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Ali Pilehvari and Robert Serth, Department of Chemical and Natural Gas Engineering, Texas A&M University-Kingsville
This paper was prepared for presentation at the AADE 2006 Fluids Conference held at the Wyndam Greenspoint Hotel in Houston, Texas, April 11-12, 2006. This conference was sponsored by the
Houston Chapter of the American Association of Drilling Engineers. The information presented in this paper does not reflect any position, claim or endorsement made or implied by the American
Association of Drilling Engineers, their officers or members. Questions concerning the content of this paper should be directed to the individuals listed as author/s of this work.
Abstract
The flow of non-Newtonian fluids through eccentric An eccentric annulus is shown in cross-section in Fig.
annuli is prevalent during drilling and cementing 1, where R1 and R2 are the radii of the inner and outer
operations of directional and horizontal wells. The flow
pattern in an eccentric annulus can differ greatly from cylinders, respectively, and δ is the center-to-center
that in a concentric annulus, and this difference affects distance between the two cylinders. The eccentricity, e,
both the pressure drop and the laminar-turbulent is defined as:
transition point. When the flow regime is the same, either
laminar or turbulent, in both geometries, the pressure δ 2δ
drop is much lower in a fully eccentric annulus. However, e= = …(1)
the transition from laminar to turbulent flow begins at a R 2 − R1 D 2 − D1
lower flow rate in an eccentric annulus. Therefore, the
pressure drop may be higher in an eccentric annulus The eccentricity ranges from zero to unity, with e = 0
under certain conditions. Errors resulting from ignoring
the effect of eccentricity on frictional pressure drop and corresponding to a concentric annulus and e = 1
equivalent circulating density can lead to formation corresponding to a fully eccentric annulus (inner cylinder
fracture or well control problems in some situations. in contact with outer cylinder).
In this paper a new method is presented for The flow pattern in an eccentric annulus can differ
calculating pressure losses in eccentric annuli. The greatly from that in a concentric annulus (Haciislamoglu
method is based on an effective diameter that accounts and Langlinais, 1990; Fang et al., 1999), and this
for the effects of both conduit geometry and fluid difference affects both the pressure drop and the
rheology. Predictions of the method are compared with laminar-turbulent transition point. When the flow regime
an extensive set of data for drilling fluids obtained from a is the same (either laminar or turbulent) in both
large-scale flow loop. The results demonstrate that the geometries, the pressure drop is lower in the eccentric
new method is capable of reliably predicting the annulus. For example, in laminar Newtonian flow the
pressure drop of most drilling fluids in both laminar and pressure drop in a fully eccentric annulus can be as low
turbulent flow regimes for eccentric annular geometries as 40% of that in an equivalent concentric annulus at the
of practical interest. same flow rate (Haciislamoglu and Cartalos, 1994).
However, the transition to turbulent flow begins at a
Introduction lower Reynolds number in an eccentric annulus.
The flow of non-Newtonian fluids through eccentric Therefore, the pressure drop may be higher in an
annuli occurs during drilling and cementing operations eccentric annulus under certain conditions, for example,
for oil and gas wells. Approximate and exact (numerical) when the flow is turbulent in the eccentric geometry but
solutions to the fundamental flow equations in this remains laminar in the concentric geometry
geometry have been published for Bingham plastic, (Haciislamoglu and Cartalos, 1994). The situation is thus
power-law and yield-power-law fluids. The purpose of complex, and neglecting the effects of eccentricity can
this article is to present a generalized method for result in serious errors.
computing frictional pressure losses in eccentric annuli
that is applicable to a wide variety of drilling fluids. Prior Work
Predictions obtained with the new method are compared Flow in eccentric annuli has been of interest for many
with experimental data from a large flow loop that are years, and a fairly extensive literature exists on the
available in the literature. subject. An extensive bibliography of work dealing with
2 ALI PILEHVARI, ROBERT SERTH AADE-06-DF-HO-45
laminar non-Newtonian flow in annular channels is Furthermore, Eq. 2 offers the possibility of generalization
presented by Escudier et al. (2002). The discussion here to non-power-law fluids by replacing the power-law
is limited to research that is of most relevance to the exponent, n , with the generalized power-law exponent,
present work. n′ .
An analytical solution of the Navier-Stokes equations Haciislamoglu and Cartalos (1994, 1996) showed that
for laminar Newtonian flow in an eccentric annulus was Eq. 2 can be used for skewed annuli by replacing the
obtained by Snyder and Goldstein (1965). Although eccentricity with an appropriate average value. They
rather complicated, the solution can be used to compute also gave critical Reynolds numbers for skewed and
geometrical parameters for eccentric annuli. Guckes uniformly eccentric annuli, and a modification of Eq. 2 for
(1975) obtained numerical solutions to the fundamental turbulent flow.
equations of motion for laminar flow of Bingham plastic Reed and Sas-Jaworsky (1996) used Equation (2) to
and power-law fluids in eccentric annuli. The results define an effective diameter for the flow of power-law
were presented graphically for limited ranges of fluids in eccentric annuli. Pressure drop calculations
parameters, and hence are not very suitable for use in based on this diameter showed good agreement with
the present context. Haciislamoglu and Langlinais experimental data for power-law fluids in both laminar
(1990) numerically solved the equations of motion for and turbulent flow regimes.
laminar flow of Bingham plastic, power-law and yield- Fang et al. (1999) and Escudier et al. (2002) obtained
power-law fluids in eccentric annuli. The results for numerical solutions to the equations of motion for the
power-law fluids were presented in the form of a laminar flow of power-law fluids in eccentric annuli with
regression equation for the ratio, R , of frictional power-law exponents in the range 0.2 to 1.0. The latter
pressure gradient in an eccentric annulus to that in a authors also studied the effects of inner cylinder rotation.
concentric annulus. Where the two studies overlap, the results are generally
in close agreement with one another. For n = 0.2,
R = 1 − 0.072 (e n )σ 0.8454 − 1.5 e 2 n σ 0.1852 + however, there are discrepancies at small values of
eccentricity. The difficulty in obtaining numerical
0.96 e 3 n σ 0.2527 …(2) solutions for small values of n is acknowledged by Fang
et al. (1999). They did not obtain solutions for n< 0.2
where R = (∆ P ∆ L )EA (∆ P ∆ L )CA due to the very large computing times required for these
cases.
n = exponent in power-law model
σ = D1 D2 Miller’s Hypothesis
D1 = OD of inner cylinder Miller (1972) proposed that the flow-rate-pressure-
drop relationship in laminar flow of any time-independent
D2 = ID of outer cylinder fluid in a conduit of arbitrary cross-section can be
EA = eccentric annulus characterized by a single geometrical parameter, S, that
CA = concentric annulus is independent of fluid rheology. This parameter allows
the conduit to be treated as an equivalent pipe. Hanks
Eq. 2 is valid (to within 5%) for the following (1974) analyzed the validity of this concept for Bingham
parameter ranges: plastic and power-law fluids flowing in conduits with
several simple geometries. Miller’s hypothesis can be
0.3 ≤ σ ≤ 0.9 stated in terms of an equivalent diameter, Deq , defined
by Eq. 3 and related through Eq. 4 to the parameter, S,
0 ≤ e ≤ 0.95
which is given by Eq. 5.
0.4 ≤ n ≤ 1.0
γ N = 8V Deq …(3)
The range for σ covers most practical applications,
and the correlation can be extrapolated to include the Deq = 16 Dh S …(4)
fully eccentric annulus ( e = 1.0 ) with little error. Thus, S = f N Re N …(5)
the only limitation of practical significance is the range of
n. where
Eq. 2 is a very useful relationship. Setting n = 1 γ N = average Newtonian shear rate at conduit wall
provides a simple solution for the pressure drop in
laminar Newtonian flow in eccentric annuli. This solution V = average fluid velocity
is much more convenient to use than the solution of Dh = hydraulic diameter =4×flow area /wetted perimeter
Snyder and Goldstein (1965) mentioned above.
AADE-06-DF-HO-45 GENERALIZED HYDRAULIC CALCULATION METHOD FOR FLOW OF NON-NEWTONIAN FLUIDS IN ECCENTRIC ANNULI 3
Dh = D2 − D1 …(10) π n D23 ⎛ D2 ∆ P ⎞
1/ n
Q= ⎜ ⎟ *
Dh [1 + σ 2 + (1 − σ 2 ) ln σ ] DL2 8 (3n + 1) ⎜⎝ 4 K L ⎟⎠
Deq = = ...(11)
where
(1 − σ ) 2 Dh {(1− λ )2 ( n +1) n
(
− σ (n−1) n λ2 − σ 2 )( n +1) n
} …(17)
{ (
DL = D22 + D12 − D22 − D12 ) ln σ }
1
2
…(12) In this equation Q is the volumetric flow rate, L is the
= Lamb’s diameter conduit length, K is the coefficient in the power-law
model and λ is the dimensionless radial position at
The equivalent diameter defined by Eq.11 has been which the fluid velocity is maximum. It is found by
used in a generalized hydraulic calculation method by solving the following integral equation:
Pilehvari and Serth (2005). It gives excellent agreement
with experimental data for laminar flow of drilling fluids in ⎛ λ2
1/ n 1/ n
λ
⎞ 1.0
⎛ λ2 ⎞
concentric annuli, and usually provides reliable results ∫ ⎜⎜ − x ⎟⎟ dx = ∫ ⎜⎜ x − ⎟⎟ dx …(18)
for turbulent flow as well. Thus, Miller’s method is σ ⎝ x ⎠ λ ⎝ x ⎠
consistent with experimental results for flow in concentric
annuli. Figs. 2-5 show the solutions for the fluid with
The above development can be extended to an
n = 0.55 in annuli of different eccentricities. For the
eccentric annulus using the pressure drop ratio, R N , for
concentric annulus, the two solutions agree quite well,
a Newtonian fluid. Setting n = 1 in Eq. 2 yields: but the agreement deteriorates with increasing
eccentricity. Fig. 6 shows solutions for the fluid with
R N = 1 − 0.072 e σ 0.8454 − 1.5 e 2 σ 0.1852 + n = 0.75 in a highly eccentric annulus ( e = 0.95 ).
Comparing Figs. 5 and 6, it is seen that the agreement
0.96 e 3 σ 0.2527 …(13) between approximate and exact solutions deteriorates
as n decreases. (Note that the two solutions coincide for
4 ALI PILEHVARI, ROBERT SERTH AADE-06-DF-HO-45
n = 1 ). Thus, Miller’s hypothesis does not provide a For a power-law fluid in an eccentric annulus, Equation
suitable basis for calculating pressure losses in eccentric (14) becomes:
annuli for non-Newtonian fluids.
From the above results it is clear that if a single f PL , EA = R f PL ,CA …(27)
parameter is to be used to characterize the flow-rate-
pressure-drop relationship in eccentric annuli, it must From this relationship, it follows that Equations (25) and
include the effect of fluid rheology as well as the conduit (26) will hold for an eccentric annulus if the effective
geometry. diameter given by Equation (24) is divided by a factor of
R 1 / n , i.e.,
Effective Diameter for Eccentric Annuli
In order to overcome the inherent limitation of Miller’s ω D2(3n +1) / n
method, it is proposed to characterize the flow-rate- Deff , PL , EA = …(28)
pressure-drop relationship in eccentric annuli by using ( D1 + D2 ) Dh( n +1) / n R 1 / n
the power-law solution rather than the Newtonian
solution. To this end, Equation (17) is recast in terms of This result differs from the effective diameter defined
friction factor and Reynolds number by making the by Reed and Sas-Jaworsky (1996), who based their
following substitutions: development on the flow rate versus pressure drop
relationship for laminar Newtonian flow in a concentric
∆ P = 4 L τ w Dh …(19) annulus rather than Eq. 17.
The above development can be extended to a
f ρV 2
generalized power-law fluid by assuming the flow curve
τw = …(20)
has the following form, where τ w is the wall shear
2 gc
Q = V A = V (π 4 ) D22 − D12 ( ) …(21)
stress:
τ w = K ′ (8V D eff )n
′
…(29)
After some algebraic manipulation, the result is:
⎛ 3n + 1 ⎞
n
where
K⎜ ⎟ = K′
ω = (1 − λ2 ) ( )
( n +1) / n ( n +1) / n …(31)
− σ ( n −1) / n λ2 − σ 2 …(23) ⎝ 4n ⎠
The effective diameter for a power-law fluid in a Eqs. 25, 26 and 28 then become:
concentric annulus is now defined as:
f Re G = 16 …(32)
ω D2( 3n +1) / n
Deff , PL ,CA = …(24)
( D1 + D2 ) Dh( n +1) / n Deffn′ V 2− n′ ρ
Re G = …(33)
8 ( n′−1) g c K ′
Equation (22) can then be written as:
f Re PL = 16 …(25)
ω ′ D2( 3n′+1) / n′
Deff = …(34)
where the Reynolds number for a power-law fluid is ( D1 + D2 ) Dh( n′+1) / n′ ( R ′)1 / n′
given by:
In these equations, Re G is the generalized Reynolds
Deffn V 2− n ρ
Re PL = …(26) number and R ′ and ω ′ are given by Eqs. 2 and 23,
8 ( n −1) g c K [(3n + 1) / 4n]
n
respectively, with n replaced by n′ . The effective
diameter given by Eq. 34 is to be used in place of the
AADE-06-DF-HO-45 GENERALIZED HYDRAULIC CALCULATION METHOD FOR FLOW OF NON-NEWTONIAN FLUIDS IN ECCENTRIC ANNULI 5
equivalent diameter of Eq. 16 for calculating the which the value of 8V / Deff is obtained.
pressure drop in an eccentric annulus.
γw
Step 4. Calculation of τw
(
8V / Deff = 4 τ w3 ) ∫ τ γ (dτ
3
dγ ) dγ …(35)
The value of τw is obtained from the cubic spline using
0
where the final converged value of 8V / Deff from Step 3.
γ = true shear rate
Step 5. Generalized Reynolds Number
γ w = true shear rate at conduit wall
The generalized Reynolds number is calculated using
τ = shear stress the following equation, which is obtained by combining
Eqs. 29 and 33:
The rheological model is used to express τ and
dτ / dγ in terms of γ , and the integral is evaluated Deff (8V / Deff ) V ρ
numerically to obtain a table of τ w vs. 8V / Deff .
Re G = …(37)
g cτ w
The above limitation notwithstanding, the overall Haciislamoglu, M. and Cartalos, U., “Fluid Flow in A Skewed
Annulus”, J. Energy Res. Tech., 118, p. 89 (1996).
AADE-06-DF-HO-45 GENERALIZED HYDRAULIC CALCULATION METHOD FOR FLOW OF NON-NEWTONIAN FLUIDS IN ECCENTRIC ANNULI 7
Haciislamoglu, M. and Langlinais, J., “Non-Newtonian Flow in Solution using Eq. (16)
Reed, T. D. and Pilehvari, A. A., “A New Model for Laminar, Figure 2. Test of Miller's hypothesis for a power-law fluid with n =
Transitional and Turbulent Flow of Drilling Fluids”, paper SPE 0.55 in a concentric annulus (e=0)
25456, presented at the SPE Operations Symposium,
Oklahoma City, OK, 21-23 March (1993).
( )
Reed, T. and Sas-Jaworsky II, A., “Flow of Power Law Fluids in
th
Eccentric Annuli”, paper presented at the 4 International 4
Developed Laminar Flow in an Eccentric Annulus”, AIChE J., Solution using Eqs. (2) & (17)
0
0 1 2 3 4 5 6 7
Flow Rate (gpm)
( )
δ 4
R1 3
Solution using Eq. (16)
P ressure D rop (psi)
R2
Solution using Eqs. (2) & (17)
2
0
0 1 2 3 4 5 6
Figure 1. Cross-section of an eccentric
Flow Rate (gpm)
annulus
5
2
P r e s s u r e D r o p ( p s i)
Pressure Drop (psi)
0.5 1
0
0 0 100 200 300 400 500 600
0 1 2 3 4 5
Flow Rate (gpm)
Flow Rate (gpm)
6
4
5 Predicted
Measured
Solution using Eq. (16)
3
P r e s s u r e D r o p (p s i)
4
Pressure Drop (psi)
0 0
0 1 2 3 4 5 6 0 100 200 300 400 500 600
3.5 4
3 Predicted Predicted
Measured
Measured
3
2.5
P re s s u re D ro p (p s i)
P r e s s u r e D r o p (p s i)
1.5
1
1
0.5
0 0
0 100 200 300 400 500 600
0 100 200 300 400 500 600
Flow Rate (gpm)
Flow Rate (gpm)
Figure 7. Predicted and measured pressure drops for Bentonite Mud 1 in Figure 10. Predicted and measured pressure drops for Glycol Mud 1 in a
a fully eccentric annulus fully eccentric annulus
AADE-06-DF-HO-45 GENERALIZED HYDRAULIC CALCULATION METHOD FOR FLOW OF NON-NEWTONIAN FLUIDS IN ECCENTRIC ANNULI 9
4 5
Predicted
4
3 Measured
P r e s s u r e D r o p (p s i)
Pressure Drop (psi)
2 Predicted
Measured
1
1
0 0
0 100 200 300 400 500 600 0 100 200 Flow Rate
300 (gpm) 400 500 600
Flow Rate (gpm)
Figure 11. Predicted and measured pressure drops for Glycol Mud 2 in Figure 14. Predicted and measured pressure drops for MMH
a fully eccentric annulus Mud 2 in a fully eccentric annulus
5
Predicted
Measured
4
Pressure Drop (psi)
0
0 100 200 300 400 500 600
Flow Rate (gpm)
Figure 12. Predicted and measured pressure drops for Vegetable Oil
Mud in a fully eccentric annulus
2.5
Predicted
Measured
2
Pressure Drop (psi)
1.5
0.5
0
0 100 200 300 400 500 600
Flow Rate (gpm)
Figure 13. Predicted and measured pressure drops for MMH Mud 1 in a
fully eccentric annulus