In extended-reach or long-horizontal drilling, cuttings usually deposit at the bottom of the annulus. Once cuttings accumulate to a certain thickness, complex problems such as excessive torque and drag, tubing buckling, and pipe stuck probably occur, which results in a lot of non-productive time and remedial operations. Cuttings bed remover can efficiently destroy deposited cuttings in time through hydraulic and mechanical stirring effects. This paper aims to build a method for hole cleaning evaluation and installation spacing optimization of cuttings bed remover to improve the wellbore cleaning effect. Firstly, a Computational Fluid Dynamics approach with Eulerian–Eulerian multiphase model was utilized to investigate the mechanism of cuttings transportation, and a new type of cuttings bed remover was designed. Next, an evaluation method of hole cleaning effect of remover was established. After that, the effects of several drilling parameters on hole cleaning including flow rate of drilling fluid, rotational speed of drillpipe, rate of penetration, wellbore size, rheological property of drilling fluid, and remover eccentricity on the performance of cuttings bed remover were investigated. The results demonstrate that the new type of remover with streamline blade performs better than conventional removers. The efficiency of hole cleaning is greatly improved by increasing the rotational speed of drillpipe, flow rate of drilling fluid, remover eccentricity, and 6 rpm Fann dial reading for drilling fluid. While higher rate of penetration and large wellbore size result in worse hole cleaning. These findings can serve as an important guide for the structure optimization design of cuttings bed remover and installation spacing of removers.

Casing wear and casing corrosion are serious problems affecting casing integrity failure in deep and ultra-deep wells. This paper aims to predict the casing burst strength with considerations of both wear and corrosion. Firstly, the crescent wear shape is simplified into three categories according to common mathematical models. Then, based on the mechano-electrochemical (M-E) interaction, the prediction model of corrosion depth is built with worn depth as the initial condition, and the prediction models of burst strength of the worn casing and corroded casing are obtained. Secondly, the accuracy of different prediction models is validated by numerical simulation, and the main influence factors on casing strength are obtained. At last, the theoretical models are applied to an ultra-deep well in Northwest China, and the dangerous well sections caused by wear and corrosion are predicted, and the corrosion rate threshold to ensure the safety of casing is obtained. The results show that the existence of wear defects results in a stress concentration and enhanced M-E interaction on corrosion depth growth. The accuracy of different mathematical models is different: the slot ring model is most accurate for predicting corrosion depth, and the eccentric model is most accurate for predicting the burst strength of corroded casing. The burst strength of the casing will be overestimated by more than one-third if the M-E interaction is neglected, so the coupling effect of wear and corrosion should be sufficiently considered in casing integrity evaluation.