Drilling Bits

And Hydraulics Calculations

Drilling Bits

Types of bits

Drag Bits
Roller Cone Bits
Diamond Bits

Cutting Mechanisms
a) Shearing the formation as PDC and TSP
diamond bits do

b) Ploughing / Grinding the formation, as

natural diamond do
c) Crushing; by putting the rock in compression
as a roller bit

The Ideal Bit *

1. High drilling rate
2. Long life
3. Drill full-gauge, straight hole
4. Moderate cost
* (Low cost per ft drilled)

Bit Selection

Minimum Cost Per Unit length $/ft

Bit cost + rig cost X (tripping time + Drilling time)

C /L = ----------------------------------------------------------------Footage Progress

$ Per Foot

The Roller Cone Bits

Two-cone bit (Milled tooth soft formation only)

Three cone bit (milled tooth, Tungsten carbide inserts)
Four-cone bit (milled tooth, for large hole size)

Fluid flow through jets in the bit (nozzles)

Tungsten
Carbide Insert
Bit

Milled
Tooth
Bit

Rotary Drill Bits

Roller Cutter Bits - rock bits
First rock bit introduced in 1909 by
Howard Hughes
2 - cone bit
Not self-cleaning

Rotary Drill Bits

Improvements
3 - cone bit

(straighter hole)

Intermeshing teeth

(better cleaning)

Hard-facing on teeth and body

Change from water courses to jets
Tungsten carbide inserts
Sealed bearings
Journal bearings

Rotary Drill Bits

Advantages
For any type of formation there is a
suitable design of rock bit
Can handle changes in formation
Acceptable life and drilling rate
Reasonable cost

Proper
bottomhole
cleaning is very
important

Fluid flow through water courses in bit

Fluid flow through jets in the bit (nozzles)

Three Cone Bit

Three equal sized cones

Three Identical legs
Each cone is mounted on bearings run on a pin from the leg
The three legs are welded to make the pin connection
Each leg is provided with an opening ( to fit Nozzle)

Design Factors

Dictated by the Hole size and Formation properties

JOURNAL
ANGLE

Angle formed by the axis of the

Journal and the axis of the bit

The Angle of the Journal influence the size of the cone

The smaller the Journal angle the greater the gouging and
scrapping effect by the three cones

Offset Cones
Hard

Soft

Medium

Teeth

Bearing
Outer & Nose
Bearings
Support Radial Loads
Ball Bearing
Support axial loads
Secure the cons on
the legs

Rotary Drill Bits

Milled Tooth Bit (Steel Tooth)
Long teeth for soft formations
Shorter teeth for harder formations
Cone off-set in soft-formation bit results in
scraping gouging action
Self-sharpening teeth by using hardfacing
on one side
High drilling rates - especially in softer
rocks

Milled
Tooth Bit
(Steel
Tooth)

Rotary Bits
Tungsten Carbide Insert Bits

Long life cutting structure in hard rocks

Hemispherical inserts for very hard rocks
Larger and more pointed inserts for softer rock
Can handle high bit weights and high RPM
Inserts fail through breakage rather than wear

(Tungsten carbide is a very hard, brittle material)

Tungsten
Carbide
Insert
Bits

Sealed Bearing
Lubrication System

INSERTS

SILVER PLATED BUSHING

RADIAL SEAL
BALL RACE
BALL RETAINING
PLUG

BALL BEARING

Sealed, selflubricated roller bit

journal bearing
design details
GREASE RESERVOIR CAP

Roller
Cone
Bearings

Bearings
Ball Bearings (point contact)
Roller Bearings (line contact)
Journal bearing (area contact)
Lubrication by drilling fluid . . . or . . .

Bearings
Sealed Bearings (since 1959)
Grease lubricant (much longer life)

Pressure surges can cause seal to leak!

Compensate?

Journal Bearings (area contact)

Wear-resistant hard surface on journal
Solid lubricant inside cone journal race
O - ring seal
Grease

Grading of Dull Bits

How do bits wear out?

Tooth wear or loss

Worn bearings
Gauge wear

Grading of Dull Bits

How do bits wear out?
Steel teeth - graded in eights of original
tooth height that has worn away

e.g. T3 means that

3/8 of the original
tooth height is worn
away

Grading of Dull Bits

Broken or Lost Teeth

Tungsten Carbide Insert bit

e.g. T3 means that 3/8 of the inserts

are broken or lost

Grading of Dull Bits

How do bits fail?

Bearings: B3 means that an estimated

3/8 of the bearing life is gone

Balled up Bit

Cracked Cone

Grading of Dull Bits

How do bits fail?

Washed out Bit

Lost Cone

Grading of Dull Bits

How do bits wear out?

Gauge Wear:
Bit is either in-Gauge or out-of-Gauge
Measure wear on diameter (in inches),
using a gauge ring

4 Examples:

BIT

T3 B3 - I
T5 B4 - 0 1/2

GAUGE RING

Roller cone
bit wear
problems

IADC ROLLER CONE

BIT CLASSIFICATION
SYSTEM

IADC System
Operational since 1972
Provides a Method of Categorizing Roller Cone
Rock Bits
Design and Application related coding
Most Recent Revision
The IADC Roller Bit Classification System
1992, IADC/SPE Drilling Conference
Paper # 23937

IADC Classification
4-Character Design/Application Code
First 3 Characters are NUMERIC
4th Character is ALPHABETIC

135M

or

447X

or

637Y

Examples

135M

447X

637Y

soft formation

soft formation insert bit;

Milled tooth bit;

friction bearings

medium-hard insert
bit;

roller bearings with

with gage protection;

friction bearing with

gage protection;

chisel inserts

gage protection;

motor application

conical inserts

Sequence
135M

or

447X

or

Numeric Characters are defined:

Series

1st

Type

2nd

Bearing & Gage

3rd

Alphabetic Character defined:

Features Available

4th

637Y

Series
135M

or

447X

or

637Y

FIRST CHARACTER
General Formation Characteristics
Eight (8) Series or Categories
Series 1 to 3 Milled Tooth Bits
Series 4 to 8 Tungsten Carbide Insert Bits
The higher the series number,
the harder/more abrasive the rock

Define Hardness
Hardness

UCS (psi)

Examples

Ultra Soft

< 1,000

gumbo, clay

Very Soft

1,000 - 4,000

unconsolidated sands, chalk,

salt, claystone

Soft

4,000 - 8,000

coal, siltstone, schist, sands

Medium

8,000 - 17,000

sandstone, slate, shale,

limestone, dolomite

Hard

17,000 - 27,000

quartzite, basalt, gabbro,

limestone, dolomite

Very Hard

> 27,000

marble, granite, gneiss

UCS = Uniaxial Unconfined Compressive Strength

Bearing & Gage

135M

or

447X

or

637Y

THIRD CHARACTER
Bearing Design and Gage Protection
Seven (7) Categories

1. Non-Sealed (Open) Roller Bearing

2. Roller Bearing Air Cooled
3. Non-Sealed (Open) Roller Bearing Gage Protected
4. Sealed Roller Bearing
5. Sealed Roller Bearing Gage Protected
6. Sealed Friction Bearing
7. Sealed Friction Bearing Gage Protected

Features Available
135M

or

447X

or

637Y

FOURTH CHARACTER
Features Available (Optional)
Sixteen (16) Alphabetic Characters
Most Significant Feature Listed
(i.e. only one alphabetic character should be selected).

IADC Features Available

A - Air Application
B - Special Bearing/Seal
C - Center Jet
D - Deviation Control
E - Extended Nozzles
G - Gage/Body Protection
H - Horizontal Application
J - Jet Deflection

135M

or

L - Lug Pads
M - Motor Application
S - Standard Milled
Tooth
T - Two-Cone Bit
W - Enhanced C/S
X - Chisel Tooth Insert
Y - Conical Tooth Insert
Z - Other Shape Inserts

447X

or

637Y

Drag Bits
Cutter may be made from:

Steel
Tungsten carbide
Natural diamonds
Polycrystalline diamonds (PDC)

Drag bits have no moving parts, so it is less likely

that junk will be left in the hole.

Fishtail type drag bit

Drag Bits
Drag bits drill by physically plowing
or machining cuttings from the
bottom of the hole.

Natural Diamond Bits

PDC Bits

Natural
Diamond
bit

junk slot
cuttings
radial flow
high p
across face

Soft
Formation
Diamond bit

Larger diamonds
Fewer diamonds
Pointed nose

Hard
Formation
Diamond bit

Smaller diamonds
More diamonds
Flatter nose

Natural Diamonds

The size and spacing of diamonds on a

bit determine its use.

NOTE: One carat = 200 mg

What is 14 carat gold?

precious stones

Natural Diamonds
2-5 carats - widely spaced diamonds
are used for drilling soft formations such as
soft sand and shale

1/4 - 1 carat - diamonds are used for drilling

sand, shale and limestone formations of
varying (intermediate) hardness.

1/8 - 1/4 carat - diamonds, closely spaced, are

used in hard and abrasive formations.

When to Consider Using a Natural

Diamond Bit?
1. Penetration rate of rock bit < 10 ft/hr.
2. Hole diameter < 6 inches.
3. When it is important to keep the bit and
pipe in the hole.
4. When bad weather precludes making trips.
5. When starting a side-tracked hole.
6. When coring.
* 7. When a lower cost/ft would result

Top view of diamond bit

Side view of
diamond bit

PDC
bits

Courtesy
Smith Bits

PDC Cutter

PDC Bits

At about $10,000-150,000 apiece, PDC bits cost five to 15 times more

than roller cone bits

The Rise in Diamond Bit Market Share

Coring
bit

PDC +
natural
diamond

Bi-Center bit

Courtesy Smith Bits

Relative Costs of Bits

$/Bit
Diamond
Bits

WC Insert
Bits

Milled
Tooth Bits

Diamond bits typically cost several times as much as tricone bits with tungsten carbide inserts (same bit diam.)
A TCI bit may cost several times as much as a
milled tooth bit.

PDC Bits
Ref: Oil & Gas Journal, Aug. 14, 1995, p.12

Increase penetration rates in oil and gas

wells
Reduce drilling time and costs
Cost 5-15 times more than roller cone bits
1.5 times faster than those 2 years earlier
Work better in oil based muds; however,
these areas are strictly regulated

PDC Bits
Parameters for effective use
include
weight on bit

mud pressure
flow rate
rotational speed

PDC Bits
Economics
Cost per foot drilled measures Bit
performance economics
Bit Cost varies from 2%-3% of total cost, but
bit affects up to 75% of total cost
Advantage comes when
- the No. of trips is reduced, and when
- the penetration rate increases

PDC Bits
Bit Demand
U.S Companies sell > 4,000 diamond drill
bits/year
Diamond bit Market is about $200
million/year
Market is large and difficult to reform
When bit design improves, bit drills longer

PDC Bits
Bit Demand, contd
Improvements in bit stability, hydraulics,
and cutter design => increased footage per bit
Now, bits can drill both harder and softer
formations

PDC Bits
Bit Design,
PDC bit diameter varies from 3.5 in to 17.5 in

Goals of hydraulics:
clean bit without eroding it
clean cuttings from bottom of hole

PDC Bits
Bit design, contd
Factors that limit operating range
and economics:
Lower life from cutter fractures
Slower ROP from bad cleaning

PDC Bits
Cutters
Consist of thin layer of bonded diamond
particles + a thicker layer of tungsten carbide
Diamond
10x harder than steel
2x harder than tungsten carbide
Most wear resistant material
but is brittle and susceptible to damage

PDC Bits
Cutters, contd
Diamond/Tungsten Interface
Bond between two layers on cutter is
critical
Consider difference in thermal
expansion coefficients and avoid
overheating
Made with various geometric shapes to
reduce stress on diamond

PDC Bits
4 Cutters, contd
Various Sizes
Experimental dome shape
Round with a buttress edge for high
impact loads
Polished with lower coefficient of friction

PDC Bits
Bit Whirl (bit instability)
Bit whirl = any deviation of bit rotation
from the bits geometric center
Caused by cutter/rock interaction forces

PBC bit technology sometimes

reinforces whirl
Can cause PDC cutters to chip and break

PDC Bits
Preventing Bit Whirl
Cutter force balancing
Bit asymmetry
Gauge design
Bit profile
Cutter configuration
Cutter layout

PDC Bits
Applications
PDC bits are used primarily in
Deep and/or expensive wells
Soft-medium hard formations

PDC Bits
4 Application, contd
Advances in metallurgy, hydraulics
and cutter geometry
Have not cut cost of individual bits
Have allowed PDC bits to drill longer
and more effectively
Allowed bits to withstand harder
formations

PDC Bits
Application, contd
PDC bits advantageous for high rotational
speed drilling and in deviated hole section
drillings
Most effective: very weak, brittle formations
(sands, silty claystone, siliceous shales)
Least effective: cemented abrasive sandstone,
granites

Grading of Worn PDC Bits

CT - Chipped Cutter

BT - Broken Cutter

Less than 1/3 of cutting

element is gone

More than 1/3 of cutting

element is broken to
the substrate

Grading of Worn PDC Bits contd

LT - Lost Cutter

LN - Lost Nozzle

Bit is missing one or

more cutters

Bit is missing one or

more nozzles

Diamond bit wear problems

Best Penetration Rate

Approach B
Approach A
Achieved by removing Drilling fluid hits
bottom of the hole
cuttings efficiently
with greatest force
from below the bit
Maximize the
hydraulic power
available at the bit

Maximize Jet Impact

Force

Optimum bit hydraulics

Find the flow rates for different pump pressures (before POOH)
Use the values to calculate C and N
Get the expression for optimum flow rate
Establish optimum flow rate Q
Find the system pressure drop
Get the optimum system pressure drop (from either approach A or
Establish optimum Stand pipe pressure and check with pump capacity
Calculate optimum Pb
Calculate optimum AT (TFA) and select jets

Bit Nozzles

Bit Nozzles

Nozzle Velocity
vn = C d

pb
8.074 104

Cd = Nozzle discharge coefficient

usually equal to 0.95

Bit Pressure Drop

8.33 10 q
pb =
2 2
Cd At
5

Hydraulic Power
pq
PH =
1714
1169 400
PH =
= 272.8 HP
1714

Hydraulic Impact Force

F j = 0.01823Cd q pb
F j = 0.01823 .95 400 12 1169
F j = 820.5lbs

Jet Bit Nozzle Size Selection

Proper bottom-hole cleaning
will eliminate excessive regrinding of drilled
solids, and
will result in improved penetration rates

Bottom-hole cleaning efficiency

is achieved through proper selection of bit
nozzle sizes

Total Pump Pressure

Pressure loss in surf. equipment
Pressure loss in drill pipe
Pressure loss in drill collars
Pressure drop across the bit nozzles
Pressure loss in the annulus between the drill
collars and the hole wall
Pressure loss in the annulus between the drill
pipe and the hole wall
Hydrostatic pressure difference

( varies)

Jet Bit Nozzle Size Selection

- Optimization Through nozzle size selection,
optimization may be based on
maximizing one of the following:
Bit Nozzle Velocity
Bit Hydraulic Horsepower
Jet impact force

There is no general agreement on which of

these three parameters should be maximized.

Maximum Nozzle Velocity

Nozzle velocity may be maximized consistent with
the following two constraints:

1. The annular fluid velocity needs to be high

enough to lift the drill cuttings out of the hole.
- This requirement sets the minimum
fluid circulation rate.
2. The surface pump pressure must stay within the
maximum allowable pressure rating of the
pump and the surface equipment.

Maximum Nozzle Velocity

Nozzle Velocity

i.e.

vn = Cd

Pb
4
8 . 074 * 10

v n Pb

so the bit pressure drop should be maximized in

order to obtain the maximum nozzle velocity

Maximum Nozzle Velocity

This (maximization) will be achieved when
the surface pressure is maximized and the
frictional pressure loss everywhere is
minimized, i.e., when the flow rate is
minimized.
v n is maximized when 1& 2 above are satisfied,
at the minimum circulation rate
and the maximum allowable surface pressure.

Maximum Bit Hydraulic Horsepower

The hydraulic horsepower at the bit is
maximized when (p bit q) is maximized.

p pump = p d + p bit

p bit = p pump p d
where p d may be called the parasitic pressure
loss in the system (friction).

Maximum Bit Hydraulic Horsepower

The parasitic pressure loss in the system,

p d = p s + p dp + p dc + p dca + p dpa = cq

1.75

if the flow is turbulent.

In general,

p d = cq

where 0 m 2

Maximum Bit Hydraulic Horsepower

p bit = p pump p d
PHbit

p d = cq

pbit q p pump q cq
=
=
1714
1714

dPHbit

= 0 when
dq

m +1

p pump c(m + 1)q = 0

m

Maximum Bit Hydraulic Horsepower

p pump c(m + 1)q = 0
m

i . e ., when
i . e ., when

p pump = ( m + 1 ) p d
pd

1
=
p
m +1

P Hbit is maximum

pd

pump

when

1
=
p pump
m +1

Maximum Bit Hydraulic Horsepower

- Examples In turbulent flow, m = 1.75

1
p d =
p p
m +1

p d =
p pump * 100 %
1 . 75 + 1
= 36% of p pump
p bit = 64 % of p pump

Maximum Bit Hydraulic Horsepower

Examples - contd
In laminar flow, for Newtonian fluids,
pd

1
=
p pump * 100 %
1+1
= 50% of p pump

p b = 50 % of p pump

m=1

Maximum Bit Hydraulic Horsepower

In general, the hydraulic horsepower is not
optimized at all times
It is usually more convenient to select a
pump liner size that will be suitable for
the entire well
Note that at no time should the flow rate be
allowed to drop below the minimum
required for proper cuttings removal

Maximum Jet Impact Force

The jet impact force is given by Eq. 4.37:

F j = 0.01823 cd q pbit
= 0.01823 c d q ( p pump p d )

Maximum Jet Impact Force

F j = 0.01823 c d q ( p pump pd )
But parasitic pressure drop,

p d = cq
F j = 0 .01823 c d

p p q cd q
2

m+2

Maximum Jet Impact Force

Upon differentiating, setting the first derivative
to zero, and solving the resulting quadratic
equation, it may be seen that the impact
force is maximized when,

2
p d =
p p
m+2

Maximum Jet
Impact Force
- Examples Thus, if m = 1.75,

2
p d =
p p
m+2

pd = 53% of pp
and pb = 47% of pp

Also, if m = 1.00

pd = 67% of pp
and pb = 33% of pp

Nozzle Size Selection

- Graphical Approach -

1. Show opt. hydraulic path

2. Plot pd vs q
3. From Plot, determine
optimum q and pd
p bit = p pump p d
4. Calculate
5. Calculate
2
5
8 .311 * 10 q opt
Total Nozzle Area: ( At ) opt =
2
C d ( p b ) opt
(TFA)

6. Calculate Nozzle Diameter

With 3 nozzles:

4Atot
dN =
3

Example 4.31
Determine the proper pump operating
conditions and bit nozzle sizes for max.
jet impact force for the next bit run.
Current nozzle sizes: 3 EA 12/32
Mud Density = 9.6 lbm.gal
At 485 gal/min, Ppump = 2,800 psi
At 247 gal/min, Ppump = 900 psi

Example 4.31 - given data:

Max pump HP (Mech.) = 1,250 hp
Pump Efficiency

= 0.91

Max pump pressure

= 3,000 psig

Minimum flow rate

to lift cuttings

= 225 gal/min

Example 4.31 - 1(a), 485 gpm

Calculate pressure drop through bit nozzles:
Eq .( 4 . 34 ) : p b =
p b =

8.311(10

-5

8 . 311 * 10
2

c d At

)( 9 .6 )( 485 )2

12
2
(0.95) 3

4 32

= 1,894 psi

parasitic pressure loss = 2,800 - 1,894 = 906 psi

Example 4.31 - 1(b), 247 gpm

pb =

8 . 311 (10

)( 9 . 6 )( 247 )

2
( 0 . 95 ) 3
4

12

32
2

= 491 psi

parasitic pressure loss = 900 - 491 = 409 psi

(q1, p1) = (485, 906)
(q2, p2) = (247, 409)

Plot these two

points in Fig. 4.36

Example 4.31 - contd

3
2

2. For optimum hydraulics:

(a ) Interval 1,
q max =

1,714 PHp E
Pmax

(b) Interval 2,

1,714(1,250)(0.91)
=
= 650 gal/min
3,000

2
2
p d =
Pmax =
( 3, 000 )
m+2
1 .2 + 2
= 1,875 psi

(c) Interval 3,

q min = 225 gal/min

Example 4.31
3. From graph, optimum point is at
gal
q = 650
, p d = 1,300 psi p b = 1,700 psi
min
8 .311 * 10 q opt
5

( At ) opt =

C d ( p b ) opt

Aopt = 0.47 in

-5

8.311*10 * 9.6 * (650)

=
2
(0.95) * (1,700)

(d N )opt = 14

nds

32

in

gal
q = 650
, p d = 1,300 psi p b = 1,700 psi
min

Example 4.32
Well Planning
It is desired to estimate the proper pump
operating conditions and bit nozzle sizes for
maximum bit horsepower at 1,000-ft
increments for an interval of the well
between surface casing at 4,000 ft and
intermediate casing at 9,000 ft. The well
plan calls for the following conditions:

Example 4.32
Pump: 3,423 psi maximum surface pressure
1,600 hp maximum input
0.85 pump efficiency
Drillstring: 4.5-in., 16.6-lbm/ft drillpipe
(3.826-in. I.D.)
600 ft of 7.5-in.-O.D. x 2.75-in.I.D. drill collars

Example 4.32
Surface Equipment: Equivalent to 340
ft. of drillpipe
Hole Size: 9.857 in. washed out to 10.05 in.
10.05-in.-I.D. casing
Minimum Annular Velocity: 120 ft/min

Mud Program
Depth
(ft)

Mud
Density
(lbm/gal)

Plastic
Yield
Viscosity
Point
(cp)
(lbf/100 sq ft)

5,000

9.5

15

6,000

9.5

15

7,000

9.5

15

8,000

12.0

25

9,000

13.0

30

12

Solution
The path of optimum hydraulics is as
follows:
Interval 1

q max =

1,714 PHp E
p max

1,714(1,600)(0.85)
=
3,423

= 681 gal/min.

Solution
Interval 2
Since measured pump pressure data are not
available and a simplified solution technique
is desired, a theoretical m value of 1.75 is
used. For maximum bit horsepower,

1
1
p d =
(3,423 )
pmax =
1.75 + 1
m +1
= 1,245 psia

Solution
Interval 3
For a minimum annular velocity of
120 ft/min opposite the drillpipe,

q min = 2.448 10 .05 4.5

= 395 gal/min

120

60

Table
The frictional pressure loss in other
sections is computed following a
procedure similar to that outlined above for
the sections of drillpipe. The entire
procedure then can be repeated to
determine the total parasitic losses at
depths of 6,000, 7,000, 8,000 and 9,000 ft.
The results of these computations are
summarized in the following table:

Table

Depth ps pdp pdc pdca pdpa pd

5,000
6,000
7,000
8,000
9,000

38
38
38
51
57

490
601
713
1,116
1,407

320
320
320
433
482

20 20
20 25
20 29
28 75*
27* 111*

* Laminar flow pattern indicated by

Hedstrom number criteria.

888
1,004
1,120
1,703
2,084

Table
The proper pump operating conditions
and nozzle areas, are as follows:
( l) Depth (2)Flow Rate (3) p d (4) p b
( ft )

(gal/min)

5,000
6,000
7,000
8,000
9,000

600
570
533
420
395

(psi)

1,245
1,245
1,245
1,245
1,370

(5)A t

(psi) (sq in.)

2,178
2,178
2,178
2,178
2,053

0.380
0.361
0.338
0.299
0.302

Table
The first three columns were read directly
from Fig. 4.37. (depth, flow rate and pd)
Col. 4 (pb) was obtained by subtracting pd
shown in Col.3 from the maximum pump
pressure of 3,423 psi.
Col.5 (Atot) was obtained using Eq. 4.85

Surge Pressure due to Pipe Movement

When a string of pipe is
being lowered into the
wellbore, drilling fluid is
being displaced and forced
out of the wellbore.
The pressure required to
force the displaced fluid out
of the wellbore is called the
surge pressure.

Surge Pressure due to Pipe Movement

An excessively high surge pressure can
result in breakdown of a formation.
When pipe is being withdrawn a similar
reduction is pressure is experienced. This
is called a swab pressure, and may be
high enough to suck fluids into the wellbore,
resulting in a kick.

For fixed

v pipe ,

Psurge = Pswab

Figure 4.40B

- Velocity profile for laminar flow pattern when closed

pipe
is being run into hole

The Hydraulics Parameters

Pump Volumetric output and circulation pressure Pt
Flow rate
Bit nozzle jet velocity
Annular velocity
Pressure losses in the system
Pump Hydraulic power output
Pressure drop across the bit nozzles
Hydraulic Power at the bit
Jet impact force

Pump volumetric output and circulating pressure

Q= K.L(2D2-d2).spm.v/100 for double acting pump

Q= K.L.D2.spm.v/100

for single acting pump

Q in

GPM

if

K=.00679

Q in

BPM

if

K=.000126

Circulating Pressure = Total Pressure loss (except at the bit)

+ Pressure drop across the bit nozzle

Flow rate Q

Can be measure directly (flow-meter)

Can be calculated

Average Velocity in Drillpipe

Assuming the total string is DP;

24.51 x Q
Velocity Vdp = -----------------IDp2

ft/min

Annular Average Velocity

Assuming the total string is DP;
24.51 x Q
Annular Velocity Vann = -----------------Dh2 - ODp2

ft/min

Minimum velocity govern by the lifting capacity of the drilling fluid

Maximum velocity in sensitive formation 100 ft/min.
Optimum Annular Velocity is at the minimum flow rate required
to efficiently remove cuttings from the hole

Nozzle Jet Velocity

Vn = 0.321 (Q/A)

ft/s

Minimum 350 ft/s or 100 m/s

Fluid Flow
Newtonian fluid
Non Newtonian fluid
Bingham Plastic Fluid
Power-Law Fluid
Re = 15.46 DV /
Laminar Flow

Re < 2000

Turbulent Flow

Re > 4000

Bingham Plastic Model

At the wall zero Fluid velocity
Viscosity independent of time
Particles travel parallel to the
pipe axe (max. velocity at the
center).

Critical Velocity Vc

97 pv + 97 pv + 8.2 D YP
Vc =
D
2

V > Vc

Turbulent flow

V < Vc

Laminar flow

ft/min

Pressure Drop

Pressure Loss in the System

Pressure losses in the surface equipment

Pressure loses in the drilling string
Pressure loses in the annulus

Pressure drop in the surface

equipment

P1 = E N-1 (PV)2-N QN

N=1.8 or can be measures

Pressure Drop in Drillpipe

P2 = f V2 L / 25.8 d
f

is a friction factor depends on the type of flow

P2 = c . QN
c

P2

8.91 x 10-5 N-1 PV2-N . L

= ------------------------------------IDpN+3
8.91 x 10-5 N-1 QN PV2-N . L
= ----------------------------------------IDpN+3

Pressure Drop in annulus

P3 = f V2 L / 21.1 (Dh - ODp)
f is a friction factor depends on the type of flow
P3 = c . QN
c = 8.91 x 10-5 N-1 PV2-N L / (Dh - ODp)3 (Dh + ODp)N+3
P3

8.91 x 10-5 N-1 QN PV2-N . L

= ------------------------------------(Dh - ODp)3 (Dh + ODp)N+3

Pressure drop across the bit

Pb = Pstandpipe - (P1+P2+P3)
Q2
Pb = --------------------12,032 Cn2 AT2
Cn = Nozzle Coefficient (~ 0.95)

Nozzle Velocity Vn ft/s

Vn = 33.36

Pb

Best Penetration Rate

Approach B
Approach A
Achieved by removing Drilling fluid hits
bottom of the hole
cuttings efficiently
with greatest force
from below the bit
Maximize the
hydraulic power
available at the bit

Maximize Jet Impact

Force

Optimum bit hydraulics

Find the flow rates for different pump pressures (before POOH)
Use the values to calculate C and N
Get the expression for optimum flow rate
Establish optimum flow rate Q
Find the system pressure drop
Get the optimum system pressure drop (from either approach A or
Establish optimum Stand pipe pressure and check with pump capacity
Calculate optimum Pb
Calculate optimum AT (TFA) and select jets

Max. Hydraulic Power at the bit

Pb . Q / 1714
Pb = (Psp - PCS)

hp

Pcs = c QN

HHPb = (Psp Q - c QN+1 )/1714

Differentiate wrt Q = 0

Pb = (N/N+1) Psp

Jet Impact Force below the bit

IF = Q/58 ( Pb)0.5 Max IF when Pb = [N/(N+2)] Psp
61.6 x 10-3 Q2 / AT

Nozzle Selection

AT = 0.0096 Q ( /Pb)0.5 = .32 Q/Vn

dn = 32 (4 AT /3)0.5

Total Pump Pressure

Pressure loss in surf. equipment
Pressure loss in drill pipe
Pressure loss in drill collars
Pressure drop across the bit nozzles
Pressure loss in the annulus between the drill
collars and the hole wall
Pressure loss in the annulus between the drill
pipe and the hole wall
Hydrostatic pressure difference

( varies)

Types of flow
Laminar

Turbulent

Fig. 4-30. Laminar and turbulent flow patterns in a circular pipe: (a) laminar
flow, (b) transition between laminar and turbulent flow and (c) turbulent flow

Turbulent Flow Newtonian Fluid

N Re =

928 v d

= fluid density, lbm/gal

where
_

v = avg. fluid velocity, ft/s

d = pipe I.D., in
= viscosity of fluid, cp.

We often assume that fluid flow is

turbulent if Nre > 2100

Turbulent Flow Newtonian Fluid

Turbulent Flow Bingham Plastic Fluid

In Pipe

_ 1 . 75

dp f

=
1 . 25
dL
1800 d
0 . 75

0 . 25

_ 1 . 75

v
p
dp f
=
dL
1800 d 1 . 25
0 . 75

0 . 25

In Annulus
_ 1 . 75

dp f

=
1 . 25
dL
1,396 (d 2 d 1 )
0 . 75

0 . 25

_ 1 . 75

p
v
dp f
=
1 . 25
dL
1,396 (d 2 d 1 )
0 . 75

0 . 25

API Power Law Model

K = consistency index
n = flow behaviour index

API RP 13D

=K n

SHEAR
STRESS

psi
0

SHEAR RATE, , sec-1

Rotating Sleeve Viscometer

(RPM * 1.703)
VISCOMETER
RPM

SHEAR RATE

3
100

ANNULUS

5.11
170.3

300
600

DRILL
STRING

511
1022

sec -1

BOB

SLEEVE

Pressure Drop Calculations

Example

Calculate the pump pressure in

the wellbore shown on the next page, using the
API method.

The relevant rotational viscometer readings

are as follows:

R3 = 3
R100 = 20
R300 = 39
R600 = 65

(at 3 RPM)
(at 100 RPM)
(at 300 RPM)
(at 600 RPM)

Pressure Drop
Calculations
Q = 280 gal/min

= 12.5 lb/gal
PPUMP = PDP + PDC
+ PBIT NOZZLES
+ PDC/ANN + PDP/ANN
+ PHYD

PPUMP

Pressure Drop In Drill Pipe

Power-Law Constant (n):
R 600
n = 3 . 32 log
R 300

65
= 3 . 32 log
= 0 . 737
39

Fluid Consistency Index (K):

K =

5.11 R600
n

1,022

5.11 * 65
dyne sec n
=
= 2.017
0.737
1,022
cm 2

Average Bulk Velocity in Pipe (V):

0 . 408 Q
V =
D2

0 . 408 * 280
ft
=
= 8 . 00
2
3 . 78
sec

OD = 4.5 in
ID = 3.78 in
L = 11,400 ft

OD = 4.5 in
ID = 3.78 in
L = 11,400 ft

Pressure Drop In Drill Pipe

Effective Viscosity in Pipe (e):

96V
e = 100 K
D

96 * 8
e = 100 * 2.017

3.78

n 1

3n + 1

4n

0.7371

0.737

3 * 0.737 + 1

4 * 0.737

= 53 cP

Reynolds Number in Pipe (NRe):

NRe

928 D V
=
e

928 * 3.78 * 8.00 * 12 .5

=
= 6,616
53

Pressure Drop In Drill Pipe

NOTE: NRe > 2,100, so
Friction Factor in Pipe (f):

a=

b=

So,

log n + 3.93

50

1.75 log n

a
NRe

a
NRe

log 0.737 + 3.93

= 0.0759
50

1.75 log 0.737

=
= 0.2690
7

f =

f =

OD = 4.5 in
ID = 3.78 in
L = 11,400 ft

0 .0759
=
= 0 .007126
0 .2690
6,616

Pressure Drop In Drill Pipe

OD = 4.5 in
ID = 3.78 in
L = 11,400 ft

Friction Pressure Gradient (dP/dL) :

f V
dP

=
25.81 D
dL
2

psi
0.007126 * 8 2 * 12 .5
=
= 0.05837
25.81 * 3.78
ft

Friction Pressure Drop in Drill Pipe :

dP
P = L
dL

= 0.05837* 11,400

Pdp = 665 psi

Pressure Drop In Drill Collars

OD = 6.5 in
ID = 2.5 in
L = 600 ft

Power-Law Constant (n):

R 600
n = 3 . 32 log
R 300

65
= 3 . 32 log
= 0 . 737
39

Fluid Consistency Index (K):

K=

5.11R 600
1,022

5.11 * 65
dyne sec n
=
= 2.017
0.737
1,022
cm 2

Average Bulk Velocity inside Drill Collars (V):

0 . 408 Q
V=
D2

0 . 408 * 280
ft
=
= 18 . 28
2
2 .5
sec

Pressure Drop In Drill Collars

Effective Viscosity in Collars(e):

96V
e = 100 K

n 1

3n + 1

4n

96 * 18.28
e = 100 * 2.017

2.5

OD = 6.5 in
ID = 2.5 in
L = 600 ft

0.7371

3 * 0.737 + 1

4 * 0.737

0.737

= 38.21cP

Reynolds Number in Collars (NRe):

NRe

928 D V
=
e

928 * 2.5 * 18 .28 * 12 .5

=
= 13,870
38 .21

Pressure Drop In Drill Collars

NOTE: NRe > 2,100, so
Friction Factor in DC (f):

f =

a
NRe

log n + 3.93
a=
50

log 0.737 + 3.93

=
= 0.0759
50

1.75 log n

1.75 log 0.737

=
= 0.2690
7

b=

So,

a
f =
b
NRe

OD = 6.5 in
ID = 2.5 in
L = 600 ft

0.0759
=
= 0.005840
0 .2690
13,870

Pressure Drop In Drill Collars

Friction Pressure Gradient (dP/dL) :
f V
dP
=

25.81 D
dL
2

0.005840 * 18 .28 2 * 12 .5
psi
=
= 0.3780
25 .81 * 2.5
ft

Friction Pressure Drop in Drill Collars :

dP
P =
L
dL

= 0.3780 * 600

Pdc = 227 psi

OD = 6.5 in
ID = 2.5 in
L = 600 ft

Pressure Drop across Nozzles

P =

156 Q

(D

N1

P =

+ DN2 + DN3
2

156 * 12.5 * 280 2

(11

+ 11 + 12
2

2 2

PNozzles = 1,026 psi

DN1 = 11 32nds (in)

DN2 = 11 32nds (in)
DN3 = 12 32nds (in)

Pressure Drop
in DC/HOLE
Annulus
Q = 280 gal/min

= 12.5 lb/gal
DHOLE = 8.5 in
ODDC = 6.5 in
L
= 600 ft

8.5 in

Pressure Drop
in DC/HOLE Annulus

DHOLE = 8.5 in
ODDC = 6.5 in
L
= 600 ft

Power-Law Constant (n):

R
n = 0 . 657 log 100
R3

20
= 0 . 657 log
= 0 . 5413
3

Fluid Consistency Index (K):

K =

5.11R100
170 .2

5.11 * 20
dyne sec n
=
= 6.336
0.5413
170 .2
cm 2

Average Bulk Velocity in DC/HOLE Annulus (V):

ft
0 . 408 Q
0 . 408 * 280
V =
=
= 3 . 808
2
2
2
2
8 .5 6 .5
sec
D 2 D1

Pressure Drop
in DC/HOLE Annulus

DHOLE = 8.5 in
ODDC = 6.5 in
L
= 600 ft

Effective Viscosity in Annulus (e):

144V

e = 100 K
D2 D1

n 1

2n + 1

3n

144 * 3.808
e = 100 * 6.336

8 .5 6 .5

0.5413 1

2 * 0.5413 + 1

3 * 0.5413

0.5413

= 55.20 cP

Reynolds Number in Annulus (NRe):

NRe =

928 (D2 D1 ) V
e

928 (8.5 6.5) * 3.808 * 12.5

=
= 1,600
55.20

Pressure Drop
in DC/HOLE Annulus

DHOLE = 8.5 in
ODDC = 6.5 in
L
= 600 ft

NOTE: NRe < 2,100

Friction Factor in Annulus (f):
24
f =
NRe

24
=
= 0 .01500
1,600
f V
2

dP

=
dL 25.81(D 2 D1 )

0.01500 * 3.808 2 * 12.5

psi
=
= 0.05266
25.81 (8.5 6.5 )
ft

dP
P =
L
dL

So,

= 0 .05266 * 600

Pdc/hole = 31.6 psi

Pressure Drop
in DP/HOLE Annulus
q = 280 gal/min

= 12.5 lb/gal
DHOLE = 8.5 in
ODDP = 4.5 in
L
= 11,400 ft

Pressure Drop
in DP/HOLE Annulus

DHOLE = 8.5 in
ODDP = 4.5 in
L
= 11,400 ft

Power-Law Constant (n):

R 100
n = 0 .657 log
R3

20
= 0 .657 log
= 0 .5413
3

Fluid Consistency Index (K):

K =

5.11R100
n

170.2

5.11* 20
dyne secn
=
= 6.336
0.5413
170.2
cm2

Average Bulk Velocity in Annulus (Va):

0.408 Q
V = 2
2
D2 D1

ft
0.408* 280
=
= 2.197
2
2
8.5 4.5
sec

Pressure Drop
in DP/HOLE Annulus
Effective Viscosity in Annulus (e):
144V

e = 100 K
D2 D1
144 * 2.197
e = 100 * 6.336

8 . 5 4 .5

n1

0.5413 1

2n + 1

3n

2 * 0.5413 + 1

3 * 0.5413

0.5413

= 97.64 cP

Reynolds Number in Annulus (NRe):

NRe =

928 (D2 D1 ) V
e

928 (8.5 4.5) * 2.197 * 12.5

= 1,044
97.64

Pressure Drop
in DP/HOLE Annulus
NOTE: NRe < 2,100
Friction Factor in Annulus (f):
f=

24
NRe

24
= 0 .02299
1,044

fV
dP
=

dL 25.81(D2 D1 )
2

0.02299 * 2.1972 * 12.5

psi
=
= 0.01343
25.81(8.5 4.5)
ft

dP
P =
L
dL

So,

= 0 . 01343 * 11,400

psi psi
Pdp/hole = 153.2

Pressure Drop Calcs.

- SUMMARY PPUMP = PDP + PDC + PBIT NOZZLES
+ PDC/ANN + PDP/ANN + PHYD
PPUMP = 665 + 227 + 1,026
+ 32 + 153 + 0

PPUMP = 1,918 + 185 = 2,103 psi

PPUMP = PDS + PANN + PHYD

PDS = PDP + PDC + PBIT NOZZLES

= 665 + 227 + 1,026 = 1,918 psi
PANN = PDC/ANN + PDP/ANN
= 32 + 153 = 185
PHYD = 0

PPUMP = 1,918 + 185

= 2,103 psi

2,103 psi

P
=
0

"Friction" Pressures

"Friction" Pre ssure , psi

2,500
DRILLPIPE

2,000
1,500

DRILL COLLARS

1,000

BIT NOZZLES

500

ANNULUS

0
0

5,000

10,000

15,000

20,000

Cumulative Distance from Standpipe, ft

25,000

H ydrostatic Pre ssure , psi

Hydrostatic Pressures in the Wellbore

9,000
8,000

BHP

7,000
6,000
5,000

DRILLSTRING

ANNULUS

4,000
3,000
2,000
1,000
0
0

5,000

10,000

15,000

20,000

Cumulative Distance from Standpipe, ft

25,000

Pressures, psi

Pressures in the Wellbore

10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0

CIRCULATING

STATIC

5,000

10,000

15,000

20,000

Cumulative Distance from Standpipe, ft

25,000

Wellbore Pressure Profile

0
2,000

DRILLSTRING

Depth, ft

4,000
6,000

ANNULUS
8,000
10,000

(Static)

12,000

BIT
14,000
0

2,000

4,000

6,000

Pressure, psi

8,000

10,000

Pipe Flow - Laminar

In the above example the flow down the
drillpipe was turbulent.
Under conditions of very high viscosity,
the flow may very well be laminar.
NOTE: if NRe < 2,100, then
Friction Factor in Pipe (f):
Then

f =

16
N Re

f V
2

and

dP

=
25 .81 D
dL

n = 1.0

_
2

dp
f v
=
dL 25 .8 d