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By Thomas P. Mahoney

Phelps Dodge Corporation's Tyrone Mine is a large open pit copper operation located in the southwestern corner of New Mexico. The Tyrone concentrator processes approximately 50,000 tons per day of copper ore. The waste ratio for this operation is 3:1; e.g., for every one ton of ore mined, three tons of waste material are also removed. This results in a mining rate of about 200,000 tons per day.

Jan 1, 1986

By Richard H. Willey

EFFICIENT handling of large tonnages in open-pit mining demands, primarily, an abundance of well fragmented rock. To accomplish this, a drilling and blasting department composed of a well-knit, versatile group of workers and supervisors must be established. Some costs will remain relatively on the same level over a period of years, while others can be greatly lowered as will be shown. The Utah Copper Division, Kennecott Copper Corp., Bingham Canyon, Utah, has been ever alert for improvements in operating methods and equipment to gain increased efficiency and lower costs. BINGHAM CANYON MINE The greatest dimension of the mine is 8000 ft northeast-southwest with a width of 5000 ft southeast-northwest. From the lowest level, at an elevation of 6040 ft above sea-level, the mountain rises in 27 benches on the west side to W level (elevation 7800 ft) and 21 benches on the east side to Q level (elevation 7460 ft). At the inception of open-pit mining in 1906, the overcapping of leached porphyry had to be removed to reach a commercial grade of sulphide ore. The overcapping or waste now remaining is quartzite with intercalated limestone beds. The limestones are usually soft in nature except in the south-middle portion of the mine where they have been metamorphized along the contact zone. This area usually gives drilling and blasting operations a great deal of trouble. Here occurs the greatest amount of secondary blasting, as the well-established fracture planes cause the altered beds to break into large boulders. Several massive quartzite "ribs" occur in the overburden, and as a result, the uniform breakage is difficult to obtain. The major quartzite areas have been subjected to complex folding, fracturing and faulting because of the intrusion of the underlying stock. The monzonite porphyry, which carries the commercial values, presents no serious drilling problem because of its softness and extensive minute fracturing throughout the mass. A series of major slips or faults pass through the ore body which, although of considerable advantage to the drilling and blasting department, sometimes works to the disadvantage of the track department. Drilling and blasting of the porphyry apparently becomes easier as depth is attained, but highly siliceous streaks throughout the pit still present difficulties. At no place is the rock of such character as to allow excavation without preparations. On certain higher elevations or levels, old fill material can be dug by the shovels, but only at some risk to equipment because of bank slippage. PAST METHODS At the outset of shovel operations in 1906, drilling was done with the Ingersoll-Rand F-24 piston drill mounted on an un-

Jan 1, 1947

By L. van Hijfte, A. Piché

"Drilling and blasting are fundamental operations in the mining cycle and constitute an important component of the mining costs. Problems associated with improper drilling and blasting practices can create losses of several millions of dollars per year. For this reason, a Blasting Technology program was initiated in 1984 at the Noranda Technology Centre (NTC). In this paper, advances made at NTC in drill and blast technology are reviewed. Impacts of drilling and basting for Noranda are assessed in terms of dilution and ore losses. Future challenges are addressed. IntroductionUp to 1997, Noranda was a diversified natural resources company that operated in three sectors: mining and metallurgy, forest products, and oil and gas. The company employs more than 33 000 people in operations and sales offices around the world. Today, Noranda has returned to its roots in mining and metallurgy. The new vision of Noranda is to be dedicated to the responsible and profitable development of mineral resources around the world for the benefit of its shareholders. In so doing, Noranda will continue to be deeply committed to the environment, health, workplace safety, cost competitiveness and return on capital. Technology is an integral part of Noranda’s success strategies. For this reason, the Noranda Technology Centre, formerly known as Noranda Research Centre, was founded in 1963. Since then, it has undergone four expansion phases to keep up with the increasing needs of the businesses. Today, NTC employs more than 220 specialists who work in partnership with different Noranda companies to identify, develop, and transfer technology to the operations, as well as to explore new sectors of activity."

Jan 1, 2000

By Richard W. Amerman

The final cost and quality of a project employing equipment, labor, and materials is dependent upon the expediency and extent to which each of these parameters are used. An ideal solution then, would be one in which three solvable equations were given for each particular situation. The equipment, labor, and materials could then be solved for, and the perfect job would result. In reality, however, the ideal and most economical solution is seldom attainable by solving three given equations. Therefore, knowledge, experience, and sometimes guesswork must be relied upon when correlating equipment, labor, and materials. Drilling and blasting, in particular, is one operation which normally involves more uncertainty than other operations. It is also an operation in which the outcome is extremely critical for two reasons. First, the cost of the operation that follows drilling and blasting is dependent upon how well the material is fragmented. Second, once the drilling and blasting has taken place, it is impossible to return to the area, without considerable expense, and correct any mistakes that might have been made. Therefore, what is desired is a method by which drilling and blasting operations can be performed yielding optimum results at the lowest cost; this can best be accomplished by having the relationships between equipment, labor, and materials prior to their use. For obtaining best results, the selection of these three relationships must be based on knowledge, experience, and as little guesswork and uncertainty as possible.

Jan 1, 1969

By Darrel W. Hansen

Morrow Point Dam and Power Plant are principal features of the Bureau of Reclamation's Curecanti Unit of the Colorado River Storage Project. They are under construction on the Gunnison River 20 miles east of Montrose, Colo. Johnson-MK is the prime contractor, and represents a joint venture of Al Johnson Construction Co., Minneapolis, Minn., and Morrison-Knudsen Co., Inc., Boise, Idaho. The power plant will be housed in an underground chamber in the left abutment, approximately 250 ft behind the original canyon wall. The chamber is 206 ft long and 57 ft wide. The distance from the foundation to the spring line of the roof arch varies from 51 ft in the service bay to 120 ft in the control bay. The roof arch has a rise of 16 ft. The longitudinal center line of the chamber is orientated east-west with the draft tubes discharging nearly due north. Access to the power plant chamber was possible through the cable tunnel, access tunnel, two draft tube tunnels, two penstock tunnels, exploratory tunnel, which became the ventilation tunnel, or the grouting and drainage tunnel leading to the dam. (See Fig. 1.) The shortest and fastest access was through the cable and access tunnels, and the contractor drove these two tunnels simultaneously. The cable tunnel and cable gallery excavation exposed a transverse section, at the west end of the chamber, that was 15 ft wide and extended from the crown to 5 ft below spring line. It was here that arch excavation began. The first 34 ft of advance along the arch was driven on three headings, and the muck was removed through the cable tunnel. Meanwhile, the access tunnel was completed, and a raise was driven from its crown to intersect the advancing arch excavation near the longitudinal centerline

Jan 1, 1968

By Deepesh Yadav, B. S. Choudhary

Underwater drilling and blasting is conducted for deepening of sea channels for port berths, lake or reservoirs for water supply etc. so that rock dredging becomes easier. During this process there are several associated unwanted effects having potential to cause damage to surrounding structures and the environment, flora and fauna. Though all these ill effects can’t be completely eliminated but adopting controlled blasting techniques can minimize these to tolerable levels. It is recognized that ground vibrations resulting from rock blasting below water near dam may endanger the safety of earthen dams. Therefore, controlled blasting technique was used to ensure the safety of dam and its efficacy was established by monitoring of blast vibrations. The usage of small quantity of explosives confined in blast holes, non-electrical delay detonators and initiating each hole with a separate delay helped to minimize the ground vibration effects on surrounding structures.

Jan 1, 2018

By Barber J

The manganese ore of Groote Eylandt is a shallow sedimentary deposit of Cretaceous age. There are a number of deposits which vary greatly in ore texture, density, percentage of matrix and thickness. The thickness in the present five operating quarries varies from 1-5 metres. The mine output in 1973 was 3 million tonnes of which 60% was blasted, the remainder ripped and bulldozed. The shallow deposit and its varying thickness create rather unique blasting problems which must be overcome in order to produce a minimum overall mining cost but not necessarily resulting in a minimum drilling and blasting cost per tonne. Future planning envisages the introduction of site mixed slurry explosives following test work and the application of a twin boom single operator rotary percussion drill. The paper outlines the overall developments,present and envisaged practices and the reasons for these changes.

Jan 1, 1974

By T Galvin

Drilling and blasting at Westside Mine near Wallsend, NSW, has presented a challenge for Orica Explosives, Australia. The colliery produces 600 000 tonnes of steaming coal per year from two seams using surface mining techniques. Tapping into underlying coal will greatly improve the yield, but there are many issues which make this an enormous challenge. Hunter Valley Earthmoving engaged Orica Explosives to supply the explosives products and to provide much of the blasting expertise that is needed on the minesite. Hunter Valley Earthmoving and Orica Explosives have proven to be an outstanding, unified technical team on this project. The success of the team is based on good communication, progressive attitudes, extensive expertise in blast design and most importantly, care and accuracy in implementing the agreed upon designs.

Jan 1, 1999

By Lemberg D. W, Friday R. G

Potential means of lowering overall costs to permit deeper stripping include : 1. the use of larger diameter blastholes in highly-fissured strata (to reduce drilling costs); 2. dewatering from semi-permanent bores to reduce blasting costs (by maximising the use of bulk ANFO) and promote highwall stability; and 3. the use of inclined blastholes, bulk AN, staggered V1 patterns, adequate backfill and more cost-effective stemming columns. Each of these is covered. The pumping of bulk watergels continuously raises the blasthole water column, thereby perpetuating the demand for these blasting agents. This must be a principal consideration when choosing between a bulk and a packaged watergel. Any packaged product should exhibit dimensional permanence and an energy yield per metre length equal to that of bulk ANFO. Possible ways in which controlled trajectory blasting (CTB) could benefit deeper stripping operations are outlined. By allowing the maximum use of bulk ANFO, de- watering may be a prerequisite of a viable CTB Operation.

Jan 1, 1981

By John Dean Smith

In order to discuss problem solving techniques for the future. we must first review the past. This paper will discuss the drilling and blasting problems and techniques that were used by .Imax Coal in the past few years, tn those of today.

Jan 1, 1991

By Mattos J. L. C

Drilling and blasting with explosives in mining operations near communities require careful planning to mitigate socio-environmental impacts. Ground vibration, noise emission, flyrock, and dust dispersion are factors that may trigger conflicts with local populations. However, large-scale operations demand high productivity and intense material handling, making it essential to balance operational performance with impact control. The adoption of best practices, combined with advanced monitoring and mitigation technologies, enables sustainable mining even in proximity to inhabited areas. This study proposes the use of double and triple-deck blasting techniques with large-diameter boreholes (12 ¼” – 311 mm), addressing the sizing of charges and decks, as well as measures aimed at reducing noise perceived by nearby communities. The approach seeks to maintain the use of large drilling rigs already present in the operation, avoiding costs related to premature equipment replacement or expensive alternatives, while minimizing environmental and social impacts and promoting a more balanced and responsible mining model.

Jan 26, 2026

By William D. Hissem

The purpose of this paper is to advise people about the methods, use, and possible applications of current "personal computer" hardware and software with regard to the economic cost analysis of percussion drilling equipment. The material content and orientation of this paper is toward those people who have just begun "PC" (personal computer) operations, and (or) those who are considering their use.

Jan 1, 1986

By Joel Moskowitz

In 1990, the United States General Services Administration (GSA) issued a contract for design and construction of a new federal court building in New York City. Mueser Rutledge Consulting Engineers (MRCE) served as Project Geotechnical Engineers. The project site is in the historic government district at Foley Square. It is surrounded by the New York County Courthouse to the west, an existing federal prison building and federal courthouse across Pearl Street to the south and southwest, an office structure to the north, and a residential tower to the east. The interior of the site was crossed by streets which have now been demapped. As with many urban sites, this site was previously occupied by tenement buildings or industrial structures demolished near the turn of the century. Remains of old building foundations were exposed during construction excavation. In addition, buried fuel oil tanks servicing the adjacent courthouse were removed and the usual assortment of urban utilities had to be relocated for the new building foundations. Ground surface elevations vary from about 4.5 to 6 m above the local Mean High Water Datum Plane.

Jan 1, 1996

By B. E. Morgan, C. K. Dumbauld

The need for a low-strength cementing composition for use in well cementing is reviewed and results are presented of laboratory and experimental field tests of a modified cement having a controlled ultimate tensile strength of approximately 200 psi. The modified cementing composition may he prepared from either high early strength or normal portland cements by the addition of bentonite clay and a suitable agent for dispersing and controlling the set of the slurry. Substitution of the modified cement for conventional slow-set cements may give better completion results in many wells because the modified cementing composition has lower set strength, lower slurry density, and greater slurry stability than conventional cement slurrieh. The lower ultimate strength allows greater penetration with less shattering of the set cement when perforating casing and cement. The lower elurry density allows the placement of longer columns of cement slurry, and the greater slurry stability reduces the possibility of having an uncemented section caused by the settling of cement particles before the cement set.. INTRODUCTION High strength lias always been one of the accepted criteria of a good cement. During the early use of portland cement in well cementing. emphasis was placed upon securing cements with higher strengths. In 1931, Barkis' reported that, "Normal oil well cements have been improved to develop greater strengths and uniformity of product, which has aided in producing successful jobs in cementing the deeper strings." As long as most wells were completed by the open-hole method. the use of cements having high strengths seemed desirable, and there was no objection raised against high-strength cementing compositions. For a number of years. how-ever, the industry has been completing a large numher of wells by setting and cementing casing through productive horizons and then obtaining production by gun-perforating the section of casing opposite the desired interval. Although this method has been generally successful, difficulties have been experienced in some cases in completing or recompleting wells because of apparent lack of adequate penetration by the bullets through the casing and surrounding sheath of cement and into producing formation. In addition to the penetration trouble: there have been indications that fracturing and shattering of the set cement by perforating might he a contributing factor in causing the failure of some jobs to exclude water or gas from oil producing zones. The possibility that cements having high set strengths were contributing to til difficully ill obtaining satihfartory perforating results has re. ceived attention during recent years. Gun perforating tests conducted in 1944 showed that the depth of bullet penetration into set cement varied with the hardness of the cement, the greater the strength of the cement the less being the penetration. In 1946, Farris2 pointed out that high strength cements were not needed in well cementing, and in 1947, data published by Oliphant and Farris3 showed that set cement was perforated without shattering at approximately 150 psi tensile strength. whereas at approximately 300 psi tensile strength severe cracking and shattering occurred. Oliphant and Farris suggested that wells be perforated at the proper time interval after placement of the cement so that the set cement would have the desired strength. Several difficulties may he encountered in trying to perforate a cement job at the correct time to catch the tensile strength near 150 psi. The rate of strength development of different cements varies considerably. This fact is illustrated by results of tensile strength measurements presented in Fig. 1. These data show that at 175°F the tensile strengths of three conventional slow-set cements varied from 75 to 235 psi at the end of 12 hours. After 24 hours, the tensile strengths varied from 200 to 455 psi. The rate of strength development is affected. also. by the temperature of the forniation, and this adds to the uncertainty of perforating at the rorrect time, since accurate well cementing temperatures may not he known in many cases. Furthermore, in the recomple-tion of wells it is sometimes necessary to perforate cement which has set for a long period and has developed maximum or final strength. In view of the apparent need for a cementing composition having a controlled ultimate strength, an investigation was

Jan 1, 1951

By C. K. Dumbauld, B. E. Morgan

The need for a low-strength cementing composition for use in well cementing is reviewed and results are presented of laboratory and experimental field tests of a modified cement having a controlled ultimate tensile strength of approximately 200 psi. The modified cementing composition may he prepared from either high early strength or normal portland cements by the addition of bentonite clay and a suitable agent for dispersing and controlling the set of the slurry. Substitution of the modified cement for conventional slow-set cements may give better completion results in many wells because the modified cementing composition has lower set strength, lower slurry density, and greater slurry stability than conventional cement slurrieh. The lower ultimate strength allows greater penetration with less shattering of the set cement when perforating casing and cement. The lower elurry density allows the placement of longer columns of cement slurry, and the greater slurry stability reduces the possibility of having an uncemented section caused by the settling of cement particles before the cement set.. INTRODUCTION High strength lias always been one of the accepted criteria of a good cement. During the early use of portland cement in well cementing. emphasis was placed upon securing cements with higher strengths. In 1931, Barkis' reported that, "Normal oil well cements have been improved to develop greater strengths and uniformity of product, which has aided in producing successful jobs in cementing the deeper strings." As long as most wells were completed by the open-hole method. the use of cements having high strengths seemed desirable, and there was no objection raised against high-strength cementing compositions. For a number of years. how-ever, the industry has been completing a large numher of wells by setting and cementing casing through productive horizons and then obtaining production by gun-perforating the section of casing opposite the desired interval. Although this method has been generally successful, difficulties have been experienced in some cases in completing or recompleting wells because of apparent lack of adequate penetration by the bullets through the casing and surrounding sheath of cement and into producing formation. In addition to the penetration trouble: there have been indications that fracturing and shattering of the set cement by perforating might he a contributing factor in causing the failure of some jobs to exclude water or gas from oil producing zones. The possibility that cements having high set strengths were contributing to til difficully ill obtaining satihfartory perforating results has re. ceived attention during recent years. Gun perforating tests conducted in 1944 showed that the depth of bullet penetration into set cement varied with the hardness of the cement, the greater the strength of the cement the less being the penetration. In 1946, Farris2 pointed out that high strength cements were not needed in well cementing, and in 1947, data published by Oliphant and Farris3 showed that set cement was perforated without shattering at approximately 150 psi tensile strength. whereas at approximately 300 psi tensile strength severe cracking and shattering occurred. Oliphant and Farris suggested that wells be perforated at the proper time interval after placement of the cement so that the set cement would have the desired strength. Several difficulties may he encountered in trying to perforate a cement job at the correct time to catch the tensile strength near 150 psi. The rate of strength development of different cements varies considerably. This fact is illustrated by results of tensile strength measurements presented in Fig. 1. These data show that at 175°F the tensile strengths of three conventional slow-set cements varied from 75 to 235 psi at the end of 12 hours. After 24 hours, the tensile strengths varied from 200 to 455 psi. The rate of strength development is affected. also. by the temperature of the forniation, and this adds to the uncertainty of perforating at the rorrect time, since accurate well cementing temperatures may not he known in many cases. Furthermore, in the recomple-tion of wells it is sometimes necessary to perforate cement which has set for a long period and has developed maximum or final strength. In view of the apparent need for a cementing composition having a controlled ultimate strength, an investigation was

Jan 1, 1951

By George C. Howard, P. P. Scott

During the drilling of wells, fractures which are created or widened by drilling fluid pressure are suspected of being a frequent cause of lost circulation. A study of the variables which are believed by the authors to he related to fracturing led to the premise that the presence of an effective lost circulation material in a drilling mud stream would serve to plug small fractures at the moment they are encountered or created and thereby a a possible cause of lost Circula. tion by preventing fluid pressure from widening and extending the fractures. A large number of lost circulation materials were classified and tested in simulated fractures and in shallow wells. Granular type materials with a gradation of particle sizes were found to be the most effective for plugging. Within the limits of pumpahility, the concentration in mud of each lost circulation material tested was found to be a controlling factor in determining the maximum size fracture which could be sealed. A new type centrifugal sorter was given preliminary tests and found to be capable of concentrating cuttings for rejection and reclaiming lost circulation materials. INTRODUCTION The control and prevention of lost circulation of drilling fluids is a problem frequently encountered during the drilling of oil and gas wells. Lost circulation or lost returns may be defined as the loss to formation voids of the drilling fluids or cement slurries used in the process of rotary drilling and well completion. The loss may vary from n gradual lowering of mud level in the pits to a complete loss of returns. Not to be confused with lost circulation is the continuous reduction in mud volume caused by the loss of the fluid phase of muds as filtrate and the solid phase as filter cake during the continuous filt~ation process which occurs on permeable formation surfaces. The loss of drilling fluids and their costly constituents is only one of the detrimental effects experienced when circulation is lost. The loss of drilling time, plugging of potentially productive formations, stuck drill pipe, blow-outs, excessive inflow of water, and excessive caving of formatioils are other effects which contribute to make the control and prevention

Jan 1, 1951

By P. P. Scott, George C. Howard

During the drilling of wells, fractures which are created or widened by drilling fluid pressure are suspected of being a frequent cause of lost circulation. A study of the variables which are believed by the authors to he related to fracturing led to the premise that the presence of an effective lost circulation material in a drilling mud stream would serve to plug small fractures at the moment they are encountered or created and thereby a a possible cause of lost Circula. tion by preventing fluid pressure from widening and extending the fractures. A large number of lost circulation materials were classified and tested in simulated fractures and in shallow wells. Granular type materials with a gradation of particle sizes were found to be the most effective for plugging. Within the limits of pumpahility, the concentration in mud of each lost circulation material tested was found to be a controlling factor in determining the maximum size fracture which could be sealed. A new type centrifugal sorter was given preliminary tests and found to be capable of concentrating cuttings for rejection and reclaiming lost circulation materials. INTRODUCTION The control and prevention of lost circulation of drilling fluids is a problem frequently encountered during the drilling of oil and gas wells. Lost circulation or lost returns may be defined as the loss to formation voids of the drilling fluids or cement slurries used in the process of rotary drilling and well completion. The loss may vary from n gradual lowering of mud level in the pits to a complete loss of returns. Not to be confused with lost circulation is the continuous reduction in mud volume caused by the loss of the fluid phase of muds as filtrate and the solid phase as filter cake during the continuous filt~ation process which occurs on permeable formation surfaces. The loss of drilling fluids and their costly constituents is only one of the detrimental effects experienced when circulation is lost. The loss of drilling time, plugging of potentially productive formations, stuck drill pipe, blow-outs, excessive inflow of water, and excessive caving of formatioils are other effects which contribute to make the control and prevention

Jan 1, 1951

By G. H. Bruce, C. E. Williams

The trend toward deeper drilling, together with the attcndant increase in power requirements for circulation of the drilling fluid, has emphasized the need for a critical examination of the factors affecting the removal of bit cuttings from the hole by the drilling fluid. The ability of drilling fluids to lift cuttings is called their carrying capacity. A series of laboratory and field experiments has been conducted to determine the minimrim annular velocity necessary to remove cuttings, and to investigate the effects of properties of drilling fluids on their carrying capacities. Consideration of the results of these experiments led to the following conclusions: 1. Turbulent flow in the well annulus is most desirable from the standpoint of cutting removal. 2. Low viscosity and low gel are advantageous in removing cuttings. 3. Increase in mud weight is effective in increasing carrying capacity. 4. The carrying capacity is higher when the pipe is rotated than when it is not. 5. If turbulent flow can be maintained, an annular velocity slightly higher than the slip velocity of the largest cuttings to be transported should keep the bore hole clean. This implies velocities of 100 to 125 ft per minute rather than the presently used 175 to 225 ft per minute. INTRODUCTION Power Savings by Reduction of Annular Velocities A large portion of the power expended in drilling operations is consumed in circulating the drilling fluid. An important factor in establishing the rate of mud circulation is the minimum velocity in the annulus necessary to remove bit cuttings. Empirically, it has been found that average annular mud velocities of about 200 ft per minute will remove cuttings. It was not definitely known, however, whether annular velocities of about 200 ft per minute were just above the minimum necessary to remove cuttings, or whether such velocities could be materially reduced without sacrifice of the ability of the mud to remove cuttings. It is apparent that if annular velocities could be reduced without impairment of cutting removal, a considerable saving in power requirements would result. Need for Research on Carrying Capacity The ability of a drilling fluid to transport cuttings is called its carrying capacity. Although it has been recognized that the carrying capacity of a mud is affected by mud properties such as viscosity and density1,2,3,4 there have been various views in the industry as to the effects of these mud properties on carrying capacity. The economic importance of the problem of carrying capacity and the scarcity of information on the subject indicated that research on the problem was needed. THE FACTORS AFFECTING CARRYING CAPACITY Qualitative Determination of Factors The mechanism of cutting transport is closely related to that involved in the separation of material by settling processes. A considerable amount of research has been done on settling problems, and discussions of sedimentation theory can be found in standard texts.5,6 Consideration of the information available from these sources, together with consideration of the mechanism of cutting transport, leads to the conclusion that the factors affecting carrying capacity are the dimensions of the system, the physical properties of the cuttings. and the physical properties of the drilling fluid. system Dimensions and Their Effect The dimensions of the fluid circulating system of importance to carrying capacity are the bore hole size, drill pipe size, pump capacity, and pump speed. These dimensions determine the annular velocity of the drilling fluid. Physical Properties and Their Effects The physical properties involved in the interaction between mud and cuttings are the density and shape of the cuttings and the density, viscosity and gel strength of the drilling fluid. The effect of the density factor on carrying capacity is fairly obvious; high density difference between cuttings and fluid results in a low buoyant force and therefore decreases carrying capacity. The effect of cutting shape is less obvious. Although

Jan 1, 1951

By C. E. Williams, G. H. Bruce

The trend toward deeper drilling, together with the attcndant increase in power requirements for circulation of the drilling fluid, has emphasized the need for a critical examination of the factors affecting the removal of bit cuttings from the hole by the drilling fluid. The ability of drilling fluids to lift cuttings is called their carrying capacity. A series of laboratory and field experiments has been conducted to determine the minimrim annular velocity necessary to remove cuttings, and to investigate the effects of properties of drilling fluids on their carrying capacities. Consideration of the results of these experiments led to the following conclusions: 1. Turbulent flow in the well annulus is most desirable from the standpoint of cutting removal. 2. Low viscosity and low gel are advantageous in removing cuttings. 3. Increase in mud weight is effective in increasing carrying capacity. 4. The carrying capacity is higher when the pipe is rotated than when it is not. 5. If turbulent flow can be maintained, an annular velocity slightly higher than the slip velocity of the largest cuttings to be transported should keep the bore hole clean. This implies velocities of 100 to 125 ft per minute rather than the presently used 175 to 225 ft per minute. INTRODUCTION Power Savings by Reduction of Annular Velocities A large portion of the power expended in drilling operations is consumed in circulating the drilling fluid. An important factor in establishing the rate of mud circulation is the minimum velocity in the annulus necessary to remove bit cuttings. Empirically, it has been found that average annular mud velocities of about 200 ft per minute will remove cuttings. It was not definitely known, however, whether annular velocities of about 200 ft per minute were just above the minimum necessary to remove cuttings, or whether such velocities could be materially reduced without sacrifice of the ability of the mud to remove cuttings. It is apparent that if annular velocities could be reduced without impairment of cutting removal, a considerable saving in power requirements would result. Need for Research on Carrying Capacity The ability of a drilling fluid to transport cuttings is called its carrying capacity. Although it has been recognized that the carrying capacity of a mud is affected by mud properties such as viscosity and density1,2,3,4 there have been various views in the industry as to the effects of these mud properties on carrying capacity. The economic importance of the problem of carrying capacity and the scarcity of information on the subject indicated that research on the problem was needed. THE FACTORS AFFECTING CARRYING CAPACITY Qualitative Determination of Factors The mechanism of cutting transport is closely related to that involved in the separation of material by settling processes. A considerable amount of research has been done on settling problems, and discussions of sedimentation theory can be found in standard texts.5,6 Consideration of the information available from these sources, together with consideration of the mechanism of cutting transport, leads to the conclusion that the factors affecting carrying capacity are the dimensions of the system, the physical properties of the cuttings. and the physical properties of the drilling fluid. system Dimensions and Their Effect The dimensions of the fluid circulating system of importance to carrying capacity are the bore hole size, drill pipe size, pump capacity, and pump speed. These dimensions determine the annular velocity of the drilling fluid. Physical Properties and Their Effects The physical properties involved in the interaction between mud and cuttings are the density and shape of the cuttings and the density, viscosity and gel strength of the drilling fluid. The effect of the density factor on carrying capacity is fairly obvious; high density difference between cuttings and fluid results in a low buoyant force and therefore decreases carrying capacity. The effect of cutting shape is less obvious. Although

Jan 1, 1951

By W. B. Lilienthal, J. C. Melrose

The application of Bingham's law to the behavior of drilling fluids in a rotational viscometer permits the expression of viscometric data in terms of plastic viscosity and yield value, the flow properties of a plastic fluid. A commercially available rotational viscometer is described, and when modified to a multispeed type viscometer, is shown to provide a simple and convenient instrument for the measurement of these properties both in the laboratory and in the field. The data obtained are shown to be useful in defining and understanding mud control problems relating to chemical treatment and to the hydro-dynamic behavior of muds. INTRODUCTION The highly complex drilling fluids which are required for deep drilling often give rise to new and unusual mud control problems. Rapid and economic solutions to these problems may require, on the one hand, better understanding of the changes which contaminants and chemical treating agents produce in the colloidal and inert solids of the mud, or, on the other hand, closer control of the hydrodynamic behavior of the mud. The latter objective obviously can be achieved only if a correct rheological analysis of the flow behavior of drilling muds is available and if this is accompanied by the appropriate rheological measurements. The purpose of this paper is to describe such measurements in the field, and to show how the resulting data can be of value in solving difficult mud control problems. It is now generally recognized that Bingham's law of plastic flow can be utilized in describing the hydrodynamic behavior of drilling fluids in the non-turbulent flow range. Beck, Nuss, and Dunn' have recently applied this law to the flow of mud in small pipes, and Rogers2 has reviewed the rather extensive literature on this subject. So far, however, the use of Bingham's law has been restricted to the analysis of mud flow in pipes or capillary tubes, and it has not been directly applied to the flow in rotational viscometers. In the work to be reprted, the Reiner-Riwlin3 equation for the flow of a plastic fluid in a rotational viscometer has been utilized to permit the expression of multispeed viscometric data in terms of plastic viscosity and yield value. the two absolute flow properties of a plastic fluid. With regard to the application of these measurements, the calculation of the relationship between pumping rate and pressure drop, both in the drill pipe and annular space, has long been a subject of interest. Beck, Nuss, and Dunn,' following Caldwell and Babbitt: base their calculations for non-turbulent flow on Buckingham's integration of Bingham's law for pipe flow and measurements of the plastic viscosity (rigidity in their terminology) and yield value. In the case of turbulent flow, Fanning's equation is employed, and the pressure drop is relatively insensitive to the flow properties of the mud. Since flow in the drill pipe is likely to be turbulent at usual circulation rates, the plastic flow properties will chiefly influence the pressure drop in the annular space. As pointed out by Beck,' the control of this component of the total pressure drop may be of special importance where lost circulation problems are encountered. Other hydrodynamic problems to which it should be possible to apply measurements of the plastic flow properties include predictions of the velocity distribution in non-turbulent flow and the critical velocity for transition to turbulence. Plastic viscosity and yield value. as abmlute flow propertie.;, will reflect the colloidal or surface-active behavior of the solids present in drilling fluids. Measurements of these properties should therefore find application in developing a better understanding of such behavior and in characterizing the type and condition of these solids. Garrison and ten Brink have utilized multispeed viscometric data in this manner. although their measurements were not expressed in terms of the absolute flow properties. In connection with the application of these measurements, it should be recognized that the presently used one-point viscosity measurements are relative in nature. The API Stormer 600-rpm measurement, for example. is a function of both plastic viscosity and yield value, as well as mud weight, and will often be misleading when its application to mud control problems is attempted. NOMENCLATURE, UNITS, AND DEFINITIONS In Fig. 1 an idealized plot is given of the flow variables involved in any viscometric measurement. It is seen that the flow behavior of plastic fluids is characterized by two constants — plastic viscosity, µp, and yield value, F. Other workers hate used the term rigidity for plastic viscosity or the term mobility for its reciprocal. The term plastic viscosity, however, emphasizes the close relation this property bears to the viscosity of a true fluid and is expressed in the familiar viscosity units of centipoises. The yield value is expressed in lbs/100 sq ft, the units adopted for gel strength measurements with the APT shearometer. Definitions of these properties based on rheological or macrc)scopic flow considerations follow from Fig. 1. The plastic viscosity of a substance obeying Bingham's equation is defined

Jan 1, 1951