6.

1 Bit Hydraulic Design

6.1.1 PDC Hydraulics

Hydraulic design for PDC bits is determined by:
Geometry of the bit
Nozzles
Cutting Structure Cleaning
Cuttings Evacuation

6.1.1.1 PDC Hydraulic Issues

The main hydraulic issues when it comes to PDC bits are:
Bit Balling
Bit Erosion
Plugged Nozzles
Cavitation

PDC Bit Balling

Mentioned at the beginning of chapter 3, it is related to the accumulation of
cuttings, most commonly clay to the Junk Slots of the bit. See Fig. 6.6.

Fig. 6.6 Examples PDC Bit Balling

As discussed earlier the following conditions are conducive to bit balling:

Soft and Sticky Formations (Shales/Claystones)
Low Flow Rates
Low HSI
Mud Properties -Water Based VS. Oil Based Muds
High mud weights (densities)
Some additives may promote balling some will help prevent
balling.
Erosion. See Fig. 6.7
It can be caused by:
6.1 Bit Hydraulic Design
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Fig. 6.7 Examples of Bit Erosion

Increased circulation time

Increased solids/sands (abrasives) content
Increased fluid jet velocity
Soft bit body materials.
Decreased distance between the jet exit and the bit body or cutter
substrate.
Distinguishing between Erosion and Abrasion (See Fig. 6.8):
Erosion
Usually non-circumferential
Affects material along side of and behind cutter faces
May affect the bit body material and the Cutter substrate

Fig. 6.8 Distinguishing between Erosion and Abrasion

6.1.1.1 PDC Hydraulic Issues

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 Abrasion
Usually Circumferential
Generally takes place between cutters or where cutter faces are
missing
Generally affects the bit body between cutters
Nozzle Plugging
Nozzle plugging happens in multiple ways. See Fig. 6.9
Internal Plugging
Junk material from surface or motors
Use of Lost Circulation Material with small nozzle sizes

Fig. 6.9 Example Internal and External Nozzle Plugging

External Plugging
Packing of formation in nozzle bore due to low flow rates or HSI

Distance between hole bottom and nozzle exit is too close

Variation of formation hardness
Maintaining a minimum of 200ft/s fluid velocity at the jet (jet velocity) is
recommended to prevent nozzle plugging, this will be further elaborated in
6.2 Hydraulic Optimization

Cavitation
Cavitation is the formation or collapse of vapor bubbles in a liquid caused by
a change in the fluid pressure. If the fluid pressure drops below the vapor
pressure point, bubbles can occur. Cavitation causes erosion, as bubbles
form in a low pressure region and then collapse in a higher pressure region,
this creates a small implosion that can damage material surfaces leading to
surface erosion.

The problem is present in "shallow" holes (3000ft - 5000 ft or ~ 914 - 1524 m),
nozzle velocity can reach a point where local internal nozzle pressure
approaches vapor pressure. When this happens liquid and bubbles start
flowing through the nozzle. Cavitation is usually not an issue after 3000ft -

6.1.1.1 PDC Hydraulic Issues

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5000 ft (~ 914 - 1524 m) due to the high Hydrostatic pressure "overcoming"
the low nozzle pressure from the annulus.
Issues:
Unexpected increases in Stand Pipe Pressure. Low flow rate produce
expected Stand Pipe Pressure (SPP), higher flow rates produce
increases in SPP out of proportion. Using larger nozzles or limiting
flow rate may address the issue.
As an example of erosion due to cavitation, internal tube of Erosion in
nozzles or the inside of the bit body. See Fig. 6.10

Fig. 6.10 Example of Erosion inside an SHO due to cavitation. Flow passing through the
SHO has a change in direction due to the tube of the nozzle pointing up, this creates an area
prone to erosion due to cavitation.

6.1.1.2 Factors Determining PDC Cutting Structure Cleaning

The following are key components that define the ability to clean the face of
the bit:
Junk Slot Area. Ability to evacuate cuttings from the face of the bit is
usually indicated by the size of the Junk Slot Area (JSA) The greater
the JSA, the more efficient the bit is at evacuating cutters, particularly
in fast drilling environments. Also a greater JSA may help prevent bit
balling. Computational Fluid Dynamics, (CFD) Analysis shows
however that a greater JSA may result in re-circulation of flow and
only part of the JSA being used to evacuate cuttings. Hydraulic
optimization focuses on maximizing the usable JSA. SeeFig. 6.11
Open Face Volume. Volume of empty space between blades, the face
of the bit, measured up to the beginning of the gauge pad. High Open
Face volume is desirable for fast drilling in soft and sticky formations.

6.1.1.1 PDC Hydraulic Issues

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 Nozzles
Hydraulic design of the bit is a critical component to increase
the probability of success when it comes to bit performance.
The hydraulics design group in Houston use Computational
Fluid Dynamics Software to optimize the hydraulics of the bit.
These are the parameters considered:
Number of nozzles
Location of the nozzles.
Orientation of the nozzles. See Fig. 6.12

Fig. 6.11 CFD Analysis to determine usable JSA. Picture shows JSA (junk slot area) for a
particular slot. Yellow color indicates higher velocity, blue (darker) is lower. Note how part
of the JSA is used to evacuate cuttings.

Fig. 6.12 CFD Analysis to Improve Cutting Structure Cleaning. A CFD (Computational Fluid
Dynamics) software aids in determining the orientation of nozzles according to the design of
the bit body. This diagram shows high velocity vectors in red and low velocity vectors in
darker blue.

6.1.1.2 Factors Determining PDC Cutting Structure Cleaning

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 Blade Geometry:
The blade helix angle has an impact on how good the fluid is
able to clean the face of the PDC cutters. See Fig. 6.13
Blade Height

Fig. 6.13 Cutting Structure Cleaning - Effect of Blade Helix. Reducing cutter/blade helix
angle helps keep fluid attached to cutter faces.

Cutting Structure Layout. Adding side rake to cutters helps fluid stay
attached. See Fig. 6.14

Fig. 6.14 Cutting Structure Cleaning - Effect of Side Rake Angle. In this CFD analysis, lighter
colors indicate higher fluid energy, note how the bit with lower helix and higher side rake
results in higher fluid energy at the cutters.

6.1.1.2 Factors Determining PDC Cutting Structure Cleaning

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When performing Hydraulic design optimization, design engineers will focus
on:
Minimizing re-circulation zones
Good flow going up and away from the face of the bit
No Back-flow
High and Low Energy Zones.

6.1.1.3 Nozzles

In bit hydraulics, the total area of the nozzles that would allow the
flow of drilling fluid at the bit is commonly known as Total Fluid Area
or TFA.
TFA is not fixed on a bit PDC bit with exchangeable nozzles, hydraulic
software packages are used for determination of the optimal TFA or
nozzle sizes for a given flow, drilling fluid and drillstring
configurations, from the point of view of Smith Bits, such optimization
of TFA should allow the ROP of the bit to be maximized. More details
on this will be studied in 6.2 Hydraulic Optimization.
The size of nozzles is commonly defined in 1/32nds of an inch.
Different values of TFA can be accomplished by combining nozzle
sizes. See Fig. 6.15. These are some guidelines to select proper nozzle
sizes:
PDC bits should be nozzle with one nozzle size, when possible.
Circumstance may dictate different nozzle sizes are required.
Always ensure that the maximum nozzle size difference
corresponds to the Allowable Nozzle Size Combinations table.
Failure to do so will nearly always result in reduced ROP and/or
bit balling. See Fig. 6.16
Place the largest diameter nozzles in the center of the bit. For
example if bit has 5 nozzles, 3x13/32" and 2x12/32", the 13/32"
nozzles should be installed in the center of the bit.

Fig. 6.15 Total Flow Area (TFA) of Standard Nozzles (in2)

6.1.1.2 Factors Determining PDC Cutting Structure Cleaning

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Fig. 6.16 PDC Allowable Nozzle Size Combinations

Nozzle functions:
Nozzles provide hydraulic energy to both the hole bottom and the
cutting structure.
Highest energy is along hole bottom. SeeFig. 6.17
The further the nozzle is moved away from the hole bottom, the less
hydraulic energy transferred to hole bottom.

Fig. 6.17 Flow Pathlines in the JSA.. A Computational Fluid Dynamics software shows the
flow path lines and the velocity contours at the face of the cutters. (blue is slow, red is fast)

Number of Nozzles
In order to understand the effect of the number of nozzles on the cleaning of
the bit, an experiment with a constant Total Fluid Area (TFA) was conducted,
in this experiment fluid properties and flow were also kept constant.

6.1.1.3 Nozzles
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Note that Jet velocity is a function of Flow Rate and TFA, and is the same for
all the nozzles installed on a bit regardless of their size, what varies is the
amount of flow that will pass through each nozzle; if different nozzle sizes
are installed, the bigger nozzle sizes will "see" more flow. Jet velocity =
0.32Q/TFA, where Q is the flow in gpm.

The results (See Fig. 6.18) showed that:

Less number of nozzles (bigger area per nozzle, to keep a fixed TFA):
Increase the individual nozzle energy, more flow per nozzle
Improve cleaning in the proximity of the nozzle
Could result in local erosion in the proximity of the nozzle
Less likely to plug

Fig. 6.18 Nozzle Power and Nozzle Quantity

More Nozzles (smaller area per nozzle, to keep a fixed TFA):

Reduces nozzle energy, less flow per nozzle.
Can reduce cleaning in the proximity of the nozzle
Can reduce erosion in the proximity of the nozzle
More prone to being plugged
Nozzle Diameter for a given jet velocity (TFA), then represents the ability to
deliver energy to the bottom of the hole. See Fig. 6.19. And nozzle exit
velocity or jet velocity: Ability to clean and/or erode the bit.

H Feature Guidelines:

6.1.1.3 Nozzles
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Fig. 6.19 Nozzle Size and Hole Bottom Energy. Jet Velocity remained constant in the 3
examples at 214ft/s. 8x11/32" vs. 5x14/32" vs. 3 x 18/32", note how the bigger nozzles deliver
more energy to the bottom of the hole.

H feature indicates higher number of nozzles than the base bit design.
Bit Sizes greater than 12 1/4" will usually benefit from H option (higher
nozzles count than standard), to clean the outer region of the bit.
12 1/4" Bits may or may not benefit from H-option. See Fig. 6.20.
Bit Sizes less than 12 1/4" generally look better with standard option
compared to H option; however if blades have helix, then H option
may be required. See Fig. 6.21
For high blade count, possible pinch point prevents the energy of the
flow to reach the outer cutters, in this case H options is necessary. See
Fig. 6.22

Fig. 6.20 12 1/4" Bit - Example Cutter Face Velocity "H" vs. Standard

6.1.1.3 Nozzles
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Fig. 6.21 H feature and blade Helix. For blades with helix, H feature may be required,
however if no helix, standard configuration is better.

Fig. 6.22 Example H Option to Improve Cleaning. Note how the addition of a nozzle in the
junk slot pass the pinch point (picture at the right) results in better cutter cleaning in the
outer part of the blade.

N Feature Guidelines:
N feature indicates less number of nozzles than the base bit design. It should
only be used when absolutely necessary for TFA requirements, in CFD
modeling this option very rarely looks optimal for cutting structure cleaning.
See Fig. 6.23

Q Feature:

6.1.1.3 Nozzles
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Fig. 6.23 N Feature vs. Standard

In some bit designs with high blade count or small diameter, due to the
limited space between blades, is not possible to allow for nozzle ports to be
manufactured on the bit. For cases like this, bit designers use a combination
of adjustable nozzle ports and fixed ports to optimize the hydraulics of the
bit. As the name indicates those ports have a fixed size, it cannot be
changed on the field.
For Steel body bits, port size availability goes from 8/32" to 12/32"
For Matrix body bits, port size availability varies from 8/32" to 16/32"

Nozzle types
Smith offers several series of nozzles to meet space and application
requirements.
Standard Nozzles

N30 (1/32in) N40 (1/32in) N50 (1/32in) N60 (1/32in)

Orifice Size 7-13 8-13 7-15 7-22
Nomenclature Y W U -
-Feature

See Fig. 6.24

6.1.1.3 Nozzles
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 Pin Restrictor Nozzles
A Pin/Box Restrictor is a nozzle installed in the pin to use
hydraulic energy when high back pressures are required for
upstream BHA equipment. See Fig. 6.25
Allows larger nozzles to be installed in bit face reducing nozzle
exit velocities.
Reduces body erosion and potentially increases bit life.
Currently available for 4 1/2" and 6 5/8" API Pin/Box
connections.

Fig. 6.24 Standard Nozzles for PDC bits

Fig. 6.25 Example Pin/Box Restrictor Nozzles

Location and Orientation of the nozzles

This topic will be discussed in the next chapter: Hydraulic Configurations.

6.1.1.3 Nozzles
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6.1.1.4 Hydraulic Configurations
Standard Hydraulic Configuration (Hydraulics Standard or HS)

Application:
Designed for applications where neither balling nor erosion is a major
concern.
Characteristics:
Nozzles exit at bit body surface.
Nozzles directed primarily down the junk slot with a slight tilt towards
the cutters.
Attempt to keep fluid in designated junk slot(s).
Strive to prevent reverse flow in junk slots
Aggressive Hydraulic Characteristics (Hydraulics Anti-Balling or
HAB)

Application:
Designed for softer formations that are prone to balling.
In many applications, increases ROP. Even when balling formations
are not apparent.
Characteristics:
Nozzles exit point level with bit body.
Nozzles tilted more towards the cutters to increase energy levels.
More fluid moves across the blade tops.
Can accelerate bit body erosion in high flow applications with hard
particles. Generally not a problem when using GM44.
See Fig. 6.26 for a comparison of Standard vs. Aggressive Hydraulic
configuration. See also Fig. 6.27

Passive Hydraulic Configuration (Hydraulics Anti-Erosion or HAE)

Application:
Designed for applications where bit body erosion limits the length of a
run or the number of rebuilds.
Characteristics:
Using a better body material is easiest change.
Objective is to reduce the energy levels on the blades, therefore
reducing erosion. See Fig. 6.28
Nozzles are recessed below bit body up to 2". See Fig. 6.29.
Nozzles directed down, middle of junk slot.
Nozzles moved back from cutter surfaces.
A more erosion resistant matrix can be selected for the body.
May be more prone to balling in balling prone intervals.

6.1.1.4 Hydraulic Configurations

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Fig. 6.26 Aggressive vs. Standard Hydraulic Configuration - PDC bits. Aggressive hydraulic
layouts direct more energy towards the cutters to increase energy levels on the cutters and
the blades.

Fig. 6.27 CFD for Aggressive vs Standard Hydraulic Configuration

6.1.1.4 Hydraulic Configurations

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Fig. 6.28 Example Velocity Scatter Plot before and after Passive Hydraulics. Approx. 65%
reduction in velocity peaks at area of most extreme erosion. Very few peaks above 60 ft/s

Fig. 6.29 Example Passive Hydraulic Configuration (HAE)

6.1.1.4 Hydraulic Configurations

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6.1.1.5 SPEAR Bits
Spear is the PDC product line from Smith Bits for unconventional shale
plays; it has achieved rapid recognition and approval after field deployment,
it has defined a new level of performance in the shale play applications. The
design goal was to deliver improved ROP, durability and steerability. Main
characteristics (see Fig. 6.30) as follows:
Enhanced bit body bullet profile in order to maximize Open Face
Volume (OFV) and improve the evacuation of cuttings. See Fig. 6.31.
New enhanced bullet-shaped bit body improves cuttings
evacuation for higher ROP
Higher angled bit body slope allows cuttings to more readily
flush away from the cutters and into the junk slots
Open face volume improves management of high cuttings
volume to enhance their removal
Reduced risk of cuttings pack-off between and around blades

Fig. 6.30 Main Spear Design Characteristics

Fig. 6.31 Bit Body Bullet Profile

6.1.1.5 SPEAR Bits

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 Thinner blades to maximize Junk Slot Area (JSA)
CFD analysis and optimization
Flow modeling is critical given the poor hydraulic environment
Spear bits are run in
Improving cutter face velocity cleans cutters more efficiently
Optimized hydraulic configuration delivers up to 30%
improvement in cutter face velocity
Maintaining clean cutters helps prolong cutter life and increases
ROP for improved bit performance
Shale evacuation channel to prevent bit balling. See Fig. 6.32
Designed into the body to eliminate plugging
Delivers improved fluid flow pathway
Fluid is unobstructed and flows more efficiently from
nozzle exit to annulus
Combined with enhanced bullet profile, aids in the
removal of cuttings

Fig. 6.32 Shale Evacuation Channel

Provides significant benefit in low/poor hydraulic conditions at

the bit
Cutting structures designed using IDEAS simulator (See 1.1 What is
IDEAS?, in Drill Bit Performance Indicator 3: Stability) to meet
customer requirements
See Fig. 6.33 for an example of Spear bit development.

Fig. 6.33 Example Spear Bit Development. Evolution of Bit application in the Haynesville
Shale Application

6.1.1.5 SPEAR Bits

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6.1.1.6 Anti-Balling Coating (ABC)
Smith Bits developed a coating to be applied to the surface of matrix body
PDC bits with the objective of preventing bit balling. See Fig. 6.34. This bit
feature is available as ABC or Anti-Balling Coating. These are the properties
of it:
Low roughness (low contact area, low friction, minimize sticking
tendencies)
Seal any porosity in the matrix
Highly durable (significantly higher erosion resistance than the binder
alloy)
High toughness (avoid cracking)
Significant thickness (for durability)

Fig. 6.34 PDC Bit with Anti-Balling Coating

How it works:
The coating is applied to the matrix in an electro-chemical process
(bath).
The thickness is in the region 0.5 - 0.7 mm (thicker layers may be
applied).
Significantly higher erosion resistance than the binder alloy.
Low friction surface (smooth), minimizing the tendencies of clays /
shales to stick.
The materials used in the coating ensure that a positive charge can
not build up on the surface of the coating (reduces sticking
tendencies).
This technology is successful in drilling interval with potential for bit balling.
In an application India, 17.5" MDI619LHBPX-O managed to improve ROP by
44% and save a trip, when comparing with 2 runs with 17.5" HCD606ZX from
Hughes. See Fig. 6.35. Notice how in the section prone to bit balling the bit
with Anti Balling Coating is drilling faster with lower WOB, see Fig. 6.36

6.1.1.6 Anti-Balling Coating (ABC)

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Fig. 6.35 Example successful application of ABC

Fig. 6.36 Successful application of ABC.

6.1.2 Roller Cone Hydraulics

Objective of this section is to learn to determine the appropriate Roller Cone
Hydraulics configuration depending on the lithology and compressive
strength of formations being drilled.

Bit Hydraulic performance depends on the following factors:

6.1.1.6 Anti-Balling Coating (ABC)

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 Nozzle Type Selection
Nozzle Arrangement according to the needs:
Formations Hard vs Soft
Reactive vs Non-Reactive Formations(shales and clay that react
with water and become sticky, potentially balling up the bit)
Deep vs Shallow (Amount of Overbalance pressure)
For roller cone bits, there are 3 main hydraulic functions that help address
the needs: (SeeFig. 6.37):

Fig. 6.37 Main Hydraulic Functions for Roller Cone Bits

1. Cutting Structure Cleaning and Cooling

2. Bottom Hole Cleaning
3. Cutting Evacuation
The dominant function should be chosen depending on the needs. See Fig.
6.38.

Fig. 6.38 Hydraulic Function vs. Formation

6.1.2 Roller Cone Hydraulics

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6.1.2.1 Roller Cone Nozzle Types

Smith has one of the largest selections of nozzle types in the industry
to optimize bit hydraulics
Nozzle types and sizes used in the bit are determined in the field.
Sales and Product Engineers can have a significant impact on product
performance by understanding applications needs and selecting
appropriate hydraulics.
Smith Bits threaded nozzle retention system is one of the most secure
systems (vs snap ring) retention systems in the industry. This allows
for the use of mini-extended nozzles. Note that Smith Value roller
cone products actually use snap ring nozzle retention system.
See Fig. 6.39 for a list of the different nozzle series and their type:
Standard, Diverging, or Mini Extended.
Standard Nozzles. Nozzles are manufactured with a converging
section to help direct the flow. The size of the nozzle should be
determined by measuring with a nozzle gauge on the opposite side of
the converging section. See Fig. 6.40. The following are standard
nozzles: 55, 65, 70, 75, 95 and 100 series.
70 series is standard for Xplorer
95 is the standard for bit sizes 077-122
100 is the standard series for sizes greater than 122

Fig. 6.39 Roller Cone Nozzle Types. Series 65 and series 99 are obsolete. Series 70's are
commonly used for center jets. Series 74 is a modifed nozzle with stronger body, less likely
to break than series 72.

6.1.2.1 Roller Cone Nozzle Types

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Fig. 6.40 Standard Nozzle and Nozzle Gauge. The nozzle gauge should be used in the
opposite side of the Converging Section to determine the size of the nozzle.

Diverging nozzles (Also known as Difussers). These nozzles are

installed in the center of the bit, they efficiently clean the cutting
structure in high cuttings volume and/or sticky formations. These
nozzles feature a slanted section where the velocity of the fluid is
reduced in order to minimize cone erosion and fluid wash. See Fig.
6.41. Note that the size of these nozzles is usually referred to in terms
of the Diverging Nozzle Diameter (see Fig. 6.41), this diameter cannot
be measured with a nozzle gauge. For hydraulic calculations, the
correspondent equivalent nozzle size for the specific Diverging Nozzle
Diameter needs to be calculated, see Fig. 6.42. However it is possible
to determine the exiting diameter of a diverging nozzle with a nozzle
gauge; in this case the diameter measured should be used as if it were
a Standard Nozzle for hydraulic calculations. e.g. If by measuring a
diverging nozzle is determined that the size is 14/32", this number
should be used for hydraulics calculations as a 14/32" standard nozzle.

Mini Extended Nozzles. These nozzles increase the impingement

pressure, they have a long straight section that helps streamline the
fluid while moving the nozzle exit closer to the bottom of the hole or
to the cutting structure of the bit in the case of V-flow.
For a comparison of mini extended nozzles vs. standard nozzles see
Fig. 6.43.
97 is a mini extended 1" for bit sizes 077-122
98 is a mini extended 1.5" for bit sizes 077-122
99 is a super extended, now obsolete.
72 older style mini
74 looks like a bullet, it can be used some times as center jet.
105 is mini extended for sizes greater than 122

For a list of nozzle series and bit sizes please see Fig. 6.44
For a list of nozzle size availability for each nozzle series see Fig. 6.45

6.1.2.1 Roller Cone Nozzle Types

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Fig. 6.41 Example Center Jet Diffusser. The diverging section of the nozzle will result in
lower fluid velocity, therefore reducing the risk of erosion to the cutting structure.

Fig. 6.42 Determine the size of Diverging Nozzles for Hydraulic Calculations

6.1.2.1 Roller Cone Nozzle Types

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Fig. 6.43 Mini Extended vs. Standard Nozzle

Fig. 6.44 Roller Cone Nozzle Series and Bit Sizes

Fig. 6.45 Nozzles Size Availability Chart (Roller Cone Bits)

6.1.2.2 Cutting Structure Cleaning and Cooling

The main objectives of this type of function are:
Prevent bit balling Fig. 6.46
Prolong cutting structure life through cooling and cleaning
Maximize ROP

6.1.2.1 Roller Cone Nozzle Types

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Fig. 6.46 Example of bit balling

6.1.2.3 Bottom Hole Cleaning

The objectives of this hydraulic function are:
Prevent cuttings regrind
Prolong cutting structure life
Maximize ROP
Regrinding of cuttings may happen due to the cutting mechanism of insert
bits. See Fig. 6.47.

Fig. 6.47 Footprint of an Insert Fracturing the Rock

Impigement Pressure
Is an easy way to measure the degree of hydraulic energy reaching
the bottom of the hole
It is the "true" impact force of the fluid in the formation.
Higher values indicate increased ability to clean the hole bottom.
Extended nozzles help bring higher impact forces to the bottom of the hole,
see Fig. 6.48 for a comparison with Standard and Difusser nozzles.

6.1.2.2 Cutting Structure Cleaning and Cooling

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Fig. 6.48 Roller Cone Nozzle Types

Mini-extended nozzles offer dramatic increases in Impingement Pressure for

the same H.S.I. as compared to non-extended (standard) nozzles or diffuser
nozzles since the radial fluid movement caused by the converging section is
dissipated in the straight length portion and the nozzle exit is moved closer
to the hole bottom, See Fig. 6.49

Fig. 6.49 Mini extended Nozzles and Impingement Pressure. Higher fluid velocity in red.
Higher velocity reaching the bottom of the hole results in higher pressure acting on it.

6.1.2.4 Cuttings Evacuation

The main objectives of this hydraulic function are:
Preventing cuttings re-drill
Improve ROP
Extends seal life
Prevents balling
Reduces erosion of the cones

6.1.2.3 Bottom Hole Cleaning

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6.1.2.5 FlexFlo Hydraulics
FlexFlo is a guideline in Smith Bits for the selection of nozzles types and
nozzle configurations to be installed on the bit. See Fig. 6.50 for the
configurations available depending on the bit size. See

Fig. 6.50 Flex Flo Hydraulics Configuration

Fig. 6.51 for examples of S-Flo, V-Flo and Typhoon.

Fig. 6.51 Examples Flex Flo Hydraulic Configuration

S-Flo. See Fig. 6.52

Directs the fluid between the cones and impacts the hole bottom in
the corner of the bore hole.
Used to maximize energy on the hole bottom
Used to minimize energy on the cone shell

6.1.2.5 FlexFlo Hydraulics

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 S-Flo X-Flo - Type II X-Flo - Type III
3 symmetrical nozzles with same 1 blank nozzle to promote cross Different nozzle sizes and/or
extension flow extensions to promote mild cross
flow action.

Fig. 6.52 S-Flo. Higher velocity vectors in red.

V-Flo. See Fig. 6.53

A roller cone bit manufactured with jets that direct the fluid towards
the cuttings structure for improved cone cleaning. The flow is directed
to the leading side of the following bit cone. See Fig. 6.53
Energy on the hole bottom is reduced
Energy on the cone shell in increased.
Nozzle blanks are not recommended.
Creates a helical flow field around the bit that improves cuttings
removal and reduces regrinding of cuttings. See Fig. 6.54

Fig. 6.53 V-Flo

6.1.2.5 FlexFlo Hydraulics

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Fig. 6.54 V-Flow Bottom Hole Pattern

Thypoon. See Fig. 6.55

16" to 28" bits have problems concerning cutting removal and cone
cleaning:
Poor distribution of hydraulic energy around cones and bore
hole
Limited energy on the hole bottom.

Fig. 6.55 Thypoon Hydraulics

Typhoon Hydraulics are optimized by using CFD Analysis to:

Optimize Cutting Structure Cleaning
Improve Cutting Evacuation
Enhance Bottom Hole Cleaning
Vectored Extended Nozzles (VE)
Direct fluid to outer area of cone

6.1.2.5 FlexFlo Hydraulics

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 Nozzle is oriented at gauge/drive row where highest cutting
generation occurs
VE Extension increases energy on the hole bottom
Flow is closer to the hole bottom and cutting structure
Provide increased flexibility for vectoring hydraulics
VE tubes have been designed for both performance and reliability.
When compared to standard hydraulic configurations, VE tubes move
the nozzle exit 2 to 4 inches closer to the hole bottom. By using a 105
series mini-extended nozzle, the nozzle exit can be moved an
additional 1.75 inches closer making nozzles exits up to about 6 inches
closer to the hole bottom. As can be seen in Fig. 6.56, the velocity
contour plots show how the high energy core is moved closer to the
bottom of the hole which increases bottom hole impingement
pressures up to 50%. This equates to better bottom hole energy and in
many applications to better penetration rates.
J3 Typhoon Hydraulics
Fluid passes through intermesh without directly impacting the
cone surface
Minimizes cone shell erosion
Improves distribution of hydraulic energy for cones and hole
bottom
Without center jet, J3 jets cleans mainly the middle rows of the
leading cone and to some extent the trailing cone. See Fig. 6.57

When a center jet is installed, cleaning is mainly aimed at the

cone tip area. See Fig. 6.58

Fig. 6.56 VE configuration and Velocity Profiles. Vector Extended nozzles move the nozzle
exit closer to the hole bottom when compared to standard VFlo bits.

6.1.2.5 FlexFlo Hydraulics

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Fig. 6.57 J3 Typhoon Hydraulics Without Center Jet

Fig. 6.58 J3 Typhoon Hydraulics With Center Jet

6.1.2.6 Hydraulics Needs vs. Formation - Zone 1

See Fig. 6.59. Characteristics:
Soft/sticky formations
Gumbo, loose sands
Aggressive bits
Steel body with low number of blades
Very large cuttings volumes
Weak hole-wall
Needs:

6.1.2.5 FlexFlo Hydraulics

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 Clean entire cutting structure
Evacuate cuttings quickly

Fig. 6.59 Hydraulic Function vs. Formation

Risks of not addressing the needs:

Low ROP
Balling
Poor dull:
Cutting structure
Bearing condition
Recommended configurations

Configuration Upside Downside

V-Flo with diverging center jet, None
maximized flow rate and TFA with Maximum cone cleaning
H.S.I.>4.0 using series 95 nozzles power dissipated directly on
the cutting structure.

Minimum hole washout for

flow/H.S.I combination.

Efficient cuttings removal

into the annulus.

S-Flo with diverging center jet,

maximized flow rate and TFA with Cones are cleaned by center Hole-wall erosion from high
H.S.I. >4.0 using series 95 nozzles jet and wide series 95 jet H.S.I. and wide series 95
flow fluid jet
Cuttings are aided into Less efficient cone cleaning
annulus by Flex-Flo forging

6.1.2.6 Hydraulics Needs vs. Formation - Zone 1

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 Configuration Upside Downside
X-Flo with diverging center jet, high
flow rate and TFA with H.S.I. >4.0 Cones are cleaned by center Significantly less efficient
using series 97 nozzles jet and high hole bottom cone cleaning
shear velocities Extend nozzles prone to
Cuttings are aided into the balling in very sticky
annulus by Flex-Flo forging formations

6.1.2.7 Hydraulics Needs vs. Formation - Zone 2

See figure Fig. 6.59.
Characteristics:
Low strength formations
Claystones, mudstones & sands
Moderately aggressive bits
Large cuttings volumes
Occasional stringers
Needs:
Clean gage/drive area
Evacuate cuttings quickly
Hole Bottom Cleaning becoming important
Risks of not addressing the needs:
Low ROP
Poor dull
Cutting structure
Bearing condition
Recommended configurations

Configuration Upside Downside

V-Flo with 3 series 97 nozzles with None
maximum flow rate and TFA Maximum cone cleaning
adjusted to give2.5<H.S.I.<3.5 power dissipated directly on
the gage and
adjacent-to-gage
Minimal hole washout for
flow/H.S.I combination.

Efficient cuttings removal

into the annulus.

V-Flo with 3 series 95 nozzles with

maximum flow rate and TFA Much of the flow is directed Less efficient cone cleaning
adjusted to give 2.5<H.S.I.<3.5 to the desired area
Efficient cuttings removal
into the annulus

6.1.2.6 Hydraulics Needs vs. Formation - Zone 1

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 Configuration Upside Downside
X-Flo with high flow rate and TFA
adjusted to give 2.5<H.S.I.<4.0 using Cones are cleaned by high Significantly less efficient
series 97 nozzles hole bottom shear velocities cone cleaning
Extend nozzles prone to
Cuttings are aided into the balling in very sticky
annulus by Flex-Flo forging formations
Significant cone-shell
Can lift cuttings from erosion mud not cleaned at
hole-bottom if harder surface
formations are encountered

6.1.2.8 Hydraulics Needs vs. Formation - Zone 3

See Fig. 6.59
Characteristics:
Firm/hard formations
Developed shales, limestones, dolomites, sandstones
Low offset, flatter profile bits
Moderate cuttings volumes
Higher drilling fluid solids
Needs:
Bottom hole cleaning
Risks of not addressing the needs:
Low ROP
Poor dull
Cutting structure
Bearing condition
Increased drill solids
Recommended configurations

Configuration Upside Downside

X-Flo using 2 different series 98 None
nozzles and a blank. Flow rate and Optimal bottom-hole
TFA adjusted to give 3.0 <H.S.I.< cleaning
5.0 Minimal cone-shell erosion
for flow/H.S.I combination.

Good cuttings evacuation

X-Flo with 3 different nozzle lengths

and diameters with maximum flow Flow is presented in front of Lower local hydraulic shear
rate and TFA adjusted to give 2.5<H. all 3 cones stresses
S.I.<3.5 Moderate bottom-hole Less efficient cuttings
hydraulic shear stresses evacuation

Stagnation zones displaced

way from cones and center

6.1.2.7 Hydraulics Needs vs. Formation - Zone 2

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 Configuration Upside Downside
X-Flo using 2 different series 95
nozzles and a blank. Flow rate and Strong fluid cross-flow Much lower hydraulic shear
TFA adjusted to give 3.0 <H.S.I.< stress on the hole-bottom
5.0 Reasonable cuttings
evacuation Wider stagnation zones
Less splash-back

6.1.2.9 Hydraulics Needs vs. Formation - Zone 4

See Fig. 6.59
Characteristics:
Very hard and abrasive formations
Quartzitic sandstones, basalt, granite
Low/non offset bits with flat profiles
High blade counts, impregs
Very low cuttings volumes
Needs:
Bottom hole cleaning
Removal of cuttings
Risks of not addressing the needs:
Low ROP
Durability issues
Poor dull
Cutting structure
Bearing condition
Shirt-tail and leg-back damage
Erosion
Recommended configurations

Configuration Upside Downside

Modified X-Flo using 3 different None
series 97 nozzles. Flow rate and Optimal bottom-hole
TFA adjusted to give 2.0 <H.S.I.< cleaning
3.0 Minimal cone-shell erosion

Good cuttings evacuation

Minimal leg-back erosion

Modified X-Flo with 3 different

nozzle lengths and diameters with Good bottom-hole cleaning Series 98 may cause some
maximum flow rate and TFA cone-shell erosion
adjusted to give 2.0<H.S.I.<3.0 Good cuttings evacuation Series 95 is less effective at
bottom-hole cleaning
Low leg-back erosion

6.1.2.8 Hydraulics Needs vs. Formation - Zone 3

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 Configuration Upside Downside
Modified X-Flo using 3 different
series 95 nozzles. Flow rate and Reasonable bottom-hole Risks poor bottom-hole
TFA adjusted to give 2.0 <H.S.I.< cleaning cleaning
3.0 Good cuttings evacuation Wider stagnation zones may
cause cone-shell erosion
Less splash-back

6.1.2.10 Hydraulic Configurations - Quick Guide

Zone 1: Cutting Structure Cleaning > Cuttings Evacuation

Configuration Upside Downside

V-Flo with diverging center jet, None
maximized flow rate and TFA with Maximum cone cleaning
H.S.I.>4.0 using series 95 nozzles power dissipated directly on
the cutting structure.

Minimum hole washout for

flow/H.S.I combination.

Efficient cuttings removal

into the annulus.

S-Flo with diverging center jet,

maximized flow rate and TFA with Cones are cleaned by center Hole-wall erosion from high
H.S.I. >4.0 using series 95 nozzles jet and wide series 95 jet H.S.I. and wide series 95
flow fluid jet
Cuttings are aided into Less efficient cone cleaning
annulus by Flex-Flo forging

X-Flo with diverging center jet, high

flow rate and TFA with H.S.I. >4.0 Cones are cleaned by center Significantly less efficient
using series 97 nozzles jet and high hole bottom cone cleaning
shear velocities Extend nozzles prone to
Cuttings are aided into the balling in very sticky
annulus by Flex-Flo forging formations

Zone 2: Bottom Hole Cleaning > Cutting Structure Cleaning > Cuttings
Evacuation

Configuration Upside Downside

V-Flo with 3 series 97 nozzles with None
maximum flow rate and TFA Maximum cone cleaning
adjusted to give2.5<H.S.I.<3.5 power dissipated directly on
the gage and
adjacent-to-gage
Minimal hole washout for
flow/H.S.I combination.

Efficient cuttings removal

into the annulus.

6.1.2.9 Hydraulics Needs vs. Formation - Zone 4

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 Configuration Upside Downside
V-Flo with 3 series 95 nozzles with
maximum flow rate and TFA Much of the flow is directed Less efficient cone cleaning
adjusted to give 2.5<H.S.I.<3.5 to the desired area
Efficient cuttings removal
into the annulus

X-Flo with high flow rate and TFA

adjusted to give 2.5<H.S.I.<4.0 using Cones are cleaned by high Significantly less efficient
series 97 nozzles hole bottom shear velocities cone cleaning
Extend nozzles prone to
Cuttings are aided into the balling in very sticky
annulus by Flex-Flo forging formations
Significant cone-shell
Can lift cuttings from erosion mud not cleaned at
hole-bottom if harder surface
formations are encountered

Zone 3. Bottom Hole Cleaning > Cuttings Evacuation

Configuration Upside Downside

X-Flo using 2 different series 98 None
nozzles and a blank. Flow rate and Optimal bottom-hole
TFA adjusted to give 3.0 <H.S.I.< cleaning
5.0 Minimal cone-shell erosion
for flow/H.S.I combination.

Good cuttings evacuation

X-Flo with 3 different nozzle lengths

and diameters with maximum flow Flow is presented in front of Lower local hydraulic shear
rate and TFA adjusted to give 2.5<H. all 3 cones stresses
S.I.<3.5 Moderate bottom-hole Less efficient cuttings
hydraulic shear stresses evacuation

Stagnation zones displaced

way from cones and center

X-Flo using 2 different series 95

nozzles and a blank. Flow rate and Strong fluid cross-flow Much lower hydraulic shear
TFA adjusted to give 3.0 <H.S.I.< stress on the hole-bottom
5.0 Reasonable cuttings
evacuation Wider stagnation zones
Less splash-back

Zone 4. Bottom Hole Cleaning ~ Cuttings Evacuation

Configuration Upside Downside

Modified X-Flo using 3 different None
series 97 nozzles. Flow rate and Optimal bottom-hole
TFA adjusted to give 2.0 <H.S.I.< cleaning
3.0 Minimal cone-shell erosion

Good cuttings evacuation

Minimal leg-back erosion

6.1.2.10 Hydraulic Configurations - Quick Guide

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 Configuration Upside Downside
Modified X-Flo with 3 different
nozzle lengths and diameters with Good bottom-hole cleaning Series 98 may cause some
maximum flow rate and TFA cone-shell erosion
adjusted to give 2.0<H.S.I.<3.0 Good cuttings evacuation Series 95 is less effective at
bottom-hole cleaning
Low leg-back erosion

Modified X-Flo using 3 different

series 95 nozzles. Flow rate and Reasonable bottom-hole Risks poor bottom-hole
TFA adjusted to give 2.0 <H.S.I.< cleaning cleaning
3.0 Good cuttings evacuation Wider stagnation zones may
cause cone-shell erosion
Less splash-back

6.1.2.10 Hydraulic Configurations - Quick Guide

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