OTC-26421-MS

Innovative Conical Diamond Element Bits Deliver Superior Performance

Drilling a Geothermal Well in the Philippines
Farah Farhana Iskandar, Davide Fanti, and Tan Tai Liang, Schlumberger

Copyright 2016, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference Asia held in Kuala Lumpur, Malaysia, 22–25 March 2016.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Developing reserves in the southern Negros, Philippines, requires the operator to drill through volcanic
formations known for their abrasiveness and high unconfined compressive strength (UCS). Efficient
penetration with conventional bits through the volcanic rock, which contains silicified andesitic tuff,
breccia, quartz, chert, and pyrites, historically has been very challenging. Typically, when a bit encounters
the hard formation, the strong impact exerted on the bit induces cutter damage, forcing a round trip of the
BHA for a new bit.
PDC bits have many advantages over roller cone bits and have outperformed them in many applica-
tions. However, in geothermal applications, roller cone has been performing better than PDC bits.
Traditionally, it was believed that it impossible to drill this type of formation using conventional PDC bits.
In an offset well, the operator chose to use a tungsten carbide insert (TCI) bit in an attempt to reduce bit
consumption and trip time and to increase rate of penetration (ROP). However, postrun analysis shows
that the offset well requires at least three TCI bits with and average meterage of 200 m at an ROP of 3.5
m/h. The bits were pulled out with broken cutters and graded with 5-8-LT-TQ, 4-7-WT-PR, and
7-8-WT-TD.
To deliver a bit solution, a research initiative was launched to investigate new types of cutting elements.
The project was successful and yielded an innovative conical diamond element (CDE). This element has
twice the diamond thickness of conventional PDC cutters, resulting in higher impact strength and 25%
more resistance toward abrasive wear. A new bit type was designed with the CDEs strategically placed
across the bit face from gauge to the bit center utilizing a finite-element-analysis (FEA) -based modeling
system. The placement of CDEs is mainly to support and protect the conventional PDC cutters from
impact damage and to strengthen the overall cutting structure.
Before the job commenced, engineers used an FEA-based modeling system to predict the bit perfor-
mance in a virtual environment. The analysis was completed by comparing simulation results between
drilling dynamics of a conventional PDC bit, TCI bit, and the new CDE bit. The simulation output
indicated that the CDE bit is more suitable to drill the hard compact carbonate formation compared with
the conventional PDC bit and TCI bit. The CDE bit appeared to be more stable and yielded significantly
lower vibration at the bit and along the BHA.
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The 8½-in CDE bit was run and drilled the entire 8½-in hole section through the hard volcanic
formation to TD at a significantly higher ROP compared with the offset well. Compared with the offset
well that required three TCI bits to reach TD, the CDE bit delivered more drilled interval at a higher ROP
while providing a smooth, high-quality wellbore, enabling casing to be set on the first attempt. Also, the
dynamic response predicted by the modeling system matched the bit, BHA, and drillstring vibration
profile recorded during the actual field run. Improvement in drilling performance for this particular run
has saved the operator 10 days off their AFE.
Introduction
This paper will discuss the integration of the new bit design coupled with advanced finite element analysis
(FEA) modeling, which resulted in reliable bit selection compared with the traditional field method of trial
and error. The improved engineering-calculated selection process helps to reduce uncertainty in bit
selection by providing technical data to support the recommendations made to the operator. The traditional
method of bit selection depends solely on field experience, which can vary significantly from well to well,
and because exposure to risk is high, the failure cost can be high if the wrong bit is selected.
In the new campaign, the operator expected to drill through hard volcanic formation in the 8½-in hole
section. Although TCI bits had demonstrated better performances compared to PDC bit, drilling in this
formation still remains a major challenge because PDC cutters are less durable and result in slow ROP and
shorter drilling intervals. The operator sought a technical solution from the drilling service provider to
improve drilling performance and eventually reduce the total cost of the drilling campaign.
This paper will elaborates the engineering solution for the bit selection process following the following
steps:
1. Problem statement & background
2. Key technologies introduction
3. Technical solution
4. Field result analysis
Problem Statement & Background
Drilling through volcanic rock that contains silicified andesitic tuff breccia, quartz, chert, and pyrites
historically is very challenging and requires the operator to complete the section with multiple bit runs.
Based on previous offset wells, most of the bits used during the drilling campaign from the field turned
out to be worn out on the TCI bit and ringed out on the conventional PDC bit after suffering from high
vibrations after drilling a short interval. The main objective of this study is to introduce new technology
invented as a technical solution to the rough drilling environment that was undrillable by the conventional
PDC bit. The main goal for the upcoming wells was to efficiently drill the volcanic formation in the 8½-in
hole section in a single run.
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Offset Well Study (within 1-km radius)

Before the new drilling campaign, the service provider took proactive measures by performing engineer-
ing analysis on the offset wells to better understand the environment of the new well to be drilled. The
study conducted on the offset well covers bit records from the previous runs, formation lithology,
formation strength, and the drilling dynamics while drilling. The offset wells that were chosen for this case
study are within a 1-km radius from the current well. Figure 1 shows the location of the offset wells from
the current well.

Figure 1—Location of offset wells relative to current well.

Figure 2 shows the performance of each bit in the 8½-in section from the offset well, where many TCI
bits were required to complete the section. Most of the bits were pulled out because of a slow down in
ROP or hours. On surface, the operator encountered heat checking and severe broken gauge inserts caused
by high vibration in the hard abrasive formation while drilling. Some of the TCI bits were reported
undergauge. Another offset where the PDC only drilled 10 m and was reported severely ringed out

Figure 2—Measured depth and ROP versus hole section for each bit ran in the offset well.

Figures 3 and Figures 4 show the physical appearance of the bits POOH. The damage on the gauge and
shoulder demonstrate that the bit was suffering severe impact damage while drilling. This further
confirmed that the bit was not suitable for this application, and durability was the main concern in the
application. In the current well, similar lithology and formation strength is expected while drilling the
8½-in hole section. Hence, thorough prejob analysis is required to select the right bit for this application.
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Figure 3—Typical dull with severe damage on gauge.

Figure 4 —Broken and chipped cutters on the PDC bit.

An overall study on the offset well shows that the conventional PDC bit and TCI bits are not the best
option for this hard abrasive volcanic formation. Durability of the bit, dynamics, stability, and ROP are
the main issues that need to be addressed for the target well.

Key Technologies Introduction

Once the issues of the offset well were fully understood, a new bit design was introduced to the operator
along with engineering data that utilizes FEA-based modeling to support the proposal.
a) FEA-Based Modeling Software The FEA-based modeling is a software running on Linux platform.
It is a four-dimensional, time-based simulation that can accurately simulate the performance of the entire
drilling system from bit to surface.
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Figure 5—Full 4D drilling simulation, from top drive to bit, in FEA software.

This software is mainly used by the bit designer when designing a bit. Each cutter is tested under a
series of indentations to replicate the exact interaction between the cutter and rock. The tests were
prepared at different confining pressures for different rock samples. The result of this rigorous testing
provides an improved understanding of the exact forces generated while the cutters cut the formation. The
information obtained was then processed by FEA software and captured in the system, becoming the main
input for the modeling. The elimination of assumption in how the cutters and rock interact is the main
advantage of the improved FEA modeling software over other available FEA softwares.
The improved FEA-based modeling software is also used by the engineers when studying the dynamics
of the entire system while drilling. It is mainly used to perform drillbit selection, BHA optimization,
drilling parameters selection, and directional tendency prediction. The entered inputs must be as accurate
as possible to produce a reliable output. This includes accurate selection of the drill bit based on actual
bit design, rock properties that will be encountered while drilling, well trajectory, and drilling parameters.
Based on the provided inputs, the system will predict the behavior of the entire drillstring from bit to
surface.
Because the bit and string components are modeled individually, the software accurately captures the
dynamics at every component over time. This allows the users to identify and qualify the source of
vibrations and to optimize the BHA, cutting structures, and drilling parameters for the field to improve
drilling efficiency.
b) New Bit Type Introduction Recent research initiative has developed a new bit type as an enhance-
ment to the conventional PDC bit. This new cutting structure is made up of conventional PDC cutters with
newly designed cutting elements strategically placed across the bit face from center to gauge. The new bit
type was designed as a solution to the durability issues of conventional PDC bits, especially in hard and
abrasive formations.
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Similar to conventional PDC cutters, this new cutting elements is made of polycrystalline diamond.
However, the conical design of this element makes the diamond layer approximately twice as thick
compared with conventional PDC cutters. The ultrathick polycrystalline diamond layer and innovative
conical shape make it more durable. Furthermore, these elements are manufactured using proprietary
equipment to achieve the required pressures to produce significant impact strength and wear resistance.

Figure 6 —Thicker diamond layer improves impact strength and wear resistance on CDE.

Extensive laboratory testing was conducted to determine how the conical element would fail difficult
rock formations. Virtual testing using FEA-based modeling was utilized to eliminate the high-cost
trial-and-error field method. Results showed that as the element hits the formation, the tip of the conical
element creates high stress levels that allow failing high-compressive-strength rock using less force than
is required with conventional PDC cutters. The concentrated point loading generated at the tip of the
element enables it to first crush the rock and then shear the remaining rock. The combination of these two
cutting mechanisms improves the ability of the bit to crush the hard rock. These extensive laboratory
results deliver higher confidence for the new technology to be released in the field.

Figure 7—Concentrated point loading of conventional PDC (left) cutters and CDE (right).

The next challenge is to identify how to incorporate the CDE into a PDC cutting structure. First, bit
designers identified the areas where most conventional PDC cutter damage was accrued during drilling.
Next, the designers utilized FEA-based modeling to ensure that the CDE cutting elements’ placement
would strengthen the overall cutting structure. Figure 8 shows the example of a CDE bit where the CDEs
were placed as backup cutters to the conventional PDC cutters. The main objective of this design is to
protect the conventional PDC cutters from impact damage.
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Figure 8 —New cutting structure developed with CDEs placed as backup cutters across the bit face from center to gauge.

Technical Solution
To convince the operator that the newly designed bit would outperform TCI and conventional PDC bit,
the service provider performed a thorough prejob analysis using FEA-based modeling software. This time,
the FEA-based modeling was used to model the overall dynamics of the drilling system from the cutting
structure to the surface in the planned well trajectory. The simulation model was set up to be as close as
the actual environment for maximized accuracy. Simulation was run at certain parameters to provide a
parameter roadmap while drilling.
The main objectives of this FEA-based modeling were to
1. Run simulation for the new well based on information obtained
2. Perform bit comparisons between CDE bit and conventional PDC bit.
a) Prejob Analysis on the Well to be Drilled Three bits were selected in the prejob simulation to
compare the dynamics stability between a TCI bit, conventional PDC bit, and CDE bit. Multiple
simulations were performed at a wide range of drilling parameters at the depth where carbonates were
expected.Figure 9 shows the two different type of bits used in the simulation.

Figure 9 —CDE bit (left) versus TCI bit (middle) and conventional PDC bit (right).

Figures 10 and 11 show that the drilling system using the new bit type as the cutting structure is
behaving in a stable manner in regards to lateral and axial vibrations. Figure 12 shows the expected ROP
in ft/h for the respective bits simulated. The result showed here matches the ROP that was obtained in the
field especially for TCI and conventional PDC bit. As expected, the CDE bit yielded higher ROP
compared to other bits.
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Figure 10 —Lateral vibration results between CDE bit, TCI bit, and conventional PDC bit.

Figure 11—Axial vibration results between CDE bit, TCI bit, and conventional PDC bit.

Figure 12—ROP Comparisons between CDE bit, TCI bit, and conventional PDC bit.

Field Result Analysis

After cementing the 9 5/8-in casing and performing a cleanout run, the recommended CDE bit was
successfully made up to the steerable motor BHA. It drilled the whole tangent section from 2,068-m to
TD at 2,810 m in one run. While drilling, the bit needed to perform a wiper trip and ream due to a tight
spot that was encountered. The bit drilled a total footage of 742 m and average ROP of 9.7 m/h. Figure
13 shows the bit was pulled and graded 3-2-BT-A-X-I-WT-TD. Minor wear on the CDE with no damage
was recorded, validating the initial simulation conclusion that it is more impact resistant compared with
conventional PDC cutters. If the TD was prolonged, the same bit would have drilled further at reasonable
ROP.

Figure 13—Broken cutter on the on PDC cutters caused by high impact encountered, while the CDE has only minor wear.
OTC-26421-MS 9

Figure 14 shows the comparisons between the target well and the offset well performance. The target
well took one CDE bit run to complete the interval; however, the offset wells took many bits and were
POOH due to bad ROP, hours, and torque. Most offset bits came out in very bad condition. On average,
for the same interval, the CDE bit drilled the formation a minimum of 3 times faster and at 2.7 times
higher ROP compared with the best offset and saved the operator at least 3 trips. With improved bit
stability, the CDE bit yielded a smooth, high-quality wellbore that enabled setting casing on the first
attempt without issue.

Figure 14 —Comparison of bit performance between CDE bit (subject well) with offsets.

Conclusion
The introduction of the new CDE bit has set a new benchmark and best practices for volcanic rock in the
Philippines. Unlike conventional PDC bits, the innovative CDE bit has proven its durability, which
enables it to drill faster and improves overall drilling efficiency.
The accuracy of the improved FEA-based modeling in predicting the dynamics of the overall system
allows engineers to accurately select the right bit for the right application. Also, following the optimal
parameters suggested from the field simulation allowed the bit to drill at high ROP while maintaining
stability while drilling. The application of prejob FEA modeling delivered significant economic impact to
both the service provider and the operator by eliminating the costly trial-and-error approach.

Acknowledgement
The authors would like to express their gratitude to management at Schlumberger for permission to release
the modeling information, quantitative results, and well data contained in this paper. Finally, thanks to Nik
Fahusnaza Nik Mohd Najmi and Samantha Perkins of Schlumberger for their editorial contributions.

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10 OTC-26421-MS

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