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Roller Cone Bits Fundamentals

Roller Cone Bits Milled Tooth Bits Tungsten Carbide Bits

Roller Cone Bit Components

Cone Gage Shirttail Jet Nozzle/Bore Arm Seam Weld Jet Nozzle Nail Lock Reservoir System Pin

RC Drill Bits

Cutting Structure (MT or TCI) Teeth shape and projection Bearing type (sealed or open) Bearing type (friction or roller) Compensation system Arm shape and protection

RC Bit Geometry Journal (or Pin) Angle Basic element in the design of cone Angles
Soft formations - 33 Hard formations - 36
Journal Angle Journal

Centerline of Bit

Influences the cone contour (profile) and aggressiveness

Journal (Pin) Angle

Soft Formation

Hard Formation
Of Bit

Of Cone & Journal Of Cone &Journal Journal Angle Cone Angle Oversize Angle Journal Angle Cone Angle

Oversize Angle

Cone Angle Large Cone Angle Soft to Medium Formation Rounder cone profile Gouging & Scrapping Small Cone Angle Hard Formation Flatter cone profile Crushing

Offset (Skew Angle)


Direction of Rotation - Bit

Offset

Direction of Rotation - Cone

Offset Soft Formation Offset Hard Formation

Increased ROP in soft formation More offset increases gouging and scraping (action on bottom)

Less offset for medium formations Little or no cone offset for hard formation Weight applied to crushing rock

Oversize Angle Soft


Of Bit

Hard

Of Cone & Journal Of Cone &Journal Journal Angle Cone Angle Oversize Angle Journal Angle Cone Angle

Oversize Angle

Soft formation bits


higher oversize angle Increases action on gage, cone diameter, reaming

Hard formation bits


little to no oversize angle
Reduces action on gage, cone diameter, reaming

Intermesh
Intermesh clearance

Prevents packing of formation Better use of space for the cutting structure Greater cone shell thickness Extended tooth/insert length Larger bearing size

Projection and Pitch


Projection

Projection is the height of the tooth (Aggressiveness)


Pitch

Pitch is the spacing between the teeth (Agressiveness and Antitracking feature)

Insert Bit Cutting Structure

10 Surf 17 Full Faced Diamond Surf

20 Ovoid 28 Diamond Enhanced Ovoid

24 Hemispherical

30 Conical 38 Diamond Enhanced Conical

40 Double Conical

50 Tooth 58 Diamond Enhanced Tooth

55 Spear Shaped Tooth

60 Shaped Gauge 68 Diamond Enhanced Shaped Gage

65 Angled Shape Gauge 66 Diamond Enhanced Angled Shaped Gage

Insert Bit Cutting Structure

Insert Bit Cutting Structure


Diamond Enhanced Inserts Maintain Bit Gage Diamond surf protection used in 33% (D), 50% (D2) and 100% (D3) increments Reduce shirttail wear in directional and horizontal applications

Diamond

33% Increment

50% Increment

100% Increment

Roller Cone Technology

Cutting Efficiency Optimization

Roller Cone General Design Characteristics

Mill Tooth Attributes vs. Performance

Insert Attributes vs. Performance

Roller Bearings

Large Diameter Bits Larger than 13 Low friction Reduces heat Sealed and non-sealed

Non-Sealed Roller Bearing

Tooth cutting structures Generally for top hole and cement drilling applications

Double Sealed Roller Bearing

Rollers captured in arm Single compensation system Insert and Tooth Generally for rotary and motor applications

Roller-Ball-Roller (RBR)
Radial seal Spring-loaded face seal

Premium Double Sealed Roller Bearing

Larger than 15 Rollers captured in cone Dual compensation system Insert and Tooth Generally for motor or high energy applications

Roller-Ball-Roller (RBR)

Tandem radial seals

Sealed Journal Bearings

Smaller Diameter Bits


13 1/2 and smaller Insert and tooth O-ring Seal Friction bearing High load capacity Silver plated to reduce friction Motor and rotary

Thrust Bearing Improvements


Increased load bearing surface area 11% (green) Reduced pilot pin diameter Virtually eliminate thrust bearing slot

High Energy

Standard

High Energy Bearing

Improve Bearing lubrication through enhanced grease communication (Heat cooling and pressure compensation)

Standard

High Energy

Advanced Diamond Hardfacing

Ample hardfacing is applied to flanks, crests and gage surfaces for maximum wear resistance Steel teeth are sculptured in high wear areas for added hardfacing material

Gage

Flank

Fluid Circulation Purpose Remove cuttings Keep the cutting structure clean Cool the bit Stabilize the borehole wall Shales inhibition etc Drilling fluid Liquid (water or oil-based) Air, Aerated Mud Foam

Bit Hydraulics
With high pressure drop across the nozzles, high velocity fluid flows past the cones and impacts against the formation, flushing out cuttings in the hole

Drilling Fluid

Nozzle Arm

Center Jet (if equipped)

Roller Cone bit Selection vs Formation Hardness

R ock H a rd n e s s V e ry s o ft S o ft m e d iu m H a rd V e ry h a rd

c o m p r e s s iv e s t r e n g t h ( p s i) < 4 ,0 0 0 4 , 0 0 0 - 8 ,0 0 0 8 ,0 0 0 - 1 6 , 0 0 0 1 6 ,0 0 0 - 3 2 , 0 0 0 > 3 2 ,0 0 0

ROP ft/h r >70 35 - 70 15 - 35 15 - 5 <5

HDBS Roller Cone New Technology

HDBS Roller Cone Technology Cutting Efficiency Optimization

Force & Energy Balancing


Force Balancing
Reduced vibration Lower impact damage to CS Extended Bearing / Seal life by reducing wobble motion of cones Improved Directional Responsiveness Increased ROP Force Balancing

Cutting Efficiency Optimization

HDBS Unique Anti-tracking Feature (Insert Orientation) (US Patents: 6095262, 6213225)

Double Positive Seals


Dual compensation system permits use of two positive seals to extend bearing life The high aspect ratio seals provide additional squeeze with low stress levels resulting in lower operating temperatures

Seal Design Improvements


487 Double Seal
Radial seal and spring-loaded face seal

C29 Double Seal


Radial seal and modified face seal

C49 Double Seal


Tandem radial seals

Grease hand-packed in cavity between seals No means to equalize pressure between seals

Grease hand-packed in cavity between seals Series of small filtering holes in outer seal to equalize between seals pressure

Cavity between seals vacuum filled with lubricant Dedicated reservoir to equalize pressure between seals

Improved Bearing Design Capacity Increase vs. Previous Designs


Bearing code 487 represents baseline values 57% 76%

Bearing A
12% 24%

Bearing B

487

C29

C49

Roller Bearing Radial Load distribution


Greater distance between roller bearing
centers improves load distribution Longer roller bearing elements increase bearing capacity Combined improvements extend expected bearing life
9.4 8.8

Typical loading diagram

Relative life expectancy

7.1

A B

5.4

2.9

1.0

487

C49 C29 Bearing code

Bearing loads calculated as resultants of moments generated from weight on bit

Optimizing Technology
Bearings system optimized using Bearing Simulation Software, FEA and custom laboratory testers for bearing materials, seals and full scale bit testing.

Optimized Contact Pressure Profile Seal


Highest contact pressures at the edge of sealing interface where it is needed. Lower contact pressures reduce heat and torque at center of sealing face. In controlled laboratory testing:
53% increase in seal life 24% reduction in torque 16% decrease in temperature

Optimized Contact Pressure Profile


Sealing mechanics. High Aspect Ratio Seals Developing improved thermally stable and wear resistant elastomers
400 350 300 250 200 150 100 50 0

New Seal
Standard O Ring

Contact Pressure (psi)

0.05

0.1

0.15

0.2

0.25

Contact Length (in.)

Roller Cone Technology Compensation Development Mechanical Pressure Compensator (MPC)


Dome compensation and mechanical pressure relief Increased reliability & repeatability Reduced hysteresis Improved seal condition due to consistent pressure Flexibility with mechanical spring to adjust relief pressure

Optimizing Technology Enhanced and Directed Hydraulics


Remove cutting from crucial areas (sealing area & CS) Improved arm geometry Directed flow channels

Directed Nozzles

Optimizing Technology Bit Cleaning


AFTER BEFORE

Bit Cleaning Higher Flow; Higher ROP

Bit Cleaning Low Flow Under Cutting Structures

Optimizing Technology Controlled Upward Flow

Controlled Upward Flow Effective Cuttings Removal

Optimizing Technology Forging Design

New Forging Design Engineered Lifting Surfaces

Old Forging Design

Discussion

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