Drilling Bit Dull Grading

Contents

Reference Material

Definitions and Guidelines

System Structure
– Detailed Review of the 8-digit system

Dull Characteristics
– Information and Photographs
Reference Material

“The IADC Roller Bit Dull Grading System”

– Authors: McGehee et al.
– 1992 IADC/SPE Drilling Conference
– Paper #23938

Smith Bits Dull Grading Manual - Geodiamond/Smith Tool

Combined
– Available from Reader Services
– Item #90090
Definitions and Guidelines

The Smith Tool Definitions and Guidelines shown within are

not IADC standards.

They were created to reduce ambiguities and to improve our

consistency in grading dull bits, within the current IADC
structure.
IADC Roller Bit Dull Grading System

T B G REMARKS

1 2 3 4 5 6 7 8
CUTTING STRUCTURE B G REMARKS
Inner Outer Dull Loca- Brng. Gage Other Reason
Rows Rows Char. tion Seal 1/16 Dull Pulled
(I) (O) (D) (L) (B) (G) (O) (R)
 I: Inner Rows

Used to report the condition of the
Tooth Height Measurement

cutting elements not touching the
wall of the hole.

Linear scale from 0 - 8 measuring

the combined cutting structure
reduction due to lost, worn and/or
broken cutting elements.
 O: Outer Rows

Used to report the condition of the
Tooth Height Measurement

cutting elements that touch the
wall of the hole

Linear scale from 0 - 8 measuring

the combined cutting structure
reduction due to lost, worn and/or
broken cutting elements.
– Smith Tool guideline - Do not
include heel elements
Gauge Configurations

Conventional Trucut (T) Binary (B)

Identifying TCI Rows

Heel Row Heel Row

Gauge Row Gauge Row
Inner Row (off-gauge row) Inner Row

Conventional Gauge Structure Trucut Gauge Structure

Identifying Milled Tooth Rows

Gauge Row Heel Row

Inner Row Gauge Row
(off-gauge row) Inner Row

Conventional Gauge Structure Trucut Gauge Structure

D: Dull Characteristics

BC - Broken Cone*
LN - Lost Nozzle

BF - Bond Failure#
LT - Lost Teeth/Cutters

BT - Broken Teeth/Cutters
NO - No Dull Characteristic

BU - Balled Up
OC - Off Center Wear

CC - Cracked Cone*
PB - Pinched Bit

CD - Cone Dragged*
PN - Plugged Nozzle

CI - Cone Interference
RG - Rounded Gauge

CR - Cored
RO - Ring Out#

CT - Chipped Teeth/Cutters
SD - Shirttail Damage

ER - Erosion
SS - Self Sharpening Wear

FC - Flat Crested Wear
TR - Tracking

HC - Heat Checking
WO - Washed Out Bit

JD - Junk Damage
WT - Worn Teeth/Cutters

LC - Lost Cone*
* Show cone number or numbers under location (L)
# Not used for roller cone bits
D: Dull Characteristics

Two letter code to indicate the major dull characteristic of

the cutting structure.
– Smith Tool guideline - input only one dull characteristic code
– This column is only for codes that apply to cutting structures

Which code do I select?

– Smith Tool guideline - The cutting structure dull characteristic is the
observed characteristic that would most likely limit further usage of
the bit in that application
L: Location

Uses a letter or number code to indicate the location on the face of

the bit where the cutting structure dull characteristic occurs
– G = Gauge: those cutting elements which touch the hole wall.
– N = Nose: the centermost cutting elements of the bit.
– M = Middle: the cutting elements between the nose and the gauge.
– A = All rows
– Cone numbers

– Smith Tool guideline - a maximum of two characters to be input

L: Location

Smith Tool Guidelines

– In general, the #1 cone typically contains the centermost cutting
element. The #2 and #3 cones follow in a clockwise rotation.

– However, accurate determination of #1 cone, on any roller cone

bit, by visual examination is not always possible.
General Cone Identification Rule

#1 Centermost Cutting Element #1

(Spearpoint)

#3 #2 #3 #2
Roller Cone Bit: Location

Gauge

Middle

Nose
B: Bearings/Seals

Smith Tool Guidelines

– This column is used to indicate the condition of the bearing and
seal assembly. If either component in the assembly has failed,
then the code is ‘F’.
– If any portion of the bearing is exposed or missing, it is considered
an ineffective (F) assembly.
– Use ‘N’ if unable to determine the condition of both components.
– Smith Tool grades each assembly separately.
– If grading all assemblies as one, list the worst case.
B: Bearings/Seals

Sealed Bearing Bits

– E – Seals effective
– F – Seals failed
– N – Not able to grade

Non-Sealed Bearing Bits

– Linear scale from 0 to 8
– Estimating bearing life used
B: Bearings/Seals

Items to check when determining Bearing/Seal effectiveness

– Ability to rotate cone
– Cone ‘springback’
– Seal squeak
– Internal sounds
– Weeping grease
– Shale burn / Shale packing
– Gaps - backface or throat
– Bearing letdown - inner or outer
G: Gauge

Used to report the undergauge condition of the cutting

elements that touch the wall of the hole.
– Based upon a nominal ring gauge.
– New bits are built to API specifications.

API Tolerances for Roller Cone Bits

– 3⅜” to 13¾” API Tolerance: + 1/32 : - 0
– 14” to 17½” API Tolerance: + 1/16 : - 0
– >17⅝” API Tolerance: + 3/32 : - 0
‘Specification for Rotary Drilling Equipment’, API Specification 7 (Spec 7)
G: Gauge

Smith Tool guidelines

– Round to nearest 1/16”
– Bits with bearing/seal failures: can measure amount out of gauge
as long as the cones do not have any axial or radial movement
– Measurement to be made on either the gauge or heel elements
which ever is closer to gauge
– Applies to cutting structure elements only
– If nominal ring gauges are not available true gauge condition can
not be determined.
– There are no API specifications for nominal ring gauges for roller
cone bits — only for diamond and PDC bits
 G: Gauge

‘Two-Thirds Rule’

Applies to all 3-cone bits
Amount out of gauge =
Measured distance x ⅔

Amount Undergauge in 16ths

IN = In Gauge
1 = 1/16”
2 = 2/16”
3 = 3/16”
Etc..

Rotate all cones to MAXIMUM offset

 G: Gauge

Two-Cone Bits

Amount out of gauge =

Measured distance

Amount Undergauge in 16ths

IN = In Gauge
1 = 1/16”
2 = 2/16”
3 = 3/16”
Etc..

Rotate all cones to MAXIMUM offset

O: Other Dull Characteristics

BC - Broken Cone*
LN - Lost Nozzle

BF - Bond Failure#
LT - Lost Teeth/Cutters

BT - Broken Teeth/Cutters
NO - No Dull Characteristic

BU - Balled Up
OC - Off Center Wear

CC - Cracked Cone*
PB - Pinched Bit

CD - Cone Dragged*
PN - Plugged Nozzle

CI - Cone Interference
RG - Rounded Gauge

CR - Cored
RO - Ring Out#

CT - Chipped Teeth/Cutters
SD - Shirttail Damage

ER - Erosion
SS - Self Sharpening Wear

FC - Flat Crested Wear
TR - Tracking

HC - Heat Checking
WO - Washed Out Bit

JD - Junk Damage
WT - Worn Teeth/Cutters

LC - Lost Cone*
* Show cone number or numbers under location (L)
# Not used for roller cone bits
R: Reason Pulled

BHA - Change Bottom Hole Assembly

CM - Condition Mud

CP - Core Point

DMF - Downhole Motor Failure

DP - Drill Plug

DSF - Drill String Failure

DST - Drill Stem Test

DTF - Downhole Tool Failure

FM - Formation Change

HP - Hole Problems

HR - Hours on Bit

LIH - Left in Hole

LOG - Run Logs

PP - Pump Pressure

PR - Penetration Rate

RIG - Rig Repair

TD - Total Depth / Casing Depth

TQ - Torque

TW - Twist Off

WC - Weather Conditions

WO - Washout in Drill String
Dull Characteristics

IADC Definition
– As defined by the IADC, in the most recent paper (#23938)

Smith Tool Definition and Guideline
– Clarification of the IADC definition
– Guidelines to improve dull grading consistency

Potential Causes
– Listing of potential causes for the observed dull characteristic
– See Dull Grading Manual for application recommendations*

*For Application Recommendations, please refer to the Smith Bits Dull Grading Manual - Item #SB-2260
BC - Broken Cone
BC: Broken Cone

IADC Definition
– A bit with one or more cones that have been broken into two or
more pieces, but with most of the cone still attached to the bit.

Smith Tool Guideline

– Cone shell peeling is considered to be a broken cone
BC - Broken Cone

Potential Causes
– Cracked Cone
– Excessive impact load / Improper drilling practices
– Reduction in cone shell thickness
– Drilling Environment
BT - Broken Teeth
BT - Broken Teeth

IADC Definition
– None

Smith Tool Definition

– A cutting element is considered broken if over ⅓ of the cutting
element is gone regardless of the cause.
BT - Broken Teeth

Potential Causes
– Formation / Improper bit selection
– Excessive WOB for application and specific bit type
– Excessive RPM for application and specific bit type
– Broken formations (includes boulders)
– Improper bottom hole pattern break-in
– Excessive impact load / Improper drilling practices
– Cone Interference
– Heat checking
– Rounded gauge
– Erosion
BU - Balled Up
BU - Balled Up

IADC Definition
– A balled up bit will show tooth wear due to skidding, caused by a cone, or cones,
not turning due to formation being packed between the cones. The bit will look
as if a bearing had locked up even though the bearings are still good.

Smith Tool Definition

– Bit balling is a condition whereby formation becomes packed between the cones
and bit body or between the cutting elements such that the ROP suffers.
– There may or may not be any evidence of skidding or physical damage to the
bit.
BU - Balled Up

Potential Causes
– Formation
– Inadequate hydraulics
– Poor fluid distribution
– Improper drilling practices
– Improper bit selection
– Drilling environment
CC - Cracked Cone
CC - Cracked Cone
.

IADC Definition
– A cracked cone is the start of a broken or lost cone and has many
of the same possible causes.

Smith Tool Definition

– This characteristic describes a bit with one or more cones that
have a crack or cracks, but the cones are still wholly intact and not
separated.
– If separated or if any portion of the cone is missing, it is a broken
cone
CC - Cracked Cone

Potential Causes
– Excessive WOB for particular bit type
– Excessive hours for application and specific bit type
– Overbalanced drilling conditions
– Excessive impact load / Improper drilling practices
– Heat checking
– Broken teeth / worn teeth / lost teeth
– Reduction in cone shell thickness
– Drilling environment
– Overheating
CD - Cone Dragged
CD - Cone Dragged

IADC Definition
– A bit in which one or more cones did not turn during part of the run,
indicated by one or more flat wear spots.
CD - Cone Dragged

Potential Causes
– Bearing / seal failure
– Bit balling
– Improper drilling practices
– Running on junk
– Cone interference
– Pinched bit
– Insufficient WOB
– Packed open bearing bits
– Improper bottom hole pattern break-in
CI - Cone Interference
CI - Cone Interference

IADC Definition
– Cone interference often leads to cone grooving and broken teeth
and is sometimes mistaken for formation damage.

Smith Tool Definition

– A condition where the cutting structure of at least one cone has
impacted upon at least one of the adjacent cones.
– This contact can range from a singular cutting element indentation
to a groove.
– A bearing / seal failure may or may not have occurred.
CI - Cone Interference

Potential Causes
– Bearing / seal failure
– Pinched bit
– Improper drilling practices
CR - Cored
CR - Cored

IADC Definition
– A bit is cored when its center most cutters are worn and /or broken
off. A bit can also be cored when the nose part of one or more
cones is broken.

Smith Tool Definition

– A bit is cored (or coring) when its centermost cutting elements are
worn and/or broken and/or lost to the extent that the nose area of
a cone shell or cone shells is showing significant wear from the
formation.
– If any evidence of a fracture surface is seen, then broken cone
(BC) is the cutting structure dull characteristic.
CR - Cored

Potential Causes
– Improper bottom hole pattern break-in
– Junk damage
– Erosion
– Formation / Improper bit selection
– Excessive WOB for application and specific bit type
– Excessive hours for application and specific bit type
– Off center wear
– Improper drilling practices
CT - Chipped Teeth
CT - Chipped Teeth

IADC Definition
– A tooth is considered chipped, as opposed to broken if a
substantial part of the tooth remains above the cone shell.

Smith Tool Definition

– A cutting element is considered chipped if less than ⅓ of the
cutting element is gone regardless of the cause.
– Chipped hardfacing on mill tooth bits is considered to be chipped
teeth.
CT - Chipped Teeth

Potential Causes
– Rough running in air drilling application
– Formation / Improper bit selection
– Excessive WOB for application and specific bit type
– Excessive RPM for application and specific bit type
– Broken formations (includes boulders)
– Improper bottom hole pattern break-in
– Excessive impact load / Improper drilling practices
– Cone Interference
– Heat checking
– Drilling environment
ER - Erosion
ER - Erosion

IADC Definition
– Fluid erosion leads to cutter reduction and / or loss of cone shell
material.

Smith Tool Definition

– Erosion is used to describe the loss of material on the cutting
structure due to the impact of the drilling fluid, the solids and the
cuttings against the cutting structure.
ER - Erosion

Potential Causes
– Inadequate and/or poor hydraulics
– Excessive hydraulics
– Abrasive formations
– Drilling environment
FC - Flat Crested Wear
FC - Flat Crested Wear

IADC Definition
– Flat crested wear is an even reduction in height across the entire
face of the cutters.

Smith Tool Definition

– Flat crested wear is an even reduction in height across the entire
cutting structure.
– The worn surfaces will be ‘flat’ and have little or no radii at the
tooth flanks.
FC - Flat Crested Wear

Potential Causes
– Tracking
– Not enough WOB
HC - Heat Checking
HC - Heat Checking

IADC Definition
– This dulling characteristic happens when a cutter is overheated
due to dragging on the formation and is then cooled by the drilling
fluid over many cycles.

Smith Tool Definition

– A biaxial or cross hatched pattern of surface cracks intersecting at
approximately right angles.
– The number of cracks on a insert can vary significantly.
HC - Heat Checking

Potential Causes
– Insufficient WOB to prevent heat checking on inner rows
– Reaming a slightly undergauge hole at high RPM
– Drilling at high RPM
– Formation
JD - Junk Damage
JD - Junk Damage

IADC Definition
– Junk damage can be detected my marks on any part of the bit.

Smith Tool Definition

– A condition where the bit has indentations caused by contact with objects other
than formation.
– It is to be used in the “Cutting Structure Dull Characteristic” column when
describing damage to a bit knowingly caused by external sources of junk.
– The use of ‘JD’ in the “Remarks Other Dull Characteristic” column implies
damage caused by junk from the bit itself.
JD - Junk Damage

Potential Causes
– Run on junk
LC - Lost Cone
LC - Lost Cone

IADC Definition
– None

Smith Tool Definition
– A bit condition when one or more cones are missing from the leg
assembly(s).
– Also, since there is no existing IADC code for a broken leg, use LC
to indicate the loss of a cutter / leg assembly.
LC - Lost Cone

Potential Causes
– All conditions that lead to a broken cone (BC) and cracked cone
(CC) can result in lost cone
– Excessive hours after bearing / seal failure
LN - Lost Nozzle
LN - Lost Nozzle

IADC Definition
– While LN is not a cutting structure dulling characteristic, it is an important “Other
Dulling Characteristic” that can help describe a bit condition. A lost nozzle
causes a pressure decrease which requires that the bit be pulled out of the hole.
A lost nozzle is also a source of junk in the hole.

Smith Tool Definition

– This characteristic describes a bit that is missing one of more jet nozzles.
– It is not a “Cutting Structure Dull Characteristic” and should only be used in the
“Remarks Other Dull Characteristic” column.
LN - Lost Nozzle

Potential Causes
– Improper nozzle installation
– Mechanical damage to nozzle and/or nozzle retaining system
– Wrong nozzle type for application
– Erosion damage to nozzle and/or nozzle retaining system
– Bit balling
LT - Lost Teeth
LT - Lost Teeth

IADC Definition
– This dulling characteristic leaves entire tungsten carbide inserts in
the hole which are far more detrimental to the rest of the bit than
are broken inserts. Lost teeth often cause junk damage. Lost
teeth are sometimes preceded by rotated inserts

Smith Tool Definition

– This characteristic describes a cutting structure that is missing one
or more cutting elements.
LT - Lost Teeth

Potential Causes
– Excessive WOB for particular bit type
– Excessive hours for particular bit type
– Erosion
– Cone cracking
– Broken cone
– Drilling environment
– Overbalanced drilling conditions
OC - Off Center Wear
OC - Off Center Wear

IADC Definition
– This dull characteristic occurs when the geometric center of the bit
and the geometric center of the hole do no coincide. This results
in an oversized hole. Off center wear can be recognized on he
dull bit by wear on the cone shells between the rows of cutters,
more gauge wear on one cone, and by a less than expected
penetration rate.
OC - Off Center Wear

Smith Tool Definition

– This dulling characteristic occurs when the geometric center of the bit and the
geometric center of the hole do not coincide.
– Drilling in this mode results in an oversized hole.
– Off center wear can be recognized on the dull bit by wear on the cone shells
between the rows of cutters, potentially more wear on one or more cone, gauge
row, leg or nozzle boss.
– The wear on the cone shell may have a have a “swirling” pattern or may be
symmetrical.
– Wear may or may not occur on the cutters themselves, but if it occurs, it will
typically be on the inner and/or outer flanks.
OC - Off Center Wear

Potential Causes
– Slow ROP
– Inadequate WOB for formation and bit type
– Bent collar
– Inadequate stabilization
– Steerable systems of downhole motors
– Overbalanced drilling condition
PB - Pinched Bit
PB - Pinched Bit

IADC Definition
– A condition in which the bit is mechanically forced to a less than
original gauge.
PB - Pinched Bit

Smith Tool Definition

– A condition in which a cone or cones on the bit have been mechanically
forced together to a less than original gauge condition at some point
during its run.
– Evidence of insert to cone shell contact between an opposing cone or
cones may or may not be seen. The bit may or may not be less than
nominal gauge when measured. The bearings/seals may or may not be
effective when the dull is seen, but they were intact when the pinching
occurred.
– If cone shell contact did not occur and one or more bearing/seal failures
has occurred, there is no conclusive external evidence of pinching.
– Pinched Bit (PB) is not used in the “Cutting Structure Dull Characteristic”
column.
PB - Pinched Bit

Potential Causes
– Improper drilling practices
PN - Plugged Nozzle
PN - Plugged Nozzle

IADC Definition
– This dulling characteristic does not describe the cutting structure
but can be useful in providing information about a bit run. A
plugged nozzle can lead to reduced hydraulics or force a trip out of
the hole due to excessive pump pressure.

Smith Tool Definition

– A characteristic where one or more of the nozzles are obstructed .
– This characteristic is used only in the “Remarks Other Dull
Characteristic” column.
PN - Plugged Nozzle

Potential Causes
– Improper drilling practices
– Pumped foreign material
– Formation plugging
RG - Rounded Gauge
RG - Rounded Gauge

IADC Definition
– A bit that has experienced gauge wear in a rounded manner, but
will still drill a full size hole. The gauge inserts may be less than
nominal bit diameter but the cone backfaces are still at nominal
diameter.

Smith Tool Definition

– Rounded gauge is a condition where the outermost tip of the
gauge insert has rounded over such that it is not cutting nominal
gauge.
– Rounded gauge can occur regardless if the bit is in nominal
gauge.
RG - Rounded Gauge

Potential Causes
– Reaming an undergauge hole in an abrasive formation
– Formation / Improper bit selection
– Excessive RPM for application and specific bit type
– Off center wear
SD - Shirttail Damage
 Shirttail Definitions

Shirttail
– The shirttail is that area below a
horizontal line drawn through the
ball plug. Leg

Shirttail Tip
– The area in the shirttail between 90° Shirttail
to 120°
Ball Plug

Shirttail Tip
SD - Shirttail Damage

IADC Definition
– Shirttail damage may be different than junk damage and is not a
cutting structure dulling characteristic. Shirttail wear can lead to
seal failures.

Smith Tool Definition

– A condition whereby damage due to wear, erosion or junk occurs
in the shirttail area.
– Shirttail Damage (SD) in not used in the “Cutting Structure Dull
Characteristic” column. This characteristic is used only in the
“Remarks Other Dull Characteristic” column.
SD - Shirttail Damage

Potential Causes
– Run on junk
– Reaming undergauge hole
– Deviated holes
– Off center wear
– Inadequate and/or poor hydraulics
– Inadequate stabilization
– Pinched bit
– Rounded gauge
SS - Self Sharpening Wear
SS - Self Sharpening Wear

IADC Definition
– This is a dulling characteristic which occurs when cutters wear in a
manner such that they retain a sharp crest shape.

Smith Tool Definition

– This characteristic is reserved for milled tooth bits.
– It is a condition that occurs when the milled teeth wear in a manner
such that they retain a sharp crest shape.
– This characteristic is considered an indication of proper bit
selection on bits with a self-sharpening feature at normal operating
parameters.
SS - Self Sharpening Wear

Potential Causes
– This characteristic is considered an indication of proper bit
selection on bits with self sharpening feature at normal operating
parameters
TR - Tracking
TR - Tracking

IADC Definition
– This dulling characteristic occurs when the teeth mesh like a gear
into the bottom hole pattern. the cutter wear on a bit that has
been tracking will be on the leading and trailing flanks. The cone
shell wear will be between the cutters in a row.
TR - Tracking

Smith Tool Definition

– A condition where the cutting elements on a given row impact on
the same bottom hole location with each successive cone
revolution.
– The action of the cutting element sliding into the previously formed
pattern produces individualistic and distinctive wear which can
vary between the rows on different cones.
– The wear is not limited to a particular area on the cutting element,
nor does wear on the cone shell have to occur.
TR - Tracking

Potential Causes
– Formation
– Overbalanced drilling conditions
WO - Washed Out Bit
WO - Washed Out Bit

IADC Definition
– Bit washouts are not cutting structure dulling characteristics but
can provide important information when used as an “Other” dulling
characteristic. This can occur at anytime during the bit run. If the
bit weld is porous or not closed, then the bit will start to washout as
soon as circulation starts. Often the welds are closed but cracked
during the bit run due to impact with bottom or ledges on
connections. When a crack occurs and circulation starts through
the crack, the washout is established very quickly.
WO - Washed Out Bit

Smith Tool Definition

– A washout is where drilling fluid has eroded a passage from an
internal flow area to the exterior of the bit.
– It is not limited to welds.
– This characteristic is used only in the “Remarks Other Dull
Characteristic” column.
WO - Washed Out Bit

Potential Causes
– Excessive impact load / Improper drilling practices
– Improper nozzle installation
– Mechanical damage to nozzle and/or nozzle retaining system
– Wrong nozzle type for application
– Erosion damage to nozzle and/or nozzle retaining system
– Bit balling
WT - Worn Teeth
WT - Worn Teeth

IADC Definition
– This is a normal dulling characteristic of the tungsten carbide insert
bits as well as for the steel tooth bits. When WT is noted for steel
tooth bits, it is also often appropriate to note self sharpening (SS)
or flat crested (FC) wear.

Smith Tool Definition

– Worn teeth is a condition that describes the reduction in the cutting
element height due to the drilling action.
– This is a normal and expected wear mode.
WT - Worn Teeth

Potential Causes
– Flat crested wear
– Self sharpening wear
– Tracking
– Not enough WOB
– Formation / Improper bit selection
– Excessive RPM for application and specific bit type
– Excessive hours for application and specific bit type
– Inadequate hydraulics
NO - No Dull Characteristic

IADC Definition
– This code is used to indicate that the dull shows no sign of the other dulling
characteristics described. This is often used when a bit is pulled after a short
run for a reason not related to the bit, such as a drill string washout.

Smith Tool Definition

– This code is used to indicate that the dull shows no signs of dulling or that no
dulling characteristics are seen.
– Do not grade a cutting structure greater than 0 and input ‘NO’ into the “Cutting
Structure Dull Characteristic” column.
 General Definitions

Leading Edge
– Leading edge is the area of 1st
contact for cutting the hole bottom Trailing
on the tooth flanks
– This will always be on the opposite
side of the offset
– Left is leading Leading
Offset

Trailing
General Definitions

Crest Length

Crest Width

Tooth Root
Cone Profile