Optimization of Hydraulics Parameters

Optimization of Hydraulic Parameters
Introduction
Significant increases in ROP can be achieved through the proper choice of bit
nozzle.
Most commonly used hydraulic design parameters are:
Bit nozzle velocity
Bit hydraulic horsepower
Jet impact force
Current field practice involves the selection of the bit nozzle sizes that will cause
one of these parameters to be a Maximum
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Maximum and Minimum Values - Review
y = f(x)
: The tangent to the curve is
horizontal.
Solve this equation we can get the critical

values (either max or min): x = a or x = b.
Second derivative:
The function has a minimum value at x = b if f /

(b) = 0 and f //(b) is a positive number
The function has a maximum value at x = a if

f / (a) = 0 and f //(a) is a negative number
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Maximum Nozzle Velocity
Flow velocity through bit nozzle
So velocity is directly proportional to the square root of the pressure drop across the bit
The nozzle velocity is a maximum when the pressure drop available at the bit is a maximum.
This can be achieved when the pump pressure is a maximum and the frictional pressure loss in
the drillstring and annulus is a minimum; the frictional pressure loss is a minimum when the flow
rate is a minimum
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Maximum Nozzle Velocity
Nozzle velocity may be maximized consistent with the following two constraints:
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.
The surface pump pressure must stay within the maximum allowable pressure rating of the
pump and the surface equipment.
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Maximum Bit Hydraulic Horsepower
Effectiveness of jet bits could be improved by increasing the hydraulic power of the pump.
Penetration rate would increase with hydraulic horsepower until the cuttings were removed as
fast as they were generated. After this level, there should be no further increase in the
penetration rate. Note that the hydraulic horsepower developed by the pump is different from the
hydraulic horsepower at the bottom of the hole. This is due to the friction losses in the drillstring
and in the annulus. Therefore, the bit horsepower was not necessarily maximized by operating
the pump at the maximum possible horsepower.
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The Pump Pressure is expended by:
1. Frictional pressure losses in the surface equipment, Δp s
2. Frictional pressure losses in the drillpipe, Δp dp , and drill collars, Δp dc
3. Pressure losses caused by accelerating the drilling fluid through the nozzle
4. Frictional pressure losses in the drill collar annulus, Δp dca , and drillpipe annulus, Δp dpa
Let:
43
Hence, the pressure loss at the pump will be sum of pressure loss at the bit and total frictional
pressure loss to and from the bit:
It is well know that the frictional pressure loss is a function of flow rate and can be expressed as
44
Hence, Δpd can be expressed as
m is a constant has a value near 1.75 (Depend on density and viscosity of the fluid), c is a constant that
depends on the mud properties and wellbore geometry
Pressure drop across the bit
The bit Hydraulic horsepower
45
Bit horsepower is a function of flow rate
The bit horsepower reaches maximum when:
Or
46
Bit hydraulic horsepower is a maximum when
Since
The hydraulic horsepower will be maximum at
Or:
47
Maximum Jet Impact Force
Jet impact force is a function of Δpbit = Δppump – Δpf . Note that Δpf is the total pressure loss in
pipes and annuli.
48
Maximum Jet Impact Force
The impact force is maximized when,
Solve the above equation yields,
or
Since , the jet impact force will be maximum at
49
Nozzle Size Selection – Graphical Analysis
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 rather than periodically
changing the liner size as the well depth increases to achieve the theoretical maximum. Thus, in
the shallow part of the well, the flow rate usually is held constant at the maximum rate that can
be achieved with the convenient liner size. Note that at no time should the flow rate be allowed
to drop below the required for proper cuttings removal
For a given pump horsepower rating P HP
E is the overall pump efficiency, pmax is the maximum allowable pump pressure set by contractor.
This flow rate will be used until the depth is reached at which Δpd/Δpp at the optimum value.
Then the flow rate will be reduced to the minimum value which it can still lift the cuttings.
50
Three intervals
Interval 1: defined by q = qmax .Shallow portion of the well where the pump is operated at
the maximum allowable pressure
Interval 2: defined by constant Δp f .Intermediate portion of the well where the flow rate is
reduced gradually to maintain Δp d/pmax at the proper value for maximum bit hydraulic
horsepower or impact force.
Interval 3: defined by q = qmin . Deep portion of the well where the flow rate has been
reduced to the minimum value that efficiently will lift the cuttings to the surface.
51
Slope -1
Slope 1.75
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1. Show opt. hydraulic path
2. Plot Δpf vs q
3. From Plot, determine optimum q and Δpf
4. Calculate
5. Calculate total nozzle area
6. Calculate Nozzle Diameter
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Example
Determine the proper pump operating conditions and bit nozzle sizes for maximum jet impact
force for the next bit run. The bit currently in use has three 12/32-in nozzles. The driller has
recorded that when the 9.6lbm/gal mud is pumped at a rate of 485 gal/min, a pump pressure of
2800 psig is observed and when the pump is slowed to a rate of 247 gal/min, a pump pressure
of 900 psig is observed. The pump is rated at 1,250 hp and has an efficiency of 0.91. The
minimum flow rate to lift the cuttings is 225 gal/min. The maximum allowable surface pressure is
3000psig. The mud density will remain unchanged in the next bit run.
54
Example
Pressure drop through the bit:
Total frictional pressure loss inside the drillstring and in the annulus at different flow rate:
55
Example
m = 1.2, for optimum hydraulics
Interval 1:
Interval 2:
Interval 3:
56
Example
57
Example
From graph, the optimum point:
The proper total nozzle area is:
The nozzle size
58
Example
59

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Optimization of Hydraulic Parameters

Most commonly used hydraulic design parameters are:

Bit nozzle velocity

Bit hydraulic horsepower

Jet impact force

: The tangent to the curve is

Solve this equation we can get the critical

The function has a minimum value at x = b if f /

The function has a maximum value at x = a if

Flow velocity through bit nozzle

The Pump Pressure is expended by:

1. Frictional pressure losses in the surface equipment, Δp s

2. Frictional pressure losses in the drillpipe, Δp dp , and drill collars, Δp dc

Pressure drop across the bit

The bit Hydraulic horsepower

Bit horsepower is a function of flow rate

The bit horsepower reaches maximum when:

Bit hydraulic horsepower is a maximum when

The hydraulic horsepower will be maximum at

The impact force is maximized when,

Solve the above equation yields,

Since , the jet impact force will be maximum at

For a given pump horsepower rating P HP

Nozzle Size Selection – Graphical Analysis

1. Show opt. hydraulic path

3. From Plot, determine optimum q and Δpf

5. Calculate total nozzle area

6. Calculate Nozzle Diameter

Pressure drop through the bit:

m = 1.2, for optimum hydraulics

From graph, the optimum point:

The proper total nozzle area is:

The nozzle size

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