polycrystalline diamond compact bit; ultimately, the whirl and tilt motion can be reduced, and the drilling efficiency can be improved.

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“…where u c represents the angle between plane M and plane ORH and is named the circumferential angle. Then, the lateral force F l can be represented by equation (9)…”

Section: Lateral Force Model Of Pdc Bitmentioning

confidence: 99%

Section: Construction Of the Optimization Modelmentioning

confidence: 99%

Section: Optimization Approachmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Optimal design of a global force-balanced polycrystalline diamond compact bit considering wear condition

Lian

Huang

et al. 2019

Advances in Mechanical Engineering

View full text Add to dashboard Cite

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Unique Backup Cutter Layout Method Leads to Step Change in Bit Durability and Performance when Transition Drilling Through Hard Limestone Formations at High Inclinations

Vrnak

Boutot

Anderle

2018

Day 2 Tue, August 28, 2018

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In the mature fields in Norway's North Sea, extended-reach drilling (ERD) well designs were implemented to reach distant reservoir target zones. Resulting from this change, the 12.25-in. overburden section, which drills through mostly shale with various hard and thin dolomitic limestone sections, had to be modified from a 5,000- to 7,000-ft vertical section to a 10,000- to 12,000-ft section at a tangent inclination anywhere from 35 to 70°. Drill-bit designs that used to drill the vertical overburden section consistently in one run currently require up to three bits to complete the modified tangent sections caused by excessive damage to the diamond cutting structure. An extensive study into the offset ERD wells and corresponding bit dull conditions helped identify that the cutting structure damage originated from high-point load impacts to the shoulder of the bit while transitioning through the thin, hard dolomitic limestone formations; the damaged cutters were being tangentially overloaded. Through further bit modifications, it was determined that this type of damage could not be addressed using typical bit design modifications (e.g., increased cutter density, increased blade count, etc.); therefore, a unique design solution was developed and implemented. This solution involved combining analytical simulations and a dull condition analysis to develop an improved method for using the backup cutting structure to support the high tangential loading on the primary cutting structure during hard, high-inclination transitions. In most dual-row cutting structure designs, the backup cutters are on the same radial position as their parent primary cutters and are underexposed, engaging the formation only at a specific depth of cut or after the primary cutters are worn down a certain amount. When positioned as such, the backup cutters do nothing to support the tangential loading on the primary cutters. By moving the backup cutters actively on profile with the primary cutters and offsetting them to their own radial positions, the backups could now actively support the high tangential loads occurring on the primary cutters when engaging the hard dolomitic limestone. This simple but unique modification enabled the bit to handle the transitions and drill the entire next 11,000-ft+ ERD section in one run while also providing the fastest rate of penetration (ROP) to date, with an increase ranging from 30 to 40% compared to previous runs. The success has been repeated a dozen more times since, each time providing a new record ROP for an ERD section. The improved dull condition could also allow for more efficient designs in the future for further improvements to drilling performance. The successful reduction of tangential impact damage could have implications for various bit designs globally that incur a similar dull condition.

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Efficient PDC Bit Designs Reduced Vibrational Impact While Drilling with Rotary Steerable Systems in the Geological Conditions of the Yamalo-Nenets Autonomous District

Garipov

Rebrikov

Galimkhanov

et al. 2021

Day 1 Tue, October 12, 2021

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This article is a description of a comprehensive engineering approach to new designs of PDC (Polycrystalline Diamond Compact) Bits and bottomhole equipment for efficient horizontal wells drilling in the Yamal-Nenets Autonomous Okrug (YNAO) fields with Rotary Steerable Systems (RSS) Point the Bit (PTB) type. The paper represents an analysis of the efficiency of drilling rocks of various hardness depending on the bits, the bottom hole assembly (BHA), and type of vibrations. In the Yamal region fields a main constraint of sub horizontal sections drilling performance for liner run in hole is the occurrence of vibrations. The predominant vibration types are Stick and Slip (S&S) and High Frequency Torsional Oscillations (HFTO). These types of vibrations often had to be reduced by limiting drilling regime (weight on bit (WOB), drill pipe (DP) RPM, and flow rate), which directly affected on the rate of penetration (ROP). To find solutions to this problem for drilling performance improvement, geological and geomechanically modeling of rock properties and an analysis of burst-files of vibrations (modeled in specialized software) were carried out based on downhole data. The studies have found key factors that cause the high vibration impact and reasons for premature wear of the PDC bits, which served as a basis for identifying the shortcomings of previous bit designs. Test beam experiments were also performed to assess the bits wear while drill-out of the casing accessories. The results formed the basis for development of new PDC bits designs using specialized software. As an output new 155.6/152.4 mm bits designs with an innovative cutting structure that considers the geological features and technical aspects of drilling liner sections in YNAO fields were manufactured. The new bit designs have significantly reduced vibration levels, improved ROP performance in the liner section using RSS PTB, and decreased the overall well construction time. These solutions open wide opportunities for their further implementation on other projects both in Russia and in other CIS countries.

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A New Method of Backup Cutter Layout to Extend Bit Life Without Sacrificing Rate of Penetration

Cited by 4 publications

References 9 publications

Optimal design of a global force-balanced polycrystalline diamond compact bit considering wear condition

Optimal design of a global force-balanced polycrystalline diamond compact bit considering wear condition

Unique Backup Cutter Layout Method Leads to Step Change in Bit Durability and Performance when Transition Drilling Through Hard Limestone Formations at High Inclinations

Efficient PDC Bit Designs Reduced Vibrational Impact While Drilling with Rotary Steerable Systems in the Geological Conditions of the Yamalo-Nenets Autonomous District

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