Remedial Tools

REMEDIAL
TOOLS
DATA HANDBOOK
REMEDIAL TOOLS
DATA HANDBOOK
8
Eighth Edition
P.O. Box 60068 • Houston, Texas 77205-0068

U.S. and Canada: 800/US SMITH • Tel: 281-443-3370
Fax: 281-233-5121 • www.siismithservices.com
Requests for permission to reproduce or translate all or any part of

the material published herein should be addressed to the Marketing
Services Manager, Smith International, P.O. Box 60068, Houston,
Texas 77205-0068.
PREFACE
The 8th edition of this Data Handbook contains useful, prac-
tical information on specialized downhole solutions utiliz-
ing remedial tools and services. The content focuses on areas
in which we have built a combined, renowned reputation for
quality service for more than 90 years. These remedial tools
and services include downhole milling, sidetracking, under-
reaming, hole opening, pipe cutting, well abandonment and
multi-lateral systems.
The Smith Services team applies their craft daily in oil
and gas fields worldwide. These experienced hands provide
downhole solutions to your remedial operations. We hope
this 8th edition will aid you in expediting your downhole
remedial objectives.
We value customer comments and will consider them
for addition to our next handbook.
The Field Operations, Sales,

Business Development and
Engineering Departments.
The following are marks of Smith International, Inc.: Anchor-Stock, Bearclaw, Chip Breaker,
Dyna-Cut, Economill, Econo-Stock, Ezy-Change, Flo-Tel, Hevi-Wate, K-Mill, Master Driller, Millmaster,
Pack-Stock, Piranha, Reamaster, Servcoloy, Superdome, Trackmaster, Tri-Mill and UWD.
TABLE OF CONTENTS
Section 1 - Downhole Milling
K-Mill ............................................................................. 6
Pilot Mill ........................................................................ 28
Piranha Mill ................................................................... 34
Junk Mill ........................................................................ 38
Junk Sub ........................................................................ 44
Taper Mill ...................................................................... 46
Special Mills ................................................................... 52
Servcoloy Products ........................................................ 56
Section 2 - Whipstock Operations
Retrievable Pack-Stock ................................................... 64
Retrievable Anchor-Stock .............................................. 66
Retrievable Econo-Stock ................................................ 69
Trackmaster ................................................................... 74
Section 3 - Underreaming
Underreamer Cutters ..................................................... 88
Reamaster (XTU) ........................................................... 90
Drilling Type (DTU) ....................................................... 106
Rock Type (RTU) ........................................................... 116
SPX/Drag Type .............................................................. 124
Section 4 - Hydraulics
Bit Hydraulics ................................................................ 135
Hydraulics ..................................................................... 141
Section 5 - Hole Opening
Master Driller ................................................................. 158
SDD Hole Opener ........................................................... 164
GTA Hole Opener ........................................................... 172
Hole Enlargers ............................................................... 182
Hole Enlarger Cutters .................................................... 189
Changing Cutter Assemblies .......................................... 198
Section 6 - Well Abandonment
Pipe Cutter ..................................................................... 216
Marine Support Swivel ................................................... 221
Dyna-Cut System ........................................................... 227
Section 7 - Conversion Tables
Tables ............................................................................. 231
Section 8 - Index of Product References
Product References ........................................................ 295
1
SECTION 1
DOWNHOLE
SECTION ONE MILLING
DOWNHOLE MILLING
Downhole Milling 1
DOWNHOLE MILLING
The word “milling” means to cut, grind, pulverize or break
down metal into smaller particles. These particles are then
circulated up the annulus. The mills cut up objects that fall
or get stuck in the hole or can mill away entire sections of
casing. All mills are dressed with Servcoloy T “S”, special
tungsten carbide blend, specially designed to improve
milling performance.
The mills are available in two basic categories: fixed-
milled tools and hydraulically activated mills.
General Guidelines
• Annular velocity should be maintained at 80 to 120 ft/min.
• Oil-base mud should be avoided whenever possible.
• Ordinarily, no difficulty is encountered in circulating
drilled cuttings under normal drilling practices. However,
milled cuttings are much heavier so weighing the mud
has little effect on cutting lift. A ratio of Plastic Viscosity to
Yield Point (PV/YP) as ratio as close to 0.5 is ideal for steel
cutting removal. If the ratio is higher than 1.0, a common
remedy is to add lost-circulation materials, pills or agents
to the mud system. This will help to “sweep” the hole and
will aid in carrying the steel cuttings up the annulus and
out of the hole.
• Polymer muds are best for milling. Clay-base muds would
be a second choice. Oil-base muds would be third. These
choices are based on the carrying ability of the mud. Oil-
base muds have poor carrying capabilities and often result
in more troublesome jobs.
• Never mill faster than it is possible to remove cuttings.
• In optimum conditions, it is recommended to start with a
high laminar flow. Small adjustments can be made in the
flow rates, rotary speed and weight while monitoring the
cuttings for size, shape and thickness.
• If bird nesting occurs, pull up and circulate until proper
cutting return is achieved.
2 Downhole Milling
• On small workover rigs and deep drilling jobs with limited

hydraulics, “sweep” the hole with viscous slugs every two
to three hours. During long milling jobs this procedure
should be repeated frequently to maintain an optimum
Rate of Penetration (ROP).
• Place ditch magnets in the mud system prior to milling. This
will decrease pump damage from cutting contamination.
• The first 4 to 5 ft of a milling job are extremely critical,
especially during section milling. Cuttings tend to accu-
mulate at the cutting knife, causing bird nesting. If this
occurs, pull the kelly up 5 ft and ream down slowly.
• Always inspect the ID of subs and other tools to ensure
they are full bore. This will minimize hydraulic problems.
• A junk basket can aid in catching the larger cuttings. This is
especially true when milling old, split or corroded casing.
Junk baskets are placed in the string just above the mill.
How to Read Cuttings

The ideal cutting is usually 1⁄32 to 1⁄16 in. thick and 1 to
2 in. long. If cuttings are thin, long stringers, penetration
rates are too low. Increase weight on the tool.
If fish-scale-type cuttings are being returned when
pilot or section milling, penetration rates will improve by
decreasing weight and increasing RPM. This is more com-
mon when milling H-40 and K-55 casing. When milling
N-80, P-110, Q-135, etc., longer cuttings will be returned.
Recommendations on Weights and Speeds

Generally the most efficient milling rates are obtained by
running the rotary at 80 to 100 RPM. Milling with washover
shoes is an exception; they are usually more efficient when
run at 60 to 80 RPM. (As with all milling tools, speed and
weight will be dictated by actual conditions.)
Always start rotating about 1 ft above the fish. Lower
onto the fish and vary the weight to improve penetration.
Whenever possible, maintain a constant milling weight.
Feed the drum slowly, allowing the draworks to “creep;”
do not drill off.
Downhole Milling 3
The wear pattern on section and pilot mills is a great

indication of its performance. If the blades show a hook
wear pattern, then the mill is working efficiently. If a
tapered pattern exists, ease off on the weight applied.
Some Factors That Affect Milling Rates

The type and stability of the fish (cemented or not), the
weight on the mill, the speed at which it is run, and proper
carbide dressing of the mill are all factors which will affect
milling rates. The hardness of the fish or cement will also
affect a mill’s performance.
When milling cemented casing, penetration rates can be
increased by using higher weight and speeds. Uncemented
casing should be milled at lower speeds with less weight.
When severely corroded casing is encountered, a high-
speed, light-weight run will prevent tearing or splintering
of the fish.
Recommended milling rates can be found in the Normal
Milling Rate table on Page 5.
Encountering Rubber in the Hole

Rubber always presents a problem during milling. When
encountered, pull up and spud the mill to get a bite on the
rubber. When necessary, pull the mill and clean the fish by
running a drill bit.
Stabilizing the Mill

A mill that moves eccentrically does a poor job. Stabilize
above the mill at 60 or 90 ft intervals. The stabilizer OD
should not exceed the dressed OD of the mill. Section and
pilot mills should also be stabilized to the drift diameter of
the casing.
What to do About Rough Operation

When bouncing or rough running occurs, decrease speed and
weight, then slowly increase speed and weight until an accept-
able ROP is obtained. If rough running reoccurs, once again
decrease and then gradually increase to a maximized ROP.
4 Downhole Milling
Operating Recommendations for Milling

The RPMs required for good milling rates will vary. If run at
high rotary speeds, the mill can hang up and stick momen-
tarily. The string will then violently untwist, often breaking
tools joints or twisting off pipe. Thus, RPM is limited by the
drillstring and hole conditions.
High speed can burn or damage the tungsten carbide
which is critical to milling the steel. Tungsten carbide cuts
steel best at 250 to 340 surface feet per minute or 3,000 to
4,000 surface inches per minute. The following rule of
thumb will help you determine the minimum/maximum
recommended RPMs:
Surface speed
Min./max. RPM =
Tool OD x 3.14
Thus, for a 85⁄8-in. milling tool:
3,000
RPM min. = = 111 RPM
8.625 x 3.14
4,000
RPM max. = = 148 RPM
8.625 x 3.14
Note: Slow rotary speed to avoid fracture damage to the
carbide if mill is bouncing or torquing up.
Downhole Milling 5
General Operating Recommendations for Milling

Weight
Type of Mill (lb) Remarks
Junk mill 4,000-10,000 Spud mill from time
to time
Pilot mill 6,000-10,000 Vary weight to attain
best cutting speed
Taper mill/ 2,000-4,000 Start with light
string taper mill weight and low speed
EconomillT 2,000-8,000 Maintain light
weight and low speed
Washover shoe 2,000-6,000 Pick up from
time to time
Section Mill 4,000-8,000 Do not mill faster than
cuttings are removed
Drill mill 2,000-4,000 Start with light
weight and low speed
Junkmaster 2,000-4,000 Do not mill faster than
cuttings are removed
Normal Milling Rate

Milling Rate (ft/hr)
Rotary
Shoe
Junk Pilot Section Washing
Material Mill Mill PiranhaE EconomillE Mill Over
Casing 4-6 8-12 4-8
Drill 2-6 6-8 6

pipe
Drill 1-2 2-3 4
collars
Packers 4 2-3 2-3
Bits,
cones, 2-4
etc.
General 3-5 2-4
junk
Wash- 4-6
pipe
6 Downhole Milling
Section Milling
MillmasterT Assembly Showing Chip BreakerE Cutting Structure
Millmaster systems are only available on a rental basis in conjunction with

Smith job supervision.
*U.S. Patent Number:

Carbide Insert Milling Tool – 4,710,074
Downhole Milling 7
K-MILLT
The K-Mill is a hydraulically actuated tool used to mill a
section in casing or tubing. The K-Mill is simple in design,
easy to operate and has an outstanding reputation for
milling performance.
Milling knives are dressed with Servcoloy “S” or
Millmaster tungsten carbide. Servcoloy “S” is effective
for milling casing which is poorly cemented, split or
corroded. Whereas, Millmaster systems utilize patented
tungsten carbide inserts to provide extended footage with
maximum penetration rates. The cutting structure consists
of Millmaster carbide arranged in a brick-work pattern. The
carbide being specially developed for downhole application
prevents premature wear and breakage.
Upon circulation through the tool, a pressure drop is cre-
ated across the piston. This forces the cam down and expands
the cutter knives into contact with the casing. Cut-out knives
part the casing then all the knives participate in milling.
When circulation is stopped, the piston spring will retract the
piston, causing the cam to withdraw from between knives.
The knives are now free to collapse back into the body and the
tool can be retrieved. The tool’s cutting action is very effective.
Typically up to 60 ft sections are completed with one set of
knives dressed with Millmaster.
Flo-Tel T Option Assures Positive Tool Opening

The exclusive Flo-Tel option on the K-Mill provides the
positive indication that the cut-out has been made. This
eliminates the possibility of “skinning” the inside of the pipe,
instead of milling it up. When the cut-out is complete, flow
areas through the tool more than doubles. This results in
a decreased stand pipe pressure between 200 to 250 psi
noticeable at the surface. These are positive signs to the oper-
ator that cut-out is complete. Weight can now be set on the
tool to start milling. The Flo-Tel system provides maximum
cutting force against the casing during cut-out.
8 Downhole Milling
Schematic of Staged Knife Opening
Higher pressure against casing for cut-out
Pressure drop for milling
6 Cutter knives — 3 for cut-out, 6 for milling

Downhole Milling 9
General Suggestions for Effective Section Milling

It is important that the mill completely cut through the cas-
ing so the blades can be firmly seated on the casing. When
operating a section mill without a Flo-Tel, prolong the initial
cut-out operation to ensure complete cut through.
Note: Without Flo-Tel there will not be a 200 to 250 psi
indication at surface once cut-out is achieved.
If you suspect the casing to be corroded, use lower weights
with increased RPM.
If you experience a sudden drop off in the milling rate,
the decrease may be the result of a loose ring of steel from
the casing coupling. This ring will rotate with the section
mill, preventing the mill from cutting properly. Try spud-
ding the section mill gently. This should break up the ring
and help position it for milling.
Recommended Procedure for Milling a Section

Run in the hole to the desired depth of cut-out.
Pump rates for the K-Mill are predetermined and depend
on tool size. Therefore, the correct GPM must be selected
to produce the desired pressure drop through the K-Mill,
assuring good tool operation. To determine the best GPM,
see the following table.
K-Mill GPM Range Required
Series
Number During Cut-Out During Milling
3600* 110-160 110-160
4100 80-125 110-160
4500 80-125 150-200
5500 80-125 200-250
6100 80-125 200-250
7200** 80-125 200-300
8200** 80-125 300-400
9200** 80-125 350-450
11700 350-450 350-600
** Does not have Flo-Tel option.
** Jetted top sub is required for flow rates exceeding 300 GPM in order
to minimize excessive velocity through piston which could result in
erosion and/or washout.
10 Downhole Milling
Start rotation at 60 RPM and build pressure slowly until

cut-out GPM is achieved. Keep rotating until the pipe has
been severed, as indicated by the Flo-Tel (approximately
200 to 250 psi pressure drop). After the cut has been com-
pleted, increase GPM to recommended milling flow rate.
Now start applying weight and increase the rotational
speed to 80 to 120 RPM. The most efficient weight range is
normally 4,000 to 8,000 lb.
Once the section is milled or when the knives are worn
out, circulate for 5 to10 min. This will ensure proper clo-
sure (hydrostatic equalization). You may pull the tool into
the shoe and trip out in the conventional manner.
Difficulties Encountered in Cutting Out

The most common cause of difficulties in cutting out is
insufficient pressure at the tool. Approximately 300 psi is
the minimum necessary to keep the cutting knives open
and part the casing.
Excessive pump surging in the drillstring, with subse-
quent “yo-yoing” of the pipe, may cause the blades of the
mill to try to part the casing over a considerable interval.
Lost-circulation material, pieces of drill pipe rubbers or
other substances may block the orifice of the tool, causing
the mill to function improperly and delay cut-out.
Watch the shaker for cuttings. Good cutting return is
essential or problems can develop. Periodic hole sweeps
at 2 to 3 hr intervals are recommended in order to aid
cutting lift.
Downhole Milling 11
M-I DRILLING FLUIDS RECOMMENDATION FOR MUD

PREP PRIOR TO SECTION MILLING
Mud
XC (xanthan gum)-treated polymer muds are preferred due
to their high viscosity at low shear rates. These XC polymer
muds have good plastic viscosity to yield point ratios (usu-
ally 0.50:1 or better). Partially Hydrolyzed Poly Acrylamide
(PHPA) polymer muds are not recommended for milling
due to the rapid shear degradation of the viscosity.
While the plastic viscosity to yield point ratio is often
specified to be between (0.75 to 0.50 to 1), more meaning-
ful parameters to monitor are the 3-RPM Fann reading and
initial gel strength. M-I recommends the 3-RPM Fann read-
ing and gel strength to be between 1 to 2 times the hole size
in inches.
Clay-base systems are also acceptable if the 3-RPM value
and initial gel are kept in this 1 to 2 times hole size (in.)
range. Clay-base milling fluids usually require a XC polymer-
type additive to achieve these levels of viscosity or must be
flocculated with lime, a polymer (like PHPA or GELEX), or
with a Mixed Metal Hydroxide (MMH)-type product.
Oil-base muds are usually not recommended for milling
because it is more difficult to obtain this level of 3-RPM and
initial gel. Oil-base fluids require a rheology modifying
additive and higher water contents for this purpose.
Mud Properties
Maintain in the 3-RPM Fann and initial gel strength read-
ings between 1 to 2 times the hole size in inches. This level
of low shear viscosity should give a plastic viscosity to yield
point ratio between 0.50 and 0.75. This value should not be
allowed to go over 0.75.
12 Downhole Milling
Flow Rate
A flow rate capable of producing a annular velocity between
250 and 350 ft/min is recommended for all milling opera-
tions. This is similar to the 35 to 50 GPM times casing ID (in.)
recommendation. A bypass jet (jetted top sub) may need to
be used for the higher flow rates due to the risk of washout or
cavitation in the mill. Remember that it is the combination of
high annular velocity and high viscosity which provides hole
cleaning when milling; if the viscosity needs to be increased,
so does the velocity.
Hole Sweeps
Periodic high viscosity sweeps should be used on a frequent
basis depending on milling rate and cutting size to prevent
shavings from accumulating in the well. Lost-Circulation
Materials (LCMs) are also beneficial for these sweeps due to
mechanical lifting capability of fiberous materials. While
fiberous LCMs like cottonseed hulls or cane fiber work best,
granular LCMs like nut plugs are also effective.
FLOW GUIDELINES FOR MILLMASTER SYSTEM TOOLS

Total Flow Area (TFA)
Fixed piston ID = .442 TFA equivalent
Fluid Velocity
Maintain internal piston velocity at 150 to 200 ft/sec. Piston
cavitation in longer section milling intervals will occur at
velocities over 200 ft/sec.
GPM Rate
GPM flow rates from 35 to 50 times casing ID is a good
rule of thumb. However, since velocity is a function of
flow rate (GPM) and TFA (fixed at .442 in.2), the flow
rates must be adjusted so as not to exceed the maximum
velocity stated above.
Pressure Drop
Maintain pressure drop (∆P) at 200 to 500 psi across piston;
higher values can be used for short milling intervals only.
Downhole Milling 13
Mud
Polymer muds would be a first choice and clay-base muds
would be second. Most oil-base muds have inferior steel
cutting carrying capabilities, which can cause serious hole
cleaning problems and bird nest accumulation. When lease
water is used, gel additives will provide some lift for the
steel cuttings. In this situation, extra rathole to fall cuttings
is an option when environmentally possible.
Hole Sweeps
Periodic gel sweeps or even LCMs such as walnut hulls,
etc., and working the pipe every 2 to 3 hr will minimize
cutting accumulation.
STANDARD MILLMASTER BHA RECOMMENDATIONS

1. Guide mill (dressed approximately 1.5 in. below drift
diameter).
• Verify through Automated Bottom-Hole Assembly Profile
(ABHAP) analysis, no touching of casing ID allowed.
2. Millmaster (stabilizer sleeve dressed to casing drift
diameter).
• Straight hole vs. angle hole diameters may vary
slightly. Verify through ABHAP analysis.
3. Millmaster top sub and float sub
or
Millmaster top sub with box-up connection bored for float.
4. Pony collar at 8 to 10 ft long.
• Makeup in shop with lifting sub to save rig time.
5. Drill collars.
• Quantities based on size and weight of casing to be milled.
6. Stabilizer.
• For hole angles 15° or less only (over 15° verify
through ABHAP analysis).
• Use a milling-type stabilizer staged so it will always
remain in upper casing stub.
7. HWDP.
• Enough joints to accommodate normal transition
to/from drill pipe.
8. Drill pipe.
14
Casing and K-Mill Correlation
API Casing
Casing Specifications K-Mill Specifications
Weight per Tool Knife
Casing ft with Casing Series Maximum Dressed
Casing Coupling Coupling ID Drift Body Collapse Open Stop
Size Diameter OD (lb) of Casing ID Diameter Diameter Diameter Stabilizer
9.50 4.090 3.965 33⁄4 55⁄8 37⁄8
41⁄2 5.000 11.60 4.000 3.875 3600 33⁄4 55⁄8 37⁄8
13.50 3.920 3.795 35⁄8 35⁄8 51⁄2 33⁄4
11.50 4.560 4.435 41⁄4 65⁄16 43⁄8
1
5 ⁄2 5.563 13.00 4.494 4.369 4100 41⁄8 63⁄16 41⁄4
15.00 4.408 4.283 41⁄8 41⁄8 63⁄16 41⁄4
18.00 4.276 4.151 4 61⁄16 41⁄8
13.00 5.044 4.919 43⁄4 77⁄16 47⁄8
Downhole Milling
14.00 5.012 4.887 43⁄4 77⁄16 47⁄8
51⁄2 6.050 15.50 4.950 4.825 4500 45⁄8 75⁄16 43⁄4
17.00 4.892 4.767 41⁄2 45⁄8 75⁄16 43⁄8
20.00 4.778 4.653 41⁄2 73⁄16 45⁄8
23.00 4.670 4.545 43⁄8 71⁄16 41⁄2
Note: All dimensions are given in inches unless otherwise stated.
Casing and K-Mill Correlation (continued)
Downhole Milling
API Casing
15.00 5.524 5.399 51⁄4 715⁄16 53⁄8
6 6.625 18.00 5.424 5.299 4500 51⁄8 713⁄16 51⁄4
20.00 5.352 5.227 41⁄2 51⁄8 711⁄16 51⁄8
23.00 5.240 5.110 47⁄8 79⁄16 51⁄8
17.00 6.135 6.010 57⁄8 811⁄16 61⁄8
65⁄8 7.390 20.00 6.049 5.924 5500 53⁄4 89⁄16 57⁄8
24.00 5.921 5.796 51⁄2 55⁄8 87⁄16 53⁄4
28.00 5.791 5.666 51⁄2 85⁄16 55⁄8
32.00 5.675 5.550 53⁄8 83⁄16 51⁄2
15
16
API Casing
17.00 6.538 6.413 61⁄4 91⁄16 63⁄8
20.00 6.456 6.331 61⁄8 815⁄16 61⁄4
23.00 6.366 6.241 67⁄8 813⁄16 61⁄8
7 7.656 26.00 6.276 6.15 1 5500 67⁄8 813⁄16 61⁄8
29.00 6.184 6.059 51⁄2 57⁄8 811⁄16 67⁄8
32.00 6.094 5.969 53⁄4 89⁄16 57⁄8
35.00 6.004 5.879 53⁄4 89⁄16 57⁄8
38.00 5.920 5.795 55⁄8 87⁄16 53⁄4
17.00 6.538 6.413 61⁄4 91⁄16 63⁄8
Downhole Milling
7 7.656 20.00 6.456 6.331 6100 61⁄8 815⁄16 61⁄4
23.00 6.366 6.241 61⁄8 67⁄8 813⁄16 61⁄8
26.00 6.276 6.15 1 67⁄8 813⁄16 61⁄8
Downhole Milling
API Casing
20.00 7.125 7.000 67⁄8 911⁄16 73⁄4
24.00 7.025 6.900 63⁄4 99⁄16 67⁄8
75⁄8 8.500 26.40 6.969 6.844 5500 65⁄8 97⁄16 63⁄4
29.70 6.875 6.750 51⁄2 65⁄8 97⁄16 63⁄4
33.70 6.765 6.640 61⁄2 95⁄16 65⁄8
39.00 6.625 6.500 63⁄8 93⁄16 61⁄2
20.00 7.125 7.000 67⁄8 911⁄16 73⁄4
24.00 7.025 6.900 63⁄4 99⁄16 67⁄8
75⁄8 8.500 26.40 6.969 6.844 6100 65⁄8 97⁄16 63⁄4
29.70 6.875 6.750 61⁄8 65⁄8 97⁄16 63⁄4
33.70 6.765 6.640 61⁄2 95⁄16 65⁄8
39.00 6.625 6.500 63⁄8 93⁄16 61⁄2
17
18
API Casing
24.00 8.097 7.972 73⁄4 115⁄8 77⁄8
28.00 8.017 7.892 73⁄4 115⁄8 77⁄8
32.00 7.921 7.796 75⁄8 117⁄16 73⁄4
85⁄8 9.625 36.00 7.825 7.700 7200 71⁄2 115⁄16 75⁄8
40.00 7.725 7.600 71⁄4 73⁄8 113⁄16 71⁄2
44.00 7.625 7.500 73⁄8 113⁄16 71⁄2
49.00 7.511 7.386 71⁄4 111⁄16 73⁄8
29.30 9.063 8.907 83⁄4 1211⁄16 87⁄8
32.30 9.001 8.845 85⁄8 129⁄16 83⁄4
Downhole Milling
36.00 8.921 8.765 85⁄8 129⁄16 83⁄4
95⁄8 10.625 40.00 8.835 8.679 7200 81⁄2 127⁄16 85⁄8
43.50 8.755 8.599 71⁄4 83⁄8 125⁄16 81⁄2
47.00 8.681 8.525 83⁄8 125⁄16 81⁄2
53.50 8.535 8.379 81⁄4 123⁄16 83⁄8
Downhole Milling
API Casing
29.30 9.063 8.907 83⁄4 125⁄8 187⁄8
32.30 9.001 8.845 85⁄8 127⁄16 183⁄4
36.00 8.921 8.765 85⁄8 127⁄16 183⁄4
95⁄8 10.625 40.00 8.835 8.679 8200 81⁄2 125⁄16 185⁄8
43.50 8.755 8.599 81⁄4 83⁄8 123⁄16 181⁄2
47.00 8.681 8.525 83⁄8 123⁄16 181⁄2
53.50 8.535 8.379 81⁄4 121⁄16 183⁄8
32.75 10.192 10.036 97⁄8 133⁄4 101⁄2
40.50 10.050 9.894 93⁄4 135⁄8 197⁄8
103⁄4 11.750 45.50 9.950 9.794 9200 95⁄8 137⁄16 193⁄4
51.00 9.850 9.694 91⁄4 91⁄2 135⁄16 195⁄8
55.50 9.760 9.604 93⁄8 133⁄16 191⁄2
19
20
API Casing
38.00 11.150 10.994 103⁄4 1411⁄16 107⁄8
42.00 11.084 10.928 103⁄4 1411⁄16 107⁄8
113⁄4 12.750 47.00 11.000 10.844 9200 105⁄8 149⁄166 103⁄4
54.00 10.880 10.724 91⁄4 101⁄2 147⁄166 105⁄8
60.00 10.772 10.616 103⁄8 145⁄166 101⁄2
48.00 12.715 12.559 123⁄8 1711⁄16 121⁄2
54.50 12.615 12.459 121⁄4 179⁄166 123⁄8
133⁄8 14.375 61.00 12.515 12.359 11700 121⁄8 177⁄166 121⁄4
68.00 12.415 12.259 113⁄4 121⁄8 177⁄166 121⁄4
Downhole Milling
72.00 12.347 12.19 1 123⁄8 175⁄166 121⁄8
55.00 15.375 15.187 153⁄8 191⁄266 151⁄8
163⁄8 17.000 65.00 15.250 15.062 11700 147⁄8 193⁄866 153⁄8
75.00 15.125 14.936 113⁄4 143⁄4 191⁄466 147⁄8
84.00 15.010 14.822 145⁄8 191⁄866 143⁄4
Downhole Milling 21
Section Planning for Sidetracking

In preparation for milling sections, the following should
be reviewed:
• If a formation log is available and there is a choice of
where to cut your section, a section cut in a sand forma-
tion will normally result in fewer problems than one that
is cut in a shale formation.
• First, a plug will have to be set to isolate the old well.
• A bond log is preferred to determine if cement is behind
the casing to be milled. If you are not sure of a good
cement, you should plan to block squeeze the section.
• Never start just below a casing collar.
• Plan an extra rathole (100 to 150 ft) below the section:
• - This extra length may be needed during milling if cutting
removal becomes a problem.
• - It can be used to block squeeze if needed.
• Polymer muds are best for milling since they have
reduced PV/YP ratios and can be maintained as close
to 0.5 as possible.
• Clay-base muds have good carrying capabilities and
result in more troublesome jobs and, therefore, should
be avoided when possible.
• Oil-base muds have poor cutting carrying capabilities and
result in more troublesome jobs and therefore should be
avoided when possible.
The length of section needed will depend upon the following:
• Type of well plan and objective.
• The necessary rate of build.
• Type of deflection tool used.
Properties and Flow Rates

The fastest way to remove steel cuttings from the hole is
with a turbulent flow. Turbulent flow, however, can also
be the fastest way to get into trouble due to:
• Bird nesting of the cuttings.
• Loading of the hole creates turbulent flow due to the
restriction caused by cuttings in the annulus.
• - This is especially critical at the beginning of the section
where the drill collars are still inside the casing. Laminar
flow increases slip velocity, causing particles to fall
through the mud and fill up the lower stub.
22 Downhole Milling
• - Small adjustments in the flow rate, rotary speed and

weight-on-tool can be made while carefully monitoring
the returns from the size, shape and thickness.
Underreaming for Sidetrack Plug

Underreaming may be required (especially in small casing
sizes) to allow for a large plug to be set.
The cement for the plug has to be calculated to allow for
correct displacement of the lower stub, the open hole in the
section area and at least 100 ft of cement inside the casing
above the section. This is needed to allow the operator to
test the plug and dress off the top contaminated part of the
plug before starting the sidetrack.
• The cement plug must be hard enough to perform the
sidetrack.
• The cement in the section area must have a uniform
consistency.
• It has to be large enough to prevent going off the side of
the plug and creating a sharp dogleg.
Trip in hole with a bit to dress off and test the plug after
approximately 16 hr. A minimum of 3 ft into the section
should be drilled before picking up the mud motor and
directional assembly.
Using the K-Mill as a Pipe Cutter

The K-Mill is very effective in cutting single strings of cas-
ing. The efficiency of the knives in conjunction with the
Flo-Tel feature ensures optimum results.
Cutting the Pipe

• Pick up the tool and run in hole to cutting depth.
• Start rotary speed at 80 to100 RPM; note torque.
• Start pump slowly and increase volume and pressure,
until you notice a reaction at the rotary or torque (amps)
increases significally.
• Maintain a rotary speed of 80 to 100 RPM.
• When cut is complete, there is a definite indication — a
momentary loss of returns or an increase of mud in the
annulus. Quite often excessive noise will indicate when
the casing is parted.
Downhole Milling 23
• The loss of torque, a decrease in pump pressure or both,

are indications the cut has been completed.
• Shut off pumps.
• Stop rotary.
• Pull out the hole.
K-Mill Disassembly
• Remove top sub.
• Remove Flo-Tel assembly. (Note: Flo-Tel not available for
3600 Series.)
• Remove arm-stop stabilizers.
• Remove hinge pins.
• Remove the knives. Do not remove lugs.
• Using wrenches furnished in tool kit, remove cam locknut
and cam.
• Piston and spring may not be withdrawn from the body.
• Remove piston head retaining screws.
• Remove orifice and anti-wash tube from piston ID.
Note: The 3600, 4100 and 4500 Series tools, due to the
restricted piston diameter, do not have an anti-wash
tube. Remove orifice O-ring.
Service Instructions
• The tool should be thoroughly cleaned after completion
of each job. Steam cleaning is best. When not available,
cleaning solvents may be used. All packing should be
inspected after cleaning and replaced if any wear is visible.
• When the tool is reassembled, all parts should be thoroughly
lubricated. Any light grease is suitable.
24 Downhole Milling
K-Mill Components
Top sub
Flo-Tel assembly
Cone cap
Flo-Tel tensions screw

Piston head
O-ring
Piston packing
Spring
Piston head
Orifice
retaining screw
Anti-wash tube Lug
Arm hinge pin

Piston
Hinge pin
retaining screw
Cam Milling knife
Cam lock nut Retaining screw
Body Arm stop body stabilizer

Downhole Milling 25
Assembly
• Replace the Flo-Tel orifice (complete with packing) into
the piston, after sliding the anti-wash tube into place.
Note: The 3600, 4100 and 4500 Series tools do not have
anti-wash tubes.
• Replace the piston packing and piston head. Secure the
piston head to piston with the piston head retaining
screws. Make up firmly. Make sure the V-type lips of
the packing are face up.
• Place spring over piston and slide assembly into the body.
• Using wrenches furnished on tool kit, make cam up firmly
on the piston.
• Make up cam locknut firmly to prevent backing off.
• Assemble Flo-Tel loosely:
• - Place stinger in seat.
• - Place bail on cone cap.
• - Align holes in seat and cone cap and start threads of the
tension screws. Do not make screws up tightly at this
point, as this will expand the bail and the assembly
will not enter the body.
• - Slide the Flo-Tel assembly into the body. The bail will
snap into place when properly positioned.
• - Tighten tension screws firmly. This expands the bail into
its mating groove in the body and locks the assembly into
its proper place.
• Install new knives, hinge pins and hinge pin retaining
screws.
Note: The spare knives are packaged complete with hinge
pins and retaining screws. Do not attempt repeated
use of these items.
• Install and tighten arm-stop body stabilizers.
26
K-Mill
Top pin
connection
Fishing
Fishing neck length
neck
diameter
Body
diameter
Nominal overall length

Downhole Milling
Section Mill Specifications
Downhole Milling
Fishing Fishing
Tool Casing Body Neck Neck Overall Top Pin Weight
Series Sizes Diameter Length Diameter Length Connection (lb)
3600 41⁄2 35⁄8 18 31⁄8 56 23⁄8 135
4100 5 41⁄8 18 31⁄4 66 23⁄8 175
4500 51⁄2, 6 41⁄2 18 41⁄8 70 27⁄8 220
5500 65⁄8, 7 51⁄2 18 43⁄4 74 31⁄2 350
6100 75⁄8 61⁄8 18 43⁄4 74 31⁄2 368
7200 8 ⁄8, 95⁄8
5
71⁄4 18 53⁄4 89 41⁄2 554
8200 95⁄8 81⁄4 18 53⁄4, 8 87 4 ⁄2, 65⁄8
1
900
9200 10 ⁄4, 113⁄4
3
91⁄4 18 53⁄4, 8 87 41⁄2, 65⁄8 980
11700 133⁄8, 16 111⁄2 18 8, 9 90 65⁄8, 75⁄8 1,725
Notes: Ordering Instructions:
1. All dimensions are given in inches unless When ordering or requesting quotations on section
otherwise stated. mills, please specify:
2. All weights are approximate. 1. Tool series.
3. Standard API regular pin connections. 2. Size and weight of casing to be milled.
Others available upon request. 3. Top pin connection.
4. Flo-Tel is standard equipment for 4100
through 11700 Series.
27
28 Downhole Milling
Pilot Mill
Downhole Milling 29
PILOT MILLS
Pilot mills are recommended for milling washpipe, safety
joints, crossover swages and washover shoes. Liner hang-
ers can be milled efficiently, eliminating inside cuts and
running spears. The nose, or pilot, can be dressed to mill
out junk which may be encountered.
Pilot mills can be used to mill:
• Adapters • Casing • Liners
• Washpipe • Drill pipe • Swaged casing
General Guidelines for Using Pilot Mills

In selecting a pilot mill, the blade OD should be about 1⁄4 in.
larger than the OD of the tool joint or coupling to be milled.
The pilot OD should be the same as the drift diameter of
the tubular.
The best speed and weight to run a pilot mill must be
determined for each job. Also, conditions may change from
one pilot milling job to the next in the same well.
This may require different speeds and weights at differ-
ent times. In the absence of experience, start with a rotary
speed between 80 and 100 RPM and a tool weight of 2,000
to 6,000 lb or less.
If, when milling swaged casing, a sudden drop-off in
milling rate occurs, the trouble may be caused by a loose
ring of steel formed at a joint or weld which is turning with
the pilot mill. Try spudding the pilot mill gently. This
should break up the ring and help position it for milling.
If cutting stops altogether when milling washpipe, cas-
ing or liner, and there is no noticeable increase in torque,
there is a good chance a section of the casing or tubular
is turning. If this is the case, pull the mill and attempt
retrieval using a spear.
Considerations When Milling Liner Hangers and Adapters

On most liner milling jobs, a pilot mill is used to first mill
the liner hanger or adapter, and then the liner. In some
cases the liner hanger or adapter is milled using a junk mill.
Then the liner is milled with a pilot mill. This latter method
is preferred if there is hard cement behind the liner or if the
liner has numerous bow-springs, slips, etc.
30 Downhole Milling
A Pilot Mill is Ideal for Washpipe

The pilot mill is the most efficient tool for milling stuck wash-
pipe. If drill pipe or collars are inside washpipe, however, they
must first be milled with a junk or smaller pilot mill.
Milling Drill Pipe and Drill Collars

If the ID is open, drill pipe and collars are sometimes milled
with pilot mills. If the drill pipe or collar is cemented inside
the casing, particularly in deviated holes, the pipe is proba-
bly lying on the low side with its center eccentric to the cas-
ing. Most often this makes the job extremely difficult for a
pilot mill. Under these conditions, we recommend a full
gage junk mill. A pilot mill will do a reasonable job on
drill collars, provided the cuttings can be removed as the
milling progresses. If cuttings tend to fall into the ID and
plug it, then a junk mill must be used.
Using the Pilot Mill in Swaged Completion

The pilot mill is ideally suited to mill out the necked down
portion of casing in swaged completion. Necked-down
lengths of casing, corresponding in length to the thickness
of the producing zones, are made up with swages to the
regular casing collars in the string. The casing is cemented
and water shutoff is obtained at all zone intervals. The
necked portions are then milled out with a pilot mill and
the resulting sections are opened with an underreamer.
This underreaming operation removes cement and wall
cake, providing a clean producing area.
Using a Pilot Mill

1. Lower the mill about 5 in. above the tubular. Set the brake
and start rotating. Slowly increase rotation to 125 RPM.
Raise and lower the mill 3 to 6 ft but do not touch the tubu-
lar while rotating. This action will show the neutral torque
to be determined. By noting the torque in the string when
the pilot of the mill enters the tubular, you can determine
if the pilot has been entered properly.
2. Reduce rotation to about 30 RPM and enter the pilot
into the tubular. Apply 2,000 lb of weight. Stop rotation
quickly while you note the torque action of the string. A
gradual slow down or spin indicates that the mill has
entered the tubular with proper alignment.
Downhole Milling 31
3. To mill H-40 or K-55 casing, use a weight between 4,000

and 6,000 lb and a speed of 80 to 100 RPM, whereas N-80,
P-110 and Q-135, etc. casing requires a weight of 8,000 to
10,000 lb and a RPM of 100 to 120. If the casing is sur-
rounded by hard cement, or if the open hole diameter
is the same or less than the blade OD of the mill, more
weight may be needed to drill cement and formation.
When working below the shoe of the casing, ream the
hole up and down after every 15 to 20 ft of tubular milled
to clean out any accumulation of cuttings which may have
collected at the shoe. Periodic reaming to ensure cutting
removal is also a good practice in holes with deviation of
30° or more.
4. Normally, milling should be continued at an even rate
without interruption once it has been started. Milling
weight should be applied at a constant rate. Do not allow
weight to drilloff.
32 Downhole Milling
Pilot Mill
Fishing neck diameter
Top pin
Fishing connection
length
neck
Pilot diameter
Blade diameter
Pilot Mill Specifications

Pin Fishing Fishing
Blade Connection Pilot Overall Neck Neck Weight
Diameter API Reg. Diameter Length Length Diameter (lb)
31⁄4 - 137⁄8 23⁄8 13⁄4 - 123⁄4 27 12 31⁄8 40
41⁄8 - 143⁄8 23⁄8 13⁄4 - 123⁄4 27 12 31⁄8 45
41⁄8 - 153⁄8 27⁄8 21⁄8 - 131⁄4 27 12 33⁄4 120
51⁄2 - 155⁄8 31⁄2 21⁄2 - 143⁄4 38 16 41⁄4 240
53⁄4 - 173⁄8 31⁄2 21⁄2 - 143⁄4 38 16 43⁄4 255
61⁄8 - 197⁄8 41⁄2 43⁄4 - 163⁄4 42 18 53⁄4 305
97⁄8 - 171⁄2 65⁄8 73⁄4 - 151⁄8 45 18 73⁄4 550

1. All dimensions are given in When ordering or requesting quota-
inches unless otherwise stated. tions on pilot mills, please specify:
2. All weights are approximate. 1. Size and weight of casing to
3. Standard API regular pin. be milled.
Other sizes available upon 2. Size and weight of casing to
customer request. be run through, if available.
3. Top pin connection.
Downhole Milling 33
Notes
34 Downhole Milling
Piranha Mill
Millmaster
Carbide inserts
Millmaster-dressed Piranha mills are only available on a rental basis in

conjunction with Smith job supervision.
*U.S. Patent Numbers:

Carbide Insert Milling Tool – 4,710,074
Piranha Mill – 5,074,356
Downhole Milling 35
PIRANHA MILL
The Piranha mill is a tool which has been solely designed
for the efficient removal of downhole casing strings.
Millmaster technology ensures maximum ROP, ideal
cutting size and extended milling duration.
Offshore Slot Recovery

Today, many fields are either reaching the end of their use-
ful lives or are beyond the break-even point for production.
Smith has worked closely with many major oil companies
and their engineering divisions to develop a platform slot
recovery system.
This system provides an economical method to re-drill
non-producing wells to a new target. Abandonment is
eliminated by recovering existing slots.
The main objective is the successful removal of the inter-
mediate casing strings back to the surface string/conductor
pipe. Depending on the quality of the casing cement job, a
combination of retrieval and milling operations are nor-
mally employed. Where casing strings are cemented back
to the casing spools, milling must be used exclusively.
The need to remove the intermediate string of casing is
carried out to expose a clear string of conductor pipe and
formation around the shoe. This allows the well to be devi-
ated as per normal practices.
Description of the Piranha Mill

• The cutting structure consists of Millmaster carbide
arranged in a brick pattern. The carbide being specially
developed for downhole application prevents premature
wear and breakage.
• The blade is manufactured from high-grade alloy steel
and positions the cutting edge at the precise angle for
maximum cutting efficiency.
• Extended blade length provides maximum footage
per mill.
36 Downhole Milling
Slot Recovery Operating Parameters

As with all types of downhole milling, some specific guide-
lines must be followed to obtain optimum performance
from the tool. The Millmaster cutting structure differs in its
requirements from the “conventional” crushed tungsten
carbide type.
• The two major components to be considered when deciding
on parameters are RPM and weight-on-bit. The rotary speed
is calculated as found on page 4 of the Data Handbook using
the optimum cutting surface speed for tungsten carbide (250
to 340 ft/min) vs. the outside diameter of the casing.
• The effective milling weights for the Piranha have been
found to be in the range of 5,000 to 10,000 lb.
Mill Stability
• Stabilization is necessary to optimize the overall perform-
ance of the Piranha. An Ezy-ChangeT sleeve-type stabilizer
is included in the tool’s design. This allows the stabilizer to
be changed at the rig site. Interchangeability is important,
especially when milling eccentric casing strings.
• In deviated hole sections or where a casing string has been
forced to one side, the blade design will not skin the next
casing string.
• Included in the stabilization is a standard taper mill, running
directly ahead of the Piranha mill. This is used to give the
assembly the capability of clearing any junk or enlarging
the stub of the casing. The OD and stabilization diameter is
calculated to prevent damage to outer casing strings.
Piranha Mill Specifications
Downhole Milling
Number Fishing Fishing
Tool Casing Body Blade of Top Pin Neck Neck Overall Weight
Series Sizes Diameter Diameter Blades Connection Length Diameter Length (lb)
4500 41⁄2 43⁄4 5.250 3 31⁄2 IF BU 12 43⁄4 36 100
5000 51⁄2 43⁄4 5.813 3 31⁄2 IF BU 12 43⁄4 36 110
5500 51⁄2 43⁄4 6.300 3 31⁄2 IF BU 12 43⁄4 36 120
6000 61⁄2 43⁄4 6.875 3 31⁄2 IF BU 12 43⁄4 42 150
6600 65⁄8 53⁄4 7.640 3 41⁄2 IF BU 12 53⁄4 42 175
7000 71⁄2 53⁄4 7.906 3 41⁄2 Reg. BU 12 53⁄4 42 190
7600 75⁄8 61⁄4 8.750 5 41⁄2 IF BU 18 61⁄4 48 250
8600 85⁄8 63⁄4 9.875 5 51⁄2 Reg. BU 18 63⁄4 48 275
9600 95⁄8 81⁄2 10.875 5 65⁄8 Reg. BU 18 81⁄2 60 300
10700 103⁄4 91⁄2 12.000 5 75⁄8 Reg. BU 18 91⁄2 60 325
11700 113⁄4 101⁄4 13.000 5 85⁄8 Reg. BU 18 101⁄4 60 375
13300 133⁄8 111⁄2 14.625 5 85⁄8 Reg. BU 18 111⁄2 72 400
16000 161⁄2 141⁄2 17.250 5 85⁄8 Reg. BU 18 141⁄2 72 425
1. All dimensions are given in inches unless otherwise stated. When ordering or requesting quotations on Piranha mills,
2. All weights are approximate. please specify:
3. Pilot stabilization dressed to casing drift diameter. 1. Tool series.
4. Guide mill or taper mill dressed to casing drift diameter. 2. Size and weight of casing to be milled.
5. Ezy-Change II stabilizer sleeve available on casing sizes 75⁄8 in. 3. Top pin connection.
and larger.
37
38 Downhole Milling
Junk Mill
Conventional
Conebuster
Super
Dressing Options
Downhole Milling 39
JUNK MILLING
The junk mills chew their way through the toughest materi-
als. Junk mills are said to be the true workhorse of downhole
milling operations.
When drill pipe is cemented inside and out, a junk mill
is the only tool that will do the work. However, if the drill
collars or drill pipe are not collapsed and the ID is open, a
pilot mill can sometimes be used to better advantage.
When casing has been milled with a pilot mill or section
mill to the point where it begins to rotate, it can often be
pounded down and milled using a junk mill made up at the
end of a joint of slightly eccentric or bent drill pipe.
Junk mills can be used to mill almost anything in the
hole, including cement and rubber products.
Junk Milling Procedures

1. Tag bottom and pick up 3 ft. Begin circulating as for
normal drilling conditions.
2. Begin rotation at 60 to 80 RPM.
3. Apply weight at 4,000 RPM.
4. If there is an indication junk may be turning, spud two or
three times.
5. After milling 1 to 2 ft, pick up the kelly 15 to 20 ft off
bottom and reduce pump pressure or shut off pumps
(depending on hole conditions). This action will let the
loose junk settle to the bottom.
6. Once again feel for the bottom and spud. Begin rotation
at 80 to 100 RPM using normal pump pressure. Begin
weight at 4,000 to 6,000 lb.
7. Repeat Steps 3 and 4 every few feet. Procedures from here
on will be governed by feel.
Note: In hard formation it will take fewer feet of the hole
to mill up the junk than in softer formation. This differ-
ence is due to the junk’s ability to lodge itself into the
softer formation.
40 Downhole Milling
General Guidelines
When milling loose junk, operations can be improved by
frequent spudding. This action will pound the junk onto
the bottom, positioning it for more effective milling.
Never permit a sliver or piece of junk to lodge next to
the mill. Force it down by spudding the mill. A noticeable
increase in torque will indicate that a sliver or piece of junk
is alongside the mill. Picking up the mill and lowering it peri-
odically will decrease the possibility of a deep wear pattern to
develop, thus evening the wear on the mill face.
When milling cast-iron bridge plugs, the mill OD should
be approximately 1⁄8 in. under the size of the bridge plug —
this will prevent “skinning” the casing.
Loose Junk in Open Hole

• Use a junk mill with an OD of 1⁄8 in. less than
hole diameter.
• Use at least 10,000 lb of drill collars.
• Run a junk sub directly above the mill.
Note: Junk subs for 43⁄4 in. along with smaller drill collars
are not strong enough for repeated spudding.
• Frequent spudding improves milling efficiency on
loose junk. To spud the junk and force it down, proceed
as follows:
1. Determine the neutral or zero point. Mark the kelly at
the top of the kelly bushing.
2. Pick up the kelly 4 to 6 ft (4 ft in shallow holes, 6 ft in
deeper holes).
3. Drop the kelly and catch (not slow down, but catch it)
with the brake about 18 to 20 in. above the zero mark.
(Example: Pick up 10 ft and drop it 81⁄2 ft.) This action
causes the drillstring to stretch and spud the junk on
bottom with great force while the string is still in a state
of tension. This prevents damage to the string which
might be expected if the string is in compression at the
moment of impact.
4. Spud the junk three or four times, turning the mill a
quarter-turn each time between drops.
Downhole Milling 41
Stationary Junk in Open Hole

• Use a junk mill with a diameter about 1⁄8 in. less than the
hole diameter.
• Mill with 4,000 to 10,000 lb of weight, depending upon the
strength of the junk being milled.
• After 3 to 5 ft of junk milled, pick up the mill 10 to 15 ft
and ream the hole down to the junk.
• After reaming the hole down, always set down on the junk
while turning and bring the weight up to milling weight.
Never apply weight first and then start rotating.
• Never set down on the junk with a light weight and spin.
If you wish to stop milling for any reason, always pick
up the mill. Spinning in one spot can cause the steel to
work-harden to such an extent that it will be difficult to
re-start the milling process.
Loose and Stationary Junk in Open Hole
Procedures for running a junk mill inside the casing are the
same except for the following:
• Run a stabilizer directly above the mill which has the
same OD as the mill.
• The mill head OD should be the same as the drift diameter
of the casing.
• Wear pads having the same OD as the diameter of the mill
head are provided on the junk mill. These will eliminate
possible damage to the casing.
42 Downhole Milling
Junk Mill
Fishing
neck
diameter
Top pin
connection
Fishing
neck
length
Dressed
diameter
Downhole Milling 43
Junk Mill Specifications

Overall Length
Standard Top Pin Junk Mill Super Fishing Fishing
Cutting Conn. and Cone Junk Neck Neck Weight
Diameter API Reg. Buster Mill Length Diameter (lb)
31⁄2 - 41⁄2 23⁄8 20 20 12 3 45
41⁄2 - 51⁄2 27⁄8 21 21 12 33⁄4 62
51⁄2 - 55⁄8 31⁄2 23 21 12 41⁄4 95
53⁄4 - 71⁄2 31⁄2 23 21 12 43⁄4 105
71⁄2 - 9 41⁄2 27 27 12 53⁄4 180
9 ⁄2 - 121⁄4
1
65⁄8 29 29 12 73⁄4 350
13 - 15 6 ⁄8 or 75⁄8
5
30 30 12 73⁄4 or 91⁄2 500
17 - 171⁄2 65⁄8 or 75⁄8 33 33 12 73⁄4 or 91⁄2 625
181⁄2 - 26 65⁄8 or 75⁄8 37 37 12 73⁄4 or 91⁄2 1,200
Notes:
1. All dimensions are given in inches unless otherwise stated.
2. All weights are approximate.
Ordering Instructions:
When ordering or requesting quotations on junk mills, please specify:
1. Mill diameter.
2. Size and weight of casing to be run through, if available.
3. Top connection.
44
Junk Sub
Body
diameter
Bore
diameter
Sleeve
Bottom-box length Top pin
connection connection
Body
Mud
diameter
bleed
under
holes
sleeve
Fishing
neck
diameter
Downhole Milling
Downhole Milling 45
JUNK SUBS
Junk subs capture and trap junk too heavy to circulate. They
are designated to be used in the drill collar string just above
the rock bit or milling tool. The tool consists of a steel man-
drel with an oversized sleeve or “skirt” attached over the
mandrel. The “skirt” is welded at the lower end. The “skirt”
will trap the large cuttings and junk which are too heavy to
be circulated out the hole. The “skirt” is manufactured with
bleed holes to allow the mud to drain once it is brought out
of the hole. It is recommended that two junk subs be run in
tandem to decrease the possibility of junk bypassing a single
junk sub.
Junk Sub Specifications
Body
Top and Fishing Dia.
Body Bottom Overall Neck Under Bore Sleeve Weight
Dia. Conn. Length Dia. Sleeve Dia. Length (lb)
35⁄8 23⁄8 33 31⁄16 25⁄8 15⁄8 12 50
5 3 1
4 ⁄8 2 ⁄8 33 3 ⁄2 21⁄2 11⁄4 12 62
5 7 5
4 ⁄8 2 ⁄8 37 3 ⁄8 21⁄2 11⁄4 12 66
1 7 7
4 ⁄2 2 ⁄8 37 3 ⁄8 21⁄2 11⁄4 12 91
5 1 3
5 ⁄8 3 ⁄2 38 4 ⁄8 31⁄4 11⁄2 12 120
1 1 5
5 ⁄2 3 ⁄2 38 4 ⁄8 31⁄4 11⁄2 15 144
1 1 7
6 ⁄2 4 ⁄2 48 5 ⁄8 41⁄2 25⁄8 15 261
5 1 7
6 ⁄8 4 ⁄2 48 5 ⁄8 41⁄2 25⁄8 15 270
3 1 7
6 ⁄4 4 ⁄2 48 5 ⁄8 41⁄2 25⁄8 15 280
5 1 5
7 ⁄8 4 ⁄2 48 6 ⁄8 41⁄2 25⁄8 15 298
1 5 1
8 ⁄2 6 ⁄8 50 7 ⁄2 53⁄4 13
2 ⁄16 15 438
5 5 1
8 ⁄8 6 ⁄8 50 7 ⁄2 53⁄4 213⁄16 15 451
5 5 1
9 ⁄8 6 ⁄8 50 8 ⁄2 53⁄4 213⁄16 15 529
3 5 5
10 ⁄4 7 ⁄8 51 9 ⁄8 75⁄8 35⁄8 15 806
3 5 5
12 ⁄4 7 ⁄8 51 11 ⁄8 75⁄8 35⁄8 15 1,065
Notes:
3. Standard API regular connections. Other sizes and lengths available
upon customer request.
When ordering or requesting quotations on junk subs, please specify:
1. Tool size.
2. Top and bottom connections.
46 Downhole Milling
Taper Mills
CP
CT
Downhole Milling 47
TAPER MILLS
Taper mills are generally used to eliminate restrictions or
to mill through “pinched”or collapsed casing. They are
equipped with a tapered or a short blunt nose which serves
as a guide. Smith offers a CP taper mill or a CT taper mill.
CP Taper Mill Designed for the Toughest Taper Mill Job

The CP taper mill features a blunt-nose design that makes it
useful in those taper milling applications where the possibil-
ity of using a longer tapered nose might break. The CP mill
generates considerably less torque than a conventional taper
mill because of its shorter taper section. Because of this low-
torque feature, the CP mill can be run with more weight
when necessary.
CT Taper Mill Perfect for Milling Restrictions

The CT taper mill was designed for milling through restric-
tions. The spiral blades and the pointed nose make the CT
ideal for reaming out collapsed casing and liners, cleaning
up permanent whipstock windows, milling through jagged
or split shoes, and enlarging restrictions through retainers
and adapters.
General Guidelines for Using a Taper Mill

• Start rotation at 75 RPM above the collapsed area.
• Taper milling RPM is governed by torque. To overcome
torque problems, maintain at least 75 RPM.
• Use less weight when running a taper mill than a junk or
pilot mill. After you have entered the collapse, increase
the weight slowly from 1,000 to 2,000 lb. Watch for any
torque increase.
48 Downhole Milling
How to Clean Up Whipstock Windows Using a Taper Mill

1. Use a taper mill of the same diameter as the largest mill
used to mill the window (or slightly larger than the bit to
be used).
2. Run the taper mill into the hole to within 5 ft from the top
of the window.
3. Rotate slowly 40 RPM, down the full length of the
whipstock. Do not attempt to make hole using this tool.
4. Keep weight under 1,000 lb. Excessive weight may cause
the taper mill to slip out of the window prematurely.
5. To clean up all rough edges, repeat the above procedure
several times until the mill runs smoothly for the full length
of the whipstock which is indicated by minimal torque.
Procedures for Reaming Out Collapsed Casing

1. Determine the approximate diameter using a bit that will
pass through the collapsed interval. Do not use a taper
mill if the collapsed interval has passed center.
2. Use a taper mill about 1⁄4 in. larger than the minimum ID
of the collapse and mill out in stages. In other words, if the
collapse is great, use several different sizes of mills to
bring the ID of the pipe to full gage. This will minimize
any tendency to sidetrack.
3. A string taper mill can be used if there is any danger of
sidetracking.
4. Begin milling at a table speed of about 50 RPM.
5. The milling weight is governed by the torque encoun-
tered. In most cases, milling weights of around 2,000 to
3,000 lb are used.
6. Where the pipe is greatly collapsed, the lower portion of
the collapsed interval may act as a whipstock. The taper
mill, in this case, may cut through the upper portion of
the collapsed interval and be deflected into the formation
by the lower section of the damaged casing. In some cases
of extreme collapsed pipe, it is better to run a stabilized,
rigid hookup with a junk mill. Use very light weight with
a table speed of about 125 RPM to mill out the collapsed
portion and enter the undamaged casing below.
Downhole Milling 49
Enlarging Restriction Through Retainers and Adapters

1. Use a taper mill with a diameter equal to the desired
enlargement (usually the drift ID of the casing).
2. Mill about 70 RPM and with weight from 2,000 to 6,000 lb.
Both the speed and the weight should be governed by the
torque. If the torque is high, speed and weight should be
reduced until the mill turns with minimal torque.
3. After milling through the restriction, increase speed to
between 80 and 100 RPM. Rotate up and down through
the interval several times until it is smooth and nearly
torque free.
Using a Taper Mill to Ream Out Guide Shoes

In some cases, the bull plug on the bottom of liners or casing
may be jagged or split to such degree that the string hangs
up coming out of the hole. This condition can be remedied
by reaming through the guide shoe with a taper mill. Follow
the procedure recommended above for enlarging restrictions
through retainers and adapters.
50 Downhole Milling
CP/CT Taper Mill
Fishing Fishing
neck neck
diameter diameter
Top pin Top pin

connection connection
Fishing Fishing
neck neck
length length
Dressed
diameter
CP
Dressed
diameter
CT
Downhole Milling 51
Taper Mill Specifications

Pin Overall Fishing Fishing
Dressed Conn. Length Neck Neck Weight (lb)
Diameter API Reg. CT CP Length Diameter CT CP
131⁄4 - 137⁄8 23⁄8 34 30 10 3 80 60
3 3
14 ⁄8 - 14 ⁄8 23⁄8 34 30 10 31⁄8 90 70
1 3
14 ⁄2 - 15 ⁄8 27⁄8 38 31 10 33⁄4 106 75
1 5
15 ⁄2 - 15 ⁄8 31⁄2 42 32 13 41⁄4 155 115
3 3
15 ⁄4 - 16 ⁄8 31⁄2 44 32 13 43⁄4 160 120
1 3
16 ⁄2 - 17 ⁄8 31⁄2 46 34 13 43⁄4 170 130
1 7
17 ⁄2 - 17 ⁄8 41⁄2 54 36 13 53⁄4 250 185
3 1
18 ⁄8 - 19 ⁄2 41⁄2 54 36 14 53⁄4 280 220
19 ⁄8 - 19 ⁄8 4 ⁄2 or 65⁄8
3 7 1
54 36 14 5 ⁄4 or 73⁄4
3
345 280
103⁄8 - 113⁄8 65⁄8 57 38 14 73⁄4 415 355
1 1
11 ⁄2 - 12 ⁄4 65⁄8 60 40 14 73⁄4 455 390
3 3
14 ⁄4 - 15 ⁄8 65⁄8 70 60 18 73⁄4 525 460
3 1
17 ⁄8 - 17 ⁄2 65⁄8 70 60 18 73⁄4 595 530
20 ⁄8 - 26 ⁄8 6 ⁄8 or 75⁄8
3 3 5
76 66 18 7 ⁄4 or 91⁄2
3
1,250 1,125
Notes:
52 Downhole Milling
SPECIAL MILLS
Economills
Economills are a low-cost alternative for light-duty milling
jobs. Dressed with tungsten carbide, Economills are an effec-
tive tool for milling packers, retainers, bridge plugs and
cement. Manufactured with standard API connections, the
mill is made up and broken out with a standard bit breaker.
No additional subs are required. Circulation is directed
along each cutting blade and through the center of the head
for proper cutting removal and cooling.
Stabilizing ribs immediately above the cutting blades
prevents damage to the casing. Note: Economills are fabri-
cated from a casting and should not be used as junk mills.
The cast products do not have the same material strength!
Top pin
connection
Dressed
diameter
Economill Specifications
Top Pin Recommended
Tool Dressed Conn. Overall Weight Torque
Series Diameter API Reg. Length (lb) (ft/lb)
3000 31⁄4 - 43⁄8 23⁄8 75⁄8 17 3,000 - 3,500
1 3 7
4000 4 ⁄2 - 5 ⁄8 2 ⁄8 85⁄8 26 6,000 - 7,000
1 3 1
5000 5 ⁄2 - 7 ⁄8 3 ⁄2 9 40 7,000 - 9,000
7000 71⁄2 - 83⁄4 41⁄2 111⁄2 76 12,000 - 16,000
10000 101⁄4 - 121⁄4 65⁄8 161⁄2 125 28,000 - 32,000
Notes: 1. Mill dressed diameter.
1. All dimensions are given in 2. Size and weight of casing to
inches unless otherwise stated. be run through, if available.
2. All weights are approximate. 3. Protective subs available
Ordering Instructions: upon request.
When ordering or requesting quota-
tions on Economills, please specify:
Downhole Milling 53
Drill Mills
The cast drill mill is a rugged tubing mill designed for ream-
ing hardened cement, sand and scale out of tubing or drill
pipe with maximum efficiency, even when wireless and
other light junk inside the tubing or pipe must be milled
simultaneously. A wall contact area of three square inches
ensures proper stabilization and eliminates possible damage
to tubing or pipe walls.
Drill mills are available for all sizes of tubing and drill
pipe and can be supplied in a wide selection of drill rod
tool joints.
Top pin
connection
Wall contact
area 3 in.2
Dressed
diameter
Drill Mill Specifications

Series Dressed Standard Pin
Number Length Diameter Connections*
2800 53⁄8 13⁄4 - 3 Drill rod: A, B,
AW, EW, E
3800 53⁄8 23⁄4 - 37⁄8 Drill rod: N, NW
* Other connections made to customer specifications can be furnished.
Note:
All dimensions are given in inches unless otherwise stated.
54 Downhole Milling
Junkmaster
ID Fishing
neck
diameter
Top pin
connection
Fishing
neck
length
Skirt
ID
Skirt
OD
Downhole Milling 55
Junkmaster
Junkmaster is a three-piece, demountable skirted junk
mill. It is the ideal tool for milling inside casing or milling
up torn or plugged tubular junk. The three-piece design of
the junkmaster-driver sub, Economill and skirt, permits a
worn part to be replaced without discarding the complete
tool. The thrifty Economill can be replaced for a fraction
of the cost of a one-piece skirted junk mill. The skirt slips
over distorted or split pipe and the fish to protect the casing
while keeping the Economill from slipping off the top of
the fish.
Four designs are available: Tooth type, V-notch, perfo-
rated type, or fishing lip type. Both the Economill and skirts
are dressed with Servcoloy “S” tungsten carbide.
Three-Piece Skirted Junk Mill Specifications
Top Pin Fishing
Tool Skirt Skirt Conn. Neck Length Weight
Series OD* ID** API Reg. Diameter (ft) (lb)
3500 31⁄2 27⁄8 23⁄8 31⁄4 46 45
4000 45⁄8 37⁄8 27⁄8 33⁄4 46 70
4500 41⁄2 33⁄4 27⁄8 33⁄4 46 80
5700 53⁄4 55⁄8 31⁄2 43⁄4 47 110
7000 75⁄8 53⁄4 41⁄2 53⁄4 47 165
7600 73⁄4 61⁄2 1
4 ⁄2 53⁄4 47 220
10700 103⁄4 93⁄8 65⁄8 73⁄4 59 368
11700 113⁄4 103⁄8 65⁄8 73⁄4 59 417
* OD of skirt can be dressed larger.
** ID of skirt can be dressed smaller.
Notes:
3. Standard API regular connections. Others available upon
customer request.
When ordering or requesting quotations on the junkmaster,
please specify:
1. Dressed OD and ID of skirt.
2. Size and weight of casing to be run through, if available.
3. Tooth design of skirt (V-notch, Wavy bottom, Fish lip, T-type, etc.).
4. Top connection.
56 Downhole Milling
SERVCOLOY PRODUCTS
Since the early 1950s, we have been providing our customers
with the necessary hardmetal and dressed tools to effectively
perform their operations. Only the highest quality carbides
are selected for all the Servcoloy products.
Servcoloy “S”
An “S” grade carbide is composed of tungsten, titanium and
tantalum carbides as a binder.
The Servcoloy rod is deposited with an oxy-acetylene
torch. The material can be used as a cutting compound or
for abrasion resistance. Made of sharp particles of tungsten
carbide suspended in a resilient nickel-silver alloy matrix.
The matrix protects the carbide from extreme shock condi-
tions, at the same time exposing new sharp edges during the
cutting operation. Available in concentrate form (approxi-
mately 2 lb rod bare) or composite (approximately 11⁄2 lb
rod, flux coated or bare). Kits are available, including
Servcoloy, with the necessary flux and tinning rod to
prepare the base metal before application (see tables
on Page 60).
Servcoloy Rod Application

1. The material to which Servcoloy is to be applied should be
thoroughly cleaned and be free from corrosion and other
foreign matter. Grit blasting is the preferred method, but
grinding, wire brushing or sanding is also satisfactory.
4. Note: Sandblasting the surface will cause difficulty in
tinning.
2. Arrange the work area so the tool is positioned for down
hand welding; when possible, secure the tool in a suitable
turning jig fixture.
3. Staying 3 to 4 in. off surface, slowly preheat to approxi-
mately 600°F (316°C) to 800°F (427°C);
maintain a minimum of 600°F (316°C).
Downhole Milling 57
4. Use a spoon or spatula to sprinkle the surface to be

dressed with brazing flux. The flux will bubble and boil
if the surface of work piece is sufficiently heated. This
flux will help to prevent the formation of oxides in the
molten matrix during dressing.
4. Caution: Make sure that the working area is well venti-
lated so that any gases generated from the flux or filler
are carried off and away from the welder. These gases are
toxic and prolonged inhalation may produce nausea or
sickness. The welder must wear a face shield, long
sleeves and gloves during application.
5. Use an oxy-acetylene torch; tip selection will depend
upon situation: No. 8 or 9 for dressing large areas; No. 5,
6 or 7 for smaller areas or tight corners. Adjust the torch
flame to a low-pressure neutral flame, one in which the
light blue excess acetylene feather just disappears.
6. Continue to heat the surface to be dressed until the
brazing flux is fluid and clear.
7. Staying 3 to 4 in. off surface, localize the heat in one area
to a dull cherry red, 1,600°F (871°C). Begin tinning by
melting on about 1⁄32- to 1⁄16-in. thick cover of filler rod.
If the surface is hot enough, the filler rod will flow and
spread to follow the heat; if not, the molten metal will
bead up. Continue to heat and tin the surface to be
dressed as fast as the molten filler metal will bond.
8. Separate Servcoloy composite or concentrate rod into
small pads, 1⁄2- to 1-in. sections. This can be done by heat-
ing a rod on a non-stick surface (carbon block)
until the matrix becomes molten.
9. For easier handling, heat the composite of concentrate
rod and tack the filler rod to the pad. Dip the rod in the
brazing flux, heat tinned surface with torch and place the
Servcoloy piece in position. Heat Servcoloy and base steel
just enough to melt the matrix, then move the torch away
from the surface, continuously moving across the area
to keep the matrix molten. The filler rod is used to help
position the carbide for proper concentration.
58 Downhole Milling
14. Caution: Do not use excessive amount of filler rod as it

will only dilute the carbide. Do not overheat carbides or
matrix. Never permit the dark blue inner cone of the
flame to contact the carbide as the heat is too high in
this portion of the flame. If carbides refuse to tin, they
must be flipped out of the puddle and kicked off.
10. Both Servcoloy composite and concentrate rods are
available in a number of graded fragment sizes; the
desired buildup can usually be made with a single layer
of the correct particle size. More experienced welders
prefer to apply one layer, float it and then apply a sec-
ond. The deposit thickness should never exceed the
thickness of the steel being dressed. Proper application
and positioning will reduce the amount of grinding
necessary for sizing.
11. After each blade has the proper amount of Servcoloy
dressed, apply a light overlay of filler rod. Use care and
do not heat the carbides or matrix already in place.
12. Once dressing is complete, cool the tool slowly in ver-
miculite. Never cool with a liquid. Do not reheat the
dressed area by performing any welding near it.
Servcoloy Removal
When removing Servcoloy dress, use the same size torch
tip used in the application. Heat the Servcoloy until it is just
molten, then flip it off the surface using a suitable rod.
Caution: Under no condition should the operator
attempt to melt the Servcoloy enough to make it flow or
run off. Never attempt to re-use Servcoloy which has been
previously used or applied.
Downhole Milling 59
Servcoloy Furnace Products

Concentrate Rod Composite Rod
1
⁄2 x 1 x 151⁄2 3
⁄8 x 15
Weight Weight
Carbide (lb) (lb)
3
⁄8 x 3⁄8 2.0 0.76
5
⁄16 x 1⁄4 2.0 0.53
1
⁄4 x 3⁄16 2.0 0.53
3
⁄16 x 1⁄8 1.8 0.53
1
⁄8 x 1⁄16 1.5 0.53
10/20 Mesh N/A 0.53
Notes:
When ordering or requesting quotations on Servcoloy furnace products,
please specify:
1. Composite or concentrate rod.
2. Quantity (lb).
3. Carbide particle size.
4. Tinning rod and flux quantities (20 lb tinning rod and 5 lb flux
per 100 lb composite).
60 Downhole Milling
Servcoloy “S” Field Kits

Mills
Kit Number Size and Type Kit Will Redress (in.)
J6 1, 6-in. junk mill or 2, 41⁄2-in. junk mills or
1, 5-in. pilot mill
J7 1, 75⁄8-in. junk mill or 2, 55⁄8-in. junk mills or
1, 6-in. pilot mill
J8 1, 85⁄8-in. junk mill or 2, 6-in. junk mills or
1, 71⁄2-in. pilot mill
J10 1, 105⁄8-in. junk mill or
2, 81⁄4-in. junk mills
3, 75⁄8-in. junk mills or 1, 12-in. pilot mill
J14 1, 15-in. junk mill or 2, 105⁄8-in. junk mills or
1, 15-in. pilot mill
Servcoloy “S” Field Kits

Washover Shoes
Mills
Kit Number Size and Type Kit Will Redress (in.)
W5 1, 5-in. OD shoe
W6 1, 6-in. OD shoe
W7 1, 7-in. OD shoe
W8 1, 8-in. or 2, 5-in. OD shoes
W9 1, 9-in. OD shoe
W12 1, 12-in. OD shoe
When ordering or requesting quotations on Servcoloy “S” field kits,
please specify:
1. Number of kits.
2. Kit number.
2
SECTION 2
WHIPSTOCK
SECTION TWO OPERATIONS
WHIPSTOCK OPERATIONS
Whipstock Operations 63
WHIPSTOCKS
Due to the increased cost of drilling, technology for sidetrack-
ing has rapidly accelerated. The tool used in this application is
referred to as a whipstock. Today most whips are retrievable,
whether they are a packer type, anchor type or mechanical set
bottom trip. With more and more multilaterals being drilled,
the whipstock generally suites this application.
In the future milling assemblies will be capable of setting
the whip, milling the window and drilling as much as 500 to
1,000 ft of new hole. Sidetracking is and will continue to be a
very important part of well drilling, whether it is for enhanced
oil recovery, exploration, redrilling or utilizing an old well for
one of the many complexities in multilateral applications.
64 Whipstock Operations
WHIPSTOCKS
RETRIEVABLE PACK-STOCKE
This system, developed through years of experience, is a
one-trip, combination packer/whipstock sidetracking sys-
tem. It’s a patented tool that offers significant advantages
over the original, mechanically set whipstocks prevalent
since the 1930s, and it’s an attractive alternative to conven-
tional sidetracking procedures. The Pack-Stock system
yields significant savings in both time and cost.
It’s ideal for sidetracking cased holes during re-drill or
re-entry in old or marginal wells. The Pack-Stock can be set
at any depth, immediately above a casing collar. The sys-
tem offers substantial advantages over the conventional
two-trip whipstock/packer assembly:
• Economical and efficient – one trip to locate packer depth,
orient, set packer and start milling.
• The custom-designed packer prevents movement or
rotation of the Pack-Stock.
• Clearance provided minimizes hole-swabbing or hang-ups.
• The shear bolt ensures setting of the packer prior
to milling.
• A large slip area reduces casing stress and provides a more
positive anchor set.
• The ability to mill through two strings of casing.
• A proven 3° face angle to provide positive kickoff,
regardless of formation or hole angle.
• Retrievable in one trip.
Operational Recommendations
The Pack-Stock system is run in the hole to depth on a starter
mill. For a preferred angle or direction, a muleshoe sub can
be run and surveyed with an orienting device. If orientation
in a specific direction is required, or if the hole angle will
exceed 4°, the Pack-Stock assembly should be set 90° or
less to the right or left of the hole’s high side.
Retrievable Pack-Stock
Whipstock Operations
Whipstock Bypass Valve
Body Packer Face Face Angle Weight Weight
Pack-Stock Length OD Length Length (degrees) (lb) Length OD (lb)
51⁄2 182 43⁄169 76 106 3 585 25 33⁄8 40
5 3 3
7 ⁄8 216 5 ⁄899 84 133 3 980 43 4 ⁄4 150
75⁄8 229 515⁄16 84 146 3 1,400 43 43⁄4 150
95⁄8 261 85⁄899 84 178 3 2,500 46 63⁄4 240
133⁄8 338 113⁄499 87 251 3 6,595 38 81⁄4 400
Notes:
Retrievable Pack-Stock
65
RETRIEVABLE ANCHOR-STOCKE
When a packer is not required, the hydraulically set
Anchor-Stock casing sidetrack system can be used. It
is a combination whipstock and anchor.
The custom-designed anchor meets the same operating
criteria as the Pack-Stock packer except for hole sealing; it is
also very cost-effective. The procedure for using an Anchor-
Stock hookup is identical to that for a Pack-Stock system.
• Fewer hole-cleaning problems because cutting a window
with the Anchor-Stock system removes only 5% of the
metal required for a 60-ft section.
• Retrievable in one trip.
• No troublesome plugs to set.
• Less time required to complete a job; packer (or anchor),
starter mill and whip in one trip.
• Typical cost is less than a section milled below 10,000 ft.
The Anchor-Stock system also offers these user benefits
when compared to conventional, two-trip whipstock and
packer-assembly systems:
• Custom-designed anchor utilizes one-piece mandrel
with anti-rotation keys, locking tapers between the cone
and slips, and ratchet ring to prevent rotation or vertical
movement of the whipstock.
• Larger slip area reduces casing stress and provides a more
positive anchor.
• A strong shear bolt verifies complete setting of the packer
prior to milling.
This system must be run in the hole to depth on a starter
mill. If you have a preferred angle and direction for the side-
track, a muleshoe sub may be run and surveyed with an ori-
enting device. If orientation in a specific direction is required
or if the hole angle exceeds 4° at setting depth, we recom-
mend that the Anchor-Stock assembly be set not more than
90° to the right or left of the hole’s high side.
Two Other Unique Advantages

With an Anchor-Stock system, you can also:
• Mill through two strings of casing.
• All whipstocks have a proven 3° face angle to provide
positive kickoff regardless of formation or hole angle.
Retrievable Anchor-Stock
Whipstock Bypass Valve
Anchor- Body Anchor Face Face Angle Weight Weight
Stock Length OD Length Length (degrees) (lb) Length OD (lb)
51⁄2 165 43⁄169 591⁄16 74 3 535 25 33⁄8 40
5 3 3 3
7 ⁄8 197 5 ⁄ 89 63 ⁄49 95 3 895 43 4 ⁄4 150
75⁄8 210 515⁄16 633⁄49 107 3 1,380 43 43⁄4 150
85⁄8 229 71⁄ 89 643⁄49 124 3 1,875 43 43⁄4 150
95⁄8 241 81⁄ 89 643⁄49 142 3 2,285 46 63⁄4 240
133⁄8 322 117⁄ 89 711⁄ 89 212 3 6,200 38 81⁄4 400
Notes:
Retrievable Anchor-Stock
67
ANCHOR-STOCK/PACK-STOCK RUNNING PROCEDURE

11. Make gage ring and casing scraper run utilizing a water-
melon mill. Make collar locator run or cement bond log
if cement bond is questionable. (Bottom of Anchor-
Stock must be set 2 to 6 ft above collar.)
12. As an option, if the casing is unbonded, a block squeeze
should be considered at this point because if left unsup-
ported will cause excessive vibration and hamper
milling performance. Squeeze the zone around the
kickoff point or move to Step 3.
13. Condition mud to provide good milling parameters and
weight required to drill new hole section. Pull out of hole.
14. Pick up one joint of high-grade drill pipe.
15. Pick up whip running assembly and Anchor-Stock.
16. Pick up assembly and scribe a line to align the face of
the Anchor-Stock along the assembly to the orientation
sub; orient sub with the scribed line. Drill collars and
Hevi-Wate IDs must be checked for proper clearance
for orienting tools.
Note: Depending on depth and angle drill collars
and Hevi-WateE can be reduced or eliminated
from the Bottom-Hole Assembly (BHA) and
run with straight drill pipe with hydraulically
set Anchor-Stocks or Pack-Stocks.
17. Trip in hole slowly to setting depth, monitoring
hole drag.
18. At depth work string up and down to work out torque.
19. Orient Anchor-Stock to your specification. (Either run
surface readout gyro or multi-shot surveys.)
10. Gradually apply 3,000/3,500 psi pressure and hold.
11. Work shear bolt up and down 4 to 5 times. Shear off
Anchor-Stock.
12. Make starter mill cut out.
13. Pull out of hole, lay down starter mill and running
assembly.
14. Trip in hole with Tri-MillE system on drill collars or

drill pipe to clean and elongate window and drill
4 to 6 ft of formation.
15. Pull out of hole. Lay down Tri-Mill.
Note: Do not rotate a bit or stabilizer down the face of
the whip. If window is to be squeezed it must be
reopened with a window mill not a roller cone bit.
Retrievable Econo-StockE
The Econo-Stock* is a retrievable, mechanically set whip-
stock that offers substantial design improvements over
competing products. Activation occurs when 3,600 lb of
weight are set down after a trigger rod contacts a plug in
the casing. Applying additional weight sets the anchor and
shears the starter mill bolt. The starter mill and shear bolt
block are newly designed features. A “shear-down” shoul-
der prevents the starter mill from jamming and enhances
the setting of the anchor. Multiple slips provide excellent
load and torque capacity. The slips are held in position by
a ratchet ring that provides equal loading in all directions.
To release the anchor, the whip is engaged using the
same retrieving tool as the field-proven retrievable Anchor-
Stock. An upward pull releases the anchor, and the slips
fully retract as the tool is pulled from the well.
Unlike many competing “economy” tools, the Econo-
Stock provides a full complement of important benefits:
• Anchor setting requires no hydraulic pressure.
• Retrievable with conventional tools.
• Multiple-tongue-and-groove slip design provides
uniform stress-loading on casing and maximizes
anti-rotation capabilities.
• Simultaneously activated, full-contact slips centralize
the anchor assembly in the casing.
• Retractable slips prevent casing drag during retrieval.
• Ratchet ring and nut ensure and maintain “set.”
• Bi-directional loading capability.
*Patent pending.
70
Retrievable Econo-Stock
Whipstock
Retrievable Body Anchor Face Face Angle Weight
Econo-Stock Length OD Length Length (degrees) (lb)
5 – 51⁄2 1423⁄8 45⁄16 351⁄8 74 3 570
1 7 1
7 172 ⁄8 5 ⁄16 38 ⁄8 95 3 875
85⁄8 1891⁄2 77⁄16 431⁄2 124 3 1,175
Notes:
3. Product can also be set permanently.
4. 75⁄8- and 95⁄8-in. Econo-Stock available upon request.
Retrievable Econo-Stock
STANDARD ECONO-STOCK RUNNING PROCEDURE

11. Make gage ring and casing scraper run utilizing a water-
melon mill. Make collar locator run or cement bond log
if cement bond is questionable. (Bottom of Econo-Stock
must be set 2 to 6 ft above collar.)
12. If the casing is unbonded, a block squeeze should be
considered at this point because if left unsupported will
cause excessive vibration and hamper milling perform-
ance. Squeeze the zone around the kickoff point or
move to Step 3.
13. Condition mud to provide good milling parameters and
weight required to drill new hole section. Pull out of hole.
14. Pick up one joint of high-grade drill pipe.
15. Pick up whip running assembly and Econo-Stock in
mouse hole.
16. Pick up assembly and scribe a line to align the face of
the Econo-Stock along the assembly to the orientation
sub; orient sub with the scribed line. Drill collars and
Hevi-Wate IDs must be checked for proper clearance
for orienting tools.
Note: Depending on depth and angle, enough drill col-
lar or Hevi-Wate weight must be calculated for
shearing purposes when setting the Econo-Stock.
17. Trip in hole slowly to setting depth, monitoring hole drag.
18. At depth work string up and down to work out torque.
19. Orient Econo-Stock to your specification. (Either run
surface readout gyro or multi-shot surveys.)
10. Apply 15 to 20,000 lb of shear down force to shear bolt
and set anchor.
11. Work BHA up and down to ensure shear bolt has
sheared off the Econo-Stock.
12. Make starter mill cut out.
13. Pull out of hole, lay down starter mill and
running assembly.
14. Trip in hole with Tri-Mill system on drill collars or drill pipe
to clean and elongate window and drill 4 to 6 ft of formation.
15. Pull out of hole. Lay down Tri-Mill.
Note: Do not rotate a bit or stabilizer down the face of the
whip. If window is to be squeezed it must be
reopened with a window mill not a roller cone bit.
TIPS FOR A SUCCESSFUL RE-ENTRY

Whipstock Sidetracking
Casing Preparation
Ensure that casing scraper, gage ring and collar locator
runs are made. Often the gage ring and collar locator runs
can be combined for efficiency.
Cement Bond
A cement bond log can be run if desired. A good cement
bond enhances milling rates, but is not absolutely required
for a successful sidetrack.
Window Placement
A sidetrack window can be located in any type of formation. If
the formation is extremely consolidated, diamond mills may
be needed to mill the window. It is imperative that the window
not be cut through a casing collar. Try to position the bottom of
the anchor or packer about 5 ft above the collar.
Hole Angle
On holes with more than 4° deviation, the whipstock face
should not be oriented more than 105° to either side of the
well’s high side.
Mud Properties
Milling mud is not needed for a successful sidetrack, and
many jobs have been completed using water. High-viscosity
sweeps can be used periodically to clean the hole if desired.
No specific annular velocities are needed due to the small
quantity and fine size of the cuttings.
Rig, Pump and Drillstring
The rig must have sufficient capacity to handle the
drillstring weight and have enough reserve capacity
to shear the shear bolt.
The rig pump must have the capability to apply the 3,000
to 3,500 psi setting pressure to the drillstring.
The drill pipe and rotation device (power swivel or rotary
table) must have enough capacity to turn milling tools down-
hole without stalling. This will vary with depth of kickoff
point and hole straightness. Generally, a 3.5 power swivel
and 23⁄8-in. drill pipe is required for 51⁄2-in. casing, 31⁄2-in. drill
pipe and a rotary table for 7- and 75⁄8-in. casing, 41⁄2-in. drill
pipe and a rotary table for 85⁄8- and 95⁄8 -in. casing, and 5-in.
drill pipe and a rotary table for 133⁄8-in. casing.
Milling Sequence
The whipstock is run in hole and set on a starter mill. After
setting, a shear bolt is sheared, separating the starter mill
from the whipstock. Rotation is begun and the starter mill
is slacked off until the tapered nose cams the tungsten car-
bide blades into the wall. It is imperative for the proper
length of starter mill travel be attained to assure subsequent
efficient milling runs.
The window is then milled using a window mill. Run the
window “limber” (one joint of drill pipe above the mill fol-
lowed by drill collars). This will allow the window mill to
flex off the face of the whipstock as it mills into formation.
The window is then “polished” or elongated using a win-
dow mill and one or two watermelon mills run directly
below the drill collars. Make enough open hole below the
bottom of the window to provide adequate room for subse-
quent drilling assemblies.
Post-Window-Milling Precautions
Never rotate a bit or stabilizer down the face of the whipstock.
Treat a whipstock window as a casing shoe. Slack off and
pull through the window slowly, carefully noting any unusual
drag. If drag is encountered when running bent housing
motors through a window, pull up, rotate the drillstring
slightly and then slack off through the window. When the
bend in the motor aligns with the whip, the BHA will pass
through the window with minimal drag.
General Planning
Pre-job planning meetings (pre-spud meetings) to coordi-
nate with the service companies involved in a sidetrack will
result in a more efficient operation.
TRACKMASTERE OPERATIONS
Special meritorious
engineering award
for innovation and
efficiency.
Trackmaster: The Only One-Trip Window-Milling System

The Trackmaster is the only full-gage system that lets you
open a sidetrack window in just one trip. It’s a self-contained
unit that reduces sidetracking costs by as much as 50%. In a
single trip in and out of the hole, you accomplish all seven of
the major steps needed for cutting a sidetrack window:
• Run the assembly.
• Orient the whipstock (with Measurement While
Drilling (MWD)).
• Set the whipstock hydraulically.
• Shear the mill from the whipstock assembly.
• Mill and dress the window.
• Drill a full-gage rathole.
• Pull out of the hole.
The result is a full-size window completed in minimal time,
providing a full-gage rathole for the directional assembly.
The Trackmaster system is available in a full range of
sizes for 41⁄ 2- through 133⁄ 8-in. casing. The system includes
all necessary auxiliary equipment.
Trackmaster System Description

The system is comprised of four major components:
the bypass valve, running tool, milling tool and the
whip assembly.
High-Flow Bypass Valve

The high-bypass valve performs several functions for the sys-
tems. First, it allows for circulation of drilling fluid so the
whip assembly may be oriented with MWD. The high-bypass
valve can then be closed to facilitate hydraulic setting of the
anchor. Last, after shear-off, the valve closes each time circu-
lation is started so all the drilling fluid goes to the mill where
it is needed for cooling and cuttings removal. When not with
a mud, a standard bypass valve may be used.
Running Tool
The running tool is used for the actual setting of the whip
assembly. It provides a barrier between the drilling mud
and the oil in the whip assembly to ensure the setting
mechanism stays clean and free of debris.
Milling Tool
The milling tool includes 3 mills each with different objec-
tives and dressed with high-performance carbide.
Lead Mill
The lead mill is a full-gage mill designed to initiate the cut-
out and mill the window further as it slides down the whip
face. It also drills the rathole.
Follow Mill
The follow mill is also a full-gage mill and engages with the
casing as the lead mill travels down the ramp and elongates
the window.
Dress Mill
The dress mill is a full-gage mill and is designed to dress the
window as the entire assembly passes through the casing.
Each mill is dressed with Millmaster carbide for consistent
and efficient milling performance.
Whip Assembly
The whip assembly consists of a whipstock attached to an
anchoring assembly. The whipstock has a multi-ramp
design to guide the milling tool effectively and expediently
through the casing and into the formation.
Conclusions
• Using Trackmaster will save time and money.
• MWD orientation eliminates the need for a wireline trip.
• The bypass valve controls drilling fluid for maximum
efficiency of the Trackmaster components.
• Millmaster carbide on dressed mills ensures consistent
and efficient window cutting.
Note: The Trackmaster retrievable whip can be attached
to any anchoring assembly, i.e.: Pack-Stock, Anchor-Stock
or Econo-Stock. These products provide you with the option
of mechanical anchor, hydraulic packer or mechanical bot-
tom trip. In addition, a big bore inflatable packer can also
be attached to the whip for open hole application.
Trackmaster Whipstock
Pack-Stock Econo-Stock
Anchor-Stock
(Bottom trip)
One-Trip Sidetracking System
Objectives
The objective of the Trackmaster is to accomplish the
following steps in a single trip:
• Run the assembly.
• Orient the whipface (with MWD or gyro).
• Set the whip assembly (hydraulically).
• Shear the mill from the whip assembly.
• Mill the window.
• Drill the rathole.
• Pull out of hole.
The result is a full-size usable window with a minimum
of milling time and a full-gage rathole for the directional
drilling assembly.
TRACKMASTER
Benefits
• Eliminate starter mill run.
• Aggressive initial ramp to ensure quick efficient cut out.
• Millmaster technology for consistent milling performance.
• Mid-whip ramp to reduce core problems and milling time.
• Full-gage mills to ensure full-gage window and rathole.
• Entire procedure is finished in one trip into the hole.
Typical Running Assembly
MWD
61⁄ 2-in. OD
Bypass valve 61⁄ 2-in. OD
Drill collar
61⁄ 2-in. OD
or HWDP
Running tool 61⁄ 2-in. OD
61⁄ 2-in. OD
Mill
Mill gage 81⁄ 2-in. diameter
Whipstock
Notes
3
SECTION 3
SECTION THREE UNDERREAMING
UNDERREAMING
Underreaming 83
UNDERREAMING
Underreaming is the process of enlarging a section of well-
bore beneath a restriction. The most frequently encountered
restrictions are the Internal Diameter (ID) of the casing and
the size of the wellhead. Both limit the maximum Outside
Diameter (OD) of the tools that can pass through.
The term “hole opening” is often used interchangeably
with underreaming. Essentially, both operations enlarge
the existing pilot hole. Hole opening involves enlarging the
wellbore starting from the surface. Therefore, hole openers
have cutters rigidly attached to the body on a fixed diame-
ter. No hydraulic actuation is needed for the tool operation.
Underreaming takes place at some point below the sur-
face. Since the tool has to first pass through the restricted
bore, it incorporates expandable cutters which stay col-
lapsed while the tool is run in and once the tool has cleared
the casing and wellhead, the cutters expand into the forma-
tion by utilizing the differential pressure of the drilling fluid
or pneumatic medium.
Once the hole is underreamed to the desired depth, the
pumps are turned off allowing the arms to collapse back
into the body. The tool is then pulled out of the hole
through the restricted section.
Underreaming as an Alternative
Underreaming is a highly underrated technology. It has been
viewed primarily as an undesirable, yet often inevitable, cost
in too many wells or standard methodology in remedial
applications. Recent advances in deeper drilling have created
the need for multiple casing strings in straight and direc-
tional wells. As a result, the demand for more durable, reli-
able underreamers has increased. Underreaming allows the
operator to run minimum clearance casing programs which
optimize casing sizes and reduces tubular costs on multiple
string wells.
84 Underreaming
Application of Underreamers
Underreamers are used whenever it is necessary to open
the diameter of a portion of the borehole, beginning some-
where below the surface. Typical applications include:
• Opening the hole below the casing shoe, to provide a larger
annular space for cementing the next casing string. This
permits the use of a larger intermediate casing diameter
than could be used otherwise.
• BOP or wellhead size restricts the tool diameter.
• Enlarging the hole annulus within the producing zone for
gravel-pack completions.
• Opening a pocket to start a sidetrack.
• Enlarging “heaving areas” through problem fault zones.
• Reducing dogleg severity.
Selection of an underreamer depends on the formation
and on whether or not simultaneous drilling is required.
Smith offers a ReamasterE underreamer capable of simulta-
neous Underreaming-While-Drilling (UWDE), a Drilling-
Type Underreamer (DTU), a Rock-Type Underreamer
(RTU) and a Drag-Type Underreamer (SPX).
Underreaming 85
GENERAL GUIDELINES FOR UNDERREAMING

Formation Considerations
• ROP of soft formation reacts better to rotary speed.
• ROP of PDC cutters react better to rotary speed.
• ROP of medium-hard formation reacts better to weight.
• Soft formations underream faster than the pilot-hole bit
(25 ft/hr average).
• Medium formations underream equal to the pilot-hole bit
(10 to 25 ft/hr average).
• Hard formations underream slower to the pilot-hole bit
(10 ft/hr average).
Maximum Weight on Tools with Milled Tooth/TCI Cutters

• Drag type — 700 lb x body diameter.
• Rock type — 1,000 lb x body diameter.
• Drilling type with bullnose — 1,000 lb x body diameter.
• Drilling type with bit — 1,500 lb x body diameter.
• Reamaster with bit or bullnose — 4,000 lb x body diameter.
Maximum Weight on Tools with PDC-Type Cutters

• Drag type with SPX/PDC — 500 lb x number of PDCs.
• Rock and drilling type with BearclawE PDC — 500 lb x
number of PDCs.
• Reamaster type with parabolic PDC — 500 lb x number
of PDCs*.
*This pertains to PDCs in contact with formation excluding redundant
gage coverage.
86 Underreaming
Anticipated Life of Cutters

Cutter Life Maximum
(hr) rpm
15-20 Servcoloy “S” (crushed carbide) 180
20-30 Open roller 130
30-40 Sealed roller 140
40-50 Sealed journal 100
50-60 SPX/PDC 140
60-80 Bearclaw/PDC 180
60-80 Reamaster/parabolic-PDC 200
• Optimum circulation rate is 35 GPM x
underreamed diameter.
• Reamaster circulation rate is 50 GPM x
underreamed diameter.
• Fluid velocity in the RTU/DTU and drag-type
underreamers should not exceed 150 ft/sec.
• Fluid velocity in Reamaster underreamers should not
exceed 75 ft/sec.
Underreaming 87
Tool Selection
In recent years Smith has made several improvements
to underreamers. Several internal parts have been
redesigned to improve performance, extend component
life, reduce maintenance and decrease cost. Cutter arm
selection has been expanded to include:
Cutting Structures
• Servcoloy “S” (tungsten carbide).
• Milled tooth.
• TCI (Tungsten Carbide Inserts).
• SPX-PDC (Polycrystalline Diamond Compacts).
• Bearclaw-PDC.
• SuperdomeE (parabolic-PDC).
Bearing Packages
• Open-roller bearing.
• Sealed-roller bearing.
• Sealed-journal bearing.
We can provide a variety of underreamers, depending on
customer requirements and performance needs, either
unaccompanied, or with experienced operators who
maximize tool performance.
The cutting structures available for underreamers are
illustrated on the following page.
88 Underreaming
DTU/RTU Underreamer Cutters
DS, K2
DT
DG, C4
V2
Bearclaw
F1
TCI
Underreaming 89
DTU/RTU Underreamer Cone Availability

Milled Tooth TCI
IADC IADC
Code 1-1 1-2 1-3 2-1 4-3 5-1 Code
Open (1) K2 DS DT C4 V2
Sealed (4) K2 DS DT DG
Journal (6) K2 C4 F1 F2 Journal (7)
Underreamer Bit Cone
Series Size (in.)
3600 RTU X
35⁄8
3600 DTU X
4500 RTU X X X X
41⁄2
5700 DTU X X X X
5700 RTU X X X X X
7200 DTU X X X X X 55⁄8
8200 DTU X X X X X
7200 RTU X X
8200 RTU X X 63⁄4
9500 DTU X X
8200 RTU X X 73⁄8
9500 RTU X X X X X
91⁄2
11700 DTU X X X X X
11700 RTU X X X X X
15000 DTU X X X X X
121⁄4
15000 RTU X X X X X
17000 DTU X X X X X
15000 RTU X X
133⁄4
17000 DTU X X
17000 DTU X 143⁄4
22000 DTU X X 15
22000 RTU X 171⁄2
Note: Bearclaw-PDC or parabolic-PDC Superdome cutter heads may be

fabricated for any of the above underreamers.
90 Underreaming
Reamaster (XTU)
Milled Tooth
TCI
PDC
Cutter Types
Underreaming 91
REAMASTER (XTU)
Innovative Design Improves Underreaming
A major addition to the Smith line of underreamers, the
Reamaster underreamer* or XTU is the result of years of
development and testing. The objective was to develop an
underreamer that far exceeded the inherent limitations of
conventional underreamers: low weight-carrying capacity,
short bearing life and marginal hydraulics. The Reamaster
tool has achieved these improvements and excels over con-
ventional underreamers. It features:
• Sustained drilling weight equivalent to bit.
• Larger cones and bearings for extended on-bottom time.
• Enhanced hydraulics for better hole cleaning.
• Capable of simultaneous Underreaming-While-Drilling
(UWD).
Substantially Reduces Overall Casing and Cementing Costs

Now you can save money by optimizing casing sizes on
multiple string wells. The Reamaster underreamer is specif-
ically designed to underream long intervals and provide the
cementing space needed to run minimum clearance casing
programs. You can design a slimmer top hole for a given
diameter production zone or for a larger-than-standard pro-
duction zone for a given hole size.
Refer to the chart on page 93 to show possible combina-
tions of casing with minimum clearance. Based upon rec-
ommendations provided by cementing firms and casing
manufacturers, the chart assumes minimum clearance of
less than 1⁄ 2 in. between outer string drift diameter and
inner string coupling diameter for cased holes.
* Reamaster systems are only available on a rental basis in conjunction

with Smith job supervision.
92 Underreaming
Features
One-Piece Forged Arms
• One-piece forged arms with integral journals to hold cutters.
• Simple and strong internal components.
• Carry four to five times more drilling weight than
conventional tools.
• Withstand high shock loads and torque downhole.
• Increase penetration rates.
• Positive lock keeps arms in open position.
• Feature large diameter single-hinge pin.
Customized Cutters
• Cutters and cutting structures designed exclusively for
underreaming.
• Cutters available with milled tooth, TCI or PDC cutting
structures.
• Large sealed bearings.
• Milled tooth and TCI cutters are designed with compen-
sated sealed bearings.
• Specially designed large cutters achieve lower RPM,
resulting in longer bearing life.
• Optimum journal angle provided during drilling, plus
other features, substantially increases bearing life for
longer on-bottom time and increased penetration rates.
Improved Hydraulics
• Unique internal design more than doubles allowable drill-
ing fluid flow through the tool.
• Features four nozzles, two jetting directly on the bench
and one on top of each cutter.
• Increases amount of hydraulic energy for better hole
cleaning efficiency and faster penetration rate.
• Strategic placement of nozzles keeps cutters clean and cool.
Underreaming 93
Recommendations to Set Small Clearance Consecutive

Strings of Casings
Outer Largest Underreaming (in.)
Casing Inner Casing Minimum Reamaster
Size Size Pilot Underreamed Tool
(in.) (in.) Hole Diameter Series
24 20 181⁄2 26 16000
20 16 171⁄2 22 16000
16 133⁄8 143⁄4 171⁄2 11750
133⁄8
(48-68 lb) 103⁄4 121⁄4 15 11750
113⁄4 85⁄8 105⁄8 121⁄4 9500
95⁄8
(29.3 lb) 75⁄8 83⁄4 111⁄2 8250
85⁄8
(24-32 lb) 65⁄8 75⁄8 91⁄2 7200
85⁄8
(36-49 lb) 6 73⁄8 9 5750
75⁄8 51⁄2 61⁄4 81⁄2 5750
7
(17-32 lb) 5 6 8 5750
Note: Recommendations are based on:
• The minimum clearance of 0.400 in. on diameter between the
outer string drift diameter and inner string coupling diameter.
• The clearance between the hole wall and the coupling OD is at least
2 in. on diameter. Less clearance than this may create a back pres-
sure which will dehydrate the cement so that it cannot be pumped.
94 Underreaming
REAMASTER OPERATING PARAMETERS

The following operating parameters will serve as a guide-
line for all Reamaster jobs:
a. Smallest jet to be used in system is 12⁄ 32 in. If possible, the
lowest jet in system should be the largest. A variety of
jets, including blanks, should be provided for all compo-
nents. Diverging jets are required for cone pocket jets in
the 9500 and smaller series Reamasters. The maximum
flow per jet will be limited to 250 GPM. A float sub is
always recommended when the BHA allows.
b. Flow velocities through the Reamaster will be limited to
the following providing that solids control is in effect
including desanders and desilters.
100 ft/sec < 12 lb/gal mud
75 ft/sec > 12 lb/gal mud
Upper body or bench jets should be used to divert sufficient
flow to achieve acceptable main bore velocities.
c. Lateral force on cutters derived from BHA analysis will be
maintained below the following:
PDC Cutters Milled Tooth/TCI
Reamaster Series (lb) (lb)
5750 1,000 500
7200 1,000 500
8250 1,500 750
9500 1,500 750
11750 2,000 1,000
16000 2,000 1,250
Note: The lateral force exerted on the cutters should

always be minimized if possible through BHA analysis.
Underreaming 95
d. Although formation characteristics will normally deter-

mine the appropriate RPM the following is to be used as
a guideline:
PDC Diameter (mm)
Underreamed
Diameter 9 13 16 Milled Tooth/TCI
(in.) Recommended rpm rpm
19 7⁄ 8 140 160 n/a 80-150
121⁄4 130 155 n/a 80-150
143⁄4 110 130 n/a 80-150
171⁄ 2 n/a 110 130 80-150
20 n/a 95 110 80-150
26 n/a 75 85 80-150
e. Bottom-hole temperatures in excess of 300°F require the

use of Viton packings.
f. BHA recommendations should be as follows:
Underream only — Undergage stabilizer should be run
above the underreamer at a distance to minimize lateral
force at underreamer cutters. The assembly below the
underreamer should be an undergage bit or slick bullnose.
Minimum diametral clearance for either bit or bullnose
should be 1 in. in pilot hole. Any full-gage assemblies will
require BHA analysis to meet lateral force requirements.
Drill and underream — The BHA will be determined
by BHA analysis for lateral force requirements and
directional objectives.
g. Flow distribution and pressure drop should be maintained
on the following guidelines based on 12 lb/gal mud:
Underream Drill and
Pilot Hole Underreamed Only Underream
(in.) (in.) gpm psi gpm psi
61⁄ 2 9 7⁄ 8 340 400 n/a n/a
9 7⁄ 8 121⁄4 430 475 600 525
105⁄ 8 143⁄4 520 550 740 600
121⁄4 171⁄ 2 600 600 900 700
143⁄4 20 750 700 1,000 850
171⁄ 2 26 1,050 850 1,300 1,000
96 Underreaming
Flow distribution between underreamer and bit/bull-

nose should be based upon application as follows:
Underream only — Minimum of 65% of total flow rate
should exit the Reamaster underreamer.
Drill and underream — minimum of 20% of the total
flow rate should be directed to the bit, the balance of the
flow rate should be divided between the bit and under-
reamer based on the area of formation removed by each.
h. Hydraulic horsepower per square inch should be
maintained at the following
Underream only - 1.3 hhp/in.2 for underreamer
- .5 for bit or bullnose
Drill and underream - 1.3 hhp/in.2 for underreamer
- 1.0 hhp/in.2 for bit
i. Effective weight-on-bit should be determined by allowable
torque available based on the limitations of drillstring
components. Maximum PDC weight is based on the num-
ber of PDC inserts that actually contact the underreamed
bench area excluding redundant gage cutters.
PDC Diameter (mm)
Maximum Weight
Reamaster 9 13 16 Milled Tooth/TCI
Series Max. Weight/PDC (lb) (lb)
5750 600 500 n/a 15,000
7200 600 500 n/a 25,000
8250 600 500 n/a 30,000
9500 n/a 500 400 35,000
11750 n/a 500 400 50,000
16000 n/a 500 400 60,000
Underreaming 97
Reamaster Underreaming Guidelines

The tool is normally run above the bit or bullnose. However,
it can also be run in the drill collars string, up to 90 ft above
the bit.
1. Lower the tool into the hole until it reaches the top of the
section to be enlarged. Take care when running in the
hole, as surge pressures can start opening the arms,
which may damage the casing.
2. Rotate the tool slowly (30 to 50 RPM) after reaching
the desired shoulder cut-out depth.
3. While rotating the drillstring, start pumps and
establish flow.
4. Gradually increase flow rate and RPM until desired
operating parameters are reached.
Cutting the Shoulder
1. After correct pump pressure is reached, rotate the tool at
80 to 150 RPM maximum. Mark the kelly for 3 ft and drill
off slowly. Rotate for 5 to 10 min.
2. Disengage rotary table and pick back up while pump is
still on.
3. Cutter arms should be fully open now. To make quite
sure, repeat the above steps. When you reach the shoul-
der, you should start taking weight, indicating that you
have a shoulder.
Underreaming
With the arms in the full open position the pilot hole can be
underreamed. Maintain constant drilling weight. A good
rule of thumb is 1,500 to 2,000 lb/in. of body diameter.
Example: 12,375 to 16,500 lb for a 81⁄4-in. tool.
Reduce table speed to 80 RPM and proceed as follows:
• Allow drum to “creep.” Do not drill off.
• Establish a constant ROP and proceed.
• Do not spud tool.
• Pull at the first sign of dulling (look for the same signs as on
a dull rock bit). Running time will depend on formation and
cutter type.
• When a hard streak layer of formation is encountered,
reduce speed and add weight in order to maximize
penetration rate.
98 Underreaming
Adding a Connection
1. After adding a connection, lower the kelly bushing so
that it is barely in the table, and engage the rotary at
slow speed.
2. Apply pump pressure.
3. Disengage rotary and lower tool to shoulder.
4. Set down on shoulder and apply weight to check if cutter
arms have reopened.
5. Pick back up about 2 ft, engage rotary, bring to operating
RPM and continue underreaming.
Tripping Out of the Hole

Pick up a few feet and turn pumps off. Allow 5 to 10 min
rotation before coming out of the hole or into the casing
shoe. Always pull into the casing slowly. Be sure hydrostatic
head in the drillstring is allowed to equalize before pulling
into the casing; otherwise, forces of the fluid column may
expand cutter arms during entry.
Reamaster Disassembly
1. Unscrew the hinge pin retaining screw and remove the
washer and cap.
2. With snap ring pliers, remove the bail and slide the seat
out of the hinge pin hole.
3. Using the long bolt supplied in the tool kit, pull the hinge
pin out of the tool.
4. Slide the arm set out of the tool.
5. Break out the top sub and remove it from the tool. If a bit
sub, bit or bullnose is made up to the tool, remove it also.
6. Break out the connection between the upper body and
lower body.
CAUTION: When breaking out this connection special care
should be taken to keep the bodies perfectly
aligned. Otherwise, severe damage caused by
galling could occur. It is advisable to stand the
tool in the vertical position to unscrew the con-
nection. (On 16000 Reamaster, DO NOT torque
on the sleeve. Remove the upper body to
expose the inside of the tool. Remove the
sleeve at this time.)
Underreaming 99
17. Using the small screw supplied in the tool kit, remove
the two guide pins.
18. Slide the piston bore sleeve out of the lower body.
19. Insert the piston assembly tool, found in the tool kit, into
the slot on top of the piston and hold in place with a bar.
10. Unscrew the cam and slide it out of the piston bore
sleeve on 16000 Reamaster. Remove the floating seal
cartridge at this time.
CAUTION: Do not vise on the thin wall of the piston
bore sleeve.
11. Remove the piston assembly tool and slide the piston
and spring out of the piston bore sleeve.
12. Unscrew the arm stop retaining screw and remove the
arm stops and washers.
13. Unscrew the orifice retainer and remove the orifices and
O-rings. Remove and discard all O-rings, packings and
screws used in the tool. Thoroughly clean all parts and
check for damage. Replace parts if necessary.
XTU Underreamer Makeup Torque Specifications

Upper Body to Lower Body
Makeup Torque
Tool Series (ft-lb)
5750 10,500
7200 33,000
8250 43,000
9500 63,000
11750 88,000
16000 88,000
100 Underreaming
Reamaster Components
Top sub
Upper body
Piston bore sleeve
Piston
Guide pin Spring
Cam
Arm stop
Hinge pin
Cutter arm
Lower body
Underreaming 101
Reamaster Assembly
When the tool is assembled all parts should be thoroughly
lubricated. Any light grease is adequate.
1. Install packings on piston. Make sure the packings are
installed facing upward.
2. Slide the spring and the piston into the piston bore sleeve.
3. Install the O-rings on the piston bore sleeve. (On 16000
Reamaster install the O-ring onto the floating seal car-
tridge and slide it onto the piston bore and sleeve at this
time. Make sure the holes in the floating seal cartridge
are aligned with the holes in the piston bore sleeve.)
4. Slide the cam through the lower end of the piston bore
sleeve and screw it into the piston. To prevent the piston
from turning during tightening, install the piston assem-
bly tool into the piston and retain it with a bar.
CAUTION: Do not vise on the thin wall of the piston
bore sleeve.
5. When the cam is tight, remove the piston assembly tool.
Continue to turn the cam until its slots are aligned with
the holes in the piston bore sleeve.
6. Next, slide the piston bore sleeve into the lower body.
Align the holes in the piston bore sleeve with the holes in
the lower body and install the two guide pins.
7. Install the O-rings onto the lower body. (On 16000
Reamaster slide the sleeve onto the lower body and
install the O-ring into the upper body at this time.)
8. Slide the upper body over the piston bore sleeve and down
onto the lower body. Makeup the connection between the
lower body and the upper body.
CAUTION: When making up this connection special care
should be taken to keep the bodies perfectly
aligned. Otherwise severe damage, caused by
galling could occur. It is advisable to stand the
tool in the vertical position while installing
the upper body. (On 16000 Reamaster DO
NOT torque on the sleeve.)
9. Install the O-rings, orifices and orifice retainers into the
lower body.
102 Underreaming
10. Put the arm stops in place and install the washers and
screws to hold them in place.
NOTE: Hold the arm stops against the top of the slots
in the lower body to ensure adequate clearance
for the arm set.
11. Slide the arm set into the tool, one arm assembly in
each side.
12. Slide the hinge pin into the tool and through the two
arm assemblies.
13. Install the hinge pin retainer seat, bail and pin. Make sure
the gap in the bail straddles the hinge pin retainer pin.
14. Install the cap, washer and screw, and tighten down.
NOTE: Make sure the arm assemblies swing freely
before continuing.
15. Pull both arm assemblies out to the fully extended
position and slide the proper sized ring gage over
the cutters to ensure proper opening size.
Underreaming 103
Notes
104
Reamaster Underreamer (XTU)
Fishing neck
Bottom-box
diameter
connection
Fishing
Body diameter neck length
Opening Top pin
diameter
Underreaming
connection
Overall length
Reamaster Underreamer (XTU) Specifications
Underreaming
Tool Opening Pilot Hole Body Diameter/ Fishing Neck Overall Top Pin/Bottom-Box Weight
Series Diameters Size Collapsed Dia. Length Diameter Length Conn. API Reg. (lb)
5750 81⁄2, 9 57⁄8 - 61⁄2 53⁄4 18 43⁄4 90 31⁄2 500
7200 9 ⁄8, 11, 113⁄4, 121⁄4
7
71⁄2 - 11 71⁄4 18 53⁄4 99 41⁄2 700
8250 97⁄8, 105⁄8, 11, 81⁄2 - 97⁄8 81⁄4 18 53⁄4 123 41⁄2 900
121⁄4, 131⁄2
9500 12 ⁄4, 131⁄2, 15, 16
1
97⁄8 - 121⁄4 91⁄2 24 85⁄8 136 65⁄8 1,100
11750 14, 15, 16, 171⁄2 121⁄4 - 141⁄2 113⁄4 20 85⁄8 130 65⁄8 1,700
16000 20, 22, 24, 26 171⁄2 - 22 165⁄8 20 105⁄8 140 85⁄8 3,200
1. All dimensions are given in inches unless otherwise stated. When ordering or requesting quotations on the Reamaster
2. All weights are approximate. underreamer (XTU), please specify:
3. Optional opening diameter available upon customer request. 1. Top and bottom connections.
4. Standard cutters are sealed-bearing milled tooth. TCI or PDC 2. Fishing neck diameter.
cutting structures must be specified. 3. Expanded diameter.
5. The 5750 Series replaces the 5700, the 8250 replaces the 8200 and 4. Size and weight of casing to be run through, if available.
the 11750 replaces the 11700 Series. 5. Bullnose ordered separately.
6. Type of cutting structure (milled tooth, TCI or PDC).
U.S. Patent Number:

Underreamer – 4,660,637
PDC Underreamer – 4,431,065
105
106 Underreaming
Drilling-Type Underreamer (DTU)
DS, K2 DT
DG, C4 V2
Bearclaw PDC
F1
TCI
Cutter Options
Underreaming 107
DRILLING-TYPE UNDERREAMER (DTU)

The Smith drilling-type underreamer will underream previ-
ously drilled pilot holes. A bottom-box connection allows
either a bit or bullnose to be run below the underreamer. The
DTU may be used to drill and underream simultaneously.
The tool design allows mud flow to the bit or bullnose.
Flow can be divided depending upon application. Orifice jets
can be selected in order to better utilize existing hydraulics.
The jetting placement aids in keeping the cutters cool, and in
annular lift of the cuttings. Selections include jetted bullnose
and a jetted top sub in order to divert additional flow when
necessary. These tools can be operated with water, mud, air,
aerated mud or any other circulating medium.
Operating Guidelines
The tool is normally run above the bit or bullnose. However,
it can also be run in the drill collars, up to 90 ft above the bit.
2. Rotate the tool slowly (30 to 50 RPM) after reaching the
desired shoulder cut-out depth.
establish flow.
108 Underreaming

still on.
have a shoulder.
Underreaming
With the arms in the full open position the pilot hole can be
underreamed. Maintain constant drilling weight. A good
rule of thumb is 1,000 lb/in. of body diameter:
Example: 9,500 lb for a 91⁄2-in. tool.
Reduce table speed to 80 RPM and proceed as follows:
• Allow drum to “creep.” Do not drill off.
• Establish a constant ROP and proceed.
• Do not spud tool.
• Pull at the first sign of dulling (look for same signs as on a
dull rock bit). Running time will depend on formation and
cutter type.
• When a hard streak layer of formation is encountered,
reduce speed and add weight in order to optimize the
penetration rate.
Underreaming 109
Adding a Connection
slow speed.
4. Set down on shoulder and apply weight to check if cutter
arms have reopened.
5. Pick back up about 2 ft, engage rotary, bring to operating

shoe. Always pull into the casing slowly. Be sure hydrostatic
Underreaming Key Seats

1. Locate the DTU in the middle of the drill collars.
2. Diameters of the expanded arms must be equal to the bit
size or larger.
3. Place a full gage stabilizer 60 to 90 ft above and another
60 to 90 ft below the underreamer.
4. Slowly begin underreaming about 30 ft above the
key seat.
5. After underreaming the key seat, circulate for about 5 to
10 min, for tool clean-up. Stop circulation and wait a few
minutes for pressure to equalize. This will allow the
arms to collapse.
6. Slowly pull up. If you still have drag, repeat Steps 4 and 5.
110 Underreaming
DTU Disassembly
1. Remove top sub. Break connections while tool is still in
the rotary.
2. Remove hinge pin retaining screws, stop pins and
hinge pins.
3. Slide cutter arm down and out. (Do not remove arm lugs
unless necessary.)
4. Remove cam retainer.
5. Remove piston from body. Cam will slide off lower end of
piston and may be removed through cone pockets.
6. Remove piston spring from body.
7. Remove bit or bullnose.
8. Remove snap ring from lower bore of tool body.
9. Remove piston stem packing housing from lower bore of
tool body.
Underreaming 111
Drilling-Type Underreamer (DTU) Components
Top sub
Body
Piston stop
Piston packing
Piston spring
Lug retaining
Cutter arm screws
hinge pin and
retaining screw
Cutter arm lug
Cutter arm
Piston
Cam and Cutter arm stop pin

cam retainer and retaining screw
Piston stem
Jet nozzles
Piston housing Piston stem

housing packing
Piston
housing retainer
Bottom-box
connection (shown
with bit sub and bit)
112 Underreaming
Drilling-Type Underreamer (DTU) Assembly

11. Thoroughly lubricate all parts with a light grease.
12. Replace O-rings and the packing in the piston stem
housing. Be sure the V-lips of the packing face the bot-
tom of the tool.
13. Slide piston stem housing into lower bore of tool body.
14. Replace snap ring below piston stem housing.
15. Replace piston packing on piston head. Be sure V-lips
face top of tool.
16. Place piston spring over piston stem and slide piston
into body.
17. Reach through cone pocket and slide cam over lower
end of piston stem. Move into position against shoulder.
Be sure angle of cam faces down.
18. Replace cam retainer.
19. Replace cutter arms.
10. Replace hinge pins and stop pins.
11. Replace pin retaining screws.
12. Open and close tool with pneumatic air to check that all
moving parts are functioning properly.
13. Ring gage the arms in open position.
Underreaming 113
Notes
114
Drilling-Type Underreamer (DTU)
Fishing neck
diameter
Standard
opening Body
diameter diameter
Fishing
neck
length
Underreaming
Optional Bottom-box Top pin
rock bit connection connection
or bullnose
Drilling-Type Underreamer (DTU) Specifications
Underreaming
Standard Optional Through Casing Fishing Fishing Top Pin
Tool Opening Opening Body Collapsed dia. x wt. Neck Neck Overall Connection Weight
Series Diameter Diameter Dia. Diameter (lb/ft) Length Diameter Length API Reg. (lb)
3600 6 51⁄2 - 6 35⁄8 35⁄8 41⁄2 x 15 8 33⁄8 35 23⁄8 170
5700 83⁄4 7 - 83⁄4 53⁄4 6 7 x 38 18 43⁄4 70 31⁄2 360
7200* 11 9 - 11 71⁄4 71⁄2 85⁄8 x 40 18 53⁄4 74 41⁄2 770
8200* 14 10 - 14 81⁄4 81⁄4 95⁄8 x 53 18 53⁄4 or 8 79 41⁄2 or 65⁄8 900
9500* 15 12 - 15 91⁄2 101⁄4 113⁄4 x 71 18 8 82 65⁄8 1,150
11700* 171⁄2 143⁄4 - 20 113⁄4 113⁄4 133⁄8 x 92 20 8 96 65⁄8 1,670
15000* 171⁄2 - 26 171⁄2 - 26 143⁄4 143⁄4 16 x 75 20 8 or 9 97 65⁄8 or 75⁄8 2,800
17000* 32 24 - 32 17 17 185⁄8 x 78 20 9 or 10 87 75⁄8 or 85⁄8 3,000
22000 36 28 - 36 22 22 241⁄2 x 113 20 9 or 10 100 75⁄8 or 85⁄8 4,400
* Available with PDC Bearclaw cutters.
Notes: Ordering Instructions: 5. Size and weight of casing to be run
1. All dimensions are given in inches unless When ordering or requesting quotations on through, if available.
otherwise stated. the Drilling-Type Underreamer (DTU), 6. Bullnose or bits are ordered separately.
2. All weights are approximate. please specify: 7. Type of cutting structure (milled tooth,
3. Optional opening diameter available upon 1. Tool series. TCI or PDC).
customer request. 2. Top and bottom connections.
4. Standard cutters are open-bearing milled 3. Fishing neck diameter.
tooth. TCI or PDC Bearclaw cutting 4. Opening diameter.
structures must be specified.
115
116 Underreaming
Rock-Type Underreamer (RTU)
DS, K2 DT
DG, C4 V2
Bearclaw PDC
F1
TCI
Cutter Options
Underreaming 117
ROCK-TYPE UNDERREAMER (RTU)

The Smith RTU is a rugged three-cone underreamer. The
large cones enable the RTU to underream a hole nearly
twice its own body diameter. A complete range of cone
availability ensures proper cutter to formation selection. A
variety of orifice sizes enable the operator to tailor perform-
ance to hydraulics and other conditions at the rig. The tool
can be serviced on location, and the cutter arms can be
quickly and easily changed on the rig floor. The tool design
allows full volume circulation at all times. The RTUs can be
operated with water, mud, air, aerated mud, foam or any
other circulating medium.
Operating Guidelines
2. Rotate the tool slowly (30 to 50 RPM) after reaching the
desired shoulder cut-out depth.
establish flow.

still on.
have a shoulder.
118 Underreaming
Flo-Tel-Equipped Rock-Type Underreamer (RTU)

Rotate the tool at 80 to 150 RPM with maximum pump pres-
sure. Flo-Tel-equipped underreamers indicate when the cut-
ter arms are fully extended and the tool is underreaming at
full gage. Flo-Tel effectively substitutes for a larger orifice
when the cutter arms are extended. Pressure on the mud
pump gage then drops by about 200 to 250 psi or the number
of pump strokes increases. These clear signals from Flo-Tel
assure that the hole has the right diameter everytime, elimi-
nating second trips. Flo-Tel is especially recommended for
cutting shoulder in hard formations.
Underreaming the Interval

Having cut the shoulder, add weight. A good rule of thumb
is 1,000 lb for each inch of body diameter.
Example: 6,000 lb for a 6-in. tool.
Reduce speed to 80 RPM and proceed with underreaming.
• Allow drum to creep. Do not drill off.
• Do not allow tool to penetrate faster then 100 ft/hr or the
hole may not open to the desired drift gage.
• DO NOT spud the tool.
• Pull the underreamer at first sign of dulling (look for same
signs as on a dull rock bit). Running time will depend on
formation and cutter type.
• In a sidetracking operation, remove the cement ring with
an underreamer whose cutter opening is slightly larger
than the original hole.
• When you encounter a hard streak formation layer,
reduce table speed and add weight.
Underreaming 119
Adding a Connection
slow speed.
2. Apply pump pressure for normal underreaming operations.
3. Disengage table and lower tool to shoulder.
4. Set down on shoulder and apply weight to check whether
cutter arms have reopened.
5. Pick back up about 2 ft, engage table, bring to operating
Follow the above procedure after each connection.

Pick up a few feet and turn pump off. Allow 5 to 10 min
rotation before coming out of the hole or into the casing.
Always pull into the casing shoe slowly. Be sure hydrostatic
Rock-Type Underreamer (RTU) Disassembly

1. Remove top sub. Break connection while tool is still in
the drillstring.
2. Remove Flo-Tel retainer, if applicable.
3. The Flo-Tel unit may now be withdrawn from the body.
4. Remove pin retaining screws. Remove arm stop pins and
arm hinge pins.
5. Remove cutter arms. Do not remove cutter arm lugs.
6. Use wrenches furnished with tool kit to remove cam
locknut and cam.
7. Withdraw piston and spring from the body.
120 Underreaming
Rock-Type Underreamer (RTU) Assembly

1. Thoroughly lubricate all parts with a light grease.
2. Assemble piston:
• Replace piston packing with V-lips facing top end
of tool.
• Replace orifice, orifice O-ring and orifice retainer.
3. Place spring over piston stem and slide piston assembly
into body.
4. Depress piston to full open position.
5. Insert cam through cone pockets, and assemble cam on
the piston with cam wrench furnished in tool kit.
6. Install the cam locknut firmly.
7. Install arms. Use new hinge pins and retaining screws.
Underreaming 121
Rock-Type Underreamer (RTU) Components
Top sub
Body
Piston packing
Piston stem
Piston
Spring
Arm lug
Arm lug
retaining screw
Arm hinge pin and

Cam retaining screw
Arm stop pin and

Orifice O-ring
retaining screw
and assembly
Cutter arm
Spade
122
Rock-Type Underreamer (RTU) Components
Fishing Fishing
neck neck
length diameter
Top pin
connection
Body
Underreaming
Standard diameter
opening
diameter
Rock-Type Underreamer (RTU) Specifications
Underreaming
Standard Optional Through Casing Fishing Fishing Top Pin
Tool Opening Opening Body Collapsed dia. x wt. Neck Neck Overall Connection Weight
Series Diameter Diameter Dia. Diameter (lb/ft) Length Diameter Length API Reg. (lb)
3600 6 43⁄4 - 61⁄2 35⁄8 33⁄4 41⁄2 x 15 8 33⁄8 261⁄2 23⁄8 175
4500 61⁄2, 81⁄2 6-9 41⁄2 45⁄8 51⁄2 x 20 18 41⁄8 67 27⁄8 235
5700 11 8 - 11 53⁄4 57⁄8 7 x 38 18 43⁄4 761⁄2 31⁄2 380
5800 11 8 - 11 57⁄8 57⁄8 65⁄8 x 20 18 43⁄4 761⁄2 31⁄2 380
6000 12 11 - 12 6 61⁄8 7 x 26 18 43⁄4 781⁄2 31⁄2 380
6100 12 11 - 12 61⁄8 61⁄8 7 x 20 18 43⁄4 781⁄2 31⁄2 380
6200 12 11 - 13 61⁄4 61⁄4 7 x 17 18 43⁄4 781⁄2 31⁄2 380
7200* 14 9 - 14 71⁄4 73⁄8 85⁄8 x 40 18 53⁄4 86 41⁄2 775
8200* 16 10 - 16 81⁄4 83⁄8 95⁄8 x 47 18 53⁄4 or 8 89 41⁄2 or 65⁄8 920
9500* 171⁄2 13 - 18 91⁄2 93⁄4 103⁄4 x 45 18 8 91 65⁄8 1,160
11700* 171⁄2 143⁄4 - 22 113⁄4 121⁄4 133⁄8 x 68 20 8 91 65⁄8 1,670
15000 LP* 26 171⁄2 - 30 143⁄4 143⁄4 16 x 75 20 8 or 9 97 65⁄8 or 75⁄8 2,800
22000 32 - 40 32 - 40 22 22 241⁄2 x 113 20 9 or 10 1241⁄4 75⁄8 or 85⁄8 5,900
* Available with PDC Bearclaw cutters. 4. Standard API regular pin connections. 3. Fishing neck diameter.
Notes: Others available upon customer request. 4. Opening diameter.
1. All dimensions are given in inches unless Ordering Instructions: 5. Size and weight of casing to be run
otherwise stated. When ordering or requesting quotations on the through, if available.
2. All weights are approximate. Rock-Type Underreamer (RTU), please specify: 6. Bullnose or bits are ordered separately.
3. Optional opening diameter available upon 1. Tool series. 7. Type of cutting structure (milled tooth,
customer request. 2. Top and bottom connections. TCI or PDC).
123
124 Underreaming
SPX/Drag-Type Underreamer
Special meritorious
engineering award
for innovation and
efficiency.
Underreaming 125
SPX/DRAG-TYPE UNDERREAMER
SPX (PDC) drill blanks on the cutting edge of the drag tool
provides the hardness and wear resistance of man-made
polycrystalline diamond, backed by the strength and
toughness of cemented tungsten carbide. These cutters
shear through soft to medium-hard formations faster than
conventional tools would, and require less tool weight.
The tool features a special circulation jet nozzle which
directs a portion of the flow out of each arm pocket. This
action effectively cleans the cutting surfaces, improves
removal of cuttings and dissipates frictional heat. Advantages
of using the SPX/drag-type underreamer are:
• Increased penetration rate.
• Increase on-bottom time.
• Reduced rig time due to faster penetration.
• Reduced total cost-per-foot.
• Faster penetration through producing zones minimizes
formation damage and hole stability problems.
Drag-type underreamers are used in poorly consolidated
soft to medium formations where larger diameter intervals
are required for gravel packing or cementing. Pilot holes can
be enlarged up to three times body diameter in a single trip.
These tools can be operated with water, mud, air, aerated
mud, foam or any other circulating medium. Low-cost cutter
arms and orifices can be replaced in the field.
The arms of drag-type tools are dressed with long wearing
Servcoloy “S” cutting grade tungsten carbide.
Operating Instructions
Lower the tool into the hole until it reaches the top of the
section to be enlarged. Take care when running in the hole,
as surge pressures can start opening the arms, which may
damage the casing.
126 Underreaming

1. Begin rotation at 40 to 60 RPM.
2. Turn on the mud pump; gradually increase flow rate
250 to 450 GPM.
3. Begin to apply weight at 3,000 lb.
4. Continue rotating the tool until the cutter arms are fully
extended. Models with Flo-Tel will show a sudden drop
in pump pressure or increase in pump strokes.
5. Mark the kelly for 3 ft and drill off slowly.
6. After 3 ft drill off, rotate the tool for 5 to 10 min.
7. Disengage rotary and pick up while the pump is still on.
8. Cutter arms should be fully open now. To make sure,
repeat the above steps. When you reach the shoulder,
you should start taking weight. Adjust weight and speed
for optimum ROP.
Flo-Tel-Equipped SPX/Drag-Type Underreamer

Rotate the tool at 80 to 150 RPM with a maximum pump
pressure. Flo-Tel-equipped underreamers indicate when
the cutter arms are fully extended and the tool is under-
reaming at full gage. Flo-Tel effectively substitutes for a
larger orifice when the cutter arms are extended. Pressure
on the mud pump gage then drops by about 200 to 250 psi
or the number of pump stroke increases. These clear sig-
nals from Flo-Tel assure that the hole has the right diameter
everytime, eliminating second trips. Flo-Tel is especially
recommended for cutting a shoulder in hard formations.
Underreaming the Interval

1. When the cutter arms are fully extended, apply weight.
Begin with 3,000 lb and increase up to 10,000 lb.
2. Continue rotating until completing the section of the hole
or until a new joint of pipe has to be added to the drillstring.
Underreaming 127
Adding a Connection
that it is barely in the table and engage the rotary at
slow speed.
4. Set down on shoulder and apply weight, to check
whether cutter arms have reopened.
5. Pick back up about 2 ft, engage rotary, bring to
operating RPM and continue underreaming.

shoe. Always pull into the casing shoe slowly. Be sure
hydrostatic head in the drillstring is allowed to equalize
before pulling into the casing; otherwise, forces of the fluid
column may expand cutter arms during entry.
SPX/Drag-Type Underreamer Disassembly

1. Remove Flo-Tel retaining ring and Flo-Tel assembly,
if applicable.
2. Push piston down to open cutter arms.
3. Remove hinge pin retaining screws and hinge pins.
4. Remove arms.
5. Remove arm stops.
6. Release piston and remove from tool.
7. Remove piston tube retaining ring, piston head, O-rings
and packing.
128 Underreaming
SPX/Drag-Type Underreamer Components
Top sub
Body
Piston stem Flo-Tel assembly

retaining screw
Piston head
O-ring Piston packing
Spring
Piston stem
Arm stop Arm stop

retaining screws
Cutter arm
Three-way
Arm hinge pin and
jet nozzle
retaining screw
Spade
Underreaming 129
SPX/Drag-Type Underreamer Assembly

1. Thoroughly lubricate all parts with light grease.
2. Assemble piston:
• Replace piston packing with V-lips, facing up.
• Replace orifice, packing, washer and retainer.
3. Place spring over piston stem and slide assembly
into body.
4. Push piston down to full open position.
5. Install arms in open position using new hinge pins and
retaining screws.
130
SPX/Drag-Type Underreamer
Fishing
Body
neck
diameter
diameter
Fishing
neck
length
Underreaming
Expanded
diameter
SPX/Drag-Type Underreamer Specifications
Underreaming
Min. Recom. Standard Expanded Diameter Fishing Neck
Tool Body Pilot Hole Overall Top Pin Weight
Series Diameter Diameter SPX Servcoloy “S” Length Diameter Length Conn. API (lb)
3600 33⁄8 33⁄4 N/A 9 8 33⁄8 261⁄2 23⁄8 Reg. 185
4500 41⁄2 43⁄4 61⁄2, 63⁄4, 81⁄2 Upon request 18 41⁄4 69 31⁄2 IF 230
4700 43⁄4 5 Upon request 12 18 41⁄8 67 27⁄8 Reg. 250
5700 53⁄4 6 71⁄2, 8, 81⁄2, 12, 13 16 18 43⁄4 70 31⁄2 Reg. 350
7200 71⁄4 75⁄8 10, 121⁄4, 13, 14, 15, 16 22 18 53⁄4 78 41⁄2 Reg. 750
8200 81⁄4 81⁄2 10, 121⁄4, 14, 15, 16, 17 23 18 53⁄4, 8 78 4 ⁄2 or 65⁄8 Reg.
1
900
9500 91⁄2 97⁄8 121⁄4, 171⁄2 28 18 8 78 65⁄8 Reg. 1,100
11700 113⁄4 121⁄4 Upon request 36 18 8, 9 86 6 ⁄8 or 75⁄8 Reg.
5
1,400
Notes: Ordering Instructions: 5. Size and weight of casing to be run

1. All dimensions are given in inches unless When ordering or requesting quotations on the through, if available.
otherwise stated. SPX/Drag-Type Underreamer, please specify: 6. Bullnose or bits are ordered separately.
2. All weights are approximate. 1. Tool series. 7. Type of cutting structure (milled tooth,
3. Other expanded diameters available 2. Top and bottom connections. TCI or PDC).
upon request. 3. Fishing neck diameter.
4. Orifices other than standard available 4. Opening diameter.
upon request.
5. Standard API pin connections. Others
available upon request.
131
132 Underreaming
Gage Diameter Tolerances — Underreamers

Size Tolerance
6-9 (Incl.) + 1⁄16 -0
91⁄2 - 13 (Incl.) + 3⁄32 -0
14 - 18 (Incl.) + 1⁄8 -0
20 - 30 (Incl.) + 3⁄16 -0
Notes:
2. The above gage diameters apply to a set of arms in open position when
assembled in a tool.
3. The specification covers arm sets used on all RTU, DTU, Drag and
XTU underreamers.
4. The specification applies to milled tooth, TCI and PDC cutting structures.
4
SECTION 4
SECTION FOUR HYDRAULICS
HYDRAULICS
Hydraulics 135
BIT HYDRAULICS
Hydraulic and mechanical energy are needed for efficient
rock cutting and removal when drilling. The hydraulic
energy is provided by the drilling medium or mud being
pumped down the ID of the drillstring. The mechanical
energy is supplied by the speed or RPM at which the string
turns and the amount of weight applied to the bit. The
Weight-on-Bit (WOB) controls the chip size and quantity
of the cuttings. The RPM controls the fracture rate or ROP.
The removal of these cuttings is both mechanical and hydrau-
lic; the teeth of the bit being mechanical and the hydraulics of
the orifice to lift the cuttings away from the bit and up the
annulus. In order to increase the hydraulic energy necessary
at the bit, select the correct orifice. Once the orifice is selected,
consider other factors which will affect cutting removal.
• Particle slip velocity.
• Mud properties (density, viscosity).
• Circulation rate (annular velocity).
• WOB.
• Drillstring rotation (RPM).
• Pump pressure.
• Formation type.
Once all these factors are taken into consideration we
can proceed with our drilling objectives, confident we will
have optimum performance from our mechanical and
hydraulic energy available.
The Flow of Fluid Under Pressure

Most noted for his study of the effects of flowing fluid under
pressure was Mr. Daniel Bernoulli. Bernoulli, an eighteenth
century scientist, was a member of a famous European family
of scientist and mathematicians. He devoted a good portion of
his life to studying hydraulics and the flow of fluid under pres-
sure. He is most famous for his theory or equation (Bernoulli’s
Theorem): when a fluid is flowing under high pressure it has a
slow velocity or slow traveling time. Once restricted down to a
smaller diameter the pressure is less and velocity is increased
or the fluid travels much faster. For example, let’s put some
numbers to this to make it clearer:
136 Hydraulics
We are pumping 300 GPM through our drillstring and

return flow is 300 GPM. In the larger diameter (our drillstring
ID) let’s say we have 1,000 psi pressure and a velocity or trav-
eling time of 20 ft/sec. Once the fluid reaches the smaller
diameter (orifice jet in bit), the psi pressure would drop to
800 psi and our velocity would exceed 100 ft/sec — low pres-
sure/high velocity. Thus, we have created a pressure drop or
pressure differential of 200 psi (1,000 – 800 psi = 200 psi) at
the orifice of the bit.
Underreamer Hydraulics
Having explained bit hydraulics and factors involved, let us
move on to underreamer hydraulics:
Smith underreamers are hydraulically actuated. The
mud pumped down the string flows into the tool’s piston
bore. The pressure then moves the piston (with attached
cam) down the tool mechanically actuating the cutter arms
by contact on the cam ramp. These arms will stay open as
long as the pumps are on; once shut off, the piston will
retract due to the piston spring moving back into a free state.
All underreamers can be actuated by a minimal amount of
pneumatic pressure (65 psi-shop air) but we recommend
a minimum pressure differential of 350 to 650 psi to main-
tain the open position of the tool downhole. Note: This
will be higher during Underreaming While Drilling
(UWD) operations.
In order to maintain the proper pressure differential or
pressure drop we must select the correct orifice. (See example
in this handbook on pages 143 through 147.) In addition
to maintaining the tool open we also rely on hydraulics in
underreaming to cool and clean the cutters and lift the cutting
up the annulus. So our orifice selection has to be very accu-
rate. Problems can arise if the orifice jet is incorrect or we are
pumping high flow rates (GPMs). In addition, if our mud has
a high solid content premature erosion or a washout can take
place. This action can cause excessive tool damage and due
to the need to trip out of the hole, costly rig time. All Smith
underreamers use 70 or 95 Series jets. The 70 Series is the jet
model, a second number such as 1⁄2 or 16 (16⁄32’s) will be given
to denote size. Based on all the same factors as we discussed
in Bit Hydraulics (factors 1 through 7) we will be able to
Hydraulics 137
choose the necessary jets to keep the underreamer open, cool

and clean the cutters, and lift the cuttings up the annulus,
keeping our hole clean. If we attach a bit or bullnose to the
bottom of our drilling-type underreamer, we must also take
into consideration any extra jets which might change our
pressure differential or pressure drop. So as you can see
underreamer hydraulics, like bit hydraulics, are very critical
to the tool performance.
In order to determine opening force of underreamer cutters
against formation use the following chart and formula:
Hydraulic Tool Opening Force

Piston Head Area (in.2)
Tool
Series DTU RTU Reamaster Drag PDC
3600 3.142 3.142
4100
4500 7.069
4700 8.296
5500 12.566
5700 12.566 12.566 9.621 12.566 12.566
5800 12.566
6000 12.566
6100 12.566
6200 12.566
7200 18.655 19.635 9.621 18.665
8200 18.655 18.665 19.635 18.665
9200
9500 30.680 18.665 30.680
10500 19.635
11000 30.680 50.266
11700 50.266 50.266 38.485 38.485
15000 30.680 50.266
16000 38.485
17000 50.266
22000 50.266 50.266
Hydraulic tool opening force:
Fh = PD Ap
Where:
Fh = Hydraulic opening force, lb
PD = Pressure drop across tool, psi
Ap = Piston head area, in.2
138 Hydraulics
In order to select a flow that will not erode tool prematurely,

opening force of underreamer cutters, use the following chart
and formula:
Maximum Hydraulic Tool Flow Rate

Piston Bore TFA (in.2)
Tool
Series DTU RTU Drag K-Mill PDC
3600 .624 .624 .307
4100 .442
4500 .442
4700 .307
5500 .442
5700 .442 .442 .442 .785
5800 .442
6100 .442
6200 .442
7200 1.227 .785 1.485 .442
8200 1.227 .785 2.406 .442 1.227
9200 .442
9500 1.227 .785 3.143 1.227
10500 .994 1.227
11000 .785 3.143 1.227
11700 3.142 1.624 .994 1.227
15000 3.142 1.624
17000 3.142
22000 3.142 7.069
Maximum hydraulic tool flow rate:
VAb
GPMm =
0.32
Where:
GPMm = Maximum flow rate, GPM
V = Piston bore velocity, ft/sec
V = 150 all tools except 45 to 117 km
V = 200, 45 to 117 km
Ab = Area of piston bore, in.2
Notes:
1. Reamaster is not included since bore velocity depends on nozzle TFA.
2. Use a piston bore velocity of 150 ft/sec to prevent erosion.
3. Values in bold under K-Mills may use 200 ft/sec velocity due to
anti-wash tubes.
Hydraulics 139
The Reamaster velocity should not exceed 75 ft/sec,

whereas velocity in the DTUs and RTUs should not
exceed 150 ft/sec.
In order to determine velocity through underreamers
and minimize erosion, use the following equation:
Piston Bore Velocity

0.32 GPM
Vp =
Ab
Where:
Vp = Piston bore velocity, ft/sec
GPM = Flow rate
Ab = Area of piston bore, in.2
In order to determine pressure drop across the under-

reamer piston use the following equation:
Hydraulic Tool Pressure Loss

(MW) (GPM)2
PD =
10,858 (TFA)2
Where:
PD = Pressure Drop across piston, psi
MW = Mud Weight, lb/gal
GPM = Pump volume through tool
TFA = Total Flow Area of jet nozzles, in.2
The chart on the following page will determine the ratio

of formation removed between the underreamer (or hole
opener) vs. the previously drilled pilot hole. This chart can be
used to determine the correct jet nozzle selection based on the
percentage of formation removed between the two holes.
140
Net Annular Area Removed with Underreamer or Hole Opener vs. Bit Pilot Hole
Bit Size Opening Diameter (in.)
Area 6.50 7.87 8.50 9.00 9.87 11.00 12.25 13.00 13.50 14.75 16.00 17.50 20.00 22.00 24.00 26.00 28.00 30.00 32.00 36.00 38.00 40.00 42.00
in. in.2 33.18 48.71 56.75 63.62 76.59 95.03 117.86 132.73 143.14 170.87 201.06 240.53 314.16 380.13 452.39 530.93 615.75 706.86 804.25 1,017.88 1,134.12 1,256.64 1,385.44
1
4 ⁄ 8 13.36 19.8
43⁄ 4 17.72 15.4 30.9
57⁄ 8 27.11 21.5 35.2 38.5
67⁄ 8 28.27 20.3 28.4 35.3
61⁄ 8 29.47 19.1 27.2 34.1 47.0 65.5 88.3 103.2
61⁄ 4 30.68 26.0 32.9 45.8 64.3 87.1 102.0
61⁄ 2 33.18 23.5 30.4 43.3 61.8 84.6 99.5
63⁄ 4 35.79 27.8 40.7 59.2 82.0 96.9
77⁄ 8 48.71 27.8 46.3 69.1 84.0
83⁄ 8 55.09 39.9 61.9 77.6 88.0
81⁄ 2 56.75 38.2 61.1 75.9 86.4
83⁄ 4 60.13 34.8 57.7 72.5 83.0 110.7 140.9
91⁄ 2 70.88 24.1 46.9 61.8 72.2 99.9 130.1
9 7⁄ 8 76.59 18.4 44.3 56.1 66.6 94.3 124.5 163.9 237.6
10 5⁄ 8 88.64 29.1 44.0 54.4 82.2 112.3 151.8 225.5
117⁄ 8 95.03 37.6 48.1 75.8 106.0 145.4 219.1
121⁄ 4 117.86 53.0 83.1 122.6 196.2 262.2
131⁄ 2 143.14 27.7 57.9 97.3 171.0 236.9
143⁄ 4 170.87 30.1 69.6 143.2 209.2
171⁄ 2 240.53 73.6 139.5 211.8 290.3 375.2 465.9
207⁄ 8 314.16 138.2 216.7 301.5 392.3
Hydraulics
227⁄ 8 380.13 72.3 150.8 235.6 326.7 424.1 637.8 754.0 876.5 1,005.3
247⁄ 8 452.39 78.5 163.3 254.1 351.8 565.5 681.7 804.3 933.1
267⁄ 8 530.93 84.8 175.5 273.2 486.9 603.2 726.6 854.5
287⁄ 8 615.75 91.1 188.5 402.1 518.4 640.9 769.7
Area = πR2, where π = 3.141592654. Note: Opening area minus pilot area equals total area to be removed by underreamer or hole opener.
Hydraulics 141
HYDRAULICS
To ensure a successful underreaming job, it is very impor-
tant to select the proper orifice sizes for the underreamer,
bit or bullnose. Different jobs will require different orifice
sizes based on parameters such as pilot hole size, under-
reamer opening diameter, flow rate, mud weight, etc.
A good rule of thumb for flow is the following: 35 GPM x
hole size = minimum; 50 GPM x hole size = maximum.
Example: 105⁄8-in. hole to be underreamed to 121⁄4 in.:
35 x 121⁄4 in. = 429 minimum GPM
50 x 121⁄4 in. = 612 maximum GPM
Correct Orifice Selection

Orifice size controls the force at the top of the piston which
pushes the cam down and opens the cutter. In a Reamaster
or DTU, the total flow area of the combination of jets in the
underreamer and bit or bullnose will determine the pres-
sure drop in the system. The correct orifice size or TFA is
necessary for proper operation of the tool. The following
charts and examples will help you select the proper orifice
size for your flow requirements.
Reamaster and Drilling-Type Underreamers (DTU)

Example: 16-in. duplex mud pump with 61⁄4-in. liner rated
at 50 SPM.
1. Find flow rate in GPM from pump volume tables located
in the conversion /data tables (Section 5).
2. Use orifice curves on Page 143. Flow 400 GPM line into
shaded area, until the GPM line intersects an orifice
size line.
This establishes the correct orifice size (TFA) for efficient tool
operation. In this case, a combination of 3 (12⁄32’s or 12’s) .330
TFA in a drilling-type underrreamer and 3 (12⁄32’s or 12’s) in
the bit .330 TFA will provide a system TFA of .660. This
would be a 50-50% flow split. The corresponding pressure
drop would be 340 psi at the piston. The 340 psi added to the
total drillstring system losses will determine your actual
standpipe pressure ie: 1,600 psi losses in system plus 340 psi
drop at tool = approximately 1,940 psi standpipe indication.
When the GPM line intersects more than one orifice size line,
142 Hydraulics
either size is correct; but when available, an intersection at

mid-range of the shaded area is recommended.
K-Mill, SPX/Drag- and Rock-Type Underreamers

Example: 16-in. duplex mud pump with 61⁄4-in. liner rated
at 50 SPM.
1. Find flow rate in GPM from pump volume tables located in
the conversion data tables (Section 7). Flow rate is 350 GPM.
2. Use orifice curves on Page 144. Follow 350 GPM line
into shaded area, until the GPM line intersects an orifice
size line.
This establishes the correct orifice size for efficient tool opera-
tion. In this case, either a 26⁄32-in. (TFA .590) or a 28⁄32-in.
(TFA .601) orifice may be used. Corresponding pressure
drops are 310 and 390 psi, respectively. When the GPM line
intersects more than one orifice size line, either size is cor-
rect; but when available, an intersection at mid-range of the
shaded area is recommended.
SPX/Drag and Rock-Type Underreamers with Flo-Tel

Flo-Tel-equipped underreamers signal the operator that the
cutter arms are fully extended and the tool is underreaming
at full gage. The Flo-Tel device effectively substitutes a larger
orifice when the cutter arms are extended. As a result, pres-
sure on the pump gage drops by approximately 200 lb or the
number of pump strokes increases. These clear signals from
the Flo-Tel assure that the arms have opened completely,
thus eliminating the need for any re-reaming or additional
trips. We recommend using the Flo-Tel especially when
cutting a shoulder in hard formation.
Orifice Sizes for Drilling-Type and Reamaster Underreamers
Hydraulics
Orifice Size
TFA .186 .330 .389.450 .518 .588 .665 .744 .831 .918 1.015 1.113 1.217 1.323
500
400
Pressure drop (psi)
300
200
Orifice coefficient .95

100
10 lb/gal 75 lb/ft3
0
100 200 300 400 500 600 700 800 900 1,000
gpm
143
144
Orifice Sizes for K-Mill, SPX/Drag- and Rock-Type Underreamers
12
Orifice Size ⁄32 14⁄32 16⁄32 18⁄32 20⁄32 22⁄32 24⁄32 26
⁄32 28⁄32 30
⁄32 32
⁄32 11⁄8
TFA .110 .150 .196.249 .307 .371 .441 .518 .601 .690 .785 .994
500
400
Pressure drop (psi)
300
200
Orifice coefficient .95

100 10 lb/gal 75 lb/ft3
Hydraulics
0
100 200 300 400 500 600 700
gpm
Hydraulics 145
Determining System Hydraulics

To calculate total system pressure (the standpipe pressure
gage reading) after selecting the correct orifice, use the fol-
lowing procedure:
• While marking a bit run before underreaming, run the
mud pump at the underreaming flow rate (GPM).
• Record the standpipe pressure with a bit at the approximate
underreaming depth.
Refer to orifice curves on Pages 143 and 144. Find the top of
the curve for the TFA of the bit. The intersection of the flow-
rate line (gpm) with the orifice curves indicates the bit pres-
sure drop at left, correct for mud weight other than 10 lb/gal
(see Page 147.) Subtract this bit pressure drop from the stand-
pipe pressure previously recorded. This yields the bore and
annular pressure losses. Add this number to the expected
reading of standpipe pressure when underreaming. See the
following example:
Rock-Type Underreamer, Pumping Rate 250 GPM

Given:
1. Approximate depth of bit 5,428 ft
2. Number and size of bit nozzles 3 - 14⁄32 in.
(.450 TFA)
3. Flow rate when opening hole 250 GPM
4. Standpipe pressure at 250 GPM 600 psi
(from pump gage)
Find:
5. Bit pressure drop
(from orifice curves) 280 psi
6. Bore and annular pressure losses 320 psi
7. Flow rate (from # 3) 250 GPM
8 Pressure drop across underreamer 290 psi
(from orifice curves, 24⁄32-in. =
.441 TFA orifice — see Page 144)
9. Expected standpipe 610 psi
pressure (add #6 and #8)
146 Hydraulics
Pressure Drop Across One Orifice for 10 lb/gal Mud Weight

Volume Pressure Drop (P) Across Nozzle of Indicated Diameter
Flow Rate P in psi (in.)
12 14 16 18 20 22 24 26 28 32
in gpm ⁄32 ⁄32 ⁄32 ⁄32 ⁄32 ⁄32 ⁄32 ⁄32 ⁄32 ⁄32 11⁄8 11⁄4
TFA .110 .150 .196 .249 .307 .371 .441 .519 .601 .785 .994 1.227
50 189
60 272
70 370 200
80 483 261
90 611 330
100 408 239
110 493 289
120 587 344 215
130 689 404 252
140 468 292 192
150 537 336 220
160 611 382 251
180 483 317 217
200 597 391 267 189
220 474 323 228
240 564 385 272 197
260 661 452 319 232
280 524 370 269 200
300 601 425 308 229
320 684 483 351 261
340 545 396 294
360 611 444 330
380 495 368 216
400 548 408 239
450 694 516 303 189
500 637 374 233
600 538 336 220
700 457 300
800 597 392
900 496
1,000 612
Hydraulics 147
Pressure Drops for Mud Weights Other Than 10 lb/gal

Pressure from across the orifice is directly proportional
to the mud weight. Therefore, if the circulating fluid has
weight other than 10 lb/gal, the correct pressure drop can
be determined by multiplying the figure obtained for the
table by the factor:
Actual mud weight (lb/gal)
10
Example: If 130 GPM of 12.5 lb/gal fluid is being circulated
through a 16⁄32-in. (.196 TFA) nozzle, the pressure drop is
as follows:
1. From the table (130 GPM, 16⁄32-in. nozzle):
Pressure drop = 404 psi (for 10 lb/gal mud)
2. 404 x 12.5
= 505 psi
10
The correct pressure drop of 130 GPM of 12.5 lb/gal mud,
circulated through a 16⁄32-in. nozzle, is 505 psi.
148
Jet Combinations for Hydraulic Tools
Jet Size (in.)
Diffuser Standard
Jet Jet Number of Jet Nozzles
32 1 2 3 4 5 6 7 8 9 10 11 12
7 0.038 0.076 0.114 0.152 0.190 0.228 0.266 0.304 0.342 0.380 0.418 0.456
8 0.049 0.098 0.147 0.196 0.245 0.294 0.343 0.392 0.441 0.490 0.539 0.588
9 0.062 0.124 0.186 0.248 0.310 0.372 0.434 0.496 0.558 0.620 0.682 0.744
8/32 10 0.077 0.154 0.231 0.308 0.385 0.462 0.539 0.616 0.693 0.770 0.847 0.924
9/32 11 0.093 0.186 0.279 0.372 0.465 0.558 0.651 0.744 0.837 0.930 1.023 1.116
10/32 12 0.110 0.220 0.330 0.440 0.550 0.660 0.770 0.880 0.990 1.100 1.210 1.320
11/32 13 0.130 0.260 0.390 0.520 0.650 0.780 0.910 1.040 1.170 1.300 1.430 1.560
12/32 14 0.150 0.300 0.450 0.600 0.750 0.900 1.050 1.200 1.350 1.500 1.650 1.800
15 0.173 0.346 0.519 0.692 0.865 1.038 1.211 1.384 1.557 1.730 1.903 2.076
13/32 16 0.196 0.392 0.588 0.784 0.980 1.176 1.372 1.568 1.764 1.960 2.156 2.352
14/32 17 0.222 0.444 0.666 0.888 1.110 1.332 1.554 1.776
15/32 18 0.249 0.498 0.747 0.996 1.245 1.494 1.743 1.992
16/32 19 0.277 0.554 0.831 1.108 1.385 1.662
20 0.307 0.614 0.921 1.228 1.535 1.842
22 0.371 0.742 1.113 1.484 1.855 2.226
24 0.442 0.884 1.326 1.768 2.210 2.652
26 0.519 1.038 1.557 2.076 2.595 3.114
28 0.601 1.202 1.803 2.404 3.005 3.606
30 0.690 1.380 2.070 2.760 3.450 4.140
32 0.785 1.570 2.355 3.140 3.925 4.710
Hydraulics
11⁄16 0.887 1.774 2.661
11⁄8 0.994 1.988 2.982
11⁄4 1.227 2.454 3.681
13⁄8 1.485 2.970 4.455
11⁄2 1.767 3.534 5.301 Area = πR2, where π = 3.14.
Hydraulics 149
Mud Weight (7 to 13.9 lb/gal)

(52.36 to 103.97 lb/ft3)
Gradient Gradient
lb/ lb/ Specific psi/100 ft lb/ lb/ Specific psi/100 ft
gal ft3 Gravity Depth gal ft3 Gravity Depth
7.0 52.36 0.84 36.33 10.5 78.54 1.26 54.51
7.1 53.11 0.85 36.86 10.6 79.29 1.27 55.03
7.2 53.86 0.86 37.38 10.7 80.04 1.28 55.55
7.3 54.60 0.88 37.89 10.8 80.78 1.30 56.06
7.4 55.35 0.89 38.41 10.9 81.53 1.31 56.58
7.5 56.10 0.90 38.93 11.0 82.28 1.32 57.10
7.6 56.85 0.91 39.45 11.1 83.03 1.33 57.62
7.7 57.60 0.92 39.97 11.2 83.78 1.34 58.14
7.8 58.34 0.94 40.49 11.3 84.52 1.36 58.66
7.9 59.09 0.95 41.01 11.4 85.27 1.37 59.18
8.0 59.84 0.96 41.53 11.5 86.02 1.38 59.70
8.1 60.59 0.97 42.05 11.6 86.77 1.39 60.22
8.2 61.34 0.98 42.57 11.7 87.52 1.40 60.74
8.3 62.08 0.99 43.08 11.8 88.26 1.42 61.25
8.4 62.38 1.00 43.29 11.9 89.01 1.43 61.77
8.5 63.58 1.02 44.12 12.0 89.76 1.44 62.29
8.6 64.33 1.03 44.65 12.1 90.51 1.45 62.81
8.7 65.08 1.04 45.17 12.2 91.26 1.46 63.33
8.8 65.82 1.06 45.68 12.3 92.00 1.48 63.85
8.9 66.57 1.07 46.20 12.4 92.75 1.49 64.37
9.0 67.32 1.08 46.72 12.5 93.50 1.50 64.89
9.1 68.07 1.09 47.24 12.6 94.25 1.51 65.41
9.2 68.82 1.10 47.76 12.7 95.00 1.52 65.93
9.3 69.56 1.12 48.27 12.8 95.74 1.54 66.44
9.4 70.31 1.13 48.80 12.9 96.49 1.55 66.96
9.5 71.06 1.14 49.32 13.0 97.24 1.56 67.48
9.6 71.81 1.15 49.84 13.1 97.99 1.57 68.01
9.7 72.56 1.16 50.36 13.2 98.74 1.58 68.53
9.8 73.30 1.18 50.87 13.3 99.48 1.60 69.04
9.9 74.05 1.19 51.39 13.4 100.23 1.61 69.56
10.0 74.80 1.20 51.91 13.5 100.98 1.62 70.08
10.1 75.55 1.21 52.43 13.6 101.73 1.63 70.60
10.2 76.30 1.22 52.95 13.7 102.48 1.64 71.12
10.3 77.04 1.24 53.47 13.8 103.22 1.66 71.63
10.4 77.79 1.25 53.99 13.9 103.97 1.67 72.16
150 Hydraulics
Mud Weight (14 to 20 lb/gal)

(104.72 to 149.60 lb/ft3)
Gradient Gradient
lb/ lb/ Specific psi/100 ft lb/ lb/ Specific psi/100 ft
gal ft3 Gravity Depth gal ft3 Gravity Depth
14.0 104.72 1.68 72.68 17.0 127.16 2.04 88.25
14.1 105.47 1.69 73.20 17.1 127.91 2.05 88.77
14.2 106.22 1.70 73.72 17.2 128.66 2.06 89.29
14.3 106.96 1.72 74.32 17.3 129.40 2.08 89.80
14.4 107.71 1.73 74.75 17.4 130.15 2.09 90.32
14.5 108.46 1.74 75.27 17.5 130.90 2.10 90.84
14.6 109.21 1.75 75.79 17.6 131.65 2.11 91.37
14.7 109.96 1.76 76.31 17.7 132.40 2.12 91.89
14.8 110.70 1.78 76.83 17.8 133.14 2.14 92.40
14.9 111.45 1.79 77.35 17.9 133.89 2.15 92.92
15.0 112.20 1.80 77.87 18.0 134.64 2.16 93.44
15.1 112.95 1.81 78.39 18.1 135.39 2.17 93.96
15.2 113.70 1.82 78.91 18.2 136.14 2.18 94.48
15.3 114.44 1.84 79.42 18.3 136.88 2.20 94.99
15.4 115.19 1.85 79.94 18.4 137.63 2.21 95.51
15.5 115.94 1.86 80.46 18.5 138.38 2.22 96.04
15.6 116.69 1.87 80.98 18.6 139.13 2.23 96.56
15.7 117.44 1.88 81.50 18.7 139.88 2.24 97.08
15.8 118.18 1.90 82.07 18.8 140.62 2.26 97.59
15.9 118.93 1.91 82.54 18.9 141.37 2.27 98.11
16.0 119.68 1.92 83.06 19.0 142.12 2.28 98.63
16.1 120.43 1.93 83.58 19.1 142.87 2.29 99.15
16.2 121.18 1.94 84.10 19.2 143.62 2.30 99.67
16.3 121.92 1.96 84.61 19.3 144.36 2.32 100.19
16.4 122.67 1.97 85.13 19.4 145.11 2.33 100.71
16.5 123.42 1.98 85.65 19.5 145.86 2.34 101.23
16.6 124.17 1.99 86.17 19.6 146.61 2.35 101.75
16.7 124.92 2.00 86.89 19.7 147.36 2.36 102.27
16.8 125.66 2.02 87.21 19.8 148.10 2.38 102.78
16.9 126.41 2.03 87.73 19.9 148.85 2.39 103.30
20.0 149.60 2.40 103.82
Hydraulics 151
Areas of Circles and Nozzles (in.)

Nozzle
Size Dia. Area Dia. Area Dia. Area Dia. Area
1
— ⁄32 .000767 11⁄8 .9940 51⁄8 20.629 91⁄8 65.397
1
— ⁄16 .003068 11⁄4 1.2272 51⁄4 21.648 91⁄4 67.201
3
— ⁄32 .006903 13⁄8 1.4849 53⁄8 22.691 93⁄8 69.029
1
— ⁄8 .01227 11⁄2 1.7671 51⁄2 23.758 91⁄2 70.882
5
— ⁄32 .01917 15⁄8 2.0739 55⁄8 24.850 95⁄8 72.760
3
— ⁄16 .02761 13⁄4 2.4053 53⁄4 25.967 93⁄4 74.662
7
7 ⁄32 .03758 17⁄8 2.7612 57⁄8 27.109 97⁄8 76.589
1
8 ⁄4 .04909 2 3.1416 6 28.274 10 78.540
9
9 ⁄32 .06213 21⁄8 3.5466 61⁄8 29.465 101⁄8 80.516
5
10 ⁄16 .07670 21⁄4 3.9761 61⁄4 30.680 101⁄4 82.516
11
11 ⁄32 .09281 23⁄8 4.4301 63⁄8 31.919 103⁄8 84.541
3
12 ⁄8 .1104 21⁄2 4.9088 61⁄2 33.183 101⁄2 86.590
13
13 ⁄32 .1296 25⁄8 5.4119 65⁄8 34.472 105⁄8 88.664
7
14 ⁄16 .1503 23⁄4 5.9396 63⁄4 35.785 103⁄4 90.763
15
15 ⁄32 .1726 27⁄8 6.4918 67⁄8 37.122 107⁄8 92.886
1
16 ⁄2 .1963 3 7.0686 7 38.485 11 95.033
17
17 ⁄32 .2217 31⁄8 7.6699 71⁄8 39.871 111⁄8 97.205
9
18 ⁄16 .2485 31⁄4 8.2958 71⁄4 41.282 111⁄4 99.402
19
— ⁄32 .2769 33⁄8 8.9462 73⁄8 42.718 113⁄8 101.623
5
20 ⁄8 .3068 31⁄2 9.6212 71⁄2 44.179 111⁄2 103.869
21
— ⁄32 .3382 35⁄8 10.3206 75⁄8 45.664 115⁄8 106.139
11
22 ⁄16 .3712 33⁄4 11.0447 73⁄4 47.173 113⁄4 108.434
23
— ⁄32 .4057 37⁄8 11.7933 77⁄8 48.707 117⁄8 110.753
3
24 ⁄4 .4418 4 12.566 8 50.266 12 113.10
25
— ⁄32 .4794 41⁄8 13.364 81⁄8 51.849 121⁄8 115.47
13
26 ⁄16 .5185 41⁄4 14.186 81⁄4 53.456 121⁄4 117.86
27
— ⁄32 .5591 43⁄8 15.033 83⁄8 55.088 123⁄8 120.28
7
28 ⁄8 .6013 41⁄2 15.904 81⁄2 56.745 121⁄2 122.72
29
— ⁄32 .6450 45⁄8 16.800 85⁄8 58.426 125⁄8 125.19
15
— ⁄16 .6903 43⁄4 17.721 83⁄4 60.132 123⁄4 127.68
31
— ⁄32 .7371 47⁄8 18.665 87⁄8 61.862 127⁄8 130.19
— 1 .7854 5 19.635 9 63.617 13 132.73
Area = πR2, where π = 3.14.
152 Hydraulics
Areas of Circles and Nozzles (in.) (cont.)

Nozzle
Size Dia. Area Dia. Area Dia. Area Dia. Area
— 131⁄8 135.30 163⁄8 210.60 195⁄8 302.49 227⁄8 410.97
— 131⁄4 137.89 161⁄2 213.82 193⁄4 306.35 23 415.48
— 133⁄8 140.50 165⁄8 217.08 197⁄8 310.24 231⁄8 420.00
— 131⁄2 143.14 163⁄4 220.35 20 314.16 231⁄4 424.56
— 135⁄8 145.80 167⁄8 223.65 201⁄8 318.10 233⁄8 429.13
— 133⁄4 148.49 17 226.98 201⁄4 322.06 231⁄2 433.74
— 137⁄8 151.20 171⁄8 230.33 203⁄8 326.05 235⁄8 438.36
— 14 153.94 171⁄4 233.71 201⁄2 330.06 233⁄4 443.01
— 141⁄8 156.70 173⁄8 237.10 205⁄8 334.10 237⁄8 447.69
— 141⁄4 159.48 171⁄2 240.53 203⁄4 338.16 24 452.39
— 143⁄8 162.30 175⁄8 243.98 207⁄8 342.25 241⁄8 457.11
— 141⁄2 165.13 173⁄4 247.45 21 346.36 241⁄4 461.86
— 145⁄8 167.99 177⁄8 250.95 211⁄8 350.50 243⁄8 466.64
— 143⁄4 170.87 18 254.47 211⁄4 354.66 241⁄2 471.44
— 147⁄8 173.78 181⁄8 258.02 213⁄8 358.84 245⁄8 476.26
— 15 176.71 181⁄4 261.59 211⁄2 363.05 243⁄4 481.11
— 151⁄8 179.67 183⁄8 265.18 215⁄8 367.28 247⁄8 485.98
— 151⁄4 182.65 181⁄2 268.80 213⁄4 371.54 25 490.87
— 153⁄8 185.66 185⁄8 272.45 217⁄8 375.83 211⁄8 495.79
— 151⁄2 188.69 183⁄4 276.12 22 380.13 251⁄4 500.74
— 155⁄8 191.75 187⁄8 279.81 221⁄8 384.46 253⁄8 505.71
— 153⁄4 194.33 19 283.53 221⁄4 388.82 251⁄2 510.71
— 157⁄8 197.93 191⁄8 287.27 223⁄8 393.20 255⁄8 515.72
— 16 201.06 191⁄4 291.04 221⁄2 397.61 253⁄4 520.77
— 161⁄8 204.22 193⁄8 294.83 225⁄8 402.04 257⁄8 525.84
— 161⁄4 207.39 191⁄2 298.65 223⁄4 406.49 26 530.93
Area = πR2, where π = 3.14.
5
SECTION 5
SECTION FIVE HOLE OPENING
HOLE OPENING
Hole Opening 155
HOLE OPENING
Hole opening is defined as enlarging the wellbore with a
cutter of a fixed diameter, unlike an underreamer which is
activated hydraulically to a predetermined diameter and
then closed to a smaller diameter once interval is completed.
Hole openers are typically used to enlarge previously
drilled pilot holes. This enlargement is often necessary to
ensure adequate clearance for the casing and cement.
For example, a 121⁄4-in. bit would drill the pilot hole. A
1
17 ⁄2-in. hole opener would then be run in order to provide
enough room to run and cement the 133⁄8-in. casing.
Smith offers a full range of hole openers, as well as the
complete line of hole enlargers:
• Fixed Diameter Hole Openers (FDHO) with SDD cutters
up to 26-in. opening diameter.
• FDHO with GTA cutters up to 40-in. opening diameter.
• Master DrillerE with cone segment cutters opening up to
36-in. diameter.
• Master Driller II available with Polycrystalline Diamond
Compact (PDC) SuperdomeE cutters in requested sizes.
• Hole enlargers available in 26 varying sizes up to
26-in. opening diameter.
156 Hole Opening
Weights and Rotary Recommendations for

Hole Openers/Hole Enlargers
Soft Formations (Soft Shale, Sand, Red Beds):
Cutter Weight Rotary Speed
Hole Size Type (lb) (rpm)
57⁄8 - 77⁄8 Milled Tooth 5,000 - 10,000 50 - 75
81⁄8 - 11 Milled Tooth 10,000 - 15,000 90 - 120
111⁄4 - 151⁄4 Milled Tooth 10,000 - 25,000 125 - 150
151⁄2 - 191⁄2 Milled Tooth 10,000 - 25,000 125 - 150
193⁄4 - 26 Milled Tooth 15,000 - 25,000 125 - 150
Medium Formations (Medium Shale, Sand, Lime):
57⁄8 - 77⁄8 Milled Tooth 5,000 - 10,000 50 - 75
81⁄8 - 11 Milled Tooth 10,000 - 20,000 90 - 100
111⁄4 - 151⁄4 Milled Tooth 15,000 - 30,000 90 - 100
151⁄2 - 191⁄2 Milled Tooth 15,000 - 30,000 90 - 100
193⁄4 - 26 Milled Tooth 20,000 - 35,000 75 - 85
Hard Formations (Hard Lime, Dolomite, Quartzite):
57⁄8 - 77⁄8 Button Type 10,000 - 15,000 50 - 75
81⁄8 - 11 Button Type 25,000 - 30,000 60 - 65
25,000 - 30,000* 35 - 40
111⁄4 - 151⁄4 Button Type 35,000 - 45,000 60 - 65
30,000 - 45,000* 35 - 45
151⁄2 - 191⁄2 Button Type 35,000 - 50,000 60 - 65
30,000 - 50,000* 35 - 45
193⁄4 - 26 Button Type 35,000 - 45,000 50 - 60
30,000 - 45,000* 30 - 40
*TCI button type for extremely hard formations.
Hole Opening 157
Gage Diameter Tolerances — Hole Openers/Hole Enlargers

Size Tolerance
77⁄8 - 133⁄4 (Incl.) + 1⁄16 - 1⁄32
14 - 171⁄2 (Incl.) + 3⁄32 - 1⁄16
18 - 26 (Incl.) + 1⁄8 - 1⁄16
27 - 42 (Incl.) + 5⁄32 - 1⁄16
43 and Larger + 3⁄16 - 1⁄16
Notes:
1. All dimensions given in inches unless otherwise stated.
2. The above gage diameters apply to SDD, GTA, STA, Master Driller and
hole enlargers.
3. Unlike rock bits, the gage area of the cutters is “as dressed” and
not ground.
4. Above gage tolerances are not applicable to those orders that require
specific gage diameters. (Some applications may require tighter
gage control.)
5. The above gage diameters apply to milled tooth and TCI cutting structures.
158 Hole Opening
Master Driller Hole Opener

Hole Opening 159
MASTER DRILLER
The Master Driller is well suited for soft to medium-hard
formations where a variety of hole sizes and formations are
encountered. The tool is also used where rotary table size
restrictions exist.
• One body can accomodate several sizes for arms;
an advantage in locations with limited rig space or
logistics problems.
• Cutter arms may be installed below the rotary table when
rotary table size restricitons exist.
• The tool utilizes specifically designed cones for hole open-
ers. A large selection of cones including milled tooth, TCI
and PDC Superdome cutters.
• All Master Driller hole openers feature replaceable
nozzles to assure effective hole cleaning and to cool
cutter cones.
• Bottom-box connection allows the selection of bit or
bullnose for guidance.
Master Driller Tool Servicing

• It is advisable to clean the tool after use and before stor-
age. Steam cleaning is preferred but washing in petroleum
solvent or diesel fuel is acceptable.
• If the tool is painted prior to storage, avoid letting paint
run into the arm pin holes and into the cone bearing races.
• Coat the tool joint connections with a good grade of
thread lubricant and reinstall the thread protectors
supplied with tool.
160 Hole Opening
Changing Cutters
• Remove 3⁄8-in. arm pin retaining screws:
(1⁄2 in. for Series 15000-2 Master Driller).
• Using drift punch furnished with tool, knock the arm
pins out toward arm pin retaining screw holes.
• Discard arm pins and arm pin retaining screws as new
pins and screws are furnished with each set of arms.
• Replace new cutter arm in pocket, grease lightly and
install new arm pins and new arm pin retaining screws.
Changing Jet Orifice

• Clean threads in orifice seat.
• Install new O-ring packing in O-ring groove on jet, grease
lightly and screw jet into seat.
• Jet nozzles are available in all standard sizes
(32nd increments).
Changing Arm Pin Bushings

• After a number of sets of cutters have been run in the tool,
the arm pins will become loose when installed in the arm
pin holes. This is due to wear in the arm pin bushings and
should be replaced.
• These bushings may be pressed or driven out and replaced
by new bushings.
• The bushing on the side with the arm pin retaining screw
may be removed in either direction. The bushing on the
other side can only be removed toward the arm pocket.
Hole Opening 161
• Heat is neither necessary nor desirable in the removal of

the bushings.
• After the arm pin holes have been cleaned and lightly
greased, the greased arm pin bushings may be replaced by
pressing or driving into place. Replace the short bushing
in the side without the arm pin retaining screw first.
Body
• Examine the body for excessive wear. Critical areas are
as follows:
1. The hardfaced edge of the pilot wiper pads.
2. The shirttail area of the cutter segment.
3. Jet nozzles and jet nozzle retainer sleeves.
162
Master Driller
Overall length
Fishing neck length
Standard
opening
diameter
Body
diameter
Bottom
neck Fishing
diameter neck
diameter
Bottom-box connection Top pin connection

Hole Opening
Master Driller Specifications
Hole Opening
Standard Minimum Fishing Neck Connections API Reg.
Body Opening Pilot Hole Body Overall Top Bottom Weight
Series Diameter Diameter Diameter Length Diameter Length Pin Box (lb)
8200 121⁄4 81⁄2 81⁄4 24 8 60 65⁄8 41⁄2 640
121⁄4 81⁄2 91⁄2 24 8 67 5
6 ⁄8 65⁄8 915
9500
143⁄4 91⁄2 91⁄2 24 8 67 5
6 ⁄8 65⁄8 915
171⁄2 91⁄2 115⁄8 24 8 70 5
6 ⁄8 65⁄8 1,100
11000
225⁄8 91⁄2 115⁄8 24 8 70 5
6 ⁄8 65⁄8 1,100
171⁄2 91⁄2 155⁄8 24 10 74 5
7 ⁄8 75⁄8 1,900
15000 265⁄8 121⁄4 155⁄8 24 10 74 5
7 ⁄8 75⁄8 1,900
365⁄8 245⁄8 155⁄8 24 10 74 5
7 ⁄8 75⁄8 1,900
Notes: 4. Top and bottom connections, if other than standard.
1. All dimensions are given in inches unless otherwise stated. 5. Fishing neck diameter, if other than standard.
2. All weights are approximate. 6. Type of formation (soft, medium).
When ordering or requesting quotations on the
Master Driller, please specify:
1. Body series.
2. Hole opening size.
3. Pilot hole size.
163
164 Hole Opening
SDD Fixed-Diameter Hole Opener

Hole Opening 165
SDD FIXED-DIAMETER HOLE OPENERS

SDD hole openers are designed for use in soft to medium-
hard formations, soft clays and shales and medium lime-
stone. The tool is particularly effective in sticky formations
where balling problems are encountered.
• The SDD hole opener features demountable cutters which
are easily replaced on the rig floor.
• All SDD hole openers feature jets with replaceable diffuser
jet nozzles behind each cutter to clean cutters, prevent
balling and assure fast penetration.
• On sizes 171⁄2 in. and larger, there are three additional jets
with replaceable jet nozzles to assure effective hole cleaning.
Type SDD Tool Servicing

• Wash down the hole opener as soon as possible after it is
pulled. Clean the mud and cuttings off the cutters; from
between each cutter and the cutter leg bearing surfaces
and out from under the cutters. Clean the wrench slots in
the jet nozzle retainers.
• Flush the circulation passages with water until full flow
can be acheived from all jet nozzles and through the ID to
the box connection. Allow the hole opener to drain and
dry. Blow out the circulation passages, if possible.
Nozzles
• Clean and inspect all jet nozzles for cracks, nicks and ero-
sion damages. If either the retainer or jet nozzle appeared
damaged, replace them with the appropriate assembly.
• Note: SDD hole openers 15 in. and smaller have three
fixed diffuser jet nozzles located directly behind the cut-
ters. Hole openers 171⁄2 in. and larger have six jet nozzles:
three diffuser jet nozzles behind the cutters and three jet
nozzles located between the cutters for hole cleaning.
• For threaded jet nozzles, clean and inspect jet nozzle
sleeve threads, O-ring and O-ring sealing surfaces. If the
threads are damaged, rechase them with a tap to a mini-
mum of seven full threads. If the O-ring is damaged,
replace it.
166 Hole Opening
• To replace the diffuser jet nozzle behind the cutter,

remove the existing jet nozzle by air arcing the weld all
the way around. Grind the shoulder area to remove all slag
and carbon deposits. Install new assembly and tack weld
3
⁄4 in. long tack on opposite side using 1⁄8-in. AWS E-7918
rod. Remove slag.
• To replace threaded jet nozzle, first grease the O-ring and
install it in the sleeve below threaded section and then
grease the sleeve threads. Apply a coat of grease to the
O-ring sealing surface and the threads of the retainer.
Screw the retainer into the sleeve. Tighten the retainer
with the jet nozzle wrench.
Cutters and Legs

• If the cutters are reusable, regrease immediately.
• The cutters on 15-in. and smaller hole openers may be
regreased through the main pin. Remove cap screw from
top of the pin and install fittings.
• The cutters on 171⁄2-in. and larger hole openers may be
greased by first removing the cutters and then pumping
grease through the ball plug located in the journal. The
cutters may be removed as follows:
1. Remove main pin retaining screw located in leg
pin hole.
2. The main pin holder can be removed by attaching cut-
ter pin puller to the tapped hole on the top of the pin
and using the sliding hammer to jar the main pin until
it slides free. The cutter will now lift out of the body.
• If necessary, remove the cutters to inspect the legs and
main pins for wear damage.
1. The cutters on hole openers 15 in. and smaller can be
removed by driving the spring pin out of the leg and
the main pin with a drift pin and hammer.
2. For cutters on hole openers 171⁄2 in. and larger, follow
the cutter removal procedure as outlined above.
3. Solvent wash the entire main pin, cutter assembly
bore, leg faces and leg bore. Inspect all mating sur-
faces for galling, damage or excessive wear.
4. If the main pin is worn or damaged, it must be
replaced. Main pin replacements are furnished with
new grease fittings, retaining pins and screws.
Hole Opening 167
5. If entire cutter structure is damaged install a new

cutter set.
• If the leg pin bushing (171⁄2-in. and larger hole openers) is
damaged or worn, replace it with new bushings.
• The leg should be replaced if (1) excessive wear or dam-
age is found on the shirttail area or (2) any cracks are
detected by magnetic particle inspection. Replacement
will be as follows:
1. Welding materials
• Use 1⁄8- or 3⁄16-in. AWS E12018-D2 electrode or AWS
E120T rod.
• Weld rod coating must be kept dry to prevent hydro-
gen embrittlement. Store at 200°F (93°C) after open-
ing container. If rod has been exposed to humid air,
bake rod one hour at 700°F (371°C). Do not bake at
any temperature over 800°F (427°C).
2. Leg removal
• Use 3⁄8-in. carbon arc for removal and shop air at
90 psi minimum.
• Start leg removal by air arcing a gouge on front of leg
1
⁄8 in. above the base to locate the seam. Remove the
weld all the way around leaving the weld across the
back until last.
• Grind reaming base as required to remove all slag
and carbon deposits.
3. Leg attachment
• Leg base weld bevels should be ground or air arced to
remove any precipitated carbides prior to welding.
• Remove all grease, dirt or paint from the areas to
be welded.
• Position the legs. Check the correct hole opener gage
diameter with new cutter assemblies temporarily in
place. Shim if necessary.
• Tack weld the leg with 1 in. long tacks on all four
sides. Use 1⁄8- or 3⁄16-in. AWS E120T rod.
• Preheat the base of the leg to 700°F (371°C) to 800°F
(427°C) and verify temperature with a TEMPSTIK.
Deposit root pass using 3⁄16-in. AWS E120T rod. Make
alternate or staggered pass pattern on sides of the leg.
All welds will be multiple pass fillet or bevel welds.
168 Hole Opening
Interpass temperature on all welds will be 700°F

(371°C).
• Remove slag and peen welds. Peening of all welds is
recommended to induce favorable residual stresses
and prevent cracking. Peening should be hard
enough to cause the surface to yield. Peening, how-
ever, will not remove locked in stress if the weld
metal is cool when peened. It is recommended that
each pass be peened immediately after depositing
weld metal.
• Cool body slowly preferably with vermiculite.
• Magnetic particle inspect all welds and repair as
required.
• Final ring gaging is required using new cutters
to ensure that the correct hole opener diameter
(see hole opener gage tolerances on Page 157)
has been maintained.
Body Repair
as follows:
1. The hardfaced edge of the pilot hole wearpads.
2. The shirttail area of the legs.
3. Jet nozzle retainer sleeves.
4. The hardfaced area on the outer side of legs.
• Hardfaced surfaces may be repaired in the field. The
resulting metal deposit will not equal the hardness of
the tungsten carbide, but if properly applied, it will give
additional wear protection to the hole opener body.
1. Use rods equivalent to Servcotube 40/60 mesh in 3⁄16-
or 5⁄32-in. diameters.
2. Set the welding machine for 150/200 amp at 30/40
volts for 5⁄32-in. rod, 200/260 amp at 30/40 volts for
3
⁄16-in. rod. AC or DC, either polarity may be used.
3. Preheat the area to be resurfaced to 300°F (149°C)
to 400°F (204°C).
4. Apply the hardfacing as stringer or weaving beads in
two passes to a maximum thickness of 1⁄8 in. If weav-
ing beads are applied, the bead width shall not exceed
21⁄2 times the rod diameter.
Hole Opening 169
Cutter Installation
• Wipe a light coat of grease on the main pin, leg bores and
cutter journal bores.
• Position the cutter in the leg with the anti-rotation lug
against the lock bushing in the body.
• Push the main pin through the leg and journal bore and
into the lock bushing located in the body.
• In hole openers, 15 in. and smaller sizes, rotate the main pin
until the retaining hole is aligned with the hole in leg. For
hole openers 171⁄2 in. and larger, push the pin down until it
clears the tapped hole located on the side of the leg bore.
• Insert the retaining spring pin or install the retaining
socket head cap screws, whichever is applicable. Tighten
the cap screws to 150 ft/lb maximum.
• Cutters from stock should already be fully greased. However,
the cutters may be regreased by using procedure described
earlier in the “Cutters and Legs” section.
Corrosion Prevention
After thorough cleaning, coat the following surfaces with a
quality rust-preventative compound:
• Tool joint threads and shoulders.
• Inner faces of the leg and body.
• Main pin bores of the leg.
• Cutter ends and main bore.
170
SDD Hole Opener
Overall length
Bottom Fishing neck length

neck length
Standard
opening
diameter
Fishing
neck
Bottom diameter
neck
diameter Bottom-box connection Top pin connection
Hole Opening
SDD Hole Opener Specifications
Hole Opening
Fishing Neck Bottom Neck
Minimum Bottom- Weight Weight
Standard Pilot Top Pin Box with Cutters
Opening Hole Connection Connection Overall Cutters Per Set Std.
Diameter Diameter Length Diameter API Reg. Length Diameter API Reg. Length (lb) (lb) Bore*
77⁄8 53⁄8 24 53⁄4 41⁄2 30 5 Bullnose 73 460 11 1
1 3
8 ⁄2 - 8 ⁄4 61⁄8 24 3
5 ⁄4 41⁄2 12 51⁄8 31⁄2 55 380 17 1
91⁄2 - 97⁄8 61⁄4 24 73⁄4 65⁄8 12 51⁄4 31⁄2 59 685 23 1
121⁄4 81⁄2 24 8 65⁄8 12 53⁄4 41⁄2 61 750 48 11⁄2
143⁄4 - 15 97⁄8 24 8 65⁄8 12 8 65⁄8 68 930 68 11⁄2
171⁄2 97⁄8 24 8 65⁄8 12 8 65⁄8 68 1,000 108 11⁄2
20 121⁄4 30 8 5
6 ⁄8 12 8 65⁄8 68 1,200 108 11⁄2
22 121⁄4 30 8 65⁄8 - 75⁄8 12 8 65⁄8 70 1,800 240 11⁄2
24 143⁄4 30 8-9 65⁄8 - 75⁄8 12 9 75⁄8 70 1,850 240 11⁄2
26 143⁄4 30 8-9 5 5
6 ⁄8 - 7 ⁄8 12 9 75⁄8 70 1,900 240 11⁄2
*Standard bore is bore in bottom of tool. Top bore is larger. 2. Hole size.
1. All dimensions are given in inches unless otherwise stated. When ordering or requesting quotations on SDD hole openers,
2. All weights are approximate. please specify:
3. Replacement cutter sets include all parts necessary for replacement. 1. Pilot hole size.
4. Bullnoses available upon request. 2. Hole opening size.
Ordering Instructions for Cutters: 3. Top and bottom connections, if other than standard.
When ordering or requesting quotations on cutters, please specify: 4. Fishing neck diameter, if other than standard.
1. Type of formation (soft, medium, medium hard).
171
172 Hole Opening
GTA Fixed-Diameter Hole Openers

Hole Opening 173
GTA FIXED-DIAMETER HOLE OPENERS

These tools are primarily used for surface holes and conduc-
tor casing. The selection of cutters allows the tool to handle
a wide range of formations from soft to hard-abrasive.
Features
• GTA cutter sizes available from 26 to 42 in.
• The GTA hole openers feature demountable cutters which
are easily replaced on the rig floor.
• GTA hole openers are available with sealed bearing milled
tooth or tungsten carbide insert cutters.
• Tools feature long fishing necks which can be made up
below the rotary because of size limitations.
• All GTA hole openers feature replaceable nozzles to assure
effective hole cleaning.
GTA Tool Servicing

• Wash down the hole opener as soon as possible after it is
pulled. Clean the mud and cuttings off the cutters, from
between each cutter, the leg bearing surfaces, and out
from the cutter in the throat of the leg. Clean the wrench
slots in the jet nozzle retainer.
• Flush the circulation passages with water until full flow
can be seen from all nozzles and the ID to the box con-
nection. Allow the hole opener to drain dry. Blow out
the circulation passages, if possible.
Nozzles
• Use the jet nozzle wrench to remove the nozzle retainer
from the sleeve.
• Clean and inspect all jet nozzle sleeve threads. Check the
O-ring seal surface at the bottom of the bore. Make sure
that the surfaces are clean and undamaged. If the threads
are damaged, rechase them with a 11⁄2-in. 12 NF tap to a
minimum depth of 3⁄4 in.
174 Hole Opening
• Inspect the O-ring for cuts, abrasion or other damage. If

the O-ring is damaged or shows signs of permanent set,
replace it.
• Check the retainer and jet nozzle. Make sure that the
threads and O-ring sealing surfaces are clean and undam-
aged. Examine the jet nozzle for cracks, nicks and erosion
damage. If either the retainer or the jet nozzle appear dam-
aged, replace the assembly with a Smith Tool 95 Series jet
nozzle with the required orifice diameter.
• To replace the jet nozzle, first grease the O-ring and install
it in the sleeve below the threaded section and then grease
the sleeve threads. Apply a coat of grease to the O-ring
sealing surface and the threads of the retainer and screw
the retainer into the sleeve. Tighten the retainer with the
jet nozzle wrench.
Cutters and Legs

• If the cutters are reusable, regrease immediately. Remove
the outer retainer pin, for access to the lube fitting, and
pump a high-quality molydenum disulfide-base grease
through the main pin into the center of the bearing sleeve.
Rotate the cutter while pumping to distribute the grease
through the bearing.
• If necessary, remove the cutters to inspect the legs and
main pins for wear or damage. The cutters may be
removed as follows:
1. GTA main pins are released by removing the 7⁄8-in. 12
NF set screw in the main pin end then slipping the
retainer pin sideways out of the main pin and leg.
Note: A single retainer pin is used in the outer leg on
small diameter hole openers. The inner end of the
main pin is inaccessible.
2. The main pin can now be pulled with the main pin
puller. On GTA main pins use the 7⁄8-in. set screw
hole threads.
Hole Opening 175
3. Use the sliding hammer portion of the puller to jar the

main pin until it slides free of the cutter assembly and
the leg. The cutter will now lift out of the body.
4. Use solvent to wash clean the entire main pin, cutter
assembly bore, leg faces and leg bores. Inspect all
mating surfaces for galling, damage or excessive wear.
5. If the main pin is worn or damaged it must be replaced.
Replacement main pins are furnished with new grease
fitting, retaining pins and set screws.
6. If the cutter bearing sleeve is damaged, rebuild
the cutter in accordance with the tool kit manual.
Rebuilding the sleeve and the leg should not exceed
.040 in.
7. The clearance between the end of the cutter bearing
sleeve and the leg should not exceed .040 in.
• The leg should be replaced if:
1. The main pin bore is damaged or measures in excess
of 2.520 in.
2. The anti-rotation flat (for the sleeve) on the leg is
deformed in excess of .060 in.
3. Any cracks are detected by magnetic particle inspec-
tion. Replacement will be as follows:
• Welding materials
1. Use 1⁄8- or 3⁄16-in. AWS E7018 low hydrogen rod.
2. Weld rod coating must be kept dry to prevent hydro-
gen embrittlement. Store at 200°F (93°C) after open-
ing container. If rod has been exposed to humid air,
bake rod one hour at 700°F (371°C). Do not bake at
any temperature over 800°F (427°C).
3. Use machine setting of 30/35 volts at 130/150 amps
for 3⁄16-in. rod.
176 Hole Opening
• Leg removal
1. Use 3⁄8-in. carbon arc for removal and shop air at
90 psi minimum. Machine setting is 70/80 volts at
300/350 amps.
2. Start leg removal by air arcing a gouge on front of
the leg 1⁄8 in. above the base plate to locate the seam.
Remove the weld all the way around leaving the
weld across the back until last. This procedure is
also correct for leg removal.
3. Grind remaining base as required to remove all slag
and carbon deposits.
• Leg attachment
1. All legs are supplied with temporary steel straps welded
on both sides of the leg to minimize distortion. Leave the
straps in place until assembly welding is done.
2. Leg base weld bevels should be ground or air arced to
remove any precipitated carbides prior to welding.
3. Remove all grease, dirt or paint from the areas to
be welded.
4. Set dowel pins and position the legs. Check the
correct hole opener gage diameter with new cutter
assemblies temporarily in place.
5. Tack weld the leg with 1 in. long beads on all four
sides. Use 1⁄8- or 3⁄16-in. AWS E7018 rod.
6. Preheat the base of the leg to 150°F (66°C) and verify
temperature with a TEMPSTIK. Deposit root pass
using 3⁄16-in. AWS E7018 rod. Make alternate or stag-
gered pass pattern on sides of leg. All welds will be
multiple pass fillet or bevel welds. Interpass temper-
ature on all welds will be 250°F (121°C). Machine
setting: 30/35 volts at 130/150 amps.
Hole Opening 177
17. Remove slag and peen welds. Peening of all welds is

recommended to induce favorable residual stresses
and prevent cracking. Peening should be hard
enough to cause the surface to yield. Peening, how-
ever, will not remove locked in stress if the weld
metal is cool when peened. It is recommended that
each pass be peened immediately after depositing
weld metal.
18. Magnetic particle inspect all welds and repair as
required.
19. Remove the straps and grind off excess tack welds.
10. Leg attachment is done as per paragraphs 2 through
8 using a special leg positioning fixture. Anchor and
fixture main pin to the body with a rod or bolt. Slip a
cutter assembly and the new leg onto the fixture
main pin with a 0.040-in. shim between the cutter
and the leg. Put the tapered block, washer and nut on
the pin and tighten the entire assembly into position.
Weld as specified above.
11. Final ring gaging is required using new cutters to
ensure that the correct hole opener diameter has
been maintained (see hole opener gage tolerances
on Page 157).
• Leg tolerances
11. After installing a new cutter assembly and main pin,
the total clearance between the cutter bearing sleeve
and the leg face should be no greater than 0.040 in.
nor less than 0.020 in.
12.Peening: Straightening of a leg by peening is recom-
mended when necessary. Opening of leg for proper
clearance is done by peening on the inside of the
yoke. For closing the leg, peen on the outside.
13. Heating: Straightening a leg by heating, although sat-
isfactory, requires extreme care that the carburized
main pin bores do not exceed 425°F (218°C) at any
time. The leg uprights may be heated to a maximum
of 1,200°F (649°C), if necessary, providing the 425°F
(218°C) temperature of the pin bore is not exceeded.
Temperatures during this procedure shall be verified
by TEMPSTIK.
178 Hole Opening
Body Repair
as follows:
1. The hardfaced edge of the pilot hole reamer plates
supporting the circulation jet nozzles.
2. The shirttail area of the leg.
3. Nozzle retainer sleeves.
4. The milled surface on the outer portion of the leg.
• Hardfaced surfaces may be repaired in the field. The
resulting metal deposit will not equal the hardness of
the tungsten carbide, but if properly applied, it will give
additional wear protection to the hole opener body.
1. Use welding rods equivalent to Servcotube 40/60
mesh in 3⁄16- or 5⁄32-in. diameters.
2. Set the welding machine for 150/200 amp at 30/40
volts for 5⁄32-in. rod, 200/260 amp at 30/40 volts for
3
⁄16-in. rod. AC or DC, either polarity may be used.
3. Preheat the area to be resurfaced to 300°F (149°C)
to 400°F (204°C).
Caution: Do not heat the carburized bore of the leg
above 425°F (218°C), under any conditions.
4. Apply the hardfacing as stringer or weaving beads in
two passes to a maximum thickness of 1⁄4 in. If weav-
ing beads are applied, the bead width shall not exceed
21⁄2 times the rod diameter.
Cutter Installation
• Wipe a light coat of grease on the main pin, leg bores and
cutter bearing sleeve bore (be sure O-rings are in place in
the sleeve bore).
• Position the cutter in the leg with the anti-rotation lug
flush on the flat on the outer portion of the leg.
• Push the main pin through the leg and bearing sleeve
bore and into the inner leg until the retaining pin holes
are aligned.
Caution: The square end of the gage main pin is the
inboard end and the beveled end will be flush or slightly
below the outboard face of the leg.
Hole Opening 179
• Using the notch in the end of the main pin, rotate the main
pin until the retainer pin holes are aligned with the holes in
the leg.
• Insert the retainer pins with the flat side out toward the set
screw hole and centered on the set screw hole. The screw-
driver slot in the end of the retainer pin is parallel with
the flat to help with alignment. Tighten the set screws
to 100 ft/lb torque maximum.
• Cutters from stock should already be fully greased. However,
the cutters may be regreased while on the body.
Corrosion Prevention
After thorough cleaning, coat the following surfaces with a
quality rust-preventative compound:
• Tool joint threads and shoulders.
• Inner faces of the legs or in the case of smaller bodies the
leg and body faces.
• Main pin bores of the leg.
• Cutter bearing sleeve ends and main bore.
180
GTA Hole Opener
Overall length
Fishing neck length

Bottom
neck length
Standard
opening
diameter
Bottom Fishing
neck neck
diameter diameter
Top pin connection
Bottom-box connection
Hole Opening
GTA Hole Opener Specifications
Hole Opening
Fishing Neck Bottom Neck Body
Standard Minimum Top Pin Bottom-Box Minimum
Opening Pilot Hole Connection Connection Bore
Diameter Diameter Length Diameter API Reg. Length Diameter API Reg. Length Diameter
26 14 60 191⁄2 65⁄8 - 75⁄8 12 91⁄2 75⁄8 96 1
28 16 60 197⁄8 65⁄8 - 75⁄8 12 91⁄2 75⁄8 96 1
30 18 60 197⁄8 65⁄8 - 75⁄8 12 91⁄2 75⁄8 100 2
32 20 60 10 75⁄8 - 85⁄8 15 91⁄2 85⁄8 100 2
34 22 60 10 75⁄8 - 85⁄8 15 91⁄2 85⁄8 101 2
36 24 60 10 75⁄8- 85⁄8 15 91⁄2 85⁄8 103 3
38 26 60 10 85⁄8 15 91⁄2 85⁄8 106 3
40 28 60 10 85⁄8 15 91⁄2 85⁄8 106 3
42 30 60 10 85⁄8 15 91⁄2 75⁄8 106 3
Notes: 3. Tungsten carbide insert cutters are available for GTA and STA
1. All dimensions are given in inches unless otherwise stated. hole openers.
2. All weights are approximate. Ordering Instructions:
3. Replacement cutter sets include all parts necessary for replacement. When ordering or requesting quotations on the GTA hole opener,
4. Cutter bearing rebuild kits are available on special order. please specify:
Ordering Instructions for Cutters: 1. Pilot hole size.
When ordering or requesting quotations on cutters, please specify: 2. Hole opening size.
1. Hole size. 3. Top and bottom connections, if other than standard.
2. Soft or medium formation. 4. Fishing neck diameter, if other than standard.
3. Milled tooth or tungsten carbide insert type cutter. 5. Specifications for intermediate sizes or sizes larger than 42 in. are
available upon request.
181
182 Hole Opening
Hole Enlargers
Model 6980 Hole Enlarger,

Standard Type, with Pin
Up/Box Down
Directional Model
Hole Enlarger
with One-Piece Body
Hole Opening 183
HOLE ENLARGER
Hole enlargers are available in 26 sizes to provide hole
enlargements from 6 through 36 in.
Body Types
• Standard model furnished box down for use with a rock
bit as the pilot, but also may be used with a bullnose.
Bullnoses specified either round or sidehill.
• Directional model has an integral bullnose or stinger down.
• Cluster model, with four to six cutters, is for holes larger
than 26 in., opening a 171⁄2-in. hole to 36 or 42 in. in a
single pass.
Features
• Rigid locking system improves safety and service life of
cutter by eliminating rotation of the sleeve, yet allowing
the cutter to rotate freely on ball and roller bearings.
• Jet circulation and efficient tool design provides low cost-
per-foot cutting. Jet nozzles, positioned between each of
the three cutters direct flow to shoulder of enlarged hole,
can be changed to accommodate pump capacities or
hydraulics programs.
• Rig floor cutter replacement is fast and easy, with no need
for cutting torches or welding.
• Cutter interchangeability allows a given cutter size to be
used in more than one body size.
• Long-term reliability provided by ease of part replacement
or repair of cutter arms and jet holders, ensuring long life
and full return on tool investment.
• Ability to match to formation provides the correct
cutting structure for the rock type, thus maximizing
tool performance.
184 Hole Opening
0625-2600 M6980 HOLE ENLARGER BODIES

FIELD REPAIR AND SERVICE PROCEDURES
Design and Construction Background
1. 0625-1250 — Machined bar stock bodies, 3-pocket jets
(recent mfg. 1250 has 3-wing jets).
2. 1550-2600 — Cast-steel bodies, 3-pocket jets and 3-wing
jets (2 types of wing-jet holder designs available).
3. 1550-2600 — Bar stock bodies, 3-pocket jets and 3-wing
jets (2 types of wing-jet holder designs).
4. Jets behind the pockets are mounted in a jet holder that is
welded into the body.
Standard wing jets are held by wash pipes that are
welded into position in a channel formed by a pair of
wing-jet guardrails. The water passage is completed by
cover plates between the body and the wash pipe. A plate
is also welded at the top of the wash pipe to the guardrails
as a mechanical protector — prevents wash pipe damage.
5. In the factory, the bodies are assembled using gages, fix-
tures, etc. For field repair, actual new cutter may be used
as a gage.
6. Cross lock pins (holds cutter pin to the arm).
a. Double spring pins — best suited for soft digging jobs
using soft milled tooth cutters or medium formation —
hard formation milled tooth cutters.
6. On 1550 and larger tools, a second type is in use:
b. Solid pins held in place by concentric (double)
short spring pins. Intended for button cutters or
hard digging jobs.
It is the intent of the design that arm pins and bushings
are the main expendable wear components in the service
life of the tool body. In soft digging, body will generally
come out with no body repair required so the arm-bushing
servicing is a long-range requirement. On the other hand,
in extremely hard digging, the arms as well as bushings
may require the same servicing as the cutters.
Hole Opening 185
Repairs
After each run or prior to the next run, inspect the tool.
Wash cutters and tool body. Mag inspect tool/joints.
Visually evaluate the following wear areas:
1. If cutter is in good shape and will be rerun (i.e. will not
be removed from the body) the body must meet the
following criteria:
a. Check arms shirttail area — negligible wear since
cutter must be to gage.
b. Check cutter pin to arm hole clearance. Should be less
than 1⁄64 in.
c. Check cross pin locks. If using double spring pins and
no sign of corrosion, and cutter pin end appears prop-
erly oriented, one can assume spring pins are ok. It is
prudent precaution to replace if time permits.
d. No signs of washout on body, jets/holders area.
e. Wings hardface still visible.
f. No lower necks, excessive wear or cracks on bit
strap’s welds.
g. Tool/joints passes mag inspection.
2. If cutter has some degree of wear and decision is not to
rerun, wash body and cutter and arrange to remove cut-
ters from body as soon as possible to prevent parts from
being rust frozen.
Evaluate repair work:
a. Arms — remove (torch or arc air) and replace if:
• Shirttail is abraded to where cutter pin end is now
even to the arm.
• The hole for the cutter pin is deformed/elongated,
oversized 1⁄ 32 in. or more.
• Body pocket has been abraded by the cutter or
eroded, because to build up the pocket, access is
required by removing arm.
• Any crack is observed between shirttail and arm base.
• Arm weld shows cracks.
• Bushings need to be replaced.
• Arms bent out of shape (excessive sleeve to arm
clearance more than 1⁄ 32 in.).
186 Hole Opening
Clean arm pad on the body. Grind off weld spatters,

high spots. Wire brush to clean weld area.
Using a new cutter assembly and pin as a fixture,
position arm on the body arm pad. Verify pin center-
line or cutter centerline is perpendicular (radial) to the
body centerline and inclined at 60° to the length of the
tool. Cutter teeth must clear body pocket minimum of
1
⁄ 8 in. Verify cutter gage height is correct. Shim the arm
if required to hold the pin hole parallel and concentric
to the bushing hole. If the pin can be rotated and push-
pulled freely, the arm hole is fairly aligned to the bush-
ing hole. Tack weld arm to body to prevent any
movement. After tacking, verify pin does not bind in
position. If it does, tap arm to free it.
Repeat on other two pockets. Verify ring gage diam-
eter (see hole opener gage tolerances Page 157). Then
full weld arms to the body in rotation. Welding in rota-
tion prevents excessive localized heat build up. Protect
jet nozzles and bushings from weld spatter. New arms
are supplied hardfaced.
b. Bushings — remove and replace if:
• Cam ear damaged (cracked, deformed).
• Hole for pin is worn oversized or elongated.
• Use a new pin to check. Maximum clearance 1⁄ 32 in.
• Evidence of cracks in weldment.
Arms must be removed first, then remove bushing
by arc airing out or torching the weld around it.
Minimize burning of base metal (tool body). Protect
adjacent machined components from damage due to
weld spatter. Grind off any protruding irregularities to
allow new bushing to seat properly. Grind off or chip
away weld spatters. Wire brush base metal clean.
Position new bushing. Using a new cutter assembly
as fixture, position new arm (previously removed old
arm) and cutter over the bushing. Slide cutter pin
through. Check gage radius. Shim bushing to achieve
proper gage radius (1⁄ 2 gage diameter). Tack weld in
position. Remove arm and cutter assembly. Repeat on
other two pockets. Full weld bushings to body. Protect
Hole Opening 187
new bushing working surfaces and jet’s bores from

weld spatters. Then proceed to attach arm as above.
c. Washpipes
If any indication of leaks past seals of jets, remove
snap rings, O-rings and jets. While the jet nozzles are
out of the washpipe, check ID of wash pipe for traces
of erosion, washout and plugging. If ok, replace
O-rings, jet nozzles and snap-rings. Grease O-rings
to facilitate assembly. Grease jet nozzle cavities in
the washpipe ends.
If indications of washout is present, note position of
washpipe. Remove protector plate, washpipe, and
cover plate by arc airing or torching. Repair washouts
on body and replace washpipe. New cover plates and
protector plates required. If washout is too extensive
evaluate for continued use.
d. Pocket jet holders
Erosion cutting across O-ring grooves and excessive
body cutter pocket wear could necessitate replacing the
holder. If required, torch/arc air fillet weld at end of
holder. Remove holder. Grind bore edge surfaces to
clean up weld spatters and irregularities. Position new
holder with bore protecting fixture T-5632 (1550-3600),
T-5696 (0625-1250). Weld to body (water-tight weld).
Remove fixture. Note: Preheat body area to be welded
and holder. Use stainless steel welding rod for pocket jets.
e. Wings
Measure height. Rehardface to correct height using
a brazed tungsten carbide hardfacing. Tinning may be
required if worn to base metal.
f. Cutter pockets
If abraded or excessively eroded, remove arms to
allow access for weld build up. Protect bushing and
jet holder bore from weld spatter if not to be replaced.
Jet holder may have to be replaced. Weld build up
pocket back to size using a new milled tooth cutter as
a guide. Nominal clearance between cutter teeth and
pocket wall is 1⁄ 8 in. After welding, grind weld to blend.
Replaces jet bushing (see Section 2). Weld new arms
as described above.
188 Hole Opening
g. Lower neck
Regular bodies (box joint) — due to the practice
of strapping pilot bits to the hole enlarger lower neck,
cracks are generated on the welds/edge of welds. This is
probably due to the use of welding rods not compatible
with the material of the body or welding procedure. If it is
absolutely necessary to weld straps, use a low hydrogen
electrode (8018-C3), to minimize damage to the body.
After removing the straps, grind off torched surface
to clean up. Mag inspect. If a few well-separated cracks
are observed, grind off crack till all traces of cracks are
eliminated. If too deep, arc air. Then weld repair allow-
ing for remachining or grinding to blend to adjacent
unworn surfaces.
If extensive cracks are found, convert to smaller neck
by turning down. This may or may not eliminate cracks.
h. Bullnose types
If required to replace integral bullnose, contact
Smith Engineering Department in Houston for infor-
mation as to where to cut the bullnose. This is critical!
Hole Opening 189
1. SM 2. H 3. Chisel Button
4. Conical Button 5. Ovoid/Ogive Button
1. Type ‘SM’ for soft to medium formations:

Non-sealed: IADC Code 121
Sealed: IADC Code 124
2. Type ‘H’ for medium-hard to hard formations:
Non-sealed: IADC Code 321
Sealed: IADC Code 324
3.Chisel button type for medium formations:
Sealed only: IADC Code 415
4. Conical button type for medium-hard to hard formations:
5. Ovoid/ogive button type for hard formations:
190 Hole Opening
3600 M6980 HOLE ENLARGER BODIES

FIELD REPAIR AND SERVICE PROCEDURE
Design Background
3600 Hole enlarger cluster-type bodies are made of 4142
alloy bar machined to receive washpipes and flanges. The
gussets and flanges are mild steel plates.
Typically, cluster-type hole enlarger bodies use 1750 cut-
ters in 4 to 6 clusters, with 4 jets directed to the shelf (a fifth
jet is a lift booster pointed upward on 3600).
Cutters are mounted on saddles which is composed of
upper arm (1750 arm), lower arm and bushing.
Cutters are radially positioned to a predetermined gage
diameter. Cutters on the same gage diameter are positioned
at the same height from the flange.
Cross lock pins hold cutters to saddles. Two types are
in use:
1. Solid retained by short concentric spring pins for button
cutters in hard formation jobs.
2. Concentric spring pins.
It is the intent of the design that the saddles are the
major replaceable components of the body.
Inspection/Repair
After each run and prior to a new run, inspect the overall
tool condition. If cutter will be rerun make sure:
1. All pins/lock pins are secure.
2. No indication of damage to the cutters or body (tool
joints, jets, body welds, necks).
3. Check pilot bit.
4. Wash cutters, air dry and lubricate bearings.
5. Check tool joints by magnetic inspection and
threads gaging.
If cutters need to be replaced, remove cutters promptly
so as to avoid being rust frozen. Wash body and inspect the
body for wear on the following areas:
Saddle evaluation (the cutter saddle is serviced as a unit).
1. Bushing — cam ear wear or damage. Weld crack.
Hole Opening 191
2. Saddle shirttail area — Pin hole fit to cutter pin tight or at

worse no more than 1⁄ 64-in. clearance. Cross lock pin
hole. No visual damage. No cracks between holes or
edges of holes. Shirttail hardfacing is not worn.
To replace saddles, preheat body to about 300 to 400°F
(149 to 204°C), then flame cut or arc air welds holding the
saddle to the flange. Be careful to minimize base metal
(flange) burning. Clean up saddle mounting area to receive
a new saddle.
Also, check condition of welds and materials on the
following areas:
1. Saddles to flange — no cracks.
2. Gussets.
3. Washpipes.
4. Worn wings.
If any welds are cracked, arc air or torch away weld
and reweld.
If washpipes are damaged at the jet nozzle cavities, bore
out jet cavity to install a jet nozzle holder. Preheat area to be
welded to 600 to 700°F (316 to 371°C), fit holder and weld
to be water tight.
If the washpipes are cracked or ends mashed or bent, it
must be removed and replaced. Preheat body 300 to 400°F
(149 to 204°C). Remove braces, gussets or wings holding
the washpipe. Cut washpipe weld to body. Clean up weld
areas removed. Inspect washpipe bore for erosion. Weld
repair cracks or washouts prior to reassembly.
Rebuild wing top to correct diameter (pilot hole) and the
hardfaced leading side.
192 Hole Opening
0625-1250 HOLE ENLARGER BODIES M-6980

(BAR STOCK) WELD ASSEMBLY PROCEDURE #276
The objective of this procedure is to provide a basic guide-
line to properly weld the various components to the body
so that:
1. Residual welding stresses are minimized.
2. Tempers of various parts are maintained.
3. Define a basic sequence.
Welding Rod
8013-C3 or MIG 86-C2 (structural welds).
3
⁄ 32-in. Ø 312/347 S.S. weld rods/tig wire (jet holders).
Haystellite alloy 60 cm3.
Procedure
1. Preheat pocket jet nozzle holder cavities and lower neck
jet holder cavity if circulation bullnose-type body to
600°F (316°C). Protect jet nozzle holder bores by
installing weld plug T-5696. Retain with weld bead.
Assemble and weld jet holders using stainless steel rod.
2. Allow body to cool.
3. Assemble bushing, master cutter (gage), arm and pin in
one pocket. Shim bushing to bring master cutter gage
surface to gage diameter. Shim and align arm. Check that
pin does not bind. Position bushing cam ear to straddle
body centerline. Tack weld back. Tap front down tight to
body boss and tack weld. Tack weld sides.
Tack weld arm four places (Note: Pin must rotate
freely after tack welding. Tap arm to realign if required).
Repeat on other two pockets.
4. Assemble pilot wings; shim wings to diameter if
required. Check diameter (neck diameter plus twice
wing height) and tack weld. If weld buildup type wings
are required, omit Step 4.
5. Ring gage. Adjust bushings and arms if required. Check
profile.
6. Remove master cutters (gages) and install welding fixtures.
Hole Opening 193
17. Proceed to preheat body to 700°F (371°C) and weld arms,

bushings and wings. Weld one pass on each working
around the body to avoid localized overheating.
18. Note: If directional-type body, flame cut and grind 30°
stinger. If circulation-type preheat jet holder cavity,
assemble and weld jet holder (refer to Steps 1 and 2).
19. Hardface wings (Proc. 245) and stinger if required.
If weld buildup-type wings are required, buildup
hardfacing to wing diameter 3⁄ 4 in. wide x 4 in. long (3)
places. Check diameter (refer to Step 4).
10. Stress relieve at 900°F (482°C) for 3 hours.
11. After body has cooled, remove fixture, plugs, etc. If fix-
tures bind between arm and bushings, heat underside of
arm with torch.
12. Air leak test welds around jet holders.
13. Verify ring gage diameter using master cutters.
14. Check pocket with master cutter. Master cutter to turn
freely. Grind bottom side of arm if required. Pin should
not bind. Grind arm hole if required for hand slip fit of
pin (not loose).
15. Spray ID of jet holders with heat and corrosion resistant
paint (optional).
Note: District locations may use cutters if master gage
cutters are not available.
194 Hole Opening
1550-2600 HOLE ENLARGER BODIES M-6980

(CASTING OR FORGED) WELD ASSEMBLY PROCEDURE
The objective of this procedure is to provide a basic guide-
line to properly weld the various components to the body
so that:
1. Residual welding stresses are minimized.
2. Tempers of various parts are maintained.
3. Define a basic sequence.
Welding Rod
8013-C3 or MIG 85-C2 (structural welds).
3
⁄32-in. Ø 312/347 S.S. weld rods/tig wire (jet nozzle holders).
Haystellite alloy 60 cm3.
Procedure
1. Preheat pocket jet nozzle holder cavities to 600°F
(316°C). Protect jet nozzle holder bores by installing
weld plug T-5632. Retain with weld bead.
Assemble and weld jet holders using stainless steel rod.
2. Allow body to cool.
3. Assemble bushing, master cutter (gage), arm and pin in
one pocket. Shim bushing to bring master cutter gage sur-
face to gage diameter. Shim and align arm. Check that pin
does not bind. Position bushing cam ear to straddle body
centerline. Tack weld back. Tap front down tight to body
boss and tack weld. Tack weld sides.
Tack weld arm four places (Note: Pin must rotate
freely after tack welding. Tap arm to realign if required).
Repeat on other two pockets.
4. Assemble washpipe and tack weld. Install weld plug
T-5632. Refer to Step 1.
5. Ring gage. Adjust bushings and arms if required. Check
profile.
6. Remove master cutters (gages) and install welding fixture.
7. Proceed to preheat body to 700°F (371°C) and weld
arms, washpipes, cover plates, jet nozzle protectors
and bushings. Weld one pass on each working around
the body to avoid localized overheating.
Hole Opening 195
18. Hardface wings, washpipes, protector plates and

leading guardrails.
10. After body has cooled, remove fixtures, plugs, etc. If fix-
tures bind between arm and bushings, heat underside
of arm with torch.
11. Air leak test welds around washpipes and jet nozzle
holders.
12. Verify ring gage diameter using master cutters.
13. Check pocket with master cutters. Master cutters to turn
freely. Grind bottom side of arm if required. Pin should
not bind. Grind arm hole if required for hand slip fit of
pin (not loose).
14. Spray ID of jet nozzle holders with heat and corrosion
resistant paint (optional).
Note: Use new cutters if gages are not available.
196 Hole Opening
3600 (CLUSTER TYPE - 3 GAGE POINT) M6980

HOLE ENLARGER BODY WELD ASSEMBLY PROCEDURE
The body is welded in two stages:
• Flange, gussets, washpipes, wings/air leak test.
• Cutter saddles, flange cut out.
II. Body assembly (8018-C3 welding rod/3/16 20/30 60 cm3
#700008 hardfacing rod).
Set body on a rack, horizontal.
1. Assemble flange to body. Preheat flange to 300°F
(149°C) and shrink fit if necessary. Tack weld. Layout
gusset positions, wings, cutter saddles and flange cut
out. Start preheating. Protect bore of booster jet with a
plug (T-5632).
2. Position washpipes per Figures 3 and 4. Shim bottom
to provide for weld strain relief. Tack weld. Bring body
to preheat temperature of 700°F (371°C). Full weld
washpipes to body, water tight welds. Cool to ambient
(clean bore of washpipes for sealing off).
3. Blank off washpipes using blank jets, O-rings and
retaining rings. Install body bore plug/cap — adapter
and air leak test. No allowable leak. Use soap to detect
air bubbles around washpipe welds.
4. Protect washpipe bores with plug T-5632 held with a
weld bead. Start preheat. Position wings, gussets and
braces by tack welding. Position also counter weights
on gussets.
5. Bring body to preheat temperature of 700°F (371°C).
6. Weld per drawing. Weld around body to avoid local
overheating. Hardface wings.
8. Furnace cool to 300°F (149°C), then air cool to ambient.
9. If body is to be stored at this stage, remove plugs
T-5632 (except on booster jet).
Hole Opening 197
II. Cutter saddle assembly (8018-C3 welding rod).

1. Set body on end, flange facing up. Verify saddle locations.
2. Position inner most cutter saddle (25 in.) using a gage
cutter and pin (T-3155 and T-3327-1). Measure diame-
ter position “D” of gage surface by measuring off
lower neck diameter. Make sure cutter centerline is
radial to body and saddle is at 90° to flange. Mark
location. Tack weld. Verify location. Replace gage
cutters with welding fixture T-3327. Tighten screw
against pin T-3327-1.
Repeat above procedure on next saddle (283⁄ 4, 29
and 36 in.).
On 36-in. saddles leave gage cutters on for ring gag-
ing. Check also cutter height from flange, which
should be within 1⁄ 16 in. of each other. Shim if required.
The tack welded gage cutter saddles should ring gage
to 36 in . + 3⁄ 16 in. —0. If okay, remove gage cutters.
Install welding sleeves.
3. Preheat saddles and body flange to 600°F (316°C).
Weld saddles to flange per welding drawing.
4. Flame cut flange circulation cut outs.
5. Stress relieve assembly at 750°F (399°C) for 3 hours.
Air cool to ambient, then remove fixtures.
198 Hole Opening
CHANGING CUTTER ASSEMBLIES

Removal of Old Assembly
11. Wash hole enlarger thoroughly when removing from
the hole.
12. Unlock the eccentric-cam locking segment by turning
slightly in the direction of the drillstring rotation, using
the driving bar and hammer (See A).
13. Drive out the lock pin using drift pin and a hammer
(See B).
14. Screw puller assembly into cutter pin (See C). Force
cutter pin out with several sharp thrusts of the sliding
knocker (See D).
15. Slide and/or pry out the used cutter.
16. Inspect circulation jet, bushing, snap ring and O-ring. If
necessary, replace these parts.
17. Clean body surfaces adjacent to cutter and cutter pin hole.
Installing New Assembly

18. Set the new cutter assembly in the pocket with the flat in
the locking segment toward the bottom end of the body.
19. Adjust the locking segment until the pin holes in the
cutter and arm are in alignment.
10. Screw pin assembly wrench into cutter pin and insert
to bottom of pocket, rotating slowly until lock pin slot
in the cutter pin lines up with the lock pin hole in the
cutter arm.
11. Drive in outer lock pin with hammer. Then the inner
lock is driven inside the outer lock pin.
12. Unscrew and remove pin assembly wrench.
13. The eccentric cam locking segment will now be in the
“relaxed” position. The cam will automatically lock
itself with cutter rotation.
Hole Opening 199
Arm Replacement
The Model 6980 hole enlarger is machined from a high-
quality alloy steel and heat treated to metallurgical stan-
dards. Occasionally cutter arms may have to be replaced.
New cutter arms, reusable welding fixtures and complete
instructions are available for this type of repair. Contact your
local Smith representative.
A. Eccentric cam is loosened by driving segment in direction of drillstring

rotation.
200 Hole Opening
B. Locking pin is driven out through the side of the cutter arm.
Hole Opening 201
C. Pin puller assembly is screwed into cutter pin and tightened.

202 Hole Opening
D. Cutter pin is removed by jarring upward with several sharp thrusts of

knocker.
Hole Enlarger Specifications
Hole Opening
Minimum Body Cutter
Pilot Hole Assembly Assembly
Size Upper Upper Lower Lower Number Weight Weight
Size Enlarging Range Diameter Neck Neck Pilot Pilot of w/Cutters Per Set
Number From To Required Diameter(s) Length Diameter(s) Length Cutters (lb) (lb)
0625 67⁄8 61⁄4 47⁄8 43⁄4 36 31⁄4 15 3 200 - 230 8
1 3 1 3
0675 6 ⁄2 6 ⁄4 4 ⁄2 4 ⁄4 36 31⁄4 15 5 220 - 250 10
†0787 61⁄2 77⁄8 57⁄8 53⁄4 36 41⁄2 15 3 270 - 300 14
0862 83⁄8 85⁄8 51⁄8 53⁄4 36 41⁄4 15 3 280 - 310 16
0900 83⁄4 97⁄8 51⁄2 53⁄4 36 41⁄4 15 3 285 - 315 16
0950 91⁄4 91⁄2 67⁄8 53⁄4 - 173⁄4 36 41⁄4 15 3 295 - 325 23
0987 95⁄8 97⁄8 61⁄2 53⁄4 - 173⁄4 36 41⁄4 15 3 310 - 440 35
†1062 101⁄2 105⁄8 71⁄4 73⁄4 - 181⁄4 36 51⁄2 15 3 400 - 490 35
†1100 107⁄8 117⁄8 75⁄8 73⁄4 - 181⁄4 36 51⁄2 15 3 405 - 600 35
1250 107⁄8 121⁄4 73⁄4 73⁄4 - 181⁄4 36 51⁄2 15 3 490 - 690 55
†1375 107⁄8 131⁄2 97⁄8 73⁄4 - 181⁄4 36 51⁄2 15 3 670 - 830 55
†1400 107⁄8 133⁄4 91⁄4 73⁄4 - 181⁄4 36 73⁄4 15 3 680 - 840 55
1550 143⁄4 151⁄2 91⁄4 73⁄4 - 107⁄8 36 73⁄4 - 10 15 3 835 - 995 100
Continued on Page 204.
203
204
Hole Enlarger Specifications (continued)
Minimum Body Cutter
Pilot Hole Assembly Assembly
Size Upper Upper Lower Lower Number Weight Weight
Size Enlarging Range Diameter Neck Neck Pilot Pilot of w/Cutters Per Set
Number From To Required Diameter(s) Length Diameter(s) Length Cutters (lb) (lb)
†1650 153⁄4 161⁄2 101⁄4 73⁄4 - 19 36 73⁄4 - 19 15 3 915 - 1,075 100
3 1 1 3
1750 15 ⁄4 17 ⁄2 10 ⁄4 7 ⁄4 - 10 36 73⁄4 - 10 15 3 995 - 1,155 155
†1850 153⁄4 181⁄2 111⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,075 - 1,235 155
†2000 153⁄4 207⁄8 123⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,245 - 1,405 155
†2100 153⁄4 217⁄8 133⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,260 - 1,420 155
2200 153⁄4 227⁄8 113⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,445 - 1,605 235
†2300 153⁄4 237⁄8 123⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,645 - 1,805 235
2400 153⁄4 247⁄8 133⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,845 - 2,005 235
2500 153⁄4 257⁄8 143⁄4 73⁄4 - 10 36 73⁄4 - 10 15 3 1,895 - 2,055 235
2600 153⁄4 267⁄8 157⁄8 73⁄4 - 10 36 73⁄4 - 10 15 3 1,945 - 2,105 425
†*3000 153⁄4 307⁄8 171⁄2 97⁄8 - 10 36 97⁄8 - 10 15 4 2,095 - 2,255 205
*3600 153⁄4 367⁄8 171⁄2 97⁄8 - 10 36 97⁄8 - 10 15 6 2,405 - 2,565 310
Hole Opening
*Over 2600 — cluster arm-type construction. 1. Body type: “standard” or “directional” type; if “directional” type,
† Available on special order only. specify “round” or “side-hill” bullnose, or “extra-long stinger.”
Notes: Also specify whether it is to be solid or if circulation through
1. All dimensions are given in inches unless otherwise stated. bullnose or stinger is required.
2. All weights are approximate. 2. Body size number, pilot hole size and enlarged hole size.
Ordering Instructions: 3. Upper and lower neck diameters and connection sizes.
When ordering or requesting quotations please specify: 4. If tool is to be dressed and cutter type desired.
6
SECTION 6
WELL
SECTION SIX ABANDONMENT
WELL ABANDONMENT
Well Abandonment 207
WELL ABANDONMENT
Well abandonment is a specialized art. It requires experi-
enced personnel who can handle any kind of equipment,
on any kind of rig, in any type of situation. And it takes the
right type of equipment. Smith well-abandonment profes-
sionals are available worldwide to perform these critical
services with the excellent tools we describe below.
Pipe Cutters
Pipe cutters feature tungsten-carbide-dressed cutting
arms. The arms are expanded into cutting position
actuated by pump pressure.
The P-cutter can be equipped with a Flo-Tel device, which
signals the operator that a string has been cut through by a
sudden drop in pump pressure. This prevents coming out of
the hole prematurely or skinning the casing.
Pipe cutters are available in three popular sizes with
various arm lengths enabling the operator to cut from 6- to
58-in. diameters. P-cutters can be used to cut concentric or
eccentrically hung strings of casing, cemented or not, both
quickly and safely. Unlike explosive parting, the P-cutter
assures a clean cut.
208 Well Abandonment
Pipe Cutting Operating Parameters

• For best results, run arms long enough to cut only one
string of pipe each trip (see Page 220).
• At the point of cut-out, begin rotation at 50 RPM. Typically
the rotary will be 50 to 80 RPM when cutting knives
encounter casing, there will be a noticeable increase in
torque. The difference from free rotating torque will depend
upon casing condition, cement integrity, depth and other
well conditions. After rotary is established, torque will
become more erratic until severed. Once cut through,
torque and rotary will smooth out.
• A weight gain is noticed on all cuts following the first
string. Slack off slightly to relieve the hydraulic draw-
down of the tool. The result will be faster cutting.
• Because of the eccentricity of the multiple casing strings,
circulation can be lost after the cut is partially made. This
is normal, however, cuttings are still being removed and
the cutter arms are being lubricated.
• At times the P-cutter Flo-Tel action does not show a good
pump pressure drop at the surface because of the shallow
depth. However, pump strokes will increase, indicating
full cut-out.
• Milling upward with a P-cutter can result in backing off
a short length of the casing above the cutter arms. In the
event this happens and cement in the annulus prevents
pulling the upper section of the pipe, move the tool up
and re-cut above the point of back-off.
• The most severe torque and noise occurs just prior to the
final parting of the string.
Recommended Flow Rates and Rotary Speeds

Begin Cutout While Cutting
Series No. gpm rpm gpm rpm
5700-V 125-175 50 250-300 100-120
8200-2 125-175 50 250-325 80-100
11700-V 250-450 50 400-600 60-80
Jackups and Submersibles

P-cutters are relatively simple to operate on these rigs. The
rig is stationary, therefore all vertical changes in depths can
be made by the length of kelly used below the rotary bush-
ing. When the cutter reaches the predetermined cutting
depth, the rotary is started and brought to the correct RPM
to cut that size of casing. The rotary torque should be
recorded. Start the pump slowly and bring pressure up to
recommended level for the size of cutter used. The rotary
torque will increase when pump pressure is applied, and
the RPM will usually slow down. Increase rotary to bring
the RPM back up to the desired speed. When the torque has
more than doubled, this is an indication that the cutter has
parted the casing.
A typical string would consist of the pipe cutting assem-
bly on bottom, crossover sub and drill pipe. When cutting
133⁄ 8-in. and larger casing, a top sub with stabilizer blades
should be used.
Semi-Submersibles and Drill Ships

To compensate for the vertical movement of floaters, it is nec-
essary to run the marine support swivel above the pipe cutter
assembly as illustrated on Page 211. In order to have the cut-
ter at the correct depth, the distance between the landing
ring and cutter should be adjusted. It is also necessary to
run a long-stroke bumper sub above the marine support
swivel. This will allow the cutter to remain at a constant
depth while the rig moves up and down. A bumper sub with a
6-ft stroke will compensate for the rig movement. It is not nec-
essary to use the bumper sub on those rigs equipped with a
motion compensator. Set the motion compensator to allow
for 5,000 to 8,000 lb of weight resting on the landing ring.
Pipe Cutter Assembly for Floaters

The following illustration shows our recommended assembly.
Smith’s well-abandonment systems consist of the marine sup-
port swivel, the stabilizer top sub and the pipe cutter. The
pipe cutter assembly is located below the marine support
swivel in the wellhead. The marine support swivel permits
the operator to vertically position the pipe cutter assembly
and maintain that position during operation. The stabilizer
top sub is used to center the pipe cutter in the casing.
Pipe Cutter Assembly for Floaters
Casing Marine swivel

head
Spacer sub
30-in.
casing
Drill collar or
20-in. drill pipe
casing
133⁄ 8-in.
casing
Stabilizer or
conventional
top sub
Pipe cutter
95⁄ 8-in.
casing
Calculating Spacer Sub Lengths for P-Cutters

When cutting multiple strings of casing and using a marine
support swivel as a landing device, it is necessary to use
shorter spacer subs as the length of the arm increases. This
allows the new arm to enter the window in casing already cut.
The formula shown below determines the length of sub
required for the next run using a longer set of arms.
LR = LU – (dr – du + 1)
Where:
LR = Required sub length for next run
LU = Length of sub used on last run
dr = Arm length from center of pin hole to cutter tip
required for next run
du = Arm length from center of pin hole to cutter tip
used on last run
Examples of Spacer Sub Length Sizing

Given:
LU = 33 in.
Arm opening sizes required are 12, 16 and 24 in. The
required sub lengths are 33 in. (12-in. opening), 30 in.
(16-in. opening) and 24 in. (24-in. opening).
Spacer Sub Length Sizing

Arm Opening Arm Length
Size (in.) (d) dr – du + 1 LU LR
12 41⁄ 4 — 33 —
16 61⁄ 2 31⁄ 4 33 30
24 111⁄ 4 53⁄ 4 30 24
Note: Tolerances of ± 1⁄ 4 in. on sub length are acceptable.
Spacer Sub Arrangement
Drillstring
Spacer LR
LU
sub
dU
dR
Pipe
cutter
Short arms
1st cut
Long arms
2nd cut
Selecting P-Cutter Lengths and Diameters

The table below will determine arm length for cutting
eccentric pipe. It is recommended to add 1 to 3 in. of arm
length allowing for extreme eccentric condition.
Eccentric Diameters
(dimensions shown in inches)
Casing Combinations Eccentric Casing Combinations Eccentric
Size A Size B Size C Dia. Size A Size B Size C Dia.
195⁄ 8 133⁄ 8 20 27.881 133⁄ 8 26 30 49.873
195⁄ 8 133⁄ 8 24 34.839 133⁄ 8 26 36 55.873
5 3
19 ⁄ 8 16 ⁄ 8 20 27.916 163⁄ 8 20 26 32.290
195⁄ 8 163⁄ 8 24 34.874 163⁄ 8 20 30 40.290
195⁄ 8 163⁄ 8 26 38.874 163⁄ 8 20 36 52.290
3 3
10 ⁄ 4 16 ⁄ 8 20 26.791 163⁄ 8 24 30 41.248
103⁄ 4 163⁄ 8 24 33.749 163⁄ 8 24 36 53.248
103⁄ 4 163⁄ 8 26 37.749 163⁄ 8 26 30 41.248
3 3
13 ⁄ 8 20 ⁄ 8 26 34.915 163⁄ 8 26 36 53.248
133⁄ 8 203⁄ 8 30 42.915 203⁄ 8 24 30 37.248
3 3
13 ⁄ 8 20 ⁄ 8 36 54.915 203⁄ 8 24 36 49.248
133⁄ 8 243⁄ 8 30 43.873 203⁄ 8 26 30 37.248
3 3
13 ⁄ 8 24 ⁄ 8 36 55.873 203⁄ 8 26 36 49.248
Example of Arm Size Selection

Casing A: 95⁄ 8 in., Casing B: 133⁄ 8 in., Casing C: 20 in.
Eccentric diameter: 28 in.
Cutter arm opening diameter: 29 to 31 in.
For combination of casings not listed in the preceding
table, the eccentric diameter can be calculated by the fol-
lowing formula:
DECC = DBID + DCID + DCCOUP. – DACOUP. – DBCOUP.
Eccentric Diameters
Casing C
Casing B
Casing A
Tool and
casing A
CL
DACOUP. =
Coupling diameter
of A
DBID =
ID of casing B
DBCOUP. =
Coupling diameter
of B
DCID =
ID of casing C
DCCOUP. =
Coupling diameter
of C
DECC = Eccentric diameter

Pipe Cutter Components
Stabilizer
(optional)
Body
Piston
spring
Piston packing
Piston Hinge pin
Cutter arm
Pipe Cutter Disassembly

1. Remove hinge pin retainer screws.
2. Remove hinge pins.
3. Remove cutter arms.
4. Remove Flo-Tel snap ring, if applicable.
5. Remove Flo-Tel, if applicable.
6. Remove piston. Remove and inspect piston packing.
7. Remove piston spring and piston stop ring.
Servicing
The tool should be disassembled and thoroughly cleaned
after the completion of each job. Steam cleaning is preferred;
however, when facilities are not available, cleaning solvents
may be used. The piston packing should be inspected after
cleaning and replaced if any wear is visible. It is essential
for proper performance that the V-type lips face the top of
the tool.
Note: Before the tool is reassembled, all parts should be
thoroughly lubricated. Any type of light grease is suitable.
Assembly
1. Replace piston spring and stop ring.
2. Replace piston.
3. Replace Flo-Tel, if applicable.
4. Replace Flo-Tel snap ring, if applicable.
5. Replace cutter arms, hinge pins and hinge
pin retaining screws.
218
Pipe Cutter
Body (Shown with optional stabilizer) Fishing neck

diameter diameter
Maximum
cutting
diameter
Top pin
connection
Fishing
neck length
Well Abandonment
Ordering Instructions: 3. Fishing neck diameter.
When ordering or requesting quotations on pipe 4. Size(s) and weight(s) of casing to be cut.
cutters, please specify: 5. Type of rig (drillship, semi, jackup, etc.).
1. Tool series. 6. If known, specify whether casing is concentric
2. Standard or stabilizer top sub. or eccentric and whether it is cemented.
Specifications
Well Abandonment
Cutting Dia. Stabilizer Top Sub Standard Top Sub*
Top Pin Fishing Fishing Fishing
Tool Body Conn. Min. Max. Neck Neck Overall Weight Neck Overall Weight
Series Dia. API Reg. ID OD Dia. Length Length (lb) Length Length (lb)
5700-V 153⁄ 4 31⁄ 2 161⁄ 2 25 43⁄ 4 18 70 350 Removable stabilizers for 75⁄ 8-in.
casing are included with pipe cutter
8200-2 181⁄ 4 65⁄ 8 181⁄ 2 48 8 18 89 925 18 115 1,400
11700-V 113⁄ 4 6 ⁄ 8, 75⁄ 8
5
121⁄ 2 58 8–9 20 107 1,885 32 134 2,400
*Recommended when using 133⁄ 8-in. casing and larger.
Notes:
3. Includes tool and top sub.
219
Recommended Stabilizer Blade Diameters

Casing Stabilizer
Size Blade Diameter
133⁄ 8 123⁄ 8
163⁄ 8 143⁄ 4
203⁄ 8 181⁄ 2
263⁄ 8 233⁄ 8
303⁄ 8 273⁄ 8
363⁄ 8 333⁄ 8
Pipe Cutter Arms Specifications

Tool Body Blade Maximum Exp.
Series Diameter Length Diameter
131⁄ 2 101⁄ 2
161⁄ 4 143⁄ 4
5700-V
153⁄ 4 101⁄ 4 213⁄ 4
121⁄ 4 251⁄ 4
131⁄ 2 121⁄ 4
171⁄ 4 191⁄ 4
8200-2 181⁄ 4 101⁄ 2 261⁄ 4
161⁄ 2 381⁄ 4
221⁄ 4 491⁄ 2
161⁄ 4 171⁄ 2
101⁄ 4 241⁄ 2
161⁄ 4 351⁄ 4
11700-V 113⁄ 4 201⁄ 4 413⁄ 4
221⁄ 4 451⁄ 4
261⁄ 4 521⁄ 4
301⁄ 4 591⁄ 4
Note:
All dimensions are given in inches unless otherwise stated.
MARINE SUPPORT SWIVEL

The marine support swivel design allows free and full
rotation of tools while preventing vertical movement and
allows for full circulation downhole. The bearing design
will withstand the most severe thrust and radial loads
encountered during cutting operation.
Marine Support Swivel Disassembly

1. Remove socket head cap screws and seating plate.
2. Remove all socket head cap screws and bottom
retaining plate.
3. Check the O-ring and the packings in the bottom
retainer plate.
4. Remove all socket head cap screws and two socket
set screws from the top retaining plate.
5. Check the O-ring and the packings in the top
retainer plate.
6. Slide the bearing housing off the top of mandrel.
7. Remove thrust bearing.
8. Remove both radial bearing and bearing spacer.
Servicing
The tool should be thoroughly cleaned after the completion of
each job. Steam cleaning is the preferred method. However,
where these facilities are not available, cleaning solvent can
be used. All packings and O-rings should be inspected after
cleaning and replaced if any wear is visible.
After these parts have been cleaned with solvent, they
must be lubricated with anti-galling compound. All bear-
ings must be packed with grease. All rotary shouldered
connections must be lubricated with a thread compound.
Assembly
11. Slide radial bearing, bearing spacer and second radial
bearing from the top end of mandrel into position.
12. Slide thrust bearing from the bottom end of mandrel.
13. Slide bearing housing over the mandrel.
14. Install all packings and O-rings.
15. Replace the top retaining plate packings, making sure
the V-type lips of the packing face up. Replace O-ring.
16. Slide top retaining plate into place, secure with cap screws.
17. Replace two thread protector set screws.
18. Install seating plate and secure in place with screws.
19. Fill bearing housing with S.A.E. 90-weight oil or
equivalent. Install grease fitting and relief valve.
10. Check for leakage after plugs are installed, and
smooth turning of the bearing housing assembly
over the mandrel.
Marine Support Swivel
Well Abandonment
ID
Bore
Fishing neck length diameter
Bearing
housing
diameter
OD Bottom
Bottom pin
neck connection Seating Fishing
diameter plate neck
diameter diameter
Specifications
Bearing Std. Seating Fishing Fishing Bottom Top and
Tool House Plate Neck Neck Neck Bottom Conn. Overall Weight
Series Diameter Diameter Diameter Length Diameter API Reg. Length Bore (lb)
6200-2 121⁄ 4 135⁄ 8 or 143⁄ 8 61⁄ 4 36 61⁄ 4 41⁄ 2 IF 78 213⁄ 16 850
7700-2 1315⁄ 16 143⁄ 8, 24, 30 73⁄ 4 or 8 36 73⁄ 4 65⁄ 8 Reg. 82 213⁄ 16 1,300
1. All dimensions are given in inches unless otherwise stated. When ordering or requesting quotations on the marine support swivel, please
2. All weights are approximate. specify the seating plate diameter, or make and model of subsea casing head.
223
THE DUAL-PLUG AND ABANDONMENT SYSTEM —

ONLY SMITH HAS IT
Mechanical Cutting vs. Explosive Severing
Thousands of plug and abandonment jobs have shown us
that they can both be the best way. If you are trying to decide
which method is best suited to your particular plug and
abandonment requirements, it makes good sense to talk to
the one company that can offer you either or both services
anywhere in the world. We have been saving operators time
and money on offshore plug and abandonment jobs for
more than 25 years, so we feel qualified to recommend the
combination that is right for your well.
One Trip Cut and Recovery

Features:
• Reduces rig operation time because spear and casing
cutter are run in the same trip.
• Bumper ring rests on casing hanger so that spear grapple
and outer housing remain stationary in the casing hanger
during rotation of the cutting string, thus reducing the
possibility of damage.
• Unique grapple design eliminates grapple damage
to wellhead.
• Rugged three-blade cutter design cuts fast.
• Cutter arms expand up to five times the tool diameter and
achieve maximum stability under adverse cutting condi-
tions such as hard spots, eccentricity and interrupted cuts.
• Arms retracted by stopping circulation and picking up
drillstring.
• Optional patented Tension Cut and Recovery System
cuts faster because casing is held in tension rather
than compression.
Dual-Plug and Abandonment System

Wellhead Severing System

DYNA-CUTT DEEPWATER WELLHEAD SEVERING SYSTEM

Features:
• Patented Deepwater Wellhead Severing System operable
in water depths beyond 10,000 ft.
• One-trip sever and retrieve operation.
• Severs multiple strings of casing.
• Used in pipe sizes 7 in. or larger.
• Reduces rig-up and running time because electrical cable
is eliminated.
• Electrical power to fire charge removed from charge
except when detonation is desired.
• Electrical power conveyed to charge by dropping unit
through drill pipe or by running unit on slickline or
sandline.
• Removable power source permits safe recovery of
downhole charge should a malfunction occur.
• Backup method of downhole disconnection provides
additional protection should retrieval of power source
be necessary.
• Shallow water system using cable-fired detonation is
also available.
The Dyna-Cut wellhead severing system charge is stored in
separate containers as a flammable liquid (nitromethane) and
as a corrosive acid (diethylenetriamine). Both are biodegrad-
able and are not explosive until combined in the proper per-
centages by a Smith technician. The Exploding Bridge Wire
(EBW) detonators contain no primary explosives and can
only be actuated by the power unit. Since the detonators can-
not be actuated by extraneous sources such as radio sig-
nals, the rig can maintain full communication throughout
the operation. The unarmed charge is run into the hole on
drill pipe and armed only after it is safely positioned below
the wellhead.
Notes
7
SECTION 7
CONVERSION
SECTION SEVEN TABLES
CONVERSION TABLES
Conversion Tables 231
FIELD INSPECTION PROCEDURES FOR

MAGNETIC PARTICLE AND DRY PENETRANT
For All Hydraulic Tools
A. Visually inspect entire tool to determine obvious
damage and overall condition.
B. Measure ODs, IDs and overall length of tool.
Identify connections and verify tool type. Ensure
that identification stampings are visible and legible.
C. Thoroughly clean box and pin threads. Follow immedi-
ately with wet fluorescent magnetic particle inspection
for detection of cracks.
D. Use profile gage to inspect thread form and to check for
stretched pins.
E. Inspect for box swell.
F. Inspect box and pin shoulders for damage.
G. Magnaflux fishing necks or any area where strap welding
has taken place, grind out minor cracks, re-inspect.
H. Magnaflux all arm pocket areas, including highly
stressed areas such as hinge and stop pin holes (inside
pocket and on OD) and retaining screw areas for same.
Inspect cone pockets, grind out minor cracks, re-inspect.
I. Magnaflux radii at intersection of fishing necks and body
upset. Visually inspect body upsets and magnaflux if any
cracks are obvious. Grind out and re-inspect.
J. Visually inspect for fluid wash and cracking around all
nozzle jet housing areas. Magnaflux for cracks. Grind
out minor cracks and re-inspect.
K. Stencil rejected connections to ensure minimum cutoff
at machine shop.
L. Once disassembled, dry penetrant arm assemblies
(arm/cone weldment), hinge pin areas and stop slots.
M. Dry penetrant cam threads and cam lobes for damage
and cracking.
N. Dry penetrant piston for cracking and/or erosion. If
threaded type, check for deformed threads and crack-
ing. If nozzle type, check nozzle for cracking and/or
washing at end.
232 Conversion Tables
API Casing Data

Casing Specifications
Weight with
Casing Coupling Coupling Casing Drift Bit
OD OD (lb/ft) ID ID Size
9.50 4.090 3.965 37⁄ 8
41⁄ 2 5.000 11.60 4.000 3.875 37⁄ 8
13.50 3.920 3.795 33⁄ 4
11.50 4.560 4.435 41⁄ 4
13.00 4.494 4.369 41⁄ 4
5 5.563
15.00 4.408 4.283 41⁄ 4
18.00 4.276 4.151 41⁄ 8
13.00 5.044 4.919 43⁄ 4
14.00 5.012 4.887 43⁄ 4
15.50 4.950 4.825 43⁄ 4
51⁄ 2 6.050
17.00 4.892 4.767 43⁄ 4
20.00 4.778 4.653 45⁄ 8
23.00 4.670 4.545 41⁄ 2
15.00 5.524 5.399 43⁄ 4
18.00 5.424 5.299 43⁄ 4
6 6.625
20.00 5.352 5.227 43⁄ 4
23.00 5.240 5.115 43⁄ 4
17.00 6.135 6.010 6
20.00 6.049 5.924 57⁄ 8
65⁄ 8 7.390 24.00 5.921 5.796 55⁄ 8
28.00 5.791 5.666 55⁄ 8
32.00 5.675 5.550 55⁄ 8
17.00 6.538 6.413 61⁄ 4
20.00 6.456 6.331 61⁄ 4
23.00 6.366 6.241 61⁄ 4
26.00 6.276 6.151 61⁄ 8
7 7.656
29.00 6.184 6.059 6
32.00 6.094 5.969 6
35.00 6.004 5.879 57⁄ 8
38.00 5.920 5.795 53⁄ 4
20.00 7.125 7.000 63⁄ 4
24.00 7.025 6.900 63⁄ 4
26.40 6.969 6.844 63⁄ 4
75⁄ 8 8.500
29.70 6.875 6.750 63⁄ 4
33.70 6.765 6.640 65⁄ 8
39.00 6.625 6.500 61⁄ 4
API Casing Data (continued)

Casing Specifications
Weight with
Casing Coupling Coupling Casing Drift Bit
OD OD (lb/ft) ID ID Size
24.00 8.097 7.972 77⁄ 8
28.00 8.017 7.892 77⁄ 8
32.00 7.921 7.796 75⁄ 8
85⁄ 8 9.625 36.00 7.825 7.700 75⁄ 8
40.00 7.725 7.600 75⁄ 8
44.00 7.625 7.500 73⁄ 8
49.00 7.511 7.386 73⁄ 8
29.30 9.063 8.907 83⁄ 4
32.30 9.001 8.845 83⁄ 4
36.00 8.921 8.765 83⁄ 4
95⁄ 8 10.625 40.00 8.835 8.679 85⁄ 8
43.50 8.755 8.599 85⁄ 8
47.00 8.681 8.525 81⁄ 2
53.50 8.535 8.379 83⁄ 8
32.75 10.192 10.036 97⁄ 8
40.50 10.050 9.894 97⁄ 8
45.50 9.950 9.794 93⁄ 4
103⁄ 4 11.750 51.00 9.850 9.694 95⁄ 8
55.50 9.760 9.604 95⁄ 8
60.70 9.660 9.504 91⁄ 2
65.70 9.560 9.404 91⁄ 2
38.00 11.150 10.994 113⁄ 8
42.00 11.084 10.928 103⁄ 4
113⁄ 4 12.750 47.00 11.000 10.844 103⁄ 4
54.00 10.880 10.724 105⁄ 8
60.00 10.772 10.616 105⁄ 8
48.00 12.715 12.559 121⁄ 4
54.50 12.615 12.459 121⁄ 4
133⁄ 8 14.375 61.00 12.515 12.359 121⁄ 4
68.00 12.415 12.259 121⁄ 4
72.00 12.347 12.191 123⁄ 8
55.00 15.376 15.188 153⁄ 8
65.00 15.250 15.062 153⁄ 8
163⁄ 8 17.000 75.00 15.124 14.936 143⁄ 4
84.00 15.010 14.822 143⁄ 4
94.00 19.124 18.936 171⁄ 2
106.50 19.000 18.812 171⁄ 2
203⁄ 8 21.000
133.00 18.730 18.542 171⁄ 2
234
Maximum Cone Dimensions for Three-Cone Rock Bits
ROCK BIT COMPARISON CHART

Maximum Maximum Milled Tooth TCI
Size Range Diameter Length Weight Weight
in. mm in. mm in. mm lb kg lb kg
131⁄ 2 – 137⁄ 8 189 – 198 23⁄ 8 60 15⁄ 8 41 10 5 12 5
143⁄ 4 121 27⁄ 8 73 21⁄ 8 54 15 7 20 9
15 ⁄ 8 – 161⁄ 4
7
149 – 159 41⁄ 4 108 31⁄ 8 79 35 16 45 20
161⁄ 2 – 163⁄ 4 165 – 172 41⁄ 2 114 31⁄ 2 89 45 20 55 25
173⁄ 8 – 181⁄ 8 187 – 203 51⁄ 4 133 41⁄ 8 102 75 34 85 39
181⁄ 8 – 181⁄ 2 206 – 216 57⁄ 8 149 41⁄ 8 105 90 41 95 43
185⁄ 8 – 191⁄ 8 219 – 229 61⁄ 8 156 45⁄ 8 117 95 43 100 45
191⁄ 8 – 191⁄ 2 232 – 241 61⁄ 2 165 43⁄ 8 111 125 57 130 59
195⁄ 8 – 197⁄ 8 245 – 251 63⁄ 4 171 43⁄ 4 121 135 61 145 66
101⁄ 8 – 105⁄ 8 254 – 270 71⁄ 4 184 51⁄ 2 140 165 75 175 80
Conversion Tables
111⁄ 8 – 117⁄ 8 279 – 302 77⁄ 8 200 57⁄ 8 149 195 89 210 95
121⁄ 8 – 121⁄ 4 305 – 311 81⁄ 8 203 61⁄ 8 156 205 93 225 102
131⁄ 4 – 151⁄ 8 337 – 381 95⁄ 8 244 75⁄ 8 194 345 157 380 173
161⁄ 8 406 101⁄ 4 260 81⁄ 8 206 410 186 450 205
171⁄ 2 445 111⁄ 2 292 85⁄ 8 219 515 234 545 248
181⁄ 2 470 121⁄ 8 305 91⁄ 8 229 525 239 570 259
201⁄ 8 508 121⁄ 2 318 95⁄ 8 244 625 284 700 318
Maximum Cone Dimensions for Three-Cone Rock Bits (continued)
Conversion Tables
Maximum Maximum Milled Tooth TCI
Size Range Diameter Length Weight Weight
in. mm in. mm in. mm lb kg lb kg
221⁄ 8 559 133⁄ 4 349 101⁄ 2 267 1,000 455 1,170 532
241⁄ 8 610 151⁄ 4 387 111⁄ 4 286 1,385 629 1,400 636
261⁄ 8 660 161⁄ 8 406 123⁄ 4 324 1,450 659 1,550 704
281⁄ 8 711 171⁄ 8 432 131⁄ 8 330 1,550 704 1,650 750
235
236
Recommended Rock Bit Makeup Torque
Size Range API Pin Size Recommended Makeup Torque
in. mm in. mm ft–lb N–m
31⁄ 2 – 141⁄ 2 89 – 114 23⁄ 8 Reg. 60 3,000 – 13,500 4,000 – 14,800
45⁄ 8 – 15 118 – 127 27⁄ 8 Reg. 73 6,000 – 17,000 8,000 – 19,500
51⁄ 8 – 173⁄ 8 137 – 187 31⁄ 2 Reg. 89 7,000 – 19,000 9,500 – 12,000
75⁄ 8 – 19 194 – 229 41⁄ 2 Reg. 114 12,000 – 16,000 16,000 – 22,000
91⁄ 2 – 28* 241 – 711 65⁄ 8 Reg. 168 28,000 – 32,000 38,000 – 43,000
143⁄ 4 – 28* 375 – 711 65⁄ 8 Reg. or 75⁄ 8 Reg. 168 or 194 34,000 – 40,000 46,000 – 54,000
181⁄ 2 – 28* 470 – 711 75⁄ 8 Reg. or 85⁄ 8 Reg. 194 or 219 40,000 – 60,000 54,000 – 81,000
*Makeup torque must correspond to API pin connection for each bit size.
Note: Some of the above bit sizes are available with alternate pin connections on special order.
Conversion Tables
Nozzle Types and Applications for Smith Bits
Conversion Tables
Milled Tooth Jet/Air TCI
Series Series Series All Three-Cone Bits
A1, Sealed/ Full-
Mini-Jets
Bit Size Open Sealed Journal Open Two-Cone Journal Center Extended
(in.) Bearing Bearing Bearing Bearing Outer Jets Bearing Jets Nozzles MT TCI
131⁄ 2 – 143⁄ 4 55 55
157⁄ 8 – 163⁄ 4 65 70 70
173⁄ 8 – 175⁄ 8 95 95 95
177⁄ 8 – 183⁄ 8 95 95 95 95 75 95 65 97 98
181⁄ 2 – 183⁄ 4 95 95 95 95 75 95 70 97 98
191⁄ 2 – 197⁄ 8 95 95 95 95 95 95 65 97 98
105⁄ 8 – 121⁄ 4 95 95 95 95 100 95 95 70 97/98 98
131⁄ 2 – 143⁄ 4 100 100 100 100 100 95 70 105 105
161⁄ 2 – 171⁄ 2 100 100 100 100 100 95 95 105 105
201⁄ 2 – 281⁄ 2 100 100 100 95/100 105 105
237
238
Rock Bit Comparison Chart
1. Standard 4. Sealed 5. Sealed Roller Bearing
Milled Tooth Roller Bearing Roller Bearing Gage Protected
Series
Types
Formations Smith Hughes Reed Security Smith Hughes Reed Security Smith Hughes Reed Security
1 DSJ R1 Y11 S3SJ SDS ATX1 S11 S33S MSDSH ATXG1 MS11G S33SG
GTX1 SS33S MSDSSH MAXG1 SS33SG
MS33S MSDSHOD MAXGT1
Soft Formations/
1 Low-Compressive 2 DTJ R2 Y12 S3J S33 S33G
Strength S3TJ SS33G
3 DGJ R3 Y13 S4J ATX3 S44 SDGH ATXG3 S13G S44G

S4T GTX3 MSDGH MAXG3 MS13G SS44G
S4TJ MSDGHOD MAXGT3
Medium to Medium- 1 V2J R4 M4NJ M44N SVH S21G M44NG
Hard Formations/ MSVH MS21G MM44NG
2 High-Compressive 2 DR5 M4
Strength 3
1 R7 H7 H77 S31G
H7J
Hard, Semi-Abrasive 2
3 Formations 3 H77SG
Conversion Tables
4
Rock Bit Comparison Chart (continued)
Conversion Tables
6. Sealed 7. Sealed Friction Bearing
Milled Tooth Friction Bearing Gage Protected
Series
Types
Formations Smith Hughes Reed Security Smith Hughes Reed Security
1 FDS ATJ1, GT1 HP11 S33SF MFDSH ATMG1 MHP11G S33SGF

FDS+ ATJ1S HP11+ MFDSSH ATMG1S
FDSS+ ATM1 MFDSHOD ATJG1H
ATM1S ATMGT1
Soft Formations/ GTG1
1 Low-Compressive 2 FDT ATJ2 HP12 S33F JG2 S33GF
Strength EHP12 S33TGF
SS33GF
3 FDG J3 S44F FDGH JG3 HP13G S44GF
MFDGH ATMG3 MHP13G
MFDGHOD
Medium to Medium- 1 FV J4 M44NF FVH JG4 HP21G M44NGF
Hard Formations/
2 High-Compressive 2
Strength 3
1 H77F JG7 HP31G
3 Formations 3 H77SGF
4 JG8
239
240
Rock Bit Comparison Chart
2. Roller Bearing 5. Sealed Roller Bearing 7. Sealed Friction Bearing
TCI Air Cooled Gage Protected Gage Protected
Series
Types
1 M01S MAX00 MS41A SS80 MF02 ATJ00 EHP41A S80F

M01SOD MAXGT00 ATM00
M02S GTX03 GT00 EHP41H
M02SOD MAX03 ATMGT00
MAXGT03 GT03
ATMGT03
ATX05 ATJ05
MAX05 ATM05
Soft Formations/ 2 M05S SS81 F05 ATJ05C S81F
4 Low-Compressive MF05 ATM05C
Strength F07 GT03C
3 M1S GTX09 S43A S82 F1 ATJ11 HP43 S82F
M1SOD MAX09 MS43A SS82 MF1 ATM11 SS82F
MAXGT09 F1OD ATJ11S HP43A S82CF
MF10D ATM11HG EHP43A
ATX11 GT09 HP43H HZS82F
MAX11 ATMGT09 EHP43H
ATX11H ATJ11H
MAX11H ATM11H
Conversion Tables
4 15JS ATX11C S44A SS83 F15, F15D ATJ11C HP44A S83F
M15S MS44A F15OD, MF15 ATM11C SS83F
M15SD MA15, MF15D ATM11CG
M15SOD MF15OD GT09C
Conversion Tables
Series
Types
1 A1JSL ATX22 S51A 2SS82 A1, F15H ATJ22 HP51 S84F

MA1SL MAX22 MS51A F2, F2H ATM22 HP51A SS84F
2JS GTX18, S84 F17, F25 ATM18 HP51H S84CF
M2S MAXGT18 SS84 F25A ATMGT18 HP51X DS84F
M2SD MF2, F2D GT18 EHP51A HZS84F
MF2D ATMGT20 EHP51H 2S82F
Soft to Medium- ATJ22S HP51XM SS84FD
5 Hard Formations/ ATM22G
Low-Compressive 2 M27S ATX22C S52A SS85 F27 ATJ22C HP52 S85F
Strength M27SD F271 ATM22C HP52A
MF27 GT18C HP52X S85CF
MF27D ATM28
3 3JS ATX33 S53A S86 F3, MF3 ATJ33 HP53 S86F
M3S SS86 MF3D ATM33 EHP53 SS86F
M3SOD ATX33A F3H ATJ33A HP53A S86CF
MF3H ATJ33S EHP53A
F3D ATJ35 HP53AM
MF30D
4 S8JA ATX33C S88 F35 ATJ33C HP54 S88F
GS88 F35A ATM33C S88FA
SS88C F37, MF37 ATJ35C S88CF
F37A S88CFH
F37D
MF37D
241
242
Series
Types
1 4GA G44 4JS ATX44 M84 F4, F4H ATJ44 HP61 M84F
F4A ATJ44A EHP61 M84FA
F45A HP61A M84CF
F45H EHP61A
Medium-Hard F47, F47A M85F
Formations/ 2 5GA Y62JA M8JA 5JS ATX44C S62A M88 F47H, F5 ATJ44C HP62 M88F
6 High-Compressive GM88 F5OD EHP62 M88FA
Strength 47JA 47JS M89T MF5 HP62A M89TF
MF5D EHP62A
3 G55 Y63JA F57, F57A ATJ55 HP63 M89F
F57D, F57OD ATJ55A EHP63
F57DD ATJ55R M90F
4 F67OD ATJ66
1
7 and Abrasive 3 7GA G77 Y73JA F7, F7OD ATJ77 HP73 H87F
Formations MF7 EHP73
4 H8JA H88 ATJ88 H88F
1 H9JA F8OD, F8DD H99F
Conversion Tables
Extremely Hard 2
8 and Abrasive 3 9JA G99 Y83JA H10JA H100 F9 ATJ99 HP83 H100F
Formations HH100 ATJ99A EHP83
4
Smith Tool Bit Nomenclature

Prefixes TCI Cutting
Structure Designations
F = Journal (pfinodal) bearing
01 = Very soft formation chisel crest
M = Steerable-motor bit bearing
cutting structure
S = Sealed roller bearing
02 = Very soft formation chisel crest
Suffixes cutting structure
A = Designed for air applications 05 = Very soft formation chisel crest
cutting structure
C = Center jet
07 = Soft formation conical cutting
D = Diamond-enhanced gage inserts
structure
DD = Fully diamond-enhanced
1 = Soft formation chisel crest
cutting structure
cutting structure
E = Full-extended nozzles
15 = Soft-medium formation chisel
G = Super D-GunE coating crest cutting structure
H = Heel inserts on milled tooth bits. 17 = Soft-medium formation conical
Different, high wear-resistant cutting structure
grade of carbide on TCI bits for
2 = Soft-medium formation chisel
abrasive formations
crest cutting structure
L = Lug pads
25 = Medium formation chisel crest
N = Nominal gage diameter cutting structure
OD = Diamond-enhanced heel 27 = Medium formation conical
row inserts cutting structure
P = Carbide compact in the leg back 3 = Medium formation chisel crest
cutting structure
PD = Diamond SRT in the back of
the leg 35 = Medium formation chisel crest
cutting structure
Q = “Flow Plus” extended nozzles
37 = Medium formation conical
R = SRT inserts pressed in leg
cutting structure
for stabilization
4 = Medium formation chisel crest
S = Sealed roller bearing
cutting structure
Milled Tooth Cutting
45 = Medium-hard formation chisel
Structure Designations
crest cutting structure
DS = Very soft formation cutting
47 = Medium-hard formation conical
structure
cutting structure
DT = Soft formation cutting structure
5 = Medium-hard formation chisel
DG = Medium formation cutting crest cutting structure
structure
57 = Medium-hard formation conical
V = Medium-hard formation cutting cutting structure
structure
67 = Hard formation conical cutting
structure
structure
structure
structure
244
IADC Dull Bit Grading
Inner Cutting Structure (1) Cutting Structure Bearings/ Other Dull Reason
(All Inner Rows) Inner Outer Dull Char. Location Seals Gage Char. Pulled
(For fixed cutter bits, use the 1 2 3 4 5 6 7 8
inner 2/3 of the bit radius)
Outer Cutting Structure (2)
(Gage Row Only) Dull Characteristics (3) Location (4) Gage (6) Reason Pulled or
(For fixed cutter bits, use the (Use only cutting structure related codes) Measure to nearest Run Terminated (8)
Roller Cone
outer 1/3 of the bit radius) N - Nose Row 1/16 of an inch BHA - Change Bottom-Hole
In columns 1 and 2 a linear scale from 0 to 8 is *BC - Broken Cone *PB - Pinched Bit I - In Gage
M - Middle Row Assembly
used to describe the condition of the cutting *BF - Bond Failure *PN - Plugged 1 - 1/16" Out of Gage
G - Gage Row DMF- Downhole Motor
structure according to the following: *BT - Broken Nozzle/Flow 2 - 2/16" Out of Gage
A - All Rows Failure
Teeth/Cutters Passage 4 - 4/16" Out of Gage
Steel Tooth Bits Cone # DTF - Downhole Tool
*BU - Balled Up Bit *RG - Rounded Gage 1 2 3 Failure
A measure of lost tooth height due to abrasion *CC - Cracked Cone *RO - Ring Out
and/or damage DSF - Drillstring Failure
*CD - Cone Dragged *SD - Shirttail Damage Fixed Cutter
0 - No Loss of Tooth Height Other Dull DST - Drill Stem Test
*CI - Cone Interference *SS - Self Sharpening C - Cone
8 - Total Loss of Tooth Height DP - Drill Plug
*CR - Cored Wear N - Nose Characteristics (7) CM - Condition Mud
Insert Bits *CT - Chipped *TR - Tracking T - Taper
S - Shoulder Refer to column 3 codes CP - Core Point
A measure of total cutting structure reduction Teeth/Cutters *WO - Washed Out BIt FM - Formation Change
due to lost, worn and/or broken inserts *ER - Erosion *WT - Worn G - Gage
Conversion Tables
HP - Hole Problems
0 - No Lost, Worn and/or Broken Inserts *FC - Flat Crested Wear Teeth/Cutters A - All Areas
LIH - Left in Hole
8 - All Inserts Lost, Worn and/or Broken *HC - Heat Checking *NO - No Dull HR - Hours on Bit
*JD - Junk Damage Characteristic Bearings/Seals (5) LOG - Run Logs
Fixed Cutter Bits
*LC - Lost Cone PP - Pump Pressure
A measure of lost, worn and/or broken *Show cone number(s) Non-Sealed Bearings Sealed Bearings
*LN - Lost Nozzle PR - Penetration Rate
cutting structure under location (4) A linear scale estimating E - Seals Effective
*LT - Lost Teeth/Cutters RIG - Rig Repair
0 - No Lost, Worn and/or Broken Cutting bearing life used F - Seals Failed
*OC - Off Center Wear TD - Total Depth/Casing
Structure 0 - No Life Used N - Not Able to Grade
8 - All of Cutting Structure Lost, Worn 8 - All Life Used, ie. no X - Fixed Cutter Bit Depth
and/or Broken bearing life remaining (Bearingless) TW - Twist Off
TQ - Torque
WC - Weather Conditions
Notes
HOW TO CONVERT “WAGS” TO SWAGS”

Listed on the next five pages are bit selection, bit weight
and RPM, hydraulic and drilling fluid property equations
for the benefit of other “SWAG” users. Many should be used
with a sprinkling of good judgement and a liberal amount
of common sense.
A. Bit Selection Equations

1. Cost per foot
B + R1 (T1 + t)
C1 = 1
F1
2. Breakeven time, at constant rate of penetration
B2 + R1 (t)
T2 =
() F
C1 1 – R1
T1
B. Bit Weight-Rotational Speed Equations

3. Drilling rate (soft formation)
ROP = kf1 WR
4. Drilling rate (hard formation)
ROP = kf1 W R
1.2 0.5
5. Bit size vs. penetration rate

a. Up to 171⁄ 2 in.
ROP2 = ROP1
()
b. 171⁄ 2 to 36 in.
D1
D2
ROP2 = ROP1
() D1
D2
x 1.25
6. Bearing wear constant

Hours
CB =
100
( W x R
1,000
7. Tooth wear constant
) 100
–
W
1,000
Hours x e(.01 R + .0032 W)

CT =
189.2
8. Mechanical horsepower at bit
HP = kb Wb1.5 Db2.5 R
9. Bit weight-RPM relationship to bit pressure drop
From Fullerton, for (WbR)<250
∆Pb = 0.678 Dh (WbR)0.5
for 250<(WbR)<350
∆Pb = 0.044 Dh (WbR)
for (WbR)>350
∆Pb = 0.80 Dh (WbR)0.5
C. Hydraulic Calculation Equations

10. Drill stem bore pressure losses (turbulent flow)
a. From Fanning
f V2L
∆P =
25.8d
b. From Security
0.000061 LQ1.86
∆P =
d4.86
c. From Smith
.0000765PV0.18 0.82 Q1.82 L
∆P =
d4.82
11. Bit hydraulic horsepower
∆Pb x Q
BHHP =
1,714
12. Jet nozzle pressure loss
Q2
∆Pb =
10,858 (An)2
13. Total nozzle area
Q
( )
0.5
An =
104.2 ∆Pb
14. Jet velocity
0.32Q
Vn =
An
15. Jet impact force
If = 0.000516 QVn
If = 0.0173Q√∆PB x
16. Bottom-hole pressure
BHP = 0.052 L
17. Bottom-hole circulating pressure
BHCP = BHP + ∆Pa
18. Annular pressure losses
a. From Hagan-Poiseuille for Newtonian laminar flow
µLV
∆Pa =
1,500 (Dh – Dp)2
C. Hydraulic Calculation Equations (continued)

b. From Beck, Nuss and Dunn for plastic laminar flow
LYP VLPV
∆Pa = +
225(Dh – Dp) 1,500(Dh – Dp)2
c. From Fanning for turbulent flow
f LV2
∆Pa =
25.8(Dh – Dp)
d. From Security for turbulent flow
(1.4327 x 10-7) LAV2
∆Pa =
Dh – Dp
e. From Smith for turbulent flow
0.0000765PV0.18 0.82 Q1.82 L
∆Pa =
(Dh – Dp)3 (Dh + Dp)1.82
19. Equivalent circulating density
BHCP
ECD =
.052L
20. Reynolds’ number
a. Newtonian fluids
928 Vd
Re =
b. Plastic fluids (to determine “f”)
2,970 Vd
Re =
PV
21. Average annulus flow velocity
24.5Q
AV =
(Dh2 – Dp2)
22. Annulus critical velocity
1.08PV + 1.08 √PV2 + 9.3(Dh – Dp)2YP
Vc =
(Dh – Dp)
23. Optimum annular velocity
From Fullerton
11,800
AVo =
Dh

24. Optimum flow rate
From Fullerton
482(Dh2 – Dp2)
Qo =
Dh
25. Rock chip slip velocity
a. From Stokes for laminar flow, spherical chips
8,310dC2( C – )
VS =
µ
b. From Pigott for laminar flow, spherical chips
3,226dC2( C – )
VS =
µ
c. From Rittinger for turbulent flow, spherical chips
VS = 155.9
√ dC( C– )
d. From Pigott for turbulent flow, spherical chips
VS = 60.6
√
26. Effective viscosity
dC( C– )
a. Viscosity definition
S
µ= s
Sr
b. Bingham Plastic
399 YP (Dh – Dp)
µ = PV +
AV
c. Shear stress, Power Law fluids
Ss = kSrn
d. Effective viscosity, Power Law
µe = kSrn–1
e. Annular shear rate
2.4 AV
Sr =
Dh – Dp
f. Consistency index
511 (YP + PV)
k=
511n

g. Power Law Index
n = 3.32 log10( )
YP + 2PV
YP + PV
27. Total system losses or pump discharge pressure
∆Pt = ∆Ps + ∆Pc + ∆Pp + ∆Pb + ∆Pca + ∆Ppa
D. Drilling Fluid Property Equations

28. Effects of plastic viscosity
ROP = ROP x 10.003(PV1 – PV2)
2 1
29. Bentonite clay effects
ROP = ROP x e.051(vol%1 – vol%2)
2 1
30. Total solids effects
ROP2 = ROP1 x 10.0066(vol%1 – vol%2)
31. Effects of water loss
WL2 + 35
ROP2 = ROP1 x
WL1 + 35
32. Oil content effects (vol% oil < 30%)
ROP2 = ROP1 [ sin(10.6 vol%2 – 4.83) + 10.33
sin(10.6 vol%1 – 4.83) + 10.33 ]
33. Total drilling fluid effects (density, viscosity, solids,
pressure loss)
For depths from 8,000 to 12,000 ft
ROP = ROP e 0.382( 1 – 2)
2 1
34. From Fullerton for density effects
log10kf2 = .000208(BHP1 – BHP2) + log10kf1
Nomenclature
An = Total nozzle area, in.2
AV, AVo = Average, optimum annulus velocity, fpm
BHP = Bottom-hole pressure, psi
BHCP = Bottom-hole circulating pressure, psi
BHHP = Bit hydraulic horsepower, hp
B1, B2 = Cost of control, proposed bit, dollars
C1 = Cost per foot of control bit, dollars/ft
CB = Bearing wearing wear constant
Cn = Nozzle coefficient, 95%
CT = Tooth wear constant
d = Inside pipe diameter, in.
Db = Bit diameter, in.
dc = Chip diameter, in.
D1, D2 = Smaller, larger bit diameter, in.
Dh = Hole diameter, in.
Dp = Outside pipe diameter, in.
e = 2.718 Naperian base
ECD = Equivalent circulating density, lb/gal
f = Fanning friction factor
F1 = Footage drilled, ft
k = Consistency index
kb = Formation factor for horsepower calculation
ranging from 4 x 10–5 for very hard to 14 x
10–5 for very soft formations
kf , kf = Apparent, corrected formation
1 2
drillability factor
L = Pipe length or hole depth, ft
n = Power Law Index
PV = Plastic viscosity, cP
PV1, PV2 = Initial, final plastic viscosity, cP
= Mud density, lb/gal
c = Density of cuttings, lb/gal
1, 2 = Initial, final mud density, lb/gal
Nomenclature (continued)
∆P = Pressure loss, psi
∆Pa = Annulus pressure loss, psi
∆Pc, ∆Pca = Drill collar bore, annulus pressure loss, psi
∆Pp, ∆Ppa = Drill pipe bore, pipe annulus pressure loss, psi
∆Ps = Surface connection pressure loss, psi
∆Pt = Total system losses, psi
∆Pb = Bit pressure loss, psi
Q = Pump volume, gpm
Qo = Optimum flow rate, gpm
R = Bit rotational speed, rpm
R1 = Rig cost or operating rate, dollars/hr
Re = Reynolds number, dimensionless
ROP = Rate of penetration, ft/hr
ROP1, ROP2 = Initial, final rate of penetration, ft/hr
SS = Shear stress, dynes/cm2
Sr = Shear rate, sec–1
t = Round trip time, hr
T1, T2 = Rotating time for control, proposed bit, hr
µ, µe = Apparent, effective viscosity, cP
V = Fluid velocity, fps
Vc = Critical velocity in annulus, fps
Vn = Nozzle velocity, fps
VS = Chip velocity, fpm
W = Weight per inch of bit diameter, lb/in.
Wb = Bit weight, 1,000 lb/in. of bit diameter
WL1, WL2 = Initial, final water loss, cm3/30 min
YP = Yield point, lb/100 ft2
Recommended Minimum Makeup Torque

(ft-lb) [See Note 2 — page 256]
Bore of Drill Collars
Size and Type
of Connection OD 1 11⁄ 4 11⁄ 2 13⁄ 4
3 2,500† 2,500† 2,500†
API NC 23 31⁄ 8 3,300† 3,300† 2,600
31⁄ 4 4,000 3,400 2,600
3 3,800† 3,800† 2,900
27⁄ 8 PAC 31⁄ 8 4,900† 4,200 2,900
(SEE NOTE 4) 31⁄ 4 5,200 4,200 2,900
23⁄ 8 API IF
API NC 26 31⁄ 2 4,600† 4,600† 3,700
27⁄ 8 SH 33⁄ 4 5,500 4,700 3,700
27⁄ 8 XH 33⁄ 4 4,100† 4,100† 4,100†
31⁄ 2 DSL 37⁄ 8 5,300† 5,300† 5,300†
27⁄ 8 MOD. OPEN 41⁄ 8 8,000† 8,000† 7,400
37⁄ 8 4,600† 4,600† 4,600†
27⁄ 8 API IF 41⁄ 8 7,300† 7,300† 7,300†
API NC 31 41⁄ 4 8,800† 8,800† 8,100
31⁄ 2 SH 41⁄ 2 10,000† 9,300 8,100
41⁄ 2 8,900†
API NC 35 43⁄ 4 12,100
5 12,100
41⁄ 4 5,100†
31⁄ 2 XH 41⁄ 2 8,400†
4 SH 43⁄ 4 11,900†
31⁄ 2 Mod. Open 5 13,200
51⁄ 4 13,200
43⁄ 4 9,900†
31⁄ 2 API IF 5 13,800†
API NC 38 51⁄ 4 16,000
41⁄ 2 SH 51⁄ 2 16,000
43⁄ 4 8,700†
31⁄ 2 H-90 5 12,700†
(See Note 3) 51⁄ 4 16,900†
51⁄ 2 18,500
5 10,800†
4 FH 51⁄ 4 15,100†
API NC 40 51⁄ 2 19,700†
4 Mod. Open 53⁄ 4 20,400
41⁄ 2 DSL 6 20,400
51⁄ 4
51⁄ 2
4 H-90 53⁄ 4
(See Note 3) 6
61⁄ 4
Notes:
Recommended Minimum Makeup Torque (continued)

(ft-lb) [See Note 2]
2 21⁄ 4 21⁄ 2 213⁄ 16 3 31⁄ 4 31⁄ 2 33⁄ 4
4,600†
6,800
6,800
6,800
8,900† 8,900† 7,400
10,800 9,200 7,400
10,800 9,200 7,400
5,100† 5,100† 5,100†
8,400† 8,400† 8,200
11,700 10,000 8,200
11,700 10,000 8,200
11,700 10,000 8,200
9,900† 9,900† 9,900† 8,300
13,800† 12,800 10,900 8,300
14,600 12,800 10,900 8,300
14,600 12,800 10,900 8,300
8,700† 8,700† 8,700† 8,700†
12,700† 12,700† 12,700† 10,400
16,700 15,000 13,100 10,400
16,700 15,000 13,100 10,400
10,800† 10,800† 10,800† 10,800†
15,100† 15,100† 14,800 12,100
18,600 16,900 14,800 12,100
18,600 16,900 14,800 12,100
18,600 16,900 14,800 12,100
12,500† 12,500† 12,500† 12,500†
17,300† 17,300† 17,300† 16,500
22,300† 21,500 19,400 16,500
23,500 21,500 19,400 16,500
23,500 21,500 19,400 16,500

Size and Type
of Connection OD 1 11⁄ 4 11⁄ 2 13⁄ 4
51⁄ 2
53⁄ 4
41⁄ 2 API Reg. 6
61⁄ 4
53⁄ 4
6
API NC 44 61⁄ 4
61⁄ 2
51⁄ 2
53⁄ 4
41⁄ 2 API FH 6
61⁄ 4
61⁄ 2
41⁄ 2 XH 53⁄ 4
API NC 46 6
4 API IF 61⁄ 4
5 DSL 61⁄ 2
41⁄ 2 Mod. Open 63⁄ 4
53⁄ 4
6
41⁄ 2 H-90 61⁄ 4
(See Note 3) 61⁄ 2
63⁄ 4
61⁄ 4
5 H-90 61⁄ 2
(See Note 3) 63⁄ 4
7
63⁄ 4
51⁄ 2 H-90 7
(See Note 3) 71⁄ 4
71⁄ 2
63⁄ 4
7
51⁄ 2 API Reg. 71⁄ 4
71⁄ 2
41⁄ 2 API IF 61⁄ 4
API NC 50 61⁄ 2
5 XH 63⁄ 4
5 Mod. Open 7
51⁄ 2 DSL 71⁄ 4
2. Basis of calculations for recommended makeup torque assumed the use of a
thread compound containing 40 to 60% by weight of finely powdered metallic
zinc or 60% by weight of finely powdered metallic lead, applied thoroughly to
all threads and shoulders.

2 21⁄ 4 21⁄ 2 213⁄ 16 3 31⁄ 4 31⁄ 2 33⁄ 4
15,400† 15,400† 15,400† 15,400†
20,300† 20,300† 19,400 16,200
23,400 21,600 19,400 16,200
23,400 21,600 19,400 16,200
20,600† 20,600† 20,600† 18,000
25,000 23,300 21,200 18,000
25,000 23,300 21,200 18,000
25,000 23,300 21,200 18,000
12,900† 12,900† 12,900† 12,900† 12,900†
17,900† 17,900† 17,900† 17,900† 17,700
23,300† 23,300† 22,800 19,800 17,700
27,000 25,000 22,800 19,800 17,700
27,000 25,000 22,800 19,800 17,700
17,600† 17,600† 17,600† 17,600†
23,200† 23,200† 22,200 20,200
28,000 25,500 22,200 20,200
28,000 25,500 22,200 20,200
28,000 25,500 22,200 20,200
17,600† 17,600† 17,600† 17,600†
23,400† 23,400† 23,000 21,000
28,500 26,000 23,000 21,000
28,500 26,000 23,000 21,000
28,500 26,000 23,000 21,000
25,000† 25,000† 25,000† 25,000†
31,500† 31,500† 29,500 27,000
35,000 33,000 29,500 27,000
35,000 33,000 29,500 27,000
34,000† 34,000† 34,000† 34,000
41,500† 40,000 36,500 34,000
42,500 40,000 36,500 34,000
42,500 40,000 36,500 34,000
31,500† 31,500† 31,500† 31,500†
39,000† 39,000† 36,000 33,500
42,000 39,500 36,000 33,500
42,000 39,500 36,000 33,500
22,800† 22,800† 22,800† 22,800† 22,800†
29,500† 29,500† 29,500† 29,500† 26,500
36,000† 35,500 32,000 30,000 26,500
38,000 35,500 32,000 30,000 26,500
38,000 35,500 32,000 30,000 26,500
Also using the modified jack screw formula as shown in the IADC Tool Pusher’s
Manual and the API Spec. RP 7G (seventh edition, April 1976) and a unit stress of
62,500 psi in the box or pin, whichever is weaker.

Size and Type
of Connection OD 1 11⁄ 4 11⁄ 2 13⁄ 4
71⁄ 4
71⁄ 4
51⁄ 2 API FH 71⁄ 2
73⁄ 4
71⁄ 4
71⁄ 2
API NC 56 73⁄ 4
81⁄ 4
71⁄ 2
73⁄ 4
65⁄ 8 API Reg. 81⁄ 4
81⁄ 4
71⁄ 2
65⁄ 8 H-90 73⁄ 4
(See Note 3) 81⁄ 4
81⁄ 4
81⁄ 4
81⁄ 4
API NC 61 81⁄ 2
83⁄ 4
91⁄ 4
81⁄ 4
81⁄ 4
81⁄ 2
51⁄ 2 API IF 83⁄ 4
91⁄ 4
91⁄ 4
81⁄ 2
83⁄ 4
65⁄ 8 API FH 91⁄ 4
91⁄ 4
91⁄ 2
91⁄ 4
91⁄ 4
91⁄ 2
API NC 70 93⁄ 4
101⁄ 4
101⁄ 4
101⁄ 4
101⁄ 4
API NC 77 101⁄ 2
103⁄ 4
111⁄ 4

2 21⁄ 4 21⁄ 2 213⁄ 16 3 31⁄ 4 31⁄ 2 33⁄ 4
32,500† 32,500† 32,500† 32,500†
40,500† 40,500† 40,500† 40,500†
49,000† 47,000 45,000 41,500
51,000 47,000 45,000 41,500
40,000† 40,000† 40,000† 40,000†
48,500† 48,000 45,000 42,000
51,000 48,000 45,000 42,000
51,000 48,000 45,000 42,000
46,000† 46,000† 46,000† 46,000†
55,000† 53,000 50,000 47,000
57,000 53,000 50,000 47,000
57,000 53,000 50,000 47,000
46,000† 46,000† 46,000† 46,000†
55,000† 55,000† 53,000 49,500
59,500 56,000 53,000 49,500
59,500 56,000 53,000 49,500
54,000† 54,000† 54,000† 54,000†
64,000† 64,000† 64,000† 61,000
72,000 68,000 65,000 61,000
72,000 68,000 65,000 61,000
72,000 68,000 65,000 61,000
56,000† 56,000† 56,000† 56,000† 56,000†
66,000† 66,000† 66,000† 63,000 59,000
74,000 70,000 67,000 63,000 59,000
74,000 70,000 67,000 63,000 59,000
74,000 70,000 67,000 63,000 59,000
74,000 70,000 67,000 63,000 59,000
67,000† 67,000† 67,000† 67,000† 66,500
78,000† 78,000† 76,000 72,000 66,500
83,000 80,000 7,6000 72,000 66,500
83,000 80,000 76,000 72,000 66,500
83,000 80,000 76,000 72,000 66,500
75,000† 75,000† 75,000† 75,000† 75,000†
88,000† 88,000† 88,000† 88,000† 88,000†
101,000† 101,000†100,000 95,000 90,000
107,000 105,000 100,000 95,000 90,000
107,000 105,000 100,000 95,000 90,000
107,000 105,000 100,000 95,000 90,000
107,000†107,000†107,000† 107,000†
122,000†122,000†122,000† 122,000†
138,000†138,000†133,000 128,000
143,000 138,000 133,000 128,000
143,000 138,000 133,000 128,000

Size and Type
of Connection OD 1 11⁄ 4 11⁄ 2 13⁄ 4
Connections with Full Face
8*5⁄ 8
7 H-90 81⁄ 4*
(See Note 3) 81⁄ 2*
81⁄ 2*
83⁄ 4*
75⁄ 8 API Reg. 9*5⁄ 8
91⁄ 4*
91⁄ 2*
9*5⁄ 8
75⁄ 8 H-90 91⁄ 4*
(See Note 3) 91⁄ 2*
10*5⁄ 8
85⁄ 8 API Reg. 101⁄ 4*
101⁄ 2*
85⁄ 8 H-90 101⁄ 4*
(See Note 3) 101⁄ 2*
Connections with Low Torque Face
7 H-90 83⁄ 4
(See Note 3) 95⁄ 8
91⁄ 4
91⁄ 2
75⁄ 8 API Reg. 93⁄ 4
105⁄ 8
93⁄ 4
75⁄ 8 H-90 105⁄ 8
(See Note 3) 101⁄ 4
101⁄ 2
103⁄ 4
85⁄ 8 API Reg. 115⁄ 8
103⁄ 4
85⁄ 8 H-90 115⁄ 8
(See Note 3) 111⁄ 4
3. Normal torque range — tabulated minimum value to 10% greater. Largest diameter
shown for each connection is the maximum recommended for that connection. If
the connections are used on drill collars larger than the maximum shown, increase
the torque values shown by 10% for a minimum value. In addition to the increased
minimum torque value, it is also recommended that a fishing neck be machined to
the maximum diameter shown.
4. H-90 connection makeup torque based on 56, 250 psi stress and other factors as
stated in Note 1.
5. 2-7/8-in. PAC makeup torque based on 87,500 psi stress and other factors as stated
in Note 1.

2 21⁄ 4 21⁄ 2 213⁄ 16 3 31⁄ 4 31⁄ 2 33⁄ 4
Connections with Full Face
53,000† 53,000† 53,000† 53,000†
63,000† 63,000† 63,000† 60,500
71,500 68,500 65,000 60,500
60,000† 60,000† 60,000† 60,000†
71,000† 71,000† 71,000† 71,000†
83,000† 83,000† 79,000 74,000
88,000 83,000 79,000 74,000
88,000 83,000 79,000 74,000
72,000† 72,000† 72,000† 72,000†
85,500† 85,500† 85,500† 85,500†
98,000† 98,000† 98,000† 95,500
108,000†108,000†108,000† 108,000†
123,000†123,000†123,000† 123,000
139,000 134,000 129,000 123,000
112,500†112,500†112,500† 112,500†
128,500†128,500†128,500† 128,500†
Connections with Low Torque Face
67,500† 67,500† 66,500 62,000
74,000 71,000 66,500 62,000
72,000† 72,000† 72,000† 72,000†
85,000† 85,000† 82,000 77,000
91,000 87,000 82,000 77,000
91,000 87,000 82,000 77,000
91,000† 91,000† 91,000† 91,000†
105,000†105,000†103,500 98,000
112,500 108,000 103,500 98,000
112,500 108,000 103,500 98,000
112,000†112,000†112,000† 112,000†
129,000†129,000†129,000† 129,000†
92,500† 92,500† 92,500† 92,500†
110,000†110,000†110,000† 110,000†
128,000†128,000†128,000† 128,000†
*6. Largest diameter shown is the maximum recommended for those full face con-
nections. If larger diameters are used, machine connections with low torque faces
and use the torque values shown under low torque face tables. If low torque faces
are not used, see Note 2 for increased torque values.
†7. Torque figures succeeded by a cross (†) indicate that the weaker member for the
corresponding outside diameter and bore is the BOX. For all other torque values
the weaker member is the PIN.
Rotary Shouldered Connection Interchange List

Common Name Pin Base
Diameter Threads Taper Thread Same As or
Style Size (Tapered) per in. (in./ft) Form* Interchanges With
23⁄ 8 2.876 4 2 V-0.065 27⁄ 8 SH
(V-0.038 rad) NC 26**
27⁄ 8 3.391 4 2 V-0.065 31⁄ 2 SH
(V-0.038 rad) NC 31**
Internal 31⁄ 2 4.016 4 2 V-0.065 41⁄ 2 SH
Flush (V-0.038 rad) NC 38**
(IF)
4 4.834 4 2 V-0.065 41⁄ 2 XH
(V-0.038 rad) NC 46**
41⁄ 2 5.250 4 2 V-0.065 5 XH
(V-0.038 rad) NC 50**
51⁄ 2 DSL
Full 4 4.280 4 2 V-0.065 41⁄ 2 DSL
Hole (V-0.038 rad) NC 40**
(FH)
27⁄ 8 3.327 4 2 V-0.065 31⁄ 2 DSL
(V-0.038 rad)
31⁄ 2 3.812 4 2 V-0.065 4 SH
Extra (V-0.038 rad) 41⁄ 2 EF
Hole 41⁄ 2 4.834 4 2 V-0.065 4 IF
(XH) (V-0.038 rad) NC 46**
(EH) 5 5.250 4 2 V-0.065 41⁄ 2 IF
(V-0.038 rad) NC 50**
51⁄ 2 DSL
27⁄ 8 2.876 4 2 V-0.065 23⁄ 8 IF
(V-0.038 rad) NC 26**
31⁄ 2 3.391 4 2 V-0.065 27⁄ 8 IF
Slim (V-0.038 rad) NC 31**
Hole 4 3.812 4 2 V-0.065 31⁄ 2 XH
(SH) (V-0.038 rad) 41⁄ 2 EF
41⁄ 2 4.016 4 2 V-0.065 31⁄ 2 IF
(V-0.038 rad) NC 38**
31⁄ 2 3.327 4 2 V-0.065 27⁄ 8 XH
(V-0.038 rad)
Double 41⁄ 2 4.280 4 2 V-0.065 4 FH
Streamline (V-0.038 rad) NC 40**
(DSL) 51⁄ 2 5.250 4 2 V-0.065 41⁄ 2 IF
(V-0.038 rad) 5 XH
NC 50**
Rotary Shouldered Connection Interchange List (continued)

Common Name Pin Base
Diameter Threads Taper Thread Same As or
Style Size (Tapered) per in. (in./ft) Form* Interchanges With
26 2.876 4 2 V-0.038 rad 23⁄ 8 IF
27⁄ 8 SH
31 3.391 4 2 V-0.038 rad 27⁄ 8 IF
31⁄ 2 SH
38 4.016 4 2 V-0.038 rad 31⁄ 2 IF
Numbered 41⁄ 2 SH
Conn. 40 4.280 4 2 V-0.038 rad 4 FH
(NC) 41⁄ 2 DSL
46 4.834 4 2 V-0.038 rad 4 IF
41⁄ 2 XH
50 5.250 4 2 V-0.038 rad 41⁄ 2 IF
5 XH
51⁄ 2 DSL
External 41⁄ 2 3.812 4 2 V-0.065 4 SH
Flush (V-0.038 rad) 31⁄ 2 XH
(EF)
** Connections with two thread forms shown may be machined with either thread
form without affecting gaging or interchangeability.
** Numbered Connections (NC) may be machined only with the V-0.038 radius
thread form.
Top Sub Makeup Torque Table (ft-lb)

Makeup
Series Tool Tool Top Sub Torque
Connection OD ID (ft-lb)
3600 23⁄ 8 IF 35⁄ 8 1.00 5,700
4500 31⁄ 2 IF 41⁄ 2 1.25 6,350
2.25 6,350
5700 4 IF 53⁄ 4 1.50 17,800
5800 2.25 17,800
6000 4 IF 61⁄ 2 1.50 23,500
6100 2.25 23,500
7200 51⁄ 2 IF 71⁄ 4 2.25 28,000
3.00 28,000
8200 65⁄ 8 Reg. 81⁄ 2 2.25 60,600
3.00 51,500
2.81 54,000
9500 65⁄ 8 Reg. 81⁄ 2 2.81 54,000
3.00 51,500
2.25 60,600
11700 Servco T-20 111⁄ 2 3.00 88,000
15000 Servco T-20 111⁄ 2 3.00 88,000
75⁄ 8 Reg. 3.00 88,000
22000 Servco T-20 133⁄ 8 3.00 88,000
3.50 88,000
Recommended Maximum-Minimum Tool Joint Dimensions (in.)
A C B
Nom. Nom. “A” “B” “C”

Joints OD ID Max. Max. Min. Max.
API Reg. 31⁄ 8 1 11⁄ 8 15⁄ 8 215⁄ 16 31⁄ 4
23⁄ 8 API IF 33⁄ 8 13⁄ 4 13⁄ 4 2 3
3 ⁄ 16 35⁄ 8
Hydril IF 33⁄ 8 13⁄ 4 13⁄ 4 17⁄ 8 1
3 ⁄8 35⁄ 8
API Reg. 33⁄ 4 11⁄ 4 13⁄ 8 17⁄ 8 1
3 ⁄2 47⁄ 8
API FH 41⁄ 4 21⁄ 8 21⁄ 8 23⁄ 8 1
4 ⁄ 16 45⁄ 8
27⁄ 8 API IF 41⁄ 8 21⁄ 8 21⁄ 8 21⁄ 2 7
3 ⁄8 43⁄ 8
Hydril IF 37⁄ 8 21⁄ 8 23⁄ 16 23⁄ 16 5
3 ⁄8 41⁄ 8
Hughes XH 41⁄ 4 17⁄ 8 17⁄ 8 21⁄ 8 4 45⁄ 8
3 Union Tool 41⁄ 4 11⁄ 2 11⁄ 2 21⁄ 8 3
3 ⁄4 41⁄ 2
API Reg. 41⁄ 4 11⁄ 2 13⁄ 4 21⁄ 4 4 45⁄ 8
API FH 45⁄ 8 27⁄ 16 27⁄ 16 23⁄ 4 1
4 ⁄2 57⁄ 8
31⁄ 2 API IF 43⁄ 4 211⁄ 16 211⁄ 16 3 1
4 ⁄2 57⁄ 8
Hydril IF 41⁄ 2 23⁄ 4 23⁄ 4 213⁄ 16 3
4 ⁄8 47⁄ 8
Hughes XH 43⁄ 4 27⁄ 16 27⁄ 16 23⁄ 4 1
4 ⁄2 57⁄ 8
API FH 51⁄ 4 213⁄ 16 213⁄ 16 31⁄ 4 5 53⁄ 8
4 API IF 53⁄ 4 31⁄ 4 35⁄ 16 31⁄ 2 1
5 ⁄2 67⁄ 8
Union Tool 53⁄ 4 21⁄ 4 27⁄ 8 31⁄ 2 3
5 ⁄8 67⁄ 8
API Reg. 53⁄ 4 21⁄ 4 25⁄ 8 31⁄ 4 3
5 ⁄8 67⁄ 8
API FH 53⁄ 4 3 35⁄ 32 31⁄ 2 1
5 ⁄2 67⁄ 8
41⁄ 2 API IF 61⁄ 8 33⁄ 4 33⁄ 4 41⁄ 8 7
5 ⁄8 61⁄ 2
Hydril IF 67⁄ 8 33⁄ 4 37⁄ 8 4 13
5 ⁄ 16 61⁄ 4
Hughes XH 67⁄ 8 31⁄ 4 31⁄ 4 33⁄ 8 5
5 ⁄8 61⁄ 4
API Reg. or UT 63⁄ 4 23⁄ 4 31⁄ 4 37⁄ 8 3
6 ⁄8 77⁄ 8
51⁄ 2 API FH 77⁄ 8 4 4 41⁄ 2 1
6 ⁄2 71⁄ 4
API IF 73⁄ 8 413⁄ 16 413⁄ 16 51⁄ 4 1
7 ⁄8 77⁄ 8
API Reg. or UT 73⁄ 4 31⁄ 2 4 43⁄ 4 1
7 ⁄8 77⁄ 8
65⁄ 8 API FH 87⁄ 8 5 5 51⁄ 2 1
7 ⁄2 81⁄ 4
API IF 81⁄ 2 529⁄ 32 529⁄ 32 61⁄ 4 3
8 ⁄8 97⁄ 8
75⁄ 8 API Reg. 87⁄ 8 4 41⁄ 4 51⁄ 4 1
8 ⁄8 97⁄ 8
85⁄ 8 API Reg. 107⁄ 8 43⁄ 4 51⁄ 4 61⁄ 4 9 101⁄ 8
DRILL PIPE DATA

Internal Upset
Pipe Weight ID ID Pipe Weight ID ID
Size OD (lb) Pipe Upset Size OD (lb) Pipe Upset
23⁄ 8 2.375 4.80 2.000 1.437 5 5.000 19.50 4.276 3.781
2.375 6.65 1.815 1.125 51⁄ 2 5.500 21.90 4.778 3.812
2.875 6.45 2.469 1.875 5.500 24.70 4.670 3.500
27⁄ 8 2.875 8.35 2.323 1.625 5.563 19.00 4.975 4.125
2.875 10.40 2.151 1.187 59⁄ 16 5.563 22.20 4.859 3.812
3.500 8.50 3.063 2.437 5.563 25.25 4.733 3.500
31⁄ 2 3.500 11.20 2.900 2.125 6.625 22.20 6.065 5.187
3.500 13.30 2.764 1.875 65⁄ 8 6.625 25.20 5.965 5.000
3.500 15.50 2.602 1.750 6.625 31.90 5.761 4.625
4 4.000 14.00 3.340 2.375 75⁄ 8 7.625 29.25 6.969 6.000
4.000 15.70 3.240 2.250 85⁄ 8 8.625 40.00 7.825 6.625
4.500 12.75 4.000 3.250
4.500 13.75 3.958 3.156
41⁄ 2 4.500 16.60 3.826 2.812
4.500 18.10 3.754 2.687
4.500 20.00 3.640 2.812
External Upset
Pipe Weight ID ID Pipe Weight ID ID
Size OD (lb) Pipe Upset Size OD (lb) Pipe Upset
23⁄ 8 2.375 6.65 1.815 2.656 41⁄ 2 4.500 16.60 3.826 5.000
27⁄ 8 2.875 10.40 2.151 3.219 4.500 20.00 3.640 5.000
31⁄ 2 3.500 13.30 2.764 3.824 59⁄ 16 5.563 22.20 4.859 6.063
3.500 15.50 2.602 3.824 5.563 25.25 4.733 6.063
4 4.000 14.00 3.340 4.500 65⁄ 8 6.625 25.20 5.965 7.125
4.000 15.70 3.240 4.500
HEVI-WATE DRILL PIPE

Capacity and Displacement Table — Hevi-Wate Drill Pipe
Capacity Displacement
Nom. gal bbl gal bbl gal bbl gal bbl
Size per per per per per per per per
(in.) Joint* Joint* 100 ft 100 ft Joint* Joint* 100 ft 100 ft
31⁄ 2 5.30 .126 17.7 .421 11.61 .276 38.7 .921
4 8.13 .194 27.1 .645 13.62 .325 45.4 1.082
41⁄ 2 9.37 .223 31.2 .743 18.82 .448 62.7 1.493
5 11.14 .265 37.1 .883 22.62 .539 75.4 1.796
* Capacity and displacement per joint numbers are based on 30-ft joints.

Dimensional Data Range II
Tube Mechanical
Properties
Normal Tube Tube
Dimension Section
Tor-
Wall Tensile sional
Nom. Thick- Area Center Elevator Yield Yield
Size ID ness (in.2) Upset Upset (lb) (ft-lb)
31⁄ 2 21⁄ 16 .719 6.280 4 35⁄ 8 345,400 19,575
4 29⁄ 16 .719 7.409 41⁄ 2 41⁄ 8 407,550 27,635
41⁄ 2 23⁄ 4 .875 9.965 5 45⁄ 8 548,075 40,715
5 3 1.000 12.566 51⁄ 2 51⁄ 8 691,185 56,495
Tool Joint Approx.

Weight
Incl. Tube
Mechanical and
Properties Joints (lb) Make-
Tensile Torsional up
Nom. Connection Yield Yield 30 ft Torque
Size Size OD ID (lb) (ft–lb) wt/ft wt/jt (ft–lb)
31⁄ 2 NC 38(31⁄ 2 IF) 43⁄ 4 23⁄ 16 748,750 17,575 25.3 760 9,900
4 NC 40(4 FH) 51⁄ 4 211⁄ 16 711,475 23,525 29.7 880 13,250
41⁄ 2 NC 46(4 IF) 61⁄ 4 27⁄ 8 1,024,500 38,800 41.0 1,230 21,800
5 NC 50(41⁄ 2 IF) 61⁄ 2 31⁄ 16 1,266,000 51,375 49.3 1,480 29,400

Dimensional Data Range II (continued)
Tube Mechanical
Properties
Normal Tube Tube
Dimension Section
Tor-
Wall Tensile sional
Nom. Thick- Area Center Elevator Yield Yield
Size ID ness (in.2) Upset Upset (lb) (ft-lb)
41⁄ 2 23⁄ 4 .875 9.965 5 45⁄ 8 548,075 40,715
5 3 1.000 12.566 51⁄ 2 51⁄ 8 691,185 56,495
Tool Joint Approx.

Weight
Incl. Tube
Mechanical and
Properties Joints (lb) Make-
Tensile Torsional up
Nom. Connection Yield Yield 30 ft Torque
Size Size OD ID (lb) (ft–lb) wt/ft wt/jt (ft–lb)
41⁄ 2 NC 46(4 IF) 61⁄ 4 27⁄ 8 1,024,500 38,800 41.0 1,750 21,800
5 NC 50(41⁄ 2 IF) 61⁄ 2 31⁄ 16 1,266,000 51,375 49.3 2,130 29,400
TUBING DATA
Non-Upset
Coup- Coup-
API ling API ling
Size OD lb ID OD Size OD lb ID OD
1.900 1.900 2.75 1.610 2.200 31⁄ 2 3.500 9.20 2.992 4.250
23⁄ 8 2.375 4.00 2.041 2.875 31⁄ 2 3.500 10.20 2.922 4.250
23⁄ 8 2.375 4.60 1.995 2.875 4 4.000 9.50 3.548 4.750
27⁄ 8 2.875 6.40 2.441 3.500 41⁄ 2 4.500 12.60 3.958 5.200
31⁄ 2 3.500 7.70 3.068 4.250
External Upset
Coup- Coup-
API ling API ling
Size OD lb ID OD Size OD lb ID OD
1.660 1.660 2.40 1.380 2.200 31⁄ 2 3.500 9.30 2.992 4.500
1.900 1.900 2.90 1.610 2.500 4 4.000 11.00 3.476 5.000
23⁄ 8 2.375 4.70 1.995 3.063 41⁄ 2 4.500 12.75 3.958 5.563
27⁄ 8 2.875 6.50 2.441 3.668
DRILL COLLAR WEIGHTS (LB/FT)

Collar Bore of Collar (in.)
OD 11⁄ 2 13⁄ 4 2 21⁄ 4 21⁄ 2 23⁄ 4 3 31⁄ 4 31⁄ 2 33⁄ 4 4
33⁄ 8 24.4 22.2
31⁄ 2 26.7 24.5
33⁄ 4 31.5 29.3
37⁄ 8 34.0 31.9 29.4 26.5
43⁄ 8 36.7 34.5 32.0 29.2
41⁄ 8 39.4 37.2 34.7 31.9
41⁄ 4 42.2 40.0 37.5 34.7
41⁄ 2 48.0 45.8 43.3 40.5
43⁄ 4 54.2 52 49.5 46.7 43.5
53⁄ 8 60.1 58.5 55.9 53.1 49.9
51⁄ 4 67.5 65.3 62.8 59.9 56.8 53.3
51⁄ 2 74.7 72.5 69.9 67.2 63.9 60.5 56.7
53⁄ 4 82.1 79.9 77.5 74.6 71.5 67.9 64.1
63⁄ 8 89.9 87.8 85.3 82.5 79.3 75.8 71.9 67.8 63.3
61⁄ 4 98.1 95.9 93.5 90.6 87.5 83.9 80.1 75.9 71.5
61⁄ 2 106.6 104.5 101.9 99.1 95.9 92.5 88.6 84.5 79.9
63⁄ 4 115.5 113.3 110.8 107.9 104.8 101.3 97.5 93.3 88.8
73⁄ 8 124.6 122.5 119.9 117.1 113.9 110.5 106.6 102.5 97.9 93.1 87.9
71⁄ 4 134.1 131.9 129.5 126.6 123.5 119.9 116.1 111.9 107.5 102.6 97.5
71⁄ 2 143.9 141.7 139.3 136.5 133.3 129.8 125.9 121.8 117.3 112.5 107.3
73⁄ 4 154.1 151.9 149.5 146.6 143.5 139.9 136.1 131.9 127.5 122.6 117.5
83⁄ 8 164.6 162.5 159.9 157.1 153.9 150.5 146.6 142.5 137.9 133.1 127.9
81⁄ 4 175.4 173.3 170.8 167.9 164.8 161.3 157.5 153.3 148.8 143.9 138.8
81⁄ 2 186.6 184.4 181.9 179.1 175.9 168.6 172.5 164.5 159.9 155.1 149.9
83⁄ 4 198.1 195.9 193.9 190.6 187.4 183.9 180.1 175.9 171.4 166.6 161.5
93⁄ 8 207.8 205.3 202.4 199.3 195.8 191.9 187.8 183.3 178.5 173.3
91⁄ 2 232.4 229.9 227.1 223.9 220.4 216.6 212.4 207.9 203.1 197.9
103⁄ 8 255.9 253.1 249.9 246.4 242.6 238.4 233.9 229.1 223.9
101⁄ 2 283.3 280.4 277.3 273.8 269.9 265.8 261.3 256.4 251.3
113⁄ 8 305.9 302.4 298.6 294.4 289.9 285.1 279.9
To obtain the weights of spiral collars, subtract 4%.
WEIGHTS OF 30-FT DRILL COLLARS (LB)

Collar Bore of Collar (in.)
OD 11⁄ 2 13⁄ 4 2 21⁄ 4 21⁄ 2 23⁄ 4 3 31⁄ 4 31⁄ 2 33⁄ 4 4
33⁄ 8 730 665
31⁄ 2 799 734
33⁄ 4 944 879
37⁄ 8 1,020 955 880 795
41⁄ 2 1,099 1,034 959 874
41⁄ 8 1,180 1,115 1,040 955
41⁄ 4 1,264 1,199 1,124 1,039
41⁄ 2 1,439 1,374 1,299 1,214
43⁄ 4 1,624 1,559 1,484 1,399 1,304
51⁄ 2 1,819 1,754 1,679 1,594 1,499
51⁄ 4 2,024 1,959 1,884 1,799 1,704 1,599
51⁄ 2 2,239 2,174 2,099 2,014 1,919 1,814 1,699
53⁄ 4 2,464 2,399 2,324 2,239 2,144 2,039 1,924
61⁄ 2 2,699 2,634 2,559 2,474 2,379 2,274 2,159 2,034 1,899
61⁄ 4 2,944 2,879 2,804 2,719 2,624 2,519 2,404 2,279 2,144
61⁄ 2 3,199 3,134 3,059 2,974 2,879 2,774 2,659 2,534 2,399
63⁄ 4 3,463 3,398 3,323 3,238 3,143 3,039 2,924 2,799 2,664
71⁄ 2 3,738 3,673 3,598 3,513 3,418 3,313 3,199 3,074 2,939 2,794 2,639
71⁄ 4 4,023 3,958 3,883 3,798 3,703 3,598 3,483 3,358 3,223 3,078 2,924
71⁄ 2 4,318 4,253 4,178 4,093 3,998 3,893 3,778 3,653 3,518 3,373 3,219
73⁄ 4 4,623 4,558 4,483 4,398 4,303 4,198 4,083 3,958 3,823 3,678 3,523
81⁄ 2 4,938 4,873 4,798 4,713 4,618 4,513 4,398 4,273 4,138 3,993 3,838
81⁄ 4 5,263 5,198 5,123 5,038 4,943 4,838 4,723 4,598 4,463 4,318 4,163
81⁄ 2 5,598 5,533 5,458 5,373 5,278 5,058 5,173 4,933 4,798 4,653 4,498
83⁄ 4 5,943 5,878 5,803 5,718 5,623 5,518 5,403 5,278 5,143 4,998 4,843
91⁄ 2 6,233 6,158 6,073 5,978 5,873 5,758 5,633 5,498 5,353 5,198
91⁄ 2 6,972 6,897 6,812 6,498 6,717 6,613 6,373 6,238 6,093 5,938
101⁄ 2 7,677 7,592 7,497 7,392 7,277 7,152 7,017 6,872 6,717
101⁄ 2 8,497 8,412 8,317 8,212 8,097 7,972 7,837 7,692 7,537
111⁄ 2 9,177 9,072 8,957 8,832 8,697 8,552 8,397
To obtain the weights of spiral collars, subtract 4%.
BUOYANCY FACTOR AND SAFETY FACTOR

Buoyancy Effect on the Drillstring
Due to the buoyancy effect, all drill collar weight is not
actually available for loading the bit in fluid-drilled holes.
To find the corrected, or buoyed, drill collar weight, use the
buoyancy correction factor from the Buoyancy Factors table
on Page 274 of this section.
Example:
A drill collar string weighs 79,000 lb in air. How much
will it weigh in 12 lb/gal mud?
Buoyed drill collar weight =
Drill collar weight x buoyancy factor =
79,000 lb x .817 =
64,543 lb
Safety Factor
Drill pipe can be seriously damaged if run in compression.
To make sure the drill pipe is always in tension, the top 10
to15% of the drillstring has to be in tension. This will shift
the point of changeover from tension to compression, i.e.,
the neutral zone, down to the stiff drill collar string, where
it can be tolerated. The calculation of the maximum bit
weight available therefore has to include a 10 to15% Safety
Factor (SF), written as 1.10 or 1.15. In harder formations, the
safety factor should increase up to 25%.
Example: Using the same example as above:
Maximum bit weight available =
Buoyed drill collar weight
=
1.15
64,543 lb
=
1.15
56,124 lb
The buoyed weight of the drill collar string, incorporating
the safety factor, is thus 56,124 lb.
BUOYANCY FACTORS
Mud Mud Mud
Weight Buoyancy Weight Buoyancy Weight Buoyancy
lb/gal Factor lb/gal Factor lb/gal Factor
8.4 .872 13.0 .801 17.6 .731
8.6 .869 13.2 .798 17.8 .728
8.8 .866 13.4 .795 18.0 .725
9.0 .863 13.4 .795 18.2 .723
9.2 .860 13.6 .792 18.4 .720
9.4 .856 14.0 .786 18.6 .717
9.6 .853 14.2 .783 18.8 .714
9.8 .850 14.4 .780 19.0 .711
10.0 .847 14.6 .777 19.2 .708
10.2 .844 14.8 .774 19.4 .705
10.4 .841 15.0 .771 19.6 .702
10.6 .838 15.2 .768 19.8 .698
10.8 .835 15.4 .765 20.0 .694
11.0 .832 15.6 .76 20.2 .691
11.2 .829 15.8 .759 20.4 .688
11.4 .826 16.0 .755 20.6 .685
11.6 .823 16.2 .753 20.8 .682
11.8 .820 16.4 .750 21.0 .679
12.0 .817 16.6 .747 22.0 .664
12.2 .814 16.8 .744 23.0 .649
12.4 .811 17.0 .740 24.0 .633
12.6 .808 17.2 .737
12.8 .805 17.4 .734
Pump Volume vs. Liner Size 10-in. Duplex Pump
Conversion Tables
Liner sizes vary depend- Gallons per Minute Using Liner Shown
Strokes
ing on the pump size, per
strokes per minute and Minute 3 31⁄ 2 4 41⁄ 2 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4 71⁄ 2 8
required circulation rate 25 30 40 50 60 80 90 90 100 110 120 130 140 150 170 180 200
in GPM. The following 30 30 40 60 70 90 100 110 120 140 150 160 170 190 200 210 240
tables give the circulation 35 40 50 70 90 110 120 130 140 160 170 190 200 220 230 250 280
rates possible when var- 40 40 50 70 90 120 130 140 160 170 190 200 220 230 250 270 310
ious sizes of duplex and 45 40 60 80 110 130 150 160 180 190 210 230 240 260 280 300 350
triplex pumps are used, 50 50 70 90 120 150 160 180 200 210 230 250 270 290 310 340 380
based on the pumps 55 50 70 100 130 160 180 200 220 230 260 280 300 320 350 370 420
volumetric efficiency 60 60 80 110 140 180 190 210 230 260 280 300 330 350 380 400 460
of 95%. 65 60 90 120 150 190 210 230 250 280 300 330 350 380 410 440 500
GPM calculated in 70 70 100 130 160 200 230 250 270 300 330 350 380 410 440 470 540
10 GPM increments for 75 70 100 140 180 220 240 270 290 320 350 380 410 440 470 510 580
purposes of reading 80 80 110 150 190 230 260 290 310 340 370 400 440 470 500 540 620
curves and proper 85 80 120 150 200 250 280 300 330 360 390 430 460 500 540 570 650
orifice selection.
275
276
12-in. Duplex Pump
Strokes Gallons per Minute Using Liner Shown
per
Minute 41⁄ 2 43⁄ 4 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4
25 70 80 90 100 110 120 130 140 160 170 180 200
30 90 100 110 120 130 150 160 170 190 200 220 240
35 100 110 130 140 150 170 190 200 220 240 260 280
40 110 120 140 150 170 180 200 220 240 260 280 300
45 120 140 150 170 190 210 230 250 270 290 310 340
50 140 150 170 190 210 230 250 270 300 320 350 370
55 150 170 190 210 230 250 280 300 330 350 380 410
60 160 180 200 230 250 280 300 330 360 390 420 450
65 180 200 220 250 270 300 330 360 390 420 450 490
70 190 210 240 270 290 320 350 380 420 450 490 520
Conversion Tables
14-in. Duplex Pump
Conversion Tables
per
Minute 43⁄ 4 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4 71⁄ 2 73⁄ 4
25 90 100 110 130 140 150 170 180 190 210 230 240 260
30 110 120 140 150 170 180 200 220 230 250 270 290 310
35 130 140 160 180 190 210 230 250 270 290 320 340 360
40 140 150 170 190 210 230 250 270 290 320 340 370 390
45 150 170 190 210 240 260 280 310 330 360 390 410 440
50 170 190 210 240 260 290 310 340 370 400 430 460 490
55 190 210 240 260 290 320 340 370 410 440 470 510 540
60 210 230 260 290 310 340 380 410 440 480 510 550 590
65 220 250 280 310 340 370 410 440 480 520 560 600 640
70 240 270 300 330 370 400 440 480 520 560 600 640 690
277
278
15-in. Duplex Pump
per
Minute 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4 71⁄ 2 73⁄ 4
25 110 120 130 150 160 180 190 210 230 240 260 280
30 130 150 160 180 190 210 230 250 270 290 310 330
35 150 170 190 210 230 250 270 290 320 340 360 390
40 170 180 200 220 250 270 290 320 340 370 390 420
45 190 210 230 250 280 300 330 360 380 410 440 480
50 210 230 250 280 310 340 360 400 430 460 490 530
55 230 250 280 310 340 370 400 430 470 510 540 580
60 250 280 310 340 370 400 440 470 510 550 590 630
65 270 300 330 360 400 440 470 510 550 600 640 690
70 290 320 360 390 430 470 510 550 600 640 690 740
Conversion Tables
16-in. Duplex Pump
Conversion Tables
per
Minute 43⁄ 4 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4 71⁄ 2 73⁄ 4 8 81⁄ 4 81⁄ 2
25 100 110 130 140 150 170 190 200 220 240 260 270 290 310 340 360
30 120 140 150 170 190 200 220 240 260 280 310 330 350 380 400 430
35 140 160 180 200 220 240 260 280 310 330 360 380 410 440 470 500
40 150 170 190 210 230 260 280 310 330 360 390 420 450 480 510 540
45 170 190 220 240 260 290 320 340 370 400 440 470 500 540 570 610
50 190 210 240 270 290 320 350 380 420 450 480 520 560 600 640 680
55 210 240 260 290 320 350 390 420 460 490 530 570 610 660 700 740
60 230 260 290 320 350 390 420 460 500 540 580 620 670 720 760 810
65 250 280 310 350 380 420 460 500 540 580 630 680 720 770 830 880
70 270 300 330 370 410 450 490 540 580 630 680 730 780 830 890 950
279
280
18-in. Duplex Pump
per
Minute 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4 71⁄ 2 73⁄ 4 8 81⁄ 4 81⁄ 2
25 130 140 160 170 190 210 230 250 270 290 310 330 350 380 400
30 150 170 190 210 230 250 270 300 320 340 370 400 420 450 480
35 180 200 220 240 270 290 320 350 370 400 430 460 500 530 560
40 190 220 240 260 290 320 340 370 400 440 470 500 540 570 610
45 220 240 270 300 330 360 390 420 450 490 530 560 600 640 690
50 240 270 300 330 360 400 430 470 510 540 590 630 670 720 760
55 270 300 330 360 400 440 470 510 560 600 640 690 740 790 840
60 290 320 360 400 430 480 520 560 610 650 700 750 800 860 910
65 310 350 390 430 470 510 560 610 660 710 760 820 870 930 990
70 340 380 420 460 510 550 600 650 710 760 820 880 940 1,000 1,070
Conversion Tables
20-in. Duplex Pump
Conversion Tables
per
Minute 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4 71⁄ 2 73⁄ 4 8 81⁄ 4 81⁄ 2
25 140 160 180 190 210 220 250 270 300 320 340 370 390 420 450
30 170 190 210 230 250 260 300 330 360 380 410 440 470 500 540
35 200 220 250 270 300 310 350 380 410 450 480 510 550 590 630
40 210 240 270 290 320 350 380 420 450 480 520 560 600 640 680
45 240 270 300 330 360 400 430 470 510 540 590 630 670 720 760
50 270 300 330 370 400 440 480 520 560 610 650 700 750 790 850
55 290 330 370 400 440 480 530 570 620 670 720 770 820 870 930
60 320 360 400 440 480 530 570 620 670 730 780 840 890 950 1,020
65 350 390 430 480 520 570 620 680 730 790 850 910 970 1,030 1,100
70 370 420 460 510 560 620 670 730 790 850 910 980 1,040 1,110 1,180
281
7-in. Stroke, Triplex Pump

per
Minute 41⁄ 2 5 51⁄ 2 6 61⁄ 2 7
40 60 70 80 100 120 130
60 80 100 120 150 170 200
70 100 120 140 170 200 230
80 110 140 160 200 230 270
90 120 150 180 220 260 300
100 140 170 200 240 290 330
110 150 190 230 270 320 370
120 170 200 250 290 340 400
140 190 240 290 340 400 470
160 220 270 330 390 460 530

per
Minute 3 31⁄ 4 31⁄ 2 4 41⁄ 2 5 51⁄ 2 6 61⁄ 4
40 30 30 40 50 60 80 100 110 120
60 40 50 60 80 90 120 140 170 180
70 50 60 70 90 110 140 160 200 210
80 60 70 80 100 130 160 190 220 240
90 60 70 90 110 140 170 210 250 270
100 70 80 100 120 160 190 240 280 300
110 80 90 110 140 170 210 260 310 330
120 80 100 120 150 190 230 280 340 360
140 100 120 130 170 220 270 330 390 430
160 110 130 150 200 250 310 380 450 490
180 130 150 170 220 280 350 420 500 550
81⁄ 2-in. Stroke, Triplex Pump

per
Minute 41⁄ 4 41⁄ 2 43⁄ 4 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4
40 60 70 70 80 90 100 110 120 130
60 90 100 110 120 140 150 160 180 190
70 100 120 130 140 160 170 190 210 230
80 120 130 150 160 180 200 220 240 260
90 130 150 170 190 200 220 250 270 290
100 150 170 190 210 230 250 270 300 320
110 160 180 200 230 250 270 300 330 350
120 180 200 220 250 270 300 330 360 390
140 210 230 260 290 320 350 380 420 450
160 240 270 300 330 360 400 440 470 520
180 270 300 330 370 410 450 490 530 580

per
Minute 41⁄ 2 5 51⁄ 2 6 61⁄ 2
40 70 90 110 130 140
60 110 130 160 190 200
70 120 150 180 220 240
80 140 170 210 250 270
90 160 200 240 280 310
100 180 220 260 310 340
110 190 240 290 350 370
120 210 260 320 380 410
130 230 280 340 410 440
140 250 310 370 440 480
150 270 330 390 470 510
91⁄ 4-in. Stroke, Triplex Pump

per
Minute 41⁄ 2 43⁄ 4 5 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4
40 70 80 90 100 110 120 130 140
60 110 120 130 150 160 180 190 210
70 130 140 160 170 190 210 230 250
80 150 160 180 200 220 240 260 280
90 160 180 200 220 240 270 290 320
100 180 200 220 250 270 300 320 350
110 200 220 250 270 300 330 360 390
120 220 240 260 300 330 360 390 420
130 240 260 290 320 350 390 420 460
150 270 300 340 370 410 450 490 530
170 310 340 380 420 460 510 550 600

per
Minute 51⁄ 4 51⁄ 2 53⁄ 4 6 61⁄ 4
40 70 90 110 130 140
40 110 120 130 140 150
60 160 180 190 210 230
70 190 210 220 240 280
80 210 230 260 280 300
90 240 260 290 310 340
100 270 290 320 350 380
110 290 320 350 380 420
120 320 350 390 420 450
130 350 380 420 450 490
140 370 410 450 490 530
160 430 470 510 560 610

per
Minute 51⁄ 2 6 61⁄ 2 7
40 130 150 180 210
50 160 190 230 260
60 190 230 270 310
70 230 270 320 370
80 260 310 360 420
90 290 350 410 470
100 320 380 450 520
110 350 420 500 580
120 390 460 540 630
130 420 500 590 680

per
Minute 51⁄ 2 53⁄ 4 6 61⁄ 4 61⁄ 2 63⁄ 4 7 71⁄ 4
40 140 150 170 180 200 210 230 240
50 180 190 210 230 250 270 290 310
60 210 230 250 270 300 320 340 370
70 250 270 290 320 340 370 400 430
80 280 310 330 360 390 420 460 490
90 320 350 380 410 440 480 510 550
100 350 390 420 450 490 530 570 610
110 390 420 460 500 540 580 630 670
120 420 460 500 550 590 640 680 730
130 460 500 540 590 640 690 740 800
140 490 540 590 640 690 740 800 860
Hardness Conversion Table

Approximate Values
Rockwell Brinell Rockwell Brinell
C No. C B No.
66 31 293
65 745 30 285
64 712 29 277
62 682 28 269
60 653 27 262
59 627 25 255
58 601 24 248
57 578 23 100 241
55 555 22 99 235
54 534 21 98 229
52 514 19 97 223
51 495 18 96 217
50 477 16 96 212
49 461 15 95 207
47 444 14 94 201
46 429 13 93 197
45 415 12 92 192
43 401 10 91 187
42 388 9 90 183
40 375 8 89 179
39 363 6 88 174
38 352 5 87 170
37 341 4 86 167
36 331
34 321
33 311
32 302
Impression Diameter Hardness Table

Brinell
500 kg 3,000 Rockwell
Dia. B.H.N. kg C B Tensile
2.00 158 946 Rockwell hardness and
2.05 150 896 tensile strengths apply
2.10 143 857 only to B.H.N.
2.15 136 817 with 3,000 kg load
2.20 130 782 68 368
2.25 124 744 67 360
2.30 119 713 65 354
2.35 114 683 63 341
2.40 109 652 62 329
2.45 105 627 60 317
2.50 100 600 58 305
2.55 96 578 56 295
2.60 93 555 55 120 284
2.65 89 532 53 119 273
2.70 86 512 52 119 263
2.75 83 495 50 117 253
2.80 80 477 48 116 242
2.85 77 460 47 116 233
2.90 74 444 46 115 221
2.95 72 430 44 114 211
3.00 70 418 43 114 202
3.05 67 402 42 113 193
3.10 65 387 41 112 185
3.15 63 375 39 112 178
3.20 61 364 38 110 171
3.25 59 351 37 110 165
3.30 57 340 36 109 159
3.35 55 332 35 108 154
3.40 54 321 34 108 148
3.45 52 311 32 107 143
3.50 50 302 31 106 139
3.55 49 293 30 105 135
3.60 48 286 29 104 131
3.65 46 277 28 104 127
3.70 45 269 27 104 124
3.75 44 262 26 103 121
3.80 43 255 25 102 117
3.85 41 248 24 102 115
3.90 40 241 23 100 112
3.95 39 235 22 99 109
Impression Diameter Hardness Table (continued)

Brinell
500 kg 3,000 Rockwell
Dia. B.H.N. kg C B Tensile
4.00 38.0 228 21 98 107
4.05 37.0 223 20 97 105
4.10 36.0 217 18 96 103
4.15 35.0 212 17 96 100
4.20 34.5 207 16 95 98
4.25 33.6 202 15 94 96
4.30 32.6 196 14 93 95
4.35 32.0 192 12 92 93
4.40 31.2 187 12 91 91
4.45 30.4 183 11 90 89
4.50 29.7 179 10 89 87
4.55 29.1 174 9 88 85
4.60 28.4 170 8 87 84
4.65 27.8 166 7 86 82
4.70 27.2 163 6 85 81
4.75 26.5 159 5 84 79
4.80 25.9 156 4 83 78
4.85 25.4 153 3 82 76
4.90 24.9 149 2 81 75
4.95 24.4 146 1 80 74
5.00 23.8 143 0 79 72
5.05 23.3 140 -2 78 71
5.10 22.8 137 -3 77 70
5.15 22.3 134 76 68
5.20 21.8 131 74 66
5.25 21.5 128 73 65
5.30 21.0 126 72 64
5.35 20.6 124 71 63
5.40 20.1 121 70 62
5.45 19.7 118 69 61
5.50 19.3 116 68 60
5.55 19.0 114 67 59
5.60 18.6 112 66 58
5.65 18.2 109 65 56
5.70 17.8 107 64 55
5.75 17.5 105 62 54
5.80 17.2 103 61 53
5.85 16.9 101 60 52
5.90 16.6 99 59 51
5.95 16.2 97 57 50
CONVERSION FACTORS
Fraction to Decimal
1 17 33 49
⁄ 64 .0156 ⁄ 64 .2656 ⁄ 64 .5156 ⁄ 64 .7656
1 9 17 25
⁄ 32 .0312 ⁄ 32 .2812 ⁄ 32 .5312 ⁄ 32 .7812
3 19 35 51
⁄ 64 .0468 ⁄ 64 .2968 ⁄ 64 .5468 ⁄ 64 .7968
1 5 9 13
⁄ 16 .0625 ⁄ 16 .3125 ⁄ 16 .5625 ⁄ 16 .8125
5 21 37 53
⁄ 64 .0781 ⁄ 64 .3281 ⁄ 64 .5781 ⁄ 64 .8281
3 11 19 27
⁄ 32 .0937 ⁄ 32 .3437 ⁄ 32 .5937 ⁄ 32 .8437
7 23 39 55
⁄ 64 .1093 ⁄ 64 .3593 ⁄ 64 .6093 ⁄ 64 .8593
1 3 5 7
⁄8 .1250 ⁄8 .3750 ⁄8 .6250 ⁄8 .8750
9 25 41 57
⁄ 64 .1406 ⁄ 64 .3906 ⁄ 64 .6406 ⁄ 64 .8906
5 13 21 29
⁄ 32 .1562 ⁄ 32 .4062 ⁄ 32 .6562 ⁄ 32 .9062
11 27 43 59
⁄ 64 .1718 ⁄ 64 .4218 ⁄ 64 .6718 ⁄ 64 .9218
3 7 11 15
⁄ 16 .1875 ⁄ 16 .4375 ⁄ 16 .6875 ⁄ 16 .9375
13 29 45 61
⁄ 64 .2031 ⁄ 64 .4531 ⁄ 64 .7031 ⁄ 64 .9531
7 15 23 31
⁄ 32 .2187 ⁄ 32 .4687 ⁄ 32 .7187 ⁄ 32 .9687
15 31 47 63
⁄ 64 .2343 ⁄ 64 .4843 ⁄ 64 .7343 ⁄ 64 .9843
1 1 3
⁄4 .2500 ⁄2 .5000 ⁄4 .7500 1 1.0000
CONVERSION FACTORS
English and Metric
Multiply By To Obtain
Acres 43,560 Square feet
Acres 0.001562 Square miles
Acres 4,840 Square yards
Barrels, water 31.5 Gallons
Barrels, water 263 Pounds
Barrels, oil (API) 42.0 Gallons
Barrels per day 0.02917 Gallons per minute
Centimeter 0.3937 Inches
Cubic centimeters 0.006102 Cubic inches
Cubic feet 1,728 Cubic inches
Cubic feet 0.03704 Cubic yards
Cubic feet 7.481 Gallons
Cubic feet 0.1781 Barrels (oilfield)
Cubic feet 28.3160 Liters
Cubic feet 0.03704 Cubic yards
Cubic feet per minute 0.4719 Liter per second
Cubic inches 16.3871 Cubic centimeters
Cubic yards 27 Cubic feet
Cubic yards 0.764555 Cubic meters
Degrees (angle) 0.01745 Radians
Degree Fahrenheit (F) [Degree F-32]÷1.8 (or x 5/9) Degree Celsius (C)
Feet 30.48 Centimeters
Feet 12 Inches
Feet 0.3048 Meters
Feet .0001894 Miles
Feet of water (depth) .4335 Pounds per square inch
Feet 0.3048 Meters
Foot pounds 1.35582 Joules
Foot pounds 0.138255 Meter-kilograms
Furlongs 660 Feet
Gallons(imperial) 1.209 Gallons (U.S.)
Gallons (imperial) 4.54609 Liters
Gallons (U.S.) 3,785.434 Cubic centimeters
Gallons (U.S.) .02381 Barrels, oil
Gallons (U.S.) .1337 Cubic feet
Gallons (U.S.) 3.785 Liters
Gallons per minute .002228 Cubic feet per second
Gallons per minute 34,286 Barrels per day
Grains 64.79891 Milligrams
Grams .03527 Ounces
Inches .08333 Feet
Inches 25.4 Millimeters
Inches of water .03613 Pounds per square inch
CONVERSION FACTORS (CONTINUED)

English and Metric
Kilometers 3,281 Feet
Kilometers .6214 Miles
Kilometers per hour .6214 Miles per hour
Knots 6,080 Feet
Knots 1.152 Miles
Knots per hour 1.152 Miles per hour
Liters .03531 Cubic feet
Liters .2642 Gallons
Meters 3.281 Feet
Meters 39.37 Inches
Meters 1.094 Yards
Miles 5,280 Feet
Miles 1.609 Kilometers
Miles 1,760 Yards
Miles per hour 88 Feet per minute
Miles per hour 1.609 Kilometers per hour
Miles per hour .8684 Knots per hour
Minutes .01667 Hours
Minutes (angle) .0002909 Radians
Minutes (angle) 60 Seconds (angle)
Ounces (fluid) 1.805 Cubic inches
Ounces per cubic inch 1.72999 Grams per cubic centimeter
Paschal (unit or force,
pressure) 1.0 Newton per square meter
Pints 28.87 cubic inches
Pints .125 Gallons
Pounds 453.6 Grams
Pounds .4536 Kilograms
Pounds of water .01602 Cubic feet of water
Pounds of water 27.68 Cubic inches of water
Pounds of water .1198 Gallons
Pounds per cubic foot .01602 Grams per cubic centimeter
Pounds per cubic foot 16.0185 Kilograms per cubic meter
Pounds per square foot 4.88241 Kilograms per square meter
Pounds per square foot 47.8803 Newtons per square meter
Pounds per square inch 2.307 Feet of water
Pounds per square inch 2.036 Inches of mercury
Pounds per square inch 0.689476 Newtons per square centimeter
Quarts (U.S.) 57.75 Cubic inches
Quarts (U.S.) 946.4 Cubic centimeters
Quarts (U.S.) 0.946331 Liters
Radians 57.30 Degrees
Radians per second 9.549 Revolutions per minute
CONVERSION FACTORS (CONTINUED)

English and Metric
Square centimeters .1550 Square inches
Square feet 144 Square inches
Square feet .00002296 Acres
Square feet 929 Square centimeters
Square inches 6.4516 Square centimeters
Square inches .006944 Square feet
Square miles 640 Acres
Square miles 2.59 Square kilometers
Square kilometer 247.1 Acres
Square meters 10.76 Square feet
Square meters .0002471 Acres
Square yards 9 Square feet
Square yards .8361 Square meters
Temperature
(degrees Cent.) 1.8 (add 32 deg.) Temp. (degrees Fahr.)
Temperature 5/9 or 0.5556
(degrees Fahr.) (subtract 32 deg.) Temp. (degree Cent.)
Tons (long) 2,240 Pounds
Tons (metric) 2,205 Pounds
Tons (short) 2,000 Pounds
Yards .9144 Meters
Yards 91.44 Centimeters
8
SECTION 8
INDEX OF
SECTION EIGHT PRODUCT
REFERENCES
INDEX OF PRODUCT REFERENCES

Index of Product References 295
Anchor-Stock, Retrievable .......................................................... 67

API Casing Data ........................................................................ 232
Areas of Circle and Nozzles ...................................................... 151
Bit Selection Equations ............................................................. 247
Bit Weight — Rotational Speed Equations ................................ 247
Bouyancy Factors ...................................................................... 274
Casing Data, API ....................................................................... 232
Casing, Dimensions .................................................................. 232
Casing, Eccentric Diameter ....................................................... 214
Casings, Recommendations to Set Small
Clearance Consecutive Strings ................................................ 93
Connection Interchange List, Rotary Shouldered ..................... 262
Conversion Factors, English and Metric ................................... 290
Conversion Factors, Fraction to Decimal .................................. 289
Conversion Factors, Hardness .................................................. 286
Conversion Factors, Mud Weight ............................................. 149
Drill Collar Weights .................................................................. 271
Drill Mill Specifications .............................................................. 53
Drill Pipe Data .......................................................................... 266
Drill Pipe Data, Hevi-Wate ........................................................ 267
Drilling Fluid Property Equations ............................................ 251
Drilling-Type Underreamer Specifications (DTU) .................... 115
DTU Underreamer Cone Availability .......................................... 89
Dull Bit Grading, IADC ............................................................. 244
Duplex Mud Pump Data ........................................................... 275
Eccentric Diameter, Casing ....................................................... 214
Economill Specifications ............................................................ 52
Econo-Stock, Retrievable ............................................................ 70
Equations, Hydraulic Calculation ............................................ 248
Gage Diameter Tolerances — Hole Openers/Hole Enlargers .... 157
Gage Diameter Tolerances — Underreamers ............................. 132
GTA Hole Opener Specifications ............................................... 181
Hardness Conversion Table ...................................................... 286
Hardness Impression Diameter ................................................ 287
Hevi-Wate Drill Pipe Data ......................................................... 267
Hole Enlarger Specifications .................................................... 203
Hole Opener, GTA Specifications .............................................. 181
Hole Opener, Master Driller Specifications ............................... 163
Hole Opener, Net Annular Area Removed ................................ 140
Hole Opener, SDD Specifications .............................................. 171
Hole Openers/Hole Enlargers, Gage Diameter Tolerances ....... 157
Hole Openers/Hole Enlargers,
Weights and Rotary Recommendations ................................ 156
Hydraulic Calculation Equations ............................................. 248
296 Index of Product References
Hydraulic Tool Flow Rate, Minimum ....................................... 138

Hydraulic Tool Opening Force .................................................. 137
Hydraulic Tools, Jet Combinations ........................................... 148
IADC Dull Bit Grading .............................................................. 244
Impression Diameter, Hardness ............................................... 287
Jet Combinations for Hydraulic Tools ...................................... 148
Jet Nozzle Area ......................................................................... 148
Junk Mill Specifications ............................................................. 43
Junk Sub Specifications .............................................................. 45
Junkmaster Specifications .......................................................... 55
K-Mill, Casing Specifications ...................................................... 14
K-Mill, Flow Rates ........................................................................ 9
K-Mill Specifications ................................................................... 14
Makeup Torque, Recommended Minimum ............................. 254
Makeup Torque, Top Sub ......................................................... 264
Marine Pipe Cutter, Cutter Length Specifications ..................... 220
Marine Pipe Cutter, Flow Rates ................................................ 209
Marine Pipe Cutter, Specifications ............................................ 218
Marine Support Swivel, Specifications ..................................... 223
Master Driller Specifications .................................................... 163
Milling, General Operating Recommendations ............................ 5
Milling, Normal Rates .................................................................. 5
Mud Pump Data, Duplex .......................................................... 275
Mud Pump Data, Triplex .......................................................... 282
Mud Weight .............................................................................. 149
Mud Weight, Bouyancy Factors ................................................ 273
Mud Weight, Conversion Factors ............................................. 149
Net Annular Area Removed with
Underreamer or Hole Opener ............................................... 140
Nozzle/Orifice Area .................................................................. 151
One-trip Trackmaster .................................................................. 74
Orifice Sizes for Drilling-Type and Reammaster ....................... 143
Orifice Sizes for K-Mill, SPX/Drag- and Rock-Type .................. 144
Pack-Stock, Retrievable .............................................................. 65
Pilot Mill Specifications .............................................................. 32
Pipe Cutter, Cutter Length Specifications ................................. 220
Pipe Cutter, Flow Rates and Rotary Speeds .............................. 209
Pipe Cutter, Specifications ........................................................ 219
Pressure Drop Across One Orifice ............................................. 146
Reamaster Operating Parameters ............................................... 94
Reamaster Underreamer (XTU) Specifications ......................... 105
Retrievable Anchor-Stock ........................................................... 67
Retrievable Econo-Stock ............................................................. 70
Retrievable Pack-Stock ............................................................... 65
Index of Product References 297
Rock Bit Comparison Chart ...................................................... 234

Rock-Type Underreamer (RTU) ................................................ 123
Rotary Shouldered Connection Interchange List ...................... 262
RTU Underreamer Cone Availability .......................................... 89
SDD Hole Opener Specifications ............................................... 171
Section Mill, Flow Rates ............................................................... 9
Section Mill Specifications ......................................................... 27
Servcoloy Composite Rod ........................................................... 59
Servcoloy Concentrate Rod ........................................................ 59
Servcoloy “S” Field Kits .............................................................. 60
Skirted Junk Mill, Specifications ................................................ 55
Small Clearance Consecutive Strings of
Casings, Recommendations ................................................... 93
Spacer Sub Length Sizing ......................................................... 212
SPX/Drag-Type Underreamer Specifications ............................ 131
Stabilizer Top Sub, Blade Diameters ......................................... 220
Stabilizer Top Sub, Specifications ............................................. 219
Swivel, Marine Support Specifications ..................................... 223
Taper Mill Specifications ............................................................ 51
Tool Joint Dimensions, Recommended Min-Max .................... 265
Torque, Recommended Minimum Makeup ............................. 254
Torque, Top Sub Makeup ......................................................... 264
Total Flow Area (TFA) .............................................................. 223
Trackmaster ................................................................................ 74
Triplex Mud Pump Data ........................................................... 282
Tubing Data .............................................................................. 270
Underreamer, Cone Availability ................................................. 89
Underreamer, Drilling-Type (DTU) Specifications .................... 115
Underreamer, Net Annular Area Removed ............................... 140
Underreamer, Reamaster (XTU) Specifications ........................ 105
Underreamer, Rock-Type (RTU) Specifications ........................ 123
Underreamer, SPX/Drag-Type Specifications ........................... 131
Underreamer, STU Makeup Torque Specifications ..................... 99
Underreamer, XTU Makeup Torque Specifications .................... 99
Underreamers, Gage Diameter Tolerances ............................... 132
Washover Shoes, Specifications ................................................. 60
Weights and Rotary Recommendations for
Hole Openers/Hole Enlargers ............................................... 156
XTU Underreamer Makeup Torque Specifications ..................... 99
Notes
P.O. Box 60068 • Houston, Texas 77205-0068
U.S. and Canada: 800/US SMITH
Tel: 281-443-3370 • Fax: 281-233-5121
www.siismithservices.com
©1999 Smith International, Inc. All rights reserved.

SE-1000 5M 9/99 Litho in U.S.A.

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REMEDIAL

P.O. Box 60068 • Houston, Texas 77205-0068

Requests for permission to reproduce or translate all or any part of

The Field Operations, Sales,

• On small workover rigs and deep drilling jobs with limited

How to Read Cuttings

Recommendations on Weights and Speeds

The wear pattern on section and pilot mills is a great

Some Factors That Affect Milling Rates

Encountering Rubber in the Hole

Stabilizing the Mill

What to do About Rough Operation

Operating Recommendations for Milling

General Operating Recommendations for Milling

Normal Milling Rate

Drill 2-6 6-8 6

MillmasterT Assembly Showing Chip BreakerE Cutting Structure

Millmaster systems are only available on a rental basis in conjunction with

*U.S. Patent Number:

Flo-Tel T Option Assures Positive Tool Opening

Schematic of Staged Knife Opening

Higher pressure against casing for cut-out

Pressure drop for milling

6 Cutter knives — 3 for cut-out, 6 for milling

General Suggestions for Effective Section Milling

Recommended Procedure for Milling a Section

Start rotation at 60 RPM and build pressure slowly until

Difficulties Encountered in Cutting Out

M-I DRILLING FLUIDS RECOMMENDATION FOR MUD

FLOW GUIDELINES FOR MILLMASTER SYSTEM TOOLS

STANDARD MILLMASTER BHA RECOMMENDATIONS

Section Planning for Sidetracking

Properties and Flow Rates

• - Small adjustments in the flow rate, rotary speed and

Underreaming for Sidetrack Plug

Using the K-Mill as a Pipe Cutter

Cutting the Pipe

• The loss of torque, a decrease in pump pressure or both,

Flo-Tel tensions screw

Anti-wash tube Lug

Arm hinge pin

Cam lock nut Retaining screw

Body Arm stop body stabilizer

Nominal overall length

General Guidelines for Using Pilot Mills

Considerations When Milling Liner Hangers and Adapters

A Pilot Mill is Ideal for Washpipe

Milling Drill Pipe and Drill Collars

Using the Pilot Mill in Swaged Completion

Using a Pilot Mill

3. To mill H-40 or K-55 casing, use a weight between 4,000

Pilot Mill Specifications

Notes: Ordering Instructions:

Millmaster-dressed Piranha mills are only available on a rental basis in

*U.S. Patent Numbers:

Offshore Slot Recovery

Description of the Piranha Mill

Slot Recovery Operating Parameters

Junk Milling Procedures

Loose Junk in Open Hole

Stationary Junk in Open Hole

Junk Mill Specifications

CP Taper Mill Designed for the Toughest Taper Mill Job