Drilling Bits

And HydraulicsOtimization
 Jet Bit Nozzle Size Selection
- Optimization -

Through nozzle size selection,

optimization may be based on
maximizing one of the following:
¾ Bit Nozzle Velocity
¾ Bit Hydraulic Horsepower
¾ Jet impact force

• There is no general agreement on which of

these three parameters should be maximized.
 Maximum Nozzle Velocity

Nozzle velocity may be maximized consistent with

the following two constraints:

• 1. 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.
• 2. The surface pump pressure must stay within the
maximum allowable pressure rating of the
pump and the surface equipment.
 Maximum Nozzle Velocity

∆ Pb
Nozzle Velocity vn = Cd
8 . 074 * 10 ρ
−4

i.e. v n ∝ ∆Pb

so the bit pressure drop should be maximized in

order to obtain the maximum nozzle velocity
 Maximum Nozzle Velocity

This (maximization) will be achieved when

the surface pressure is maximized and the
frictional pressure loss everywhere is
minimized, i.e., when the flow rate is
minimized.

∴ v n is maximized when 1& 2 above are satisfied,

at the minimum circulation rate
and the maximum allowable surface pressure.
Maximum Bit Hydraulic Horsepower

The hydraulic horsepower at the bit is

maximized when (∆p bit q) is maximized.

∆ p pump = ∆ p d + ∆ p bit

∆ p bit = ∆ p pump − ∆ p d

where ∆p d may be called the parasitic pressure

loss in the system (friction).
 Maximum Bit Hydraulic Horsepower

The parasitic pressure loss in the system,

∆p d = ∆p s + ∆p dp + ∆p dc + ∆p dca + ∆p dpa = cq 1.75

if the flow is turbulent.

In general, ∆ p d = cq m
where 0 ≤ m ≤ 2
Maximum Bit Hydraulic Horsepower

∆ p bit = ∆ p pump − ∆ p d ∆ p d = cq m

m +1
∆pbit q ∆p pump q − cq
∴ PHbit = =
1714 1714

dPHbit
∴ = 0 when ∆p pump − c(m + 1)q = 0 m

dq
Maximum Bit Hydraulic Horsepower

∆p pump − c(m + 1)q m = 0

i . e ., when ∆ p pump = ( m + 1 ) ∆ p d
 1 
i . e ., when ∆pd =  ∆p pump
 m +1

∴ P Hbit is maximum when

 1 
∆pd =  ∆ p pump
 m +1
Maximum Bit Hydraulic Horsepower

 1 
∆pd =  ∆ p pump
 m +1

∆ p bit = ∆ p pump − ∆ p d
∴ P Hbit is maximum when

 m 
∆ p bit =  ∆ p pump
 m +1
 Maximum Bit Hydraulic Horsepower
- Examples -
1
In turbulent flow, m = 1.75 ∆p d = ∆p p
m +1
 1 
∴ ∆p d =   ∆ p pump * 100 %
 1 . 75 + 1 

= 36% of ∆ p pump

∴ ∆ p bit = 64 % of ∆ p pump
Maximum Bit Hydraulic Horsepower
Examples - cont’d

In laminar flow, for Newtonian fluids, m=1

 1 
∴ ∆pd =   ∆ p pump * 100 %
1+1

= 50% of ∆ p pump

∴ ∆ p b = 50 % of ∆ p pump
Maximum Bit Hydraulic Horsepower

• 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

• Note that at no time should the flow rate be

allowed to drop below the minimum
required for proper cuttings removal
 Maximum Jet Impact Force

The jet impact force is given by Eq. 4.37:

F j = 0.01823 cd q ρ ∆pbit

= 0.01823 c d q ρ ( ∆p pump − ∆p d )
 Maximum Jet Impact Force

F j = 0.01823 c d q ρ ( ∆p pump − ∆pd )

But parasitic pressure drop,

∆ p d = cq m

∴ F j = 0 .01823 c d ρ ∆p p q − ρ cd q
2 m+2
 Maximum Jet Impact Force

Upon differentiating, setting the first derivative

to zero, and solving the resulting quadratic
equation, it may be seen that the impact
force is maximized when,

2
∆p d = ∆p p
m+2
Maximum Jet Impact Force

2
∆p d = ∆p p
m+2

∆ p bit = ∆ p pump − ∆ p d

∴ P IFbit is maximum when

 m 
∆ p bit =  ∆ p pump
m +2
 Maximum Jet ∆p d =
2
∆p p
Impact Force m+2

- Examples -

Thus, if m = 1.75, ∆pd = 53% of ∆pp

and ∆pb = 47% of ∆pp

Also, if m = 1.00 ∆pd = 67% of ∆pp

and ∆pb = 33% of ∆pp
 Optimum Bit Hydraulics
• Under what conditions do we get the best
hydraulic cleaning at the bit?
– maximum hydraulic horsepower?
– maximum impact force?

Both these items increase when the circulation

rate increases.
However, when the circulation rate increases, so
does the frictional pressure drop.
 Optimum Bit Hydraulics - cont’d

• Since the pump pressure has an upper

limit, any increase in flow rate reduces
the pressure drop available at the bit
(for bottom-bole cleaning).

• The pressure drop at the bit may be

increased by decreasing the nozzle sizes,

• ... but what is the optimum nozzle size?

 Maximum Bit Horsepower
Under LAMINAR flow conditions, ∆PFRICTION = C Qn
Under TURBULENT flow conditions, ∆PFRICTION = C Q1.75

In general, ∆PFRICTION = C Qm

It can be shown that hydraulic horsepower at the bit

is maximized when:

 1 
∆PFRICTION = PPUMP  
 m + 1
 Maximum Jet Impact Force
Similarily, it can be shown that jet impact force
at the bit is maximized when:

 2 
∆PFRICTION = PPUMP  
m+ 2
For example, if m = 1.75, then 1/(m+1) = 0.3636
2/(m+2) = 0.5333
In this case, hydraulic horsepower is maximized when
about 36% of the pump pressure is used to overcome friction.
Jet impact force is maximized when ∆PFRICTION is about
53% of the pump pressure.
Nozzle Size Selection

- Graphical Approach -
 1. Show opt. hydraulic path
2. Plot ∆pd vs q
3. From Plot, determine
optimum q and ∆pd

4. Calculate ∆ p bit = ∆ p pump − ∆ p d

5. Calculate
8 .311 * 10 − 5 ρ q opt
2

Total Nozzle Area: ( At ) opt = 2

(TFA) C d ( ∆ p b ) opt

6. Calculate Nozzle Diameter

4Atot
With 3 nozzles: dN =
3π
END
 Example 4.31

Determine the proper pump operating

conditions and bit nozzle sizes for max.
jet impact force for the next bit run.

Current nozzle sizes: 3 EA 12/32”

Mud Density = 9.6 lbm.gal
At 485 gal/min, Ppump = 2,800 psi
At 247 gal/min, Ppump = 900 psi
 Example 4.31 - given data:

Max pump HP (Mech.) = 1,250 hp

Pump Efficiency = 0.91

Max pump pressure = 3,000 psig

Minimum flow rate

to lift cuttings = 225 gal/min
 Example 4.31 - 1(a), 485 gpm
Calculate pressure drop through bit nozzles:
8 . 311 * 10 −5
ρ q 2

Eq .( 4 . 34 ) : ∆ p b = 2 2
c d At
-5
8.311(10 )( 9 .6 )( 485 )2
∆p b = 2
= 1,894 psi
2
 π  12  
2

(0.95) 3   
 4  32  

∴ parasitic pressure loss = 2,800 - 1,894 = 906 psi

 Example 4.31 - 1(b), 247 gpm

−5 2
8 . 311 (10 )( 9 . 6 )( 247 )
∆ pb = 2
= 491 psi
2
 π  12  
2

( 0 . 95 )  3   
 4  32  

∴ parasitic pressure loss = 900 - 491 = 409 psi

(q1, p1) = (485, 906) Plot these two

(q2, p2) = (247, 409) points in Fig. 4.36
 Example 4.31 - cont’d 3
2
2. For optimum hydraulics:
(a ) Interval 1, 1
1,714 PHp E 1,714(1,250)(0.91)
q max = = = 650 gal/min
Pmax 3,000
 2   2 
(b) Interval 2, ∆p d =   Pmax =   ( 3, 000 )
m+2  1 .2 + 2 

= 1,875 psi
(c) Interval 3, q min = 225 gal/min
 Example 4.31
3. From graph, optimum point is at
gal
q = 650 , ∆ p d = 1,300 psi ⇒ ∆ p b = 1,700 psi
min

8 .311 * 10 ρ q opt
−5 2
8.311*10-5 * 9.6 * (650)2
∴ ( At ) opt = =
2
C d ( ∆ p b ) opt (0.95)2 * (1,700)

Aopt = 0.47 in 2 ⇒ (d N )opt = 14 32nds in

 gal
q = 650 , ∆ p d = 1,300 psi ⇒ ∆ p b = 1,700 psi
min
 Example 4.32

Well Planning

It is desired to estimate the proper pump

operating conditions and bit nozzle sizes for
maximum bit horsepower at 1,000-ft
increments for an interval of the well
between surface casing at 4,000 ft and
intermediate casing at 9,000 ft. The well
plan calls for the following conditions:
 Example 4.32

Pump: 3,423 psi maximum surface pressure

1,600 hp maximum input
0.85 pump efficiency

Drillstring: 4.5-in., 16.6-lbm/ft drillpipe

(3.826-in. I.D.)
600 ft of 7.5-in.-O.D. x 2.75-in.-
I.D. drill collars
 Example 4.32

Surface Equipment: Equivalent to 340

ft. of drillpipe

Hole Size: 9.857 in. washed out to 10.05 in.

10.05-in.-I.D. casing

Minimum Annular Velocity: 120 ft/min

 Mud Program

Mud Plastic Yield

Depth Density Viscosity Point
(ft) (lbm/gal) (cp) (lbf/100 sq ft)

5,000 9.5 15 5
6,000 9.5 15 5
7,000 9.5 15 5
8,000 12.0 25 9
9,000 13.0 30 12
 Solution

The path of optimum hydraulics is as

follows:
Interval 1
1,714 PHp E 1,714(1,600)(0.85)
q max = =
p max 3,423

= 681 gal/min.
 Solution

Interval 2
Since measured pump pressure data are not
available and a simplified solution technique
is desired, a theoretical m value of 1.75 is
used. For maximum bit horsepower,
 1   1 
∆p d =   pmax =   (3,423 )
 m +1  1.75 + 1 
= 1,245 psia
 Solution

Interval 3
For a minimum annular velocity of
120 ft/min opposite the drillpipe,

(
q min = 2.448 10 .05 − 4.5
2 2
)  120 
 
 60 
= 395 gal/min
 Table

The frictional pressure loss in other

sections is computed following a
procedure similar to that outlined above for
the sections of drillpipe. The entire
procedure then can be repeated to
determine the total parasitic losses at
depths of 6,000, 7,000, 8,000 and 9,000 ft.
The results of these computations are
summarized in the following table:
 Table

Depth ∆ps ∆pdp ∆pdc ∆pdca ∆pdpa ∆pd

5,000 38 490 320 20 20 888
6,000 38 601 320 20 25 1,004
7,000 38 713 320 20 29 1,120
8,000 51 1,116 433 28 75* 1,703
9,000 57 1,407 482 27* 111* 2,084
* Laminar flow pattern indicated by
Hedstrom number criteria.
 Table
The proper pump operating conditions
and nozzle areas, are as follows:
( l) Depth (2)Flow Rate (3) ∆ p d (4) ∆ p b (5)A t
( ft ) (gal/min) (psi) (psi) (sq in.)

5,000 600 1,245 2,178 0.380

6,000 570 1,245 2,178 0.361
7,000 533 1,245 2,178 0.338
8,000 420 1,245 2,178 0.299
9,000 395 1,370 2,053 0.302
 Table

The first three columns were read directly

from Fig. 4.37. (depth, flow rate and ∆pd)

Col. 4 (∆pb) was obtained by subtracting ∆pd

shown in Col.3 from the maximum pump
pressure of 3,423 psi.

Col.5 (Atot) was obtained using Eq. 4.85

 Best Penetration Rate
• Approach A • Approach B
• Achieved by removing • Drilling fluid hits
cuttings efficiently bottom of the hole
from below the bit with greatest force

• Maximize the • Maximize Jet Impact

hydraulic power Force
available at the bit
 Optimum bit hydraulics
Find the flow rates for different pump pressures (before POOH)
Use the values to calculate C and N
Get the expression for optimum flow rate
Establish optimum flow rate Q
Find the system pressure drop
Get the optimum system pressure drop (from either approach A or
Establish optimum Stand pipe pressure and check with pump capacity
Calculate optimum Pb
Calculate optimum AT (TFA) and select jets
 Max. Hydraulic Power at the bit

Pb . Q / 1714 hp
Pb = (Psp - PCS) Pcs = c QN
HHPb = (Psp Q - c QN+1 )/1714 Differentiate wrt Q = 0

Pb = (N/N+1) Psp
Jet Impact Force below the bit
IF = Q/58 (ρ Pb)0.5 Max IF when Pb = [N/(N+2)] Psp
61.6 x 10-3 ρ Q2 / AT
 Nozzle Selection

AT = 0.0096 Q (ρ /Pb)0.5 = .32 Q/Vn

dn = 32 (4 AT /3π)0.5
 Nozzle Seection
• Max. HHP line, Max Pp to get Qmax
• From Different Q and P Draw line A and
calculate m&c
• Get Optimum Pb using JIF or MaxHHP,
Draw Line B
• Intercipt of line A and B get Qopt
• Calculate Nozzle Area @ Qopt.