5.

1 Drilling Mud rheology

5.1.1 Introduction

The Drilling mud rheological properties were studied based on the prepared mud sample of (9.1)
ppg. It is very important to study the mud rheological properties. The mud rheological properties
such as Plastic viscosity (PV) and Yield point (YP) are very essential for determining the type of
flow regime in the circulatory system. Variation in these values affects in pressure loss in the
circulatory system and changes the flow regime and largely affects the hole cleaning efficiency.

5.1.2 Experimental work

The very first step of our case study was to prepare a water based drilling mud which is suitable
for the formation and then obtaining its rheological properties.

5.1.2.1 Equipments Used

(a) Mud Balance:

( Image courtesy: filescript.org)

A mud balance is used to measure the mud weight which consists of base and a balance arm with
cup, lid, knife edge, rider, level glass, and counterweight. The cup is attached to one end of the
balance arm and the counterweight is at the opposite end.
(b) Mud mixer: A mixer grinder is used to prepare the mud sample of density (9.1) ppg for the
experimental work. The mud is prepared by mixing three different components such as Barite,
Bentonite and Water.

Where,
Pmix= Density of the Mud mixture (ppg)
M1= Mass of barite (gm)
M2= Mass of bentonite (gm)
M3= Mass of water (gm)
P1= Density of barite(ppg)
P2= Density of bentonite (ppg)
P3= Density of water (ppg)

API densities used for some additives for preparing the Mud sample is given below:

(c) Fann Viscometer: A Fann Viscometer is used for obtaining the rheological properties of the
mud sample in the laborotory.
Experimental Procedure:

The following test procedures were carried out in the laboratory at a temperature of 730F

 The mass of water is measured using a measuring flask while barite and bentonite were
measured using an electronic weighing machine.

 Water, bentonite and barite were then mixed together using a mixer grinder and the
sample is then allowed to settle for next 24 hours.

 The mud sample is then poured in the mud cup of the mud balance and the mud density
was measured by adjusting the rider in the balance arm until a point of equilibrium was achieved.
The mud density was then read from the level glass indicator of the mud balance. The masses of
additives were adjusted until we got the desired value of the density of the mud.

 The mud of density 9.1 (ppg) was filled in the stainless steel sample test cup of the
viscometer to the scribed line and placed on the instrument stage.
 The lock nut of the viscometer was loosened and the instrument stage with the stainless
steel in it was raised until the rotor was immersed to the proper immersion depth of the stainless
steel cup and the lock nut was tightened.

 The rotor of the viscometer was operated in a high speed position of 600 rpm with the
gear shifted down. The dial reading on the viscometer is recorded when the indicator became
steady.

 The rotor of the viscometer was then switched to 300 rpm speed with the gear still shifted
down. The dial reading on the viscometer is also recorded when the indicator became steady.

The Plastic Viscosity (PV) and the Yield Point (YP) were calculated using the following
equations:

PV = Ø600-Ø300

YP = PV- Ø300

Where,
PV= Plastic Viscosity (cp)
YP= Yield Point (lb/100 ft)
Ø600= dial reading of viscometer at 600RPM
Ø300= dial reading of viscometer at 300RPM
5.1.3 Composition of Mud additives:
The mud sample was prepared using the following data given below:

Mud additives Mass

Water 500 g
Bentonite 50 g
Barite 40 g

5.1.4 Results obtained from the viscometer using the Mud sample:

Ø600= 35
Ø300= 24
Therefore,
PV= Ø600-Ø300
PV= 11 cp

and YP = PV- Ø300

YP = 13

5.2 Pressure Loss in the Mud circulatory system:

The pressure loss in the mud circulatory system were calculated using the obtained value of the
mud rheological properties and the data collected from the rig site. The maximum flow rate is
calculated using the available data and the minimum flow rate then assumed.
Pressure loss in the circulatory system includes pressure loss in the Surface equipment, pressure
loss inside the drill pipe, pressure loss inside BHA, and pressure loss around drill pipe and BHA.
Therefore maximum flow was calculated using the following formula ( Bourgoyne 1991):
Qmax=1714* ɳ*Hhp/Pmax

Where ,
Qmax= Maximum flow rate (gpm)
ɳ= Pimp efficiency
Hhp= Pump Horse power
Pmax= Maximum Pump pressure

Therefore, the operating flow rate ranges from 800gpm to 1050gpm ( From Drilling data
handbook). A flow rate of 900 gpm will be chosen for the calculation purpose.

5.2.1 Calculating pressure loss in the surface equipment:

The pressure loss in the surface equipment calculated using the Bingham plastic model equation
given below:

P1 = E ρ0.8 Q1.8 (PV)0.2 psi

P1 = pressure loss, psi
ρ = Density, ppg
Q = flow rate, gpm, l/min
PV = plastic viscosity, cp
E = constant depends type of surface connections.
The value of E was selected based on the equipment used in the field given in (Appendix B)

P1= 4.2x10-5x(9.1)0.8x(550)1.8x(11)0.2
P1= 34 psi
5.2.2 Calculating pressure loss inside the drill pipe:
The flow regime at a depth of 4975.5 ft was calculated using the equations given below:

Average velocity,
24.5Q
𝑣̅ =
D2
24.5x550
𝑣̅ =
4.2762
𝑣̅ = 736.97 ft/min

Critical velocity,
97PV+97√PV2 +8.2ρD2 YP
𝑣𝑐 =
ρD

97x11+97√112 +8.2x9.1x4.2782 x13

𝑣𝑐 =
9.1x4.276
𝑣𝑐 = 360.54 ft/min
Since the critical velocity is less than the average velocity, therefore the flow is turbulent.

Therefore pressure loss in the drill pipe can be calculated as:

8.91x10−5 xρ0.8 xQ1.8 xPV0.2 xL
P2 =
D4.8
8.91x10−5 x9.10.8 x5501.8 x110.2 x4975.5
P2 =
4.2784.8

P2= 335.65 psi

 5.2.3 Pressure loss in the bottom hole assembly:
5.2.3.1 Calculating pressure loss inside HWDP
Average velocity,
24.5Q
𝑣̅ =
D2
24.5x550
𝑣̅ =
32
𝑣̅ = 1497.22 ft/min
Critical velocity,

97PV+97√PV2 +8.2ρD2 YP
𝑣𝑐 =
ρD

97x11+97√112 +8.2x9.1x32 x13

𝑣𝑐 =
9.1x3
𝑣𝑐 = 387.159 ft/min
Since the critical velocity is less than the average velocity, therefore the flow is turbulent.

Therefore pressure loss in the HWDP can be calculated as:

8.91x10−5 xρ0.8 xQ1.8 xPV0.2 xL
Pa =
D4.8
8.91x10−5 x9.10.8 x5501.8 x110.2 x462.25
Pa =
34.8

Pa= 414.68 psi

5.2.3.2 Pressure loss inside Bit sub:
Average velocity,
24.5Q
𝑣̅ =
D2
24.5x550
𝑣̅ =
7.882
𝑣̅ = 217 ft/min

Critical velocity,
97PV+97√PV2 +8.2ρD2 YP
𝑣𝑐 =
ρD
 97x11+97√112 +8.2x9.1x7.882 x13
𝑣𝑐 =
9.1x7.88
𝑣𝑐 = 350.07 ft/min
Since the critical velocity is higher than the average velocity, therefore the flow is turbulent.

Therefore pressure loss in the bit sub can be calculated as:

𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
Pb = +
60000(IDc −ODp )
2 200 (IDc−ODp)
30.30𝑥11𝑥217 30.30𝑥13
Pb= +
60000(17.5−9.625)
2 200 (17.5−9.625)
Pb= 0.27 psi

5.2.3.3 Pressure loss inside rest of the equipment (float sub, crossover sub, Poly NMDC,
PUP lower saver sub, PUP upper saver sub, NMDC, DC(8”),jar) etc:

Average velocity,
24.5Q
𝑣̅ =
D2
24.5x550
𝑣̅ =
2.832

𝑣̅ = 1682.50 ft/min

Critical velocity,
97PV+97√PV2 +8.2ρD2 YP
𝑣𝑐 =
ρD

97x11+97√112 +8.2x9.1x7.882 x13

𝑣𝑐 =
9.1x7.88
𝑣𝑐 = 389.77 ft/min

Since the critical velocity is less than the average velocity, therefore the flow is turbulent.

Therefore pressure loss in the bit sub can be calculated as:

 8.91x10−5 xρ0.8 xQ1.8xPV0.2 xL
Pc =
D4.8
8.91x10−5 x9.10.8 x5501.8 x110.2 x323.47
Pc =
2.834.8

Pc= 158.23psi
5.2.3.4 Pressue loss inside drill collar:

Average velocity,
24.5Q
𝑣̅ =
D2
24.5x550
𝑣̅ =
2.8132
𝑣̅ = 1702.9 ft/min
Critical velocity,

97PV+97√PV2 +8.2ρD2 YP
𝑣𝑐 =
ρD

97x11+97√112 +8.2x9.1x2.8132 x13

𝑣𝑐 =
9.1x2.813

𝑣𝑐 = 390.05 ft/min
Since the critical velocity is less than the average velocity, therefore the flow is turbulent.
Therefore pressure loss in the drill collar can be calculated as:
8.91x10−5 xρ0.8 xQ1.8 xPV0.2 xL
Pd =
D4.8
8.91x10−5 x9.10.8 x5501.8 x110.2 x89.28
Pd =
2.8134.8

Pd= 44.955 psi

5.2.3.5 Pressure loss inside telescope:

Average velocity,
24.5Q
𝑣̅ =
D2
 24.5x550
𝑣̅ =
5.902
𝑣̅ = 387.10 ft/min
Critical velocity,
97PV+97√PV2 +8.2ρD2 YP
𝑣𝑐 =
ρD

97x11+97√112 +8.2x9.1x5.902 x13

𝑣𝑐 =
9.1x5.90

𝑣𝑐 = 366.31 ft/min

Since the critical velocity is less than the average velocity, therefore the flow is turbulent.
Therefore pressure loss in the telescope can be calculated as:
8.91x10−5 xρ0.8 xQ1.8 xPV0.2 xL
Pe =
D4.8
8.91x10−5 x9.10.8 x5501.8 x110.2 x23.1
Pe =
5.904.8

Pe= 0.33 psi

Therefore pressure inside the BHA is then:

P3= Pa+Pb+Pc+Pd+Pe
P3= 170.89+0.27+158.23+109.08+0.33
P3=374.675 psi

4.2.4 Pressure loss around Drill pipe:

The pressure losses around drill pipe is calculated by dividing into two sections
(a) Cased hole section: The pressure loss calculated here is in between the drill pipe and upto
the last casing string which was at a depth of 492 ft.
Therefore pressure in the cased hole section can be calculated using the following formula:
Average velocity,
 24.5xQ
𝑣̅ =
I2Dc −O2Dp

Where,
IDc2= Inside diameter of casing. (inch)
IDp2= Outside diamtere of Pipe. (inch)

24.5x550
𝑣̅ =
202 −52

𝑣̅ = 35.93ft/min
Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )

97x11+97√112 +6.2x(20−5)2 x9.1x13

𝑣𝑐 =
9.1x(20−5)

𝑣𝑐 = 300 ft/min

Since the critical velocity is higher than the average velocity, therefore the flow is turbulent.

Therefore pressure loss in the telescope can be calculated as:

𝐿(𝑃𝑉)𝑣̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )2 200(IDc − ODp )

492𝑥11𝑥35.93 492𝑥13
P= 2 + 200(20−5)
60000x(20−5)

P41 = 2.146 psi

(b) Open hole section: The pressure loss is calculated in the open hole section of length 4474
ft.
 Therefore pressure in the open hole section can be calculated using the following formula:
Average velocity,
24.5xQ
𝑣̅ =
I2Dc −O2Dp

24.5x550
𝑣̅ =
17.52 −52

𝑣̅ = 47.91ft/min

Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )

97x11+97√112 +6.2x(17.5−5)2 x9.1x13

𝑣𝑐 =
9.1x(17.5−5)

𝑣𝑐 = 298.21ft/min

Since the critical velocity is higher than the average velocity, therefore the flow is laminar

Therefore pressure loss in the telescope can be calculated as:

𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )
2
200 (IDc − ODp )

4474𝑥11𝑥47.91 4474𝑥13
P= 2 + 200(17.5−5)
60000x(17.5−5)

P42 = 23.51 psi

Therefore pressure loss around Drill pipe is:
P4= 2.146+23.51
P4= 25.65 psi

4.2.5 Pressure loss around BHA:

4.2.5.1 Calculation for pressure loss around HWDP

Average velocity,
24.5xQ
𝑣̅ =
I2Dc −O2Dp

24.5x550
𝑣̅ =
17.52 −52

𝑣̅ = 47.91ft/min
Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )

97x11+97√112 +6.2x(17.5−5)2 x9.1x13

𝑣𝑐 =
9.1x(17.5−5)

𝑣𝑐 = 298.21ft/min
Since the critical velocity is higher than the average velocity, therefore the flow is laminar

Therefore pressure loss around HWDP can be calculated as:

𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )
2
200 (IDc − ODp )
 462.25𝑥11𝑥47.91 462.25𝑥13
P= 2 + 200(17.5−5)
60000x(17.5−5)

Pa = 0.74 psi
4.2.5.2 Pressure loss around Drill collar

Average velocity,
24.5xQ
𝑣̅ =
I2Dc −O2Dp

24.5x550
𝑣̅ =
17.52 −6.52

𝑣̅ = 51.04ft/min
Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )

97x11+97√112 +6.2x(17.5−5)2 x9.1x13

𝑣𝑐 =
9.1x(17.5−6.5)

𝑣𝑐 = 298.21ft/min
Since the critical velocity is higher than the average velocity, therefore the flow is laminar

Therefore pressure loss around the Drill collar can be calculated as:
𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )
2
200 (IDc − ODp )

89.38𝑥11𝑥51.04 89.38𝑥13
P= +
60000x(17.5−6.5)2 200(17.5−6.5)
Pb = 0.53 psi

4.2.5.3 Pressure loss around Bit sub:

Average velocity,
24.5xQ
𝑣̅ =
I2Dc −O2Dp

24.5x550
𝑣̅ =
17.52 −9.622

𝑣̅ = 63.08ft/min
Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )

97x11+97√112 +6.2x(17.5−9.62)2 x9.1x13

𝑣𝑐 =
9.1x(17.5−9.62)

𝑣𝑐 = 303.76ft/min
Since the critical velocity is higher than the average velocity, therefore the flow is laminar

Therefore pressure loss around the Bit sub can be calculated as:
𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )
2
200 (IDc − ODp )

30.30𝑥11𝑥63.08 30.3𝑥13
P= 2 + 200(17.5−9.62)
60000x(17.5−9.62)

Pc = 0.250 psi

4.2.5.4 Pressure loss around telescope:

Average velocity,
24.5xQ
𝑣̅ =
I2Dc −O2Dp

24.5x550
𝑣̅ =
17.52 −8.252
 𝑣̅ = 56.57ft/min
Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )

97x11+97√112 +6.2x(17.5−8.25)2 x9.1x13

𝑣𝑐 =
9.1x(17.5−8.25)

𝑣𝑐 = 302.1ft/min
Since the critical velocity is higher than the average velocity, therefore the flow is laminar

Therefore pressure loss around the telescope can be calculated as:

𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )
2
200 (IDc − ODp )

23.1𝑥11𝑥56.57 23.1𝑥13
P= 2 + 200(17.5−8.25)
60000x(17.5−8.25)

Pd = 0.15 psi

4.2.5.5 Pressure loss around rest of the equipments:

Average velocity,
24.5xQ
𝑣̅ =
I2Dc −O2Dp

24.5x550
𝑣̅ =
17.52 −8.292

𝑣̅ = 56.73ft/min
Critical velocity,

97PV+97√𝑃𝑉 2 +6.2x(IDc −ODp )2 xρYP

𝑣𝑐 =
ρx(IDc −ODp )
 97x11+97√112 +6.2x(17.5−8.29)2 x9.1x13
𝑣𝑐 =
9.1x(17.5−8.29)

𝑣𝑐 = 301.69ft/min
Since the critical velocity is higher than the average velocity, therefore the flow is laminar

Therefore pressure loss can be calculated as:

𝐿(𝑃𝑉)𝑣
̅ 𝐿(𝑌𝑃)
P= +
60000(IDc − ODp )
2
200 (IDc − ODp )

323.47𝑥11𝑥56.73 323.47𝑥13
P= +
60000x(17.5 − 8.29)
2
200 (17.5 − 8.29)
Pe = 2.32 psi

Therefore pressure loss around the BHA is:

P5= Pa+Pb+Pc+Pd+Pe
P5=0.74+0.53+0.25+0.15+2.32
P5=4 psi

4.3 Optimization using Maximum Hydraulic horsepower criterion:

The condition for maximum drill bit horse power derived by Kendal and Goins (1960) states that
bit hydraulic horse power is maximum when the parasitic pressure loss is given by the equation
shown below.
Pmax
(𝑃𝑓 )Dopt = m+1

Kendal and Goins (1960) stated that the theoretical value for the flow exponent (m) is 1.75
Therefore the optimum parasitic pressure loss using the maximum bit horsepower criteria for this
case study is given below:
3423
(𝑃𝑓 )Dopt = 1.75+1
 (𝑃𝑓 )Dopt = 1244.727 psi
Kendal and Goins further stated that for bit hydraulic horse power to be maximum the pressure
across the drill bit is given by the relationship below.
(𝑃𝑓 )𝐵𝑜𝑝𝑡 = 𝑃𝑚𝑎𝑥 − (𝑃𝑓 )Dopt

Where,
(𝑃𝑓 )𝐵𝑜𝑝𝑡 = optimum pressure drop on the drill bit (psi)
(𝑃𝑓 )Dopt = optimum Parasitic pressure drop (psi)
𝑃𝑚𝑎𝑥 = maximum pump pressure (psi)

Therefore for optimum condition to be achieved the pressure across the drill bit must be maintained,
in this case study the pressure across the drill bit is given below :

(𝑃𝑓 )𝐵𝑜𝑝𝑡 = 3423 − 1244.77 psi

(𝑃𝑓 )𝐵𝑜𝑝𝑡 = 2178.23 psi

4.3.1 Optimum flow rate to operate the mud pump.

Pressure drop increases with depth, hence in order to drill at the optimum condition the pump
must be operated at the optimum flow rate. In order to achieve this objective in this case study a
graphical approach is used. The optimum flow rate is obtained from the hydraulic plot. The
hydraulic plot is a log-log plot of parasitic pressure loss against flow rate.
4.3.2 Optimum Total nozzle area and nozzle sizes:

The total nozzle flow area is determined using the using the equation given below:
𝜌
𝐴𝑇𝑜𝑝𝑡 = 0.0096 𝑄𝑜𝑝𝑡 √𝑃 𝑖𝑛2
𝐵𝑜𝑝𝑡

Where,
𝐴𝑇𝑜𝑝𝑡 = optimum nozzle area (in2)
𝑄𝑜𝑝𝑡 = optimum flow rate (gpm)

𝜌 = Mud density (ppg)

(𝑃𝑓 )𝐵𝑜𝑝𝑡 = optimum pressure drop on the drill bit (psi)

Therefore, optimum nozzle area obtained for proper hole cleaning is:

9.1
𝐴𝑇𝑜𝑝𝑡 = 0.0096 𝑥 467.73√2178.27 𝑖𝑛2

𝐴𝑇𝑜𝑝𝑡 = 0.30 in2

Optimum nozzle sizes can be calculated as:

4𝐴𝑇𝑜𝑝𝑡
𝑑𝑜𝑝𝑡 = 32√ 3𝜋

d= 11.42
Where,
dopt= Optimum Nozzle diameter as fraction of 32 (in)
𝐴𝑇𝑜𝑝𝑡 = Optimum nozzle area. (In2)

Therefore, Nozzle sizes for optimum condition are: Two 11s and one 12.
.
4.3.3 Determination of Bit hydraulic horsepower (BHHP):

The hydraulic horsepower at the bit bit can be determine using the following equation:

𝑃𝐵𝑜𝑝𝑡 𝑥𝑄𝑜𝑝𝑡
BHHP= hp
1714

BHHP= 594.4244 hp