BP uses 3D-printed armor to increase average bit ROP 36% and reduce drilling time 179 hours over eight runs

By replacing a matrix bit with a modified steel-bodied bit shielded with Aegis™ 3D-printed armor, BP made significant gains in drilling performance. The 12 1/4-in vertical interval in each of eight wells was drilled shoe-to-shoe in a single run. ROP increased by an average of 36% compared with direct offset runs of matrix PDC bits, saving an estimated 179 hours of drilling time across the eight runs.

The operator’s concerns

BP wanted the highest possible ROP while drilling 12 1/4-in vertical intervals from shoe-to-shoe in single runs. The series of wells are in Oklahoma, through a formation that includes soft shale interbedded with sandstone and limestone.

What was tried first

Previous bit runs used 12 1/4-in matrix PDC bits to successfully drill the interval in a single run, but it was thought that there could be an opportunity to further improve ROP by modifying the bit design.

What SLB recommended

Steel-bodied bits enable bit-body geometries more favorable to better evacuate cuttings from the bit face. But conventional steel-bodied bits are prone to erosion, so bit balling occurs by positioning the nozzles to direct the hydraulic energy away from the cutting structure. SLB solved this with the introduction of Aegis 3D printed armor. The advanced strips of shielding protect blade faces on steel-bodied bits, enabling SLB to design steel bits with taller blades and an increased junk-slot area.

What BP achieved

Two new-built steel-bodied bits with Aegis armor were run in eight different wells, for a total of eight bit runs. BP was able to drill the respective intervals from shoe-to-shoe in a single run. ROP with bits shielded by Aegis armor increased by an average of 36%, compared with direct offset runs of matrix PDC bits. This enabled BP to save an estimated 179 hours of drilling time across the eight runs.