SPE-197864-MS

Digital Solutions Using Advanced Computational Techniques to Simulate

Hole Cleaning

Kedar Deshpande, Weatherford; Miguel Angel Celigueta, Salvador LaTorre, and Eugenio Onate, International
Centre for Numerical Methods in Engineering; Pravin Naphade, Weatherford

Copyright 2019, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 11-14 November 2019.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Cuttings transport and hole-cleaning is a challenging issue associated with the efficiency of wellbore
hydraulics and drilling operation. Traditional methods used to understand hole cleaning problems are based
on field observations and extensive flow loop testing to formulate empirical correlations and mechanistic
models. The focus of this study is to create digital twin utilizing advanced simulation techniques that
provides better insight for cuttings transport and hole-cleaning. This study explores the use of Eulerian-
Lagrangian based numerical techniques to estimate critical flow rate needed for efficient hole cleaning.
Digital twin for the cuttings transport is formulated utilizing three dimensional Navier stokes equations
employing combination of Eulerian and lagrangian approaches to model the drilling mud flow and cuttings
interaction with the drilling mud, wellbore walls and between cuttings themselves. One of the important
model to estimate the drag force on cuttings is modified for non-spherical cuttings shape coupled with
non-newtonian Herschel Bulkley behavior of the drilling mud in this work. The influence of important
parameters, such as fluid rheology, rotation of drill-string, and inclination of wellbore on the hole-cleaning
process is investigated. Digital solutions are compared against the published data for Newtonian and non-
Newtonian drilling fluids under different wellbore configurations. The advanced computational simulation
involving novel drag force correlation and unique combination of numerical methods allowed to create
digital twin for cuttings transport process accurately. The numerical strategy utilizing modified drag law
showed a very good match with experimental results for straight vertical wellbore, the cuttings transport
velocity estimated by digital solutions was within 5% difference of experimental results. Further upon
validation, numerical results are successfully computed for drill -string rotation effects which clearly showed
physics of cuttings transported efficiently with added energy due to rotation. The phenomenon of cuttings
bed sliding in inclined and horizontal wellbores is also correctly simulated with the proposed drag law
and numerical methods. The proposed methodology works without any issues with high concentration of
cuttings and provides detailed insight into cuttings flow path and effect of various operational parameters
on hole cleaning. Advanced computational simulations and modification of drag force law assisted in
formulating digital twin that provided excellent insights in understanding effects of operational parameters
for efficient hole cleaning.
2 SPE-197864-MS

Introduction
Cuttings transport (hole cleaning) phenomenon is a major challenging issue associated with efficiency of
wellbore drilling process. The cuttings transport process involves complex interaction between cuttings and
the surrounding drilling mud that exhibits Non-Newtonian fluid behavior. Lack of efficient hole cleaning
can lead to serious drilling problems such as stuck pipe, annular pack off, excessive torque and drag, lost
circulation, high mud costs and severe erosion to the wellbore components. Oil & gas industry has invested
significant amount of effort in investigating the cuttings transport problem using experimental techniques,
formulating empirical models and developing lower order mechanistic models. Estimation of the minimum
flow rate needed for efficient hole cleaning and estimating the cuttings concentration has been one of the
major focuses of research for last 30 years. In the first part of this paper different empirical models and
mechanistic model to calculate minimum flow rate, cuttings concentration and cuttings bed height are
investigated. The latter part of this paper will focus on formulation and usage of advanced computational
techniques to study the hole cleaning process.

Literature Review
Cuttings transport process plays an important role in effective drilling operation, specifically in horizontal
and inclined wells hole cleaning issues can cause significant problems during drilling operations. The
operational parameters such as ROP, drill string rotation, fluid rheology, well hole inclination, drill-pipe
eccentricity, cuttings characteristics have significant effect on hole cleaning process. A detailed literature
review is conducted to determine the importance of the drilling parameters and fluid rheology on hole
cleaning process and to investigate the existing modeling capabilities. The two most common accepted
approaches for modeling are:
1. Empirical modeling: Based on experimental observations.
2. Mechanistic models: Lower order models based on theory.
Initial efforts for cuttings slip velocity calculations were focused on vertical wells. Piggot et al. in 1940 [1]
and Chien et al. in 1950 [2] developed slip velocity correlations for vertical wells. In 1980, Iyoho and Azar
[3] formulated semi-empirical correlation for particle slip velocity calculations and studied the eccentricity
effects in directional wells. Tomren et al. [4] conducted rigorous experimental studies for directional well
using different drilling fluids and actual drilling cuttings. These studies underscore the importance of drill
pipe eccentricity, pipe inclination and different flow regimes on the cuttings transport process. Tomeren et
al. concluded that angles between 35 to 55 degrees were critical angles since they caused bed forming and
a bed sliding downwards against the flow. Okrajni and Azar [5] performed experimental studies in deviated
wells and suggested laminar flow regimes for hole cleaning in 0 to 45 degrees inclination and turbulent flow
conditions in 45 to 90 degrees for efficient hole cleaning.
Gavignet and Sobey [6] developed a two-layer mechanistic model for cuttings transport in eccentric
annulus and estimated critical flow rate below which cuttings bed will start forming, they compared the
mechanistic model results with the experimental studies. Brown et al. [7] conducted experimental studies
for deviated well and concluded that angles between 50 to 60 degrees are the most problematic sections for
hole cleaning, they also indicated that water in turbulent flow regime was most effective drilling fluid. Peden
et al. [8] presented an experimental study where the y investigated the influence of hole angle, dill pipe
eccentricity, drill pipe rotation and fluid rheology, these studies also identified the wellbore angle between
40 to 60 degrees as the most problematic section for transporting cuttings in rolling and suspension form.
Becker et al. [9] investigated the influence of mud rheology on the cuttings transport process, for
hole inclination angle between 0 to 45 degrees a laminar fluid flow is more effective and for hole
inclination between 45 to 90 degrees a turbulent flow regime is more effective. Luo et al. [10] developed
a correlation to predict the critical flow rate for hole cleaning and compared model results with the
SPE-197864-MS 3

experimental studies. Martins and Santana [11] presented a two-layer mechanistic model in horizontal and
near horizontal eccentric annuli. The model consisted of bottom layer made up solids and top layer made
up of heterogeneous suspension.
Sifferman and Becker [12] conducted detailed experimental studies, where they assessed hole cleaning
in full-scale inclined wellbores to gauge the influence of annular fluid velocity, mud density, mud rheology,
mud type, cuttings size, ROP, drill pipe rotation speed (RPM), eccentricity of drill pipe, drill pipe diameter
and hole angle on cuttings accumulation and bed buildup. The experiment showed that beds forming at
inclination angles between 45° and 60° degrees might slide or tumble down, while at the angle between 60°
and 90° degrees from vertical, cuttings bed was less movable. They also concl uded that cuttings bed was
accumulated easier in oil-based mud than in water-based mud.
Larsen et al. [13] developed a cuttings transport model for high inclination angle wellbores using
extensive experimental testing for angle interval from 55 to 90 degrees from the vertical. The experimental
study was conducted to account for flow rate, hole inclination, rheology, eccentricity, drill pipe rotation.
The developed model predicted the minimum fluid velocity necessary for cuttings transport. Larsen's study
gave three important definitions:

• Critical Transport Fluid Velocity is the minimum velocity needed for continuous transport of
cuttings to the surface.
• Cuttings transport velocity is the velocity of cuttings during transport.

• Sub-Critical fluid flow is the velocity below Critical transport fluid velocity at which cuttings will
start to accumulate.
A three-layer model consisting of two beds, a stationary bed at the bottom, a moving bed layer above it,
and a heterogeneous mixture at the top was presented by Doron and Barnea [14] for horizontal and inclined
wellbores. Lockett et al. [15] demonstrates the influence of Taylor vortices on cuttings bed formation using
numerical simulations. Clark and Bickham [16] formulated a mechanistic model that modeled particle
settling, lifting and rolling, and model results showed a good match with the experimental data. Extensive
experimental studies focusing on erosion of the cuttings bed was conducted by Martins et al. [17] and
developed a correlation for prediction of cuttings bed height and minimum flow rates for horizontal
wellbores. Kenny et al. [18] underscored the importance of rheological parameters and specifically fluid
index "n" on the hole cleaning process and developed a new model for horizontal wellbore.
A three-layer model was introduced by Nguyen and Rahman [19] that consisted of three major
components: uniform concentration cuttings bed, a dispersed layer with varying particle concentration and
fluid flow layer that can be clear fluid or turbulent suspension. This model showed good agreement with the
experiments and was applicable to deviated to horizontal wellbores. Hemphill and Larsen [20] conducted
extensive experimental studies to check the influence water and oil-based drilling muds on hole cleaning
efficiency. Based in these studies for inclined well oil-based mud did not clean the wellbore as efficiently as
water-based mud at similar operating parameters. Philip et al. [21] investigated the influence of the Taylor
vortices on the cuttings transport process and concluded that Taylor vortices does influence the lift force on
the cuttings. This study also stated that higher value of "n" and "k" are more beneficial for cuttings transport.
Sanchez et al. [22] observed that drill pipe rotation played an important role on hole cleaning for deviated
wells, it was also indicated that benefits of pipe rotation were function of rotary speed, hole inclination,
flow rate, mud rheology and cuttings size.
Kamp and Rivero [23] developed a two-layer mechanistic model for calculation of cuttings bed heights,
pressure drop and cuttings transport velocities at different rate of penetration and flow rates. The results
showed good comparison with the correlation results based on Larsen's model. Rubiandini [24] modified the
Moore's slip velocity calculations for vertical wells and developed an empirical model to estimate critical
flow rate for inclined wells. Correction factors were introduced using regression analysis to account for drill
4 SPE-197864-MS

pipe eccentricity, drill pipe rotation and density correction based on Larsen's and Peden's experimental data.
A one-dimensional two-phase mechanistic model was developed by Li and Kuru [25] to simulate cuttings
transport with foam in vertical wellbore. The model was solved numerically to predict the optimum foam
flow rate and rheological properties to maximize the cuttings transport efficiency in the vertical wells.
Base on the literature review the cuttings transport studies can be categorized by two main approaches,
empirical and mechanistic models. The first approach, empirical models aids to identify the influence of
operating parameters such as ROP, drill pipe rotation, rheology etc. on the hole cleaning process. The second
approach is mechanistic models that deals with set of equations which obtained from analyzing forces
involved in the cuttings transport process. Thus, we can conclude from literature review that we have large
number of models that can be used for predicting the cuttings transport process. The main parameters that
govern the hole cleaning process are indicated in figure (1) and are listed as below:
1. Inclination of the well.
2. Eccentricity of the drill pipe.
3. Movement of the drill pipe (Rotation and Sliding).
4. Cuttings size, shape and composition.
5. Rheology of the fluid.
6. Thermal effects.
7. Chemistry effects.

Figure 1—Parameters controlling the hole cleaning process

Major challenges in predicting the cuttings transport involves resolving following aspects of the physics:
1. Drilling fluid behavior using non-Newtonian models.
2. Cuttings interaction with the drilling fluid.
3. Cuttings interaction with each other.
4. Cuttings interaction with the surrounding formation.
Detailed resolution of the complex physics associated with hole cleaning process needs involved models
and can be computationally intensive.
SPE-197864-MS 5

Advanced Computational Models for Hole Cleaning

Numerical simulation of cuttings coupled with drilling mud can be resolved using different numerical
models. A useful classification of the various methods is defined by their target scales [26].
1. Fully resolved scales: The fluid phase is treated as a continuum in a domain around the disperse phase
(cuttings). The disperse phase is treated as a discrete element method (DEM) or is, in turn, further
discretized with the finite element method (FEM). This approach is useful to calibrate bigger scale
models but is computationally expensive for more than thousands of particles.
2. DEM-computational fluid dynamics (CFD) in a single domain. It treats the fluid as a continuum
covering the space taken up by both phases. Therefore, any field defined in it cannot be interpreted as
its analogue in the fully resolved approach. Rather, its values must be understood as a homogenization
or local average of its fully resolved counterpart. In this sense, this approach mimics the one defined
by the two-fluid flow model, corresponding to the next scale level. The coupling between phases is
done via:
a. Disperse phase volume fraction, which is computed from the DEM solution
b. Interaction forces, the most important of which are the drag force and its reaction.
3. Two-fluid flow model. It is the theoretical origin of the DEM-CFD approach. The main difference
with the previous approach is that here the disperse phase is modeled as a continuum defined in
the same domain as the fluid phase, making use of the theory of interpenetrating continua. The
coupling is achieved via mass conservation equations analogues. This approach bears a higher amount
of empiricism in its modeling of the disperse phase, leading to higher uncertainty in principle. On
the other hand, it is not limited by the number of particles that can be modeled with a reasonable
computational cos t like the DEM- CFD approach, for which this limit is probably around the order
of millions.
4. CFD of suspensions. The mixture is modeled as a continuum by considering some suspension
rheology model. This approach is, in general, only adequate for very disperse suspensions.
We are interested in the second approach in this project, namely DEM-CFD model. The solution
algorithm for the DEM-CFD runs like this:
1. Solve the fluid equations for the next time step.
2. Evaluate the average velocities that have been solved for at the particles' centers and calculate the
corresponding drag force.
3. With the updated drag force, perform the time integration of the equations of motion (translation and
rotation) of the particles.
4. When the next time step (in fluid time stepping terms) is reached by the particles, compute the new
solid fraction at the fluid nodes.
5. Go back to step 1.
The drag forces on particles immersed in a Newtonian fluid [26] are well known. However, when dealing
with Non-Newtonian fluids different approaches for computing these forces can be followed depending on
the type of fluid. Non-Newtonian fluids, for instance, can be shear thickening, shear thinning or Bingham
plastics, and each one of these has a different drag law. Most drag laws require finding a suitable value for
the drag coefficient (Cd) and the Reynold's number.
In this work a linear drag force law is proposed for cuttings transport in drilling muds as show in equation
(1)

(1)
6 SPE-197864-MS

where ai is a parameter that is a function of the gel strength of the fluid and its dynamics, si is the skin surface
of the particle [28], Wi = |Fwi| is the weight of the particle, Fib the modulus of the buoyancy force vector vri is
the relative velocity of the particle with respect to the fluid and vti is the relative terminal velocity obtained
by Shah's method [28]. The drag law must be regularized near the value of vri = 0 for practical purposes.
Note that ai is equal to the gel strength for every part of the fluid where the equivalent shear rate is zero.

Numerical Studies
To validate the proposed numerical strategy [29] computational results are compared with Sifferman' s
[27] experimental results. This validation is based on cuttings transport in vertical wellbore for different
rheologies of fluid as shown in table (1). Numerical studies were conducted with both spherical and non-
spherical particles [30].

Table 1—Rheological Properties

As seen figure (2) good match between experimental and numerical results with formulated FEM and
DEM solver is observed. figure (2) also shows comparison of numerical results using commercial CFD
solver with modified drag law and sphericity correction, discrepancy is observed in commercial CFD results
with experimental as well as proposed FEM+DEM approach. Commercial CFD code discrepancy may be
attributed to numerical approach at lower shear rates and use of Discrete Particle method (DPM) as opposed
to FEM+DEM approach proposed in this work.

Figure 2—Comparison of Cuttings velocity using mumerical and experimental results

All the results shown in paper henceforth are based on FEM+DEM approach with modified drag law and
sphericity correction [28]. Further to demonstrate the influence of well bore inclination series of transient
SPE-197864-MS 7

simulations were conducted to observe the bed sliding motion as shown in figure (3), in figure (4) the close-
up view of cuttings bed is shown indicating distinct cuttings bed layers which are stationary and moving.
figure (5) shows velocity vectors of fluid along with presence of cuttings to showcase coupling of fluid and
cuttings dynamics and effect of increase in fluid velocity due to reduction in flow area due to cuttings bed.

Figure 3—Sequence of cuttings bed sliding

Figure 4—cuttings bed at bottom of wellbore

8 SPE-197864-MS

Figure 5—Velocity Vectors of fluid as cuttings bed slides downwards

The effects of rotation along a curved well bore geometry on cuttings transport is shown in figure (6)
and figure (7) at different time steps. It can be clearly seen the effect of curvature as well as rotation effects
of drill pipe on cuttings motion.

Figure 6—Curved wellbore at 100 rpm.

SPE-197864-MS 9

Figure 7—Curved wellbore at 100 rpm @ end of time step

In figure (8) effects of rotation and eccentricity along vertical well bore are shown indicating higher
volumetric concentration of cuttings in larger annular area as expected. In figure (9) effect of tool joint on
cuttings volumetric concentration is shown.

Figure 8—Eccentric drill pipe effect on cuttings

10 SPE-197864-MS

Figure 9—Tool Joint effect on cuttings transport

Figure (10) shows horizontal well bore and cuttings bed formation, further effects of rotation and
eccentricity are also evaluated for horizontal wellbore.

Figure 10—Horizontal wellbore showing cuttings bed formation

The formulated numerical methodology coupled with modified drag law provided excellent insights
into various wellbore scenarios and underscored effects of rotation and eccentricity. One of the challenges
observed in these numerical studies is the need for computational resources to conduct these studies in
timely manner.

Conclusions
In this work detailed literature review is presented for prevalent hole cleaning models utilized in Oil & Gas
industry. A digital twin formulation utilizing advanced simulation techniques that provides better insight
for cuttings transport and hole-cleaning is presented in this work. Eulerian-Lagrangian based numerical
techniques are presented which can estimate critical flow rate needed for efficient hole cleaning. A modified
drag law on cuttings is presented in this work. The influence of important parameters, such as fluid
rheology, rotation of drill-string, and inclination of wellbore on the hole-cleaning process is investigated.
Digital solutions are compared against the published data for Newtonian and non-Newtonian drilling fluids
under different wellbore configurations. The advanced computational simulation involving novel drag
SPE-197864-MS 11

force correlation and unique combination of numerical methods allowed to create digital twin for cuttings
transport process accurately.

Acknowledgments
Timely help provided by CIMNE staff in completion of this work and permission granted by "Weatherford"
to publish this work is also greatly appreciated.

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