Varel International announced the development and deployment of two patent pending PDC cutter testing technologies. These innovative tools measure cutter toughness and abrasion resistance to enhance and improve the development and selection of PDC cutter technology for drilling applications.

Cutter Toughness Testing

Cutter toughness is the ability to withstand the effects of drilling dynamics. Toughness is related to the strength of the diamond-to-diamond bonding created during the High Pressure High Temperature (HPHT) sintering of the PDC cutter. Historically, test methods in the industry have been qualitative and have fallen short of providing effective data for field cutter selection. To better measure cutter toughness, Varel has developed its patent pending Acoustical Emissions Toughness Test (AETT), which AETT quantitatively assesses the strength of the diamond-to-diamond bonding. With this test, a load is applied to the cutters and increased at a constant rate while an acoustic sensor detects acoustic emissions from microcracking in the diamond table. Measuring the energy released during microcracking yields a concrete assessment of the PDC toughness.

Multiple types and grades of PDC cutters can be cross-compared according to their resistance to load-induced microcracking, yielding a highly predictive valuation of impact strength.

Abrasion Resistance Testing

Abrasion resistance is the cutter's ability to stay sharp as it drills. The primary drawback of traditional abrasion tests is the lack of an accurate simulated geological environment. Current tests use a homogenous rock structure that does not calibrate how moments of high impact energy affect a cutter's abrasion resistance. Varel's Bimodal Abrasive Rock Test (BART) is a laboratory abrasion resistance test that employs an engineered rock sample with highly abrasive cement casting around upright layers of high compressive strength granite to measure a cutter's abrasion resistance. The two rock samples create a load/unload cycle to simulate interbedded formations and formation transitions. By recreating this environment, BART provides a more suitable measurement of abrasion resistance correlating to field performance and yields of a cutter's applicability to transition drilling.

When used in combination, AETT and BART testing regimens promise to significantly accelerate cutter development by speeding the qualification of new cutters and by providing more accurate quantification of prototype cutter attributes. These processes aid in the development of new cutter technology and in the selection of the best existing technology while enhancing Varel's ability to deliver drill bits with world-class performance.

Still Finishing First

In the fall of 2009, Downhole Products (DHP) launched its Zero Fail campaign with the message of delivering dependability as promised. The campaign focuses on the company's commitment to never accept failure and its dedication to provide better tools that deliver premium performance.

An ad in the campaign featuring Spir-o-lizer and BladeRunner products highlights one of the company's goals — "Always Finish First" — and includes an image of World Superbike Champion Moto GP Rider #5 Colin Edwards. The image, provided by Tech3 Racing, may not strike a chord with the casual observer, but it does with those who know how the worldwide leader in downhole products began from humble beginnings in a small motorcycle shop in Aberdeen.

The Beginning
DHP founders Bill Barron and Ian Kirk were hardly ever strangers. Growing up in the same neighborhood in Aberdeen, the men have been friends since they were seven years old.

Motorcycles have been part of their lives since graduating high school when both men bought their first bikes and a lifelong hobby was born. While Ian pursued his degree in Mechanical Engineering, Bill went to work with a drill crew in the Northern North Sea, becoming a fully qualified cementer and tool hand, installing more than 200 liner hanger systems throughout Europe. After obtaining his degree, Ian opened a motorcycle shop where his specialty was performance engineering. While working to perfect a supercharger system, Ian met and befriended Colin Edwards, Sr., also a motorbike enthusiast and the father of two-time world champion rider Colin Edwards.

In 1994, Bill, Ian and a third partner established Downhole Products, operating from the offices of Ian Kirk Engineering in Peterculter, Aberdeen, locally known as Ian's motorbike shop. With just a 4'x4' section of floor space for the new company, the partners shared a single desk and computer in a small upstairs room of the facility. The situation did not stay that way for long.

Growth
After the successful deployment of the company's first Spir-o-lizer centralizer on a world-record shallow extended reach well, news began to travel fast about the company, and soon product orders overwhelmed their niche in the motorcycle shop. Four weeks later, Ian took steps to offload the motorcycle business, moving some 60 motorbikes, and DHP established itself as a quality oilfield product supplier.

Eighteen months later, the company moved to their present Aberdeen facility at Portlethen and it has not slowed down since.

In April 2008, Varel International Energy Services (VIES) acquired DHP, establishing the former owners as executives in the company. And in June 2008, DHP was the recipient of The Queen's Award for Enterprise International Trade Winners, receiving the award at Buckingham Palace from Queen Elizabeth. DHP continues to produce its expertly engineered, globally deployed completion equipment and has enjoyed tremendous success in performances throughout a spectrum of applications.

Continuing to Finish First
Through all of the successes of the company, Bill and Ian still remain strong to their roots. The friends continue to visit Colin Edwards, Sr., and show their support of "Young Colin" through attendance at Moto GP racing events around the world. Their commitment to their products and customers continues to be unwavering and shows through the company's 15 years of continued success.