Astonishing advancements have been made in directional drilling during the past few years allowing drillers greater control in reaching a specified target zone. However, the goal of every driller is also to achieve a high rate of penetration (ROP) because high ROPs shorten drilling times and therefore, reduce overall drilling costs. To achieve higher ROPs, technologies involving every aspect of the drilling operation are continually being examined and refined. One of these technologies involves the selection of drill bits for rotary steerable systems (RSS). Security DBS Drill Bits now offers a full line of RSS bits through its FullDrift and HyperSteer product lines. Rotary steerable systems allow operators to plan complex wellbore geometries, including horizontal and extended-reach wells, which could not be drilled efficiently or effectively with conventional drilling methods. RSS accomplish this by enabling full directional drilling control in three dimensions while drilling with continuous drillstring rotation from the surface. This capability requires a special bottomhole assembly (BHA) to be installed above the bit. This BHA directs the wellpath in the desired direction while keeping the orientation of the drilling trajectory separate from its rotation and the rotation of the drillpipe above it. Point vs. Push Currently, rotary steerable systems can be divided into two groups, "push-the-bit" systems and "point-the-bit" systems. Both systems utilize complex working mechanisms to accomplish the desired independent 3D directional control. Push-the-bit systems steer the bit by applying a side load that forces the bit laterally in the direction of the desired curve. Point-the-bit systems steer the bit by tilting the bit in the direction of the desired curve.
Selecting the Right Drill Bit for Any Rotary Steerable System and Application
Jeff Crockett
Global Product Champion - Directional/Performance Drilling
Push-the-Bit and Point-the-bit systems. (Click to enlarge). No matter which type rotary steerable system is selected by the operator, the drill bit selection must be matched to the operating methodology of the RSS for maximum drilling optimization. By matching the most capable bit with both the RSS and the formation, key drilling factors such as efficiency, steerability and stability can be obtained. And, by obtaining these desirable factors, directional control, hole quality and vibration can be maximized as well. After the decision has been made on which type RSS will economically meet the objectives of the drilling program, the focus shifts to the drill bit that will make reaching the target zone possible. Considerations for bit selection include factors such as lateral and axial drilling efficiency, gauge pad length, cutting structure aggressiveness and durability. Depending on the system chosen, matching the bit with the system becomes a balancing act to achieve the desired deviation without introducing factors that disallow optimal bit performance.
Image shows various Gauge Pad lengths. (Click to enlarge). Bits Properties for Push Systems Push-the-bit rotary steerable systems generally require a bit design that is more laterally aggressive. Because it is a rotary
application, there is usually less concern about bit-induced torque and typically, there is plenty of power for a more aggressive design. However, features used to make the bit laterally aggressive can also make it somewhat less stable and more susceptible to vibration damage. Depending on the directional objectives, push-the-bit systems may require bits with varying degrees of lateral aggressiveness to achieve the desired build rate. Bit designs can be tailored specifically for applications requiring: Laterally aggressive bits with little or no passive gauge area in high steerability applications to yield the highest degree of dogleg severity, Laterally passive bit designs with increased passive gauge area in low steerability well designs where wellbore quality is of highest importance, A combination of these features to reach a given set of designer well objectives. Therefore, it is necessary to balance what is needed from a directional standpoint with what is needed for optimal bit performance. For example, a bit can be designed with optimized impact arrestors to minimize gauge cutter damage caused by side loading. Once the bit has been designed for the application, system-induced vibration will not cause impact damage to the cutting structure. While laterally aggressive PDC bit designs may be required to enable push-the-bit tools to steer, the side cutting capabilities of the bit must be tailored to achieve the desired deviation without introducing unnecessary tortuosity to the well path or creating excessive bit-induced lateral vibration (whirl). Particular attention should be paid to choosing the right amount of active/passive gauge in deviated and high-angle applications. Otherwise, micro- tortuosity could be introduced. This condition can result from an unwanted natural drop tendency that can occur while trying to hold a tangent or allowing the weight on bit to drill off. It is especially likely to develop during controlled drilling situations. A further challenge for modern rotary steerable systems is the destructive, low-frequency vibrations caused by stick-slip conditions which are common to straight rotary applications. The cutting structure layout's design features and blade geometry can limit the bit's contribution to this phenomenon. Bit Properties for Point Systems Today, several different point-the-bit systems are being utilized. Unlike push-the-bit systems, point-the-bit systems generally do not rely upon lateral aggressiveness. Typically, point-the-bit systems increase the gauge length for
stability and utilize "bit tilt" for directional changes. While the objectives are similar, the bit design requirements can be quite different. Not only does the particular application influence the bit requirements, but so does the working mechanism of the system. Lateral and axial drilling efficiency for the cutting structure, gauge pad length and aggressiveness, and cutting structure durability must all be matched to the particular application and the specific system being utilized. Systems such as Halliburton's Geo-Pilot system from Sperry Drilling Services with a Security DBS FullDrift bit can be ideal for applications where excessive torque and drag can inhibit drilling operations. Due to the system's ability to accurately place the well bore through multiple drilling targets, it can greatly improve production from a single well. It can also improve overall drilling efficiency by eliminating aggressive, side-cutting, unstabilized short-gauge bits that cause spiraling. As a result, this system enhances hole cleaning, bit life and downhole tool reliability while yielding more efficient casing and logging tool running operations. Drilling-by-Design - Custom Matched Solutions Matching the bit to the drilling system and the formation represents the key to optimizing directional drilling success. Three factors that influence drilling system performance are drilling efficiency, stability and steerability. Bits must be designed with these factors in mind because when they are achieved, directional control, vibration control and hole quality are assured. To realize the full potential of bit design, Security DBS employs the unique process of Design at the Customer Interface SM
(DatCI) which uses a global network of application design and evaluation specialists who work directly with customers to affect bit designs for specific applications. Using proprietary well planning software, these specialists match bit designs to applications to fully optimize bit characteristics and features. Later, during actual drilling, the software is utilized again to model the specific drilling environment in order to determine the optimum parameters and bit usage in real time. As a result, from initial application analysis to optimizing and evaluating bit performance, a continuous improvement loop produces significant performance results. This process has resulted in innovative bit technology utilizing the proven FM3000 series platform that matches bit designs to specific rotary steerable systems. Each steerable bit is custom designed to optimize directional control, vibration and bore hole quality. These rotary steerable bit design solutions have been applied successfully in a variety of geographical areas of the world to produce results that include:
In a push-the-bit application, the HyperSteer FMR3663Z bit drilled the longest rotary steerable run in the Viosca Knoll area, Gulf of Mexico, drilling to 14,200' with an average ROP of 65.6 ft/hr. In Offshore Brunei, a Geo-Pilot 9600 point-the-bit rotary steerable system with a 12-1/4" FMF3653Z FullDrift bit drilled the entire section in a single run while a competitor's product required four trips and two bits in a similar, adjacent section. Completion of three open-hole sidetracks with a point-the- bit offshore, Qatar drilling a total of 16,894' in 242.1 hrs. The HyperSteer FMR3755ZR bit was pulled in re- runnable condition, and all directional objectives were achieved. And in Saudi Arabia, an FMR3661 bit drilled 4055 feet at 45.1 ft/hr in the Arab D Formation, completing the interval in one bit run on a push-the-bit RSS. Conclusion The matching of an optimal bit design to a rotary steerable system is critical to the performance of that system in a drilling application. The result is increased efficiency, ROP and cost- effectiveness.
Whether a push-the-bit or point-the-bit system is selected, the bit must be designed and matched to the system. For push-the- bit systems, the bit should generally feature laterally aggressive design, with a shallow cone profile and short makeup length. For point-the-bit systems, which steer by tilting the bit, bit designs may feature longer gauge lengths. Powerful bit design tools are now available to optimize bit and
drilling performance through in-depth planning, bit design and post-well evaluation. Such tools are the result of new technologies, such as the FM3000 bit design platform, that are creating new highly successful RSS bits for operator drilling programs.
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