07.politecnico Di Torino - Bits SELECTION 2011

CHAPTER
BITS TECHNOLOGY
07. DRILLING BITS TECHNOLOGY

1
BIT
SELECTION
The selection of the proper bits for a well is an important decision that has a big
impact on costs. Many factors need to be considered and evaluated:
Method of drilling (rotary, turbine, downhole motor, air)
Formation type and properties
Mud system
Rig cost
Bit cost
Drilling bit optimization is based on three main phases:
a) Selection of the proper bit as a function of drilling conditions.
b) Monitoring of the drilling performance and conditions on the well
under evaluation so that the performance is equal to or better than the
average in the area.
c) Implementation of bit weight, rotary speed and hydraulic programme
based on theoretical calculations that will improve the performance
above the previous best performances in the area. This phase is
difficult to be implemented in one or two wells, but is valuable in
development drilling.
2
BIT
DEFINITION
Bits can be divided into two main categories:

Roller Cone Bits
-Milled Tooth Bits
-Insert Bits
Fixed Cutter Bits

-Natural Diamond Bits
-Synthetic Diamond Bits (PDC Bits, TSP Bits,
Impregnated Bits)
- Drag bits (usually employed to drill water wells)
3
ROLLER CONE BITS

4
Roller Cone Structure
API Pin
Lubricant Reservoir
Cover
Nozzle Boss
Tungsten Carbide
Hardfacing
Leg
Nozzle
Shirttail
Cone
Outer Row (Gage)

Cutting Structure
Inner Row
Cutting Structure
5
How Bits Drill

The main mechanisms according to which a bit works are the following:
scraping or gouging
ploughing and grinding
chipping and crushing
shearing
erosion (from the drilling fluid)
In some cases, a bit can work according to some of these mechanisms at the same
time, though, very often, one mechanism prevails on the others depending on the type
and characteristics of the bit in use.
Roller cone bits work:
- with the mechanisms of gouging and scraping when drilling soft formations;
- with the mechanisms of chipping and crushing (crater mechanism) when drilling hard
formations.
Diamond bits work:
- with the mechanism of ploughing and grinding.
PDC bits work:
- with the mechanism of shear
6
Roller Cone Bit Cutting Action: Soft Formations
Scraping & Gouging

Indentation & Fracture
Tooth Displacement

7
Roller Cone Bit Cutting Action: Hard Formations
Chipping & Crushing
3. Fracture
1. Tooth Impact
2. Wedge Formation
8
4. Post-Fracture
Geometric Elements of Bit Design
Directly influence the type of Cutting Action
A. Offset
B. Journal Angle
C. Cone Profile Angles

9
A. Bit Offset
Definition of Offset:
..the horizontal distance of the cone axis from the centre of the
wellbore or as the angle of which is necessary to rotate the
cone axis to make it pass through the centre of the wellbore.
Offset measured in inches

Very Soft formations
typically 3/8 or up to 4o
Very Hard formations
typically 1/32 or down to 0o

10
A. Bit Offset

11
B. Journal Angle
Definition
Bit Axis
..is the angle formed

by a line perpendicular
to the axis (or
centerline) of the
journal and the axis (or
centerline) of the bit.
Journal Angle
Journal Axis

12
B. Soft vs. Hard Journal Angle

Soft to Medium
Formations
32 Journal Angle
Medium to Hard
Formations
36 Journal Angle

13
Inner Cone Profile Angle

Intermediate Cone Profile Angle
Outer Cone Profile Angle

14

Outer Cone Angle
(Gage Row)
Intermediate Cone Angle

(Middle Row)
Inner Cone Angle

(Nose Row)
15
Bearings and Seals

16
Major Bearing Types

a. Roller Bearings
Typically used in large
bit sizes
Also referred to as
Anti-Friction bearings
b. Friction Bearings
Typically used in small
bit sizes
Also referred to as
Journal bearings

17
a. Roller Bearing
Rollers

18
a. Roller Bearing Exploded View
Bearing
Seals(s)
Rollers
Ball Bearings
Thrust Washer
Rollers
Thrust Plug
19
b. Friction Bearing
Bearing Sleeve

20
b. Friction Bearing Exploded View
Bearing
Seals(s)
Bearing Sleeve
Ball Bearings
Thrust Washer
Thrust Cap

21
b. Friction Bearing

22
c. Seals
Cone lubrication is an essential factor in determining a bit life. Two types of
bearing are adopted for ensuring an adequate lubrication:
open bearing
sealed bearing
In the open bearing type bits, the lubrication is ensured by the drilling fluid
itself; but because of the presence in the mud of abrasive solids, this type of
lubrication is used only in large size bits (above 17 ), where the bits are not
required to drill for long periods of time.
The sealed bearing type bits have a sealed lubrication system, which
prevents contaminants to enter the bearing and lubricant to escape. The
sealing can be provided by:
- an o-ring, manufactured with elastomers;
- a metal-to-metal seal.

23
Open Bearing
Figure 20
CONE

24
b. Friction Bearing
Figure 21
Pressure
Compensator
Lubricant
Reservoir
Connecting
Hole
Seal

25
c. Seals
Seals must be compatible with downhole environment:
Load
Solids
Temperature
Pressure
Time
Nitrile Butadiene Rubber (NBR) (-40 to +135oC): presently this is the most
widely used elastomer for an o-ring. It has excellent resistance to petroleum
based oils and fuels, silicone greases, hydraulic fluids, water and alcohols. It
has a good balance of working properties such as low compression set, high
tensile strength, high abrasion resistance, combined with a low cost.
Highly Saturated Nitrile (HSN) (-26 to +160oC): Hydrogenated Nitrile

Butadiene Rubber (HNBR), also known as Highly Saturated Nitrile (HSN), is a
special class of nitrile that has been hydrogenated to increase saturation of the
butadiene part of the carbon polymer. New improvements in the material
properties include greater chemical resistance, more thermal stability and
greater tensile strength.
26
Cutting Structures

27
Cutting Structure
The cutting structure determines the distinction of the roller cone bits
into:
- milled tooth bits
- tungsten carbide insert bits.

28
Milled Tooth Bits: Cutting Structure

Roller Cone Bits: Construction
The manufacturing of drilling bits is done in accordance with strict
metallurgical standards:
cones are manufactured with a nickel-steel (4815-H) alloy;
the bit legs are made from a special nickel chrome steel (8720-H)
alloy;
the bearings are made from a high-resistance steel capable of
sustaining high shock loads.
Bit cones and journals are carburized, a process which includes the
addition of carbon to the steel surface and heating to a temperature of
925oC for a minimum of 19 hours.

29

Milled tooth bits for soft and hard formations are visually recognizable
on account of the height and number of their cutters:
Bits for soft formations have long and sparse cutters.
Bits for hard formations have short and closely arranged cutters.
Another feature of roller-cone bits is the cutters location on the cones;
this is arranged so that each cutter row of each cone strikes its own
rock portion on its circumferential path. This feature allows the entire
borehole surface area to be subject to the bit action.

30

Number 1 Cone
Partially Deleted
Tooth
Heel Row
Spearpoint
Tooth Hardfacing
(Leading flank)
Nose Row
Intermesh Area
or Groove
Middle Row
Gage Row
Number 3 Cone
Number 2 Cone
Pitch Break
31

Soft Formation Bits
A soft formation bit is characterized by
a limited number of teeth, the way they
are relatively spaced from one another
and their considerable length.
Soft formation
through:
scraping
gouging
bits
mainly
work
Operations are carried out with light

weights (approximately 2 t/in of
diameter) and a high rotational speed
(100-200 RPM) of the drill string.

32

Hard Formation Bits
Hard formation bits have a high number
of teeth and a high density of short
cutters.
Hard formation bits mainly work through:
crushing
chipping
Operation are carried out with heavy
weights (approximately 3.6 t/in of
diameter), because formations oppose
considerable resistance to penetration,
and a slow rotational speed of
approximately 50-60 RPM.

33
Very Soft
Soft
Medium-Soft Medium
12 Bits
0.375
(3/8)
0.281
(9/32)
0.281
(9/32)
0.186
(3/16)
Total Rows
12
Total Teeth
65
78
109
160
Offset

34

Roller Cone Bits Hardfacing
Hardfacing is the application of
tungsten-carbide on the gauge
and teeth to provide increased
resistance to abrasion. Without
hard-facing a bit would lose
gauge and the teeth would dull
quickly.
Hardfacing
provides
wear
resistance to the teeth and
resistance to fracture.

35
Steel Tooth Bits
Advantages
Disadvantages
Long teeth are better in soft Can drill only a limited

formations because they dig variety of formations
more
Cheaper than TC insert
cutters

36
Tungsten Carbide Insert Bits

In these three-cone bits the cutting structure is formed by tungsten
carbide INSERTS pressed into appropriate holes bored in the cones.
Designations of cones (1-2-3) and insert rows are the same as with
tooth bits.
Inserts have different lengths and shapes in function of the bit
hardness:
soft formations require long and sparse inserts;
hard formations require short and closely arranged inserts;
small and round inserts are placed on the shoulders of the bit.
Figure 7

37
Insert Shape: Inner Rows
Soft
Medium
to Hard
Soft
to Medium

38
Hard
Insert Shape: Gage Rows

39
Pitch Break
Number 1 Cone
Gage Row Insert

Inner Row
Chisel Crest Insert
Teeth Rows
Intermesh Area
or Groove
Number 3 Cone
Number 2 Cone

40

Tungsten Carbide (WC) provides Wear Resistance
Third hardest material known to man
However, it is structurally weak
Cobalt provides Strength and Toughness
Cobalt binder typically 6 to 16% by weight
Tungsten Carbide (1500x)

84% Tungsten Carbide
16% Cobalt

41

Very Soft
10 rows / 92 inserts
Soft
Medium-Soft
Medium-Hard
Hard
Very Hard
77/8 Bits

42

Advantages
Disadvantages
Tungsten carbide wears

very little so the inserts last
longer
Much more expensive than

milled tooth bits
The same tungsten carbide

bit can drill many different
types of formations
Cannot drill as fast as a

steel tooth bit in soft-tomedium formations
Harder than steel but also
more brittle

43
Roller Cone Bits

Watercourses
An important part of a rock bit is the
watercourse, without which the bit
could not function as intended.
The design of the passageways and
nozzles that direct the fluid when
coming out from the bit differentiates
between two types of watercourses:
1. Conventional watercourse that
directs the fluid onto the cutters
2. Jet watercourses that direct the
fluid onto the bottom of the hole
(central nozzle and extended nozzles)

44
Figure 23
Design Factors Summary

Formation Strength
Soft
Med. Soft
Med. Hard

45
Hard
Very Hard
IADC ROLLER CONE BIT

CLASSIFICATION

46
IADC Bit Classification

A wide range of bits is available in the marketplace. There are many
different kinds of bits with different features.
For this reason, the International Association of Drilling Contractors,
IADC, approved a standard classification system to compare bits
having similar features through the use of a numeric code.
This standardization, which has been introduced in 1972 and revised in
1992, is extremely useful, because it allows engineers to rapidly find
bits with similar features, even if they are built by different
manufacturers.

47
ROLLER CONE BITS CLASSIFICATION ACCORDING TO SERVICE COMPANIES

48
IADC ROLLER CONE BIT Classification

4-Character Design/Application Code
First 3 Characters are NUMERIC
4th Character is ALPHABETIC
Examples
135M
447X

49
637Y
Numeric Characters define:

Series
Type
Bearing & Gage
1st
2nd
3rd
Alphabetic Character defines:

Features Available
4th

50
Series
1. First Character: Series

General Formation Characteristics
Compressive Strength
Abrasivity
Eight (8) Series

Milled Tooth Bits : Series 1, 2 and 3
Insert Bits
: Series 4, 5, 6, 7 and 8
51
Classification Chart: Series
135M
447X
52
Typical Formations Hardness
Hardness
UCS (psi)
Examples
Ultra Soft
< 1,000
gumbo, clay
Very Soft
1,000 - 4,000
unconsolidated sands, chalk,

salt, claystone
Soft
4,000 - 8,000
coal, siltstone, schist, sands
Medium
8,000 - 17,000
sandstone, slate, shale,

limestone, dolomite
Hard
17,000 - 27,000
quartzite, basalt, gabbro,

limestone, dolomite
Very Hard
> 27,000
marble, granite, gneiss
UCS = Uniaxial Unconfined Compressive Strength

53
Type
2. Second Character: Type

Degree of Formation Hardness
Each Series is divided into 4 Types
Type 1
Softest Formation in a Series

Increasing Rock Hardness
Type 4
Hardest Formation in a Series

54
Classification Chart: Type
135M
447X
55
Bearing & Gage
3. Third Character: Bearing & Gage

Bearing Design and Gage Protection
Seven (7) Categories
1. Non-Sealed (Open) Roller Bearing
2. Roller Bearing Air Cooled
3. Non-Sealed (Open) Roller Bearing Gage Protected
4. Sealed Roller Bearing
5. Sealed Roller Bearing Gage Protected
6. Sealed Friction Bearing
7. Sealed Friction Bearing Gage Protected
56
Classification Chart: Bearing & Gage
135M
447X
57
Example - Milled Tooth
MSDGH
IADC 135

58
Example - TCI
F2

59
IADC 517
Features Available
4. Fourth Character
Features Available (Optional)
Sixteen (16) Alphabetic Characters
Most Significant Feature or Application Listed

60
IADC Features Available
A - Air Application
L - Lug Pads
B - Special Bearing/Seal
M - Motor Application
C - Center Jet
S - Standard Milled Tooth
D - Deviation Control
T - Two-Cone Bit
E - Extended Nozzles
W - Enhanced Cutting Structure
G - Gage/Body Protection
X - Chisel Tooth Insert
H - Horizontal Application
Y - Conical Tooth Insert
J - Jet Deflection
Z - Other Shape Inserts

61
Classification Chart: Features Available
135M
447X
62
FIXED CUTTER BITS

63
Types
Fixed Cutter Bit Styles

Drag Bits
Natural Diamond Bits
Synthetic Diamond Bits (PDC: Polycrystalline Diamond
Compact Bits, TSP: Thermally Stable Polycrystalline
Diamond Bits, Impregnated Bits)

64
Types
Drag Bits
A drag bit is a drill bit usually designed
for use in soft formations such as sand,
clay or some soft rock. They do not
work well in coarse gravel or hard rock
formations.
Uses include water wells drilling, mining,
geothermal,
environmental
and
exploration drilling. Whenever possible,
they should be used to drill pilot holes
because they produce cuttings that are
very easy to log.
They are not in current use and are
mentioned here only for their historical
importance.

65
Figure 27 Drag Bits

Natural diamond bits are constructed with diamonds embedded into a
matrix and are used in conventional rotary, turbine and coring
operations. Diamond bits can provide improved drilling rates over roller
bits in some particular formations and all the diamond bit suppliers
provide comparison tables between roller bit and diamond bit
performance to aid users in bit selection based on economic evaluation.
Some of the most important benefits of diamond bits over roller bits are:
Bit failure potential is reduced because there are no moving parts.
Less drilling energy is required by their shearing cutting action
compared to the cracking and grinding action of the roller bit.
Bit weight is reduced, therefore deviation control is improved.
The low weights required and lack of moving parts make them well
suited for turbine drilling.

66

Natural Diamond Bits are made by three main components:
the cutters;
the body or blank;
the shank.
The cutters are natural diamonds placed on the surface of the bit, from
the nose to the gage, according to well-defined configurations or plots.
They are immersed in a matrix composed by a mixture of tungsten
carbide and a metallic binder.
During the construction process, diamonds are included in the matrix
by fusing it (each natural diamond bit is hand-built according to the
instructions received from the oil company that placed the order).

67

68
Diamond Bit Terminology & Features
Crown
Junk Slot
Cutters
Diamond Gauge
Shank
Breaker Slot
API Pin
Connection

A Diamond Bit can have different profiles depending on the formation to
be drilled:
a single-cone profile presents a rounded shape, which determines
a limited load on each cutter. The bit is subjected to a slow wear and
long life;
the double-cone profile has a narrower attack front and is very
aggressive in its central part. The tapered zone maintains the hole in
gauge. The bits with this profile ensure higher ROP, but also a more
rapid wear;
the parabolic profile has a front more rounded than the previous
type; it represents a compromise between the two previous profiles;
the concave profile has a flat front; it is mainly used in directional
drilling.

70
Figure 40 Profiles of Natural Diamond Bits

71

This type of bits is not equipped with nozzles. Hydraulics has the main
purpose of cooling the bit face and removing drilled cuttings.
The exit holes of the drilling fluid are positioned in the centre of the bit.
Fluid is then directed into grooves carved out of the bit face.
Grooves are designed according to two main configurations:
Radial flow
Cross-pad flow or feeder-collector flow.
In both configurations, the outflow of drilling fluid from the bit centre
takes place through a crowfoot that distributes the flow into three
branches.
72

Collector
Crowfoot
Feeder
Waterways
Pad / Rib
Crowfoot
Cross-Pad Flow
Radial Flow

73

Natural diamond bits work by ploughing, hence with low weights (a few
tons) and a high rotation speed.
For this reason, they are almost always employed in association with
turbines.
These bits are very expensive. Their use is limited to special situations
and/or needs. They are employed to drill directional wells, in side-track
operations, or in homogeneous medium-hard to hard rocks, in
association with turbines.

74
Natural Diamond Mechanics

Natural Diamond Bits drill
by ploughing and grinding
the rock
Normally require higher
RPM for better
performance (e.g. high
speed motor or turbine)

75
Synthetic Diamond Bits

Synthetic diamond bits fall into two main categories:
PDC polycrystalline diamond compact bits
TSP thermally stable polycrystalline bits
General Electric was the first company to produce synthetic
diamonds on an industrial scale in the Fifties.

76
Synthetic Diamond Bits

Production Process of Synthetic Diamonds
The process is basically the following:
thin circular layers of carbon are alternated with a metallic solventcatalyst in a small container made of refractory metal;
all objects are brought to the pressure of 1,500,000 psi and heated at
a temperature of 1500oC;
these parameters are maintained for a certain period of time (5
minutes usually) during which the metallic solvent-catalyst melts and
dissolves graphite depositing diamond crystals.

77
TSP Bits
If uses in high temperature environments are predicted, it is possible to employ
construction techniques capable of producing industrial diamonds with a higher
degree of thermal stability, namely the TSP diamonds or thermally stable
polycrystalline diamonds.
There are two main construction techniques:
a technique is based on the acid treatment of the synthetic diamonds
produced by the method described above, in order to dissolve cobalt;
the second technique requires the use of silicon carbide as a bonding agent
for the diamond particles.
Both these techniques allow the realization of industrial diamonds with a
thermal stability of about 1150oC. The disadvantage is that TSP diamonds can
not be welded onto any substrate, differently from PDC bits, but they must be
included in the bit matrix. TSP bits are produced by means of techniques similar
to those described about natural diamond bits. In general terms, they are
suitable to drill hard and abrasive formations.
78
Polycrystalline Diamond Compact PDC Bits

Production Process of a Compact
A PDC cutter consists of a thin layer (1 mm usually) of polycrystalline diamond
completely welded onto a tungsten carbide substrate. This structure is called a
compact.
The production process is as follows:
a layer of diamond crystals of predetermined granulometry is placed in a
container made of refractory metal (zirconium or molybdenum). The container
shape is going to determine the final shape of the compact;
a layer of tungsten carbide is then placed on top of the diamond crystals;
the container is then brought to a pressure of 1,000,000 psi and heated at a
temperature of 1400oC. Bonding between diamond crystals takes place as an
effect of the catalyzing action of cobalt, that migrates from the tungsten carbide
substrate (where it acts as a bonding agent), thus creating a strong bond
between the substrate and the polycrystalline diamond layer.
The presence of cobalt makes the PDC unstable at temperatures higher than
700C; at this temperature cobalt expands so much that it begins to break the
bonding between the diamond crystals, actually causing the break of the
compact (this is why TSP bits are used in HT conditions)..
79

80

PDC bits were introduced in the 1970s and combine the high abrasion
resistance of the diamonds with the strength and impact resistance of
tungsten carbide.
The advancement in PDC design and performance in recent years has
been significant and there are now many manufacturers with a wide
variety of bits available.
Due to the diversity of bits and bit features available, there is no IADC
classification system similar to roller bits but simply a code to provide a
means of characterizing the general physical characteristics of fixed
cutter drill bits.

81

PDC cutters are built in standard dimensions ranging from 8 mm to 24 mm:
Very small cutters (8 mm wide) are used in hard formations.
Small cutters (13 mm wide) are used in medium to medium hard formations.
Large cutters (19 mm wide) are suitable for soft to medium formations.
Very large cutters (24 mm wide) are used in soft formations. Cutters as wide
as 48 mm have also been used sporadically.
Diameter (mm)
8
13
Years intoducted
1973
1976
19
1986
24
1986
Figure 31 Dimensions of PDC CUTTERS

82

PDC bits can be manufactured as:
steel body bits
matrix body bits
Steel body bits consist of a single steel block and are characterized by a high
structural resistance, in terms of both impact and torque. Production takes place by
means of computer-controlled equipment, hence manufacturing is particularly
accurate with high quality and repeatability standards. The main disadvantage of
this kind of bit is low resistance to erosion, that makes it susceptible to the damage
caused by abrasive drilling fluids. To solve this problem, reinforcements made of
anti-abrasion material (hard-facing) are applied onto certain areas of the bit.
Matrix body bits are built by pouring a mixture of tungsten carbide powder and a
bonding agent over a steel body (called blank). Besides joining carbide particles to
one another, the bonding agent allows a good association between the external
matrix and the internal steel body. A second steel body (called shank) is then
welded onto the blank. The bit connection is carved out of the shank. The matrix is
resistant to erosion but more brittle than steel.

83
PDC Bits
Steel Body
Matrix Body

Profiles of PDC Bits
PDC bits have three basic profiles:
(a) Flat profile, used to drill hard but not abrasive formation
(b) Double cone profile offers a larger work surface and is thus suitable
to drill harder formations.
(c) Parabolic profile, used in combination with a turbine to drill soft but
abrasive formations
b
Figure 37- PDC BIT PROFILES
85

A further discriminating construction feature is the number of blades, that
have the following main functions:
Supporting the cutting structure. The positioning of cutters on
blades creates an adequate support structure capable of absorbing the
forces engendered on the cutter itself. Generally speaking, when
moderately hard formations require a bit with many cutters, the tool will
also be equipped with many blades.
Determining the hydraulic flow profile. Blades are set according to
well defined paths, so that the drilling fluid flows optimizing both cutting
removal from the bit surfaces and its cooling.
Increasing the frontal exposure of the cutter.

86
PDC Mechanics
PDC cutters cut the
formation in shear.
The shearing action is the
most efficient cutting
action when operating
under identical
conditions.
PDC Bit - Shearing
PDC Mechanics
Unlike Natural Diamonds and

Roller cone teeth, PDC cutters
exhibit self-sharpening wear.
The Tungsten Carbide carrier

wears faster than Diamond table
forming a sharp Diamond lip.
As cutting elements wear, the

specific energy requirement
increases reducing the drilling
efficiency.
PDC Bit - Self Sharpening
The self sharpening mechanism of

PDC cutters improves drilling
efficiency.
PDC Mechanics
One important feature of PDC bits is their back rake angle.
Angle at which a PDC cutter attacks a formation.
Higher back rake angles improve impact and wear
resistance.
Lower back rakes increase ROP.
Back rakes can be varied to achieve maximum ROP and
durability.
B.R
PDC Mechanics
Back Rake Angle

5 to 10
15
20
Formation Hardness
Very soft clays/shales.
Low angle produces highest
ROPs
All formations.
Best in soft formations (e.g. shale)
All formations.
Improves cutter life.
Best in abrasive/sand formations
Harder formations
Typically used on gage
30

90
IADC FIXED CUTTER BITS CLASSIFICATION

To take into account the wide range of fixed cutter bits including natural
diamond and PDC, IADC introduced a classification system consisting of a
four character code:
Code 1 - Cutter Type and Body Material (D, M, T, S, O)
Code 2 - Bit Profile (1-9)
Code 3 - Hydraulic Design (1-9)
Code 4 - Cutter Size and Density (1-9).

91

Code 1: Cutter Type and Body Material
The subgroup classification is simply a five letter designation categorizing the
type of cutter and body material.

92

Code 2: Bit Profile
The code numbers (1-9) categorize the bit profile by shape.

93

Code 3: Hydraulic Design
The code numbers (1-9) describe the hydraulic features.

94

Code 4: Cutter Size and Density
The code numbers (1-9) categorize the cutter size and cutter material.
EXAMPLE OF CLASSIFICATION
A fixed cutter bit with the code M442 corresponds to a PDC bit with matrix
body, medium taper-deep cone, changeable jets-ribbed design with large size
cutter of medium density.
95
Eni Corporate University
Eni Divisione E&P
EVALUATION OF ROLLER CONE

BIT DULLNESS

96
DULL BIT GRADING

For drilling wells as efficiently and as economically as possible, some things
are mandatory:
- best drilling information
- experienced crews
- correctly selected bits.
One way for obtaining timely and accurate drilling information is grading the
dullness of rock bits. When the dull bit comes out of the hole, an evaluation of
its cutting structure and bearing conditions can provide fundamental
information for the optimization of the next bit runs. An accurate dull grade
gives a good picture of how the hole was drilled and can allow to answer to
questions like:
Did the bit perform to its full potential?
If not, what changes do we need to make before we go back into the hole
again?
97
DULL BIT GRADING

Careful inspection of the dull cutting structure and bearings can give us a
good handle on the bits dull characteristics which can affect our next bit
selection, break-in procedures and operating practices. Grading a dull bit and
evaluating the consequent findings is a simple operation that can increase
drilling efficiency while lowering drilling costs.
The Industry has developed a dull bit grading method and symbols that
simplify this important operation. The dull grading symbols indicated here can
be used to grade all types of bits, including:
Journal bearing bits, carbide and steel tooth
Sealed ball and roller bits of both types
Non-sealed bearing bits
Natural diamond bits
Polycrystalline diamond bits
Thermally stable polycrystalline diamond bits.

98
DULL BIT GRADING: SYSTEM STRUCTURE FOR ROLLER CONE BITS

SYSTEM STRUCTURE FOR ROLLER CONE BITS
The dull grading method described herein follows the IADC Grading System.
Eight columns of information are used for reporting dull bit conditions on bit
records.
REM ARKS
1
4
5
7
8
6
3
2
REM ARKS
B
C U T T IN G S T R U C T U R E
G
In n e r O u te r D u ll L o c a - B r n g . G a g e O th e r R e a s o n
R o w s R o w s C h a r. tio n
S e a l 1 /1 6
D u ll P u lle d
(I)
(O )
(D )
(L )
(B )
(G )
(O )
(R )

99
1.Column 1 (I-Inner): is used to report the condition of the

cutting elements not touching the wall of the hole (inner).
2. Column 2 (O-Outer): is used to report the condition of
the cutting elements that touch the wall of the hole (outer).
In Columns 1 and 2 a linear scale from 0-8 is used to

describe the condition of the cutting structure for:
- Steel tooth bits
- Insert bits.

100

Steel Tooth Bits
The numbers from 0 to 8 give a measure of lost tooth height, meaning:
0 = no loss of tooth height
8 = total loss of tooth height.

101

Insert Bits
The numbers from 0 to 8 give a measure of
combined cutting structure reduction due to
lost, worn and/or broken insert, meaning:
0 = no loss of cutting structure
8 = total loss of cutting structure.
Example:
A bit missing half of the inserts/teeth on the
inner rows of the bit, due to loss or breakage,
with the remaining inserts/teeth on the inner
rows having a 50% reduction in height due to
wear should be graded a 6 in Column 1.
If the inserts/teeth on the outer row of the bit
were all intact but were reduced by wear to
half of their original height, the proper grade
for Column 2 would be 4.

102

3. Column 3 (D-Dull Characteristics Cutting Structure): uses a two-letter
code to indicate the major dull characteristic of the cutting structure. Table 1 lists
the two-letter codes for the dull characteristics to be used in this Column 3.

103

4. Column 4 (L-Location): uses a letter or number code to indicate the
location on the face of the bit where the cutting structure dulling characteristics
occurs. Table 2 lists the codes to be used for describing location on roller cone
bits.
Location is defined as follows:

Gauge: those cutting elements which touch the hole wall
Nose: the centermost cutting element(s) of the bit
Middle: cutting elements between the nose and the gauge
All: all rows
Cone numbers are identified as follows:
The number 1 cone contains the centermost cutting element
Cones 2 and 3 follow in a clockwise orientation looking down at the cutting
structure with the bit sitting on the pin.
104
General Cone Identification Rule
#1
#3
Centermost Cutting Element

(Spearpoint)
#2
#3

105
#1
#2

5. Column 5 (B-Bearing/Seals): uses a letter or a number code, depending
on bearing types, to indicate bearing condition of roller cone bits.
For non-sealed bearing roller cone bits, a linear scale from 0-8 is used to
indicate the amount of bearing life that has been used. A zero (0) indicated that
no bearing life (a new bearing) has been used and an 8 indicated that all of the
bearing life has been used (locked or lost).
For sealed bearings (journal or roller) bits, a letter code is used to indicate the
condition of the seal:
- E indicates an effective seal
- F indicates a failed seal
- N is used when seal/bearing conditions cannot be determined.

106

6. Column 6 (G-Gauge): is used to report on the gauge of the bit:
- the letter I (IN) indicated no gauge reduction
- if the bit does have a reduction in gauge it is to be recorded in 1/16 of an
inch.
.
Amount
Amountout
outof
ofgage
gage==
Measured
Measureddistance
distancexx
Amount
AmountUndergage
Undergage
ths
in
in16
16ths
IN
IN==In
InGage
Gage
1
11== 1/16
/16
22==22/16
/16
33==33/16
/16
Etc..
Etc..
107

The two thirds rule, as used for three-cone
bits, requires that the gauge ring be pulled so
that it contacts two of the cones at their
outermost points. Then the distance between
the outermost point of the third cone and the
gauge ring is multiplied by 2/3s and rounded to
the nearest 1/16 of an inch to give the correct
diameter reduction.
GAUGE
RING
The bit centering is another and more

accurate method. It consists in centering the bit
in the gauge ring; a ruler is then used to
measure the distance from the ring of the most
outermost cutting surface. This measurement
must be multiplied by 2 to obtain the total
amount of undergauge.
GAUGE
RING
108

7. Column 7 (O-Other Dull Characteristics): is used to report any dulling
characteristic of the bit in addition to the cutting structure dulling characteristics
listed in Column 3 (D). Note that this Column is not restricted to only cutting
structure dulling characteristics. Table 1 lists the two-letter codes to be used in
this Column.

109

8. Column 8 (R-Reason Pulled): is used to report the reason for terminating
the bit run. Table 3 shows the two-letter or three-letter codes to be used in this
Column.

110

GRADED DULL EXAMPLE No.1
This bit was graded 7,1,BT,M,E,I,WT,PR.
The bit looks to have been dulled by encountering
a harder formation than the bit was designed for.
This is indicated by the heavy tooth breakage on
the inner rows and by the fact the bit was pulled for
penetration rate. The reduced penetration rate was
caused by tooth breakage occurring when the bit
encountered the hard formation. Excessive weight
on bit also could cause the dull to have this
appearance.
The bit application was proper if the run was of
reasonable duration, there was no evidence of
other dulling characteristics, the seals were
effective and the bit was pulled in gauge. If,
however, the bit had a shorter than expected run,
the application probably was improper. The bit may
have been too soft for the formation or it may have
been run under excessive weight.
111

GRADED DULL Example No. 2
This bit was graded 5,8,WT,A,3,2,FC,HRS.
This dull grade indicates proper bit selection and
application. There is not a great deal more tooth wear
(WT) on the outer cutters than on the inner cutters, which
suggests proper rpm and weight on bit.
Worn teeth is a normal dull characteristic in the harder
tungsten carbide insert bits, as opposed to chipped or
broken teeth, both of which could indicate excessive rpm
or weight. When pulled, the bit was still drilling well as
indicated by listing HRS as reason pulled. The bit,
however, was slightly under gauge (2/16) at this point
and may well have rapidly lost more gauge if left in the
hole. This supports the decision to pull the bit based on
hours.
A bearing condition 3 on the air bearings suggests
adequate bearing life still remaining. Since there are no
harder bits available and the dull grade indicates a softer
bit would not be appropriate, this seems to have been a
proper bit application.

112
Fixed Cutter Dull Grading

System

113
DULL BIT GRADING: SYSTEM STRUCTURE FOR FIXED CUTTER BITS

IADC DULL GRADING SYSTEM FOR FIXED CUTTER BITS
Information provided by dull grading bits can be very significant for an effective
drilling optimization. This value was recognized by IADC over 25 years ago
with the introduction of the dull grading system for roller cone bits.
For fixed cutter bits that is all non-roller cone bits this dull grading system
could not be applied and a new system had to be established. The fixed cutter
dull grading system was developed by the IADC Drill Bits Sub-Committee in
1987 and revised in 1991.
The fixed cutter dull grading system can be used for all non-roller cone bits,
including natural diamond, polycrystalline diamond compact (PDC), thermally
stable polycrystalline (TSP) diamonds, impregnated bits, core bits and nonroller cone bits which do not employ diamond material as a cutting element.
The system does not distinguish between drilling and coring bits. This guide
will only show examples of PDC, TSP, natural diamond and impregnated or
sintered drill bits.
114

IADC DULL GRADING SYSTEM FOR FIXED CUTTER BITS
The Dull Grading System Chart adopted by IADC includes all codes necessary
to dull grade roller cone bits and fixed cutter bits.
The Chart describes 8 factors on drill bits as follows:
The first 4 spaces describe the Cutting Structure; the 5th space refers to
Bearing Seals and does not apply to fixed cutter bits; this space is always
marked with an X when fixed cutter bits are graded. The 6th space (G)
refers to Gauge Measurement, while the last 2 Remarks spaces indicate
Other Dull Characteristics and Reason Pulled.
115

1. COLUMNS 1&2: INNER/OUTER ROWS
Using a linear scale from 0 to 8, a value is given to cutters in the inner and
outer rows of surface-set bits to indicate the amount of wear. Grading numbers
increase with amount of wear with 0 representing no wear and 8 meaning
no usable cutter left. Accordingly, 4 indicates 50% wear.
PDC cutter wear is measured in a linear scale from 0 to 8 across the diamond
scale, regardless of the cutter shape, size, type or exposure. The following
figure schematically shows the cutter wear grading system.

116

The following figure schematically shows the
cutter wear grading system. As shown here, 2/3
of the radius represents the inner rows: the
five cutters in this area would be graded 2.
This is calculated by averaging the individuals
grades for each cutter in the area:
The average wear for the outer area is

calculated in the same manner:
6 would be the average wear gradient for the outer area. The information can now be
transferred to the IADC Dull Grading System Chart above.

117


118

2. COLUMNS 3&7: DULL CHARACTERISTICS/OTHER CHARACTERISTICS
The 3rd and 7th columns are for use in noting dull characteristics of the bit, i.e.
the most evident physical changes from its conditions as new.
Codes for these characteristics are listed in the Table of the following page.
In general four different wear characteristics can be distinguished for fixed cutter
bits.

119

2. COLUMNS 3&7: DULL CHARACTERISTICS/OTHER CHARACTERISTICS

120

3. COLUMN 4: LOCATION
The Location space is used to indicate the location of the primary Dull
Characteristics noted in the third space. Four possible fixed cutter bit profiles
are shown in Figure, along with the codes used to identify locations on the bit.
One or more of these codes are used to indicate the location of the dull
characteristics noted.

121

4. COLUMN 5: BEARING SEALS
This space is used only for roller cone bits. Therefore, it will always be marked
X when grading fixed cutter bits.

122

5. COLUMN 6: GAUGE
The Gauge (G) space is used to record the condition of the bit gauge. Record
an I here if the bit is still in gauge. Otherwise, the amount the bit is undergauge
is recorded to the nearest 1/16, as shown below.

123

6. COLUMN 8: REASONS FOR PULLING OUT

124

6. COLUMN 8: REASONS FOR PULLING OUT

125

EXAMPLE No.1
This R437GN was run in a horizontal well to
drill brittle to plastic shale and sandstone. It
drilled 387 meters in 29.5 hours with an
average ROP of 13.1 m/hr on a Mach 1
Adjustable Kick Off Motor.
The bit was pulled at 1820 meters because
of slow penetration rates. Upon pulling out,
the bit resulted to be cored out and without
all four nozzles. The remaining cutters
did not show any significant wear.

126

PRACTICAL APPLICATIONS
The IADC Dull grading System can be used for multiple purposes.
Manufacturers evaluate the bit design and bit application. Operators evaluate
and improve their drilling programs. The system can also be computerized to
build up a worldwide database to coordinate bit applications.
The major target of the dull grading system is to draw a standardized picture
of a bit regardless of where or under which conditions the bit may have been
used. This standardization is expected to lead to further improvements in bit
application and design.
These slides are obtained by Hughes Christensen booklets IADC Dull

Grading System for Roller Cone Bits and IADC Dull Grading System for
Fixed Cutters Bits.
127
BIT SELECTION
AND
OPTIMIZATION

128
BIT SELECTION
The bit selection process is complex; however there are still simple
guidelines that can be used to increase drill rates and hence reduce drilling
costs.
Below, are listed some indications about bit selection.
Formation Hardness/Abrasiveness
In hard and abrasive formations roller bits in IADC code range 6-1-7 or
higher are usually more successful.
Numerous reports confirm that in soft to medium-soft rocks, PDC bits drill
faster than mill tooth or diamond bits unless they are sticky.

129
BIT SELECTION
Mud Types
Oil based muds often reduce the drilling rates with roller cone bits.
Oil based mud is actually believed to enhance the performance of PDC
bits since they inhibit clay hydration and stickiness.
Air drilling almost certainly requires the use of roller cone bits as air can
not provide sufficient cooling as liquids do, therefore causing bit failure.

130
BIT SELECTION
Directional Control
Rotary drilling operations are inclined to right-hand walk. This tendency is
increased when roller bits are used and as cone offset from the bit centre
increases. The advantage of increased drilling rate when using cones with
higher offsets must be balanced with the difficulty in maintaining directional
control.
Turbine drilling may have a tendency to left-hand walk. This is controlled
by the type of turbine used, bit gauge length and BHA stabilization.
High bit weights, WOB, tend to increase directional control problems,
while, vice versa, low bit weights help maintain straight holes but with
reduced drilling rates.

131
BIT SELECTION
Drilling Method
Due to turbine drilling efficiency, bits with long life expectancies should be
used such as PDC, diamond and journal bearing insert bits.
In deep wells, PDC bits are preferred when using surface rotary systems
as reduced weight on bit reduces torque due to bit and wall friction which
can be significant.

132
BIT OPTIMIZATION
CALCULATION OF THE COST/METER OF A BIT
To make an evaluation of the cost per meter of a bit, the following
parameters have to be considered:
time the bit remains on bottom;
time required to run in hole and pull out of hole the bit;
rig cost per hour taking into account also all ancillary costs such as: rig
cost per hour, mud logging unit cost, mud engineering cost, etc.;
meters drilled by the bit;
cost of the bit.

133
BIT OPTIMIZATION
1) The equation used to calculate the cost/meter of a bit is as follows:
K1 = A x (C + E) + B
D
where:
- K1 = cost/meter
- A = rig cost/hour
- B = bit cost
- C = bit drilling hours
- D = meters drilled by the bit
- E = trip hours

134
BIT OPTIMIZATION
2) To have an idea if the cost/meter of a given bit is acceptable or not, it is
necessary to build a comparison curve, called the economicity curve,
which allows a comparison between the cost/meter of the bit under
evaluation and the performances of the last bits used in the same well or in
the same area or of the bits considered having performed in the best way in
the area and therefore taken as reference.
To make this comparison the following three constants, regarding the
reference bits, have to be calculated:
K1 = A x (C + E) + B
D
(cost/m)
K2 = A/K1
(m/h)
K3 = (A x E) + F
K1
(m)

135
BIT OPTIMIZATION
where:
- K1 = average cost/meter calculated on the bits taken as comparison, /m
- A = rig cost/hour, /h
- B = average cost of the bits taken as reference,
- C = average drilling time of the bits taken as reference, h
- D = average footage drilled by the bits taken as reference, m
- E = average tripping time of the bits taken as reference, h
- F = cost of the bit under evaluation,

136
BIT OPTIMIZATION
3) To build the economicity curve of the bit, it is necessary to calculate the
meters, which are necessary to drill, Di, and the corresponding rates of
penetration, Vi, which is necessary to achieve, in order to obtain an
economic bit run. To do this, it is made the hypothesis that the bit under
consideration will drill a certain number of hours, for instance: h1 = 10 h, h2
= 20 h, h3 = 30 h, . hn= 800 h with the constants, K1, K2 and K3 equal to
those of the bit runs taken as reference, and then the pairs Di and Vi, the bit
under evaluation has to satisfy, are calculated using the following equations:
Di = hi x K2 + K3
Vi = Di/hi
where:
- Di = meters drilled, m
- Vi = rate of penetration, m/h
137
BIT OPTIMIZATION
4) These values Di and Vi are plotted obtaining a graph which represents
the economicity curve the bit under evaluation has to satisfy.
5) On this graph, the actual performance of the bit under evaluation is
plotted; the bit will result economic when its points (meter drilled vs rate of
penetration) are above the comparison curve. When the points go below
the comparison curve, the bit has to be pulled out of the hole.
Cost/Meter
Cost/Meter
10,00
ROP, m/h
Economicity
Curve
Economicity
Curve
8,00
6,00
4,00
2,00
0,000,0
500
1000
Meters Drilled m

138
1500
2000
BIT OPTIMIZATION EXAMPLE

EXAMPLE: CALCULATION OF THE COST/METER OF A BIT
Data:
Rig cost/hour, A: 516 /h
Average reference bits cost, B: 2580
Average drilled hours by the reference bits, C = 80 h
Average meters drilled by the reference bits, D = 180 m
Average tripping hours of the reference bits, E = 12,50 h
Cost of the bit under evaluation, F = 7750
Equations:
K1 = [A x (C + E) + B]/D
K2 = A/K1
K3 = [(A x E) + F]/K1
Di = hi x K2 + K3
Vi = Di/hi
139

hi
Di
Vi
K1
K2
K3
10
69,3
6,93
279,5
1,85
50,80
20
87,8
4,39
30
106,3
3,54
40
124,8
3,12
50
143,3
2,87
60
161,8
2,70
70
180,3
2,58
80
198,8
2,49
90
217,3
2,41
100
235,8
2,36
150
328,3
2,19
200
420,8
2,10
250
513,3
2,05
300
605,8
2,02
350
698,3
2,00
400
790,8
1,98
140

hi
Di
Vi
K1
K2
K3
450
883,3
1,96
279,5
1,85
50,80
500
975,8
1,95
550
1068,3
1,94
600
1160,8
1,93
650
1253,3
1,93
700
1345,8
1,92
750
1438,3
1,92
800
1530,8
1,91
850
1623,3
1,91

141

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CHAPTER

07. DRILLING BITS TECHNOLOGY

Bits can be divided into two main categories:

Fixed Cutter Bits

ROLLER CONE BITS

07. DRILLING BITS TECHNOLOGY

Roller Cone Structure

Outer Row (Gage)

How Bits Drill

Roller Cone Bit Cutting Action: Soft Formations

Scraping & Gouging

07. DRILLING BITS TECHNOLOGY

Roller Cone Bit Cutting Action: Hard Formations

Chipping & Crushing

Geometric Elements of Bit Design

Directly influence the type of Cutting Action

07. DRILLING BITS TECHNOLOGY

Offset measured in inches

Very Hard formations

typically 1/32 or down to 0o

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

..is the angle formed

07. DRILLING BITS TECHNOLOGY

B. Soft vs. Hard Journal Angle

07. DRILLING BITS TECHNOLOGY

C. Cone Profile Angles

Inner Cone Profile Angle

07. DRILLING BITS TECHNOLOGY

C. Cone Profile Angles

Intermediate Cone Angle

Inner Cone Angle

Bearings and Seals

07. DRILLING BITS TECHNOLOGY

Major Bearing Types

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

a. Roller Bearing Exploded View

07. DRILLING BITS TECHNOLOGY

b. Friction Bearing Exploded View

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

Highly Saturated Nitrile (HSN) (-26 to +160oC): Hydrogenated Nitrile

07. DRILLING BITS TECHNOLOGY

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure

Milled Tooth Bits: Cutting Structure

Operations are carried out with light

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure

07. DRILLING BITS TECHNOLOGY

Milled Tooth Bits: Cutting Structure