Development of Digital Twins for Drilling Fluids: Local Velocities for Hole Cleaning and Rheology Monitoring

In this work, we present our advances to develop and apply digital twins for drilling fluids and associated wellbore phenomena during drilling operations. A drilling fluid digital twin is a series of interconnected models that incorporate the learning from the past historical data in a wide range of operational settings to determine the fluids properties in realtime operations. From several drilling fluid functionalities and operational parameters, we describe advancements to improve hole cleaning predictions and high-pressure high-temperature (HPHT) rheological properties monitoring. In the hole cleaning application, we consider the Clark and Bickham (1994) approach which requires the prediction of the local fluid velocity above the cuttings bed as a function of operating conditions. We develop accurate computational fluid dynamics (CFD) models to capture the effects of rotation, eccentricity and bed height on local fluid velocities above cuttings bed. We then run 55,000 CFD simulations for a wide range of operational settings to generate training data for machine learning. For rheology monitoring, thousands of lab experiment records are collected as training data for machine learning. In this case, the HPHT rheological properties are determined based on rheological measurement in the American Petroleum Institute (API) condition together with the fluid type and composition data. We compare the results of application of several machine learning algorithms to represent CFD simulations (for hole cleaning application) and lab experiments (for monitoring HPHT rheological properties). Rotating cross-validation method is applied to ensure accurate and robust results. In both cases, models from the Gradient Boosting and the Artificial Neural Network algorithms provided the highest accuracy (about 0.95 in terms of R-squared) for test datasets. With developments presented in this paper, the hole cleaning calculations can be performed more accurately in real-time, and the HPHT rheological properties of drilling fluids can be estimated at the rigsite before performing the lab experiments. These contributions advance digital transformation of drilling operations.

Investigation: Cutting Transport Mechanism in Inclined Well Section under Pulsed Drilling Fluid Action

Due to gravity, drilling cuttings are easily accumulated in an inclined well section, ultimately forming a cuttings bed, which places the drill pipe under strong friction torque. In severe cases, this can cause dragging, stuck drills, and broken drill tools. Because conventional drilling fluids are difficult to prevent the formation of cuttings in inclined well sections, a method of carrying cuttings with the pulsed drilling fluid to improve wellbore cleanness is proposed. Experiments and numerical simulations are conducted to investigate the effects of cuttings bed transport velocity, cuttings size, cuttings height, drill pipe rotation speed, cuttings bed mass, and roughness height. The optimal pulse parameters are determined per their respective impact on cuttings transport concerning varied periods, amplitudes, and duty cycles of the pulsed drilling fluid. Compared to cuttings transport under the conventional drilling fluid flow rate, the pulsed drilling fluid produces the turbulent dissipation rate, increases cuttings transport velocity, and thus improves the wellbore clearance rate.

Experimental Study of Cuttings Transport with Non-Newtonian Fluid in an Inclined Well Using Visualization and Electrical Resistance Tomography Techniques

Summary Hole cleaning is a concern in directional and horizontal well drilling operations where drill cuttings tend to settle in the lower annulus section. Laboratory-scale experiments were performed with different non-Newtonian fluids in a 6.16-m-long, 114.3- × 63.5-mm transparent annulus test section to investigate cuttings transport behavior. This experimental study focused on understanding the cuttings transport mechanism in the annulus section with high-speed imaging technology. The movement of cuttings in the inclined annular section was captured with a high-speed camera at 2,000 frames/sec. Also, cuttings bed movement patterns at different fluid velocities and inner pipe rotations were captured with a digital single-lens reflex video camera. The electrical resistance tomography (ERT) system was used to quantify the cuttings volume fraction in the annulus. Different solid bed heights and cuttings movements were observed based on fluid rheology, fluid velocity, and inner pipe rotation. The mechanistic three-layer cuttings transport model was visualized with the experimental procedure. This study showed that solid bed height is significantly reduced with an increase in the inner pipe rotation. This study also identified that cuttings bed thickness largely depends on fluid rheology and wellbore inclination. The image from the high-speed camera identified a downward trend of some rolling particles in the annulus caused by gravitational force at a low mud velocity. Visual observation from a high-speed camera identified a helical motion of solid particles when the drillpipe is in contact with solid particles and rotating at a higher rev/min. Different cuttings movement patterns such as: rolling, sliding, suspension, helical movement, and downward movement were identified from the visualization of a high-speedcamera.

Wet Drilled Cuttings Bed Rheology

The cuttings transport efficiency of various drilling fluids has been studied in several approaches. This is an important aspect, since hole cleaning is often a bottleneck in well construction. The studies so far have targeted the drilling fluid cuttings’ transport capability through experiments, simulations or field data. Observed differences in the efficiency due to changes in the drilling fluid properties and compositions have been reported but not always fully understood. In this study, the cuttings bed, wetted with a single drilling fluid, was evaluated. The experiments were performed with parallel plates in an Anton Paar Physica 301 rheometer. The results showed systematic differences in the internal friction behaviors between tests of beds with oil-based and beds with water-based fluids. The observations indicated that cutting beds wetted with a polymeric water-based fluid released clusters of particles when external forces overcame the bonding forces and the beds started to break up. Similarly, it was observed that an oil-based fluid wetted bed allowed particles to break free as single particles. These findings may explain the observed differences in previous cutting transport studies.

Achieving Improved Drilling Performance with Hole Cleaning Technology in Horizontal Shale Gas Wells in Sichuan Basin of China

The horizontal section length of shale gas horizontal wells in Sichuan Basin in the south-west of China generally exceeds 2000m. Cuttings are apt to accumulate and form cuttings beds along such long and curve horizontal sections due to low cuttings carrying capacity, which often results in excessive torque and drag or even stuck pipes during drilling process. According to the statistics dada inthe period of Jan. - Oct. 2019, more than 25 stuck pipe incidents and 15 rotary steering tools loss in borehole were reported due to inefficient cuttings transportation in the long horizontal wells in Sichuan Basin. This paper studies the cuttings transportation and cuttings bed formation in horizontal wells. A prediction model for the distribution of cuttings bed was established. A monitoring and analysis software for the cuttings bed and cuttings cleaner with V-shaped spiral blades that is used to agitate the cuttings bed wasdeveloped. The software calculates the distribution and thickness of the cuttings bed according to the well trajectory, wellbore structure, drilling fluid characteristics, etc., and provides the optimal operating parameters for the removal of the cuttings bed by the rotating and reciprocating drill string. Then, the drill cuttings remover in the drill string moves to the predicted position of the drill cuttings, scrapes the drill cuttings and creates a swirling flow during the pipe rotation. The combined application of software and makeup remover can effectively solve the issue of borehole cleaning in long horizontal wells. One of the field applications was carried out in the well Ning 209H12, a shale gas horizontal well in Sichuan Basin. The well experienced excessive torque and drag issue during the tripping of drill string of long horizontal section. Thesoftware ran based on oil well data, and it determines the placement and thickness of cuttings beds in the well and calculates the optimal operating parameters for a flow rate of about 32L/s and a speed of 100rpm to remove them. By rotatingand reciprocating the drill string with recommended operating parameters along the cuttings bed interval, the removers helped cleaning the cuttings bed efficiently and significant amount of cuttings was observed at vibration screen. After cleaning the cuttings bed interval, the trip smoothly ran to the bottom without any excessive torque and drag, and then continues to drill in cooperation with the removers to the total depth. During the well completion, there was no problem with the operation of electrical logging and production casing. This cuttings removal technology has been used in other shale gas formations and tight gas formations where horizontal wells are widely used.

Application of Innovative Extended Reach Well Operation Technology in Nanhai East

Extended reach well (ERW) can be extremely drilled to distant reservoirs to reduce the infrastructure and operational footprint. Drilling ERW and extending their reach to greater depths requires both improved equivalent circulating density (ECD) and frictional resistance due to large horizontal displacement, long open hole and borehole unstability. ECD is one of the keys to safe and efficient drilling, especially in complex formations with narrow pressure profile, and wellbore frictional resistance appreciably influences drilling torque and drag, as well as casing running. This paper presents several methods, including continuous circulating valve(CCV) drilling technology, cuttings bed removal technology and chemical friction reduction technology, to promote the success of ERW drilling. The applications are realized by means of adding CCV, cuttings bed cleaner to the drill string and chemical friction reducer into the drilling fluid. Respectively the CCV drilling technology realizes the continuous circulation of drilling flooding, and cuttings bed removal technique utilize integrated design of hydraulic machinery with hydraulic parameter adjustment and flow passage design, to enhance turbulence velocity and strength of drilling fluid flow field, which both can effectively improve the efficiency of carrying bit cuttings, and reduce the fluctuation of ECD. Chemical friction reduction technology is mainly composed of chemical frictional drag reduction agent which belongs to organic anion compound products, and has excellent super anti-wear lubrication. Results show that the fluctuation of ECD in the high-risk well section with well loss was controlled within 2.5%, and narrow density window formation (0.18g/cm3) was drilled safely without any caving and leakage. The friction coefficient ranged from 0.4 to 0.25, with 40% decrease compared with previous wells in Huizhou Oilfield. And also the ROP increased by 45% due to effective transmission of WOB. The technologies shown in this paper comprise key innovative technologies in ERW operation in Nanhai East. Less time is occupied in equipment installation, as well as simple operation flow, however with improved stability and remarkable performance. It lays a foundation for further study of ultra extended reach wells with greater difficulty and challenge.

Fundamentals and Physical Principles for Drilled Cuttings Transport—Cuttings Bed Sedimentation and Erosion

The increasing necessity of challenging wellbore structures and drilling optimization for improved hole cuttings cleaning has been growing along time. As a result, operator companies have been researching and applying different hole cleaning techniques. Some of these are applied as traditional rules of thumb but are not always suitable for the new and up-coming challenges. This may result in inefficient hole cleaning, non-productive times, pipe stocking and low rate of penetration (ROP), among other problems. Here are presented some results and improvements for hole cleaning optimization obtained by the different research groups. The different authors mainly focus on specific cuttings transport parameters and sometimes combination of some of them. For this reason, there has not been a study that takes into account all of the different factors at the same time to accurately predict the cuttings bed height, formation and erosion, critical fluid velocity and properties and other key parameters. Consequently, there is a lack of understanding about the relation between different factors, such as the cohesiveness of the drilled cuttings with the different interstitial drilling fluids within the cuttings-bed. This relation can be analyzed establishing a wet-granular approach to obtain more efficient cuttings transport mechanism in challenging conditions.