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H YDRAULICS
INTRODUCTION
The application of hydraulics in rotary drilling is simultaneously simple in concept and difficult to
achieve on the rig. Simplicity results from the purity of the mathematics involved in the study of
hydraulics.
Few components of the overall drilling system offer the possibility of concise, arithmetic
conclusions. Analysis of the various parts of a hydraulics program, however, can lead drilling
engineers to clear conclusions.
Unfortunately, things clear to engineers are not always clear to other drilling personnel.
Consequently, most rigs drill with mediocre bit cleaning (hydraulics). Rig supervisors often are
reluctant to participate in or even accept the thesis that improved hydraulics will always result in
an increase in drilling efficiency.
CLASSIC HYDRAULICS
Various approaches to hydraulics have been developed since early work done circa 1948. To
include a summary of the principal, workable methods would be overly burdensome and
potentially confusing. A simple and practical method exists which is termed "classical" by some
in drilling. Commonly, bit hydraulic horsepower is optimized, or rather maximized, in order to
improve bit cleaning. Hydraulic horsepower can be computed by the following equation:
Hp =
PQ
1,714
Equation 7-1
Hpbit =
Pbit Q
1,714
Equation 7-2
In virtually all drilling situations, pump pressure or standpipe pressure is limited by either
equipment design or arbitrarily limited by someone on the rig. In either case, the following
procedure has been used to maximize Hp bit :
1. Write an equation relating Hp bit to the available power in the system.
2. Differentiate the equation with respect to independent variables and set the first
differential equal to zero.
3. Solve the equation developed in Step 2 to see if a maximum or minimum has
resulted.
7-1
Drilling Practices
Chapter 7
Example 7-1
Given:
Determine:
Solution:
Equation 7-3
Pc = KQ s
Equation 7-4
Hp s = Hp c + Hp bit
Equation 7-5
Also:
Ps Q
PQ P Q
= c + bit
1,714 1,714 1,714
Equation 7-6
Equation 7-7
Equation 7-8
Ps (s + 1)KQ s = 0
Minimum
Equation 7-9
Maximum
Equation 7-10
7-2
Ps (s + 1)Pc = 0
Equation 7-11
Ps = (s + 1)Pc
Equation 7-12
1
Pc =
Ps
s + 1
Equation 7-13
Drilling Practices
Hydraulics
Therefore, a maximum value of hydraulic horsepower at the bit develops when Pc is a defined
fraction of Ps , so long as Ps is also at the maximum selected pressure. If the common value of
s = 1.86 is used, then Hp bit is maximum when:
Pc = 0.35Ps
Equation 7-14
Pbit = 0.65Ps
Equation 7-15
It is then clear that the only way to increase Hp bit in any fixed situation is to increase standpipe
pressure, Ps . It is also clear that any arbitrary decisions to limit pump pressure is also a
decision to limit hydraulic horsepower at the bit (bit cleaning) and is also a decision to reduce
drilling rate. Credit for such a decision should certainly be borne by the individual responsible
for making it.
Hydraulic impact force at the bit can be maximized to promote bit cleaning as a reasonable
alternative to maximizing Hp bit . The procedure used in Example 7-2 in maximizing impact force
is similar to that used in Example 7-1. Equation 7-16 is used to define impact force.
IF =
mVn Q
Equation 7-16
1,932
Example 7-2
Given:
Determine:
Solution:
Step 1. Equation 7-17 can be used to calculate the pressure drop across
the bit nozzles.
Pbit =
mVn2
Equation 7-17
1,120
mVn2
= Ps KQ s
1,120
Equation 7-18
P KQ s
Vn = s
m
1,120
1
2
Equation 7-19
7-3
Drilling Practices
Chapter 7
Q P KQ s
IF = m s
m
1,932
1,120
1/ 2
Equation 7-20
Simplifying:
IF = APs Q 2 AKQ s + 2
1/ 2
Equation 7-21
m
3,333
0=
1
APs Q 2 AKQ s +2
2
1/ 2
] [2AP Q (s + 2)AKQ ]
1/ 2
s +1
Step 3.
0 = 2Ps (s + 2)Pc
2
Pc =
Ps
s + 2
Equation 7-22
Equation 7-23
Pbit = 0.48Ps
Equation 7-24
Similar to bit horsepower, the maximum impact force possible is seen to be dependent upon the
maximum standpipe pressure used. Figure 7-1 shows a plot of horsepower and impact force
versus flow rate. At some flow rate, the horsepower and impact force are a maximum. The
7-4
Drilling Practices
Hydraulics
maximum surface pressure in Figure 7-1 is 3,000 psi. Note that the maximum impact force will
always be at a higher flow rate than the maximum horsepower.
1400
1200
IMPACT FORCE
1000
Hp or IF
800
600
400
HORSEPOWER
200
0
0
100
200
300
400
500
600
700
Flow Rate, Q
Figure 7-1. Plot of
Example 7-3 illustrates methods for hydraulics planning and compares the results for two values
of allowable standpipe pressures. In the planning phase, pressure losses are calculated at
various depths and nozzle sizes are determined for various depth ranges.
Example 7-3
Given:
7-5
Drilling Practices
Chapter 7
Determine:
Solution:
LINER SIZE
MAX Ps
GPS
6"
2,120
3.88
6"
2,490
3.30
5"
2,965
2.78
5"
3,590
2.29
Nozzle sizes to be used at 9,000, 12,000 and 15,000 feet using two
cases.
Case 1:
Case 2:
Case 1 :
In Case 1 the maximum surface pressure will be 2,500 psi.
The liner with a 2,500 psi rating is 6 inches. The maximum flow rate is
calculated as follows:
Qmax = (3.30 gps )(110 spm ) = 363 gpm
First, calculate the pressure losses in the circulating system using the
equations given in Chapter 6: "Pressure Losses in the Circulating
System." Since this is for planning purposes, the pressure losses in the
surface connections will be ignored. Calculate the pressure losses in the
drill pipe. The length of drill pipe at a total depth of 9,000 feet will be
8,400 feet. (Total depth less the length of the drill collars.) Assume a
flow rate of 200 gpm.
Pdp =
Pdp =
7-6
7.68 10 5 (16 )
Drilling Practices
Hydraulics
( )
7.68 105 m
Pdc =
0.81 1.81
PV 0.19l
D 4.83
7.68 10 5 (16 )
Pdc =
Calculate the pressure losses in the drill collar annulus. The rheology
constants n and k must be calculated first.
2PV + Yp
n = 3.32 log
PV + Yp
(2)(25) + 12
n = 3.32 log
= 0.7743
25 + 12
k=
k =
PV + Yp
511n
25 + 12
5110.7743
= 0.3567
24.5Q
v =
(D
v =
(24.5)(200 )
2
h
(8.5
D p2
6.5 2
) = 163 fpm
2n + 1
kl
3n 300 (Dh D p )
Pdca
2.4v
=
Dh D p
Pdca
(2.4)(163 ) (2)(0.7743 ) + 1
=
0.7743
(0.3567 )(600 )
300(8.5 6.5 ) = 20 psi
( 24.5)(200 )
(8.5
4.5 2
) = 94fpm
7-7
Drilling Practices
Chapter 7
( 2.4)(94 ) ( 2)(0.7743 ) + 1
Pdpa =
0.7743
(0.3567 )(8,400 )
300 (8.5 4.5 ) = 55 psi
PC =
Pdp +
Pdc +
Pdca +
Pdpa
200
560
252
233
20
55
500
2,734
1,321
1,226
57
130
The same calculations are made at 12,000 and 15,000 feet. The results
of those calculations are presented in Table 7-3 and Table 7-4.
Table 7-3. Pressure Losses at 12,000 ft
PC =
Pdp +
Pdc +
Pdca +
Pdpa
200
669
342
233
20
74
500
3,252
1,793
1,226
57
176
PC =
Pdp +
Pdc +
Pdca +
Pdpa
200
777
431
233
20
93
500
3,771
2,265
1,226
57
223
7-8
Drilling Practices
Hydraulics
The same calculations are made where impact force is maximized using
Equation 7-23 and Equation 7-24.
Pc = 0.52Ps
Pc = (0.52 )( 2,500 ) = 1,300 psi
Pbit = 0.48Ps
Pbit = (0.48 )( 2,500 ) = 1,200 psi
For the horsepower method and the impact force method, the pressure
losses in the circulating system, Pc , will be 875 psi and 1,300 psi,
respectively. Figure 7-2 can be plotted with the previously determined
data. It is a plot of flow rate versus pressure losses in the circulating
system. The pressure losses in the circulating system include all
pressure losses except pressure drop across the bit. The graph is used
to determine the flow rate at, which Pc is equivalent to 875 and 1,300 psi.
In the graph, plot the pressure losses at 9,000, 12,000 and 15,000 feet
from Table 7-2 through Table 7-4. Plot the pressure losses in the
circulating system where horsepower and impact force will be maximized.
In addition, the maximum flow rate can be placed on the graph. The point
where the Pc line for horsepower and impact force crosses the Pc line for
each depth is the desired flow rate.
The desired flow rates can also be determined mathematically. The slope
of the Pc line can be determined from the information in Table 7-2.
s=
s=
Equation 7-25
7-9
Drilling Practices
Chapter 7
For the horsepower method, the flow rate where Pc is equal to 875 psi
can be calculated.
1.7304 =
Q2 = 259 gpm
10000
15,000'
12,000'
294
270
9,000'
325
Pc Max IF = 1300
1000
Pc Max Hp = 875
214
259
234
Q Max = 363
100
100
1000
Flow Rate, Q
Figure 7-2. Plot of Flow Rate versus Circulating Pressure Loss for Case 1
7-10
Drilling Practices
Hydraulics
This can be done for each depth using both method: impact force and
horsepower. Table 7-5 and Table 7-6 show the results for Case 1.
Table 7-5. Results based on Horsepower Method for Case 1
DEPTH
Pc
Pbit
NOZ's
Hp bit /in2
IF/in2
9,000
875
1,625
259
10,10,11
4.32
12.74
12,000
875
1,625
234
10,10,9
3.91
11.51
15,000
875
1,625
214
10,9,9
3.58
10.56
DEPTH
Pc
Pbit
NOZ's
Hp bit
IF
9,000
1,300
1,200
325
12,12,13
4.02
13.76
12,000
1,300
1,200
294
12,12,12
3.63
12.44
15,000
1,300
1,200
270
12,11,11
3.33
11.40
The nozzle sizes are calculated based on Pbit and the flow rate as follows
using the equation from Chapter 6: Pressure Losses in the Circulating
System:
Pbit =
( )
9.14 10 5 m Q 2
An2
1,625 =
9.14 10 5 (16)(259 ) 2
An2
An = 0.2457in2
Nozzle diameters are available in 32nd's of an inch and most bits are run
with three nozzles. Equation 7-26 can be used to calculate the average
nozzle diameters with any number of nozzles.
7-11
Drilling Practices
Chapter 7
Sn =
1,304 An
Nn
Equation 7-26
The pressure losses in the system would remain the same, so Table 7-2
through Table 7-4 are applicable for Case 2 also. However, Pc for both
methods will be different because they are a function of the maximum
surface pressure.
For the horsepower method:
Pc = (0.35 )(3,590 ) = 1,256 psi
Pbit = (0.65 )(3,590 ) = 2,334 psi
Figure 7-3 is a graphical plot of the data for Case 2. Table 7-7 and Table
7-8 show the results of the analysis.
Table 7-7. Results for Case 2 based on HorsePower Method
7-12
DEPTH
Pc
Pbit
NOZ's
Hp bit /in2
IF/in2
9,000
1,256
2,334
319
11,11,10
7.65
18.82
12,000
1,256
2,334
288
10,10,10
6.91
17.01
15,000
1,256
2,334
264
10,10,9
6.34
15.60
Drilling Practices
Hydraulics
The jet sizes are calculated the same way as in Case 1. Note in Figure
7-3 that the circulation rate at 9,000 and 12,000 feet exceed the
maximum flow rate with 5 inch liners. Therefore, Table 7-8 shows the
maximum flow rate of 343 gpm at these depths.
Table 7-8. Results for Case 2 based on Impact Force Method
DEPTH
Pc
Pbit
NOZ's
Hp bit /in2
IF/in2
9,000
1,378
2,212
343
11,11,11
7.79
19.72
12,000
1,637
1,953
343
11,11,12
6.87
18.52
15,000
1,867
1,723
333
11,12,12
5.89
16.71
10000
15,000'
362
12,000'
333
401
9,000'
Pc Max IF = 1867
Pc Max Hp = 1256
1000
264
319
288
Q Max = 343
100
100
1000
Flow Rate, Q
Figure 7-3. Plot of Flow Rate versus Circulating Pressure Loss for Case 2
7-13
Drilling Practices
Chapter 7
Comparison of the results computed for Case 1 and Case 2, leads to several noteworthy
conclusions for the 5" liner situation:
1. Case 2 results in a bit horsepower gain from 3.58 Hp/in2 to 6.34 Hp/in.2 at 15,000
feet. This represents an increase of 77%.
2. Case 2 requires a total output of only 555 HP at 15,000 feet. (P=3,590 psi, Q=265
GPM) for maximized Hp bit . This would require only 77% of rated input power or 617
HP at 90% mechanical efficiency.
3. Dependent upon depth of the drilling operations, Case 2 represents increases in
impact force of 42% to 47% over Case 1.
4. Any gains seen in Case 2 are realized without exceeding design limits of the rig's
pumps. If the contractor pays for a stated capacity and the operator contracts for a
stated capacity, how can either reasonably justify using less? Remember, 77% of
rated capacity is all that is needed to gain a significant level of bit hydraulic
horsepower in this example.
The method defined above as being "classical" can be summarized as follows:
1. On a log Q versus log P plot, mark equipment limitations, i.e., maximum volumes for
liners selected. If used, an arbitrarily selected maximum standpipe pressure should
also be shown.
2. Predict pressure/volume behavior at various depths of interest. The depths used can
be arbitrarily selected or selected based on anticipated trips from the bit program.
3. Mark lines representing the desired system pressure loss, Pc , which is dependent
upon the hydraulic design criterion (maximized Hp bit or maximized IF ).
4. From the intercepts of desired Pc and Pc 's predicted, determine flow rates, Q, to be
used at various depths.
5. The difference between the selected maximum pressure, Ps , and the desired
circulating pressure, Pc , is the bit nozzle pressure loss, Pbit , to be used at a specific
depth and circulating rate. Select nozzles that most nearly provide the Pbit needed
at the Q selected for each bit run.
Hydraulic slide rules or charts provided by bit manufacturers have simplified hydraulics
planning. Approximately one hour of engineering time would be required to plan hydraulics for a
typical 15,000 foot well with the use of charts or hydraulic slide rules. Hand-held calculators and
computers can reduce the planning time to approximately 15 minutes for a typical 15,000 ft.
well. Further, the use of well written programs with such calculators places the power for good
planning in the hands of rig personnel. The industry no longer must tolerate mediocre
hydraulics in drilling operations.
7-14
Drilling Practices
Hydraulics
Equation 7-4 was used in the derivation of Pc versus Ps ratios for maximum Hp bit and for
maximum IF . If Equation 7-4 is written in logarithmic form, then Equation 7-27 results:
Log Pc = Log K + sLog Q
Equation 7-27
Historically, the value of s has been taken to be 1.86. This value may have been statistically
correct over many situations when it was given to the industry decades ago; however, the use of
s = 1.86 often results in errors that can be avoided if s can be determined correctly. That the
value of s is easy to determine on the rig is shown in Example 7-4.
Example 7-4 also demonstrates a method of improving hydraulics performance on the rig as a
result of improved knowledge of the flow characteristics of a specific rig at a certain time.
Example 7-4
Given:
Rig is drilling at 8,430 feet and is preparing to trip for bit. The following
information is given:
Hole size = 9"
Bit is STC F3 w/ 3x18/32" nozzles
Drill collars are 7" by 2" and 582 feet long
Drill pipe is 4", Grade E, 16.6 ppf, with 4" XH connections
The inside diameter of the pipe is 3.826 inches
Mud Properties: m = 12 . 0 ppg , PV = 20 , Yp = 18
7-15
Drilling Practices
Chapter 7
Ps
(gpm)
(psi)
500
3,000
300
1,345
Determine:
The flow rate, nozzle sizes and pressures for the next bit run.
Solution:
First determine the bit nozzle pressure losses from given data.
The area of the nozzles is:
2
S1
2
2
S3
S2
An = +
+
4 32
32
32
An =
Equation 7-28
2
2
18
18
+ + = 0.7455 in 2
4 32
32
32
2
18
Calculate the pressure drop across the bit nozzles at the two flow rates
given in Table 7-9.
Pbit =
Pbit =
Pbit =
9.14 10 5 m Q 2
An2
9.14 10 5 (12)(500 )
(0.7455 )2
9.14 10 5 (12)(300 )
(0.7455 )2
= 493 psi
= 178 psi
7-16
Drilling Practices
Hydraulics
s=
s=
Ps
- Pbit
= PC
500
3,000
493
2,507
300
1,345
178
1,167
Pc =
(3,000 ) = 1,201psi
1.4969 + 1
Pbit = Ps Pc
Pbit = 3,000 1,201 = 1,799 psi
Pc =
(3,000 ) = 1,716 psi
1.4969 + 2
Pbit = Ps Pc
Pbit = 3,000 1,716 = 1,284 psi
The data in Table 7-10 and the above calculations can be used to
construct Figure 7-4. This figure can be used to determine the flow rate
where horsepower or impact force will be a maximum. Alternatively, the
flow rates can be calculated as in Example 7-3. The nozzles sizes are
also determined as in Example 7-3. Table 7-11 shows the results of
maximizing the hydraulics on the drilling rig.
7-17
Drilling Practices
Chapter 7
Table 7-11. Results of Example 7-3
Pc
Pbit
Ps
NOZ's
Hp bit /in2
Vn
IF/in2
Hp t
Before Trip
500
2,507
494
3,000
175
18,18,18
2.03
215
9.42
875
Max. Hp
306
1,201
1,799
3,000
107
10,10,11
4.53
410
10.99
536
Max. IF
388
1,716
1,284
3,000
136
12,12,13
4.11
346
11.78
679
10000
388
306
Pc Max IF = 1716
Pc Max Hp = 1201
1000
100
1000
Flow Rate, Q
Figure 7-4. Plot of Flow Rate versus Circulating Pressure Loss for Example 7-4
As seen from Example 7-4, improving the hydraulics parameters on the rig results in the
following improvements:
1. Bit hydraulic horsepower per square inch, Hp bit /in2, is increased by 123% (2.03 Hp
to 4.53 Hp) while simultaneously reducing total pump output power by 39% (875 Hp
to 536 Hp).
2. By adjusting for maximum impact force, a gain of 25% is realized (9.42 lbf /in2 to
11.78 lbf /in2) while reducing total pump power by 22% (875 Hp to 679 Hp).
7-18
Drilling Practices
Hydraulics
3. In this example, rig personnel were working their heart out to do a good job, but they
were not getting full benefits of their efforts.
Over the past 40 years, various methods of hydraulics planning and conceptual developments
have been published and discussed. Some of the work has been good; some has been either
incorrect or of little value to the industry. The methods described in this chapter have been
effective under a variety of applications. Properly applied, these procedures are totally
satisfactory for all situations.
NOMENCLATURE
A
An
Constant
D
Dh
Dp
Hp
Horsepower, Hp
Hp bit
Hp c
Hp s
Hp t
IF
Constant
Nn
Power Law constant, normally the slope of shear stress-shear rate diagram
on log-log plot
P
P1
=
=
Pressure, psi
Circulating pressure loss corresponding to flow rate Q1 , psi
P2
Pbit
Pc
Pdc
Pdca
Pdp
Pdpa
Ps
PV
Plastic viscosity, cp
7-19
Drilling Practices
Chapter 7
Q1
Q2
Qmax
S1
S2
S3
Sn
Vn
v
Yp
=
=
SI UNITS
The equations given in the chapter are converted to SI units below
PQ
60
Equation 7-1:
Hp =
Equation 7-2:
Hp bit =
Equation 7-16:
IF =
Pbit Q
60
Equation 7-30
mVnQ
Equation 7-31
60
Equation 7-17:
Pbit =
Equation 7-26:
Sn =
Equation 7-28:
An =
7-20
Equation 7-29
mVn2
Equation 7-32
1,810
1.27 An
Nn
[(S )
4
+ (S 2 )2 + (S3 )2
Equation 7-33
Equation 7-34
Drilling Practices
Hydraulics
Constant
D
Dh
Dp
Diameter of hole, mm
Hp
Horsepower, kWatts
Hp bit
Hp c
Hp s
Hp t
IF
Impact force, Nt
Constant
Nn
Power Law constant, normally the slope of shear stress-shear rate diagram
on log-log plot
P
P1
=
=
Pressure, kPa
Circulating pressure loss corresponding to flow rate Q1 , kPa
P2
Pbit
Pc
Pdc
Pdca
Pdp
Pdpa
Ps
PV
Q
Q1
minute
Flow rate corresponding to circulating pressure loss P2 , cubic meters per
Q2
minute
Qmax
S1
Diameter of nozzle 1, mm
7-21
Drilling Practices
Chapter 7
S2
Diameter of nozzle 2, mm
S3
Diameter of nozzle 3, mm
Sn
Vn
v
Yp
Yield point, Pa
REFERENCE
1
Scott, K. F.; "A New Practical Approach to Rotary Drilling Hydraulics," SPE 3530, 1971.
7-22