Hole Cleaning

How Cuttings Are Transported

Hole Cleaning

How Cuttings Are Transported

Figure 19 illustrates the transport mechanism for a range of well inclinations. The
cuttings are effectively suspended by the fluid shear and beds do not form (Zones 1 &
3) for holes inclined less than 30°. Beyond 30°, the cuttings form beds on the low side
of the hole which can slide back down the well, causing the annulus to pack-off.
These cuttings can be transported out of the well by a combination of two different
mechanisms. Cuttings which form on the low side of the hole can:
• Slide as a block (Zone 4)
• Be transported at the bed/mud interface as ripples or dunes (Zone 2)

This latter transport mechanism, referred to as saltation, is best induced by low

viscosity fluids pumped in turbulence (high flowrate). The ideal zones for good hole
cleaning are 1 and 2. Zone 5 essentially guarantees tight hole problems.

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June 3, 1998
Hole Cleaning
How Cuttings Are Transported

0°—30° 30°—60°

60°—90°

Zone 1 Zone 2
Efficient Good cleaning
Moving bed

1 2
Increasing Annular

4
3
Velocity

0°—30°
5 30°—60°

0° 30° 60° 90°

Zone 3 Well Inclination Zone 4
Slow Some cleaning
removal Bed formed

30°—60°

0°—30° 60°—90°
Zone 5
No cleaning

Figure 1 Hole Cleaning Mechanisms

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June 3, 1998
 Hole Cleaning
Influence of Drilling Variables on Hole Cleaning

Influence of Drilling Variables on Hole Cleaning

Hole Angle
Cuttings removal generally becomes more difficult as hole angle increases. Angles
between 50° – 60° present most problems because the cuttings have a tendency to
slide down the annulus and cause packing off. In wells deviated beyond 60°, the
cuttings form stable beds. These beds are supported by the sliding friction against the
wellbore. The angle range for cuttings bed slide depends largely on mud rheology and
problems cleaning the hole can be experienced from 40° – 60°.

ROP
Increases in penetration rate result in higher cuttings concentrations in the annulus.
Past experience has shown that 0.5% is the maximum allowable annular concentration
to efficiently drill vertical and near vertical wells. For deviated wells, deeper cuttings
beds form as the penetration rate increases. Removing these deeper beds require
higher flowrates. It is important to control and limit instantaneous ROP’s in deviated
wells since deep beds are difficult to remove. (Figure 20)

FLOWRATE (gpm)
250 300 350 400 450 500 550 600 650
1.0

4.6 m/hr (15 ft/hr)

0.8 9.1 m/hr (30 ft/hr)
13.7 m/hr (45 ft/hr)

0.6
PERCENT (%)

0.4

0.2

0
15.8 18.9 22.1 25.2 28.4 31.5 34.7 37.9 41.0
FLOWRATE (L/s)

Figure 2 Cutting Volume vs. R.O.P

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Hole Cleaning
Influence of Drilling Variables on Hole Cleaning

MUD Rheology
Mud viscosity affects cuttings slip velocity. This greatly influences transport
efficiency in vertical and near vertical wells. However, changes in conventional mud
rheology have little benefit once cuttings beds form (>30°). Low viscosity fluids are
most effective at angles above 30° since they induce turbulence and encourage
cuttings removal by saltation.

Plastic viscosity should be minimized to reduce pressure losses and obtain a flatter
viscosity profile. This creates higher annular velocity in the outer portion of the hole
for the same pump rate. This is easily achieved for both 445 mm (17-1/2 in) and
311 mm (12-1/4 in) holes. Rheology modifiers provide the required low shear
viscosities when using oil muds.

A paper by S. Okrajhi and J.J. Azar of the University of Tulsa (SPE Drilling
Engineering August ’86) described cuttings transport agreements with varying
rheology hole inclination, flow rates, and pipe eccentricity. Three clear hole angle
ranges were identified:
0° – 45° Effects of laminar flow dominated and increased rheology (especially
yield point) aided cuttings transport.
45° – 55° Effects of laminar and turbulent flow have similar characteristics. Cut-
tings bed slide occurred in this range.
55° – 90° The effects of an increased YP/PV lacked real effect. Turbulent flow
cleaned the hole best.

Increased mud rheology only had an effect at low mud velocities. It had no effect in
turbulent flow at any hole angle. (Figure 21)

100
Bingham Plastic
45
90
40
80
35 Generalized Bingham 70 SHEAR STRESS (lb/100 ft2)
SHEAR STRESS (Pa)

Newtonian
30
60
25
Power Law 50
20 40
15 30

10 20

5 10

0 0
0 200 400 600 800 1000 1200
SHEAR RATE (s-1)

Figure 3 Common Fluid Models

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 Hole Cleaning
Influence of Drilling Variables on Hole Cleaning

However, at low angles under laminar flow, a raised yield point improves cuttings
transport (decreases annular particle concentration). (Figure 22)

YIELD VALUE (lbf/100 ft2)

0 5 10 15 20 25
5

ANNULAR PARTICLE CONCENTRATION (%)

4 Turbulent Flow

2 q = 30° Laminar Flow

ecc = +0.5
RPM = 50
1 Va = 0.81 m/sec (2.66 ft/s)
YP (lb/100ft2)
=1
PV (cp)
0
0 2 4 6 8 10 12
YIELD VALUE (Pa)

Figure 4 Combine Effects of Mud Yield Value and Flow Regimes

As the hole angle increases, cuttings transport in laminar flow can be improved by
raising the YP/PV ratio. (Figure 23)

10
Laminar Flows
ANNULAR PARTICLE CONCENTRATION (%)

9
q = 90°
8
q = 70°
7

6
ecc = +0.5
5 RPM = 50
Va = 1.16 m/s (3.82 ft/s)
4 YP = 20 lb/100 ft2
3

2
q = 30°
1

0
0 0.5 1.0 1.5 2.0 2.5
YP (lb/100ft2) / PV (cp)

Figure 5 Effect of YP/PV Ratio

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June 3, 1998
Hole Cleaning
Influence of Drilling Variables on Hole Cleaning

However, the effect of increasing YP/PV ratio decreases as the flow rate increases.
(Figure 24)

10

ANNULAR PARTICLE CONCENTRATION (%)

9

6 Laminar Flows
q = 30°
5 ecc = +0.5 0.58 m/s
RPM = 50 (1.91 ft/s)
4 YP = 20 lb/100 ft2
3
0.87 m/s
2 (2.86 ft/s)
1 1.16 m/s
(3.82 ft/s)
0
0 0.5 1.0 1.5 2.0 2.5
YP (lb/100ft2) / PV (cp)

Figure 6 Combined Effects of YP/PV Ratio and Annular Mud Velocity

The effect of pipe eccentricity on cuttings transport is small for angles up to 55°. In
laminar flow above 55°, the effect of pipe eccentricity becomes significant.

Later work on the subject by T.E. Becker, J.J. Azar, and S. Okrajhi SPE 19535
(Correlations of Mud Rheological Properties With Cuttings Transport Performance In
Directional Drilling - Oct ’89) provided the following conclusions:
• The best correlation between cuttings transport and mud rheological parameter
was the 6 rpm Fann VG Meter reading.
• Three other rheological parameter correlated well with cuttings transport:
• Mud shear stress at average annular shear rate
• The 3 rpm Fann VG Meter dial reading
• Initial gel strengths

Pump Rate
The single most crucial factor for successful hole cleaning is mud flow rate, especially
for deviated holes. As a rough guide, the annular velocity needed for cleaning wells
deviated 50° – 60° is approximately twice that required for the vertical case. Take all
reasonable steps to reduce frictional pressure. Doing so will extend the range of
available flowrate. In critical cases, careful consideration should be given to BHA
design, nozzle selection, and additional losses due to mud motors/MWD tools.

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June 3, 1998
 Hole Cleaning
Influence of Drilling Variables on Hole Cleaning

Bit Nozzle Selection

If sufficient flow rate is available for hole cleaning, then bit nozzles can be selected
for optimum hydraulics in the normal way.

When sizing bit nozzles, it is also important to note that:

• Certain mud motors have optimum bit differential pressure ranges
• Nozzles should be selected to minimize potential hole erosion problems for
friable formations

The table, Bit Pressure Losses & Velocities below, shows the calculated bit pressure
losses and nozzle velocities for a 1.2 sg (10 ppg) mud over the normal range of flow
rates for 216 mm (8-1/2in) hole. Until more information is available, the jet nozzle
velocities should not exceed 91 m/sec (300 ft/s) in friable formations.

Bit Pressure Losses & Velocities for

216 mm (8-1/2 in) Hole
Nozzle Size
350 gpm 400 gpm 500 gpm
(32nds)
133 psi 174 psi 272 psi
3 * 20
122 ft/sec 140 ft/sec 175 ft/sec
325 psi 425 psi 664 psi
3 * 16
191 ft/sec 218 ft/sec 272 ft/sec
1455 psi 1900 psi 2970 psi
3 * 11
404 ft/sec 462 ft/sec 572 ft/sec
Pressure drop data based on 1.2 SG (10.0) PPG) mud

Using 168 mm (6 5/8 in) Drillpipe

Using 168 mm (6-5/8 in) drillpipe significantly reduces pressure drop. This allows
higher flow rates. However, experience shows that turbulence in the annulus is seldom
achieved in deeper, horizontal wells by using 168 mm (6-5/8 in) drillpipe. The
increase in annular velocity must be traded against the cost of changing out the
drillstring for the smaller hole sections to follow.

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June 3, 1998
Hole Cleaning
Hole Angles Above 40°

Hole Angles Above 40°

Turbulent/transitional flow is most effective in cleaning and evacuating/minimizing

cuttings bed formation. Lower mud rheologies (at the corresponding annular shear
rates) will be required to obtain the Reynolds numbers above 2,100. In this case the
cuttings/cuttings beds will be removed as ripples or dunes.

However, turbulent flow cannot be achieved in most of the 445 mm (17-1/2 in) holes
and some of the 311 mm (12-1/4 in) holes. This is due to a variety of reasons
including limitation of surface/down hole equipment, washouts, etc. A compromise
for hole cleaning may be made using laminar flow.
• Use the highest possible pump output/annular velocities.
• Optimize the low shear rheology using low shear rate rheology modifiers in oil
muds and XC Polymer type material with WBM to suppress the formation of
cuttings beds.
• High initial gel strength gives rapid suspension of cuttings when the pumps are
off during surveys or trips. This should be combined with flatter gel strength
development with time.
• Use mechanical means (e.g., wiper trips, pipe rotation, reciprocation,
backreaming when top drive is available, etc.) and pills pumped in turbulence to
assist hole cleaning.

Mud Weight
Mud weight influences hole cleaning by affecting the buoyancy of the drilled cuttings.
This applies for both vertical and deviated holes. For small changes in density, the
flowrate required to maintain adequate hole cleaning is directly proportional to the
cuttings mud density differential.

However, the selection of mud weight in most cases is predetermined. The selection is
based on pore pressures, rock mechanics, in situ tectonic stresses, density required to
stabilize the hole/avoid cavings at a given hole/dip angle, and the resulting fracture
gradient.

It is very important to use the correct mud density based on rock mechanics to avoid
borehole stability problems. Once a hole stability problem starts (i.e., hole caving), it
is difficult to cure.

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June 3, 1998
 Hole Cleaning
Short Trips/Backreaming

Cuttings Type
Increased cuttings density make hole cleaning more difficult for both vertical and
inclined wells. Cuttings shape and size is also important in vertical transport. The
larger, more rounded particles are the hardest to remove. Shape and size have little
influence in highly deviated wells because the cuttings move in blocks rather than
discrete particles.

Drillpipe Rotation
Rotating the drillstring will assist in mechanically disturbing cuttings beds in deviated
wells. The rotating pipe forces cuttings upwards to the high side of the hole, and into
the fast moving mud stream. Drillpipe rotation also encourages mud flow in the
narrow gap between the pipe and the settled bed. When a downhole motor in oriented
mode is used in a deviated well, the cuttings beds are probably not being disturbed.
Consider rotating the string prior to tripping. Field studies show that pipe rotation
while drilling enhances the hole cleaning efficiency.

Short Trips/Backreaming

Periodic short trips and/or backreaming is used to remove cuttings beds by

mechanical agitation. This is very effective when top drive is available as the short
trip/pumping out is enhanced hydraulically and rotationally.

If necessary, use riser booster pumps while drilling the 311 mm (12-1/4 in) and
216 mm (8-1/2 in) hole sections.

Any indication of a failure to clean the hole adequately should be countered by

increasing the frequency of wiper trips, increasing circulation time on connections
and before trips by maximizing pump rates.

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June 3, 1998
Hole Cleaning
Supplementing Hole Cleaning

Supplementing Hole Cleaning

Cuttings Bed Suppression

Cuttings beds formation in deviated holes can be suppressed by using muds with
exceptionally good suspension characteristics. However, high flow rates are still
necessary since the beds can never be totally eliminated. For water based mud, the
best conventional additive for this purpose is XC polymer. All the major service
companies now offer low shear enhancers (sometimes referred to as rheology
modifiers) for oil based muds.

A simple force balance approach can be used to determine the minimum mud
rheology necessary to maintain drilled cuttings in suspension:

( 2 × θ 3 ) – θ 6 = 110 × ( CuttingSG – MudSG ) × D ρ

Where:
θ6 = Fann 6 rpm reading
θ3 = Fann 3 rpm reading
Dρ = Cuttings diameter (in)

For example, a 1.4 sg (11.7 ppg) mud, with Fann 6/3 readings of 21/20 lb/100 ft2, will
support a 6mm (1/4 in) cuttings with an sg of 2.1.

Fluid Pills
For wells deviated below 30°, use conventional high viscosity/high weight slugs to
help remove cuttings from the annulus.

For wells deviated beyond 30°, the best method to remove cuttings from settled bed is
by pumping thin fluids (e.g., base oil, water) in turbulent flow. These pills should be
followed immediately by high viscosity/high weight pills which increase their
effectiveness by carrying the cuttings raised from the cuttings bed out of the hole.

The base oil/weighted pill size must be matched to balance out the equivalent
circulating density. The effect on hydrostatic pressure of the base oil (underbalance)
and the heavy mud (formation breakdown) in the annulus must be calculated in
advance.

If possible, use the maximum weight heavy pill (2.16 sg or 18 ppg).

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 Hole Cleaning
Circulation Prior to Tripping

The size and frequency of these pills should also ensure minimal contamination to the
active mud system. Typical total pill volumes (low vis + high vis) are 50–100 bbls for
445 mm (17-1/2 in) hole and 30–60 bbls for 311 mm (12-1/4 in) hole.

Thin fluids have demonstrated a destabilizing effect on some formations. Highly

laminated shales where laminars lie at acute angles to the wellbore can be destabilized
by the whipping action of the thin fluid pumped at high speed. The thin fluid rheology
should be increased in these instances.

High Density Sweeps

High density pills of 0.24 sg (2 ppg) above the mud density in use assist in the
carrying capacity. However, this type of pill will have limited effect on removing
existing cuttings beds in highly deviated wells unless it is preceded by a scouring pill
in turbulent flow. Care should be taken to avoid lost circulation or formation
breakdown.

Circulation Prior to Tripping

Hole size and inclination will influence the minimum “off-bottom” circulation time
prior to tripping. The figures in the table below are guidelines based on simple slip
velocity considerations and field experience.

Section Length Factor

Well Inclination
Range 445 mm 311 mm 216 mm
17-1/2 in Hole 12-1/4 in Hole 8-1/2 in Hole
0°–10° 1.5 1.3 1.3
10°–30° 1.7 1.4 1.4
30°–60° 2.5 1.8 1.6
60°+ 3.0 2.0 1.7

In practice, some of the section back to surface will not be deviated at the same angle.
The overall minimum circulation time prior to tripping should be apportioned in direct
relation to the relative lengths of section at each angle. This is shown in Figure 25 for
tripping out of 445 mm (17-1/2 in) hole at 2350 m (7710 ft).

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Hole Cleaning
Circulation Prior to Tripping

Actual Effective
Length Factor Length

17-1/2 in Hole 850 * 1.5 = 1275

300 1.7 = 510
400 * 2.5 = 1000
800 3.0 = 2400
Total 2350 5185

850 m
@
0–10° 5185 m
Number of Circulations = 2350 m

= 2.2

300 m
@
10–30°

400 m
@
30–60°

800 m
@ 60°

Figure 7 Circulation Prior to Tripping

Mud circulation significantly in excess of the above guidelines may not have any real
benefit. If cuttings beds have formed in the deviated sections and have not been
removed by circulation while drilling, then these will only be removed by a
combination of pills and mechanical methods (e.g., pumping out of the hole).

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June 3, 1998
 Hole Cleaning
Monitoring Hole Cleaning

Monitoring Hole Cleaning

The cuttings transport efficiency must be maximized by optimizing the mud system
carrying capacity, annular mud velocities, drill cuttings size, maximum allowable
ROP, etc. A reliable hole cleaning monitoring system should also be followed to flag
cuttings transport inefficiencies before they become a problem. These include:
• Correlate the total volume of drilled cuttings being generated to the total volume
being processed by the solids control equipment and the amount of solids retained
in the mud.
• Closely monitor the SPM/PSI, drag-up/drag-down/rotating string weight. Higher
than normal values may be the first indicators of potential hole or hole cleaning
problems.
• Do not assume that all the drilled cuttings are being evacuated from the hole. If
necessary, check this using sweeps (appropriate to the hole deviation/geometry)
and make check/wiper trips to disturb and clean out possible cuttings beds at
regular intervals.

Horizontal 216 mm (8-1/2 in) Section

Figure 26 shows hole cleaning model predictions for the minimum flow rate required
to clean the hole.

MUD WEIGHT (ppg)

8.3 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 16.7
600

35

MINIMUM FLOW RATE (gpm)

MINIMUM FLOW RATE (L/s)

500
30

25 20 m 400
/hr (
65 f
t/hr
10 m )
/hr (
20 33 ft
/hr)
300

15 Instantaneous ROP

200
1.0 1.2 1.4 1.6 1.8 2.0
MUD WEIGHT (SG)

Figure 8 Flow Rate for Cleaning 216 mm (8-1/2 in) Horizontal Hole

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Hole Cleaning
Flow Regimes

Hole cleaning becomes more difficult as penetration rates increase. Conversely,

cleaning becomes easier as the mud weight increases. Over the normal range of
anticipated ROP’s, flow rate of about 300 – 500 gpm are required for adequate hole
cleaning.

Flow Regimes

Hole cleaning in horizontal holes will be enhanced by turbulent flow which promotes
efficient cuttings removal. Flow in the annulus is generally laminar for hole diameters
311 mm (12-1/4 in) and above.

For 216 mm (8-1/2 in) sections and below, flow can become turbulent depending upon
mud rheology and flow rate.

The mud Yield Point has a strong influence over the critical flow rate. The data in
figure 27 are for a 1.6 sg (13.3 ppg) mud. Lower mud weights will require higher flow
rates to reach turbulence. The figure also shows that turbulence will be difficult to
achieve at YP’s above 10 lb/100 ft2, for the normal range of circulating range.
However, the mud rheology (and gels) must remain sufficient to provide adequate
suspension of barites. This is particularly important for lengthy periods when the mud
remains stationary in the hole (e.g., logging or running casing).

YIELD POINT (lb/100 ft2)

0 5 10 15 20
44 700

40 Turbulent
600

MUD FLOW RATE (gpm)

MUD FLOW RATE (L/s)

35

Transitional 500
30

25 400

20 Laminar 300

15
12 200
0 1 2 3 4 5 6 7 8 9
YIELD POINT (Pa)

Figure 9 Calculated Flow Regimes for 216 mm (8-1/2 in) Hole

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June 3, 1998
 Hole Cleaning
Summary of Recommended Hydraulics

Although turbulence is an advantage for cleaning lateral sections, it is not an essential

(or even achievable) condition. The most important factor is to control ROP within the
range given by the hole cleaning curves.

Address any evidence of poor hole cleaning by increasing flowrate rather than
changing rheology or flow regime.

Summary of Recommended Hydraulics

Hole Cleaning Practices

• Use “Hole Cleaning Curve” to determine optimum flow rate for cleaning.
Flow rates in the 300 – 500 gpm range will generally be adequate for cleaning
216 mm (8-1/2 in) horizontal sections.
• Select mud properties which provide turbulent flow, if possible.
• To achieve turbulence, maintain maximum mud YP close to 10 lb/100 ft2.
• ECD increases when drilling horizontally, but formation strength remains fixed.
Ensure that ECD does not cause formation breakdown when drilling horizontal
section.
• Select MWD/downhole motors that do not restrict flow rates for hole cleaning.
• Limiting nozzle pressure drop for motor considerations (i.e., maximum allowable
bit pressure drop for motor being used) may be necessary.
• If possible, plan well trajectory to avoid drilling long sections of large diameter
holes above 50°. Look closely at the pump capacity of the rig.

Drilling
• Deviated wells require higher flow rates.
• Design BHA’s for minimum pressure loss in critical wells.
• Hole angles 50° – 60° are most difficult to clean (can be 45° – 60° dependent on
mud rheology).
• Control instantaneous ROP’s.
• Increase flowrate rather than changing rheology when cleaning deviated wells.
• Increased mud weight assists cuttings removal.
• Drillpipe rotation assists hole cleaning in deviated holes. A minimum of 60 rpm is
recommended. Higher rpm’s assist.
• Minimize hole washouts by developing a good hydraulic design.
• Drill “minimum rat hole” consistent with safe running of casing.
• Use a riser booster pump on semi-submersibles, if necessary.

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Hole Cleaning
Summary of Recommended Hydraulics

Tripping
• Always circulate the hole clean prior to tripping. Use “minimum” circulation
times.
• Rotate the pipe at maximum of 60 rpm when circulating prior to tripping.
• Use low vis/low wt pills for wells > 30°. Calculate volumes to ensure well
control.
• Make a rotary wiper trip after a long section is drilled with downhole motor.
• Make sure cementing pumps are available to pump in the case of an emergency.

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June 3, 1998