Secoroc Rock Drilling Tools

ROTARY
Safety, Maintenance & Troubleshooting

Safety, Maintenance & Troubleshooting

This booklet is designed to help you handle your Secoroc rock drilling tools.
Please pay special attention to the safety instructions titled Danger,
Warning and Caution and thereby ensure a safe working environment.
The maintenance section covers routines for the maintenance of Rotary
equipment.
In the cases where premature faults in Secoroc equipment can occur, we have
created a special troubleshooting system. The main fault causes are classified
using individual codes. Each code describes probable causes of the fault as well
as relevant remedies. This enables you to rectify the fault quickly and
efficiently.
By then reporting these failures to Atlas Copco Secoroc, you enable us to improve
product reliability.

Contents
SAFETY - Safety instructions

6-13

GUIDES FOR BEST TRICONE BIT PERFORMANCE

14-19

MAINTENANCE Best practices for tricone bit maintenance

20-21

TROUBLESHOOTING
How to grade dull bits

22-25

Tricone bits

26-59

Cones

2835

Teeth

3645

Lugs & Shirttails

46-51

Threads

52-53

General

54-59

Drill Pipes

60-77

Drill pipe body

62-65

Drill pipe pin thread connections

66-69

Tools joints & Shoulders

70-73

Threads

74-77

Safety

To reduce risk of serious or mortal injury to yourself or

others, read these safety instructions before using rock
drilling tools.
Post these safety instructions at the work place, provide copies
for employees and make sure that everyone reads
the safety instructions before using rock drilling tools.
Comply with all safety regulations.

Symbols
The indications DANGER, WARNING and CAUTION have the following meanings:

DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in
serious or mortal injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
serious or mortal injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.

Safety instructions

Silica/dust hazard
WARNING
Exposure to crystalline silica (sometimes called silica dust) as a result
of rock drilling may cause silicosis (a serious lung disease), silicosis related
illnesses, cancer, or death. Silica is a major component of rock, sand, and
mineral ores. To reduce silica exposure:
Use proper engineering controls to reduce the amount of silica in the
air and the build-up of dust on equipment and surfaces. Examples of such
controls include: exhaust ventilation and dust collection systems, water
sprays, and wet drilling. Make sure that controls are properly installed and
maintained;
Wear, maintain, and correctly use approved particulate respirators when
engineering controls alone are not adequate to reduce exposure below
permissible levels;
Participate in air monitoring, medical exams, and training programs
offered by your employer and when required by law;
Wear washable or disposable protective clothes at the worksite; shower
and change into clean clothes before leaving the worksite to reduce exposure of silica to yourself, other persons, cars, homes, and other areas;
Work with your employer to reduce silica exposure at your worksite.

WARNING
Some dusts, vapors, or mists created during rock drilling may contain materials or chemicals known to the state of California to cause cancer and birth
defects or other reproductive harm.

Safety

Noise hazard
WARNING
High sound levels may cause permanent hearing loss. Use hearing
protection in accordance with occupational health and safety regulations.

Projectile hazard
WARNING
During rock drilling, splinters or other particles of rock may become projectiles and cause bodily injury by striking the drilling operator or other persons.
Use approved personal protective equipment, including impact resistant eye
protection, to reduce the risk of being injured by a projectile.

Rock drilling tools modification hazard

WARNING
Rock drilling tools must not be modified. Modification may result in bodily
injuries to yourself or others.

Electrical hazard
DANGER
Drilling rigs are not electrically insulated. If a drill rig comes into
contact with electricity, it may result in serious or mortal injuries. To reduce
the risk of such injury or death, never drill near any overhead electric wires or
other sources of electricity. Make sure that there are no concealed wires or
other sources of electricity.

Safety instructions

Explosion hazard
DANGER
If a rock drilling tool comes into contact with an explosive, an explosion
may occur. Explosions may cause serious or mortal injuries. To reduce such
risk of explosion, never drill near any explosive in the rock. Make sure that
there are no explosives in the rock. Never drill in an old loaded hole. Avoid
unexploded holes.

Operating hazards
WARNING
Avoid coming in contact with operating tools. Rock drilling tools in operation
move with significant force. If you come in contact with an operating tool,
you may be seriously injured.

WARNING
Never grab or touch an operating tool. There is a risk of getting dragged into
or caught by an operating rock drilling tool, which may cause serious injury.
Avoid loose clothing and other items that may get caught. If you have long
hair, restrain it by some mine approved method.

CAUTION
Rock drilling tools may become hot during operation, and remain hot for a
period of time even after drilling has stopped. To avoid burns or other injuries,
avoid direct skin contact with hot drilling tools.

Safety

DANGER
Compressed-air hoses between an off rig air compressor and the
drill rig must be secured by means of an approved whip check, which
must be fastened in a mine approved manner to the drill rig.
Always check that hoses, hose nipples and hose clamps are not
damaged, and that they are properly tightened and secured.

CAUTION
Always check the condition of drill string components. Bent or worn pipes
can cause damage and excessive wear to other drilling components and
the rig.

DANGER
The rig must be set-up correctly in order to give stability and safety. If this is
not done, the effects of feed force and rotation torque can cause the rig to
move or even to overturn. This can incur the risk of serious or fatal injury as
well as damage to the drill rig and equipment.

WARNING

10

Heavy lifting. Take care when handling tricone bits and other drilling
tools. When lifting drilling tools use mechanical lifting equipment and/or
approved slings, and/or approved lifting bails, and/or approved lifting
eyes.

Transportation. Do not let drilling tools lie unsecured in or on a vehicle

or drill rig. Always secure drilling tools for transportation.

Safety instructions

DANGER
When drilling on soft or unstable ground, great care must be taken
because the flushing air from the hole can erode the material around
the drill hole collar, and so undermine the ground beneath the drill rig. This
can pose a great danger to personnel and risk damaging the equipment.

CAUTION
Always wear hearing protection during drilling.

WARNING
Take great care when jointing the drill pipes and handling the drill bit.
Mind your fingers!
Keep your clothing, hair etc. well clear of rotating components!

11

Safety

Safety Regulations
Note! Only qualified and trained operators should operate drilling equipment.
Always use your common sense and good judgment
Do not operate or handle any drilling equipment or tools if you are under
the influence of alcohol, drugs, or medication
Participate in safety and training courses
Never hit a rock drilling tool with a hard object
Do not use rock drilling tools for any other purpose than for drilling
Make sure that the drill pipe is properly attached to the drill
before you start to drill
Always inspect the rock drilling tool prior to use. Never use a damaged rock
drilling tool
Make sure that the rock drill is properly serviced prior to attaching
the rock drilling tool onto the rock drill

12

Safety instructions

Protective equipment
Always use approved personal protective equipment, according to local Health
and Safety regulations. We recommend that operators and other persons in the
work place wear the following protective equipment:
Protective helmet
Hearing protection
Eye protection
Respiratory protection, when appropriate
Protective gloves
Protective boots

13

Guides for best tricone bit performance

Guides for best tricone bit performance

Exercise care in making-up and breaking-out the drill bit to avoid damaging
the bit threads and drill pipe.

I.

A.

After the connection is broken, avoid down pressure on the bit breaker when unscrewing. Hoist the drill pipe high enough for the bit to
drop from the box connection into the bit breaker.

B.

Make sure the deck is clean and the bit breaker is properly mounted
in its holder.

C.

Clean the threads on the new bit and on thedrill pipe, make sure
the mating shoulders are clean and a quality anti-galling lubricant
has been applied.

D.

Stab carefully avoid excessive pressure on high angle thread flank.

Re-level the machine if the drill stem box doesnt align with bit pin.

E.

Always use low torque and slow RPM when making up connections.
Mating shoulders should smoothly make up to 1/8 with low torque.

F.

When properly made up, the bit shoulder should be in complete and
even contact with the end of the drill pipe.

When a new bit is installed, drill at reduced weight for a short break-in
period. Use the 1/3 2/3 rule: 1/3rd of normal weight and RPM for 1/3
first hole, 2/3rd of normal weight and RPM for next 1/3rd of hole. Normal
drilling parameters to finish hole.

II.

A.

After the break-in period, bit cones should be checked to be sure

that all are about the same temperature. One hot cone generally
indicates that the air passage to that particular bearing has become
obstructed. If one cone is hot the bit should be inspected before any
damage occurs.

B.

Make sure that all assembly grease is blown out of all three cutters.
When the air is turned on, air should blow out the back of each cone.

Provide adequate air to the bit to insure trouble free bearing performance
and reduced abrasion wear on cones and shirttails.

III.

14

A.

The compressed air serves two functions:

Air to the bearings, to cool and clean the bearing assembly.

Hole cleaning, to remove cuttings from blasthole.

To insure maximum bearing life, a 45 psi minimum pressure at

the bit is recommended.

B.

Hole cleaning is based on feet/minute of up hole annular velocity.

Air volume should produce a minimum of 5,000 linear feet per

minute annular return velocity for removal of light cuttings and
7,000 feet per minute for heavy material.

Low up-hole velocity causes cuttings to fall back to bottom until

they are reground small enough to be carried out of the hole.

An increase in torque, torque fluctuations, either hydraulic

pressure or amps, or an increase in air pressure, are all indications
that the hole is not being cleaned.

Some indications that the hole is not being properly cleaned are:

C.

Increase in torque indication through higher hydraulic pressure or

higher amp meter reading.

Increase in air pressure.

Excess of cuttings in the bottom of the hole (more than one foot
after completion of hole and after making a cleaning pass).

Heavy wear and/or damage indications on shirttails.

Some reasons for an increase in air pressure while drilling:

D.

Fast penetration, not cleaning the holes.

Foreign material in the bit, coming from inside the air system, or
cuttings coming in through the air nozzles or shirttails.

Air passages to the bearings becoming plugged with cuttings.

IV.

Turn the air on before lowering the bit to collar the hole. Keep the air on
until the bit is finished drilling and is out of the hole. Always rotate the bit
when moving in or out of the hole.

A. Make sure the cab gage pressure is at its normal reading and air

is circlating through the bit before starting to drill. Inadequate air to

the bearings is a principal cause of overheating and early bearing
failure.

15

Guides for best tricone bit performance

Guides for best bit performance

B. Always rotate when coming out of the hole to:

Keep cuttings from entering the bearings around the back face
of the cone.

Eliminate the possibility of clogging and jamming of the roller

stabilizer rollers (if used).

C. Always rotate when going in the hole to:

Decrease the possibility of damaging the bit or stabilizer on a

ledge or other protrusion in the hole.

D.
Never use the hydraulic down pressure on the bit to aid in levelling the
machine.

In wet conditions, increase bit pressure.

V.

A.

The increased bit pressure will help to keep water and cuttings from
entering the bearings.

B.

When multipass drilling in wet holes, always make three or four

cleaning passes before adding your next pipe to get the bottom of
the hole as clean as possible.

C.

Never remove any device that the manufacturer has installed in the
bit.

VI.

16

Regularly inspect the bit and feel the cones to be sure that all are about the
same temperature.

A.

When making this inspection rotate the cones and make sure the
bearings are clean and not locked with cuttings.

B.

If the cones dont rotate freely, start the air compressor and blow the
cuttings from the bearings, then repeat the inspection.

C.

Any time the cones cannot be freed, the bit should be taken off for
inspection and cleaned.

D. One hot cone generally indicates that the passages to that particular
bearing have become obstructed.

Never allow the bit to drop while on the end of the drill pipe, even for
a distance of a few inches dropping the bit can cause cracking of the
cones and/or welds, and causing indentations in the bearing races.
Results will be premature bearing failure.

VIII.

When a partially dull bit sits idle for a shift or longer, rotate the cones by
hand to insure that they turn freely before drilling.

A. In freezing conditions, and where water injection is used, water can

freeze inside the bearings and air passages. The air temperature
from compressor will normally melt the ice if enough time is allowed
before starting to drill.

B. The drill pipe and bit should be warm before the water injection is
used. This will prevent the water from freezing to the cold surfaces.

C. A partially dull bit should never be left down the hole when any maintenance is required. This bit should be substituted with a dead bit to
protect the drill pipe threads.

D. Procedures for cleaning a bit that has been taken off the drill and will
be reused:

Flush the bearings with water making sure the water is going
through each bearing.

Force air through each bearing.

Oil bearings and submerge in non-detergent oil.

IX.

Occasionally check the air pressure with the bit off to insure that there are
no obstructions in the piping system.

A.

A pressure reading with the bit off can be taken at each bit change
and recorded on the drill report. A change from the prior reading will
help determine if a new obstruction or new leak has developed.

B.

C.

D.

At each bit change, any foreign material in the dull bit should be
noted or investigated.
At each bit change, check for any foreign material in the new bit and
remove if found.
At each drill pipe change, blow the pipe clean before attaching the
bit.

17

Guides for best tricone bit performance

VII.

Guides for best bit performance

X.

A.

A bent drill pipe will cause excess loading on one or two cones with
resulting bearing failure on those cones.

B.

Wear patterns on one side of the drill pipe and stabilizer are also
indications of the problem.

XI.

Blast hole bits drill best when sufficient weight is applied to cause
spalling of the formation.

A.

When spalling occurs, the cuttings are large and the penetration rate
is improved.

B.

If a sufficient amount of weight is not applied, the cutting structure

tends to grind the rock, causing rapid carbide wear, thus reducing
penetration rate and shortening bit life.

C. If too much weight is used for the formation, the cutting structure can be buried to full depth, trapping cuttings beneath
the bit. This will cause erosion of the cone metal, prevent the
formation from chipping, and reduce the penetration rate.

D.

E. Excessive bit weight will also reduce bearing life.

XII.

If cuttings are forced into the cone, bearings can lock up.

Selecting correct rotary speed is usually a matter of practice, depending

upon the formation being drilled.

A.

Slower RPMs will generally reduce the penetration rates and

increase bit life.

B.

Faster RPMs generally increase the penetration rate, but if excessive RPMs are used, it tends to shorten bit life.

18

Properly maintain the drill pipe and its threaded connections. A bent pipe
will often cause early failure.

Guides for best tricone bit performance

19

Maintenance
Best practices for tricone bit maintenance
Always make sure to keep air turned on when drilling
Ensure air pressure at the bit of minimum 45 psi. Cab pressure is normally higher
Never leave drill bit in a hole while not drilling
Clean bit after drilling if drill rig is to be parked
In multi-pass drilling, always flush the hole for minimum 15-30 seconds before
uncoupling drill pipe
In multi-pass drilling, always turn air on before moving the bit after adding drill pipe
Periodically, check temperature of cones and lugs. If one or more cones or lugs
are hotter than other cones or lugs, bit should be removed and air passages
cleaned and oiled
20

Best practices for tricone bit maintenance

Ensure a total of minimum 2 inch (50 mm) drill string annular clearance
Maintain minimum 7000 feet (2134 meters) per minute bailing velocity
(based on drilling experience)
Use bit lubrication injection (Teamlube recommended) whenever possible
If using water injection for dust suppression, use just enough water to settle the
dust, do not create mud
In cold climates, always blow air through the bit for a minimum of 5 minutes
before starting to drill, if drill has been sitting idle
Please consult an Atlas Copco Product Specialist for more information.

21

Troubleshooting

How to grade dull bits

When a rock bit comes out of the hole, a study of its condition can tell a very
important story. Grading a dull bit and evaluating those findings is a simple operation that can increase drilling efficiency while lowering drilling cost. This examination of the dull bit can often furnish information that will assist the selection of bit
types and also help determine the advisability of changing operating practices.
When grading a rock bit, consider the condition of both the cutting structure and
the bearings. The bits life need not be totally used before it is graded, since the
purpose of grading is to determine what is happening to the bit during its life as
well as determining the condition of the dull bit.
Studying rock drill bits will:
1. Lead to an evaluation of the performance and dulling characteristics of bits
based on the drilling practices used.
2. Lead to informed decisions aimed at more economical drilling operations.
3. Provide information about the performance of bit designs used under a variety
of operating conditions. This data provides a background for bit improvements.
Design engineers at Atlas Copco Secoroc use the dull grading system to
help improve future designs. Dull grading also allows operators to better understand drilling conditions and to adapt drilling parameters.
Lets consider only the first two benefits: evaluation of dulls leading to more
efficient drilling operations. Dull grading is a simple procedure, if you use good
judgment and reasonable accuracy. Proper grading of dull bits will give information indicating what should be done to correct drilling practices. A better job of
selecting proper bit types can also be done, leading to lower total drilling costs.
In grading a dull bit, its condition is recorded in a simple and understandable way.
This code measures the condition of bit teeth and bearings, permitting anyone to
visualize that dull bit in his own mind with reasonable accuracy.

0 1 2 3 4
Fig 1-1

22

The current IADC dull grading system can be applied to all types of roller cone
bits. Steel tooth and tungsten carbide insert bits can all be described with this
system. However, rotary blasthole bits are known to have somewhat different
dulling characteristics than the oilfield bits the IADC dull grading system was
originally developed for. Therefore, for blasthole work, a modified IADC dull grading system is used. A description of this modified system follows with each of the
components explained as they apply to rotary blasthole bits.

Cutting structure

Remarks

Bearings

Inner
row

Gage
row

Dull
char.

Location

Worst
bearing

Worst
location

Other
dull

ST
wear

(I)

(G)

(D)

(L)

(B)

(BL)

(O)

(ST)

Table 1-1

1. Column 1 (I) is used to report the condition of the cutting structure on all rows
of teeth not touching the hole wall.
2. Column 2 (G) is used to report the condition of the cutting structure on only
those teeth touching the hole wall: the outermost row on each cone.

5 6 7 8

23

How to grade dull bits

System structure

Troubleshooting

In column 1 and 2 a linear scale from 08 is used to describe the condition of

the cutting structure as follows:

Tungsten Carbide Insert (TCI) and Steel Tooth bits use the same system of dull
grading. Fig 1-1 shows tooth grading for steel tooth bits. TCI bits are graded
the same way:

Figure 1-1 illustrates grading worn or broken tooth height.

0 Indicates no loss of tooth height due to wear or breakage.

8 Indicates total loss of tooth height due to wear or breakage.

For example: A bit missing half of the inserts on the inner rows of the bit due
to loss or breakage with the remaining teeth on the inner rows having a 50%
reduction in height due to wear, should be graded a 6 in column 1.

If the inserts on the gage of the bit were intact but were reduced by wear to
half of their original height, the proper grade for column 2 would be 4.

3. Column 3 (D) uses a two letter code to indicate the dull characteristic of the
cutting structure. Table 1-2 lists the two-letter codes for the dull characteristics
to be used in this column.
4. Column 4 (L) uses a letter or number code to indicate the location of the face of
the bit where the cutting structure dulling characteristic occurs. Table 1-3 lists the
codes used for describing locations on roller cone bits.
5. Column 5 (B) uses a letter or number code, depending on bearing type, to
indicate the condition of the WORST bearing on the rotary bit. For non-sealed
bearing roller cone bits a linear scale for 08 is used to indicate the amount
of bearing life that has been used. 0 indicates that no bearing life has been
used (a new bearing), and an 8 indicates that all of the bearing life has been
used (locked or lost). For sealed bearing (journal or roller) bits a letter code is
used to indicate the condition of the seal. An E indicates an effective seal,
and a F a failed seal.
6. Column 6 (BL) in blasthole work is used to give the location of the WORST
bearing. 1 cone 1; 2 cone 2; 3 cone 3.
7. Column 7 (O) is used to report any dulling characteristic of the bit, in addition
to the cutting structure dulling characteristic listed in column 3 (D). Note that
this column is not restricted to only cutting structure dulling characteristics.
Table 1-2 lists the two-letter codes to be used in this column.

24

Dull/other dull characteristics

*BC
BT
BU
CC
CD
CI
CR
CT
ER
FC
HC
JD

Broken Cone
Broken Teeth/Cutters
Balled Up
Cracked Cone
Cone Dragged
Cone Interference
Cored
Chipped Teeth
Erosion
Flat Crested Wear
Heat Checking
Junk Damage

*LC
LN
LT
PB
PN
RG
SD
SS
TR
WT
NO

Lost Cone
Lost Nozzle
Lost Teeth/Cutters
Pinched Bit
Plugged Nozzle
Rounded Gage
Shirttail Damage
Self-Sharpening Wear
Tracking
Worn Teeth/Cutters
No Dull/Other Wear

* Show cones or #'s under Location (L) Table 1-1.

Table 1-2

Location Roller cone bits

N
M
H
GB
A

Nose rows
Middle rows
Heel (gage) row
Gage bevel
All rows

Cone # or #'s
1
2
3

Table 1-3

25

How to grade dull bits

8. Column 8 (ST) is used to report the amount of wear on the bit shirttails. L =
Light shirttail wear (ST inserts present); M = Medium shirttail wear (ST inserts
being exposed and or undercut); H = Heavy shirt tail wear (ST inserts missing
or gone, bearings exposed).

Troubleshooting

Damage classification
Tricone bits
Code

Description

Code

Description

BC

Broken Cone

SS

Self-Sharpening wear

BU

Balled Up

TR

Tracking

CC

Cracked Cone

WT

Worn Teeth

CD

Cone Dragged

LBP

Lost Ball Plug

CI

Cone Interference

LN

Lost Nozzle

CR

Cored

PB

Pinched Bit

LC

Lost Cone

PN

Plugged Nozzle

OC

Off Center wear

SD

Shirttail Damage

BT

Broken Teeth

Ab

Abrasion

CT

Chipped Teeth

ER

Erosion

FC

Flat Crested wear

JD

Junk Damage

HC

Heat Checking

PL

Plugged bit

LT

Lost Teeth

SB

Sandblasting

RG

Rounded Gage

XT

Cross Threaded

SP

Spalling

NO

No Dull/No Other Wear

Note:

The failure codes only identifies the reason that the drill bit was pulled from
operation and not the root cause of the failure.
Root cause of failure is determined through materials and application
investigation.
Not all causes and remedies are listed. Please consult an Atlas Copco Product
Specialist for more information.

26

Tricone bits

27

Troubleshooting

BC

Broken Cone

Definition: When a cone is broken and has a piece missing.

Cause

Remedy

Cone interference where the cones

run on each other after a bearing
failure and break one or more of the
cones

See remedy for cone interference

(page 32)

Dropped drill string

Conduct drill rig audit for maintenance issues

Hitting ledges in the hole

Avoid hitting ledges in the hole

28

Tricone bits - Cones

BU

Balled Up

Definition: When one or more cones become so covered with sticky material
(e.g. clay, mud, etc.) that the teeth stop indenting the formation and breaking
rock.

Cause

Remedy

Inadequate cleaning of the bottom

of the hole

Check air compressor volume

output. Ensure rated volume and
pressure is being delivered. Ensure
suggested bailing velocity and bit
pressure; adjust if necessary.

Forcing the bit into formation

cuttings with the air off

Always have air on when moving

bit in hole

Drilling a sticky formation (wet

mudstone/shale)

Keep bailing velocity and bit

pressure as high as possible

29

Troubleshooting

CC

Cracked Cone

Definition: Cracks appear on cone shell.

Please note: Illustration above shows Radial cracking. Other types of cracks
may occur - circumferential and axial.
Cause

Remedy

Junk on the bottom of the hole

Keep junk out of hole

Bit hitting a ledge or bottom

Be aware of location of ledges

and total hole depth. Approach each
slowly.

Dropped drill string

Conduct drill rig audit for

maintenance issues

Cone shell erosion

Ensure proper bottom hole cleaning

30

Tricone bits - Cones

CD

Cone Dragged

Definition: When one or more cones stop rotating for any reason and are
dragged by the bit over the formation.

Cause

Remedy

Bearing failure on one or more of

the cones

Ensure proper bit air pressure and

air volume

Junk lodging between the cones

Keep junk out of hole

Pinched bit causing cone

interference

Do not jam bit into cuttings in

bottom of hole

Bit balling up
Plugged air courses

Be sure bit is cleaned and free of

mud and rocks

31

Troubleshooting

CI

Cone Interference

Definition: When the teeth of one cone interfere with an adjacent cone.

Cause

Remedy

Bit being pinched

Do not run bit into a previously

drilled hole
Make sure the bit basket is properly
sized for the bit
Do not hold new bit with deck
wrench during changes

Extreme bearing wear on one or

more cones

Check the air pressure, rotation and

drill string alignment

32

Tricone bits - Cones

CR

Cored

Definition: When abrasion and/or erosion remove the noses of the cones.

Cause

Remedy

Abrasiveness of formation wears

nose carbide teeth rapidly allowing
cone nose to contact hole bottom

Change nose insert carbide grade

Spacing of nose inserts allows cone

nose to contact hole bottom

Re-design of cone nose

Cone shell erosion resulting in lost

inserts

Check air compressor volume

output. Ensure rated volume and
pressure is being delivered. Ensure
suggested bailing velocity and bit
pressure; adjust if necessary.

Junk in the hole causing breakage of

the nose inserts

Keep junk out of hole

Low air volume causing cuttings to

pile up in center of the hole

Check air compressor volume

output. Ensure rated volume and
pressure is being delivered. Ensure
suggested bailing velocity and bit
pressure; adjust if necessary.
33

Troubleshooting

LC

Lost Cone

Definition: One or more cones are completely missing from the journals.

Cause
Broken cone

34

Remedy
Avoid dropping the drill string and bit
down the hole
Avoid hitting ledges in the hole

Off Center wear

Definition: When the centerline of the bit rotates (orbits) around the centerline
of the hole. One or more rows of teeth rub against a ridge of uncut hole
bottom, wearing the cone shell away from the insert. This will expose the insert
shank. Can be on the front or back of a row of inserts. Always found between
rows.

Cause

Remedy

Uncut hole bottom

Change WOB
Change RPM

Bent drill pipe, stabilizer, etc.

Replace drilling tools

Worn deck bushing

Replace deck bushing

35

Tricone bits - Cones

OC

Troubleshooting

BT

Broken Teeth

Definition: Tooth has no projection above cone shell. Carbide remains in the
insert hole.

Cause

Remedy

Bit run on junk

Keep junk out of hole

Bit hitting a ledge or hitting bottom

suddenly

Select bit with harder carbide

Be aware of location of ledges
and total hole depth. Approach each
slowly.

Excessive RPM for application.

Indicated by broken teeth on the
heel or gage row

Reduce RPM

Formation too hard for bit type.

Indicated by broken teeth on inner
rows

Change to harder bit type or reevaluate production vs. service life

requirement

36

Tricone bits - Teeth

CT

Chipped Teeth

Definition: Tooth projects above cone shell.

Cause

Remedy

Impact loading due to rough drilling

Use shock sub

Regulate RPM to prevent bouncing
Change carbide grade (tougher)

Slight cone interference

Replace the bit

37

Troubleshooting

FC

Flat Crested wear

Definition: The original shape of the teeth has become flattened, not rounded,
due to wear.

Please note: Flat crested wear may appear on more than one row, and be
normal in specific drilling situations.
Cause

Remedy

Low WOB (and/or high RPM) for the

formation

Increase WOB and/or lower RPM

Carbide inserts used in bit are too

soft for the formation being drilled

Select bit with harder carbide

38

Tricone bits - Teeth

HC

Heat Checking

Definition: A network of fine cracks on the surface of a carbide insert.

Cause

Remedy

Repeated rapid heating and cooling

of insert due to working against,
twisting, or dragging on the formation.

Adjust RPM if causing inserts to fail

Dragged insert(s)

Replace bit

39

Troubleshooting

LT

Lost Teeth

Definition: When one or more teeth have been completely removed from the
cone. With TCI bits there will be an entirely empty insert hole, containing no
carbide.

Cause

Remedy

Cone shell erosion

Ensure proper hole bottom cleaning

A crack in the cone that loosens the

grip on the insert

Replace the bit

40

Tricone bits - Teeth

RG

Rounded Gage

Definition: When the cone gage teeth wear in a smooth curve from the hole
wall side to the hole bottom side of the insert.

Please note: Rounded gage may be normal in specific drilling situations.

Cause

Remedy

Excessive RPM

Adjust to lower RPM

Reaming an undersized hole

Avoid reaming holes whenever

possible

Gage carbide is too soft for the

formation being drilled

Use bit with more wear resistant

gage carbide

41

Troubleshooting

SP

Spalling

Definition: Micro chipping of carbide around the worn edges of a tooth.

Please note: Spalling may be normal in heavy bit weight drilling applications.
Cause
The teeth are working on the edge
of their failure envelope in an
extremely high stress condition,
causing very small pieces of carbide
to be chipped from the worn edges
of the teeth

42

Remedy
If spalling leads to chipped teeth:
Use shock sub
Regulate RPM to prevent bouncing
Change carbide grade (tougher)

Tricone bits - Teeth

SS

Self-Sharpening wear

Definition: When the carbide insert wears itself to a sharp point.

Please note: Self-sharpening wear may be normal in specific drilling situations.

Cause
Bit design in specific applications

Remedy
No remedy necessary, unless
causing bit failure

43

Troubleshooting

TR

Tracking

Definition: Wear on the sides of the teeth, between teeth in a single row.

Cause
Cutting structure interaction with
formation (bit design)
Teeth fall into the same hole they
created on the previous bit revolution

44

Remedy
Select bit with different cutting
structure
Slight changes to WOB and RPM

Worn Teeth

Definition: When the teeth show uniform wear which can include any or all of
the following: spalling, minor chipping, and/or normal wear of the tooth caused
by interaction with the rock.

worn

new

Cause
Operating a bit

Remedy
Replace bit when necessary

45

Tricone bits - Teeth

WT

Troubleshooting

LBP

Lost Ball Plug

Definition: The ball plug is missing from lug.

Cause

Remedy

Backreaming

Use back reaming package

Caving or collapsing holes

Use high projection armor package

Off Center wear

Refer to OC section

Erosion due to poor hole cleaning

Use correct air volume and bit

pressure

46

Tricone bits - Lugs & Shirttails

LN

Lost Nozzle

Definition: One or more nozzles are missing.

Cause

Remedy

Improper nozzle installation

Install nozzles properly

Improper nozzle

Do not use other bit manufacturers

nozzles. They may not fit properly

Mechanical or erosion damage to

nozzle and/or nozzle retaining
system

Replace the bit

47

Troubleshooting

PB

Pinched Bit

Definition: The lugs have been squeezed inwards to where the bit is no longer
at gage diameter.

Cause

Remedy

Bit being forced into undersized hole

Do not put a bit into an undersized

hole

Bit being pinched in the bit breaker

Check bit breaker for wear and

replace if necessary

Wrong size of bit breaker

Use proper size bit breaker

48

Plugged Nozzle

Definition: One or more nozzles has become obstructed with foreign material.

Cause

Remedy

Jamming the bit into cuttings with

the air off

Always ensure air is on before

moving bit in hole

Solid material entering the drill string

through the bit on a connection and
lodging in a nozzle when circulation
is resumed

Use backflow valve

Rubber, rust, or other material breaking loose from inside the air hoses
or air piping

Be sure drill air piping system is

clean and free of debris

Junk - rocks, dirt, paper, soda cans,

etc. - left in a new drill pipe just
installed on the drill

Inspect drill pipe for foreign objects

and remove before installing on drill

49

Tricone bits - Lugs & Shirttails

PN

Troubleshooting

SD

Shirttail Damage

Definition: Cracking or loss of parts of the shirttail.

Cause

Remedy

Junk in the hole

Keep junk out of the hole

Broken shirttail lip

Replace the bit

50

Tricone bits - Lugs & Shirttails

51

Troubleshooting

XT

Cross Threaded

Definition: When bit is screwed into the drill string at an angle, resulting in
damage to the pin threads.

Cause

Remedy

Misalignment of drill string to new

bit

Make sure the alignment is correct

Bit sub or stabilizer threads are

damaged

Replace bit sub or stabilizer

52

Tricone bits - Threads

53

Troubleshooting

Ab

Abrasion

Definition: Non-erosional wear of the bit body or parts resulting from cutting
and scraping by collapsed or caved materials.

Cause
Drilling out of collapsing holes

54

Remedy
Stabilize hole
- Use roller stabilizer
- Use pasting technique
Use bit with back reaming feature

Tricone bits - General

ER

Erosion

Definition: When cuttings wear away the steel of the cone shell and/or lugs.
Can occur on all areas or only a few.

Cause

Remedy

Abrasive formation cuttings eroding

the cone shell due to inadequate air
(Running on cuttings)

Check air compressor volume

output. Ensure rated volume and
pressure is being delivered. Ensure
suggested bailing velocity and bit
pressure; adjust if necessary.

Excessive air resulting in high

velocity erosion

Reduce air volume to suggested

levels
Provide larger annulus

Abrasive formation contacting the

cone shell between the inserts due
to excessive WOB (overdrilling)

Reduce WOB

55

Troubleshooting

JD

Junk Damage

Definition: Gouging, heavy scratching and/or denting of the lugs, shirttails and
cones by non-formation objects, such as broken teeth or objects dropped down
the hole from the drill.

Cause

Remedy

Junk dropped in the hole from the

surface

Dont drop junk down the hole.

Keep drill deck uncluttered

Junk from the drill string (reamer

pins, stabilizer blades, etc.)

Replace drilling tools before wear

becomes excessive

Junk from the bit itself (tungsten car

bide inserts. etc.)

Check bit frequently for damage and

replace as necessary

56

Tricone bits - General

PL

Plugged bit

Definition: Obstruction of the internal air passages of the bit.

Cause

Remedy

Cuttings and grit inside bit and air

passages. Low air volume and/or
low air pressure

Increase air pressure in bit

Lack of backflow valve

Use backflow valve in bit

Jamming the bit into cuttings with

the air off

Always ensure air is on before

moving bit in hole

Foreign objects or substances

entering bit from air system

Be sure air system is clean and free

of foreign objects, rust, scale and air
compressor oil residue

57

Troubleshooting

SB

Sandblasting

Definition: A distinct, sharp edged feature caused by a directed jet of air

escaping some part of the bit which blows cuttings against another part of the
bit. A much more defined feature than erosion.

Cause
Directed jet of high energy air,
blowing cuttings against a part of a
bit (is not erosion or abrasion)

58

Remedy
If causing bit failure, reduce bit air
pressure with larger nozzles, or add
hardfacing to lug above journal

Tricone bits - General

59

Troubleshooting

Damage classification - Drill pipes

Drill pipes
Code

Description

Code

Description

Worn too small

10

Broken male tool joint

Bent

11

Female tool joint cracked

Cracked

12

Female tool joint broken

Broken

13

Damaged male or female

shoulder

Pin thread wear

14

Damaged female (box) thread

Pin thread cracked

15

Female thread cracked

Pin thread broken

16

Female thread broken

Damaged male (pin) shoulder

17

Male or female thread cut

(torched)

Cracked male tool joint

Note:

The failure codes only identifies the reason that the drill pipe was pulled from
operation and not the root cause of the failure.
Root cause of failure is determined through materials and application
investigation.
Not all causes and remedies are listed. Please consult an Atlas Copco Product
Specialist for more information.

60

Drill pipes

61

Troubleshooting

Drill pipe body

Worn too small

Definition: Outside diameter of drill pipe worn too small, compromising

strength and bailing velocity.

Cause

Remedy

Abrasive drilling conditions

Wear protection applied to tool joints

Alloy tubing body rather than mild
steel pipe body
Rotate drill pipe from bottom to top
position on single-pass drilling at
50 to 60 % wear life of the bottom
drill pipe

Sandblasting due to small annulus

area resulting in high bailing velocity

Reduce drill pipe diameter

Reduce air delivery of compressor

62

Drill pipes - Drill pipe body

Bent

Definition: Pipe bent off of center line.

Cause

Remedy

Excessive diameter wear

Change out the drill pipe sooner

Increase drill pipe wall thickness
Use Teamalloy drill pipe

Leaking drill support jacks

Proper drill maintenance required

Deviated hole telemetry

Proper hole collaring technique

Use of a roller stabilizer

Tramming off of the hole with drill

pipe still in the hole

Driller training
Drill limit switch (drill pipe in hole)

Excessively worn deck bushing

Repair or replace deck bushing

63

Troubleshooting

3-4

Cracked or broken

Definition: Crack or break in pipe tubing body.

Cause

Remedy

Excessive pipe body wear

Establish maximum wear criteria by

application

Tramming off of the hole with pipe

still engaged

Driller training
Drill limit switch (drill pipe in hole)

Deviated hole telemetry

Proper hole collaring technique

Use of a roller stabilizer

Excessive pull down

Pulldown limits
Re-evaluate drilling parameters

64

Drill pipes - Drill pipe body

65

Troubleshooting

Drill pipe pin thread connections

Pin thread wear

Definition: Thread wear resulting in leaks and reduced strength.

Heavily worn threads are usually the result of a multi-pass drilling

application. Each time a connection is made up or broken out, thread
wear occurs. This wear can be accelerated due to factors such as:
Cause

Remedy

Rotary head misalignment

Proper drill maintenance

Not taking care and attention when

making up connections

Driller training

Lack of proper thread lubrication

Apply suitable thread lubrication

each time drill pipes are connected

Operating without a floating spindle

Shock Sub in a multi-pass application

Use of a Shock Sub with a

floating spindle in a multi-pass
application

66

30

290

109

500
Stage 1:

Stage 2:

Stage 3:

New thread

Worn thread
crest

Thread crest
worn to sharp
point
Replace!

Stage 4:

Stage 5:

First indication
of rounding
thread

Final thread
wear stage

67

Drill Pipes - Drill pipe pin thread connections

5 stages of thread wear

Troubleshooting

68

Drill Pipes - Drill pipe pin thread connections

6-7

Pin thread damaged (cracked or broken)

Definition: Pin thread broken off or cracked.

Cause

Remedy

Rotary head misalignment

Proper drill maintenance

Not taking care and attention when

making up connections

Driller training

Lack of proper thread lubrication

Apply suitable thread lubrication

each time drill pipes are connected

Operating without a floating spindle

Shock Sub in a multi-pass application

Use of a Shock Sub with a

floating spindle in a multi-pass
application

Hole deviation

Use correct drilling tools for the

application
Use correct hole collaring technique

Pipe support on drill not working

when mast is down

Proper drill maintenance

Flats on box end shoulder of drill

pipe

Select optional drill pipe design

69

Troubleshooting

Tools joints & Shoulders

Damaged male (pin) shoulder

Definition: Integrity of pin shoulder compromised.

Cause

Remedy

The integrity of the male shoulder

has been compromised due to
welding and air arcing

Do not weld on the shoulder

connections between two drill pipe

Debris on the shoulder of the thread

during making up the connections

Make sure the connection is clean

and suitable thread grease is applied
prior to make up

70

Drill Pipes - Tools joints & Shoulders

9-12

Cracked or broken male or female tool joint

Definition: Crack or break occurring at where the male or female tool joint is
welded to the pipe tubing body.

Cause
Excessive pipe body wear

Remedy
Pull pipe from operation before the
OD reaches the established
maximum wear criteria

71

Troubleshooting

13

Damaged female (box) shoulder

Definition: Integrity on box shoulder compromised.

Cause

Remedy

The integrity of the Female shoulder

has been compromised due to
welding and air arcing

Do not weld on the shoulder

connections between two drill pipe

Debris on the shoulder of the thread

during making up the connections

Make sure the connection is clean

and thread grease is applied during
make up

Worn drill pipe in the lead position

Always install the new pipe in the

lead position

Head misalignment

Align rotary head, drill maintenance

72

Drill Pipes - Tools joints & Shoulders

73

Troubleshooting

Threads

14

Damaged female (box) thread

Definition: Damage to profile of box thread.

Cause

Remedy

Misalignment of the drill string

Proper drill maintenance

Not taking care and attention when

making up the connections

Drill training

Debris in the threads during make

up

Clean threads and apply thread

grease on every make up

74

Drill Pipes - Threads

15-16

Cracked / Broken female (box) thread

Definition: Box thread cracked or broken.

Cause

Remedy

Heavy box end wear

Monitor and pull from operation

when too worn

Severe hole deviation

Make sure the collar for the hole is

straight
Use of a Roller Stabilizer

Tool joint shoulders not making up

properly

Ensure that the threads and

shoulders are clean prior to making
up the connection

Field welding on box end tool joint

Do not weld on box end

75

Troubleshooting

17

Male or female thread cut (torched)

Definition: Damage to pin or box thread due to cut (torched).

Cause

Remedy

Pipe stuck in hole

Necessary to move drill

Unable to disconnect drill pipe

mechanically

Application of suitable thread grease

prior to make up
Use a properly maintained breakout
wrench
Pre-torque of connections prior
to drilling

76

Drill Pipes - Threads

77

Notes

78

Notes

79

Notes

80

Notes

81

Notes

82

Notes

83

Subjected to alterations without prior notice. Atlas Copco Secoroc AB. All rights reserved. 2012.11 Elanders
9851 6627 01

Atlas Copco Secoroc AB

Box 521, SE-737 25 Fagersta, Sweden
Phone +46 223 461 00
E-mail: secoroc@se.atlascopco.com
www.atlascopco.com