Proceedings of the ASME 2022 41st International

Conference on Ocean, Offshore and Arctic Engineering

OMAE2022
June 5-10, 2022, Hamburg, Germany

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OMAE2022-79273

DRILLING PERFORMANCE EVALUATION THROUGH BIT CUTTERS RE-

CONFIGURATIONS AND MICRO FRACTURES INITIATION

Abdelsalam Abugharara1,2 Oluwafemi Tytler 1 Stephen Butt 1

Memorial University of Newfoundland, St. John’s, Newfoundland, Canada1

Sebha University, Sebha, Libya2

ABSTRACT
Drilling operations of petroleum wells are primarily applied NOMENCLATURE
to create channels through subsurface formations for oil and gas BHA Bottom-Hole Assembly
production. For best drilling performance, drilling parameters CHP Coring Hole Opener
including weight on bit (WOB), rotary speed in Revolutions per DHO Drilling Hole Opener
Minute (rpm), drilling Fluid Rates (FR), etc. need to be applied FB Flat Base Bit
optimally to enhance drilling performance, to reduce cost, and LDS Large-scale Drilling Simulator
to minimize wear of downhole tools. In this research, the drilling PDC Polycrystalline Diamond Compact
performance was evaluated based on examining the Drilling ROP Rate Of Penetration
Rate of Penetration (ROP) in granite blocks through changing rpm, RPM Revolution Per Minutes
the face of a multi diameter Polycrystalline Diamond Compact WOB Weight On Bit
(PDC) bit into three different design scenarios including the Flat
Base bit (FB), Drilling Hole Opener bit (DHO), and Coring Hole 1. INTRODUCTION
Opener bit (CHO). All input drilling parameters were kept Drilling Rate Of Penetration (ROP) has been put under
constant and the only variable was the bit configuration. research focus for decades. Numerous models have been
The purpose of this research was to evaluate the change in developed for calculating and predicting ROP. ROP has also
the ROP and to establish an investigation on why ROP varies been continuously emphasized as the key factor for drilling
when bit is reconfigured just by repositioning cutters. By linking performance evaluation.
the ROP variation to the bit configuration, a possible Numerous factors are required to be also considered to have
phenomenon of creating micro fracturing could be the reason for the ROP as a valid key of evaluating the drilling performance.
the ROP enhancement. Taking the FB as a baseline, results These factors include optimal applications of drilling fluid flow
showed an increase in ROP using DHO and CHO over FB bit. rate for hole perfect cleaning, drilling rotational speed, adequate
The idea behind this could lay behind initiating micro fractures of drill bit design and bit type and configuration with the
resulting a weaker rock portion by the 1st drill path to be drilled formation, analysis of rate of wear to the bit and Bottom-Hole
by the upper part of the bit. Assembly (BHA), analysis of Mechanical Specific Energy
Based on the averaged results, ROP of DHO increased by (MSE) consumed [1-6 ].
37.5 % at 5 kN and by 47.1 % at 10 kN. Similarly, the ROP of Conventionally, the factors that have been looked at as main
CHO increased by 12.5% at 5 kN and by 11.8 % at 10kN influence parameters that have direct effect on ROP include (i)
indicating that initiation of micro fractures could play a role in Weight On Bit (WOB) applied at the surface and transmitted to
the enhancement of the ROP. the bit through the entire drill string. (ii) Drill string rotational
Keywords: Drilling performance, micro fractures, ROP, speed (Revolution Per Minutes: RPM that is initiated at the
hole opener, PDC bit. rotary table at the surface and transmitted through the drill string

V010T11A087-1 Copyright © 2022 by ASME

to the drill bit. (iii) Drilling fluid Flow Rate (FR) that is used to a LabVIEW operating system that was used for drilling (Figure
cool down, lubricate BHA, and circulate cuttings to the surface 1).
as well as allowing the bit to be in a continuous contact with the The LDS that has a stroke of about 45 cm is equipped with

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fresh surface of the rock. These factors are fundamentals for multiple sensors that enable recording a wide range of input and
achieving optimal drilling performance [1,2]. Efficiently, output parameters including position of bit, applied WOB,
conducting a Drill Off Test (D.O.T) at the start of drilling new torque, rpm, and axial oscillation.
formation provides an instant and reliable data set for the optimal
input drilling parameters, mainly the WOB to be applied for
drilling the entire encountered interval. Therefore, applying
drilling parameters optimally has a positive influence on the
drilling performance through the increase of ROP [4,5].
With the continuation of research on factors influencing
ROP, numerous studies reported that there is a long list of
parameters that either directly or indirectly influence ROP,
including (i) geological factors ( formation strength, anisotropy,
abbrasivity, etc.), (ii) bit and cutters design (bit geometry, teeth
dimensions and distributions, cutters shape and materials, etc.).
and (iii) mechanical factors of the drill string and BHA
(flexibility, rigidity) [6,7, 8, 9].
More specifically, research reported a noticeable
contribution due to reconfiguring the PDC bit and the cutters on
the drilling performance in general and on the ROP in specific.
Gerbaud et al. (2006) [10] modeled numerous experimental
data and results of redesigning PDC cutters and reported
significant positive impacts of PDC cutters on improving ROP,
stabilizing the bit, and controlling the bit wear. Shao et al. (2012)
[11] investigated the effect of the chamfer of the PDC cutter and
reported the important role of considering it on improving the
cutter cutting efficiency and durability. Thomas et al. (2021) [12]
reported an improvement on drilling performance through an
enhancement of ROP via resizing PDC cutters. Zhang et al.
(2019) [13] reported the improvement of ROP and life extension
of PDC cutters via the implementation of PDC Hollowed
Cutters.
In the Drilling Technology Laboratory at Memorial
University of Newfoundland (DTL-MUN) intensive research
has been put on studying factors influencing ROP. These studies
have been covering rock formation types from shale, granite, FIGURE 1: LARGE SCALE DRILLING SIMULATOR
sandstone, quartile, and various strengths of Rock Like Materials WHILE DRILLING GRANITE.
(RLM) [13-19].
The research of this paper focuses on the influence of The LDS is capable to provide up to 1000 rpm, 1200 Nm
reconfiguring the drill bit from Flat Base bit (FB) to (i) Drill Hole torque and up to a 100 kN applied axial force representing
Opener (DHO) bit and (ii) Core Hole Opener (CHO) bit on ROP. applied weight on bit through dual supporting systems of
This study also investigates the possible phenomena of pneumatic and hydraulic. The components of LDS shown in
generating micro fractures by the advanced part of DHO and Figure 1 consists of (1) 1-Large-scale laboratory Drilling
CHO that could weaken the residual portion of the rock to be Simulator (LDS) frame, (2) drill string components (top to
drilled by the passive part of the bit. bottom): swivel, pVARD, drill bit, (3) Sample holder setup for
drilling under atmospheric pressure conditions, (4) a natural
granite rock block, (5) transparent plastic container for drilling
2. MATERIALS AND METHODS fluid and cutting flow control, (6) Data Acquisition System with
This sections covers the materials that were used in this LabVIEW for automatic drilling operation, and (7) manual
research. operation controller and an automatic/manual switch key.
2.1 Large-scale Drilling Simulator 2.2 Drill bits
A fully instrumented Large-scale Drilling Simulator (LDS) In order to provide equal and balanced alteration and change
was used for the drilling. The LDS, as an automated drilling in the drill bit configuration, three drill bits were used including
frame that utilized a Data Acquisition System (DAQ-SYS) with

V010T11A087-2 Copyright © 2022 by ASME

(i) a Flat Bottom or Flat Base (FB) bit, (ii) a Drill Hole Opener The dimension of granite blocks used for drilling in this
(DHO) bit, and (iii) a Core Hole Opener (CHO) bit as shown in research was (~ 30cm long, ~ 30cm wide and ~ 15cm thick) as
Figure 2 top. Each bit of the three consists of two main parts: an shown in Figure 2 bottom.

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inner part, which is a 35mm dual cutter PDC bit and an outer
part, which is a 50.8 mm PDC coring bit. Both bit parts were set 3. EXPERIMENTAL METHOLOLOGY
at different levels to produce three bit types shown in Figure 2 As numerous research reported the positive influence of the
top. reconfigurations of bits and cutters on the drilling performance,
For the case of the FB bit type, the bottom end of the inner the idea of utilizing the DHO to more than a guide as a hole
and the outer parts were set at the same level. In the case of the opener to a tool be used for drilling performance evaluation by
DHO bit, the bottom level of the inner part was set in advance to examining its influence on ROP became under focus. The idea
the outer part bottom level by about 25mm. In the case of the involved two main stages including (i) isotropic rocks without
CHO bit, the bottom level of the outer part was set in advanced pre-existed fractures, in which micro fractures could be
to the bottom level of the inner by about 20mm. generated via DHO or CHO, and (ii) anisotropic rocks or rocks
with pre-existed fractures, whose fractures could be reactivated
and cracks could be extended by DHO or CHO.
The isotropic granite without preexisted fractures was used
for rock source for drilling in this research as shown in Figure 2
bottom. As an initial step of evaluating the use of the application
of this research, three bit configurations were implemented
including DHO, CHO, and FB. The drilling performance
evaluation used the FB as the base, which the results of DOH and
CHO were compared to.

4. RESULTS AND DISCUSSION

This section covers the results of drilling granite blocks
using three different drill bit types at two main sets of WOB.
These two sets of WOB were used only for evaluating this
research ideology at first, taking into account wider and higher
WOB increments in the future. The drilling performance was
evaluated based on the resultant rate of penetration (ROP) and
was categorized based on bit type (FB, DHO, or CHO) and the
WOB. The ROP was calculated by dividing a drilled interval by
the required time for drilling each interval. Figure 3 shows an
example of the procedure of calculating ROP from data recorded
by the bit position sensor for D1-1 and D1-2, which represent a
FIGURE 2: THREE DIFFERENT BIT CONFIGURATIONS first run of the FB bit at 5kN and the second run of the DHO bit
USED FOR DRILLING (TOP), GRANITE BLOCK at 10kN, respectively.
(BOTTOM).

Each reconfigured drill bit consisted of two main parts

including a 35mm dual-cutter PDC bit as an inner part and a 50.8
mm PDC coring bit as an outer part. Different length sleeves
were used to elevate the base of the outer part to match the
selected bit configuration between FB, DHO, and CHO.

2.3 Granite blocks

Granit was the rock type used for drilling tests. The
sufficient size of the granite rock blocks allowed drilling
multiple holes using all bit configurations and sets of WOB. This
granite was characterized to be isotropic rocks utilizing a
developed baseline procedure reported by Abugharara et al.
2016, 2017, and 2019 [11, 12, 14], indicating that its mechanical
and physical properties are orientation independent. Further
investigation on granite,
FIGURE 3: PROCEDURE OF CALCULATING ROP.

V010T11A087-3 Copyright © 2022 by ASME

Figure 4 (top) shows individual results of ROP obtained from
using FB bit against DHO bit applying WOB = 5kN. Results
show that each individual drilling ROP by DHO is higher than

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that of using FB bit. Zero intersect linear relationships were also
established. Figure 4 (bottom) shows individual results of ROP
from using FB bit against DHO bit applying WOB = 10kN.
Results show ROP were higher using DHO than that of using
FB bit.

FIGURE 5: AVERAGED ROP RESULTS USING FB BIT VS.

DHO BIT AT 5KN (TOP) AND 10KN (BOTTOM).

FIGURE 4: INDIVIDUAL ROP RESULTS USING FB BIT

VS. DHO BIT AT 5KN (TOP) AND 10KN (BOTTOM).

ROP results shown in Figure 4 are averaged and presented

in Figure 5. The averaged ROP using FB bit type vs. DHO bit
type at 5.7kN as shown in Figure 5 top was 0.08 m/hr vs.
0.11m/hr, respectively, showing ROP increase using CHO over
FB by a 37.5%. The averaged ROP using FB bit type vs. DHO
bit type at 10.6kN as shown in Figure 5 bottom was 0.17 m/hr
vs. 0.25 m/hr, respectively, showing ROP increase using DHO
over FB by 47.1%.
The initial indications of the ROP increase could be related
to the effectiveness of the bit and cutter reconfigurations that
could have led to generating micro fractures in the undrilled part
of the rock. Such initiation of the micro fractures could lead to
weaken the rock part to be drilled by the second pass of the drill FIGURE 6: AVERAGED ROP RESULTS USING FB BIT VS.
bit. CHO BIT AT 5KN (TOP) AND 10KN (BOTTOM).

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 The averaged ROP resulted from using FB and CHO 5. CONCLUSION
applying two sets of WOB are presented in Figure 6. The Laboratory experiments were conducted on drilling granite
averaged ROP using FB bit vs. CHO bit at 5.5kN as shown in blocks using different PDC bit configurations. The purpose of

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Figure 6, top was 0.08 m/hr vs. 0.09 m/hr. Such change in ROP the experiments was to investigate the influence of varying the
showed a 12.5% increase in ROP using CHO over FB at 5.5 kN configurations of bits on the drilling performance through the
applied WOB. Moreover, the averaged ROP using FB bit vs. calculated ROP.
CHO bit at 10.5kN as shown in Figure 6, bottom was 0.17 m/hr When the applied drilling parameters were the same, the
vs. 0.19 m/hr. Such change in the ROP showed an 11.8% results showed an increase in ROP as a response of the increase
increase in ROP using CHO over FB. of WOB when bit configurations modified from FB bit type to
The increase in ROP due to the bit reconfiguration could be DHO and CHO.
of a support to the published reports that indicated the The work of this paper, with all positive results requires a
importance of bit cutters on enhancing ROP and therefore continuation research and more investigation for validation,
improving the overall drilling performance. development, and implementations with more values of input
Table 1 summarizes the averaged ROP results obtained drilling parameters including WOB and rpm.
from all drilling tests. When using FB bit as a bit base, the results
show increase in ROP when using DHO and CHO against FB. FUTURE WORK
Such increase could be related to bit reconfiguration from FB to Although, the results of this research are promising in term
DHO and CHO the way could assist in generating micro of ROP increase using different bit configurations, the results are
fractures that could weakened the portion of the rock that was still initial and they require intensive follow up tests and
drilled by the first pass of the bit. experiments for validation.
Using the same bit configurations, other rock types
TABLE 1: PERCENTAGE INCREASE IN ROP BASED ON (isotropic rocks are recommended), comparative ROP analysis
DRILL BIT TYPE USED AND WOB APPLIED. should be constructed and reported based on the initial results
reported in this work.
ROP (m/hr)
WOB (kn)
FB DHO CHO Increase % ACKNOWLEDGEMENTS
5.7 0.08 0.11 37.5 This research is funded by Atlantic Canada Opportunity
Agency (AIF contract number: 781-2636- 1920044), involving
5.5 0.08 0.09 12.5 Husky Energy, Suncor Energy and Research and Development
10.6 0.17 0.25 47.1 Corporation (RDC) of Newfoundland and Labrador.
10.5 0.17 0.19 11.8
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