Modeling of Cutting Rock: From PDC Cutter to PDC Bit—Modeling of PDC Bit

SPE Journal ◽  
2021 ◽  
pp. 1-23
Author(s):  
Pengju Chen ◽  
Stefan Miska ◽  
Mengjiao Yu ◽  
Evren Ozbayoglu
Keyword(s):  
Polycrystalline Diamond ◽  
Field Application ◽  
Design Parameters ◽  
Depth Of Cut ◽  
Side Force ◽  
Pdc Bit ◽  
Weight On Bit ◽  
Torque On Bit ◽  
Two Parameters ◽  
Drilling Conditions

Summary In this paper, we integrated our polycrystalline diamond compact (PDC) cutter model (Chen et al. 2021) into a PDC bit model that can predict the weight on bit (WOB), torque on bit (TOB), and imbalanced side force on a bit under given drilling conditions. We first proposed a method to determine the actual cutting plane and depth of cut of each cutter on a PDC bit. Once the two parameters for each cutter are determined, the cutter model can then be applied to calculate the cutting force of each cutter. The final bit force and moment (i.e., WOB, TOB, and imbalanced side force) are calculated as the resultant force and moment of cutting forces of all cutters. The PDC bit model in this paper considers all bit design parameters, including bit matrix geometry, blade profile, cutter layout, and the inclination of each cutter. Furthermore, the bit model also considers some bottomhole assembly (BHA) parameters (e.g., bit tilt angle, location of first fulcrum point, and tool face/steering plane angle), which allows the bit model to simulate a bit under different drilling modes. The bit model is also validated by published test data and field applications. Finally, case studies are conducted, and the influence of bottomhole stresses, BHA parameters, and drilling modes on bit force and moment are discussed. A field application of the bit model is also provided. The bit model can be directly used for PDC bit design and simulation. In fact, this paper presents a general way to integrate a cutter model into a PDC bit model. Readers are also encouraged to apply this method to integrate their own cutter model into a PDC bit model.

Hydraulic Percussion Drilling System with PDC Bit Increases ROP and Lowers Drilling Costs

2015 ◽  
Author(s):  
Scott W. Powell ◽  
Ertai Hu
Keyword(s):  
Distribution System ◽  
Drilling Fluid ◽  
New Technology ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
Rapid Variation ◽  
Pdc Bit ◽  
Weight On Bit ◽  
Drilling System ◽  
Percussion Drilling

Abstract Drilling the Severnaya Truba Field in Aktobe, Kazahkstan, has proved to be a costly and time consuming challenge for operators trying to maximize profits. The formation is typically drilled with roller cone bits that take multiple runs to complete an interval. To increase effectiveness and drilling efficiency, a hydraulically powered percussion drilling system along with a fixed cutter PDC bit were added. In place of a conventional drilling system, a new energy distribution system was introduced that would induce axial oscillations and percussion impacts while applying the same weight and torsional energy to the bit. In combination with a drilling fluid powered percussion hammer (FPPH), a fit for application polycrystalline diamond compact (PDC) bit with depth of cut (DOC) control features was used to minimize the exposure of the cutting structure and prevent breakage. The system combines the torsional power of a conventional positive displacement motor with a high frequency axial pulse created with each rotation. The torque is transferred directly to the bit and 100% of the hydraulic flow is utilized by the bit nozzles to maintain hole cleaning and keep PDC cutters cool. The mechanical lifting and falling action creates a rapid variation in weight on bit (WOB), allowing the bit's depth of cut to fluctuate while overcoming different stresses. These variations, along with the percussion pulse created with each stroke, lead to increased rates of penetration. This system has been used throughout the world on a variety of formations, using both PDC and roller cone insert bits. This paper will focus on an 8½ in interval drilling operation in the Severnaya Truva field, located 60 km from Zhanazhol field in Kazakhstan. The formations consisted of soft to medium siltstone, red/grey clays, sandstone, hard cemented dolomite, limestone, and very dense clay stone. This new technology proved to increase both ROP and interval drilled, saving seven days of drilling compared to offset wells.

Study of the Influence of Shale Anisotropy Orientation on Directional Drilling Performance in Shale

2017 ◽  
Author(s):  
Abdelsalam N. Abugharara ◽  
Charles A. Hurich ◽  
John Molgaard ◽  
Stephen D. Butt
Keyword(s):  
Depth Of Cut ◽  
Directional Drilling ◽  
Laboratory Procedure ◽  
Drilling Rig ◽  
Drilling Performance ◽  
Mechanical Measurements ◽  
Different Types ◽  
Pdc Bit ◽  
Weight On Bit ◽  
Shale Anisotropy

The influence of shale anisotropy orientation on shale drilling performance has been studied using a new laboratory procedure. This procedure includes drilling and testing three sets of shale samples in different orientations from a single rock sample. Shale samples of different types were collected from outcrops located at Conception Bay South (CBS) in Newfoundland, Canada. For predrilling tests, oriented physical and mechanical measurements on each type of shale were conducted on the same rocks that will be drilled later. For drilling tests, three sets of tests were conducted. Each set was in a different orientation, corresponding to those in the physical and mechanical measurements. Each set was conducted under the same drilling parameters of pressure, flow rate (FR), and weight on bit (WOB) using a fully instrumented laboratory scale drilling rig. Two different types of drill bits were used, including a 35 mm dual cutter PDC bit and a 25.4 mm diamond coring bit. The drilling data was analyzed by constructing relationships between drilling rate of penetration (ROP) versus orientation (i.e. 0°, 45°, or 90°). The analysis also included relationships between WOB and bit cutter Depth of Cut (DOC), Revolution Per Minute (RPM), and Torque (TRQ). All the above relations were evaluated as a function of shale bedding orientation. This evaluation can assist in understanding the influence of shale anisotropy on oriented drilling. Details of the conducted tests and results are reported.

Study of the Influence of Controlled Axial Oscillations of pVARD on Generating Downhole Dynamic WOB and Improving Coring and Drilling Performance in Shale

2019 ◽  
Author(s):  
Abdelsalam N. Abugharara ◽  
John Molgaard ◽  
Charles A. Hurich ◽  
Stephen D. Butt
Keyword(s):  
Sampling Rate ◽  
Polycrystalline Diamond ◽  
Rotary Drilling ◽  
Labview Software ◽  
Drilling Performance ◽  
Drilling Parameters ◽  
Wide Range ◽  
Pdc Bit ◽  
Weight On Bit ◽  
Polycrystalline Diamond Compact

Abstract This work concentrates on the investigation of enhancing drilling performance through increasing drilling rate of penetration (ROP) by using a passive vibration assisted rotary drilling (pVARD) tool. It also involves analysis of how ROP was significantly increased when drilling using pVARD compared to drilling using conventional system “rigid” using coring and drilling in shale rocks. The apparatus used was a fully instrument laboratory scale rig and the bits were dual-cutter polycrystalline diamond compact (PDC) bit for drilling and diamond impregnated coring bit for coring. The flow rate was constant of (7 litter / min) using clean water at atmospheric pressure. In addition, for accuracy data recording, a data acquisition system (DAQ-Sys) using a LabVIEW software was utilized to record data at 1000HZ sampling rate. The output drilling parameters involved in the analysis included operational rpm, torque (TRQ), and ROP. All the output-drilling parameters were analyzed with relation to downhole dynamic weight on bit (DDWOB). The result of this work explained how pVARD can increase the DDWOB and improve ROP. The result also demonstrated generating a balanced and concentric increase in DDWOB and minimizing the wide-range fluctuation of DDWOB generated in rigid drilling, particularly at high DDWOB.

Experimental Investigation of the Effect of Shale Anisotropy Orientation on the Main Drilling Parameters Influencing Oriented Drilling Performance in Shale

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
A. N. Abugharara ◽  
Bashir Mohamed ◽  
C. Hurich ◽  
J. Molgaard ◽  
S. D. Butt
Keyword(s):  
Drilling Fluid ◽  
Polycrystalline Diamond ◽  
Bedding Plane ◽  
Depth Of Cut ◽  
Fine Aggregate ◽  
Drilling Rig ◽  
Drilling Performance ◽  
Bedding Planes ◽  
Weight On Bit ◽  
Shale Anisotropy

The influence of shale anisotropy and orientation on shale drilling performance was studied with an instrumented laboratory drilling rig with a 38.1-mm dual-cutter polycrystalline diamond compact (PDC) bit, operating at a nominally fixed rotational speed with a constant rate of flow of drilling fluid—water. However, the rate of rotation (rpm) was affected by the weight on bit (WOB), as was the torque (TRQ) produced. The WOB also affected the depth of cut (DOC). All these variables, WOB, rpm, TRQ, and DOC, were monitored dynamically, for example, rpm with a resolution of one-third of a revolution (samples at time intervals of 0.07 s.) The shale studied was from Newfoundland and was compared with similar tests on granite, also from a local site. Similar tests were also conducted on the concrete made with fine aggregate, used as “rock-like material” (RLM). The shale samples were embedded (laterally confined) in the concrete while drilled in directions perpendicular, parallel, and at 45 deg orientations to bedding planes. Cores were produced from all three materials in several directions for the determination of oriented physical properties derived from ultrasonic testing and oriented unconfined compressive strength (OUCS). In the case of shale, directions were set relative to the bedding. In this study, both primary (or compression) velocity Vp and shear ultrasonic velocity Vs were found to vary with orientation on the local shale samples cored parallel to bedding planes, while Vp and Vs varied, but only slightly, with orientation in tests on granite and RLM. The OUCS data for shale, published elsewhere, support the OUCS theory of this work. The OUCS is high perpendicular and parallel to shale bedding, and is low oblique to shale bedding. Correlations were found between the test parameters determined from the drilling tests on local shale. As expected, ROP, DOC, and TRQ increase with increasing WOB, while there are inverse relationships between ROP, DOC, and TRQ with rpm on the other hand. All these parameters vary with orientation to the bedding plane.

Drilling Action of Roller-Cone Bits: Modeling and Experimental Validation

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Luiz F. P. Franca
Keyword(s):  
Polycrystalline Diamond ◽  
Quantitative Information ◽  
Rock Properties ◽  
Drilling Rig ◽  
Proposed Model ◽  
Theoretical Predictions ◽  
Weight On Bit ◽  
Torque On Bit ◽  
Polycrystalline Diamond Compact ◽  
Potential Use

This paper presents a new model of the drilling response of roller-cone bits. First, a set of relations between the weight-on-bit W, the torque-on-bit T, the rate of penetration V, and the angular velocity Ω is established in the spirit of the model developed for polycrystalline diamond compact (PDC) bits. In contrast to models that depend on a precise description of the bit, the drilling response is investigated by lumping the effect of the bit geometry into a few parameters and on averaging the drilling quantities (W,T,V,Ω) over at least one revolution of the bit. Within the framework of the model, quantitative information from drilling data related to rock properties, bit conditions, and drilling efficiency can be extracted. Finally, a series of laboratory tests at atmospheric pressure conducted with an in-house designed drilling rig, together with published experimental data, is used to evaluate the proposed model. The good match between the experimental results and the theoretical predictions are promising in regard to the potential use of this model to investigate the drilling response of roller-cone bits.

A New Dynamic Model of Coupled Axial–Torsional Vibration of a Drill String for Investigation on the Length Increment Effect on Stick–Slip Instability

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
Ali Hosseinzadeh ◽  
Firooz Bakhtiari-Nejad
Keyword(s):  
Torsional Vibration ◽  
Angular Speed ◽  
Drill String ◽  
Body Motion ◽  
Depth Of Cut ◽  
Stick Slip ◽  
Input Parameters ◽  
Length Increment ◽  
Weight On Bit ◽  
Torque On Bit

In this paper, a new model is proposed to study the coupled axial–torsional vibration of the drill string. It is assumed that rotary table angular speed is constant and equals to the nominal angular speed of the drill string. In addition, axial displacement of any point on the drill string is considered to be as the sum of rigid-body motion and elastic vibrations. The depth of cut is defined using instantaneous dynamic states instead of using the delayed model as presented in previous researches. A velocity-weakening function is introduced for modeling the behavior of the frictional component of the torque-on-bit (TOB) with respect to the bit angular speed. After discretizing vibration equations, stability analysis of the system is investigated by linearizing the nonlinear system around its steady-state response point. Considering nominal weight-on-bit (WOB) (W0) and nominal rotational speed (Ω) as the input parameters of the drilling, variation of maximum allowable value of (W0) is presented with respect to variation of Ω . It is shown that the maximum allowable value of W0 has an increasing–decreasing behavior with respect to Ω. The effect of drill string upper and lower part lengths is studied on the stability of the system, and practical results are presented both in the condition that W0 is constant and in the condition that the hook upward force is constant. It is shown that by increasing the drill string length, the system is more exposed to instability, and this must be considered in regulating the input parameters of drilling.

The Use of a Sensor Modules System for Measuring Drilling Parameters in a Bit, Significantly Reduces the Construction Time of Wells in Eastern Siberia

2021 ◽  
Author(s):  
Andrey Alexandrovich Rebrikov ◽  
Anton Anatolyevich Koschenkov ◽  
Anastasiya Gennadievna Rakina ◽  
Igor Dmitrievich Kortunov ◽  
Nikita Vladimirovich Koshelev ◽  
...  
Keyword(s):  
Oil And Gas ◽  
New Technologies ◽  
Field Tests ◽  
Depth Of Cut ◽  
Drilling Process ◽  
Eastern Siberia ◽  
Construction Time ◽  
Stage Of Development ◽  
Drilling Parameters ◽  
Pdc Bit

Abstract Currently, production and exploration drilling has entered a stage of development where one of the highest priority goals is to reduce the time for well construction with new technologies and innovations. One of the key components in this aspect is the utilizing of the latest achievements in the design and manufacture of rock cutting tools – drill bits. This article presents some new ideas on methods for identifying different types of vibrations when drilling with PDC bits using a system of sensors installed directly into the bit itself. In the oil and gas fields of Eastern Siberia, one of the main reasons for ineffective drilling with PDC bits are vibrations, which lead to premature wear of the cutting structure of the bit and the achievement of low ROPs in the dolomite and dolerite intervals. For efficient drilling of wells of various trajectories with a bottom hole assembly (BHA), including a downhole motor (PDM) and a PDC bit, special attention is paid to control of the bit by limiting the depth of cut, as well as the level of vibrations that occur during drilling process. Often, the existing complex of surface and BHA equipment fails to identify vibrations that occur directly on the bit, as well as to establish the true cause of their occurrence. Therefore, as an innovative solution to this problem, a system of sensors installed directly into the bit itself is proposed. The use of such a system makes it possible to determine the drilling parameters, differentiated depending on the lithological properties of rocks, leading to an increase in vibration impact. Together with the Operators, tests have been successfully carried out, which have proven the effectiveness of the application of this technology. The data obtained during the field tests made it possible to determine the type and source of vibration very accurately during drilling. In turn, this made it possible to precisely adjust the drilling parameters according to the drilled rocks, to draw up a detailed road map of effective drilling in a specific interval. Correction of drilling parameters based on the analysis of data obtained from sensors installed in the bit made it possible to reduce the resulting wear of the PDC bit cutting structure and, if necessary, make changes to the bit design to improve the technical and economic indicators. Thus, the use of a system of sensors for measuring the drilling parameters in a bit ensured the dynamic stability of the entire BHA at the bottomhole when drilling in rocks of different hardness, significantly reduced the wear of the drilling tools and qualitatively improved the drilling performance.

scholarly journals An Overview on Major Design Constraints, Impact and Challenges for a Conventional Wastewater Treatment Design

2020 ◽  
Vol 9 (1) ◽  
pp. 7-16
Keyword(s):  
Wastewater Treatment ◽  
Analytical Calculation ◽  
Treatment Plant ◽  
Field Application ◽  
Design Parameters ◽  
Plant Design ◽  
Political Commitment ◽  
Design Constraints ◽  
Technical Requirements ◽  
Set Up

The conventional wastewater (WW) treatment plant includes physical, chemical, and biological treatment processes that can protect the receiving water bodies from water pollution. The common design constraints, challenges as well as environmental impact would make the wastewater treatment plant’s (WWTP) construction and operation more complex and demanding tasks. Major project constraints for WW plant design are economic, accessibility, fulfilling technical requirements, institutional set-up, health and environment, personnel capacity, and political commitment etc. Design methodology adopted in the current study included project location, unit selections, the design capacity, design period as well as proximity to the population and layout plan. The present manuscript discussed briefly about effluent quality requirements, design issues, environmental impacts, details, and safety concerns. It also highlighted the necessary flexibility to carry out satisfactorily within the desired range of influent WW characteristics and flows. In the present study, every step of the design was verified with Environmental Regulations and suggested to overcome all constraints while designing WWTPs so that standard operational code for the specific region could be implemented to achieve the best treatment performance. The results obtained from analytical calculation were optimized to achieve the best design parameters for field application. The optimized values also reduce the construction and operation cost during the field application.

Closed-Form Synthesis of Force-Generating Planar Four-Bar Linkages

1995 ◽  
Author(s):  
R. Randall Soper ◽  
Michael Scardina ◽  
Paul Tidwell ◽  
Charles Reinholtz ◽  
Michael A. Lo Presti
Keyword(s):  
Closed Form ◽  
The Other ◽  
Design Parameters ◽  
Synthesis Methods ◽  
Function Generator ◽  
Mechanical Advantage ◽  
Nonlinear Mechanical ◽  
Two Parameters ◽  
Selection Of ◽  
Weight Force

Abstract This paper presents a technique for synthesizing four-bar linkages to produce a specified resisting force or torque. The resisting energy is provided by a weight acting on the other grounded link. The linkage serves as a nonlinear mechanical advantage function generator. Force and velocity synthesis methods have been extensively discussed in the literature. The general approach, however, has been to assume that the specified force or velocity occurs at a prescribed position. This results in the loss of design parameters that are being used unnecessarily to control position. In this application, force input to the linkage is specified as a function of only the input link position and the magnitude and direction of the weight force. Mechanical advantage synthesis can be achieved at as many as seven precision points. The method presented in this paper allows free selection of two parameters and viewing one infinity of solutions.

Particle Dampers for Workpiece Chatter Mitigation

2005 ◽  
Author(s):  
Neil D. Sims ◽  
Ashan Amarasinghe ◽  
Keith Ridgway
Keyword(s):  
Wide Frequency Range ◽  
Machining Process ◽  
Design Parameters ◽  
Depth Of Cut ◽  
Vibration Absorbers ◽  
Tuned Vibration Absorbers ◽  
Highly Nonlinear ◽  
Machining System ◽  
Order Of Magnitude ◽  
Particle Dampers

It is well known that the chatter stability of a machining process can be improved by increasing the structural damping of the system. To date this approach has been effectively used on various components of the machining system, for example boring bars, milling tools, and the machine structure itself. Various damping treatments have been proposed, including tuned vibration absorbers, active methods, and impact dampers. However, to date there has been little or no work to investigate the issue of particle dampers for this application. This special class of damper comprises a container of thousands of small granular particles which dissipate energy by friction and impact when the container vibrates. The resulting behaviour is highly nonlinear but can provide very high levels of damping across a wide frequency range. In the present study, particle dampers were applied to a workpiece to mitigate chatter during milling, and the limiting critical depth of cut was increased by an order of magnitude. This article gives an overview of the particle damper’s behaviour and key design parameters. Cutting trials employing the device are then described.

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