Optimal Drill Bit Nozzle Sizing

Drilling Engineering
Prepared by: Tan Nguyen

Drilling Engineering PE 311

Drill Bit Optimization
Significant increases in ROP can be achieved through the proper choice of bit
nozzle.
Most commonly used hydraulic design parameters are:
Bit nozzle velocity
Bit hydraulic horsepower
Jet impact force
Current field practice involves the selection of the bit nozzle sizes that will cause
one of these parameters to be a Maximum

Optimization of Hydraulic Parameters
Introduction
y = f(x)
: The tangent to the curve
is horizontal.
Solve this equation we can get the critical
values (either max or min): x = a or x = b.
Second derivative:
The function has a minimum value at x = b if
f
/
(b) = 0 and f
//
(b) is a positive number
The function has a maximum value at x = a if
f
/
(a) = 0 and f
//
(a) is a negative number

Maximum and Minimum Values - Review
Flow velocity through bit nozzle

So velocity is directly proportional to the square root of the pressure drop across the bit
The nozzle velocity is a maximum when the pressure drop available at the bit is a maximum. This
can be achieved when the pump pressure is a maximum and the frictional pressure loss in the
drillstring and annulus is a minimum; the frictional pressure loss is a minimum when the flow rate
is a minimum

Maximum Nozzle Velocity
4
10 074 . 8

A
=
bit
n
p
v
b n
p v A
Nozzle velocity may be maximized consistent with the following two constraints:
The annular fluid velocity needs to be high enough to lift the drill cuttings out of the hole. This
requirement sets the minimum fluid circulation rate.
The surface pump pressure must stay within the maximum allowable pressure rating of the pump
and the surface equipment.

Maximum Nozzle Velocity
Effectiveness of jet bits could be improved by increasing the hydraulic power of the pump.
Penetration rate would increase with hydraulic horsepower until the cuttings were removed as fast
as they were generated. After this level, there should be no further increase in the penetration
rate. Note that the hydraulic horsepower developed by the pump is different from the hydraulic
horsepower at the bottom of the hole. This is due to the friction losses in the drillstring and in the
annulus. Therefore, the bit horsepower was not necessarily maximized by operating the pump at
the maximum possible horsepower.

Maximum Bit Hydraulic Horsepower
The Pump Pressure is expended by:
1. Frictional pressure losses in the surface equipment, Ap
s
2. Frictional pressure losses in the drillpipe, Ap
dp
, and drill collars, Ap
dc
3. Pressure losses caused by accelerating the drilling fluid through the nozzle
4. Frictional pressure losses in the drill collar annulus, Ap
dca
, and drillpipe annulus, Ap
dpa

Let:
bit dpa dca dc dp s pump
p p p p p p P A + A + A + A + A + A =
dpa dca dc dp s f
p p p p p P A + A + A + A + A = A
Hence, the pressure loss at the pump will be sum of pressure loss at the bit and total frictional
pressure loss to and from the bit:

It is well know that the frictional pressure loss is a function of flow rate and can be expressed as

f bit pump
p p P A + A =

75 . 1
q p
f
A
75 . 4
25 . 0 75 . 1 75 . 0
25 . 0
25 . 0
75 . 1
75 . 0
8624 1800 d
q
d
v
dL
dp
= =
Hence, Ap
d
can be expressed as

m is a constant has a value near 1.75, c is a constant that depends on the mud properties and
wellbore geometry
Pressure drop across the bit

The bit Hydraulic horsepower

m
f
cq p = A
m
pump bit
cq p p A = A
1714 1714
1 +
A
=
A
=
m
pump
bit
Hb
cq q p
q p
P
Bit horsepower is a function of flow rate

The bit horsepower reaches maximum when:

Or

1714 1714
1 +
A
=
A
=
m
pump
bit
Hb
cq q p
q p
P
0
1714
) 1 (
1714
=
+ A
=
|
.
|
\
| A
=
m
pump
bit
Hb
cq m p
dq
q p
d
dq
dP
f
m
pump
p m cq m p A + = + = A ) 1 ( ) 1 (
1 +
A
= A
m
p
p
pump
f
Bit hydraulic horsepower is a maximum when

Since
The hydraulic horsepower will be maximum at
Or:

1 +
A
= A
m
p
p
pump
f
1 +
A
= A
m
p
p
pump
f
1
1
+
=
A
A
m p
p
pump
f
Jet impact force is a function of Ap
bit
= Ap
pump
Ap
f
. Note that Ap
f
is the total pressure loss in
pipes and annuli.

Maximum Jet Impact Force
) ( c 0.01823 01823 . 0
d f pump bit d j
p p q p q c F A A = A =
2 2
01823 . 0
+
A =
= A
m
d pump d j
m
f
q c q p c F
then cq p With

The impact force is maximized when,
Solve the above equation yields,
or
Since , the jet impact force will be maximum at

Maximum Jet Impact Force
pump f
p
m
p A
+
= A
2
2
0 =
dq
dF
j
pump f
p
m
p A
+
= A
2
2
2
2
+
=
A
A
m p
p
pump
f
In general, the hydraulic horsepower is not optimized at all times . It is usually more convenient to
select a pump liner size that will be suitable for the entire well rather than periodically changing
the liner size as the well depth increases to achieve the theoretical maximum. Thus, in the
shallow part of the well, the flow rate usually is held constant at the maximum rate that can be
achieved with the convenient liner size. Note that at no time should the flow rate be allowed to
drop below the required for proper cuttings removal
For a given pump horsepower rating P
HP

E is the overall pump efficiency, p
max
is the maximum allowable pump pressure set by contractor.
This flow rate will be used until the depth is reached at which Ap
d
/Ap
p
at the optimum value. Then
the flow rate will be reduced to the minimum value which it can still lift the cuttings.

Nozzle Size Selection Graphical Analysis
max
max
1714
p
E P
q
HP
=
Three intervals
Interval 1: defined by q =q
max
.Shallow portion of the well where the pump is operated at
the maximum allowable pressure
Interval 2: defined by constant Ap
f
.Intermediate portion of the well where the flow rate is
reduced gradually to maintain Ap
d
/p
max
at the proper value for maximum bit hydraulic
horsepower or impact force.
Interval 3: defined by q =q
min
. Deep portion of the well where the flow rate has been
reduced to the minimum value that efficiently will lift the cuttings to the surface.

75 . 4
25 . 0 75 . 1 75 . 0
8624 d
q
dL
dp
=

) log( ) 1714 log( ) log( q P p
H pump
=
Slope -1
Slope 1.75
1714
q p
P
pump
H
=
1. Show opt. hydraulic path
2. Plot Ap
f
vs q
3. From Plot, determine optimum q and Ap
f
4. Calculate

5. Calculate total nozzle area

6. Calculate Nozzle Diameter
f pump bit
p p p A A = A
opt b d
opt
opt t
p C
q
A
) (
10 * 311 . 8
) (
2
2
5
A
=


Determine the proper pump operating conditions and bit nozzle sizes for maximum jet impact
force for the next bit run. The bit currently in use has three 12/32-in nozzles. The driller has
recorded that when the 9.6lbm/gal mud is pumped at a rate of 485 gal/min, a pump pressure of
2800 psig is observed and when the pump is slowed to a rate of 247 gal/min, a pump pressure of
900 psig is observed. The pump is rated at 1,250 hp and has an efficiency of 0.91. The minimum
flow rate to lift the cuttings is 225 gal/min. The maximum allowable surface pressure is 3000psig.
The mud density will remain unchanged in the next bit run.

Example
Pressure drop through the bit:

Total frictional pressure loss inside the drillstring and in the annulus at different flow rate:
Example
psig
A c
q
p
t d
b
1894
32
12
*
4
* 3 * 95 . 0
485 * 6 . 9 * 10 * 311 . 8 10 * 311 . 8
2
2
2
2 5
2 2
2 5
1
=
(
(
|
.
|
\
|
= = A

t
psig
A c
q
p
t d
b
491
32
12
*
4
* 3 * 95 . 0
247 * 6 . 9 * 10 * 311 . 8 10 * 311 . 8
2
2
2
2 5
2 2
2 5
2
=
(
(
|
.
|
\
|
= = A

t
psig p p p
bit pump f
906 1894 2800
1
= = A A = A
psig p p p
bit pump f
409 491 900
2
= = A A = A
m = 1.2, for optimum hydraulics

Interval 1:

Interval 2:

Interval 3:
Example
gal/min 650
000 , 3
) 91 . 0 )( 250 , 1 ( 714 , 1
714 , 1
q
max
max
= = =
P
E P
Hp
psig 875 , 1 ) 000 , 3 (
2 2 . 1
2
2
2
p
max f
=
|
.
|
\
|
+
=
|
.
|
\
|
+
= A P
m
gal/min 225 q
min
=

Example

From graph, the optimum point:

The proper total nozzle area is:

The nozzle size
Example
psi p psi
gal
q
bit opt
700 , 1 300 , 1 p ,
min
650
f
= A = A =
2
2
2 5 -
2
2
5
in 0.47
) 700 , 1 ( * ) 95 . 0 (
) 650 ( * 6 . 9 * 10 * 8.311
) (
10 * 311 . 8
) ( = =
A
=

opt bit d
opt
opt t
p C
q
A

( ) in
A
d
t
opt N 32
14
3
4
= =
t

Example
psi
gal
q
opt
300 , 1 p ,
min
650
d
= A =
The goal of bit selection is to obtain the lowest cost per foot. The cost per foot can be
calculated by using the equation:

Where C is the overall cost per foot, $/ft; C
b
is the cost of the bit, $; C
r
is the cost of
operating the rig $/hr; t
b
is the rotating time with bit on bottom, hours; t
t
is the round
trip time, including connection time, hours; t
o
is the other time, which is not rotating
time or trip time, hours; and AD is the total depth as a given total time, ft.

Cost-per-foot Calculation
Optimization of Economics
Drilling costs tend to increase exponentially with depth. Thus, when curve fitting
drilling cost data, it is often convenient to assume a relationship between cost, C and
depth, D given by
C = ae
bD

Where a, $, and b, ft
-1
, depend primarily on the well location.
The cost per day of the drilling operations can be estimated from considerations of
rig rental costs, other equipment rentals, transportation costs, rig supervision costs,
and others. The time required to drill and complete the well is estimated on the basis
of rig-up time, drilling time, trip time, casing placement time, formation evaluation,
borehole survey time, completion time and trouble time.
Example: A recommended bit program is being prepared for a new well using bit
performance records from nearby wells. Drilling performance records for three bits
are shown for a thick limestone formation at 9000 ft. Determine which bit gives the
lowest drilling cost if the operating cost of the rig is 400 $/hr, the trip time is 7 hours,
and connection time is 1 minute per connection. Assume that each of the bits was
operated at near the minimum cost per foot attainable for that bit.
Bit Bit cost
$
Rotating time
hours
Connection time
hours
Mean penetration rate
ft/hr
A 800 14.8 0.1 13.8
B 4900 57.7 0.4 12.6
C 4500 95.8 0.5 10.2
Bit
Bit cost
$
Rotating time
hours
Connection time
hours
Mean ROP
ft/hr
Total cost
$/ft
A 800 14.8 0.1 13.8 46.80768
B 4900 57.7 0.4 12.6 42.55729
C 4500 95.8 0.5 10.2 46.89099
The performance of a bit can also be determined by using run-cycle speed (RCS).
The RCS is defined as:

Where D is the total footage determined by the particular bit.
Run Cycle Speed
Break-even Analysis
Break-even Analysis
Break-even Analysis
There is almost always some uncertainty about the best time to terminate a bit run
and begin tripping operations. The use of the tooth-wear equation and the bearing-
wear equation will provide, at best, a rough estimate of when the bit will be
completely worn. In addition, it is helpful to monitor the rotary-table torque. In the
case of a roller-cone bit, when the bearings become badly worn, one or more of the
cones frequently will lock and cause a sudden increase or large fluctuation in the
rotary torque needed to rotate the bit. With a PDC or fixed-cutter bit, when cutter
elements are heavily worn or broken, or the bit becomes undergauge, the bit will
exhibit much lower than expected ROP and cyclic or elevated torque values.
Termination of a Bit Run
When the ROP decreases rapidly as bit wear progresses, it may be advisable to pull
the bit before it is completely worn. If the lithology of the formation is homogeneous,
the total drilling cost can be reduced by minimizing the cost of each bit run. In this
case, one way to determine when to terminate the bit run is by keeping a current
running calculation of the cost per foot for the run, assuming that the bit would be
pulled at the current depth. Even if significant bit life remains, the bit should be pulled
when the computed cost per foot begins to increase.
However, if the lithology of the formation is not uniform, this procedure will not always
result in the minimum total cost. In this case, an effective criterion for determining
optimum bit life can be better established after offset wells are drilled in the area,
thus defining the lithological variations, and the contribution of the rock properties
can be studied and understood better.
Example: Determine the optimum bit life for the bit run described in the table below.
The lithology of the formation is known to be essentially uniform in this area. The bit
cost is $5000. The rig cost is 4000 $/hr; and the trip time is 10 hours.
footage, AD
ft
drilling time, t
b
+ t
o

hrs
Remarks
Drilling Cost, C
$/ft
0 0 New 0.0
30 2 1766.7
50 4 1220.0
65 6 1061.5
77 8 1000.0
87 10 977.0
96 12 968.8
104 14 971.2
111 16 Torque Increased 982.0
t
total
= t
t
+ t
e

t
e
= C
b
/C
r

Example: Determine the optimum bit life for the bit run described in the table
below. The lithology of the formation is known to be essentially uniform in this
area. The bit cost is $5000. The rig cost is 4000 $/hr; and the trip time is 10 hours.
Footage, AD ft
drilling time
t
b
+ t
o
, hrs
Remarks
0 0 New
30 2
50 4
65 6
77 8
87 10
96 12
104 14
111 16 Torque Increased
Solution:
C
b
= 5000 USD
C
r
= 4000 $/hr
C
b
/C
r
= 5000/4000 = 1.25 hrs

Using the equation above with different dD/dt. t
e
= C
b
/C
r
= 1.25 hrs. The optimal
line corresponds to dD/dt = 4.2. Time to change the drill bit is 12 hours and at the
depth of 96 ft.


Optimal Drill Bit Nozzle Sizing

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Optimal Drill Bit Nozzle Sizing

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Drilling Engineering

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

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