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SKPP 3413 - DRILLING ENGINEERING

Chapter 4 - Drilling Hydraulics


Assoc. Prof. Abdul Razak Ismail

Petroleum Engineering Dept.


Faculty of Petroleum & Renewable Energy Eng.
Universiti Teknologi Malaysia
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Contents
• Newtonian fluid flow
• Plastic fluid flow
• Pressure drop calculation
3
Drilling Mud Circulating System

Mud Mud Surface Stand


pit pump piping pipe

Rotary
hose
Annulus
dp/hole
Inside drill
pipe (dp)

Annulus Bit Inside drill


dc/hole nozzles collar (dc)

Drill string
p1
Hole
Nozzle

vn2 vn3
vn1 p2

Fluid flow through jets in the bit (nozzles)


4

 Since the mud enters the drill string and leaves the annulus
at essentially the same elevation, the only pressure
required is to overcome the frictional losses in the system.
 Hence, the discharge pressure at the pump is defined by:

∆pt = ∆ps + ∆p p + ∆pc + ∆pb + ∆pac + ∆pap ....... (3.1)

where:
∆pt = pump discharge pressure
∆ps = pressure loss in surface piping, standpipe, and mud hose
∆pp = pressure loss inside drill pipe
∆pc = pressure loss inside drill collars
∆pb = pressure loss across bit nozzles
∆pac = pressure loss in annulus around drill collars
∆pap = pressure loss in annulus around drill pipe
5

Pressure Losses in a Circulating Mud System


6

 The solution of Eq. (3.1) is rather tedious; separate


calculations are needed for each section
 There are 4 different types of model used to calculate
frictional pressure losses in mud circulating system:
− Newtonian
− Bingham plastic
− Power-law
− API Power-law
 Due to the limitation of the syllabus, Power-Law and API
Power-Law models will not be discussed in this subject.
 All calculations will be focused on Newtonian and plastic
fluid models.
7

Newtonian Fluid Flow Calculations


 Similar to generalized flow system approach, calculation of ∆p for
pipe flow requires a knowledge of which flow pattern pertains to the
specific case, since different equations apply for each situation.
 Definition of the existing flow pattern is given by a dimensionless
quantity known as the Reynolds number (NRe ):
928 ρ vd
N Re = .......... (3.2)
where:
µ
N Re = Reynolds’s number
v = average velocity of flow, ft/sec
ρ = fluid density, ppg
d = pipe inside diameter, in.
µ = fluid viscosity, cp
q = circulating volume, gal/min
8

 Similar to generalized flow system approach, that if


− laminar flow : N Re < 2000
− transition flow : 2000 < N Re < 4000
− turbulent flow : N Re > 4000
 The ∆p in laminar flow is given by the Hagan-Poiseuille law; this,
in practical units, is
µ Lv
∆p = 2
.......... (3.3)
where: 1,500d
∆p = laminar flow ∆p, lb/in2
L = length of pipe, ft
 For turbulent flow, Fanning’s equation applies: turbulent flow
f ρ Lv 2
∆p = .......... (3.4)
25.8 d
where:
∆p = turbulent flow ∆p, lb/in2
f = Fanning friction factor
9

 The friction factor f is a function of and pipe


roughness, and has been evaluated experimentally
for numerous materials (see Fig. 7.1)
 ∆p calculation for Newtonian fluid flow systems in
the following manner:
a. Calculate NRe from Equation (3.2).
b. If NRe < 2000, use Equation (3.3) to calculate the
pressure drop.
c. If NRe > 2000, use Equation (3.4). In this case the
friction factor f is obtained from Figure 7.1 or its
equivalent.
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11

Plastic Fluid Flow Calculations

 Drilling fluids is non-Newtonian fluid


 Newtonian fluid equations must be altered for application
to typical drilling mud systems
12

Surface Equipment Losses (∆ps)


● The surface equipment consist of standpipe, hose, swivel, kelly
joint, and the piping between the pump and standpipe.
● In practice, there are only four types of surface equipment; each
type is characterized by the dimensions of standpipe, kelly,
rotary hose and swivel. Table 3.1 summarizes the four types of
surface equipment.

Table 3.1: Types of surface equipment & value of constant E


Standpipe Hose Swivel, etc. Kelly Eq. length,
Type 3.826” ID E
ID Length ID Length ID Length ID Length
1 3” 40 ft. 2.5” 45 ft. 2” 20 ft. 2.25” 40 ft. 2,600 ft. 2.5 x 10-4

2 3.5” 40 ft. 2.5” 55 ft. 2.5” 25 ft. 3.25” 40 ft. 946 ft. 9.6 x 10-5

3 4” 45 ft. 3” 55 ft. 2.5” 25 ft. 3.25” 40 ft. 610 ft. 5.3 x 10-5

4 4” 45 ft. 3” 55 ft. 3” 30 ft. 4” 40 ft. 424 ft. 4.2 x 10-5


13

To determine surface equipment losses (∆ps):


Use the following formula:

E ρ m0.8 q1.8 µ 0.2


∆ps = p .......... (3.5)

where:
∆ps = surface pressure losses, psi
q = flow rate, gpm
ρm = mud density, ppg
E = a constant depending on type of surface equipment used
µp = mud plastic viscosity, cp
Fluid Flow Inside the Pipe
A. Laminar Flow Region
4
144∆p= Yt + mv
3

Shearing stress or pressure


(True laminar flow)

Yb, Bingham yield

Transition from plug to laminar flow


Plug flow
Yt, True yield

Rate of shear or velocity


Fig. 3.1: Flow behavior of plastic and Newtonian fluids.
4
144∆p= Yt + mv
3
where:
144∆p = pressure drop, lb/ft2
4
3 Yt
= Yb, lb/ft2
m = µL/(1500d2), slope of linear portion (from Eq. (3.3))
15

 For practical values of v , the behavior of plastic fluids may be


expressed as:

LYb µp vL

=p +
300d 1500d 2 laminar flow
L  µp v 
=
∴ ∆p  Yb +  .......... (3.6)
300d  5 d 
where:
µ p = plastic viscosity, cp.
Yb = yield point, lb/100ft2.
 Eq. (3.6) may be used in cases where laminar flow exists
 Determination of flow characteristic (laminar or turbulent) is
made by comparing the actual velocity with a calculated critical
velocity
16

Average Velocity Calculation

q ft 3 /sec
v=
A ft 2
1 ft 3 1 min
q gal/min × ×
7.48 gal 60 sec
=
(π /4)(d /12) 2
q
v= 2
....... (3.7a)
Avg. velocity 2.45 d OD
inside the pipe ID
Hole
q
v= 2 2
....... (3.7b)
Avg. velocity 2.45 (d h - d p )
in the annulus
Drill pipe
where :
v = average velocity, ft/sec. Annulus
q = flow rate, gpm = Ah − Ap
Annulus Area
d = diameter, in. π
= (d h2 − d p2 ( OD ) )
4
17

Critical Velocity Calculation


● If Eqs. (3.3) and (3.6) are equated, an equivalent Newtonian
viscosity in terms of d , v , µ p and Yb is obtained:
5dYb
= µ + µp
v
● Substituting the above Eq. for µ in the Reynolds’s number of Eq.
(3.2), equating the resulting equation to 2000, and solving for v
gives:
1.08µp + 1.08 µ p2 + 9.3ρ d 2Yb
vc = .......... (3.8)
ρd
where:
vc = critical velocity, ft/sec, above which turbulent flow
exists and below which the flow is laminar.
● Eq. (3.8) assumes that turbulence occurs at NRe = 2000. Therefore,
if:
v < vc , flow is laminar
v > vc , flow is turbulent
18

B. Turbulent Flow Region


● Before Fanning Eq. can be used, alteration to NRe expression have to
be done (after Beck, Nuss & Dunn)
µp
µt = .......... (3.9)
3.2
where:
µt = turbulent viscosity of plastic fluids, cp

● Substitution of µt, for µ in the general NRe expression (Eq. (3.2)) gives:
928 ρ vd
N Re =
µt
2,970 ρ vd
N Re = .......... (3.10)
µp

● By using Fig. 7.1, determine f


● This f may then be used in Eq. (3.4) for calculation of pressure
19

In summary, ∆p calculation for plastic fluid flow systems can


be done as follows:
(1) Calculate the average velocity, v , from Eq. (3.7a) or (3.7b)
(2) Calculate vc from Eq. (3.8)
(3) If v < vc → flow is laminar, Eq. (3.6) applies
(4) If v > vc → flow is turbulent, requiring:
a. Calculation of NRe from Eq. (3.10)
b. Determination of f from Fig. 7.1 at the calculated
for the conduit in question
c. Calculation of pressure drop from Eq. (3.4)
20

Example 3.1
Mud is flowing through 4 1/2 in. OD (ID = 3.64 in.), internal
flush drill pipe. Calculate the frictional pressure drop per 1000
ft of pipe if the circulating rate (q) = 400 gal/min.

Mud properties
Mud density, ρm = 10 lb/gal
Bingham yield, Yb = 10 lb/100 ft2
Plastic viscosity, µp = 30 cp
21

q
Eq. (3.7a) : v =
Solution 3.1 2.45d 2

1.08µp + 1.08 µ p2 + 9.3ρ d 2Yb


Eq. (3.8) : v =
c
ρd

400
=
(1) v = 2
12.3 ft/sec
2.45(3.64)

(1.08)(30) + (1.08) (30) 2 + (9.3)(10)(3.64) 2 (10)


(2) vc = 4.3 ft/sec
(10)(3.64)

(3) Since v > vc , flow is turbulent.


(2,970)(10)(12.3)(3.64)
(a) N Re = 44,300
30
(b) f = 0.0062 from Curve II, Fig. 3.1
(0.0062)(10)(1000)(12.3) 2
(c) ∆p p = 100 psi/1000 ft
(25.8)(3.64)
22

Hydraulically Equivalent Annulus Diameter


• For annular flow, it is necessary to use a hypothetical circular diameter,
da, which is the hydraulic equivalent of the actual annular system
• The hydraulic radius is defined as:
cross-sectional area of flow system
hydraulic radius, rh =
wetted perimeter of conduit Annulus

π (r12 − r2 2 ) r1 − r2
for an annulus → rh = = r2
2π (r1 + r2 ) 2
r
π r2 r r1
for a circular pipe → h
r = =
2π r 2
• The frictional loss in an annulus is equal to the loss in a circular pipe
having the same hydraulic radius; hence, in general terms:
re = r1 − r2 or d e = d1 − d 2 .......... (3.11)

where re and de are the hydraulically equivalent radius and diameter


23

Pressure Drop Across Bit Nozzles


 Consider the diagram below for incompressible fluid:

Fig. 3.2: Schematic sketch of incompressible fluid flowing


through a converging tube or nozzle.
 Assuming steady state, adiabatic, and frictionless:

p1 v12 p2 v22
+ = + .......... (a )
where: ρ 2g ρ 2g
p1 , p2 = turbulent flow pressure drop, lb/ft2
ρ = density, lb/ft3
v1 , v2 = velocities at points 1 and 2, ft/sec
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p1 v12 p2 v22
+ = + .......... (a )
w 2g w 2g
or
∆p v22 − v12
=
ρ 2g
 Practically, v22 − v12 ≅ v22 , therefore:
∆p
v2 = 2 g
2 .......... (b)
ρ
 The ideal rate of flow, qi = A2 v2 . The actual flow rate q is:
q = Cqi .......... (c)
where C is the flow or nozzle coefficient for particular design.
25

 By substituting Eq. (c) into Eq. (b), and rearranging it, the equation
becomes:
ρ q2
∆p = 2 2 .......... (3.12)
2 gC A2
 Altering Eq. (3.12) to practical units for mud flow, we:
q2 ρ
∆pb = .......... (3.13)
7, 430 C 2 d e 4

where de = hydraulically equivalent nozzle diameter, in.


 The value of C is around 0.8 – 0.98.
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Multiple Nozzles

 The calculation of ∆p across a multiple nozzle bit may be simplified


by substituting the sum of the nozzle areas for A in Equation (3.12).
 For single nozzle:
ρ q2
∆p = 2 2
2 gC A
 For several nozzles, each of area A1:
ρ q12
∆pm = 2 2
2 gC A1
27

q
 For parallel flow, q1 = , where n = number of nozzles.
n
therefore:
∆pm q12 A2 q12 A2
= =
∆p q 2 A12 n 2 q12 A12

 Cross sectional area of flow, A, is defined as


A2
2 2
=1
n A1
∴ A2 =
n 2 A12
or
A = nA1 .......... (3.14)
28

 Similarly, for use in Eq. (3.13)


d e = nd 2 .......... (3.15a)
 If the multiple nozzles vary in size,
de = ad12 + bd 22 + etc. .......... (3.15b)
where:
a = number of nozzles having diameter d1.
b = number of nozzles having diameter d2.
d e = hydraulically equivalent single nozzle diameter, in.
29

Example 3.2
A 10 lb/gal mud is being circulated at the rate of 500 gal/min.
through a tri-cone bit having three 3/8 in. diameter jets. What
is the pressure drop across the bit?
Solution 3.2
Drill string
p1
Hole
Nozzle

vn2 vn3
vn1 p2

d e=
or d =
3( 83 ) 2 0.65 in. (equivalent single nozzle diameter)
Using Eq. (3.13):
(500) 2 (10)
=
( p1 − p2 ) or ∆p = 2 4
2,100 psi
(7430)(0.95) (0.65)
30

Pressure Drop Calculations for a Typical Systems


Example 3.3
Operating Data

Depth = 6,000 ft (5,500 ft drill pipe, 500 ft drill collars)


Drill pipe = 4 ½-in. internal flush, 16.6 lb/ft (ID = 3.826 in.)
Drill collars = 6 ¾ in. (ID = 2.813 in.)
Mud density, ρm = 10 lb/gal
Plastic viscosity, µp = 30 cp
Bingham yield, Yb = 10 lb/100ft2
Bit = 7 7/8-in., 3 cone, jet rock bit
Nozzle velocity required = at least 250 ft/sec through each nozzle (this
value is obtained by a commonly applied rule of thumb). Assume C = 0.95
Surface equipment type = 2
What hydraulic (pump output) horsepower will be required for these conditions?
31

Gbr ni tak perlu


ubah
Solution 3.3
Circulation rate: This is obtained from the
desired annular velocity necessary for
proper hole cleaning (cutting removal).
Assume that this is a fast drilling, soft rock
5,500 ft.
area and that 180 ft/min (3 ft/sec) upward
velocity based on a gauge hole is required
(i.e. annular velocity around the drill pipe).

The flow rate , q is:

=q (annulus area) × velocity


= 2.45(d h2 - d p2 )v 500 ft.

= 2.45 ( 7 78 ) − ( 4 12 )  (3)
2 2

 
= 307 gpm
32

(a) Surface equipment losses (∆ps) Eq. (3.16) ∆ps =E ρ m0.8 q1.8 µ 0.2
p

Table 3.1
Surface equipment type 2 =
E 9.6 × 10-5
∴ ∆p=
s (9.6 × 10 -5
)(10) 0.8
(307)1.8
(30) =
0.2
36 psi

(b) Pressure losses inside drill pipe (∆pp)


The average velocity inside the drill pipe:
q 307
=v = 2
= 2
8.56 ft/sec
2.45d 2.45 (3.826)

The critical velocity:


1.08µp + 1.08 µp2 + 9.3ρ m d 2Yb
vc =
ρm d
1.08 (30) + 1.08 (30) 2 + (9.3)(10)(3.826) 2 (10)
=
(10)(3.826)
= 4.25 ft/sec
33

v > vc ⇒ ∴ turbulent flow (use Eq. 3.4)

2,970 ρ vd (2,970)(10)(8.58)(3.826)
=
N Re = = 32, 423 ≅ 32, 400
µp 30

N Re = 32, 400 Fig. 7.1 f = 0.0066


Curve II

Applying Eq. (3.4):


f ρ Lv 2 (0.0066)(10)(5,500)(8.56) 2
=
∆pp = = 269 psi
25.8 d (25.8)(3.826)
34

(c) Pressure losses inside drill collar (∆pc)

The average velocity inside the drill collar:


q 307
= v = 2
= 2
15.84 ft/sec
2.45d 2.45 (2.813)

The critical velocity:


1.08µp + 1.08 µp2 + 9.3ρ m d 2Yb
vc =
ρm d
1.08 (30) + 1.08 (30) 2 + (9.3)(10)(2.813) 2 (10)
=
(10)(2.813)
= 4.64 ft/sec
35

v > vc ⇒ ∴ turbulent flow (use Eq. 3.4)

2,970 ρ vd (2,970)(10)(15.84)(2.813)
=
N Re = = 44,112 ≅ 44,100
µp 30

N Re = 44,100 Fig. 7.1 f = 0.0062


Curve II

Applying Eqn. (3.4):


f ρ Lv 2 (0.0062)(10)(500)(15.84) 2
=
∆pc = = 107 psi
25.8 d (25.8)(2.813)
36

(d) Pressure losses through bit (∆pb)


Three nozzles (one for each cone) will be used, hence 1/3 q will flow
through each. For v = at least 250 ft/sec through each nozzle,
q
1
q 307 / 3
=d = 3
= 0.41 in.
2.45v (2.45)(250)

Nozzle sizes are sell in multiples of 1/32 in.


Therefore, the nearest stock nozzle available is
13/32 in. (i.e. 0.40625 in.):
1 1
∴ nozzle diameter of 13
32
in. is chosen 3
q 1
3
q 3
q

This nozzle allows an actual velocity of:


102
=v = 13 2
252 ft/sec
2.45 ( 32 )
37

Eq. (3.15a) d e = nd 2

Eq. (3.15b) d e = ad12 + bd 22 + etc.

Using Eq. (3.15) or (3.15a), the actual nozzle diameter:

=d =
3( 13
32
) 2
0.704 in.
q 2 ρm
Eq. (3.13) ∆pb =
7, 430C 2 d 4
∴ Pressure drop across the bit, ∆pb :

(307) 2 (10)
=∆pb = 2 4
573 psi
7, 430(0.95) (0.704)
38

(e) Pressure losses around drill collar (∆pac)

The average velocity around the drill collar:


307
v = 7.62 ft/sec
(2.45) (7 8 ) − (6 4 ) 
7 2 3 2

The hydraulically equivalent diameter of the annulus:


d=
a d1 − d 2
d = 7 78 − 6 34 = 1 18 in.

The critical velocity:


1.08 (30) + 1.08 (30) 2 + (9.3)(10)(1 81 ) 2 (10)
vc = 1
7.26 ft/sec
(10)(1 8 )
39

v > vc ⇒ ∴ turbulent flow (use Eq. 3.4)

2,970 ρ vd (2,970)(7.62)(1 18 )
=
N Re = = 8, 487 ≅ 8,500
µp 30
N Re = 8, 400
Fig. 7.1 f = 0.0098
Curve IV (for annuli
in uncased hole)

Applying Eqn. (3.4):


f ρ Lv 2 (0.0098)(10)(500)(7.62) 2
∆=
pac = 1
= 98 psi
25.8 d (25.8)(1 8 )
40

(f) Pressure losses around drill pipe (∆pap)


The average velocity around the drill collar (as assume/given earlier):
v = 3 ft/sec
The hydraulically equivalent diameter of the annulus:
d=
a d1 − d 2
d = 7 78 − 4 12 = 3 83 in.
The critical velocity:

1.08(30) + 1.08 (30) 2 + (9.3)(10)(3 83 ) 2 (10)


vc = 3
4.39 ft/sec
(10)(3 8 )

L  µp v 
v < vc ⇒ ∴ laminar flow (use Eq. 3.6)
= ∆p  Yb + 
300d  5 d 
5,500  30 (3) 
=
∴ ∆pap 10=
+ 3 
83 psi
300 (3 83 )  5(3 8 ) 
41

(g) The total pressure drop in the system (∆pt)


∆pt = 36 + 269 + 107 + 573 + 98 + 83 ≅ 1,166 psi

(h) Horsepower output at the pump


q × ∆p
HP = .......... (3.17)
1, 714 × ηv × ηm
where :
q = flow rate, gpm
ηv = volumetric efficiency
ηm = mechanical efficiency
Assuming volumetric and mechanical efficiencies of the pump are 90% and 85%
respectively:
307 (1,166)
=
∴ HP = 273 horsepower
1, 714(0.90)(0.85)
42

Summary
Bingham Plastic Model: Calculation Steps
∆pt = ∆ps + ∆p p + ∆pc + ∆pb + ∆pac + ∆pap

∆ps vc v de
Eq. (3.16) or Fig. 3.3 Eq. (3.8) Eq. (3.7 a ) or (3.7b) Eq. (3.15a) or (3.15b)

∆pb
(Eqn. 3.13)
No if Yes
(laminar)
v > vc (turbulent)

∆p p , ∆pc , ∆pac , ∆pap N Re


Eq. (3.6) Eq. (3.2)

f
(Fig. 7.1)

∆p p , ∆pc , ∆pac , ∆pap


Eq. (3.4)
43

Graphical Method
● The Baker Tool Company has prepared set of curves and
tables (see Figs. 7.3 – 7.11)
● These charts were constructed based on Fanning’s equation
for mud having a viscosity of 3 cp and a density of 9.5 ppg
● The friction factor f has been accounted for in terms of flow
rate and pipe size
● Pressure drop read from these charts must be corrected for
density and viscosity other than 3 cp and 9.5 ppg respectively:
ρm  µ p 
0.14

∆p =∆pu × ×
9.5  3.2(3) 
where :
∆p = corrected value for mud of density ρ m , ppg
∆pu =uncorrected value from the charts, ppg
44
45
46
47
48
49
50
51
52
53

ρ  µp 
0.14

∆p =∆pu × m × 
Example 3.4 9.5  3.2(3) 
Using a data as in Example 3.3, calculate the circulating pressure required.
Solution 3.4
From Example 3.3: q = 307 gpm, bit = 3 13/32 in. nozzles
(a) Surface equipment losses (∆ps)
q = 307 gpm Fig. 7.3
∆pu =
27 psi
Curve type 2
0.14
10  30 
∴ ∆ps= 27 × ×  = 33 psi
9.5  3.2(3) 
(b) Pressure losses inside drill pipe (∆pp)
q = 307 gpm Fig. 7.5 (for 4.5” d/p) ∆p= 32
u × 5,500
= 176 psi
Curve 7 (assume ID = 3 ¾”) 1, 000
0.14
10  30 
∴ ∆p=
p 176 × ×  = 217 psi
9.5  3.2(3) 
54

ρ  µp 
0.14

∆p =∆pu × m × 
9.5  3.2(3) 
(c) Pressure losses inside drill collar (∆pc)
q = 307 gpm Fig. 7.7 15
Curve 2 ¾ bore ∆pu = × 500 = 75 psi
(assume ID = 2 ¾”) 100
0.14
10  30 
∴ ∆pc= 75 × ×  = 93 psi
9.5  3.2(3) 

ρm
(d) Pressure losses through bit (∆pb) ∆p =∆pu ×
9.5
q = 307 gpm Fig. 7.9
∆pu =550 psi
3− 13 "
32
nozzle (no viscosity effect)

10
∴ ∆p=
b 550 × = 579 psi
9.5
55

ρ  µp 
0.14

∆p =∆pu × m × 
(e) Pressure losses around drill collar (∆pac) 9.5  3.2(3) 
q = 307 gpm Fig. 7.10 25
6 ¾ drill collar ∆pu = × 500 = 125 psi
(bit size = 7 7/8”) 100
0.14
10  30 
∴ ∆pac
= 125 × × =
9.5  3.2(3) 
154 psi

(f) Pressure losses around drill pipe (∆pap)


q = 307 gpm Fig. 7.10 1.4
4 ½ drill pipe ∆pu = × 5,500 = 77 psi
(bit size = 7 7/8”) 100
0.14
10  30 
∴ ∆pap= 77 × × =
9.5  3.2(3) 
95 psi

(g) The total pressure drop in the system (∆pt)

∆pt = 33 + 217 + 107 + 579 + 154 + 95 ≅ 1,185 psi


56

Comparison of ∆p Calculation Methods


System Plastic flow calculation Hughes Tools Co. charts
component (psi) (psi)
Surface connections, ∆ps 36 33

Inside drill pipe, ∆pp 269 217

Inside drill collar, ∆pc 107 107

Bit nozzles, ∆pb 573 579

Outside drill collar, ∆pac 98 154

Outside drill pipe, ∆pap 83 95

Total circulating 1,166 1,185


pressure, ∆pt
57

Additional Information
 Besides Newtonian and Bingham Plastic Models, there are
several other model used to predict pressure losses in mud
circulating systems.
 Generally, each model is based on a set of assumptions which
cannot be completely fulfilled in any drilling situation.
 Power law, Herschel-Bulkley (Yield Power Law @ API Power
Law) models are the most widely used in the oil industry.
 Table 3.3 shows a summary of pressure loss equations
58
59

Exercise
Plastic viscosity = 12 cp
Yield point = 12 lb/100ft2
Mud weight = 8.824 ppg
Drill pipe = 4.276” ID, 5” OD, 6,480’ length
Drill collar = 2.875” ID, 8” OD, 620’ length
Hole size = 12.25 in
Flow rate = 700 gpm
The last casing is 133/8 in. with ID of 12.565 in and
was set at 2550 ft.
Calculate pump output horsepower.
Assumption:
Surface equipment type 4.
Internal flush drill pipe and drill collar.
Volumetric and mechanical efficiencies of the
pump are 90% and 85% respectively.
60

Solution:
(a) Surface equipment losses (∆ps) E ρ m0.8 q1.8 µ 0.2
∆ps = p ...(3.5)

Surface equipment type 4 Table 3.1


=E 4.2 × 10-5
∴ ∆p=
s (4.2 × 10 -5
)(8.824) 0.8
(700)1.8
(12)=0.2
52 psi
(b) Pressure losses inside drill pipe (∆pp)
q
The average velocity inside the drill pipe: v=
2.45d 2
....(3.7 a )

q 700
= v = 2
= 2
15.63 ft/sec
2.45d 2.45 (4.276)
The critical velocity: v =
1.08µ p + 1.08 µ p2 + 9.03ρ d 2Yb
....(3.8)
c
ρd
1.08µp + 1.08 µp2 + 9.3ρ m d 2Yb
vc = Eq. (3.8)
ρm d
1.08 (12) + 1.08 (12) 2 + (9.3)(8.824)(4.276) 2 (12)
= 4.25 ft/sec
(8.824)(4.276)
Assoc. Prof. Abdul Razak Ismail, UTM
61

v > vc ⇒ ∴ turbulent flow (use Eq. 3.4)


2,970 ρ vd (2,970)(8.824)(15.63)(4.276)
=N Re = ≅ 146, 000
µp 12
N Re = 146, 000 Fig. 3.1
f = 0.005
Curve II

Applying Eq. (3.4):


f ρ Lv 2 (0.005)(8.824)(6, 480)(15.63) 2
=
∆pp = = 633 psi
25.8 d (25.8)(4.276)

Assoc. Prof. Abdul Razak Ismail, UTM


62

(c) Pressure losses inside drill collar (∆pc)

The average velocity inside the drill collar:


q 700
=v = 2
= 2
34.57 ft/sec Eq. (3.7 a )
2.45d 2.45 (2.875)
The critical velocity:

1.08µp + 1.08 µp2 + 9.3ρ m d 2Yb


vc = Eq. (3.8)
ρm d
1.08 (12) + 1.08 (12) 2 + (9.3)(8.824)(2.875) 2 (12)
=
(8.824)(2.875)
= 4.39 ft/sec
Assoc. Prof. Abdul Razak Ismail, UTM
63

v > vc ⇒ ∴ turbulent flow (use Eq. 3.4)


2,970 ρ vd (2,970)(8.824)(34.57)(2.875)
=N Re = ≅ 217, 000
µp 12
N Re = 217, 000 Fig. 3.1
f = 0.0046
Curve II

Applying Eq. (3.4):


f ρ Lv 2 (0.0046)(8.824)(620)(34.57) 2
=
∆pp = = 405 psi
25.8 d (25.8)(2.875)

Assoc. Prof. Abdul Razak Ismail, UTM


64

(d) Pressure losses through bit (∆pb)


Three nozzles (one for each cone) will be used, hence 1/3 q will flow
through each. For = at leastv250 ft/sec through each nozzle,

1 Eq. (3.7 a ) q
q 700 / 3
=d = 3
= 0.62 in.
2.45v (2.45)(250)
Nozzle sizes are sell in multiples of 1/32 in.
Therefore, the nearest stock nozzle available is 20/32 in.
(i.e. 0.625 in.) or 19/32 in.
∴ nozzle diameter of 19
32
in. is chosen 1 1
q 1 q
This nozzle allows an actual velocity of:
3
3
q 3

233
=v = 19 2
270 ft/sec v=
q
2
....(3.7 a )
2.45 ( 32 ) 2.45d

Assoc. Prof. Abdul Razak Ismail, UTM


65

The actual (equivalent) single nozzle diameter:

=de =
3( 19
32
) 2
1.028 in. de = nd 2 ....(3.15a )

∴ Pressure drop across the bit, ∆pb :


q 2 ρm
∆pb = 2 4
Eq. (3.13)
7, 430C d e
(700) 2 (8.824)
= 2 4
577 psi
7, 430(0.95) (1.028)

Assoc. Prof. Abdul Razak Ismail, UTM


66

(e) Pressure losses around drill collar (∆pac)

 The average velocity around the drill collar:


700
v = 3.32 ft/sec
(2.45) (12.25) − (8) 
2 2

 The hydraulically equivalent diameter of the annulus:


d=
e d1 − d 2
d= 12.25 −= 8 4.25 in.
1.08µ p + 1.08 µ p2 + 9.03ρ d 2Yb
vc = ....(3.8)
 The critical velocity: ρd

1.08 (12) + 1.08 (12) 2 + (9.3)(8.824)(4.25) 2 (12)


vc =
(8.824)(4.25) Eq. (3.8)
= 4.20 ft/sec
Assoc. Prof. Abdul Razak Ismail, UTM
67

v < vc ⇒ ∴ laminar flow (use Eq. 3.6) L  µp v 


=∆p  Yb + 
300d  5d 
620  12 (3.32) 
∴ ∆p 12 +=  6.75 psi
300 (4.25)  5(4.25) 

Assoc. Prof. Abdul Razak Ismail, UTM


68

(f) Pressure losses around drill collar (∆pap)-1

 The average velocity around the drill pipe:


700
v = 2.28 ft/sec
(2.45) (12.25) − (5) 
2 2

 The hydraulically equivalent diameter of the annulus:


d=
e d1 − d 2
d= 12.25 −= 5 7.25 in.
1.08µ p + 1.08 µ p2 + 9.03ρ d 2Yb
vc = ....(3.8)
 The critical velocity: ρd

1.08 (12) + 1.08 (12) 2 + (9.3)(8.824)(7.25) 2 (12)


vc =
(8.824)(7.25) Eq. (3.8)
= 4.05 ft/sec
Assoc. Prof. Abdul Razak Ismail, UTM
69

v < vc ⇒ ∴ laminar flow (use Eq. 3.6) L  µp v 


=∆p  Yb + 
300d  5d 
3930  12 (2.28) 
∴ ∆p 12 +=  23psi
300 (7.25)  5(7.25) 

Assoc. Prof. Abdul Razak Ismail, UTM


70

(g) Pressure losses around drill pipe-2

 The average velocity around the drill pipe:


700
v = 1.86 ft/sec
(2.45) (13.375) − (5) 
2 2

 The hydraulically equivalent diameter of the annulus:


d=
e d1 − d 2
=
d 13.375= − 5 8.375 in.
1.08µ p + 1.08 µ p2 + 9.03ρ d 2Yb
vc = ....(3.8)
 The critical velocity: ρd

1.08 (12) + 1.08 (12) 2 + (9.3)(8.824)(8.375) 2 (12)


vc =
(8.824)(8.375) Eq. (3.8)
= 4.02 ft/sec
Assoc. Prof. Abdul Razak Ismail, UTM
71

v < vc ⇒ ∴ laminar flow (use Eq. 3.6) L  µp v 


=∆p  b
Y + 
300d  5d 
2550  12 (1.86) 
∴ ∆p 12=
+  12.72 psi
300 (8.375)  5(8.375) 
(g) The total pressure drop in the system (∆pt)
∆pt =52 + 633 + 405 + 577 + 6.75 + 23 + 12.72 ≅ 1, 710 psi
(h) Horsepower output at the pump
q × ∆p
HP = ............... (3.17)
1, 714 × ηv × ηm
700 (1, 710)
=
∴ HP = 913 horsepower
1, 714(0.90)(0.85)

Assoc. Prof. Abdul Razak Ismail, UTM

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