pdc bits slides
DESCRIPTION
PDC Bits SlideTRANSCRIPT
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Fixed Cutter Bits
Early Diamond Bit History
• Prior to 1940 natural diamonds were “peened”into a steel head to create a diamond bit.
• Due to the high cost and marginal manufacturing technique, diamond drill bit were rarely used.
• The primary diamond application was in core bits.
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Milestones• 1947 - Christensen Develops matrix bit
technology for practical attachment of natural diamonds to a drill or core bit head.
• 1954 - GE is the first to synthesize diamond.• 1975 - First practical application of man-made
diamond with introduction of GE’s “Stratapax”polycrystalline diamond compact (PDC) stud cutter.
• 1981 - Introduction of thermally stable polycrystalline (TSP) cutters.
PDC Design Presentation• Cutter Technology• PDC Bit Design
• Profiles and Blades• Cutter Orientations• Hydraulics• Bit Gauge
• Bit Mechanics• Design Optimization
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Natural Diamond Cutters
• Original diamond cutting element.• Monocrystalline diamond.• Different size and quality diamonds for different applications.
• Size range expressed as stones per carat (SPC).
Natural Diamond Cutters• Natural diamonds are furnaced into the bit head.
• Versatile application range when synthetic diamonds are not applicable.
• Medium to very hard formations.
• Fixed TFA.
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BallasetCutters
• Thermally Stable Polycrystalline (TSP) diamond cutters.
• Extension of PDC cutter technology.• Cutter size expressed as stones per carat
(SPC).
Ballaset Cutters• Thermal stability allows
cutters to be directly furnaced into the bit.
• Developed for medium to hard applications, particularly carbonates.
• Fixed Total Flow Area (TFA).
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Impregnated Cutters
• Diamond grit is “hot-pressed” into tungsten carbide matrix to form impregnated segments.
• Diamond grit is synthetic diamond material.
• Pre-formed segments furnaceddirectly into bit crown.
• Grinding tool for very hard and abrasive applications.
• Especially effective at high rotation speeds.
Impregnated Cutters
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Polycrystalline Diamond Compact
Diamond Table
TungstenCarbide
Substrate
Conventional PDC Cutter
PDC Cutter Sizes
0.529” - 13.3 mm 0.323” - 8.2 mm
0.642” - 16 mm
0.750” - 19 mm
0.315” - 8 mm 0.315” - 8 mm
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Sharp vs. Chamfered Cutting Action
Failure Plane Failure Plane
Built-Up Edge
Polished Cutter
Polished Cutters
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Carbide Supported Edge
CSE Geometry Strengthens The Diamond Edge Against The Cutting Force
Chamfer Angle
Cutting Force
Tungsten Carbide Body
Standard CutterCSE Cutter
Materials & Bit Construction
Nozzles
Junk SlotArea
PDC Cutters
API Connection
WeldBlank
Blank Blade
Matrix Body
PDC GaugeCutters
PDC FaceCutters
Cone Nose
Shoulder
Nozzle
Gauge Pad
Crown Chamfer
Breaker Slot
Stamp Area- Serial #- Style- TFA - ND/Ballaset
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Bit Profiles• Bit profile and cutter layout are closely related. • Layout is a compromise between the following:
• Maximum number of cutters (longer bit life)
• Lowest blade count (better hydraulics, penetration rate)
• Shortest possible profile (better bit stability and cleaning)
Volume of Rock Removed
• Volume of rock removed is a function of• Cutter radius• Depth of cut• Width of cut
• There is a direct relationship between the volume of rock removed and the work rate of a cutter.
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• The volume of rock removed is calculated for a given penetration rate (depth of cut).
• We use profile and blade count to manipulate the amount of work done in each area of the bit.
Cutter #60 RPM, 60 ft./hr
Vorr
(in3 )
Volume of Rock Removed
0
1
2
3
4
5
1 2 3 4
LIGHT MEDIUM HEAVY
Blade Count & Cutter Density
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• Tapered blades provide optimum strength and hydraulic efficiency
• The blade strength is calculated using the blade height, width, length and the leading edge root radius.
• Blade strength is given as a percentage of the API connection strength. (i.e., 204%)
Blade Strength
Blade Width
Root Radius
Force
BladeLength
BladeHeight
Conventional Blade Configuration
Backrake & Siderake
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• A cutter will see a different magnitude & direction of forces depending on it’s location on the bit profile.
Depth of Cut
F Torque
Fwob
Fwob
FsFwob
Fn
Fn
Fs
Single Cutter Forces
Force Vector Groups Force Vector Summation
Group #1
Group #2
Group #3
Group #4
Net Imbalance Force
Group #3
Group #4
Group #1
Group #2
Resultant Cutter Force Vector
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• The gauge is considered the stabilizing, full hole section of a bit.
• Gauge begins at the gauge point and continues up to the crown chamfer.
• Typical materials include natural diamonds and tungsten carbide segments.
• For optimum stability a flush set gauge pad is used.
Gauge Design
PDC Bit Gauge
• Cutter layout & orientation are purposely designed to create a net imbalance force, pushing the bit against the hole wall and creating a stable rotating condition.
Anti-Whirl Force Balancing
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PDC Applications
Quartzite(metamorphic)
Granite(Igneous)
Marble(metamorphic)
Sandstone LimestoneMarlstone
10,00020,00030,00040,00050,00060,00070,00080,00090,000
100,000U
CS
(psi
)
SEC PDC Application Limit
Standard PDC Limit
IADC Dull Grading System
Cutting Structure Bearing Gauge Comments
Inner Rows
Outer Rows
Dull Characteristic
Location Bearing & Seal
Gauge Other Characteristic
Reason Pulled
X
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Cutter Wear
Bit Dull / Other Characteristics
BC - Broken ConeBF - Bond FailureBT - Broken Teeth/CuttersBU - Balled UpCC - Cracked ConeCD - Cone DraggedCI - Cone InterferenceCR - CoredCT - Chipped Teeth/CuttersER - ErosionFC - Flat Crested WearHC - Heat CheckingJD - Junk DamageLC - Lost ConeLN - Lost Nozzle
LT - Lost Teeth/CuttersNR - Not RerunnableOC - Off-Center WearPB - Pinched BitPN - Plugged Nozzle/Flow AreaRG - Rounded GaugeRO - Ring OutRR - RerunnableSD - Shirttail DamageSS - Self-Sharpening WearTR - TrackingWO - Wash Out on BitWT - Worn teeth/CuttersNO - No Other Major Dull
Characteristics
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Fixed Cutter Bit Profiles
A - All overC - Cone - shown on all profilesN - Nose - Part of profile that would rest on the table if bit set upside downT – Taper – Straight portion tangent to nose and shoulderS - Shoulder - Outer area adjacent to the nose and gauge areasG - Gauge - Area ground to API specifications and cuts a “gauge” hole
Worn Cutter
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Diamond Lip
Worn Cutter
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Chipped Cutter
Broken Cutters
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Lost Cutters
Heat Checking
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Erosion
Ring Out
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Junk Damage
Cored
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Broken Blade
Balled
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Plugged Nozzle
Acknowledgement
We wish to thank the Hughes Christensen division of Baker Hughes for their valuable assistance in the preparation of this material.
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