Mud Report 1

Vorlesung Tiefbohrtechnik 1
Introduction to Rotary-Drilling Technology (inc. Rig Count)

Drilling a Well, Drilling methods
Rock Mechanics I
Drilling Mud: Functions, Properties, Rheology
Rock Mechanics II, Well stability
Borehole hydraulics, Overbalance vs. Underbalance
Drilling bits, Selection criteria
Drilling optimisation concepts
Drill-string basics
Downhole motors I (Theory, Moineu Motoren)
Downhole motors II (Turbinen, Selection Criteria)
Special drilling systems (Drilling Hammer, Coring)
Formation pressure, Frac-gradienten
Measuring drilling parameters
Dr. Catalin Teodoriu
Institut fr Erdl- und Erdgastechnik
TBT I 2014
Drilling Hydraulics Applications

Calculation of subsurface hydrostatic pressures that may tend to
burst or collapse well tubulars or fracture exposed formations
Several aspects of blowout prevention
Displacement of cement slurries and resulting stresses in the

casing string
Bit nozzle size selection for optimum hydraulics

Surge or swab pressures due to vertical pipe movement
Carrying capacity of drilling fluids

TBT I 2014
Pressure drop in a well

Pp=Psc + Pdp + Pdc + Pdt + Pb + Pdca + Pdpa
DP
Less than 50%

>50%
DC
PP Pump pressure
PSC surface equipment
Pdp Drill pipe
Pdc Drill collar
Pb - Bit
Pdca Annulus in DC Range
Pdpa Annulus in DP range
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Wellbore hydraulics
HYDROSTATICS
HYDRODINAMCS

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Buoyancy Force = weight of fluid displaced

(Archimedes, 250 BC)
Figure
4-9. Hydraulic forces acting on a foreign body
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Effective (buoyed) Weight
We W Fb
W - f V
W
W - f
s
We = buoyed weight
W = weight in air
f = fluid density
s = steel density
Fb = buoyancy force
V = volume
f
We W
1

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Effective (buoyed) Weight
f
We W
1
Buoyancy Factor (BF)
f
BF 1
s
Valid for a solid body or an open-ended pipe! (WHY?)

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Types of Flow: Laminar Flow
Flow pattern is linear (no radial flow)

Velocity at wall is ZERO
Produces minimal hole erosion

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Types of Flow: Laminar Flow

Mud properties strongly affect pressure losses
Is preferred flow type for annulus (in vertical wells)
Laminar flow is sometimes referred to as sheet flow, or
layered flow:
* As the flow velocity increases, the flow type changes from laminar to
turbulent.

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Types of Flow: Turbulent Flow
Flow pattern is random

(flow in all directions)
Tends to produce hole erosion
Results in higher pressure losses
(takes more energy)
Provides excellent hole cleaningbut
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Types of flow : Turbulent flow

Mud properties have little effect on pressure losses
Is the usual flow type inside the drill pipe and collars
Thin laminar boundary layer at the wall
High turbulent flow is found under the bit and
sometime in the annular area around drill collars and
stabilizers

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11
Types of f low: Turbulent flow
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

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12
Dpf = 11.41 v 1.75

turbulent flow
Dpf = 9.11 v
laminar flow

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13
Turbulent Flow - Newtonian Fluid

The onset of turbulence in pipe flow is characterized
by the dimensionless group known as the Reynolds
number
_
N Re
In field units,
vd
N Re
928 v d
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14
Turbulent Flow - Newtonian Fluid in SI units

_
N Re
vd
where fluid density, Kg/m3

lbm/gal
_
v avg. fluid velocity,m/sec

ft/s
m
d pipe I.D., in
viscosity of fluid, Pa
cp.
s
We often assume that fluid flow is

turbulent if Nre > 2,100
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Turbulent Flow - Newtonian Fluid in field units

_
N Re
928 v d
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 > 2,100
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Non-static Well Conditions

FLUID FLOW
Physical Laws
Rheological Models
Equations of State
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17
Physical Laws
Conservation of mass
Conservation of energy
Conservation of momentum

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18
Physical Laws
Conservation of mass
A1 v1 A2 v2 q constant
Conservation of energy
2
v
p 0 g h konstant
2

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19
Law of Conservation of Energy (Brnoulli)
States that as a fluid flows from A to B:
E 2 E1 p2V2
p1V1
1 2
2
g D2 D1
v 2 v1
2
W Q
In the wellbore, in many cases
Q = 0 (heat)
= constant
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Physical Laws
Stokes Law
(c m ) g d
vs
18
Cutting transport
v r vs
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Settling velocity, after Bourgoyne et al.

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22
Slip Velocity, after Bourgoyne et al.
d s s
vs 1.89
1
f f
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Particle Slip Velocity - small particles

138(s f )ds
vs
v s slip velocity, ft/s
s density of solidparticle, lbm/gal

f density of fluid, lbm/gal
ds diameter of particle, in
fluid viscosity, cp
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Particle Slip Velocity other than laminar
Intermediate:
2.90d s ( s f ) 2/3
vs
( f a )1/3
Fully Turbulent:
d s ( s f )
vs 1.54
f
Note: all equations are in field units

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Rheological Models
Newtonian
Bingham Plastic
Power Law
API Power-Law

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Typical Drilling Fluid Vs. Newtonian, Bingham and Power Law Fluids

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27
Equations of State
Incompressible fluid
Slightly compressible fluid

Ideal gas
Real gas

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28
Average Fluid Velocity (SI units)

Pipe Flow
Annular Flow
q
d
v
2
d
4
q
2
2
d12
WHERE
v = average velocity, m/s

q = flow rate, m3/s
d = internal diameter of pipe, m
d2 = internal diameter of outer pipe or borehole, m
d1 = external diameter of inner pipe, m
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Average Fluid Velocity (field units)

Pipe Flow
q
v
2
2.448 d
Annular Flow
q
v
2
2
2.448 d 2 d1
WHERE
v = average velocity, ft/s

q = flow rate, gal/min
d = internal diameter of pipe, in.
d2 = internal diameter of outer pipe or borehole, in.
d1 = external diameter of inner pipe, in.
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Velocity Profiles (laminar flow)
(a) pipe flow and (b) annular flow

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31
Representing the Circular Annulus as a Slot
Equal
Area
and
Height
Simpler
Equations
-yet
accurate
Area of equivalent slot Wh r2 r1

2
Height of slot h (r2 r1 )

Width of slot W (r2 r1 )
{ slot approximation is OK if (d1/d2 > 0.3TBT

} I 2014

32
Free body diagram for fluid element in a narrow slot

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Representing the Annulus as a Slot

F1 pWDy
dp f
F2 p 2 WDy p
L WDy
dL
F3 = WDL
F4 = y + DyWDL = + d Dy WDL
dy
Consider:
- pressure forces
- viscous forces
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34
Summing forces along flow:
At steady state,
F = ma
F=0
F2 + F3 F4 = 0
d
dp f
pWDy - p L WDy WDL - y WDL 0

dL
dy
dp f
Simplifying,
d = 0
dL
dy

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35
d dp f
=
dy
dL
dp f
y
0
dL
Separate variables and integrate:

Evaluate 0 at wall where y = 0
With Newtonian Fluid Model,
dv
So,
But,
dy

dv
= -
dy
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dv
dp f
-
=y
+ o
dy
dL
dv -
dp f
y 0 dy
dL
0 y
y dp f
v
v0
2 dL
Since v 0 when y 0,
v0 0
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Since v 0 when y h,
h 2 dp f 0 h
02 dL
h dp f
0 2 dL
Hence, substituting for v0 and 0 :
1 dp f
v
2 dL
hy y
2
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38
1 dp f
v =
2 dL
(hy - y 2 )
The total flow rate:
q vdA vWdy
W dp f
q
2 dL
hy y dy
h
Wh dp f
Integrating, q
12 dL
But Wh (r2 2 r12 ) and h r2 r1

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dp f 2 2
2
q
(r2 r1 )(r2 r1 )
12 dL
Wh 3 dp f
q
12 dL
q
q
But average velocity, v
2
2
A (r2 r1 )
_
12 v
dp f
dL
(r2 r1 ) 2
TBT I 2014
40

_
12 v
dp f
2
dL
(r2 r1 )
_
dp f
v
2
psi/ft, cp., ft/sec, in dL 1000(d 2 d1 )
In field units,

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41
Hydraulics Optimization
The Art of Compromise

- Improve Annulus cutting transport versus Bit
flow regime (high velocity vs. Low pressure
drop)
Optimising Targets
- Maximizing Hydraulic Horsepower (HHP)
- Maximizing Impact Force (HIP)
- Maximizing Nozzle velocity (HNV)
TBT I 2014
42
Horsepower
Horsepower is defined as work per time

Hydraulic horsepower is calculated as follows:
Q DP
Where:
Q = Flowrate in cubic meters/minute
P = bit pressure drop in Pa

Q DP
1714
Where:
Q = Flowrate in gallons/minute
P = bit pressure drop in psi
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43
Horsepower
Please derive this equation for: flowrate in L/min

and pressure in bar
Q DP ?

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44
Input Horsepower Requirement
Input horsepower requirement is the

horsepower required to be used to develop the
desired output horsepower. Note that there is
always the efficiency that reduces the output/
- Function of Energy conversion efficiency
-
Energy conversion to energy source (Diesel Engines, Generators)

Energy source to pump prime mover (Electric motor, Diesel Engine)
Prime mover losses through coupling (transmission, gearbox, belt slip, friction, etc.)
Pump efficiency

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Setting Flow Rates
Q maximum
Q optimum
Q minimum

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46
Q Minimum
Roller Cone Bits: Bottom Hole Cleaning

(removing cuttings and transport them in annular section)
- Additionally: Bit cooling and cleaning
Fixed Cutter Bits: Cutter cooling and

cleaning (temperature sensible tools)
- Additionally: Hole cleaning (why?)
Delay time to get cuttings samples to surface which

reduce the ability to react.
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47
Q Maximum
Hole erosion
-
Turbulent Flow (very controversial today)
E.C.D. effects
-
Fracture Gradient (max. Q > increase pressure loss)

R.O.P. Reduction (Why?)
Pump capacity (limited power)

Surface volume handling and treating
capacity
Energy expenses and costs
Equipment wear
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48
Setting QMinimum
Hole Cleaning:
- Rule of Thumb (v = 0.3 to 0.8 m/s)
- Observation (experience)
- Slip Velocity (Stokes or other)
Bit Cooling and Cleaning:

- Empirical Recommendations
- Observation
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49
Setting QMaximum
Hole Erosion
-
Turbulent Flow
Strength of Formation Being Drilled
E.C.D. Effects
-
Mud Rheology
Fracture Gradient
R.O.P. Reduction
Pump Capacity
-
Pressure Limits
Flow Rate Limits
Horsepower Limits
Surface Equipment Pressure Limitations

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Setting QMaximum
Surface Volume Handling and Treating
Capacity
-
Solids Control Equipment Limits

Gas Handling Limits
Energy Expenses and Costs

-
High Horsepower Use Leads to Increased Fuel

Consumption
Equipment Wear
-
High Pressure and Flow Rates Leads to Increased Wear

and Tear on Equipment

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51
Bit Hydraulics Optimization Methods
Hydraulic effectiveness can be optimized

two ways:
- Maximum hydraulic horsepower at the bit
- Maximum impact force at the bit
Maximum cleaning efficiency is limited by

surface equipment limits and energy limits
(i.e. pumps, lines).
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52
Pressure Loss at the Bit
Dp b Dp p Dp v
Pump pressure
System losses
Hydraulic Horse Power at bit
H b Dp b q q Dp p Dp v
Flow rate

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53
Jet velocity at bit nozzle
2 Dp b
vn
v n cd
2 Dp b
cd = 0,95 - 0,98

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54
Maximum Impact Force at the Bit
McLean performed experimental work that

indicated that bit cleaning was maximized when the
impact force was maximized at the bit. This was
supported by studies performed by Eckel who found
that maximum impact force lead to maximum rate of
penetration.

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Maximum Horsepower at the Bit
Bit horsepower is maximized when the bit pressure

loss is equal to:
0.57 x Psystem
Psystem is limited by equipment and power available.

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56
Maximum Impact Force at the Bit
Kendall and Goins determined the impact force was

maximized when bit pressure loss is equal to:
0.47 x Psystem
Psystem is limited by equipment and power available.

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57
Maximum Horsepower at the Bit
Kendall and Goins derived a relationship for

maximizing horsepower at the bit. The derivation
of this relationship is left to the class participant.

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58
Setting QOptimum
Maximizing ROP
Cutting transport

Pump limitation
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59
Example of Hydraulic calculations

Konzept
vj max
Hb max
HHP
Fj max
HIF
Pump pressure
pp [MPa]
25,00
25,00
25,00
Flow rate
qopt
[L/min]
800
1019
1209
Bit pressure Drop
pb [MPa]
18,66
15,69
11,33
System pressure loss
pv [MPa]
6,34
9,31
13,67
Total input Power
Hp [kW]
333
425
504
Bit (horse) power
Hb [kW]
248,77
266,50
228,31
Impulse force
Fj [N]
2675,88
3146,22
3312,30
Jet velocity
vj [m/s]
171,13
156,91
133,33

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60
80
Bit pressure drop

pressure loss
[%pp]
70
60
50
40
30
20
10
0
vj
HHP
HIF
optimization concept

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61

3500
Hb
250
Fj
vj [m/s]
Hb [kW]
200
3000
2500
2000
150
1500
vj
100
50
Fj [kW]
300
1000
500
0
800
900
1000
1100
1200
1300
Pump rate[L/min]

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Pressure loss in surface equipment

Pump
Surface pipes
Mud Hose
Swivel
Kelly
1,86
q
Dp C
z
C = Pressure loss coefficient
z = Unit coefficient

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63
Alternative Hydraulic Designs
Vortex
Nozzles
Clean Sweep
Mudpick
Switchblade
Asymmetric
Nozzles
All pictures courtesy of Schlumberger

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Viewing the Well as a Manometer

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65

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Vorlesung Tiefbohrtechnik 1

Introduction to Rotary-Drilling Technology (inc. Rig Count)

Drilling Hydraulics Applications

Several aspects of blowout prevention

Displacement of cement slurries and resulting stresses in the

Bit nozzle size selection for optimum hydraulics

Dr. Catalin Teodoriu

Pressure drop in a well

Less than 50%

Dr. Catalin Teodoriu

Dr. Catalin Teodoriu

Buoyancy Force = weight of fluid displaced

Effective (buoyed) Weight

Dr. Catalin Teodoriu

Effective (buoyed) Weight

Buoyancy Factor (BF)

Valid for a solid body or an open-ended pipe! (WHY?)

Types of Flow: Laminar Flow

Flow pattern is linear (no radial flow)

Dr. Catalin Teodoriu

Types of Flow: Laminar Flow

Dr. Catalin Teodoriu

Types of Flow: Turbulent Flow

Flow pattern is random

Types of flow : Turbulent flow

Dr. Catalin Teodoriu

Types of f low: Turbulent flow

Fig. 4-30. Laminar and turbulent flow patterns in a

Dr. Catalin Teodoriu

Dpf = 11.41 v 1.75

Dr. Catalin Teodoriu

Turbulent Flow - Newtonian Fluid

Turbulent Flow - Newtonian Fluid in SI units

where fluid density, Kg/m3

v avg. fluid velocity,m/sec

We often assume that fluid flow is

Turbulent Flow - Newtonian Fluid in field units

where fluid density, lbm/gal

v avg. fluid velocity, ft/s

We often assume that fluid flow is

Non-static Well Conditions

Dr. Catalin Teodoriu

Dr. Catalin Teodoriu

Law of Conservation of Energy (Brnoulli)

States that as a fluid flows from A to B:

Settling velocity, after Bourgoyne et al.

Dr. Catalin Teodoriu

Slip Velocity, after Bourgoyne et al.

Particle Slip Velocity - small particles

v s slip velocity, ft/s

s density of solidparticle, lbm/gal

Particle Slip Velocity other than laminar

Note: all equations are in field units

Dr. Catalin Teodoriu

Dr. Catalin Teodoriu

Dr. Catalin Teodoriu

Slightly compressible fluid

Dr. Catalin Teodoriu

Average Fluid Velocity (SI units)

v = average velocity, m/s

Average Fluid Velocity (field units)

v = average velocity, ft/s

Velocity Profiles (laminar flow)

(a) pipe flow and (b) annular flow