ADVANCED CUTTINGS TRANSPORT STUDY

Abstract

The Advanced Cuttings Transport Study (ACTS) was a 5-year JIP project undertaken at the University of Tulsa (TU). The project was sponsored by the U.S. Department of Energy (DOE) and JIP member companies. The objectives of the project were: (1) to develop and construct a new research facility that would allow three-phase (gas, liquid and cuttings) flow experiments under ambient and EPET (elevated pressure and temperature) conditions, and at different angle of inclinations and drill pipe rotation speeds; (2) to conduct experiments and develop a data base for the industry and academia; and (3) to develop mechanistic models for optimization of drilling hydraulics and cuttings transport. This project consisted of research studies, flow loop construction and instrumentation development. Following a one-year period for basic flow loop construction, a proposal was submitted by TU to the DOE for a five-year project that was organized in such a manner as to provide a logical progression of research experiments as well as additions to the basic flow loop. The flow loop additions and improvements included: (1) elevated temperature capability; (2) two-phase (gas and liquid, foam etc.) capability; (3) cuttings injection and removal system; (4) drill pipe rotation system; and (5) drilling section elevation system. In parallel with the flow loop construction, hydraulics and cuttings transport studies were preformed using drilling foams and aerated muds. In addition, hydraulics and rheology of synthetic drilling fluids were investigated. The studies were performed under ambient and EPET conditions. The effects of temperature and pressure on the hydraulics and cuttings transport were investigated. Mechanistic models were developed to predict frictional pressure loss and cuttings transport in horizontal and near-horizontal configurations. Model predictions were compared with the measured data. Predominantly, model predictions show satisfactory agreements with the measured data. As a part of this project, instrumentation was developed to monitor cuttings beds and characterize foams in the flow loop. An ultrasonic-based monitoring system was developed to measure cuttings bed thickness in the flow loop. Data acquisition software controls the system and processes the data. Two foam generating devices were designed and developed to produce foams with specified quality and texture. The devices are equipped with a bubble recognition system and an in-line viscometer to measure bubble size distribution and foam rheology, respectively. The 5-year project is completed. Future research activities will be under the umbrella of Tulsa University Drilling Research Projects. Currently the flow loop is being used for testing cuttings transport capacity of aqueous and polymer-based foams under elevated pressure and temperature conditions. Subsequently, the effect of viscous sweeps on cuttings transport under elevated pressure and temperature conditions will be investigated using the flow loop. Other projects will follow now that the ''steady state'' phase of the project has been achieved.