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Conservation Equations 冋
1共Cs1兲 = 4f Cs1 .8 + .767共 fi − 1兲 +
1
共 fi − 1兲
册 . . . . . . . . . . . . (8)
There are three mass conservation equations: one for Region 1 The coefficients ␣1, ␣2, 1, and 2 in Eq. 5 for turbulent and
(deposit bed), one for the fluid phase, and one for the solid phase laminar flow are to be calibrated using experimental data.
(cuttings) in Region 2. These equations, together with the three Hydrodynamic interfacial shear stress (existing at the interface
momentum conservation equations, are listed in Appendix A. In between the two layers) is assumed to be a function of the fluid
the momentum conservation equations, the following aspects of hydrodynamics only. It is expressed in terms of relative velocities
multiphase flow were considered. Multiparticle drag forces, Fsf, between fluid flowing in suspension and the moving bed regions.
between solid and fluid are considered in the suspension Region 2
(Shook and Roco13). 12 = 12 共uf 2 − u1兲
1
Fs,2 = Cs2F2 + Fsf 12 = f12f |uf 2 − u1|. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (9)
2
Ff,2 = Cf2F2 − Fsf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1)
The interfacial friction coefficient, f12, in Eq. 9 is evaluated using a
For 1D flow, modified Colebrook formula for rough pipes (Televantos et al.16).
sf = , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) The interface Reynolds number, Re12, is evaluated using power-
4dp 共1 − Cs2兲1.65 law form for the non-Newtonian flow associated with the fluid
flowing in suspension relative to the moving bed’s rough surface
where the drag coefficient CD is determined from the Reynolds
(of roughness dimension equal to the particle diameter, dp), as
number, Rep.
shown in Eq. 11.
Cf 2f |uf 2 − us2 |2−n dnp Cf 2f |uf 2 − u1|2−n Dn2
Rep = Re12 = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (11)
8n−1 f 8n−1f
D = .44
C* Rep ⱖ 989 Deposition and entrainment rates, vDEP and vENT, determine the
volumetric material transfer rate across the interfacial boundary,
24共1 + 0.15Rep 0.687
兲 aligned in the direction normal to bulk flow. The deposition rate,
D=
C* Rep ⬍ 989
Rep vDEP, is determined as the hindered terminal settling velocity of a
single particle, vp. A force balance on a single particle equates the
CD = ␣DC*
D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) drag force FD to the gravitational force Fg.
A drag factor, ␣D, is assumed as a corrective measure to be cali- d3p
brated with experimental results. The particle Reynolds number is Fg = 共s − f兲g
determined using power-law for non-Newtonian flow with fluid 6
flow index, n. Hydrodynamic shear stresses are modeled by the 1 d2p
FD = CDf v2p , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (12)
following expressions (Doron et al.14): 2 4
vp = 冑 4共s − f兲gdp
3f CD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (13)
bed to move (Doron et al.14). The definition for this dry friction is
given by Eq. A-7 in Appendix A.
The system of six nonlinear first-order partial differential equa-
tions for mass balances and momentum balances completely de-
Doron et al.14 suggest the following equations to consider the fine the behavior of six unknown variables, Xⴕ, including the area
concentration effects on the hindered terminal settling velocity: (height) of the deposit bed, deposit bed velocity, cuttings concen-
tration in the suspension layer, mud velocity and cuttings velocity
in the suspension layer, and pressure.
vDEP = vpCf2m
m = 4.45ReDEP−0.1 ReDEP ⬍ 596 X⬘ = 关A2,u1,Cs2,us2,uf 2,p兴T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (17)
m = 2.39 ReDEP ⱖ 596, . . . . . . . . . . . . . . . . . . (14)
The equations were differenced and solved simultaneously using New-
where ReDEP⳱the Reynolds number iterated with respect to the ton’s method with relaxation to obtain stable numerical solutions.
hindered terminal velocity deposition rate, vDEP .
The entrainment rate, vENT, is assumed to be a function of the Discussion of Results
interfacial shear velocity u12, as suggested by Doron et al.14 The numerical model was run to generate results for a variety of
hydrodynamic conditions, including fluid rheology, mud rate and
冑 冑
viscosity, and cuttings size. The results were analyzed and com-
12 12|uf2 − u1|
u12 = = . . . . . . . . . . . . . . . . . . . . . . . . . . (15) pared to experimental data obtained from a cuttings transport flow
f f loop system (CTFLS) at TRC/JNOC’s Kashiwazaki Test Facility
in Japan. Masuda et al.17 provided a comprehensive description of
For this study, a simple linear dependence on the interfacial shear the experimental apparatus and procedure to determine the cuttings
velocity with slope, mENT, and a critical threshold, u12
* , is assumed. velocity and concentration values inside the test section. Fig. 3 is
a schematic drawing of the flow loop. The annular test section was
vENT = 0 u12 ⱕ u12
* 9 m long, and consisted of a 5-in. (127.0 mm) ID transparent
vENT = mENT共u12 − u12
*兲 u12 ⬎ u12
* . . . . . . . . . . . . . . . . . . . (16) acrylic outer pipe (borehole or casing). A 2.063-in. (52.4 mm) or
2.875-in. (73.0 mm) OD steel inner pipe (drillpipe) was used. The
test section was mounted on a movable frame, and the inclination
As such, it is seen that below the critical threshold, no deposited of test section could be set at an angle ranging from 0 (horizontal)
cuttings are re-entrained into the flowing suspension layer. Above to 90° (vertical) in 15° increments. Drillpipe eccentricity could be
the critical threshold, the re-entrainment rate is assumed to be changed from 0 to 100%. Inner drillpipe could rotate at speeds
directly proportional to the velocity difference: the larger the ve- ranging from 0 to 80 rpm.
Fig. 3—Schematic drawing of TRC/JNOC’s Kashiwazaki Cuttings Transport Flow Loop System (CTFLS) at Kashiwazaki Test
Facility.
Fig. 4—Pressure distribution profile for a simulation run (Mud 2 Fig. 5—Solid-phase concentration distribution profile for a
drilling fluid, f=1.19 g/cm3, µ=216.0 mPaⴢs, n=0.61, s=2.40 simulation run (Mud 2 drilling fluid, f=1.19 g/cm3, µ=216.0
g/cm3; cuttings size=0.366 cm), mud rate=40 m3/hour; cuttings mPaⴢs, n=0.61, s=2.40 g/cm3; cuttings size=0.366 cm), mud
injection rate=2.148 L/min. rate=40 m3/hour; cuttings injection rate=2.148 L/min.
Fig. 8—Deposit bed velocity distribution profile for a simulation Fig. 9—Deposit bed height distribution profile for a simulation
run (Mud 2 drilling fluid, f=1.19 g/cm3, µ=216.0 mPaⴢs, n=0.61, run (Mud 2 drilling fluid, f=1.19 g/cm3, µ=216.0 mPaⴢs, n=0.61,
s=2.40 g/cm3; cuttings size=0.366 cm), mud rate=40 m3/hour; s=2.40 g/cm3; cuttings size=0.366 cm), mud rate=40 m3/hour;
cuttings injection rate=2.148 L/min. cuttings injection rate=2.148 L/min.
deviation of 6% of simulated velocity from measured data). It is to extend the experimental range and establish critical conditions
noted that in the experiments, cuttings velocity and concentration for each of the cases. The results were plotted to produce an
were (essentially) measured at a single point along the 9-m test envelope of minimum and maximum velocity observed over the
section (where the CCD video system was stationed). The numeri- entire length of the test section at the terminal simulation time.
cal model, on the other hand, enabled the cuttings velocity and Within the envelope, velocities averaged over the length of the test
concentration to be determined at different points along the whole section were also included to represent the flow profile in compact
test section. Consequently, these ranges of values allowed the form. Critical and subcritical conditions are represented when the
minimum, average, and maximum cuttings velocity and concen- minimum cuttings velocities are zero. Therefore, at some point
tration for the whole test section to be determined. along the length of the annulus, a stagnation point (as discussed
In these and other cases (of different mud rheologies and cut- earlier) will be encountered. Cuttings rate above the critical will
tings sizes), the simulator was run at different inlet cuttings rates lead to subcritical condition. Cuttings rate below the critical will
to determine the corresponding cuttings velocity profiles. This was lead to nonzero cuttings velocity.
Fig. 11—Comparison of experimental data and simulation results, horizontal borehole, Mud 1 drilling mud (f=1.00 g/cm3, µ=355
mPaⴢs, n=0.469, s=2.40 g/cm3); mud rate=40 m3/hour; cuttings injection rate=0.013 and 0.018 L/min.
It is seen that for the cases simulated, the minimum cuttings envelope of minimum and maximum velocity observed over the
velocity tends to concave downward and approaches critical at an length of the test section at terminal simulation time followed the
inlet cuttings rate of approximately 1.4 l/min. What this means is same trend as that observed in Fig. 10. For the hydrodynamic con-
that for inlet cuttings rates above this critical value, a mud rate of ditions associated with Mud 1, the minimum cuttings velocity tends to
40 m3/hour would not be sufficient to remove cuttings effectively approach critical at an inlet cuttings rate of approximately 1.3 l/min.
from the system. A point must be made regarding the relatively poorer match
Similar simulation runs were made for non-Newtonian muds. between simulation results and experimental data of cuttings ve-
In Fig. 11, Mud 1 was used. Its flow rate was also 40 m3/hour. Two locity in this case (Mud 1) compared to the previous case (water).
different injected cuttings rates were used: 0.013 and 0.018 l/min, It was observed that simulation results deviated from experimental
respectively. The simulator calculated cuttings velocity values of data at extreme dilute cuttings rates (for the cases studied, less than
17.2 and 19.0 cm/s for the two runs, compared to their measured 0.05 l/min). In these cases, it is believed that the two-layer model
values of 21.5 and 10.8 cm/s, correspondingly. For this mud, the with a level interface does not represent the system adequately.
Fig. 13—Comparison of experimental data and simulation results, horizontal borehole, Mud 1 drilling mud (f=1.00 g/cm3, µ=355
mPaⴢs, n=0.469, s=2.40 g/cm3); mud rate=40 m3/hour; cuttings injection rate=0.169 L/min.
冤 冥
in Highly Inclined Wellbores,” paper SPE 53942 presented at the 1999
A2 ⌬s + A2⌬ss g sin ␣
SPE Latin American and Carribean Petroleum Engineering Confer- ⭸s
ence, Caracas, 21–23 April. = −Cs2 + 12共uf 2 − u1兲L12⌬s
13. Shook, C.A. and Roco, M.C.: Slurry Flow: Principles and Practice,
Butterworth-Heinemann, Burlington, Massachusetts (1991).
+ 2uf 2共L2,outer + L2,inner兲⌬s
14. Doron, P., Granica, D., and Barnea, D.: “Slurry Flow in Horizontal + u1vENTCs1sL12⌬s − us2vDEPCs2sL12⌬s
Pipes—Experimental and Modeling,” Intl. Jour. of Multiphase Flow
(1987) 13, No. 4, 535. + A2sf 共uf 2 − us2兲⌬s, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (A-5)
冤 冥
A2 ⌬s + A2⌬sf g sin ␣ cializing in mathematical modeling, numerical simulation, and
⭸s software development in the areas of engineering, manage-
= −Cf2 + 12共uf 2 − u1兲L12⌬s ment, and finance. Currently, he is developing stochastic dy-
namic programming decision-making tools to value optimal
+ 2uf 2共L2,outer + L2,inner兲⌬s operating policies and path-dependent action plans for peak-
ing power plants and gas reservoir storage assets with con-
Cf1 straints contingent on economic, physical, operational, and
+ u1vENTCf1fL12⌬s − uf2vDEP Cs2fL12⌬s contractual states. Oguztoreli holds a PhD degree in engineer-
Cs1
ing management, MBA and MSc degrees in petroleum engi-
− A2sf 共uf 2 − us2兲⌬s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (A-6) neering, and a BSc degree in physics. Yoshihiro Masuda is cur-
rently an associate professor in the Dept. of Geosystem Engi-
The sum of driving forces in Region 1 must overcome the dry neering at the U. of Tokyo, Japan. e-mail: masuda@geosys.t.
friction resistance force, F1, in direction opposing flow for the bed u-tokyo.ac.jp. His current research activities include hole
to move (Doron et al.14), as follows: cleaning in underbalanced drilling, in-situ polymer gelation in
再 冋冉 冊冉 冊册冎
sediments, and development of a numerical simulator predict-
2共1 + 兲
1 −1 + ing gas production behavior from methane-hydrate reservoirs.
F1 = 共 − f兲gC1sDouter
2
Douter 2 He previously was a petroleum engineer with Japan Petroleum
2 s + cos Exploration Co., Ltd. He holds a doctoral degree in engineer-
⌬s sgnu1cos␣ ing from the U. of Tokyo. Tetsuo Yonezawa is currently a Project
Manager of the Research Project Team, Methane Hydrate,
⭸p Technology Research Center of Japan National Oil Corp., Ja-
F1 = A1 ⌬s − 12L12⌬s + 1共L1,outer + Li,inner兲⌬s
⭸s pan. e-mail: yonezw-t@jnoc.go.jp. His current activities include
+ F1 and 兺
Fdriving ⬎ F1 for |u1| ⬎ 0, . . . . . . . . . . . . . . . (A-7)
drilling and completion R&D projects including, among others,
UBD and borehole stability. He holds a BA degree in engineer-
where ⳱the dry friction coefficient, and sgnu1 cos ␣ accounts for ing from Hokkaido U., Japan. Atsushi Kobayashi is currently a
the inclined flow direction. section manager in the Tokyo Technology Center of Telnite
Co., Ltd. e-mail: atsushi_kobayashi@telnite.co.jp. He previously
joined with JNOC/TRC for the Underbalanced Drilling Project in
Quang T. Doan is a reservoir engineer at APA Petroleum Engi- JNOC. Kobayashi holds a BSc degree in chemical engineering
neering Inc. in Calgary, Canada. e-mail: qdoan@apa- from Akita U., Japan. Shigemi Naganawa is currently a re-
inc.com. He was previously a senior engineer in the R & D search associate in the Dept. of Geosystem Engineering at the
Group of the Computer Modelling Group Ltd. in Calgary. Be- U. of Tokyo, Japan. e-mail: naganawa@kelly.t.u-tokyo.ac.jp.
fore joining CMG Ltd., he was a consultant involved in devel- His current research activities include cuttings transport in di-
oping simulators for multiphase flow in production and drilling rectional wells and modeling of drill-bit/strings dynamics. Na-
processes and undertaking a number of reservoir analysis and ganawa holds a Meng degree in mineral development engi-
well-performance studies. He has taught courses in production neering from the U. of Tokyo, Japan. Arjan M. Kamp was until
engineering, reservoir engineering, and simulation, as well as recently employed as researcher and project leader in PDVSA
supervised MSc and PhD theses on thermal recovery pro- Intevep in Venezuela. e-mail: caroyarjan@cantv.net. His re-
cesses, cold production of heavy oil, and multiphase flow search activities include multiphase flow applications in the oil
modeling. His interests include heavy oil recovery and mul- industry, varying from drill cuttings transport, underbalanced
tiphase flow phenomena. Doan holds BSc, MSc, and PhD de- drilling, flow in horizontal wells, and heavy oil flow in reservoirs.
grees in petroleum engineering, all from the U. of Alberta, Mr. Kamp is an applied physicist from the Eindhoven U. of Tech-
Canada. Mustafa Oguztoreli is currently Director of Quantita- nology in the Netherlands. He holds a PhD degree in fluid me-
tive Resources at Shell Trading Gas and Power in Houston. chanics from the Inst. Natl. Polytechnique de Toulouse, France.