Since introducing the first Rotary Rock Bit in 1909, research and development programs at Baker Hughes have systematically advanced drill bit technology. A century and 1,200 patents later, Baker Hughes carries on the tradition of delivering new possibilities for the industry. Today, the Hughes Christensen Talon 3D high-efficiency vector-accurate PDC1.
Shale Applications drill bit is providing superior results to operators drilling wells in unconventional shale plays. The Talon 3D PDC bit can shorten the time it takes to drill a well, offering the directional control necessary to drill curve and lateral sections in a single run.
“When operations call for reducing trips, especially in shale play environments, our Talon 3D bit can help operators shorten their days on a well and increase the rate of penetration [ROP] in situations once considered off limits,” says Scott Schmidt, Baker Hughes President of Drilling and Evaluation. “Bottom line: this bit allows those using it to drill farther, faster and with more control.”
Dean Monkman, Operations Director, Baker Hughes Drill Bits Canada region, adds, “Already proven successful in US wells, the Talon 3D PDC drill bit designs are applicable to unconventional shale plays that include the Montney, Cardium, and Bakken in the western Canada basin. We are seeing that more and more of these unconventional shale wells are designed as horizontal wells; the bit design must be application-specific to horizontal drilling. As well as durability, the Talon PDC bits are designed for bit stability and are able to effectively achieve the required build-up rate for these horizontal wells,” explains Monkman.
“The bit will benefit conventional drilling operations in tough formations,” Rod Sheldrake, Sales Director, Baker Hughes drill Bits Canada region agrees, saying, “The applications include any directional drilling, build sections, horizontal wells, or drillout to kickoff point.”
Haynesville Example
While recent Canadian results are not yet available for release, in the Haynesville shale Baker Hughes deployed a 63⁄4-in. Talon 3D PDC drill bit for an operator seeking to improve drilling time through the curve and lateral sections in an interbedded formation. The horizontal lateral sections of wells in this shale play are typically 1200 to 1500 m and present challenges including bit, bottomhole assembly (BHA) and hole cleaning in highly weighted mud at a shale under high pressure. Performance of active wells had also been affected by the limited hydraulic and mechanical horsepower at the bit. The Talon 3D PDC drill bit was able to increase hydraulic efficiency, converting a traditionally two-bit interval run into one fast run—drilling up to 41% faster and 181% farther than direct offsets. technology such as the improved tool face control, consistent build-up rate, and reduced motor stalling, for example, made the difference in this run. The operator saved 67 hours and $101,000. The crew drilled a total of 1728 m at 11 m/hr compared with the average 61 m at 8 m/hr.
AFE Confidence: No surprises
Monkman explains, “We understand that confidence in AFE [Authority For Expenditure] is very important to our clients, and we see that there is a direct correlation of drill bit performance to achieving AFE. We are improving the overall drilling efficiency and effectively lowering their drilling costs. We share their desire to come in at or under their AFE—through drill bit performance, level of service, and execution—to drill the well accurately and in the allotted time frame they have programmed.”
Technical Features
The confidence in AFE cost estimates is due in part to the technical features built into the Talon 3D PDC drill bit’s design, including hydraulic efficiency, durability, bit profile design and cutting structures. each of these design elements contribute to the goal of achieving the desired build-up rate with directional control, while minimizing the number of drilling days and pipe trips. Sheldrake summarizes the drill bit’s benefits succinctly: “Fast and durable.”
Hydraulic Efficiency
The Talon 3D PDC drill bit is designed to improve hydraulic efficiency and provide longer life in tough formations. For instance, optimized junk slot volume and geometry provide hydraulic efficiency in low hydraulic horsepower per square inch situations. efficiently shaped and positioned blades, nozzles, and cutters are designed to increase the capacity and flow of cuttings, and resist packoff incidents to keep operators drilling at the desired ROP.
Durability
To improve run life, the Talon 3D PDC drill bit uses the Baker Hughes proprietary hardfacing for drill bit durability, and application-specific patented polished cutters. The polishing eliminates build up on the cutter face, enhancing the cutting action and cuttings transport. “The proprietary cutter technology gives us the ability to keep the bit effectively clean, reducing bit balling and therefore avoiding costly trip-outs,” says Sheldrake.
Directional Control
Directional control is enhanced by the Baker Hughes patented torque management technology. The drill bit strikes a balance to support axial and radial forces that BHA imposes on it while drilling. This enhanced control improves steerability, improving buildup rate aggressiveness. Monkman elaborates, “If we have the ability to drill curved and lateral sections in one run, this is a cost-savings to our clients. The applications for this bit mean that we are seeing, more and more, the ability to continue on in the wellbore and complete lateral sections with one assembly in the ground. At the end of the day, drill bit performance directly lowers the operator’s drilling time and costs in unconventional shale.”
Sheldrake also notes that, “The Talon PDC drill bit is available not only in a matrix body design, but also in a steel body design. As well as enabling large-volume junk slots for cuttings flow, steel offers the ability to build a shorter bit-to-bend dimension, useful in horizontal drilling with high build-up rates, such as 10°/30 m or higher.”
Design, Testing, and Manufacture
It is also noteworthy that the drill bits are actually designed and manufactured by Baker Hughes. This means the design can be tailored to the parameters of the specific formation and operation. In this way, Baker Hughes can provide application specific bit profile and cutting structures—such as cutter layouts, number of blades, size of cutters—that will exactly meet each customer’s needs. The distributions of stresses and strains are modeled and visualized so that the design parameters can be refined before the drill bit is manufactured. For example, the design can be adjusted to move harmful residual stress away from the PDC cutters’ edges, significantly increasing cutter life. Materials research work has also brought in improved matrix body materials and PDC cutter materials.
Drill bit performance is evaluated at Baker Hughes’ high-pressure drilling test facility, which has a full-scale drilling simulator to reproduce the harsh downhole environment so that researchers can assess the performance of new designs.
In the product evaluation laboratory, product wear and failure modes are examined to determine the causes for various dull bit conditions and to identify lessons learned and opportunities for design improvements.
A Century of Innovation
In 1907, Reuben C. Baker developed a casing shoe, modernizing cable tool drilling. In 1909, Howard r. Hughes Sr. introduced the first roller cutter bit, making it possible to drill through deeper, harder rock. Baker Hughes has carried on a century of technological and drilling innovation ever since. And in speaking to today’s employees, it is clear that the company still takes pride in anticipating and meeting their customers’ drilling needs. Monkman states, “We embrace the opportunity to work side by side with our customers to come to the table with the best product solution available.”
Further information may be found at www.bakerhughes.com.
