Slide 1Prepared by: Tan Nguyen
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
Optimization of Hydraulic Parameters
: 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
Maximum and Minimum Values - Review
Optimization of Hydraulic Parameters
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
Maximum Nozzle Velocity
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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.
Maximum Nozzle Velocity
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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.
Maximum Bit Hydraulic Horsepower
Optimization of Hydraulic Parameters
Frictional pressure losses in the surface equipment, ps
Frictional pressure losses in the drillpipe, pdp, and drill
collars, pdc
Pressure losses caused by accelerating the drilling fluid through
the nozzle
Frictional pressure losses in the drill collar annulus, pdca, and
drillpipe annulus, pdpa
Let:
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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
Maximum Bit Hydraulic Horsepower
Optimization of Hydraulic Parameters
Hence, Dpd can be expressed as
m is a constant has a value near 1.75, c is a constant that depends
on the mud properties and wellbore geometry
Pressure drop across the bit
The bit Hydraulic horsepower
Maximum Bit Hydraulic Horsepower
Optimization of Hydraulic Parameters
The bit horsepower reaches maximum when:
Or
Since
Or:
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Jet impact force is a function of Dpbit = Dppump – Dpf . Note that
Dpf is the total pressure loss in pipes and annuli.
Maximum Jet Impact Force
Optimization of Hydraulic Parameters
Solve the above equation yields,
or
Maximum Jet Impact Force
Optimization of Hydraulic Parameters
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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 PHP
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 Dpd/Dpp at the optimum value. Then
the flow rate will be reduced to the minimum value which it can
still lift the cuttings.
Nozzle Size Selection – Graphical Analysis
Optimization of Hydraulic Parameters
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 pf .Intermediate portion of the
well where the flow rate is reduced gradually to maintain pd/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.
Nozzle Size Selection – Graphical Analysis
Optimization of Hydraulic Parameters
Optimization of Hydraulic Parameters
Calculate
Optimization of Hydraulic Parameters
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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.
Example
Pressure drop through the bit:
Total frictional pressure loss inside the drillstring and in the
annulus at different flow rate:
Example
Interval 1:
Interval 2:
Interval 3:
The proper total nozzle area is:
The nozzle size
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The goal of bit selection is to obtain the lowest cost per foot.
The cost per foot can be calculated by using the equation:
Where C is the overall cost per foot, $/ft; Cb is the cost of the
bit, $; Cr is the cost of operating the rig $/hr; tb is the
rotating time with bit on bottom, hours; tt is the round trip time,
including connection time, hours; to is the other time, which is
not rotating time or trip time, hours; and DD is the total depth as
a given total time, ft.
Cost-per-foot Calculation
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Drilling costs tend to increase exponentially with depth. Thus,
when curve fitting drilling cost data, it is often convenient to
assume a relationship between cost, C and depth, D given by
C = aebD
Where a, $, and b, ft-1, depend primarily on the well
location.
The cost per day of the drilling operations can be estimated from
considerations of rig rental costs, other equipment rentals,
transportation costs, rig supervision costs, and others. The time
required to drill and complete the well is estimated on the basis
of rig-up time, drilling time, trip time, casing placement time,
formation evaluation, borehole survey time, completion time and
trouble time.
Cost-per-foot Calculation
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Example: A recommended bit program is being prepared for a new well
using bit performance records from nearby wells. Drilling
performance records for three bits are shown for a thick limestone
formation at 9000 ft. Determine which bit gives the lowest drilling
cost if the operating cost of the rig is 400 $/hr, the trip time is
7 hours, and connection time is 1 minute per connection. Assume
that each of the bits was operated at near the minimum cost per
foot attainable for that bit.
Cost-per-foot Calculation
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The performance of a bit can also be determined by using run-cycle
speed (RCS). The RCS is defined as:
Where D is the total footage determined by the particular
bit.
Run Cycle Speed
Optimization of Economics
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There is almost always some uncertainty about the best time to
terminate a bit run and begin tripping operations. The use of the
tooth-wear equation and the bearing-wear equation will provide, at
best, a rough estimate of when the bit will be completely worn. In
addition, it is helpful to monitor the rotary-table torque. In the
case of a roller-cone bit, when the bearings become badly worn, one
or more of the cones frequently will lock and cause a sudden
increase or large fluctuation in the rotary torque needed to rotate
the bit. With a PDC or fixed-cutter bit, when cutter elements are
heavily worn or broken, or the bit becomes undergauge, the bit will
exhibit much lower than expected ROP and cyclic or elevated torque
values.
Termination of a Bit Run
Optimization of Economics
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When the ROP decreases rapidly as bit wear progresses, it may be
advisable to pull the bit before it is completely worn. If the
lithology of the formation is homogeneous, the total drilling cost
can be reduced by minimizing the cost of each bit run. In this
case, one way to determine when to terminate the bit run is by
keeping a current running calculation of the cost per foot for the
run, assuming that the bit would be pulled at the current depth.
Even if significant bit life remains, the bit should be pulled when
the computed cost per foot begins to increase.
However, if the lithology of the formation is not uniform, this
procedure will not always result in the minimum total cost. In this
case, an effective criterion for determining optimum bit life can
be better established after offset wells are drilled in the area,
thus defining the lithological variations, and the contribution of
the rock properties can be studied and understood better.
Termination of a Bit Run
Optimization of Economics
Prepared by: Tan Nguyen
Example: Determine the optimum bit life for the bit run described
in the table below. The lithology of the formation is known to be
essentially uniform in this area. The bit cost is $5000. The rig
cost is 4000 $/hr; and the trip time is 10 hours.
Termination of a Bit Run
Optimization of Economics
Optimization of Economics
footage, DD ft
Remarks
Optimization of Economics
Optimization of Economics
ttotal = tt + te
Optimization of Economics
Optimization of Economics
Example: Determine the optimum bit life for the bit run described
in the table below. The lithology of the formation is known to be
essentially uniform in this area. The bit cost is $5000. The rig
cost is 4000 $/hr; and the trip time is 10 hours.
Footage, DD ft
Remarks
0
0
New
30
2
50
4
65
6
77
8
87
10
96
12
104
14
111
16
Optimization of Economics
Cb/Cr = 5000/4000 = 1.25 hrs
Using the equation above with different dD/dt. te = Cb/Cr = 1.25
hrs. The optimal line corresponds to dD/dt = 4.2. Time to change
the drill bit is 12 hours and at the depth of 96 ft.
Drilling Engineering
Optimization of Economics