10/22/2017

Drilling Bits
Dr Masood Mostofi

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COMMONWEALTH OF AUSTRALIA

Copyright Regulation 1969

WARNING
This material has been copied and communicated to you by or on
behalf of Curtin University of Technology pursuant to Part VB of
the Copyright Act 1968 (the Act)

The material in this communication may be subject to copyright under

the Act. Any further copying or communication of this material by you
may be the subject of copyright protection under the Act.

Do not remove this notice

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Lecture Note

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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Drilling Bits for Different Rocks

• Different variety of

rocks (strength, shale,

unconsolidated,

naturally fractured,

abrasive,…)

• Different types of bits

with different price, life

and rate of penetration. Mostofi (2014) and Leine et.al (2002)

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Drilling Bits Also called

surface set
diamond bit
Drilling Bits

http://www.geoproduct-bg.com/

Natural
Roller Cone Bits
Diamond Bits

Drag Bits PDC Bits

Impregnated
Hybrid Bits
Diamond Bits

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Rotary Bits

Mostofi (2014)

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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Roller Cone Bits:

• Composed of number of cones.

• Drilling action: a combination of

indentation and dragging.

https://www.youtube.com/watch?v=l7rrCFZ
xIL0

http://www.ericsiegmund.com/ Franca (2010)

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Roller Cone Bits:

Roller Cone Properties:

• Number of cones

• Cone geometry

• Teeth type

• Bearing types http://www.varelintl.com/

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Roller Cone Bits: Number of Cones

http://www.alibaba.com/
http://www.drillersupply.net/

http://www-odp.tamu.edu/
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Roller Cone Bits: Cones

• Cone offset to improve rate of

penetration by adding more

dragging action to the existing

crushing/indentation action.

• But for harder rocks, cone offset

tends to be closer to zero. Bourgoyne et al. (1991)

• More teeth wear occurs as the

offset increases.
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Roller Cone Bits: Teeth

Mitchell and Miska (2011)

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http://www.bitbrokers.com/ 13

Roller Cone Bits: Teeth

• Button or Insert Bit: Tungsten
carbide cutters are placed inside
the cones. (medium to hard rock
drilling)
• Milled Teeth bit: The teeth are
made of steel but covered by
tungsten carbide coating improving Diamond Enhanced!
bit life (soft rock drilling).
• There are some new versions
using PDC coated bottoms.

http://www.varelintl.com/

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Roller Cone Bits: Bearing

• Bit life, performance (range of WOB and RPM) and price of roller cone bits

constrained by the teeth and bearing properties.

• Important parameters related to bearing properties: type of bearing (journal

or ordinary) and the seal mechanism.

• Three Types of Bearing:

• Non-sealed Roller Bearing

• Sealed Roller Bearing

• Sealed Journal Bearing

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Roller Cone Bits: Bearing - Sealing

• Non-sealed bearing: Lubrication

provided by drilling fluid.

• Solid content of the drilling fluid

damages the bit.

• Higher bit life achieved by

http://www.dthrotarydrilling.com/

having sealed bearing.

• A hydraulic reservoir is used to

seal the bearing.

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Roller Cone Bits: Bearing

• Bearing:

• Non-sealed Roller Bearing All have ball bearings

Medium keeping cone in place
load and and support dragging
medium to • Sealed Roller Bearing
action of the roller
high rpm cone.
• Sealed Journal Bearing

Responsible for
indentation and
crushing action of
the bit.

Roller bearing
Ball bearing

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Roller Cone Bits: Bearing

• Bearing:

• Non-sealed Roller Bearing

• Sealed Roller Bearing

• Sealed Journal Bearing

• Bearing life is prolonged using

journal bearing.
• As journal/roller bearing wears
out, ball bearing would be
exposed to stress due to WOB.
• The damage of ball bearing can
lead to cone lost!
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http://www.bitbrokers.com/ 18

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Roller Cone Bits: Wear Mechanisms

Roller Cone Bit Wear

Teeth Wear
http://petroleumsupport.com/

Portwood (2001)

Bearing Wear

http://www.bitbrokers.com/

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Socrative In-class Quiz

Drilling Eng – Drilling bit P1

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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Drag Bits: Natural Diamond Bit (Surface Set

Bit)
• Almost are extinct in oil and gas, but still

being used in some mining operations.

• A layer of natural diamond is placed

inside a tungsten carbide structure.

• Most of the times being used for coring.

http://www.geoproduct-bg.com/
• Application for hard and abrasive rocks.

• Once diamonds are fractured or polished,

the bit is dull (as opposed to ID bit).

Not really!
• Sensitive to impact (diamond fracturing).
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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Drag Bits: PDC or PCD Bit

• Polycrystalline Diamond Compact (PDC) bits.

PDC layer

Tungsten
carbide
substrate

Important properties:
Abrasion and impact resistance.

http://www.pdcrecycling.com/

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Drag Bits: Steel Body vs Tungsten Carbide

Body

http://www.rock-drill-bit.com/

Tungsten Carbide
Body: Cutters are Steel Body: PDC cutters
welded to the body. pressed into a steel body.
(very rare)
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Detournay and Defourny (1993) 25

Drag Bits: PDC Bit

• Each cutter create a groove.

• For each cutter a normal and

tangential force is applied,

which are representative to

weight on bit and torque on bit

respectively.

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Drag Bits: PDC Bit

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Drag Bits: Properties

• Profile
• Back rake and side rake angles
• Shape and size of PDC cutters
• Abrasion resistance of PDC cutters
• Number of cutters and blades
Spiral Profile

Straight Profile
Different profile for steerability of the bit
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Drag Bits: Back-rake

Very high back-
Cutting direction rake angle

A PDC cutter

Back-rake angle:
The angle between normal
to cutting direction and
cutter.
Cutting mechanism is dominantly controlled by the back-rake angle. It is
typically between 12 to 15 degrees.

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Drag Bits: Back-rake

Example of Impact of Back-

Rake angle on the drilling

response:

Sinor et al. (1998)

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Drag Bits: Side Rake Angle Top View of Bit

Zero side-rake
angle
• Few degrees of side

rake angle help to

direct the cuttings to

the annulus,

improving the

cleaning in the front of Side-rake angle

the bit.

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PDC Cutter: Size, Shape and Angle

• Typically 12, 13 and 19 mm

• Available in other sizes.

• Mostly circular, but other types

used for research. http://vk.com/

• Have Chamfer angle and length.

http://www.pdccutters.com/

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Abrasion Resistance

• Abrasion resistance: The

resistance of the cutter for

development of wear flat area.

• PDC bit life has been prolonged

by improving the abrasion

resistance of the PDC cutters.

https://www.slb.com/

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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Impregnated Diamond Bits: Structure and

Applications
• Impregnated Diamond (ID) bit structure
• Diamond size (37 1000 )
• Bonding matrix (soft, medium, hard)
• Diamond concentration (7.5 25%)
• Diamond quality!

• Application:

• Hard sedimentary rock

• Hard and abrasive metamorphic and igneous rock

• Can be used with Downhole motors

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Impregnated Diamond Bits: Sharpening

Exposing sharp diamonds at the bit face.

At 0.77

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Hybrid Bits

http://www.ericsiegmund.com/

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Hybrid Bits

http://www.ericsiegmund.com/

http://www.drillingcontractor.org/

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Socrative In-class Quiz

Drilling Eng – Drilling bit P2

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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Bit/Rock Interaction

Two new variables are

defined, depth of cut and
tangential velocity.

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Depth of cut and Tangential Velocity

Thickness of rock removed

over one revolution.
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Depth of cut and Tangential Velocity

Travelling velocity of a cutter
2
Normal force
(related to
WOB)

Tangential
force (related
to TOB)

: depth of cut (bit, cutter)

: tangential velocity

100 to 1,000
Thickness of rock removed
by one PDC cutter.

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Depth of cut and Travelling Velocity

Travelling velocity
of a segment Travelling velocity
2 of a diamond
2

: depth of cut (bit, segment, diamond)

: tangential velocity

0.5 to 10

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Factors Affecting Drilling Process – Confining

Pressure

Traditional Perception of
Drilling Response

Scaled Weight on bit

Bit Diameter

Detournay et al. (2008)

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Factors Affecting Drilling Process – Confining

Pressure
Optimum operating
condition
Zone
dominated
by bit Cleaning
sharpness dominate
zone

Scaled Weight on bit

Bit Diameter

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Variation of Drilling Response at Different

Depth of Cut

Regime III
Regime II
Regime I
Scaled Weight on bit

Bit Diameter

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Rock Scratch Test

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Rock Scratch Test

400
y = 47.2x + 64.1
350
300
250
Fs (N)

200
150
100
50
0
0 2 4 6 8
Cutting Area (mm2)

300

250 y = 29.4x + 98.0

200
Fn (N)

150

100

50

0
0 2 4 6 8
Cutting Area (mm2)
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Bit vs Cutter Scale

Drilling Optimisation
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Bit vs Cutter Scale

Drilling Optimisation
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Factors Affecting Drilling Process – Confining

Pressure
• As confining stress 200

increases, rock
A xial s tres s, 1 (M P a)

150
exhibits a higher
1= 4.63 3+42.67
strength. 100
• Triaxial testing can
be used to 50
UCS = 42.6 MPa, C = 9.90 MPa, 40.28o
determine the
0
strength of the rock 0 5 10 15 20 25
at different Confining pressure, 3 (MPa)

confining stresses.

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Factors Affecting Drilling Process – Confining

Pressure Differential pressure:
The difference between
drilling fluid and pore
pressures

200
• Higher the drilling fluid
density, higher the
A xial s tress, 1 (M P a)

150
differential pressure and
1= 4.63 3+42.67
100 thus higher confining.
• The rock strength
50
UCS = 42.6 MPa, C = 9.90 MPa, 40.28o
increases with confining,
0 thus it is more difficult to
0 5 10 15 20 25
Confining pressure, 3 (MPa) drill the rock.

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Factors Affecting Drilling Process – Confining

Pressure

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Factors Affecting Drilling Process – Mud

Properties
Exercise Book:
To justify these trends.

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Research – Petroleum Engineering

Department Linear Actuator
Segment/rock
interaction Force sensor

Chuck
Tailstock

LVDT sensor
Rock sample

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Research – Petroleum Engineering

Department Rotary Drive
Load sensor Mechanism

Linear Actuator
LVDT sensor

Torque sensor
ID Bit

Fluid Tank Swivel and Pulley

System

Rock

Pump

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Outlines

• Why different type of bit?

• Roller Cone Bits

• Natural Diamond (Surface Set) Bits

• PDC Bits

• Impregnated Diamond Bits

• Factor Affecting Drilling Performance

• Drilling Optimisation – Cost Calculation

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Drilling Optimisation: Cost Per Foot Analysis

An example:

Which one do you choose??

Bit Bit cost Downhole ROP (ft/hr) Bit life

Motor cost ($) (ft)
PDC 60,000 NA 20 3,000
Bit
ID Bit 80,000 100,000 21 6,000
Roller 20,000 NA 22 1,000
Cone

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Drilling Optimisation: Cost Per Foot Analysis

Cost Equation, the solution:

where,
: Cost per foot drilled, $/ft
: Cost of bit (total), $
: Downhole motor cost, $
: Daily rate of drilling rig, $/day
: bit rotating time, day
: non-rotating time, day
: trip time, day
Δ : Distance drilled, ft

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Cost Per Foot Analysis: Tripping

Start of Reaching Reaching Trip out

Trip out
drilling to first trip Trip in to target

for trip New bit

out for
: for length of string length of for trip in
for length
drill string
of drill string
for trip
: for L out for
Δ length of length of
string drill string

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Cost Per Foot Analysis:

The drilling rig daily rate for an offshore rig is $500,000. The tripping-in and

out time is the same and equal to 3 hours per 1,000 ft, while the connection

time is 5 minute per stand (100 ft). Conduct the bit selection for drilling a

6000 ft interval using below bits:

Bit Bit cost Downhole ROP (ft/hr) Bit life

Motor cost ($) (ft)
PDC 60,000 NA 20 3,000
Bit
ID Bit 80,000 100,000 21 6,000
Roller 20,000 NA 22 1,000
Cone

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Cost Per Foot Analysis:

Bit Bit cost Downhole Motor ROP (ft/hr) Bit life (ft)
cost ($)
PDC Bit 60,000 NA 20 3,000
ID Bit 80,000 100,000 21 6,000
Roller 20,000 NA 22 1,000
Cone
PDC Bit:
6,000 ft
300 hrs
ft Δ
20
hr 5
6,000 300 5
100
@ 3000 @ 3000 @ 6000
3
3000 3000 6000 36
1,000

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Cost Per Foot Analysis:

Bit Bit cost Downhole Motor ROP (ft/hr) Bit life (ft)
cost ($)
PDC Bit 60,000 NA 20 3,000
ID Bit 80,000 100,000 21 6,000
Roller 20,000 NA 22 1,000
Cone
ID Bit:
6,000 ft
286 hrs
ft Δ
21
hr 5
6,000 300 5
100
@ 6000
3
6000 18
1,000

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Cost Per Foot Analysis:

Bit Bit cost Downhole Motor ROP (ft/hr) Bit life (ft)
cost ($)
PDC Bit 60,000 NA 20 3,000
ID Bit 80,000 100,000 21 6,000
Roller 20,000 NA 22 1,000
Cone
Roller cone:
6,000 ft
273 hrs
ft
22
hr

5
6,000 300 5
100

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Cost Per Foot Analysis:

Bit Bit cost Downhole Motor ROP (ft/hr) Bit life (ft)
cost ($)
PDC Bit 60,000 NA 20 3,000
ID Bit 80,000 100,000 21 6,000
Roller 20,000 NA 22 1,000
Cone
Roller cone:

@ 1,000 @ 1,000 @ 2,000 @ 2,000

@ 3,000 @ 3,000 @ 4,000 @ 4,000
@ 5,000 @ 5,000 @ 6,000
1,000 2 2000 2 3000 2 4000 2 5000 2 6000
3
108
1,000

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Cost Per Foot Analysis:

Bit Downhole ROP Bit life Number Cost

Bit
cost($) Motor ($) (ft/hr) (ft) of bit (hr) (hr) (hr) ($/ft)
PDC 60,000 NA 20 3000 2 300 5 36 1204
ID 80,000 100,000 21 6000 1 286 5 18 1103
Roller
20,000 NA 22 1000 6 273 5 108 1360
Cone

PDC bit Calculation:

500,000 300 5 36
2 60,000 0
24
Δ 6,000
1,204 $/

Cost of bit Rig cost

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References
Bourgoyne, A. T., Millheim, K. K., Chenevert, M. E., & Young, F. (1986). Applied
drilling engineering.

JONASSON, K., & MACK, C. (2009). Web page. Petroleum exploration, production
and development activity in Western Australia in, 12.

Mitchell, R. F., & Miska, S. Z. (2011). Fundamentals of drilling engineering.

Mostofi, M. (2015). Quality Control of Bentonite Samples of Australian Mud

Company. External report submitted to AMC.

Portwood, G., BOKTOR, B., MUNGER, R., QURAINI, K., MUTAIRI, B., & AZMI, B.
(2001). Improved-performance roller-cone bits for middle eastern
carbonates. Journal of petroleum technology, 53(12), 55-56.

Pusch, R., & Ramqvist, G. (2008). Borehole project-Final report of phase 3: Posiva
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