Latest PDC Technology and Optimization Process Enable Replacement of Multiple Impregnated and Roller Cone Bits with One PDC Bit Run

Abstract

The Cambro-Ordovician formation in onshore Algeria consists of hard and abrasive sandstones that have proven challenging to drill. Up until now, no bit has completed the section in one run, and these formations have been considered beyond the limit of what is drillable by PDC cutters. Previous sections have used impregnated diamond and roller cone bits that achieved low penetration rates and required multiple bit runs. The impregnated runs require the additional cost of turbo drills or high-speed motors to deliver the rotation speeds necessary to achieve acceptable rates of penetration, while a bearing seal failure of a roller cone bit increases the risk of losing bit pieces in hole. The operator conducted an optimization process based on rock mechanics including an analysis of prior performances to conclude that the formation could be drilled more economically applying the recent advances in PDC bit technology. Collaboration between the bit manufacturer and the operator facilitated the implementation and development of the latest bit technology, including enhanced bit stability, improved cutter layout and more resistant cutters. After an initial, partially successful run, new bit improvements were implemented. The two subsequent runs completed their sections, enabling the operator to drill with one bit through what was previously a multiple-bit section. Rates of penetration were improved significantly over previous impregnated and roller cone runs. Requirements for down hole drive tools and bit trips were eliminated as was the risk of bit junk being left in hole. This paper outlines the process that led to improved understanding of the formation drill ability, the research and development behind this new bit technology, the continuous optimization of the specific bit, its field performance, and the resulting cost saving for the operator.