IADC/SPE 59113
New Technology in Diamond Drill Bits Improves Performance in Variable Formations
Tim Beaton, GeoDiamond; Keith Johnson, Tesoro Petroleum
Copyright 2000, IADC/SPE Drilling Conference
This paper was prepared for presentation at the 2000 IADC/SPE Drilling Conference held in
New Orleans, Louisiana, 23–25 February 2000.
This paper was selected for presentation by an IADC/SPE Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the International Association of Drilling
Contractors or the Society of Petroleum Engineers and are subject to correction by the
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Abstract
Recent advances in diamond bit technology have helped to
bridge the gap between polycrystalline diamond compact
(PDC) and diamond impregnated bit applications. A new type
of diamond bit has been developed to effectively drill hard,
abrasive formations, while retaining the ability to efficiently
drill through non-abrasive sections. This new type of diamond
bit utilizes a three part cutting structure consisting of PDC
cutters, diamond impregnated blades, and hot pressed diamond
impregnated inserts.
Technological advances in the design and manufacture of
diamond bits have greatly expanded the applications of both
PDC and diamond impregnated bits. However, there are still
many intervals of hard rock drilling which have sections that
are too hard or abrasive for a conventional PDC bit, but also
contain sections that are not sufficiently abrasive to be
effectively drilled with a conventional diamond impregnated
bit. Drilling these types of intervals with conventional drill
bits has proven very costly. Operators have been forced to
choose between incurring expensive trip times, due to the need
to frequently change out bits to maximize the rate of
penetration (ROP) in the different formations, or suffering
through the very slow penetration rates typical of conventional
impregnated drilling in non-abrasive formations.
A very successful run has recently been completed with this
new diamond bit in the Huamampampa formation in Tarija,
Bolivia. In a long, 8 ½” hole size section, where the shale
content ranged from 10 to 90%, this new bit type drilled to TD
with a higher overall rate of penetration than any offset. The
combination of PDC cutters with hot pressed diamond
impregnated inserts in a diamond impregnated matrix has
proven to be a very versatile cutting structure in variable
formations.
Introduction:
The introduction and development of drag type drill bits with
diamond cutting elements has greatly reduced the cost
associated with many drilling programs. Due to the excellent
abrasion resistance of diamond cutting elements, and to the
fact that this type of drill bit has no moving parts, diamond
bits are capable of drilling very long sections relative to roller
cone type bits. The long bit life of a diamond bit has proven
to greatly reduce the number of trips required to drill a given
interval, particularly in areas where rig costs tend to be high.
Diamond bit technology has recently come full circle. As a
result of material and manufacturing constraints, the first drag
type drill bits that used diamonds for the cutting elements
were of the impregnated type (diamond impregnated bits are
constructed such that the diamond cutting elements are
suspended throughout the tungsten carbide matrix blades).1
As materials and manufacturing processes advanced, the
diamond bit drilling industry moved away from diamond
impregnated bits into surface set diamond bits (surface set
diamond bits use a single layer of fairly large natural
diamonds arranged on the face of the bit). These surface set
diamond bits are capable of retaining much larger diamonds
for higher diamond exposure, which translates to a higher rate
of penetration (ROP) potential for a given rotary speed.2
Therefore, surface set diamond bits provided the advantage of
a fixed diamond cutter design (no moving parts), and also
offered a reasonably wide range of diamond sizes for varying
formation hardness.
The next major advancement in the diamond bit industry
occurred with the introduction of PDC bits, which use
relatively large (3/8” diameter to 1” diameter) diamond
compact discs as the cutting elements. For a variety of
reasons, when PDC bits were first introduced, they were
limited to drilling soft to medium strength formations. At this
stage in the development of diamond drilling technology,
surface set diamond bits were used in medium hard to hard
applications, while PDC bits were used in soft to medium
applications.
2 T. BEATON, K. JOHNSON
Since the introduction of PDC bits, there have been many
significant advances in the properties and design of the PDC
cutting elements (cutters).3,4,5 In addition to the development
of the cutters themselves, drill bit manufacturers have made
large strides in understanding the drilling mechanisms
involved in the shearing action of this type of drill bit. This
improved understanding has led directly to new advanced bit
designs that are greatly increasing the application envelope of
PDC bits.6,7,8 In many cases, this increased application
envelope has taken away a large portion of the “softer end” of
the surface set diamond bit market.
The circle of diamond bit development was completed with
the fairly recent re-introduction of impregnated type diamond
bits. With the proliferation of turbines and high-speed motors,
capable of higher rotary speeds than previously possible,
diamond bit manufacturers were able to produce diamond bit
designs with smaller diamonds without sacrificing ROP
potential. Further, as a result of advances in the design,
materials and manufacturing processes involved in producing
diamond impregnated bits, drill bit manufacturers are able to
deliver diamond impregnated bits which can drill as fast as,
and longer than, surface set diamond bits in hard and abrasive
applications. The combination of high rotary speeds and
improved diamond impregnated materials has allowed
diamond impregnated bits to nearly displace surface set
diamond bits in the “harder end” of that market.
The challenge that remains to the diamond bit industry is to
expand the existing market in order to continue to reduce
operators’ drilling costs. Significant strides have been made
in this area through a more thorough understanding of the
formations being drilled. The tools that are available and in
common use today for formation evaluation are a major reason
for the increase in the application envelope of diamond bits.9
Nonetheless, in spite of the excellent work that has been
completed in the development of both PDC bits and diamond
impregnated bits, there are still many applications that fall
between the two. The industry has seen, and continues to see,
significant technological developments in PDC bits which
enable these bits to perform economically in harder and more
abrasive applications than ever before, yet there are still many
applications that are either too hard or too abrasive for PDC
bits. Conversely, while traditional diamond impregnated bits
drill effectively in hard and abrasive applications, bit balling
and ineffective cutting action are common in non-abrasive
formations.
There are many hard rock drilling applications around the
world where certain hole intervals have very mixed
lithologies. For example, many intervals contain wide-ranging
percentages of sandstone and shale. In these applications, the
costs associated with drilling are very high. The traditional
options available for drilling these intervals are to either run a
drill bit that will produce a fairly high rate of penetration
(ROP) for a short period of time, or to run a bit which will
drill for a fairly long period of time at a slow ROP.
IADC/SPE 59113
The three main types of drill bits for these applications are
PDC, diamond impregnated, and roller cone bits. PDC bits
traditionally exhibit good ROP through the shale sections, but
quickly dull out in abrasive sands. Roller cone bits also
exhibit good ROP in these sections, but cannot drill for the
extended times typical of fixed cutter diamond bits. The main
problem with using roller cone or PDC bits is the cost induced
by tripping out of the hole frequently to change out dull bits.
On the opposite end of the spectrum lies traditional diamond
impregnated bits. This type of drill bit is ideally suited for
drilling in abrasive / sandy applications, but does not drill
efficiently through sections with a high percentage of shale.
The limited exposure of the diamond cutting structure,
coupled with the limited amount of space available for the
ejection of cuttings, equates to very slow rates of penetration.
Therefore, while traditional diamond impregnated bits can
drill through these formations for fairly long times, their
corresponding rates of penetration tend to be very low.
This paper will present a novel diamond bit design that
bridges the gap between diamond impregnated and PDC bit
applications. This new type of diamond bit combines the
advantages of PDC and diamond impregnated cutting
structures, and introduces a unique concept in diamond bit
cutting elements.
Background:
The Palo Marcado field in Tarija, Bolivia contains a very hard,
variable formation. The current drilling campaign on this
field, located in Southern Bolivia, just north of the
Argentinean border, began early in 1997.
The formation in question is called the Huamampampa. In
this field, the formation top comes in just below the Los
Monos at a depth of ~ 4100 meters, and continues down to
finish just above the Icla at a depth of ~ 4800 meters. This
formation is of Devonian age, and contains mostly sandstone
and shale. The compressive strength of the Huamampampa
averages around 18,000 psi, with a high of 30,000 psi. The
difficulty in drilling this hard formation is evident through
investigation of the lithology. In this area, the shale content of
the Huamampampa is highly variable and can range from 10%
to 90%.
Much effort has been devoted to determining the most
economical method of drilling this challenging interval. As
with many other applications of this nature, the three main
types of drill bits discussed above have been utilized. Roller
cone bits have proven to perform with respectable ROP (1 – 2
m/hr), but have historically drilled short sections (20 – 30 m).
PDC bits have displayed even better ROP (up to 2.5 m/hr), but
have similarly been dulled quickly (~ 60 m). The bit type that
has historically exhibited the best performance in this
formation is the diamond impregnated style. However,
although they have been able to drill fairly long sections (135
– 170 m), the rate of penetration of these bits still remains
relatively low (0.5 – 1.75 m/hr).
IADC/SPE 59113 NEW TECHNOLOGY IN DIAMOND DRILL BITS IMPROVES PERFORMANCE IN VARIABLE FORMATIONS
It became obvious that a different type of drill bit was required
to effectively drill a variable formation such as this one.
Based on the performance of the drill bit types that had been
used to date, the decision was made to use a diamond
impregnated bit as the platform upon which to develop this
new bit style.
New Technology:
In order for a new bit type to achieve optimum performance in
variable formations, it was necessary to implement features
from both PDC and diamond impregnated bits. As mentioned
previously, the basis of the design is a diamond impregnated
cutting structure. However, in order to maximize the
performance of the bit in shale sections, PDC cutters have
been added in crucial locations. In addition to these two
cutting structures, a third, novel, diamond impregnated cutting
structure has been developed. This new cutting structure
consists of hot-pressed diamond impregnated inserts
strategically placed over the surface of the bit. These inserts
have proven to provide three times greater wear resistance
than traditional diamond impregnated material.
PDC Cutters:
One of the greatest challenges in impregnated bit design
concerns the center of the bit. A frequent failure mode of
impregnated bit designs is coring. This is a result of many
factors, including the fact that it is difficult to incorporate
sufficient diamond density for long-lasting and efficient
drilling while maintaining sufficient void volume for the
proper ejection of cuttings. To overcome this challenge, PDC
cutters have been employed in the center of this new type of
drill bit. As a result of the relatively high diamond density of
a PDC cutter as compared to a traditional diamond
impregnated cutting structure, the void volume in the center of
the bit can be greatly increased without sacrificing durability.
Also, due to the fact that the surface speed of the formation
with respect to the PDC cutters is low, as a result of the small
distance from the axis of rotation, the PDC cutters experience
very long life. Thus, there is no decrease in durability, yet a
greatly decreased chance of balling in the center of the bit.
This reduces the possibility of failure due to coring.
Another positive effect of the use of PDC cutters in the center
of the bit is increased ROP potential. Again, due to the large
void volume that is produced by the relatively enormous
exposure of the PDC cutters, as compared to the diamonds in
the diamond impregnated cutting structure, the center of the
bit is much more aggressive than the remainder of the bit’s
profile. Therefore, the ROP is governed by the cutting action
of the diamond impregnated cutting structure located further
along the profile of the bit where surface speeds are
significantly higher than in the center.
A further challenge in the design of diamond impregnated bits
is the retention of gage diameter. The challenge stems from
the fact that these bit types commonly drill in very abrasive
applications at very high rotary speeds (1000+ RPM). This
3
challenge, too, was overcome with the inclusion of PDC
cutters. In addition to traditional matrix gage protection,
which consists of natural diamonds, tungsten carbide, and
thermally stable polycrystalline diamond (TSP), this new bit
type incorporates PDC gage trimmers. These PDC cutters are
pre-ground to produce a large flat area that maximizes the
diamond available for maintaining gage diameter.
Diamond Impregnated Blades:
As previously mentioned, the traditional diamond impregnated
bit is the basis for this new type of diamond bit. The entire
structure of the blades on this novel drill bit is constructed
from diamond impregnated material. Therefore, in the
absence of the other two components of this new diamond bit
(PDC cutters and hot-pressed inserts), there remains a
complete cutting structure comprised of diamond impregnated
material.
The advanced materials used in the diamond impregnated
blades have been designed to maximize diamond quality and
diamond retention. In order to manufacture a diamond
impregnated bit, it is necessary to suspend the diamonds in a
tungsten carbide matrix and then infiltrate the matrix in a
furnace operation. Thus, the quality of the diamond cutting
structure is dependent on the temperature of the infiltration
process and the cycle time required to complete the
infiltration. The advanced materials and manufacturing
processes used to create the diamond impregnated blade
structure of this unique diamond bit were specifically
developed to minimize the infiltration temperature and total
time at temperature.
In order to quantify the improvement realized in diamond
quality, an extensive set of laboratory tests was undertaken.
The tests were based on the industry standard, granite log test
that is utilized to test the abrasion resistance of PDC cutters.
This represents a unique application of the granite log test to
the quantification of the performance of a diamond
impregnated matrix. In the tests, a cylindrical sample is
produced to mimic the materials and processes of the matrix
blade structure. Next, a wear ratio value is calculated based
on the volume of rock that is removed by the sample and the
volume of sample that is worn away during testing (Fig. 1).
As shown in Figure 2, the new advanced matrix used to form
the diamond impregnated blades is nearly one and one half
times more wear resistant than traditional materials.
Hot-Pressed Diamond Impregnated Inserts:
The hot-pressed diamond impregnated inserts utilized in this
new diamond bit represent the highest quality diamond
impregnated cutting structure. As mentioned above, the
quality of the diamonds in an impregnated cutting structure is
entirely dependent upon the temperature to which they are
exposed and the time for which the exposure occurs. Through
the use of the hot-pressing operation, the time that the
diamonds are exposed to elevated temperatures has been
4 T. BEATON, K. JOHNSON
reduced by 85%, and the temperature to which they are
exposed has been reduced by 35%.
In a unique application, the inserts are attached to the diamond
impregnated blade structure in a brazing operation,
simultaneously with the PDC cutters. This novel process
eliminates the need to subject the diamond in these inserts to
the elevated temperatures and long cycle times required during
the infiltration of the matrix body.
In an extension of the testing program from above, these new
hot-pressed inserts were compared against the diamond
impregnated cutting structure used in the blade structure. As
seen in Figure 3, these new inserts are nearly twice as wear
resistant as the advanced materials used in the blade structure,
and nearly three times as wear resistant as traditional diamond
impregnated materials.
In addition to the improved properties of these inserts, insert
placement has been engineered similar to that of the cutters in
PDC bits. Thus, this new diamond bit type has two complete
cutting structures. In the absence of the PDC cutters or hot-
pressed inserts, the diamond impregnated blade structure
constitutes a complete bottom hole pattern. Additionally, in
the absence of the diamond impregnated blade structure, the
PDC cutters and hot-pressed inserts comprise a full bottom
hole pattern. Therefore, there is redundancy in diamond
coverage yielding maximum durability. Also, because the
new inserts are several times more wear resistant than a
traditional infiltrated diamond impregnated cutting structure,
the void volume on the bit face can be correspondingly
increased, improving performance in shale sections.
Consequently, this new type of diamond bit can have fewer
blades, or thinner blades, than traditional diamond
impregnated bits, increasing the cleaning efficiency of the
design while concurrently increasing overall durability.
Finally, another major advantage of this new type of diamond
bit is the ability to customize each drill bit according to the
formation to be drilled. The primary cutting structure of this
new design is comprised of PDC cutters and hot-pressed
inserts, and, similar to PDC cutters, the hot-pressed inserts are
available in different compositions. Therefore, the inserts
used in each drill bit can be specially selected to match the
formations being drilled.
Performance Summary:
The next step in the development of this new type of diamond
bit was to test it in the field. An ideal opportunity was
presented in the Palo Marcado field in Tarija, Bolivia. The 8
½” hole section of the Palo Marcado-X5 well included a
significant section of the Huamampampa.
An 8 ½” diameter drill bit incorporating the advanced features
described in this article was designed, produced, and used for
drilling through the Huamampampa. The run was performed
in oil-based mud with a high speed motor, for an overall rotary
IADC/SPE 59113
speed of 363-378 revolutions per minute (RPM), with a
weight-on-bit range of 4,000-15,000 lbs. These and other run
parameters, including ROP, torque, flow rate, and standpipe
pressure, can be found in Figure 4. The shale content recorded
during this run ranged from 10% to 90%, as shown in Figure
5. Figure 5 also displays the ROP curve alongside the
lithology, demonstrating the bit performance throughout the
run.
The new diamond bit drilled 182 meters of the Huamampampa
in 62 hours, for an average ROP of 2.93 m/hr. Figure 6
reveals photographs of the dull bit. The fastest offset in this
area of the Huamampampa was a PDC bit that recorded an
average of 2.40 m/hr, but drilled only 63 meters. The longest
offset in this area was achieved with a traditional diamond
impregnated bit which drilled 172 meters at an average ROP
of 1.70 m/hr (Fig.6). Penetration depths and ROP’s for these
offset bit runs and the new diamond bit are shown graphically
in Figure 7.
This novel diamond bit achieved the desired result of drilling
at faster penetration rates for longer times than previously
possible with traditional bits. By drilling this variable
formation faster than offsets, this single run through the
Huamampampa saved the operator over $100,000.
Conclusions:
1. Advances in the design of PDC cutters and PDC bits are
expanding the envelope of drilling efficiency into harder
and more abrasive applications.
2. Advances in the materials and design of diamond
impregnated bits, along with the proliferation of turbines
and high speed motors, are expanding the envelope of the
drilling efficiency of diamond impregnated bits into
“softer” and less abrasive applications.
3. In spite of the excellent improvements in diamond bit
technology, there remain many applications where
diamond bit performance is poor.
4. For formations in which diamond bit performance is poor,
a new type of diamond bit has been developed that
combines the features of diamond impregnated and PDC
bits.
5. New materials have been developed which increase the
life of diamond impregnated blades by over 40%.
6. A novel diamond impregnated insert has been developed
which has nearly three times greater wear resistance than
traditional diamond impregnated materials.
7. The use of PDC cutters in the center and gage sections of
the new bit allows a much more open design, decreasing
balling tendency without sacrificing durability.
8. Due to a very open faced design, the new diamond bit
discussed herein displayed unsurpassed ROP in a long
hole interval where the percentage of shale ranged from
10% to 90%.
IADC/SPE 59113 NEW TECHNOLOGY IN DIAMOND DRILL BITS IMPROVES PERFORMANCE IN VARIABLE FORMATIONS 5

Acknowledgements:
6000
The authors wish to thank Tom Oldham, David Truax, Duane
Van Waes, and Jorge Vargas of GeoDiamond for their insight 5000 Wear Ratio = Volume Rock Removed
and efforts towards the completion of this project. Special Volume Sample Removed
4000

Wear Ratio
thanks also go to Paul Redfield and Christy Martin of Smith
Bits for their support and assistance. 3000

References: 2000
1. Selim, A.A. et. al.: “The Effect of Additives on
1000
Impregnated Diamond Bit Performance,” paper SPE 2387
presented at the Fourth Annual Drilling & Rock 0
Mechanics Conference, Austin, Texas Jan. 14-15, 1969. Standard Advanced
2. Garner, N.E., “Cutting Action of a Single Diamond Under Matrix Matrix
Simulated Borehole Conditions,” paper 1701 presented at
SPE Third Conference on Drilling and Rock Mechanics,
Fig. 2 - Bar graph of the wear ratio of diamond
Austin, Texas, Jan. 25-26, 1967.
impregnated samples consisting of standard and advanced
3. Mensa-Wilmot, G., “New PDC cutters improve drilling
matrix materials.
efficiency,” Oil & Gas Jornal, October 1997.
4. Mensa-Wilmot, G., et. al. “Twin Edge Cutter (TEC) –
Enhancing PDC Bit Development and Performance,”
SPE/IADC 37637, Amsterdam 1997.
5. Mensa-Wilmot, G., et. al. “Unique Polycrystalline
6000 Wear Ratio = Volume Rock Removed
Diamond Compact (PDC) Cutter Improves Drilling
Efficiency,” SPE 53954, Caracas, Venezuela, April 1999. 5000 Volume Sample Removed
Wear Ratio

6. Vargas, J.E., “Drilling Hard and Abrasive Formations 4000

with PDC Bits,” SPE 23713, II LAPEC, Caracas,
3000
Venezuela, March 1992.
7. Alexander, W.L., et. al. “New PDC Bit Design Reduces 2000
Vibrational Problems,” Oil & Gas Journal, May 1995. 1000
8. Mensa-Wilmot, G., “Innovative Cutting Structure
0 Standard Advanced Hot-
Improves Stability and Penetration Rate of PDC Bits
Matrix Matrix Pressed
Without Sacrificing Durability,” SPE/IADC 39310,
Insert
Dallas, Texas, March 1998.
9. Mensa-Wilmot, G., “Formation Drillability-Definition,
Quantification and Contributions to Bit Performance Fig. 3 - Bar graph as in Figure 2, including the
Evaluation,” SPE/IADC 57558, Abu Dhabi, UAE, performance of the hot-pressed inserts.
November 1999.

Wear Ratio = Volume Rock Removed

Volume Sample Removed

Fig. 1 - Photo of the wear on a diamond impregnated

insert as a result of the granite log test, with wear ratio
calculation.
 6 T. BEATON, K. JOHNSON IADC/SPE 59113

ROP (m/hr) LITHOLOGY (%)

FORMATION
0 2 4 6 8 10 0 20 40 60 80 100
ROP (m/hr) WOB (Klbs) RPM TQ (Lb*Ft) FLOW (gpm) SPP (psi) 4468
SHL
0 2 4 6 8 0 8 16 24 300 400 500 1000 4000 7000 300 350 400 2000 3000 4000
4473
4465 SST
4478
4470 SD
4483
4475
4488
4480
4493
4485
4498
4490
4495 4503

4500 4508

4505 4513

4510 4518

4515 4523

4520 4528

4525 4533
4530 4538
4535 4543
4540 4548
4545 4553

DEPTH (m)
4550 4558
HUAMAMPAMPA
DEPTH (m)

4555 4563
4560 4568
4565 4573
4570 4578
4575 4583
4580 4588
4585 4593
4590 4598
4595
4603
4600
4608
4605
4613
4610
4618
4615
4623
4620
4628
4625
4633
4630
4638
4635
4643
4640
4648
4645

4650

Fig. 5 - ROP curve alongside Lithology to display the

Fig. 4 - Run parameters from the successful run in Bolivia performance of the new diamond bit throughout the
(ROP, WOB, RPM, Torque, Flow Rate, Standpipe variable formation (Huamampampa).
Pressure).
IADC/SPE 59113 NEW TECHNOLOGY IN DIAMOND DRILL BITS IMPROVES PERFORMANCE IN VARIABLE FORMATIONS 7

Huamampampa Formation - Bolivia, 8 1/2" Hole Size

Footage ROP

200 3.50
PMO-X5 WELL
SAL-X10 WELL
180
3.00
160

140 2.50
Drilled
(m) 120
2.00 ROP
(m/hr)
100
1.50
80
SAL-X10 WELL SAL-X10 WELL
60 1.00

40 MGT-X1 WELL
0.50
20

0 0.00
PDC BIT TSP BIT IMPREGNATED BIT BICENTER BIT NEW DIAMOND BIT
(PDC)

Bit Type (Serial)

Fig. 7 - Bar graph of penetration depths and ROP’s for the

novel bit run and offset bit runs in the Huamampampa.

Fig. 6 – Photographs of the dull bit from the run in Bolivia.