ADVANCED CUTTINGS TRANSPORT STUDY

This is the first quarterly progress report for Year-4 of the ACTS Project. It includes a review of progress made in: (1) Flow Loop construction and development and (2) research tasks during the period of time between July 1, 2002 and Sept. 30, 2002. This report presents a review of progress on the following specific tasks: (a) Design and development of an Advanced Cuttings Transport Facility Task 3: Addition of a Cuttings Injection/Separation System, Task 4: Addition of a Pipe Rotation System, (b) New Research project (Task 9b): ''Development of a Foam Generator/Viscometer for Elevated Pressure and Elevated Temperature (EPET) Conditions'', (d) Research project (Task 10): ''Study of Cuttings Transport with Aerated Mud Under Elevated Pressure and Temperature Conditions'', (e) Research on three instrumentation tasks to measure: Cuttings concentration and distribution in a flowing slurry (Task 11), Foam texture while transporting cuttings (Task 12), Viscosity of Foam under EPET (Task 9b). (f) Development of a Safety program for the ACTS Flow Loop. Progress on a comprehensive safety review of all flow-loop components and operational procedures. (Task 1S). (g) Activities towards technology transfer and developing contacts with Petroleum and service company members, and increasing the number of JIP members

ADVANCED CUTTINGS TRANSPORT STUDY

This is the second quarterly progress report for Year-4 of the ACTS Project. It includes a review of progress made in: (1) Flow Loop construction and development and (2) research tasks during the period of time between October 1, 2002 and December 30, 2002. This report presents a review of progress on the following specific tasks. (a) Design and development of an Advanced Cuttings Transport Facility Task 3: Addition of a Cuttings Injection/Separation System, Task 4: Addition of a Pipe Rotation System. (b) New research project (Task 9b): ''Development of a Foam Generator/Viscometer for Elevated Pressure and Elevated Temperature (EPET) Conditions''. (d) Research project (Task 10): ''Study of Cuttings Transport with Aerated Mud Under Elevated Pressure and Temperature Conditions''. (e) Research on three instrumentation tasks to measure: Cuttings concentration and distribution in a flowing slurry (Task 11), Foam texture while transporting cuttings. (Task 12), and Viscosity of Foam under EPET (Task 9b). (f) New Research project (Task 13): ''Study of Cuttings Transport with Foam under Elevated Pressure and Temperature Conditions''. (g) Development of a Safety program for the ACTS Flow Loop. Progress on a comprehensive safety review of all flow-loop components and operational procedures. (Task 1S). (h) Activities towards technology transfer and developing contacts with Petroleum and service company members, and increasing the number of JIP members

Advanced Cuttings Transport Study Quarterly Report

We have tested the loop elevation system. We raised the mast to approximately 25 to 30 degrees from horizontal. All went well. However, while lowering the mast, it moved laterally a couple of degrees. Upon visual inspection, severe spalling of the concrete on the face of the support pillar, and deformation of the steel support structure was observed. At this time, the facility is ready for testing in the horizontal position. A new air compressor has been received and set in place for the ACTS test loop. A new laboratory has been built near the ACTS test loop Roughened cups and rotors for the viscometer (RS300) were obtained. Rheologies of aqueous foams were measured using three different cup-rotor assemblies that have different surface roughness. The relationship between surface roughness and foam rheology was investigated. Re-calibration of nuclear densitometers has been finished. The re-calibration was also performed with 1% surfactant foam. A new cuttings injection system was installed at the bottom of the injection tower. It replaced the previous injection auger. A mechanistic model for cuttings transport with aerated mud has been developed. Cuttings transport mechanisms with aerated water at various conditions were experimentally investigated. A total of 39 tests were performed. Comparisons between the model predictions and experimental measurements show a satisfactory agreement. Results from the ultrasonic monitoring system indicated that we could distinguish between different sand levels. We also have devised ways to achieve consistency of performance by securing the sensors in the caps in exactly the same manner as long as the sensors are not removed from the caps. A preliminary test was conducted on the main flow loop at 100 gpm flow rate and 20 lb/min cuttings injection rate. The measured bed thickness using the ultrasonic method showed a satisfactory agreement with nuclear densitometer readings. Thirty different data points were collected after the test section was put into liquid holdup mode. Readings indicated 2.5 to 2.7 inches of sand. The corresponding nuclear densitometers readings were between 2.5 and 3.1 inches. Lab tests were conducted to check an on-line viewing system. Sharp images were obtained through a CCD camera with the use of a ring light or fiber light. A prototype device for measuring the average bubble size for the foam generator-viscometer was constructed from a 1/2 inch fitting. The new windowed cell has been received and installed on the ACTF Bubble Characterization Cart

Advanced Cuttings Transport Study Quarterly Report

Final design of the mast was completed (Task 5). The mast is consisting of two welded plate girders, set next to each other, and spaced 14-inches apart. Fabrication of the boom will be completed in two parts solely for ease of transportation. The end pivot connection will be made through a single 2-inch diameter x 4 feet-8 inch long 316 SS bar. During installation, hard piping make-ups using Chiksan joints will connect the annular section and 4-inch return line to allow full movement of the mast from horizontal to vertical. Additionally, flexible hoses and piping will be installed to isolate both towers from piping loads and allow recycling operations respectively. Calibration of the prototype Foam Generator Cell has been completed and experiments are now being conducted. We were able to generate up to 95% quality foam. Work is currently underway to attach the Thermo-Haake RS300 viscometer and install a view port with a microscope to measure foam bubble size and bubble size distribution. Foam rheology tests (Task 13) were carried out to evaluate the rheological properties of the proposed foam formulation. After successful completion of the first foam test, two sets of rheological tests were conducted at different foam flow rates while keeping other parameters constant (100 psig, 70F, 80% quality). The results from these tests are generally in agreement with the previous foam tests done previously during Task 9. However, an unanticipated observation during these tests was that in both cases, the frictional pressure drop in 2 inch pipe was lower than that in the 3 inch and 4 inch pipes. We also conducted the first foam cuttings transport test during this quarter. Experiments on aerated fluids without cuttings have been completed in ACTF (Task 10). Gas and liquid were injected at different flow rates. Two different sets of experiments were carried out, where the only difference was the temperature. Another set of tests was performed, which covered a wide range of pressure and temperature. Several parameters were measured during these tests including differential pressure and mixture density in the annulus. Flow patterns during the aerated fluids test have been observed through the view port in the annulus and recorded by a video camera. Most of the flow patterns were slug flow. Further increase in gas flow rate changed the wavy flow pattern to slug flow. At this stage, all of the planned cuttings transport tests have been completed. The results clearly show that temperature significantly affects the cuttings transport efficiency of aerated muds, in addition to the liquid flow rate and gas liquid ratio (GLR). Since the printed circuit board is functioning (Task 11) with acceptable noise level we were able to conduct several tests. We used the newly designed pipe test section to conduct tests. We tested to verify that we can distinguish between different depths of sand in a static bed of sand in the pipe section. The results indicated that we can distinguish between different sand levels. We tested with water, air and a mix of the two mediums. Major modifications (installation of magnetic flow meter, pipe fittings and pipelines) to the dynamic bubble characterization facility (DTF, Task 12) were completed. An Excel program that allows obtaining the desired foam quality in DTF was developed. The program predicts the foam quality by recording the time it takes to pressurize the loop with nitrogen

An integrated fluid flow and fracture mechanics model for wellbore strengthening

Fracture-based wellbore strengthening techniques are preventive methods that can reduce the cost of lost circulation and non-productive time. The mud weight window can be extended by plugging fractures with wellbore strengthening materials (WSM) in the near-wellbore region. To maximize the strengthening effect, accurate fracture geometry prediction is of critical importance to the design of WSM. This paper presents a novel, coupled fluid flow and fracture mechanics model for wellbore strengthening applications that accounts for near-wellbore-induced fracture behavior. For fluid flow, mass conservation is considered and momentum conservation is examined; the latter shows that pressure loss with near-wellbore fracturing is low. Thus, we can neglect the pressure drop in the fractures and assume the fluid pressure inside the fractures is equal to the wellbore pressure. The pressure-width relationship (rock elastic deformation) and stress intensity factor are obtained by a dislocation-based approach. For the fracture propagation criterion, the calculated stress intensity factor is compared with fracture toughness at each time step. The stress intensity factor and fracture reopening pressure (FROP) are verified with Tada's model and Feng's model, respectively. Then, simulation results are compared with the large leak-off solutions of the Perkins-Kern-Nordgren (PKN) fracture model. The simulation results reveal that the PKN model overestimates the fracture mouth width, fracture length, and wellbore pressure. Furthermore, the simulation results of wellbore pressure show a different trend. Therefore, we cannot directly use the PKN model to design wellbore strengthening applications. The main reason is the presence of wellbore can generate near-wellbore effects that cannot be disregarded. Finally, we conduct a comprehensive parametric study (i.e., fracture toughness, Young's modulus, Poisson's ratio, horizontal stress ratio, and permeability) on wellbore strengthening fracturing. The proposed model is useful for wellbore strengthening applications using the intentionally induced fractures (i.e., near-wellbore fracturing). Particle size distribution (PSD) of WSM can be designed based on the simulated fracture geometry. No complex model mesh generation or assignment of boundary conditions are needed, which are commonly used in finite element simulation or other numerical methods. The proposed model can also be used to optimize wellbore strengthening operations by performing sensitivity analysis

Experimental investigation of fracture-based wellbore strengthening using a large-scale true triaxial cell

Fracture-based wellbore strengthening is a widely used preventive technique for lost circulation control. However, there were limited experimental studies on wellbore strengthening with an anisotropic stress state. In this paper, we describe an experimental investigation of fracture-based wellbore strengthening on cubic Berea sandstone samples (size of 12 in ) using a large-scale true triaxial cell. The true triaxial cell allows fracture containment to simulate wellbore strengthening, which was not available using a traditional small-scale traixial cell. We used drill cuttings and Chevron loss prevention material (LPM) as wellbore strengthening materials (WSM). Three independent stresses were applied on the rock samples and bi-wing fractures were generated. The final fracture reopening pressure (FROP) exceeded the formation breakdown pressure (FBP) after plugging the WSM. Further comparison between the experimental results and modeling results from a numerical model shows a good match for the injection pressure profile