Bits

New bits are constantly being developed for all hole sizes, bit performance is critical. Deep holes, directional and horizontal wells, and other high cost applications require the most durable and reliable rock bit.

It would be impossible to list all the bits manufactured to-day. So many of to-days bit are specially designed for a particular job, however the basic concept and fundamentals of the roller cone bit remain very much the same.
Good engineering and the use of new materials have change the way we have to look at and select the type of bit needed.

The development of drilling bit

The development of drilling bit has played a major role in way the petroleum industry have drilled to produce energy. In the early days of rotary drilling drag bit, "fish tail" bits were the main technique involving cable tool rigs.

In 1909 Howard Hughes Snr introduced the world's first rotary rock bit equipped with two rolling cone cutters.

This bit radically change rotary drilling by making it possible to penetrate harder formations. Hughes also established the first research laboratory to study rock bit performance in 1910 and in 1917 introduced a reaming cone bit with two regular cones in addition to a reamer built into the body of the bit.

The simplex bit introduced in 1921 had a replaceable wash pipe down the centre of the bit allowing the use of more powerful mud pumps. This again was a major mile stone in drilling as it greatly improvement in rates of penetration. In 1929 hard facing the cutting structure of cones was introduce. Major advancements were made in 1931, when the first unit-type bit with anti-friction bearings was introduced, the following year Hughes introduced two more important improvements. The staggered tooth cutting structure and the anti-friction ball and roller bearing. In 1933, Hughes created the Tricone design with inter-fitting teeth that still dominants the industry to this day.

Running simplex bit in a mid-continent well - 1925"

Using old photographs as a guide, the artist re-created this typical mid-continent rig floor scene of the mid- 20's. It shows a Simplex bit, equipped with self-cleaning cones - first introduced in 1925, about to be run in the hole. In the larger sizes, the Simplex was a huge bit, weighing up to three tons. On the floor at the left of the rotary is a Hughes Reaming Cone bit, which had disappeared from most rig floors by the mid-20's, but was saved by a few operators to drill rock encountered occasionally in surface digging. Stacked on the right of the rotary are extra Simplex bits and a Disc bit.

The latter was developed by Hughes as a soft formation bit before the advent of the self-cleaning cones.

artist John P. Cowan

Key components
The bits is the key component in establishing the penetration rate, all other components and parameter work in conjunction with the bits cutting structure designs specific to different rock types. Although the technology may have changed over the years, the basic rules are still the same and the success of the drilling operation depends on the drill bit's operational parameters Correct drill bit selection is critical to successful penetration rates and an understanding of formation compressive strengths is a key component to bit selection. Therefore the optimum utilization of the bit depends mainly on the proper selection of the bit type for a specific formation.

The 'weight-on-bit' and RPM

The 'weight-on-bit' and RPM are interlinked for the effective drilling operation by coupling higher load with reduced RPM and, inversely, lower load with increased RPM.

Bottom Hole cleaning is still one of the major factor in constant penetration rates.

The bit proposals will be reviewed with respect to offset well data and assessed on an individual bit by bit basis in order to determine suitability of the proposed bits.

When drilling directional wells the Directional Contractor should be asked to provide an assessment of the required BHA changes, motor requirements and any limitations on bit operating parameters which may impact on the selection of bits.

In addition bit characteristics in terms of walk, build and drop tendencies will need to be assessed for their impact on the well path. Formation characteristics should be studied in detail to assess the type of cutting structure required to successfully drill the formation.

Specific information on accessory minerals and cementation should be sought i.e., the presence of chert or pyrite nodules, cementation degree and type etc.

This will impact on the aggressiveness of milled teeth or inserts and, in the case of PDC bits, the requirement for hybrid design bits.

When using a mud motor in the assembly all tri-cone bits should have a motor bearing system which allows extended use at high motor RPMs or a fixed cutter bit should be selected. Due consideration should always be given to the jet system of the bit.

When drilling soft shale sections where the major limitations on ROP is bottom hole and cutter cleaning, the use of centre jet, extended jets or lateral jet bits should be considered.

When drilling abrasive sections, a degree of gauge protection should be specified.

For highly abrasive sections the use of insert bits with diamond enhanced gauge protection has proved successful in limiting the occurrence of undergauge hole.

This has led to a reduction in the degree of reaming on subsequent bit runs and thus reduces premature wear of the subsequent bit.

Rock Bit Nomenclature

Tri-cone rock roller bits

A typical Three Cone Rock bit consists of three cones and three leg sections with journals. Hard surfacing is applied to leading edge of Leg and Shirttail area, and load areas of journal. Leg and Gage protective flat tungsten carbide inserts are available in the majority of rock bits.

Each of the three cones is subjected to detailed processes of carburizing and specialized machine operations. Tooth Bit These bits have a built-in cutting mechanism either milled-teeth or carbide buttons, which rely on thrust and rotary action to make a hole. Carbide Button

Graphic courtesy Hughes Christensens

Long tooth Tri-core bits are usually categoriser by their ability to cut formations:Long tooth: Soft Formation Bits Short tooth: Medium Formation Bits Carbide button: Hard Formation Bits Long Tooth (Milled) Bits produce a hole by shearing the formation, therefore they are limited by the hardness and shearability of the formation being drilled. They work extremely efficiently in plastic clays and soft rock formations such as chalk and cemented sands, provided sufficient flushing is available to lift large cuttings and prevent the bit from "Balling".

Long tooth mill tooth bit

courtesy Read Bit Company

The teeth are staggered and the cone are slightly off centre, the well spaced teeth allow for the bit to brake up the soft format by not setting a regular cutting patten.

Short tooth

Short Tooth (Milled) Bits produce a hole by a combination of crushing and shearing.

Weight on the bit crushes the formation and the teeth then set up shear forces in the formation which causes it to break up.
Graphic courtesy Hughes Christensens Bit Type XLX

Thrust can be provided by the use of heavy drill collars, although this is limited to the rigs hoisting (Pull-back) capabilities

Design Factors
The drill bit design is dictated by the type of rock to be drilled and size of hole. The three legs and journal are identical, but the shape and distribution of cutters on the three cones differ.

The design should ensure that the three legs must be equally loaded during drilling. The following factors are considered when designing and manufacturing a three-cone bit: Journal angle Offset between cones Teeth Bearings

Journal Angle The engineering that is involve in the design of a roller cone bit is extremely complicated. The design of each cone, be it insert or teeth must fit exactly in the allots space on the legs so as the teeth perform their functions without locking with each other and keep the hole in gauge. The journal angle is the angle that forms the centre line on the bearing pin. This angle will change depending on the outside diameter of the bit. The larger the bit the larger the journal angle. Journal Angels Bit and Manufacture information stencilled here

The Journal angle is sometime referred too as the Pin Angle

Off Set
Milled Tooth Bits Milled tooth bit design depends on the geometry of the cones and the bit body and the design features of the cutting elements (teeth) The geometry of the cones and of the bit body depend on: Journal Angle Cone Profile Offset Angle

The geometry and composition of the teeth depend on: Journal Angle Angle of Teeth Length of Teeth Number of Teeth Spacing of Teeth Shape of Teeth Tooth Hard-facing Cone Profile

The degree of offset

The degree of offset is defined as the horizontal distance between the axis of the bit and a vertical plane through the axis of the journal. A drill bit with zero offset has the centre lines of the three cones meeting at the centre of the drillbit,

Skew angle is an angular measure of cone offset. A cone with zero offset has a true rolling action as the cone moves in a circle centred at the cone apex and bit centre. If the cone is offset from the bit centre, then when the bit is rotated the cone attempts to rotate around its own circle which is not centred at the bit centre.

The degree of offset

The cone is forced to rotate about the centreline of the bit and drillstring and this results in the cone slipping as its rotating. This slipping produces tearing and gouging actions which are beneficial in drilling soft rocks.

The amount of offset is directly related to the strength of rock being drilled. Soft rocks require a higher offset to produce the scraping and gouging actions. Hard rocks require less offset as rock breakage is dependent on crushing and chipping actions rather than gouging Cone offset increases ROP but also increases tooth wear, especially in the gauge area, and increases the risk of tooth breakage.

Cutter skew
The gouging action of a cutter is increased by putting skew or offset into the bit. A bit having skew or offset simply means that the centreline of the journal about which the cutter rotates does not intersect the centreline of the bit. This causes the teeth to slide or drag through the formation as the cutter turns. Low cutter skew bits are generally those that drill harder formations using high weight to crush the rock and they require cutters with reduced skew and more true-rolling profiles to ensure sufficient durability Medium cutter skew bits are generally those that drill mediumhard formations and require cutters with a slight skew and slightly more true-rolling profiles.

High cutter skew bits are generally those that drill soft formations and require cutters with a maximum skew to provide the gouging action necessary for faster penetration rates.

Tooth Hard-facing

Hard facing usually tungsten carbide is applied to one side of the tooth to encourage preferential wear and extend the life span of the cutting tooth, This hard facing has a second important feature, as the tooth wears on one side it the uncovers the steel thus leaving a sharp cutting edge on the metal faced. This is known as self-sharpening hard facing and is a common feature on many of the tooth bit of to-day

Hard facing is applied to the leading edge of all teeth. A 50% increase in tooth crest hard facing thickness retards tooth wear while sustaining high rates of penetration longer. Such Spherical cast carbide geometry provides increased strength and durability for teeth and gauge areas while reducing matrix erosion

Bead of hard facing are applied on the trailing edge of specific teeth. this application reduces the documented wear patterns by strengthening the teeth and retarding tooth wear.

Insert Bits The design factors relating to cone offset, bit profile and cone profile as discussed for milled tooth bits apply equally to insert bits. The cutting structure of insert bit relies on using tungsten carbide inserts which are pressed into pre-drilled holes in the cones of the bit. The following relates to the various design features of inserts which are again designed to suit the various rock types being drilled. Aggressive inserts, for soft formation bits have conical or more commonly chisel shapes. In soft, poorly consolidated formations the chisel shape is more efficient at penetrating the formation. Five shapes are use on this type of bit(1 to 5) the longer, chisel shape is for soft rocks The conical rounded shape is for hard rocks.

Insert protrusion

When we refer to insert protrusion we are talking about the amount of the insert protruding from the body of the cone. The more the insert protrudes the softer the formation the bit is designed for are. Inserts are pressed into the cone leaving just the cutting portion protruding and is normally less than half of the total length of the insert

New technique The majority of the drillbit work is spent around the heel and gauge area and therefore this part suffers the greatest amount of wear. Various features may be used to help to maintain the bit gauge such as the use of T-shaped teeth on milled tooth bits and very short inserts in the gauge row. All drill bits may have tungsten carbide inserts placed in the heel area of the bit.

The gauge inserts may be diamond coated and is the shirttail protection. A worn shirttail may expose the seal, leading to seal wear and bearing failure. Various devices may be used to limit or delay shirttail wear. Lug pads may be added to the upper part of the shirttail. A band of hard metal can be added to the margin of the shirttail. Tungsten Carbide Inserts may be placed in the shirttail itself.

Damaged Heal and Gauge

Modern Bearing Design

Insert and tooth bits have sealed journal bearings with conventional ball bearing cone retention. The bearing design has been optimized and incorporates a range of proprietary elements to enhance durability in difficult applications.

Free floating silver-plated beryllium copper bushings are used to help reduce galling and wear, thereby extending bearing life. The plating acts as a solid lubricant to supplement the bearing's grease. Bearing life is extended since the surfaces are micro-finished to reduce the coefficient of friction and heat build-up.

Thrust load friction and heat build-up are reduced by a patented free-floating silverplated satellite thrust washer between the journal surface and cutter face. The thrust washer's floating design and the silver plating on the satellite washer lowers friction. The result is reduced operating temperatures and more consistent bearing performance.

Bearing and seals

Bearing and seals

Bit bearings are used to perform the following functions: support radial loads support thrust or axial loads secure the cones on the legs

The bearings must take the loads generated as the bit cutting structure and gauge area engage with the formation as weight (on bit) is applied. These loads can be resolved into radial and axial forces.

The principal radial load is taken by the main journal and the axial load by the thrust face and, in some cases, the ball bearings. There are two bearing types, roller and friction (or journal). Roller bearings may be sealed or unsealed whilst friction bearings are always sealed. In roller bearings, the loads applied to the cutting structure is transmitted to the journal through a series of rollers. There may be one, two or three of these roller races depending upon the size of the bit.

Bearing design

Journal Bearing Leg A journal bearing, simply stated, is a cylinder which surrounds the shaft and is filled with some form of lubricant.

In this bearing a lubricant is the medium that supports the shaft preventing metal to metal contact.
The most common lubricant used is grease, with special applications using water or a gas.. Ball Bearing also used as the bearing retainer

Shirttail

Edge of cone Seal

Cone inlay

Bearings

Roller Bearings One of the basic purposes of a bearing is to provide a frictionless environment to support Heal and guide a rotating shaft. Properly installed and maintained, bearings have essentially Seal infinite life. Plain Bearing (Ball Bearing) The plain bearing is the simplest and most common design with a high load carrying capacity and the lowest cost. Roller bearing are cylindrical and have a better stabilising effect both the ball bearing and roller bearing are often used as a combination Seal

Cone Nose

Ball Bearings acting as retainer ring

Fully-Floating, High-Speed Dual-Bearing System

This system incorporated into a Sealed Bearing Bits, employs both a floating main bearing and a floating thrust bearing manufactured from a proprietary wearresistant alloy.

The use of silver-plated components provide multiple sliding lubrication surfaces that reduce the coefficient of friction and dissipate heat under the highest loads and maximum rotary speeds. The close tolerance machining and matched assembly of components ensures that the bearing variation does not exceed O-Ring Journal bearing Bull Bearing Retain ring .0005 in (.01 mm).

High-Speed Roller Bearing System

High-energy roller bearing system are used in bits 14 " and larger. Dual silver-plated floating thrust bearings are utilized to reduce the coefficient of friction and dissipate heat under high rotary loads.

The roller bearings are machined with close tolerance and matched at assembly at the same level of precision as the motor journal bearing bits to provide superior bearing life.

Roller Bearings

Flanges

Ball Bearings

Bearings explained Drilling bits are selected for the formation they intend to drill the type of bearing installed will have a major effect on the life expectancy of the bit. Therefore the driller will need to understand they type of bearings installed. The journal bearing is a some what more resent development that distributes the load over the complete contact area of the bearing thus giving it a much longer life span. In drill bit the bearing has a silver coat that distributes the heat evenly

contact

contact

For many years the ball bearing has been the main bearing, in fact it is still used in many applications to-day. The weight is supported by the ball but the supporting area is only a small portion of the bearing. Should one come lose it will inter lock with the rest and lock the cone.

The roller bearing was an improvement on the ball bearing as it extended the load bearing area along the length of the roller. In many applications both roller and ball bearings are used very successfully as combination bearings

contact

Sculpted Arms for Enhanced Flow Area Any mechanism that enhance hole cleaning is a bonus The arms and shirttails are streamlined to enhance fluid flow for better chip removal and bit cooling. The increased flow area allows cutting to exit the bottom of the hole quickly, preventing regrinding. Abrasive cuttings accelerate wear of seals and inserts, limiting their life on bottom. In addition to elevating wear on the bit, regrinding of drilled particles reduces the drilling efficiency of the bit by utilizing energy that should be applied to drilling the formation.
The Arm

Less energy used for regrinding chips means more energy available for drilling.

The Shirttail

Shirttail Protection
Shirttail protection is a feature which consists of tungsten carbide inserts or diamond inserts pressed into the shirttail.

This protection is frequently required in directional applications, horizontal applications, caving formations, inadequate hole cleaning and abrasive formations where increased abrasion resistance of the shirttail is necessary to minimize seal damage and thereby improve bearing life.
Each diamond insert is a micro-grain diamond coated insert optimized for impact. Standard tungsten carbide gage protection consists of flush tungsten carbide inserts pressed into the gage face of the cutters Tungsten Carbide Inserts to enhance gage abrasion resistance. Since the gage faces of the cutters contact the bore hole wall, the tungsten carbide gage protection provides the best resistance to wear especially when used in combination with other gage protection features.

Stabilizer Lugwear Pad* Strategically placed dome shaped inserts are utilized to dramatically reduce wear on the leg of the drill bit. These highly wear resistant tungsten carbide inserts have lower drag and torque than traditional flat lug pads.

The increased stability and lower overall area of contact allows the bit to perform longer at a higher performance level.

Pads also help to minimize gage insert breakage and reduce bearing damage.

The pads, are in an area of the lug manufactured up to 1/32" under gage diameter with flush mounted tungsten carbide or diamond inserts.

Special Radiused Gage Carbide*

The Radiused Gage Carbide insert option, known as the "H" feature, is a feature that can utilized when improved gage performance is required, Such as when drilling harder and abrasive formations may be encountered.

Vectored Inserts

By modelling downhole drilling action, bit manufacturers and engineering have calculated that if each row of tungsten carbide inserts has its own unique direction across the bottom of the hole the inserts will provided a more aggressive bottomhole action and breakage resistance, which resulted in the drilling of more footage at a faster rate of penetration.

More about inserts

Due to the cone offset, all inserts move inboard as they contact the formation. Inserts also scrape the formation toward or against the direction of rotation according to their position on the cone. This dynamic movement often causes individual rows of chisel-shaped inserts to drill with a particular corner of the crest, leading to excessive loading and premature chipping, wear and breakage. If the inboard and radial movements are calculated, and inserts are pressed into the cone at a skew that is relative to the angle of incidence at which the formation will be engaged. This evenly distributes the load against the crest of a chiselshaped insert.
Running Parameters

C05 IADC Code 4-1-7 employs an aggressive combination of highoffset, maximum length chisel shaped-inserts, non-uniform insert spacing and deep tooth inter-mesh in order to maintain high penetration rates through long sections of very soft formations.

Reaming Gage*

In directional drilling applications, accelerated gage wear and side loads can significantly affect both the steerability and bearing life of Sealed Bearing rock bits. The Reaming Gage feature maintains a full-gage borehole which increases bearing life and steerability.
Because these additional rows perform only a reaming function, there is no need for a long, easily-broken extended insert. This design also incorporates a clearance groove in the reaming row surface to enhance bottomhole cleaning and ensure cooling of the cutting surfaces.

Wrap Gage*

In exceptionally hard abrasive formations an increase the number of tungsten carbide inserts can be nearly 300% more than conventional or softer formation drill bits. The combination of increased gage holding capability and RBI-Gearhart's unique wrapped gage cutting design allows a more efficient cutting action. Although the obvious always comes to mind when one discusses gauged hole i.e. under gauge hole, the lack of good gauge protection can have a far more reaching effect when one conceders the damage that can be done to a bit if the bearing seals fail. If the seals go so will the bearing and it is not uncommon to see a bit pull with no cones

IADC and more

Attempting to follow all the companies that manufacture bits would be impossible Although a code has been established many manufacture have added their own code to the list explaining many of the special future their bit incorporate,
It is therefore important when selecting a bit you check and understand all the marking stamped on the bit shank. For example Gearharts new line of bits have many marking stencil on them an so as not to confuse students the class will stay with the same manufacture. Before starting a well it is advisable to check with as many manufactures in the area as possible. It is also important to check out some of the facts given by them. The most important points to remember when selecting the bit type is, it must be compatible to the pending formation too be drilled. Designing the bit program around cutting cost is the fastest way to over run the well budget

Serial Numbers
Vectored

and other information

IADC Cutting Structure Insert bit with full floating high speed Dual bearing system

Letters following numerical cutting structure type:

SP Carbide Shirttail Protection L Stabilizer Lugwear Pad H Special Radiuses Gage Carbide X Fully Extended Jet Nozzles V, VR Vectored Inserts, Reverse Vectored Inserts RG Reaming Gage D Diamond Enhanced J Centre Jet A, B, C Cutting Structure Variations BF Bearing Failure Indicator-Safety Bit WG Wrap Gage

Bit Diameter API Pin Size Serial Number

Letters preceding numerical cutting structure type

B C SS M CC One-cone sealed bit Three-cone insert bit Two-cone insert bit Insert core bit

Shirttail Protection Reaming Gauge Luged

Nozzle size Nozzle size plays an important role in bit hydraulics. The benefits of correct selection include improved bottom hole cleaning, reduced risk of bit balling, faster ROP and lower drilling cost. Shrouded nozzles provide maximum protection against snap ring erosion due to abrasive fluids, excessive turbulence or extended drilling hours. Standard jet nozzles are easier to install and recommended for situations where erosion is not a problem.

Orifice sizes are stated in 1/32 increment. The nozzle code indicates the diameter of the jet socket and nozzle O.D
In conventional bits, the flow stream strikes the bottom or bottom corner of the hole. The fluid then disperses racially 360 degrees. Some fluid flows under the cutters to remove cuttings, but most of the fluid flow is directed toward the centre and toward the whole wall without passing under the cutters. That fluid returns up the annulus without assisting the process of chip formation or removal of cuttings from the rock face.

Fully Extended Jet Nozzles

This feature is utilized to maximize hydraulic sensitive formations. The nozzles are positioned closer to the hole bottom to effectively remove cuttings achieving higher rates of penetration.

Centre Jet

In soft and stick formation that are prone to bit balling there is a need for the centre jet. The centre jet effectively cleans the centre of the cones. It also have a distinct advantage if drilling long sections of soft sand by jetting directly into the bore centre and not washing against the wellbore walls thus helping to keep the bore closer to gauge

Total flow area (TFA) of Standard nozzles (ins2)

Number of nozzles
Nozzle size
7/32 3/8 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4 1 0.038 0.110 0.062 0.077 0.093 0.110 0.130 0.150 0.173 0.196 0.222 0.249 0.277 0.307 0.338 0.371 0.406 0.442 2 0.075 0.221 0.124 0.153 0.186 0.221 0.259 0.301 0.345 0.393 0.443 0.497 0.554 0.614 0.676 0.742 0.811 0.884 3 0.113 0.331 0.186 0.230 0.278 0.331 0.389 0.451 0.518 0.589 0.665 0.746 0.831 0.920 1.015 1.114 1.217 1.325 4 0.150 0.442 0.249 0.307 0.371 0.442 0.518 0.601 0.690 0.785 0.887 0.994 1.108 1.227 1.353 1.485 1.623 1.767 5 0.188 0.552 0.311 0.383 0.464 0.552 0.648 0.752 0.863 0.982 1.108 1.243 1.384 1.534 1.691 1.856 2.029 2.209 6 0.225 0.663 0.373 0.460 0.557 0.663 0.778 0.902 1.035 1.178 1.330 1.491 1.661 1.841 2.029 2.227 2.434 2.651 7 0.263 0.773 0.435 0.537 0.650 0.773 0.907 1.052 1.208 1.374 1.552 1.740 1.938 2.148 2.368 2.599 2.840 3.093 8 0.301 0.884 0.497 0.614 0.742 0.884 1.037 1.203 1.381 1.571 1.773 1.988 2.215 2.454 2.706 2.970 3.246 3.534 9 0.338 0.994 0.559 0.690 0.835 0.994 1.167 1.353 1.553 1.767 1.995 2.237 2.492 2.761 3.044 3.341 3.652 3.976

Maximum Gage SHARP Three Cone and Two Cone Bits STEP 1: Get a ring gage that has an inside diameter measuring nominal bit size plus API tolerance Example: 7 1/8 = 7 1/8 + 1/32 = 7 29/32 ring gage 2: Rotate all coned to maximum gage point 3: Place gage over bit at the maximum gage point 4 a. On three cone bits, pull gage tight against gage tooth on two cones b. On two cone bits, pull gage tight against gage tooth on one cone 5 Measure gap at free cone 6 Multiply gap by 2/3 for three cone bit Example: 3/64 gap x 2/3 = 2/64 = 1/32 Use measured gap for two cone bit. Tight Gap

API Tolerance for new bits Two and three cones

Normal size
5 5/8 to 13 3/8 14 to 17 1/2 17 1/2 an larger

API Tolerance
+ 1/32 minus 0 + 1/16 minus 0 + 3/32 minus 0

7 Result should not be greater than "plus" tolerance in table.

Roller cone dull grading system T B

Dull char (D) Location (L) Bearing Seals (B)

G
Gauge 1/16 (G)

Remarks
Other (O) Reason pulled (R)

Cutting Structure
Inner row (1) Outer row (O)

(I) - CUTTING STRUCTURE - Inner 2/3 of bit (O) - CUTTING STRUCTURE - Outer 1/3 of bit In columns (I) and (O) a linear scale from 0-8 is used to describe the condition of the cutting. STEEL TOOTH BITS a measure of lost tooth height 0 - no loss of tooth height 8 - total loss of tooth height INSERT BITS - measure of total cutting structure reduction due to lost, worn and/or broken inserts 0 - no reduction of cutting structure 8 - total reduction of cutting structure NOTE: If any one row has a majority Of teeth broken, add the letters (B)

T3 T2

T4

T5

T6 T7 T8

T1

T1 tooth height 1/8 gone T2 tooth height 1/4 gone T3 tooth height 3/8 gone T4 tooth height 1/2 gone T5 tooth height 5/8 gone T6 tooth height 3/4 gone T7 tooth height 7/8 gone T8 tooth height all gone

Roller cone dull grading system

T Cutting Structure Inner row (1) Outer row (O) Dull char (D) Location (L) Bearing Seals (B) Gauge 1/16 (G) Other (O) Reason pulled (R) B G Remarks

BC - Broken Cone * BT - Broken Teeth/Cutters BU Balled Up CC - Cracked Cone* CD - Cone Dragged * CI - Cone Interference CR - Cored CT - Chipped teeth ER - Erosion FC - Flat Crested Wear HC - Heat Checking JD - Junk Damage LC - Lost Cone*

LN - Lost Nozzle LT - Lost Teeth/Cutters OC - Off-Centre Wear PB - Pinched Bit PN - Plugged Nozzle RG - Rounded Gauge RO - Ring Out SD - Shirttail Damage SS - Self Sharpening Wear TR - Tracking WO - Wash Out on Bit WT - Worn Teeth/Cutters NO - No Dull/No Other Wear

Roller cone dull grading system

T Cutting Structure Inner row (1) Outer row (O) Dull char (D) Location (L) Bearing Seals (B) Gauge 1/16 (G) Other (O) Reason pulled (R) B G Remarks

(L) N - Nose Rows Cone # or #'s M - Middle Rows 1 H - Heel Rows 2 A - All Rows 3
(B) BEARING/SEALS NON-SEALED BEARINGS - a linear scale

Bearing condition (check the worst cone) B1 bearing life used: 1/8 bit in gage B2 bearing life used: l/4 (tight) B3 bearing life used: 3/8 B4 bearing life used: ]/2 (medium) B5 bearing life used: 5/8 B6 bearing life used: 3/4 (loose) B7 bearing life used:7/8 B8 bearing life all gone (locked or lost)

from 0-8 is used to indicate the amount bearing life that has been used 0 - no bearing life used Example1, T2-B4-I (Teeth 1/4 gone, bearing 8 - all bearing life used medium, in gage)
SEALED BEARINGS

E - seals effective F - seals failed

Example1, T6-B6-0 1/2 teeth 3/4 bearing loose and bit out of gage 1/2 inch

Roller cone dull grading system (Gauge)

T
Cutting Structure Inner row (1) Outer row (O) Dull char (D) Location (L) Bearing Seals (B) Gauge 1/16 (G) Other (O) Reason pulled (R)

Remarks

I - in gauge 1 /16 = 1 /16" out of gauge 1 /16 = 1 /8" out of gauge 1: Get a ring gage that has an inside diameter measuring nominal bit size. Example: 7 7/8" bit= 7 7/8" ring gage

2: Rotate all cones to maximum gage point

3: Place gage over bit at maximum gage point
1

Tight

a. On three cone bits, pull gage tight against gage tooth on two cones b. On two cone bits, pull gage tight against gage tooth on one cone Example: 3/4 gap x 2/3 = 1/2 5 Measure the gap at free cone 6 a. Multiply gap 2/3 for three cone bit b. Use measured gap for two cone bit 7 Result is amount the hole is under gage. = .75 * .66 = .495 of an inc

Gap

= .495 * 25.4 12 mm undergauge

Roller cone dull grading system

T Cutting Structure Inner row (1) Outer row (O) Dull char (D) Location (L) Bearing Seals (B) Gauge 1/16 (G) Other (O) Reason pulled (R) B G Remarks

O: Could be many things, Wash-Out. Remove Jet (lost circulation), Casing Point, Fishing Operations, Wrong bit( It happens) Waiting on orders ( far to often)

(R) - REASONS PULLED BHA Change Bottom Hole Assembly DMF- Down Hole Motor Failure DSF - Drill String Failure DST - Drill Stem Test DTF - Down Hole Tool Failure LOG - Run Logs CM - Condition Mud CP - Core Point DP - Drill Plug

FM - Formation Change HP - Hole Problems HR - Hours on Bit PP - Pump Pressure PR - Penetration Rate RIG - Rig Repairs TD - Total Depth/Casing Depths TQ - Torque TW Twist Off WC - Weather Conditions

Grading an insert Bit Good bit grading takes time and every effort must be made to be as accurate as possible in the reports. A good way to do this is to discuss the condition with the crew and let every member of the crew get involve. There are also many aids that can be used to help. When grading the wear, broken or lost inserts in a bit it is very easy to get a more accurate reading by counting the number of inserts lost or broken. The chart can be use as an aid. The softer the formation the longer the inserts and the least inserts installed. Therefore by counting the missing inserts and grading accordingly a comparison can be made between soft and hard until such times as you can select the bit that is best for the formations
N u m b e r b r o k e n / w o r n

350 300 250 200 150 100 50 0 0

Total number of inserts
8
7 6 5 4 3 2 1

50 100 150 200 250 300 350

BROKEN CONE (BC)

The broken cone in this photo was caused by hydrogen sulfide embrittlement. A cone also may break when the bit hits a ledge during a trip or connection, or there is cone interference caused by the cones running on each other after a bearing failure.

Notice the two flat axial breaks on this particular bit. The circumferential break is the cup/ cone tear break.
Generally, the BT on Cone One and Cone Two is caused by junk left on the bottom by Cone Three. The crest of the broken inserts indicates the insert break was caused by the inserts impacting the cone piece during drilling.

Broken teeth (bt)

This is an example of multiple tooth breakage. The sharp edges to the junk dent marks in the cone shell indicates this chippage, or breakage, occurred near the end of the bit run. Note also that the heel inserts and nose inserts have remained in the best condition. In some formations, broken teeth, like chipped teeth, can be a normal wear characteristic of tungsten carbide insert (TCI) bits and does not necessarily indicate problems in bit application or operating practices.

Broken teeth, however, are not considered a normal wearing condition for steel tooth bits. For those, it may indicate either improper bit application or operating practices.

In TCI bits, this dull feature frequently occurs when the compressive strength of the rock exceeds the compressive strength of the cutting structure. If, however, the bit run was of unusually short duration, broken teeth could indicate excessive weight and/or rpm, improper bit application and/or the need for a shock sub. Excessive weight for the particular application is evident by broken teeth predominately on the inner and middle rows. Excessive rpm for the particular application is indicated by breaks predominately on the gauge row. Teeth can also break when the bit is run on junk, hits a ledge or suddenly strikes the bottom, or the bit has been improperly broken in, which is indicated by a major change in the bottomhole pattern. Drilling a formation that is too hard for the type of bit being used also can break teeth. The most common cause of broken teeth is striking bottom, something that is not done intentionally by most drillers and is done when washing down a connection and suddenly stopping a few inches from bottom. The sudden shock allows the pipe to stretch forcing the bit mash into the bottom. When the bit is being lowered the string is partly compressed. The sudden stop allows the string to stretch hence if close to bottom, hitting bottom with the potential of bit damage

Cone interference (CI)

On this bit, notice the BT,M 3 breakage is irregular, indicating the Number One Cone shell and inserts impacted on another. The WT,M 1 is a good example of insert wear against the adjacent cone shell material, as opposed to wear against the formation. Cone interference, which can lead to cone grooving and broken teeth, is often mistaken for formation damage. Broken teeth caused by cone interference doesn't indicate improper bit selection. Some causes of cone interference are a pinched bit, reaming an undergauge hole with excessive weight on bit (WOB), or bearing failure in one or more cones.

Cone dragged

(CD)

This dull feature means one or more of the cones did not turn during part of the bit run. This is indicated by one or more flat wear spots. Usually, a dragged cone is caused by bearing failure on one or more of the cones, junk lodging between the cones, a pinched bit that causes cone interference, or a balled-up bit.

Cone drag will be indicated by the torque picking up, often spiking. Any excess torque that start will drilling should be investigated by picking the bit from bottom and establishing a free rotating off bottom torque, once established tag bottom gently making a note of the torque and the build up. If while applying weight to the bit the torque start to spike remove the bit from the hole. Always pull sooner than later?

Cracked cone (CC)

Here we show a circumferentially cracked cone, that was caused by cone shell wear, which reduced the cone shell thickness over the cone retention groove. The heat generated by the formation wear during off-centre running is responsible for this particular crack. From an operational standpoint, a cone may crack when junk is left on the bottom, the bit hits a ledge or bottom, or the drill string is dropped. Cones can also crack by hydrogen sulfide embrittlement, cone shell erosion, or overheating.

Balled bit

(BU)

A balled-up bit will show tooth wear. This is caused by a cone, or cones, being locked and unable to turn because of formation being packed between the cones. It erroneously may appear a bearing has locked up.

After cleaning the cutting structure of this particular bit, it was discovered the bearings were in good condition, which often is the case with a balled-up bit. Balling may occur because of inadequate hydraulic cleaning of the hole, when the bit is forced into formation cutting with the pump not running, or by drilling a sticky formation. Another problem that may be caused due to bit balling is swabbing as the bit is removed from the well.

Cored bit (CR)

The centremost cutters of this bit were damaged by a rock core that was left in the hole by the preceding bit. This is merely one way in which a bit can core. A bit often cores when the nose part of one or more cones is broken, or when the abrasiveness of the formation exceeds the wear resistance of the centre cutters. Improperly breaking in a new bit after a major change in the bottom hole pattern also can result in coring. A bit will also core when cutters are lost because of cone shell erosion, or when junk left in the hole breaks the centre cutters. In number one or two rock (soft), and with proper care, the junk can be removed and drilling proceed without coring the next bit. In the harder numbers seven, eight or nine rock, it is recommended the core/junk first be cleaned up and 5-10 ft of new hole can be drilled. Afterwards, it is wise to trip and examine the bit to determine if another cleaning is called for.

Chipped teeth (CT)

This photo shows two examples of how teeth can chip. Note the chipped insert on the upper left middle row, adjacent to the heel, or gauge, row. This insert was sheared by impact from something on the bottom of the hole. The two inserts to the right in the same row each have a single break with a ridge in the center and a small one to the side. On TCI bits, chipped teeth often become broken teeth. A tooth is considered to only be chipped if a substantial part remains above the cone shell. Possible causes of chipped teeth are impact loading caused by rough running and/or slight cone interference. Usually, chipped teeth are not indicative of any problems in bit applications or operating parameters.

Erosion (ER) The erosion indicated in this photo suggests abrasive cuttings in the mud travelled at a high rate from right to left. When encountering an insert, the eddy effect caused the cuttings to remove the cone shell on the right side of the inserts. On TCI bits, the loss of cone shell material can lead to a loss of inserts, because the support and grip of the cone shell material was reduced. Erosion also can indicate a hydraulic-related problem. Abrasive cuttings can erode the cone shell because of inadequate hydraulics. On the other hand, excessive hydraulics can lead to highvelocity fluid erosion. An abrasive formation contacting the cone shell between the cutters also can lead to erosion. This is usually caused by tracking, off centre wear, or excessive WOB.

Flat crested wear (FC)

This characteristic generally reduces the rate of penetration toward the end of the run and ends many steel tooth runs. As shown here, flat crested wear is an even reduction in height across the entire face of the cutters. Flat crested wear is dependent on many factors, including formation, hardfacing and operating parameters.

This characteristic is often caused when weight is decreased and rpm is increased to control deviation.

Heat affected seal Worn seal (denoted as SF)

A bearing may fail because of a heat affected seal (would be denoted on form as SF). Thermal degradation of a seal is a time and temperature reaction and can be caused by modest temperature over long runs, or by high temperature over short runs. The damage to the bit shown here was caused when, after making a connection, drilling resumed without starting the mud pump. Worn seals Under Seals/Bearings, one possible cause of bearing failure is a worn seal. In this photo, the seal is worn on the I.D. of the mud side. This particular wear was caused by mud solids wearing away the seal material.

Heat checking (HC)

Heat checking occurs when a cutter overheats by being dragged on the formation and is later cooled by the drilling fluid over many cycles. Along with dragging the cutters, heat checking also can occur when reaming a slightly undergauge hole at high rpm. Heat checking on this particular bit was caused by reaming with a motor, which is considered a bad drilling practice. Note here that one leg of the bit was removed so the bearing could be examined.

Junk damage (JD) This can be determined by marks on any part of the bit. The deep groove in the shirttail of this bit is believed to have been caused by junk from the bit itself. The heavy cone shell erosion around the heel inserts makes it easy to understand why an entire insert would be dropped. Note the circumferential scratches, which came from sharp formation damage. It sometimes is necessary to clear the junk from the hole before proceeding. Common sources of junk, and thereby junk damage are: junk dropped in the hole from the surface, junk from the drill string, such as reamer pins, stabilizer blades, etc.; junk from a previous bit run, and junk from the bit itself.

Lost cone (LC)

Cones can be lot in a variety of ways. With few exceptions, the dropped cone must be cleared from the hole before drilling can resume. Cones can be lost by the bit striking a ledge or the bottom during a trip, or connection. A dropped drill string, bearing failure, or hydrogen sulfide embrittlement also can cause a cone to be lost.

Lost nozzle (LN) This is an important other dulling characteristic that can help explain a bit run. A lost nozzle causes a pressure decrease that requires the bit be pulled from the hole. A lost nozzle also is a source of junk in the hole. Some possible causes of lost nozzles are improper installation, improper nozzle and/or nozzle design, or mechanical or erosion damage to the nozzle and/or nozzle retaining system. On the bit shown here, the washing action indicates a nozzle without a good O-ring. It was later determined the lack of sealing was caused by installing another manufacturers nail-retained nozzle in a Hughes Christensen assembly. This meant the Hughes Christensen O-ring was left unsealed by the nail groove of the incompatible nozzle.

Lost teeth (LT)

On this bit, the middle row of the Number One cone is a good example of cone cracking running in a circumferential manner from the bottom of the insert hole to the bottom of the adjacent insert hole. This has loosened the hold of the cone on the insert, resulting in the loss of some inserts. It is important to note that the nose insert of the Number One cone is lost because of cone shell erosion. On TCI bits, this characteristic results in entire inserts being left in the hole, thereby causing potential junk damage. Lost teeth occasionally are preceded by rotated inserts. Along with cone shell erosion, teeth can be lost by a crack in the cone that loosens the grip on the inserts and by hydrogen sulfide embrittlement cracks

Off centre wear (OC)

This occurs when the geometric centre of the bit and the geometric centre of the hole do not coincide. The result is an oversized hole. Off centre wear is identified either by wear on the cone shells between the rows of cutters, more gauge
wear on one cone, or by a less than expected penetration rate. Off centre wear can reduce ROP more so than a tracking bit. On this particular bit, the cone on the right was cutting an oversized hole, while the cone to the left had little, or no engagement with the wall of the hole. Since the wear is between the rows of inserts, this indicates the bit was drilling an oversized hole.

Some causes of off centre wear are a change in the formation from brittle to plastic, inadequate stabilization in deviated hole, inadequate weight for the formation, improper bit type, and when the hydrostatic pressure significantly exceeds the formation pressure. Off centre wear can be eliminated by changing bit types, thereby changing the bottom hole pattern.

Pinched bit (PB)

Bits become pinched when they are mechanically forced to a less than original gauge. The bit shown here, for example, was forced into an undersized BOP stack. Note the broken heel inserts. Generally, the ridge from broken inserts is circumferential, while the ridge in insert breakage normally is perpendicular to the force causing the breakage. Several of these heel inserts have circumferential crests on the broken heel inserts, which indicates the undersized BOP broke the heel inserts. Other causes of pinched bits are forcing the bit into an undergauge hole, forcing a rolling cone bit into a section of hole drilled by a fixed cutter bit, forcing a bit through casing that does not drift to the bit size, or pinching a bit in the bit breaker. Pinched bits can lead to broken teeth, chipped teeth, cone interference, dragged cones and several other cutting structure

PLUGGED NOZZLE (PN)

While this dulling condition does not describe the cutting structure, it nonetheless can be useful in providing information about a bit run. A plugged nozzle can result in reduced hydraulics, or force a trip out of the hole because of excessive pump pressure. Jamming the bit into fill with the pump off can plug a nozzle. Plugging can occur when during a connection solid material going up the drill string and through the bit becomes lodged in a nozzle when circulation is resumed. Conversely, solid material being pumped down the drill string also can lodge in a nozzle.

Rounded gauge (RG)

This dulling condition describes a bit that has experienced gauge wear in a rounded manner, but has yet to wear out of normal gauge. The heel inserts may be less than gauge, but the cone backfaces are still within nominal diameter. On this particular bit, the lack of shirttail and hardfacing wear along with the remaining bevels on the gauge inserts, suggest it was still drilling a nominal gauge hole. The gauge of a bit can become rounded when drilling an abrasive formation with excessive rpm, or reaming an under gauge hole.

Shirttail damage (SD)

Damage to the shirttail may be different from junk damage and is not considered a cutting structure dulling characteristic. Shirttail wear can lead to seal failures. Junk left in the hole, reaming an under-gauge hole in faulted or broken formations, or a pinched bit that makes the shirttail the outermost part of the bit, are some of the causes of shirttail damage.

Weld wash out (WO)

Washout can occur at any time during a bit run. If the bit weld is porous, or not closed, the bit will start to wash out as soon as circulation begins. Often, the welds are closed, but will crack during the bit run because of impact with the bottom, or with ledges on connections.
When a crack occurs and circulation starts through the crack, the washout is established very quickly. Weld wash-out caused by drill string harmonics happens after the bit is in the hole long enough to indicate the weld was sealed during bit assembly. After Hughes Christensen installed triads during bit assembly, the frequency of weld washouts caused by drill string harmonics was reduced greatly.

Tracking (TR)

As shown here, the middle rows that tracked have turned the cones at an improper speed. The flat crested wear on the heel and inner rows also indicate improper speed. Another tracking indicator is the scooped wear between sharp crested teeth in a single row. A tracking bit will drill a nominal gauge hole with all three cones reaching gauge. Tracking occurs when the teeth mesh like gears into the bottom of the hole. The cutter wear on a tracking bit will be on the leading and trailing flanks. The cone shell wear will be between the cutters in a row.

Tracking sometimes can be prevented by using a softer formation bit, or by reducing, if possible, the hydrostatic pressure. Tracking can be caused by changes in the formation from brittle to plastic, or when hydrostatic pressure significantly exceeds the formation pressure.

Worn teeth (WT)

This is a normal dulling characteristic for both TCI and steel tooth bits. When WT is noted for steel tooth bits, it usually is appropriate to note either selfsharpening (SS) or flatcrested wear (FC).

Cutting Structure Inner row (7) Outer row (1) Dull char (BT) Location (M)
Graded dull

Bearing Seals (E)

Gauge 1/16 (I)

Other (WT,ER)

Reason pulled (PR)

The bit looks to have been dulled by encountering a harder formation than the bit was designed for. This is indicated by the heavy tooth breakage on the inner rows, and by the fact the bit was pulled for penetration rate. The reduced penetration rate was caused by tooth breakage occurring when the bit encountered the hard formation Excessive weight on bit also could cause the dull to have this appearance. The bit application was proper if the run was of reasonable duration, there was no evidence of other dulling characteristics, the seals were effective and the bit was pulled in gauge. If, however, the bit had a shorter than expected run, the application probably was improper. The bit may have been too soft for the formation, or it may have been run under excessive weight.

Cutting Structure Inner row (5) Outer row (8) Dull char (WT) Location (A)
Graded dull

Bearing Seals (3)

Gauge 1/16 (3/16)

Other (FC)

Reason pulled (HRS)

This dull grade indicates proper bit selection and application. There is not a great deal more tooth wear (WT) on the outer cutters than on the inner cutters, which suggests proper rpm and weight on bit. Worn teeth is a normal dull characteristic in the harder tungsten carbide insert bits, as opposed to chipped or broken teeth, both of which could indicate excessive rpm or weight. When pulled, the bit was still drilling well as indicated by listing HRS as reason pulled. The bit, however, was slightly under gauge (2/16) at this point and may well have rapidly lost more gauge if left in the hole. This supports the decision to pull the bit based on hours. A bearing condition 3 on the air bearings suggests adequate bearing life still remaining. Since there are no harder bits available and the dull grade indicates a softer bit would not be appropriate, this seems to have been a proper bit application

Cutting Structure Inner row (0) Outer row (0) Dull char (NO) Location (0)
Graded dull

Bearing Seals (E)

Gauge 1/16 (I)

Other (LO)

Reason pulled (PP)

Since there is no evidence of any cutting structure dulling, the 0,0,NO,A is used to describe the cutting structure.
If this bit had been run for an extended time before losing the nozzle, this dull grading would indicate a softer bit possibly a steel tooth - might be better suited to drill this interval. If the run was very short, it is probably the nozzle was not the proper one, or it was improperly installed. If this was the case, no other information concerning the proper or improper bit application can be determined.

Drag Bits
I would like to thank Mr Bill Short of the Short bit Company for much of the information and the graphics, while researching this file.
Other sources consulted:

Read Hycalog (The Read Bit Company) Baker Oil Tools. Schlumberger Companies Sandia National Laboratories

Roller Cone Bits

Drill String Calculations

Information provided by grading bits can be very significant. This value was recognized by the IADC some 25 years ago when a worldwide dull grading system for roller cone bits was established. For fixed cutter bits - that is, all non-roller cone bits - this dull grading system could not be applied, and a new system had to be established. The fixed cutter dull grading system was developed by the IADC Drill Bits Sub-Committee in 1987 and revised in 1991. The fixed cutter dull grading system can be used for all non-roller cone bits, including natural diamond, polycrystalline diamond compacts (PDC), thermally stable polycrystalline (TSP) diamonds, impregnated bits, core bits and non-roller cone bits which do not employ diamond material as a cutting element. The system does not distinguish between drilling and coring bits. This guide will only show examples of PDC, TSP, natural diamond and impregnated or sintered drill bits.

Drag Bits

Even though PDC drill bit technology is now over twenty years old, and diamond bit goes even further back. It may come as a surprise to many but the art of using diamonds to drill with is not new. In fact it goes way back in time.

Back around 1700 BC the Chinese learned how they could drill up to several hundred feet through very abrasive and strong limestone to reach fresh water supplies.
To accomplished this they use natural diamond hand-held cutters. To do this many workers would excavate man-sized holes several hundred feet down thus gaining access to fresh water. The tool used was a single diamond stone forced into a suitable brass alloy which composed a tool holder. With this invention, they had a method to hold the diamond and manually impact the rock without shattering the brittle diamond

Drag Bits

Hundreds of years ago, hard rock was drilled in Pennsylvania using cable drilling tools. Several hundred feet of rock was fractured by the repetitive dropping of a cable suspended steel bar on the formation.
Hard rock drilling can be defined as rock which is drilled at penetration rates of less than 3 feet per hour.

More definitively, hard rock is formations with a compressive strength in excess of 25,000 psi. Soon after the introduction of cable tool drilling, softer rock was drilled in Texas by rotary drilling using a fishtail drag bit.
Custom heat treatments of steel fishtail blades at the rig site created a cutting element suitable for a variety of rock types Tungsten carbide steel hard facing replaced steel cutting edges for longer life. After the onset of the Hughes tricone bit in 1933 up to 98 percent of the drilling was performed with a more robust roller cone bit.

Diamonds

The introduction of the natural diamond bit some years later resulted in up to 2 percent of the petroleum footage being drilled with relatively small diamond cutters

Ballas diamonds are generally not used in their natural form - they must be processed by mechanical, thermal, and chemical means to make them uniformly shaped, toughen them to impact, and make them more abrasion resistant. Shown is a raw Ballas diamond from the mines and a Grade 1 Ballas after processing. As much as 50% of the original carat weight is lost

Ballas diamonds

Bort diamonds

More about Diamonds

Grade 1 Ballas are the most commonly used diamonds in exposed diamond applications for drilling hard shales, limestones, and well-bonded, moderately abrasive sands, and are generally available in sizes from 0.05 carat (20 spc) to 1.0 carat (1 spc) Grade 2 diamonds are used in economy grade mills and in ridgeset applications where impact loading is not as large a problem and are generally available in sizes from 0.07 carat (14 spc) to 0.50 carat (2 spc)

Gauge Grade Ballas have been only partially processed and are used in the flush-set gauge of bits and mills.

BORT diamonds

BORT diamonds are used just as they come from nature and cannot be improved by processing. The diamonds are valued for their mono-crystalline structure that helps dissipate the severe heat of work in abrasive formations and for their natural points that can give a mechanical advantage in penetrating dense formations.

Grade 1 Bort diamonds range from octaherdral in shape to solid, blocky rhombic shapes and are used in the most abrasive, well-bonded sandstones as fully exposed diamonds. These diamonds are generally available in sizes from 0.04 carat (24 spc) to 0.25 carat (4 spc).
Grade 2 Bort diamonds (ringed) have a lessdefined shape and rougher surface than grade 1. These diamonds are generally used in ridge set bits that have some degree of impact protection. These diamonds are generally available in sizes from 0.04 carat (24 spc) to 0.50 carat (2 spc).

Grade 2 Bort diamonds Grade 1 Bort diamonds click for comparison

Low and high Pressure Impreg

60x view of 30-40 mesh grit Low Pressure Impreg (LPI) is moulded into the shape of blades and then infiltrated normally to make a grinding type of cutting structure with the softer matrix blend wearing away to expose new grit as the blade wears away. The low pressure impreg in which the small diamond grit is blended with a matrix mix and moulded into blade shapes when the bit is put in the furnace. High Pressure Impreg (HPI) is made at high temperature and pressure to hot-press the matrix into a much harder substance that contains about 40% diamond grit, which is intended to act as a shear cutter. HPI that is made at increased pressures, which allow a more dense diamond concentration and harder matrix blend. These inserts can be cast into the bit or brazed in later.

Diamond Bits

Bit designers can customize and make diamond drill bits with virtually any feature available to the modern bit industry. The photos are some samples of this capability made by smaller companies such a Short bit who design and hold the patent on many of the major bits being used to-day. The method by which diamond size, diamond type, diamond concentration, bit profile, and hydraulic system layout are chosen is impossible to teach in one lesson. Companies can now dictate exactly what details they want and how they would like the bits to perform

Diamond bit nomenclature

Shank Bore Pin Chamfer Bit breaker slot Wrap around Junk Slot

A.P.I. Connection (Upper Section)

Alignment Threads
Weld

Gage Chamfer
Gage Broaches Diamond Pads with Diamonds Low Pressure Collectors High Pressure Feeder Crowfoot Cone Nose Cone Angle

Steel Body

Gage Section Gage Point O.D.R.

Taper Matrix

Bit cutting action

Roller cone bits have a built-in cutting mechanism either milled-teeth or carbide buttons, which rely on thrust and rotary action to make a hole by crushing and shearing A polycrystalline diamond compact (PDC) bit employs no moving parts (i.e. there are no bearings) and is designed to break the rock in shear and not in compression. Natural diamond bitcut the formations by ploughing and are valued for their monocrystalline structure that helps dissipate the severe heat while drilling abrasive formations and for their natural points that can give a mechanical advantage in penetrating dense formations.

Polycrystalline Diamond Compacts (PDC) A little history

In the early 1970s a new type of cutter was developed by General Electric (GE). This cutter used a thin layer of synthetic polycrystalline diamond bonded to a tungsten-carbide stud or blade. Basically we were going back in time to the dragbit. but it was the cutters that were to make the huge difference. The cutter was originally developed as a machine tool but was later passed on to the drilling industry with the words develop it. By the start of the 80's the bit known as the Polycrystalline Diamond Compacts (PDC) were successfully drilling soft-rock formations in the North Sea. Codes were developed to assist the industry in the design and operation of PDC bits. The STRATAPAX code allowed the bits design so that each cutter on a bit either removed an equal volume of rock or performed an equal amount of work, as specified by the designer. This code was later changed (1986) by Sandia National Laboratories (SNL) that had and still do played a major role in the development of polycrystalline diamond compact and a lot of other drilling and down hole tools and equipment. the code: PDCWEAR code, which takes a more fundamental approach to bit design.

PDC Bits

PDC Bits provide the high strength and durability needed in today's bladed, high ROP designs. With a simple, high strength cutter retention system and tungsten carbide hardfacing. Designed for vertical, directional and horizontal applications. These bits are used in virtually every type of formation and application. By combining field proven design technology bit have been developed with spiral gage protection allowing for increased cleaning efficiency, reduced torque and less bit whirl. Stabilizing elements including shaped cutters and reverse bullets reduce vibration, PDC cutting technology is now resulting in less cutter damage, more being applied to many application. directional control and high rates of Here we see a Bi-Centre Bit penetration.

P.D.C. Drill bit nomenclature (polycrystalline diamond compact)

Bevel

API Pin

Shank
Bit identification (Serial No. Etc. ) Crown back angle Gage Protection Shoulder
~~~~

Bit Breaker slot Row Number Filters Crown

PDC Cutters
Flank Cone Nose Nozzle

PDC Bit Design

.
Proven cutter technology for increased penetration & directional control

Tapered Shaped Cutter technology provides for increased responsiveness and directional control
Junk slot design allows for better cleaning

Fixed or interchangeable nozzle systems for improved hydraulics Spiral gage pads improve cutting ability while reducing whirl

Flat profile, short shank length & other low torque features maximize steerability

Bit Profile

Bit profile affects both cleaning and stability of the bit. The two most widely used profiles are: double cone and shallow The double cone profile allows more cutters to be placed near the gauge giving better gauge protection and allowing better directional control.
The shallow cone profile gives faster penetration but has less area for cleaning. In general a bit with a deep cone will tend to be more stable than a shallow cone. Steel is generally used when the designer wants to maximises open face volume as this is known to benefit penetration rate. Steel allows the designer to incorporate very high blades into the design thereby maximising open face volume. However, the heights attainable can be limited by the bit bodys mechanical strength.

The bit body

The bit body is required to provide the following functions throughout the life of the bit: 1. Retain and provide support to both the cutters and the nozzles, 2. Maintain its strength under downhole operating conditions, 3. Direct and control the flow of mud as it cleans and cools the cutters and 4. 4. Provide attachment to the drillstring. Although both steel and matrix can satisfy all of these requirements, each material may out perform the other in specific functions.

Bit manufactures use either steel or an infiltrated matrix of tungsten carbide powder, matrix for short, as body material to build drill bits.

Design Factors

Even though PDC drill bit technology is now over twenty years old there is still not a standard for evaluating bits or for determining the price of a PDC bit based on its performance and wear. With many different systems being used but companies. There is no doubt in my mind that the (PDC) bit is economical tool, given certain drilling conditions, however for it to compete with a rock bit, it must be capable of high penetration rates and longer bit life (runs) in order to justify the added cost as most bit cost on a 4 to 1 ratio according to size

A polycrystalline diamond compact (PDC) bit employs no moving parts (i.e. there are no bearings) and is designed to break the rock in shear and not in compression as is done with roller cone bits. Rock breakage by shear requires significantly less energy than in compression, hence less weight on bit can be used resulting in less tear and wear on the rig and drillstring.

PDC vs TSD

In the mid 80s the thermally stable diamond (TSD) was introduced by G.E. Just as with the PCD diamond, the petroleum drilling industry did not have a suitable TSD diamond attachment technique in combination with suitably impact resistance. TSD cutters are also man-made at HT/HP but without the carbide substrate to form freestanding diamond shapes such as cubes, triangles, rectangles, and discs. The TSD's must be held mechanically in the tungsten carbide matrix since, as a form of carbon, they cannot bond directly to the body. The TSD has a 1200 degrees C thermal stability compared to 350 degrees C for the PDC.

PDC Cutters

TSD Cutters

Cutter Size

The cutters shown are the "standard" sizes. Almost any size and shape can be custom ordered with several weeks lead time. The cylinder-mounted cutters are used in all blade-type Matrix-body bits and mills. The post-mounted cutters are used in steel-bodied mills and in some cases light duty drill bits and core bits.

13 mm Post mounted 13 mm 16 mm

10 mm 8 mm Steel posts can be custom made for smaller 8mm and 6mm cutters on 10 mm Post mounted request.

6 mm

19 mm

Back Rake

Back Rake Cutter orientation is described by back rake and side rake angles. Back rake is the angle presented by the face of the cutter to the formation and is measured from the vertical. The amount of rake angle affects penetration rate and cutter resistance to wear. As the rake angle increase, ROP decreases but so dose the resistance to wear as the applied load is now spread over a much larger area. Small back rakes penetrate deeper and is more aggressive, thus generating higher torque, with the smaller area doing more work, it accelerated cutter wear, with a greater risk of damage due to impact. Therefore a cutter with back rake of 15 will be less aggressive than one with a 8 angle, but more aggressive than another cutter set at 20.

Impregnated backup Steel and matrix-bodied PDC drill bits both have diamond-impregnated studs, or impregs, the impregs are of different construction Matrix-bodied bits have them cast in during the manufacturing stage. Steel-bodied bits utilize separate components, which are manufactured from tungsten carbide. Both types contain many tiny natural diamonds in the end toward the formation. The impregs used in the bits help ensure a uniform wear pattern for all PDC cutters across the face of the bit. This contributes to longer bit life. Additionally, the impregs are beneficial in protecting the PDC cutters from impact damage by stabilizing the bit downhole. In essence, the impregs serve as built-in protection against bit whirl and because the impregs contain diamonds, they can continue to protect the PDC cutters from damage in hard or highly abrasive formations.

Impregnated backup in matrix-bodied bit

Impregnated backup in steel-bodied bit

Side rake

Positive side rake

Negative side rake

Normal line of direction

Side rake is a measure of cutter skew relative to a line normal to the direction of travel. Negative side rake positions the cutter face towards the bit's central axes and results in cuttings being urged inward, instead of towards the junk slots. Positive side rake positions the cutter face towards the outside diameter and produces the opposite effect. Reed-Hycalog have researched and experimented with extremely high side rake angles, both positive and negative, but no advantages were seen.

As side rake increases, the effective operating width of the cutter decreases, necessitating more cutters to obtain the same coverage. In view of the this, ReedHycalog currently orients most PDC cutting elements with zero side rake.

Application Specific Cutter Technology

Application Specific Cutter Technology - Whether you need to drill with good impact resistance in carbonates; withstand wear in abrasive formations; or retard formation build-up in plastic shales, theres a cutter to address each application. Years of research into cutter features like cutter interfaces, chamfer geometry, and polished surfaces has enabled manufactures to develop specific cutter types that demonstrate superior characteristics for given drilling environments. Engineered Cutter Placement - From an examination of dulls, its obvious certain areas of a bit undergo more wear than others. Some areas must withstand impact while other areas must be abrasion resistant. Engineered Cutter Placement where Application Specific Cutters are strategically positioned on the bit body so that their design characteristics match-up well with the loads encountered downhole. Balanced Flow Hydraulics - Each blade of a given type cuts about an equal volume of rock. The junk slots are then sized and balanced according to the cuttings generated. Flow volume is then apportioned across the face of the bit proportional to the volume of rock cut. This balanced chip management process dramatically reduces the tendency for bit balling.

Hydraulics

Fluid flow and hydraulics play a major part in penetration rate and hole cleaning. The larger size PDC bits incorporate cross-flow nozzles set at approximately 45 degrees to direct the flow across the primary blades of the bit. Flow from nozzles at this angle increases the velocity across a greater distance of the cutting face, which results in improved cleaning of cuttings and junk slot areas, better cooling, and extended bit life. There are many very obvious advantages with PDC bits. They reduced number of trips, reduce open hole time and if drilling shale this is always a top priority. Also, less bit per well can be required. Not only are the excellent for drilling out the casing equipment, if run properly they can continue with directional work.

Stabilize the cutting structure

This photo is of a used 8 3/4" PDC Drill Bit - it shows the cylinder cutter mounting method used on blade type bits. This bit had an average of over 3.0 HSI for over 150 hours and it is easy to see how this mounting method in conjunction with the oval nozzle configuration protects the blades from excessive wash while firmly holding the 13mm cutters in place. You can also see the dome-shaped carbide inserts that act as a dampening system to absorb impact loads and stick-slip WOB addition spikes that can damage PDC cutters. They also act to stabilize the cutting structure against whirl-creating factors. Please note the shape and amount of their wear during this 6500' bit run (started as dome shapes).

Bit Grading
This is an area that is difficult to explain Different manufactures tend to have different approaches as do companies. There should be a standard set up so all can comply. However there are a few basic rules. Cylinder Cutters

No Wear

Worn Cutter (WT)

Lost Cutter (LT)

Lost Cutter (LT)

Post or Stud Cutters Erosion (ER) Worn Cutter (WT) Broken Cutter (BT) Lost Cutter (LT) Lost Cutter (LT)

No Wear

Dull grading a PDC bit

Schematic of cutter wear Inner area2/3 radius Outer area1/3 radius

1 0

3 4 5 6

All bits that have been run are graded to assess the extent of the resulting wear. Two grading systems are used.

Each cutter is evaluated for the actual wear of the 7 diamond face and the wear characteristic. The information from these cutters aids in evaluating the performance of a bit in certain applications and compares the actual wear to the predicted wear. This information is also used to evaluate and compare different types of cutters and their performance.

The bits are graded using the International Association of Drilling Contractors (IADC) system This method divides the wear into eight stages.

Dull grading a PDC bit

Schematic of cutter wear Inner area2/3 radius Outer area1/3 radius

1 0

3 4

The average wear for the outer area is calculated in the same manner:

(5 + 6 + 7) = 6
3

When grading a dull bit, the average5 amount of wear for each area should be recorded. As shown above, 2/3 of the radius represents the inner rows. The five cutters in this area would be graded two. This is calculated by averaging the individual grades for each cutter in the area (4 + 3 + 2 + 1 + 0) = 2 5

6 7

Six would be the average

wear gradient for the outer area. This information can now be transferred to the IADC Dull Grading System Chart. For a core bit, the centerline in Figure 1 would be the inside of the core bit ID.

*BC- Broken Cone Dull grading characteristics BF- Bond Failure BT- Broken Teeth/Cutters BU- Balled Up *CC- Cracked Cone *CD- Cone Dragged CI- Cone Interference CR- Cored CT- Chipped Teeth/Cutters ER- Erosion FC- Flat Crested Wear HC- Heat Checking JD- Junk Damage *LC- Lost Cone LN- Lost Nozzle LT- Lost Teeth/Cutters NO- No Major/Other Dull Characteristics NR- Not Re-runnable OC- Off-Centre Wear PB- Pinched Bit PN- Plugged Nozzle/Flow Passage RG- Rounded Gauge RO- Ring Out RR- Re-runnable Dull grading characteristics are based SD- Shirttail Damage SS- Self Sharpening Wear on PDC or stud wear, but also apply TR- Tracking for TSP or Natural Diamond material. WO- Washed Out Bit WT- Worn Teeth/Cutters courtesy of Baker Hu

The Dull Grading System Chart

Cutting Structure Inner row (l) 2 Outer row (O) 6 Dull char (D) Location (L) Bearing Seals (B) X Gauge 1/16 (G) Remarks Other (O) Reason pulled (R)

Grading from the previous page

The Dull Grading System Chart adopted by IADC includes all codes necessary to dull grade roller cone bits and fixed cutter bits. The chart describes eight factors on drill bits. The first four spaces describe the Cutting Structure . The fifth space (B) refers to Bearing Seals and does not apply to fixed cutter bits. This space is always marked with an X when fixed cutter bits are graded. The sixth space (G) refers to Gauge Measurement while the last two Remarks spaces indicate Other Dull Characteristics (or secondary dull characteristics) and Reason Pulled.

Inner/Outer Rows Using a linear scale from zero to eight, a value is given to cutters in the inner and outer rows of surface set bits to indicate the amount of wear. Grading numbers increase with amount of wear, with zero representing no wear and eight meaning no usable cutter left. Accordingly, four indicates 50% wear. PDC cutter wear is measured in a linear scale from one to eight across the diamond table, regardless of the cutter shape, size, type or exposure.

The third and seventh

Cutting Structure Inner row (l) Outer row (O) Dull char (D) Location (L) Bearing Seals (B) X Gauge 1/16 (G)

Remarks Other (O) Reason pulled (R)

Other Characteristics The third and seventh spaces are for use in noting dull characteristics of the bit, i.e., the physical changes from its new condition. (L) Location, shows where the damage cutters is situated (A) All area, (C) Cone, (G) Gauge, (N) Nose, (S) Shoulder, (T) Taper

G S T C N C N T

G S
C N

G
S A

Location Cutting Structure Inner row (l) Outer row (O) Dull char (D) Location (L) Bearing Seals (B) Gauge 1/16 (G) Remarks Other (O) Reason pulled (R)

1/16

Location (L) The Location space is used to indicate the location of the primary Dull Characteristics noted in the third space.
Bearing Seals This space is used only for roller cone bits. Therefore, it will always be marked X when grading fixed cutter bits. Gauge The Gauge (G) space is used to record the condition of the bit gauge. Record an I here if the bit is still in gauge. Otherwise, the amount the bit is undergauge is recorded to the nearest 1/16. For specific undergauge markings,

Gauge Condition
Code I 1/16 2 /16 3/16 4/16 Remarks In Gauge Under-gauge to 1 /16 Under-gauge to 1 /16 to 1/8 Under-gauge to 1/8 to 3 /16 Under-gauge to 3 /16 to 1/4

Reason pulled (R)

Cutting Structure Inner row (l) 3 Outer row (O) 6 Dull char (D) Location (L) A Bearing Seals (B) X Gauge 1/16 (G) 1/16 Remarks Other (O) Reason pulled (R) WB

BHA Change Bottomhole Assemby DMF Downhole Motor Failure DSF Drillstring Failure DST Drill Stem Test DTF Downhole Tool Failure LOG Run Logs RIG CM CP DP Rig Repair Condition Mud Core Point Drill Plug

FM HP HR PP PR TD TQ TW WC WO

Formation Change Hole Problems Hours Pump Pressure Penetration Rate Total Depth/CSG Depth Torque Twist Off Weather Conditions Washout Drillstring

Bit Grading intro

Wear

Ware 20%

Ware 25%

PDC cutters retain a sharp edge as they wear, because the tungsten carbide directly behind the diamond layer wears away more rapidly than the polycrystalline diamond. This results in the formation of a diamond lip that remains sharp throughout the life of the cutter

20% ware

Here we can see how the supporting tungsten carbide is wore in comparison to the diamond cutter, this is in stark contrast to the diamonds on a natural diamond bit that dull with use, taking on a smooth, polished appearance. The teeth on a roller cone product similarly wear and, in the process, become dull. This results in a cutting mechanism that becomes less efficient as the bit drills. Roller cone bits and diamond bits tend to drill at a lower rate of penetration (ROP) as they wear, while PDC bits maintain a higher rate of penetration.

20% ware

Identifying ware

All other conditions taken into account the ware of the cutter is possible the one point that can be confusing as there would appear to be no standard procedure to determine ware between operators
Example: What is 50% ware (a) or (b)

(a)

(b)

Bit steel body With many of the main cutter sunken into the matrix of the bit it would be virtually impossible to have 100% ware unless the body was used as the finishing point of the cutters. However no matter what system is used it can be standardised within an operation so that the IADC coding can be used effectively

Worn Cutter (WT), Cutting Structure Inner row (l) Outer row (O) Dull char (D) BT,WT Location (L) A Bearing Seals (B) X Gauge 1/16 (G) I Remarks Other (O) WT Reason pulled (R) WB

Worn Cutter (WT), Round TSP Broken Cutter (BT), Round TSP

Worn Cutter (WT), Mosaic

Worn Cutter (WT), Round TSP

Factors related to terminating a bit run / Plugged or blocked nozzles

Factors related to terminating a bit run There are a variety of situations that necessitate pulling the bit, even if it is not replaced immediately thereafter. Plugged or blocked nozzles A sudden increase in standpipe and pump pressure during drilling is occasionally the result of a plugged nozzle. If this causes no other problems and the bit continues to drill without a change in the ROP at the same parameters, drilling can continue, but the problem should be noted. Plugging of more than one nozzle is usually more serious, and the bit may have to be pulled from the hole for cleaning. Before tripping out, the bit should be lifted offbottom, and full flow maintained for five minutes.

The drillstring should then be raised and allowed to fall rapidly in an attempt to clear the blockage. This must be done with extreme care, because surging may result, or the bit may tag bottom violently and damage the cutters. If the nozzles are left blocked, there is a high risk of bit balling or accelerated cutter wear in the area with reduced or no flow.

Bit balling /Drilling harder formations and stringers This is generally characterized by a decrease in rotary torque, reduced ROP and often, an increase in standpipe pressure. The bit may sometimes be cleaned by lifting off-bottom and rotating at high rates, while circulating, in an attempt to shake off the formation. One alternative to cleaning is to run the bit at a lower ROP. This will result in fewer cuttings produced in a given period of time and reduce the risk of balling. If such measures cause the average penetration rate to fall to an unacceptable rate, the bit must be pulled. Such an application will probably require a special bit specifically designed for this kind of situation. In soft reactive clays, the use of maximum flow rate, low WOB and high RPM is recommended. Drilling harder formations and stringers When encountering a harder formation, or a harder stringer, rotary speed should be slowed significantly while keeping up adequate WOB to maintain bit stability and prevent whirling. It is particularly important to establish a full bottomhole pattern within the harder interval, including gauge area, prior to increasing the rotary speed. In extreme cases, the length of the new hole may have to cover the near bit stabilizer. After the bottomhole pattern has been fully established in the harder interval, WOB and rotary speed can be optimized to increase penetration rate.

Broken Cutter (BT), T Cutting Structure Inner row (l) Outer row (O) Dull char (D) BT, WT Location (L) N Bearing Seals (B) X Gauge 1/16 (G) 1/16 Other (O) Reason pulled (R) BHA B G Remarks

Broken Cutter (BT), Triangular TSP

Broken Cutter (BT), Natural Diamond Worn Cutter (WT), Triangular TSP Broken Cutter (BT), Triangular TSP

Bit balling Bit balling usually occurs when drilling soft, sticky lithologies with water-based mud. Some rocks, including certain shales, actually react with the water in the mud, swelling considerably and becoming sticky. Montmorillonite content of the shale is the most significant factor with respect to hydration and bit balling. A key property in clay chemistry which can be Na+, Mg2+, Ca2+ and possibly others. Montmorillonite changes to illite with time and temperature. Illite containing K+ within the clay lattice does not expand in the presence of water. Mixed-layer clays such as montmorillonite and illite have poorly organized crystalline structures. They are also susceptible to expansion and base exchange and thus can cause bit balling. Kaolinite is bounded by hydrogen bonding and presents no significant balling tendencies. The order of balling tendencies or sensitivity to base exchange from least to greatest is as follows: * kaolinite * illite * mixed-layer clays * montmorillonite. The cuttings that are produced from drilling formations where the hydration occurs adhere to the bit. Eventually they completely clog all the waterways and even cover the PDC cutters, rendering the bit temporarily useless.

BU and JD and Connections

Connections When the kelly is down, lock the brake, reduce RPM to 60-70, and wait until WOB is reduced to 2-3K. Stop rotary before picking up, pick up and make connection.

Balled Up (BU), Impregnated Bit

Start at approximately 60 RPM and rapidly increase WOB to half of previous drilling WOB.

Increase WOB until at least 10'/hour is reached, and then return incrementally to previously optimized parameters

Junk Damage (JD), PDC Bit

Cored PDC Bit (CR) and Reaming

Reaming

Standard PDC bits are not designed for reaming. If it is expected that extensive reaming will be necessary, do not run a PDC bit. If tight spots are encountered, use extreme caution and follow these guidelines.
If a tight spot is encountered, reaming should be done rotating at 60 RPM and no more than 3K WOB. Local conditions and requirements may indicate necessary departures from these guidelines.

Cored PDC Bit (CR)

Ring Out (RO)

Ring Out (RO) on a TSP Bit

Ring Out (RO) on a PDC Bit

Erosion (ER)

Erosion (ER) on a PDC Bit

Erosion (ER) on a PDC Bit

Lost nozzles / Cutter wear

Lost nozzles A sudden decrease in pump pressure followed by a small, continuing pressure decrease indicates that fluid erosion has resulted in the loss of at least one nozzle. Assuming there are no problems with the pumps or other related surface equipment, the bit should be pulled. No attempt should be made to repair the bit on-site. Cutter wear Eventually, the PDC cutters will wear out. Wear that is primarily outside the nozzle radius is signalled by a decrease in penetration rate and bottomhole torque together with an increase in standpipe pressure. The pressure increase results from contact between the bit face and the formation, which restricts hydraulic flow. If the gauge area wears away first, it is not uncommon for the bit to form a wedge-shaped plug which fits tightly into the hole. This condition is characterized by high on-bottom torque with little WOB and a marked decrease in ROP. In addition, standpipe pressure can increase.

Worn Cutter (WT), Heat Checking (HC)

Indications of Unstable Bit Rotation

If the ROP drops below 10'/hour, the formation is too hard or the bit is running unstable.

Increased surface torque fluctuation Large WOB fluctuations.

Worn Cutter (WT), PDC Heat Checking (HC), PDC

Worn Cutter (WT), PDC

Chipped Cutter (CT), PDC

Note the area that could be used to give a ware grading. Only half the cutter is exposed. For a 100% ware we would be down into the matrix of the bit construction

However not all PDC bit are designed in this manner, But we still need to standardize the ware pattern in order to have an effective ware grading

Lost Cutter (LT), PDC

Lost cutters are often the result of fluid erosions and excessive pump pressure around the fluid channels.
This can stem from too much weight being applied to the bit forcing the cutters to dig deeper and restricting the free flow. Such a situation would develop more torque or if being run using a motor stalling out. therefore a drill off test should be conducted to establish the best parameters. Most bit damage is cause before the bit has a chance to form a cutting pattern.

Lost Cutter (LT), PDC

Example Coring and plugged flow channels

This S279 was used to drill a very hard and abrasive sandstone formation. The special feature on this bit is its Core Ejector (CE). It drilled 100 meters in 51 hours on a 4 3/4 Mach 2 downhole motor at an average ROP of 2.0 m/hr, and was pulled at 4750 meters to change the BHA.

Cutting Structure
Example1

Remarks Location (L) A Bearing Seals (B) X Gauge 1/16 (G) I Other (O) BU.RO Reason pulled (R) BHA

Inner row (l) 3

Outer row (O) 4

Dull char (D) WT

Plugged flow channels

Clear flow channels

After pulling the bit, a uniform wear pattern was observed with the exception of the beginning of a ring out on the bit shoulder. Eight waterways were plugged (BU) with formation, which did not slow down the penetration rate. The bit was still in gauge. You can see from the information in the IADC chart the condition of the bit when it was pulled. Such information can be used for the next selection many years later.

Risk

There will always be a given amount of risk associated with the selection of bits for a given well, at the time of writing there has never been a method of predicting the formation in front of the bit, and that the bit will go in the direction it is pushed and that is not necessarily you have planned. We can however lower the risk and many of the associated problems by accurately reporting the information being given to us by the bit at the time it is pulled. The IADC charts have been formed to help and give guide lines in order that the drillers can establish a slandered, However this information becomes useless if it is not combined with other information that is available at the time, Flow rates, Pump pressures, Formations drilled, Hole Angle, Rotary Speed and Weight On Bit are just as important. Such information must be gather just after the bit has been bought to surface as it is them while it is still warm that much of the needed information can be seen. Re Run bits is an extremely cost effective way of drilling, I can remember drilling in the early 80 using the same 3 bits to drill five wells to 9000 ft with 50+ degrees of angle and they were only disregarded when the order came from the base to junk them.

Example 2

Cutting Structure Outer row (O) 0 Dull char (D) NO Location (L) A Bearing Seals (B) X Gauge 1/16 (G) I

Remarks Other (O) NO Reason pulled (R) TD

Inner row (l) 0

This R437GN was run in a horizontal drilling operation. The first run was in shale on a 63/4 Mach 1 fixed angle-build motor.
The bit drilled 118 meters in 8.5 hours and was pulled at 1433 meters. The ROP was 13.9 m/hr. After the bit was pulled, no obvious wear could be seen, resulting in the IADC grading shown above. Condition reported after first motor run

Example 2

Cutting Structure Outer row (O) 1 Dull char (D) LT Location (L) A Bearing Seals (B) X Gauge 1/16 (G) I

Remarks Other (O) ER Reason pulled (R) BHA

Inner row (l) 1

The bit was re-run on another well in the same field in the same formation, drilling 218 meters in 13.5 hours for an average ROP of 16.2 m/hrs. The bit was pulled when the bottomhole assembly had to be changed. When dull grading the bit, little wear on the cutting structure was seen, resulting in a dull grading of 1 for inner / outer rows. Three cutters were lost due to matrix erosion from a high flow rate, as shown in the Dull and Other Characteristics columns. The bit was still in gauge, as indicated by I in the Gauge column.

Condition after second motor run

Chip Hold Down

With todays high angle wells, the mud weight is often set by wellbore stability requirements and not pore pressure. This idea that you must be 200 psi overbalance to drill fast and optimally is not always applicable. If you get more than 500 psi overbalance (and you usually are when taking into consideration wellbore stability issues), the old hydraulic optimisation equations for tricone bits are not useful.

Chip hold down: is the difference between bottom hole formation pore pressure and hydrostatic head of the mud.
e.g. High mud weight lots of overbalance normal pore pressures results in very high "chip hold down"

Chip hold-down can negatively affect all bit types to some degree, but possibly less with PDC bits in some cases. The devil is in the details though.
Some of the major problems come about when use 14 to 17 ppg water-base muds. Most shales in this application are very sensitive to overbalance and can become hard to drill even with PDC bits

Chip Hold Down force

Shales that would normally extrude in front of the cutters (as intended) at above 20 fph can sometimes be pressure compacted enough by overbalance so that PDC cutters (especially large ones) will not fail the formation in shear, but will act in compression-release like a spherical natural diamond does. It would seems as if the cuttings being held down create a plastic nature to the cuttings so that they are not as easily removed. This is sometimes made worse by incorrect bit choice. Generally (my opinion) you should not run big cutter bits in an overbalance application...you should use smaller cutters in lower ROP situations in order to better promote cutting in shear with smaller cuts. Generally I believe it is OK to run 10mm cutters in 100 fph drilling, but not OK to run 19mm cutters in 10 fph drilling. You wouldn't shovel hard pack with a snow shovel... but then there are still a lot of 3/4" cutter bits in the world drilling 5 feet per hour...I guess they just need a bigger foot on the shovel.

Making Connections When the kelly is down, lock the brake, reduce RPM to 60-70, and wait until WOB is reduced to 2-3K. Stop rotary before picking up, pick up and make connection. Start at approximately 60 RPM and rapidly increase WOB to half of previous drilling WOB. Increase WOB until at least 10'/hour is reached, and then return incrementally to previously optimized parameters. Indications of Unstable Bit Rotation If the ROP drops below 10'/hour, the formation is too hard or the bit is running unstable. Increased surface torque fluctuation Large WOB fluctuations. Reaming Standard PDC bits are not designed for reaming. If it is expected that extensive reaming will be necessary, do not run a PDC bit. If tight spots are encountered, use extreme caution and follow these guidelines. If a tight spot is encountered, reaming should be done rotating at 60 RPM and no more than 3K WOB. Local conditions and requirements may indicate necessary departures from these guidelines.