4 Optimization

Drilling Engineering
Drilling Engineering PE 311
Drill Bit Optimization
Prepared by: Tan Nguyen

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


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


Maximum Nozzle Velocity
Flow velocity through bit nozzle
pbit
vn vn pb
8.074 10 4
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
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 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.


The Pump Pressure is expended by:
1.Frictional pressure losses in the surface equipment, ps
2.Frictional pressure losses in the drillpipe, pdp, and drill collars, pdc
3.Pressure losses caused by accelerating the drilling fluid through the nozzle
4.Frictional pressure losses in the drill collar annulus, pdca, and drillpipe annulus, pdpa
Ppump ps pdp pdc pdca pdpa pbit
Let: Pf ps pdp pdc pdca pdpa


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:
Ppump pbit p f
It is well know that the frictional pressure loss is a function of flow rate and can be expressed as
1.75
dp 0.75 v 0.25 0.75 q1.75 0.25
0.25

dL 1800d 8624d 4.75
p f q1.75


Hence, pd can be expressed as
p f cq m
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
pbit p pump cq m
The bit Hydraulic horsepower
m 1
pbit q p pump q cq
PHb
1714 1714


Bit horsepower is a function of flow rate
m 1
pbit q p pump q cq
PHb
1714 1714
The bit horsepower reaches maximum when:
pbit q
d
dPHb 1714 p pump (m 1)cq m
0
dq dq 1714
Or
p pump (m 1)cq m (m 1)p f

p pump
p f
m 1


Bit hydraulic horsepower is a maximum when
p pump
p f
m 1
Since
p pump
The hydraulic horsepower will be maximum at p f
m 1
p f 1
Or:
p pump m 1


Maximum Jet Impact Force
Jet impact force is a function of pbit = ppump pf . Note that pf is the total pressure loss in
pipes and annuli.
F j 0.01823 cd q pbit 0.01823 c d q ( p pump p f )
With p f cq m then
F j 0.01823 cd p pump q 2 cd q m 2


Maximum Jet Impact Force
The impact force is maximized when,

dF j
0
dq
Solve the above equation yields,
2 p f 2
p f p pump or
m2 p pump m2
Since , the jet impact force will be maximum atp 2

f p pump
m2


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
1714 PHP E
q max
p max
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 pd/pp at the optimum value. Then
the flow rate will be reduced to the minimum value which it can still lift the cuttings.


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.


p pump q
Nozzle Size
PH Selection log(
Graphical
p ) Analysis
log(1714 PH ) log(q )
1714 pump
Slope -1
Slope 1.75
dp 0.75 q1.75 0.25

dL 8624d 4.75


1. Show opt. hydraulic path
2. Plot pf vs q
3. From Plot, determine optimum q and pf
4. Calculate pbit p pump p f
8.311 *10 5 qopt

2
5. Calculate total nozzle area ( At ) opt 2
Cd (pb ) opt
6. Calculate Nozzle Diameter


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.


Example
Pressure drop through the bit:
8.311 *10 5 q 2 8.311 *10 5 * 9.6 * 4852

pb1 2 2
2
1894 psig
cd At 12
2
2
0.95 * 3 * *
4 32
8.311 *10 5 q 2 8.311 *10 5 * 9.6 * 247 2
pb 2 2 2
491 psig
cd At 2 2
2
12
0.95 * 3 * *
4 32
Total frictional pressure loss inside the drillstring and in the annulus at different flow rate:
p f 1 p pump pbit 2800 1894 906 psig
p f 2 p pump pbit 900 491 409 psig


Example
m = 1.2, for optimum hydraulics
1,714 PHp E 1,714(1,250)(0.91)

Interval 1: q max 650 gal/min
Pmax 3,000
2 2
Interval 2: p f
max
P (3,000) 1,875 psig
m2 1.2 2
Interval 3: q min 225 gal/min


Example


Example
From graph, the optimum point:
gal
qopt 650 , p f 1,300 psi pbit 1,700 psi
min
The proper total nozzle area is:
8.311 *10 5 qopt

2
8.311 *10-5 * 9.6 * (650) 2
( At ) opt 2
2
0.47 in 2
Cd (pbit ) opt (0.95) * (1,700)
The nozzle size
4 At 14
d N opt 32 in
3


Example
gal
qopt 650 , p d 1,300 psi
min

Optimization of Economics
Cost-per-foot Calculation
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 D is the total depth as a given total time, ft.

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.

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.
Bit Bit cost Rotating time Connection time Mean penetration rate
$ hours hours ft/hr
A 800 14.8 0.1 13.8

B 4900 57.7 0.4 12.6
C 4500 95.8 0.5 10.2

Bit cost Rotating time Connection time Mean ROP Total cost
Bit
$ hours hours ft/hr $/ft
A 800 14.8 0.1 13.8 46.80768
B 4900 57.7 0.4 12.6 42.55729
C 4500 95.8 0.5 10.2 46.89099

Run Cycle Speed
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.

Break-even Analysis

Break-even Analysis

Break-even Analysis

Termination of a Bit Run
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.

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.

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, D drilling time, tb + to Drilling Cost, C

Remarks
ft hrs $/ft
0 0 New 0.0
30 2 1766.7
50 4 1220.0
65 6 1061.5
77 8 1000.0
87 10 977.0
96 12 968.8
104 14 971.2
111 16 Torque Increased 982.0


ttotal = tt + te
te = Cb/Cr


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.
drilling time
Footage, D ft Remarks
tb + to, hrs
0 0 New
30 2
50 4
65 6
77 8
87 10
96 12
104 14
111 16 Torque Increased

Solution:
Cb = 5000 USD
Cr = 4000 $/hr
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.


4 Optimization

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4 Optimization

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Drilling Engineering

Drilling Engineering PE 311

Drill Bit Optimization

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Most commonly used hydraulic design parameters are:

Bit nozzle velocity

Bit hydraulic horsepower

Jet impact force

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

: The tangent to the curve

Solve this equation we can get the critical

The function has a minimum value at x = b if

The function has a maximum value at x = a if

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Flow velocity through bit nozzle

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

The Pump Pressure is expended by:

1.Frictional pressure losses in the surface equipment, ps

Ppump ps pdp pdc pdca pdpa pbit

Let: Pf ps pdp pdc pdca pdpa

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Pressure drop across the bit

The bit Hydraulic horsepower

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Bit horsepower is a function of flow rate

p pump (m 1)cq m (m 1)p f

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Bit hydraulic horsepower is a maximum when

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

F j 0.01823 cd q pbit 0.01823 c d q ( p pump p f )

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

The impact force is maximized when,

Since , the jet impact force will be maximum atp 2

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

For a given pump horsepower rating P HP

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

Prepared by: Tan Nguyen

Optimization of Hydraulic Parameters

1. Show opt. hydraulic path

3. From Plot, determine optimum q and pf

4. Calculate pbit p pump p f

8.311 *10 5 qopt

6. Calculate Nozzle Diameter

Prepared by: Tan Nguyen

8.311 10 5 q 2 8.311 10 5 * 9.6 * 4852