Mud Hydraulics

By
Prof. Abdel-Alim Hashem

Definitions
• Shear rate (sec -1): The change in fluid
velocity divided by the width of the channel
through which the fluid is flowing in
laminar flow.
• Shear stress (lb/100 ft2): The force per
unit area required to move a fluid at a
given shear rate.
• Viscosity, μ (centipoises (cp)): This is the
ratio of shear stress to shear rate.
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 Definitions
Plastic viscosity, PV (cP):
• The contribution to total fluid viscosity of a fluid under dynamic
flowing conditions.
• Plastic viscosity is dependent on the size, shape, and number of
particles in a moving fluid.
• PV is calculated using shear stresses measured at θ600 and θ300 on
the FANN 35 viscometer.
Effective viscosity, μ (cP):
• This term takes account of the geometry through which the fluid is
flowing and is therefore a more descriptive term of the flowing
viscosity.
Yield point, YP (lb/100 ft2):
• The minimum force required to initiate flow, see Bingham Plastic
model.
Yield stress (lb/100 ft2):
• The force required to initiate flow; the calculated value of the fluid's
shear stress when the rheogram is extrapolated to the y-axis at γ = 0
sec -1
• (Note a: Yield stress is a time-independent measurement and is
usually denoted in the Herschel-Bulkley (yield-power law [YPL])
3 model as and Bingham model as YP. It can also be considered a gel
strength at zero time.)

Definitions
Gel strengths (lb/100 ft2):
• This is a time-dependent measurements of the fluid’s shear stress
under static conditions.
• Gel strengths are commonly measured after 10 seconds, 10
minutes, and 30 minutes intervals.
Reynolds number, Re:
• A dimensionless, numerical term which determines whether a
flowing fluid will be in laminar or turbulent flow.
• A Reynolds number greater than 2,100 marks the of turbulent flow in
most drilling fluids.
Critical Reynolds number, Rec:
• This value corresponds to the Reynolds number at which laminar
flow turns to turbulent flow.
Friction factor (f) a:
• This dimensionless term is defined for power law fluids in turbulent
flow and relates the fluid Reynolds number to a "roughness" factor
for the pipe.
• For laminar flow (Re < 2,100), and for turbulent flow (Re > 2,100).
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 Flow Regimes
There are three basic types of flow regimes. These
are:
1. Laminar
2. Turbulent
3. Transitional
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
5 walls is at its lowest.

Flow Regimes

Laminar and turbulent flow patterns in a circular pipe

(a) laminar flow
(b) transition between laminar and turbulent flow and
(c)
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turbulent flow

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 Flow Regimes
Turbulent flow
• Occurs at high shear rates where the fluid particle move
in a disorderly and chaotic manner.
• Fluid particles are carried forward by random loops and
current eddies.
• Friction between the fluid and the channel walls is
highest for this type of flow.
• Unlike laminar flow, mud parameters are not significant
in calculating frictional pressure losses formuds in
turbulent flow.
Transitional flow
• Occurs when the fluid flow changes from laminar to
7 turbulent or vice versa.

Fluid Types
There are two basic types of fluids:
• Newtonian and non-Newtonian.
• Hydraulic models have been developed to describe the flow
behavior of these two types of fluids.
• Newtonian fluids have a constant viscosity at a given temperature
and pressure condition.
Common Newtonian fluids include
– Diesel
– Water
– Glycerin
– Clear brines
Non-Newtonian fluids
• have viscosities that depend on measured shear rates for a given
temperature and pressure condition.
Examples of non-Newtonian fluids include:
• Most drilling fluids
• Cement slurry
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 Fluid Flow

F V
 
A L

Rheological Models

• Rheological models are used to predict fluid

behaviour across a wide range of shear rates
and provide practical means of calculating
pumping (pressure) requirements.
• Most drilling fluids are non-Newtonian,
pseudoplastic fluids.
• The three rheological models that are currently
in use are:
– Bingham model
– Power law model
– Herschel-Bulkley (yield-power law [YPL]) model
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 Rheological Models

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Bingham Models
• The Bingham model describes laminar flow using the
following equation: T= YP + PV × (γ)
where
– T = measured 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
– YP = (2 × θ300) – θ600
• Following figures describe the Bingham plastic model.
• 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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 Bingham Models

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Bingham Models
• This model usually overpredicts yield stresses
(shear stresses at zero shear rate) by 40 to 90
percent.
• The following equation produces more realistic
values of yield stress (point) at low shear rates:
• YP (Low Shear Rate)= (2 × θ3) - θ6
• This equation assumes the fluid exhibits true
plastic behavior in the low shear-rate range only.

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 Power Law Model
• The Power Law model assumes that all fluids
are pseudoplastic in nature and are defined by
the following equation:
• τ = K (γ)n
• where
• τ = Shear stress (dynes/cm2)
• K = Consistency Index
• γ = Shear rate (sec-1)
• n = Power Law Index
• The parameters 'n' and 'k' describe the fluids
behavior and its degree of Non- Newtonian.
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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 behavior of the fluid is considered to be
Newtonian.
• As 'n' decreases in value, the behavior of the fluid is
more non-Newtonian and the viscosity will decrease
with an increase in shear rate.

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 Power Law Model
• 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/100ft2, dynes-sec, N/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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Power Law Model

• Hence the Power Law model is mathematically
more complex than the Bingham Plastic model
and produces greater accuracy in the
determination of shear stresses at low shear
rates.
• The Power Law model actually describes three
types of fluids, based on the value of 'n':
a. n = 1: The fluid is Newtonian
b. n < 1: The fluid is non-Newtonian
c. n > 1: The fluid is Dilatant
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 Herschel-Bulkley
(Yield-power law (YPL) Model
• This model describes the rheological behavior of drilling
muds more accurately than any other model using the
following equation: τ = τo + (K × (γ)n
Where
– τ = measured shear stress in lb/100 ft2
– τo= fluid's yield stress 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 model when n =
1 and it reduces to the power law model when τo = 0.
• The YPL model is very complex and requires a minimum
of three shear-stress/shear-rate measurements for a
solution
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Herschel-Bulkley
(Yield-power law (YPL) Model

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 Hydraulics Calculations

By
Prof. Abdel-Alim Hashem

21

Contents
• Pressure losses
• Surface connection losses
• Pressure drop across the bit
• Optimization of bit hydraulics
• Surface pressure drop
• Hydraulic criteria
• Comparison of BHHP and IF
• Optimum flow rate
• Field methods for optimizing bit hydraulics
• A practical check of the efficiency of bit hydraulic
program
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 Pressure Losses
• The circulation system consists of: pump, surface
connections (stand pipe, hose, swivel and Kelly), drill
pipe, drill collars, bit, annulus between drill collars and
hole, annulus between drill pipe and hole, mud return
lines, and mud tanks.
• Friction of fluid through these parts causes pressure
losses
• Calculation depend on four parts
– Surface connection losses
– Pipe losses
– Annular losses
– Losses across the bit
• Losses depend on the type of fluid used and the type of
flow
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Surface Connection Losses

• Losses caused through surface connections
• Depend on the geometry and dimensions of surface
connections
• Dimensions can vary with time
• Evaluated by:

• P1 = E0.8Q1.8(PV)0.2 psi or bar

– P1 = pressure loss, psi or bar
–  = Density, ppg or kg/l
– Q = flow rate, gpm, l/min
– PV = plastic viscosity, cp
– E= constant depends type of surface connections

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 Value of E
Surface Value of E
Equipment Imperial Metric Units
Type Units
1 2.5x10-4 8.8x10-6
2 9.6x10-5 3.3x10-6
3 5.3x10-5 1.8x10-6
4 4.2x10-5 1.4x10-6
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Four Types of Surface Equipment

Surface Stand Pipe Rotary Hose Swivel Kelly

Equipment Length ID Length ID Length ID Length ID
Type (Ft) in (Ft) in (Ft) in (Ft) in

1 40 3.0 40 2.0 4 2.0 40 2.25

2 40 3.5 55 2.5 5 2.5 40 3.25

3 45 4.0 55 3.0 5 3.5 40 3.25

4 45 4.0 55 3.0 6 3.0 40 4.00

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 Pipe and Annular Losses
• Pipe losses takes place inside drill pipe and drill collars
• They are designated as P2 and P3
• Annular losses takes place around drill collars and drill
pipe
• They are designated as P4 and P5
• The magnitude of these pressures depends on
– Dimension of pipe
– Mud rheological properties, weight, plastic viscosity,
and yield point
– Type of flow, laminar or turbulent
• Several models exist to measure pressure losses
• Only two are models will be used: the Bingham
plastic and the power law
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Bingham Plastic Model: Pipe Flow

• Determine average velocity
V a  24.5Q ft / min
D2
• Determine critical velocity
97PV  97 (PV )2  8.2 D 2Y P
Vc  ft / min
D
• If Va > Vc, flow is turbulent; use
5  0.8Q1.8( PV )0.2 L
P  8.91x10 psi
D 4.8
• If Va < Vc, flow is laminar; use
P L YP  (PV )Va  psi
300D  5D 
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Bingham Plastic Model: Annular Flow
• Determine average velocity
Va  24.5Q ft /min
Dh 2 OD p 2

• Determine critical velocity

97PV  97 (PV )2  6.2 D 2Y P
Vc  ft / min
 (D h OD p )
• If Va > Vc, flow is turbulent; use
5 0.8 1.8
P  8.91x10  Q (PV ) L psi
0.2
(Dh  OD) ( Dh  OD)
3 1.8

• If Va < Vc, flow is laminar; use

P L(PV )Va 
L(YP)
psi
60,000(Dh  OD)2 200(Dh OD) 2

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Power Law Model: Pipe Flow

   
• Determine n and k n  3.32log  600  k  300n
 
(511)
(1/(2n ))  300 
 5.82(104 )k  (n /(1n ))
1.6 3n 1
Vc   . .  ft /min
    D 4n 
 
• If Va > Vc, flow is turbulent; use
5 0.8 1.8
P  8.91x10  Q (PV ) L psi
0.2
D 4.8
• If Va < Vc, flow is laminar; use
P  kL 1.6Va . (3n 1)  psi
n
 

300D  D 4n 

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Power Law Model: Annular Flow
   
• Determine n and k n  3.32log  600  k  300n
 
(511)
Va  24.5Q ft /min  300 
Dh 2 OD p 2
(1/(2n )) (n /(1n ))
 3.878(104 )k   2n 1  
.
2.4
Vc   .  ft /min
    (D h OD p )  3n  
 

• If Va > Vc, flow is turbulent; use

8.91x 105  0.8Q 1.8 ( PV )0.2 L
P psi
(D h  OD p )3 (D h  OD p )1.8
• If Va < Vc, flow is laminar; use
n
 
. (2n 1)  psi
kL 2.4V a
P 
300(D h OD p )  (D h OD p ) 3n 
 
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Pressure Loss Across Bit

• Need to be optimized to achieve maximum
cleaning
• For given length of drill string and given mud
properties, pressure from 1 to 5 remain constant
• The smaller the nozzle the greater the pressure
drop
• For soft formation, large nozzle is required
• To calculate pressure loss across and nozzle
size use
P P  (P  P  P  P  P )
bit standpipe 1 2 3 4 5
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 Pressure Loss Across Bit
• Nozzle velocity
P
V n  33.36 bit
 ft / s

• Total area of nozzles

A  0.32 Q in 2
Vn
33

Pressure Loss Across Bit

• Nozzle size 
dn   4 A .32


3 
• OD = outside diameter, in
• D = inside diameter, in
• L = length, ft
• V = velocity
• ρ = density, ppg
• PV = plastic viscosity, cp
• YP = yield value, lb/100ft2

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 Optimizing Bit Hydraulics
• All hydraulic programs start by calculating
pressure drops in the various parts of the
circulating systems
• The pressure loss in the circulating system,
except bit, is given the symbol Pc
• Several hydraulic slide rules are available for
calculating Pc
• The slide rule is inadequate for calculating
annular pressure loss
• Either annular pressure loss is beyond the sale
or flow is laminar and most slide rules used
turbulent flow
35

Surface Pump Pressure

• The system pressure shoes how much pressure loss can
be tolerated at bit
• The value of Pbit is controlled by the maximum allowable
surface pump pressure
• Most rigs have limits on maximum surface pressure with
high volume rates (500 gpm)
• On land rigs typical limits on surface pressure are in the
rang 2500 to 3000 psi for well depth of around 12000 ft
• For deep wells, heavy-duty pump can give 5000 psi
surface pressure
• Therefore, optimization of bit hydraulics is necessary

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 Hydraulic Criteria
• Two criteria for optimization
– Maximum bit hydraulic horsepower (BHHP)
– Maximum impact force (IF)
• Each criteria yields different value of bit pressure
loss
• Engineer is faced with the task to decide which
one to choose
• In most drilling operations the circulation rate is
kept constant
• Pbit is the factor to be optimized

37

Maximum Bit Hydraulic Horsepower

• The bit pressure is the difference between stand
pipe pressure and Pc
• For optimum hydraulic Pbit must be fraction of
stand pipe pressure
• Surface hydraulic horsepower (HHPs) is the sum
of hydraulic horse power at bit (BHHP) and
hydraulic horsepower in the circulating system
(HHPc)
• BHPs= BHHP + HHPc
• BHHP = BHPs - HHPc
• Hence HHP = PQ/1714

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Maximum Bit Hydraulic Horsepower
• Then PQ PQ
BHHP  s  c
1714 1714
• Pc = KQn
• K = constant
• n = index represents degree of turbulence
in the circulating system
• Differentiating equation with respect to Q
• Ps = (n+1)KQn

39

Maximum Bit Hydraulic Horsepower

• Ps = (n+1) Pc
• Also
P  n Ps
bit n 1
• Pc = Ps - Pbit
• The value of n falls in the range 1.8 – 1.86
• For n = 1.86, Pbit = 0.65 Ps
• This means the for optimum hydraulic
horsepower, the pressure drop across the
bit is 65% of surface pump pressure
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Maximum Bit Hydraulic Horsepower
• The actual value of n can be determined in
fields by running the pump pressure at
several speeds and reading the resulting
pressure
• A graph of Pc=(Ps – Pbit) against Q is then
drawn
• The slope of the graph is taken as the
index n

41

Maximum Bit Hydraulic Horsepower

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 Maximum Impact Force

P  n Ps
bit n  2
• Impact force is given by
Q P
IF  bit
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Comparison of BHHP and IF Criteria

• The ratio R, of pressure drop across bit is given
by the BHHP criteria and IF criteria
• The following table shows the value of n and R
• It shows that R decreases parabolic ally with
increasing value of n, but never assumes unity
• It means that the pressure loss calculated by
BHHP is greater than that calculated by IF
n P
R  n 1 s n P
n2 s
or
R  n2
44
n 1

22
Comparison of BHHP and IF Criteria

R as a function of n
N R
1 1.50
1.2 1.45
1.5 1.4o
1.8 1.36
2.0 1.33
45

Optimum Flow Rate

• Optimum flow rate is obtained by plotting
circulating pressure versus Q
• The intersection of optimum Pc with the
curve gives the optimum flow rate

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 Field Method of Optimizing Bit
Hydraulics
• Prior to POH current bit for next bit change, run the
pump at four or five speeds and record the resulting
stand pipe pressure
• From current nozzle size and stand pipe pressure and
mud weight determine pressure loss across the bit
• Subtract Pbit from stand pipe pressure to get Pc
• Plot a graph of Pc against Q on log-log paper and
determine the slope to get n
• For the next bit run calculate Pbit using BHHP or IF
equations
• Select nozzle size to for the value of Pbit calculated
• For particular rig and field the index n will not vary widely
if the same parameters are used

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End

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