Brocas Varel (1).pdf

Proud to be a Miner

Table of Contents

A Brief Introduction Pages 1 - 2

Ridgeback Marathon Series Blasthole Bits

TM

Pages 3 - 9

DW/QMC Product Range Page 10

RX Exploration Bit Series Page 11

PH Pilot Bit Series Page 11

Steel Tooth Product Range Pages 12 - 15

Additional Useful Data Pages 16 - 19

Varel: A “Bit” of a Success Story

Mission Statement

Founded in 1947, Varel is recognized as the world’s largest independent drill bit company serving clients in both the oil & gas and mining industries. Based in Carrollton, Texas, Varel was privately held by the Varel family until 1998. Two subsequent acquisitions have positioned the company as a world leader in drill bit technology.

“To deliver the best value to served customers and markets, finding the optimum balance of performance and price, which will result in the most effective solution to their drilling needs.”

The company provides a comprehensive range of of roller cone and polycrystalline diamond compact (PDC) bits and has manufacturing facilities in Carrollton and Houston; Matamoras, Mexico; and Tarbes, France. Using patented drill bit technologies and emerging drilling innovations, Varel aligns its engineering and manufacturing capabilities to provide high-quality products that deliver reliable performance at the lowest drilling cost.

Vision Statement To establish a culture of continuous improvement which provides ever-increasing value to our customers. We will meet or exceed the expectations of our customers, employees and shareholders in performance, quality, services, technology and opportunity by conducting our business in a safe and professional manner that supports our community and respects the environment. Our Mission and Vision will be accomplished by aligning and achieving goals tied to our critical success factors. • Continuous Improvement Culture • Innovation • Workforce Competency • Reliability • Communications

WWW.VAREL.COM

1

Development of Varel rock bits in recent years

1947 - 1998 After its foundation in 1947, Varel International remained a family owned business until 1998. Varel produced its first air to the bearing bits shortly after its foundation, and in 1978 developed the first range of sealed bearing products.

1999 Varel acquired Walker McDonald, and became the world's second largest volume producer of three cone bits for the mining industry.

2000 The introduction of the Varel Ridgeback series produced the first generation of advanced technology features directed towards longer life bearings, improved cutting structures, and the famous Ridgeback shirttail concept. All of these features greatly assist hole cleaning resulting in extended bit life.

2004 Building on the success of the Ridgeback series, the introduction of the new Ridgeback MarathonTM Series combines many of the existing field-proven features, plus a new high load bearing package, reinforced gage and shirttail protection features. These features are aimed at increasing performance in demanding high pull-down and high performance TDC (total drilling cost) situations.

2

Why develop a new blast hole bit series? Backed by years of field-proven technology and expertise, Varel has become a leading provider of high performance drill bits. Our technological advances embrace the use of highly

Innovative Concepts

sophisticated computer technology, premium raw materials and thousands of "on the job man hours", all geared towards reducing our customers’ cost of drilling.

3

Main Roller Bearing

INTRODUCING RIDGEBACK MARATHON SERIES

TM

Carbide Shirttail Protection

Ball Bearing

2nd Roller Bearing

Varel International is presently introducing a new line of three cone bits designed for the blasthole industry.

Thrust Button

TM

These products, the Ridgeback Marathon series, feature the most advanced features available today in air circulation rock bits.

RIDGEBACK DESIGN TECHNOLOGY

Air Passageways

New advances in computer technology have allowed Varel to develop proprietary rock bit design software that enables design changes to be introduced rapidly. This exclusive software aids the engineer with bit design analysis and includes such factors as drill operating parameters, bit geometry and mine lithology. By using this software Varel’s engineers are able to predict the effects of design modifications and limit the risks associated with new product development.

Thrust Faces Air Vent Holes

4 High Energy Tumbling

R I D G E B A C K M A R AT H O N

TM

S E R I E S F E AT U R E S A N D B E N E F I T S

Advanced Bearing Design All Ridgeback MarathonTM rock bits incorporate bearings designed to minimize heating. The wear elements feature advanced materials to give the maximum bearing life under a wide variety of operating conditions.

Enhanced Cutter Design The Ridgeback MarathonTM design process provides the highest penetration rates and longest life available.

Improved Thrust Capacity Bearing thrust capacity is often the limiting factor in bearing life. Ridgeback MarathonTM bits feature an improved thrust face design which minimizes outward thrust wear to prolong bearing life.

Maximum Gage Protection SRT (Semi Round Top) tungsten carbide and welded hardmetal provide superior wear resistance to the shirttail area. This feature is particularly effective in formations which tend to cave in, or when hole bailing is a problem.

High Energy TumblingTM Precision manufactured inserts are further processed for maximum toughness. Varel’s HET TM - High Energy Tumbling process (patent pending) - gives the inserts a unique surface toughness that extends bit life.

The Ridgeback Marathon Advantage TM

• Increased penetration • Larger cuttings • Less dust • Longer bit life • Cuttings suitable for stemming

Vented Cones Vented cones are standard in all Ridgeback and Ridgeback MarathonTM series bits 9” and larger in diameter. Vented cones allow a continuous air flow throughout the bearings to provide better cooling and cleaning. 5 See page 18 for recommended nozzle sizes when using bits with vented cones.

SOFT FORMATION INSERT BITS

All soft formation bits are designed with aggressive cutter profiles to provide extremely high penetration rates.

RB30 COMPRESSIVE STRENGTHS:

2,000 - 10,000 (psi)

DRILLING SPEEDS:

70 to 120 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

2,000 to 4,000 (lbs/inch of bit diameter)

GAGE TYPES:

CHISEL

FEATURES: Maximum extension conical inner row inserts provide for ultra high rates of penetration in ultra soft formations without stringers. High performance roller-ball-roller bearing with tungsten carbide thrust button and premium rollers. These advanced features maximize bearing capacity and air flow; resisting wear and prolonging bearing life.

10 5/8” - RB30

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

RB40 COMPRESSIVE STRENGTHS:

5,000 - 15,000 (psi)

DRILLING SPEEDS:

70 to 120 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

2,000 to 5,000 (lbs/inch of bit diameter)

GAGE TYPES:

CHISEL

FEATURES: Large diameter, very long extension chisel inserts for very high rates of penetration. High Performance roller-ball-roller bearing with tungsten carbide thrust button, and premium rollers. These advanced features maximize bearing capacity; resisting wear and prolonging bearing life.

12 1/4” - RB40

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

RB50 COMPRESSIVE STRENGTHS:

10,000 - 30,000 (psi)

DRILLING SPEEDS:

70 to 120 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

2,500 to 5,000 (lbs/inch of bit diameter)

GAGE TYPES:

CHISEL

FEATURES: Long extension conical inner row inserts provide for very high rates of penetration in soft formations. High performance roller-ball-roller bearing with tungsten carbide thrust button and premium rollers. These advanced features maximize bearing capacity and air flow; resisting wear and prolonging bearing life.

6 12 1/4” - RB50

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

MEDIUM FORMATION INSERT BITS

Medium formation bits are most commonly used in the mining industry, and provide long bearing life with additional insert strength for consolidated formations.

RB53 COMPRESSIVE STRENGTHS:

15,000 - 35,000 (psi)

DRILLING SPEEDS:

70 to 120 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

2,500 to 5,000 (lbs/inch of bit diameter)

GAGE TYPES:

CHISEL

FEATURES: Long extension conical inner row inserts provide for high rates of penetration while maintaining excellent durability and long wear life. High performance roller-ball-roller bearing with tungsten carbide thrust button and premium rollers. These advanced features maximize bearing capacity and airflow; resisting wear and prolonging bearing life.

12 1/4” - RB53

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

RB60 COMPRESSIVE STRENGTHS:

25,000 - 45,000 (psi)

DRILLING SPEEDS:

60 to 100 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

3,000 to 6,000 (lbs/inch of bit diameter)

GAGE TYPES:

CONICAL

FEATURES: Large diameter, medium extension conical inner row inserts balance durability with high rates of penetration. High performance roller-ball-roller bearing with tungsten carbide thrust button, and premium rollers. These advanced features maximize bearing capacity and airflow; resisting wear and prolonging bearing life.

12 1/4” - RB60

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

RB60G COMPRESSIVE STRENGTHS:

25,000 - 45,000 (psi)

DRILLING SPEEDS:

60 to 100 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

3,000 to 6,000 (lbs/inch of bit diameter)

GAGE TYPES:

CONICAL

FEATURES: Large diameter, medium extension conical inner row inserts balance durability with high rates of penetration. High performance roller-ball-roller bearing with tungsten carbide thrust button, and premium rollers. These advanced features maximize bearing capacity and airflow; resisting wear and prolonging bearing life.

9 7/8” - RB60G

On “G” package bits, the Nobby or Sidewinder feature replaces the Ridgeback leg design, providing maximum wear resistance for backreaming and other exceptionally demanding applications.

7

HARD / VERY HARD FORMATION

All hard formation bits are designed with tough low extension cutter profiles to provide maximum durability in hard formations.

RB67 COMPRESSIVE STRENGTHS:

30,000 - 50,000 (psi)

DRILLING SPEEDS:

60 to 100 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

3,000 to 6,500 (lbs/inch of bit diameter)

GAGE TYPES:

CONICAL

FEATURES: Large diameter, medium extension conical inner row inserts balance durability with high rates of penetration. High performance roller-ball-roller bearing with tungsten carbide thrust button and premium rollers. These advanced features maximize bearing capacity and airflow; resisting wear and prolonging bearing life.

10 5/8” - RB67

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

RB70 COMPRESSIVE STRENGTHS:

35,000 - 60,000 (psi)

DRILLING SPEEDS:

50 to 90 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

4,000 to 7,500 (lbs/inch of bit diameter)

GAGE TYPES:

CONICAL

FEATURES: Blunt conical inner rows provide high durability without sacrificing penetration. High performance roller-ball-roller bearing with tungsten carbide thrust button and premium rollers. These advanced features maximize bearing capacity and air flow; resisting wear and prolonging bearing life.

12 1/4” - RB70

Patented Ridgeback feature for enhanced cuttings removal. SRT tungsten carbide inserts and welded hardmetal provide superior wear resistance to the shirttail, even in formations which tend to cave in, or when hole bailing is a problem.

RB80/RB80G COMPRESSIVE STRENGTHS:

50,000 (psi) and harder

DRILLING SPEEDS:

40 to 70 rpm

JET CIRCULATION:

All sizes

DRILLING WEIGHTS:

5,000 to 8,000 (lbs/inch of bit diameter)

GAGE TYPES:

OVOID

FEATURES: Maximum durability is achieved with this tough, all ovoid cutting structure. High performance roller-ball-roller bearing with tungsten carbide thrust button and premium rollers. These advanced features maximize bearing capacity and airflow; resisting wear and prolonging bearing life.

8 12 1/4” - RB80G

On G package bits the Nobby or Sidewinder feature replaces the Ridgeback leg design providing maximum wear resistance for backreaming and other exceptionally demanding applications.

INSERT BIT PRODUCT LINE RIDGEBACK MARATHON Diameter

SOFT

Inches

mm

1

6 3/4

171

7 3/8

187

7 7/8

200

RB30

RB40

9

229

RB30

9 7/8

251

10 5/8

270

11

280

11 3/8

289

RB40

12 1/4

311

RB40

13 3/4

349

16

406.4

MEDIUM

2

3

RB40

RB50

1

2

TM

SERIES HARD

3

1

RB60

2

Pin Size Approx Wt 3

RB70

RB50 RB50

lbs

kg

3 1/2

46

21

3 1/2

58

26

4 1/2

76

35

4 1/2

96

43

6 5/8

145

66

RB53

RB60/60G

RB40

RB53

RB60/60G

RB30

RB40

RB53

RB60/60G

RB67

RB30

RB40

RB53

RB60

RB67

6 5/8

157

72

RB53

RB60

RB67

6 5/8

193

88

6 5/8

210

95

6 5/8

225

102

RB60

6 5/8

292

134

RB60

7 BECO

580

264

RB50 RB50

RB53

RB63

Inches

RB60

RB70

RB67

RB70

RB70

RB80G

RB80G

The above product range represents the bits which were available when this catalogue was published. Varel is continually expanding and developing its range of products. For an updated availability list, please contact a Varel sales representative/agent, or consult our Web site at - WWW.VARELINTL.COM

“G” SERIES PRODUCT LINE

Sidewinder

Nobby

Ridgeback

The “G” series includes many of our Marathon features with additional gage protection and a heavy duty Nobby or Sidewinder leg design. Designed for extremely abrasive applications and drilling conditions where difficult hole cleaning, or extreme formations, require maximum shirttail protection.

9

VAREL DW/QMC SERIES Diameter Inches

mm

2 15/16 - 3

75-76

3 7/8

98

4

101

4 1/4

108

4 1/2

SOFT 1

2

MEDIUM 3

1

2

HARD 3

1

2

Pin Size Approx Wt 3

lbs

kg

N Rod

8

3.6

DWH

2 3/8

10

4.5

DWH

2 3/8

10

4.5

DW7

2 3/8

12

5.5

114

DW7

2 3/8

13

5.8

4 3/4

121

DW7 QMC7

2 7/8

15

6.8

4 7/8

123

QMC7

2 7/8

15

6.8

5 1/8

130

DW53ET DW7 QMC7

2 7/8

17

7.7

5 5/8

143

DW7 QMC7

3 1/2

27

12.2

5 7/8

149

DW7

3 1/2

27

12.2

6

152

3 1/2

36

16.3

6 1/4

159

3 1/2

36

16.3

DW7 DW531

QMC9

M60

DW7

DW9 QMC53ET

QMC7

QMC76

Please note that all QMC series products may be slightly oversize. All DW series products are made strictly to API tolerance standard.

QMC9/DW9

10

QMC53ET/DW53ET

QMC7/DW7

QMC76

DWH

R E V E R S E C I R C U L AT I O N B I T S Varel has developed a range of reverse circulation bits with various bearing packages. These bits are suitable for soft/medium formation drilling and have: • Open non-sealed roller bearings, • Semi sealed non-compensated roller bearings, • Fully sealed compensated journal bearings.

REVERSE CIRCULATION AND EXPLORATION BIT AVAILABILITY Size of Bit

Type

Formation

5 1/8"

RX53

SOFT

OPEN

5 1/8"

RXS53

SOFT

SEALED*

Bearing

Varel provides a range of products for reverse circulation applications. These bits are developed to provide exceptional performance in a wide variety of formations typically encountered during mineral exploration. The center hole is the maximum diameter possible for superior hole cleaning and cuttings retrieval. All RX and RXS circulation bits are precision machined to work with most existing R/C systems.

5 1/4"

RX53

SOFT

OPEN

5 1/4"

RXS53

SOFT

SEALED*

5 3/8"

RX53

SOFT

OPEN

5 3/8"

RXS53

SOFT

SEALED*

5 1/2"

RX53

SOFT

OPEN

5 1/2"

RXS53

SOFT

SEALED*

3 7/8"

ETD24

MEDIUM

SEALED**

4 3/4"

ETD24

MEDIUM

SEALED**

Products featuring both sealed and open bearings are available. Varel fully sealed bearing products for reverse circulation applications feature fully pressure compensated, non serviceable lubrication supplied to the industry’s most sophisticated journal bearing. The bearing features hardmetal inlays on all contact surfaces with silver-plated cone bearings, specially formulated seal compounds, and high-temperature lubricant. The bearings and seals are developed for long life.

4 3/4"

ETD35

MED/HARD

SEALED**

4 3/4"

ETD48

HARD

SEALED**

5 5/8"

ETD34

MED/HARD

SEALED**

5 3/4"

ETD34

MED/HARD

SEALED**

5 7/8"

ETD34

MED/HARD

SEALED**

6"

ETD34

MEDIUM

SEALED**

6 1/8"

ETD34

MEDIUM

SEALED**

6 1/8"

ETD34

HARD

SEALED**

6 1/4"

ETD34

MEDIUM

SEALED**

Open bearing products feature precision roller bearings with special thrust elements to prevent axial wear. The cones are retained by ball bearings and the pilot pin features hardmetal inlays against a tool steel bushing.

6 1/2"

ETD34

HARD

SEALED**

5 3/8” - RX53

* Semi sealed bearing without compensator system. ** Fully sealed bearing with compensator system.

Regardless of bearing type, the cutting structures on all reverse circulation products are designed to provide a combination of fast penetration and durability. These bits consistently provide the lowest cost per foot of drilled hole in mineral exploration applications.

SEALED BEARING PILOT HOLE BITS Premium Sealed Bearing Pilot Hole Bits

CURRENT PILOT BIT AVAILABILITY

Varel International’s oilfield and mining experience provides a selection of sealed bearing journal bits designed for drilling the most demanding raise bore pilot holes, blind bore pilot holes, and underground drill and blast holes.

Bit Sizes

Each bit is designed with a premium sealed bearing system including a pressure compensator. The premium bearing package features advanced metallurgy with frictional elements silver-plated to reduce frictional heat generation and provide resistance to galling under high loads. O-ring seals made from a proprietary HSN elastomer provide extremely long seal life. The PH80 series features blunt dome-shaped inserts to provide a durable cutting structure for maximum crushing and chipping action while minimizing wear. Varel’s PH60 bits utilize conical and/or chisel shaped inserts for increased penetration rates in softer formations. Extra hardmetal and carbide inserts are installed in the surface of the shirttail to provide superior seal protection.

Bit Type

12 1/4"

PH80

12 1/4"

PHR80*

11"

PH60 - PH80

9"

PH80

* Sealed roller bearing bit for Boxhole applications. All Varel premium pilot bits incorporate specially formulated highly saturated nitrile elastomers and high temperature lubricants.

12 1/4” - PH80

(New diameters and models are under development. Please consult your nearest representative.)

11

SOFT FORMATION STEEL TOOTH BITS

Varel’s soft formation steel tooth bits have long aggressive forged teeth with maximum offset to give high penetration rates.

L111 COMPRESSIVE STRENGTHS:

500 to 3,000 (psi)

DRILLING SPEEDS:

60 to 150 rpm

JET CIRCULATION:

all sizes

DRILLING WEIGHTS:

2,000 to 5,000 (lbs/inch of bit diameter)

GAGE TYPES:

“A” Tooth

FORMATIONS: Soft limestones, soft clays, red beds, soft shales, shells and other formations with relatively low compressive strengths. FEATURES: Long, slim, widely spaced teeth. All teeth are hard faced. Skewed cone action for high penetration rates.

L111

L3S COMPRESSIVE STRENGTHS:

1,000 to 5,000 (psi)

DRILLING SPEEDS:

60 to 150 rpm

ALL REGULAR CIRCULATION:

4 1/2” and larger

DRILLING WEIGHTS:

2,000 to 5,000 (lbs/inch of bit diameter)

GAGE TYPES:

“A” Tooth

FORMATIONS: Soft limestones, soft clays, red beds, soft shales, shells and other formations with relatively low compressive strengths. FEATURES: Long slim, widely spaced teeth. Teeth are less widely spaced in smaller diameters. All teeth are hard faced. Skewed cone action for high penetration rates.

L3S

V3MO COMPRESSIVE STRENGTHS:

1,000 to 5,000 (psi)

DRILLING SPEEDS:

50 to 100 rpm

JET CIRCULATION:

5 1/8” and larger

DRILLING WEIGHTS:

2,000 to 5,000 (lbs/inch of bit diameter)

GAGE TYPES:

“A” Tooth

FORMATIONS: Engineered for rugged drilling in a wide variety of formations. FEATURES: All teeth are hard faced with extra heavy deposits of tungsten carbide for long life. Additional gage hard metal assures more protection for the shirttails. Spacing and angle of teeth allow for durability and long life.

12 V3M0

MEDIUM & HARD FORMATION TOOTH BITS

Medium series bits have “A” or “T” teeth for wear resistance. Hard formation bits have “L” or “T” shaped heel row teeth for hard formations, double “T” heel row teeth for hard and abrasive formations.

L2 COMPRESSIVE STRENGTHS:

4,000 to 10,000 (psi)

DRILLING SPEEDS:

35 to 85 rpm

ALL REGULAR CIRCULATION:

2 7/8” and larger

DRILLING WEIGHTS:

3,000 to 6,000 (lbs/inch of bit diameter)

GAGE TYPES;

“A” Tooth

FORMATIONS: Wide range of medium formations such as altered limestones, shales, anhydrite and other formations with medium compressive strengths.

FEATURES: Moderately skewed cone design. Teeth hard-faced on one flank to resist abrasion. Vented “A” type gage gives high rates of penetration.

L2

L1 COMPRESSIVE STRENGTHS:

8,000 - 18,000 (psi)

DRILLING SPEEDS:

35 to 75 rpm

REGULAR CIRCULATION:

All sizes

DRILLING WEIGHTS:

3,500 to 6,500 (lbs/inch of bit diameter)

GAGE TYPES:

‘A’ Tooth

FORMATIONS: Specifically designed for fast penetration in formations that are hard, but not particularly abrasive. FEATURES: Designed to conform to latest drilling techniques requiring heavier weights. Similar in design to the LH1, but does not have webbed heel row.

L1

LH1 COMPRESSIVE STRENGTHS:

9,000 - 20,000 (psi)

DRILLING SPEEDS:

30 to 65 rpm

REGULAR CIRCULATION:

All sizes

DRILLING WEIGHTS:

3,500 to 7,000 (lbs/inch of bit diameter)

GAGE TYPES:

Double ‘T’

FORMATIONS:: Hard formations such as pyrite, chert,dolomites, granite porphyry and other formations which have high compressive strengths and are abrasive. FEATURES: Closely spaced, strong short teeth for maximum crushing and chipping.

13 LH1

STEEL TOOTH BIT PRODUCT LINE Diameter Inches mm

SOFT 1

2

MEDIUM 3

1

2 7/8

73

2 15/16

75

3

76

3 1/4

79-82

L2

3 1/2-3 5/8 89-92

L2

3 3/4

2

HARD 3

1

2

L2

95

3

Approx Wt lbs kg

LH1

N Rod

4

1.8

LH1

N Rod

4

1.8

LH1

N Rod

4

1.8

N Rod

4 1/4

1.9

2 3/8

9

4.1

LH1

2 3/8

9

4.1

L1

L2

3 7/8-4 1/8 98-105

Pin Size

LH1

2 3/8

9

4.1

L2

LH1

2 3/8

10

4.5

114

L2

LH1

2 3/8

11

5

117

L2

2 7/8

11

5

LH1

2 7/8

16

7.3

LH1

2 7/8

16

7.3

4 1/4

108

4 1/2 4 5/8 4 3/4

121

4 7/8-5

123-127

L2 L3S

L1

L2 V3M0

5 1/8-5 1/4 130-133

L1

L2 L2

2 7/8

17

7.7

5 1/2

140

L2

2 7/8

17

7.7

5 5/8

143

L2

3 1/2

22

10

5 3/4

146

L2

3 1/2

22

10

5 7/8

149

L2

3 1/2

22

10

6

152

L2

3 1/2

26

11.8

6 1/8

156

L2

3 1/2

26

11.8

6 1/4

159

L2

3 1/2

29

13.2

6 1/2

165

L2

3 1/2

29

13.2

6 3/4

171

L2

3 1/2

33

15

7 7/8

200

L121*

L2

4 1/2

62

28

13 3/4

349

L111*

6 5/8

292

133

17 1/2

445

L111*

6 5/8 or 7 5/8

450

204

22

559

L111*

7 5/8

891

404

24

610

L111*

7 5/8

1125

510

26

660

L3A

7 5/8 or 8 5/8

1300

589

34

863

L3A

7 5/8 or 8 5/8

2200

1000

36

914

7 5/8 or 8 5/8

2400

1100

V3S0

L211*

L1

*

= JET BITS

The above chart represents commonly available sizes and types. Varel International does produce other sizes and types of rock bits which do not appear on this list. Please consult your local representative or visit our Web site - WWW.VARELINTL.COM If you have custom requirements for a specific application, please contact your local sales representative/agent.

14

F E AT U R E S Whether you are using air, water, foam or mud for circulation purposes, Varel has a full range of bits suitable for your needs.

Regular Center Fluid Circulation

Regular Air Circulation

Jet Circulation Fluid or Air

Varel regular circulation bits provide efficient circulation of fluid through the center of the bit to clean the teeth and the bottom of the hole. Available in full opening or three drilled hole courses.

Varel air blast circulation bits provide a balanced supply of air to the bearings for cooling. A balanced supply of air also is directed to clean the cutters and the bottom of the hole. Back flow valve is available with this design.

Varel jet circulation bits are engineered for use with high pressure fluid or air. The precision nozzles direct the velocity of the fluid or air at the bottom of the hole for efficient cleaning.

Optional Features 1. Jet Circulation: Specify air or fluid circulation. 2. Regular (center) Circulation: Specify fluid or air circulation and full hole or orifice plate. 3. Reverse Circulation: Precision machined to customer specifications. 4. Removable back flow valve. 5. BECO Pin thread connection.

Forged Teeth, unique to Varel Varel pioneered the research and development of forged teeth for steel tooth rotary cone bits. This technique, illustrated in the chemically etched section above, is a recognized advance in metallurgical design, resulting in stronger, uniformly compressed and unbroken flow lines in bit teeth. These stronger teeth produce longer bit life and faster penetration.

15

DULL BIT GRADING The following examples are shown to assist in the accurate identification of individual dulling characteristics.

Broken Leg This condition is the result of a dropped bit, or hitting a ledge, or hitting a down hole fracture.

Rounded Gage A common dull mode for rock bits used in abrasive applications is gage wear. This condition is aggravated by high rotary speeds and/or poor hole cleaning. Excessive gage wear often leads to bearing failure.

Cone Drag The extreme cone drag shown is the result of failed or locked bearings, causing the cones to skid against the bottom of the borehole. This is commonly caused by plugged air passages causing the bearing to overheat.

Cone Interference Cone interference can be caused by either bearing failure or forcing a bit into an undergage hole. In the case of early bearing failure, check for plugged air passages.

16

Lost Cone A lost cone is usually a more advanced form of bearing failure or cone breakage.

Broken Cone The bit shown has the cone broken circumferentially resulting in loss of the nose, or inner, portion of the cone. This condition is normally caused by cone interference due to bearing failure.

Cracked Cone Cracked cones can be caused by using too much pulldown for the formation being drilled. In this case reduce the pulldown or use a harder bit type. This condition can also be the result of mechanical damage such as dropping the bit against the bottom of the hole.

Cone Erosion Cone shell erosion is normal and should be expected. Erosion leading to lost inserts can be caused by running the incorrect bit type for the formation or excessive pulldown. In this case reduce the pulldown or use a softer bit.

U S E F U L O P E R A T I O N A L D A TA BIT AIR PRESSURE DROP CHART Bit Size Range in. 5 3/8 to 6 3/4

7 3/8 to 7 7/8

9 to 9 7/8

10 5/8 to 17 1/2

mm 137 171

187 200

229 251

270 445

Full Air Course Diameter

Jet Nozzle Diameter 3 Each

Air Pressure Drop (pounds per square inch) Bits with various air course diameters or jet nozzle sizes Air Volume Delivered Cubic Feet Per Minute

in.

mm

in.

mm

400 500

1/2 5/8 3/4 7/8 1 3/4 7/8 1 1 1/8 5/8 3/4 7/8 1 1 1/8

12.70 15.87 19.05 22.22 25.40 19.05 22.22 25.40 28.57 15.87 19.05 22.22 25.40 28.57 19.05 22.22 25.40 28.57 34.92 38.10 50.80

7.93 9.52 11.11 12.70 14.28 11.11 12.70 14.28 15.87 9.52 11.11 12.70 14.28 15.87 19.05 11.11 12.70 14.28 15.87 19.05 22.22 28.57

45 36 30 26 21 24

3/4 7/8 1 1 1/8 1 3/8 1 1/2 2

5/16 3/8 7/16 1/2 9/16 7/16 1/2 9/16 5/8 3/8 7/16 1/2 9/16 5/8 3/4 7/16 1/2 9/16 5/8 3/4 7/8 1 1/8

29 22

55 46 37 32 26 31 24

39 30 24

600

700

800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2600 2800 3000

65 54 44 36 32 38 30 23

75 64 51 44 37 45 36 29 24 57 45 36 29 22

84 72 60 51 44 52 42 35 29 65 53 42 35 28

28 21

33 26 22

49 38 30 23

22

81 68 57 50 58 48 40 34 73 61 48 41 35 22 38 30 26 22

76 64 54 66 54 46 39 80 68 56 46 39 25 44 36 30 25

82 70 59 72 62 52 44 75 63 52 44 29 49 41 34 28

76 65 78 70 58 50 82 69 57 49 34 55 46 37 30 22

82 70 84 79 64 55

74 62 52 39 61 50 41 34 25 20

76

82

87 70 60

76 65

83 71

80 67 56 43 66 55 45 37 28 22

71 61 46 72 59 49 41 31 24

76 65 50 78 63 53 45 34 26

76

82

81 69 53

73 57

77 60

81 64

68 58 49 37 28

73 62 52 40 30

78 66 56 43 31

70 60 45 33

67

71

74

78

82

75 64 48 36 20

67 51 38 22

71 54 40 28

75 57 43 30

60 45 30

64 47 32

68 50 34

In addition to adequate return air velocities, the pressure drop across the bit must be controlled to obtain the optimum bearing life. Pressure drop across the bit should be maintained in excess of 30 psi. Two (2) to ten (10) psi should be added for losses in the system ahead of the bit. For optimum bit life nozzles should be selected to hold pressure near the maximum allowable on the compressor.

Helpful Hole Cleaning Information

BAILING VELOCITY TABLE Delivered Air Volume CFM Required for a Bailing Velocity of 5,000 FPM PIPE SIZE In.

mm

2 3/8

61

2 7/8

73

3 1/2

89

4

102

4 1/2

114

5

127

5 1/2

140

6 1/4

159

6 5/8

168

7

178

7 3/4

197

8 5/8

219

9

229

10

250

10 3/4

273

13

330

13 1/2

343

13 3/4

349

4 3/4 121 461 13.06 390 11.04 281 7.96 178 5.04

5 127 528 14.95 456 12.91 348 9.86 245 6.94

5 1/8 130 562 15.92 491 13.91 382 10.82 280 7.93

5 5/8 143 709 20.08 638 18.07 529 14.98 426 12.06

5 7/8 149

6 152

716 20.28 607 17.19 505 14.30

756 21.41 648 18.35 545 15.43

BIT SIZE 6 1/4 6 3/4 159 171

732 20.73 629 17.81 513 14.53 383 10.85

909 25.74 807 22.85 691 19.57 561 15.89 418 11.84

7 3/8 187

7 7/8 200

9 229

1149 32.54 1047 29.65 931 26.37 802 22.71 658 18.63 418 11.84

1358 38.46 1255 35.54 1139 32.36 1010 28.60 867 24.55 626 17.73 495 14.02

1875 53.10 1773 50.21 1657 46.93 1526 43.27 1384 39.19 1144 32.40 1012 28.66 873 24.72 571 16.17

9 7/8 251

10 5/8 261

12 1/4 13 3/4 311 349

1978 56.02 1835 51.97 1594 45.14 1463 41.43 1323 37.47 1022 28.94 631 17.87

2397 67.88 2254 63.83 2013 57.01 1882 53.30 1742 49.33 1441 40.81 1050 29.74 870 24.64

3411 96.60 3268 92.55 3027 85.72 2896 82.01 2756 78.05 2455 69.53 2064 58.45 1884 53.35 1366 38.69 941 26.65

3517 99.59 3358 95.09 2946 83.42 2428 68.75 2004 56.75

15 381

17 1/2 445

3409 96.54 2985 84.54 1527 3744 43.24 106.03 3382 95.78 3197 90.54

In. mm CFM CU-M/MIN

For the most effective hole cleaning a minimum bailing velocity of 5000 feet per minute is considered desirable. The simple formula Q=AV can be applied to determine the volume flow of air (Q) necessary to give the desired velocity (V). (A) is the area of the hole through which the cuttingsladen air flows. This area is the area of the hole less the area filled by the drill pipe. The table shown gives the delivered air volume necessary to provide a bailing velocity of 5,000 feet per minute. This volume is calculated for the most common bit and pipe sizes. For dense materials, this volume should be increased in order to yield optimum cleaning efficiency. See page 18 for bailing velocity formula.

17

U S E F U L O P E R A T I O N A L D A TA Tips for optimizing drill bit performance

Nozzle Hole Area Chart Hole Size

Area/1 Hole

Area/3 Holes

in.

mm

Sq. in.

mm2

Sq. in.

mm2

1/4

6.35

.049

31.62

.147

94.84

9/32

7.14

.062

40.00

.186

120.01

5/16

7.93

.076

49.04

.228

147.11

11/32

8.73

.093

60.00

.279

180.01

3/8

9.52

.110

70.97

.330

219.92

13/32

10.31

.130

83.88

.390

251.63

7/16

11.11

.150

96.78

.450

290.34

15/32

11.90

.172

110.97

.516

332.92

1/2

12.70

.196

126.46

.588

379.38

17/32

13.49

.222

143.23

.666

429.70

9/16

14.28

.248

160.01

.745

480.67

5/8

15.87

.306

197.43

.918

592.29

11/16

17.46

.372

240.01

1.116

720.04

3/4

19.05

.442

285.18

1.326

855.54

7/8

22.22

.601

387.77

1.803

1163.30

1

25.40

.785

506.48

2.355

1519.45

1 1/8

28.57

.993

640.68

2.985

1925.92

1 1/4

31.75

1.228

792.31

3.684

2376.92

NOZZLE SIZE ADJUSTMENT FOR VENTED CONES Non-vented nozzle size (one) 1/2"

Nozzle size for vented cones (one) Bit size 9"

Bit size 9 7/8" - 13 3/4"

7/16"

7/16"

9/16"

1/2"

1/2"

5/8"

9/16"

9/16"

11/16"

5/8"

5/8"

3/4"

3/4"

11/16"

13/16"

13/16"

3/4"

7/8"

7/8"

13/16"

15/16"

15/16"

7/8"

1"

1"

15/16"

Unique feature at Varel International are vented cones. Bits with vented cones have significantly more airflow through the bearings than standard bits. The nozzle size should be reduced in order to maintain suitable back pressure for proper cooling and cleaning. This chart gives the proper nozzle sizes to use with bits with vented cones.

18

1. Keep rotating the bit, and turn on the air before the bit touches the ground, and keep the air on until the bit is out of the hole. If the bit is to stay in the hole while adding drill steel, blow the hole clean for 60 seconds prior to turning off the air. 2. When purchasing a new drill specify compressors with adequate capacity. Don’t forget the altitude factor when sizing the compressor. Often 7,000 to 10,000 linear feet per minute in return air velocity is required to properly clean the hole, particularly with heavier or larger cuttings. 3. Inspect the rock bit after each hole and record the condition of the rock bit at regular intervals. 4. Hot cones may indicate obstruction of the air passage to the bearings. 5. Pressure gage increases may indicate air passages are plugging. 6. An increase in air pressure may indicate unwanted restrictions in the air system. A decrease in air pressure may indicate leakage in the air system. 7. Accidental dropping of the bit and drill string can damage bearings and/or cones. 8. The I.D. (inside diameter) of the pin and box connections of the drill string should be the same as or larger than the I.D. of the pin on the rock bit. This will reduce the pressure drop loss across the drill string to the lowest possible psi. 9. Avoid early bit failures by refraining from using bent drill steel and excessively worn drill steel, stabilizers, deck bushings or shock subs. 10. When making up the rock bit use slow rotation and ensure that the drill string and rock bit mate properly shoulder to shoulder. Monitor the process carefully in order to avoid cross threading. 11. Use proper tool joint lubrication to maintain connections. 12. Use only the minimum amount of water required to suppress the dust. 13. Use the factory recommended weight and rotation speeds to accommodate the formations being drilled. 14. Rotary speed should be decreased as down pressure is increased and down pressure decreased as rotary speed is increased. 15. Accurate information is valuable knowledge. Always record footage drilled, time in the hole, rpm, weight on bit, psi, formation drilled and any unusual drilling conditions. (Water in the hole, broken formations, etc.) 16. Form drilling process improvement teams with your key suppliers. Establish improvement goals and measure progress.

Total Drilling Cost

Bailing velocity

TDC

BV

TDC B R

F

P

= B + R F P = Total drilling cost per foot or meter drilled = Total bit price = Operating cost per hour for the drill rig expressed in dollars per hour = Total life of the rock bit expressed in either feet or meters = Penetration rate of the rock bit expressed as feet or meters per hour

BV

= 183.3 x ACFM D 2 _ d2

= Bailing velocity (feet per minute) ACFM = Actual cubic feet of free air per minute delivered 183.3 = Factor for conversion D = Diameter of the hole being drilled. (inches) d = Outside diameter of the drill pipe being utilized. (inches)

CHARTS FOR MAXIMUM BIT LIFE VAREL INSERT BIT COMPARISON AND HARDNESS TABLE

2500

5000

7500 10000 12500 15000 17500 20000 22500 25000 27500 30000 32500 35000 37500 40000 42500 45000 47500 50000 52500 55000 57500 60000 62500 65000 67500 70000

MPA

17.2

34.5

51.7

69.0

86.2

FORMATION

SCHIST (SOFT)

SANDSTONE (SOFT)

LIMESTONE (SOFT)

LIMESTONE (HARD)

CONGLOMERATE

REPRESENTATIVE ROCK COMPRESSIVE STRENGTH (psi) PSI

S O F T

QUARTZITE (HARD)

BASALT (HARD)

DIABASE (DOLERITE)

AMPHIBOLITE

GRANITE

GNEISS (AVERAGE)

GABBRO

SLATE

QUARTZITE (SOFT)

DIORITE

SANDSTONE (HARD)

103.4 120.7 137.9 155.1 172.4 189.6 206.8 224.1 241.3 258.6 275.8 293.0 310.3 327.5 344.7 362.0 379.2 396.5 413.7 430.9 448.2 465.4 482.6

RB30 RB40

M E D I U M

Varel Ridgeback Marathon Series Insert Bits

RB50 RB53

TM

RB60 / RB60G

H A R D

RB67 RB70 RB80 / RB80G

VAREL STEEL TOOTH BIT COMPARISON AND HARDNESS TABLE

6000

7000

8000

9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000

MPA

6.9

13.8

20.7

27.6

34.5

41.4

48.3

55.2

62.1

TUFF

LIMESTONE (SOFT)

BASALT (SOFT)

LIMESTONE (HARD)

S O F T

M E D I U M H A R D

103.4 110.3 117.2 124.1 131.0 SCHIST (HARD)

96.5

DIORITE

89.6

MARBLE

82.7

SANDSTONE (HARD)

75.8

ANDESITE

69.0

SHALE (SOFT)

5000

DOLOMITE

4000

CONGLOMERATE

3000

SANDSTONE (SOFT)

2000

FORMATION

1000

SCHIST (SOFT)

REPRESENTATIVE ROCK COMPRESSIVE STRENGTH (psi) PSI

L111 L3S V3MO

Varel Steel Tooth Bits

L2

L1 LH1

19

VAREL’S SERVICE PACKAGE Varel International’s field sales management, design engineers, technical service staff, and factory authorized distributors are trained and experienced industry professionals. They are available for analyzing drilling parameters, and making work-friendly suggestions aimed at creating the optimum balance of performance and price in your drilling operations. Our staff is trained to deliver professional assistance on all of the following:

20

•

Bit selection

•

General bit care

•

Dull bit analysis

•

Suggesting optimum operating parameters for RPM and weight on bit

•

Applying field-proven practices

•

Mentoring drilling schools

•

Conducting air tests, load tests and drill audits

•

Advising on optimum working pressures

•

Calculating total drilling costs - TDC

LET OUR VAREL TEAM WORK WITH YOU ON A CONTINUOUS BASIS, AND DEVELOP WORLD CLASS RESULTS IN YOUR DRILLING OPERATION.

VAREL INTERNATIONAL MAKERS OF WORLD CLASS DRILLING BITS

SALES

OFFICES

WORLDWIDE:

VAREL INTERNATIONAL CORPORATE HEADQUARTERS 1434 Patton, Suite 106, Carrollton, Texas 75007 Mailing address: P.O. Box 540157, Dallas, Texas 75354-0157 Phone: +1-972-242-1160 Fax: +1-972-242-8770 Email: [email protected] Watts: 1-800-VARELCO (827-3526)

MEXICO VAREL DE MEXICO, S.A DE C.V. 3a. Y Michoacan #310 Sur Fraccionamiento Moderno, H. Matamoros Tamaulipas, Mexico C.P. 87380 Phone: +52-868-8170467 Fax: +52-868-8172106 SOUTH AMERICA VAREL INTERNATIONAL Sucursal del Peru Las Poncianas 105/107, La Molina Vieja Lima 12, Peru Phones: +51-1-365-2529 / 365-5178 Fax: +51-1-365-8305 Cellular: +51-1-999-60283 Email: [email protected] Email: [email protected] ASIA-PACIFIC VAREL INTERNATIONAL Suite 6, Kishorn Court, 58 Kishorn Road Mount Pleasant, WA 6153 Australia. Phone: +61-8-9315-9999 Fax: +61-8-9315-9800 Email: [email protected]

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