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OMAE2022-79290
Anastasia Vogl 1 , Nile Waldal 2 , Parisa Sarmadi 3 , Adam Fershtman 2 , Rodrigo S. Mitishita 2 , and Ian A. Frigaard 2,3 ∗
1 UBC Engineering Physics, University of British Columbia, 6224 Agricultural Road, Vancouver, BC, V6T 1Z1, Canada
2 Department of Mechanical Engineering, University of British Columbia, 2324 Main Mall, Vancouver, BC, V6T 1Z4, Canada
3 Department of Mathematics, University of British Columbia, 1984 Mathematics Road, Vancouver, BC, V6T 1Z2, Canada
ABSTRACT 1 Introduction
Off bottom plugs are set in both well drilling (kick-off plugs) In plug cementing one pumps a dense cement slurry over
and in well decommissioning (abandonment plugs). In both less dense fluids, expecting that this gravity-defying configura-
cases a dense fluid (cement slurry) is placed over less dense well- tion will be maintained long enough for the cement to hydrate
bore fluids. In the case of kick-off plugs, viscous pills are com- and thicken. Since the 1970’s flow-related instabilities have been
monly used, which can help stabilize this mechanically unstable identified as a potential operational failure mode [1–4]. In this
situation. Abandonment plugs however are often set on top of early era, many plugs were kick-off plugs, designed to aid devi-
the freshwater that is used to clean the well prior to abandon- ated well drilling, which meant that the plugs were set in wells
ment. This is the current practice for many wells in Northwest- filled with drilling mud and viscous pills were often used to pro-
ern Canada. It is a mystery how such cement plugs are able to vide more support underneath. Studies such as [5, 6] report sig-
stay in place for a time sufficient for the cement to thicken and nificant failure rates in offshore settings. The study of rheolog-
hydrate, but field evidence suggests they do. ical means to avoid buoyancy driven instability emerged in this
In this paper we explore the mechanically unstable scenario period [7, 8]. It was observed that plug failure often was accom-
of a heavy yield-stress fluid placed on top of a less dense New- panied by slumping-type shear flows (exchange flows). Study
tonian fluid in a cylindrical pipe, dimensionally scaled to repre- of such flows, resulting in identification of the relevant dimen-
sent an off-bottom plug. We present details of the experimental sionless groups that govern static stability of the flow, and their
setup and its calibration. We then explore the buoyancy-driven critical limits [9]. The static stability limits derived are neces-
exchange flows that occur in transitional parametric regimes be- sarily conservative, in that they concern unmixed interfaces and
tween flow and no-flow states, by using both computer modelling many different possible interfaces. More recent studies have em-
and physical experimentation. 3D numerical simulation, using a ployed computational and experimental techniques to study both
Volume of fluid method, is carried out to capture the interface miscible and immiscible flows of this type [10–14], without be-
between the fluids. The 3D model provides us with a more de- ing concerned directly with the stability conditions. However,
tailed analysis of the concentration and velocity profiles, along plug failure problems persist to the present day [15, 16].
with comparisons to snapshots of the experimental results. The
aim is to explore the phenomenology of these unstable flows and The emergence of improved directional drilling techniques
be able to estimate timescales of the destabilization. Preliminary in the late 1990’s lessened the use of kick-off plugs. Interest
results are presented. has recently shifted to abandonment plugs, which are generally
longer than kick-off plugs, but which require hydraulic integrity
(a seal) as well as structural. Cementing practices in British
∗ Corresponding
Columbia, Canada [17], reveal that it is common for abandon-
Author. Email: frigaard@math.ubc.ca
(m/s)
for fifteen minutes.
An Anton Paar DMA 35 density meter was used to measure
the density of the heavy fluid. To obtain the yield stress, three
y(m)
by a 30s controlled stress rest at 0Pa. The results from the three
tests were averaged and then the averages from the ramp-down
(m/s)
curve were fitted to the Herschel-Bulkley equation.
Case number Y = τ̂y /∆ρ̂ ĝD̂ Heavy fluid τ̂y [Pa] κ̂h [Pa.snh ] nh ρ̂h [kg/m3 ] Light fluid ρ̂l [kg/m3 ] µ̂l [Pa.s]
3 Results
3.1 Experimental results
Approximately 20 experiments were performed covering a
range of Y ∈ [0, 0.4] for various fluid combinations. These in-
cluded some that did not destabilize noticeably during the 15
minute time interval. A subsequent study will report the quan-
titative results in detail. Here we just give an overview of the
main qualitative features of those experiments that were unsta-
ble. There were two main flow features observed during the ex-
periments: a rising finger and falling droplets.
The rising finger was seen in the top half of the pipe, as the
lighter fluid flowed up the center of the pipe, leaving a film of
the heavy fluid around the inner surface, see Fig. 3. In one ex-
periment we observed a slumping flow, but most experiment dis-
played the finger flow, approximately axisymmetric. There were
variations in the speed of the finger and its thickness. As the fin-
ger elongated upwards a draining wall layer grew behind it. The
wall layers directly behind the finger tip appeared uniform (for
5-10 diameters), but lower down in the draining film a variety of
convective instabilities became visible. Some exhibited helical
patterns and symmetry breaking. Lower down, the wave ampli-
tudes grew and parts of the draining film broke off into droplets
of different size
Falling droplets were seen in the bottom half of the section,
and resulted from pieces of the yield stress fluid breaking off of
the main volume of fluid and travelling downwards in the section,
see Fig. 4 for the formation of the droplet, and Fig. 5 for the final
shape of the droplet. During the early stages of flow, the droplets
appear to form in the center of the pipe. In the late stages of the FIGURE 3. Example of a finger of the lighter fluid flowing axisym-
flow they appear to form from wave growth and break-off in the metrically into the heavy fluid. Image from trial 8
draining wall film, as described above.
The largest droplets were clearly limited by the size of the
pipe, perhaps also in terms of wavelength selection in the drain- speeds, sometimes catching the larger droplets and sometimes
ing film instability. These adopted the form of a short “slug” or moving slowly and oscillating in the flow. A final noteworthy
“jellyfish” moving downwards in the pipe e.g. Fig. 5, in steady observation is the time to destabilization. In some cases the flow
motion with some instability in the wake. Smaller droplets were would begin almost immediately, in others it took a long time for
also shed. These could take a variety of shapes, but the most the interface to destabilize.
common had a more ellipsoidal front and longer tail. The small Some trials had an initial finger and droplet form, only to
droplet diameter varied between a few millimetres and slightly collapse and stabilize. Our understanding of this is that the initial
smaller than the pipe diameter. They descended at a range of interface configuration plus motion of the gate valve may induce
it did so. Eventually the finger front appears to have reverted was cleared.
to something like its initial slope. Figure 6 illustrates well the Finally, Fig. 8 shows an experiment with a higher viscosity
varied wavespeeds found in the wall film, moving downwards ratio, here using a Xanthan gum solution instead of water as the
against the upwards moving finger. Although quite stochastic, lower light fluid. The qualitative behaviour here was quite similar
the wavespeeds seem to fall in a range. As these develop in time, to other trials, which is reflected in the spatiotemporal profile.
some develop into the streak-like droplet trajectories. The height One thing which is of note is a slight shifting of the finger front
of the pipe over which wave-like motions are found extends as speed before particularly significant droplet is created, i.e. note
the experiment progresses. the lighter orange downward streaks. This can be seen in other
In the spatiotemporal profile for experiment 11, we observed trials as well, but the sudden increase in finger speed before a
a slumping behaviour, i.e. the heavy fluid moved primarily down- large orange streak is very noticeable in this experiment. Also of
wards along one side of the pipe with the finger moving asym- note, was a rather unusual first droplet at the onset of flow. The
metrically upwards. Comparatively, this mode is characterized first droplet exhibited a long, winding tail before taking on the
by a rapid front motion with very frequent droplets; see Fig. 7. usual ”jellyfish” shape.
We see that the diffuse layer behind the ascending front is nar-
rower than for the central mode and does not spread. The tran-
sition from wave to droplet in this layer is relatively fast and 3.2 Computational results
droplets appear at high frequency. We now show examples of computational results from cases
This slumping side-by-side mode was less frequently ob- C1-C3 in Table 1. Here, we vary the density of both fluids, keep-
served than the central mode. A repeat experiment with approx- ing constant density difference, and we vary the viscosity of the
imately the same Y , gave a central finger with speed 2.57mm/s, lower fluid. The upper fluid rheology is representative of a Car-
compared to 4.05mm/s for the slump propagation in Fig. 7. Com- bopol solution the lower fluid ranges from pure water to a fairly
paring with Fig. 6, the density difference is similar and the Car- viscous Newtonian fluid. The yield stress is larger than we mea-
bopol more viscous, so we would intuitively expect a slower sured in our densified experimental solutions. It has often been
wavespeed, i.e. if the interface followed a central finger evolu- observed that sugar can reduce the yield stress. This is compen-
tion. Instead the wavespeed is 2-3 times faster. What determines sated by the larger density differences in Table 1, which are more
the propagation mode is not clear and it may depend on the ini- representative of field values. In cases C1-C3 we keep the dimen-
tial conditions as the gate valve is opened. However, the slump- sionless yield number, Y = τ̂y /∆ρ̂ ĝD̂, fixed at Y = 0.03 which is
ing mode does not seem to persist stably. In experiment 11, later below what we expect is required to stop the flow.
the flow switched modes to a central finger, causing it to slow Figure 9 shows the flow development of the heavy over light
down. It continued in central mode until the whole test section fluid in case C1. The concentration is shown in the mid-plane of
the pipe (x = 0) with view of the x+ plane in Fig. 9a and the view tial development from the asymmetric initial condition is similar,
of the x− plane in Fig. 9b. The grey body shows the iso-surface we observe that the upwardly moving finger orients centrally in
C = 0.5. This case has a low yield number, Y = 0.03, and a very the pipe (as it also did eventually in C1). As the finger moves
high viscosity ratio, the light fluid is water. The initially sheared slowly upwards, displaced upper fluid flows downwards in wall
interface changes rapidly and the flow is asymmetric, as was the layers. Although there appears to be a preference for the cen-
initial interface configuration. The light fluid fingers upwards tral mode (for the parameters that we have computed), these wall
in the heavy fluid along one side of the pipe. The correspond- layers are evidently convectively unstable. Wave growth locally
ing layer of heavy fluid moves down, the layer thickness ampli- arises in droplet break-off. The droplets are then unhindered by
fies into a droplet that breaks off. The terminal velocity of the the viscous film and fall rapidly (Fig. 11b). This constant shed-
droplet is higher than that of the water finger moving upwards. ding of droplets and unstable wave-like motions disperses the
The droplet becomes more symmetric in shape and position as it region where the 2 fluids are present, in a chaotic manner. In this
falls. particular simulation, we observe some of the droplets oscillate
In Fig. 10, the shear rate of the flow is shown for the same from side to side as they fall: also observed in our experiments.
flow of Fig. 9a. A logarithmic scale is used to show the shear rate Figure 12 shows the flow from case C3 in Table 1. The con-
for better visualization. The grey region shows the unyielded centration is again shown in the middle plane of the pipe (x = 0)
heavy fluid which is identified by τ̂ = τ̂y . The solid black line with the side view of x+ plane for earlier time (Fig. 12a) and later
represents the iso-line C = 0.5. We can see that the droplet is time of the flow (Fig. 12b). The grey body shows the iso-surface
fully yielded as it falls through the light fluid, i.e. γ̇ˆ ≫ γ̇ˆε , but the C = 0.5. This case has a smaller viscosity ratio in comparison to
shear rates are still orders of magnitude less than that in the sur- both C1 & C2. The main difference is that the upwardly mov-
rounding fluid. This “jellyfish” shape is similar to those observed ing finger meanders helically upwards, which has the effect of
with very viscous Newtonian droplets falling in water, and to breaking off chunks of heavy fluid. These shed from the wall
those in our experiments. Further up the finger progresses much into the light fluid. The earliest chunk has a tail which elongates
slower than the droplet due to the yield stress of the heavy fluid as it sinks: the droplet feeds the tail which mixes with the lighter
above. fluid. Later in the flow, the shedding volumes get smaller and we
Figure 11 shows the flow development of case C2 from Ta- can see a series of smaller droplet forming. The terminal veloc-
ble 1. The concentration is shown in the mid-plane of the pipe ity of the droplets vary: some can catch those in front and form a
(x = 0) with the side view of x+ plane. Both earlier times bigger droplet. The finger progresses upwards in a helical shape
(Fig. 11a) and later times (Fig. 11b) are shown. This case has and its progress is slower in comparison to Fig. 11
a smaller viscosity ratio in comparison to C1. Although the ini- In Fig. 13, the shear rate of the flow is shown for the same
(a) (b)