Schlumberger

Case Study: ONYX 360 Cutter Increases PDC Bit’s Run Footage 57% in Texas Panhandle’s Granite Wash Formation

Bit with rolling cutters drills 1,562 ft of a 5,113-ft, 61⁄8-in lateral gas well section at 25 ft/h

Challenge: Drill 6 1⁄8-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.

Solution: Run a 6 1⁄8-in MSiR613 PDC bit fitted with seven ONYX 360 rolling PDC cutters positioned in the areas of the bit’s cutting structure with the highest predicted wear.

Result: Drilled 1,562 ft of a 5,113-ft, 61⁄8-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 fixed-cutter-only bits, increased ROP 44% and footage drilled 57%.

Abrasive formation quickly shortens cutter life

An operator was experiencing difficulty trying to drill 6 1⁄8-in, 5000-ft lateral gas well sections through the abrasive reservoir sand that characterizes the Texas Panhandle’s Granite Wash formation. The PDC bits being used were incurring worn, chipped, and broken cutters. Beyond these dull characteristics, damage to the bit’s cutting structure quickly reduced ROP to unacceptable levels. In some cases, these conditions were forcing the operator to trip for a new bit after drilling less than 65 ft.

Innovative rotating cutter design increases durability

In answer to the operator’s bit durability challenge, Smith Bits recommended a bit with ONYX 360 rolling PDC cutters. To add ONYX 360 cutters to a PDC bit, design engineers used IDEAS drillbit design platform to position the rolling cutters in the areas of the bit’s cutting structure with the highest predicted wear.

To integrate the rolling cutter into a PDC bit’s cutting structure, a robust housing is brazed into the bit blade that encloses and secures the cutter while allowing it to rotate. The rolling cutter’s orientation in the bit blade relative to its contact with the formation, coupled with the bit’s drilling force, drives efficient rotation of the cutter. And because the entire diamond edge of the cutter is used, wear is reduced to allow more sustained rates of penetration and fewer bit replacement trips.

ONYX 360 cutters significantly increase run footage

A 6 1⁄8-in MSiR613 PDC bit fitted with seven ONYX 360 rolling cutters drilled 1,562 ft of the 5,113-ft Granite Wash lateral at an approximate inclination of 90° and at an ROP of 25 ft/h. The average dull condition of the fixed cutter-only-bits used to drill the same formation was graded 6-3, while the bit with ONYX 360 cutters graded 3-1. When compared with the best drilling performance by a fixed-cutter-only bit in the same lateral well, the PDC bit with ONYX 360 rolling cutters had a 44% greater ROP and drilled 57% more footage.


Download: ONYX 360 Cutter Increases PDC Bit’s Run Footage 57% in Texas Panhandle's Granite Wash Formation (1.05 MB PDF)

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PDC Bit with ONYX 360 Cutters Drills at a 44% Greater ROP

ONYX 360  cutters increase run footage
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ONYX 360 Rolling PDC Cutters—Drill Farther

ONYX 360
When compared with fixed-cutter-only bits, PDC bits that included ONYX 360 rolling cutters demonstrated run length increases of up to 57%, resulting in fewer bit trips and lower drilling costs.
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