Improvements in Cutter Technology Leads to Faster Drilling in Hard Abrasive Formations, East Texas Basin

Abstract

Drilling the hard, abrasive and interbedded Travis Peak and Cotton Valley formations in East Texas creates a problem for polycrystalline diamond compact (PDC) bits. Historically, conventional PDC cutting elements failed quickly due to formation abrasiveness, impact damage and thermal fatigue. These cutter limitations are the major factor restricting further advancement of PDC drilling in East Texas. New cutter technology and manufacturing processes have yielded a highly abrasion resistant PDC bit enabling faster drilling, increased footage and improved dull condition in the basin. Furthermore, intervals that normally require multiple PDC bits/runs to reach TD are now being drilled in some cases with one bit saving the operator trip time and bit cost. In spite of the advancements the majority of bits were repeatedly lacking favorable dull grades, typically a 1-2-WT or worse. Further improvements were necessary to advance the cutter's abrasion resistance for these applications. To achieve the objective and improve PDC cutter performance to save the operator additional cost, engineers refined and implemented new procedures to increase abrasion resistance. This technology platform used to produce the next generation premium cutters included: Tighter diamond packing Diamond table synthesized under extremely HP/HT for enhanced abrasion resistance Refined post-pressing process to reduce residual stress and improve thermal stability In laboratory experiments, the next generation cutter (O2) has shown a 15% improvement in abrasion resistance in wear index comparisons against the previous generation (O1) premium cutters. The tests were performed on a vertical turret lathe under cooling and non cooling conditions. Field testing of the new cutter was done in limited quantities across East Texas. In these tests the new cutter has achieved an average ROP increase of approximately 15% while producing improved dull bit condition. The next generation O2 cutters are expected to have a positive economic impact in the East Texas region and in other hard and abrasive applications worldwide.

New HTHP Cutter Technology Coupled with FEA-Based Bit Selection System Improves ROP by 60% in Abrasive Zubair Formation

“…To further advance cutter technology, an R&D initiative was launched to enhance the properties of the base diamond material especially wear resistance and thermal stability by redesigning diamond grit mixing, pre/post-processing treatment in addition to high temperature/high pressure (HTHP) sintering. [20][21][22][23][24][25] Laboratory experiments were preformed to study the wear mechanism and the progression of the wear flat under different conditions with various synthetic polycrystalline diamond (PCD) materials. Testing revealed the following:…”

Establishing Higher Oil Production Capabilities: Engineered Approach Achieves Longest Lateral Hole Section in Kuwait

“…[22][23][24][25][26][27] Laboratory experiments were preformed to study the wear mechanism and the progression of the wear flat and impact resistance under different conditions with various synthetic polycrystalline diamond (PCD) materials. The new generation HPHT PDC cutter has demonstrated a significant performance step change (Figure 7).…”

Pointing Towards Improved PDC Bit Performance: Innovative Conical Shaped Polycrystalline Diamond Element Achieves Higher ROP and Total Footage

“…[3][4][5][6][7][8] Additional research and manufacturing initiatives have produced superior cutter technology that can withstand harder and more abrasive formations. [9][10][11][12][13][14][15][16][17] In 2004, fixed cutter bits were crowned king with the total worldwide footage drilled by PDC (54%) surpassing that of rollercone (46%). However, efficiently drilling with PDC in very hard, interbedded and highly abrasive formations remains challenging.…”