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FOCUSSED HYDRAULIC ENERGY - A NEW LOOK AT TWO-
NOZZLE DRILLING

R.P. BARMBY

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jcpt89-02-06 PRODUCTION OPERATIONS Focussed hydraulic energy a new look at two-nozzle drilling R.P. BARMBY Amerada Minerals Corporation of Canada Calgary, Alberta ABSTRACT Drilling with a tri-cone bit equipped with two equal-sized noz- zles and one blank nozzle has previously been used in an attempt to increase penetration rates through improved bottom-hole cleaning. A new concept uses two unequal-sized nozzles and higher bit hydraulic power to create maximum hydraulic energy at the bit and to transmit a larger fraction of that energy to the hole bottom in a pattern more conducive to bottom-
hole clean- ing. Applications of this technology in the Valhalla Field of Alberta have increased the average rate of penetration by 42% and reduced drilling cost by 27%. Introduction The rate of penetration (ROP) achieved in conventional rotary drilling with a tri-cone bit is controlled by a dynamic equilibrium between the generation of cuttings and the removal of cuttings from the drilling surface. Ineffective cuttings removal often limits the actual ROP to much less than what would be mathematic- ally expected if perfect bottom-hole cleaning conditions had existed. In such cases,
improved bottom-hole cleaning results in increased ROP. When drilling with three equal-sized nozzles each jet impacts on the drilling surface and lifts drill cuttings off of the rock face by turbulent scouring. The fluid then reverses against itself in the confined area between the cones to transport the cuttings up the hole. There is no fluid flow underneath the cones where cut- tings generation takes place. Cuttings removal can only take place after the cones have rolled over them and they have been lifted off of the rock surface sufficiently to be entrained in the return- ing fluid
flow. The original two equal-sized nozzle hydraulics design attempted, with varying degrees of success, to improve cuttings removal by initiating crossflow under the bit and providing a flow path for the returning fluid unhampered by a downward jet. This design failed to relate the effect of nozzle diameter and jet im- pact pressure distribution on the cuttings removal process. A new two-nozzle design was proposed which incorporates un- equal nozzle diameters to focus hydraulic energy on the hole bot- tom in a pattern which improves bottom-hole cleaning. It h--. been field-tested
with consistent success in hundreds of bit runs in northem, central and eastern Alberta, and in over 100 bit runs in the Australian Outback. Keywords: Tri-cone bit, Bottom-hole cleaning, Nozzles, Impact pres- sure, Crossflow, Pressure gradient, Penetration rate, Hydraulic power. The field test summarized in this paper was conducted in the Valhalla Field of Alberta, 50 km northwest of Grande Prairie (Fig. 1). The reader should be cautioned that the study popula- tion is small, and that the tests were conducted to minimize, but could not eliminate, all the variables which could impact on
the findings. These constraints prevent the author from establish- ing conclusive proof of the effectiveness of focussed hydraulic energy. The author intends only to provide sufficient evidence to encourage thoughtful discussion. Discussion Literature Review Laboratory bottom-hole pressure surveys by Sutko and Myers(l) demonstrated that as the number of nozzles on a tri-cone bit is progressively reduced from three to two to one, the maximum impact pressure under the remaining jets is increased. Concur- rently, the minimum bottom-hole pressure is reduced. The same response was observed on
a single test of three extended noz- zles. These tests were conducted using constant jet velocity in each case. Sutko and Myers postulated that by increasing the jet impact pressure and reducing the n-iiniinum bottom-hole pressure, a more effective gradient is established along the rock face to move chips across and off the drilling surface. Warrens and Winters(2) expanded on this work with labora- tory studies on the effects of utilizing the two nozzles in a tri- cone bit on jet impact. They observed that, when the number of nozzles is reduced from three to two: - the measured
impact pressure and bottom-hole erosion beneath the jets increased; - the measured impact pressure and depth of erosion on the borehole wall was reduced; and _ fluid outflow was initiated under the two cones adjacent to the blanked jet. These results were interpreted as indicating that improvements resulted from a change in the flow path of the returning fluid. When using three jets, each jet is discharging into counterflow- ing fluid. Turbulence exists between the two flows at the jet boundary which causes destructive interference with the jet. Because the jets are aimed at 10
degrees to 15 degrees toward the corner of the hole, the counterflowing fluid also deflects the jet toward the borehole wag. This contributes to further entrain- ment of the counterflowing fluid into the jet. The blanking of one nozzle provides an alternate flow path which reduces the counterflow in the vicinity of the remaining jets. Also, the impingement of three jets on the hole bottom causes stagnation zones between each jet, which inhibits flow under the Paper reviewed and accepted for publication by the Editorial Board of the Journal of Canadian
Petroleum Technology. March-April 1989, Volume 28, No. 2 85

PRODUCTION OPERATIONS
Focussed hydraulic energy -
a new look at two-nozzle drilling
R.P. BARMBY
Amerada Minerals Corporation of Canada
Calgary, Alberta
ABSTRACT
Drilling with a tri~cone bit equipped with two equal-sized noz-
zles and one blank nozzle has previously been used in an attempt
to increase penetration rates through improved bottom-hole
cleaning. A new concept uses two unequa/-sized nozzles and
higher bit hydraulic power to create maximum hydraulic energy
at the bit and to transmit a larger fraction of that energy to the
hole bottom in a pattern more conducive to bottom-hole clean-
ing. Applications oj this technology in the Valhalla Field oj
Alberta have increased the average rate of penetration by 42%
and reduced drilling cost by 27%.
, Laboratory bottom-hole pressure surveys by Sutko and Myers(l)
" Introduction
The rate of penetration (ROP) achieved in conventional rotary
drilling with a tri-cone bit is controlled by a dynamic equilibrium
between the generation of cuttings and the removal of cuttings
:~ from the drilling surface, Ineffective cuttings removal often limits
the actual ROP to much less than what would be mathematic-
ally expected if perfect bottom-hole cleauing conditions had
existed. In such cases, improved bottom-hole cleaning results in
increased ROP,
When drilling with three equal-sized nozzles each jet impacts
on the drilling surface aud lifts drill cuttings off of the rock face
by turbulent scouring. The fluid then reverses against itself in
the confined area between the cones to transport the cuttings up
the hole. There is no fluid flow underneath the cones where cut-
tings generation takes place. Cuttings removal cau only take place
after the cones have rolled over them aud they have been lifted
off of the rock surface sufficiently to be entrained in the return-
ing fluid flow.
The original two equal-sized nozzle hydraulics design
attempted, with varying degrees of success, to improve cuttings
removal by initiating crossflow under the bit aud providing a flow
path for the returning fluid unhampered by a downward jet, This
design failed to relate the effect of nozzle diameter aud jet im-
pact pressure distribution on the cuttings removal process.
A new two-nozzle design was proposed which incorporates un-
equal nozzle diameters to focus hydraulic energy on the hole bot-
tom in a pattern which improves bottom-hole cleauing, It has
been field-tested with consistent success in hundreds of bit runs
in northern, central and eastern Alberta, and in over 100 bit runs
in the Australlau Outback.
Keywords: Tri-cone bit, Bottom-hole cleaning, Nozzles, Impact pres-
sure, Crossflow, Pressure gradient, Penetration rate, Hydraulic power.
Paper reviewed and accepted for publication by the Editorial Board of the Journal of Canadian Petroleum Technology.
March·Aprll 1989, Volume 28, No, 2
'~ ;'.
,.
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The field test summarized in this paper was conducted in the
Valhalla Field of Alberta, 50 Ion northwest of Graude Prairie
(Fig. 1). The reader should be cautioned that the study popula-
tion is small, and that the tests were conducted to minimize, but
could not eliminate. all the variables which could impact on the
findings. These constraints prevent the author from establish-
ing conclusive proof of the effectiveness of focussed hydraulic 'c'.:,·.·.',·.'.::,:.·.§, :, : ,:.
, '.~.:-~'. ~
energy. The author intends only to provide sufficient evidence
to encourage thoughtful discussion.
Discussion
Literature Review
demonstrated that as the number of nozzles on a tri-cone bit is
progressively reduced from three to two to one, the maximum
impact pressure under the remaining jets is increased. Concur-
rently, the minimum bottom-hole pressure is reduced. The same
response was observed on a single test of three extended noz-
zles. These tests were conducted using constant jet velocity in
each case.
Sutko and Myers postulated that by increasing the jet impact
pressure and reducing the minimum bottom-hole pressure, a more
effective gradient is established aiong the rock face to move chips
across and off the drilling surface. .,'
Warrens and Winters(2) expanded on this work with labora-
tory studies on the effects of utilizing the two nozzles in a tri-
cone bit on jet impact. They observed that, when the number
of nozzles is reduced from three to two: .
- the measured impact pressure and bottom-hole erosion ,"
beneath the jets increased;
- the measured impact pressure and depth of erosion on the
borehole wall was reduced; and
- fluid outflow was initiated under the two cones adjacent to
the blauked jet,
These results were interpreted as indicating that improvements
resulted from a change in the flow path of the returning fluid.
When using three jets, each jet is discharging into counterflow-
ing fluid. Turbulence exists between the two flows at the jet
boundary which causes destructive interference with the jet.
Because the jets are aimed at 10 degrees to 15 degrees toward
the comer of the hole, the counterflowing fluid also deflects the
jet toward the borehole wall. This contributes to further entrain-
ment of the counterflowing fluid into the jet. The blauking of
one nozzle provides an alternate flow path which reduces the
counterflow in the vicinity of the remaining jets.
Also, the impingement of three jets on the hole bottom causes
stagnation zones between each jet, which inhibits flow under the
':.
85
 ----------------

TABLE 1. Comparison of ROP for three nozzles vs two nozzles by bit run
WOB Mud Pump Pump Bit
Bit iADC Bit Interval X1000 Weight Jets Output Pressure HP ROP
Well No. Rig Code Co. (m) Hours (daN) RPM (kgfm 3) (mm) (m 3/min) (kPa) (kW/cm2) (m/hr)
F 3 D 517 B 1124-1846 108-75 14/16 70/80 1130 7.1,7.1,7.9 0.77 7500 0.25 6.6
B 3 B 517 A 1111-1746 91-75 15 90 1125 7.1,9.5,0 0.65 7300 0.20 6.9
D 2 D 517 B 1172-1836 65.25 14/18 90 1095 7.1,8. 7,0 0.77 11500 0.41 10.2
G 2 D 517 B 1152-1855 67.5 17 80 1100 7.1 (ext.), 0.75 11500 0.38 10.4
8.7,0
F 4 D 537 D 1846-1910 26 14117 60180 1135 7.1,7.1,7.9 0.77 7500 0.25 2.5
D 3 D 537 B 1836-1928 14 18 80 1110 7.1,8.7,0 0.75 11500 0.38 5.9
G 4 D 537 A 1864-1918 13.25 15118 70/75 1110 7.1,8-7.0 0.75 11500 0.38 4.1
A 6RR A 537 A 1967·2063 34.75 14 70 1110 7.9,7.9,7.9 0.88 8000 0.28 2.8
C 5 C 537 B 1901·2040 49.25 18 60 1150 7.1,7.1,7.1 0.75 8800 0.27 2.8
E 4 E 537 C 1928-2004 20.5 18 65 1140 7.9,7.9,7.9 0.94 9000 0.35 3.7

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F 4RR D 537 D 1923-2045 53.5 17 60 1140 7.1,7.1,7.9 0.73 7500 0.21 2.3
D 3RR D 537 B 1933·1978 10.75 18 60 1110 7.1,8.7,0 0.75 11500 0.38 4.2
G 4RR D 537 A 1931·2045 36.5 18 80 1160 7.1,8. 7,0 0.70 11500 0.34 3.1

The third nozzle is sized large enough to provide adequate

R~<J-W6
fluid flow at the maximum allowable standpipe pressure so that

t
;:;: r---'---'---'---r---~
, ... bit cooling and cuttings transport requirements are met. This
maximizes the pressure gradient between the small and blank
.."' .·C.,
•T
nozzles. and sets up a second pressure gradient between the large
and blank nozzles. This second pressure gradient is weaker be-
cause the bottom-hole impact pressure of the larger jet is lower.

•Grande Fra,ne
FIGURE 1. Study area and well locations.
cones. The blanking of one nozzle eliminates two stagnation zones
and initiates flow under two of the cones.
Warren and Winters also confirmed that smaller nozzles deliver
more hydraulic energy to the hole bottom than larger nozzles.
Larger nozzles produce larger diameter jet streams with larger
boundary areas. The larger boundary areas pennit a greater decay
of the jet stream and greater deflection against the borehole wall.
A third paper. written by Li(3), was based on a large statisti-
cal study in China. Li re-affirmed that increased hydraulic power
at the bit contributed to an increase in ROP. Li recommends
drilling with pump pressures exceeding 20 000 kPa.
Design Concept
The above papers cited the advantages of reducing the number
and size of the nozzles. and of increasing hydraulic horsepower
at the bit. The objective of focussed hydraulic energy is to
optimally combine these design elements to provide the maxi-
mum pressure gradient possible across the face of the drilling
surface. This pressure gradient is the mechanism by which drilled
cuttings are cleaned from the hole bottom.
This design includes one blank nozzle which provided a flow
path for the returning fluid. As a result, the remaining jets have
reduced borehole wall impingement and enhanced bottom-hole
impact. Also, the minimum bottom-hole pressure is reduced and
crossflow is initiated under two of the cones.
The second nozzle is sized as small as solid particles in the
mud will allow to avoid plugging. The size of this nozzle fur-
ther reduces borehole wall impact of the jet and increases
bottom-hole impact pressure. A pressure gradient along the drill-
ing surface is established between this small nozzle and the
blank. As the bit rotates, this gradient traverses the entire bot-
tom of the hole. removing drilled cuttings.
86
Field Tests
The focussed hydraulic energy experimental bit runs were con-
ducted in the Valhalla Area of Alberta. Of the twelve wells oper-
ated in the area in the last two years, seven wells have sufficiently
similar drilling parameters for comparative purposes. In the
study wells, thirteen two-nozzle bit runs were conducted, with
twenty-three, three-nozzle runs used as a datum. All bits were
200 mm diameter. The locations of the study wells are shown
in Figure 1.
Comparison by Bit Run
The ROP achieved for two and three nozzle bit runs were first
compared for a given IADC series bit over similar intervals,
as shown in Table 1. In the first group, lADe 5.1.7 bits wele
used to drill from approximately 1110 m to 1855 m. The lithol-
ogies penetrated in this interval were sandstone. siltstone and
shale, with minor stringers of coal and conglomerate. The typi-
cal three-nozzle run averaged 6.6 m/hour, while the average
of the two-nozzle runs was 35070 faster at 8.9 m/hour.
Within this first group of bit runs, the most controlled com-
parison is between D2 and the datum F3. Both bit runs utilized
the same lADe series, bit manufacture, drilling rig, and very
similar drilling parameters, with a distance between well bores
of approximately 800 m. Using the two-nozzle configuration
and 64% more hydraulic power at the bit (HPB), run D2 was
55070 faster than run F3.
The second group of bit runs in Table 1 also used lADe 5.1.7
series bits and drilled from about 1835 m to 1920 m. These runs
encountered sandstone, siltstone. shale and limestone. In this
group. the average ROP of the two-nozzle runs was l00OJo faster
than the datum three-nozzle run.
The third group of bit runs comprised of lADe 5.3.7 series
bits drilling the approximate interval from 1900 m to 2065 m.
The lithology was anhydrite, dolomite, sandstone, siltstone and
shale. The average of the three-nozzle runs was 2.7 m/hr. In
switching to two nozzles with a higher HPB this was increased
by 26'10 to 3.4 m/hr.
Comparison by Lithology
Study Wells D and F are located only 800 m apart and were
drilled by the same rig. Bit runs D2 and F3 used the same lADe
series bit, bit manufacturer and similar drilling parameters.
These are outlined in Table 2. Particular units of lithology of
at least 5 m thickness were identified from logs in each well.
and the corresponding rates of penetration were calculated using
the drilling recorder. Only sand and shale intervals were suffi-
ciently thick for this comparison.
The Journal of Canadian Petroleum Technology
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