Drill Bit Hydraulics Introduction ‘The optimum utilization of mud pump horsepower is of significant importance in rotary drilling operations. An understanding and analytical evaluation of the power-consuming components of a rotary rig are essential o the optimum use of such available power. Drill bit hydraulics is generally associated with the use of jet bits. The purpose of the jet nozzles is to improve the cleaning action of the drilling fluid at the bottom of the hole. Drilled cuttings of rocks that are not efficiently removed from underneath the drill bit will be reground and hence can cause wasteful bit wear and extend drilling time, thereby increasing drilling cost. It is recognized throughout the petroleum industry that the fluid energy expended at the rock-bit interface has a significant effect on drilling performance, However, what is not recognized is how this hydraulic energy can be best utilized in achieving optimum removal of drilled cuttings from beneath the bit. Certain advances—such as the maximizing concepts of bit hydraulic power, jet impact force, and jet velocity—have provided general guidelines for bit hydraulic optimization. These criteria haveserved toprevent severe cuttingsaccumulations, but, are far from being analytically reliable toos for achieving true optimum bottom-hole cleaning. The debate continues among investigators offering conflicting views; some contend that there is no limit to the benefit in penetration rate from the application of maximum hydraulic power, while others claim that for every formatioa type, there is an optimum power level above which those benefits will be offset by the cost o/ fuel and equipment maintenance. Drilling hydraulics is the most complicated and least understood drilling variable because of the interactive complex relationships between the drilling ud, the bit, and the formation Although fluid-flow technology is very well developed, in driling, the low mechanism on the bottom of the hole is not yet understood. There is strong evidence, however, in the literature on bit hydraulics that the cross-flow of the impinging fluid beneath the bit is the governing factor in bottom-hole cuttings removal. Nevertheless, this beliefs far from being conclusively proved. Some research has been and still is being conducted to add to the understanding of drilling-fluid momentum transfer mechanism, cross-flow velocities, fluid impact, and other concepts that are thought to be pivotal in bottom-hole cleaning. Current feld practice in bit hydraulic design involves the selection of an optimum flow rate and corresponding optimum bit nozzle sizes that maximize one of the following parameters: * Drillbit hydraulic horsepower * Jetimpact foree * Jetnozzle velocity142 Ml Drilling Engineering Recently, the concept of jetimpact pressure has been presentedin the lterature.! However, its practical field application has not yet been demonstrated. The first two criteria—namely, bit hydraulic horsepower and jet impact force—are the most commonly used and therefore will be the focus of the remainder of this chapter. Pump Pressure Requirement in Rotary Drilling ‘The available pump surface pressure, normally referred to as the circulating standpipe pressure, is expanded throughout the circulating system in the following manner: ‘+ Friction pressure loss in surface connections (P,) ‘+ Friction pressure loss inside dril pipe (Ptep) * Friction pressure loss inside drill collar (Pad) ‘+ Friction pressure loss in annulus around drill pipe (Php) * Friction pressure loss in annulus around drill collar (Pragp) © Dynamic pressure change across tit (P) Mathematically this can be written as follows: Pos Pig + Php + Prac + Pradp + Prade + Po, 41) or Pra Pi+Py a2) where Pf is the total friction pressure loss and P, is the maximum allowed surface pressure, Ps max (Ot Some specified optimum operating surface pressure, Pe op); Pp, the pressure drop ac ross the bit, can be determined using the equations developed in chapter 3. Example 4-1 A 15,000 ft well is to be drilled. It has been determined that the following maximum pressure gradients in the circulating system will be encountered while drilling the last 1,000 ft hole interval: (@) APiap = 0. psilft (b) APac=03 psift © APisip = 0.01 psisft (@) Plage = 0.07 psit (©) Py =2,200 psi Determine the surface pressure requirement for each of these maximum pressure gradients. The drill collar length is 1,000 it and the surface connections equivalent drill pipe Tength is 600 ft.Drill Bit Hydraulics Ml 143 Solution: From equations (4.1) and (42), P= (Lap Ls)APidp + LicAPitc + LaphPiadp + bicAPrade + Py = (14,600 x 0.1) + (1,000 x 0.3) + (14,000 0.01) + (1,000 x 0.07) + 2,200 = 4,170 psi Hydraulic Power Requirement Hydraulic power, Hy, is defined as the product of a flow rate Q and a corresponding pressure P—that is, My=PO (43) Multiplying both sides of equation (4.2) by @ and utilizing equation (4.3) gives the following: PQ=PO+P,0 a or Ays = Hy + Ai (45) where ‘ysis the hydraulic pump power ‘Ayes the hydraulic power due to friction pressure loss in circulating system. ‘yy is the hydraulic power due to dynamic pressure change across the drill bit. In field units, equation (4.3) becomes PO. Na (48) where A is the hydraulic horsepower (in hp), Pis in psi and Qs in gpm. Example 4-2 Inexample 4-1, determine the pump hydraulic horsepower required in order to achieve a pump volumetric efficiency of 80%. Assume a flow rate of 350 gpm. Solution: FQ _ 1970x350 Hy= “V4 L714 = 402.28 hp RQ _ 2.200% 350 7 = 449.24 by wey 1,714 E144M Drilling Engineering Thus, by use of equation (4.5), My; = 402.28 + 449.24 = 852 hp. For 80% volumetric efficiency, the pump hydraulic horsepower must be Hyp = 852/0.80 = 1,065 hp. Flow Exponent («) From chapter 3, it can be deduced easily that friction pressure loss. P, is related to flow rate, Q, by the relation P= CQe 4.2) where Cis a constant (a function of mud flow properties, hole geometry, pipe geometry, etc.) and cris a flow exponent, varying between | and 2, that either can be measured in the field, as will be shown subsequently, or can be assumed to have a value of 1.86. ‘Taking the logarithm of both sides of equation (4.7) yields logP; = log(CQ™ = logC; + clog (4.8) It equation (4.8) is plotted ona log-log paper, the resulting curve is a straight line whose slope is a. Therefore, if two points, i(Pr;, Q3) and j(Py Q,) are known, then the slope of the line is determined by log, =log2 &Tox0, —lo40, (asa) or cl PL Tos, 70.) 49) Inthe field, while drilling ata certain cepth using a known mud weight and bit nozzle sizes, the circulating pump pressure (standpipe pressure) can be easily recorded at various flow rates, Thus, al flow rates Q, and Qj, the corresponding standpipe pressures of P,yand P,, can be recorded, respectively. From equation (4.2), Py =Py + Pyyand P.;=Py, + Py. Further, Pyand Py,can be calculated from equation (4.9b): (s3x10° on ee (10) which in turn allows the determination of Py and P:: 83x10" )yQ? Ayah, _{eesteyer (4.lla) aeDrill Bit Hydraulics Ml 145 (83x10 )Q? fi tae eta (AND; AC; : With P,; and P,; and corresponding flow rates and given known Q; and Q; values, the flow exponent, c, can be determined using equation (4.9b). Example 4-3 Awell is being drilled at 12,000 ft while using a 15.5 Ibs/gal mud and a drill bit having 14-14- nozzles. At low rates of 400 gpm and 300 gpm, the circulating standpipe pressures recorded. were 4,622 psi and 2,800 psi, respectively. Determine the flow exponent,c, for the well. Solution: The flow exponent is determined using equation (4.9b), given Q, = 400 gpm and Q; = 300 gpm. From equation (4.11a), 599? p, ap, eax ‘Qi ee are, ia (8.3 x 10°5)(15.5)(400)* (a6 1 4)4(14/32)"(0.95)" = 4,622 ~3,150 = 1,472 psi Similarly, (8.310% 4 28, Ee Me AC? = 2,800 1,800 = 1,000 psi Therefore, Hog 472/1,000) 1og(400/300) =134 Maximum Drill Bit Hydraulic Horsepower Criterion The maximum bit hydraulic horsepower criterion assumes that optimum bottom hole cleaning is achieved if hydraulic horsepower across the drill bit is maximized with respect to the flow rate Q. Thus, expressing this hydraulic horsepower explicitly in terms of Q and then using differential calculus leads to the desired flow rate to ensure optimum bottom-hole cleaning.146M Drilling Engineering Drill bit hydraulic horsepower was defined previously as Hyy = PQ. However, Py is a function of flow rate and can be eliminated by making the substitution Py = P,~P,=P,—C\Q\*. Therefore, Ayp = (P= COQ =P.Q-CQe! (4.12) where Ay, is the dependent variable and is a function of flow rate, Q, which is the independent variable. Thus, by use of differential calculus, taking the first derivative of My. with respect to Q and setting the result equal to zero, dH, 0 ~(a+1)CQ*=0 (4.13) Since P; = CQ, Po (a+ Pi =0 (4.Ma) or pote oa (4.140) which is the root that makes My, a maximum, Note that d2Afyy/dQ2 < 0 at P; = [U(a+l)]Ps, which proves that 4 is maximum at this value of P Hence, on the basis of the maximum bit hydraulic horsepower criterion, the optimum bit hydraulics will be achieved if friction pressure loss in the circulating system is maintained at an optimum value of von Gg em (4.15) or at the optimum pressure drop across the naozzles, Propt = Ps max—Propt (4.16) a aa Pmax From equation (4.9b), the following can be written, l05( Pa / Pa) To, 70.) fenDrill Bit Hydraulics Ml 147 where Prop is as defined in equation (415), Pap is the friction pressure loss calculated or measured at some flow rate Q, atid Opp is the sought optimum flow rate. Solving for Qo. yields Pp On = 9, on (4.18) ‘a ‘Thus, if o is known, then Py, ‘opt caN be calculated using equation (4.18). At some assumed flow rate, Q,, Pie Can be calculated from the friction pressure loss equations developed in Ch.3 or measured in the field, then Qox: can be found, using equation (4.18). With Qugr known and Poy, from equation (4.16), equation (4.10) can be rewritten as (83x10 10. Aw rar 4.19) b= (419) ot, solving for At opt (420) With the total optimum area of the nczzles known, the corresponding optimum nozzle diameters, dygp, can be found: ATi ig Hing #4 dy) han (aan If the nozzles are all of equal size (i.e, d) = d) = d;=1=d,), then Hag? ot alton (4.22) Solving for dy opt yields d, 4 (4.23) sis nm where 7 is the number of nozzles of the drill hit. For a tri-cone roller cone bit, n = 3. For drag bits, can be more than 3,148M Drilling Engineering Importantly, the optimum flow rate, Qop, to be used in driling an interval of depth must be bounded by maximum and minimum flow rates, Qnax and Qin, respectively; that is, Onin < Qopt = Qnaxe The maximum flow rate is governed by the following ‘Available rig hydraulic horsepower and the allowed operating pressure of the pump; that is, Qnax = Hip!wPs max» Where rp, is the pump volumetric efficiency Potential hole erosion problems arising from high flow rates Potential formation-fracturing problems arising from excessive annular friction pressure losses or the induced ECD: Prac > Py + Pyr= ECD , where Piru is the formation fracture pressure, Py isthe mud hydrostatic pressure, and P,s the friction pressure loss in the annulus The minimum flow rate is governed by the cuttings transport phenomenon. For acceptable annular hole cleaning, a minimum annular fluid average velocity, v nig, must be maintained: Onin = Va mina max: Where Ay nar is the largest annulus cross-sectional area open to flow. This is discussed in detail in chapter 3 Example 4-4 You are given the following well data: Drill pipe: = OD=45in. - 1D=3.64in, — Weight = 20 bs/tt Drill collar: - D=2in — Weight = 120.3 Ibs/ft — — Length = 1,000 ft — Bingham = 21; @syy = 29 (Fann V-G meter) = Weight = 15.5 Ibs/gal Pump: — National duplex (double acting) — Maximum allowed operating pressure = 5,440 psi — Hydraulic horsepower = 1,600 hp — Volumetric efficiency = 80% Minimum required annular fluid velocity: 85 ft/min average Well geometry: — Shape as shown in figure 4—1 — Last intermediate casing is 9% in. at 12,000 ft TVD Drill bit: 12% in. tri-cone with 3-14 nozzles to 12,000 ft; next bit to be used is 8% in. tn-cone (assume that the hole 1s washed out to 9% 1n.)Drill Bit Hydraulics Ml 149 © Field data: At 12,000 ft, while using the 8% in, ri-cone 3-14 nozzles, = Q,=300 gpm Q, = 400 gpm Pr = 2,966 psi Pry = 4,883 psi ' ' 12,000 Fig. #1. Well schematic in example 4-4 Using the bit hydraulic horsepower criterion, determine the optimum nozzle sizes to be used to drill the next depth interval. Assume current depth is 12,000 ft. Solution: The pressure drops through the bit at flow rates of 300 and 400 gpm can be determined as follows: : _(B3ttxt yo" i ACE Assume that Cj = 0.95. The total nozzle area is AaB (asad? 4d2)—2{!2) cosooy in: ge ttn Te ;150 Ml Drilling Engineering Further, (8311 10°) 155) 300)" Mire eg eng * (0.95) (0.45099)" idee 31110 )(15.5) (400)° yw Eat }55) 0" ons (0.95) (0.45099)" ‘Then, the friction pressure losses at the above given flow rates are Pt = P, — Py, oF Pr, = 2,966 — 631.6 = 2,334.4 psi Pp, = 4,883 — 1,122.8 = 3,760.2 psi Therefore, the flow exponent for the given well geometry can be determined as follows: (Fia/ Fu) 18(0,/0,) log(3,760.2/2,3344) _ log (400/300) The maximum and minimum flow rates are Ho Ca =i : } on 1,600 =Lrw{ 258) = 403:3~408 gpm uu. =2.448(D,'-D. Vaio 2_ qs 85) =2.448(9.875? — 45° & = 267.9 ~268 gpmDrill Bit Hydraulics Ml 151 The optimum friction pressure loss P;.,.,using the maximum hydraulic horsepower criterion, is 1 Paw ‘enh 5,110) Th a 1 eee =2,047.4~2,047 psi The optimum pressure drop at the bit can be calculated as Poot = Po max—Propt = 5A40—2,047 = 3,383 psi The optimum flow rate is Q=0, win te =300 sg ( i] 156 (2.334 =227 gpm Thisis greater than the Opin Of 268 gpin and less than the Qj. 0f 403 gpm; therefore, the Qpp. value 0f 277 gpm is acceptable. The optimum total area of nozzles is (s311x10°)Q5, ie CARE a bon (s311<10°)(155) 277.1" “Y(0s5) (83926) =0.18in? For three equal-sized nozzles, the optimum (from eq. [4.23]) is, 0.18 49: dg =D 4 = 028i.152. Ml Drilling Engineering Therefore, three 9/32 in. nozzles should be used. The actual nozzle flow area is, on A- 4G" (9)? = 0.1863in.? whichis acceptable. Maximum Jet Impact Force Criterion ‘The maximum jet impact force criterion assumes that optimum bottom-hole cleaning is achieved by maximizing the jet impact force with respect to the flow rate, Thus, the desired value of @ that makes F, maximum is found by expressing this impact force, ;, in terms of the flow rate Q and using differential calculus, ‘The jet impact force (hydraulic impact) induced at the bottom of the hole by the mud can be derived from Newton's second law of motion and is given by F =B0,P, (4.24) for B = 0.01823C4 Vy, where Q is in gpm, 7 is in Ibs/gal, and Py is in psi. The pressure change across the drill bitis Py =p, —p; = ps— Cx. Therefore, equation (4.24) becomes F,=B0,\P,-CO" (425) Prior to carrying out the differentiation there are two limitations to the hydraulic impact, force that need to be considered: (1) limitations owing to the maximum available pump hydraulic horsepower, Hp max, and (2) limitations owing to the maximum allowed surface operating pressure, P, nay. During the drilling of the shallow portion of the well, where the system friction pressure loss requirement is small and the flow rate requirement is large, the hydraulic impact force is limited only by the limited pump hydraulic horsepower, Hp max: therefore, available surface pressure is expressed as H, yx O. (426) Substituting equation (4.26) into equation (4,25) yields IDrill Bit Hydraulics Ml 153 Differentiating equation (4.27) and setting to zero yields AF, (U2) [Hy (04 260" 1 THQ -00"* For a valid solution, the numerator in equation (4.28) must be equal to zero: (V2)B UH ax (0+ 2)CQ%*1] =0, OF Hy max ~ (Oe#2)CQ4O = 0, oF P,Q — (cx + 2)CP.Q = 0. Further, solving for the optimum friction pressure that must be maintained in circulating system yields (4.28) 1 =aaghe (4.29) Fs The optimum pressure that must be maintained across drill bit is atl Rage Fag -aah (4.30) Po As the well is drilled deeper, the system friction pressure loss requirement increases, while the flow rate requirement decreases. Therefore, the hydraulic impact force will be limited by the limited maximum allowed pump pressure, P, may. Hence, equation (4.25) becomes F; = BOV P, pax —CO€ . Differentiating and setting equal to zero yields 1/2)B}2P...0-(a+2cO"" ar, _(v2)al he (a0) pa a PPouQ® CO For valid solution, the numerator in equation (4.31) must be zero: (V2)B[2Px max — (02+ 2)CQ**1] = 0, oF 2, ax (O-42)P; = 0. Therefore, 2 Ft = Fgh (432) Hence, a Bac = BeBe = Pa ae Using equations (4.29), (4.30), (4.32), and (4.33), the optimum flow rate, Qope, and the optimum nozzles sizes, dope. can be determined on the basis of the jet impact force maximi- zation criterion.154 Ml Drilling Engineering Example 4-5 Refer to the well data given in example 44, (@)_ Using the impact force criterion, determine the optimum nouzle sizes to be used to drill the next interval of depth, stating at 12,000 ft (b) Determine the maximum total hydraulic horsepower that willbe utilized under the drilling conditions in part (a). Assume a bt life of 50 h and a drilling rate of 10 {th. Friction pressure losses at the flow rate found in part (a) are given as follows: APic = 1.587 psift; APggp = 0.0125 psift; AP = 0.0254 pst Solution: (@) From example 4-4, ct = 1.68, Qnin= 268 gpm, and Qnax = 403 gpm. Since the interval in question is at a deeper part of the well, pump surface pressure will be the limiting factor. Therefore, from equations (4.32) and (4.33), Rina ‘eU+a 2x5,440 Z 2.075 Pr opt = Ps max—Propt 400 — 2,975 = 2,465 psi Further, a .) [as “) log(2,975/2,334) | 165 = 300 antilos =347 gpm which is bound by the maximum and minimum flow rates and therefore is acceptable. Hence, (83x10*) «15.5347 hen Sr orcare acta ges 0.95" x 2,465 =0.2639in? For three equal nozzles, dy op: = 10.71/32 in.; thus, use three 11/32 in. nozzles. (b) The total footage drilled by the bit will beA = R= (500 ft) x 10h = 500 ft Then, the well TMD and TVD are found: TMD = 14,000 + 500 = 14,500 ft, and TVD = 12,000 + 500 sin 30° = 12,250 ftDrill Bit Hydraulics Ml 135 Since the frictional pressure loss gradient inside the drill pipe is not given, it must be calculated at 347.0 gpm. The average velocity inside the drill pipe (Vy) is po HID MST 93 tynin DBE B64) The plastic viscosity (PV) and the yield point (¥P), respectively, are PV = O5n9 —Ojq0 = 29-21 = centipoise YP = O39 — PV = 21-8 = 13 Ibs/100ft? ‘Then, the critical velocity for turbulent flow (v,) is found: 6457(PV)+ (6457),/(PV)'+99,0,(YP) : 156x364 =194.78fvimin Since Vip > Ve the flow regime is turbulent. ‘The Reynolds number is $280) ney 928(642.3/60) (3.64) (15.6) 8 =70,513.2 The friction factor (assuming smooth pipe) is 0.0791 ln, 0.0791 4Y70,513.2 The pressure loss gradient is = 0.004854156 Ml Drilling Engineering At the new depth, the total friction pressure loss is P, (Ay + APraplap + (APac + APacdlic 09228 + 0,0126)(13,500) + (1.587 + 0.0254) (1,000) (028 psi The pressure drop at the bitis (8311x10%)y0* Cra (8311x10°)(15.6) (3472 (0.95)'(0.2784 Thus, the total pump pressure is Po=Pp+Ph = 3,028 + 2,234 = 5,262 psi and the required hydraulic horsepower (HHP) is wp = 2. 14 BAT 5,262 =1,333hp 1714x080 Supplementary Problems Problem 4-1. You ate given the following well data and well trajectory shown in fig. 4-2: © — Open hole size = 8% in. (washed out to 9% in.) to TD of 20,250 ft © Drill pipe: - OD=Sin. — D=3in. © Drill collar: - OD=7%in. — D=3in ~ Length = 800Drill Bit Hydraulics Ml 157 = Mud: = Bingham; Yq = 13 Ibs/gal 30 Ibs/100 ft? 0; yy) = 25 (Fann V-G meter) © Last casing set at 13,000 ft 7D * Constant slope of hydraulics = 1.85 © Pump: Pyax = 4300 psi (allowed) © Minimum annular fuid velocity = $0 ft/min Neglect surface connections and assume that the minimum flow rate is allowed. {@)_ Determine the optimum nozzle sizes to be used for optimum hydraulics (bottom- hole cleaning) at a TD of 13,000 ft Use the bit hydraulic horsepower criterion, (b) Ifthe formation fracture gradient is 0.831 pst, indicate whether fracture will ‘occur (i) while drilling under the conditions specified in part (a), and (ji) when a trip is made at a TD of 20,000 ft. 10,000 ft 2. 225 “0p 7 Fig. 4-2 Well omjectory in problems 4-1 and 4-17158 Ml Drilling Engineering Problem 4-2, You are given the following data (see also fig. 4-3): ‘+ Last casing set at 10,500 TMD © Casing ID = 8.5in, * T= 16,0008 TVD ‘© Drillbit: 7% in. tri-cone roller cone (hole size washed out to 814 in.) © Maximum required WOB to TD = 40,000 Ibs = Drill pipe - OD=44in, - D=%4in, = Air weight =27 Ibs/ft * Drill eolar - OD=6vin. - D=3%in, ~ Air weight = 100 Ibs/ft * Coefficients of friction at wals: 0.1, casings; 0.2, open hole + Steel weight = 65 tbs/gal Mud: = Power law = Qs = 65; Qyq = 40 (Fann V-G meter) — Gel strength = 15/25 Ibs/100 2 ‘© Friction pressure losses while driling at 16,000 ft TVD: AP,qc = 0.012 psf; AP age = 0.079 psi/ft; APiay = APiac= 0.065 psi. * Surge/swab pressures in annulus while tripping from 16,000 ft TVD: APaarge = APoyab = 0.02 psi/ft ‘+ Rigsurface connections = 600 ft of drill pipe © Minimum allowed annular velocity = 120 ft/min © Differential pressure required = 05 Ibs/gal Casing shoe of 10,000 ft TVD to TD + Formation pressure gradient = 0.52 psi/t ‘© Formation fracture gradient = 13 lbs/gal + Pump: Duplex — Pump factor = 3.7 gaistroke Prax = 4,500 psi {@) Indicate whether any drilling problems will occur under the above conditions. Show details. (b) Using the jet impact force criterion, determine the optimum bit nozzle sizes to be used for drilling the next interval of hole starting at 10,500 ft TMD with 12-12-12 jets, given the following recordings: () at 05 gpm, pump pressure = 2,000 psi; (i) at 905 gpm, pump pressure = 2,500 psi.Drill Bit Hydraulics Ml 159 Fig. 4-3. Wellconditions in problem 4-2 Problem 4-3. You are given the following well data: © Drill pipe: - OD=4.5in. - ID=4in. —Airweight = 1275 Ibs/t © Drill collar: - OD=75in. - ID=4in. — — Airweight = 107.3 Ibs/ft = Length = 1,000 ft © Intermediate casing: = OD=10%in. — Wall thickness = 0.4 in. 0,000 ft TVD. * Current depth + M=1o0008 * Settings depth = 6,500 ft TVD Drillbit: Tri-cone roller cone jet bit; 84 in. with 9-9-8 nozzles. = Mud: Bingham plastic; y = 10 Ibs/gel = Qua =95; Osan = 50; %5 = 30 Insite160 Ml Drilling Engineering © Minimum annular velocity required for cuttings removal = 120 ft/min © Pump: = 2,000 hp — Maximum allowed surface pressure = 4,800 psi = Volumetric efficiency = 90% © Pump pressure at current depth: = ALQ) = 250 gpm, P, = 2,333 psi = AtQ) =350 gpm, P, = 4,377 psi (@) Determine the optimum flow rate and nozzle sizes to be used for drilling the next interval of depth. Use maximum jet impact force and maximum bit hydraulic horsepower criteria. (0) Determine if formation fracturing will occur during breaking circulation. Assume that the formation fracture gradient at the casing shoe is 0.545 psf. (©) Find the bottom hole equivalent cicculating mud density ata flow rate of 450 gpm for (i) normal circulation and (il) reverse circulation. Problem 4~4. You are given the following well data (See also fig. 4~4): Last casing setting = 14,000 ft TMD + T=1,5008TVD Hole size to TD = 7% in. * Drillpipe: = Airweight = 26.88 Ibs/ft © Drill collar: — OD=6in. - ID=3%in. = Airweight = 100.8 Ibs/ft — — Length = 1,500 ft + Pumps: 2,000 hp; np = 85%; Paix = 3,800 * — Minimum annular fluid velocity for hole cleaning: 120 ft/min + Coelficients of friction at walls: (.1, eased sections; 0.2, open hole section * Mud: — Bingham plastic — Specific gravity = 2.0 for next depth interval = jy) = 55; Oy) = 35; 10/10 min; gel = 18/30 0/10 f2 (Fann V-G meter) © — Formation below 14,000 ft TMD: — Fracture gradient = 18.0 Ibs/sal; — Pore pressure gradient = 0.8; psi/ftDrill Bit Hydraulics Ml 161 © Friction pressure losses: — While drilling at 14,000 ft TMD: APip = APjac = 0.075 psi; ‘APradp = 0.01 psit; APiage = 0.08 psi/ft — During tripping from 14,000 f1 TMD: APuugo = APyyap = 0.025 psit (annulus) = 5,000 8 3a tm P| 2,500 f 6,000 8 | Fig. 4-4. Well conditions in protlem 44 (@)_ Indicate whether any problem will occur while drilling at or tripping from 14,000 ft ‘TMD. Show details. (0) Determine the maximum WOB that can be applied while drilling below the last casing seat. (Stee! weight = 64.6 Its/ga.) (©). Using the impact force criterion, determine the optimum bit hydraulies at 14,000 {UTMD. Assume a flow power index of m = 1.86; APigp = 0.62 psilft, and APiage = 0.3 psift at Q = 564 gpm. Problem 4—5. You are given the following data for a directional S-shaped well (see also fig. 4-5): = Mud: — Bingham plastic 0.2 Ibs/gal — Bayo = 65; Oy = 40; 10s/10 min gel = 15/25 Ibs/100 ft? © Bit: Tri-cone roller cone jet bit + Drill pipe = OD=4%in - D=4in, = Alrwelght = 14 Ibs/tt162 Ml Drilling Engineering © Drill collar: - OD=7Kin. - D=4in. Air weight = 110 Ibs/ft Length = 1,000 ft umps: Duplex (double acting) Rated hydraulic horsepower = 2,000 hp Maximum allowed surface pump pressure = 4,800 psi Minimum pump flow rate = 200 gpm Volumetric efficiency = 90% Annular velocity = 70 ft/min (minimum) Hole: Last intermediate casing (ID = 8 in) set at 16,000 ft TVD (open hole washed out to 8% in, using 7 in, bit) + 3.000 3.00 1 Fig. 4-5, Well conditions in problem 4-5 (@) Determine the optimum bit hydraulies to be used at TVD = 16,000 ft and TVD = 20,000 it, using the hydraulic horsepower criterion, Assume a power flow index of m=18 (b) Determine the differential pressure while drilling at 18,200 ft TVD, assuming Piao = 0.0158 psi/ft, APiyj. = 0.0491 psi/ft, and APjajp = 0.073 psiDrill Bit Hydraulics Ml 163 Problem 4-6. You are given the following well data: Mud: — Plastic viscosity = 30 centipoise — Yield value = 8 Ibs/100 ft? = Gel strength = 15 Ibs/100 ft? = Weight = 12 Ibs/gal © Well depth = 10,000 ft Drill bit nozzle sizes: 13-13-13 © Pump: — Total hydraulic horsepowe — Volumetric efficiency = 1% — Maximum allowed pump pressure = 4,500 psi — Minimum flow rate = 350 gpm Pump pressures of 4,000 psi and 2,500 psi were recorded while circulating mud at 500 gpm and 390 gpm, respectively. (@) Determine the optimum nozzle sizes to be used for the next bit run, using the ‘maximum hydraulic horsepower criterion for optimum hydraulics. (b) What percentage of the pump hydraulic horsepower is wasted while flowing at 500 spm? (©) What percentage ofthe pump hydraulic horsepower is utilized under the conditions in part (a)? Problem 4~7. You are given the following well data: © Last casing set at §,000 ft © Hole size: 8% in at 5,000 ft to 10,000 ft TVD + Drillpipe: ~ OD=Sin, = D=4in — Air weight = 256 Ibs/ft + Drill collar: - OD=Tin = D=4in — Airweight = 84 Ibs/ft * Coefficients of friction at walls: 0.1, cased sections; 0.2 open hole section * Mud: = Bingham plastic; between 5,000 ft and 10,000 ft — Fann V-G cial reading: 45; Corresponding Shear Rate (sec-!)340 s+ ~ Fann V-G dial reading: 65; Corresponding Shear Rate (sec-!)510 s- Gel = 18/30 Ibs/100 12 .7 x Nsec-t, where Wis the Fann rotational speed: uy = (30003/!V) = (800%,/N)164 Ml Drilling Engineering © Formation: — Fracture gradient = 18.2 Ibs/sal — Pore pressure gradient = 0.78 psi/t ‘+ Pump: Triplex = by= lin, - D=6%in, — GPM) max = 120 = (SpIM) pin = 25 — Volumetric eficiency = [100 ~ (015 x spm)]% ‘© Maximum input horsepower = 1,300 hp + Maximum allowed surface pressure = 3,500 psi * Minimum annular velocity allowed = 120 fVmin © Maximum anticipated WOB below 3,000 ft = 60,000 Ibs * Differential pressure required for drilling safety = 0.1 Ibs/gal © Akick was taken at 5,000 ft — Pedy = 400 psi Peg = 800 psi Bit discharge coetficient: 0.95 * Drilled rock cuttings: Weight density = 20.8 Ibs/gal * Steel weight density = 65 Ibs/gal * Surface connections: 800 ft of drillpipe ‘© Hoisting system: 12 lines; efficiency = 859% + Drawwork efficiency = 908% Diesel engine efficiency © Bitin use before tripping at §,000 ft: three-jet roller cone 16-16-16 © AtQ=250 gpm, P, = 708 psi {@)_ Design the optimum hydraulic program between 5,000 ft and 10,000 ft in increments of 2,000 ft depth intervals. Use the maximum bit hydraulic horsepower criterion, (b) While criling at the conditions determined in part (a), the rock cuttings concen- tration in the mud occupying the annulus is 10% of the annulus volume. Determine ‘whether formation fracturing will occur (©) Determine the engine horsepower requirement to trip out from 10,000 fat a speed of 3 Its (@)_ Determine whether the available pump is adequate to break circulation at 9,000 ft.Drill Bit Hydraulics Ml 165 Problem 4~8. You ate given the following well data (see also fig. 4~8): * Last casing setting = 18,000 ft TMD + ™=17200 TVD * Hole size to TD = 8% in. * Dillpipe: — OD=44in, - D=3%4in, — Air weight = 26.88 Ibs/ft © Drlleolar — OD=6in - D=34in, ~ Airweight = 100.8 Ibs/t + Pumps: = 2000hp = y= 90% Prax = 4,500 psi © Minimum annular fluid velocity for hole cleaning = 120 ft/min © Coefficients of friction at walls: 0.15, cased sections; 0.25, open hole section + Mud: — Bingham plastic = G409 = 55; 84y) = 35(Fann V-G meter) — 10 sfmin; gel = 15/35 tbs/100 t2 © Formation below 18,000 ft TMD: — Fracture gradient = 172 Ibs/sal; — Pore pressure gradient = 0.78 psvft ‘Pressure changes in circulating system while drilling at 18,000 ft TMD: 0.080 psi/t (075 psitft = Py = 19M psi + Circulating standpipe pressure (pump pressure) = 3,800 psi ‘© During tripping from 18,000 ft TMD, APs = APeyan = 0.08 psift (annulus) ‘© Steel weight = 65 tbs/gal Maximum WOB betow 18,000 ft TMD = 33,000 Ibs {@)_ Indicate whether any drilling problem will occur while drilling at or tripping from 18,000 ft TMD. Show details (b) Using the bit hydraulic horsepower criterion, determine the optimum bit hydraulics at 20,000 ft TMD. Assume a flow power index of m = 1.86; also assume that total friction pressure loss inthe annulus is 25% of total friction pressure loss inthe drill string166 Ml Drilling Engineering + 5,000 f mh Mg Z 3,200 60 deg 8,000 Le Problem 4-9, Determine the optimum bit hydraulics using the maximum jet impact force criterion at 1,000 ft increments for an interval of the well between the intermediate casing at 8,000 ft and 13,000 ft. Mud data for the well are given in table 4~1, and the well data plan is as follows: © Pump horsepower = 1,400 hp Fig. 4-6, Well conditions in problem 4-8 © Pump efficiency = 0.85 * Maximum allowed standpipe pressure = 4,500 psi * Minimum annular velocity = 120 ftimin © Drill pipe: 4.5 in. by 3.875 in Drill collars: 600 ft of 8.0, by 3.00in. © Hole size = 10.5 in * Surface equipment equivalent to 400 ft of drill pipe Table 4-1. Mud data for problem 4-9 Depth (ft) Mud Density Yield Point (Ab/gal) (ib/i00 ft2) 8,000—11,000 M 50 11,000-13,000 B 8Drill Bit Hydraulics Ml 167 Problem 4-10. You are given the following well data (see also fig. 4~1): 500 ft TVD Casing (774i) set at 8,000 ft * Differential pressure = 300 psi + Drillpipe: OD = 4.25 ins 1D =3.5 in, © Drill collar: OD = 6 in; 1D = 3.5 in, length = 1,000 ft Drillbit: Tri-cone three-jet (6 7/8 in.); at 8,000 ft to 11,500 ft (assume hole will be washed out to 7% in) © Pump: Duplex — Total hydraulic horsepower = 1,200 hp — Volumetric efficiency = 85% — Maximum allowed operating pressure = 3,600 psi * Minimum allowed annular fluid velocity = 120 ft/min * Slope of line for friction pressure foss vs. flow rate: = 15, © Mud: yl = 25 centipoise; xy = 101bs/100 2 ‘Formation fracture gradient = 0.75psi/t? (@)_ Using the maximum bit hydraulic horsepower criterion for optimum bottom-hole cleaning, determine the optimum flow rates and corresponding total nozzle areas ata depth of 8,000 ft to 11500 ft for a depth interval of 1,000 ft. (b) What optimum nozzle sizes would you recommend at 11,000 ft? (©) Ifthe friction pressure loss in the annulus while drilling at 9,000 ft is given by APytdy = 0.021 and APyigc = 0.126, will a kick occur? Fig. 4-7. Well conditions in problem 4-10168 Ml Drilling Engineering Problem 4-11. You are given the following well data: (a (o) Drill pipe: = OD=45in - 1D=364in. — Weight = 20 Ibs/tt Drill collar: ID=2in = Weight = 120.3 Ibs/tt = Length = 1,000 ft = Bingham = Gggg = 21; Osa9 = 29 (Fann V-G meter) — Weight = 15.5 Ibs/gal; to 12,000 ft TVD Pump: National duplex (double acting) Maximum allowed operating pressure = 5,440 psi = Hydraulic horsepower = 1,600 hp Volumetric efficiency = 80% Drilled cuttings = Cuttings average setting velocity = 40 ft/min — Average minimum required cuttings rise velocity for annular hole cleaning = 120 ft/min Well geometry = Shape as in problem 4-1 (see fig. 4-2); — _ Lastintermediate casing is 9% in, at 12,000 ft TVD Geological formation: — Formation pore and fracture pressure gradients are 0.80 psi/ft and 0.831 psift, respectively. — Target ertical depth = 15,000 ft Drill bit = 12Ain, tricone bit with 3-14 nozzles to 12,000 ft — _ Next bit to be used is 8 in. tr-cone (assume hole washed out to $/in.) Field data at 12,000 ft, using the 12% in. bit: — AtQy =300 gpm, Py = 2,800 psi = AbQ) =400 gpm, Pye = 4,622 psi Specify a mud weight to be used to drill from 12,000 ft to 15,000 ft TVD ata differ- ential pressure of 200 psi. How much barite (Ibs/bbl) must be added to original mud? Using the impact force criterion, determine the optimum hydiraulis to be used to drill the next interval of depth, stacting at 12,000 ftDrill Bit Hydraulics Ml 169 (©) Determine the maximum total hydraulic horsepower that will be utilized under the Ariling conditions in part (b)- Assume bit life of 100 h and drilling rate of 20 fh; friction pressure losses at the flow rate found in part (b) are as follows: Pegg = 1.7 psi/ft; Pap = 0.0126 psifft; Pade = 0.0256 psivft. (@) Whatis the maximum weight on bi: that you can apply under the given mud weight and drill string conditions? Problem 4-12. You are given the following well data: + Dillpipe - OD=45in. - D=4in, — Weight = 12.5 Ibs/it © Drill collar: = OD=75in, - D=4in — Weight = 107.3 Ibs/tt — — Length = 1,000 ft © Intermediate casing: = OD=1075 in. — Wall thickness = 0.4 in, © Current depth = 10,000 ft TVD + M=10008 * Setting depth = 6,500 ft TVD Drillbit: 84in,tri-cone roller cone jet bit with 9-9-9 nozzles = Mud: — Bingham plastic ~ y= 10 Ibs/gal Problem 4-13. Using the concept ofjetimpact pressure, explain why at a given flow rate, the ROP increases for extended nozzles and blanked-off nozzles. Nomenclature Ay annulus cross-sectional area C Constant Ca Coelficient of discharge yop. Optimum nozzle diameters ECD Equivalent circulating density of mud Hi, Hydraulic power Hy Drillbit hydraulic power Hye Hydraulic power owing to friction pressure loss in circulating system170 Ml Drilling Engineering Hyg Hydraulic pump power Py Friction pressure loss in annulus P, —_Bitpressure drop P; Total frictional pressure drop Pie Formation fracture pressure Pj, Mud hydrostatic pressure Prate Annulus friction pressure loss around drill collar Pragp Atinulus Friction pressure loss around drill pipe Prac Drill collar friction pressure loss Pry Drill pipe friction pressure loss Pr. Surface friction pressure loss P, Maximum allowed surface pressure Q — Flowrate Qop, Optimum flow rate Ysnin_ annular velocity a Flowexponent ny Volumetric efficiency References 1 Smalling, D.A.,and Key, T.A. 1979. “Optimization of Jet-Bit Hydraulics Using Impact Pressure.” Paper SPE 8440, presented at the 54th Annual Fall Technology Conference, Las Vegas, Nev.