Well Bore Cleaning Procedures

INTRODUCTION
Hole cleaning is one of the main issues when drilling wells, whether in cased or
open hole. Well sections with high inclinations have been identified in the lab and
confirmed in the field to be the zones with cuttings sedimentation and recirculation
problems. In these wells, hole cleaning is often perceived as a straightforward
process, but quantifying cuttings retrieval rates and determining the residual bed
height downhole should be a management process involving two challenges:
decaying and re-circulating cuttings, and transporting solid particles to the surface.
These challenges are further linked with the compatibility between operating
parameters, wellbore quality, wellbore stability, safety margins and cost-efficiency
of the operation.
By optimizing hydraulics, mechanical parameters and drillstring construction, it is
possible to increase performance of: drilling, operating cost, safety margins and
drilling risk prevention from stuck pipe, lost circulation and hole instability.

HOLE CLEANING PRINCIPLES

How do we determine when a hole is clean? The usual approach is to monitor the
shakers for changes in the cuttings retrieval rate. Although this is a direct indicator,
it does not provide complete information and can lead to incorrect assumptions and
detrimental misunderstandings. The quantity of retrieved solid particles may not
represent the actual volumes that should be retrieved due to irregularities in the
hole section. Even if the cuttings volume remaining in the hole looks acceptable, the
distribution of cuttings along the hole can have a significant impact on drilling
efficiency. An irregular distribution profile can induce avalanching, packoff, pressure
surges and wellbore instability.
Hence the importance of defining successful hole cleaning by using a more complex
monitoring system and taking into account risk-occurrence analysis. Monitoring
systems should capture the cuttings retrieval rate, Equivalent Circulating Density
(ECD), pressure losses and torque and drag curves. Risk occurrence analysis should
include pressure surges, back reaming, hole packoff, casing/equipment wear and
stuck pipe.

HOLE CLEANING AND DRILLING PRACTICES

Hole cleaning problems start when operating parameters fail to efficiently circulate
cuttings to surface. Problems have been identified in the drilling and tripping
phases.
Drilling and tripping represent two different modes of cuttings bed buildup
processes and hole-cleaning practices. During drilling, there is an equilibrium
cuttings-bed height that can be used for hole-cleaning efficiency by measuring the
cuttings at surface versus the calculated cuttings volume expected to be generated
when drilling a formation. Even though the bed reaches a steady state (provided
parameters remain unchanged), the cuttings-bed height is not necessarily regularly
distributed along the drillstring. For this mode, hole-cleaning performance
corresponds directly to the final equilibrium bed height.

During tripping, cuttings can build up under several conditions. Natural

sedimentation of solid particles occurs when mud flow stops. Dragging the
drillstring through the existing cuttings bed creates localized dunes. Cuttings
avalanching occurs when the bed is established in the critical angle (45-60) section
of the well. For this mode, hole-cleaning performance is related to the speed at
which the system decays the cuttings and to the final cuttings-bed height.

WELL BORE CLEANUP METHODS

Displacement of the oil mud from the wellbore uses a combination of mechanical
equipment (scrapers, circulating subs etc.) with chemical spacers. Once obm is out
of the wellbore, returning fluid is assessed visually to decide if it is clean enough to
be discharged, or retained within the limitations of pit space.

Run scrapers and junk baskets for the cleanout run to remove debris and
reduce circulating time.
Use circulating subs for higher pump rates to give a cleaner interface.
Use pipe rotation (possible with some types of circulating sub) and
reciprocation to reduce fluid dead-spots providing a cleaner interface.
Jet BOP cavities, a potential source of debris, which may prolong the need to
circulate. Can be cleaned running in the hole with or without specialist tools.
Boost the riser once displacing fluid is above the BOPs where low annular
velocities can lead to an extended interface especially if heavy mud is
displaced by seawater.
Review options for Choke and Kill lines on Semi-Submersibles containing
obm, which may need to be displaced to brine before obm is out of the riser.
With a negative liner lap test, Choke and Kill lines may be the preferred
means of displacement despite low flow rates and no rotation. The riser must
then be displaced with the potential for dead-spots between rams.
Maximize flow rates for cleanest interface. As the interface returns, flow rate
is slowed to observe cleanliness of displacing fluid prior to diversion or
discharge.
Review single or two stage displacement options to minimise fluid
contamination. Single stage - obm to completion brine directly, two stage obm to seawater then completion brine. Pit logistics, or negative liner lap test
may need obm to remain on board to displace the well in the event of a leak.
Consider packers as an alternative to a negative liner lap test, which can
impact the logistics of many operations.
Measure directly oil content of the seawater/brine. Currently tests to define
oil content take at least 20 - 30 minutes. Although returns can be diverted to
a mud pit before evaluation, space may be limited. NTU readings do not
correlate with oil content. Samples can be retained for evaluating future
strategies.
Spacers.
Minimize spacers - typically base oil, surfactants (detergents), solvents, high
viscosity, low viscosity, and flocculent spacers. Volumes, sequence and
effectiveness vary. Whilst this is an important area for minimizing volumes
there are a wide variety of strongly held opinions.
Treat as produced water. Large spacer volumes and types may limit options in
later treatment e.g. potentially oil contaminated seawater could be treated as
produced water, but detergents preclude this option because of their effect
on treating equipment.
Avoid detergents if using oil absorbent filters.
Avoid viscous spacers if using oil absorbent filters.

OPERATING PARAMETERS ANALYSIS

Flowrate is the main component of hole cleaning. In most cases, required flowrates
will not be achievable due to the available rig capability. Further flowrate limitations
are restricted by maximum ECD values on the formation. In addition, high flowrates
can generate hole enlargement or caving. Increasing the flowrate to improve hole
cleaning can be done within limitations, but care must be taken to avoid worsening
the situation.
Rotational speed (rpm) is the second most well-known, and sometimes
misunderstood, hole-cleaning component. Although increasing pipe rotation
improves cuttings agitation, drillstring rotational speed has a limited effect on
cuttings recirculation and cannot achieve a completely clean hole.
The primary advantage of increased rpm is cuttings agitation, which limits cuttings
sedimentation. The lifting effect is created by the upward driving effect of mudflowing lines on the solid particles. Therefore, rpm efficiency is related more to
cuttings agitation than cuttings recirculation.
Increasing rotational speed increases the risk of drillstring fatigue and dynamic
vibration. It also increases the risk of wellbore damage and caving. In addition, it
has been shown that high rpm will increase ECD values, mainly due to drillstring
behavior at high rotation speed in conjunction with mud-flowing line disturbances.
Increasing the rotational speed to improve hole cleaning is applicable for lowcomplex wells and is of limited efficiency. However, field experience has proven that
string rotation above 120 rpm avoids excessive cuttings sedimentation, thanks to
particle agitation by the drillstring.
Mud rheology plays a significant role on cuttings suspension in the flow. The
lubricity of the mud is the main factor that helps suspend cuttings. Mud rheology is
not an optimization parameter, since it will not be variable. Mud properties are
adapted to the formation and well profile.
Hole cleaning performance was monitored based on:

Cuttings: Monitor cuttings regularly gauging their volume, size and shape to
indicate hole cleaning effectiveness.
Torque and drag: Ensure that pick up, slackoff, rotating-off-bottom weight and
torque data are recorded in a consistent manner after each stand. This is
interpreted real-time on the rig floor for immediate action. If a tight spot is
encountered (>30 kips overpull) while tripping out of hole, assume the tight
spot is from cuttings. Run-in-hole two stands, until the BHA is clear of the
obstruction. Circulate and rotate for 30 min. or longer to confirm that the
tight spot is caused by a cuttings bed.
Weighted pills: Regularly pump 14-ppg pills as the hole dictates to sweep
cuttings beds. Record sweep effectiveness in the drilling reports. If a large
amount of cuttings are seen on the shaker, then increase pill frequency
and/or reduce ROP, so as not to overload the annulus.

CONCLUSIONS
Most of the industry has identified hole cleaning problems while drilling deviated
and extended-reach wells. The main operational benefits from this new holecleaning approach were measured directly while drilling: minimized back reaming
operations, no stuck pipe or hole enlarging risks.

Using the new, mechanical hole-cleaning system, achieved enhanced hole cleaning
at selected levels of flow rate and rpm values, allowing optimized levels of ROP and
pressure losses. Field performance analysis showed torque and drag reduction due
to enhanced frictional properties of the HBZs. Better hole cleaning reduced the
remaining cuttings-bed height and decreased cuttings accumulation risks.
Prior to drilling highly deviated or complex wells, the hole cleaning system must be
accurately pre-determined to ensure that all aspects of cuttings transport are
reviewed. The full involvement of the drilling team, when implementing the cleaning
system.