Modern Techniques in Well Design
Modern Techniques in Well Design
A direct benefit of efficient wells is reduced pumping costs. Well efficiency is controlled by
several factors, including aquifer, drilling damage, and turbulent-flow losses at or near the well
screen. Screen entrance velocity is not a critical design factor if values are less than 2-4 fps (0.6-
1.2 m/s). For most wells, the required open areas of a screen need only be 3-5 percent. A new
method of designing minimum length of well screen based on laminar flow-turbulent flow
considerations is presented, along with a simple field test to calculate the efficiency of an
existing well or to provide a criterion for termination of development of a newly constructed
well.
This project simulated field conditions of groundwater flowing from aquifer sands through the
filter zone and into the well screen. This was done with a large sand tank model capable of
producing radial flow in a one-sixth section of a well and aquifer. Commercially available 10- in.
(250 mm) well screens were used, and a system of reservoirs and pumps allowed flows up to 300
gpm (19 L/s). A constant-head reservoir connected to a chamber along the back of the model
provided a line drive, allowing up to 60 ft (18 m) of available drawdown at the well (Figure 1).
Well Design
Critical Radius. Turbulence occurs in the near zone of the well filter when inertial forces
predominate over viscous forces. The transition between completely laminar and completely
turbulent is evidenced by the gradual scatter of turbulence throughout all pores of the medium.
Thus, the first deviations from Darcy's law sorrespond to the beginning of appreciable eddy
losses in the larger pores. These localized regions of turbulence spread to the smaller pores as
velocity increases (Figure 2).
The characteristic length in the standard definition of Reynolds number has been replaced by a
characteristic grain diameter, assumed equal to the 50 percent passing grain size. This
substitution was made because the microscopic passageways occupied by water in porous media
are difficult to measure. At the point of transition from laminar to turbulent flow (defined as the
critical point and denoted by the subscript c), the hydraulic gradients are equal and Eqs 1 and 2
can be equated, yielding:
(dh/dr)c = v 2 /gkd)Rc = a2 (v 2 /gkd)RV 2 (3)
and
Rc = 1/a2
The constant a2 is equal to the reciprocal of the critical Reynolds number (Rc) and is primarily a
function of grain shape, packing, and distribution. To test this relationship as well as determine
the critical Reynolds number, a series of experiments was performed using the well- aquifer
model.
The hydraulic gradient dh/dr was plotted for four filter zone materials at varying distances from
the well for different flow rates. The velocity was then calculated at each of the radial distances,
and the Reynolds number computed (Figure 3). The critical Reynolds number interpreted from
these plots is approximately equal to 30. This value was derived from observation of the general
range where the slope of the curves changed from 1 (pure laminar flow) to 2 (pure turbulent
flow).
Based on the foregoing mathematical analysis and experimental results, a critical radius can be
calculated for any given set of flow conditions. The critical radius is defined as that distance
measured from the center of the well to the point where the flow changes from turbulent to
laminar. Within the critical radius, flow is turbulent (or partially turbulent) with corresponding
head losses varying as some exponential power of the velocity (approaching 2 for fully turbulent
flow). Assuming a critical Reynolds number of 30, the critical radius may be calculated from:
in which r - critical radius - in. (m), Q/b = specific aquifer discharge - gpm/ ft (L/s/m), Q = well
discharge - gpm (L/s), b = saturated aquifer thickness (assumed equal to screen length) - ft (m), d
= characteristic diameter of material (50 percent passing size) - mm, and Ð = effective porosity
of material (fraction).
Figure 4 is a plot of the specific aquifer discharge versus the critical radius for typical filter zone
materials.
Components of drawdown in a pumping well. In a well fully screened throughout the aquifer
or aquifers penetrated, the total drawdown is composed of laminar and turbulent head loss
components. Laminar losses generally occur away from the borehole, at which point approach
velocities are low, whereas turbulent losses are confined to the immediate vicinity of the well
screen. Figure 5 shows the components of drawdown in a typical production well.
in which s = total drawdown measured in the well, ds = laminar loss in the aquifer, ds' = laminar
loss in the damage zone, ds'' = turbulent loss in the filter zone, and ds''' = well losses. Aquifer
loss. The head loss (drawdown) measured at the interface between the aquifer and the damage
zone is known as aquifer loss. The magnitude of aquifer loss can be determined from radial flow
to the damage zone from the aquifer. Aquifer drawdown may be expressed quantitatively by the
steady-state Theim equation:
in which ds = drawdown in the aquifer - ft (m), Q = well discharge - gpm (L/s), K = aquifer
hydraulic conductivity - gpd/ sq ft (mm/s), b = saturated thickness of the aquifer (assumed to be
equal to length of well screen) - ft (m), ro = radial distance from the center of the well to the
aquifer-damage- zone interface - ft (m).
ds'' = B''Q''
In which ds'' = turbulent head losses in the near-well filter zone - ft (m), B'' = turbulent filter
zone loss coefficient - ft/ gpm (m/[L/s]''), and n = exponent (1<n< 2).
Well losses. Head losses associated with the entrance of water through the well screen and the
axial flow of water toward the pump intake are known as well losses. These losses are caused by
turbulent flow conditions and vary as the square of the velocity. Well losses can be expressed as:
ds''' = CQ2
in which ds''' = well losses - ft (m) and C = well losses coefficient - ft/gpm2 (m/[L/s]2). The
majority of loss occurs as water jets through the screen openings.
Minor losses. In addition to the major drawdown components, several minor losses occur.
Laminar losses through the filter zone and head losses associated with a restricted inlet area (e.g.,
convergence of flow lines toward milled slots) are typical minor losses. Generally, much smaller
than other well losses, they are neglected in the total drawdown equation. 2
Effective well radius. As defined by Jacob,3 effective well radius is that distance measured
radially from the axis of the well at which the theoretical drawdown equals the actual drawdown
in the filter zone. It shows the effectiveness of well development on increasing the hydraulic
conductivity in the immediate vicinity of the well (Figure 6). Effective well radius may be
calculated from step-drawdown test data once transmission and storage capacities of the aquifer
are known.
In a properly constructed and fully developed well, the damage zone loss (ds') approaches zero.
Equation 11 is similar to Jacob's classical definition of well efficiency with the addition of the
turbulent filter and damage loss terms.
Step-drawdown tests are used to determine the coefficients B, B", and C; n is usually assumed
equal to 2. Interference testing (in conjunction with the step-drawdown test) is used to determine
the damage zone loss coefficient B'.
Several design factors that affect hydraulic performance should be considered in the construction
of a production water well. The most important of these are well development, screen length and
diameter, filter zone material, and critical well radius. The degree to which each of these factors
contributes to well performance depends to a certain extent on operational criteria (i.e., pumping
rate) and to some extent on each of the other factors.
To properly design a well, the various factors should be evaluated with regard to initial cost as
well as operational costs over the lifetime of the well.
Effect of well development. Well development is the process whereby material in the near-well
zone is rearranged and fines are removed to produce a highly permeable filter. This includes the
removal of any residue from formation damage, such as mud cake and invasion.
A well is considered fully developed when no further improvement can be obtained in specific
capacity and well efficiency at a particular design discharge. Also, maximum allowable sand
production must be achieved at a specified time after startup under permanent pump production
rates. Figure 8 illustrates the effect of well development on both specific capacity and well
efficiency.
Near-well turbulent losses as a function of screen length. A more efficient design can be
assured by calculating the minimum length of screen required. If enough screen is provided so
that the critical radius (rc) is equal to or less than the nominal radius (rw ), turbulent- flow head
losses in the filter zone can be minimized.
Sample calculations. Suppose it is desirable to pump 2000 gpm (126 L/s) from a 12- in.- (300-
mm- ) diameter well in an aquifer in which mechanical grading analyses show a 50-percent
passing grain size (D50 ) of 1 mm. A pack-to-aquifer ratio of 5:1 is selected , resulting in the filter
material having an average grain size of 5 mm. The specific aquifer discharge for a critical radius
of 6 in. (150 mm) is determined from Figure 4 to be 9 gpm/ ft (1.9 L/s/m). Therefore the
minimum length of well screen (b) that is required to eliminate turbulent filter zone head losses
would be:
For screen lengths shorter than 222 ft, the critical radius exceeds the nominal radius, creating
near-well turbulent head losses. These additional head losses mean higher pumping lifts and
operating costs over the life of the well. For example, if only 150 ft (45 m) of screen were
installed, the specific aquifer discharge (Q/s) would be (2000/150) = 13 gpm/ ft (2.7 L/s/m).
From Figure 4, the critical radius (rc) is determined to be 10 in. (250 mm). In this case, turbulent
flow would extend 4 in. (100 mm) into the filter zone, resulting in unnecessary turbulent head
losses.
Effect of screen entrance velocity on well efficiency. There have been considerable discussion
and controversy regarding the upper limit for screen entrance velocity corresponding to good
well design. Recent investigations have produced valid data which refute earlier conceptions of
the empirical relationship between head losses through screens and entrance velocities.1
Througho ut the testing it was apparent that below a certain entrance velocity no appreciable gain
in well efficiency was achieved. This maximum value is 2-4 fps (0.6-1.2 m/s) and can be seen in
part B of Figure 9. The upper velocity limit was obtained for model well efficiencies measured at
100-gpm (6.3 L/s). For this study the 100-gpm (6.3 L/s) model value was selected as a worst case
or upper limit for field conditions because 100 gpm (6.3 L/s) in the model corresponds to a 600-
gpm (37.9-L/s) well in the field pumping from a 5- ft (1.5- m) thick aquifer.
V = Q/(235rwbP)
Effect of screen entrance velocity on corrosion. According to Rossum, 4,5velocity has two
opposing effects on corrosion. Corrosion is initia lly accelerated by increasing velocity. As
velocity increases, the thickness of the laminar flow layer adjacent to the metallic surface
decreases, causing oxygen to diffuse from the metal. However, when protective films such as
calcite, or siderite form, velocities up to 5 fps (1.5 m/s) promote denser and more protective
coatings. In fact, within this range, the higher the velocity, the better the coating. Excessive
velocities may result in a combination of corrosion and erosion that may be severe. This occurs
when the protective coatings are swept away as they are being formed. For steel pipes, this
velocity is approximately 10 fps (3 m/s).
Water system operators know that reasonable velocities are essential in mitigating corrosion.
Where velocity is low, particularly in dead ends, corrosion is severe. Merrill and Sanks6 state that
one of the attributes of a well-conditioned water supply is a velocity of at least 2 fps (0.6 m/s).
Well photo and TV logs show that corrosion and encrustation are greatest in screens set opposite
aquifers in which production and entrance velocities are low.
Effect of filter zone material and thickness. The primary purpose of the filter zone is to
stabilize the aquifer. The well screen is correspondingly designed to stabilize the filter. In
naturally developed wells, the filter zone is developed by removal of fine particles , leaving a
zone of high conductivity surrounding the well screen. In filter pack wells, the relationship
between a characteristic grain size (usually the 50-percent passing size) of the pack and that of
the aquifer is known as the pack- aquifer ratio. There is general agreement that pack- aquifer
ratios should be between 4:1 and 6:1. Uniformity of material as measured by the uniformity
coefficient Cu (ratio of the 60-percent passing to the 10-percent passing grain size) does not seem
to be a critical design factor if proper pack- aquifer ratios are adhered to. For example, tests have
shown that highly nonuniform aquifers (e.g., Cu = 8) are stabilized using uniform filter packs (Cu
= 1.5) if pack- aquifer ratios are between 4:1 and 6:1.7
The width of the annulus between the casing-screen and the borehole should be sufficient to
facilitate installation of the filter pack. The thickness of a filter pack typically ranges from 4 to 6
in. (100 to 150 mm).
Although the grain size of the filter pack material also has an effect in the amount of near-well
turbulence (i.e., smaller pore spaces reduce turbulence), control of turbulent flow losses is
usually accomplished by reducing the pumping rate and increasing the screen length or diameter.
Effect of well screen diameter. Although screen diameter is not a critical design factor in most
cases, it can affect well performance.
Effect of diameter on well losses. For screen diame ters used in typical wells, the head losses that
occur as water moves axially toward the pump intake are generally small. However, using high
pumping rates with small screen diameters may result in significant frictional pipe head losses,
and this possibility should be taken into consideration by the well designer.
Effect of diameter on critical radius. Under some conditions small diameters result in the
phenomenon of near-well turbulence, with a corresponding loss in specific capacity. Therefore,
screen diameters should be selected to ensure that the nominal well radius equals or exceeds the
critical radius.
Effect of diameter on specific capacity. The following example illustrates the effect of screen
diameter on specific capacity. For a 12 - in.- (300- mm-) diameter well in an aquifer with a
transmissivity (Kb) of 100 000 gpd/ ft (1250 m2 /d) specific capacity can be calculated from Eq
12. Assuming re = rw and ro = 1050 ft, Q/s = 57 gpm/ ft (11.8 L/s/m). If the well screen diameter
was 24 in. (600 mm), the specific capacity would be: Q/s = 63 gpm/ ft (13 L/s/m). Therefore,
doubling the diameter increases specific capacity only 10 percent.
Maximizing efficiency in well maintenance. Over the lifetime of the well, operational costs
generally outweigh routine maintenance costs. Unnecessary operational costs result from screen
and turbulent filter zone losses, plugging at the orifice, or loss of permeability in the filter zone.
The importance of maintaining production and specific capacity is shown by the following
sample calculation, in which annual annual operating costs are determined.
A well with an original drawdown of 100 ft (30 m) and a well efficiency of 80 percent at 2000
gpm (126 L/s) was tested for efficiency. The latest data showed a total drawdown of 117 ft (35
m) and a well efficiency of 68 percent at 2000 gpm (126 L/s). the additional operating costs
resulting from this decline can be calculated as follows:
The additional head loss due to screen-slot plugging or other factors amounts to 17 ft (5.1 m).
The number of kilowatts of power P required to lift this additional 17 ft (5.1 m), assuming a
wire-to-water efficiency e = 0.65, can be calculated from:
P = = 9.854 kW
If the well is operated 16 h/d at a cost of $0.08/ kW h, the additional annual operating cost due to
the efficiency decrease would be:
Assuming a 15-year life, these additional costs amount to $69,060. Thus lower cost of operation
is a primary benefit of maximizing well efficiency. Production and drawdown measurements
should be conducted periodically and decisions made to redevelop the well should efficiencies
decline below an acceptable operating level.
Field Tests
Analysis of the step-drawdown data requires plotting the specific drawdown s/Q for each of the
steps. The following explanation shows the theory behind step-drawdown analysis. In a fully
developed well penetrating the complete thickness of the aquifer, the drawdown in the well may
be written as:
S = BQ + B"Q" + CQ2
In most wells, screen lengths are sufficiently long, and the critical radius does not exceed the
nominal radius. When all points of the test lie on a straight line, this is confirmed. If additional
drawdown does not yield an increase in production, a pointof critical discharge has been reached.
This occurs when the screened formation is incapable of producing more water because of its
internal resistive forces, or when the discharge is equal to or greater than recharge to the aquifer
(e.g., boundary effects). This can, but usually does not, take place before the incidence of
significant well or near-well turbulent flow losses.
Once the constants B, B", and C are determined, the well efficiency may be calculated for the
complete range of discharge as:
no near-well turbulence
To overcome this, the effect of the different aquifer types is removed and comparisons are made
only between turbule nt head loss terms (well losses and near-well turbulent head losses). This
latter index, defined as specific loss (SL), is expressed as:
For cases in which near-well turbulence is present, the specific loss can be written:
Design of efficient water wells requires knowledge of the various hydraulic factors that affect the
major drawdown components. Turbulent flow through the well screen and in the near-well filter
zone creates unnecessary head losses. Minimizing these turbulent-flow losses can result in
substantial cost savings over the lifetime of the well.
Efficient wells incorporate proper design of screens and filter materials with effective
development methods. The effective well radius can be used to measure the degree of filter-zone
development. Estimates of the minimum length of well screen required to eliminate near-well
turbulence can be made from knowledge of pumping rates and filter material. Recent
experimental test results show that entrance velocity and screen open area are not critical design
factors for mostfield applications. Proper pack-aquifer ratios and well development are primary
factors in the construction of efficient water wells. The step-drawdown test is an effective tool
with which to calculate the efficiency of a well and ensure that development is complete.
Acknowledgements
This research was funded by the Roscoe Moss Co. of Los Angeles, Calif. Special thanks go to
Dave Walker and John List.
Bibliography
HANTUSH, M.S. Hydraulics of Wells. Advances in Hydroscience. Academic Press, New York
(1964).
HELWEG, O.J.; SCOTT, V.H.; & SCALMONINI J.C. Improving Well and Pump Efficiency.
AWWA, Denver, Colo. (1983).
LIST, E.J. Analysis of Development Methods for Gravel Envelope Wells. The Roscoe Moss Co.
(1983).
TODD, D.K. Groundwater Hydrology. John Wiley & Sons, New York (1980).
Footnotes
1. WILLIAMS, D.E. the Well- Aquifer Model - Initial Test Results. The Roscoe Moss Co.
(1981).
2. BOULTON, N.S. Discussion in C.E. Jacob. Drawdown Test to Determine the Effective
Radius of Artesian Wells. Trans.ASCE, 112:1047 (1947).
3. JACOB, C.E. Drawdown Test to determine the Effective Radius of Artesian Wells.
Trans.ASCE, 112:1047 (1947).
4. ROSSUM, J.R. Personal Communication (1983).
5. ROSSUM, J.R. Fundamentals of Metallic Corrosion in Fresh Water. The Roscoe Moss
Co. (1980).
6. MERRILL, D.T., & SANKS, R.L., Corrosion Control by Deposition of CaCO3 Films:
Part 3, A Practical Approach for Plant Operators. Jour. AWWA, 70:1:12 (Jan. 1978).
7. SMITH, H.E., Gravel Packing Water Wells. Water Well Journal, 8:1 (1954).