TTrackmaster

k t Mill
Dull Grade System

V1.1
 Objective

• Reasons for dull grading

• Understand the purpose of the system
• Outline the 11-digit
11 digit system structure
• Guidelines for consistency
• Examine different dull characteristics
• Point out difference from IADC
 Reasons for Dull Grading

• To determine what caused the dull

condition
• Provide information of what took place
downhole

• Information used for

à Preventing similar dull in the future
à Add knowledge for running the next mill
à Future design considerations
 Reference Material

• ‘Application
pp of the New IADC Dull Grading
g
System for Fixed Cutter Bits’
à 1987 SPE/IADC Paper #16145

• ‘First Revision to the IADC Fixed Cutter Dull

Grading System’
à 1992 SPE/IADC Paper #23939

• Smith Bits Dull Grading Manual

à Available from Reader Service,
Service Item #90090
 Guidelines

• Smith Drilling and Evaluation guidelines

for mills differ from IADC standards

• Created solely for internal purposes

à TTo reduce
d ambiguities
bi i i
à To improve dull grading consistency
à To account for the uniqueness of a mill
à New system to dull grade cutrite
 Guidelines

• Mill Dull Grading Structure

à Attempt to maintain consistency with IADC
system
y for bits

à But also take into account

•Lack of bearing
•Multiple cutting elements
•Unique cutting actions
 Dull Grading System

Lead Mill Follow Mill Dress Mill Remarks

Inner Outer Dull Loc Gauge Dull Gauge Dull Gauge Other Reason
Rows Rows Char Char Char Dull Pulled

I O D L G FD FG DD DG OD R

1 2 3 4 5 6 7 8 9 10 11

Fill code categories

g not being
g used with X
Eg. For Bi-mills, codes under dress mills will be
filled with X
 Lead Mill: I – Inner Rows

• Used to record the

average wear on the
inner two-thirds (⅔) of
mill radius

• Cutter wear is recorded

using a linear scale from
0 to 8
à 0 = no cutter wear
à 8 = no cutter remaining
 Lead Mill: O – Outer Rows

• Used to record the

average wear on the
outer one-thirds (⅓) of
mill radius

• Cutter wear is recorded

using a linear scale from
0 to 8
à 0 = no cutter wear
à 8 = no cutter remaining
 Cutting Structure Division

OUTER 1/3

INNER 2/3
INNER 2/3
 Lead Mill: I /O Rows Specifics

• Cutter wear should be measured across

the cutter table regardless of the cutter
shape, size, type or exposure
• Wear values of 6 – 8 are rarely seen due
to the loss of cutter
 Lead Mill: D – Dull Characteristics

• Two letter code to indicate the major dull

characteristic of the cutting structure
à Input only one dull characteristic code
à Dull code applies only to the cutting
st uctu e
structure
• Which code?
à The observed characteristic that would most
likely limit further usage of the mill in this
application
pp
 Lead Mill: D – Dull Characteristics

Dull Characteristics Codes

• BB - Broken Blade
• BF - Bond Failure
• BT - Broken Teeth/Cutters
• BU - Balled Up
• CR - Cored
• CT - Chipped Teeth/Cutters
• DL - Cutter Delamination
• ER - Erosion
• HC - Heat Checking
• JD - Junk Damage
• LT - Lost Teeth/Cutters
• MP - Mill Parted
• NO - No Dull Characteristic
• PN - Plugged Nozzle
• RO - Ring Out
• SB - Shear Bolt
• SC - Spalled Cutter
• WO - Washed Out Mill
• WT - Worn Teeth/Cutters
 Lead Mill: L – Location

• Single letter code to indicate the location

on the cutter structure where the major
dull characteristics occurs
à C – cone
à N – nose
à T – taper
à S - Shoulder
à G – gauge
à A – all areas
 Lead Mill: L – Location

• A number can be used along with the

location code to denote the blade with
the dull characteristics if needed
à Blades will be numbered sequentially
following g the cutting
g structure
à Blade one will be the blade where the shear
bolt is located or immediately following the
shear bolt
 Lead Mill: L – Location

3 2
2
1
1

Shear Bolt
 Lead Mill: G – Gauge

• Used to record the condition of the mill

gauge
à Based on a nominal ring gauge
à Ensure that a fixed cutter and not a roller
cone
co e ring
g gauge iss used
•Roller cone and fixed cutter gauge tolerances
differ
 Lead Mill: G – Gauge

• Measure the gauge of the outmost

cutters
à Amount of gauge = measured distance

Amount Undergauge in 16th

IN In Gauge
1 1/16”
2 2/16”
2/16
3 3/16”
Etc.
 Follow and Dress Mill – Dull

• Cutrite milling structure is inherently

difficult to dull grade
à Many different configurations
à Inconsistency in the milling structure
à No uniquely identifiable cutting structure
• Two letter code will be used to describe
both the dull characteristics as well as
the location
 Follow and Dress Mill – Dull

• First letter – dull characteristics

• Second letter – location of dull condition

WG

W - Even Wear L - Leading Area

A - Asymmetrical
A ti lWWear G - Gauge Area
B - Broken Blade T - Trailing Area
P - Carbide Peeling # - Blade number
 Follow and Dress Mill – Dull

• Location of dull

Mill Head

Gauge
g
T ili
Trailing L di
Leading
 Follow and Dress Mill – Dull

• Location of dull

Mill Head
 Follow and Dress Mill - Gauge

• Measure the gauge of the outmost

diameter of the milling structure
à Amount of gauge = measured distance

Amount Undergauge in 16th

IN In Gauge
1 1/16”
2 2/16”
2/16
3 3/16”
Etc.
 Remarks: O – Other Dull

• Used to record other dull characteristics

such as secondary evidence of mill wear
à Secondary evidence may identify the cause
of the primary dull
à Also
so can
ca indicate
d cate a dull
du characteristics
c a acte st cs which
c
would eventually limited further usage of the
mill, but is not related to the primary dull
characteristic
 Remarks: O – Other Dull

Other Characteristics Codes

• BB - Broken Blade
• BF - Bond Failure
• BT - Broken Teeth/Cutters
• BU - Balled Up
• CR - Cored
• CT - Chipped Teeth/Cutters
• DL - Cutter Delamination
• ER - Erosion
• HC - Heat Checking
• JD - Junk Damage
• LT - Lost Teeth/Cutters
• MP - Mill Parted
• LN - Lost Nozzle
• NO - No Dull Characteristic
• PN - Plugged Nozzle
• RO - Ring Out
• SB - Shear Bolt
• SC - Spalled Cutter
• WO - Washed Out Mill
• WT - Worn Teeth/Cutters
 Remarks: R – Reason Pulled

• Used to record the reason the mill was

pulled
à Dull condition of the cutting structure can
attribute to the reason pulled, but should be
evaluated independent of it
• Most common reasons
à TD – mill has successfully milled the window
and/or rathole
à PR – mill is not p
progressing
g g further
 Remarks: R – Reason Pulled

Reason Pulled Codes - IADC

• BHA – Change Bottom Hole • LIH – Left in Hole
Assembly • PP – Pump Pressure
• CM – Condition Mud • PR – Penetration Rate
• DEV – hole deviation • RIG – Rig Repair
• DMF – Downhole
D h l Motor
M t F Failure
il • TD – Total Depth / Casing
• DSF – Drill String Failure Depth
• DTF – Downhole Tool Failure • TQ –Torque
• FM – Formation Change • TW –Twist Off
• HP – Hole Problems • WC – Weather Conditions
• HR – Excessive Hours • WO – Wash
Wash-out
out
 Remarks: R – Reason Pulled

Reason Pulled Codes - Smith

• ANC – Anchor Malfunction
• BPV – By-Pass
By Pass Valve Problems
• CSG – Casing Problems
• HYD – Hydraulic Hose
• LW – Lost Whip
• MWD – MWD-Gyro Problems
• RT – Running Tool
• WA – Wrong Application
• WELL – Well Control
Detailed Analysis of Dull Conditions

Lead Mill
 BB – Broken Blade

• Blade broken from the mill either

partially or totally
• Partially broken blade can be
misdiagnosed as worn cutter, if a mill
with a broken blade continues milling in
an abrasive formation
BB – Broken Blade
 BB – Broken Blade

• Potential causes
à Excessive WOB for application and specific
mill type
yp
à Excessive impact load/improper milling
practices
à Excessive heat applied during brazing
à Pre-existingg cracks not identified
à Mill vibration
 BF – Bond Failure

• Bond failure occur in the bond between

two carbide substrates
à Recognized as a smooth surface on the
remaining substrate

• Most PDC cutters from Megadiamond are

manufactured in two pieces
à GV4 are made with two substrates
à TecMax and Qmax are made from one
substrate
BF – Bond Failure
 BF – Bond Failure

• Potential Causes
à Poor PDC quality
à Excessive WOB for application and specific
mill type
à Excessive impact load/improper milling
practices
à Mill vibration
 BT – Broken Cutters

• Over ⅓ of the cutting element has broken

from the substrate

• Excessive broken cutters may indicate

problems
à In mill selection
à And/or operating practices
BT – Broken Cutters
 BT – Broken Cutters

• Potential Causes
à Excessive WOB or RPM for application and
specific
p mill type
yp
à Excessive impact load / Improper milling
practices
à Improper mill selection for environment
à Formation / Improper
p p mill selection
à Improper initial cutout procedures
à Mill vibration
 BU – Balled Up

• Formation attached to mill blade, body

and/or cutters such that mill progress is
limited
• Symptoms include decreased rotary
torque and increased pump pressure

• There may not be any evidence of

physical damage to the mill
BU – Balled Up
 BU – Balled Up

• Potential Causes
à Formation
à Inadequate hydraulics
à Poor fluid distribution
à Milling practices
à Drilling fluid (with regard to mill balling only)
 CR – Cored

• Mill shows significant wear from the

formation resulting from the centermost
cutting elements being
à Worn
à Broken
à Lost
CR – Cored
 CR – Cored

• Potential Causes
à Excessive WOB for application and specific
mill type
yp
à Improper mill selection for environment
à Erosion
à Improper drilling practices
à Problems crossing over casing
à Broken or lost cutters
à Operator error
 CT – Chipped Cutters

• Less than ⅓ of the cutting element is

missing
• Chipping generally occurs on the outer
most edge of the cutter
• Most milling operations will result in
chipped cutters in part of the mill
à Especially
E i ll on the
h gauge andd the
h nose
à Excessive amount of chipped cutters
i di t improper
indicate i mill
ill and/or
d/ operating
ti g
parameters
CT – Chipped Cutters
 CT – Chipped Cutters

• Potential Causes
à Excessive WOB or RPM for application and
specific
p mill type
yp
à Excessive impact load/improper milling
practices
à Improper mill selection for environment
à Improper
p p initial cutout procedures
p
à Heat checking
à Mill vibration
à Poor handling practice
 DL – Delamination

• Separation of the diamond table from

the carbide substrate
• Smooth carbide surface of the geometric
non-planar interface is visible
DL – Delamination
 DL – Delamination

• Potential Causes
à Improper brazing procedure
•Excessive
Excessive temperature
à Excessive impact load/improper milling
p
practices
à Improper mill selection for environment
à Heat checking
g
 ER – Erosion

• Loss of cutting structure material by

impact from drilling fluids and cuttings
• Erosion can wear away blade and body
material
• Erosion can undermine the cutters
wearing out cutter pockets resulting in
cutter loss
ER – Erosion
 ER – Erosion

• Potential Causes
à Inadequate hydraulics
à Excessive hydraulics
à Abrasive formations
à Drilling environment
à Poor solids control
 HC – Heat Checking

• Seen as biaxial or cross hatched pattern of surface

crack
• Cracks initiate on the surface due to thermal
shock/fatigue and propagate due to stress relief
• Increased contact area on the cutting element can
amplify heat generation and aggravate thermal shock
• Highly abrasive formation can wear away signs of heat
checking
• Heat
H t checking
h ki usually ll leads
l d tot chipped
hi d cutters
tt
HC – Heat Checking
 HC – Heat Checking

• Potential Causes
à Insufficient fluid flow
à Reaming a slightly under gauge hole at high
RPM
à Milling at high RPM
à Formation/casing contact
 JD – Junk Damage

• Indentations or cutter damage caused by

contact with objects other than formation
JD – Junk Damage
 JD – Junk Damage

• Potential Causes
à Run on junk
 LT – Lost Cutter

• Cutting structure missing one or more

cutting elements
• Loss of entire cutting element from the
pocket indicates brazing related failure
• Loss of one cutting element increases
workload for remaining cutting elements
à P
Potentially
i ll lead
l d to ring-out
i or core-out
LT – Lost Cutter
 LT – Lost Cutter

• Potential Causes
à Manufacturing defects
à Brazing problems
à Excessive WOB for mill type
à Erosion
à Milling environment
à Mill vibration
 MP – Mill Parted

• Part of mill broken off from the main

assembly
à Includes a break in the mill or the mandrel
MP – Mill Parted
 MP – Mill Parted

• Potential Causes
à Excessive WOB for application and specific
mill type
yp
à Brazing/welding problems
•Excessive heat or metal poisoning
p g
à Excessive impact load/improper milling
practices
à Excessive torque
à Improper
p p mill selection for the application
pp
à Improper BHA selection
 PN – Plugged Nozzle

• Obstruction of nozzles by formation,

rubber, etc
• Definition can be extended to improper
shearing of the break nozzles
• Pump pressure will generally increase
when nozzles become plugged
PN – Plugged Nozzle
 PN – Plugged Nozzle

• Potential Causes
à Improper drilling practices
à Foreign material – LCM,
LCM motor rubber
à Formation plugging
à Drill pipe scale
à Hydraulics
à U tubing
U-tubing
 RO – Ring Out

• Circular band of worn, broken or lost

cutters permitting formation wear
• Ring out most commonly occurs on
à FasTrack mill – nose
à GeoTrack mill – shoulder
• Results from BT, LT or WT in ring out area
• Symptoms include increased pump
pressure and decrease in ROP
RO – Ring Out
 RO – Ring Out

• Potential Causes
à Includes similar causes leading to BT or LT
à Improper mill selection for environment
à Improper initial cutout procedures
à Improper milling practices
à Mill vibration or impact
à Improper shearing of break bolt
à Junk damage
 SB – Shear Bolts

• Improper shearing of break bolt

à Break bolt pulled out of the pocket without
shearing
g
à Damage to the mill during shearing
SB – Shear Bolts
 SB – Shear Bolts

• Potential Causes
à Improper shearing procedures
à Improper installation of shear bolt assembly
à Material failure
à Trip in too fast
à Severe DLS
 SB – Spalled Cutter

• Loss of less than ⅓ of cutting element

parallel to the cutting surface
• Spalling occurs on the face of the cutter
as oppose to chipping which usually
occurs on the outer edge
SC – Spalled Cutter
 SC – Spalled Cutter

• Potential causes
à Diamond manufacturing problems
à Excessive WOB or RPM for application and
specific mill type
à Excessive impact load / Improper drilling
practices
à Improper
p p mill selection for environment
à Heat checking
à Mill vibration
 WO – Washed Out Mill

• Drilling fluid has eroded a passage from

an internal flow area to exterior of the
mill
• If allowed to continue, a washout may
result in a twist off
• Symptoms include decrease pump
pressure and ROP
• Mill balling may also occur
WO – Washed Out Mill
 WO – Washed Out Mill

• Potential Causes
à Excessive hydraulics
à Excessive impact load
à Improper mill/ nozzle installation
à Wrong nozzle type for application
à Erosion damage to nozzle and/or nozzle
retaining system
à Bit balling
à High and/or abrasive solids in mud
 WT – Worn Cutter

• Reduction in cutter height due to drilling

action
• This is the normal and expected wear
mode for cutters
à Corrective measures should be taken if
cutters worn beyond normal condition for the
application
à Chipping is also expected for aggressive
milling
g operations
p
WT – Worn Cutter
 WT – Worn Cutter

• Potential Causes
à Excessive RPM for application and specific
Mill type
yp
à Excessive hours for application and specific
mill type
à Inadequate hydraulics
à Improper
p p mill selection for environment
à Abrasive formation
 NO – No Dull Characteristic

• No noticeable dull characteristic seen

• Seen on mills with no or very limited
milling action
• Mill can be re-run as is without any
further rework
Detailed Analysis of Dull Conditions

Follow and Dress Mill

 W – Wear

• Normal and even wear on the follow or

dress mill
• Characterized by flattening out of the
crushed carbide particles
 W – Wear

WG
Wear on the gauge of mill
WL
Wear on the leading side
(toward lead mill)
 W – Wear

• Potential Causes
à Excessive RPM for application and specific
Mill type
yp
à Inadequate hydraulics
à Improper mill selection for environment and
whipstock
à Abrasive formation
à Lead mill under gauged
 A – Asymmetrical wear

• Uneven wear among the blades of the

mill
à Area of uneven wear will usually be clustered
towards one side of the mill
• Can help identify
à Bent mandrel or mill head
à Off center wear on mill head
à Too much WOB
 A – Asymmetrical wear

No Wear

Wear AG
Asymmetrical wear on the
gauge of mill

AG
Asymmetrical wear on the
leading side of mill
 A – Asymmetrical Wear

• Potential Causes
à Excessive WOB for application and specific
Mill type
yp
à Improper mill selection for environment and
whipstock
à Bent mandrel or mill head
 B – Broken Blade

• Blade broken from the mill either

partially or totally
• Partially broken blade can be
misdiagnosed as severe wear,
à Mill with broken blade continues mill in
abrasive formation and smoothing away
broken area
B – Broken Blade
 B – Broken Blade

• Potential Causes
à Improper welding procedures
à Excessive WOB for application and specific
Mill type
à High impact loading
à Excessive vibration
à Excessive hours on mill
 P – Carbide Peeling

• Layer of crushed carbide peels away from

the base metal or subsequent layers of
carbide
• Seen as a large laminar area of carbide
missing from the blade
P – Carbide Peeling
 P – Carbide Peeling

• Potential Causes
à Improper welding procedures
à High impact loading
à Excessive vibration