Roller Cone Bits - Oil & Gas Products 2006-2007 - Varel International

T a b l e o f C o n t e n t s 

About Varel International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 

Varel Roller Cone Drill Bit Technology . . . . . . . . . . . . . . . . . . . . . . 2 

Bit Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 

Advanced Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 

Premium Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 

Shirttail Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

Journal Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 

Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

Challenger TCI — Sealed Journal Bearing Bits . . . . . . . . . . . . 10-11 

Challenger TCI — Sealed Journal Air Bits . . . . . . . . . . . . . . . . 12-13 

Challenger Steel Tooth — Sealed Journal Bearing Bits . . . . . 14-15 

Challenger TCI — Sealed Roller Bearing Bits . . . . . . . . . . . . . 16-17 

Challenger Steel Tooth — Sealed Roller Bearing Bits . . . . . . . 18-19 

Steel Tooth — Open Bearing Bits . . . . . . . . . . . . . . . . . . . . . . . 20-21 

Roller Cone Reference Tables 

Roller Cone Bit Gage Diameter Tolerances . . . . . . . . . . . . . . 22 

Roller Cone Bit Connection Sizes . . . . . . . . . . . . . . . . . . . . . 22 

Roller Cone Nozzle Total Flow Area . . . . . . . . . . . . . . . . . . . 22 

Recommended Roller Cone Makeup Torque . . . . . . . . . . . . . .23 

Nozzle Size & Availability . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

Roller Cone Bit Shipping Weights. . . . . . . . . . . . . . . . . . . . . 24 

API Casing Dimensions and Bit Diameters. . . . . . . . . . . . . . . . . . 25 

Sales Offices/Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

V a r e l I n t e r n a t i o n a l 

A B i t o f a S u c c e s s S t o r y 

Performance…reliability…expertise … value … service. 

These are the cornerstones of Varel International, the world’s 

largest independent manufacturer of premium drill bits for 

the global oil and gas industry. Varel offers a comprehensive 

product line of roller cone, fixed cutter/polycrystalline diamond 

compact (PDC) and diamond drill bits that have evolved 

and improved through the technological advances and the 

engineering expertise of its qualified staff. 

Founded in 1947, Varel remained a privately held company 

owned by the Varel family until 1998, producing roller cone air 

bits for the mining industry. In 1978, Varel introduced its first 

range of sealed bearing products and was merged through 

two subsequent acquisitions. The changing of hands further 

advanced and improved the company to the level of success it 

holds today as a world leader in both the roller cone and fixed 

cutter drill bit industry. 

The first acquisition brought a new management team that 

helped expand Varel and grow its capabilities and product 

offerings for both the global oil and gas/mining markets. During 

this time, Varel enhanced and expanded its engineering 

and manufacturing capabilities, adding fixed cutter bits and 

focusing on delivering value to its customers. Additionally, Varel 

increased its international presence by adding a significant 

worldwide sales and support team. 

The Technological Edge 

In 2005, Varel was acquired by KRG Capital Partners, a 

private equity firm in Denver, providing the additional capital 

the company needed to further expand its product offerings, 

proprietary technology and services worldwide. Since that time, 

Varel has aligned its engineering and manufacturing capabilities 

to provide products that consistently deliver reliability and 

optimum product performance, thereby lowering customers’ per 

foot drilling costs. 

Varel is centrally located with headquarters in Carrollton, Texas, 

just north of Dallas with an additional roller cone manufacturing 

facility in place in Matamoros, Mexico—along with fixed cutter 

manufacturing facilities in Houston and Tarbes, France. 

Varel proudly serves as a major drill bit supplier to many 

supermajors, large independents and national oil companies 

operating in the international and domestic oil and gas drilling 

fronts. Innovative, yet cost-effective drilling solutions for vertical 

and directional wells for land and offshore projects is what 

customers have come to expect from Varel. 

1

V a r e l R o l l e r C o n e D r i l l B i t T e c h n o l o g y 

Varel Drill Bit Technology 

Varel Challenger roller cone bits are designed and manufactured 

to provide high levels of performance and reliability. Challenger 

products are the result of years of industry experience and 

thousands of hours of field tests in the most demanding 

applications. Every detail of the design and manufacturing 

process results in a product that meets or exceeds the 

requirements of our customers, every time. 

Using electronic logs and our proprietary geoscience program, 

Varel evaluates characteristics of rock formations to select the 

most effective bit model for the interval. This program enables 

Varel to determine rock compressive strength (drillability/ROP), 

abrasivity (bit life), shale reactivity versus depth (bit and hole 

cleaning), and characterization of heavy minerals (such as pyrite). 

Additionally, Varel has developed proprietary algorithms for 

cutting structure and bearing designs to ensure each product 

design consistently performs in a variety of applications. 

Algorithms are used to design cutting structures to achieve 

desired rates of penetration, resist tracking, and combat offcenter 

operation. Bearings and seal systems are designed using 

models that assure adequate load capacity and seal wear life 

in high rotary speed and/or applications with high solids in the 

circulation system. Every new Challenger design is peer 

reviewed to ensure that no detail is overlooked. 

Materials used in the construction of Challenger roller cone 

bits are sourced from leading suppliers who have the ability to 

produce consistently to high standards and meet firm delivery 

schedules. Varel operates using the philosophy of partnering with 

suppliers in order to build long-term relationships that provide 

quality materials and components that provide increased value to 

our customers. 

Varel develops and utilizes manufacturing processes that 

are robust and repeatable. These processes are constantly 

monitored and continuously reviewed to provide the drilling 

industry with ever-increasing value. All Varel roller cone design 

and manufacturing facilities are managed through quality 

programs meeting the requirements of both ISO 9001:2000 and 

API Q1. These quality programs are designed with an emphasis 

on consistency, quality and continuous improvement in all 

aspects of our business. 

Challenger bits are tailored for specific applications by 

customizing from a rich set of optional features. These features, 

shown throughout this catalog, provide additional value as they 

are designed to give increased wear protection in demanding 

drilling applications. This results in longer bit life and reduced 

costs for our customers. 

All Varel products are delivered with superior service. No matter 

where you are in the world, Varel sales and technical service 

personnel are experts on local drilling conditions and problem 

avoidance and can assist you with proper drill bit and operating 

parameters selection. From well proposals to onsite monitoring, 

Varel is available to help you plan and drill your well successfully. 

Varel maintains an extensive bit record database. The information 

in the database is constantly monitored and utilized to improve bit 

design and enhance performance. 

2

B i t N o m e n c l a t u r e 

Indicates Challenger Bit 

Bearing Type: 

H - Sealed Journal 

R - Sealed Roller 

CH 24 MRS 

Number System 

One digit: 

Steel tooth cutting structure 

Softest-to-hardest (1-3) 

Two digits: 

TCI cutting structure 

Softest-to-hardest (00-99) 

Even numbers - Predominately chisel-shaped inserts 

Odd numbers - Predominately conical-shaped inserts 

Feature 

Name 

Diamond Enhanced 

Back Row 


Gage and Back Row 

Feature 

Code 

D 

DD 

TCI Bit 

Optional Feature¹ 


Steel Tooth 

Bit 


— 

Fully Diamond Enhanced 

Cutting Structure 

DDD 


— 

Tungsten Carbide 

Coated Cones 

E 


— 

Cone Back Row 

Insert Protection 

G 

Standard Feature 


Steel Center 

Air Jet Nozzle 

H 

Optional Feature³ 

— 

Center Jet Nozzle 

J 

Optional Feature² 

Optional Feature² 

Mud Motor 

Shirttail Hardfacing 

M 



Stabilization Inserts 

R 



Leading Edge 

Shirttail Inserts 

S 




Shirttail Protection 

Z 



 

 

 

optional features are available at extra cost 

optional feature (on 8 3/8” and larger bits only) are available at extra cost 

optional feature on Air Circulation Bits only (available in 8 3/4” and larger bits only) 

are available at extra cost 

3

F e a t u r e s 

Cutting Structures for High Energy Applications 

High Energy Tumbling (HET) 

When it comes to cutting structures, value means lowest drilling 

cost. Challenger’s aggressive cutting structures are designed 

using Varel’s proprietary drilling model for a combination of high 

penetration rates (ROP), steerability and durability. 

Varel’s innovative High Energy Tumbling (HET) technology 

(patent pending) has been proven to increase insert toughness, 

resulting in greater overall penetration rates and reduced 

drilling costs. 

Varel’s engineered Tungsten Carbide Insert (TCI) cutting 

structures are designed for the specific formations encountered 

in today’s high-speed motor and directional applications. 

Engineers with decades of design and application experience 

review each new design prior to manufacturing. 

Tungsten Carbide 

Inserts (TCI) 

Challenger’s Steel Tooth Cutting Structures combine Varel’s 

exclusive forged teeth with thick deposits of high-density 

premium tungsten carbide hardfacing for superior wear 

resistance and toughness. Varel offers a variety of optional 

features including diamond-enhanced gage inserts for superior 

wear resistance and gage holding in abrasive formations. 

Bearings for Motor Applications 

Reliable bearings and seals deliver added value. Challenger 

Motor Series bearings are engineered with a proprietary, thermally 

stable extreme pressure (EP) lubricant; precision, silver-plated 

floating elements; and an advanced, high-aspect ratio seal made 

with Varel’s high-temperature elastomer. These elements provide 

a robust bearing capable of withstanding the high rotary speeds 

common in today’s most demanding applications. 

Premium Bearing Configurations 

4

A d v a n c e d T e c h n o l o g i e s 

Advanced Technologies for Design Analysis 

Varel engineers utilize Computational Fluid Dynamics (CFD) 

to simulate fluid flow around roller cone bits and evaluate 

Challenger hydraulics prior to field tests. This process is used 

to identify and eliminate fluid stagnation zones that impair bit 

cleaning and limit penetration rates due to bit balling. 

Using CFD analysis, nozzle orientations have been optimized 

and tested in both laboratory and field situations to ensure that 

both cone cleaning and hole cleaning is optimal. Evacuating the 

cuttings efficiently allows Challenger bits to deliver the highest 

penetrations rates possible. 

Varel engineers employ Finite Element Analysis (FEA) to 

analyze new roller cone bit designs in the early stages of the 

process to ensure product reliability under a wide variety of 

operating conditions, extending bit life. Insert hole and bearing 

geometries are analyzed using FEA and designed to enable 

them to withstand the high loads encountered in severe drilling 

applications. 

Computational Fluid Dynamics (CFD) 

Both CFD and FEA analysis increase the reliability and 

performance of Challenger roller cone bits, providing greater 

value to our customers. 

Finite Element Analysis (FEA) of 

an insert hole 

5

P r e m i u m O p t i o n s 

Diamond Enhanced Back Row (D Feature)* 

One third of the carbide, back-row inserts are replaced with 

polycrystalline diamond (PCD)-capped inserts to increase gage 

holding in abrasive applications. 

Diamond Enhanced Gage and Back Row 

(DD Feature)* 

One third of the back row and all gage inserts utilize PCDcapped 

inserts to maximize gage holding. 

Fully Diamond Enhanced Cutting Structure 

(DDD Feature)* 

All inserts are PCD-capped to extend bit life in the most 

extreme drilling conditions. The premium DDD package 

features a fully PCD-clad cutting structure providing excellent 

wear resistance in the harshest environments. 

Tungsten Carbide Coated Cones (E Feature)* 

All exposed portions of the TCI cones are coated with tungsten 

carbide to provide maximum resistance in applications where 

cone shell erosion limits bit life. 

Steel Center Air Jet Nozzle (H Feature)* 

Air type bits offer an optional center air jet nozzle featuring 

three additional ports for enhanced cutting structure and 

enhanced hole cleaning. (Available only in 8 3/4” bits 

and larger.) 

Center Jet Nozzle (J Feature)* 

A fourth interchangeable jet is installed in the center of the bit 

to reduce bit balling or provide extra flow capacity. (Available 

only in 8 3/8” bits and larger.) 

* optional features are available at extra cost 

6

S h i r t t a i l P r o t e c t i o n 

To enhance gage holding and seal protection, Varel roller cone 

bits provide value with a variety of shirttail protection packages 

for high-angle drilling, abrasive formations and steerable 

applications. These shirttail protection packages can be used 

to tailor bits to meet your drilling needs. 

Motor Hardfacing (M Feature) 

For demanding motor applications, a generous application of 

tungsten carbide hardfacing is applied to the shirttail lower 

edge and leading edge of the bit leg to provide enhanced 

seal protection. 

Leading Edge Shirttail Inserts (S Feature)* 

Tungsten carbide inserts are placed along the leading edge 

of the shirttail providing additional wear resistance in motor 

applications commanding high RPM or where additional shirttail 

protection is needed. 

Motor Hardfacing — 

M Feature 

Leading Edge and Hardfacing — 

S Feature* 

Stabilization Inserts (R Feature)* 

Stabilization inserts enhance standard shirttail patterns by 

providing bit stabilization and additional protection to the 

pressure compensator in high-angle applications or in 

deviation-prone formations. 

Diamond Enhanced Shirttail Inserts (Z Feature)* 

In Varel’s premium shirttail protection package PCD-capped 

inserts replace tungsten carbide inserts (TCI) in strategic 

locations to provide maximum shirttail protection in abrasive 

formations or directional applications. 

* optional features are available at extra cost 

Stabilization and Hardfacing — 

R Feature* 

Diamond Enhanced and 

Hardfacing — Z Feature* 

7

J o u r n a l B e a r i n g F e a t u r e s 

For sizes up to 13 ¾" (349.2 mm) 

Ball Retention 

The Challenger bearing features ball retention, designed 

to retain the cone without carrying bit weight. This design 

technique prevents ball race spalling failures and extends 

bearing life. 

Thermally Stable Extreme Pressure (EP) Lubricant 

Challenger bearings utilize a thermally stable EP lubricant 

formulated to work synergistically with the bearing materials. 

The lubricant maintains high relative viscosity even when the 

bearings are subject to extreme energy levels in demanding 

applications. 

Hardmetal Inlays 

Hard metal inlays on critical bearing surfaces are precisionmachined 

to provide superior bearing performance by reducing 

friction and wear. 

Precision, Silver-Plated Floating Elements 

All bearing surfaces feature precision, silver-plated floating 

elements between the cone and head-bearing surfaces. These 

floating elements reduce bearing heat generation and prolong 

bearing life at higher rotary speeds. 

Image shown is a 

journal bearing with 

Steel Tooth cutting 

structure. Also available 

with TCI cutting 

structure. 

HSN High Aspect Ratio Seal 

The Challenger seal design provides positive sealing against 

contaminates with lower seal face contact stresses. This 

reduces the seal operating temperature and extends seal life. 

Shale Diverting Insert/Shale Groove 

Challenger bits feature an innovative, stepped shale burn 

insert. This stepped design is more effective in diverting 

cuttings away from the seal, prolonging seal life. 

Actual photo of the shale 

diverting insert/shale groove. 

Bearing Clearance 

During assembly, components are selectively matched 

so that final bearing clearances are within a narrow, 

controlled range. This practice dramatically improves bearing 

performance and bit consistency. 

8

For sizes 14 ¾" (374.6 mm) and larger 

R o l l e r B e a r i n g F e a t u r e s 

Tool Steel Thrust Buttons 

Opposing tool steel thrust buttons provide secondary thrust 

capacity. These work in unison with the floating thrust washer 

to provide superior bearing load carrying capability. 

Precision, Silver-Plated Floating Thrust Washer 

A silver-plated floating thrust washer between the head and 

cone reduces frictional heat build-up and lowers 

bearing operating temperature. 

Hardmetal Inlay 

Hard metal inlays on critical bearing surfaces are precisionmachined 

to provide superior bearing performance by reducing 

friction and wear. 

Thermally Stable Extreme Pressure (EP) Lubricant 

Challenger bearings utilize a thermally stable EP lubricant 

formulated to work synergistically with the bearing materials. 

The lubricant maintains high relative viscosity even when the 

bearings are subject to extreme energy levels in demanding 

applications. 

Crowned Rollers 

Crowned rollers reduce peak bearing end stresses, significantly 

raising the bearing load capacity and prolonging bearing life. 

HSN High Aspect Ratio Seal 

The Challenger seal design provides positive sealing against 

contaminates with lower seal face contact stresses. This 

reduces the seal operating temperature and extends seal life. 

Image shown is a roller 

bearing with TCI cutting 

structure. Also available 

with steel tooth cutting 

structure. 

Ball Retention 

The Challenger bearing features ball retention, designed 

to retain the cone without carrying bit weight. This design 

technique prevents ball race spalling failures and extends 

bearing life. 

Shale Diverting Insert/Shale Groove 




Actual photo of the shale 

diverting insert/shale groove. 

9

C h a l l e n g e r T C I - S e a l e d J o u r n a l B e a r i n g B i t s 

Advanced Cutting Structures 

High Energy Tumbled 

(HET ) Inserts 

Semi-Round 

Top Gage 

Protection 

AdvancedShirttail 

Contouring 

Replaceable Center Jet 

Nozzle (J Feature)** 


(see page 7) 

Jet Nozzle 

PREMIUM OPTIONS* 

• Diamond Enhanced Back Row (D Feature) 

• Diamond Enhanced Gage and Back Rows 

(DD Feature) 

• Fully Diamond Enhanced Cutting Structure 

(DDD Feature) 

• Tungsten Carbide Coated Cones (E Feature) 

• Center Jet Nozzle (J Feature)** 

• Stabilization Inserts (R Feature) 

• Leading Edge Shirttail Inserts (S Feature) 

• Diamond Enhanced and Hardfacing (Z Feature) 

Shown: 8 3/4” CH67MRS 

STANDARD FEATURES 

• Gage Protection (G Feature) 

• Mud Motor Shirttail Hardfacing (M Feature) 

10 

* optional features available at extra cost 

** optional feature (on 8 3/8” & larger bits only) available at extra cost

A v a i l a b i l i t y C h a r t 


Challenger tungsten carbide insert (TCI) cutting structures 

are designed to be durable, while maintaining the highest 

efficiency in rock destruction. Insert row placement and insert 

spacing are determined using Varel’s proprietary algorithms 

designed to reduce wear, promote efficient drilling and ensure 

uniform loading across the bit face. It also prevents tracking in 

a wide range of formations and conditions. 

Gage Protection 

Advanced gage protection is standard on all Challenger TCI 

bits. Semi-round top (SRT) tungsten carbide inserts on the 

back row aid in cutting the wall of the hole. These resist wear 

better than flat-topped inserts. 


One third of the carbide back row inserts are replaced with 

polycrystalline diamond (PCD)-capped inserts to increase 

gage holding in abrasive applications. (Configurations may 

vary with cutting structure.) 

Diamond Enhanced Gage and Back Rows (DD Feature)* 

One third of the back row and all gage inserts utilize 

PCD-capped inserts to maximize gage holding. 

(Configurations may vary with cutting structure.) 

Fully Diamond Enhanced Cutting Structure (DDD Feature)* 


extreme drilling conditions. The premium DDD package 

features a fully PCD-clad cutting structure providing excellent 

wear resistance in the harshest environments. 

Tungsten Carbide Coated Cones (E Feature)* 

All exposed portions of the TCI cones are coated with 

tungsten carbide to provide maximum resistance in 

applications where cone shell erosion limits bit life. 

Shale Diverting Insert/Shale Groove — Standard 




TCI - Sealed Journal Bearing Bit Availability 

BIT TYPE IADC Inches (in) Millimeters (mm) 

CH04 417 8 ½, 8 ¾, 9 7 ⁄8, 11, 12 ¼ 215.9, 222.2, 250.8, 279.4, 311.1 

CH09 427 7 7 ⁄8, 8 ¾ 200.0, 222.2 

CH10 437 12 ¼ 311.1 

CH12 437 7 7 ⁄8, 12 ¼, 13 ½, 13 ¾ 200.0, 311.1, 342.9, 349.2 

CH13 437 7 200.0 

CH14 437 8 ½, 8 ¾, 12 ¼ 215.9, 222.2, 311.1 

CH18 447 6, 6 1 ⁄8, 7 7 ⁄8, 8 ½, 12 ¼ 152.4, 155.6, 200.0, 215.9, 311.1 

CH20 517 7 7 ⁄8, 8 ¾, 9 7 ⁄8 200.0, 222.2, 250.8 

CH24 517 3 7 ⁄8, 4 ¾, 5 7 ⁄8, 6, 6 1 ⁄8, 

6 ¼, 7 ½, 7 7 ⁄8 , 8, 

8 ½, 8 ¾, 11, 11 5 ⁄8, 

12, 12 ¼ 

CH25 517 11, 12 ¼ 279.4, 311.1 

CH26 527 7 7 ⁄8 200.0 

98.4, 120.7, 149.2, 152.4, 155.6, 

158.8, 190.5, 200.0, 212.7, 

215.9, 222.2, 279.4, 295.3, 

304.8, 311.1 

CH28 527 7 7 ⁄8, 8 ¾, 12 ¼ 200.0, 222.2, 311.1 

CH29 527 7 ½, 7 7 ⁄8, 8 ¾, 11, 12 ¼ 190.5, 200.0, 222.2, 279.4, 311.1 

CH29H (Hard) 527 7 7 ⁄8, 8 ¾ 200.0, 222.2 

CH31 537 7 7 ⁄8, 8 ¾, 11, 12 ¼ 200.0, 222.2, 279.4, 311.1 

CH33 537 7 7 ⁄8 200.0 

CH34 537 4 ¾, 4 7 ⁄8, 5 5 ⁄8, 5 7 ⁄8, 

6, 6 1 ⁄8, 6 ¼, 7 7 ⁄8, 8 3 ⁄8, 

8 ½, 8 ¾, 9 7 ⁄8, 12 ¼ 

120.7, 123.8, 142.9, 149.2, 

152.4, 155.6, 158.8, 200.0, 212.7 

215.9, 222.2, 250.8, 311.1 

CH35 547 4 ¾, 8 ½, 8 ¾ 120.7, 215.9, 222.2 

CH37 547 3 7 ⁄8, 4 ¾, 6 1 ⁄8, 6 ½ 98.4, 120.7, 155.6, 165.1 

CH38 547 7 7 ⁄8, 8 ½, 8 ¾ 200.0, 215.9, 222.2 

CH39 547 7 7 ⁄8, 8 ¾, 12 ¼ 200.0, 222.2, 311.1 

CH44 617 6 1 ⁄8, 6 ¼, 7 7 ⁄8, 8 ½, 

8 ¾, 9 7 ⁄8, 12 ¼ 

CH45 617 12 ¼ 311.1 

155.6, 158.8, 200.0, 215.9, 

222.2, 250.8, 311.1 

CH47 627 6 1 ⁄8, 7 7 ⁄8, 8 ½, 8 ¾ 155.6, 200.0, 215.9, 222.2 

ETD47 627 4 ¾, 4 7 ⁄8, 7 7 ⁄8 120.7, 123.8, 200.0 

CH48 627 8 ¾, 12 ¼ 222.2, 311.1 

CH49 627 7 7 ⁄8, 8 ¾ 200.0, 222.2 

CH54 637 6 ½, 12 ¼ 165.1, 311.1 

CH55 637 7 7 ⁄8, 8 ½, 12 ¼ 200.0, 215.9, 311.1 

CH57 637 8 ¾ 222.2 

CH67 647 7 7 ⁄8, 8 3 ⁄8, 8 ½, 8 ¾, 12 ¼ 200.0, 212.7, 215.9, 222.2, 311.1 

CH81 817 7 7 ⁄8 200.0 

CH85 837 8 ¾ 222.2 

CH91 837 8 ¾ 222.2 

11 

* optional features are available at extra cost

C h a l l e n g e r T C I - S e a l e d J o u r n a l A i r B i t s 


HET Conical Inserts 

Advanced Shirttail 

Contouring 

Semi-Round 

Top Gage 

Protection 

Semi-Round Top 



(see page 7) 

Center Air Jet 

(H Feature)** 

Nail Retention 

Replaceable Steel Jet Nozzles 



• Center Air Jet (H Feature) 




Shown: 7 7/8” CH35A 



12 




Varel’s air bits have high-performance journal bearings with 

silver-plated floating elements, advanced lubricant, and high 

aspect ratio HSN O-ring seals to provide a robust bearing 

package for both motor and standard rotary applications. A 

novel stepped shaped shale burn insert protects the seal from 

shale formation intrusion to enhance seal protection and extend 

seal life. 

Advanced Shirttail Contouring 

Extensive shirttail contouring and clearance from the wall of the 

hole ensures that fine cuttings are carried away from the seal 

area, providing longer seal life. 




efficiency in rock destruction. Varel’s Jet Air journal bearing 

bits are specially designed for underbalanced drilling 

conditions where air, mist, or foam circulation is used. These 

tungsten carbide insert (TCI) cutting structures are specifically 

engineered for very efficient drilling of the formation and hole 

cleaning to provide the most economical drilling solution. 

Medium extension conical inserts provide high penetration rates 

in medium formations with some harder streaks. This nonoffset 

cone design reduces sliding and cutter wear for longer 

bit life and toughness. Insert row placement and insert spacing 

are determined using Varel’s proprietary algorithms designed 

to reduce wear, promote efficient drilling and ensure uniform 

loading across the bit face. It also prevents tracking in a wide 

range of formations and conditions. 





better than flat-topped inserts and increase gage holding 

capabilities and seal protection. 

TCI - Sealed Journal Air Bit Availability 


CH35A 

CH37A 

547 

547 

7 7 ⁄8 

11 

200.0 

279.4 

CH45AH 617 8 ¾, 8 7 ⁄8 222.2, 225.4 

CH45A 617 

6 ¼, 6 3 ⁄ 8, 6 ½, 

7 7 ⁄8, 11 

158.8, 161.9, 165.1, 

200.0, 279.4 

CH47A 627 6 ¼, 6 ½ 158.8, 165.1 

CH57A 637 7 7 ⁄8 200.0 

CH57AH 637 8 ¾ , 8 7 ⁄8 222.2, 225.4 

Center Air Jet (H Feature)** 

Air type bits offer an optional center air jet nozzle featuring three 

additional air ports for enhanced cutting structure and enhanced 

hole cleaning. (Available in 8¾" and larger bits only) 

Replaceable Jet Nozzles 

Steel type jet nozzles feature a nail retention system for easy 

removal and installation. 

Air, Mist and Foam Applications 

All Air type sealed journal bearing bits are designed with 

aggressive cutter profiles and extensions for improved rates of 

penetration in either air, mist or foam type drilling applications. 

HET 

Varel’s High Energy Tumbling (HET) technology (patent pending) 

improves the toughness and fracture resistance of tungsten 

carbide inserts. 


Challenger bits feature an innovative, stepped shale burn insert. 

This stepped design is more effective in diverting cuttings away 

from the seal, prolonging seal life. 

13 



C h a l l e n g e r S t e e l T o o t h - S e a l e d J o u r n a l B e a r i n g B i t s 


Premium Hardfacing 

Forged Teeth 

Advanced Shirttail 

Contouring 

Shirttail 

Protection 

(see page 7) 

Semi-Round 

Top Gage 

Protection 

(G Feature)* 



Replaceable 

Jet Nozzle 








Shown: 12 1/4” CH1GJMS 



14 





Challenger steel tooth cutting structures are engineered to 

provide the lowest possible drilling costs. Each design has the 

row placement, tooth spacing and cutter geometry determined 

to provide high drilling efficiency, minimize tooth wear and 

prevent tracking in a wide variety of formations and conditions. 

Forged Teeth 

Challenger steel tooth bits 13 ¾" (349.2 mm) and smaller are 

manufactured with Varel’s exclusive forged tooth process. This 

innovative method provides stronger, more impact-resistant 

teeth when compared with milling because the metal flow lines 

from the forging process follow the tooth contour. 





Gage protection 

Challenger steel tooth bits feature superior gage protection. 

Semi-round top inserts are strategically placed between gage 

teeth, and work in unison with full tooth gage hardfacing to 

provide additional gage and seal protection. 


The tooth surfaces are fortified with premium, high-density 

tungsten carbide hardfacing applied by oxy-acetylene welding 

for superior wear resistance. 

Steel Tooth - Sealed Journal Bearing Bit Availability 


CH1G 117 6 1 ⁄ 8, 6 ¼, 7 7 ⁄8, 

8 ½, 8 ¾, 9 7 ⁄8, 

11, 11 5 ⁄ 8, 12 ¼, 

13 ½, 13 ¾ 

155.6, 158.8, 200.0, 

215.9, 222.2, 250.8, 

279.4, 295.3, 311.1, 

342.9, 349.2 

CH2G 127 7 7 ⁄8, 8 3 ⁄ 8, 8 ¾ 200.0, 212.7, 222.2 

CH3G 137 8 ½, 11 5 ⁄ 8, 12 ¼ 215.9, 295.3, 311.1 

ETD4 216 3 7 ⁄8, 4 ¾, 6 98.4, 120.7, 152.4 

CH4G 217 8 ½, 12 ¼ 215.9, 311.1 

Center Jet Nozzle (J Feature)** 



only in 8 3 ⁄ 8 " bits and larger.) 









15 



C h a l l e n g e r T C I - S e a l e d R o l l e r B e a r i n g B i t s 


Semi-Round 

Top Gage 

Protection 

Advanced 

Shirttail 

Contouring 

Shirttail 

Protection 

(see page 7) 

Replaceable 

Jet Nozzle 





• Diamond Enhanced Gage and Back Rows 

(DD Feature) 

• Fully Diamond Enhanced Cutting Structure 

(DDD Feature) 






Shown: 17 1/2” CR04JMRS 




16 







efficiency in rock destruction. Insert row placement and insert 

spacing are determined using Varel’s proprietary algorithms 

designed to reduce wear, prevent tracking, promote efficient 

drilling and ensure uniform loading across the bit face. 





better than flat-topped inserts. 


One third of the carbide back row inserts is replaced with 



Diamond Enhanced Gage and Back Rows (DD Feature)* 

One third of the back row and all gage inserts utilize PCDcapped 

inserts to maximize gage holding. 

Fully Diamond Enhanced Cutting Structure (DDD Feature)* 


abrasive applications. 

Shirttail Contouring 




TCI - Sealed Roller Bearing Bit Availability 


CR04 415 16, 17 ½ 406.4, 444.5 

CR12 435 14 ¾ 374.6 

CR13 435 16 406.4 

CR14 435 16, 17 ½ 406.4, 444.5 

CR18 445 16, 17 ½, 23 406.4, 444.5, 584.2 

ETR24 515 17 ½, 24 444.5, 609.6 

V515 515 26 660.4 

CR34 535 14 ¾ 374.6 

CR35 545 14 ¾ 374.6 

ETR38 545 17 ½ 444.5 



to reduce bit balling or provide extra flow capacity. (Available in 

8 3/8" and larger bits only) 





17 



C h a l l e n g e r S t e e l T o o t h - S e a l e d R o l l e r B e a r i n g B i t s 



Advanced 

Shirttail 

Contouring 

Advanced 

Shirttail 

Protection 

(see page 7) 

Semi-Round 

Top Gage 

Protection 



Replaceable 

Jet Nozzle 







Shown: 17 1/2” CR1GJMRS 

18 





Challenger steel tooth cutting structures are engineered to 

provide the lowest possible drilling costs. Each design has the 

row placement, tooth spacing and cutter geometry determined 

to provide high drilling efficiency, minimize tooth wear and 

prevent tracking in a wide variety of formations and conditions. 





Gage protection 

Challenger steel tooth bits feature superior gage protection. 

Semi-round top inserts are strategically placed between gage 

teeth, and work in unison with full tooth gage hardfacing to 

provide additional gage and seal protection. 





Steel tooth - Sealed Roller Bearing Bit Availability 


CR1G 115 16, 17 ½ 406.4, 444.5 

L115 115 26, 28 660.4, 711.2 

ETR1G 115 22, 23 558.8, 584.2 

CR3G 135 16, 17 ½ 406.4, 444.5 

ETR3G 135 

16, 17 ½, 23, 

26 

406.4, 444.5, 584.2, 

660.4 


A fourth interchangeable jet is installed in the center of the bit to 

reduce bit balling or provide extra flow capacity. (Available in 8 

3/8” and larger bits only) 









19 



S t e e l T o o t h - O p e n B e a r i n g B i t s 

Cutting Structures 


Forged Teeth 

Non-Sealed 

Roller Bearing 

Center Water Course 

Shown: 4 3/4” L2 

20


Cutting Structure 

High extension balling resistant cutting structure with forged 

teeth and self-sharpening tooth hardmetal for high penetration 

rates and long life in soft abrasive formations. 

Bearing Package 

Traditional ball and roller bearing, utilizing thrust buttons for 

axial bearing loads, gives reliable performance under a variety 

of rotary speeds and loads. 








only in 8 3 ⁄ 8 " bits and larger.) 

Forged Teeth 

Varel steel tooth bits 13 ¾" (349.2 mm) and smaller are 

manufactured with our exclusive forged tooth process. This 

innovative method provides stronger, more impact-resistant 

teeth when compared with milling because the metal flow lines 

from the forging process follow the tooth contours instead of 

being cut by machining. 

Steel Tooth - Open Bearing Bit Availability 

Bit Type IADC Inches (in) Millimeters (mm) 

L111 111 14 ¾, 15, 16, 

17 ½, 20, 22, 

23, 24, 26, 

34, 36 

L113 113 28 711.2 

374.6, 381.0, 406.4, 

444.5, 508.0, 558.8, 

584.2, 609.6, 660.4, 

863.6, 914.4 

L121 121 12 ¼, 13 ¾ 311.1, 349.2 

L131 131 17 ½, 22 444.5, 558.8 

L2 211 3 1 ⁄ 8 

, 3 ¼, 3 ½, 3 5 ⁄ 8 

, 

3 ¾, 3 7 ⁄ 8 

, 4 1 ⁄ 8 

, 

4 ¼, 4 ½, 4 5 ⁄ 8 

, 

4 ¾, 4 7 ⁄ 8 

, 5 1 ⁄ 8 

, 

5 ¼, 5 5 ⁄ 8 

, 6, 

6 1 ⁄ 8 

, 6 ¼, 6 ½, 

6 ¾ 

79.3, 82.5, 88.9, 92.1, 

95.2, 98.4, 104.8, 

107.9, 114.3, 117.5, 

120.7, 123.8, 130.1, 

133.4, 142.8, 152.4, 

155.5, 158.7, 165.1, 

171.4 

L1 311 3 7 ⁄8, 4 ¾, 6 1 ⁄ 8 98.4, 120.7, 155.6 

LH1 321 2 7 ⁄8, 2 15 ⁄ 16, 4, 

4½, 4 ¾, 4 7 ⁄8 

73.0, 74.6, 101.6, 

114.3, 120.6, 123.8 

21

R o l l e r C o n e R e f e r e n c e T a b l e s 

B i t C o n n e c t i o n s , T o t a l F l o w A r e a 

G a g e D i a m e t e r T o l e r a n c e s 

 

 

 

Size of Bit 

Tolerance 

in. in. mm 

1 3/4 to 13 3/4, inclusive + 1/32 - 0 + 0.80 - 0 

14 to 17 1/2, inclusive + 1/16 - 0 + 1.59 - 0 

17 5/8 and larger + 3/32 - 0 + 2.38 - 0 

 

 

 

 

Nozzle Flow Area (square inches) 

Nozzle 

Size 

1 

Nozzle 

2 

Nozzles 

3 

Nozzles 

4 

Nozzles 

7/32 

0.0376 

0.0752 

0.1127 

0.1503 

8/32 

0.0491 

0.0982 

0.1473 

0.1963 

9/32 

0.0621 

0.1243 

0.1864 

0.2485 

10/32 

0.0767 

0.1534 

0.2301 

0.3068 

11/32 

0.0928 

0.1856 

0.2784 

0.3712 

12/32 

0.1104 

0.2209 

0.3313 

0.4418 

13/32 

0.1296 

0.2592 

0.3889 

0.5185 

14/32 

0.1503 

0.3007 

0.4510 

0.6013 

15/32 

0.1726 

0.3451 

0.5177 

0.6903 

 

16/32 

0.1963 

0.3927 

0.5890 

0.7854 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

17/32 

18/32 

19/32 

20/32 

21/32 

22/32 

24/32 

26/32 

28/32 

0.2217 

0.2485 

0.2769 

0.3068 

0.3382 

0.3712 

0.4418 

0.5185 

0.6013 

0.4433 

0.4970 

0.5538 

0.6136 

0.6765 

0.7424 

0.8836 

1.0370 

1.2026 

0.6650 

0.7455 

0.8307 

0.9204 

1.10147 

1.1137 

1.3254 

1.5555 

1.8040 

0.8866 

0.9940 

1.1075 

1.2272 

1.3530 

1.4849 

1.7671 

2.0739 

2.4053 

22

M a k e u p T o r q u e T a b l e 

P i n S i z e / N o z z l e T a b l e 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in. 

 

 

mm 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3 7/8 - 4 1/2 

98.4 - 114.3 

ALL 

15669 

8 thru 16, 18 

-------- 

-------- 

-------- 

-------- 

4 3/4 - 6 

5 5/8 

120.7 - 152.4 

142.9 

ALL 

OPEN 

5940 

8 thru 16, 18, 20 

11114 

8 thru 13 

-------- 

-------- 

6 1/8 - 6 3/4 

6 1/4 

155.6 - 171.5 

158.8 

SEALED 

OPEN 

17536 

8 thru 16, 18, 20 

-------- 

-------- 

-------- 

-------- 

7 1/2 - 7 7/8 

9 5/8 - 9 7/8* 

8 1/2 

190.5 - 200.0 

244.5 - 250.8 

215.9 

SEALED 

SEALED 

OPEN 

5941 

8 thru 16, 18, 20, 

22, 24, 26, 28 

-------- 

-------- 

12102 

9 thru 16, 18, 20 

8 3/8 - 12* 

12 1/4 - 15 

212.7 - 304.8 

311.1 - 381.0 

SEALED 

ALL 

6703 

8 thru 16, 18, 20, 

22, 24, 26, 28 

-------- 

-------- 

12278 

9 thru 16, 18, 20, 22 

12 thru 16, 18, 20, 

16 - 28 

406.4 - 711.2 

ALL 

10735 

9 thru 16, 18 thru 20, 

22, 24, 26, 28 

-------- 

-------- 

17597 

22, 24, 28 

* These sizes may vary in nozzle part number. Check with your sales representative for the specific assemblier. 

23

B i t S h i p p i n g W e i g h t s 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24

25

World Headquarters 

Dallas, Texas USA 

Tel: 1.800.827.3526 

Tel: +1.972.242.1160 

Fax: +1.972.242.8770 

INFO@VARELINTL.COM 

Western Hemisphere 

Western United States 

Fort Worth, Texas USA 

Tel: 1.800.827.3526 

Tel: +1.817.439.1183 

Fax: +1.817.439.4294 

Odessa, Texas USA 

Tel: 1.800.371.1658 

Tel: +1.432.367.1658 

Fax: +1.432.550.5385 

Gulf Coast & South Texas 

Houston, Texas USA 

Tel: 1.888.273.5334 

Tel: +1.281.670.2401 

Fax: +1.281.590.6047 

Lafayette, Louisana USA 

Tel: +1.337.237.4245 

Fax: +1.337.237.4966 

Mid-Continent & Rockies 

Oklahoma City, Oklahoma USA 

Tel: 1.888.731.4046 

Tel: +1.405.672.3633 

Fax: +1.405.672.4696 

Southeastern United States 

Flint, Texas USA 

Tel: +1.903.894.5923 

Fax: +1.903.894.5925 

Canada 

c/o Perdemak Industries 

Edmonton, Alberta Canada 

Tel: 1.888.988.4988 

Tel: +1.780.435.5706 

Fax: +1.780.438.3290 

Eastern Hemisphere 

Africa 

Hassi-Messaoud, Algeria 

Tel: +213.2975.4738 

Fax: +213.2975.4737 

Cairo, Egypt 

Tel: +20.12.325.3240 

Asia/Pacific 

Booragoon, WA Australia 

Tel: +61.8.9315.9999 

Fax: +61.8.9315.9800 

Balikpapan, Indonesia 

Tel: +62.54.287.7859 

Fax: +62.54.287.7950 

Kuala Lumpur, Malaysia 

Tel: +60.32.693.2255 

Fax: +60.32.693.7550 

Ho Chi Minh City, Vietnam 

Tel: +848.823.2535 

Fax: +848.823.2537 

Europe 

Pau, France 

Tel: +33.55.914.4825 

Fax: +33.44.914.4844 

Den Helder, The Netherlands 

Tel: +31. 223.691.200 

Fax: +31.223.691.201 

Middle East 

Muttrah, Oman 

Tel: +968.789.070 

Islamabad, Pakistan 

Tel: +92.51.225.6170 

Fax: +92.51.225.6190 

Doha, Qatar 

Tel: +974.44.38.986 

Fax: +974.44. 38.986 

Al Khobar, Saudi Arabia 

Tel: +966.3887.9273 

Fax: +966.3887.4479 

Abu Dhabi, UAE 

Tel: +97.12.644.8414 

Fax: +97.12.644.8424 

Dubai, UAE 

Tel: +971.4335.3525 

Fax: +971.4335.3532 

United Kingdom 

Aberdeen, Scotland, UK 

Tel: +44.122.421.6310 

Fax: +44.122.489.1450 

MKTG 12B500-09-2006 

VA R E L I n t e r n at i o n a l 

For other regions, contact Varel’s world headquarters or email info@varelintl.com. 

w w w. va r e l i n t l . c o m

Roller Cone Bits - Oil & Gas Products 2006-2007 - Varel International

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?