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4.3 ROTARY EQUIPMENT If working space is restricted and length is an issue, a

Rotary equipment refers to all pieces of surface equipment in shorter, more compact single-piece Kelly valve can be used
drilling operations that actually rotate or introduce rotational instead (Figure 4.3.9).
force to the drill string. This equipment includes the swivel The spring-loaded mud check valve (Figure 4.3.10) can be
and the rotary hose, the upper and lower Kelly valves, the used as an alternative to the manually operated valves. When
Kelly, the Kelly bushings, the master bushing, and the rotary the mud pumps are shut off, this valve closes automatically to
table. prevent mud spilling onto therigfloor.This tool is designed
as full opening or full closing to avoid a pressure loss across
the valve during circulation.
4.3.1 Swivel and Rotary Hose
4.3.1.1 Swivel
The swivel (Figure 4.3.1) is suspended from the hook and 4.3.3 Kelly
traveling block and forms the top part of the drill stem. It The Kelly is a square or hexagonally shaped pipe (Figure
allows for the rotation of the Kelly and provides a pressure 4.3.11). It transmits the power from the rotary table to the
tight connection from the rotary hose to the drill string to drill string. At the same time it serves as a conduit for the
allow the circulation of drilling fluids. drilling fluid, it absorbs torque from the drill string and
The swivel is made up of a stationary and a rotating part carries the entire axial load. It is the most heavily loaded com-
and has to support the entire string weight during drilling ponent of the drill string. Refer to API RP7G for dimensions
operations. The rotating part turns over the main axial bear- and further specifications.
ing, which is mounted in an oilfilledhousing. The fluid-tight Square Kellies are normally forged over the drive section,
connection between the two parts consists of a wash pipe whereas hexagonal Kellies have been machined from bar
assembly. The seal unit is the most vulnerable part of the stock. Typically, the machinedflatshave a greater resistance
swivel (Figure 4.3.2). Daily greasing of the seals and ensur- to wear than the forged surfaces.
ing sufficient hydraulic fluid level will prevent leakage and Kellies are manufactured from AISI 4145-modified, fully
decrease wear on the wash pipe assembly. heat-treated alloy steel with a Brinell hardness range of 285-
341 and a minimum average Charpy impact value of 40 ft-lb.
Upper and lower upsets are kept long so that the Kelly can
4.3.1.2 Rotary Hose be rethreaded in case of thread damage.
Although the rotary hose is not a rotating element, it is For Kellies with the same outside diameter, a hexagonal
included here because of its connection to the swivel. It Kelly will have a stronger drive section than a square Kelly
serves as aflexiblehigh-pressure conduit between the stand (Figure 4.3.12). Under a given load the stress levels in the
pipe and the swivel and allows vertical travel of the swivel hexagonal Kelly will be lower, leading to a longer service life.
and block (Figure 4.3.3). Service life as mentioned previously is greatly influenced
Usual length of the rotary hose is 45 ft. The minimum by the maintenance of the drive bushing. Frequent adjust-
burst pressure rating should be 2\ times the allowable ments of the rollers should be conducted to minimize play
working pressure. A pressure test should be conducted between the Kelly and the drive bushing.
before drilling a new hole section. Further rotary hose Frequent inspections of the following items will increase
specifications are provided in API RP7G. the service life of all components:
• The corners of the drive section (surface wear)
4.3.2 Drill-Stem Subs • Transition between the upset and the drive section
Different types of drill-stem subs are depicted in Figures (cracking)
4.3.4 and 4.3.5. The classification of drill-stem subs is pre- • Straightness of the Kelly
sented in Table 4.3.1. Their location within the string can be
seen at Figure 4.3.6. Operating with a bent Kelly will cause
• Severe vibrations at surface
4.3.2.1 Swivel Sub • Additional wear on the drill pipe tools joints and the BOP
The outside diameter of the swivel sub is at least equal to the and well head
diameter of the outside of the upper Kelly box. The swivel • Additional bending stresses in the drill string
sub should have a minimum of 8 in. of tong space length. The • Rapid wear on the Kelly and master bushings.
minimum diameter is equal to the Kelly diameter. The swivel
sub is machined with a pin-up and pin-down left-handed
rotary-shouldered connection. 4.3.4 Rotary Table and Bushings
4.3.4.1 Rotary Table
The rotary table (Figure 4.3.13) serves a dual function:
4.3.2.2 Upper Kelly Valve It provides the rotary movement to the Kelly and applies
The upper Kelly valve or Kelly cock (Figure 4.3.7) is located torque to the drill string. As the rotary table runs, the master
between the swivel sub and the Kelly. The Kelly cock is a bushing, the Kelly, the drill pipe, and the bit also turn. The
flapper-type valve. This valve must be manually closed to rotary table is driven by an independent electric motor or
isolate the Kelly and drill string from the swivel and rotary on diesel mechanical drives by a compound drive by the
hose. The valve can be partially opened by starting up the drawworks engine.
mud pumps, but it must be fully opened manually to prevent When tripping pipe in and out of the well, the rotary table
mud cutting. supports the drill string when the load is not suspended from
the hook. At those times, it carries the entire weight of the
4.3.2.3 Lower Kelly Valve drill string.
The lower Kelly valve or Kelly cock is located between the The rotary table (Figure 4.3.14) rests on reinforced beams
Kelly and the lower Kelly saver sub. This valve is a full- in therigfloorthat transfer the loads to the sub structure of
opening, ball-type valve typically operated with a hex-type the rig. The rotary has a cast or reinforced steel base that
wrench (Figure 4.3.8). By closing this valve before breaking acts as a foundation to provide the strength and stability for
a joint, this valve will prevent mud spilling on to the drill floor. this piece of equipment. The turntable rotates in the base
 Gooseneck
Internal line-
pipe thread
External line-
pipe thread
Rotary drilling
hose
Swivel stem
Swivel sub
Figure 4.3.1 Swivel nomenclature.
using a heavy ball bearing and a ring gear shrunk over the
turntable.
The ring gear is driven by a pinion shaft with roller bear-
ings and seals. A detachable sprocket is connected to the
pinion shaft on diesel mechanical drives or a coupling con-
nector when driven by an electric motor. The rotary table is
equipped with a locking device that is used when making up
or breaking out the drill bit. It is also used to lock the drill
string in place when directionally drilling with a motor. This
lock should not be used when making up or breaking out pipe
during a round trip. The combination of torque and bending
moment can lead to premature pipe failure. The turntable has
an opening in the center that houses the master bushing.
4.3.4.2 Master Bushing
The master bushing fits into the turntable and makes it pos-
sible to transfer the rotational movement of the rotary table
to the Kelly. It also accommodates the slips when pipe is to
be suspended in the rotary table. Because the bushings are
MFRS
standard rotary
connection LH.
API standard rotary
connection LH.
a removable insert, they also function as a wear sleeve for
the rotary table.
There are two types of master bushings:
• Square drive master bushings (Figure 4.3.15)
• Pin drive master bushings (Figure 4.3.16)
Master bushings are constructed as a solid single piece
(Figure 4.3.17), as a split bushing in two halves (Figure
4.3.18), or as a hinged type (Figure 4.3.19). All are machined
with a taper to accommodate a range of pipe and slip
sizes.
The API requirements for rotary table openings for
square drive master bushings, and the sizes of the
square drive and pindrive master bushings are specified in
API RP7G.
4.3.4.3 Kelly Bushing
The Kelly bushing engages with the master bushing. It locks
into the master bushing and transfers the rotary torque to
 Bail

Goose neck

Wash pipe
Stuffing box
Oil seal
Stationary part
Body filled with oil
Main bearing

Oil seal

Rotating part

Connection to Kelly

Figure 4.3.2 National (ideal) swivel.

the Kelly. There are two types of Kelly bushings: Another version of the Kelly bushing is the double roller-
type Kelly bushing (Figure 4.3.23). This Kelly drive has two
• Square drive Kelly bushing that engages in a square rollers per Kelly flat stacked above each other in a roller
master bushing (Figure 4.3.20). assembly block. This Kelly bushing is used in high-torque
• Pin drive Kelly bushing that engages in the pin drive holes applications. It reduces wear to the Kelly and itself through
of the master bushing (Figure 4.3.21). a wider force distribution.
The Kelly bushing is equipped with rollers that allow axial For installation and maintenance every Kelly bushing is
movement of the Kelly while the rotary is stationary or equipped with a cover that can be removed to allow access
rotating. and removal of the rollers.
For a square Kelly, the Kelly bushing is fitted with four All rollers are adjustable to minimize the available play
plane rollers. For a hexagonal Kelly, the Kelly bushing is of the Kelly in the bushing. This will reduce vibration on
fitted with two plane rollers and two 120° V-rollers (Figure the rotary and the drill string and reduce wear on the
4.3.22) or with sixflatrollers. Kelly.
 Highest Operating Position

Length of House Traveled

Stand Pipe
Height

Lowest Operating Position

Top of
Drilling Floor

Figure 4.3.3 Rotary hose.

 Pin to Pin Pin to Box Box to Box Pin to Box Box to Pin

STRAIGHTTYPES BOTTLENECKTYPES

Figure 4.3.4 Drill-stem subs.

Rotary Pin or Box Connection

LH Pin
TYPEA TYPEB Connection

36" Marketing
(see note 1) Recess
TYPEC
48" Marking
Recess
(see note 2)
8"
45° min.
max.

45°
max.

45°
max.

Rotary Pin or Box Connection

Figure 4.3.5 Types of drill-stem subs.

Table 4.3.1 Drill-Stem Subs

1 2 3 4
Type Class Upper Connection Lower Connection
to Assemble w/ to Assemble w/
AorB Kelly sub Kelly Tool joint
Tool joint sub Tool joint Tool joint
Crossover sub Tool joint Drill collar
Drill collar sub Drill collar Drill collar
Bit sub Drill collar Bit
C Swivel sub Swivel sub Kelly
 SWIVEL
ROTARYBOX
CONNECTION LH. SWIVEL STEM
SPEC 8A
— I -
ROTARY PIN SPEC 7
CONNECTION LH. SWIVEL SUB

ROTARY BOX
CONNECTION LH.

KELLY COCK
(OPTIONAL)
ROTARY PIN
CONNECTION LH.
ROTARY BOX
CONNECTION LH.
UPPER UPSET

KELLY
(SQUARE OR HEXAGON)
(SQUARE ILLUSTRATED)
NOTE:
ALL CONNECTIONS
BETWEEN "LOWER
UPSET" OF KELLY
AND "BIT" ARE R.H. <

LOWER UPSET
ROTARY PIN
CONNECTION
ROTARY BOX KELLY COCK OR
CONNECTION KELLY SAVER SUB
PROTECTOR
RUBBER
(OPTIONAL)
ROTARY PIN
CONNECTION

Figure 4.3.6 Placement of drill-stem subs.

 E O.D.'
Omscos' newly
patented pressure-
compensated ball
A valve is now standard
in all OMSCO ball
Wrench D type valves. This
Ram key feature ensures that if
Ram Shaft the valve is closed
Blind Nut Shaft Packing with pressure below,
Shaft Washer Junk Ring-Female the valve can be
Shaft Capscr. Blind Nut Key opened in order to
Friction Ring Junk Ring-Male "kil the kick."
Shaft Spacer Retainer Pl. Scr.
Ram Body Valve Body Patented I.D.
Ram Rubber Retainer Plate Upper Sub
Lower Sub 'Spring
Seat with Seal L
Seat "O" Ring
Ball
Stem
Stem "O" Ring
& Seat with Seal
Seat "O" Ring
B Spring
Lower Sub

Figure 4.3.7 Upper Kelly valve. R

' equired for ML675 and ML750

Figure 4.3.8 Lower Kelly valve.

Stem "O" Rings

(1 Set)
0.D
Snap
Ring
Retainer
Funnel
Funnel
Wrench "O"Split
Ring B
Retainer
Funnel
Stem "O" Ring A
Ball
Lower Seat
"O" Ring Upper
Seat
Valve Body IA Lower
Seat
Length Spri
ng
Upper Seat
"O" Ring

Figure 4.3.9 Single-piece lower Kelly valve.

 (B)

Top Sub

Knock-Out Cap

, Locking Bolt

Cap Holder

Valve

(A) Upper Seal Support

STANDARD
6 1/21, 6 3/8"
or 6 1/411OD
Spring

Casing Protector

Lower Seal Housing

Slide

Body

Wear Sub

or
Figure 4.3.10 Spring-loaded mind saver valve.
 SQUARE HEXAGONAL

Top Upset
with
Left Hand
Top Upset Connection
with
Left Hand
Connection

A A
(Less (Less
3 Feet) 3 Feet)

Bottom
Bottom
Upset
Upset
with
with
Right Hand
Right Hand
Connection
Connection

Figure 4.3.11 Square and hexagonal Kelly.

Figure 4.3.12 Hexagonal and square Kelly
cross-section.

Figure 4.3.13 Rotary table with pin drive master

bushings.

ring gear split master bushing turntable

mud seals

shaft

main bearing

sprocket
pinion locking pawl wheel
Figure 4.3.14 Rotary table with split master bushing.

Figure 4.3.15 Rotary table opening and square drive master bushing.
 - G-Diameter
Drive Hole

4" ±0.018" PIN DRIVE

Taper per foot KELLY BUSHING
9° 27' 45 ± 2' 30"
Taper per side

PIN DRIVE
MASTER BUSHING

Figure 4.3.16 Pin-drive master bushing.

Figure 4.3.17 Solid-body master bushing.

 Figure 4.3.18 Split-body pin drive master bushing.

Figure 4.3.19 Hinged-body pin drive master bushing.

Figure 4.3.20 Square drive Kelly bushing for square
Kelly.
 Figure 4.3.21 Pin drive Kelly bushing for hexagonal Kelly.

• 20° V-roller

plane roller

journals

square

Figure 4.3.23 Double roller pin drive Kelly bushin

Figure 4.3.22 Kelly bushing for hexagonal Kelly.
4.4 MUD PUMPS
Mud pumps consume more than 60% of all the horsepower
used in rotary drilling. Mud pumps are used to circulate
drilling fluid through the mud circulation system while
drilling. A pump with twofluidcylinders, as shown in Figure
4.4.1, is called a duplex pump. A three-fluid-cylinder pump, as
shown in Figure 4.4.2, is called a triplex pump. Duplex pumps
are usually double action, and triplex pumps are usually
single action. Pumps with six chambers are commercially
available as well (Figure 4.4.3).
Mud pumps consists of a power input end and afluidoutput
end. The power input end, shown in Figure 4.4.4 transfers
power from the driving engine (usually diesel or electric) to
the pump crankshaft. The fluid end does the actual work of
pumping thefluid.A cross-section of the fluid end is shown
in Figure.4.4.5.
4.4.1 Pump Installation
4.4.1.1 Suction Manifold
The hydraulic horsepower produced by mud pumps depends
mainly on the geometric and mechanical arrangement of the
suction piping. If suction-charging centrifugal pumps (e.g.,
auxiliary pumps that help move the mud to the mud pump)
are not used, the pump cylinders have to be filled by the
hydrostatic head.
Incomplete filling of the cylinders can result in ham-
mering, which produces destructive pressure peaks and
shortens the pump life. Filling problems become more
important with higher piston velocities. The suction pres-
sure loss through the suction valve and seat is from 5 to
10 psi. Approximately 1.5 psi of pressure is required for
each foot of suction lift. Since the maximum available atmo-
spheric pressure is 14.7 psi (sea level), suction pits placed
below the pump should be eliminated. Instead, suction tanks
placed level with or higher than the pump should be used to
ensure a positive suction head. Figure 4.4.6 shows an ideal
suction arrangement with the least amount of friction and low
inertia.
A poorly designed suction entrance to the pump can pro-
duce friction equivalent to 30 ft of pipe. Factors contributing
to excessive suction pipe friction are an intake connection
with sharp ends, a suction strainer, suction pipe with a
small diameter, long runs of suction pipe, and numerous fit-
tings along the suction pipe. Minimizing the effect of inertia
requires a reduction of the suction velocity and mud weight.
It is generally practical to use a short suction pipe with a
large diameter.
When a desirable suction condition cannot be attained,
a charging pump becomes necessary. This is a common
solution used on many modern rigs.
4.4.1.2 Cooling Mud
Mud temperatures of 150° can present critical suction prob-
lems. Under low pressure or vacuum existing in the cylinder
on the suction stroke, the mud can boil, hence decreasing
the suction effectiveness. Furthermore, hot mud accelerates
the deterioration of rubber parts, particularly when oil is
present. Large mud tanks with cooling surfaces usually solve
the problem.
4.4.1.3 Gas and Air Separation
Entrained gas and air expands under the reduced pressure
of the suction stroke, lowering the suction efficiency. Gas
in water-base mud may also deteriorate the natural rubber
parts used. Gases are usually separated with baffles or by
changing mud composition.
4.4.1.4 Settling Pits
The normally good lubricating qualities of mud can be
lost if cuttings, particularly fine sand, are not effectively
separated from the mud. Adequate settling pits and shale
shakers usually eliminate this trouble. Desanders are used
occasionally.
4.4.1.5 Discharge Manifold
A poorly designed discharge manifold can cause shock
waves and excessive pressure peaks. This manifold should
be as short and direct as possible, avoiding any sharps turns.
The conventional small atmospheric air chamber, often fur-
nished with pumps, supplies only a moderate cushioning
effect. For best results, this air chamber should be sup-
plemented by a large atmospheric air chamber or by a
precharged pulsation dampener.
4.4.2 Pump Operation
4.4.2.1 Priming
A few strokes of the piston in a dry liner may ruin the liner.
When the pump does notfillby gravity or when the cylinders
have been emptied by standing too long or by replacement of
the piston and liner, it is essential to prime the pump through
the suction valve cap openings.
4.4.2.2 Cleaning the Suction Manifold
Suction lines are often partly filled by settled sand and by
debris from the pits, causing the pump to hammer at abnor-
mally low speeds. Frequent inspection and cleaning of the
suction manifold is required. The suction strainer can also
be a liability if it is not cleaned frequently.
4.4.2.3 Cleaning the Discharge Strainer
The discharge strainer often becomes clogged with pieces
of piston and valve rubber. This may increase the pump
pressure that is not shown by the pressure gauge beyond
the strainer. The strainer should be inspected and cleaned
frequently to prevent a pressure buildup.
4.4.2.4 Lost Circulation Materials
Usually special solids, such as nut shells, limestone,
expanded perlite, etc., are added to the drilling muds to fill
or clog rock fractures in the open hold of a well. Most of
these lost circulation materials can shorten the life of pump
parts. They are especially hard on valves and seats when
they accumulate on the seats or between the valve body and
the valve disc.
4.4.2.5 Parts Storage
Pump parts for high-pressure service are made of precisely
manufactured materials and should be treated accordingly.
In storage at the rig, metal parts should be protected from
rusting and physical damage, and rubber parts should be
protected from distortion and from exposure to heat, light,
and oil. In general, parts should remain in their original pack-
ages where they are usually protected with rust-inhibiting
coatings and wrappings and are properly supported to avoid
damage. Careless stacking of pistons may distort or cut the
sealing lips and result in early failures. Hanging lip-type or
O-ring packings on a hook or throwing them carelessly into
a bin may ruin them. Metal parts temporarily removed from
pumps should be thoroughly cleaned, greased, and stored
like new parts.
4.4.3 Pump Performance Charts
The charts indicating the pump output per stroke are shown
in Table 4.4.1 and 4.4.2 for duplex and triplex pumps,
respectively [2,3].
 Figure 4.4.1 Duplex slush (mud) pump. (Courtesy of National Oilwell.)

Figure 4.4.2 Triplex mud pumps. (Courtesy of Weatherford International, Inc.)

 Figure 4.4.3 Six chamber mud pump. (Courtesy of National Oilwell, Inc.)

Figure 4.4.4 Power end of mud pump. (Courtesy of LTV Energy Products Company.)
 Valve Cap Studs
Valve Cap
Upper Guide • Valve Cap Packing
Bushing

Valve Spring Valve Pot

Valve

Valve Disc

Gland Nut Valve Seat •

Stuffing'
Box I Piston Rod
Cylinder Head
Washer' Liner Collar
Liner
Packing
Gland Liner Set Screw
Grease Lantern Ring Fluid Cylinder Liner Cage
Connection TeIi-TaIe Hole Head Stud
Lantern Ring Head Packing
Liner Packing Rings

Figure 4.4.5 Cross-section of fluid end of mud pump. (Courtesy of International Association of Drilling Contractors.)

GOODSUCTIONHEAD

SHORT AND DIRECT

WITH NO TURNS

SAME SIZE AS
PUMP SUCTION ROUNDED
INLET

Figure 4.4.6 Installation of mud pump suction piping. (Courtesy of International Association of Drilling Contractors.)

4.4.4 Mud Pump Hydraulics where AP8 = pressure loss through surface equipment in
The required pump output can be approximated as follows psi
[4-6]: Minimum Q (gal/min): APd = pressure loss through the inside of the drill
Qmin = (30to50)D h [4.4.1] string in psi
AP3 = pressure loss in annulus in psi
or APb = pressure drop through bit nozzles in psi
D2 - D 2
Qmin = m [4A2] Table 4.4.3 shows the diameters and areas of various nozzle
~^T sizes.
The required pump hydraulic horsepower (PHHP) can be
where Dh = hole diameter in in. calculated as
Dp = pipe diameter in in.
a = mud specific weight in lb/gal PHHP - HHPdrc + HHPbit [4.4.4]
The required pump working pressure PWP (psi) can be
calculated as
where HHPCirc = total HHP loss due to pressure losses in
[4.4.3] the ciruclating system
HHPbit = hydraulic horsepower required at the bit
Table 4.4.1 Duplex Pump Output* Table 4.4.2 Triplex Pump Output*
Stroke 100% E f f i c i e n c
y 90%
Efficiency Stroke 1 0 0 % E f f i c i e n c y 90%
Efficiency
Bore (in.) (in.) Cu. Ft. BbIs. Cu. Ft BbIs. Bore (in.) (in.) Cu. Ft. BbIs. Cu. Ft. BbIs.
4 8 0.2328 0.0413 0.2095 0.0372 3 4 0.0491 0.0087 0.0442 0.0078
41 8 0.2944 0.0526 0.2650 0.0473 3± 4 0.0576 0.0103 0.0518 0.0093
5 8 0.3637 0.0648 0.3274 0.0603 31 4 0.0668 0.0119 0.0601 0.0107
4 10 0.2910 0.0517 0.2619 0.0465 3f 4 0.0767 0.0137 0.0690 0.0123
4\ 10 0.3680 0.0660 0.3312 0.0594 4 4 0.0873 0.0155 0.0786 0.0140
5 10 0.4547 0.0810 0.4092 0.0729 4| 4 0.1104 0.0197 0.0994 0.0177
5 12 0.5456 0.0972 0.4909 0.0875 5 4 0.1364 0.0243 0.1228 0.0219
6 12 0.7854 0.1396 0.7069 0.1256 6 4 0.1963 0.0350 0.1767 0.0315
6* 12 0.9217 0.1580 0.8295 0.1422 8 4 0.3491 0.0622 0.3142 0.0560
7 12 1.069 0.1904 0.9621 0.1714 3 6 0.0737 0.0131 0.0663 0.0117
1\ 12 1.227 0.2184 1.104 1.1966 31 6 0.0864 0.0155 0.0777 0.0140
5 16 0.7272 0.1296 0.6545 0.1206 31 6 0.1002 0.0179 0.0902 0.0161
6 16 1.047 0.1861 0.9423 0.1675 3| 6 0.1151 0.0206 0.1035 0.0185
Q\ 16 1.229 0.2187 1.106 0.1968 4 6 0.1310 0.0233 0.1179 0.0210
7 16 1.425 0.2539 1.283 0.2285 4\ 6 0.1656 0.0291 0.1491 0.0266
7\ 16 1.636 0.2912 1.572 0.2621 5 6 0.2046 0.0365 0.1842 0.0329
5 18 0.8181 0.1458 0.7363 0.1312 6 6 0.2945 0.0525 0.2651 0.0473
6 18 1.178 0.2094 1.060 0.1885 8 6 0.5237 0.0933 0.4713 0.0840
6| 18 1.383 0.2460 1.245 0.2214 3 8 0.0982 0.0174 0.0884 0.0156
7 18 1.604 0.2856 1.444 0.2570 3\ 8 0.1152 0.0206 0.1036 0.0186
1\ 18 1.841 0.3276 1.657 0.2948 3^ 8 0.1336 0.0238 0.1202 0.0214
7 20 1.782 0.3173 1.604 0.2856 31 8 0.1534 0.0274 0.1380 0.0246
1\ 20 2.046 0.3640 1.841 0.3276 4 8 0.1746 0.0310 0.1572 0.0280
8 20 2.330 0.4147 2.095 0.3732 4§ 8 0.2208 0.0384 0.1988 0.0354
%\ 20 2.630 0.4680 2.361 0.4212 5 8 0.2728 0.0586 0.2456 0.0438
7 24 2.138 0.3808 1.924 0.3427 6 8 0.3926 0.0700 0.3534 0.0630
7\ 24 2.455 0.4368 2.210 0.3931 8 8 0.6982 0.1244 0.6284 0.1120
8 24 2.792 0.4976 2.513 0.4478 3 10 0.1228 0.0218 0.1105 0.0195
8± 24 3.153 0.5616 2.838 0.5054 3\ 10 0.1440 0.0258 0.1295 0.0233
9 24 3.534 0.6296 3.181 0.5666 3\ 10 0.1670 0.0298 0.1503 0.0268
* Volume indicated are one complete cycle or revolution and represent 3| 10 0.1918 0.0343 0.1725 0.0308
four individual pump strokes. Multiply output/cycle by pump rpm to 4 10 0.2183 0.0388 0.1965 0.0350
get vol./min. Courtesy of Weatherford International, Inc.
A\ 10 0.2760 0.0478 0.2485 0.0443
5 10 0.3410 0.0708 0.3070 0.0548
6 10 0.4908 0.0875 0.4418 0.0788
The general hydraulic horsepower is 8 10 0.8728 0.1555 0.7855 0.1400
* Volumes indicated are for one complete cycle or revolution. Multiply
output/cycle by pump rpm to get vol./min. For quintuplex pump,
multiply output by 1.67. Courtesy of Weatherford International, Inc.
where Q = flow rate in gal/min
AP = pressure difference in psi where N = strokes per minute
The minimum bit HHP is shown in Figure 4.4.7. The S = stroke length, in.
maximum useful bit HHP is shown in Figure 4.4.8 and Figure Theoretical output Q t (gal/min) for a single action triplex
4.4.9 [2]. pump is
Qt = 0.0102 NS D/ 2 [4.4.7]
4.4.5 Useful Formulas
Theoretical output Qt (gal/min) for a double action duplex The volumetric efficiency rjv for duplex pumps or triplex
pump is pumps is

% = %• [4.4.8]
[4.4.6]
where Q a = actual volumetric flow rate in gal
Table 4.4.3 Common Flow Diameters and Areas
Nozzle Fractional Decimal Fractional Decimal Fractional Decimal
size Diameter, in. Diameter, in. Area, in 2 Diameter, in. Diameter, in. Area, in 2 Diameter, in. Diameter, in. Area, in 2

6 ^ 0.1875 0.03 7| 7.875 48.707 17 17.000 226.98

7 ^ 0.2188 0.03758 8 8.000 50.265 171 17.125 230.33
8 I 0.2500 0.04909 8| 8.125 51.849 17 J 17.250 233.71
9 ^ 0.2813 0.06213 S\ 8.250 53.456 17 § 17.375 237.10
10 ^ 0.3125 0.07670 8| 8.375 55.088 17 \ 17.500 240.53
11 g 0.3438 0.09281 8| 8.500 56.745 171 17.625 243.98
12 § 0.3750 0.1104 8§ 8.625 58.426 17| 17.750 247.45
13 i| 0.4063 0.1296 8| 8.750 60.132 171 17.875 250.95
14 ^ 0.4375 0.1503 %\ 8.875 61.862 18 18.000 254.47
15 i| 0.4688 0.1726 9 9.000 63.617 18 \ 18.125 258.02
16 \ 0.5000 0.1963 9± 9.125 65.397 18| 18.250 261.59
18 ^ 0.5625 0.2485 9± 9.250 67.201 18§ 18.375 265.18
20 § 0.6250 0.3068 9§ 9.375 69.029 18 \ 18.500 268.80
22 ^ 0.6875 0.3712 9| 9.500 70.882 181 18.625 272.45
24 I 0.7500 0.4418 9§ 9.625 72.760 181 18.750 276.12
26 H 0.8125 0.5185 9| 9.750 74.662 181 18.875 279.81
28 I 0.8750 0.6013 9| 9.875 76.589 19 19.000 283.53
30 {§ 0.9375 0.6903 10 10.000 78.540 19± 19.125 287.27
32 1 1.000 0.7854 10| 10.125 80.516 191 19.250 291.04
l| 1.125 0.9940 10± 10.250 82.516 191 19.375 294.83
l\ 1.250 1.227 10| 10.375 84.541 19| 19.500 298.65
l| 1.375 1.485 10i 10.500 86.590 191 19.625 302.49
l\ 1.500 1.767 10| 10.625 88.664 19| 19.750 306.35
l| 1.625 2.074 101 10.750 90.763 191 19.875 310.24
l| 1.750 2.405 10| 10.875 92.886 20 20.000 314.16
l| 1.875 2.761 11 11.000 95.033 20| 20.125 318.10
2 2.000 3.142 11J 11.125 97.205 20 J 20.250 322.06
2± 2.125 3.547 11 \ 11.250 99.402 20 § 20.375 326.05
2| 2.250 3.976 ll| 11.375 101.62 20 £ 20.500 330.06
2| 2.375 4.430 ll| 11.500 103.87 201 20.625 334.10
2\ 2.500 4.909 ll| 11.625 106.14 20| 20.750 338.16
2§ 2.625 5.412 111 11.750 108.43 201 20.875 342.25
2| 2.750 5.940 ll| 11.875 110.75 21 21.000 346.36
21 2.875 6.492 12 12.000 113.10 21 \ 21.125 350.50
3 3.000 7.069 Yl\ 12.125 115.47 21J 21.250 354.66
31 3.125 7.670 12 J 12.250 117.86 211 21.375 358.84
31 3.250 8.296 121 12.375 120.28 21 \ 21.500 363.05
31 3.375 8.946 12 \ 12.500 122.72 211 21.625 367.28
3| 3.500 9.621 121 12.625 125.19 211 21.750 371.54
3§ 3.625 10.321 121 12.750 127.68 21 \ 21.875 375.83
3| 3.750 11.045 121 12.875 130.19 22 22.000 380.13
31 3.875 11.793 13 13.000 132.73 22 J 22.125 384.46
4 4.000 12.566 13 \ 13.125 135.30 22 \ 22.250 388.82
41 4.125 13.364 13 \ 13.250 137.89 221 22.375 393.20
4\ 4.250 14.186 131 13.375 140.50 22 \ 22.500 397.61
4§ 4.375 15.033 13 i 13.500 143.14 22 § 22.625 402.04
o Z o
41 4.500 15.904 131 13.625 145.80 221 22.750 406.49
4§ 4.625 16.800 131 13.750 148.49 22 \ 22.875 410.97
41 4.750 17.721 131 13.875 151.20 23 23.000 415.48
4| 4.875 18.665 14 14.000 153.94 231 23.125 420.00
{continued)
Table 4.4.3 continued
Nozzle Fractional Decimal Fractional Decimal Fractional Decimal
size Diameter, in. Diameter, in. Area, in2 Diameter, in. Diameter, in. Area, in2 Diameter, in. Diameter, in. Area, in2

5 5.000 19.635 14± 14.125 156.70 23 J 23.250 424.56

5| 5.125 20.629 14 J 14.250 159.48 23 § 23.375 429.13
51 5.250 21.648 141 14.375 162.30 23 \ 23.500 433.74
5| 5.375 22.691 14± 14.500 165.13 231 23.625 438.36
5± 5.500 23.758 14 § 14.625 167.99 231 23.750 443.01
5§ 5.625 24.850 141 14.750 170.87 23 \ 23.875 447.69
51 5.750 25.967 141 14.875 173.78 24 24.000 452.39
5l 5.875 27.109 15 15.000 176.71 24j 24.125 457.11
o O
6 6.000 28.274 15 \ 15.125 179.67 24 \ 24.250 461.86
6± 6.125 29.465 15 £ 15.250 182.65 241 24.375 466.64
6| 6.250 30.680 15§ 15.375 185.66 2A\ 24.500 471.44
6§ 6.375 31.919 15 \ 15.500 188.69 241 24.625 476.26
6| 6.500 33.183 15| 15.625 191.75 241 24.750 481.11
6§ 6.625 34.472 151 15.750 194.83 24 \ 24.875 485.98
61 6.750 35.785 15 \ 15.875 197.93 25 25.000 490.87
6| 6.875 37.122 16 16.000 201.06 25± 25.125 495.79
7 7.000 38.485 Vo\ 16.125 204.22 25 J 25.250 500.74
l\ 7.125 39.871 Vo\ 16.250 207.39 251 25.375 505.71
71 7.250 41.282 161 16.375 210.60 25 \ 25.500 510.71
7§ 7.375 42.718 16 \ 16.500 213.82 251 25.625 515.72
71 7.500 44.179 161 16.625 217.08 251 25.750 520.77
71 7.625 45.664 161 16.750 220.35 251 25.875 525.84
71 7.750 47.173 16 7/8 16.875 223.65 26 26.000 530.93
Note: Area = 0.7854*(diameter)2. Courtesy of Weatherfold International, Inc.
DRILLING EFFORT (BIT Weight lbsVinches of BIT diz) x (Rotary Speed rpm)
1000

Exampel : BIT SIZE 10.625"

BIT WEG I HTN 50,000 (4700/INCH)
ROTARY SPEED 90 RPM3
WR-(4700) (80)-4231
'0
REQURI EDBHHP=10

BIT HYDRAULIC HORSEPOWER

Figure 4.4.7 Minimum bit HHP to prevent hydrauiic flounder [4]. (Courtesy of Smith International, Inc.)

Input engine power IHP (hp) required for a given Pressure loss correction for mud weight change is
pump theoretical output Qt and pump working pressure
PWP is [4.4.10]

where APi = pressure loss in system calculated using

[4.4.9] mud weight Y1 in psi
AP2 = Pressure loss in system calculated using
mud weight y2 m Psi
where nm — mechanical efficiency of the pump Y1, y2 = mud weight in Ib/gal
 Next Page

MINIMUM
HYDRAULICS
Drilling rate.
Feet/Low

AREA OF
INCOMPLETE
BIT CLEANING

MINIMUM
HYDRAULICS

BIT HHP/SQ. IN
NOTE: PLACE POINT WHERE CONTROL BIT RUN IS LOCATED; USING SHIP
CURVE, FIT Q-LINE BELOW POINT; MOVE SHIP CURVE UPlO POINT.
EFFECT OF A CHANGE IN HYDERAULICS CAN THEN BE TRACED. POINTS
OF COMPLETE BIT CLEANING ARE ON THE "MAXIMUM HYDRAULICS"
CURE.

Figure 4.4.8 Required bit hydraulic horsepower [5]. (Courtesy of Hant Publications. All rights reserved.)
BIT HYDRALULIC HORSEPOWER

HOLE DIAMETER, INCHES

Figure 4.4.9 Bottomhole hydraulic horsepower chart [2]. (Used by permission of the American Petroleum Institute
Production Department.)

References original work by Hal B. Fullerton, Jr., United Drilling

1. Hughes Tool Company, Hughes Practical Hydraulics, Services).
Houston, 1976. 5. Lummus, James L, "Drilling in the Seventies, Part
2. API Bulletin DlO, 2nd Edition: "Procedure for Selecting II: Analysis of Mud-Hydraulics Interaction," Petroleum
Rotary Drilling Equipment," API, Dallas, January 1982. Engineer, February 1974.
3. American Association of Drilling Contractors, Tool 6. Randal, B. V., "Optimum Hydraulics in the Oil Patch,"
Pusher's Manual, API, Dallas, 1955. Petroleum Engineer, September, 1975.
4. Fullerton, H. B., Constant Energy Drilling System Well 7. Weatherford Technical Data Handbook, Weatherford
Programming, Sii Smith Tool, p. 6, Irvine (adapted from US, LP, Houston, TX, 2001.