Removing cuttings from inclined and horizontal wells: Numerical analysis of the required drilling fluid rheology and flow rate

Inclined and horizontal wells are prone to the accumulation of drilling cuttings. Determination of the optimal drilling parameters that facilitate cuttings removal is a key problem. Existing experimental, theoretical and field-based empirical analyses of the hole cleaning problem have failed to fully reveal the processes of cuttings transport, settlement, and accumulation concerning drilling string rotation in large annuli with high-density non-Newtonian drilling fluids. In this study, a coupled computational fluid dynamics-discrete element method (CFD-DEM) simulation model of the interaction between cuttings and drilling fluid was established. This allows the influences of well inclination, drill pipe rotational rate, flow rate, fluid density, and rheological properties on hole cleaning efficiency to be analyzed. A multi-parameter correlation equation between wellbore cleaning efficiency and wellbore size, inclination angle, drill string eccentricity, drill string rotational speed, rate of penetration, cuttings size, flow rate, and fluid density was obtained using dimensional analysis and multivariate nonlinear regression of simulation data. Finally, with consideration of wellbore cleaning characteristics, formation pressure bearing capacity, and pump condition constraints, the proposed multi-parameter correlation model was used to provide optimal wellbore cleaning parameters. The cleaning efficiency of horizontal wells is lowest in the inclined section. Hole cleaning efficiency increases significantly with drill pipe rotational rate, flow rate, and 6 RPM Fann dial reading. The proposed model can correlate hole cleaning efficiency with the 6 RPM Fann dial reading of drilling fluid and flow rate. At a given hole cleaning efficiency, the required minimum flow rate decreases with increases in the 6 RPM Fann dial reading. Similarly, the required minimum 6 RPM Fann dial reading decreases with increases in flow rate. The models and design layout proposed in this paper provide a new approach to solving hole cleaning parameter design problems in highly inclined and horizontal wells.