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Experimental Investigation of Wellbore Fluid Displacement in Concentric and Eccentric Annulus Jan David Ytrehus SINTEF Petroleum Research Trondheim, Norway Bjørnar Lund SINTEF Petroleum Research Trondheim, Norway Ali Taghipour SINTEF Petroleum Research Trondheim, Norway Shreyansh Divyankar University of Stavanger Stavanger, Norway Arild Saasen University of Stavanger Stavanger, Norway ABSTRACT One of the most critical operations during well construction is the cementing procedure. Due to the curing nature of the cement slurry there will be only one opportunity to cement the well properly. Although one for top hole cases can fill cement in from the top in a remedial operation, this possibility cannot fully compensate for a non-optimal initial cement job. Furthermore, it cannot be applied to other well sections. In those sections, complex squeeze cementing operations may be necessary. Consequences of improper annular cement can be leakage during production phase and extensive costs when the well is to be plugged for abandonment after the production phase. To ensure that the risk of poor cement is minimised it is important to use the best procedures to place the cement properly. To be able to select the optimum procedures, it is necessary to improve the understanding of the displacement in the wellbore annulus. All wells will be cemented in several sections. Findings and improvements that can reduce risk of poor cementing results are thus highly relevant for a large number of operations every year. The article is based on analysing experimental results that illustrates a drilling fluid being displaced by a cement slurry. These fluids are represented by realistic model fluids and circulated through a transparent annular section. The geometry used is a 6,5" outer diameter with an inner string of 5" that also can rotate. The selected pipe sizes may normally be found in the lower parts of a well and often in deviated sections where the inner pipe cannot be assumed concentric at all times. Both concentric and eccentric inner pipe positions have therefore been selected. The test section was run both in horizontal and in inclined position. The test section was 10 meters long and instrumented with conductivity probes in an array around the perimeter at 4 separate positions along the pipe. Together with cameras along the test section the fluid interphases was observed along the test section. Results presented in the article show that inner string rotation provides a steeper displacement front, On the other hand such rotation will also cause more mixing at the interphase. Results also show that the displacement front in a concentric annulus is significantly affected by gravity. While for an eccentric annulus, with the low side at the bottom, the narrow gap is poorly displaced when realistic fluids are applied. It was also observed that the displacement front in concentric annulus was more stable when the test section was inclined than in horizontal position. 1. INTRODUCTION Displacement processes occur frequently in drilling and completion operations. The most important displacement operations take place during primary cementing. A good displacement quality is required to achieve a good cement job result with proper zonal isolation properties. A cementing operation is the operation in an oil well where only one chance is given to succeed. Several studies evaluating optimized displacement exist. A thorough review was performed by Daccord et al., 2006 [1], with the scope of improving primary cementing job results. Displacement processes are known not to be solely dependent on the properties of the displacing fluid or slurry [2]. The pre-conditioning of the drilling fluid prior to pumping cement or the spacers and pre-flushes are important. Normally, there is an operational requirement to circulate one bottoms up prior to displacement. There is no general theory behind the choice of exactly one bottoms up. Furthermore, the drilling fluid has been designed for optimum drilling performance like hole cleaning, wellbore stability, fluid loss and other parameters. It is just a coincidence if this drilling fluid is suitable for displacement. Proceedings of the ASME 2017 36th International Conference on Ocean, Offshore and Arctic Engineering OMAE2017 June 25-30, 2017, Trondheim, Norway OMAE2017-62028 1 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use Therefore, generally, to be able to displace the drilling fluid efficiently, it is necessary to alter the drilling fluid’s properties during the last circulations. Even if the drilling fluid viscosity and yield stress are reduced as much as possible, it is still not straightforward to obtain a good displacement result. The cement slurry properties have to be optimized for the purpose of removing the drilling fluid. It is still not known how the optimized properties are for obtaining good displacement in the entire annulus cross section. The annulus will most likely have a varying eccentricity, there will be occasional washouts and regular pipe joints. Furthermore there will be centralisers at planned positions in order to keep the pipe near center of the annulus. Several attempts have been performed to experimentally evaluate removal of drilling fluid by cement slurries. Examples of such tests include evaluation of density effects in cementing [3] by the use of clear model fluids. Learnings from these studies have been used to optimize cementing in the North Sea area. A very slow displacement with a high density cement was successfully used for a long horizontal North Sea cementing operation [4]. Later, the technique was used successfully in a yard test [5]. When it comes to rheological properties, it is difficult to select the correct properties. Neither the drilling fluid nor the cement viscosities can be described by the use of a single parameter. Then, given the large variation in annular geometries, there is almost an infinite number of combinations that can represent the optimum for displacement; making it difficult to even find rules of thumb how to improve a displacement result. To be able to design a proper primary cementing job it is necessary to have access to good numerical simulators. Most cementing companies have such simulators. These simulators are normally based on calculating laminar displacement in annuli with different eccentricities [6-9]. Still, these simulators need to be calibrated or mathematically closed by the addition of experimental results. Ideally, for presenting drilling and cementing data, full scale experiments are needed to handle all the parameter scaling issues [2,10]. This is, however, not practical. Hence, most simulators have to be calibrated towards laboratory scale experiments. Laboratory investigations has followed two directions. One direction is to use laboratory fluids [3, 11-13]. These experiments are typically conducted with fluids that allows for optical analysis. Hence, they are often conducted with transparent fluids. As being the case with the numerical simulations, they are conducted in regular annuli without any simulated washouts. The other direction is to use real cements [14,15]. The use of real cements introduce the possibility of having realistic particles into the flow. However, use of real cements creates a restriction of the number of tests to be performed. Still the focus is regular annuli without any simulated washouts. The current evaluation focuses on displacement in annuli with washouts. To be able to understand the physics of displacement, a series of experiments with laboratory fluids having a sufficient degree of transparency were used. 2. EXPERIMENTAL Test setupThe results presented here are from tests in an advanced purpose-built flow rig for testing cement displacement efficiency. The test section was designed to represent the annular section caused by a 5" liner in a 6.5" borehole. The 10 m long test section was constructed with transparent plastic pipes. The inner pipe can be rotated at 15 RPM in various fixed positions allowing tests with both eccentric and concentric inner pipe. The outer pipe's inner diameter was Do = 165 mm (6,5") and the inner pipe's outer diameter was Di= 127 mm (5"). The test section was used in both horizontal and inclined position. The test section was instrumented with conductivity probes in an array around the perimeter at 4 separate positions along the pipe. Together with cameras along the test section the fluid interphases was observed along the test section. Both concentric and eccentric inner pipe positions where applied in the reported tests. The displacing fluid was pumped with 0.5 m/s in the annulus with various other test parameters to investigate displacement efficiency. Experiments were conducted at ambient pressure and temperatures. This was considered sufficient for the purpose of these investigations, and is much more cost efficient than running experiments at reservoir conditions. The test section was mounted on a steel frame that can be tilted from horizontal and up to 30° inclination. Schematic of the test section is shown in figures 1 and 2: Figure 1. Schematic of the flow rig test section. In this configuration, the fourth sub-section of the test section is an irregular wellbore sub-section. The irregularity consists of a higher outer diameter than the other sections. Test section consist of 5 sub-sections each of them had a length of 2 meters. The fourth sub-section is a transparent pipe with the inner diameter of Di = 280 mm to represent a washout section in the borehole. The results reported here are only from the 3 first sub-sections representing a regular liner in borehole situation without washouts. The inner pipe was constrained in 6 positions with ability for adjusting the eccentricity and rotation. The inner pipe rotated with a motor located in left side. Fluids were pumped into the test section from the right side as shown in figure 2. 2 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use Figure 2. Flow rig test section in horizontal position showing flow direction. Inlet to the right. The flow rig consisted of the following main components • Transparent inclinable test section with inner pipe • Motor for rotating the inner pipe • Separate liquid slurry tanks and pumps for displaced and displacing fluid • Waste tanks • Instrumentation • Connecting hoses Instrumentation includes: • FM1: flow meters • DP1-DP3: pressure transmitters • A-B-C-D: fluid interface detectors (conductivity probe arrays) • V1-V4: valves (with pneumatic actuators) • M: fluid mixing unit • C0: global conductivity probe • Video cameras • Logging system Figure 3. Sketch of the main components of the flow loop system Conductivity probes were placed in arrays deployed at the axial positions A-D. Results from array in position D is not reported here. Each array consist of 8 conductivity probes that were mounted on each of the four non-rotating outer couplings. Each probe consisted of two electrodes placed 8 mm apart (center to center distance) in the wall of the outer non-rotating coupling. The applied electrodes were 3 mm (diameter) machine screws in stainless steel. The electrodes are threaded in order to be adjusted to the required penetration depth, which in these tests were 5 mm into the flow. The order of the probes are shown in figure 4. Figure 4. Schematics of the test section flanges including the conductivity probes and the inner pipe constraining system in an eccentric position. View from the right side of the test section. A commercial conductivity probe was located at the outlet of the test section to measure the conductivity of the fluid exiting the section. This can be used to identifying the fluid types and calculating the overall displacement efficiency in each tests. The nominal conductivity range of the displaced fluid was 0.5 mS/cm while it was 14.5 mS/cm for the displacing fluid. The displacement during the experiments was recorded with several video cameras. The video cameras were located at the side and bottom of the test section. A LED light plate illuminated the pipe from the backside opposite the video cameras. Test procedures Before conducting displacement tests, the conductivity probes were calibrated. To do the calibration, the test section was first filled with the displaced fluid and the signal received from the probes adjusted to nominal conductivity of about 0.5 mS/cm. Then the test section was filled with the displaced fluid and the signal received from the probes was adjusted to a nominal conductivity of 14.5 mS/cm. These numbers were taken from a benchmark test with the selected test fluids. All displacement tests were conducted with pump rate set to provide an annular fluid velocity of 0.5 m/s. The test matrix also included reference tests, repetitions and tests for determining pressure offset values. The main test procedure was as follow: 1. Start circulation of displaced fluid through the test section. 2. Start circulation of displacing fluid through the bypass line. Flow rate adjusted to provide the annular velocity of 0.5 m/s in the test section. 3. Continue circulation, log the conductivity probes and pressure differential cells. 4. Start circulating the displacing fluid through the test section. 5. Based on the global conductivity signal at the outlet of the test section, separate the fluids into the proper storage tanks (for either waste or re- use). Inlet Prob Nr. 1 Az: 22,5 Prob Nr. 8 Prob Nr. 7 Prob Nr. 6 Prob Nr. 5 Prob Nr. 4 Az: 157,5 Prob Nr. 3 Az: 112,5 Prob Nr. 2 Az: 67,5 3 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use During the test period, all the valves were operated automatically. State of the circulating fluid trough the test section and valves position is shown in Table 1. Table 1. State of the flow inside the test section and valve positions Several displacement tests conducted in different conditions. Test matrix includes different test conditions such as position and rotation of the inner pipe, and inclination of the test section as summarized in table 2. Table 2. Test matrix and parameters Fluid properties The two fluids used in the tests reported here are model fluids designed for the purpose of this displacement experiment. The flow loop was initialized with the fluid to be displaced and the composition of this fluid was laponite mixed with water with ca 1.4% laponite by weight. During the preparation of the laponite based fluid, it was observed that rigorous mixing was required in order to obtain a homogenous mix. Hence, the mixing procedure was modified in two stages. The first stage consisted of preparing a concentrated laponite pre-mix with water with ca 13% to 14% laponite by weight. In the second stage, this pre-mix was diluted down to the design concentration of ca 1.4% by weight by adding water, and then transferred into the test tank. The displacing fluid was a water and xanthan gum mixture. Multiple additive were included in order to achieve desired contrast with the displaced fluid. NaCl was added for electrical conductivity contrast, Na2CO3 was added for pH regulation, biocide MD-5111 was added for bacterial growth inhibition and barite was added for increasing mass densityand obtaining density and visual contrast with the displaced laponite fluid. The mass composition for the xanthan gum fluid with the additives is listed as follows: • Water = 85% • Xanthan gum = 0.67% • NaCl = 0.87% • Na2CO3 = 0.37% • Biocide = 0.093% • Barite = 12.5% to 13% The fluids were stable in the test period as ensured by internal circulation systems, frequent measurements (Fann and Anton Paar measurements) and accurate procedures for fluid handling. The fluids were selected because they are fairly simple to produce and provide a fair representation of fluids that are used on Norwegian Continental Shelf. In addition they can contain desired salinity level in order to identify the displacement front using conductivity probes. 3. RESULTS In this chapter the results from the tests are presented. In all presented result plot a piston front is included to illustrate a perfect displacement front. This piston front is calculated based on the actual flow rate for each experiment. Concentric inner pipe position In this section results from experiments with concentric geometry are presented. Figure 5. The conductivity responses are plotted for axial positions A, B and C (see drawing lower, left) for concentric test section without rotation, comparing horizontal (solid lines) and inclined wellbore (dashed lines). Upper plot shows response from probe 8 near top (see drawing lower right) and lower plot shows response from probe 5 near bottom. The vertical lines represent a perfect displacement front. In Figure 5 the results from tests with concentric inner pipe are presented, comparing horizontal and inclined wellbore. Vertical lines with calculated piston (perfect displacement) front are added for each axial position reported. It is observed that the displacement occurs in the lowest position first and that this trend becomes stronger the further into the test section the front moves. Except at the Operational state Displaced fluid Displacing fluid V1 V2 V3 Circulating displaced fluid ON OFF A B A Initialize displacement experiment OFF ON B A A Start displacement experiment (C < 5 mS/cm) OFF ON B A A Displacement experiment (5 mS/cm < C < 11 mS/cm) OFF ON B A B Displacement experiment (C > 11 mS/cm) OFF ON B A B Stop displacement experiment OFF OFF B A B Drain loop for displacing fluid OFF OFF B A B Circulate displaced fluid to remove residual displacing fluid ON OFF A B A Test Flow rate String rotation Standoff Inclination A 0.5 m/s 0 1 0 B 0.5 m/s 15 1 0 C 0.5 m/s 0 1 30 D 0.5 m/s 15 1 30 E 0.5 m/s 0 0.58 30 F 0.5 m/s 15 0.58 30 G 0.5 m/s 0 0.58 0 4 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use position closest to the inlet in inclined test section all displacement fronts at the low point are ahead of the modelled piston front. It seems like inclination angle affects the displacement at the bottom, and for the plotted cases the displacement is delayed due to inclination. For the positions on top of the pipe the results show that the displacement front arrives close to what the modelled piston function predicts. Some deviation is found, for instance at the position furthest from the inlet in the inclined section. Still it seems that the effect of inclination appears small at these positions. Eccentric inner pipe position Results from selected tests with the eccentricity on the inner pipe are reported here. Figure 6. The conductivity responses are plotted for axial positions A, B and C for test section inclined to 30 degrees from horizontal. Upper plot shows response from probe 8 near top and lower plot shows response from probe 5 near bottom.The vertical lines represent a perfect displacement front. Solid lines represent tests with concentric inner pipe and dotted lines represent tests with eccentric inner pipe. In Figure 6 results with concentric and eccentric geometry for inclined test section are compared. The results show that the displacement at the top of the test section comes ahead of the calculated piston model except at the first position after the inlet. At this position the fronts are close to the piston front, but the concentric is slightly after while the eccentric results show that the front is ahead. Although the plots for concentric and eccentric results here seem to be very close to each other it is important to compare them to their modelled piston front. The piston front comes later for the inclined tests than at the horizontal as the flow velocity did not reach correct value as quickly in this setup. Near the bottom of the annulus the effect of eccentricity is much more dominant. For the concentric case (also shown in Figure 5) the fronts are close to, or ahead, of the piston front. While for the selected eccentricity the displacement comes much later. Further, it is observed that fluid displacement at the position A closest to the inlet occurs later than at the mid-section (position B). This indicates that for the eccentric case there is also a displacement from the upper parts of the section and into the region below the inner pipe and that an axial displacement front only can be found above this region. Rotation effects Rotation effects have been investigated by conducting a set of experiments with 15 RPM inner string rotation speed, see Table 2. Figure 7. The conductivity responses are plotted for axial positions A, B and C for inclined test section and eccentric inner pipe. The two plots represent the high point, position 8 (on top) and the low point, position 5 (middle). The vertical lines represent the theoretical front. Solid lines represent tests without inner pipe rotation and dotted lines represent tests where the inner pipe is rotated at 15 RPM. In Figure 7 the effect of inner string rotation is demonstrated, comparing results for 0 RPM and 15 RPM with the test section in inclined, eccentric position. The most striking feature is the effect of the displacement in the narrow gap at the low side of the wellbore (position 5). Without rotation the displacement is severely delayed, and in fact occurs at position B before it occurs at position A. Thus, there is no true axial displacement front in the narrow 5 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use gap. With rotation we see that the displacement at radial position 5 occurs first at A, then at B and C, indicating axial displacement. This behavior is expected, considering that the displaced fluid has a non-zero yield strength and gelling tendencies. Without rotation the fluid in the narrow gap may initially be immovable but is eventually mobilized due to increased shear stress as the displacement progresses. Fluid dynamics Rotation increases the effective shear strain and shear stress in the narrow gap. This facilitates mobilization of the fluid in the narrow gap. Moreover, it creates a tangential transport of fluids due to the tangential shear stress. The first of these effects is probably the most important. The tangential velocity of the inner pipe is only 10 cm/s, compared to the average axial fluid velocity of 0.5 m/s. Nevertheless, we observe a significant effect of rotation also at the wide annular gap. This is clearly seen in the top plot of Figure 7. Figure 8. The conductivity responses are plotted for axial position B and radial positions 1 and 8 for eccentric inner pipe in inclined position with and without rotation. The flow curves of the fluids match well with the Herschel-Bulkley model. Reynolds numbers calculated based on the parameters shown in Table 3 were 340 for the displacing fluid and 540 for the displacedfluid. Here, the Reynolds number was calculated from the wall viscosity [16] Re h w UDρ µ = (1) Table 3. Herschel-Bulkley parameters from Fann measurements. Fluid K [Pa*s^n] τy [Pa] n [-] Displaced 0.15 6.7 0.62 Displacing 0.58 9.1 0.51 Thus, the flow is well into the laminar regime for both fluids. Although the tangential velocity of the inner string is only 20% of the mean axial flow velocity, we notice that the rotation has a significant effect on the flow distribution in the transversal plane. This is particularly noticeable for the eccentric configuration. This observation may be explained by transversal (tangential or swirling) fluid motion created by the pipe rotation. The steepness of the conductivity probe signals gives an indication of fluid mixing at the front at the radial position of the corresponding probe. One would intuitively expect that rotation will increase the degree of mixing at the displacement front, and thus a less steep front. This seems not to be the case in the present experiments. 4. KEY OBSERVATIONS For experiments with eccentric inner pipe it looks as if there is no displacement front to be identified in the axial direction in the narrow gap. The results imply that displacement in this region is caused by displacing fluid from the wider area above being drained down by gravitational forces Experiments with concentric geometry appears to have a well defined, but inclined, axial displacement front. It is observed that the low area is displaced sooner than the top of the pipe, expectedly due to gravitational forces. When an inclination angle is applied the displacement at the low point is delayed compared to the horizontal case as the gravitational forces likely becomes less significant. An inner string (liner) rotation of 15 RPM provided good displacement for all tested conditions. Tests with rotation gave distinct axial displacement profiles ensuring that almost all fluid in the system was mobilized. 5. CONCLUSIONS The following conclusions can be drawn from the experimental results: For the concentric geometry the density difference of the fluids dominates the displacement profile, and it is possible to identify a displacement profile through the axial positions. In eccentric geometry there are significant differences in the displacement between the narrow and wide area of the annulus. In the narrow section it is difficult to identify an axial displacement profile at all. It may be that the displacement in this region is caused by gravity-driven displacing fluid flowing down from the already displaced wide area above when there is no rotation. Rotation of the inner pipe provides a good displacement for all tested cases. Distinct axial displacement profiles were identified. This is likely due to the rotation causing a transversal transport of fluid. 7. ACKNOWLEDGMENTS This article is based on work financed through DrillWell and the authors would like to thank the Research Council of Norway, Statoil, AkerBP, Wintershall, ConocoPhillips and Lundin Norway for funding this work. The authors would also like to thank MI-SWACO, Schlumberger for providing the chemicals used for the fluid design and the technical support by Knud Richard Gyland. 6 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use REFERENCES [1] Daccord, G., Guillot, D. and Nilsson, F., “Mud Removal”. In Nelson, E.B. and Guillot, D., Well Cementing, Schlumberger, Sugar Land, 2006. [2] Saasen, A., Lund, B. and Ytrehus, J.D., “Theoretical Basis for Prediction of Drilling Fluid Removal in Annuli”, paper OMAE2017-61030, ASME 2017 36th International Conference on Ocean, Offshore and Arctic Engineering, June 25-30, 2017, Trondheim, Norway [3] Jakobsen, J., Sterri, N., Saasen, A., Aas, B., Kjøsnes, I. and Vigen, A., "Displacements in Eccentric Annuli During Primary Cementing in Deviated Wells", paper SPE 21686, The Production Operations Symposium, Oklahoma City, April 7-9, 1991. 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Poole, "Transition to turbulence in a concentric annular pipe", 7th International Symposium on Ultrasonic Doppler Methods for Fluid Mechanics and Fluid Engineering. 2010: Chalmers University, Gothenburg. 7 Copyright © 2017 ASME Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/03/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use http://dx.doi.org/10.1016/j.petrol.2015.02.007 http://sor.scitation.org/doi/abs/10.1122/1.550223 http://sor.scitation.org/doi/abs/10.1122/1.550223 http://sor.scitation.org/doi/abs/10.1122/1.550223 http://doi.org/10.1122/1.550223
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