Rig Hydraulics

Lecturer: Mohammed Ariwan Jamal

Course Name & Code: Petroleum Drilling
Engineering II (PTR 326)
6th Semester (3rd Grade Fall Semester)
Week #2/Lecture #2 (Theory)
11.2.2024
Email: [email protected]
Contact Information:

• Lecturer: Mohammed Ariwan Jamal

• Email: [email protected]

• Working Time: Sunday to Thursday (8:30 A.M to 5:00 P.M.)

• Office Hours: Tuesday, 15:00-17:00

• Office: 322 / Main Building / Tishk International University (TIU)

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 Contents
Ø Rig Hydraulics

Ø Surface Connection Losses (P1)

Ø Pipe(P2&P3) and Annular(P4&P5) Pressure Losses

Ø Pressure Drop Across the Bit (Pb)

Ø Terminology

Ø Flow Regimes

Ø Type of Fluids

Ø Rheological Models

Ø Examples, Tutorials, and Homework

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 Rig Hydraulics
• This chapter deals with practical methods of calculating pressure losses in the various parts of the
circulating system and the selection of nozzle sizes.

• Several models exist for the calculation of pressure losses in pipes and annuli.

• Each model is based on a set of assumptions which cannot be completely fulfilled in any drilling
situation.

• The Bingham plastic, Power law and Herschel-Bulkley models are the most widely used in the oil
industry.

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 Rig Hydraulics
• The circulation system is divided into four sections:
1. Surface connections.
2. Pipes including drill pipe, heavy walled drill pipe
and drill collars.
3. Annular areas around drill pipes, drill collars, etc.
4. Drill bit.
• The objective is to calculate the pressure (energy) losses in
every part of the circulating system and then find the total
system losses.
• This will then determine the pumping requirements from the
rig pumps and in turn the horse power requirements.

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 Surface Connection Losses (P1)
• Pressure losses in surface connections (P1) are those taking place in standpipe, rotary hose, swivel and
Kelly.

• The task of estimating surface pressure losses is complicated by the fact that such losses are dependent
on the dimensions and geometries of surface connections.

• These dimensions can vary with time, owing to continuous wear of surfaces by the drilling fluids.

• The following general equation may be used to evaluate pressure losses in surface connections:

𝑃1 = 𝐸 𝜌0.8 𝑄1.8 𝑃𝑉0.2

• Where:
P1 = Pressure loss, psi or bar.
E = Constant depending on type of surface equipment used.
ρ = Mud weight, ppg or kg/l.
Q = Flow rate, gpm or l/min.
PV = plastic viscosity, cP.
11 February 2024 Rig Hydraulics 6
 Surface Connection Losses (P1)
• In practice, there are only four types of surface equipment; each type is characterized by the dimensions
of standpipe, Kelly, rotary hose and swivel which are summarized in table below.

• The values of the constant E are given in below table:

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Pipe(P2&P3) and Annular(P4&P5)
Pressure Losses
• Pipe losses take place inside the drill pipe and drill
collars and are designated as P2 and P3, respectively.

• Annular losses take place around the drill collar and

drill pipe and are designated as P4 and P5.

• The magnitudes of P2, P3, P4 and P5 depend on:

a) Dimensions of drill pipe (or drill collars), e.g. inside

and outside diameter and length.

b) Mud rheological properties, which include mud

weight, plastic viscosity and yield point.

c) Type of flow, which can be laminar or turbulent.

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 Pressure Drop Across the Bit (Pb)
• Drill bits are provide with nozzles to provide a jetting action, mainly required for
cleaning and cooling, but can also help with rock breakage in soft formations.
• The largest nozzle is one inch in size, often termed open, but more often the nozzles
used are a fraction of an inch.
• Hence, the pressure requirements to pass, say 1000 gpm, through such small
nozzles will be large.
• For a given length of drill string and given mud properties, pressure losses P1, P2,
P3, P4and P5 will remain constant.
• However, the pressure loss across the bit is greatly influenced by the sizes of nozzles
used, and volume flow rate.
• For a given flow rate, the smaller the nozzles the greater the pressure drop and in
turn the greater the nozzle velocity.
• The pressure drop across the bit is obtained by subtracting Pc (= P1+ P2+ P3+ P4+
P5) from the pump pressure.

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 Terminology
Ø Shear rate, γ(sec-1): This is a term most applicable to laminar flow. It refers to the change in
fluid velocity divided by the width of the channel through which the fluid is flowing in laminar
flow.

Ø Shear stress, 𝜏(lb/100 ft2): The force per unit area required to move a fluid at a given shear
rate.

Ø Viscosity, μ (centipoises (cP)): This is the ratio of shear stress to shear rate.

Ø Yield point, YP (lb/100 ft2): The minimum force required to initiate flow.

Ø Gel strength (lb/100 ft2): All drilling fluids build a structure when at rest. The gel strength is a
time-dependent measurement of the fluid shear stress when under static conditions. Gel
strengths are commonly measured after 10 seconds, 10 minutes, and 30 minutes intervals.

Ø Reynolds number, Re: This is a dimensionless number which determines whether a flowing
fluid is in laminar or turbulent flow. Laminar flow: Re < 2000, Transitional flow: 2000 < Re <
4000 and Turbulent flow: Re > 4000.
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 Flow Regimes
• Laminar flow: In laminar flow, fluid layers flow parallel to each other in an orderly fashion.
This flow occurs at low to moderate shear rates when friction between the fluid and the
channel walls is at its lowest. This is a typical flow in the annulus of most wells.

• Turbulent flow: This flow occurs at high shear rates where the fluid particle move in a
disorderly and chaotic manner and particles are pushed forward by current eddies. Friction
between the fluid and the channel walls is highest for this type of flow. This is a typical flow
inside the drill pipe and drill collars.

• Transitional flow: Occurs when the fluid flow changes from laminar to turbulent or vice versa.

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 Type of Fluids
• There are two basic types of fluids: Newtonian and non-Newtonian.

• Newtonian fluids are characterised by a constant viscosity at a given temperature and pressure.

• Common Newtonian fluids include:

I. Water

II. Diesel

III. Glycerin

IV. Clear brines

• Non-Newtonian fluids have viscosities that depend on measured shear rates for a given temperature and pressure.
Examples of non-Newtonian fluids include:

I. Most drilling fluids

II. Cement slurries

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 Rheological Models
• Rheological models are mathematical
equations used to predict fluid behaviour
across a wide range of shear rates and
provide practical means of calculating pumping
(pressure) requirements for a given fluid.

1. Newtonian model

2. Bingham Plastic model

3. Power-Law model

4. Herschel-Bulkley (yield-power law [YPL])

model

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 Rheological Models

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 1. Bingham Plastic Model
• Fluids which behave according to the Bingham plastic model will not flow until the applied
shear stress, exceeds a certain minimum shear stress value known as the yield point.

• After the yield point has been exceeded, changes in shear stress are directly proportional to
changes in shear rate, with the constant of proportionality being called the plastic viscosity.

• This model can be used to represent a Newtonian fluid when the yield strength is equal to
zero. In this case the plastic viscosity is equal to the Newtonian viscosity.

• The slope of a line connecting any point on the straight line to

the origin is described as the apparent viscosity at that
particular shear rate.

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 1. Bingham Plastic Model
𝜏 = 𝑌𝑃 + 𝑃𝑉 𝛾
• Where:

𝜏 = shear stress in lb/100 ft2

YP = yield point in lb/100 ft2
PV = plastic viscosity in cP
γ = shear rate in sec-1
• The values of YP and PV are calculated
using the following equations:

𝑃𝑉 = 𝜃600 − 𝜃300
𝑌𝑃 = 𝜃300 − 𝑃𝑉
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 2. Power-Law Model
𝜏 = 𝐾 𝛾𝑛

𝜃600
𝑛 = 3.32 log
𝜃300

𝜃300
𝐾=
511𝑛
• Where:

𝜏 = Shear stress (dynes / cm2) • K = Consistency Index

γ = Shear rate (sec-1)

n = Power Law Index

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 2. Power-Law Model
• The constant “n” is called the POWER LAW INDEX and its value indicates the degree of non-
Newtonian behaviour over a given shear rate range.

• If 'n' = 1, the behaviour of the fluid is considered to be Newtonian. As 'n' decreases in value, the
behaviour of the fluid is more non-Newtonian and the viscosity will decrease with an increase in shear
rate. The constant “n” has no units.

• The “K” value is the CONSISTENCY INDEX and is a measure of the thickness of the mud.

• The constant 'K' is defined as the shear stress at a shear rate of one reciprocal second.

• An increase in the value of 'K' indicates an increase in the overall hole cleaning effectiveness of the
fluid.

• The units of 'K' are either lbs/100 ft2 or dynes /cm2.

• The constants n and K can be calculated from Fann VG meter data obtained at speeds of 300 and 600
rpm.

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 3. The Herschel-Bulkley (yield-power law
[YPL]) model
• The Herschel-Bulkley (yield-power law [YPL]) model describes the rheological behaviour of
drilling muds more accurately than any other model using the following equation:

𝜏 = 𝜏𝑜 + 𝐾 𝛾𝑛
• Where:

𝜏o is fluid's yield stress (shear stress at zero shear rate) in lb/100 ft2.

K = fluid's consistency index in cP or lb/100 ft sec2

n = fluid's flow index

γ= shear rate in sec-1

• The YPL model reduces to the Bingham Plastic model when n = 1

• And it reduces to the Power Law model when 𝝉o = 0.

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 Bingham Plastic Model
• A. Pipe Flow
!".$ %
• Average Velocity (𝑉𝑎) = (ft/min)
&!

'( (*+)-'( *+ !-..!/&!(0*)

• Critical Velocity 𝑉𝑐 = (ft/min)
/&

• If Va>Vc, that mean flow is turbulent, therefore use the following equation:

..'1∗13"#/$.&% '.&(*+)$.!4
𝑃= (psi)
&(.&

• If Va<Vc, that means flow is laminar, therefore use the following equation:

4 *+ +6
𝑃= 𝑃𝑉 + (psi)
533 & $&

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 Bingham Plastic Model
• B. Annular Flow
!".$ %
• Average Velocity (𝑉𝑎) = (ft/min)
&) !78&!

'( (*+)-'( *+ !-9.!/(&) 78&)!(0*)

• Critical Velocity 𝑉𝑐 = /(&) 78&)
(ft/min)

• If Va>Vc, that mean flow is turbulent, therefore use the following equation:

..'1∗13"#/$.&% '.&(*+)$.!4
𝑃= (psi)
(&) 78&)*(&) -8&)'.&

• If Va<Vc, that means flow is laminar, therefore use the following equation:

4 *+ +6 4(0*)
𝑃 = 93,333(& ! + !!$(& (psi)
) 78&) ) 78&)

11 February 2024 Rig Hydraulics 21

 Power-Law Model
• A. Pipe Flow
!".$ %
• Average Velocity (𝑉𝑎) = (ft/min)
&!

' +
$.!.∗13( ; !"+ 1.9(5<-1) !"+
• Critical Velocity 𝑉𝑐 = / & ∗"<
(ft/min)

• If Va>Vc, that mean flow is turbulent, therefore use the following equation:

..'1∗13"#/$.&% '.&(*+)$.!4
𝑃= (psi)
&(.&

• If Va<Vc, that means flow is laminar, therefore use the following equation:

;4 1.9 +6 (5<-1) <

𝑃= (psi)
533 & & ∗ "<

11 February 2024 Rig Hydraulics 22

 Power-Law Model
• B. Annular Flow
!".$ %
• Average Velocity (𝑉𝑎) = (ft/min)
&) !78&!

' +
$.!.∗13( ; !"+ 1.9(5<-1) !"+
• Critical Velocity 𝑉𝑐 = (ft/min)
/ (&) 78&)!∗"<

• If Va>Vc, that mean flow is turbulent, therefore use the following equation:

..'1∗13"#/$.&% '.&(*+)$.!4
• 𝑃= (psi)
(&) 78&)(.&

• If Va<Vc, that means flow is laminar, therefore use the following equation:

;4 1.9 +6 (5<-1) <

• 𝑃= 533(&) 78&) (&) 78&)∗ "<
(psi)

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 Pressure Loss Across the Bit +.-..∗.0=> 1 2 ?
𝑃!"# = 𝑃$#%&'("() − 𝑃* (psi) Or 𝑃𝑏𝑖𝑡 = , Cd: is usually 0.95
3 @ ? 4A ?

• 𝑃!"# : Pressure Loss Across the bit (psi), 𝑃$#%&'("() : is equal to 𝑃*+,( (psi), and 𝑃- : Circulation Pressure (psi).

𝑃* = 𝑃. + 𝑃5 + 𝑃- + 𝑃6 + 𝑃7 (psi)
• Nozzle Velocity
8BCD
𝑉𝑛 = 33.36 (ft/s)
1
• Total Area of Nozzles
2
𝐴& = 0.32 (in2)
9A
• Nozzle Size (Diameter) (note: 3 is added because we are assuming 3 nozzles)
64
𝑑& = (in)
-:
• Nozzle Size (Diameter) in multiples of (1/32)
4𝐴
𝑑& = 32
3𝜋
11 February 2024 Rig Hydraulics 24
 Example:
Example 1:

Using the Bingham plastic and power-law models, determine the various pressure drops, nozzle velocity
and nozzle sizes for a section of 12.25 in (311mm) hole. Two pumps are used to provide 700 gpm (2650
L/min).

Data:

Plastic viscosity = 12 cP Drill pipe ID = 4.276 in, OD = 5 in, and Length = 6,480 ft

Yield point = 12 lb/100 ft2 Drill collars ID = 2.875 in, OD = 8 in, and Length = 620 ft (189 m)

Mud weight = 8.8 lb/gal

Last casing was 13.375 in with an ID of 12.565 in. 13.375 in casing was set at 2,550 ft. The two pumps are
to be operated at a maximum standpipe pressure of 2,200 psi. Assume a surface equipment type of 4.

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 Bingham Solution
P1 = 52 psi

Inside drill pipe:

Va= 938 ft/min. Vc= 357 ft/min, turbulent flow, P2 = 669 psi

Inside drill collar:

Va= 2075 ft/min. Vc= 374 ft/min, turbulent flow, P3 = 430 psi

Around drill collar:

Va= 199 ft/min. Vc= 315 ft/min, laminar flow, P4 = 10 psi

11 February 2024 Rig Hydraulics 26

 Bingham Solution
Around drill pipe (open hole):

Va= 137 ft/min. Vc= 301 ft/min, laminar flow, P5a = 31 psi

Around drill pipe (cased hole):

Va= 129 ft/min. Vc= 300 ft/min, laminar flow, P5b = 20 psi

Annular flow around drill pipe P5= P5a+ P5b = 31 + 20 = 51 psi

Pc = 1212 psi

Vn = 353.5 ft/sec.

Pbit = 988 psi

A = 0.634 in2

Nozzle size (in) = 0.52 in

Nozzle size (in multiples of (1/32)) = 16.6

Hence, select two nozzles of size 17 and one of size 16.

11 February 2024 Rig Hydraulics 27