Experimental investigation of the effect of drill pipe rotation on improving hole cleaning using water-based mud enriched with polypropylene beads in vertical and horizontal wellbores

Abstract

Field experience has shown that the inefficient transport of small cuttings is a main factor contributing to excessive drag and torque during the drilling of a deviated hole; however, very little is known about the transport behavior of small cuttings. This experimental study investigates the effect of different polypropylene bead concentrations in water-based mud (WBM) on hole cleaning, along with the effects of cutting size, drill pipe rotation, and hole inclination angle. A total of 160 runs were performed using an experimental rig consisting of a 13 ft (3.96 m) long casing with a 2 in (50.8 mm) Inner Diameter (ID) and a rotary inner pipe with a 0.8 in (20 mm) Outer Diameter (OD). Four cutting size ranges, namely, 0.5–1.0 mm, 1.0–1.4 mm, 1.4–1.7 mm, and 1.7–2.0 mm, with a density of 2400 kg/m3 were tested in WBM with varying polypropylene bead concentrations ranging from 0 to 8 ppb. The concentric annulus flow test section was changed to vertical and horizontal angles with pipe rotation from 0 to 150 rpm. The mud density and viscosity were maintained at 10 ppg and 16 cp, respectively, under a flow velocity of 3.48 m/s (Reynolds number of 6620). The results indicate that smaller cuttings are easier to transport at all pipe rotations and polypropylene bead concentrations in both vertical and horizontal holes. The optimal pipe rotational speed was found to be 60 rpm. In this study, polypropylene beads undeniably enhanced the mud carrying capacity by significantly increasing the cutting transport ratio (CTR) by up to 16.57% in vertical holes and 15.73% in horizontal holes.