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Contents
• Newtonian fluid flow
• Plastic fluid flow
• Pressure drop calculation
3
Drilling Mud Circulating System
Rotary
hose
Annulus
dp/hole
Inside drill
pipe (dp)
Drill string
p1
Hole
Nozzle
vn2 vn3
vn1 p2
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:
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
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
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
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
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
● 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
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
400
=
(1) v = 2
12.3 ft/sec
2.45(3.64)
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)
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
24
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
Multiple Nozzles
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
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
= 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
2,970 ρ vd (2,970)(10)(8.58)(3.826)
=
N Re = = 32, 423 ≅ 32, 400
µp 30
2,970 ρ vd (2,970)(10)(15.84)(2.813)
=
N Re = = 44,112 ≅ 44,100
µp 30
Eq. (3.15a) d e = nd 2
=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
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)
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
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)
f
(Fig. 7.1)
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
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)
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
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
=de =
3( 19
32
) 2
1.028 in. de = nd 2 ....(3.15a )