PDC Dull Grading

IADC Dull Grading System

Examples & Exercises

Copyright Baker Hughes, Inc.

IADC Dull Grading System

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason
Cutter Wear Location Rows Rows Charact-
eristics
Seals (1/16”) Charact-
eristics
Pulled

§ For cutter grading

purposes only, the bit is
Bit Center Line

divided into two areas:

§ Inner Rows
§ Outer Rows

§ Can also use the following

equations for direct
measurement:
Inner Rows Outer Rows IR = R Bit × 0 .67
(2/3 Radius) (1/3 Radius) OR = RBit × 0.33
where: Rbit= Bit Radius

(Does Not include gauge cutters) Copyright Baker Hughes, Inc.

1
 Cutting Structure B G Remarks

Cutter Wear Inner

Rows
Outer
Rows
Dull
Charact-
Location Bearing Gauge
Seals
Other
(1/16”) Charact-
Reason
Pulled
eristics eristics

§ Wear is a linear scale from 0 (no wear) to 8 (nothing left)

§ Cutter size independent
§ A smooth wear grading will usually be up to a maximum of 4
§ A 5 - 8 grading would usually mean broken or severely chipped
cutters

0 1 2 3 4 5 6 7

Probable cutter Flush w/blade Wear into the blade

pocket wear (Half Exposure) or broken cutters
Copyright Baker Hughes, Inc.

Grading Cutter Wear

§ The average amount of wear for each area

Outer Rows Inner Rows

1/3 Radius 2/3 Radius Inner Rows:

0 + 0 +1 + 1
= 0. 5 ≈ 1
4
Outer Rows:

1+ 0
= 0.5 ≈ 1
2
Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Dull Characteristics
Inner Outer Dull Location B e a r i n g Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

BF - Bond Failure NR - Not Rerunnable

BT - Broken Teeth/Cutters OC - Off-Center Wear
BU - Balled Up PN - Plugged Nozzle/Flow Area
CR - Cored RG - Rounded Gauge
CT - Chipped Teeth/Cutters RO - Ring Out
ER - Erosion RR - Rerunnable
HC - Heath Checking SS - Self-Sharpening Wear
JD - Junk Damage WO - Wash Out on Bit
LN - Lost Nozzle WT - Worn teeth/Cutters
LT - Lost Teeth/Cutters NO - No Other Major Dull
Characteristics
(Codes specific to Fixed Cutter bits, there are some additional codes for Roller Cone bits)

Copyright Baker Hughes, Inc.

2
 Cutting Structure B G Remarks

Location
Inner Outer Dull Location B e a r i n g Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

§ Location of the primary dull characteristic

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason
Worn Teeth / Cutters Rows Rows Charact-
eristics
Seals (1/16”) Charact-
eristics
Pulled

WT X
§ For PDC bits, WT is
considered “Worn Cutters”
§ Worn Cutters exhibit
smooth wear
characteristics
§ Abrasive wear
§ Classic application of
inner/outer cutter wear

Copyright Baker Hughes, Inc.

Worn Cutter Exercise

Cutting Structure
Inner Outer Dull Location
Rows Rows Charact-
eristics 1 2
1 1 WT A
IR
Inner Rows:
OR

0 + 0 + 0 + 1+ 2
= .6 ≈ 1
5

Outer Rows:
1+ 1+ 1
=1
3

Copyright Baker Hughes, Inc.

3
 Cutting Structure B G Remarks
Inner Outer Dull Location Bearing Gauge Other Reason
Chipped Teeth / Cutter Rows Rows Charact-
eristics
Seals (1/16”) Charact-
eristics
Pulled

CT X

§ Impact damage
§ Minor damage to diamond
table and substrate
§ Includes “spalling”

Copyright Baker Hughes, Inc.

Chipped Teeth Exercise

0 +1 + 2 + 0+ 1 + 2 6 1 + 0 + 2 +1 + 0 4
IR = = =1 OR = = = .9 ≈ 1
6 6 5 5
Cutting Structure
Inner Outer Dull Location 1 2
Rows Rows Charact-
eristics

1 1 CT N
IR
OR

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason
Broken Teeth / Cutters Rows Rows Charact-
eristics
Seals (1/16”) Charact-
eristics
Pulled

BT X

§ Impact damage
§ “Broken” means damage
into the substrate
§ Cutter “wear” grade can
easily be in the 5 - 8 range
(as shown here)

Copyright Baker Hughes, Inc.

4
Broken Teeth Exercise
Cutting Structure
Inner Outer Dull Location
Rows Rows Charact-
eristics

0 8 BT S
IR
Inner Rows: OR
0+ 0 + 0
=0
3
Outer Rows:
8 +8
=8
2
Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Lost Teeth / Cutters

Inner Outer Dull Location Bearing Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

LT X

§ No portion of the cutter

BT
remains
§ Cutter appears to be
removed cleanly
§ Graded as “8”

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Inner Outer Dull Location B e a r i n g Gauge Other Reason

Heat Checking Rows Rows Charact-

eristics
Seals (1/16”) Charact-
eristics
Pulled

X HC

§ Generally a secondary
characteristic
§ Often a prelude to cutter
fracture

Copyright Baker Hughes, Inc.

5
 Cutting Structure B G Remarks
Inner Outer Dull Location Bearing Gauge Other Reason
Ring Out Rows Rows Charact-
eristics
Seals (1/16”) Charact-
eristics
Pulled

RO X

Cutting Structure B G Remarks Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason Inner Outer Dull Location Bearing Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics eristics eristics

RO S X RO N X

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason

Erosion Rows Rows Charact-

eristics
Seals ( 1 / 1 6 ” ) Charact-
eristics
Pulled

X ER

§ Usually around cutters

§ Erosion can occur on both bit
body and cutter substrate
§ Influenced by several factors:
§ Body material
§ Nozzle orientation
§ Mud properties
§ Mud weight
§ Solids content
§ Length of run
§ Number of runs
§ Often a secondary characteristic

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing Gauge Other Reason
Cored Rows Rows Charact-
eristics
Seals (1/16”) Charact-
eristics
Pulled

CR X
§ Relatively uncommon
§ Similar to ring-out
§ Can be the result of
improper break -in and
damage to cutters in the
cone

Copyright Baker Hughes, Inc.

6
 Cutting Structure B G Remarks
Inner Outer Dull Location Bearing Gauge Other Reason

Junk Damage Rows Rows Charact-

eristics
Seals (1/16”) Charact-
eristics
Pulled

JD X

§ Caused by foreign object in

the hole
§ Damage can be minor to
catastrophic
§ Random scarring of the bit
body
§ Residual material may be
left on the bit body
§ A primary characteristic if
damage is extensive

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Gauge Condition
Inner Outer Dull Location B e a r i n g Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

Code Explanation § Measure gauge at the PDC gauge

I In Gauge
cutters
1/16 Undergauge § Gauge pads may be purposely
up to 1/16” slightly undergauge when new
2/16 Undergauge (many Genesis designs)
1/16” to 1/8”
§ High Imbalance (Antiwhirl)
3/16 Undergauge designs require special care when
1/8” to 3/16”
measuring due to low friction
4/16 Undergauge area
3/16” to 1/4”

Copyright Baker Hughes, Inc.

Broken Blade

§ No formal IADC code

§ “BC” (Broken Cone) has
been used
§ “BB” has also been used
§ Blade is sheared through
from front to back
§ High torsional impacts (stick
slip) and probable bit whirl
(uneven loading of the
blades)
§ Can also be a manufacturing
or design issue although this
is less often the case

Copyright Baker Hughes, Inc.

7
 Broken Matrix

§ No formal IADC code

§ Only a portion of the blade
or body is broken
§ A result of:
§ Axial impacts
§ Junk damage
§ Lost cutters

Copyright Baker Hughes, Inc.

Cutting Structure B G Remarks

Reason Pulled
Inner Outer Dull Location B e a r i n g Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

BHA - Change Bottomhole Assembly FM - Formation Change

DMF - Downhole Motor Failure HP - Hole Problems
DSF - Drillstring Failure HR - Hours
DST - Drill Stem Test PP - Pump Pressure
DTF - Downhole Tool Failure PR - Penetration Rate
LOG - Run Logs TD - Total Depth/CSG Depth
RIG - Rig Repair TQ - Torque
CM - Condition Mud TW - Twist Off
CP - Core Point WC - Weather Conditions
DP - Drill Plug WO - Washout Drillstring

Copyright Baker Hughes, Inc.

Sample Dull Grade

Field Dull Grade Actual Dull Grade

Cutting Structure B G Remarks Cutting Structure B G Remarks
Inner Outer Dull Location Bearing Gauge Other Reason Inner Outer Dull Location Bearing Gauge Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics eristics eristics

8 7 LT N X 2 ER PP 2 3 LT N X 2 BT PP

0 + 0 +0 + 0 +0 + 0 +0 + 0 +0 + 0 +8 +8 +8 +8 5( 8) + 1 2( 0)
= 1. 7 ≈ 2 = 2. 3 5≈ 3
14 17

Copyright Baker Hughes, Inc.

8
Sample Dull Grade

Cutting Structure B G Remarks

Inner Outer Dull Location Bearing G a u g e Other Reason
Rows Rows Charact- Seals (1/16”) Charact- Pulled
eristics eristics

8 8 BB A X 4/16 JD PR

Copyright Baker Hughes, Inc.

Dull Grading Exercise Handout

Reason Pulled: TD

§ Answer: IR =
0 + 1+ 3+ 2 + 2 + 0 + 0 + 2 + 2 + 2 14
= = 1. 4 ≈ 2
2-1-WT-N-X-I-CT-TD
10 10
2 + 1+ 2 + 1+ 1+ 0 + 1+ 0 8
OR = = =1
8 8

Copyright Baker Hughes, Inc.