Enhancing PDC Bit Performance Analysis Through Reverse Engineering and Finite Element Methods in Forensic Study

Abstract Drilling is one of the most crucial operations due to its economic implications for hydrocarbon exploration and production. Optimizing a drill-bit design and process parameters can enhance the rate of penetration and well integrity, leading to more efficient drilling operations. Nevertheless, certain operating and downhole conditions aggravate the working conditions of the drill bit. When the drillbit properties cannot withstand these conditions, it results in wear and failure. This paper presents the application of forensic analysis and reverse engineering in pinpointing failure causes and patterns, towards enhancing future PDC bit performance. The Finite Element Analysis (FEA) modelling simulates the environment of the drilling system in a computer environment where the digital breaking of the rock with drillbit using similar operating conditions. During the study, appropriate observation and documentation of the dull report and run record were collected; identification of patterns and scars; proof of fracture initiation, direction of loading, and leveraging on FEA to analyze the effect of design features and operating parameters. Analysis results showed that higher energy in the drilling system by raising weight on bit (WOB) from 10kN to 15kN and rotary speed from 100rpm to 150rpm results in 36% increase in ROP and a higher deformation of the bit material when compared to initial operating parameters. Also, the high thrust force is directly proportional to the normal stress and increases the body temperature of the bit. The optimum PDC design was achieved at 6 bladed designs. This result forms the basis for continuous improvement in drillbit optimization and selection which improve overall performance and economics.