ONYX 360

Rolling PDC cutter

ONYX 360 Rolling PDC Cutter

Applications

Drilling conditions that cause and

accelerate PDC cutter wear
Abrasive environments

Benefits

Extends bit durability

Increases run footage and average ROP

Improves thermal dissipation to extend

cutter life

Features

360 revolution capability allows cutter to

stay sharper longer
Number and placement of cutters can be
customized to maximize durability in bit
cutting structures high-wear areas
Can be integrated into any PDC bit cutting
structure without changing cutter size
Available in 13-mm and 16-mm sizes

The next revolution in PDC

cutter durability
The ONYX360* rolling PDC cutter substantially increases PDC bit
durability by revolving 360. Strategically positioned in the highest wear
areas of a bits cutting structure, the rolling cutters entire diamond edge
is used to shear the formation. The cutters rotating action allows the
diamond edge to stay sharper longer, extending ONYX360 cutter life far
beyond that of premium fixed cutters.

When compared with bits that only

have fixed cutters, PDC bits that
included ONYX360 rolling cutters
demonstrated run length increases
of up to 57%.

Microscopic inspection of PDC cutters

enabled analysis of diamond edge wear after
running cutters on test formations.

Revolving edge advances PDC cutter durability

Challenge

Development

Simulation

Evaluation

Results

Improve PDC
cutterdurability:

Explore new cutter designs:

Undertake cutter analysis

using IDEAS* integrated
drillbit design platform:

Conduct extensive testing:

Quantified ONYX360
rolling cutters
effectiveness and
durability:

Extend cutter life in

high-wear applications
Employ the cutters
entire diamond edge to
minimize wear
Sustain a bits
initialhigh ROP

Determine feasibility
of a more robust cutter
system
Investigate the
functionality of dynamic
cutters
Analyze cutting forces
that generaterotation

Identify which fixed

cutters to replace
Optimize orientation
and placement of rolling
cutters in PDC bitblade

Measure durability
increases of rolling
cutter
Assess strength of
dynamic PDC cutter
system
Confirm 360 rotation
of cutter

Increased cutter
durability
Increased ROP up to
44%
Extended run lengths up
to 57%

Cutters diamond edge goes largely unused

The introduction of PDC cutters in the 1970s permanently changed well
construction programs. Now, they are readily accepted as the workhorse
cutting element of the drilling industry, accounting for over 80% of the
total footage drilled in oil and gas wells worldwide.

Despite their dominance, fixed PDC cutters have an inherent limitation:

Most of the cutters edge is fixed into the bit blade, limiting contact
with the formation. Accordingly, more than 60% of the cutters
circumferential edge goes unused during a bitrun.

Cutter used 10 to 40%

Cutter unused 60 to 90%

er
d cutt
e
s
u
n
U

e
g edg
Cuttin

Challenge

More than 60% of a fixed PDC cutters

diamond edge goes unused (green) during
a bit run, leaving only 10 to 40% of the
edge (red) to cut the formation.

Fixed cutter design limits cutter potential

The part of a fixed cutters edge that engages
the formation is subjected to mechanical and
thermal effects that cause wear and chipping.
This concentrated degradation on a small
percentage of the cutters edge results in
loss of shearing efficiency, slowing the rate
of penetration. In addition, bit durability is
substantially reduced, resulting in shorter
bitruns.
Using a rolling PDC cutter would increase
durability by ensuring that the part of the
cutters edge making contact with the
formation is continually refreshed to stay
sharper longer. In addition, the rotating action
would improve thermal dissipation preventing
concentrated heatbuildup.

NT11

+3.710e+02
+3.568e+02
+3.425e+02
+3.282e+02
+3.140e+02
+2.998e+02
+2.855e+02
+2.712e+02
+2.570e+02
+2.428e+02
+2.285e+02
+2.142e+02
+2.000e+02

Fixed PDC Cutter

A dull photo (left) illustrates the degree of wear a fixed cutter incurs and where it is most concentrated.
Finite element analysis (FEA) modeling software depicts the amount of frictional heat generated by a fixed
cutter (right), with concentrated heat buildup in red.

In an analysis of over 45,000 PDC bit runs, 60% of dull grade characteristics were identified
as worn and chipped cutters, conditions that shorten cutter life and result in lower ROP
and premature bit trips.

Challenge

Inventive design increases cutter life

Integrating a rolling cutter into a PDC bits
cutting structure required a novel and robust
design. Smith Bits R&D engineers developed
a cutter system composed of a housing that
is brazed into the bit blade, and within which
a sleeve encloses and completely secures the
cutter while allowing it torotate.

The ONYX360 cutters shaft

is fully contained within an
integrated housing to ensure
continuous rotation and cutter
retention during drilling.

The rolling cutters orientation in

the bit blade, relative to its contact
with the formation and the bits
drilling force, drives efficient
rotation of the cutter.

Durability analysis includes mounting PDC

cutters in a test fixture and running them
on formation samples.

Development

Cutter durability advances to a new level

To compare the new rolling cutter with a
premium PDC fixed cutter, durability tests
were conducted in which both cutters
were mounted on test fixtures to engage a
granite test formation with an unconfined
compressive strength of30,000psi.

ONYX360 cutters
Premium fixed cutters

1,200

1,000
Average vertical force, lbf

To maintain a constant ROP, the vertical force

required for premium fixed cutters had to be
continually increased from 100 lbf to over
1,200 lbf to compensate for their wear rate.
ONYX360 rolling cutters required
substantially less force, confirming that the
cutter was remaining sharp for the complete
test interval.

1,400

800

600

400

200

0
0

100

200

300

400

500

600

Number of cutting passes

When compared with premium fixed cutters, ONYX360 cutters required far less additional loading force as
drilling progressed, indicating improved cutting durability.

Development

700

Premium fixed cutter

Comprehensive evaluation validates rolling concept

90

The wear that fixed cutters incur is concentrated on a small percentage

of the cutters entire diamond edge. As a result, after 90 passes on a test
formation, premium fixed cutters developed extreme wear flats. Because
100% of the ONYX360 rolling cutters diamond edge engaged the test
formation, wear was evenly distributed and resulted in virtually no wear
after 300 passes and very little wear after 540 passes.

ONYX360 cutter

120

50

100

300

150

200

250

300

480

350

400

540

450

500

550

600

Rock cutting passes

Development

IDEAS platform
determines cutter
integration
Upon completion of laboratory testing, bit
design engineers entered the ONYX360
cutters design in the IDEAS platform.
This step enabled engineers to integrate
cutters into the PDC bits cutting structure.
Integration was determined by examining
the effect different geometric orientations
had on three cutter characteristics: durability,
appropriate balance of driving force,
andaggressiveness.

The IDEAS drillbit design platform

enabled engineers to optimize
placement of the rolling cutters on bit
blades to ensure reliable cutter rotation.

Simulation

By analyzing the highest wear areas of cutting

structures on PDC bits with only fixed cutters,
design engineers were able to identify where
ONYX360 cutters should be positioned on bit
blades to optimize cutter life and bit durability.

In abrasive formations, the bits shoulder

area (between the center of the
cutting structure and gauge) typically
experiences the greatest amount of cutter
wear. The ability IDEAS drillbit design
platform has to predict the degree and
precise location of this wear makes it an
essential design tool.

0.12
Wear Flat Area, in2

Drilling force
analysis optimizes
cutter placement

Wear Flat Area After 150 hours

0.14

High wear area

0.10
0.08
0.06
0.04
0.02

ONYX360 cutters
Premium fixed cutters

0
0

0.5

1.5

2.5

3.5

Distance from bit center, in

Using IDEAS design platform enables

fixed cutters, in the highest wear areas
of a PDC bits cuttingstructure, to be
selectively replaced with ONYX360
rolling cutters.

0.5

1.5

2.5

3.5

Distance from bit center, in

Simulation

Rotating action greatly extends cutter life

For the most direct comparison, ONYX360
rolling cutters were fitted to a PDC bit blade
next to premium fixed cutters. After drilling
an 1,800-ft horizontal section in abrasive
sandstone, both cutter types were compared:
The dull condition of neighboring fixed cutters
graded poor, while the rolling cutters were
in excellent condition. This resulting low and
uniform wear provided evidence that rotation
had taken place, and using ONYX 360 rolling
cutters in the shoulder area would increase
drillbit durability.

aA

cC

bB

dD

ONYX360 cutters (A-D) showed virtually no sign of wear (dull grade T0) compared with the adjacent fixed
cutters (dull grade T1 and T2).

Evaluation

B
C

Dull bit with ONYX360

cutters after drilling 1,800ft
through abrasive sandstone in
160hours.

Evaluation

Case Study

Chesapeake Energy Improves Footage per Bit and ROP in

Abrasive Formation with ONYX 360 Rolling PDC Cutters
The operator deployed bits with 16-mm rolling cutters to increase
bit run length and ROP compared with 13-mm rolling-cutter and
fixed-cutter bits, Oklahoma

Results

Challenge

Solution

Results

Improve footage and ROP per

bit while drilling horizontal
laterals in Oklahomas abrasive
Colony Wash play.

Deploy bits fitted with 16-mm

ONYX 360 rolling PDC cutters
to maintain an efficient cutting
structure for improved run
length and ROP.

Increased footage and ROP

across three wells in the same
play. Drilled the highest ROP
for a Colony Wash lateral
using 16-mm rolling PDC
cutter bits.

Average Footage, ft

Average ROP, ft/hr

2,500

25

Fixed cutters
13-mm ONYX 360 cutters
16-mm ONYX 360 cutters

2,000

20

1,500

15

1,000

10

500

0
2012

2013

2014

2015

Since 2009, Chesapeake has deployed various fixed

and rolling cutter types in the Colony Wash play.
Upon introducing 16-mm ONYX 360 cutters in 2015,
the operator increased both footage and ROP (data
averaged across 6 runs using the new cutters).

2012

2013

2014

2015

Results

Case Study

Chesapeake Energy Increases Run Footage and

Reduces NPT in Intermediate Section, Onshore Louisiana
The operator gained an additional 1,500 ft of bit life in the highly
abrasive Hosston Sands and Cotton Valley Lime with 16-mm ONYX
360 rolling PDC cutters
I think we have some significant
opportunity to make this intermediate
hole section a consistent two-bit
section. Depending on what we can
do with ROP, this may develop into a
one-bit hole section like we aspire to
in most of our other plays.
Greg Bruton
Drilling Advisor
Chesapeake Energy

Results

Challenge

Solution

Results

Increase run footage by

1,500 ftto at least 9,500-ft
MDwith one bit to enable
running a more aggressive
bit to complete the lower
intermediate section for
improved overall ROP.

Use the IDEAS platform to

determine the optimal bit
design for the application;
deploy 16-mm ONYX 360
rolling PDC cutters for
improved wear and extended
cutter life.

Increased run footage to

reduce an unnecessary bit trip
in the intermediate section
with increased overall ROP
and less rig NPT associated
with drillout (DO) runs.

Offset Pad
Well 1
Fixed Cutter
DO Run

Offset Pad
Well 2
Fixed Cutter
DO Run

Offset Pad
Well 3
Fixed Cutter
DO Run

ONYX 360 Cutters ONYX 360 Cutters ONYX 360 Cutters

Well A
Well B
Well C
DO run
DO run
DO run

An 83/4-in bit fitted with ONYX 360 cutters

outperformed conventional PDC bits with similar
drilling parameters in the same formation.

62.5
h

69.0
h

101.5
h
60.0
6,095 ft/h
ft

5,864
ft

85.0
ft/h

4,496
ft

Drilling
Parameters

47.4
ft/h

48.5
ft/h

48.6
ft/h

71.5
ft/h
8,075
ft

166.5
h

7,892
ft

166.5
h

8,062
ft

166.0
h

ONYX 360
Cutter DO
Section
Depth in, ft
1,850
Depth out, ft
9,80010,000
Section length, ft 7,8008,000
Drilling time, h
150170 (on
bottom)
Dull grade
2-3-BT-S-XXXIN-WT-BHA
Water-base mud, 9.010.5
lbm/galUS
ROP, ft/h
4555

Lower
Intermediate
Section
9,500
11,000+
1,800
3040
2-2-WT-S-XXXIN-WT-TD
9.010.5
3040

Results

Case Study

ONYX360 Cutter Increases PDC Bits Run Footage

57% in Granite Wash Formation, Texas
Bit with rolling cutters drills 1,562 ft of a 5,113-ft,
618-in lateral gas well section at 25 ft/h

Results

Challenge

Solution

Results

Drill 618-in lateral gas well

sections of at least 5,000 ft
through abrasive reservoir
sand, which caused some
fixed-cutter-only PDC bits to
be replaced after drilling less
than 65 ft.

Run a 618-in MSiR613 PDC bit

fitted with seven ONYX 360
rolling PDC cutters positioned
in the areas of the bits cutting
structure with the highest
predicted wear.

Drilled 1,562 ft of a 5,113-ft,

618-in lateral gas well section
at 25 ft/h using a bit with
rolling cutters, which when
compared with the best
drilling performances in the
same formation by fixedcutter-only bits, increased ROP
44% and footage drilled 57%.

11,000

Depth, ft

12,000
13,000

MSiR613

MSi613

MSi713

MSi613

Other bit

MSi611

Other bit

Other bit

25

30
25

17

1,562
540

15

996

14,000

14

13

10
495

15,000

15

63

10
7

115

675

667

16,000
Depth in

ONYX360 bit

20

Smith Bits PDC bits

Other bits

ROP, ft/h

10,000

The 6 18-in MSiR613

PDC bit drilled a 1,562 ft
lateral in the hard
and abrasive Granite
Wash formation. When
compared with the
best performance by
a bit with only fixed
cutters drilling the same
lateral well, the PDC bit
with ONYX360 rolling
cutters reported an
average ROP increase
of 44% and a run length
increase of57%.

ROP

Results

ONYX 360

Rolling PDC cutter

Find out more about ONYX360 rolling PDC cutter technology at

slb.com/ONYX360

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Copyright 2015 Schlumberger. All rights reserved. 15-BT-27703