Hole Cleaning

The following are possible indicators of hole cleaning problems:

 excessive overpull on connections and trips

 reduced overpull when pumping

 excessive fill after trips

 erratic and increasing torque while drilling

 lack of cuttings over shakers (or large slugs of cuttings followed by periods of very few cuttings).

Solutions to Hole Cleaning Problems

Circulation, no matter how long it is carried out, does not guarantee effective hole cleaning. Special tripping

procedures may be necessary in wells with cutting beds and in wells with severe overgauge sections.

Solutions such as pumping and backreaming out, or using undergauge stabilisers in the string to disturb cutting

beds, have been effective.

The instantaneous ROP shall be such that cuttings can be removed.

Downhole Motors in Deviated Wells

Drilling with a downhole motor in an inclined well without rotating the drillstring may result in undisturbed

cutting beds. Where possible, the string should be rotated prior to POOH in addition to implementing some or

all of the above measures.

Hi-Vis Pills in Deviated Wells

In deviated wells, increasing the mud viscosity and pumping Hi-Vis pills may not improve hole cleaning.

A series of Low-Vis pills giving a more turbulent flow, followed by a heavy pill to sweep the disturbed cuttings,

may improve hole cleaning in these sections.

The following table lists the recommended total volumes (Low-Vis + Hi-Vis pills) for pumping sweep pills in

deviated wells:
Hole Section Pill Volume Total Volume of Pills
26in 25 bbls 150-200 bbls
17 ½in/16in 25 bbls 100-150 bbls
12-1/4in 20 bbls 50-100 bbls Low-Vis & Hi-Vis
8-1/2in 20 bbls 30-50 bbls Low-Vis & Hi-Vis
6 1/8in 15 bbls 30-50 bbls
 Hydraulics Optimization - Hole Cleaning
To optimize hydraulics and achieve sufficent hole cleaning the following guidelines should be

adhered to:
Pressure Losses Through System
P1= Frictional losses in surface lines

P2= Frictional losses in Drillpipe

P3= Frictional losses in Drill collars

PB= Pressure loss across bit

P4= Annular pressure loss across Drill collars

P5= Annular pressure loss across Drillpipe

Surface Connection Losses

Pressure losses in surface connections are losses in standpipe, rotary hose, swivel and kelly.

These losses are very difficult to calculate and the general equation is

PS= Er0.8Q1.8(PV) 0.2 psi

Where, r = mud density, ppg

Q = flow rate, gal/min

PV = plastic viscosity, cP

E = Constant depending type of surface equipment

Surface Equip. Stand pipe Rotary Hose Swivel Kelly

Type Length ft ID in Length ft ID in Length ft ID in Length ft ID in
1 40 3.0 40 2.0 4 2.0 40 2.25
2 40 3.5 55 2.5 5 2.5 40 3.25
3 45 4.0 55 3.0 5 2.5 40 3.25
4 45 4.0 55 3.0 6 3.0 40 4.00

Pipe and Annular Losses

Pipe losses take place inside drill pipe (P2) and drill collars (P3). Annular losses takes place across

the drill collars (P4) and drill pipe annulus (P5). These pipe and annular losses depend on

 dimension of Drillpipe/Drill collars

 mud rheological properties

 type of flow

The two major models for calculation of these losses are the “Bingham plastic model” and the

“Power law model”.

Pressure Drop Across Bit, PB

This is the most important element in the hydraulics equation. The objective is to optimise pressure

drop across the bit such that maximum bottom hole cleaning is achieved. For a given length of drill

string and mud properties pressure losses P1, P2, P3, P4 and P5 remain constant. The pressure loss

across the bit is influenced by the size of nozzles used and also determine the amount of hydraulic

horsepower available at the bit. The smaller the nozzle area the greater the pressure drop and

velocity. In situations where the rock is soft to medium hard, hole cleaning is the major objective

and thus bigger nozzles are used to maximise nozzle areas.

PB = PS - (P1+ P2+ P3+ P4+ P5)

PS = Surface pressure

Circulation Rates
In optimisation of circulation rates, the emphasis must be placed upon supplying sufficient drilling

fluid, at a high enough rate, to ensure that drilled cuttings are removed from the annulus in the

shortest possible time. Once hole cleaning requirements are fulfilled, bit hydraulics may be

optimised.

The recommended flow rate for roller cone bit is 30 to 50 GPM/in of bit diameter.

The minimum flow rate required for PDC bit = 12.72 (D)1.47

D = Diameter of Bit

Note: If a mudmotor is used, flow rates are depended on the mudmotor requirements.

Types of Flow
There are generally two types of flow

 Laminar

 Turbulent

In Laminar flow the pattern is smooth, with fluid layers travelling in parallel lines parallel to the

conduit axis. The velocity of each layer increases towards the centre until a maximum velocity is
reached. In laminar flow shear resistance is caused by the sliding action and is independent of the

roughness of pipe. There is only one component of fluid velocity in laminar flow, a longitudinal

component. A special type of laminar flow with a flat centre is called plug flow. In the flat centre

there is no shear of fluid layers.

In turbulent flow the pattern is random in both time and space. The disordered motion of fluid

properties in turbulent flow results in two components of velocity, longitudinal and transverse

components. The longitudinal velocity attempts to make a fluid flow parallel to the conduit axis,

while the transverse component attempts to move the fluid in a direction normal to the pipe axis.

Prevention of Hole Erosion

If unconsolidated formations are to be penetrated, in an effort to minimise the potential for hole

erosion, the flow regime shall be maintained in the laminar range, and nozzle velocities shall be

limited to a maximum of 1 000 ft/sec. Pressure losses also increase with turbulence.

Annular Velocities
The low limit on annular velocities is the capability to lift the cuttings to surface. For most ordinary

mud 100 ft/min can be taken as a lower limit, however in large surface holes with limited pump

capacity, high viscosity muds can be seen to work at half this rate as long as penetration rates are

limited.

With higher penetration rates (50ft/hr) the annulus tends to overload with cuttings and the velocities

therefore have to be increased substantially. The upper limit can in most cases be taken at the point

where the fluid goes into turbulent flow around the drill collars, however in certain situations like

PDC or turbo drilling this parameter may be exceeded.

Annular Velocity = 24.51 * GPM

(Dh^2 - Dp^2)

Dh = Diameter of Hole

Dp = Outside Diameter of Pipe

Slip Velocity
The rate at which solid particles settle out of the well fluids is called the slip velocity.
Turbulent Flow
 Spherical Chips Vs = 155.9 {dc (rc - rm) / rm}1/2

Flat Chips Vs = 60.6 {dc (rc - rm) / rm}1/2

Laminar Flow
Spherical Chips Vs = 159968 * dc2 (rc - rm) / m

Flat Chips Vs = 62100 * dc2 (rc - rm) / m

Where,

m = PV + 399 YP (DH - DP) / AV

Check, VS = > 50%

Optimisation of Wellbore Hydraulics

For optimising hydraulics, since the flow rate has been fixed for providing adequate annular

velocity, the only variable to optimise is the pressure drop across the bit.

Two recognised methods exist to optimise bit hydraulics.

 hydraulic horsepower method

 hydraulic impact force method.

Hydraulic Horsepower Method
BHHP = PSQ - PCQ

1714 1714

In this method the pressure drop across the bit is

PB = PS {n / (n+1)}

where, n = slope of PS vs Q curve. The value of n is usually between 1.8 and 1.86.

When n=1.86, the hydraulic horsepower method optimised conditions exist and 65 % of available

pump horsepower (or standpipe pressure) is applied at the bit.

Hydraulic Impact Force Method
Impact Force (IF) = Q (r * Pbit)1/2

58

n this method the pressure drop across the bit is

PB = PS {n / (n+2)}

With the hydraulic impact force method optimised conditions exist when 48 % of available pump

horsepower (or standpipe pressure) is applied at the bit.

In general the hydraulic impact method should be applied in soft, fast top hole drilling and the

hydraulic horsepower method used deeper down. Whichever method is used the result will be

within 95 % of the optimum of the other.

TFA (Total Flow Area) and Nozzle Selection
Smaller nozzle sizes are obtained with BHHP method as this method gives larger values of

pressure drop across the bit.

AT = 0.0096 * Q * (r / Pbit)1/2

Where:

AT = Total flow area

dN = 32 (4AT/3) ½

Where:

dN = Nozzle size in multiples of 32

Jet Velocities
The nozzle jet velocity is the speed at which the drilling fluid travels through the nozzle. Abnormally

high nozzle velocities can cause nozzle wear.

Nozzle Velocity = 418.3 * GPM or GPM

J12 + J22 + J32 3.12 * Nozzle Area

J1, J2, J3 = Nozzle sizes

Annular Velocities
The low limit on annular velocities is the capability to lift the cuttings to surface. For most ordinary

mud 100 ft/min can be taken as a lower limit, however in large surface holes with limited pump

capacity, high viscosity muds can be seen to work at half this rate as long as penetration rates are

limited.

With higher penetration rates (50ft/hr) the annulus tends to overload with cuttings and the velocities

therefore have to be increased substantially. The upper limit can in most cases be taken at the point

where the fluid goes into turbulent flow around the drill collars, however in certain situations like

PDC or turbo drilling this parameter may be exceeded

Annular Velocity = 24.51 * GPM

(Dh2 - Dp2)

Dh = Diameter of Hole
Dp = Outside Diameter of Pipe

Bottom Hole Cleaning

To ensure sufficient cleaning at the bit 3 to 7 HHP/in2 are normally required.

7 HHP/in2 in soft, fast drilled claystone where bit balling is a problem and down to

3 HHP/in2 in harder formations like pure sandstone or granite.

Vertical and Horizontal Wells

For effective hole cleaning in vertical and horizontal wells the flow rate must exceed the minimum

values listed below.

HOLE SIZE RECOMMENDED FLOW RATE (gpm)
17.1/2in/16in 900-1000
12.1/4in 800-900
8.1/2in 400-450
6.1/8in / 6in 250-300

The table assumes average drilling conditions, i.e. that average penetration rates are achieved and

that drilled cuttings, not cavings, are to be removed from the hole. In deviated wells and if

abnormally high ROP is achieved or if a significant amount of cavings are being produced, then the

values listed may not clean the hole effectively.

The tabulated values are intended as a guide. Reference must be made to the drilling programme

for recommendations for specific wells.

If the minimum flow rate proves impossible to achieve, use of larger nozzles will permit circulation at

higher rates. Increase the bit nozzle size in increments until the minimum flow rate is achieved. If

maximum bit nozzle size is reached before this point, then contact the Operations Engineer.

As a guide, for onshore wells through the reservoir section, the minimum size of nozzles is 14/32in

in case LCM has to be pumped.

Formation of Cutting Beds

Well Inclination Greater Than 30deg
In deviated wells, with hole angles of greater than 30°, cuttings will tend to form a bed on the low

side of the hole, as shown in Figure 7.5. In such cases, the mechanism of cuttings transport is one

of inducing movement of the cuttings bed itself and of saltation, or “jumping” of individual particles
along the bed surface. The figure illustrates how increasing annular velocity improves hole cleaning.

With reference to the figure, the best hole cleaning is achieved in zones 1 and 2, whereas zone 5 is

virtually a guarantee of tight hole problems.

Well Inclination Between 45deg and 70deg
Hole angles between 45° and 70° are termed critical angle holes since, in practice, such holes are

the most difficult to clean. Moreover, when the pumps are shut off for any reason the bed tends to

slide back down the hole. Consequently, circulation before trips etc. is of critical importance.

Removal of Cuttings Beds

Mud Rheology
Mud rheology should not be adjusted in an attempt to improve hole cleaning in deviated wells.

An increase in rheology, specifically the true yield point, decreases the settling velocity of the

particles, which can often improve hole cleaning efficiency, in vertical wells, by reducing the time

that cuttings spend in the annulus. The true yield point is the intercept on the Shear Stress axis of

the plot of Shear Stress vs Shear Rate, as measured on the Fann viscometer. The conventional YP

often over predicts the true yield point, consequently, it has become fashionable to quote the 600

rpm readings as the important rheological control parameter, since this often gives a better estimate

of the true yield point.

In deviated wells, decreasing the settling velocity does little to improve hole cleaning since cuttings

only have to fall through a very short distance before they are incorporated into the cuttings bed.

Rheology must be maintained within the range detailed in the Drilling Programme.
Annular Velocity
The annular velocity is the single most important parameter in the hole cleaning process. It must be

optimised, at all times, remaining within any pressure constraints imposed by surface equipment or

ECD. In general, higher pump rates are required to clean deviated wells than comparable vertical

wells.

Circulation Before Trips

Simply pumping bottoms up before trips, may be sufficient for vertical wells but is insufficient to

ensure that a deviated hole is clean. In all cases, the hole should be circulated until the shakers are

running clear of cuttings. In horizontal wells low/high vis pills shall be used prior to POOH. The
Drilling Supervisor shall determine when the hole is clean and the pumps may be shut off to begin

the trip.

The following table provides a general guideline to calculate circulation volume.

Inclination of Well Section Length Factor
(Degrees) 17 ½” 12 ¼” 8 ½” 6”
0 - 10 1.5 1.3 1.3 1.3
10 - 30 1.7 1.4 1.4 1.4
30 - 60 2.5 1.8 1.6 1.5
60 - 90 3.0 2.0 1.7 1.6

No. of Circulation’s = Total Effective Length / Measure Depth

Cavings
In many instances, particularly in deviated wells, poor hole cleaning is diagnosed when, in fact, the

problem is one of mechanical hole instability.

Drilling Fluids and Hydraulics Programmes are designed to transport cuttings of average size.

Cavings which are significantly larger are much more difficult to transport and may present

significant cuttings transport difficulties. In this case, efforts must be made to cure the instability by

increasing gradient etc. if possible. If the hole instability is cured, then so will be the hole cleaning

problem.

Clean up Pills
Vertical Wells
In conventional vertical wells, high viscosity pills are often pumped to boost hole cleaning at critical

points in the operation.

Deviated Well with Wells Inclination greater than 45o
High Viscosity pills are largely ineffective in removing cuttings beds in deviated wells. The following

procedure should be used:

1. Pump a thin, turbulent flow low vis 20bbl pill composed solely of the mud base fluid or brine.

2. Pump a second, high gradient / viscosity 40bbl mud pill immediately behind the initial pill. The

gradient of the second pill shall be high enough such that when it is mixed with the unweighted pill

the resultant gradient will be the same as the gradient of the circulating system.

3. Monitor returns at the shakers.

4. Return both pills to the circulating system.

Use the following total volumes i.e. total volume of low viscosity + high viscosity pills:
HOLE SECTION TOTAL VOLUME OF PILLS
17.1/2in / 16in 50-100 bbls
12.1/4in 30-50 bbls
8.1/2in 30-50 bbls
6.1/8in 20-30 bbls

Use pills judiciously. Monitor shakers carefully for increased returns. If no increase is seen do not

continue to pump pills. This will result in unnecessary building of mud volume and make mud

properties variable around the system.

Analysis of Hydraulics
ROP
The ROP determines directly the amount of cuttings to be removed from the annulus.

Consequently, in some critical wells, ROP may have to be controlled for reasons of hole cleaning

efficiency. High instantaneous ROP should be avoided.

Pipe Rotation
Pipe rotation helps stir up the cuttings bed in deviated wells. Consequently, the incidence of sliding

of pipe should be reduced to a minimum in critical holes.

Backreaming
Backreaming (where top drive available) on wiper trips and trips may be necessary to remove

cuttings beds in critical holes.

Barites Sag
It is of the utmost importance to ensure that True Yield Point, and Gel Strength are sufficiently high

to suspend Barite. Barite sag can be a particular problem in deviated wells since the Barite particles

only have a very short distance to fall before they form a bed on the low side of the hole. This bed

tends to slump down the hole thus promoting further Barite sag. Evidence of Barite sag will be seen

as uneven mud gradient measured at the shakers.

Jet Selection
To run one jet blanked off can at times give a slight improvement in penetration rates. In general it

should be tried in medium to hard formations where bit balling is no problem. The concentration of
 all hydraulic horsepower on only two nozzles gives an erosive pulsating effect which in addition to

the bit cutting increases the rate of penetration.

In addition where lost circulation is a problem the chances of plugging two big nozzles is less than

the chances for plugging three small nozzles of equivalent total area.
Slug Pipe
A slug shall be pumped down the drill pipe before every trip.
Data Required
The following input data are required to carry out complete analysis of hydraulics:

 Lithology

 Cuttings gradient

 Bit type

 Cuttings size

 ROP

 Total depth of hole section

 Formation fracture gradient

 Hole geometry

 Hole angle

 String geometry (BHA)

 Mud gradient

 Mud rheology

 Type of drilling (rotary, slide)

 Equipment available

The following procedure has been designed with the aim of maximising annular velocity to ensure

hole cleaning efficiency is maximised at all times. It is assumed that system pressures and bit

optimisation hydraulics will be calculated using either a computer or a programmable calculator.

1. If unconsolidated formations are to be penetrated, in an effort to minimise the potential for hole

erosion, Maintain the flow regime in the Laminar range, and limit nozzle velocities to a maximum of

100 m/s.

2. Estimate required bit nozzles (TFA) based upon previous experience and recommendations of

the bit supplier.

3. Calculate the system pressure drop using the maximum pump output available with the current

pump/liner configuration.

4. If the calculated pressure drop is within the constraints imposed by the pressure rating of surface

equipment, and does not produce an ECD higher than the Fracture Gradient, continue with Step 5.

5. If the pressure drop is too high, reduce the pump rate in increments until both constraints are

satisfied.

6. Check the flow regime. If unconsolidated formations are to be penetrated, maintain the circulating

fluid in the Laminar Flow regime. In this case, if the flow regime is transitional or turbulent, then

reduce pump rate in increments until Laminar Flow is predicted.

7. Check that the hole is being cleaned effectively. For vertical wells, the flow rate must exceed the

minimum values listed below.

Hole Size Recommended Flow
Rate (gpm)
17 1/2” 900 -1000
12 1/4” 800 - 900
8 1/2” 400 - 450
6” 250 - 300

The table assumes average drilling conditions, i.e. that average penetration rates are achieved and

that drilled cuttings, not cavings, are to be removed from the hole. If abnormally high ROP is

achieved or if a significant amount of cavings are being produced, then the values listed may not

clean the hole effectively.

The tabulated values are intended as a guide. Reference must be made to the Drilling Programme

for recommendations for specific wells.

If the minimum flow rate proves impossible to achieve, use of larger nozzles will permit circulation at

higher rates. INCREASE the bit nozzle size in increments until the minimum

8. Check optimisation of bit hydraulics. Take into account minimum flow requirements

recommended by the bit supplier. The values below shall be used as a guide for optimisation flow

rate is achieved. If maximum bit nozzle size is reached before this point, contact the Operations

Engineer.
Optimisation Method % Of Total System Pressure
Loss Expended At Bit
Maximum Hydraulic Horsepower at Bit 65%
Maximum Hydraulic Impact Force 49%
If optimisation requires an increase in nozzle size, due to too much pressure being expended

across the bit, recalculate system pressure drop. increade flow rate if possible.

If smaller nozzles are required, ensure that the increased pressure drop does not result in the flow

rate having to be reduced below the minimum for good hole cleaning. If this is the case, do not

optimise the bit hydraulics further.

9. Check that the nozzle velocity does not exceed 300 ft/sec if unconsolidated formations are to be

penetrated. If nozzle velocity is too high, select larger nozzles.