diamond – talisman to top drive
TRANSCRIPT
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Primary funding is provided by
The SPE Foundation through member donations
and a contribution from Offshore Europe
The Society is grateful to those companies that allow their
professionals to serve as lecturers
Additional support provided by AIME
Society of Petroleum Engineers
Distinguished Lecturer Programwww.spe.org/dl
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Diamond – A Driller’s Best Friend
Terry MatthiasNational Oilwell Varco
Society of Petroleum Engineers
Distinguished Lecturer Programwww.spe.org/dl
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Overview
Natural Diamond
Tungsten CarbideCobalt
Copper Nickel
Natural Diamond Bits
PDC Bits
Synthetic Diamond
PDCPDCPerformance
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Early Use of Diamond
• Mists of Time
– Adornment
– Stoneworkers
– Talisman (Lucky Charm)
• From 1000 A.D.
– Cleave & later polish diamonds
Courtesy Wikipedia Courtesy Wikipedia
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What is diamond?
• 1700’s New science of chemistry
– Break down materials with fire –couldn’t with diamond
• 1772 Antoine Laurent Lavoisier
– Magnifying glass to burn diamond
• 1797 Smithson Tennant
– Diamond = Graphite
Courtesy Metropolitan Museum of Art
Courtesy Wikipedia
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Early attempts to make diamond
• 1772 – 1870 Temperature
– Attempts to grow diamond crystals by evaporation of carbon rich solutions
• 1870 Diamonds found South Africa
• 1870 – 1910 Temperature and Pressure
– Iron tubes, electric arcs, explosives, high velocities
All Failed
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Structure
• 1912 Crystallography
Graphite
Diamond
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High Pressure
• Percy Bridgman
1900 2,500 Cell leakage
1905 7,000 Screw press
1910 20,000 Hydraulic press
1935 50,000 Opposed tapered steel anvils
1940 70,000 Opposed tapered carbide anvils
YearPressure
(atm)
Courtesy Wikipedia
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Cobalt PowderTungsten CarbideParticles
High Pressure
Cobalt Cemented Tungsten Carbide
Carbide
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Thermodynamics predicts Phase Diagram
Energy
Early 1940’s GE & Norton engage Bridgman
High pressure & high temperature tests to establish conditions
diamond not destroyed
Conclusion
>1,000°C & >50,000 atm
to make diamond
High Pressure & High Temperature
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Natural Diamond Bits
• Diamond retention
– Cannot wet
– Mechanically lock
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Synthetic Diamond
• 1951
–Project Superpressure at General Electric
• 1954
–16th December First diamond made
• Repeated 20 times in next 2 weeks
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Man-Made® Diamond
1957 – 1977 Synthetic Diamond Grit• Improving control of
process for shape & properties
• Averaged a new product every year
• Grinding, sawing, drilling, lapping & polishing non ferrous materials
®GE registered trademark
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PCD
• Large single diamond crystals cleave
• Carbonado
– Grains of diamond, diamond-to-diamond bonded together, a natural polycrystalline diamond
• 1973 Compax® φ8mm x 3.5mm
– GE mix cobalt & fine diamond
– Press at 60,000 atm & 1400°C
®GE registered trademark
Courtesy Wikipedia
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First PDC Bits
• 1974 - 1st Bit runs
– USA
– Isle of Wight, England
Courtesy NOV
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Cutter & Bit Development
19761973
1978
19821986
19791980
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PDC Development for Drill Bits
Compromise Between
Hardness & Durability
Hard – Wear resistant but brittle
Durable – Tough but soft
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• Micron diamond size
–Mono modal - Single size of diamond
• Diamond bonds/unit volume
–Multi modal - Mix of 2, 3 or 4 sizes
• Diamond bonds/unit volume
&
• Diamond volume
PDC Development for Drill Bits
CoarseGE2500
FineGE2800MediumGE2500
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PDC Development for Drill Bits
• Diameters
• Polished diamond faces
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PDC Development for Drill Bits
• Diamond layer thickness
– From ½ mm to 2-4mm
• Chamfered/Bevelled Edge
• Internal stresses - Interfaces
– Flat to shaped – Claw, Star, Iris etc.
Bit Design
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Thermal StabilityRemoval of catalyst from surface of PCD
• 1st Generation (SPE 79797)
+40% footage
+40% rate of penetration
• 2nd Generation (SPE 102067)
+43% footage
+26% rate of penetration
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Drill Bit Market
Source Spears
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The Future for PDC and PDC Bits
• Diamond Sizes
– Sub-micron 250nm – 1000nm
– Nano 1nm – 250nm
• Diamond Mixes
– Mono or multi modal sub-micron and/or nano
– Multimodal with micron
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The Future for PDC and PDC Bits
• Challenges of Catalyst Removal
– Islands
– Dissolved
• Future Direction
– Deeper
– Smaller pathways
– Implications on time to leach
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The Future for PDC and PDC Bits
• Other catalysts
– Rare earth elements
• Catalyst free
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The Future for PDC and PDC Bits
• Pressing Equipment
– Higher pressures and/or temperatures
– Pressing volume
– Cycle time
Implications for PDC costs
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Conclusions
• PDC is a very reliable, high performance cutting tool.
• Thermally stable PDC was the biggest drilling cost reducer
• The PDC bit is now the predominant drilling product.
• With your help– New generations of PDC for even higher bit
performance
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Distinguished Lecturer Programwww.spe.org/dl 28
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