A new comprehensive, mechanistic model that allows more precise predictions of wellbore pressure and two-phase flow parameters for underbalanced drilling (UBD) is proposed. The model incorporates the effects of fluid properties and pipe sizes and, thus, is largely free of the limitations of empirically based correlations.The model is validated against actual UBD field data and fullscale experiments in which the gas and liquid injection flow rates as well as drilling fluid properties were similar to those used in common UBD operations. Additionally, a comparison against two different commercial, empirically based UBD simulators shows better performance with the mechanistic model.
IntroductionIt is generally accepted that the success of UBD operations is dependent on maintaining the wellbore pressure between the boundaries determined by formation pressure, wellbore stability, and the surface equipment's flow capacity. Therefore, the ability to accurately predict wellbore pressure is critically important for both designing the UBD operation and predicting the effect of changes in the actual operation.Because of the complex nature of the hydraulic system of UBD operations in which two or more phases (liquid, gas, and solids) commonly flow, the prediction of pressure drop and flow parameters, such as liquid holdup and in-situ liquid and gas velocities, are performed mainly with empirical, two-phase flow methods. The Beggs and Brill 1 correlation is the most popular among the current, commercial UBD simulators. However, it is recognized by the petroleum industry that most of these empirical correlations were developed from experimental databases, thereby making extrapolation hazardous. 2 Moreover, the Beggs and Brill 1 correlation has been shown to overpredict or fail to predict bottomhole pressures for both vertical and horizontal UBD operations. 3,4 Since the mid-1970s, significant progress has been made in understanding the physics of two-phase flow in pipes and production systems. This progress has resulted in several two-phase flow mechanistic models to simulate pipelines and wells under steadystate as well as transient conditions. Consequently, mechanistic models, rather than empirical correlations, are being used with increasing frequency for designing multiphase production systems. Based on this trend of improvement, the application of mechanistic models to predict wellbore pressure and two-phase flow parameters seems to be the solution to increasing the success of UBD operations by improving such predictions.Literature Review. Bijleveld et al. 5 developed a steady-state UBD program to assist well engineers in planning and executing underbalanced operations. This in-house computer program uses the mechanistic two-phase flow approach. However, there is almost no technical information in the literature about implementing the mechanistic models in UBD operations.Hasan and Kabir 6 developed a mechanistic model to estimate the void fraction during upward concurrent two-phase flow in