Performance Analysis of the Vortex Cuttings Cleaner: Turbine Hydraulic Drive and Cuttings Transport in Wellbore Annulus

Abstract

In the process of directional and horizontal well drilling, cuttings tend to settle and form a bed at the low side of the annulus due to gravity, which decreases the drilling rate and even causes accidents in severe cases. This paper analyzes the performance of a new tool, the vortex cuttings cleaner, which can be effective without rotation of the drillpipe. Based on the computational fluid dynamics (CFD) approach, together with the discrete phase, Euler, and dynamic mesh models, the vortex cuttings cleaner is investigated with respect to the turbine torque, turbine velocity, pressure drop, and cuttings transport in the annulus. The working mechanism of the vortex cuttings cleaner is clarified. Finally, field tests are conducted on the tool to evaluate its application in terms of service life, wellbore friction, and rate of penetration (ROP). The results show that the turbine can rotate continuously under hydraulic drive. The turbine torque/velocity and the tool’s pressure drop increase with increasing displacement. The cuttings transport in the annulus is jointly affected by factors such as turbine velocity, fluid velocity, and particle size. A too low or high turbine velocity is unfavorable for cuttings transport. Through the analysis of the number of particles and particle concentration, the optimal velocity is determined to be 125 rev/min. The swirling flow intensity in the annulus flow field increases with the increase in turbine velocity. Field applications suggest a service life longer than 200 hours, a notable decrease in wellbore friction, and an average increase in ROP by more than 20%. This study provides a theoretical basis for the research on wellbore cleaning tools.