Shaping the Future of PDC Bit Performance – A Superior Approach to Hard Rock Drilling

ABSTRACT This paper discusses efficiency improvements observed using Faceted, or surface-flanked, polycrystalline diamond compact (PDC) cutters in one of the toughest and most challenging hard rock sections in the Arabian Peninsula. Through lab testing and field trials, this work examines the performance of this innovative surface-shaped PDC technology. It presents results, insights, plausible prospects, and upcoming developments. Two main variants of this Faceted PDC cutter design were lab and field-tested: a V-shaped version, Faceted Point Edge (FPE), and a round version, Faceted Round Shape (FRS). Both tests centered on drilling efficiency and cutting mechanism improvements. Field tests in a hard rock application validated the results. An operator drilled similar sections across six fields. A total of 151 runs were conducted with 29 specific runs, which included both FRS and FPE variants; the results were compared with the company's legacy and competitor PDC bits in the same fields. Initial lab testing delivered excellent results for the FRS, including a 20% reduction in required vertical force compared to a conventional cylindrical/round planar cutter. This is due to its multi-faceted surface, which improves cuttings removal and rock-failing efficiency. The surface-shaped profile on the FRS also led to a 35% reduction in frictional losses. FPE showed a 30% reduction in vertical force and rate of penetration (ROP) improvements compared to a typical round and planar PDC geometry due to the efficiency of the V-shaped combined with the multi-dimensional surface flanking benefits like the FRS design. Field results from 151 total runs, including FRS and FPE cutters, correlated with laboratory efficiency observations. On average, there were up to 20% run meterage and up to 56% ROP improvements compared to planar cutter offset bit runs (combining company and competition fixed-cutter bits). These gains were seen as particularly significant in intermediate and deeper portions compared to shallower parts of this hard rock application. At the same time, they exhibited similar dull results to the legacy PDC bits used in these sections. Such positive results are also reflected in drilling economics, with a captured average Cost Per Meter (CPM) reduction between 9% and 16%. This paper proposes a structured work investigating benefits using Faceted PDCs, showcasing tangible improvements in one of the most challenging sections in the Arabian Peninsula. These findings will improve the industry's understanding of the key advantages of implementing surface-flanked cutters not only in the Middle East but also in hard rock applications globally.