PDC

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 Module Objectives
Upon completion of this module, you will be able to:
• Identify the parts and components of the PDC product line.
• Discuss the characteristics of a PDC Cutter and their effect on drilling
performance.
• Identify the effects of stability, hydraulics design and gauge design on
the bit selection process.
• Identify the matrix and steel body bit assemblies along with the torque
management feature product offerings
• Distinguish the PDC bits based on individual damage, using the dull
grading criteria and characteristics.

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 Module Overview
This module consists of the following lessons:
• PDC Bit Design
• PDC Cutters
• Stability, Hydraulics, and Gauge
• Products and Manufacturing
• Dull Grading

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 Lesson Overview
This lesson consists of the following topics:
• PDC Bit Structure
• Matrix Body Bits
• Steel Body Bits
• PDC Bit Profile
• PDC Cutter Positioning

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 PDC Bit Structure

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 Shank
• High alloy, heat treated steel (4140)
• API regular connection
• Breaker slots
• Identification slots

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 Blank

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 Crown- Cutting Structure

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 PDC Side View

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 PDC Bit Body Material- Tungsten Carbide
Matrix (WC)

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 Grades of Matrix
Red - High toughness, low erosion
resistance
• Yellow - Medium toughness, medium
erosion resistance
• Black - Lowest toughness, highest
erosion resistance
• Common bit make-up
– Yellow body matrix (toughness) with
black face powder (erosion resistance)

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 Tungsten Carbide Matrix- Advantages and
Disadvantages
Advantages Disadvantages
Mold process allows casting Low impact strength
complex shapes High cost
Minimizes erosion and abrasive
wear

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 Steel Body PDC Bit Advantages
Steel body PDC bits have two
major advantages over
matrix. The steel body alloy:
1. Allows engineers to design
bits with greater blade
height (blade standoff)
2. Has thinner blades without
compromising blade
durability

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 Steel Body Bit Manufacturing- Hardfacing

Typically, hardfacing is applied to: The front of the blades, in between

the cutter pockets, behind the cutter pockets, and on the gage pad.

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 Steel Body PDC
Benefits:
• Stronger blades
Risks:
• Abrasive formations
• High percentage of Ringouts with matrix PDC bits
• High fluid erosion or poor sand control

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 Steel Body PDC- Applications
• High ROP desired
• Soft, Non-abrasive Drilling
• High Probability of Balling
• Low HSI Applications
• Surface Intervals
• Blade Breakage on Matrix Bits

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 Bit Profile
• The profile is used to optimize bit performance.
• The objective is to optimize bit stabilization and balance wear to the
cutting structure.

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 Profile Components

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 Purpose of the Profile
• The volume of rock removed
(VORR) is a function of
—Cutter position (radius)
—Depth of cut
—Width of cut
• Direct relationship between the
volume of rock removed and the
work rate of a cutter

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 PDC Bit Profile Types
• Used on Baker Hughes PDC bits
today
• Comprised between short and
long profiles
• Maximizes cutter count without
giving up too much stability
• Best suited for most applications
• Medium nose location and cone
area. Relatively long shoulder

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 Back Rake
Measured from vertical the smaller the back rake angle the more
aggressive the cutter.

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 Side Rake
Siderake determines the angle cutter’s face makes with a radial line
from the bits center.

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 Lesson Summary
You have now completed PDC Bit Design, which consisted of the
following topics:
• PDC Bit Structure
• Matrix Body Bits
• Steel Body Bits
• PDC Bit Profile
• PDC Cutter Positioning

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 Lesson Overview
This lesson consists of the following topics:
• Polycrystalline Diamond Compacts (PDC)
• Cutter Properties
• Cutter Size
• Cutters and Rock Hardness

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 Polycrystalline Diamond Compact (PDC) Cutter

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 Basics of Diamond Manufacturing

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 PDC Cutter Assembly
• Pre-made synthetic diamond
• Pre-made tungsten carbide substrate
• High Temperature High Pressure (HTHP) process

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 PDC Cutter Properties
The toughness or durability of a cutter is dependent on two factors:
• Impact resistance
• Abrasion resistance

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 Diamond Table

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 Diamond/Carbide Interface

Non-planar interface
Residual stress reduction

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 Edge Geometry
• Cutting Efficiency
• Significant effect on ROP
• Wider the chamfer, the greater the resistance to chipping
– wider chamfer will cause slower rate of penetration

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 Polished Cutters
• Standard features
• Baker Hughes Patent
• Low Coefficient of Friction
—Conventional PDC
• Brake pads
—Polished PDC
• Ice on ice

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 PDC Cutter Sizes

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 PDC Cutter Size versus Bit Size

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 PDC Cutters and Rock Hardness

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 Lesson Summary
You have now completed PDC Cutters, which consisted of the
following topics:
• Polycrystalline Diamond Compacts (PDC)
• Cutter Properties
• Cutter Size
• Cutter Size Versus Bit Size
• Cutters and Rock Hardness

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 Lesson Overview
This lesson consists of the following topics:
• Bit Stability
• Hydraulic Design
• Gauge Design

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 Bit Stability
Primary Stability - Bit Design:
• Flatter profiles, Larger cone
• Greater back rakes, larger cutter chamfer in outer rows
• High Imbalance design
• Tracking cutter layouts – kerfing and low imbalance design

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 Primary Stability

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 Low Imbalance Design
• Low as possible
• Deviate from “ideal motion”

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 High Imbalance Designs
• Laid out so that a high imbalance force is generated.
• Used to be known as Antiwhirl.
• Design guidelines: Usually force 15% of WOB.
• A low friction area is created.

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 Secondary Stability

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 Hydraulic Design
The fundamental objective of any
hydraulic design is to efficiently utilize
the available hydraulic energy to
provide optimum cleaning and
cooling.

Cuttings Removal- Cleaning

Maximum ROP without balling

Cutter Cooling
Keep the velocity of drilling fluid
within an acceptable range at the
face of each cutter

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 Computational Fluid Dynamics (CFD)
The CFD measurements for an optimized hydraulic design are:
• Particle Residence Time (also referred to as “cuttings transport”) is
the relative time that is required for particles released into the flow
field from each cutter and nozzle to exit junk slots.
• Balanced flow is achieved by matching fluid flow volume with
cuttings volume in each blade/junk slot pair.

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 Nozzles

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 Gauge Pad
The stabilizing section of the bit.

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 Standard Gauge/Undercut Design
• Standard gauge pad diameter for the majority of PDC bit designs
• clearance between the borehole wall and gauge pads.

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 Spiral Gauge Pads

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 Gauge Protection Options

There are several materials that are used in the gauge pad for
protection, and in some cases, for directional purposes. The most
common options available are the
• Matrix body gauge
• Steel body gauge
• PDC gauge

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 PDC Gauge Option

• In-gauge PDC cutters

• Flush mounted on leading edge
• Extra durability for applications that prematurely wear a conventional
TCI/ND gauge

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 Gauge Length Options

Bit Size Range Standard Gauge Length

≤ 5.001 2.0 in.
5.001 - 9.000 2.5 in.
9.001 - 13.000 3.0 in.
13.001 - 18.000 3.5 in.

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 Updrill Options

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 Lesson Summary
You have now completed Stability, Hydraulics, and Gauge, which
consisted of the following topics:
• Bit Stability
• Gauge Design
• Hydraulic Design

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 Lesson Overview
This lesson consists of the following topics:
• Matrix Body Bit Manufacturing
• Steel Body Bit Manufacturing
• Depth of Cut Control

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 PDC Bit Manufacturing
Five Steps:

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 Steel Body Bit Manufacturing- Crown Milling

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 Steel Body Bit Manufacturing- Shank Attachment

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 Steel Body Bit Manufacturing- Hardfacing
Typically, hardfacing is applied to: The front of the blades, in between
the cutter pockets, behind the cutter pockets, and on the gauge pad.

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 Steel Body Bit Manufacturing- PDC Cutter
Attachment

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 Steel Body Bit Manufacturing- Final Inspection

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 DOC Technology

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 EZSteer Effect

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 Lesson Summary
You have now completed Products and Manufacturing, which consisted
of the following topics:
• Matrix Body Bit Manufacturing
• Steel Body Bit Manufacturing
• Depth of Cut Control

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