Numerical modeling on drilling fluid and cutter design effect on drilling bit cutter thermal wear and breakdown

Ayop, Ahmad Zhafran; Bahruddin, Ahmad Zafri; Maulianda, Belladonna; Prakasan, Aruvin; Dovletov, Shamammet; Atdayev, Eziz; Rani, Ahmad Majdi Abdul; Elraies, Khaled Abdalla; Ganat, Tarek Al-Arbi Omar; Barati, Reza; Wee, Sia Chee

doi:10.1007/s13202-019-00790-7

Cited by 12 publications

(3 citation statements)

References 8 publications

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“…Their results showed that the axe cutters have better drilling ability in hard formations and are suitable for the front row of the cutter blade of the PDC bit, while the angled cutters are more suitable for auxiliary rock breaking and should be installed in the back row of the cutter blade of the PDC bit. Conical PDC cutters are mostly used for auxiliary rock breaking in PDC bits [10,11]. Li et al [12] used the finite element method to numerically simulate the rock-breaking process of conventional PDC cutters, conical PDC cutters, and the overall rock-breaking process of the drill bit, and the results of the study showed that the conical cutters as auxiliary cutting structures could well produce pre-breaking of rocks at 100 MPa compressive strength, thus improving the overall drilling ability of the bit in hard rocks, while this approach was not effective for rocks with 50 MPa compressive strength.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Yuan

Zhang

et al. 2023

Applied Sciences

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As the depth of petroleum drilling increases, the strata environment becomes more complex. The efficiency and lifespan of Polycrystalline Diamond Compact (PDC) drill bits fail to meet current drilling demands. However, the structure and arrangement of PDC cutters are valuable determinants of drilling efficiency, although related research still has gaps and deficiencies. This study focuses on PDC cutters in axe, triangular prism, and circular forms. It establishes an inhomogeneous granite model based on the actual measurements of granite and verifies the accuracy of this model through uniaxial compression simulation. Finite element models of three types of cutters in various combination schemes are constructed to examine rock-breaking effects, with the best scheme optimized using Box-Behnken response surface methodology. The rock-breaking process of the optimal PDC drill bit layout has been compared to that of a single cutter bit. Field drilling has demonstrated the effectiveness of a mixed cutter arrangement. The results show that the inhomogeneous granite model can be trusted. The optimal arrangement involves axe cutters in the front row and an alternate arrangement of triangular prism cutters and axe cutters in the back row. The optimal lateral and longitudinal distances for the triangular cutters from the front row of axe cutters are 10 mm and 7 mm, respectively, while those for the back row of axe cutters from the front row are 10.06 mm and 7 mm, respectively. The ROP standard deviation in the drilling process of mixed cutter bits decreases by 53.06% and 43.08% compared to axe and triangular prism cutter bits, respectively. The drilling efficiency increases by 16.8% and 16.6%, respectively, demonstrating higher efficiency and stability. Field drilling results indicate that a mixed cutter bit increases efficiency by 23.5% compared to a bit with only triangular prism cutters. This study posits that research on the combination schemes and parameters of PDC cutters can significantly enhance drilling efficiency, thereby reducing the drilling cycle and costs.

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Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Yuan

Zhang

et al. 2023

Applied Sciences

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“…The roller cone drill bit (RCDB) [3], which is being investigated in this study, crushes the floor of the formation bed with exerted weights from the drill bit, rotation of the drill pipe, and the jet impact force of fluids from the drill bit nozzles. Noticeably, there is a considerable amount of heat generated from RCDB cutters during rock interactions in the formation [4,5]. The continuous thermal cooling and friction effect add an economic cost to the design and replacement of drill bits; for this reason, engineering synthetic-based muds (SBM) for this study as proposed by Van Ort [6] helps to prevent accelerated wear of the drilling bit and effectively transports solid formation particles to the surface.…”

Section: Introductionmentioning

confidence: 99%

“…Interestingly, MA's model elaborates that the C t at certain instances decreased slightly with seven nozzles as compared to a five-nozzle PDC drill bit. Further, a finite element modelling to investigate the thermal-mechanical wear of (PDC) drill bit in the wellbore and its influence on rate of penetration (ROP) was conducted by earlier researchers [5]. Their redesign of drill bit hydraulics and cutters resulted that chamfered geometric cutter was better with synthetic-based muds (SBM) while stinger designed cutter was also better with oil-based muds (OBM) as demonstrated in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

Modelling and Simulating Eulerian Venturi Effect of SBM to Increase the Rate of Penetration with Roller Cone Drilling Bit

et al. 2023

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Drilling bits are essential downhole hardware that facilitates drilling operations in high-pressure, high-temperature regions and in most carbonate reservoirs in the world. While the drilling process can be optimized, drilling operators and engineers become curious about how drill bits react during rock breaking and penetration. Since it is experimentally expensive to determine, the goal of the study is to maximize the rate of penetration by modeling fluid interactions around the roller cone drilling bit (RCDB), specifying a suitable number of jet nozzles and venturi effects for non-Newtonian fluids (synthetic-based muds), and examining the effects of mud particles and drill cuttings. Ansys Fluent k-epsilon turbulence viscous model, a second order upwind for momentum, turbulent kinetic energy, and dissipation rate, were used to model the specified 1000 kg/m3 non-Newtonian fluid around the roller cone drill bit. The original geometry of the nozzles was adapted from a Chinese manufacturer whose tricone had three jet nozzles. The results of our six redesigned jet nozzles (3 outer, 39.12 mm, and 3 proximal, 20 mm) sought to offer maximum potential for drilling optimization. However, at a pressure of 9.39 × 104 Pa, the wellbore with particle sizes between 0.10 mm and 4.2 mm drill cuttings observed an improved rate of penetration with a rotation speed of 150 r/min.

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Cutting mechanism of a special 3D concave-shaped PDC cutter applicable to the Weiyuan shale

Sun

Yang

et al. 2023

J Petrol Explor Prod Technol

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The Weiyuan shale gas field faces problems of long drilling cycles and high development costs. Improving the drilling efficiency of polycrystalline diamond compact bits in shale formations will significantly reduce the overall well cost and duration. Previous applications have demonstrated that conventional PDC bits on the market cannot meet the demand for drilling acceleration. In this work, a new three-dimensional concave-shaped PDC cutter was proposed to improve drilling efficiency. The special 3D concave-shaped cutter has two symmetrical curved ridges on the concave surface and a circular plane at the center. The cutting mechanism of the new 3D concave-shaped cutter has been studied by laboratory experiments and numerical simulations. The research data revealed that, compared with a flat cutter, the tangential force of the original 3D concave-shaped cutter was reduced by 1.4%–35.0%, the axial force was reduced by 6.7%–37.6%, and the mechanical specific energy (MSE) was reduced by 1.6%–35.59%. Simulations showed that the shear action of the 3D concave-shaped cutter was divided into two continuous parts, with the sides and the center surface being stressed successively, which is helpful for extending shear cracks, forming trilobal cuttings, and improving cutting efficiency. With the special 3D concave-shaped cutter, an 8½-inch drill bit was designed and manufactured and tested on the Longmaxi shale in the Weiyuan block. Through field tests, we further compared the performance of the 3D concave-shaped cutter PDC bit with that of the flat cutter PDC bit. The 3D concave-shaped PDC bit had a 41.8% better footage and 22.6% better rate of penetration (ROP) in field test.

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Numerical modeling on drilling fluid and cutter design effect on drilling bit cutter thermal wear and breakdown

Cited by 12 publications

References 8 publications

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Numerical Simulation and Field Test of a PDC Bit with Mixed Cutter Arrangement to Break Non-Homogeneous Granite

Modelling and Simulating Eulerian Venturi Effect of SBM to Increase the Rate of Penetration with Roller Cone Drilling Bit

Cutting mechanism of a special 3D concave-shaped PDC cutter applicable to the Weiyuan shale

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