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 Milled
Carbide Insert Tooth
Bit 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

 Angle formed by the axis of the
JOURNAL Journal and the axis of the bit
ANGLE
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, self-
lubricated 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; medium-hard insert
Milled tooth bit; friction bearings 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 637Y

Numeric Characters are defined:

Series 1st
Type 2nd
Bearing & Gage 3rd
Alphabetic Character defined:
Features Available 4th
 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

unconsolidated sands, chalk,

Very Soft 1,000 - 4,000 salt, claystone

Soft 4,000 - 8,000 coal, siltstone, schist, sands

sandstone, slate, shale,

Medium 8,000 - 17,000 limestone, dolomite
quartzite, basalt, gabbro,
Hard 17,000 - 27,000 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 447X
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
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 precious stones

What is 14 carat gold?

 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 WC Insert Milled

Bits Bits Tooth Bits

Diamond bits typically cost several times as much as tri-

cone 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 More than 1/3 of cutting
element is gone element is broken to
the substrate
Grading of Worn PDC Bits contd

LT - Lost Cutter LN - Lost Nozzle

Bit is missing one or Bit is missing one or
more cutters more nozzles
Diamond bit wear problems
 Best Penetration Rate
Approach A Approach B
Achieved by removing Drilling fluid hits
cuttings efficiently bottom of the hole
from below the bit with greatest force

Maximize the Maximize Jet Impact

hydraulic power Force
available at the bit
 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

pb
vn = C d
8.074 104
Cd = Nozzle discharge coefficient
usually equal to 0.95
 Bit Pressure Drop

8.33 10 q
5 2
pb = 2 2
Cd At
 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

Pb
Nozzle Velocity vn = Cd
8 . 074 * 10
4

i.e. 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 m
where 0 m 2
Maximum Bit Hydraulic Horsepower

p bit = p pump p d p d = cq m

m +1
pbit q p pump q cq
PHbit = =
1714 1714

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

dq
Maximum Bit Hydraulic Horsepower

p pump c(m + 1)q = 0

m

i . e ., when p pump = ( m + 1 ) p d
1
i . e ., when pd = p
m +1
pump

P Hbit is maximum when

1
pd = p pump
m +1
 Maximum Bit Hydraulic Horsepower
- Examples -
1
In turbulent flow, m = 1.75 p d = p p
m +1
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, m=1

1
pd = p pump * 100 %
1+1

= 50% of p pump

p b = 50 % of p pump
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 m

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 p d =
2
p p
Impact Force m+2

- Examples -

Thus, if m = 1.75, 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

4. Calculate p bit = p pump p d

5. Calculate
8 .311 * 10 q opt
5 2

Total Nozzle Area: ( At ) opt = 2

(TFA) C d ( p b ) opt

6. Calculate Nozzle Diameter

4Atot
With 3 nozzles: 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:
8 . 311 * 10 5
q 2

Eq .( 4 . 34 ) : p b = 2 2
c d At
-5
8.311(10 )( 9 .6 )( 485 )2
p b = 2
= 1,894 psi
12
2

(0.95) 3
2

4 32

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

 Example 4.31 - 1(b), 247 gpm

5 2
8 . 311 (10 )( 9 . 6 )( 247 )
pb = 2
= 491 psi
2
12
2

( 0 . 95 ) 3
4 32

parasitic pressure loss = 900 - 491 = 409 psi

(q1, p1) = (485, 906) Plot these two

(q2, p2) = (247, 409) points in Fig. 4.36
 Example 4.31 - contd 3
2
2. For optimum hydraulics:
(a ) Interval 1, 1
1,714 PHp E 1,714(1,250)(0.91)
q max = = = 650 gal/min
Pmax 3,000
2 2
(b) Interval 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 2 -5 2
8.311*10 * 9.6 * (650)
( At ) opt = 2
= 2
C d ( p b ) opt (0.95) * (1,700)

Aopt = 0.47 in 2
(d N )opt = 14 32nds
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

Mud Plastic Yield

Depth Density Viscosity Point
(ft) (lbm/gal) (cp) (lbf/100 sq ft)

5,000 9.5 15 5
6,000 9.5 15 5
7,000 9.5 15 5
8,000 12.0 25 9
9,000 13.0 30 12
 Solution

The path of optimum hydraulics is as

follows:
Interval 1
1,714 PHp E 1,714(1,600)(0.85)
q max = =
p max 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 = pmax = (3,423 )
m +1 1.75 + 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
2 2
) 120

60
= 395 gal/min
 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 38 490 320 20 20 888
6,000 38 601 320 20 25 1,004
7,000 38 713 320 20 29 1,120
8,000 51 1,116 433 28 75* 1,703
9,000 57 1,407 482 27* 111* 2,084
* Laminar flow pattern indicated by
Hedstrom number criteria.
 Table
The proper pump operating conditions
and nozzle areas, are as follows:
( l) Depth (2)Flow Rate (3) p d (4) p b (5)A t
( ft ) (gal/min) (psi) (psi) (sq in.)

5,000 600 1,245 2,178 0.380

6,000 570 1,245 2,178 0.361
7,000 533 1,245 2,178 0.338
8,000 420 1,245 2,178 0.299
9,000 395 1,370 2,053 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 = ------------------ ft/min
IDp2
 Annular Average Velocity
Assuming the total string is DP;

24.51 x Q
Annular Velocity Vann = ------------------ ft/min
Dh2 - ODp2

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
2 2 ft/min
Vc =
D

V > Vc Turbulent flow

V < Vc Laminar flow
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
8.91 x 10-5 N-1 PV2-N . L
c = -------------------------------------
IDpN+3

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

P2 = -----------------------------------------
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

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

P3 = -------------------------------------
(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

Pb
Vn = 33.36

 Best Penetration Rate
Approach A Approach B
Achieved by removing Drilling fluid hits
cuttings efficiently bottom of the hole
from below the bit with greatest force

Maximize the Maximize Jet Impact

hydraulic power Force
available at the bit
 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 hp
Pb = (Psp - PCS) 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 -
928 v d
Newtonian Fluid N Re =

where = fluid density, lbm/gal

_
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 - Turbulent Flow -
Newtonian Fluid Bingham Plastic Fluid

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

In Annulus

_ 1 . 75 _ 1 . 75
p
0 . 25

0 . 75 0 . 25 0 . 75
dp f v dp f v
= =
1,396 (d 2 d 1 ) 1,396 (d 2 d 1 )
1 . 25 1 . 25
dL dL
 API Power Law Model API RP 13D

K = consistency index
n = flow behaviour index
=K n

SHEAR
STRESS

psi

0
SHEAR RATE, , sec-1
Rotating Sleeve Viscometer
(RPM * 1.703)

VISCOMETER SHEAR RATE

RPM sec -1
3 5.11
ANNULUS
100 170.3
BOB
300 DRILL 511
600 STRING 1022

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 (at 3 RPM)
R100 = 20 (at 100 RPM)
R300 = 39 (at 300 RPM)
R600 = 65 (at 600 RPM)
 PPUMP
Pressure Drop
Calculations

Q = 280 gal/min
= 12.5 lb/gal

PPUMP = PDP + PDC

+ PBIT NOZZLES

+ PDC/ANN + PDP/ANN

+ PHYD
 OD = 4.5 in
Pressure Drop In Drill Pipe ID = 3.78 in
L = 11,400 ft
Power-Law Constant (n):
R 600 65
n = 3 . 32 log = 3 . 32 log = 0 . 737
R 300 39

Fluid Consistency Index (K):

5.11 R600 5.11 * 65 dyne sec n
K = = 0.737
= 2.017
n
1,022 cm 2
1,022
Average Bulk Velocity in Pipe (V):

0 . 408 Q 0 . 408 * 280 ft

V = = = 8 . 00
D2 3 . 78 2
sec
 OD = 4.5 in
Pressure Drop In Drill Pipe ID = 3.78 in
L = 11,400 ft
Effective Viscosity in Pipe (e):
n 1 n
96V 3n + 1
e = 100 K
4n
D
0.7371 0.737
96 * 8 3 * 0.737 + 1
e = 100 * 2.017 = 53 cP
3.78 4 * 0.737

Reynolds Number in Pipe (NRe):

928 D V 928 * 3.78 * 8.00 * 12 .5

NRe = = = 6,616
e 53
 OD = 4.5 in
Pressure Drop In Drill Pipe ID = 3.78 in
L = 11,400 ft
NOTE: NRe > 2,100, so a
f =
Friction Factor in Pipe (f): NRe
b

log n + 3.93 log 0.737 + 3.93

a= = = 0.0759
50 50

1.75 log n 1.75 log 0.737

b= = = 0.2690
7 7

a 0 .0759
So, f = b
= 0 .2690
= 0 .007126
NRe 6,616
 OD = 4.5 in
Pressure Drop In Drill Pipe ID = 3.78 in
L = 11,400 ft
Friction Pressure Gradient (dP/dL) :

f V
2
dP 0.007126 * 8 2 * 12 .5 psi
= = = 0.05837
dL 25.81 D 25.81 * 3.78 ft

Friction Pressure Drop in Drill Pipe :

dP
P = L = 0.05837* 11,400
dL

Pdp = 665 psi

 OD = 6.5 in
Pressure Drop In Drill Collars ID = 2.5 in
L = 600 ft
Power-Law Constant (n):
R 600 65
n = 3 . 32 log = 3 . 32 log = 0 . 737
R 300 39

Fluid Consistency Index (K):

5.11R 600 5.11 * 65 dyne sec n
K= n
= 0.737
= 2.017
1,022 1,022 cm 2

Average Bulk Velocity inside Drill Collars (V):

0 . 408 Q 0 . 408 * 280 ft
V= = = 18 . 28
D2 2 .5 2
sec
 OD = 6.5 in
Pressure Drop In Drill Collars ID = 2.5 in
L = 600 ft
Effective Viscosity in Collars(e):
n 1 n
96V 3n + 1
e = 100 K
D 4n
0.7371 0.737
96 * 18.28 3 * 0.737 + 1
e = 100 * 2.017 = 38.21cP
2.5 4 * 0.737

Reynolds Number in Collars (NRe):

928 D V 928 * 2.5 * 18 .28 * 12 .5

NRe = = = 13,870
e 38 .21
 OD = 6.5 in
Pressure Drop In Drill Collars ID = 2.5 in
L = 600 ft
NOTE: NRe > 2,100, so a
f =
Friction Factor in DC (f): NRe
b

log n + 3.93 log 0.737 + 3.93

a= = = 0.0759
50 50

1.75 log n 1.75 log 0.737

b= = = 0.2690
7 7

So, a 0.0759
f = b
= 0 .2690
= 0.005840
NRe 13,870
 OD = 6.5 in
Pressure Drop In Drill Collars ID = 2.5 in
L = 600 ft
Friction Pressure Gradient (dP/dL) :

f V
2
dP 0.005840 * 18 .28 2 * 12 .5 psi
= = = 0.3780
dL 25.81 D 25 .81 * 2.5 ft

Friction Pressure Drop in Drill Collars :

dP
P = L = 0.3780 * 600
dL

Pdc = 227 psi

 Pressure Drop across Nozzles

DN1 = 11 32nds (in)

156 Q 2
DN2 = 11 32nds (in)
P =
(D
N1
2
+ DN2 + DN3
2 2
) 2
DN3 = 12 32nds (in)

156 * 12.5 * 280 2

P =
(11 2
+ 11 + 12
2
)
2 2

PNozzles = 1,026 psi

Pressure Drop
in DC/HOLE
Annulus

Q = 280 gal/min

= 12.5 lb/gal 8.5 in

DHOLE = 8.5 in
ODDC = 6.5 in
L = 600 ft
 Pressure Drop DHOLE = 8.5 in
ODDC = 6.5 in
in DC/HOLE Annulus L = 600 ft
Power-Law Constant (n):
R 20
n = 0 . 657 log 100 = 0 . 657 log = 0 . 5413
R3 3

Fluid Consistency Index (K):

5.11R100 5.11 * 20 dyne sec n
K = n
= 0.5413
= 6.336
170 .2 170 .2 cm 2

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

0 . 408 Q 0 . 408 * 280 ft
V = = = 3 . 808
D 2 D1
2 2
8 .5 6 .5
2 2
sec
 Pressure Drop DHOLE = 8.5 in
ODDC = 6.5 in
in DC/HOLE Annulus L = 600 ft

Effective Viscosity in Annulus (e):

n 1 n
144V 2n + 1
e = 100 K
3n
D2 D1

0.5413 1 0.5413
144 * 3.808 2 * 0.5413 + 1
e = 100 * 6.336 = 55.20 cP
8 .5 6 .5 3 * 0.5413

Reynolds Number in Annulus (NRe):

928 (D2 D1 ) V 928 (8.5 6.5) * 3.808 * 12.5
NRe = = = 1,600
e 55.20
 Pressure Drop DHOLE = 8.5 in
ODDC = 6.5 in
in DC/HOLE Annulus L = 600 ft
NOTE: NRe < 2,100
Friction Factor in Annulus (f):
24 24
f = = = 0 .01500
NRe 1,600

f V
2
dP 0.01500 * 3.808 2 * 12.5 psi
= = = 0.05266
dL 25.81(D 2 D1 ) 25.81 (8.5 6.5 ) ft

dP
P = L = 0 .05266 * 600
dL

So, 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 DHOLE = 8.5 in
ODDP = 4.5 in
in DP/HOLE Annulus L = 11,400 ft
Power-Law Constant (n):
R 100 20
n = 0 .657 log = 0 .657 log = 0 .5413
R3 3

Fluid Consistency Index (K):

5.11R100 5.11* 20 dyne secn

K = n
= 0.5413
= 6.336
170.2 170.2 cm2
Average Bulk Velocity in Annulus (Va):

0.408 Q 0.408* 280 ft

V = 2 = = 2.197
D2 D1
2
8.5 4.5
2 2
sec
 Pressure Drop
in DP/HOLE Annulus
Effective Viscosity in Annulus (e):
n1 n
144V 2n + 1
e = 100 K
D2 D1 3n
0.5413 1 0.5413
144 * 2.197 2 * 0.5413 + 1
e = 100 * 6.336 = 97.64 cP
8 . 5 4 .5 3 * 0.5413

Reynolds Number in Annulus (NRe):

928 (D2 D1 ) V 928 (8.5 4.5) * 2.197 * 12.5

NRe = = = 1,044
e 97.64
 Pressure Drop
in DP/HOLE Annulus
NOTE: NRe < 2,100
Friction Factor in Annulus (f):
24 24
f= = = 0 .02299
NRe 1,044

fV
2
dP 0.02299 * 2.1972 * 12.5 psi
= = = 0.01343
dL 25.81(D2 D1 ) 25.81(8.5 4.5) ft

dP
P = L = 0 . 01343 * 11,400
dL

So, Pdp/hole = 153.2

psi psi
 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

 2,103 psi
PPUMP = PDS + PANN + PHYD

P
PDS = PDP + PDC + PBIT NOZZLES =
0
= 665 + 227 + 1,026 = 1,918 psi

PANN = PDC/ANN + PDP/ANN

= 32 + 153 = 185

PHYD = 0

PPUMP = 1,918 + 185

= 2,103 psi
 "Friction" Pressures

2,500
DRILLPIPE
"Friction" Pre ssure , psi

2,000

1,500
DRILL COLLARS

1,000
BIT NOZZLES

500 ANNULUS

0
0 5,000 10,000 15,000 20,000 25,000
Cumulative Distance from Standpipe, ft
 Hydrostatic Pressures in the Wellbore

9,000
BHP
H ydrostatic Pre ssure , psi

8,000
7,000
6,000
DRILLSTRING ANNULUS
5,000
4,000
3,000
2,000
1,000
0
0 5,000 10,000 15,000 20,000 25,000
Cumulative Distance from Standpipe, ft
 Pressures in the Wellbore

10,000
9,000
8,000
CIRCULATING
Pressures, psi

7,000
6,000
5,000
4,000
3,000
2,000
1,000 STATIC

0
0 5,000 10,000 15,000 20,000 25,000
Cumulative Distance from Standpipe, ft
 Wellbore Pressure Profile

2,000
DRILLSTRING
4,000
Depth, ft

6,000
ANNULUS
8,000

10,000

(Static)
12,000
BIT
14,000
0 2,000 4,000 6,000 8,000 10,000
Pressure, psi
 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):

f V
2
16 dP
Then f = and =
N Re dL 25 .81 D
n = 1.0

_
dp f v 2
=
dL 25 .8 d