Serrated diamond element bit achieves 20% higher ROP in Marcellus Shale

Using the SerraBlade™ serrated diamond element bit in the Marcellus Shale, a major operator drilled 5,194 ft of the 8.75-in curve and lateral section, achieving 20% higher ROP than the top-performing offset well within a 20-mile radius. The entire section was completed in a single run within 38 hours, saving 8 hours of drilling time while setting a new efficiency milestone in that area.

The Marcellus Shale in Pennsylvania is a key oil and gas region, but its low permeability and porosity pose significant challenges for well construction and completion. Curve-lateral drilling, a technique designed to maximize reservoir contact, requires high dogleg severity (DLS) and precise directional control. Meeting these demands calls for a drill bit with durable, efficient cutters to deliver high ROP and accurate trajectories.

Although the operator tested several drillbit designs with a range of PDC cutter configurations, they sought further improvements to reduce drilling costs and boost performance. The main challenge was to overcome inefficiencies, cutter-breakage risks, and directional instability in a shale-dominant environment.

The SerraBlade bit, equipped with serrated cutting elements, was deployed to drill one of the wells. To address directional challenges, the cutters were strategically placed on the cone, nose, and shoulder—the regions identified as critical for efficiency, directional stability, impact resistance, and side-cutting capability. The cutters’ multiridge, concave surfaces enhance cutting efficiency while stabilizing the cone area to maintain bit steadiness. The combination of serration and multiridge cutting tips provides additional toughness against impacts during rock transitions, while preserving cutter sharpness for effective curvature control and sustained lateral progression. This design supports maintaining a high ROP through the curve and lateral section to the end of the interval.

As a result, the SerraBlade bit drilled the entire curve and lateral from 5,700 ft to 10,894 ft, achieving a record-breaking average ROP of 136 ft/h— 20% higher than the top ROP of the curve-lateral wells within a 20-mile radius. The 5,194 ft interval was completed in 38 hours in a single run, saving 8 hours of drilling time and avoiding additional costs. The cutters remained in excellent condition upon completing the section, demonstrating the durability of this serrated diamond element bit technology.