Proceedings of the ASME 2022 41st International

Conference on Ocean, Offshore and Arctic Engineering

OMAE2022
June 5-10, 2022, Hamburg, Germany

OMAE2022-79273

DRILLING PERFORMANCE EVALUATION THROUGH BIT CUTTERS RE-CONFIGURATIONS AND MICRO

FRACTURES INITIATION

Abdelsalam Abugharara1,2 Oluwafemi Tytler 1 Stephen Butt 1

Memorial University of Newfoundland, St. John’s, Newfoundland, Canada1

Sebha University, Sebha, Libya2

ABSTRACT Keywords: Drilling performance, micro fractures, ROP,

Drilling operations of petroleum wells are primarily hole opener, PDC bit.
applied to create channels through subsurface formations for
oil and gas production. For best drilling performance, drilling NOMENCLATURE
parameters including weight on bit (WOB), rotary speed in BHA Bottom-Hole Assembly
Revolutions per Minute (rpm), drilling Fluid Rates (FR), etc. CHO Coring Hole Opener
need to be applied optimally to enhance drilling performance, DHO Drilling Hole Opener
to reduce cost, and to minimize wear of downhole tools. In this FB Flat Base Bit
research, the drilling performance was evaluated based on LDS Large-scale Drilling Simulator
examining the Drilling Rate of Penetration (ROP) in granite PDC Polycrystalline Diamond Compact
blocks through changing the face of a multi diameter ROP Rate Of Penetration
Polycrystalline Diamond Compact (PDC) bit into three rpm, RPM Revolution Per Minutes
different design scenarios including the Flat Base bit (FB), WOB Weight On Bit
Drilling Hole Opener bit (DHO), and Coring Hole Opener bit
(CHO). All input drilling parameters were kept constant and 1. INTRODUCTION
the only variable was the bit configuration. Drilling Rate of Penetration (ROP) has been put under
The purpose of this research was to evaluate the change in research focus for decades. Numerous models have been
the ROP and to establish an investigation on why ROP varies developed for calculating and predicting ROP. ROP has also
when bit is reconfigured just by repositioning cutters. By been continuously emphasized as the key factor for drilling
linking the ROP variation to the bit configuration, a possible performance evaluation.
phenomenon of creating micro fracturing could be the reason Numerous factors are required to be also considered to
for the ROP enhancement. Taking the FB as a baseline, results have the ROP as a valid key of evaluating the drilling
showed an increase in ROP using DHO and CHO over FB bit. performance. These factors include optimal applications of
The idea behind this could lay behind initiating micro fractures drilling fluid flow rate for hole perfect cleaning, drilling
resulting a weaker rock portion by the 1st drill path to be drilled rotational speed, adequate of drill bit design and bit type and
by the upper part of the bit. configuration with the formation, analysis of rate of wear to the
Based on the averaged results, ROP of DHO increased by bit and Bottom-Hole Assembly (BHA), analysis of Mechanical
37.5 % at 5 kN and by 47.1 % at 10 kN. Similarly, the ROP of Specific Energy (MSE) consumed [1-6 ].
CHO increased by 12.5% at 5 kN and by 11.8 % at 10kN Conventionally, the factors that have been looked at as
indicating that initiation of micro fractures could play a role in main influence parameters that have direct effect on ROP
the enhancement of the ROP. include (i) Weight on Bit (WOB) applied at the surface and

1 © 2022 by ASME
transmitted to the bit through the entire drill string. (ii) Drill A fully instrumented Large-scale Drilling Simulator (LDS)
string rotational speed (Revolution Per Minutes: RPM that is was used for the drilling. The LDS, as an automated drilling
initiated at the rotary table at the surface and transmitted frame that utilized a Data Acquisition System (DAQ-SYS) with
through the drill string to the drill bit. (iii) Drilling fluid Flow a LabVIEW operating system that was used for drilling (Figure
Rate (FR) that is used to cool down, lubricate BHA, and 1).
circulate cuttings to the surface as well as allowing the bit to be The LDS that has a stroke of about 45 cm is equipped with
in a continuous contact with the fresh surface of the rock. These multiple sensors that enable recording a wide range of input
factors are fundamentals for achieving optimal drilling and output parameters including position of bit, applied WOB,
performance [1,2]. Efficiently, conducting a Drill Off Test torque, rpm, and axial oscillation.
(D.O.T) at the start of drilling new formation provides an
instant and reliable data set for the optimal input drilling
parameters, mainly the WOB to be applied for drilling the
entire encountered interval. Therefore, applying drilling
parameters optimally has a positive influence on the drilling
performance through the increase of ROP [4,5].
With the continuation of research on factors influencing
ROP, numerous studies reported that there is a long list of
parameters that either directly or indirectly influence ROP,
including (i) geological factors (formation strength, anisotropy,
abrasivity, etc.), (ii) bit and cutters design (bit geometry, teeth
dimensions and distributions, cutters shape and materials, etc.).
and (iii) mechanical factors of the drill string and BHA
(flexibility, rigidity) [6, 7, 8, 9].
More specifically, research reported a noticeable
contribution due to reconfiguring the PDC bit and the cutters on
the drilling performance in general and on the ROP in specific.
Gerbaud et al. (2006) [10] modeled numerous experimental
data and results of redesigning PDC cutters and reported
significant positive impacts of PDC cutters on improving ROP,
stabilizing the bit, and controlling the bit wear. Shao et al.
(2012) [11] investigated the effect of the chamfer of the PDC
cutter and reported the important role of considering it on
improving the cutter cutting efficiency and durability. Thomas
et al. (2021) [12] reported an improvement on drilling
performance through an enhancement of ROP via resizing PDC
cutters. Zhang et al. (2019) [13] reported the improvement of
ROP and life extension of PDC cutters via the implementation
of PDC Hollowed Cutters.
In the Drilling Technology Laboratory at Memorial
University of Newfoundland (DTL-MUN) intensive research
has been put on studying factors influencing ROP. These FIGURE 1: LARGE SCALE DRILLING SIMULATOR
studies have been covering various rock formation types from WHILE DRILLING GRANITE.
(i) shale, as vertically transverse isotropic rocks, (ii) granite as
The LDS is capable to provide up to 1000 rpm, 1200 Nm
natural isotropic impermeable rocks, (iii) sandstone as natural
torque and up to a 100kN applied axial force representing
permeable isotropic rocks, and (iv) various strengths of Rock
applied weight on bit through dual supporting systems of
Like Materials (RLM) as synthetic isotropic rocks [13-22].
pneumatic and hydraulic. The components of LDS shown in
The research of this paper focuses on the influence of
Figure 1 consists of (1) 1-Large-scale laboratory Drilling
reconfiguring the drill bit from Flat Base bit (FB) to (i) Drill
Simulator (LDS) frame, (2) drill string components (top to
Hole Opener (DHO) bit and (ii) Core Hole Opener (CHO) bit
bottom): swivel, pVARD, drill bit, (3) Sample holder setup for
on ROP. This study also investigates the possible phenomena
drilling under atmospheric pressure conditions, (4) a natural
of generating micro fractures by the advanced part of DHO and
granite rock block, (5) transparent plastic container for drilling
CHO that could weaken the residual portion of the rock to be
fluid and cutting flow control, (6) Data Acquisition System
drilled by the passive part of the bit.
with LabVIEW for automatic drilling operation, and (7) manual
operation controller and an automatic/manual switch key.
2. MATERIALS AND METHODS
This section covers the materials that were used in this 2.2 Drill bits
research. To provide equal and balanced alteration and change in the
drill bit configuration, three drill bits were used including (i) a
2.1 Large-scale Drilling Simulator

2 © 2022 by ASME
Flat Bottom or Flat Base (FB) bit, (ii) a Drill Hole Opener
(DHO) bit, and (iii) a Core Hole Opener (CHO) bit as shown in
Figure 2 top. Each bit of the three consists of two main parts:
an inner part, which is a 35mm dual cutter PDC bit and an outer
part, which is a 50.8 mm PDC coring bit. Both bit parts were
set at different levels to produce three-bit types shown in Figure
2 top.
For the case of the FB bit type, the bottom end of the inner
and the outer parts were set at the same level. In the case of the
DHO bit, the bottom level of the inner part was set in advance
to the outer part bottom level by about 25mm. In the case of the
CHO bit, the bottom level of the outer part was set in advanced
to the bottom level of the inner by about 20mm.
FIGURE 2: THREE DIFFERENT BIT CONFIGURATIONS
USED FOR DRILLING (TOP), GRANITE BLOCK
(BOTTOM).
Each reconfigured drill bit consisted of two main parts
including a 35mm dual-cutter PDC bit as an inner part and a
50.8 mm PDC coring bit as an outer part. Different length
sleeves were used to elevate the base of the outer part to match
the selected bit configuration between FB, DHO, and CHO.
2.3 Granite blocks
Granite was the rock type used for drilling tests. The
sufficient size of the granite rock blocks allowed drilling
multiple holes using all bit configurations and sets of WOB.
This granite was characterized to be isotropic rocks utilizing a
developed baseline procedure reported by Abugharara et al.
2016, 2017, and 2019 [11, 12, 14], indicating that its
mechanical and physical properties are orientation independent.
Further investigation on granite,
The dimension of granite blocks used for drilling in this
research was (~ 30cm long, ~ 30cm wide and ~ 15cm thick) as
shown in Figure 2 bottom.
3. EXPERIMENTAL METHOLOLOGY
As numerous research reported the positive influence of
the reconfigurations of bits and cutters on the drilling
performance, the idea of utilizing the DHO to more than a
guide as a hole opener to a tool be used for drilling
performance evaluation by examining its influence on ROP
became under focus. The idea involved two main stages
including (i) isotropic rocks without pre-existed fractures, in
which micro fractures could be generated via DHO or CHO,
and (ii) anisotropic rocks or rocks with pre-existed fractures,
whose fractures could be reactivated, and cracks could be
extended by DHO or CHO.
The isotropic granite without preexisted fractures was used
for rock source for drilling in this research as shown in Figure 2
bottom. As an initial step of evaluating the use of the
application of this research, three-bit configurations were
implemented including DHO, CHO, and FB. The drilling
performance evaluation used the FB as the base, which the
results of DOH and CHO were compared to.
3.1 Mechanical Specific Energy (MSE)
Mechanical Specific Energy (MSE) has been used
successfully in lab settings to evaluate the drilling efficiency
of bits [23]. It is the amount of energy needed to excavate one
cubic meter of rock. It is measured in psi, N/m2, or Pascal.
The MSE surveillance procedure allows for constant detection
of changes in the drilling system's efficiency.
Teale (1965) developed the methodology for calculating
MSE to ascertain drilling performance. Teale realized that
minimizing MSE meant doing the most excavation feasible,
which would result in the highest rate of penetration.
"Breaking the material into smaller bits than necessary' may
have a disproportionate influence on the energy needed to
extract the given volume," he said of rotary drilling. This
means that breaking rocks into smaller pieces than needed for
excavation would take more energy than necessary, while
breaking rocks into pieces too large for evacuation would
require energy to rebreak. Teale’s MSE equation is based on
the combination of two components. Teale's MSE equation is
as follows [24]:
For thrust components, Specific Energy
WOB
=
Area of Bit ( A B )
For rotary components, Specific Energy
2 π × RPM ×TOB
=
Area of Bit ( A B ) × ROP
Combining both equations, MSE is derived as,
3 © 2022 by ASME
 WOB 2 π × RPM ×TOB
MSE = +¿
Area of Bit ( A B ) Area of Bit ( A B ) × ROP

Where;
MSE = Mechanical Specific Energy, (Pa)
WOB = Weight on Bit, (N)
AB = Bit Area, (m2)
TOB = Torque on Bit, (N-m)
ROP = Rate of Penetration, (m/hr)
RPM = Revolution per Minute, (rpm)

4. RESULTS AND DISCUSSION

This section covers the results of drilling granite blocks
using three different drill bit types at two main sets of WOB.
These two sets of WOB were used only for evaluating this
research ideology at first, considering wider and higher WOB
increments in the future. The drilling performance was
evaluated based on the resultant rate of penetration (ROP) and
was categorized based on bit type (FB, DHO, or CHO) and the
WOB. The ROP was calculated by dividing a drilled interval by
the required time for drilling each interval. Figure 3 shows an
example of the procedure of calculating ROP from data
recorded by the bit position sensor for D1-1 and D1-2, which
represent a first run of the FB bit at 5kN and the second run of FIGURE 4: INDIVIDUAL ROP RESULTS USING FB BIT
the DHO bit at 10kN, respectively. VS. DHO BIT AT 5KN (TOP) AND 10KN (BOTTOM).

ROP results shown in Figure 4 are averaged and presented

in Figure 5. The averaged ROP using FB bit type vs. DHO bit
type at 5.7kN as shown in Figure 5 top was 0.08m/hr vs.
0.11m/hr., respectively, showing ROP increase using CHO over
FB by a 37.5%. The averaged ROP using FB bit type vs. DHO
bit type at 10.6kN as shown in Figure 5 bottom was 0.17m/hr
vs. 0.25m/hr, respectively, showing ROP increase using DHO
over FB by 47.1%.
The initial indications of the ROP increase could be related
to the effectiveness of the bit and cutter reconfigurations that
could have led to generating micro fractures in the undrilled
part of the rock. Such initiation of the micro fractures could
lead to weaken the rock part to be drilled by the second pass of
the drill bit.

FIGURE 3: PROCEDURE OF CALCULATING ROP.

Figure 4 (top) shows individual results of ROP obtained from

using FB bit against DHO bit applying WOB = 5kN. Results
show that each individual drilling ROP by DHO is higher than
that of using FB bit. Zero intersect linear relationships were
also established. Figure 4 (bottom) shows individual results of
ROP from using FB bit against DHO bit applying WOB =
10kN. Results show ROP were higher using DHO than that of
using FB bit.

4 © 2022 by ASME

FIGURE 5: AVERAGED ROP RESULTS USING FB BIT
VS. DHO BIT AT 5KN (TOP) AND 10KN (BOTTOM).
FIGURE 6: AVERAGED ROP RESULTS USING FB BIT
VS. CHO BIT AT 5KN (TOP) AND 10KN (BOTTOM).
The averaged ROP resulted from using FB and CHO
applying two sets of WOB are presented in Figure 6. The
averaged ROP using FB bit vs. CHO bit at 5.5kN as shown in
Figure 6, top was 0.08m/hr vs. 0.09 m/hr. Such change in ROP
showed a 12.5% increase in ROP using CHO over FB at 5.5kN
applied WOB. Moreover, the averaged ROP using FB bit vs.
CHO bit at 10.5kN as shown in Figure 6, bottom was 0.17m/hr
vs. 0.19 m/hr. Such change in the ROP showed an 11.8%
increase in ROP using CHO over FB.
The increase in ROP due to the bit reconfiguration could
be of a support to the published reports that indicated the
importance of bit cutters on enhancing ROP and therefore
improving the overall drilling performance.
Table 1 summarizes the averaged ROP results obtained
from all drilling tests. When using FB bit as a bit base, the
results show increase in ROP when using DHO and CHO
against FB. Such increase could be related to bit
reconfiguration from FB to DHO and CHO the way could assist
in generating micro fractures that could weakened the portion
of the rock that was drilled by the first pass of the bit.
TABLE 1: PERCENTAGE INCREASE IN ROP BASED ON
DRILL BIT TYPE USED AND WOB APPLIED.
ROP (m/hr)
WOB (kn)
FB DHO CHO Increase %
5.7 0.08 0.11 37.5
5.5 0.08 0.09 12.5
10.6 0.17 0.25 47.1
10.5 0.17 0.19 11.8
Figure 7 shows the general trend of the relationship
between the resultant torques with ROP, which supports the
positive relationship between torque and ROP. The positive
relationship that indicates the increase in the torques can be
considered as a response to the increase in ROP. Such increase
signifies a greater bit-rock-interaction that results in the
increase of ROP and resultant torque.
FIGURE 7: GENERAL RELATIONSHIP OF TORQUE
VERSUS ROP.
Figure 8 shows the result of the MSE, and ROP obtained
from using the FB BIT when 5kN and 10kN WOB were
applied. From the graph, ROP increases as WOB increases
from 5kN to 10kN. The result show that the MSE is inversely
proportional to the ROP which indicates that the higher the
ROP, the lower the specific energy required to drill through the
granite block therefore there is an increase in drilling efficiency.
ROP increased from 0.08m/hr when 5kN is applied to 0.17m/hr
5 © 2022 by ASME
when 10kN is applied. The MSE decreases from 291.07MPa to
235.73MPa and a 19% reduction in specific energy is ROP, m/hr -CHO Bit
actualized while using the FB bit. Linear (ROP, m/hr -CHO Bit)
MSE, MPa -CHO Bit
Linear (MSE, MPa -CHO Bit)
0.20 300
ROP, m/hr-FB Bit
Linear (ROP, m/hr-FB Bit) 250
0.15
MSE, MPa - FB Bit 200
Linear (MSE, MPa - FB Bit)

ROP, m/hr

MSE, MPa
0.10 150
0.20 350
100
300 0.05
0.15 250 50
200 0.00 0
ROP, m/hr

00 000 000 000 000 000 000

MSE, MPa
0.10
150 50 6 7 8 9 0
100 WOB, N 1 11
0.05
50 FIGURE 10: AVERAGED MSE RESULT USING THE CHO
0.00 0 BIT AT 5KN AND 10KN.
00 000 000 000 000 000 000
50 6 7 8 9 10 11 MSE results obtained in Figure 10 follows the consistent
WOB, N trend as observed in the FB and DHO bits. MSE decreases from
FIGURE 8: AVERAGED MSE RESULT USING FB BIT AT 273.5MPa (5kN) to 242.74MPa (10kN) while the ROP
5KN AND 10KN. increased from 0.09m/hr to 0.19m/hr. This is a more efficient
drilling than the FB bit but not as efficient as the DHO bit. It
was observed that there was a 11.2% reduction in the specific
ROP, m/hr -DHO Bit energy that was required for drilling when the WOB was
Linear (ROP, m/hr -DHO Bit) increased from 5kN to 10kN.
MSE, MPa -DHO Bit
0.30 300
MSE, MPa - FB Bit
0.25 250 MSE, MPa -DHO Bit
0.20 200 Linear (MSE, MPa -DHO Bit)
MSE, MPa -CHO Bit
ROP, m/hr

MSE, MPa

0.15 150 Linear (MSE, MPa -CHO Bit)

0.10 100 300
0.05 50 250
0.00 0 200
MSE, MPa

0 0 0 0 0 0 0 0 0 0 0 0 0 0 150
50 60 70 80
WOB, 90 100 110
N
100
FIGURE 9: AVERAGED MSE RESULT USING THE DHO
BIT AT 5KN AND 10KN. 50
0
The averaged MSE results obtained in Figure 9 shows a 5000 10000 15000
further reduction in the mechanical specific energy from WOB, N
238.76MPa to 165.35MPa utilized in drilling the granite block FIGURE 11: AVERAGED MSE RESULT OF THE
as the ROP increases from 0.11m/hr to 0.25m/hr while using INDIVIDUAL FB-BIT, DHO-BIT, CHO-BIT.
the DHO bit. From the results, the DHO bit would provide the
most drilling efficiency as it requires the least specific energy. A Figure 11 shows the averaged MSE result for each
reduction in energy consumed of 30.7% is obtained when WOB individual bit configuration. The averaged MSE using the FB
is increased from 5kN to 10kN. bit type vs. DHO bit type at 5kN was 291.07MPa and
238.76MPa respectively, indicating that the MSE reduced by
18%.
The averaged MSE using the FB bit type vs. DHO bit type at
10kN was 235.73MPa and 165.35MPa respectively, indicating
that the MSE reduced by 29.8%.
Also, for the FB bit type vs. CHO bit type at 5kN was
291.07MPa and 273.50MPa respectively, showing a reduction
in MSE by 6%. Upon applying 10kN, a 2.9% increase in MSE
is observed which could be because of vibrations.

6 © 2022 by ASME
 Figure 12 shows the general trend of the relationship
between the ROP and the WOB, thereby corroborating the
theoretical relationship between ROP and WOB. It is expected
that the ROP will increase with an increasing WOB. For each
individual bit configuration, the FB bit type, DHO bit type,
CHO bit type, the trend is observed.
ROP, m/hr-FB Bit
Linear (ROP, m/hr-FB Bit)
ROP, m/hr -DHO Bit
Linear (ROP, m/hr -DHO Bit)
0.30
0.25
0.20
ROP, m/hr
0.15
0.10
0.05
0.00
5000 6000 7000WOB,
8000N 9000 10000 11000
FIGURE 12: AVERAGED ROP RESULT FOR
INDIVIDUAL FB-BIT, DHO-BIT, AND CHO-BIT AT 5KN
AND 10KN.
5. CONCLUSION
Laboratory experiments were conducted on drilling granite
blocks using different PDC bit configurations. The purpose of
the experiments was to investigate the influence of varying the
configurations of bits on the drilling performance through the
calculated ROP.
When the applied drilling parameters were the same, the
results showed an increase in ROP as a response of the increase
of WOB when bit configurations modified from FB bit type to
DHO and CHO.
MSE is an indicator used to quantify drilling efficiency as
well as optimize the ROP. In this study, three different bit
configurations were analyzed namely, FB bit type, DHO bit
type, and the CHO bit type and their influence on drilling
performance was observed.
From results obtained, the MSE is inversely proportional to
the ROP, which corroborates the expected theoretical trend. The
DHO bit type provides the best drilling efficiency amongst the
three-bit configurations as it produces the highest ROP while
utilizing the least amount of energy for drilling. The CHO bit
type provides a better drilling efficiency than the FB bit type
but not as efficient as the DHO
The work of this paper, with all positive results requires
continuation research and more investigation for validation,
development, and implementations with more values of input
drilling parameters including WOB and rpm.
FUTURE WORK
Although, the results of this research are promising in term
of ROP increase using different bit configurations, the results
are still initial, and they require intensive follow up tests and
experiments for validation.
Using the same bit configurations, other rock types
(isotropic rocks are recommended), comparative ROP analysis
should be constructed and reported based on the initial results
reported in this work.
ACKNOWLEDGEMENTS
This research is funded by Atlantic Canada Opportunity
Agency (AIF contract number: 781-2636- 1920044), involving
Husky Energy, Suncor Energy and Research and Development
Corporation (RDC) of Newfoundland and Labrador.
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