IADC/SPE 59143

Improved Hole Cleaning and Reduced Rotary Torque by New External Profile on
Drilling Equipment
J.G. Boulet, SPE, and J.A. Shepherd, SPE, both SMF International, and J. Batham, contracted to Kerr-McGee North Sea
(UK) Ltd, and L.R. Elliott, Offshore Rentals Ltd.

Copyright 2000, IADC/SPE Drilling Conference

This paper was prepared for presentation at the 2000 IADC/SPE Drilling Conference held in
New Orleans, Louisiana, 2325 February 2000.
This paper was selected for presentation by an IADC/SPE Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the International Association of Drilling
Contractors or the Society of Petroleum Engineers and are subject to correction by the
author(s). The material, as presented, does not necessarily reflect any position of the IADC or
SPE, their officers, or members. Papers presented at the IADC/SPE meetings are subject to
publication review by Editorial Committees of the IADC and SPE. Electronic reproduction,
distribution, or storage of any part of this paper for commercial purposes without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The
abstract must contain conspicuous acknowledgment of where and by whom the paper was
presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax
01-972-952-9435.

Abstract
This paper will describe the successful application and effects
of completely new Hydromechanical Cleaning and
Hydrodynamic Bearing profiles machined externally on
drilling equipment to improve hole cleaning and reduce rotary
friction. Qualification programmes, including initial proving
trials on a test rig, computational fluid dynamics and cuttings
transportation flow loop tests, will supplement details from
successful field operational use of this equipment.
Introduction
Drilling for Oil and Gas has reached the stage where it is more
economical to drill an extended reach well to exploit
reservoirs on the periphery of existing developments.
Similarly, long horizontal sections through the reservoir are
now the norm. The initial response to this need for extended
reach drilling was to install top drives, upgrade the mechanical
integrity of the drill string, and introduce larger outside
diameter drill pipe with better materials and stronger
connections. These improvements have been integrated into
well design and now the limits are the amount of rotary torque
and hydraulic power available to rotate the drill string and
circulate sufficient drilling fluid to clean the well.
The initial challenge was to build a sub which would
reduce rotary drilling torque while maintaining the integrity of
the drill string. In the initial design of the low torque sub an
experimental hydromechanical cleaning zone was added. This
tool proved to be very successful, showing up to 40%
reduction in rotary torque. More importantly, the operator
noticed improvements in hole cleaning. These included

cuttings appearing at surface in close to theoretical bottoms up

time, an increase in the size of cuttings, reduced pick-up and
slack-off weights and improved steerability.
The success of the hydromechanical hole cleaning design
led to the development of heavy weight drill pipe and standard
drill pipe with this feature. A critical part of the design of this
hydromechanical cleaning drill pipe is that the cleaning zone
is supported off the bore wall and only comes into contact
with fluid or loose cuttings sedimentation.
Success with concurrent field trials and testing led to the
further development of the features described above and the
addition of a dual upset tool joint to provide five bearing areas,
each coated with industry standard hardfacing material to
control friction and wear.
The remainder of this paper will describe the design
principles, numerical modelling, application on drilling
equipment, cuttings transport flow loop tests and on-going
field operations of this Hydroclean System.
Design Principles & Effects of New Profile
Design & Functional Principles. (see fig. 1). The profile is
designed with two different zones, the hydromechanical
cleaning zone (HCZ) and the hydrodynamic bearing zone
(HBZ), which interact and provide the two basic effects of the
profile; hole cleaning and reduction of friction factor between
the bearing areas on the modified drilling equipment and the
borewall.
By design principles, the geometry of the profile modifies
the trajectory of flowing lines in the annular passage, at the
rotational speed , and the variation of geometry for drilling
fluid passage, (either in terms of passage area or a
combination of channel angles through which drilling fluid is
forced to flow).
There are two different alterations of flowing line patterns
corresponding to the two different zones of the profile, where
there is a hydromechanical cleaning effect and a
hydrodynamic bearing effect. In order to have a better
understanding of the effects developed by the profiles, the
following will firstly describe the principles of the geometry.

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

Construction Principles. (Fig 1)

Hydromechanical Cleaning Zone (HCZ). The profile at the
hydromechanical cleaning zone features three construction
angles, hc, hc and ^hc angles. The geometry of this profile
is composed of helicoidal grooves, usually five, making the
hc angle relative to the XX axis of the equipment, (as shown
in fig. 1). The grooves feature a hc negative angle, called
negative leading edge angle, running in the direction of the
rotational speed , while the opposite angle ^hc creates a
positive angle. The maximum outside diameter Dhc of the
hydromechanical cleaning zone (HCZ) is always smaller than
the minimum diameter of the hydrodynamic bearing zone
(HBZ). This will ensure that the hydromechanical zone will
never be in contact with the borewall, as contact is at the
larger diameter of the hydrodynamic bearing zone (HBZ).
Hydrodynamic Bearing Zone (HBZ). The profile of the
hydrodynamic bearing zone also has five grooves, which are
aligned with the five grooves of the hydromechanical cleaning
zone (HCZ). The hydrodynamic bearing zone sections have
positive edge angles 1 and 2. (As shown in Fig 1) The depth
dhb, and width of the Hydrodynamic bearing zone grooves
decreases from inlet to outlet, in order to provide a continuous
decrease of the passage areas inside the grooves. The inlet
groove on the hydrodynamic bearing zone is aligned with the
outlet groove on the hydromechanical cleaning zone. External
grooves, at inlet and outlet angles, enhance the geometric
continuity between the external surfaces of the drilling
equipment and the profile itself. The helix angle hc, of the
hydromechanical cleaning zone will be smaller than the helix
angle hb of the hydrodynamic bearing zone.
In order to have continuous axial bearing while rotating the
inclination angle, hb, of the profile ensures a tight design
configuration.
The two zones of the profile are usually machined together
on the outside of drilling equipment, although separate
utilisation of each zone is possible depending on the primary
function of the drilling tools. (It should be noted however that
the performance of the hydrodynamic bearing zone (HBZ) will
be enhanced when it is used with the hydromechanical
cleaning zone (HCZ), which will optimise the fluid charge at
the HBZ).
Effect on Mud Flowing Lines & Solid Particles.
(See Figures 1 and 2)
Effects of Hydromechanical Cleaning Zone. The combined
action of the rotational speed , the flow rate Q and the
features of the hydromechanical cleaning zone will produce
several effects on the cuttings lying on the low side of the well
bore:

Lifting effect
Scoop effect

IADC/SPE 59143

Archimedian screw effect

Particle Boosting and Recirculating

All these effects are the result of either direct mechanical

action by the profile on the particles, or hydraulic effects, due
to the modification of flowing line trajectories, (modifying the
velocity and pressure fields across the tools).
Lifting Effect. When the shaped grooves of the
hydromechanical cleaning profile (as shown in Fig. 2) are
rotating over a solid particle, this particle will be drawn up
from the bore wall to the cavity in the groove formed by the
negative leading edge angle hc. A hydraulic venturi effect lifts
the particles and the vortex created forces them to stay inside
the groove cavity of the hydromechanical cleaning zone.
Scoop Effect. The consequences on solid particles of the
scoop effect are identical to the lifting effect described above,
however this action is purely mechanical. The face of
negative angle hc will first dig into cuttings in sedimented
beds, and will then keep them in the groove cavities.
Archimedian Screw Effect. The helix angle hc combined
with the hc negative leading edge angle will force the
particles to remain in the groove cavities, and rotation and
flow will drive them upwards. The helix angle hc is selected
to suit average conditions of flow rate Q and rotational speed
. This will generate an axial velocity, of flowing lines and
solid particles, higher than the average velocity in the annular
passage where there is none of this equipment. The
Archimedian screw effect is possible only because of the
negative hc angle, without this angle the solid particles would
escape rapidly from the grooves and settle back to the bore
wall. (As shown in Fig. 2).
Particle Boosting and Recirculating. The solid particles
conveyed inside the profile will slide to the opposite curved
face of the ^hc tangential angle, and then they will be
returned to circulation with an increased velocity resulting
from the continued archimedian screw and spinning effects,
(as a consequence of the turbulent trajectories of particles in
the groove cavities of the hydromechanical cleaning zone).
The recirculating effect is also enhanced by the decreasing
groove depth at the outlet of the hydromechanical cleaning
zone, which produces a deflecting action on solid particles in
the annular passage.
Effect of the Hydrodynamic Bearing Zone. The combined
action of the rotational speed and the flow rate Q and the
geometry of the hydrodynamic bearing zone will produce two
effects:

Hydrodynamic Bearing
Particle Boosting and Recirculating.

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 3

Hydrodynamic Bearing. This hydrodynamic bearing

effect, also known as a marine bearing effect, is created by the
tangential flowing lines of fluid, when the hydrodynamic
bearing zones are in contact with the low side of the bore wall.
(See Fig 1). If we consider a certain flow rate, qhbi, entering
the inlet of the grooves, due to the decreasing passage area,
only a restricted flow rate qhbo, smaller than qhbi, will flow
through the groove outlet, therefore, we assume that a flow
rate of qht will generate a tangential flowing line pattern at the
bearing area.
qht = k (qhbi qhbo) with k 1.
In addition the archimedian screw effect of the
hydromechanical cleaning zone will enhance the tangential
flow, by guiding fluid with increased velocity to the inlets of
the hydrodynamic bearing zone grooves. This tangential flow
qht of viscous drilling fluid will produce a lubricating film
between the bore wall and the bearing area decreasing the
friction factors and improving the sliding properties.
Particle Boosting and Recirculating. When associated with
the hydromechanical cleaning zone, solid particles
recirculating in the annulus will be induced firstly, by the
decreasing passage angles between the grooves, (i.e. deflecting
effect) and secondly, by the increase of inclination angle hb
of the hydrodynamic bearing zone grooves from the hc angle
of the cleaning zone grooves.
The analysis of all induced effects show that there is an
interaction of functioning principles between the
hydromechanical cleaning and the hydrodynamic bearing
profiles providing several potential benefits to the drilling
process:

Improved hole cleaning

Enhanced cuttings transportation
Reduced friction factors
Lubricated and cleaned bearing surfaces to help reduce
differential sticking and improve mechanical function.

Purposes of the CFD Analysis

To better understand the hydraulic functioning of the
hydromechanical cleaning zone (HCZ), a computational fluid
dynamics (CFD) analysis was carried-out on this profile to
simulate drilling conditions. Performed at an early stage of
the project development, the primary purpose of this analysis
was to visualize the velocity and pressure gradients, which
would highlight the potential solid particle lifting effect
developed by the hydromechanical cleaning profile. Although
the input data did not take into account all the actual downhole
working conditions, this primary CFD analysis allowed us to
visualize the operation and function of this profile. (See
figures 3, 4 and 5).

Hypothesis and Data

Table 1
Hole Size
Outside Diameter (Dhc)
Flow Rate (Q)
Rotary Speed ()
Fluid Density
Inlet Velocity in Annular

8
6 5/8
425 gpm
150 RPM
10 lbs/gal
6.06 ft/lbs

The main operating data is given in Table 1. The profile

was considered as centered in the hole for this first analysis,
with only drilling fluid in the annulus and no solid particles
(i.e. single-phase fluid). Regarding the fluid characteristics, as
the dynamic viscosity () is a function of the shear strain rate
(), the fluid is considered as of non-newtonian type. The
Power Law model was used for this first approximation
instead of the Herschel-Bulkley model.
() = K -n (Power Law)
: dynamic viscosity [Pa . s]
: shear rate of strain [ s -1]
n : power index [-]
K : consistency constant [Pa . s 1-n ]
Which, for the selected drilling fluid properties used for
the CFD analysis, gives
() = 0.9 x -0.49
Physical Model and Objectives. (See figure 3) The CFD
analysis software calculates the flowing lines around the
profile by solving Navier-Stokes fluid dynamic equations
numerically. This grid is automatically generated by the CFD
analysis software. The CAD geometry of the profile was used
as direct input data for the calculations.
Result of the Primary CFD Analysis. (See figures 4 and 5)
According to the visualization and calculation of the velocity
and pressure gradient vectors, representing the hydraulic
patterns as induced by the hydromechanical cleaning profile
zone, the initial technical results were:

A fluid particle entering the domain is conveyed upwards,

following the groove of the profile.

The figures 4 and 5 show that the cavity region of the

negative leading edge angle HC acts as a sink, the fluid
which is then recirculated creates a vortex, or spinning
effect, which pulls fluid particles from the low side of the
hole.

Particles located in the narrower annulus section will be

pulled from the bore wall by a strong pressure gradient

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

and induced into the vortex in the area below ambient

pressure.

These particles will be the trapped in this vortex region

and will be conveyed upwards by the archimedian screw
effect of the HC angle.

The pressure and velocity gradients show that the drilling

fluid has a suction effect on the bore wall creating a
distinct scoop function for particles in the mud. The mud
particles would be attracted from regions of high pressure
to regions of lower pressure. The figures 4 and 5
demonstrate that the higher pressure gradients are due to
the negative HC leading edge angle of the profile, and
that the regions of the HC positive angle produce lower
pressure gradients.

General Design and Construction Principles

At original design, consideration was given to existing
machined profiles such as stabilzers and spiral grooved drill
collars. These tools agitate but do not successfully reintroduce cuttings to the annular flow (see figure 2). The
general construction principles for this new range of
equipment, were to integrate both the hydromechanical
cleaning (HCZ) and hydrodynamic bearing (HBZ) zones in the
drill string. (See figures 7 and 8).
The primary design considerations for these tools were:

Optimize Hole Cleaning efficiency while reducing

torque
Ensure new equipment has torsional and tensile
properties equal to or better than standard equipment.
Minimize mechanical damage to external profile

By providing additional functions at the bearing areas, the

new profile will participate directly in the overall performance
and efficiency of the drilling process. This will improve
hydraulic and mechanical energy transmission, firstly between
drill bit and surface, and secondly between drill string and
borewall.
This will reduce drilling costs and extend
operational limits.
Three different types of drilling tools have been developed
to date, each integrating either the hydromechanical cleaning
and hydrodynamic bearing zones, or only the profile for
hydromechanical cleaning, these new tools are:

Torque Reducing Subs

Heavy Wall Drill Pipe
Standard Drill Pipe

Torque Reducing Subs

Construction and Functioning Features. The first tool with
the new profile was the torque reducing sub. It features a
sleeve, which is non-rotating in relation to the borewall, and
the hydromechanical cleaning profile adjacent to and below

IADC/SPE 59143

the sleeve (see fig. 6).

The primary design purpose of this tool is to reduce rotary
torque and to provide additional hole cleaning features over a
standard non-rotating sleeve construction. The torque reducing
sub may be used either in open hole or cased hole.
Heavy Wall Drill Pipe
Construction and Functioning Features. The heavy wall drill
pipe features two center upsets with the hydrodynamic bearing
zone (HBZ) profile and two hydromechanical cleaning zones
at each upset. (see fig. 7) Downhole and uphole zones of the
hydromechanical cleaning profiles feature five grooves which
are in alignment with the five grooves of the hydrodynamic
bearing (HBZ) profile. For bearing continuity in rotation, and
wear resistance, the five ribs of the HBZ feature a tight design
configuration and are hardfaced with chromium carbide hard
material.
The length of the downhole section of the
hydromechanical cleaning profile is greater than the uphole
length in order to optimize cutting bed decay in critical zones
such as in the horizontal sections close to the bit. Flow loop
test results confirmed the effectiveness of this design feature.
This new design should be used in critical zones where
there is a risk of cuttings sedimentation or differential pressure
sticking problems.
Table 2
Heavy Wall Drill Pipe
Nominal OD
Tool Joint OD
Tube ID
Centre Upset OD
Torsional Yield Tube
Tensile Yield Tube
Adj. Weight / ft

Standard
5
6
3
5
56,500 ft.lbs
691,200 lbs
49.3 lbs

Hydroclean
5"
6 5/8
3
6 5/8
58,233 ft.lbs
864,767 lbs
50.6 lbs

This new Heavy Wall Drill Pipe has mechanical properties

equal to or stronger than standard pipe (see Table 2).
Standard Drill Pipe.
Construction and Functioning Features. This new drill pipe
features three central upsets and has five bearing areas. Three
bearing areas are located on the three central upsets, featuring
both the hydromechanical cleaning (HCZ) and the
hydrodynamic bearing (HBZ) zones, and two on the dual upset
pin and box tool joints. These dual upset tool joints have a
secondary outside diameter which is equal to the diameter of
the HBZ zone and larger than the outside diameter of the
threaded connections. The central upsets and dual upset tool
joints are shown in figure 8.
This five bearing area construction provides steady
mechanical stability of the typically flexible construction of
standard drill pipe, mainly by decreasing the pressure contact
at bearing areas and increasing the critical buckling load. The
dual upset tool joints also ensure that the contact between tool

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 5

joints and the borewall is contained to the area which has been
coated in low friction hardfacing material. This enlarged O.D
section will also improve the mechanical integrity and reduce
wear at the outside diameter and bevel of the connection. In
addition, the five bearing area construction of the modified
drill pipe improves the hydraulic function of the new profile
by ensuring a standoff between the hydromechanical cleaning
zones and the borewall.
Like the new design heavy wall drill pipe, the new standard
drill pipe has equal or higher mechanical strength, than
standard drill pipe (as shown in table 3).
Table 3
Drill Pipe
Nominal OD
Nominal Weight lbs/ft
Tool Joint OD (1)
Tool Joint IOD (2)
Tube ID
Centre Upset OD
Torsional Yield Tube
Tensile Yield Tube
Adj. Weight / ft

Standard
5
19.5 lbs
6 5/8
6 5/8
4.276
N/A
74,100 ft.lbs
712,070 lbs
22.6 lbs

Hydroclean
5
25.4 lbs
6 5/8
7
4
7
83,611 ft.lbs
848,230 lbs
37.4 lbs

Drill pipe modified with this new profile is available to

match all sizes and thread configurations of standard and
heavy wall drill pipe.
Field Experience
Following consultations with several operators, drill pipe and
Heavy Weight incorporating the new external profile was run
in wells where hole cleaning was identified as a critical issue.
These initial field trials were intended to determine the
durability of the new design and confirm the improvements in
hole cleaning as noted when using the original torque
reduction subs.
Example 1. 16,500 ft MD well with approximately 12,600 ft.
of 62 deg. tangent section then building to 2000 ft. of
horizontal hole.
The operators primary concern was hole cleaning, due to
the high angle of the well and the relatively long horizontal
section. High reservoir pressure and increased mud weight
meant that ECDs were critical and flow rate had to be kept
below the recommended optimum level. Differential sticking
was considered a possibility if the reservoir pressure was
lower than anticipated.
Placement of tools incorporating the external profile
consisted of six joints of Heavy Weight (one per stand) in the
BHA and twenty joints of 5 drill pipe (one per two stands)
run behind the BHA during the drilling of the 8 hole
section.

Observations:
When drilling the 8 section, the required flow rate of

500gpm was reduced to 450 gpm with no noticeable

reduction in hole cleaning efficiency.
Torque and drag readings remained below the predicted
values.
After sliding, a very quick return to cuttings bed
equilibrium was apparent.
Well was drilled to TD with no requirement for back
reaming or wiper trips.
No significant wear or mechanical damage was apparent
at post operation inspection.

Example 2. 12 hole drilled to 13,600ft MD. 7000ft. of 57

deg. tangent angle followed by a further 2600 ft. with 90 deg.
turn while maintaining the tangent angle.
Several factors contributed to the operators primary
concern being hole cleaning. These factors included low flow
rates due to limited pump capability at surface, high expected
penetration rate (120ft/hr) and a weak 13 3/8 casing shoe
which meant they could not afford to pack off without risking
the entire well.
Tool placement involved running 1 joint of new profile
drill pipe every 90 feet for the entire 2700-ft. length of 5 drill
pipe being run behind the BHA.

Observations:
Optimum flow rate was 950gpm but they were able to
achieve only a maximum of 850 gpm. No hole cleaning
problems experienced through out the entire section.
Noticed no torque and drag problems as predicted by the
models.
Reduced circulating time by 20-25%.
Eliminated the requirement to run any of the planned
wiper trips.
No significant wear or mechanical damage was apparent
at post operation inspection.

The results of these and similar successful field operations

justified further research to quantify the improvements noticed
while drilling, and to optimize placement in the drill string.
Hole Cleaning and Cuttings Transportation Results
from Bed Erosion and Equilibrium Bed Height Tests
at the Tulsa University Flow Loop (TUDRP)
Conditions and Aims of Testing Program
In order to investigate and quantify performance of the new
profile, comparative tests were undertaken at the Tulsa
University Cuttings Transport Flow Loop. This transparent
flow loop allows full scale simulation of well bore conditions
for cuttings transport. Tests were first performed with a
standard drill string equivalent and then with a drill string
including equipment with the new profiles. Two series of
cuttings transportation experiments were conducted for each
string:

Bed erosion tests typical of hole conditions when

drilling has stopped

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

Equilibrium bed height tests typical of actual drilling

Both series of experiments were performed at horizontal

inclination. The testing program included various cuttings
injection rates [equivalent to rate of penetration (ROP)], flow
rates (Q) and rotary speeds (). Only one water polymer type
mud rheology was used. Due to the loop installation, the
drilling equipment rotated but did not advance along the
cuttings bed.
The main aims of this testing program, representing a total
of 28 experiments were:

Visual examination of all the functioning modes of the

hydromechanical cleaning profile (HCZ)

Investigation of efficiency for hole cleaning and ability to

transport cuttings.

Establishment of rules to optimize placement of the new

equipment in the bottom hole assembly and throughout
the drill string.

The main measuring criteria of the TUDRP loop is the

total weight of steady cuttings bed Wcb. The values recorded
were obtained under the specific conditions of the TUDRP
flow loop: Transparent casing, ID: 8", Drill pipe size: 4 ",
Maximum OD of the hydromechanical cleaning profile (DHC):
6 5/8", Average cutting size 3.65 mm (quartz). No translation
speed of equipment (equal to ROP in actual drilling and
considered beneficial to the actual speed of cuttings bed decay,
i.e. flow loop construction minimizes actual profile
performances).
Analysis of Results. (see figures 9 to 14). The results of the
TUDRP testing program were analyzed at three levels:

Functioning modes of new profiles

Optimization of placement of new equipment in drill
string.
Hole cleaning and cuttings transportation performance

Functioning modes of new profile. Visual examination

during tests and final weight of cuttings bed Wcb at steady
state, highlighted three different actions of the
hydromechanical cleaning profile, the action at the profile and
at the areas uphole and downhole from the profile. The main
effects observed were: -

IADC/SPE 59143

Gradual decrease of steady bed height, downhole from the

bed decay at the profile, as the cuttings bed cannot reach
equilibrium.

Powerful boosting action on solid particles in full annular

passage during simulation of bed erosion conditions.

Optimization of placement of new equipment in the Drill

String (from hydraulic point of view). As the main region
of cuttings bed decay is located at the equipment, and in the
uphole zone, the first approach for spacing equipment with the
hydro-mechanical cleaning profile can be summarized as
follows:

Maximize the total length of hydromechanical cleaning

profile in the bottom hole assembly to achieve thorough
cleaning of the cuttings bed. This is especially beneficial
for directional control and drilling process efficiency, and
to minimize total circulating time.

In all areas where there is a risk of cuttings sedimentation

a minimum of one joint of hydromechanical cleaning
profile per 90 feet is recommended.

For the remainder of the drill string these joints should be

placed at a minimum of one per 180 feet to complete
cleaning to surface.

These recommendations are based on the test results

achieved at the Tulsa University Cuttings Transport Flow
Loop by considering the total length of hydromechanical
cleaning profile installed in the 84 foot flow loop length and
without considering differential pressure sticking, stability of
the drill string or need for torque reduction.
Hole cleaning and cuttings transportation performances.
Samples of test plots are given by figures 9 and 10 for the bed
erosion tests and by figures 11 and 12 for the equilibrium bed
height tests. By comparative analysis of the experimental
results, figures 13 and 14 show the measured differences in
hole cleaning and cuttings transportation between standard
drill pipe, and drill pipe featuring the new profile. As already
mentioned the criteria for quantifying the cleaning ability is
the remaining weight of the steady cuttings bed for a given
combination of typical parameters, as used in this test matrix.
These experimental results can be summarized as follows:

Near-instantaneous decay of cuttings bed at the profile

levels.

Helical turbulences in the uphole zone for the

recirculation of solid particles, previously lifted off low
side of hole. This boosting effect on particles, due to the
combined scoop action and the archimedian screw effect,
was clearly marked.

For bed erosion tests. Depending upon operating

parameters, equipment with the new profile may be used at a
flow rate 30 to 50% less than that used for standard equipment
and still achieve a similar cuttings bed height or weight. This
represents a potential decrease of pressure losses (P) from 60
to 75%, assuming the pressure loss formula: -

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 7

P = kp x Q 1,85
For equilibrium bed height tests. As for bed erosion tests,
depending on operating parameters, flow rate (Q) may be
reduced by 20 to 30%, from that used on standard equipment,
which represents a potential decrease of pressure losses from
40 to 60%.
Conclusions
1. The Hydromechanical Cleaning Zone (HCZ) and the
Hydrodynamic Bearing Zone (HBZ) have been
successfully integrated in the following drilling
equipment:

The analysis of all effects produced by the new profiles

show there is an interaction between the hydromechanical
cleaning zones and the hydrodynamic bearing zones.
These provide several benefits to the drilling process,
mainly:

3.

Improved hole cleaning/cuttings transportation

Reduced frictional loads
Extended operating limits

The scoop effect, archimedian screw effect and the

deflecting effect on particles work in combination to clean
the hole in three different areas:

Field experience demonstrates that the five bearing point

construction, including dual O.D. tool joints, spreads the
bearing load and minimises tool wear.

7.

Indications are that even when not rotating the

hydromechanical cleaning profile will induce turbulence
and create cuttings lift in the uphole zone.

8.

The hydromechanical cleaning zone profile proved its

efficiency both during the bed erosion and equilibrium
bed height tests conducted in the TUDRP flow loop at
Tulsa University. Depending upon operating parameters,
the new profile may be used at flow rates 30 to 50% less
than that used for standard equipment and still achieve a
similar cuttings bed height for bed erosion tests. For
equilibrium bed height tests, flow rate with new profile
may be reduced by 20 to 30%.

Torque reducing subs

Standard Drill Pipe
Heavy Weight Drill Pipe

Modifying both mechanical and hydrodynamic

properties, at the bearing areas is a new approach to
drilling equipment construction.
2.

6.

Near instantaneous decay of cuttings bed at profile

area.
Helical turbulences in uphole zone for cuttings
transport.
Gradual decrease of steady bed height in downhole
zone

4.

The hydromechanical cleaning zone may be combined

with non-rotating sleeve low torque subs for efficient hole
cleaning and reduced rotary torque.

5.

The construction of this new heavy wall drill pipe

maximizes the effective length of hydromechanical
cleaning zone. Flow loop observations indicate that
placement of these tools should be as near as possible to
the bottom hole assembly where optimized mechanical
behaviour of the drill string and hole cleaning are of the
utmost importance.

Nomenclature
HCZ
= Hydromechanical Cleaning Zone
HBZ
= Hydromechanical Bearing Zone

= Rotary speed, RPM

hc
= Helix angle of HCZ profile (deg )
hb
= Helix angle of HBZ profile (deg )
hc
= Negative edge angle of HCZ grooves (deg )
^hc
= Positive edge angle of HCZ grooves (deg )
1, 2
= Positive edge angles of HBZ grooves (deg )
dhb
= Variable depth of HBZ grooves (inches)
Dhb
= Maximum outside diameter of HBZ (inches)
Dhc
= Maximum outside diameter of HCZ (inches)
Q
= Drilling flow rate (gpm)
qht
= Tangential flow rate at HBZ (gpm)
qhbi
= Inlet flow rate at HBZ grooves (gpm)
qhbo
= Outlet flow rate at HBZ grooves (gpm)

= Dynamic viscosity (Paxs)

^
= Shear rate of strain (s- in )
Wcb
= Weight of steady cutting bed of flow loop (lbs)
ROP
= Rate of penetration (ft/hr)
Acknowledgements
The authors would like to thank Dr. Stefan Miska, Dr. Ergun
Kuru and the research staff at the Tulsa University Drilling
Research Unit for their assistance and expertise in the flow
loop tests. We would also like to thank Don Sitton (Shell
Expro) and Peter Bern (BP Amoco) for their input and
direction in the development of the testing programme.
References

1.

2.

Charlez, Ph. A., Easton, M., Morrice, G., Cenergys,

Tardy, P., Validation of Advanced Hydraulic Modeling
using PWD Data paper OTC 8804 presented at 1998
Offshore Technology Conference held in Houston, Texas
4-7 May.
Sanchez, R.A., Azar, J.J., Bassal, A.A., and Martins, A.L.:
The Effect of Drillpipe Rotation on Hole Cleaning
during Directional Well Drilling, paper SPE 37626

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

presented at the 1997 Drilling Conference, Amsterdam

(Mar. 4-6. 1997).
3. Martins, A.L., et al.: On the Erosion Velocity of a
Cuttings Bed During the Circulation of Horizontal and
Highly Inclined Wells, paper SPE 39021, presented at
Rio de Janeiro, Brazil, (30 August 3 September, 1997).
4. Arild Saasen and Oljeselskap A.S.: Hole Cleaning
During Deviated Drilling The Effects of Pump Rate and
Rheology, SPE 50582, October (1998).
5. Azar, J.J; Sanchez, R. Alfredo.: Important Issues in
Cuttings Transport for Drilling Directional Wells, paper
SPE 39020 presented in 1997 at the Fifth Latin American
and Caribbean Petroleum Engineering Conference, Brazil.
6. Alli A. Pilehvari, J.J. Azar.: State-of-Art Cutting
Transport in Horizontal Welllbores, paper SPE 37079
presented at the 1996 conference on Horizontal Well
Technology held in Calgary.
7. Rishi B. Adari.: Development of Correlations Relating
Bed Erosion to Flowing Time for Highly Inclined Wells
(How Clean is Clean?). MS Thesis, University of Tulsa,
Tulsa, OK (1999).
8. Green, M.D., Thomesen, C., Wolfson, L., Bern, P.A.: An
Integrated Solution of Extended-Reach Drilling Problems
in the Niakuk Field, Alaska: Part II Hydraulics, Cuttings
Transport and PWD, paper SPE 56564 presented at the
1999 SPE Annual Technical Conference and Exhibition,
Houston, Texas, USA, October 3-6.
9. Naegel, M., Pradi, E., Delahaye T., Mabile C.,
Roussiaux G.: Cuttings Flow Meters Monitor Hole
Cleaning in Extended Reach Wells, paper SPE 50677
presented at the 1998 SPE European Petroleum
Conference held in The Hague, The Netherlands, 20-22
October.
10. Hazell, M.W., and Cocking D.A., The Wytch Farm
Extend Reach Drilling Project, 6th World Oil
International Horizontal Well Technology Conferences,
Houston, Nov. 9-11 1993.
11. Naegel M., Pradie E., Beffa K., Ricaud J., Delahaye T.,
Extended Reach Drilling at the End of the Earth, paper
SPE 48944, New Orleans, 27-30 September 1998.
12. Adari, Rishi., Miska, Stefan., Kuru, Ergun., Bern, Peter.,
Saasen, Arild., Cuttings Bed Erosion Curves Help
Predict Optimum Circulation Time for Hole Cleaning
Purposes, paper ETCE2000/DRILL-10131 presented at
ETCE/OMAE2000 Joint Conference: Energy for the
Millennium, February 14-17, 2000 New Orleans, LA

IADC/SPE 59143

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 9

qhbo
(
2)

Hydrodynamic
Bearing Zone (HBZ)

(
1)

qht

Helix Angle
(
hb)

Dhb

Hydromechanical
Cleaning Zone (HCZ)

qhbi

Helix Angle
(
hc)

(
hc)

(^
^ hc)
Dhc

Figure 1 : New profile and functioning principles of the HBZ

10

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

IADC/SPE 59143

(
hc)

Rotation

(
hc)
Standard Spiral Drill Collar
or Stabilizer Profile

HCZ Profile

Figure 2 : Functioning principles of the Hydromechanical Cleaning Zone (HCZ).

(Solid particles are lifted off the borewall and boosted upwards).

SMFI Hydroclean Profile

Mesh used in CFX-5 Simulation

Positive ALPHA usual screw angle

Negative Slope HYDROCLEAN

Figure 3 Close up of the grid used to model the Hydromechanical Cleaning Zone (HCZ)
Profile Geometry

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 11

Figure 4 CFD Analysis of HCZ Profile / Vector plots for pressure gradient

Figure 5 CFD Analysis of HCZ Profile / Vector plots for velocity

12

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

IADC/SPE 59143

Dual O.D.
Tool Joint

HCZ

HBZ

HBZ

HCZ

HCZ

Non
Rotating
Sleeve
HCZ

Figure 6 Torque
Reducing Sub with
HCZ Profile

Figure 7 Heavy Wall

Drill Pipe with HCZ and
HBZ Profiles

Figure 8 Drill Pipe with

HCZ and HBZ profiles
and Dual O.D. Tool
Joints

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 13

Q = 200GPM / = 80 RPM / Wcb = 460 lbs

300

Wcb

2000

200

1500

150

1000

100

500

Pressure Losses, Drillpipe Rotation (RPM), Flow Rate (gpm)

Cuttings Content (lbs), Collection Rate (lbs/min), ROP (ft/hr)

250

50

0
0

1000

2000

3000

4000

5000

6000

7000

0
8000

Time (secs)

Figure 9 Bed Erosion Test with Standard Equipment

(Ref: TUDRP/Tulsa University Flow Loop)

Q = 200 GPM / = 80 RPM / Wcb = 175 lbs

2500

450

2000

350

Wcb

300

1500
250

200
1000
150

100

500

50

0
0

1000

2000

3000

4000

5000

6000

Time (secs)

Figure 10 Bed Erosion Test with New Profile Equipment

(Ref: TUDRP/Tulsa University Flow Loop)

0
7000

Pressure Losses, Drillpipe Rotation (RPM), Flow Rate

(gpm)

Cuttings Content (lbs), ROP (ft/hr), Torque (in-lbs)

400

14

J.G. BOULET, J.A. SHEPHERD, J. BATHAM, L.R. ELLIOTT

IADC/SPE 59143

Q = 300 GPM / ROP = 30 ft/hr / = 50 RPM / Wcb = 961 lbs

1200

100

80

800

60

600

40

400

20

200

Pressure Drop (DP12 & DP13), Drillpipe Rotation

(RPM)

Cuttings Content (lbs), ROp (ft/hr),Torque (in-lbs)

Wcb
1000

0
0

500

1000

1500

2000

2500

3000

-20
3500

Time (secs)

Figure 11 Equilibrium Bed Height Test with Standard Equipment

(Ref: TUDRP/Tulsa University Flow Loop)

1000

500

900

450

800

400

700

350

600

300

500

250
Q

400

200
Wcb
150

300

100

200

100

50

0
0

500

1000

1500

2000

2500

3000

Time (secs)

Figure 12 Equilibrium Bed Height Test with New Profile Equipment

(Ref: TUDRP/Tulsa University Flow Loop)

0
3500

Pressure Losses, Drillpipe Rotation (RPM), Flow Rate

(gpm)

Cuttings Content (lbs),ROP (ft/hr),Torque (in-lbs

Q = 300 GPM / ROP = 30 ft/hr / = 50 RPM / Wcb = 515 lbs

IADC/SPE 59143 IMPROVED HOLE CLEANING AND REDUCED ROTARY TORQUE BY NEW EXTERNAL PROFILE ON DRILLING EQUIPMENT 15

800

700

Standard
equipment

600

Wcb (lbs)

500

400

300

Equipment with
new profile
200

100

= 50 RPM
0
0

50

100

150

200

250

300

350

Q (GPM)

Figure 13 Comparative Performance Bed Erosion Tests

(Ref: TUDRP/Tulsa University Flow Loop)
1600

1400

Standard
equipment

1200

Wcb (lbs)

1000

800

600

Equipment with
new profile
400

ROP = 30 ft/hr
= 50 RPM

200

0
0

50

100

150

200

250

300

350

Q (GPM)

Figure 14 Comparative Performance Equilibrium Bed Height Tests

(Ref: TUDRP/Tulsa University Flow Loop)

400

450