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HALLIBURTON
Dri l l Bi ts & Se r v i ce s
IADC DULL GRADING SYSTEM
In this manual, all causes and recommendations are purely focused on
application parameters and conditions. There is no discussion of bit
design. Halliburton’s Application Design Evaluation (ADESM) specialists
can analyze the bit dull then optimize the bit design to minimize or
eliminate described bit dull features in subsequent runs. The proper
evaluation of a dull drill bit is critical to improving bit type selection and
identifying those drilling parameters which can be altered to improve
drilling performance and obtain maximum bit life.
The IADC Dull Grading System is intended to bring consistency across
the drilling industry and to facilitate the creation of a “mental picture”
of the worn bit’s condition through standardized evaluation of certain
bit characteristics. The purpose of this manual is to help create consistency
and reduce uncertainty when dull grading drill bits.
THE MECHANICS OF DULL GRADING
Roller Cone Drill Bits
The most efficient and accurate dull grading technique is one that is
thorough and consistent. The best way to accomplish this is to examine
dulls in exactly the same manner every time. In other words, develop
a procedure that is repeatable and uses the same system or steps every
time you look at a dull. Too many times we get caught up in focusing
on one aspect of the dull and miss other factors that contributed to the
total dull condition.
The first step is to examine the cutting structure. Start with the number
one cone and rotate it as you are examining the cutting structure. Not
only will you be able to examine the teeth and cone condition, the
rotation of the cone will allow you to determine the seal and/or bearing
condition. Examine the gauge row carefully, then the middle rows, and
finally the inner rows. Look for worn, broken, chipped, and lost teeth.
Examine the cone shell for cone interference, cone erosion, junk marks,
off center wear, and tracking. Once you have examined the number one
cone in this manner, rotate the bit and examine the number two cone
and the number three cone in the same manner. After the cutting structure
and all bearings are examined, ring gauge the dull as explained on
page 8.
After you have graded the cutting structure of all three cones, return to
the number one cone and examine the cone backface, shirttail, and arm.
Look for broken and lost compacts, erosion and fluid cuts on the cone
backface. Examine the shirttail and arm for wear and junk damage.
Examine the ball plug weld and filler plug for weeping of oil from
lubricant. Look at the reservoir cap for cap or snap ring damage. Check
the nozzle boss for wear, erosion or damage. Examine all welds for any
signs of cracking. Again, once you have examined the number one arm,
rotate the bit and examine the number two arm and then the number
three arm in the same manner.
The last thing to examine is the pin and shoulder. Look at the pin for
signs of cross threading and pay special attention to the shoulder for
any signs of galling. This is an indication of improper make-up torque.
Turn the bit up on the cones and look down inside the pin. Look for signs
of erosion and washing.
This system sounds complicated, but it is not. It is a simple routine that
if followed every time a dull is examined, will ensure a thorough and
complete grading evaluation procedure. Start at the cones and work
your way to the pin and look at everything in between.
Fixed Cutter Drill Bits
Evaluating a fixed cutter bit follows a similar procedure as for roller
cone designs, examining each characteristic in the same order each
time. As you consider cutter wear, bear in mind that the IADC Fixed
Cutter Dull Grading System grades all PDC cutters based on condition
of the visible diamond table of the cutter, regardless of cutter shape or
exposure. Therefore, your examination should focus on diamond table
wear.
First, examine the inner and outer rows of cutters, looking at cutter wear
in terms of remaining visible diamond table, as noted above. For these
cutters, you are going to rate the amount of wear, from 0 meaning no
wear to 8, meaning no remaining diamond table. Then, based on the
overall condition of these cutters, determine the average wear by simply
averaging the individual grades for each cutter in the area, as described
on page 37.
Next, examine the bit face as a whole to determine the most prominent
or “primary” dull characteristic, and note where on the bit it occurred.
You are looking for the most significant physical change from new
condition. This may be junk damage, a plugged or lost nozzle, ring out,
or worn cutters. If cutter wear is the primary dull characteristic, next
determine the type of wear, such as broken, chipped or delaminated
cutters. The Dull Grade System gives a full list of wear descriptions for
the primary dull characteristic on page 38.
Having determined the primary dull characteristic, next you want to
determine average overall wear to the bit. At this point, you are looking
for secondary evidence of wear. This may be some clearly identifiable
wear to the bit as a whole, such as "erosion,” or may relate specifically
to the primary cutting structure wear, such as “chipped cutter.” For
example, if “lost nozzle” is the primary dull characteristic, then the
“erosion” may be the resulting secondary characteristic.
Finally, examine the bit shoulder and gauge, and run a “no go” ring
gauge test as described on page 39.
Following these procedures will help ensure proper bit evaluation as
you gain experience in dull grading. In the meantime, it is helpful to
familiarize yourself with the various dull characteristics of the IADC
System and photographs which are included in this manual.
TABLE OF CONTENTS ( ro l l e r c on e dri ll b i ts )

( ro l l e r c on e dri ll b i ts ) ( fi x e d c u tte r d ri l l bit s)

IADC Dull Grading System – Quick Reference Chart 1-2 IADC Dull Grading System – Quick Reference Chart 35-36

IADC Dull Grading System – Overview IADC Dull Grading System – Overview
Inner Cutting Structure 3 Inner Cutting Structure 37
Outer Cutting Structure 3 Outer Cutting Structure 37
Dull Characteristics 4 Dull Characteristics 38
Location 5 Location 39
Bearings/Seals 6 Bearings/Seals 39
Gauge 7 Gauge 39
Other Dull Characteristics 8 Other Dull Characteristics 40
Reason Pulled or Run Terminated 9 Reason Pulled or Run Terminated 41

Dull Evaluation Dull Evaluation

(BC) Broken Cone 11 (BF) Bond Failure 43
(BT) Broken Teeth 12 (BT) Broken Cutters 44
(BU) Balled Up 13 (BU) Balled Up 45
(CC) Cracked Cone 14 (CR) Cored 46
(CD) Cone Dragged 15 (CT) Chipped Cutters 47
(C I) Cone Interference 16 (DL) Delaminated Cutters 48
(CR) Cored 17 (ER) Erosion 49
(CT) Chipped Teeth 18 (HC) Heat Checking 50
(ER) Erosion 19 (JD) Junk Damage 51
(FC) Flat Crested Wear 20 (LM) Lost Matrix 52
(HC) Heat Checking 21 (LN) Lost Nozzle 53
(JD) Junk Damage 22 (LT) Lost Cutters 54
(LC) Lost Cone 23 (PN) Plugged Nozzle/Flow Passage 55
(LN) Lost Nozzle 24 (RO) Ring Out 56
(L T) Lost Teeth 25 (WO) Washed Out 57
(OC) Off Center Wear 26 (WT) Worn Cutters 58
(PB) Pinched Bit 27 Broken Blade 60
(PN) Plugged Nozzle/Flow Passage 28 Reaming Wear 61
(RG) Rounded Gauge 29 Spalling 62
(SD) Shirttail Damage 30
(SS) Self-Sharpening Wear 31
(TR) Tracking 32
(WO) Washed Out 33
(WT) Worn Teeth 34
1
CUTTING STRUCTURE

|
INNER OUTER DULL BEARINGS/ OTHER DULL REASON
ROWS ROWS CHAR. LOCATION SEALS GAUGE CHAR. PULLED
1 2 3 4 5 6 7 8

1 INNER CUTTING STRUCTURE CI - Cone Interference 5 BEARINGS/SEALS DSF - Drill String Failure

Drill Bits and Services

(All inner rows) CR - Cored Non-Sealed Bearings DST - Drill Stem Test
CT - Chipped Teeth A linear scale estimating DTF - Downhole Tool Failure
2 OUTER CUTTING STRUCTURE ER - Erosion bearing life used. FM - Formation Change
(Gauge row only) FC - Flat Crested Wear 0 - No life used HP - Hole Problems
QUICK REFERENCE CHART

In columns 1 and 2, a linear scale from HC - Heat Checking 8 - All life used, i.e., no HR - Hours on Bit
0 to 8 is used to describe the condition JD - Junk Damage bearing life remaining LIH - Left in Hole
of the cutting structure according to LC - Lost Cone* LOG - Run Logs
the following: Sealed Bearings
LN - Lost Nozzle PP - Pump Pressure
E - Seals effective
LT - Lost Teeth PR - Penetration Rate
Steel Tooth Bits F - Seals failed
NO - No Dull Characteristic RIG - Rig Repair
A measure of lost tooth height due to N - Not able to grade
abrasion and/or damage. NR - Not Rerunnable TD - Total Depth/Casing Depth
0 - No loss of tooth height OC - Off Center Wear TQ - Torque
ROLLER CONE IADC DULL GRADING SYSTEM –

8 - Total loss of tooth height PB - Pinched Bit TW - Twist Off

WC - Weather Conditions

Insert Bits PN - Plugged Nozzle/Flow Passage 6 GAUGE

A measure of total cutting structure RG - Rounded Gauge (Measure in fractions of an inch) * Show cone # or #’s under location 4.
reduction due to lost, worn and/or RR - Rerunnable I - In Gauge Cone numbers are identified as follows:
broken inserts. SD - Shirttail Damage 1 - 1/16” Out of Gauge • The number one cone contains the
0 - No lost, worn and/or broken SS - Self-Sharpening Wear 2 - 1/8” Out of Gauge centermost cutting element.
inserts
TR - Tracking 4 - 1/4” Out of Gauge • Cones two and three follow in a
8 - All inserts lost, worn and/or clockwise orientation as viewed looking
WO - Washed Out
broken down at the cutting structure with the
WT - Worn Teeth 7 OTHER DULL CHARACTERISTICS bit sitting on the pin.
(Refer to column 3 codes)
3 DULL CHARACTERISTICS
4 LOCATION
(Use only cutting structure related
codes) N - Nose Row 8 REASON PULLED OR RUN
Cutting Structure Wear
M - Middle Row TERMINATED
BC - Broken Cone*
G - Gauge Row BHA - Change Bottom Hole Assembly
BT - Broken Teeth
A - All Rows CM - Condition Mud T4 T5
BU - Balled Up T3
CP - Core Point T2 T6
CC - Cracked Cone*
Cone # DMF - Downhole Motor Failure T1 T7
CD - Cone Dragged*
1 DP - Drill Plug NEW T8
2
3

Dull Grading Manual

|
2
(r oller con e dr ill b it s)
IADC DULL GRADING SYSTEM – ROLLER CONE
T B
3 DULL CHARACTERISTICS (D)
Uses a two letter code to indicate the major dull characteristics of
the cutting structure. Input only one (two-letter) dull characteristic
G Remarks
code and use the standard abbreviation only.

1 2 3 4 5 6 7 8 (BC) Broken Cone *

Cutting Structure Remarks (BT) Broken Teeth
Inner Outer Dull Location Bearings/ Gauge Other Reason
Rows Rows Char. Seals 1/16” Dull Pulled (BU) Balled
I O D L B G O R
(CC) Cracked Cone *
(CD) Cone Dragged *
1 INNER CUTTING STRUCTURE (I) (CI) Cone Interference
(All inner rows) (CR) Cored
Used to report the condition of the teeth not touching the wall of (CT) Chipped Teeth
the hole. (ER) Erosion
(FC) Flat Crested Wear
2 OUTER CUTTING STRUCTURE (O) (HC) Heat Checking
Used to report the condition of the teeth that touch the wall of the (JD) Junk Damage
hole. These teeth are also called gauge row (gauge condition is (LC) Lost Cone *
important to good bit performance). (LN) Lost Nozzle
(LT) Lost Teeth
Steel Tooth Bits
(NO) No Dull Characteristic
A measure of lost tooth height due to abrasion and/or damage.
(NR) Not Rerunnable
0 - No loss of tooth height
(OC) Off Center Wear
8 - Total loss of tooth height
(PB) Pinched Bit
Insert Bits (PN) Plugged Nozzle/Flow Passage
A measure of total cutting structure reduction due to lost, worn (RG) Rounded Gauge
and/or broken inserts. (RR) Rerunnable
0 - No lost, worn and/or broken inserts (SD) Shirttail Damage
8 - All inserts lost, worn and/or broken (SS) Self-Sharpening Wear
(TR) Tracking
Cutting Structure Wear (WO) Washed Out
(WT) Worn Teeth

* Show cone # or #’s under location 4. Cone numbers are

T4 identified as follows:
T3 T5
• If two cones contain a “centermost cutting” element, or single
T2 T6 (ro lle r co ne d rill bit s)
insert, the insert with the greatest tilt is designated as cone
number one.
T1 T7
• Cones two and three follow in a clockwise orientation as
viewed looking down at the cutting structure with the bit
NEW T8 sitting on the pin.

3 | Drill Bits and Services Dull Grading Manual | 4

 4 LOCATION (L) Cone numbers are identified as follows:
Uses a letter or number code to indicate the location on the face of • The number one cone contains the center most cutting
the bit where the cutting structure dulling characteristic occurs. The element; the spear-point on a steel tooth cone and the nose
IADC Dull Grading System chart lists the codes to be used for insert on a tungsten carbide insert cone. On certain TCI designs
describing locations on roller cone bits. two cones may have a nose insert. In this case the nose insert
that is offset is on the number one cone.
Location is defined as follows: • Cones two and three follow in a clockwise orientation as
N = Nose Row - the center most cutting element(s) of the bit viewed looking down at the cutting structure with the bit
M = Middle Row - cutting elements between the nose and the gauge sitting on the pin.
G = Gauge Row - those cutting elements that touch the hole wall
A = All Rows - all rows 5 BEARINGS/SEALS (B)
Uses a letter or number code, depending on bearing types, to indicate
the bearing condition of roller cone bits.
Steel Tooth Bit
C ONE 3
Nose Row Non-Sealed Bearings
“Spear Point” A linear scale from 0 - 8 is used to indicate that no bearing life has
(Row 3) been used (a new bearing) and an 8 indicates that all of the bearing
Middle Row life has been used (locked or lost).
(Row 2)

Gauge Row Sealed Bearings (Journal or Roller)

(Row 1) A letter code is used to indicate the condition of the seal.
C ON E 1
C ON E 2

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

Indication of Failed Seals

• Locked cone (not always true sign of failure)
• Intermitted locking or “catching” cone
• Scratchy and/or grinding feeling while turning cone
Insert Bit • Ability to rock cone axially
CONE 1
Nose Row • Gaps between cone and arm
(Row 4) • Signs of grease weeping
Middle Row • Shale packing (not always true sign of failure)
(Row 3)

Middle Row
C O NE 3

C O NE 2

(Row 2)

Gauge
(r oller c one dr ill b its )
(Row 1)

Surf Row

Groove

5 | Drill Bits and Services Dull Grading Manual | 6

 6 GAUGE (G) 7 OTHER DULL CHARACTERISTICS (O)
Used to report on the gauge of the bit. The letter “I” (In Gauge) Used to report any dulling characteristic of the bit, in addition to the
indicates no gauge reduction. If the bit does have a reduction in cutting structure dulling characteristic listed in column 3 (D). Use
gauge it is to be recorded in 1/16ths of an inch. the same standard two-letter codes as used in column 3. Note that
this column is not restricted to only cutting structure dulling
Dull Three Cone Bits ** characteristics.

1
• Obtain a nominal size ring gauge.
A nominal ring gauge is one that is (BC) Broken Cone
exact in size. For example, a (BT) Broken Teeth
12-1/4 inch ring gauge is 12-1/4 (BU) Balled Up Bit
inch exactly.
+ (CC) Cracked Cone
• Rotate all cones so that one of the (CD) Cone Dragged
gauge teeth on each cone is at the *
(CI) Cone Interference
maximum gauge point*. (Remember,
soft formation bits with large offsets * (CR) Cored
have the maximum gauge points (CT) Chipped Teeth
on each cone located towards the leading side of the cone.) (ER) Erosion
• Place the ring gauge over the bit and locate it at the maximum (FC) Flat Crested Wear
gauge point. (HC) Heat Checking
• Pull the ring gauge tight against the gauge points of two cones (JD) Junk Damage
as shown. (LC) Lost Cone
(LN) Lost Nozzle *
• Measure the gap between the third cone’s gauge point and the
ring gauge**. (LT) Lost Teeth
(NO) No Dull Characteristic
• Multiply this measurement by 2/3 for accuracy. This result is the
amount the bit is under gauge. In the illustration, for example, (NR) Not Rerunnable
measurement shows 3/8 inch, while the bit is actually 1/4 inch (OC) Off Center Wear
out of gauge. (PB) Pinched Bit *
• Report this amount to the nearest 1/16 of an inch. (PN) Plugged Nozzle/Flow Passage *
(RG) Rounded Gauge
Sharp Bits (RR) Rerunnable
(SD) Shirttail Damage *
• When ring gauging a sharp (new) roller cone bit, a nominal ring
gauge may not fit over the cones due to the “plus” tolerances. (SS) Self-Sharpening Wear
Obtain the appropriate “go” and “no go” gauges for each bit size. (TR) Tracking
(WO) Washed Out Bit *
• The “go” gauge is manufactured to the maximum roller cone bit
(WT) Worn Teeth
tolerance (see API Standard Roller Cone Rock Bit Tolerances) plus
its own tolerance +.003 to -0 inches for clearance.
* Used only in the “Other Dull Characteristics” column.
• The “no go” gauge is manufactured to the minimum roller cone (ro lle r co ne d rill bit s)
bit tolerance, which is nominal bit diameter, plus its own tolerance
+0- to -.003-in.

API STANDARD ROLLER CONE BIT TOLERANCES

BIT SIZE (IN) O.D. TOLERANCE (IN)
3-3/8 to 13-3/4 +1/32, -0
14 to 17-1/2 +1/16, -0
17-5/8 and Larger +3/32, -0

7 | Drill Bits and Services Dull Grading Manual | 8

 8 REASON PULLED OR RUN TERMINATED (R) NOTES
Following are the two or three letter codes used to report termination
of the bit run.

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

(ro lle r co ne d rill bit s)

9 | Drill Bits and Services Dull Grading Manual | 10

 B C – B R O K EN CO NE BROKE N TE E TH – B T

A broken cone is A cutting element is

described as a bit with considered broken if
one or more cones that more than 50% of the
have been broken into cutting element is
two or more pieces, clearly broken with an
but with most of the angular or jagged
cone still attached to break.
the bit.

POSSIBLE CAUSES POSSIBLE CAUSES

• Cone interference, where the cones contact each other after a
bearing failure causing breakage of one or more of the cones
• Cutting structure failure (lost, broken or worn) resulting in cone
shell thickness reduction
• Bit hitting a ledge on trip or connection
• Running on junk
• Dropped drill string
• Hydrogen sulfide embrittlement - a condition of low ductility in
metals resulting from the absorption of hydrogen; hydrogen atoms
diffuse readily into steel during exposure to hydrogen sulfide;
after stressing, delayed brittle fracture may occur, particularly in
higher strength steels
• Propagation of cracks generated by heat after bearing failure
APPLICATION RECOMMENDATIONS
• Monitor and reduce bit on bottom hours
• Review application and bit selection
• Check running parameters (WOM, RPM, hydraulics)
• Check running in hole procedures
• Excessive WOB for application indicated by broken teeth,
predominantly on the inner and middle row
• Excessive RPM for application indicated by broken teeth
predominantly on the gauge row teeth
• Highly interbedded formations or conglomerates causing uneven
loading across the cutting structure
• Improper bit selection
• Drill string vibrations
• Bit run on junk
• Bit hitting a ledge or hitting bottom suddenly
• Improper break-in of bit when a major change in bottomhole
pattern is made
• Cone interference
• Bit tracking and off center wear
APPLICATION RECOMMENDATIONS
• In some formations broken teeth may be a typical dull characteristic
and not necessarily a problem with bit selection. However, if the
bit run was of uncommonly short duration, broken teeth could
indicate problems in bit selection for the application
• For harder formations and/or higher energy levels, select a bit (r oller con e dr ill b it s)
with less offset, and/or less tooth extension, and/or greater tooth
count, and/or tougher tooth shape and/or tougher carbide material
• When drilling torque varies greatly, reduce RPM and/or lower
WOB
• Avoid drilling out metal objects in the wellbore with insert type
bits; use short tooth steel tooth bits
• Some breakage may occur during a run; excessive breakage would
indicate changes in drilling parameters or bit type is required

11 | Drill Bits and Services Dull Grading Manual | 12

 B U – B A LL ED U P CRACKE D CON E – C C

Balled up is when A cracked cone is

formation packs off the start of a broken
between the cones or lost cone. If any
and/or bit body. This portion of the cone is
usually prevents the missing then it is a
cones from turning broken cone.
resulting in lower ROP
and possible impeded
cone rotation. Possible
signs of balled up bits
could be wear flats on
cutting structure or
indications of cone
skidding with effective
bearings.

POSSIBLE CAUSES POSSIBLE CAUSES

• Inadequate hydraulic cleaning of the bottomhole
• Forcing the bit into formation cuttings with the pump not running
• Drilling a sticky formation
APPLICATION RECOMMENDATIONS
• This dull characteristic occurs primarily on steel tooth bits
• Review hydraulics parameters (consider center jet, SidePort or
Multi-Port nozzles)
• Consider control drilling
• Review mud properties
• Consider alternate bit type if necessary
• Cone interference, where the cones contact each other after a
bearing failure causing breakage of one or more of the cones
• Cutting structure failure (lost, broken or worn) resulting in cone
shell thickness reduction
• Bit hitting a ledge on trip or connection
• Running on junk
• Dropped drill string
• Hydrogen sulfide embrittlement - a condition of low ductility in
metals resulting from the absorption of hydrogen. Hydrogen atoms
diffuse readily into steel during exposure to hydrogen sulfide.
After stressing, delayed brittle fracture may occur, particularly in
higher strength steels
• Propagation of cracks generated by heat after bearing failure

APPLICATION RECOMMENDATIONS
• Monitor and reduce bit on bottom hours
• Review application and bit selection
• Check running parameters (WOM, RPM, hydraulics)
• Check procedures for running bit in hole
• Consider advanced hydraulics bit design
(r oller con e dr ill b it s)

13 | Drill Bits and Services Dull Grading Manual | 14

 C D – C O N E D RA G G ED CON E IN TE RF E RE N CE – C I

This dull characteristic Cone interference is

indicates that one or described as the
more of the cones did cutting structure of at
not turn during part of least one cone that
the bit run, indicated has impacted the cone
by one or more flat shell of an adjacent
wear spots. This cone. This results in
should not be cone shell grooving
confused with flat and can lead to cutting
crested wear. Heat element breakage.
checking might be This can lead to
visible on flattened cracked or broken
inserts. cones.

POSSIBLE CAUSES POSSIBLE CAUSES

• Bearing failure on one or more of the cones • Bearing failure on one or more cones
• Junk lodging between the cones • Bit being pinched causing cone interference
• Pinched bit causing cone interference (see Dull Characteristic - Pinched Bit)
• Bit balling up • Excessive WOB
• Inadequate break-in
APPLICATION RECOMMENDATIONS
APPLICATION RECOMMENDATIONS • Reduce energy levels
• Reduce energy levels • Use proper reaming guidelines for undergauge hole sections
• Use solids control equipment to remove abrasives • Review application and bit selection
• Increase flow rate; use better bit hydraulics to clean the bit
• Observe drilling torque continually while drilling out cementing
equipment and pick-up off bottom to avoid wedging pieces
between cones if high torque exists
• Use proper break-in procedures

(r oller c one dr ill b its )

15 | Drill Bits and Services Dull Grading Manual | 16

 C R – C O R ED CHIPPE D TE E TH – C T

A bit is cored when the On tungsten carbide

center most cutting insert bits, chipped
elements are worn, inserts often become
lost, or broken, broken teeth. A tooth
resulting in cone wear. is considered chipped,
The center most as opposed to broken,
portion of the cone is if more than 50% of
usually worn more the cutting element
than the outer remains above the
sections. cone shell.

POSSIBLE CAUSES POSSIBLE CAUSES

• Cone shell erosion resulting in lost or washed cutting elements
• Improper break-in of a new bit when there is a major change in
bottomhole pattern
• Improper bit selection (too aggressive)
• Excessive WOB and RPM
• Abrasiveness of formation exceeds the wear-resistance of the
center teeth
• Junk in the hole causing breakage of the center teeth
APPLICATION RECOMMENDATIONS
• Avoid drilling on junk/metal debris
• Avoid running too much WOB and RPM through hard, interbedded
or conglomerate lithologies
• Insure proper bottomhole pattern break-in (see Drill Bit Handbook
for drilling procedures)
• Use diffusing nozzle in center jet assembly to reduce erosion
• Excessive WOB for application indicated by chipped teeth
predominantly on the inner and middle row
• Excessive RPM for application indicated by chipped teeth
predominantly on the gauge row teeth
• Tracking and off center wear
• Impact loading due to rough drilling or drill string vibration
• Running on junk
• Improper bit selection
• Slight cone interference
• Rough running in air drilling applications
APPLICATION RECOMMENDATIONS
• For harder formations and/or higher energy levels, select a bit
with less offset, and/or less tooth extension, and/or greater tooth
count, and/or tougher tooth shape and/or tougher carbide material
• Reduce RPM when drilling torque varies greatly and/or lower
WOB
• Some chipped teeth may occur during a run; excessive chipping
could indicate changes in drilling parameters or bit type is required
• Control drill through transition sections
(r oller con e dr ill b it s)
Note: In some formations chipped teeth may be a typical dull
characteristic and not necessarily a problem with bit selection;
however, if the bit run was of uncommonly short duration, chipped
teeth could indicate problems in bit selection for the application

17 | Drill Bits and Services Dull Grading Manual | 18

 E R – E R O S IO N F LAT CRE STE D WE AR – F C

Erosion describes the Flat crested wear is an

loss of cutting even reduction in
structure material due height across the
to the effect of drilling entire face of the
fluid, cuttings or cutting elements. This
formation against the is often considered a
cones. Loss of cone typical and desirable
shell by erosion is a
dull characteristic
major cause of lost
when the wear is
inserts. It can also lead
evenly distributed
to cone shell cracking
which can result in a across the cutting
broken cone. structure.

POSSIBLE CAUSES POSSIBLE CAUSES

• Excessive hydraulics resulting in high velocity fluid erosion
• Abrasive formation contacting the cone shell between the teeth,
caused by tracking, off center wear, or excessive WOB
• Abrasive formation cuttings eroding the cone shell due to
inadequate hydraulics
• Abrasive drilling fluids or poor solids control
• Use of a center jet may cause inner cutting structure erosion
APPLICATION RECOMMENDATIONS
• Reduce hydraulic energy by changing flow rate or nozzles on
subsequent runs
• Improve mud properties and run solids control equipment
• Review hydraulics parameters (consider center jet, SidePort or
Multi-Port nozzles)
• Control drill if necessary
• Consider use of diffusing center jet
• Low WOB and high RPM, often used in attempting to control
deviation
• Bit selection too aggressive for hard, abrasive formations
• Tracking on the drive or heel rows may cause the inner portion
to skid excessively
APPLICATION RECOMMENDATIONS
• Adjust to a more abrasion resistant cutting element material
grade
• Select proper bit type for the formation
• Review and optimize WOB and RPM

(r oller con e dr ill b it s)

19 | Drill Bits and Services Dull Grading Manual | 20

 H C – H E AT CH ECK ING JUN K DAMAGE – JD

Heat checking Junk damage is

happens when an typified by irregular
insert is overheated grooves or scraped
due to dragging on the
indentations in the
formation and is then
cooled by the drilling cone steel or bit body.
fluid over many cycles. Typically, inserts or
It is often associated teeth would also
with inserts on the be broken.
gauge and drive rows
(resulting in larger
contact areas) but can
occur anywhere on the
cutting structure.

POSSIBLE CAUSES POSSIBLE CAUSES

• Insufficient cooling due to balling or inadequate hydraulics • Junk dropped in the hole from the surface (tong dies, tools, etc.)
• Cone drag or restricted cone rotation • Junk from the drill string (reamer pins, stabilizer blades, etc.)
• Reaming an undergauge hole at high RPM • Junk from a previous bit run (tungsten carbide inserts, ball bearings,
• Low WOB and high RPM, often used in attempting to control etc.)
deviation • Junk from the bit itself (tungsten carbide inserts, etc.)
• Damage due to contact with casing
APPLICATION RECOMMENDATIONS
• Increase fluid flowrate APPLICATION RECOMMENDATIONS
• Reduce RPM while reaming hole • Plan on running junk basket with next bit and anticipate reduced
• Review and control WOB and RPM bit life
• Alternate cutting element materials such as diamond enhanced • Ensure hole is clean before running bit to drill ahead
inserts • Circulate and rotate just above hole bottom to lift junk above bit
face prior to drilling
• Run a cleanout bit if necessary

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21 | Drill Bits and Services Dull Grading Manual | 22

 L C – L O S T CO NE LOST N OZ Z LE – L N

Lost cone is described Lost nozzle describes

as a condition when one or more missing
one or more cones are nozzles. While lost
lost from the bit arm. nozzle is not a cutting
This may include the structure dull
loss of the journal or characteristic, it is an
bearing portion of the important “Other Dull
arm with the cone. Characteristic” that
can help describe a bit
condition.

POSSIBLE CAUSES POSSIBLE CAUSES

• Any of the conditions that lead to a cracked or broken cone may
eventually result in the loss of the cone
• Excessive hours after bearing failure causing the cone retention
system to fail
APPLICATION RECOMMENDATIONS
• Review and adhere to recommended operational parameters
• Monitor drilling parameters during run and react properly to
indications of a potential problem, such as erratic or increased
torque values
• Missing or damaged O-ring and/or improper nozzle installation
• Mechanical or erosion damage to nozzle and/or nozzle retaining
system
• Improper nozzle selection for hydraulic conditions
• Junk in the hole can damage nozzle or nozzle retention
APPLICATION RECOMMENDATIONS
• Insure O-ring is in place and confirm nozzles are properly installed
(refer to Drill Bit Handbook for nozzle installation procedures)
• Review nozzle selection and hydraulics parameters
• Check for unusual bit damage and use proper procedures to deal
with junk in the hole
• A lost nozzle causes a pressure decrease which may require the
bit be pulled out of the hole

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23 | Drill Bits and Services Dull Grading Manual | 24

 L T – L O S T TEETH OF F CE N TE R WE AR – O C

Lost teeth is a Off center wear occurs

characteristic when the geometric
center of the bit and the
described as tungsten geometric center of the
carbide inserts that hole do not coincide. Off
are missing from the center wear can be
cutting structure. The recognized by wear on
the cone shells between
loss of an insert
the rows of teeth, more
increases loading on wear on one or more
the adjacent inserts cones on the cone shell,
and can result in a gauge, arm and by a less
than expected ROP. Wear
series of lost or broken
may or may not occur on
inserts. the cutting elements.

POSSIBLE CAUSES POSSIBLE CAUSES

• Insert breakage causing excess cyclic loading on adjacent inserts
• Improper bit selection
• Cone shell erosion reducing insert retention
• Excessive hours on bit
• Tracking or insert burial too deep into formation causing cyclic
loading, twisting and insert hole enlargement due to movement
• Cone steel residual stress relieved due to cone cracking or major
insert breakage
• Hydrogen sulfide embrittlement cracks
APPLICATION RECOMMENDATIONS
• Adjust energy levels in interbedded and hard lithologies
• Change to a more durable bit type
• Review hydraulic parameters or running procedures to avoid
excessive cone erosion (see dull characteristic under “Erosion”)
• Reduce operating hours
• Bent drill collar or other BHA tool
• Steerable motor or rotary steerable system
• Inadequate stabilization resulting in possible bit whirl/vibration
• Insufficient WOB for formation and bit type
APPLICATION RECOMMENDATIONS
• Change drilling parameters to optimize ROP using drill-off tests
• Proper stabilization which enables directional control and optimum
bit performance should be discussed prior to running bit
• Increase WOB to engage cutting structure
• Review BHA condition and components

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25 | Drill Bits and Services Dull Grading Manual | 26

 P B – P INCH ED B IT PLUGGED NOZZLE/FLOW PASSAGE – PN

A pinched bit occurs This characteristic is

when one or more described as one or
cones have been more nozzles being
mechanically forced
obstructed. This
together to a less than
original gauge problem can lead to
diameter. Pinched bits reduced hydraulics
can lead to bearing/ and may require a trip
seal failures, broken out of the hole due to
teeth, chipped teeth, excessive pump
cone interference, pressure.
dragged cones and
many other dull
characteristics.

POSSIBLE CAUSES POSSIBLE CAUSES

• Bit being forced into an undergauge hole
• Roller cone bit being forced into a section of hole drilled by fixed
cutter bits, due to different API O.D. tolerances
• Forcing a bit through casing that does not drift to the bit size used
• Bit being pinched in the bit breaker
• Bit being forced into an undersized blowout preventer stack
• Improper break in of new bit type due to bottomhole profile
differences
APPLICATION RECOMMENDATIONS
• Trip in hole with care and wash and ream tight spots
• Use proper bit size for the casing set; check API casing charts
and ensure bit is under the listed drift diameter
• Use correct and undamaged bit breaker; use proper procedures
for bit make-up (refer to Drill Bit Handbook)
• Exercise caution when reaming undergauge hole
• Use proper break-in techniques (refer to Drill Bit Handbook)
• Solid material going up the drill string through the bit on a
connection and becoming lodged in a nozzle when circulation is
resumed
• Solid material pumped down the drill string and becoming lodged
in a nozzle
• Improper nozzle selection
• Debris from failed or failing drill string components (such as rubber
from a motor) plug nozzle openings
• Jamming the bit into fill with the pump off
APPLICATION RECOMMENDATIONS
• Run in hole carefully; break circulation 60ft from bottom and wash
and ream to bottom
• Consider running a float valve
• Avoid mixing nozzle sizes which differ by more than 2/32”
• Insure no debris is pumped down drill string
• When a nozzle plugs while drilling there will be an obvious sudden
rise in standpipe pressure - monitor hydraulic parameters during
running for signs of standpipe pressure increase

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27 | Drill Bits and Services Dull Grading Manual | 28

 R G – R O UND ED G A U G E SHIRTTAIL DAMAGE – S D

Rounded gauge is Shirttail damage is a

described as the condition where
outermost tip of the damage due to wear,
erosion or junk occurs
gauge cutting element
in the shirttail area.
that has rounded over Shirttail damage is not
in a way that it is not a “Cutting Structure
cutting nominal gauge. Dull Characteristic”,
Rounded gauge will although it can be
decrease the ROP and affected by the
can increase torque. condition of the cutting
structure. Shirttail wear
can contribute to
bearing system failures.

POSSIBLE CAUSES POSSIBLE CAUSES

• Drilling an abrasive formation with excessive RPM
• Reaming an undergauge hole
• Running on a steerable motor or rotary steerable system
• Formation too abrasive for selected bit type
APPLICATION RECOMMENDATIONS
• Reduce RPM and increase flow rate to cool and clean more
effectively
• Select a bit with more durable gauge protection
• Consider using diamond enhanced gauge protection
• Junk in hole
• Reaming undergauge hole
• A pinched bit causing the shirttails to be the outermost part of
the bit
• Improper hydraulics
• High angle or horizontal wellbore
• Gauge rounding or breakage causing undergauge hole condition
• Rotary steerable (push-the-bit) system
APPLICATION RECOMMENDATIONS
• Review procedures for running in hole (refer to Drill Bit Handbook)
• Insure hole is free of debris or junk (see dull characteristic Junk
Damage for application recommendations)
• Exercise caution if reaming undergauge hole
• Evaluate running parameters and hours on bit
• Consider using enhanced shirttail protection
• Improve cutting structure gauge protection (see dull characteristic
Gauge Rounding for application recommendations)

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29 | Drill Bits and Services Dull Grading Manual | 30

 S S – S E L F- S H A RPENING WEA R TRACKIN G – T R

Self-sharpening wear Tracking occurs when

is a dull characteristic the teeth mesh like a
that occurs when teeth gear into the
bottomhole pattern. The
wear in a manner such
tooth or insert wear on
that they retain a sharp a bit that has been
crest shape but are tracking will be on the
reduced in height. leading and trailing
flanks. The cone shell
wear will be between
the teeth in a row.
Slower than expected
ROP may be an
indication of tracking.

POSSIBLE CAUSES POSSIBLE CAUSES

• Abrasion from engagement with formation • Formation changes from brittle to plastic
• In many applications, self-sharpening wear is a desirable • Hydrostatic pressure that significantly exceeds the formation
characteristic on the cutting structure pressure (overbalanced drilling)
• Improper weight/RPM combination
APPLICATION RECOMMENDATIONS
• Review bit design and selection criteria if self-sharpening wear APPLICATION RECOMMENDATIONS
is a concern for the specific application • Optimize ROP for each formation change using drill-off tests
• Reevaluate hydrostatic versus formation pressures to manage
overbalanced drilling
• Lower mud weight if possible
• Tracking can sometimes be alleviated by using a softer bit to drill
the formation
• Review bit selection

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31 | Drill Bits and Services Dull Grading Manual | 32

 W O – W A S H ED O U T WORN TE E TH – W T

Bit washout occurs Worn teeth is used to

when the drilling fluid describe the reduction
erodes a passage from in the height of the
the internal area to the cutting elements due to
exterior of the bit. It is the drilling action, which
not exclusive to welds. is a normal and
This is not to be expected wear mode.
confused with the dull When worn teeth (WT)
characteristic “Lost is indicated on steel
Nozzles”. This tooth bits, it is
characteristic is used appropriate to note self-
only in the “Other Dull sharpening (SS) or flat
Characteristics” column. crested (FC) wear.

POSSIBLE CAUSES POSSIBLE CAUSES

• Very abrasive particles in the mud system or poor solids control • Bit selection is incorrect for application
• High flow rates coupled with elevated mud weights • Energy levels may be excessive
• Bit damage occurring during the bit run due to impact with bottom • Applying excessive energy in transition zones
or ledges on connections • Tracking
• Dropping the drill string
• Excessive flow rates APPLICATION RECOMMENDATIONS
• O-ring missing when nozzle installed • Review bit selection
• Review WOB and RPM applied
APPLICATION RECOMMENDATIONS • Adjust energy levels when drilling through transition zones and
• Review drilling mud parameters (Hematite or abrasive muds) and formation changes
adjust bit running procedures accordingly • Monitor bit performance and review bit pulling procedures
• Use proper running procedures when tripping in hole and making
connections (refer to Drill Bit Handbook)
• Spend extra time ensuring nozzles are correctly in place prior to
running in the hole; check O-ring for rips or tears and replace

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33 | Drill Bits and Services Dull Grading Manual | 34

35
CUTTING STRUCTURE

|
INNER OUTER DULL BEARINGS/ OTHER DULL REASON
ROWS ROWS CHAR. LOCATION SEALS GAUGE CHAR. PULLED
1 2 3 4 x 6 7 8

Drill Bits and Services

Inner Area Outer Area 1 INNER CUTTING STRUCTURE 4 LOCATION DTF - Downhole Tool Failure
2/3 Radius 1/3 Radius 2 OUTER CUTTING STRUCTURE C - Cone FM - Formation Change
A measure of lost, worn and/or broken N - Nose HP - Hole Problems
cutting structure. T - Taper HR - Hours
QUICK REFERENCE CHART

Linear Scale: 0-8 S - Shoulder LIH - Left in Hole

0 - No lost, worn and/or broken G - Gauge LOG - Run Logs
cutting structure A - All Areas PP - Pump Pressure
8 - All of cutting structure lost, PR - Penetration Rate
worn and/or broken
5 X RIG - Rig Repair
TD - Total Depth/Casing Depth
3 DULL CHARACTERISTICS
TQ - Torque
BF - Bond Failure
TW - Twist Off
BT - Broken Cutters
WC - Weather Conditions
FIXED CUTTER IADC DULL GRADING SYSTEM –

BU - Balled Up
WO - Washout - Drill String

CR - Cored 6 GAUGE
CT - Chipped Cutters I - In Gauge
DL - Delaminated Cutters 1 - 1/16” Out of Gauge
No Wear Worn Cutter ER - Erosion 2 - 1/8” Out of Gauge
HC - Heat Checking 4 - 1/4” Out of Gauge
JD - Junk Damage
LM - Lost Matrix 7 OTHER DULL CHARACTERISTICS
Lost Cutter Delaminated LN - Lost Nozzle (Refer to column 3 codes) Gauge
LT - Lost Cutters
Shoulder
NO - No Dull Characteristics 8 REASON PULLED OR RUN
Halliburton Drill Bits and Services’ fixed NR - Not Rerunnable TERMINATED Taper
cutter bits are tip ground to exacting Cone
PN - Plugged Nozzle/Flow Passage BHA - Change Bottom Hole Assembly Nose
tolerances at gauge O.D. per API spec
7. Depending on the specific design and RO - Ring Out CM - Condition Mud
application, as much as .080 of an inch RR - Rerunnable CP - Core Point
of the cutter diameter may be ground WO - Washed Out DMF - Downhole Motor Failure
flat. This can be mistaken for gauge WT - Worn Cutters DP - Drill Plug
wear if unfamiliar with our products. DSF - Drill String Failure
Please ensure that dull bits are in gauge
with a calibrated PDC No Go ring gauge. DST - Drill Stem Test

Dull Grading Manual

|
36
(f ixe d c u tte r d ri l l b i ts )
IADC DULL GRADING SYSTEM – FIXED CUTTER Impregnated bits use a ratio of remaining blade height to original
blade height (Figure 3). If the original blade height was .5 inches
and the remaining blade height is .25 inches, the grading would
T B G Remarks be a “4” (50% wear). Always measure the blade height vertically
and not perpendicular to the blade profile.
1 2 3 4 X 6 7 8
Cutting Structure Remarks
Inner Outer Dull Location Bearings/ Gauge Other Reason Original
Rows Rows Char. Seals 1/16” Dull Pulled 0
Waterway Depth
I O D L B G O R
4

1 INNER CUTTING STRUCTURE (I) 8

No Waterway
The first 2/3 of the radius represents the inner rows (Figure 1). Using Remaining
a linear scale from 0-8, a value is given to cutter wear in the inner
rows of cutters (Figure 2). Grading numbers increase with amount
of wear, with 0 representing no wear, and 8 meaning no usable Figure 3
cutters left. A grade of 4 indicates 50% wear. For surface set bits,
the scale of cutter wear is determined by comparing the initial cutter
height with the amount of usable cutter height remaining. PDC cutter 3 DULL CHARACTERISTICS (D)
wear is measured across the diamond table, regardless of the cutter
shape, size, type or exposure. For example, when the cutter is worn The most prominent or “primary” physical change from the new
flat with a bit blade, a grade of 4 is given. condition of the bit is recorded in the third space. “Other”or
secondary dull characteristics of the bit are noted in the seventh
space. If this primary dull characterization is a PDC type failure,
2 OUTER CUTTING STRUCTURE (O) then the PDC failure mode box in the header must match.
The outer row of cutters represents the last third of the bit radius.
Using a linear scale from 0-8, a value is given to cutter wear in the
(BF) Bond Failure
outer rows of cutters (Figure 2). Grading numbers increase with
amount of wear, with 0 representing no wear, and 8 meaning no (BT) Broken Cutters
usable cutters left. A grade of 4 indicates 50% wear. For surface (BU) Balled Up

(f ixe d c u tte r d ri l l b i ts )
set bits, the scale of cutter wear is determined by comparing the (CR) Cored
initial cutter height with the amount of usable cutter height remaining. (CT) Chipped Cutters
PDC cutter wear is measured across the diamond table, regardless (DL) Delaminated Cutters
of the cutter shape, size, type or exposure. (ER) Erosion
0 (HC) Heat Checking
Inner Area Outer Area
2/3 Radius 1/3 Radius
1 (JD) Junk Damage
2
(LM) Lost Matrix
3
4
(LN) Lost Nozzle
5 (LT) Lost Cutters
6 (NO) No Dull Characteristics
7 (NR) Not Rerunnable
8
(PN) Plugged Nozzle/Flow Passage
Figure 1 Figure 2 (RO) Ring Out
(RR) Rerunnable
(WO) Washed Out
(WT) Worn Cutters
Broken Blade
Reaming Wear
Spalling

37 | Drill Bits and Services Dull Grading Manual | 38

 4 LOCATION (L) 7 OTHER DULL CHARACTERISTICS (O)
The fourth space is used to indicate the location of the primary dull Used to report any dulling characteristics of the bit, in addition to
characteristic noted in the third space. Locations are designated as: the cutting structure dulling characteristic listed in column 3 (D).
Such evidence may relate specifically to cutting structure wear, as
C – Cone S – Shoulder recorded in the third space, or may note identifiable wear of the bit
as a whole, such as “erosion” or “broken blade”. Many times, this
N – Nose G – Gauge
secondary dull grade identifies the cause of the dull characteristic
T – Taper A – All Areas noted in the third space.
Note that if the primary failure is bit related failure (broken blade,
erosion, nozzle failure, etc.), and the secondary failure is a PDC type
GAUGE
GAUGE failure (spall, chipped cutter, delamination, etc.), then this secondary
SHOULDER SHOULDER
characterization box must match what is entered into the PDC failure
TAPER
NOSE
TAPER mode box in the header.
CONE CONE
NOSE

GAUGE
(BF) Bond Failure
GAUGE
(BT) Broken Cutters
SHOULDER
SHOULDER
(BU) Balled Up
CONE NOSE
TAPER
(CR) Cored
NOSE (CT) Chipped Cutters
CONE
(DL) Delaminated Cutters
(ER) Erosion
(HC) Heat Checking
5 BEARINGS/SEALS (JD) Junk Damage
This space is only used for roller cone bits. It will always be marked (LM) Lost Matrix
“X” for fixed cutter bits. (LN) Lost Nozzle
(LT) Lost Cutters
6 GAUGE (G) (NO) No Dull Characteristic

(fi xe d c u tte r d ri l l b i ts )
Used to report on the gauge of the bit. The letter “I” (In Gauge) (NR) Not Rerunnable
indicates no gauge reduction. If the bit does have a reduction in (PN) Plugged Nozzle/Flow Passage
gauge it is to be recorded in 1/16ths of an inch. (RO) Ring Out
Any fixed cutter bit should be ring gauged prior to running in the (RR) Rerunnable
hole. Stabilizers should also be calipered or gauged to verify they (WO) Washed Out
meet API-approved outside dimension tolerances as shown in the (WT) Worn Cutters
following table. Fixed cutter bits should not be larger than the nominal
diameter.
A “no go” gauge is used to ensure a bit is not smaller than allowed
and, as the name implies, it should not go or slip down the entire
length of the bit. A “go” gauge ensures a bit is not larger than
allowed and should slip down the entire bit.
API STANDARD FIXED CUTTER BIT TOLERANCES
BIT SIZE (IN.) O.D. TOLERANCE (IN.)
6-3/4 and Smaller -0.015 to +0.00
6-25/32 to 9 -0.020 to +0.00
9-1/32 to 13-3/4 -0.030 to +0.00
13-25/32 to 17-1/2 -0.045 to +0.00
17-17/32 and Larger -0.063 to +0.00

39 | Drill Bits and Services Dull Grading Manual | 40

8 REASON PULLED OR RUN TERMINATED (R) NOTES
Following are the two or three letter codes used to report termination
of the bit run.
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
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 Drill String

(f ix e d c u tte r d ri l l b i ts )

41 | Drill Bits and Services Dull Grading Manual | 42

 B F – B O N D FA IL U RE BROKE N CUTTE RS – B T

Bond failure is a A cutting element is

characteristic that considered broken if
describes where the more than 1/3 of the
braze joint between cutter is broken and
the PDC cutter and the the break occurs in
bonded extension both the diamond layer
shears or breaks off. and the tungsten
carbide substrate.

POSSIBLE CAUSES POSSIBLE CAUSES

• Incorrect bit selection • Incorrect bit selection
• Improper WOB • Improper WOB
• Inadequate bottomhole pattern break-in • Inadequate bottomhole pattern break-in
• Excessive impact load / improper drilling practices • Excessive impact load / improper drilling practices
• Interbedded formations • Interbedded formations
• Bit vibration • Bit vibration
• Junk damage
APPLICATION RECOMMENDATIONS • Dropped bit
• Utilize SPARTA™ software to identify and locate interbedded • Running in hole too fast and encountering ledges or obstructions
formations and the relative rock strength

( fix ed c u tte r d ri l l b i ts )
• Optimize drilling parameters APPLICATION RECOMMENDATIONS
• Utilize SPARTA™ software to identify and locate interbedded
FEATURE RECOMMENDATIONS formations and the relative rock strength
• Secondary cutting structure such as R1™ and MDR’s • Optimize drilling parameters
• Impact arrestors
• Increase cutter density FEATURE RECOMMENDATIONS
• Less aggressive cutter profile • Secondary cutting structure such as R1™ and MDR’s
• Impact arrestors
• Increase cutter density
• Less aggressive cutter profile
• Decrease cutter size

43 | Drill Bits and Services Dull Grading Manual | 44

 B U – B A LL ED U P CORE D – C R

Balled up occurs when Cored is defined as

cuttings are packed loss of cutting
around the cutters structure extending all
and/or blades. This the way to the center
condition can limit of the bit.
drilling rate, possibly
decrease drilling
torque and increase
pump pressure.

POSSIBLE CAUSES POSSIBLE CAUSES

• Drilling formations with hydratable clays or soft carbonates • Damage during drilling out float equipment
• Inadequate hydraulics • Junk damage
• Improper nozzle selection • Erosion
• Inadequate cleaning of the hole after making a connection • Significant change in bottomhole profile from previous bit run
• Improper break-in
APPLICATION RECOMMENDATIONS • Excessive WOB
• Optimize bit hydraulics • Bit vibration
• Increase flow rate • Formations too hard for bit type selected
• Optimize drilling fluid properties • Bit run following a core bit run
• Increase RPM

( fix ed c u tte r d ri l l b i ts )
APPLICATION RECOMMENDATIONS
FEATURE RECOMMENDATIONS • Confirm PDC drillable float equipment
• Consider use of a steel body bit with anti-balling coating • Optimize operating parameters
• Lighter set bits – fewer blades
FEATURE RECOMMENDATIONS
• Increase blade standoff in cone
• Optimize nozzle placement
• Increase cutter density in cone

45 | Drill Bits and Services Dull Grading Manual | 46

 C T – C H I PPED CU TTERS DE LAMIN ATE D CUTTE RS – D L

A chipped cutter is Delaminated cutters is

characterized as a a condition in which
cutter that has minor the diamond layer, or
breakage and less a predominant portion
than 1/3 of the cutter of the layer, has
has been broken. cleanly come off the
Chipping of diamond tungsten carbide
tables generally occurs interface.
in the outer most edge
of a cutter.

POSSIBLE CAUSES POSSIBLE CAUSES

• Incorrect bit selection • Excessive heat that degrades the diamond layer
• Improper WOB • Incorrect bit selection
• Inadequate bottomhole pattern break-in • Improper WOB
• Excessive impact load / improper drilling practices • Inadequate bottomhole pattern break-in
• Interbedded formations • Excessive impact load / improper drilling practices
• Bit vibration • Interbedded formations
• Bit vibration
APPLICATION RECOMMENDATIONS
• Utilize SPARTA™ software to identify and locate interbedded APPLICATION RECOMMENDATIONS
formations and the relative rock strength • Utilize SPARTA™ software to identify and locate interbedded

( fix ed c u tte r d ri l l b i ts )
• Optimize drilling parameters formations and the relative rock strength
• Optimize drilling parameters
FEATURE RECOMMENDATIONS
• Secondary cutting structure such as R1™ and MDR’s FEATURE RECOMMENDATIONS
• Impact arrestors • Secondary cutting structure such as R1™ and MDR’s
• Increase cutter density • Impact arrestors
• Less aggressive cutter profile • Increase cutter density
• Decrease cutter size • Less aggressive cutter profile
• Increase cutter chamfer size • Decrease cutter size
• Optimize cutter type with regards to impact resistance • Increase cutter chamfer size
• Optimize cutter type with regards to impact resistance
• Optimize Thermal Mechanical Integrity™ (TMI) cutters

47 | Drill Bits and Services Dull Grading Manual | 48

 E R – E R O S IO N HE AT CHE CKIN G – H C

Erosion is used to Heat checking is

describe the loss of characterized by many
material on the cutting small cross-hatched
structure and bit body pattern microcracks on
due to drilling fluids, any surface showing
solids and cuttings abrasive wear, such as
flowing against the cutter wear flats and
drill bit. gauge areas.

POSSIBLE CAUSES POSSIBLE CAUSES

• Excessive HSI amplified by abrasive mud and formation • Cyclic excessive frictional heating and cooling
• High velocity fluid creating turbulence and impingement on the • Inadequate bit cooling
blades and cutting elements • Improper drilling parameters, particularly excessive RPM for the
• Excessive level of low gravity solids in the mud application
• Plugged nozzles • Reaming hole at high RPM

APPLICATION RECOMMENDATIONS APPLICATION RECOMMENDATIONS

• Reduce jet velocity / HSI • Consider bit design with improved hydraulic distribution
• Decrease low gravity solids in the mud • Increase cutter density to decrease wear rate
• Optimize nozzle placement • Use a more wear-resistant PDC cutter

( fix ed c u tte r d ri l l b i ts )
• Utilize matrix body bits

49 | Drill Bits and Services Dull Grading Manual | 50

 JD – J U N K D A M A G E LOST MATRIX – L M

Junk damage is Lost matrix is a

described as a condition in which a
condition where the section of the blade
bit has drilled objects and or bit body has
other than formation, chipped or broken
causing indentations, off the bit.
cutter damage and
broken blades. It is to
be used in the remarks
“Other Dull
Characteristics”
column.

POSSIBLE CAUSES POSSIBLE CAUSES

• Junk dropped in the hole from the surface (tong dies, tools, etc.)
• Junk from the drill string (reamer pins, stabilizer blades, etc.)
• Junk from a previous bit run (tungsten carbide inserts, ball bearings,
etc.)
• Junk from the bit itself (tungsten carbide inserts, etc.)
• Damage due to contact with casing
APPLICATION RECOMMENDATIONS
• Plan on running junk basket with next bit and anticipate reduced
bit life
• Impact - junk in hole, excessive torque
• Intentional spudding of the bit or tagging the bottom too hard
• Dropping the drill string
• Hitting ledges while tripping into the well
• Exceeding recommended WOB parameters
APPLICATION RECOMMENDATIONS
• Ensure hole is clean before running bit to drill ahead
• Review drill string handling procedures
• Optimize drilling parameters

( fix ed c u tte r d ri l l b i ts )
• Circulate and rotate just above hole bottom to lift junk above bit • Trip into hole at reduced rate when ledges are suspected
face prior to drilling
• Run a cleanout bit if necessary
• Ensure hole is clean before running bit to drill ahead

51 | Drill Bits and Services Dull Grading Manual | 52

 L N – L O S T NO ZZL E LOST CUTTE RS – L T

Lost nozzle describes Lost cutter is a condition

one or more missing in which a cutter is
nozzles. While lost completely gone from
the cutter pocket.
nozzle is not a cutting
Lost cutters can be
structure dull damaging to the
characteristic, it is an remainder of the cutting
important “Other Dull structure. The loss of
Characteristic” that one cutting element can
can help describe a bit increase the workload
condition. for the adjacent cutting
elements, and poten-
tially decrease bit life.

POSSIBLE CAUSES POSSIBLE CAUSES

• Missing or damaged O-ring and/or improper nozzle installation • Braze bond fails to retain the carbide in the cutter pocket
• Mechanical or erosion damage to nozzle and/or nozzle retaining • Junk in the hole
system • Extreme downhole vibration
• Improper nozzle selection for hydraulic conditions • Fluid erosion of surrounding blade material
• Junk in the hole can damage nozzle or nozzle retention
APPLICATION RECOMMENDATIONS
APPLICATION RECOMMENDATIONS • Optimize drilling parameters
• Insure O-ring is in place and confirm nozzles are properly installed • Check for unusual bit damage and use proper procedures to deal
(refer to Drill Bit Handbook for nozzle installation procedures) with junk in the hole
• Review nozzle selection and hydraulics parameters • Run BHA analysis and identify critical rotary speeds

( fix ed c u tte r d ri l l b i ts )
• Check for unusual bit damage and use proper procedures to deal • See recommendations under “Erosion”
with junk in the hole

Note: A lost nozzle causes a pressure decrease which may require

the bit be pulled out of the hole.

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 P N – P L UG G ED NO ZZL E/ FL O W PASSAGE RIN G OUT – R O

Plugged nozzle/flow Ring out is described

passage is a condition when a circular ring of
where one or more of cutting elements are
the nozzles are blocked. worn down, typically
This problem can lead to the blade top. It is
to reduced hydraulics often accompanied by
efficiency and may
the dull characteristic
require a trip out of the
“Heat Checking” due
hole due to excessive
to the extreme heat
pump pressure. This
build-up which may
characteristic is used
only in the "Other Dull have occurred.
Characteristics" column.

POSSIBLE CAUSES POSSIBLE CAUSES

• Foreign material such as pump parts or mud motor parts in drill • Improper bottom hole profile break-in
string • Junk in the hole
• Lost circulation material • Fluid erosion of surrounding blade material
• Cement cuttings during drillout • Improper bit selection
• Cuttings moving into the bit through the nozzles during a connection • Excessive WOB for the application
plugging the nozzle when circulation is resumed • Formation change
• Running the bit back to bottom without turning on the pumps
APPLICATION RECOMMENDATIONS
APPLICATION RECOMMENDATIONS • Ensure hole is clean before running bit to drill ahead
• Use pipe screens • Use proper break-in procedures

( fix ed c u tte r d ri l l b i ts )
• Use nozzle strainers • Optimize hydraulics
• Run float • Utilize SPARTA™ software to identify and locate interbedded
• Increase nozzle size if possible formations and the relative rock strength
• Insure pumps are on when approaching bottom • Optimize drilling parameters
• As a rule of thumb, avoid mixing nozzle sizes which differ • See recommendations under “Junk Damage”
by more than 2/32”
FEATURE RECOMMENDATIONS
• Increase cutter density to decrease wear rate
• Use a more wear-resistant PDC cutter
• Secondary cutting elements

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 W O – W A S H ED O U T WORN CUTTE RS – WT

Washout occurs when Worn cutters are a

drilling fluid has normal characteristic
eroded a passage from that describes PDC
an internal flow area wear with an even
to the exterior of the wear flat. The
bit. This characteristic diamond layer is, for
is used only in the the most part, without
“Other Dull major chips, spalling
Characteristics” or cracks along the
column. worn edge.

POSSIBLE CAUSES POSSIBLE CAUSES

• Excessive loading in which a crack may occur during the bit run • Abrasive formation or formation change
• Improper nozzle installation • Incorrect bit selection
• Excessive hydraulic energy, predominately in steel bodied bits • Inadequate hydraulics for application
• Damaged API threads or mud seal • Excessive RPM for application
• Improper make-up torque
APPLICATION RECOMMENDATIONS
APPLICATION RECOMMENDATIONS • Optimize hydraulics
• Insure O-ring is in place and confirm nozzles are properly installed • Reduce RPM
(refer to Drill Bit Handbook) • Utilize SPARTA™ software to identify correct bit type
• Optimize hydraulics

( fix ed c u tte r d ri l l b i ts )
• Follow proper make-up procedures (refer to Drill Bit Handbook) FEATURE RECOMMENDATIONS
• Use premium PDC cutters
• Increase cutter density
• Secondary cutting elements

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 BROKE N BLAD E

The following pages show additional descriptions for dulling fixed Broken blade is
cutter bits that are not IADC standard, but help in identifying areas described when an
that are not listed under the standard IADC codes. entire blade has
broken off of the bit.
The fracture must have
been located between
the body and 1/2 the
height of the blade.

POSSIBLE CAUSES
• Severe impact such as from hitting a ledge during trip in or a
dropped drill string
• Severe bit whirl or slip stick
• Junk in hole
• Extreme change in formation, excessive torque

APPLICATION RECOMMENDATIONS
• Review drill string handling procedures
• Run BHA analysis and identify critical rotary speeds
• See dull characteristic under “Junk Damage”

( fix ed c u tte r d ri l l b i ts )

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 R E A M ING WEA R SPALLI NG

Reaming wear is Spalling is where

characterized by areas of the diamond
extreme wear on the table have chipped off
gauge and/or shoulder in thin layers or chips;
area which can lead to however, the chips and
an undergauged bit. fracturing of the
diamond layer are
never deep enough to
reach the tungsten
carbide interface.

POSSIBLE CAUSES
POSSIBLE CAUSES • Excessive heat
• Excessive WOB/RPM during reaming • High impact due to stick slip, bit whirl, junk or interbedded
• Insufficient gauge cutting structure for application formations
• Excessive heat
APPLICATION RECOMMENDATIONS
APPLICATION RECOMMENDATIONS • Increase cutter density
• Increase flow rate • Optimize drilling parameters to reduce vibration
• Refer to Drill Bit Handbook for reaming procedures
• Select a bit with higher cutter density on gauge FEATURE RECOMMENDATIONS
• Use impact arrestors
• Use secondary cutting structure such as R1™ and MDR’s

( fix ed c u tte r d ri l l b i ts )
• Less aggressive cutter profile
• Decrease cutter size
• Increase cutter chamfer size

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