Introduction and Objectives

Technical/Scientific Aspects
Function and Properties
Wellbore Hydraulics, Cuttings
Transport
Fundamentals of Rheology
Drilling Fluids and Borehole
Stability
Filtration Properties
Balancing Formation Pressure
Lost Circulation Problems
Lubrication/Friction Reducing
Corrosion Prevention
Testing Methods/Equipment
Mud Additives Controlling
Properties
Solids Control
Unweighted/Weighted Muds
Types of Drilling Fluid
Systems
Waterbased Mud
Oilbase Mud/Emulsion Systems
KTB-Experiences
Strategy
Pilot Hole
Ultradeep Hole
Conclusions
Lesson I
Lesson II
Drilling Fluid Technology
Drilling Mud Why do we deal with?
Drilling Tasks Information Carrier
Engineers
Scientists
Mud/Fluids
Gas
Tracers
Cuttings
Mud
Gas
Fluids
!Bottomhole Cleaning
!Cuttings Transport
!Borehole Wall Support
!Balancing Formation Pressure
!Cooling the Bit
!Hydraulic Power Transmission
!Data Transmission (MWD)
!Reducing Friction
!Corrosion Protection
Mud
Cores
Cuttings
A
i
d
i
n
g
S
c
i
e
n
t
i
f
i
c
E
v
a
l
u
a
t
i
o
n
Borehole
Logging
Swivel
Kelly
Rotary
Table
Annulus
Casing
Drillstring
Shale
Shaker
Rotary Hose
Standpipe
Mud Pits
Charging Pumps
Transport of Cuttings
to Surface
Support of
Borehole Wall
Transmission of
Data/Hydraulic Power
Cooling Bit
Balancing Formation
Pressure
Cleaning the Bottom of the Hole
Reducing Friction
Torque/Drag
Protection against
Corrosion
Aiding Solids Removal
Mud Pumps
Pump Pressure=f(Pumprate,MudViscosity)
Hydraulic Optimization
Mud CirculationSystem
Technical Key Functions of Drilling Fluids
Mud Properties Controlling Technical Key Functions
Functions
Properties
Complex Interaction
!Aiding Cuttings Removal and
Solids Control
5
Solids Content
weighted/unweighted
Rheological Parameters
Viscosity
Thixotropy
!Cleaning the Bottom of the Hole
!Transport of Cuttings to Surface
!Hydraulic Power
!Data Transmission
!Cooling the Bit
1
!Borehole Wall Support/Stabilization
!Balancing Formation Pressure
Density
Filtration Parameters
Free Water Capacity
2
Lubricity Coefficient !Reducing Friction/Torque and Drag
3
!Protection against Corrosion
Chemical Composition
pH
physico-chemical Parameters
4
V
sett
: Cutting Settling Velocity
depends on:
Mud Parameters
- Rheology (Viscosity)
- Density
Cutting Parameters
-Density
-Diameter
-Shape
Fundamentals of Cutting Transport
D
r
i
l
l

P
i
p
e
Drill
Collar
BHA
Drill Bit
Roundtrip/Circulation Break
Transporting of Cuttings to Surface
V
ann
>>V
sett
V
ann
: Mud Velocity in Annulus
depends on:
Pumprate,
Basic Law of Cuttings Transport
(V
ann
-V
sett
)/V
ann
> 50%
A
n
n
u
l
u
s
1
Drilling/Mud Circulation
Annular Geometry
Fundamentals of Cutting Transport
D
r
i
l
l

P
i
p
e
Drill
Collar
BHA
Drill Bit
Holding Cuttings in Suspension

cutt
<
0

cutt
=(d
c
*g(
c
-
m
))/6

0
: Yield Strength of Mud
depends on:
Rheological Behaviour
Gel Strength, Thixotropy

cutt
: Tangential/Normal Stress
due to Cutting Weight
depends on:
-Cutting Diameter (d
c
)
-Cutting Density (
c
)
-Cutting Shape
-Mud Density (
m
)
A
n
n
u
l
u
s
1
Roundtrip/Circulation Break
Drilling/Mud Circulation
Circulation/Drilling
Dynamic Carrying Capacity
Rheological Behaviour while Flowing
Viscosity dependent on Shear Rate
Cuttings Transport The Role of Drilling Fluid Rheology
Circulation Break/Roundtrip
Static Carrying Capacity
Rheological Behaviour while Stationary
Thixotropy: Fluid Gel reversible
1
Shear Stress - Shear Rate Diagram
Shear Rate
S
h
e
a
r
S
t
r
e
s
s

Theory of Fluid Rheology

Viscosity
P
s
e
u
d
o
p
l
a
s
t
i
c
F
l
u
i
d
(
D
r
i
l
l
i
n
g

M
u
d
)
V
i
s
c
o
s
i
t
y
d
e
p
e
n
d
e
n
t
o
n

S
h
e
a
r
R
a
t
e
1

Newtonian Fluid (Water, Mineral Oil):
Straight Line with Constant Slope
L
o
w
N
e
w
t
o
n
i
a
n
V
i
s
c
o
s
i
t
y

Slope = Viscosity
Slope =
H
i
g
h

N
e
w
t
o
n
i
a
n
V
i
s
c
o
s
i
t
y
A
p
p
a
r
e
n
t
V
i
s
c
o
s
i
t
y
Typical Drilling Muds are
Shear Thinning
Viscosity decreases with
increasing Shear Rate
Drilling Mud Viscosity Measuring Equipment
Marsh Funnel
Rotational Viscosimeter
Determination of Shear Dependent
Viscosity by Measuring Flow Curve at
different Rotational Speeds
Measuring Outflow time (s)
Water: 26 s
946 cm
3
1
Measuring Rheological Behaviour of Drilling Fluids
Determination of Flow Model
1
RPM Reading
600 xx
300 xx
200 xx
100 xx
6 xx
3 xx
Measuring Points
Flow Curve
Reading
Rotational
Speed (RPM)
RPM Reading
3 after 10 s xx
3 after 10 min xx
Measuring Points
Gel Strength
Rotational Viscosimeter
0 100 200 300 400 500 600
0
20
40
60
80
100
120
S
h
e
a
r
S
t
r
e
s
s

(
V
i
s
c
o
s
i
m
e
t
e
r
R
e
a
d
i
n
g
)
Shear Rate (Viscosimeter RPM)
Flow Models Describing Pseudoplastic Drilling Fluid Rheology
True Viscosimeter Readings
R@300 RPM
R@600 RPM
B
i
n
g
h
a
m
S
t
r
a
i
g
h
t
L
i
n
e
Bingham Fluid
YP
YP: Yield Point= 2*R
300
-R
600
Slope = PV
PV: Plastic Viscosity=R
600
-R
300
=YP+PV*
Power Law Fluid
=K*
n
K: Konsistency Index=R
300
/511
n
n: Power Law Coefficient=log(R
600
/R
300
)/0.301)
1
Shear Stress Shear Rate Diagram
High Shear-Range
Low Viscosity
Drillpipe -> Pressure Loss
Bit Nozzles -> Hydraulic Power at Bit
Solids Control -> Cutting Removal
Low Shear-Range
High Viscosity
Annulus -> Cuttings
Transport
A
p
p
a
r
e
n
t
V
i
s
c
o
s
i
t
y

a
p
p
(
m
P
a
s
)
Shear Rate
Shear Thinning of Drilling Fluids Impacts on Drilling Process

app
= / / / /
Bingham Asymptotic Line
for high Shear Rates
app
-> PV

app
= = const
Bingham Fluid
Newtonian Fluid
Power Law Fluid
1
Influence of Yield Point on Cuttings Transport Efficiency
T
r
a
n
s
p
o
r
t

R
a
t
i
o

(
%
)
Yield Point YP (lbs/100sqft)
Annular Geometry: 5 Drillpipe/12 Hole
1
Impact of Mud Rheology on Cutting Lag Depth Correction
L
a
g

D
e
p
t
h
C
o
r
r
e
c
t
i
o
n
(
m
)
L
a
g

D
e
p
t
h
C
o
r
r
e
c
t
i
o
n
(
m
)
Cutting Density (kg/dm
3
)
Corundum
Zircon
Magnetite
Amphiboles
Garnets
Mica
Cutting Diameter: 1 mm
Cutting Shape: Sphere
Mud Rheology:
Rotational Viscosimeter:R(300)=16; R(600)=21
Power Law (K=0,68;n=0,39)
Bingham (YP= 5,3 Pa; PV=5 mPas)
Hole Diameter: 8
Drillpipe Diameter: 5
Hole Depth: 10 km
Mud Density: 1,01 kg/dm3
1
Typical Density Ranges of Rock Minerals
Quarz/Feldspars
Gel Building Properties of Drilling Fluids
Time (min)
G
e
l

S
t
r
e
n
g
t
h
G
S

(
P
a
)

fragile Gel
Drilling Fluids show
thixotropic properties
desirable
While static: Gel
While dynamic: Fluid
Measured with Rotational
Viscosimeter @ 3 RPM
Thixotropy: GS@10min-GS@10s
10 30
progressive Gel
dangerous
Initial GS
after 10s
!Excessive Pump Pressures
!Formation Fracturing/Lost Circulation
!Borehole Instability
!Uncontrolled Influx of Formation Fluids
high Surge/Swab Pressures GS too high
GS too low
Insufficient Static
Carrying Capacity for Cuttings
Time dependent Gel Strength
1
0 2 4 6 8 10 12 14 16 18 20
0
20
40
60
80
100
Pump Pressure necessary for
Breaking Gel
G
e
l

B
r
e
a
k
i
n
g
P
r
e
s
s
u
r
e
Gel Strength GS (Pa)
Mining Drilling
5 DP/6Hole
KTB Pilot Hole
R
o
t
a
r
y
D
r
i
l
l
i
n
g
5

D
P
/
1
2

H
o
l
e
5

D
P
/1
7


H
o
le
R
o
t
a
r
y
D
r
i
ll
in
g
Narrow
Annulus
Bit
Pump Rate
H
y
d
r
a
u
l
i
c
P
o
w
e
r

H
P
S
u
r
f
a
c
e
P
a
r
a
s
i
t
i
c
P
r
e
s
s
u
r
e
L
o
s
s
HP
Bit
= HP
Surface
-HP
Parasitic
Optimum
Optimizing Drilling Hydraulics
Jet Nozzles in a Roller Cone Bit
Rule of Thumb for Rotary Drilling:
2/3 of total Pressure Loss at Bit
Minimizing Parasitic Pressure Losses
Drillpipe
Annulus
Surface
Objective: Maximizing Hydraulic Power at Bit
Impact Parameters on Parasitic PL
!Annular Geometry
!Surface Equipment
!Drillpipe Size
!Mud Rheology (YP and PV)
PV as low as possible,
YP as high as necessary for Cuttings Transport
1
Mud Additives Controlling Rheology
!Clays
Bentonite
Attapulgite
Sepiolite
Hectorite
!Polymers
Biopolymers
-Xanthan
- Guar Gum
Polyacrylate/Polyacrylamides
HEC (Hydroxyethylcellulose)
CMC (Carboxymethylcellulose)
Viscosifiers
Dispersants/Deflocculants
!Lignosulfonates
!Lignites
!Phosphates
!SSMA (Styrene Sulfonate Maleic Anhydride)
1
(important for High Temperature Applications)
H
2
0
Mineralogical Structure of Montmorillonite used in Drilling Muds
1
-
Dispersion of Clay in Water
Na
+
, H
2
0
-
Faces negatively charged
Edges positively charged
+
+
+ +
+
Cardhouse Structure
Edge/Face Aggregation
+
+
+
+
+
+
-
+
+
+
-
+
Gel
State Diagram of Colloidal Montmorillonite Suspension in Water
dispersed
Clay
Platelets
D
i
s
p
e
r
s
i
o
n
I
n
c
r
e
a
s
i
n
g
P
l
a
s
t
i
c
V
i
s
c
o
s
i
t
y
(
P
V
)
D
e
c
r
e
a
s
i
n
g
F
i
l
t
r
a
t
i
o
n

R
a
t
e
,

I
n
c
r
e
a
s
i
n
g
W
a
t
e
r
B
o
n
d
i
n
g
aggregated
aggregated and flocculated A
g
g
r
e
g
a
t
i
o
n
d
e
c
r
e
a
s
i
n
g
p
l
a
s
t
i
c
V
i
s
c
o
s
i
t
y
(
P
V
)
I
n
c
r
e
a
s
i
n
g
f
i
l
t
r
a
t
i
o
n
r
a
t
e
,

r
e
d
u
c
e
d
w
a
t
e
r
b
o
n
d
i
n
g
i
r
r
e
v
e
r
s
i
b
l
e
Face to Face
reversible
dispersed and flocculated
Flocculation
Increasing Yield Point (YP) and Gel Strength
Face to Edge
1
Support of the Borehole Wall Balancing Formation Pressures
Sufficient Mud Density
Good Filtration Properties
While Drilling Open Hole
Mud Column should act as Hydraulic Casing
2
Insufficient Mud Density
Bad Filtration Properties
-Uncontrolled Fluid Entry
-Borehole Instabilities
-Differential Sticking
Pressure (MPa
D
e
p
t
h
(
k
m
)
Sub
hydrostatic
Formation
Pressure Profile
overhydrostatic subhydrostatic
geopressured Aquifer
Balancing Formation Pressures
Pressure of Mud Column
P
mud
= Density
mud
* g * Depth
Normal Drilling (overbalanced)
Mud Pressure > Formation Pressure
2
Instruments for Measuring Mud Density
Hydrometer
Mud Balance
2
Weighting Materials for Drilling Muds
Mud Density (kg/dm
3
)
Mud Density (kg/dm
3
)
S
o
l
i
d
s
F
r
e
e

S
a
l
t

S
o
l
u
t
i
o
n
s
I
n
e
r
t
S
o
l
i
d
s
2
Solids Content and Mud Density for Various Weighting Materials
Mud Density (kg/dm
3
)
S
o
l
i
d
s
C
o
n
c
e
n
t
r
a
t
i
o
n
(
V
o
l
u
m
e
F
r
a
c
t
i
o
n
)
2
Good Filtration Characteristics
!Quick Filtercake Buildup
!Low Filtration Rate
!Filtercake
-thin
-impermeable
-slick
Supporting the Borehole Wall Hydraulic Casing Effect
Mud Properties
!Mud Density -> Pressure Support
!Filtration Characteristics -> Wall Sealing
!Free Water Activity -> Interaction Rock
Pore Pressure
Filter Cake
Pore Pressure
Buildup of Filtercake
M
u
d
M
u
d
Wall sealed
Beginning Filtration
M
u
d
M
u
d
Invasion of:
Mud Filtrate
Mud Particles
Minimizing Formation Damage
Impermeable
Formation
2
Filtercakes and Differential Sticking Mechanism
Overpull required to unstick BHA
Thick
Mudcake
2
Measuring Filtration Properties
API Filter Press
Parameters measured:
!Filtrate Volume (ml) after 30 min
!Cake Thickness (mm)
Normal Conditions
T: Room Temperature
P: 100 psi (7 bar)
HTHP Conditions
T: 300F( 149C)
P: 500 Psi (35 bar)
P: 100 psi (7 bar)
2
Measuring Free Water Activity of Drilling Fluids
2
Sample after 20 min in Water
CST < 70 s
Destabilisation of Red Shale Caused by Contact with Water
Original Sample
Sample after 24h in Dehydril HT (2%)
CST >3600 s
Destabilisation Process is favoured
by High Free Water Activity
High Free Water Activity <-> Low CST
Low Free Water Activity <-> High CST
2
Additives Controlling Filtration Properties and Free Water Activity
Bentonite
Polymers act as Protection Colloids
Preventing Aggregation of
Clay Particles
Polymers
!Starch
!Polyanionic Cellulose (PAC)
!Sodium
Carboxymethylcellulose(CMC)
!Hydroxyethylcellulose(HEC)
!Polyacrylates/Polyacrylamides
!Vinylsulfonate/Vinylamide-
Copolymers (VS/VA)
2
Types of Materials used:
Fibrous (Raw Cotton, Mineral Fibers, Glass Fibers)
Flaky (Cellophane, Mica, Cotton Seed Hulls)
Granular (Perlite, Ground Plastic, Nut Shells, Wood)
Thick Slurry Pills (Bentonite/Polymer, Cement)
Prevention of Lost Circulation Factors to Consider
Types of Lost Circulation Zones
High Permeable Gravel
Natural/Artificial Fractures
Caverneous Formation
Preventive Methods
Reducing Mud Density
Avoiding Pressure Surges
Lowering Gel Strength
Lowering Equivalent Circulation Density
(ECD)
Fighting Against Lost Circulation
Application of Sealing Material
Sealing at
Fracture
Face
Sealing within
The Fracture
Proper Size Distribution
2
Rotating
Drillstring
Trip In/Out
Drillstring
B
o
r
e
h
o
l
e
C
u
r
v
a
t
u
r
e
Borehole Curvature
Dogleg Severity: deg/m
Reducing Friction Controlling Torque/Drag
3
Normal Force F
N
Drag (Trip In/Out)
Torque (Rotation)
Friction Force F
R
F
R
= * F
N
Mud Lubricity Coefficient
Lubricity Coefficients of Drilling Muds
3
Inhibiting Corrosion
!Uniform Corrosion
!Localized Corrosion (Pitting)
Bimetallic Corrosion
Oxygen Concentration Cells
-Crevice Corrosion
-Air/Water Interface
-Oxygen Tubercles
-Scaling/Sludges
!Corrosion Fatigue
!Stress Corrosion
Sulfide Cracking
Hydrogen Embrittlement
Corrosion is the Major Cause
of Drillpipe Failures
Forms of Corrosion
!Raising pH of Mud
!Reducing dissolved Oxygen in
Mud
Vacuum Degassing
Oxygen Scavengers
-Sodium Sulfite
-Sodium Nitrite
!Addition of Corrosion Inhibitors
Filming Amines
Sulfide Scavengers
Zinc Carbonate
Sodium Molybdate
Measures
4
Pitting Corrosion Inside Drillpipe Stress Corrosion at DP-Tooljoint
Mud Additives for pH and Alkalinity Control
4
Shaker Screen
Mud Circulation System and Solids Control Equipment
Centrifuge
Degasser
Desilter
Desander
Mud Return
Flowline
Swivel
Kelly Hose
Standpipe
Suction Pit
Mud Pump
Mixing Hopper
5
Mud Properties Must Aid
Effective Cuttings Removal
Solids Control Equipment
Is the Base for
Cutting Sampling