Experimental study on cuttings transport with foam under simulated horizontal downhole conditions

The use of drilling foams is increasing because foams exhibit properties that are desirable in many drilling operations. A good knowledge of cuttings transport efficiency under downhole conditions is essential for safe and economical foam drilling. Previous cuttings transport studies with foam are limited to low pressure and ambient temperature conditions. No experimental study has been conducted under downhole (i.e., elevated pressure and temperature) conditions. This paper presents an experimental study of cuttings transport with foam in a horizontal annulus under simulated downhole conditions. Experiments were conducted to determine the effects of polymer additives, foam quality, flow velocity, temperature, and pressure on foam cuttings transport. Experiments were carried out at elevated pressures (100 to 400 psi) and temperature (80 to 170117) conditions in a unique full-scale flow loop with a 73-ft long test section (5.76x3.5 in. concentric annulus). A field-tested commercial foam system consisting of surfactant (1% v/v) and hydroxylethylcellulose polymer (HEC) was used in the experiments. Three different polymer concentrations (0.0, 0.25, and 0.5% v/v) were tested. Foam quality was varied from 70 to 90%. During a test, cuttings were injected continuously to the flow loop until a steady state condition was established in the test section. In-situ cuttings volumetric concentration (i.e., the ratio of the volume of cuttings in the suspension and the cuttings bed to the volume of the annulus) in the test section was determined using nuclear densitometers, load cell measurements, and by weighing cuttings flushed out of the flow loop. Test parameters recorded during the experiments were: liquid and gas injection rates, cuttings weight in injection and removal towers, mixture density, friction pressure loss, and pressure and temperature in the annulus. Two flow patterns, stationary cuttings bed, and fully suspended flow, were observed during the cuttings transport tests. The flow pattern depends on polymer concentration, foam quality, and annular velocity. Annular flow velocity, foam quality, and polymer concentration all affect cuttings transport efficiency and frictional pressure loss. This paper will help to better design foam drilling and cleanup operations.