Bit Engineering & Operation Manual

Provided By:
Jalal Neshat

Drilling & Completion Dept.

March-2021
 Section 1

Bit Running Procedure

1
Table of Contents
Overview....................................................................................................................................4
Step 1: Planning & Simulation...................................................................................................4
BHA........................................................................................................................................5
Vertical Well Drilling.........................................................................................................5
Directional Well Drilling....................................................................................................5
Hydraulics...............................................................................................................................6
Nozzle Selection.................................................................................................................6
Step 2: Rig & Surface Equipment Evaluation............................................................................7
Solid control equipment.........................................................................................................7
Mud pumps.............................................................................................................................8
Mud condition........................................................................................................................8
LCM.......................................................................................................................................9
Surface parameters gauges.....................................................................................................9
Evaluate Hole Condition........................................................................................................9
Step 3: Prepare the Bit................................................................................................................9
Nozzle Installation................................................................................................................10
Handling the Bit...................................................................................................................13
Step 4: Drilling.........................................................................................................................13
Bit make-up..........................................................................................................................13
Tripping in............................................................................................................................14
Drilling.................................................................................................................................17
Bit Break-in.......................................................................................................................18
Normal Drilling.................................................................................................................18
Drill-Off Test....................................................................................................................19
General Rules of Drilling.....................................................................................................22
Torque...............................................................................................................................22
Weight on Bit....................................................................................................................23
Rotary Speed.....................................................................................................................24
Flow Rate..........................................................................................................................25
Wash & Ream...................................................................................................................27
Make a Connection...........................................................................................................27
Problems Related to Drilling Bit..........................................................................................27
Vibrations.............................................................................................................................28

2
 Axial Vibration.................................................................................................................28
Torsional vibration............................................................................................................28
Lateral Vibration...............................................................................................................29
Step 5: Hole Condition.............................................................................................................42
Step 6: POOH and Check Bit...................................................................................................43
-remove nozzles....................................................................................................................43
-Clean the bit........................................................................................................................43
-Dull Grading........................................................................................................................43
Appendices:..............................................................................................................................54
A. Bits Make-up Torque....................................................................................................54
B. TFA Table.....................................................................................................................55
C. Vibrations Cure Chart...................................................................................................56

3
Overview
The drilling bit is among the master pieces in the drilling system which has to be planned,
prepared, followed during operations and evaluated after operations to gather maximum
information in order to optimize next runs and operations.

This document covers aspects of running drilling bit from arriving at the rig site through
recommending drilling parameters, run recording and reporting.

Step 1 Step 2 Step 3

Planning & Simulation Rig & Surface Equipment Prepare the Bit
Inspection/Evaluation
(data query)

Step 6 Step 5 Step 4

POOH and Check Bit Hole Conditioning Drilling

Step 1: Planning & Simulation

The first part of a successful job is planning. Important factors which to be reviewed with the
Operator and service companies are: predicted lithology, drilling interval, drill string drive
system, directional objectives, BHA configurations, rig hydraulics capabilities, drilling fluid
properties, and casing program. These factors must be understood and planned to achieve the
most successful job. Hydraulic calculations must be performed to optimize the bit
performance. Bottom hole assembly (BHA) must be agreed upon to attain the well objectives.
This is important specially during drilling with a PDM.

Planning

Hydraulic
BHA Drilling
s

4
BHA
BHA is a key component of the drilling system, consisting of various components and tools
which operate at the bottom of the wellbore and physically drill the rock.

When designing the BHA, engineer must consider the operational objectives, characteristics
of the formation being drilled, planned drilling parameters, and available tubular size.
Operational objectives include: hole angle being drilled, directional targets, the expected
ROP, and the way to achieve designed build/drop rate. The geological characteristics that
influence the design of the BHA include: abrasiveness of the rock, bed dip angle, and the
pressure regime in the hole being drilled. Drilling parameters that must be anticipated to
design the BHA include applied RPM range, desired WOB, torque, and the anticipated shock
or vibration pattern.

For vertical wells:

26” Hole Section:{ 1 Std . 11 DC # 1 Std. 9 3/4 DC

17-1/2” Hole Section:¿

12-1/4” Hole Section: { 2 Stds . 9 3/4 DC # 3 Stds. 8 1/2 DC

Vertical Well Drilling

Vertical well is drilled straight with some minor deviations. There are many different designs
of BHA that are used to drill well vertically, but most of them have little or no stabilization
near the drill bit, combined with the weight of the drill collars, to allow the BHA to
constantly drop back to vertical under gravity and maintain a vertical hole. A down hole
motor with a straight housing is sometimes used to improve performance by adding extra
RPM and power directly to the bit.

Directional Well Drilling

Directional drilling is a type of drilling method that is intended to hit a predetermined
subsurface target through a planned trajectory. These targets are precisely pre-planned so that
the drilled well goes exactly where needed within the reservoir rock, often when the target
reservoir cannot be accessed using a straight vertical hole from surface. A directional BHA
has almost an infinite number of designs depending on what targets are required and what
tools will be incorporated. Typically, though, the BHA for a directional hole will incorporate
either a down hole motor or a rotary steerable system in order to point, push, or steer the bit
in the correct direction. The directional BHA will also include an MWD tool which measures

5
the angles and trajectory of the well bore and relays them back to surface to make sure the
well is still on course.

Hydraulics
The optimum utilization of mud pump horsepower is of significant importance in drilling
operation. An analytical evaluation of power consuming components of rig is essential to
optimize the available power. Drilling bit hydraulics is optimized by correct selection of
nozzles. The purpose of jet nozzles is to improve hole cleaning, otherwise the drilled cuttings
will be reground beneath bit and reduce ROP. Bit hydraulics energy, also could increase ROP
in soft formations by jet force. There are some criteria for optimizing bit hydraulic energy:
maximum bit HHP, maximum jet impact force, maximum jet nozzle velocity.

Nozzle Selection
Bit hydraulics can greatly affect drilling performance, e.g.: HSI and cuttings removal for high
ROP, cutter cooling for drill bit life, etc. It is important that both the nozzles and pump liner
size are selected to optimize the hydraulics for that application. The limiting factor may be
available rig power. The drilling rig motor that drives the mud pumps, combined with the
pump liners sets the maximum SPP and flow rate available.

 Flow is the critical medium that cleans, cools and lubricates the cutting structure and
bit, (critical for unsealed roller cone bits). In some applications, drilling with
minimum flow rate will cause rapid degradation of the drill bit cutting structure.
 HSI is a primary factor considered for maximizing ROP. HSI is the energy at the bit
that transports the cuttings from the bit face into the annulus.
 Flow rate is another important factor. High flow rate cleans the hole bottom and helps
lift the cuttings to surface.
 Turbulent flow is generally achieved around the drill bit.
 Laminar flow is generally preferred around the drill pipe to prevent hole instability.
 If there is the possibility of pumping lost circulation material, small jet sizes should
not be run as the risk of plugging them is high. As a general rule, nozzle sizes under
12/32nds are not suggested.
 The expected pressure changes in case of plugging or losing one or more nozzles
should be calculated.
 Hydraulic parameters vs. depth should be drawn by Software.

6
Try to use symmetric nozzle configuration to have minimum stagnant area and low deviation
tendency (more important in vertical wells).

Note: Use nozzles with maximum 2 different sizes, also install higher size nozzles at central
area of bit.

Step 2: Rig & Surface Equipment Evaluation

Evaluation and checking the rig and surface equipment will give a range of maximum and
minimum operational parameters. Understanding of equipment limitations will help to
develop a practical and reasonable solution for operation problems.

Solid control equipment

Checking the solid control equipment is very important because poor solid control can cause
serious problems during drilling operation:

 Ineffective or few numbers of shale shakers limits the speed at which cuttings
removed from mud system which in turn limits the rate at which cuttings are
generated (i.e. ROP).
 If the solids are not removed from mud system effectively it will become highly
erosive which shorten the bit and downhole tools life.
 Poor solid control also causes dumping more mud and increase the total cost.

7
Mud pumps
Mud pumps are the main element of circulation system, any failure in mud pumps will affect
the drilling operation directly. Mud pumps can be set in 2 arrangement of high pressure-low
flow rate or low pressure-high flow rate. Pump's liner size can be designed by running
hydraulic calculations.

Write down the following information:

 Mud pump manufacturer (BOMCO, NOV, …)

 Model
 Type (triplex/duplex)
 Pump liner/piston diameter size (stroke length x piston dia.)
 Max. allowable SPP
 Difference between strokes count in 1 min and SPM on the monitor

Mud condition
Drilling mud has two fundamental functions: the primary function is to keep the well bore in
good condition by balancing pore pressure, inhibiting shale reaction, stabilizing the wellbore
and etc. . The secondary function is to aid the drilling process by transporting cuttings to
surface, cleaning and cooling the drilling bit, etc. For maximum drilling performance the mud
system must be maintained in good condition.

Following information should be reflected in drilling report:

 Type (OBM, WBM, POBM, Silicate, etc)

 MW
 Solids content
 PV/YP

The best ROP results have been achieved with oil-based muds but a good deal of success has
been achieved with Water Based Mud.

Reasons for the improved performance in oil-based muds is due to increased lubricity,
decreased cutter wear temperature and preferential oil wetting of the bit body. The
performance of PDC bits in respect to other mud properties is consistent with that found with
Roller Cone Bits i.e. increase in mud solids content or mud weight decreases ROP.

8
LCM
Lost circulation material comes in various sizes and types, e.g.: nut plug, cottonseed husks,
cellophane, etc. LCM as well as plugging holes in the well bore can, unintentionally, plug
nozzles in a drill bit. If determined that lost circulation material may be required, ensure that
the size and type is known so that drill bit nozzles can be selected that will allow LCM to
pass through with a least risk of plugging i.e. the longest LCM must be less than one third
the diameter of the smallest nozzle or port.

Surface parameters gauges

Ensure that following gauges are calibrated and show real values:

 SPP gauge
 RPM gauge
 Martin Decker weight indicator
 Make-up torque gauge
 Top drive/rotary table torque gauges
o Torque sensor is installed in SCR room or rotary table, torque is measured in
Amps (mostly in workover rigs) or [Link] .
 SPP gauge inside driller’s cabin

9
Evaluate Hole Condition
Find out the well history to assess the any possible incidents affecting the operation. Collect
following information:

-Always after pulling out previous bit to surface answers of following questions will specify
the hole condition:

 Did previous bit leave any junk bottom hole? If so, a junk sub trip (with used bit)
would be necessary.

10
  Was the bit in gage? If not, some reaming is to be expected at next run.
 Was its cutting structure effective? (worn? balled up?,…)
 What was the previous bit's dull grade?

*Note the problematic intervals (specified during hole condition, wash and ream or drilling)

Step 3: Prepare the Bit

-Check the bit

Bit engineer should check and note the following items:

 Size and number of cutters (13mm, 16mm, 19mm)

 Ensure that correct size, type and number of nozzles are installed on bit and note type
of nozzles (standard, series 65, …)
 Bit dimensions (total length, make-up length)
 Bit information (manufacturer, serial number, type, profile, IADC code)
 Bit body, shank and pin condition (for any pitting, thread damages, pin washout, …),
if either damaged, rerun or a repaired bit:
o Record the dull grade
o Take photographs and shots of damaged and worn areas of bit.
 In case of DHM, it is recommended to use dull bit during surface test to eliminated
the risk of damaging the new bit.

Specify the bit is either "New" or "Used" in report, in case of being "Used", write dull
grade in last run.

It also should be ensured that correct bit breaker is used by fitting it inside related slot.

Nozzle Installation
Installing nozzle seems to be simple and easy but usually mistakes are made during installing
jet nozzles applying improper make up torque, nozzle damage due to impact, debris, choosing
wrong O-ring or damage to the O-ring in nozzle recesses, in the field, to avoid such mistakes
a standard method of installing tungsten carbide nozzles into matrix/steel body PDC bits will
be followed as below:

Necessary Equipment and Tools

-Nozzle Wrench

11
-Nozzles

-Safety Gloves

-Loctite

-Lubricating Grease

-Lint-free Towels

To install nozzles:

1-Open the box and remove/prepare bit by standing it on it's pin or in case of larger diameter
bits (>9-7/8") or where not possible to stand, lay the bit on it's sides.

2-Clean any debris or residue on nozzle threads or O-ring grooves. Use Loctite ODC free
cleaner and towels for cleaning. Check threads in nozzle ports, inspect the O-ring condition
and ensure that it seals effectively.

12
3-Lubricate the lower end of nozzle with grease to prevent damaging O-ring. Apply Loctite
to first 2-3 threads of nozzle (the Loctite will spread on other threads).

4-Place the nozzle in the port and hand tighten the nozzle, then continue tighten it with
wrench until nozzle bottoms out. A slight resistance (torque increase) will be observed before
bottoming out nozzle and compressing O-ring to recesses. Any abnormal torque increase
should be checked by removing nozzle and inspecting threads.

13
5-Once nozzle bottoms out, apply proper torque by torque wrench, or if you don’t have
torque wrench, tighten the nozzle gently and remember not to apply shock to wrench or don’t
use hammer. Ensure that wrench is aligned with nozzle during applying torque.

Applying excess torque to nozzles could break the nozzle or fluid leakage around nozzle and

Handling the Bit

Always transport the PDC bit in its box (closed), especially when moving it on to the rig
floor. After placing the bit box on the rig floor, remove the bit from box gently and stand it
on pin on the wooden or rubber surface, placing PDC bit on steel surfaces cause cutter
chipping. check the cutters and nozzles, ensure that correct size of nozzles is installed. Use
water jet to clean debris inside the bit and ensure that nozzles are open. Clean the pin threads
with dry cloth.

Step 4: Drilling
Bit make-up
Put the bit breaker on the bit and close the gate on the bit breaker. The gate should not be on
the draw works side. Clean and dope the pin. Make up DHM or bit sub then lower the drill
string to the top of the bit’s pin (put float valve inside bit sub). Clean and grease API
connection of bit and drill string, then engage threads. Before applying torque ensure that

14
torque cell is connected to tongue’s arm. Apply the recommended torque for the API
connection.

DO NOT over torque the bit.

Before make-up bit, ensure that bit is in-gage.

Tripping in
During run in hole:

 Take care during running through diverters, BOPs, well heads, and casing shoes.
 If tight spots were encountered during last trip, approach to them slowly, otherwise
the cutting structure would be damaged.
 Lower the string slowly through any restricted spots in the well. (Hangers, ledges,
dog legs, etc.) DO NOT attempt to push the PDC bit through any obstruction.
This can potentially damage the cutters or plug nozzles.

-Wash and ream tight spots

 During reaming tight spots following parameters are recommended:

Flow Rate: maximum according to circulation system capacity

Rotary Speed: 50-60 RPM (keep [Link] to minimize vibration)

WOB: Max 500 klbs/ODbit

 Reaming should be continued until torque decreases by 50% of normal drilling torque
and becomes steady.
 Wash down the last stand/Kelly with high flow rate to bottom to prevent nozzle
plugging with fill and clean the hole.

15
  Wash down the last stand/Kelly with high flow rate to bottom and low [Link] to
prevent plugging nozzle and bit being balled up due to cuttings cumulated at bottom
hole.

In tight spot weight is applied only to gage and shoulder cutters resulting in higher force
on each cutter, insert or teeth than normal condition. Hence working with low weight is
recommended.

If previous bit is under gage, reaming hole would be necessary.

Drill out Plug/Wiper/[Link] Plug

Drilling out the shoe track can be problematic unless many parameters are evaluated and
understood. These key factors are:
• PDC bit type and style – cutter size and angle, blade layout and bit profile
• Drilling procedures – including WOB, RPM, and flow rate
• Cutting’s transport – software simulations to best understand the relationship between
cutting size, flow rate, and hole cleaning effectiveness
• Target materials being drilled – drillable, non-rotating components are preferred. By
understanding the parameters that affect how a shoe track is drilled – along with a bit of
experimentation and modeling, it will be easy to design and implement a predictable,
repeatable shoe track drilling program.

Before everything, always look at bit and plug specifications and catalogue and parameters
recommended by manufacturer. Using near bit stabilizer and reamer could help keep the bit
on plug. Use junk basket to collect downhole debris.

Tri-Cone Bit

1- Using milled tooth bit (soft to medium) is preferred to drill out plug and float
equipment.
2- Always circulate mud to balance mud properties before starting any operation.
3- Take SCR, [Link]/[Link] Wt./Rotating Wt. (RPM=60) before tagging plug.

MP# SP F.R (gpm) SPP (psi)

M [Link] MudLogging Driller’s Gauge
1

16
 2
3

Depth Time [Link] Wt. [Link] Wt. Rot. Wt.

1- RIH W/Rotation (RPM=40-100), monitor TRQ, tag and engage with plug W/low
flow rate (40 gpm/in ODb;min H.S.I=2), apply 200-300 lbs/in ODb WOB.
2- In case of not engaging with plug (low and constant TRQ), decrease RPM and gpm, if
not successful, stop rotation and turn off mud pump(s) for 5-10 minutes. Resume drill
out. Spotting cement slurry before drilling out plug is another solution to prevent
rotation of plug.
3- Pick up string occasionally and increase flow rate or pump HI-Vis pill to clean debris
out.
4- Check return on shakers periodically and observe shape and nature of debris. If
weight of plug(s) is known, the debries can be collected and measured to ensure well
is cleaned out of drilled out plug debries.

PDC Bit

1- RIH W/Rotation (RPM=50-100), monitor TRQ, tag and engage with higher flow rate
than Tri-cone bits (40 gpm/in ODb; min H.S.I=2). Increasing gpm may cause
disengaging PDC bit from plug.
2- Apply 0.8-1.5 klbs/in ODb WOB. If aggressive PDC Bit is used, increase WOB
gradually and carefully. In case of observing vibration, decrease WOB.
3- Pick and reciprocate string with RPM several times to clean the hole from debris. This
action will help clear material from the bit and prevent the bit from gouging large
pieces from the plugs. High penetration rates, while favorable may result in drilling
through the plugs rather than drilling up the plugs. This can result in the wiper fins of
the plugs not being drilled and subsequently becoming dislodged and wrapping the
wiper fins around the drill collars / drill pipe.
4- Check return on shakers periodically and observe shape and nature of debris. Debries
should be collected and measured to ensure well is cleaned out of drilled out plug
debries.

17
Aluminum core plugs will take longer to drill out than plastic core plugs. Excessive RPM or
bit pressure cause the bit to gall up and increase drill out times.

Drill-out Float Equip.

CONVENTIONAL BITS: Bit Rotation 40 to 60 RPM/WOB 2000 to 3000 lb/Circulation

Rate Maximum
FLAT BOTTOM PDC BITS: Bit Rotation 40 to 75 RPM/WOB 6000 to 12000
lbs/Circulation Rate Maximum
BLADED PDC BITS: Bit Rotation 40 to 75 RPM/WOB 3000 to 9000 lbs/Circulation Rate
Maximum.
Raise and lower the bit every 6” of penetration while continuing circulation and rotation will
help clear debris from the bit.
-On the exploration/appraisal wells in which formations uncertainty is high, using used or
redressed PDC Bit for drilling float equipment would be best way.
-Make sure that there is no junk in the well, be careful about high doglegs at shoe depth
which could damage the PDC Bit.
-Use PDC Bit with minimum number of cutters on the gage area or use bit with gage cutters
of flat profile in this area rather that circular profile, to prevent damages during drilling out
shoe.
Following key factors affect bit performance while drilling cementing plugs and float
equipment:
• Bit style (i.e., cutter size and angle, blade layout, bit profile)
• Bit hydraulics and hole-cleaning issues (flow rate, number of blades)
• Drilling procedures (i.e., weight on bit, pump rate, rev/min)
• Target materials being drilled (rubber, cast or wrought aluminum, bronze, plastic, concrete,
etc.) Note: All target materials are best drilled with fixed-cutter bits when the target itself is
not allowed to rotate. Proper cementing procedures can help ensure effective placement of
cement near and around the target.
Drilling
 Watch the torque and weight gauge carefully to bottom hole, aggressive PDC bits
usually show an abrupt increase in torque by tagging the bottom.
 After tagging the bottom, pick up string off bottom (about 1 m). Circulate mud until
shaker got clean and mud gets balanced. Record the following information:
o String slack off and pick up weight

18
 o Free torque
o Slow pump rate (SCR); it’s value will be updated after drilling every 2-3
stands.

Bit Break-in
Return to bottom and start drilling with following parameters until the bit drilled at least its
own length. At first touch only some of the cutters will be in contact with formation so if
weight is added too quickly, especially in hard formations, these cutters may be overloaded
and premature damage and consequently slow penetration rate.

WOB=2-6 klbs

Rotary Speed=50-60 RPM ([Link]=30-60 on motor)

Flow Rate=max as possible (minimum flow rate; usually 80% of normal Flow Rate)

Normal Drilling
After drilling at least bit length:

 Increase WOB to targeted value:

a) on rotary in 2-3 klbs increments.

b) on motor firstly bring the flow rate to planned value then increase WOB to normal
value in 2 klbs increments.

 Increase R. Speed to target value.

Avoid high RPM till getting all the stabilizers/DHM out of the casing. This is applied to
avoid dropping cement around the casing shoe which can lead to mechanical stuck pipe
and prevent damaging casing.

Following range of parameters are recommended during drilling:

WOB

0.5-2 klbs/ODbit for soft formations (max 2.500 klbs)

1-2.5 klbs/ODbit for medium-soft formations (max 3 klbs)

1.5-4 klbs/ODbit for medium formations (max 4.5 klbs)

Rotary Speed

19
Nonabrasive formations: 100 to 180 rpm on rotary

Abrasive formations: 60 to 80 rpm

In soft formations, increasing the RPM can increase the ROP. Relative low bit weights
are recommended.

Flow Rate

Hole Flow Rate (gpm)

Size
17 1/2” 800-1000
12 ¼” 600-750
8 ½” 300-450
6” 150-200

HSI

In OBM: 1-5 hp/in2

In WBM: 2-7 hp/in2

DO NOT exceed the maximum allowable WOB. The recommended weight provided by
bit manufacturers is determined by factors such as the structural integrity of the bit
body and blades, cutter quantity and the cutter orientation, size, and shape with 10-
20% safety factor. This safety factor provides a guarantee that the bit will not break if
the maximum specified weight on bit is applied. As a general rule, the optimum WOB is
less than half of WOB for roller cone bit.

Drill-Off Test
Drill-off tests are methods for determining the optimum combination of WOB and RPM that
yield the highest ROP (within other constraints). Drill-off tests should be run when:

 Change in bit
 Formation change
 Changes in other operational parameters (hydraulics, mud properties, etc.)

20
In formations that lithology changes frequently (like Gachsaran formation) results of
Drill-off test could not be reliable. In this case the parameters should be applied
according to lithology.

In this process the driller applies a high WOB, locks the top-drive position, and continues
rotation. By drilling ahead, the locked string elongates, transferring the WOB to the hook.
The amount of drill string elongation is called “stretch”. The rate at which the hook load
increases then provides an indication of how fast the string is elongating, which is also the bit
drilling rate.

1. Maintain constant RPM, build to the maximum practical WOB.

2. Lock the brake.

3. Record the time required to "drill-off" a predetermined weight increment (typically

between 2000-5000 lbs.).

4. Continue until all of WOB is drilled off, and last should be at the same value as first test to
be sure that formations didn’t change. The shortest time will indicate the optimum weight for
that rotary speed.

5. Increase the RPM on steps and repeat the above procedure. For hard formations or slow
ROP conditions, increase the RPM in 5 to 20 RPM increments. For soft formations or high
ROP conditions, increase the RPM in 10 to 40 RPM increments. Continue testing until the
optimum condition is determined.

The ROP during DOT can be calculated by following equation (Stretch constants for API DP
may be found in reference manuals):

DPStretch= ( Stretch Constantfor specific DP (¿ /klb.1000 ft) )∗( DP Length (1000 ft ) )∗( Step Change∈WOB(klb

21
ROP(ft /hr )=(DP Stretch(¿)/Time(sec))∗¿

22
General Rules of Drilling
Torque
Rotary torque is an indicator of resistance against drill bit’s rotation. The surface torque is
resultant torque of:

 Drilling mud (which depends on MW, rheology, solid content, presence of lubricating
agents)
 Formation (which depends on lithology, abrasiveness, compressive strength,
drillability, …)
 Contact between drill string and hole wall (which depends on hole condition, mud
condition: filtrate loss, mud cake thickness, solid content...

For example

 PDC high torque means the bit is likely to be digging or if there is low ROP
the torque could be being generated from the BHA and not the bit.
 PDC low torque -the bit could be skidding in a hard formation; the cutting
structure could be dull or the bit could be balled up.
 Roller cone medium torque -the bit is likely to be digging.

23
  Roller cone high torque -the bit could have locked cones, if this is the case the
torque will reduce as the inserts/teeth wear down.
 Roller cone low torque -the cutting structure could be dull or balled up.
 In soft formations torque may indicate the bit is on bottom before the weight on bit gage
does. In such formations the torque gauge may be the best surface measurement by which
to drill.
 The torque could be considered to be too high when it starts to slow down surface rotary
speed.
 The torque is too high when it stalls the motor, rotary table or the top-drive.
 Homogenous formations should produce a smooth constant torque signal.
 Interbedded formations will produce torque changes as the bit and/or the BHA moves in
and out of formation beds that have different rock strength and 'drillability'.
 If downhole torque measurements are available, they can be used in combination with
surface measurements to gain a more accurate representation of what is happening in the
well bore.

Weight on Bit
 As a drill bit cutting structure wears more weight will be required to achieve the same
ROP in a homogenous formation.
 PDC wear flats, worn inserts and worn milled tooth teeth will make the bit will have
lower depth of cut.

24
 Increase weight in increments of 2,000lbs approximately.

 In general, weight should be applied before excessive rotary speed so that the cutting
structure maintains a significant depth of cut to stabilize the bit and prevent whirling.
 If downhole weight measurements are available, they can be used in combination with
surface measurements to gain a more accurate representation of drag forces.

Rotary Speed
 Total bit rotary speed is equal to the surface rotary speed plus the down hole
motor/turbine rotary speed.

RPM=RPMrotary + RPMmotor(KxGPM)

K: speed ratio

 Rotary speed is not limited when running PDC drill bits (depends on rig type and it’s
rotation system’s capacity)
 High rotary speed should be avoided in abrasive formations to prevent rapid abrasive
wear of cutting structure
 High rotary speed should be avoided if the drill bit starts to whirl. Bit whirling
reduces bit life.
 Rotary speed may be limited due to drill pipe or drive limitations.

2 2 1 /2
(OD + ID )
Critical RPM=33055×
L2

L: Length of one joint of drill pipe, ft

OD/ID: Outside/inside diameter of drill pipe, in

25
Ex: for 5”, 19.5# drill pipe (L=31.2 ft)RPMc=223

 Some rotary speeds can initiate drill string resonance (high levels of vibration) and
should be avoided. These speeds depend on drill string configuration and hole
geometry. Either increase or decrease RPM to avoid operating in drill string harmonic
frequencies.
 High rotary speeds in hard formations may reduce ROP as the cutters are unable to
‘engage’ with formation.
 The rotary speed that maximizes ROP without causing other drilling problems is
likely to be the ‘right’ one.

In directional drilling:

 In clean shale increasing motor speed increases bit speed that will generally increase
ROP without damaging the bit cutting structure or other downside.
 In hard abrasive sandstone increasing motor speed increases bit speed that will
generally increase penetration rate momentarily. However, the higher rotary speeds
will tend to increase the wear rate of the bit cutting structure that will reduce
penetration rate and ultimately bit life.
 Increasing motor and consequently bit speed can change the directional tendency of
the bottom hole assembly with a bigger effect on building/dropping tendency than
azimuth. The compromise between instantaneous penetration rate and sliding
corrections must be considered.

Flow Rate
• Flow rate is important in terms of bit face and hole cleaning, bit hydraulic energy, cooling
bit and lubricate the string.

• Flow rate greatly effects bit cleaning. Generally high flow rates provide better bit cleaning
than low flow

• If a motor is in the hole increasing flow rate will increase the rotary speed developed by the
motor.

• High flow rates can cause formation damage and increases the drilling fluid low (by
increasing ECD) especially in highly fractured formations and reduce the surface
equipment’s life and excessive flow rates must be avoided.

26
 Hole Size Qmin(gpm)
6 ½” 130
7 7/8” 220
8 ¾” 270
9 7/8” 340
10 5/8” 400
12 ¼” 490
17 ½” 815
18 ½” 880
26” 1350

Drilling clean shales can be performed with high RPM. Increasing RPM is more
effective than increasing WOB on ROP. Drilling through chalk and limestones can be
maximized by increasing the WOB to fracture the formation. This WOB increase has to
be combined with moderate RPM. Drilling bit can suffer from abrasive wear when
drilling through sandstone. ROP can be maximized by increasing both RPM and WOB,
but it has to be well monitored to avoid premature damage for the bit by reducing
parameters to reasonable level.

During drilling, bit engineer should:

 Apply proper drilling parameters to maximize ROP with considering hole condition
 Record and report drilling parameters
 Take fast actions in case of encountering any problem
 Optimize bit performance and lengthen the bit life
 Check the hole condition
 Evaluate bit condition after POOH
 Check the cutting samples on shale shakers to have sense about what lithology is
being drilled by bit. The time which takes for cuttings to reach surface is lag time:

Ann .Vol . Ann .Cap . × Depth Depth

Lag Time= = =C ×
q q q

27
Wash & Ream
After drilling each stand/Kelly the hole should be reamed as bellow

following parameters are recommended during wash and ream:

Rotary Speed=50-60 RPM

Flow Rate=max as possible (acc. to max SPP)

Make a Connection
Before wash and ream:

 Allow drill off then Reduce RPM

 Wash & Ream
 Make a connection (the mud screen should be pulled out and the other one should be
placed inside box connection of next stand)
 Turn on mud pumps
 Take SCR (if necessary)
 Approach the bottom gently with full flow rate and 60-80 RPM (usually 50% of target
RPM), resume drilling.
 Increase WOB to target value (avoid stick-slip)
 Increase RPM to target value

Prior to make a connection, it is recommended to keep full flow rate when pulling out of
bottom.

Problems Related to Drilling Bit

There are many issues related to bits which have to be considered when running a drilling bit
and can affect the overall drilling performance till getting to costly operations like fishing.

Vibrations
A drill string vibrates due to load or displacement excitations applied at various depths and
frequencies. There is a wide range of potential excitation sources: mass imbalance,
misalignment and kinks or bends, cutting action of bit, stabilizer type, mud motors (nutation,
or wobbling of rotor inside stator), and friction factor between the drill string and wellbore.

Drill string vibration can be divided into three types: axial, torsional and lateral. Depending to
BHA design, lithology, bit type and applied parameters each or combination of these types
may occur during drilling.

28
Axial Vibration
Axial Vibration can cause bit bounce and damage bit cutters and bearings. It is reflected by
WOB fluctuations and cause a sudden decrease in ROP.

Torsional vibration
Torsional vibrations or stick-slip is often observed during drilling, can cause uneven rotation
of bit and string and even bit becomes stationary for a period.

By increasing severity of stick-slip the length of the stuck period increases, as do the
acceleration as bit breaks free. Torsional vibration cause tubulars body and connection
fatigue, even presence of mud motor does not prevent the stick-slip. Correct adjustment of
torque limit during drilling alleviates this type of vibration.

29
Lateral Vibration
It is the most destructive type of vibration and can cause large shocks as the BHA impacts the
wellbore wall. The interaction between BHA and drillstring contact point may drive the
system to backward whirl. Backward whirl creates high-frequency large magnitude bending
moment fluctuations that result in high rates of component and connection fatigue. Imbalance
in an assembly will cause centrifugally induced bowing of the drillstring, which may produce
forward whirl and result in one side wear of component.

Induced axial vibration at the bit can lead to lateral vibrations in BHA, and torsional
vibrations observed at rig floor may in actually related to lateral vibrations downhole.
Sometimes axial vibrations near bit may show no vibrations at surface.

Axial and Lateral vibrations are more violent in vertical or low angle wells and displacement
and bending moments due to lateral vibrations increase the ratio of hole size to drill collar.

30
Balling up
The surface symptoms of balling up bit is reducing Torque and ROP, increasing SPP. To
balling off the bit:

 Increase flow rate to the maximum for at least 5 mins.

 Spin the bit as fast as possible to ‘fling’ the material off.
 Lift and drop the string rapidly to ‘shake’ the formation off, (take care not to surge the
hole and damage the formation or drop the bit on bottom and damage the cutting
structure).
 Pump a pill, (eg: Nut Plug) to try and wash the material off.
 A combination of the above.
 When returning to bottom after un-balling a bit use maximum flow rate and high
rotary speed. Tag bottom gently as there may be huge chunks of balled material that
need to be cut up. If weight is added too quickly the bit may just push into the balled
material and become immediately balled again.
 Where balling is expected the risk of occurrence can be reduced by limiting
penetration rate. This means that a reduced and more manageable amount of cuttings
can be transported away from the bit face and annulus to surface.

31
Plugged Nozzles
Nozzles can be plugged by a variety of materials. Some examples are:

 Formation
 Lost circulation material
 Motor stator rubber

When a nozzle becomes plugged, an increase in SPP will be observed while flow rate is
constant. The SPP increase can be determined by:

2 2
MW q MW q
∆ P b= 2
− 2
12032 TFA 2 12032TFA 1

TFA1: total flow area of nozzles before plugging

TFA2: total flow area of nozzles after plugging

∆ SPP ≈ ∆ Pb

So we can realize how many of nozzles are plugged.

To unplug bit nozzle(s):

 Increase flow rate to the maximum for at least 5mins.

 Pick up and drop the string to ‘shake and surge’ the plugging material free, (take care
not to surge the hole and damage the formation or drop the bit on bottom).
 A bit with plugged nozzles has an increased probability of balling in softer formations
and accelerating cutter wear in abrasive formations.

Sometimes above actions may not be effective, in this case pumping low vis./high vis.
Mud may clear the plug from nozzle.

32
If nozzle unplugging was not successful and ROP was acceptable, drilling can be continued
but SPP should be monitored carefully.

Lost Nozzle
Losing a nozzle causes a sudden decrease in SPP. The simulation can give an indication of
the number of lost nozzles. If the nozzle bore start to be washed out, the pressure continues to
decrease gradually.

The drilling can be carried out with lost nozzle with acceptable rate of penetration but the
nozzle can damage the cutter structures leading to other problems as bit gauge decrease or
water ways damage.

The nozzle can be pushed toward soft formation and drilling can be performed with low
damage on bit body. The loss of nozzle can cause bit balling due the decrease in horse power
per square inch HSI parameter and consequently reduced ROP.

Washout
Sometimes washout may occur in bit’s body, pin connection and also nozzle circumference.

 Wrong placement or misalignment of float valve inside bit sub

 High solid content in drilling fluid
 Improper installation of nozzles (applying low torque, not using o-rings,…)
 Weak metallurgy of materials used in bit

33
Washout mostly happen in steel body PDC bits and in large size holes in which flow rate is
very high. Surface indication of washout is increasing stroke counts of pumps and decreasing
SPP after taking SCR.

Drilling Problems

34
35
Torque

Increased torque is usually due to:

36
  Lithology change
 Improper WOB & RPM

Note: WOB is proportional to RPM.

 Under gauge bit

 Hole Inclination
 High mud cake thickness (due to high filtration loss of mud)
 Formation of cutting bed

Normal
WOB Drilling
High Torque
Stick-Slip
Motor Stall
Bit Whirling
Fluc. Torque
Bit Gauge wear

RPM

37
Decreased torque may be sign of:

 Lithology change (like changing from anhydrite To marl.)

 Low WOB/RPM
 Bit balling
 Worn bit
 Improper design of bit elements (cutting structure, blade geometry…)
 Add lubricant to drilling fluid system

Fluctuating torque may be due to:

 Reaming by stabilizer (always use under gauge stabilizer;1/32-1/16”-using F.G

stabilizer may mislead about surface parameters like torque)
 Under gauge bit
 Interbedded formations (like sandstone beds among marl. Lithology)
 Junk in bottom hole
 High dogleg
 Excessive WOB

Standpipe pressure (SPP)

Increased SPP may be indicator of:

 Plugging string or bit nozzle(s) (with decreasing pump strokes)

 Plugging screens at suction and discharge of mud pumps
 Bit balling
 Increasing mud properties (MW, PV)
 Increasing gpm
 Transferring mud between mud tanks (driller should be informed)
 Ring out bit
 Cuttings ring around string
 In case of long time between drill pipe connections (low ROP), drill pipe screen may
be plugged.

Note: Always read SPP from at least two gauges/sensors: mud logging screen, analogue
gauge on driller’s panel, pressure gauge (usually Halliburton gauge) on rig floor against
driller’s cabin.

38
Decreased SPP may be due to:

 Wash out in drill string or bit (with increasing pump strokes)

Note: to determine depth of string washout, first fine particles/distinguishable color is added
to mud system and time needed for particles to move from surface to shakers is measured (t):

gpm× t=V ( string )+V ( annulus )

¿ [Cap ( string ) +Cap ( annulus ) ]× D

t × gpm
D=
[Cap ( string ) +Cap ( annulus ) ]

 Lithology change
 Kick
 Lost nozzle
 Decreased gpm
 Decrease some mud properties (MW,PV,…)
 Mud loss
 Decreasing pump’s volumetric efficiency (Ev)

In case of lost bit nozzle(s) SPP decreases suddenly and becomes steady, this SPP behavior is
related to lost nozzle. For example, according to following figure, SPP dropped by 170 psi at
1164 m.

39
 SPP sudden
decrease

Turn off
mud pumps

Turn on
mud pumps,
SPP
continued to
decrease

 Mud pump failure (piston failure, module leakage, valve/seat damage,…)

40
Note: pumping pill during drilling causes changes in SPP as below:

SPP SPP

Case a) Pumping Lo-Vis pill Case b) Pumping Hi-Vis pill

ROP

Decreased ROP is sign of:

 Lithology change
 Increasing MW and PV (chip hold down effect)
 Poor hole cleaning
 Improper drilling parameters
 Dull bit (worn cutting structure)

Increased ROP may be sign of:

 Lithology change
 Kick
 Good hole cleaning
 Decreasing MW, PV

Indicators

Bit Balling

 Torque decrease
 ROP decrease

41
  SPP increase

Unbaling Procedure

1- [Link] string about 1-2 m.

2- Pump saltwater (if possible) with maximum flow rate/SPP and rotate string with max.
speed for 10-15 min.
3- Change RPM to max and decrease it during this 15 min.
4- If SPP and TRQ didn’t become normal, decrease RPM and apply an axial shock to
string.
5- If not successful to mitigate bit balling, chemical (caustic pill, pipe lax) should be
spotted around BHA.

Note: spotting chemical will dissolve filter cake, so after spotting chemical, mud circulation
should be performed to stabilize wellbore.

After unbaling bit, RIH to BTM with following parameters:

1- Max. gpm
2- 80% of original RPM
3- 50% of original WOB

Step 5: Hole Condition

In following cases the hole condition should be improved:

 After confirmation of TD
 Bit changeover point
 In some points of long hole sections
 Tripping out due to any reason

Before hole condition:

 Circulate mud to take last sample by geologist and clean the bottom hole

42
  POOH to last casing shoe while monitor possible drag forces
 Circulate mud
 Turn off mud pumps and observe well for 1 hr
 RIH to bottom while checking the hole condition, if tight spots observed RIH with 50-
60 RPM rotation and full flow rate

Step 6: POOH and Check Bit

Witness the bit and BHA being pulled out of hole as evidence for run analysis can be
collected. Take photos of:

 All the tool joints worn on the same side suggests forward whirl.
 BHA balling, (Roughnecks will frequently clean the BHA off and this information
will be lost and not recorded).
 Bit balling, (Roughnecks will frequently clean the bit off and this information will be
lost and not recorded).
 Dull grade the bit using the IADC system, (dull grading manuals for each drill bit type
can be found on the
SLB website).
 Roller cone bits and fixed cutter bits have different sized gauge rings. Ensure that the
correct gauge ring is used. i.e: if an in-gauge PDC bit is measured with a roller cone
gauge it will appear to be under gauge.

-remove nozzles
After pulling out bit to surface, remove nozzles as soon as possible.

-Clean the bit

Clean and wash bit face, between blades and nozzle ports.

-Dull Grading
Why dull grade?

 Quick and simple way to describe bit dull condition in a standard format
 Gives a comprehensive image about bit's performance
 Improves future bit selection

43
44
45
46
47
48
49
50
Gage cutters are pre-ground during the manufacturing process

51
52
53
Appendices:

A. Bits Make-up Torque

ROCK BITS
Make - up torque Line Ib . Pull x Tong type
Size Threads daN.m Ib . Ft AAX(4 ft) H (4.5 ft)
3 3/4" - 4 1/2" 2 3/8 REG 400 - 480 3000 - 3500 750 - 875 670 - 770
4 5/8" - 5" 2 7/8 REG 800 - 950 6000 - 7000 1500 - 1750 1340 - 1550
5 1/8" - 7 3/8" 3 1/2 REG 950 - 1200 7000 - 9000 1750 - 2250 1560 - 2000
7 1/2" - 9 3/8" 4 1/2 REG 1600 - 2200 12000 - 16000 3000 - 4000 2670 - 3550
9 1/2" - 14 1/2" 6 5/8 REG 3800 - 4300 28000 - 32000 7000 - 8000 6230 - 7110
14 5/8" - 18 1/2" 7 5/8 REG 4600 - 5400 34000 - 40000 8500 - 10000 7550 - 8880
18 5/8" and + 8 5/8 REG 5400 - 8100 40000 - 60000 10000 - 15000 8880 - 13330

PDC BITS
Make - up torque Line Ib . Pull x Tong type
Size Threads daN.m Ib . Ft AAX(4 ft) H (4.5 ft)
3 11/16" - 4 1/2" 2 3/8 REG 400 - 480 3000 - 3500 750 - 875 670 - 770
4 17/32" - 5" 2 7/8 REG 800 - 950 6000 - 7000 1500 - 1750 1340 - 1550
5 1/32" - 7 3/8" 3 1/2 REG 950 - 1200 7000 - 9000 1750 - 2250 1560 - 2000
7 13/32" - 9 3/8" 4 1/2 REG 1600 - 2200 12000 - 16000 3000 - 4000 2670 - 3550
9 13/32" - 14 1/2" 6 5/8 REG 3800 - 4300 28000 - 32000 7000 - 8000 6230 - 7110
14 9/16"- 18 1/2" 7 5/8 REG 4600 - 5400 34000 - 40000 8500 - 10000 7550 - 8880
18 9/16" and + 8 5/8 REG 5400 - 8100 40000 - 60000 10000 - 15000 8880 - 13330

54
B. TFA Table

55
C. Vibrations Cure Chart

56
 Section 2

Operation Simulation and Planning

57
Drillout Float Equipment

Drilling

Hole Conditioning

58