Roller Cone & PDC Bit Dull Grading

Andrii Vytiaz
Drilling Product Engineer
July 2020
Contents

▪ Reference Material
▪ Definitions and Guidelines
▪ System Structure
◼ Detailed Review of the 8-digit system
▪ Dull Characteristics
◼ Dull samples;
◼ SHO Dull Grading;
◼ Scraping criteria’s;
◼ Q&A;
Reference Material

▪ “The IADC Roller Bit Dull Grading System”

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

▪ Roller Cone & Fixed Cutter Bit Manual

◼ Available from Intouch
◼ #6269987
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.
Roller Cone Dull Grading
 IADC Roller Cone Bit Dull Grading System

T B G REMARKS

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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)

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 I: Inner Rows
• Used to report the condition of • Tooth Height Measurement
the cutting elements not
touching the wall of the hole.

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• Linear scale from 0 - 8 measuring
the combined cutting structure
reduction due to lost, worn or
broken cutting elements.

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 O: Outer Rows
• Used to report the condition of ▪ Tooth Height Measurement
the cutting elements that touch
the wall of the hole

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• Linear scale from 0 - 8 measuring
the combined cutting structure
reduction due to lost, worn and/or
broken cutting elements.

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 Identifying TCI Rows

Heel Row Heel Row

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

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Conventional Gauge Structure Trucut Gauge Structure

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 Identifying Milled Tooth Rows

Gauge Row Heel Row

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

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Conventional Gauge Structure Trucut Gauge Structure

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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
 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

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• 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
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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;

 General Cone Identification Rule

#1 Centermost Cutting Element #1

(Spearpoint)

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#3 #2 #3 #2

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 Roller Cone Bit: Location

Gauge

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Middle

Nose

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B: Bearings/Seals
▪ Smith Tool Guidelines
◼ This column (digit) 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 ‘spring back’;
◼ 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 under gauge 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
 G: Gauge
▪ Smith Tool guidelines
◼ 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.
 G: Gauge
• ‘Two-Thirds Rule’
• Applies to all 3-cone bits
Amount out of gauge =
Measured distance x ⅔

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Amount Undergauge in 16ths
IN = In Gauge
1 = 1/16”
2 = 2/16”
3 = 3/16”
Etc..

Rotate all cones to MAXIMUM offset

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 G: Gauge
• Two-Cone Bits

Amount out of gauge =

Measured distance

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Amount Undergauge in 16ths
IN = In Gauge
1 = 1/16”
2 = 2/16”
3 = 3/16”
Etc..

Rotate all cones to MAXIMUM offset

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 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

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• 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
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 R: Reason Pulled
• BHA - Change Bottom Hole Assembly • HR - Hours on Bit
• CM - Condition Mud • LIH - Left in Hole
• CP - Core Point • LOG - Run Logs
• DMF - Downhole Motor Failure • PP - Pump Pressure

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• DP - Drill Plug • PR - Penetration Rate
• DSF - Drill String Failure • RIG - Rig Repair
• DST - Drill Stem Test • TD - Total Depth / Casing Depth
• DTF - Downhole Tool Failure • TQ - Torque
• FM - Formation Change • TW - Twist Off
• HP - Hole Problems • WC - Weather Conditions
• WO - Washout in Drill String

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 BC - Broken Cone

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 BT - Broken Teeth

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 BU - Balled Up

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 CC - Cracked Cone

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 CD - Cone Dragged

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 CI - Cone Interference

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 CR - Cored

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 CT - Chipped Teeth

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 ER - Erosion

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 FC - Flat Crested Wear

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 HC - Heat Checking

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 JD - Junk Damage

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 LC - Lost Cone

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 LN - Lost Nozzle

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 LT - Lost Teeth

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 OC - Off Center Wear

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 PB - Pinched Bit

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 PN - Plugged Nozzle

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 RG - Rounded Gauge

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 SD - Shirttail Damage

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 SS - Self Sharpening Wear

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 TR - Tracking

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 WO - Washed Out Bit

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 WT - Worn Teeth

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NO - No Dull Characteristic

▪ 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.
PDC Dull Grading
Fixed Cutter Bit Dull Grading

IADC PDC 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

Row Designation (Inner / Outer)

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 I: Inner Rows

Row Designation (Inner / Outer)

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1/3
2/3
(O)
(I)

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 I: Inner Rows
▪ Used to record the average
wear on the inner two-thirds
(⅔) of the bit radius

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▪ Cutter wear is recorded using
a linear scale from 0 to 8
– 0 = no diamond wear
– 8 = no diamond remaining

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 O: Outer Rows O: Outer Rows

▪ Used to record the average

wear on the outer one-third
(⅓) of the bit radius

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▪ Cutter wear is recorded using
a linear scale from 0 to 8
– 0 = no diamond wear
– 8 = no diamond remaining

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 PDC Cutter Exposure

• In IADC system the 0

Top of the
entire PDC cutter is Blade Cutter
graded: Exposure

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◼ “PDC cutter wear should
be measured across the
diamond table regardless 8

of the cutter shape, size,

type or exposure”

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 L: Location
▪ Uses a letter code to indicate the location on the bit face
where the major dull characteristic occurs
– C = Cone
– N = Nose

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– T = Taper
– S = Shoulder
– G = Gauge
– A = All Areas

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 B: Bearing and Seals

▪ Not Applicable
– This space is used only for roller cone bits
– Always mark ‘X’ for fixed cutter bits

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 G: Gauge
▪ Used to record the condition of the bit gauge
– Based upon a nominal ring gauge

API DIAMOND BIT TOLERANCES

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Nominal Bit Size Tolerance
Inches mm* Inches mm*
6-3/4" and smaller 171.45mm and smaller +0.0" : -0.015" +0.0mm : -0.381mm
6-25/32" to 9" 172.24mm to 228.6mm +0.0" : -0.020" +0.0mm : -0.508mm
9-1/32" to 13-3/4" 229.39mm to 349.25mm +0.0" : -0.030" +0.0mm : -0.762mm
13-25/32" to 17-1/2" 350.04mm to 444.50mm +0.0" : -0.045" +0.0mm : -1.143mm
17-17/32" and larger 445.29mm and larger +0.0" : -0.063" +0.0mm : -1.600mm
*converted from inches

API ROLLER CONE BIT TOLERANCES

Nominal Bit Size Tolerance
Inches mm* Inches mm*
3-3/8" to 13-3/4" 85.73mm to 349.25mm -0.0" : +0.031" (1/32") -0.0mm : +0.794mm
14" to 17-1/2" 355.6mm to 444.50mm -0.0" : +0.063" (1/16") -0.0mm : +1.588mm
17-5/8" and larger 447.66mm and larger -0.0" : +0.094" (3/32") -0.0mm : +2.381mm
*converted from inches

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 G: Gauge
▪ PDC Bits
– Measure on the gauge pads

Amount out of gauge =

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Measured distance

Amount Undergauge in 16ths

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

Note: Use a PDC “no-go” ring gauge that measures the nominal size minus API tolerance
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 R: Reason Pulled
• BHA - Change Bottom Hole Assembly • HR - Hours on Bit
• CM - Condition Mud • LIH - Left in Hole
• CP - Core Point • LOG - Run Logs
• DMF - Downhole Motor Failure • PP - Pump Pressure

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• DP - Drill Plug • PR - Penetration Rate
• DSF - Drill String Failure • RIG - Rig Repair
• DST - Drill Stem Test • TD - Total Depth / Casing Depth
• DTF - Downhole Tool Failure • TQ - Torque
• FM - Formation Change • TW - Twist Off
• HP - Hole Problems • WC - Weather Conditions
• WO - Washout in Drill String

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 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

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• 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
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 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

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• 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
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Fixed Cutter Bit Dull Examples
 PDC Cutter Configurations

• Terms used:
◼ PCD layer:
– The diamond table

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◼ Carbide Substrate:
– Support for the diamond table, provides
toughness
◼ LS bond line:
– Cemented boundary between two carbide One piece Two piece
substrates cylinder cylinder

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 BF: Bond Failure

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 BC: Broken Cutters
MORE than 1/3 of the insert is broken

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 BU: Balled Up

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 CR: Cored

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 CT: Chipped Teeth
LESS than 1/3 of the insert is broken

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 ER: Erosion

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 HC: Heat Checking

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 JD: Junk Damage

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 LN: Lost Nozzle

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 LT: Lost Teeth

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 PN: Plugged Nozzle / Waterway

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 RO: Ring Out

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 WO: Washed Out

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 WT: Worn Cutters

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 Schlumberger-Private
Other Dull Characteristics

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 BB: Broken Blade

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 CO: Cutter Corrosion

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 DL: Delamination

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 SP: Spalling

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 Bi-Center Bits

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 I: Inner Rows and O: Outer Rows

• Bi-Center Bits
– Inner section is considered the
entire pilot section;

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– Outer section is considered the
reamer section;

• Amount of cutter wear is

determined by the same
method as for PDC bits

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G: Gauge – Bi-Center Bits

▪ Bi-Center Gauge Measurement Procedure

▪ Step 1 of 3
▪ Measure the shank diameter with a caliper, making sure the full shank is
measured
▪ Do not measure inside the breaker slots

Shank
Diameter
G: Gauge – Bi-Center Bits

▪ Bi-Center Gauge Measurement Procedure

▪ Step 2 of 3
▪ Measure the height of the longest reamer blade from the outer surface of
the shank
▪ Use a straight edge and a ruler

Height of Longer
Reamer Blade
(from shank)
G: Gauge – Bi-Center Bits

▪ Bi-Center Gauge Measurement Procedure

− Step 3 of 3
• The bit’s diameter is then calculated by taking the diameter of the shank
and 2 times the height of the longest reamer blade

Gauge Diameter = + 2x
(Shank Diameter) (Reamer Height)

= inches

• Compare this diameter to Nominal Drilling Diameter

 Central Stinger Dull Grading

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Guideline

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 Central Stinger Dull Grading
Stinger
Dull Wear

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 Blade # 1 Identifier – Matrix Bits
TSP will be placed behind blade # 1 on Stinger
bits for blade #1 identification.
Blade with a TSP on trailing edge is blade # 1.

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Blade # 1

TSP behind blade # 1 for identification

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 Central Stinger Dull Characteristics
WORN TEETH (WT) CHIPPED TEETH (CT) SPALLING (SPA)

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BROKEN TEETH (BT) STINGER DELAMINATION (DEL) BOND FAILURE (BF)

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 Central Stinger Dull Characteristics Contd.

LOST STINGER (LT) NO DULL (NO)

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 Central Stinger Wear Progression

NO DULL
0
1
2
3
4
5
6
7

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T1 8

T2

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 Schlumberger-Private
ONYX 360 Dull Grading Guideline

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 Objectives
➢ There are two aspect of capturing the dull on the ONYX
360 cutter
❑ Retention Mechanism dull
❑ Cutter diamond table dull

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➢ The objective of this paper is to define and document the
dull condition of the Retention Mechanism.
✓ Sleeve Condition
✓ Shaft Condition
✓ Cutter Condition

Above Schematic does not

depict actual/correct dimensions
➢ This dull condition is different than IADC dull condition (8 and it is for illustration purpose
digits) while you are entering in DRS. only.

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 Dull Grading
Dominant Condition Rolling Effectiveness %
ONYX 360 Cutter Condition Sleeve Condition
BS Broken Shaft BL Broken Sleeve NA
BT Broken Teeth/Cutter BU Balled Up 0
BU Balled Up CHL Chipped Sleeve 2
COR Corrosion COR Corrosion 3
CT Chipped Teeth CRS Cracked Sleeve 4
CW Circumferential Wear ER Erosion |
DEL Delamination New New, Sharp Sleeve |

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ER Erosion NO No Major/Other Characteristics |
FC Flat Crested Wear SPK Shale Pack |
GD Gauge Damage WL Worn Sleeve |
HC Heat Checking |
JD Junk Damage |
LD Lost Diamond |
LT Lost Teeth/Cutter |
NEW New, Sharp Bit |
NO No Major/Other Characterstics |
OC Off Center Wear |
SPA Spalling |
SPK Shale Pack |
WT Worn Teeth/Cutter 100
Rolling Effectiveness = (Number of Rotating cutters with signs of rotation) / (Total numbers of rotating cutters on the bit)

Example: 100% - All rotated

0% - None Rotated

NA - Not Applicable due to LT, BS, BL conditions.

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 Dull Progression – Impact Damage (I) leading to
Lost Diamond (LD)

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 Dull Differentiation – Lost Diamond (LD) Vs
Broken Shaft (BS)

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 Sample Dull Condition

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CW-NO-100% NO-NO-100%

CT-WL-0% LT-BL-NA

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 Sample Dull Condition

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DEL-WL-100%

SPA-NO-100%

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 Sample Dull Condition

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NO-CHL-100%

LD-BL-100%

BS-BL-NA

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Dull Grading of Staged Hole Opener
Inner and Outer Area of the SHO

SHO Dull Grading

Scraping Criteria's
 Thank you for your attention!

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