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DRILLING FLUID HYDRAULICS

&
OPTIMIZATION
By: Titus N. Ofei
Petroleum Engineering Department
Universiti Teknologi PETRONAS, Malaysia
2016

FLOW PATTERNS (REGIMES)


&
REYNOLDS NUMBER

SPECIFIC LEARNING OUTCOME


At the end of the lecture, students should be able to:
Describe the importance of Reynolds number.

Explain the various flow regimes and the criteria in identifying them in
drilling operations.
Perform calculations on predicting flow regimes for various fluid models.

INTRODUCTION: DRILLING HYDRAULICS


This is the study of fluid flow mechanics or fluid movement and the forces
exerted by them.
In drilling engineering, drilling hydraulics or sometimes called rig hydraulics,
provide information of the pressure profiles along the wellbore.
It also provides a productive tool hydraulic calculations and optimization of
ROP to the drillers, tool pushers, engineers, students and professionals.

INTRODUCTION: DRILLING HYDRAULICS CONTD.


To optimize for efficient, safe, and cost effective drilling
operations, there must be accurate use of hydraulic energy

for:
a) Drill bit selection

b) Calculations of frictional pressure losses through the


pipe and surface equipment

INTRODUCTION: DRILLING HYDRAULICS CONTD.


c) Efficient cleaning hole cleaning of the drilling system
d) Proper utilization of mud pump horsepower

Incorrect design of hydraulic system can result in slow


ROP, inefficient hole cleaning, lost circulation, and well

blowout.

CHARACTERISTICS OF PIPE FLOW


A pipe is a closed conduit through which a fluid (liquid or
gas) flows.

A closed conduit is called pipe if is round or circular in


cross section. Circular cross section is able to withstand

higher pressure differentials without distortion.


A closed conduit is called duct if it is square in cross
section. This has lower pressure differentials across wall.

CHARACTERISTICS OF PIPE FLOW CONTD.


The liquid flowing down the conduit completely fills the
conduit.

If the liquid does not fill the conduit, the flow is called
channel flow.

Since channel is not filled, no pressure differential


occurs between the ends of the pipe.
Gravity is usually the driver of channel flow.

CHARACTERISTICS OF PIPE FLOW CONTD.

Fully filled conduit

Channel flow
Fig. 1: Pipe Flow Types

FLOW REGIMES
The flow regime can be defined as a stream of flows that have similar bed forms,
flow resistance, and means of transporting sediments. During drilling operations,
flow regimes may occur depending on the fluid properties, length and size of the
wellbore, and flow rate.
The flow regimes commonly encountered in drilling operations are laminar,
transitional and turbulent.
Laminar flow regime: the fluid behaves like a series of parallel layers moving at
uniform or near-uniform velocity. There is no large-scale movement of fluid
particles between layers. Fluid layers closer to the pipe/annulus center generally
moves faster than those nearer to the pipe wall or wellbore.

FLOW REGIMES CONTD.


Turbulent flow regime: this is characterized by velocity fluctuations among the
fluid stream particles, both parallel and axial to the mean flow stream. These
fluctuations break down the boundaries between the fluid layers, resulting in a
chaotic flow pattern.
Transitional flow regime: this exhibits the characteristics of both laminar and
turbulent regimes. It describes the often hard-to-define region where flow is
neither completely laminar nor turbulent.
Plug flow regime: often describes the low-velocity, sub-laminar condition of a
fluid moving as a homogeneous, relatively undisturbed body. It behaves as
though a solid.

LAMINAR TO TURBULENT FLOW REGIME

Fig. 2: Flow Regimes

APPLICATIONS
Laminar flow is usually preferred especially in vertical
wellbores to move cuttings up and prevent erosion
(washout).

On the other hand, turbulent flow is more desirable in


inclined and horizontal wellbores to promote hole
cleaning and prevent excessive cuttings accumulation.

APPLICATIONS CONTD.
It should be noted that flow regimes may be
difficult to identify practically, since more than
one flow regime may exist at the same point in a
system.
For example, while the main flow stream in the
annulus may exhibit laminar behavior, the
adjacent fluid at the pipe boundary may be in
turbulent flow.
Fig. 3: Flow Profiles

LAMINAR TO TURBULENT FLOW


The laminar flow has a constant uA

which is smallest.
The transitional flow has a mostly

constant uA with occasional


fluctuation.
The turbulent flow has a fluctuating
uA about some mean value. The flow
rate is the largest.
Fig. 4: Flow Regimes: Velocity versus Time

FLOW ENTRANCE REGION


What happens when fluid enters a circular pipe at a uniform velocity?

Fig. 5: Flow Entrance Region

FLOW ENTRANCE REGION CONTD.


Because of the no-slip condition, the fluid particles in the layer in
contact with the surface of the pipe come to a complete stop.

This layer also causes the fluid particles in the adjacent layer to
slow down gradually as a result of friction.

To make up for the this velocity reduction, the fluid velocity at the
mid-section of the pipe has to increase to keep the mass flow rate

through the pipe constant.

TERMINOLOGIES
Inviscid or Irrotational Region: the region in which frictional effects
are negligible (zero viscosity) and the velocity remains constant in

the radial direction.


Boundary Layer Region: the region of the flow in which the effect

of the viscous shearing forces caused by fluid viscosity are felt.


Hydrodynamic Entrance Region: the region from the pipe inlet to

the point at which the boundary layer merges with the center line.

TERMINOLOGIES CONTD.
Hydrodynamic Entry Length: the length of the hydrodynamic
entrance region.

Hydrodynamically Developing Flow: the flow profile in the


entrance region where the velocity profile develops.

Hydrodynamically Fully Developed Flow: the flow profile beyond


the entrance region in which the velocity profile is fully developed

and remains unchanged.

FLOW ENTRANCE REGION CONTD.


The velocity profile in the fully developed region is parabolic in
laminar flow.

However, the velocity profile is somewhat flatter (or fuller) in


turbulent flow due to eddy motion and more vigorous mixing in

the radial direction.


The flow is said to be fully developed when the time-averaged

velocity profile remains unchanged.

ENTRY LENGTHS
In laminar flow, the hydrodynamic entry length for water flowing in a
circular pipe is given approximately as (Shook & Roco, 1991):

, = .
For turbulent flow,

, = .

The entry length is much shorter in turbulent flow and its dependence
on the Reynolds number is weaker.

ENTRY LENGTHS CONTD.


In many pipe flows of practical engineering interest, the entrance
effects become insignificant beyond a pipe length of 10 diameters.
In limiting laminar case of = , the entry length is
For < < , the entry length can be approximated as:
< <

TYPES OF FLUIDS
There are different types of fluids. Almost all the fluids
follow the following categories:
a) Newtonian fluid: these are fluids where low molecular
weight substances exist. Examples include water, light
crude oil, organic and inorganic liquids, gases, molten
metal and salts.
A Newtonian fluid can be defined as the shear stress
directly proportional to shear rate at a constant
temperature and pressure. The proportionality constant
is called dynamic viscosity.

Fig. 3: Characteristics of Newtonian fluid

TYPES OF FLUIDS CONTD.


b) Non-Newtonian fluids: these are fluids which the
fundamental rate of shear is not proportional to the
corresponding stress and cannot be described by
single constant value of viscosity.
Examples include foams, suspensions, polymer
solutions, xanthan gum solutions and melts. NonNewtonian fluids can be categorized as i) Bingham
plastic, ii) Power law, iii) Yield power law fluids etc.
Fig. 4: Characteristics of fluid types

Reynolds Number

REYNOLDS NUMBER
Reynolds number, , is a dimensionless quantity that is used to help predict
similar flow patterns in different fluid flow situations.

The concept was introduced by George Gabriel Stokes in 1851 and Osborne
Reynolds popularized its use in 1883.
Reynolds number is defined as the ratio of inertial forces to viscous forces.

Reynolds number definition is a function fluid properties of density and viscosity,

fluid velocity and a characteristic length.

REYNOLDS NUMBER CONTD.


They are used to characterize different flow regimes such as laminar or

turbulent flow.
Laminar flow occurs at low Reynolds numbers where viscous forces are
dominant, and is characterized by smooth, constant fluid motion.
Turbulent flow occurs at high Reynolds numbers where inertial forces

are dominant. This tend to produce chaotic eddies, vortices and other
flow instabilities.

REYNOLDS NUMBER - NEWTONIAN FLUIDS


Pipe flow (field units)

= 928

=
2.4482
FLOW CRITERIA
Laminar flow: < 2100
Turbulent flow: > 4000

Transitional flow: < <

Annular flow (field units)

(2 1 )
= 757

=
2.448(22 12 )
Where in ppg;
in ft/s;
in gpm;
, 1 , 2 in inches;
in cP

REYNOLDS NUMBER - BINGHAM PLASTIC FLUIDS


Pipe flow (field units)

= 928

Annular flow (field units)

(2 1 )
= 757

6.66
= +

5 (2 1 )
= +

=
2.4482

=
2.448(22 12 )

FLOW CRITERIA
Laminar flow: < 2100
Turbulent flow: > 4000
Transitional flow: < <

Where in ppg;
in ft/s;
in gpm;
, 1 , 2 in inches;
in cP

REYNOLDS NUMBER - POWER LAW FLUIDS


Pipe flow (field units)

= 928

(1)
=
96 (1)

1
3+

0.0416

FLOW CRITERIA

upper limit of laminar flow =


lower turbulence limit =

= 89,100

(2) 0.0416
1

3+

=
2.4482
Where in ppg;
in ft/s;
in gpm;
, in inches;
in cP
in eq. cP

REYNOLDS NUMBER - POWER LAW FLUIDS


Annular flow (field units)

(2 1 )
= 757

)(1)

(2 1
=
144 (1)

1
2+

0.0208

FLOW CRITERIA

Upper limit of laminar flow =


Lower turbulence limit =

(2) 0.0208(2 1 )
= 109,000
1

2+

=
2.448(22 12 )
Where in ppg;
in ft/s;
in gpm;
, in inches;
in cP
in eq. cP

REYNOLDS NUMBER - YIELD POWER LAW FLUIDS


Parameter
Reynolds
number
Average
velocity

Constant

Flow rate

Pipe

2 3 + 1
=

1
= 1
2 + 1

Annulus

2
2

3 + 1
+
2

4 2 + 1
=

2.448 2

2
1
2
2
2(2 + 1)
2 1
+
2

3 + 1
3

2
=
0.408

1
=1
+1

2.448(22 12 )

2 2 + 1
+
2 1 2 2
1
2 2

2
2

22 12
=
0.408

Where in ppg; in ft/s; in gpm; , 1 , 2 in inches; in lbf sn/100ft2; in lbf/100ft2


Note: 1 lbf secn/100ft2 = 478.8 eq.cP

REYNOLDS NUMBER - YIELD POWER LAW FLUIDS


CONTD.
Parameter
Critical
Reynolds
number

Pipe

4 3 + 1
=

Annulus
1
1

8 2 + 1
=

Where
+ 3.93
=
;
50

1.75
=
7

If NRe < NRec, flow is laminar, otherwise, turbulent

1
1

TRANSITIONAL FLOW
A transitional flow is a mixture of laminar and turbulent flow where turbulence occurs in
the centre of the pipe or annulus and laminar flow near the edges.
It is sometimes easy to characterize the transition zone by the critical fluid velocity. It is
used to define the velocity at which the flow regime changes from laminar to turbulent.
Since no single Reynolds number defines the transitional zone, a range of critical

velocities may be necessary to determine the flow regime.


The critical velocity and flow rate for Bingham plastic model is defined as:
2 +12.34 2
1.08 +1.08

if

>

, flow is laminar

if

<

, flow is turbulent

if

= 2.448 2

flow is transitional

TRANSITIONAL FLOW CONTD.


The onset of turbulence is not immediate. There is a transitional zone in which the flow is
neither laminar nor fully turbulent.
Turbulence is promoted by rough or wavy walls, increases in pipe diameter, flow
variations and vibration.
For Power law fluids, the lower limit of the transitional flow regime occur at a Reynolds

number of 3470 1370n. The transitional flow regime extends over a Reynolds number
range of 800, its upper limit being 4270 1370n.
For non-Power law fluids, it is assumed that turbulence begins at a Reynolds number of
2000 with the criterion of the laminar friction factor of 0.008.

TRANSITIONAL FLOW CONTD.

Hanks and Pratt recommended a method for locating the critical Reynolds number for

Bingham fluids in turbulent flow as follows:


1. Calculate the Hedstrom number, which is a dimensionless number that characterizes a
Bingham fluid as:

2
2

2. Solve a cubic equation to determine the dimensionless reciprocal pressure drop, , at


the critical point, as:
16,800 = 1

3. Determine the critical Reynolds number from the equation below:

4 4
=
1
+
8
3
3

TRANSITIONAL FLOW CONTD.

END OF PRESENTATION

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