The effect of drillpipe rotation on hole cleaning during directional well drilling

The effect of drillpipe rotation on hole cleaning during directional well drilling is investigated. An 8 diameter wellbore simulator, 100 ft long, with a 4 drillpipe was used for the study. The variables considered in this experimental work are: rotary speed, hole inclination, mud rheology, cuttings size, and mud flow rate. Over 600 tests were conducted. The rotary speed was varied from 0 to 175 rpm. High viscosity and low viscosity bentonite muds and polymer muds were used with 1/4 crushed limestone and 1/10 river gravel cuttings. Four hole inclinations were considered: 40, 65, 80, and 90 degrees from vertical. The results show that drillpipe rotation has a significant effect on hole cleaning during directional well drilling, contrary to what has been published by previous researchers who forced the drillpipe to rotate about its own axis. The level of enhancement due to pipe rotation is a function of the simultaneous combination of mud rheology, cuttings size, and mud flow rate. Also it was observed that the dynamic behavior of the drillpipe (steady state vibration, unsteady sate vibration, whirling rotation, true axial rotation parallel to hole axis, etc.) plays a major role on the significance in the improvement of hole cleaning. Generally, smaller cuttings are more difficult to transport. However, at high rotary speed and with high viscosity muds, the smaller cuttings seem to become easier to transport. Generally, in inclined wells low viscosity muds clean better than high viscosity muds, depending on cuttings size, viscosity, and rotary speed level.