Drill Bit Operating

Parameters &
Procedures
While correct bit selection is crucial to successful performance in any
application, running the bit correctly -- using the right operating
parameters in the right way -- is equally important.

Learning Objectives
Upon completion of this module, you should be able to:
„ Identify the five pre-run procedures for drilling.
„ Describe drill-out procedures for Fixed Cutter and Roller Cone bits
„ Describe the difference between passive and optimized drill-off tests.
„ Identify solutions for abnormal or troublesome problems such as bit
balling.
„ Define different factors affecting penetration rate.
Introduction
The selection of the correct bit is vital for successful performance in any
application. But running the bit correctly is just as important -- if not more
so.
This learning module describes the process of determining bit operating
parameters, and the procedures used when running a bit. The sections
generally follow the sequence of a bit run, from receiving the bit in the
field to final dull grading and performance report preparation.

5 Step Pre-Run Procedure

Before the bit passes through the rotary table and enters the hole, it is
important that damage did not occur during delivery to the field, that
nozzles have been properly installed, and that the bit has been properly
made-up to the drill string. A flaw in any of these areas could affect the
customer’s confidence in the bit and in Security DBS.

1. Bit Packaging and Handling

Bits made with diamond cutter material must be handled carefully.
Diamonds can be easily damaged if dropped or struck. At the
manufacturing plant, the bit is placed in a wooden or metal container
designed to prevent damage.
A fixed cutter bit should be stored in its shipping container while not in
use. Care must be taken not to drop the bit, even if it is properly
packaged. When moving the bit outside its container, a piece of wood or
rubber should be placed under the bit face to protect it from damage. Do
not set the cutters down against steel rig floors. Be careful not to bang the
bit around in the rotary table; this can chip the diamond cutters and
shorten bit life.
Care should be taken not to hit or drop the bit on the pin connection.
Damage to the pin connection can prevent the bit from properly making-
up or can reduce pin strength. Fixed cutter bits of the same size as a roller
cone bit will weigh considerably more, so be careful when lifting. Lift
with your legs, not your back. Don’t strain your back; get help from
someone or use a winch. Comparative weights are given in the following
table.

Drill Bit Operating Parameters & Procedures 2

Comparative approximate bit weights
Roller Cone Bit Fixed Cutter Bit
Size
Weight (lbs.) Weight (lbs.)
4-1/2” 12 50
6” 39 100
6-3/4” 46 130
8-1/2” 83 260
10-5/8” 158 400
17-1/2” 536 1380

2. Final Field Inspection

It is your responsibility to visually inspect the bit before turning it over to
the rig hands. Check for:
„ Proper bit design configuration and size, TFA/nozzles, and API rotary
connection (Total flow area (TFA) is difficult to verify on natural
diamond or TSP bits utilizing a crowfoot configuration.)
„ Broken or fractured cutting elements
„ Indications of damage to the pin connection and make-up shoulder
„ Foreign material in the center bore of the bit and flow passageways
„ Proper nozzle installation

3. Ring Gauging
Any roller cone or fixed cutter bit should be ring gauged, and stabilizers
should be either callipered or gauged to verify they meet American
Petroleum Institute (API)-approved outside dimensions tolerances as
shown in the following table. You will notice that fixed cutter bits cannot
be larger than stated, because a larger fixed cutter bit could become stuck
in the hole. Therefore, the tolerance is all in the direction of the bit being
smaller.
Roller cone bit tolerances are just the opposite. Because the arms can
“give” a little, the tolerance is allowed in the direction of larger to assure
they continue to drill a full gauge hole.

Drill Bit Operating Parameters & Procedures 3

 Fixed Cutter Bit Roller Cone Bit O.D.
Bit Size (in)
O.D. Tolerance (in) Tolerance (in)
6-1/2” & smaller -0.015 to +0.00 -0.0 to +1/32
6-25/32 to 9 -0.020 to +0.00 -0.0 to 1/32
9-1/32 to 13-3/4 -0.030 to +0.00 -0.0 to 1/32
13-25/32 to 17-1/2 -0.045 to +0.00 -0.0 to 1/16
17-17/32 & larger -0.063 to +0.00 -0.0 to +3/32

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 length of the bit. A
“go” gauge is to ensure a bit is not larger than allowed and should go
(slip) down the entire length of the bit.
If you do not use the “go” gauge and a bit gets stuck in the hole, the
customer will wonder if it was overgauge. If the following bit gets stuck,
the customer will wonder if “your” bit was undergauge. Ring gauging the
bit before and after the run will show the customer you care about his
business.
Fixed cutter bit undergauge is a direct reading. Do not factor as you do
with roller cone bits.
A major field problem can arise from trying to use a roller cone ring gauge
on a fixed cutter bit. In one actual field instance, this was done with a 17
1/2-inch bit, and the customer claimed the bit was undergauge.
The allowable dimensions for a 17 1/2-inch fixed cutter bit are 17.455 to
17.5 inches. The maximum allowable dimension of a fixed cutter bit
gauged by the maximum roller cone “go” gauge are 17.5 to 17.562 as
shown in the above table.

4. Nozzle Installation and Removal

All Security DBS Diamond Product nozzle systems, standard body, hex
flow and DBS are made of tungsten carbide. This material is extremely
erosion-resistant, yet relatively brittle, therefore special care is required
when installing and removing nozzles. Unlike steel nozzles that “give”
slightly when over-tightened, tungsten carbide nozzles do not “give” at all.
They are susceptible to cracking when make-up beyond their
recommended torque or when they experience sudden impact. SO,
UNDER NO CIRCUMSTANCE SHOULD “HAMMER” BLOWS BE
APPLIED TO THE NOZZLE WRENCH DURING INSTALLATION OR
REMOVAL. On the other hand, under-tightening can result in leakage or
nozzle loss while drilling.

Drill Bit Operating Parameters & Procedures 4

The following installation and removal instructions will provide
maximum, trouble-free service from your standard body, hexflow and
retainer nozzle systems.

Standard Body and Hexflow Nozzle Installation:

1. Gauge the flow orifices of the selected nozzles.
2. Check to make sure an O-ring has been installed and the threads are
clean. If the O-ring seal is not in place, install one in the groove
positioned below the threads in the nozzle recess. Make sure the O-
ring has seated around its complete circumference.
3. Remove the nozzle and apply about five drops of Permatex Removable
Thread Locker (“Loctite”) evenly around the last thread near the
bevel.
4. Place brass crush washer in the nozzle recess.
5. Insert the nozzle by hand to ensure proper nozzle orientation and
make-up until the nozzle seats.
6. Secure the bit and insert the sliding “T” handle, or a torque wrench.
Apply torque in a clockwise motion, using both hands to align the hex
tool so that no binding occurs in the hex recess. Proper alignment
prevents most fractures.
7. After the retainer is against the rubber washer, ensure the wrench is
squared up, then tighten the retainer up to but not over fifty (50) ft.-
lbs. torque. DO NOT USE A LEVER OR “CHEATER” ON THE
WRENCH. Adequate torque can be achieved by hand tightening the
retainer.

Nozzle Removal Procedure:

1. Care should also be taken when removing nozzles. Ensure that all
tools are perpendicular (squared up) to the nozzle before applying
counter-clockwise force. Avoid any sudden impact to the nozzle.
2. Clean away any mud or debris from the face of the nozzle.
3. With the hex tool squared up on the nozzle, apply a constant, steady
force in a counter-clockwise direction.
4. If the nozzle resists loosening, a SLIGHT bump with the heel of the
hand may be necessary.
Note: Installation and removal procedures should be supplied to the
customer.

Drill Bit Operating Parameters & Procedures 5

Special Considerations
A junk basket is recommended for use with the bit run immediately before
the intended fixed cutter run. Sidewall cores, roller cone inserts, or any
other potentially damaging material in the wellbore will destroy fixed
cutter bits.
When tripping out the preceding bit, any tight spots should be reamed out
after pulling up through them.
A drilling screen may be used all the time as a precaution against plugging
the bit or nozzles; however, it is specifically recommended when using
nozzle orifices smaller than 10/32 of an inch. The screen is placed in the
box of the single immediately below the kelly. The screen must be moved
as the drill pipe is added, so it continually remains in the box connection
made up to the kelly pin.

Drill Bit Operating Parameters & Procedures 6

5. Bit Make-up
Bit breakers are necessary for the proper make-up of a bit. Fixed cutter
bits use a different style of bit breakers than roller cone bits. These
breakers have been standardized by the American Petroleum Institute and
the specifications are shown in the following table.
PDC
Recommended Make-UP Torque
A.P.I. Make-up Bit Typical Size Range
Regular Pin Torque (inches)
(inches) (feet/pound)
2 3/8 3,150 to 3,750 3 11/16 to 4 1/2
2 7/8 4,650 to 5,600 4 17/32 to 5
3 1/2 7,900 to 9,500 5 1/32 to 7 3/8
4 1/2 17,750 to 21,300 7 13/32 to 9 3/8
6 5/8 42,550 to 51,000 9 13/32 to 14 1/2
7 5/8 67,300 to 80,750 14 9/16 to 18 1/2

Roller Cone
Recommended Make-Up Torque*
A.P.I. Regular Make-up Torque Bit Typical Size
Pin (inches) (feet/pound) Range (inches)

2 3/8 3000 to 3500 4 1/2

2 7/8 4500 to 5500 4 3/4
3 1/2 7000 to 9000 5 7/8 to 7 3/8
4 1/2 12000 to 16000 7 5/8 to 8 3/4
6 5/8 28000 to 32000 9 1/2 to 13 3/4
7 5/8 34000 to 40000 14 3/4 to 28
* The tool joint type for the 14 3/4 - 17 1/2 inch rock bit range is either 6 5/8 or 7
5/8 inches API Reg.
* Calculations based on recommendations from API and tool-joint manufacturers.

Drill Bit Operating Parameters & Procedures 7

Bit Make-Up Procedure
1. A general procedure for bit make-up is suggested below:
2. Be sure you have the appropriate bit breaker for the bit.
3. Ensure that the rotary is covered and that the bit is always placed on
wood or rubber (wiper rubber works well). Additional measures may
be used to prevent anything from falling into the hole.
4. For smaller bits, use the bit breaker to lift the bit from the box. Two
people can “walk” the doped pin into the hanging box connection until
the shoulders of both box and pin meet. Any difficulty indicating a
connection problem should be checked before proceeding. For larger
bits, either move the bit in its box, or lift the bit and place the center of
the bit over the rotary table center. The rotary can be reversed while
the hanging box connection is lowered onto the doped threads of the
pin.
5. Lift the stand, uncover the rotary, and lower the bit breaker onto the
bushings or breaker holder.
6. Place the open end of the U-shaped breaker away from the draw works
when locking the rotary table. Otherwise, the bit may slip along the
U-shaped slot when tong pull is applied and the gauge or shoulder
cutters may impact the rotary bushing.
7. Obtain the correct torque when making up the bit onto the drill string.
Fixed cutter bit make-up torques are greater than roller cone bits.
Figure 10.3 provides make-up torques for fixed cutter bits.
8. When making up bits larger than 12 1/4 inches, it is advisable to hold
the drill collars as vertical as soon as possible to avoid tilting the bit
during the make-up and breaking cutters in the rotary. Use a cathead
backup or an air backup to pull drill collars away from the make-up
cathead while torquing up the bit.

Drill Bit Operating Parameters & Procedures 8

Drilling Procedures
After a new bit has entered the hole several key activities must be
performed to ensure the success of the run. Procedures used in running
fixed cutter vs. roller cone vary, sometimes significantly. These variations
are noted where appropriate.
The mechanical properties of the cutters, cutting element, and formation
interaction require that break-in procedures and operating parameters be
monitored to ensure optimum performance.

Starting a Bit
The following sections contain procedures on running in the hole, break-
in, reaming, drilling out, dry and pressure drilling, and tagging bottom.
Rig Floor and Blow-Out Preventer (BOP) Stack
The make-up bit should not rest on the rig floor. Carefully guide the bit
through the rotary table, bell nipple and BOP stack.

Running in the Hole

Running in the hole should be done carefully. Unlike roller cone bits,
fixed cutter bits can have an increased surge pressure effect while tripping.
Pipe movement should be carefully controlled and mud properties
monitored. Rough areas in the hole pose a real danger, and may damage
fixed cutter bits. The cutting elements, especially on the gauge and
shoulder, are vulnerable.

Cased
In a cased hole, care should be taken when entering conductor pipe or
liners and when passing through drilled out cementing equipment, because
ledges may exist in these areas.

Uncased
In an uncased or open hole, care should be taken with suspected or known
tight spots, ledges, doglegs or keyseats. Roller cone bits can be damaged
or pinched when running in the hole, but they provide some protection
because of the ability to roll off a ledge or tight spot. If bottomhole
assembly stiffness has been increased, be especially cautious. A fixed
cutter bit is more likely to become stuck than a roller cone bit because the
roller cone bit has some “give” that a fixed cutter bit does not have.

Drill Bit Operating Parameters & Procedures 9

Reaming
Avoid using a new bit as a reamer whenever possible, particularly a fixed
cutter bit. However, when a tight spot or section is encountered while
running through open hole, reaming may be necessary.
When approaching bottom, reaming is always recommended for the length
of the last two joints (60 feet) of hole to ensure that the previous hole in
not undergauge or that fill is not present. Undergauge may have occurred
because of formation swelling, or the previous bit may have finished the
end of its run worn below gauge.
Reaming should be done with no more than 500 pounds/inch of bit
diameter weight on bit, low rotary speed (40-60 RPM), and maximum
flow rate. Do not impact or jar the bit during reaming.
For more than two hours of reaming, running a roller cone bit instead of
the fixed cutter bit should be considered.
Reaming is far better than washing down when a fixed cutter bit reaches a
tight spot, because it allows all gauge cutters to participate equally in
opening the hole. When a bit is washed down without rotation, the tight
spot may act on only a relatively small number of the cutters, increasing
the risk of damage.

Drilling Out
Drilling out with a fixed cutter bit carries a greater degree of risk than with
a roller cone bit, due to costs and cutting actions.

Drilling out with a Fixed Cutter Bit

Drilling out with fixed cutter bits has proven successful with the following
considerations:
All downhole cementing equipment (plugs, shoes, float collars) must be
made of rubber, nylon, plastic, cement or other homogenous material.
Brass and ferrous metals should not be drilled with fixed cutter bits.

Drill Bit Operating Parameters & Procedures 10

The above figure shows the typical equipment used for cementing when a
float shoe and collar are used. Specialists will design the best equipment
for individual well requirements. The float shoe is usually located on the
end of the casing string and float collar, one joint up. The bottom plug is
pumped down, followed by the cement, and finally, the top wiper plug is
pumped down to meet the bottom plug. This forces the cement into the
open hole annulus.
Normal drill-out procedures use low (60-100 RPM) rotary speed and
maximum available flow rate. These parameters are maintained
throughout the drilling out. Minimum weight-on-bit (WOB) should be
used since rate of penetration (ROP) is not the priority. Torque and ROP
will indicate proper WOB selection.

Drill Bit Operating Parameters & Procedures 11

Torque should be monitored during drill-out to keep it as low and
consistent as possible. This will reduce any potential bit damage and the
possibility of rotation by the wiper plug. Excessive or erratic torque can
be caused by junk under the bit, which must be circulated away, or by a
broken bond between the wiper plug and casing, which will allow the plug
to spin with the bit.
Spinning causes an increase in drilling out time.
Convex bits tend to perform better when drilling out float equipment than
do concave bits, since convex bits are less likely to trap foreign materials
under the bit.
Spinning Wiper Plug Difficulties - Two methods are suggested to
overcome wiper plug spinning.
Pressure Drilling: With the pressure drilling technique, begin with
maximum circulation flow rate and no bit rotation. Weight on bit is
increased until one of the following occurs:
„ A standpipe pressure of 200-300 psi over normal is encountered.
„ 3,000 pounds/inch of bit diameter weight on bit is achieved.
The bit is then rotated at drillout speed (40-60 RPM) for five minutes.
This procedure is repeated until the wiper plug is drilled out.
Dry Drilling: Dry drilling must be done with extreme care and is not
recommended. The procedure to dry drill the plug alternates running the
pumps at maximum circulation rate, then with no circulation, in intervals
of 15-60 seconds. Use standard drill-out rotary speeds of 40-60 RPM.
The risk of bit thermal damage or plugging bit flow passageways with
rubber is extremely high.

Drilling out with a Roller Cone Bit

Drilling Cement - Rotary drill bits are not specifically designed to drill
casing cement, cementing plugs, and float equipment, however, the best
performance will be obtained with a “long” steel tooth bit made for soft to
medium formations. The gouging action generated by materials. (The
soft chisel tooth insert bit designs with more offset have also been
effective.) Hard steel tooth and hard insert bits with short tooth extension
and no offset to give a gouging action are less efficient.
Recommendations: XS1, XS2
XS4, XS5
XS02, XS22, XS33

Drill Bit Operating Parameters & Procedures 12

WARNING - Experience has shown that the cones on the longer tooth bit
can become locked due to rubber, cement or plastic jamming between the
teeth on the cones. Also, cones on non-sealed bits can lock due to
material jamming in the bearings.
As a result, the following recommendations are made:
„ Utilize a soft formation, sealed bearing bit. Increased tooth extension
and offset should be more effective. However, if cones are becoming
locked and then develop skid flats, switch to shorter tooth bits with
less offset.
„ For a starting point, tests have shown that 40/60 RPM and about 2000
to 3000 pounds per inch of bit diameter and sufficient flow rate will
be effective. A minimum of about 40 gallons per minute per inch of
bit diameter should be used.
„ Occasional raising and lowering of the bit while circulating will help
clear debris from the face and sides of the bit.
„ Constantly monitor the penetration rate to determine if cones are
locked. If the ROP decreases at any time, then the drill-out procedure
should be altered. A temporary increase in weight on bit may provide
more torque to clear locked cones.

Tagging Bottom
About 60 feet before reaching and tagging the bottom of the hole, begin
pumping the previously determined optimum flow rate, continue the 40-60
RPM rotary speed and note the off-bottom string torque. Use no more
than 500 pounds bit weight per inch of bit diameter. When bit weight
increases along with the torque reading, bottom should be considered
tagged as long as the pipe tally is close. TSP and diamond bits with
crowfoot openings may show an increase in pump pressure when bottom
is reached.
Raise the kelly 6-12 inches off bottom while continuing to rotate, and
circulate fluid for five minutes to help wash away any fill or junk. Return
to bottom and begin drilling with no more than the 500 pounds per inch of
bit diameter bit weight. The bit will usually drill off immediately. If it
does not, be patient, a proper break-in is essential to overall bit life. Add
more bit weight only if 500 pounds is insufficient to overcome formation
strength. Drill enough new hole for the entire bit crown and gauge pad
length to become established before beginning to optimize bit weight and
RPM for the desired goal.

Drill Bit Operating Parameters & Procedures 13

If a new bottomhole assembly (BHA) has been put together, or if a new
full-gauge near bit stabilizer has been added to the string, optimization of
drilling parameters should not be finalized until the new stabilizer(s) have
entered the new hole drilled by the fixed cutter bit. It is typical of new
stabilizers to cause string torque and hold roller cone bits off bottom after
a trip. With fixed cutter bits, the increased torque from new stabilizers
should drop off when they enter the portion of the hole drilled by the full
gauge fixed cutter bit. At this point, it is usually a safe assumption that
weight transfer indications will be as close as is possible. Parameters
should then be optimized for ROP.

Breaking in the Bit

Begin by comparing expected hydraulics calculations with the actual
pump pressure and flow rate before bit break in. This procedure can help
detect plugged or blown nozzles, or pump problems.
Always break-in the bit with full pump volume. Set rotary speed to 100-
120 RPM and advance the bit slowly to the bottom of the hole. In soft
formations, set weight on bit to 2,000-4,000 pounds. Drill 3-5 feet before
optimizing weight and RPM.
Take the time necessary to properly break-in the bit. The firmer the
formation, the longer the break-in will take.

Bottomhole Pattern
The gradual break-in described above can be understood by looking at the
potential difference between the bottomhole pattern left by a previous bit
and the profile of the new bit. The previous bit had its particular profile
and was worn in a unique way.
Even when following with another bit of the same type or model, the
bottomhole pattern is different between the new bit and the previous dull
bit. The new bit must first drill off this old pattern before it can begin to
be fully optimized.

Running the Bit

Rotary speed (RPM) and weight on bit (WOB) are the two major control
parameters set during drilling optimization. They should be closely
monitored during continued drilling and the interaction with the following
indicators noted.

Drill Bit Operating Parameters & Procedures 14

Weight on Bit
The effect of bit weight on penetration rate is well known. With adequate
cleaning, doubling bit weight also doubles penetration rate. There are
some limitations. For example, in an extremely hard formation, the
drilling rate in the marble follows the expected pattern. In the quartzite the
rate of penetration more than doubled when bit weight was increased from
30,000 to 40,000 lb. If the upper part or the straight-line portion of this
curve is extended to a zero drilling rate, it shows the compressive strength
of the rock in terms of bit weight at those drilling conditions.
In this case, the quartzite exhibited a compressive strength equal to 21,500
lb of bit weight. This means that 21,500 lb of bit weight must be used to
fracture the rock. If less bit weight is used, drilling rate and footage per
bit will be very low. The reason for this is that drilling will be possible
only by a scraping action of the bit teeth. In this type of action the teeth
are worn off rapidly, and very little progress is made. This result often
occurs where operators are forced to reduce bit weight in hard formations
because of crooked-hole problems.
Another case where drilling rate is not directly proportional to bit weight
is the lack of cleaning below the bit - formation chips are being reground.
In many areas, particularly in soft rock, the bit weight that can be used
effectively is limited by the amount of fluid cleaning available below the
bit. Even though the amount of cleaning cannot be predicted on a general
basis, it may be possible to make this determination in large development
areas. As long as drilling rate is directly proportional to bit weight, it is
probable that additional cleaning below the bit will offer very little
benefit.

Rotary Speed
In soft formations, such as those in the Gulf Coast, drilling rate is directly
proportional to rotary speed. In this type of formation, the drilling rate
may be plotted against the product of bit weight and rotary speed and this
product may be used in planning drilling programs.
In hard formations, the drilling rate is not directly proportional to rotary
speed. In this case high rotary speeds (above 150 RPM) should not be
used routinely. The use of a weight and rotary speed product would be a
misleading way of presenting results.

Even in medium-hard formations the rate of increase in penetration

decreases rapidly at high rotary speeds. Operators often experiment to
determine the best combination of bit weight and rotary speed.

Drill Bit Operating Parameters & Procedures 15

The reason drilling rate is not proportional to rotary speed in medium and
hard formations is believed due to the requirement that some finite time is
required to fracture the harder rocks.
Some evidence of this has been observed in actual drilling tests. Bit
torque per revolution is reduced as rotary speed is increased. In this case,
torque is a measure of the amount of formation that is being removed by
each rotation of the bit. This seems to confirm that some finite time is
necessary to fracture the rock.
Use drill-off tests to determine the optimum weight-on-bit and rotary
speed. Be aware of changes in formation. PDC bits particularly, are very
sensitive to lithology. As formations change, it is often necessary to
change operating parameters. If bouncing begins, a change or reduction in
WOB and RPM will usually eliminate it.
After making connections, the pump rate should be returned to full
volume. Gradually increase the rotary speed with the bit slightly off
bottom. Ease the bit to the bottom of the hole. Do not jam the bit on
bottom. After contacting hole bottom, gradually increase the weight to the
optimum level. As weight or RPM is increased, increase the flow rate
when possible to help offset the increased heat generated at the face of the
cutters.
It is obvious from what has just been discussed, that rig personnel play a
very important role in the overall performance of any bit. This begins
with the proper selection of the bit, “making-up” of the bit, lowering the
bit to bottom, “breaking-in” of the new bit, and continues throughout the
life of the bit with a diligent effort being made in obtaining maximum
performance.

Drill-off Tests
A drill-off test is used to determine the best bit weight and rotary speed
possible, given the above considerations. It is a step-by-step process of
altering these parameters to achieve maximum penetration rate. During
drill-off, other surface indicators should be monitored to be sure they
remain within acceptable limits. These tests should be done after
establishing bottomhole pattern and when a significant formation change
is encountered and expected to continue for a substantial time.

A drill-off test is performed in a “passive” form and generally defines a

fixed rotary speed and weight on bit range. To optimize the bit weight
range, an “active” optimization test may be carried out.

Drill Bit Operating Parameters & Procedures 16

Passive Drill-off
The procedure should:
„ Begin with a moderate rotary speed (80 RPM) and maximum bit
weight (22,000 pounds). Lock down the brake handle.
„ Allow the bit weight to drill off by a predetermined increment, such
as 4,000 pounds down to 18,000 pounds. Record the time taken to
drill off.
„ Continue to record the time at each increment of weight reduction
(such as 18,000 to 14,000 or 14,000 to 10,000) until the P-rate
becomes too slow.
„ Select the weight increment requiring the least amount of time to drill
off.
„ This should be repeated at different rotary speeds to determine
optimum speed.

Active Optimized Drilling Test

To be worthwhile, the active drilling optimization test should be done in
relatively homogeneous formation. Rapid fluctuations in lithology will
negate the reliability of the test.
Using the rotary speed and bit weight from the passive drill-off, an active
optimized test can determine the specific values for best ROP.
„ Set the RPM at 100 and for each incremented bit weight within the
18,000- to 14,000- pound range, record the penetration rate over
about five minutes. This produces a more specific bit weight of
16,000 to 17,000 pounds.
The “active” optimized drilling test can be done independently of the
“passive” test, and the customer should be encouraged to perform this
active test periodically.
„ Begin by selecting a mid-range bit weight and moderate rotary speed.
„ Maintain rotary speed and bit weight for about five minutes and
record the penetration rate.
„ Increase the bit weight and repeat the above. Then decrease the bit
weight and repeat.
„ Determine the two fastest penetration rates and select a bit weight
between the two associated rates.

Drill Bit Operating Parameters & Procedures 17

„ Using the selected bit weight, vary the rotary speed in the same way,
recording the penetration rate for each time period.
„ Select a rotary speed between the two best penetration rates.

Surface Indicators
Once penetration rate has been optimized and routine drilling continues,
monitor available surface indicators to assure continued best results and
avoid problems. Changes and problems that occur in the hole may be
shown on more than one indicator. In the field, you should cross check all
indicators before making any parameter changes. Indicators are the same
for all types of fixed cutter bits unless otherwise listed.

Torque
Torque is measured in foot pounds. Diesel electric and SCR rigs use an
indicator of the electrical power required by the motors, which is
measured in amps (amperes).
Torque is induced into the drill stem due to rotating in the borehole. Part
of this torque comes from the bit, and the rest from the bottomhole
assembly and drill pipe. Torque is a function of rotary speed and hole
conditions.
Constant Torque: Relatively constant torque is normal. Two levels reflect
formation hardness:
„ Soft or plastic, homogeneous formations maintain a low level of
torque.
„ Medium-soft to medium shales and other similar homogeneous
formations maintain a medium level of torque.
Irregular torque may indicate:
„ Reaming of stabilizers
„ Bit undergauge
„ Interbedded formation
„ Junk in the hole
„ Keyseats or doglegs
„ Excessive bit weight
Decrease in torque may indicate:
„ Formation change

Drill Bit Operating Parameters & Procedures 18

„ Unoptimized bit weight
„ Unoptimized rotary speed
„ Decreasing hole inclination
„ Bit balling

Pump Pressure (PP) or Standpipe Pressure (SPP)

Pump circulating pressure may be measured at the pump or at the
standpipe.
Inconsistent SPP with a PDC bit may indicate:
„ Bit Balling
„ Annulus packing off
„ Flow rate variations
Increase in SPP may indicate:
„ Flow rate increase
„ A restriction in the annulus
„ Ring out or core out
„ Increased mud weight or viscosity
„ Bit balling
Decrease in SPP may indicate:
„ Washout*
„ Flow rate reduction
„ Decreased mud weight or viscosity
„ Aerated drilling mud
„ Taking a gas “kick” - Check pits
„ Losing mud or formation breakdown
„ A lost nozzle
*Washouts in the drill string usually get worse over time (pump pressure
declines) and the mud can become flocculated depending on the fluid
type.

Drill Bit Operating Parameters & Procedures 19

Pump Stroke Rate (SPM)
The pistons on the mud pump stroke forward and backward several times
each minute to pump fluid through the system. Pump circulation rate is
calculated by multiplying the SPM by the volume per stroke.
Increase in SPM with the PP constant, may indicate:
„ Washout
„ Aerated drilling mud
„ Taking a gas “kick”
„ Losing mud or formation breakdown
„ Decrease mud weight or viscosity
„ Lost nozzle
Decrease in SPM with the PP constant, may indicate:
„ Annular restriction
„ Fully or partially plugged bit
„ Increased mud weight or viscosity
„ Bit balling
„ Ring out

Penetration Rate (PR, ROP or P-rate)

Penetration rate is the speed at which a new formation is being drilled.
Increased Penetration rate may indicate:
„ Formation change
„ Reduced mud weight or improved properties
„ Optimized bit weight
„ Optimized rotary speed
„ Optimized bit cleaning

Drill Bit Operating Parameters & Procedures 20

Decreased Penetration rate may indicate:
„ Formation change
„ Increased mud weight or less favorable properties
„ Worn-out bit
„ Unoptimized bit weight
„ Unoptimized rotary speed
„ Decreased bit cleaning or bit balling
Varying Penetration rate may indicate:
„ Layered, interbedded or broken formations
„ Bit balling

Formation Samples
These are the drilled formation cuttings washed over the shale shakers.
Samples provide important information about the rock being drilled. For
example:
„ Changes in formation type and characteristics
„ Pressure zones (shale samples will be long and splintery)
„ Borehole sloughing (shale samples will be fat with rounded edges)

A Final Note on Bit Balling

Bit balling most commonly occurs when drilling a hydratable shale or
marl with a water-based drilling mud. The shale or marl absorbs water
from the mud and becomes sticky or “gumbo” shale which clings to the bit
and prevents it from failing the formation.
Symptoms - The following symptoms indicate bit balling:
„ Extreme reduction in drilling torque.
„ Extreme reduction in penetration rate. P-rate may return to normal
after bit face cleaning procedures, but is followed by another sudden
drop.
„ Substantial increase in pump pressure.

Drill Bit Operating Parameters & Procedures 21

Cleaning Procedure
Cleaning the formation off the face of a balled-up bit requires:
Spinning
Raise the bit and lower it to about two inches off bottom. Use maximum
pump circulation rate and remain here for 15 to 30 minutes.
During the 15-30 minute interval, the rotary speed should be operated as
follows,
On mechanical drilling rigs, use maximum allowable rotary speed for
about one minute, then stop rotation for about one minute. Repeat for
time interval.
On variable speed drilling rigs, begin at the previously used drilling rotary
speed and increase the speed to the maximum allowable for one minute,
then reduce the original speed for three minutes. Repeat for time interval.
Varying rotary speeds maximizes the available centrifugal force to help
throw the sticky formation from the bit face.
Washing
Pick up the bit off bottom and circulate with 150-180 RPM for two
minutes or so. Stop the rotary and return to bottom with previous drilling
weight plus 15,000-20,000 pounds.
Circulate a maximum volume for 5-15 minutes at 0 RPM. Pick up the bit
off bottom 3-6 inches and spin at maximum RPM for 1-2 minutes.
This should not be attempted where differential sticking is a problem.
Nut Plug Sweeping
Slow down RPM to 40-60 if torque and rotary permit. Drill ahead with
2,000-4,000 pounds WOB. Pump nut plug pills, if possible fine mesh,
(sometimes called sweeps) across the bit. Drilling rate should pick up
when the pill reaches the bit.
Control drill the bit at 20 percent higher RPM than before the pill. Pump
additional pill(s) and repeat the procedures as necessary.

Drill Bit Operating Parameters & Procedures 22

Setting New Parameters
After the bit face has been cleaned, new drilling parameters are needed to
prevent repeated bit balling:
„ Maximize rotary speed before tagging bottom.
„ Maximize pump circulation speed before tagging bottom.
„ Use 80 percent of the previous bit weight.

Drill Bit Operating Parameters & Procedures 23