Hydraulics of Drilling With Aerated Muds Under Simulated Borehole Conditions

Maintaining optimum circulation rates is important in aerated mud drilling operations. However, reliable predictions of the optimum rates require accurate modeling of the frictional pressure loss at bottom-hole conditions. This paper presents a mechanistic model for underbalanced drilling with aerated muds. Extensive experiments in a unique field-scale high pressure and high temperature flow loop were performed to verify the predictions of the model. This flow loop has a $150×89mm2$$(6″×3.5″)$ horizontal annular geometry and is 22 m long. In the experiments, cuttings were introduced at a rate of 7.5 kg/min, representing a penetration rate of 15 m/h in the annular test section. The liquid phase flow rates were in the range of $0.30–0.57m3/min$⁠, representing superficial liquid velocities in the range of 0.47–0.90 m/s. The gas liquid ratio (gas volume fraction under in situ condition) was varied from 0.0 to 0.38. Test pressures and temperatures ranged from 1.28 to 3.45 MPa, and $27°C$ to $80°C$⁠, respectively. Gas liquid ratios were chosen to simulate practical gas liquid ratios under downhole conditions. For all the test runs, pressure drop and cuttings bed height over the entire annular section were measured. Flow patterns were identified by visual observations through a view port. The hydraulic model determines the flow pattern and predicts frictional pressure losses in a horizontal concentric annulus. The influences of the gas liquid ratio and other flow parameters on the frictional pressure loss are analyzed using this model. Comparisons between the model predictions and experimental measurements show a satisfactory agreement. The present model is useful for the design of underbalanced drilling applications in a horizontal wellbore.