American Oil and Gas Reporter - April 2015 - 144

SpecialReport: Bits & BHAs
According to Cary Maurstad, Varel International's global product manager for
roller cone and fixed cutter bits, the SlipStream RC Pro® marries tungsten carbide
insert roller cone and steel tooth roller cone
technology in a hybrid design to significantly increase frac plug drill-out speed
and the number of plugs drilled per run.
To illustrate, he cites an Eagle Ford study
that compared 25 wells drilled with firstand second-generation SlipStream RC
Pro bits to 32 wells drilled with standardsteel-tooth roller cone bits. "The hybrid bits
were 13.6 percent faster than standardtooth bits and averaged 3.3 more plugs per
use," he reports.
The bits work so well because they are
designed for the unique challenges associated with the coiled tubing drill-out process,
says Karl Rose, Varel's Western Hemisphere operations engineering manager. He
points out that this process exposes the bits
to high rotational speeds and temperatures
as hot as 350 degrees Fahrenheit.
"In addition, the drill-out process
washes out and recovers small-grain frac
sand at wellhead pressures between 4,000
and 5,000 psi," Rose continues. "Pressure
spikes encountered drilling into each iso-

The SlipStream RC Pro® frac plug drillout bit from Varel International features
a high-capacity grease reservoir to extend the bit's life, enabling it to drill more
plugs on each run.

lated zone can cause rapid cone pumping
and grease loss that reduces bearing life.
At the same time, hydrocarbons can cause
seals to become hard and ineffective."
The plugs themselves can present an issue, Rose adds, noting that most have a
hard outer portion and a soft middle. The
outer portion quickly degrades cutters,
while the middle generates large cuttings
that are hard to circulate, he explains.
"To effectively drill the two very different plug materials, the Slipstream RC
Pro has both steel tooth and TCI cutting
structures on each cone," Maurstad reports.
"We also developed a new bearing and
compensation system that provides greater
resistance to pressure spikes and chemicals."
The TCI cutting structure is on the outside of the cones to drill the hard part of
the plug, Maurstad details, noting the inserts are subjected to a patented high-energy tumble process to increase durability. Short and closely spaced steel-tooth inner rows provide small cuttings for easy
transport, Rose adds. He estimates the cuttings typically are smaller than half the size
of conventional-tooth-bit cuttings, significantly reducing wash-down time between plugs.
To mitigate pressure spikes and ensure
adequate grease, the bit's lubrication system employs a patented attenuator and has
a grease reservoir with 250 percent more
capacity than previous designs, Maurstad
continues. The fully contained grease diaphragm offers greater durability under
rapid cone pumping. Seals are manufactured from a highly saturated nitrile material with more thermal stability, broader chemical resistance, and greater tensile
strength than regular nitrate compounds,
he reports.
These durability enhancements have
paid off, Rose assures. As an example, he
offers an application in Atascosa County,
Tx., in which the bit drilled one bridge plug
and 25 frac plugs in 234 minutes for an average drilling time of nine minutes per
plug. The bit experienced minimal wear
with a dull grade of 1-2-WT-G-EEE-XER-TD.
"More than 254 drill-out runs have
been completed using the bits. The latest
generations have almost doubled the
number of plugs drilled out during each
run while remaining in excellent shape,"
Rose concludes.

Carbonate Conqueror
To help operators drill challenging

144 THE AMERICAN OIL & GAS REPORTER

curve sections in carbonate formations,
Baker Hughes has introduced the
Kymera™ FSR directional hybrid bit.
"The bit delivers fast, smooth, and reliable
performance," says Alan Holliday,
Kymera product manager. "It provides increased drilling speeds, greater distance
between runs, and improved directional
precision."
The bit excels in carbonate formations
because it combines the features of PDC
and tricone technologies, Holliday says.
The sharper, more aggressive teeth on the
bit's roller cones crush carbonate formations with ease, while the PDC cutters
sweep away debris and efficiently clean
the borehole, he explains.
The FSR's design enables it to drill
much faster than a tricone bit while reducing the reactive torque fluctuations associated with PDC bits, Holliday reports.
"Reducing torque decreases damage to the
bit and drill string, and provides added
tool-face control, resulting in faster, more
precise, and smoother drilling for long distances," he says.
The bit was tested initially in the
Wolfcamp formation in the Permian
Basin, but has expanded to five U.S.
basins. Holliday says that in field tests in
the Permian Basin, Eagle Ford Shale,
Canada and Latin America, the bit increased penetration rates an average of 80
percent compared with the offset average,
and had an 82 percent success rate in getting to total depth with only one bit.

With features from PDC and tricone bits,
the KymeraTM FSR from Baker Hughes
offers both durability and speed when
drilling through carbonate formations.



American Oil and Gas Reporter - April 2015

Table of Contents for the Digital Edition of American Oil and Gas Reporter - April 2015

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American Oil and Gas Reporter - April 2015 - Cover3
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