Fluid Circulating System
• Mud pump is the heart of the fluid circulating
system
• There are two types of pumps
– Centrifugal Pumps
– Positive Displacement Pumps (PDP)
• Pumps used in drilling operations are PDP
113
Schematic of Rig Circulating System for liquid drilling fluid
114
Fluid Circulating System
• Centrifugal Pumps: uses impeller to move the
fluid rather than pistons
• They are used in drilling operations to
– Supercharge mud pumps
– Solid control equipment's
115
Fluid Circulating System
• Positive Displacement Pump (PDP) preferred
over centrifugal pumps because they are
– easy to operate and maintain
– able to pump fluids with high abrasive solids and
large solid particles
– reliable and durable
– able to pump fluid and operate under wide range of
rate and pressure
116
Fluid Circulating System
• PDP composed of two major parts
– Power End
• Receives power from engines and transform the rotating
movement into reciprocating movement.
• The efficiency of the power end (Em: Mechanical
efficiency) is the efficiency of the rotating mechanical
power and it is about 90%.
– Fluid End
• Converts the reciprocating power to displace fluid with
a flow rate and pressure
• The efficiency of the fluid end (Ev: volumetric
efficiency) is the efficiency of the fluid displacement 117
Fluid Circulating System
• Drilling Rigs usually equipped with two or three pumps.
(one for backup or to run with the other pumps.
• During drilling shallow depths (surface casing section)
pumps are connected in parallel to Provide highest flow
rate necessary to clean borehole.
• During drilling deep sections, less rate is required with
higher pressure, hence only one pump is used and the
other stands as backup
• Pump size is determined b the length and the stroke of the
liner
118
Fluid Circulating System
• A basic mud pump consists of a piston (liner)
in various sizes which reciprocate inside a
cylinder
119
Fluid Circulating System
• Pump liner fits inside the pump
• For a given pump, liner has the same outer
diameter (OD) but different inner diameters
(ID).
• Large liners used for drilling shallow portions
of the well where high flow rate is needed
• Small liners used for drilling deep portions of
the well where high pressure is needed
120
Fluid Circulating System
• Mud Pumps are designed for
– Pressure Output
– Flow Rate
– Horsepower
• Fluid is discharged through pump liner and
mud pumps are designed based on number of
liner (duplex or triplex) and the discharge
actions (single or double acting)
121
Fluid Circulating System
• Single Acting Pump
– Fluid is pumped on the forward stroke
– single acting pumps has three liners (triplex
pumps)
• Double Acting Pump
– Fluid is pumped on both forward and backward
stroke
– Double acting pumps are equipped with two liners
(duplex)
122
Fluid Circulating System
123
Fluid Circulating System
The volume displaced at each forward pump stroke is
2
d L Ls
4
The volume displaced at each backward pump stroke is
2
4
d L d r Ls
2
The total volume diaplced per complete pump cycle (Pump Factor)
For Duplex Pump :
Fp Ls E v 2d L2 d r2 .........1.10
2
For Triplex Pump :
Fp 3 d L2 LS E v ..........1.11
4 124
Fluid Circulating System
• Pump flow rate (q) is obtained as
q Fp N
N : Number of cycles per unit time
• Hydraulic horsepower output of the pump (PH)
is obtained as Pq
PH .........1.12
1714
PH : Pump hydraulic power, hp
P : Discharge pressure, psi
q : Pump rate, gal/min 125
Fluid Circulating System
• Example 1.3: Compute the pump factor in
units of barrels per stroke for a double-acting
duplex pump having 6.5-inch liners, 2.5 inch
rods, 18-inch strokes and a volumetric
efficiency of 90%.
dL = 6.5”
dr = 2.5”
Ls = 18”
Ev = 90% 126
Fluid Circulating System
• Example 1.3
Fp L s E v 2d 2L d 2r
2
Fp 180.9 26.5 2.5
2
2 2
Fp 1991in 3 / stroke
1gal 231in 3 1991in 3 1gal 1bbl
3
1bbl 42gal stroke 231in 42gal
Fp 0.2052bbl / stroke 127
Drill String
• Drill pipes are the major portion of the drill
string.
• Drill pipes are classified according to API as
• Range 2 drill pipe is the Range Length
most commonly used (ft)
1 18-22
2 27-30
3 38-45
128
Capacity of Drill Pipe
• In rotary drilling the knowledge of the volume
contained in or displaced by the drill pipe is
required.
• The term “capacity” is used to refer to the cross
sectional area of the pipe or annulus.
• Capacity is reported in volumes per length units
( e.g. bbl/ft)
• The capacity of the drill pipe in terms of the pipe
inner diameter (d) is Ap = (/4) d2
129
Capacity of Drill Pipe
• The capacity of the annulus is calculated in
terms of the inner hole diameter and drill pipe
outer diameters as follow
2
Aa d 2 d1
2
4
• The displacement of a drill pipe is
2
As d1 d
2
4 130
Capacity and Displacement
Nomenclature
131
Drill Pipe Capacity
• Volume tables are used to directly obtain pipe
capacity and displacement, e.g.
– Shlumberger i-Handbook
– Halliburton eRedBook
• Pipes is defined with either an outer diameter
and weight or outer and inner diameter
132
What is the volume inside a 10,000 ft of 5”
OD, 19.50 lb/ft drillpipe?
Vp A p * L
2 2 1gal 1bbl 12in
A p d in 3
4 231in 42 gal 1ft
2 2 1gal 1bbl 12in
A p 4.276 in 3
4 231in 42 gal 1ft
A p 0.01776 bbl / ft
bbl
Vp 0.01776 10, 000 ft 177.6 bbl
ft
133
The capacity can be calculated as
d 2 (in )
Ap (bbl / ft )
1029.4
Example
For a 4.5" , 16.6 lb/ft drill pipe
3.826 2
Capacity 0.01422 bbl / ft
1029.4
Displacement
4.5 2 3.826 2
Open 0.00545 bbl / ft
1029.4
4 .5 2
Plugged 0.01967 bbl / ft
1029.4
134
Example 1.4
• Given:
– Drill pipe (OD = 5 in, ID = 4.276 in, L = 7000 ft)
– Drill Collar (OD = 8 in, ID = 2.75 in, L = 500 ft)
– Borehole is 9.875 in
• The total volume inside the drill pipe and collar is
• Vtotal = (0.01776*7000+0.00735*500) =128 bbl
• Vann = (0.0704*7000+0.0326*500)=509 bbl
135
Example 1.4 - Cont
• How many strokes required to displace the mud from
bottom hole to the surface for a triplex pump with a 9
in stroke length, a liner size of 5 in and a 95%
volumetric efficiency?
• Given:
– dL = 5 in, LS = 9 in, and Ev = 0.95
– Fp = (3 * (/4) * dL2 * LS * Ev ) / (231 * 42)
– Fp = 0.0546*0.95 = 0.05187 bbl/stroke
– Total number of strokes = 509 bbl / 0.05187 (bbl/stk)
– Total number of strokes = 9813 strokes
136
Example 1.4 - Cont
• If the pump is operating with 80 strokes per minute,
how long will it take to circulate the mud from
bottom hole to the surface?
• Answer:
– It will take 9813 strokes to circulate the mud
– Circulation time (tcirc) = 9813 strokes / (80 (strokes/min))
– tcirc = 122 min
137
138
Drop in Fluid Level
• When pulling drillstring out of hole without
filling the hole fluid level will drop and it is
require to monitor the reduction in hydrostatic
pressure
• A Dry pipe is a pipe in which the bit is not
plugged
• A Wet pipe is a pipe in which the pipe is
plugged
139
Drop in Fluid Level
Dry Pipes Wet Pipes
• h = Vdisp / (Aann + Apipe) • h = Vdisp / Aann
where
h: Drop in fluid level, ft
Vdisp :Volume displaced when pulling dry
pipe, bbl
Aann : Annular capacity, bbl/ft
Apipe : Pipe capacity, bbl/ft
140
Drop in Fluid Level
• If fluid level in the hole falls as pipe joints are
removed, a reduction in bottomhole pressure
will occur.
• Hole must be kept full as pipe joints are
removed.
• Failure to keep hole full could lead to a kick
141
Example – Drop in Fluid Level
• Given the following data for a vertical well at
after setting surface casing at a depth of 7000
ft
– Drillpipe: 5” x 4.276”
– Drill Collar: 6.25” x 2.5”, 1000 ft
– Casing: 9-5/8” x 9.00”
• Determine the drop in fluid level when pulling
15 stands of dry pipe?
• Determine the drop in fluid level when pulling
5 stands of dry drill collars? 142
Example – Drop h
in Fluid Level
ADP AS
143
Example – Drop in h
Fluid Level
Vdisp L removed A s
ft bbl
Vdisp 15std 90 0.00652
std ft
Vdisp 8.802 bbl
For dry pipe
A Ann
2
IDCSG OD 2DP
9 2 52
0.0544 bbl / ft
1029.4 1029.4
A DP 0.01776 bbl / ft [Table]
Vdisp 8.802bbl
h
A Ann A DP 0.0544 0.01776bbl / ft
h 121.97 122 ft
144
Drilling Cost Analysis
• The main function of drilling engineer is to
recommend the drilling procedure that will
yield a completed well with a safe and an in-
expensive cost as possible
• Drilling cost is broken into
– Fixed cost
– Variable cost
145
Drilling Cost Analysis
Cb Cr (tb tc tt ) $
Cf
D ft
Cf = drilling cost, $/ft Cb= cost of bit, $/bit
Cr= fixed operating cost of rig, $/hr
tb= total rotating time, hrs
tc= total non-rotating time, hrs
tt= trip time (round trip), hrs
D = footage drilled with bit, ft 146
Drilling Cost Analysis
• Examples of routine rig
operations
– drilling fluid treatment
DEPTH
– pump operation ft
– bit selection
– problems during the
drilling process
TD
DAYS or DOLLARS
147
Time Distribution of GOM Deep
Water Well
148
Example 1.5
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 9,000 ft. Determine which bit gives
the lowest drilling cost if the operating cost of
the rig is $400/hr, the trip time is 7 hours, and
connection time is 1 minute per connection.
149
Example 1.5 cont’d
Assume that each of the bits was operated at near
the minimum cost per foot attainable for that bit.
Mean
Bit Rotating Connection Penetration
Cost Time Time Rate
Bit ($) (hours) (hours) (ft/hr)
A 800 14.8 0.1 13.8
B 4,900 57.7 0.4 12.6
C 4,500 95.8 0.5 10.2
Which bit would you select? 150
Solution:
The cost per foot drilled for each bit type can
be computed using Eq. 1.16. For Bit A, the
cost per foot is
Cb Cr (tb tc tt ) $
Cf
D ft
800 400(14.8 0.1 7)
Cf $46.81/ft.
13.8(14.8)
151
Solution, cont’d
Bit A: $46.81 /ft
Bit B: $42.56 /ft
Bit C: $46.89 /ft
The lowest drilling cost was obtained
using Bit B. - Highest bit cost …but -
longest life and intermediate ROP...
152
Drilling Cost Analysis
• Drilling costs tend to increase exponentially
with depth. Thus, when curve-fitting drilling
cost data, it is often convenient to assume a
relationship between total well cost, C ($), and
depth, D (ft), given by
• C = aebD …………………..(1.17)
153
C = aebD
a = 1x105 $
b = 2 x 10-4 ft-1
Fig. 1-65. Least-square curve fit of 1978 completed well costs 154
for
wells below 7,500 ft in the south Louisiana area.
Drilling Cost Analysis
• Plotting depth vs. drilling time from past
drilling operations:
– Allows more accurate prediction of time and
cost for drilling a new well
– Used in evaluating new drilling procedures
(designed to reduce drilling time to a given depth).
155
Cost Per ft for One Entire Bit Run
Minimum Cost
156
Factors that affect Penetration Rate
• Variables
– Drill Bit
– Weight on Bit (WOB) and Rotary Speed (N)
– Bottomhole cleaning
– Mud Properties
• Fixed
– Rock Hardness
– Formation Pore Pressure
157
Assignments
Assignment 2 is assigned
Problems
1.12, 1.14 (a-g) , 1.18
158
