Drilling Fluid Programme For Petromine

Drilling Fluid Programme : John Energy/ONGC Well No: Rig:
DRILLING FLUID PROGRAMME FOR:

WELL TYPE: EXPLORATORY/ DEVELOPMENT
Well Name:
ONGC - X
Prepared By:
M Manic kam
Offset Wells: Reviewed by:
B K Naik
Approved by:
Dat e: 15 June 2010
Index
MUD PROGRAMME: WELL NO-
17 1/2Hole:0M to 550M-Spud Mud/Bentonite/CMC/CFLS
1.1 Interval Discussion
1.2 Recommended Fluid Properties
1.3 Operation & Procedures
1.4 Volume and Costs
8 1/2Hole:550M to 1700M-KCl/PHPA/CPG/POLYAMINE/POLYMER
8 Hole:1700M to 3000M-NON DAMAGINGDRILLINGFLUID
ONGC-X DRILLING FLUID PROGRAM SUMMARY
Hole
size
Casing
Size
Casing
Program
Depth
(m)
Mud
System
Bentonite Gel
171/ 2 133/ 8 0m M Wt: ALAP
F/ Vis: 50-55sec/ qt
550m YP: 24-30 lb/ 100ft2
KCl-PHPA-CPG-Poly
Amine-Polymermud
121/ 4 95/ 8 M Wt: 9-10ppg
PV-ALAP
YP: 25-30lb/ 100ft
2
F.Loss : <5ml
1700m KCl: 33ppb, CPG-14ppb
KCl-CPG-Poly Amine-
CaCO3 ND Mud
81/ 2 7 Liner M Wt: 9.5-10.5ppg
PV-ALAP
YP: 25-30lb/ 100ft
2
Floss : <5ml
KCl: 33ppb
3000m CPG: 14ppb
17.5 Interval: 0m 550m for 13-3/8 casing
INTERVAL DISCUSSION
SPUD MUD FROM0M TO550M
Fluid A Bentonite mud has been programmed for this section. This system is a
highly effective and economical fluid for drilling top hole especially in the areas
where we are expecting lost circulation problems. This system has been used
with success drilling similar wells nearby and it will be most suited for this
particular section. Spud the well with 7% prehydrated gel, treat with CFLS TO
disperse the mud as drilling continue and add CMC to control the fluid loss.
Pump Hi Vis time to time prepared with Guar Gum, add DD for lubrication and
avoid bit balling. Keep sufficient quantity of LCM as per plan.
Objectives Maintain a clean well-bore with adequate hole cleaning
Concerns Hole cleaning / overloading annulus / ECD /losses
Losses while running casing
Solutions Maintain 6 RPM in recommended range
Control drilling rate to avoidoverloading annulus.
Follow a sweep program
Adjust fluid properties to minimal rheology prior to cementing
Key Products and Formulation
PRODUCT FUNCTION CONCENTRATION CHMICAL NAME
Caustic Soda
Bentonite
CMC
DD
CFLS
1.1
1.2 Barite
Control PH
Primary viscosifying agent
Fluid loss agent(if required)
Anti bit balling
Dispersent(if required)
1.3 Weighing material
0.25-0.50 ppb
20.0 ppb
2.0-3.0 ppb
0.2-0.3 ppb
2-4 ppb
1.4 As per wt requirement
Sodium hydroxide
Hydrated Aluminium silicate
Carboxy methyl cellulose
Drilling detergent
Chrome free lignosulphonate
1.5 Barium sulphate
Recommended Fluid Properties
PROPERTY PLAN UNIT REMARKS
Mud Weight
8.7-9.5 ppg As hole condition dictate
Funnel Viscosity
50-55 SEC/Qt To provide laminar flow and minimize
chances of losses
PV
ALAP cp To be kept as lowest possible
YP.
25-30 Ib/100 ft2 To be calculated for maximum hole cleaning
API FluidLoss
NC ml No control
pH
9-9.5
PREPARATION:
Fill the tanks with the required amount of drill water, check the total hardness and reduce it to
below 150 mg/lt with additions of SODA ASH.
Raise the pH to 9.5 with addition of CAUSTIC SODA.
Mix 7%BENTONITE and allow to hydrate for as long as possible under maximum shear
Conditions (at least 6 hours).
Maintenance:
As drilling progresses, the viscosity should be maintained with gel as required.
The mud weight and solids content should be maintained as low as possible with water
dilution, dumping sand traps and utilizing all solid control equipment.
The primary objective on the section will be to ensure that the hole remains clean during all
operations.
The high viscosity pills will help stabilize any exposed sands preventing hole washout and
collapse.
Lime could also be added if extra viscosity is required.
The purpose of spud mud is to drill the surface hole section as cheap as possible. Mud
volumes should be minimized to maintain treating cost as low as possible.
If hole is circulated for any reason then the bit should be continuously moved as not to
washout the hole, which could result in poor cement jobs.
Control drilling rate and maximize annular velocitys to avoid creating mud rings, pack offs
and losses due to an overloaded annulus.
Run all solids control equipments including Desander and Desilter to discard the drill solids.
Dump sand traps as often as possible and employ the finest possible shaker screens.
Due to possible losses, constant observation of pit volumes will be very important and any
change should be reported immediately.
If required CMC can be added while drilling down. Also CFLS can be added to disperse the
mud and to assist in controlling the water loss and rheology.
Sand traps and header boxes should be inspected regularly and dumped as required during
connections.
Mud rings and bit balling are expected to be encountered whilst drilling the surface hole in
this area these problems can be minimized by pumping SAPP & DRILLING DETERGENT
pills.
NUT PLUG / CAUSTIC pill to overcome the tendency of bit to ball up the BHA.
Hereby thefollowings optionsand formulation are commonly used in case of mud rings and bit
balling.
DRILLING DETERGENT PILL:
Formulate a pill ( 50 bbl) of active fluid with 2 % DRILLING DETERGENT, spot the bit and
allows soaking.
NUT PLUG / CAUSTIC PILL:
Mix a 30 - 40 ppb NUT PLUG, 3 - 4 ppb CAUSTIC, 50 - 75 bbl pill and circulate through bit,
pill size is dependent on bit balling severity as is product concentrations. No hard and fast
rules can be set for this particular problem.
CAUSTIC/SPERSENE PILL:
If bit balling is suspected, build a 30 bbl caustic pill containing 4.0ppb caustic soda and 2ppb
Spersene in fresh water. Spot on bottom and allow to soak for 10minutes.
Volume and Material Estimation
VOLUME ESTIMATE BBL
SURFACE VOLUME
CONDUCTOR VOLUME
OPEN HOLE VOLUME WITH 15% WASH OUT
TOTAL VOLUME
MAINTAINENCE VOLUME
TOTAL VOLUME REUIRED
Old Mud Received
Mud Remaining
Dilution Factor bbl/m
600
591
1191
1100
2291
0
1191
Material Estimation
PRODUCT UNIT
SIZE
Qty Unit Cost Tot. Cost
BENTONITE
CAUSTIC SODA
SODAASH
BARITE
CMC
CFLS
DD
50 Kg
50 Kg
50 Kg
50 Kg
25 Kg
25 Kg
200 Lt
280
10
6
100
40
40
3
12.25 Interval: 550M 1700Mfor9-5/8 casing
INTERVAL DISCUSSION
KCL/GLYCOL/POLYAMINEFROM550Mto1700M
Fluid The KCL/GLYCOL/POLYAMINE system is an extremely successful filed proven
water base mud. the system has been used under severe conditions and it
exhibiting stable properties not only while drilling , but alsoduringprolonged static
conditions experienced during tripping ,logging , and testing operations , in
additions , this system minimizes hole problems , providing excellent shale
inhibition as well as resistance contamination . This mud system is considered as
theenvironmental friendlysubstituteto OBM.
Provide shaleinhibition and maintain well-bore stability to ensure the
use of minimum mud weights.
Losses while running casing
Solutions Maintain 6 RPM in recommended range
Control drilling rate to avoid overloading annulus
Maintain thin, tough filter cake
Adjust fluid properties to minimal rheology prior to cementing
Barite
Soda Ash
XC-Polymer
PAC-UL
PAC_R
1.6
PHPA
1.7 Glycol
Poly amine
KCL
CaC03
Soltex
Weighing Material
Alkanity and Hardness control
Primary Viscosifying agent
Fluid loss control
Viscosifier and FL reducer
Encapsulation of cuttings
1.8
1.9 Primary Shale Inhibitor
1.10 Additional Shale inhibitor
Secondary Inhibitor
Bridging agent
Shalestabilizer
As per requirement
0.25-0.5 ppb
0.5-1.0 ppb
3.0-4.0 ppb
1-2 ppb
1.11 1.0 ppb
1.12
1.13 14ppb
3.5PPB-12PPB
33ppb
5-15 ppb
5 ppb
Barium Sulphate
Sodium Carbonate
Clarified Xanthan gum
1.14
Poly anionic cellulose
Poly anionic cellulose
Partially Hydrolyzed
Polyacrylamide
Polyalkalineglycol
Polyamine
Potassium chloride
Calcium carbonate
Sulphonated asphalt
MudWeight
9-10.0 ppg As hole condition dictate
Funnel Viscosity
chances of losses
PV
YP.
25-30 Ib/100 ft2 To be calculated for maximum hole cleaning
API FluidLoss
<5 cc To be minimized as per the hole condition
KCL
CP Glycol
Polyamine
33
14
12
Ppb
Ppb
ppb
As hole dictates
Inhibitor
Inhibitor
pH
8.5-9.0
PREPARATION:
1 Clean thoroughly mud pit with water.
2 Take water in the pit + add soda ash + mix caustic soda to adjust pH to 8.0- 8.5+KCL.
Determine calcium ppm and neutralize by adding calculated quantity of sodium-bi-
carbonate(ca++ ppm * 0.00074 = ppb sodium-bicarbonate) / soda ash (ca++ ppm *
0.00093=ppb soda ash)
3 Treat with 4.0 ppb of PAC-LV, 1.0ppb PAC R, Mix thoroughly.
4 Treat with 1 ppb XC-POLYMER at slow mixing rate.
5 Load CaCO3 and mix barite up to desired weight.
6 Agitate for 6-8 hours.
7 After mixing all the chemicals the mud becomes highly viscous, but the viscosity will come
down by thorough intermixing within the tanks.
8 Glycol (14ppb), Polyamine (12ppb) and PHPA (0.75-1ppb) may be added after change over
during first circulation. Make sure that, pH is less than 9.5 and Ca++ in the mud is below
200ppm, before addition of the PHPA.
Method ofMixing of PHPA
Ensure that the pit is thoroughly clean and that the mix line from the Slug Pit to the Premix Tank
has been has been flushed thoroughly with fresh water. Place fresh water in the slug pit to
maximum. Have standing by the hopper calculated bags of PHPA to treat the whole system of
1ppb and two competent roustabouts. Start transferring water from the slug pit to the Premix
Tank (and continue to fill slug pit from water line). As soon the water transfer starts, add PHPA
as rapidly as possible into the hopper while the water is being transferred to the Premix Tank.
When all the sacks of PHPA are added close the hopper valve. Fill Premix Tank from the Slug
Pit if you need volume. Continue to circulate the pre-solubilised PHPA through the mix line. You
can prepare concentration of approximately 10.0 ppb (28.5 kg/m3) by this method. This method
of mixing PHPA is known as slam dunk and is the most efficient and effective way of mixing
powdered PHPA. Then Pre-solubilised PHPA can be bleed to the active system in one or two
cycles. Care should be taken, that after every use of mixing or shearing device, lines should be
flushed with clean water to avoid chocking of the hopper suction lines and hopper jets.
CHANGE OVER
Sufficient quantity (csg + hole volume + sand trap+100 bbls) of mud must be ready before
change over.
After drilling, 13 3/8 casing shoe sweep hole thoroughly with 50-60 bbl of viscous pill.
Ensure cleaning of all the channels, sand traps thoroughly to avoid cement contamination of
polymer mud.
Then a cushion 30 bbl of water plus 1sx soda ash, followed by gel of 50 meter of annulus
volume is to be chased by KCL-POLYMER mud. This will ensure minimum calcium
contamination.
On surfacing of gel, discard gel. Circulation of mud through bit nozzles helps shearing of all the
polymers.
Add Glycol 14ppb V/V in one circulation.
Add 12ppb Polyamine slowly in staged to avoid the flocculation.
Add 0.75-1.0 ppb PHPA after confirmation of pH is less than 9.5 and Ca++ below 200ppm.
Do the pilot test with this formulation, before mixing in the tank.
.
KCL/GLYCOL INHIBITION MECHANISM
How Does it wok ?
By plugging shale pores, Glycol a barrier against water migration thereby reducing
well bore instability caused by fluid influx
Inhibition Mechanisms
Primary Mechanism
Water displaced by interaction of polyglycol with potassium ions at clay surfaces. polyglycol
complex formed.
Secondary Mechanisms
Glycol- glycol interactions with some species.
KCL/GLYCOL/POLYAMINE SYSTEM DISCUSSION.
Glycol Mud was chosen as one of the preferred possible candidate in this section for the following
reason:
Benefits
In gauge well bores
Lower fluid losses & leak off values.
Lower potential for differential sticking.
Less torque, drag and bit balling problems.
Lower dilution rates.
Slicker, firmer filter cake.
Greater well bore stability.
Allows full use of PDC bits
Provides excellent lubricity characteristics
Applications
Reactive shale sequences where a highly inhibitive drilling fluid is required
High-angle or extended-reach wells where well bore stability and lubricities are key factors
Replacement for oil-based muds in environmentally sensitive areas
Cost-effective alternative to pseudo oil-based muds
Polyamines
Polyamines are also added with glycol for additional inhibition. Liquid polyamine shale
inhibitor is normaly used in drilling and drilling fluids. Shale inhibition is achieved
by preventing water uptake by clays, and by providing superior cuttings integrity. Polyamines
effectively inhibits shale or clays from hydrating and minimizes the potential for bit balling.
Benefits:
Highly inhibitive across a wide range of shale types
Significant reduction in clay dispersion and hydration compared to existing state-ofthe-
art inhibitive systems
Lower risk of accretion and cuttings agglomeration related problems
Environmentally acceptable
Highly flexible in formulation easily controllable filtration and rheology profiles, and
usable with various base brines
Highly solids tolerant
Fig-1
Fig-2
Fig-3
Fig-1. Shows theaccretioncharacteristicof
Polyamine system.
.
So glycol added with polyamine will enhance
the accretion suppressant action preventing
any buildup of drill solids below the bit,
allowing the cutters good contact with new
formation for improved rate-of penetration.
The component also lowers torque and drag
byreducing the coefficient of friction.
Fig-2 Shows the graph of bentonite
inhibition test with the base fluid.
Fig 3 and 4 Shows unconfined shale fracture
test of the systems with base fluid.
Fig-4
KCL/GLYCOL/POLYAMINE SYSTEM DISCUSSION
The KCL/GLYCOL/POLYAMINE System is inhibitive water based drilling fluid designed to meet
difficult drilling targets with minimal environmental impact. It achieves its unique inhibition through
the synergistic action of a polyglycol and the provided Potassium ions, which contribute to cuttings
and borehole stability through Cation exchange to provide a more stable non-swelling type of clay.
The KCL/GLYCOL mud system exhibit higher degree of inhibition due to the presence of Glycol
Which have an ability to stabilize the swelling clays by preventing and minimizing water absorption to
the clays platelet. The GLYCOL is compatible and remains effective over a very wide range of
salinities and temperatures. It provides the secondary benefit of improvements in lubricity and
filtration characteristics. It also displays extremely low environmental impact. No incompatibilities
with other mud additives or contaminants have been found or are predicted.
Wellbore Stability
The KCL/Glycol /POLYAMINE system provides outstanding wellbore stability to minimize stuck pipe
tendencies and reduce valuable and costly reaming time. The combination of salt, cation, polymer
Glycol and polyamine, highly inhibitive fluids to be formulated which minimize the hydration and
dispersion of clay minerals. This prevents many common drilling problems such as mud rings, tight
hole caused by swelling clays and chemically induced caving or hole washouts. Thus, water-
sensitive formations can be drilled with a high degree of confidence. The inhibitive nature of the fluid
also ensures that cuttings are not dispersed in the annulus. This translates directly to better solids
control efficiency and low dilution and maintenance costs.
Lubricity
The KCL/Glycol system has excellent lubricity characteristics, leading to low torque and drag during
drilling operations. Figure shows that 3% glycol stabilizer produces a greater torque reduction than
KCL Polymer.
Reservoir protection
The KCL/Glycol/Polyamine system minimizes formation damage in the
crucial reservoir section. The system prevents swelling and dispersion of
formation clays and has low static and dynamic fluid loss for reduced
solids and filtrate invasion. The filter cake is easily removed by conventional acid treatments. The
Glycol shale inhibitor remains soluble even at down hole temperatures and, therefore, does not
"cloud out" to produce a damaging micro emulsion. The filtrate from the CPG system gave 86%
return permeability.
GLYCOL Shale Stabilizer
Glycol Shale Stabilizer is the major ingredient of this System, added at typically 3 to 6% by volume
of mud. It is a polyalkylene glycol used to stabilize hydratable and dispersible shales and to improve
fluid loss and lubricity. The product is completely water soluble so that high concentrations of organic
material are not expected to accumulate with the cuttings on the sea floor (as occurs with oil based
and synthetic based fluids). It does not contain oil and demonstrates very low aquatic toxicity. The
product is also completely biodegradable and will not bioaccumulate.
.
Thesystemhasexcellent
lubricityandfiltrationcontrol
properties, andisthermally
stableandnon-damagingto
sensitivereservoirs. Themajor
component,Glycolshale
stabilizer, is
completelybiodegradable.
RHEOLOGY
Any premium grade Xanthan gum is recommended to provide shear-thinning viscosity for the Glycol
system. It provides minimal plastic viscosity and a shear thinning Rheological profile with high
LSRVs for optimum cuttings transport and suspension. The 6-RPM and 3 RPM specifications are
dependent on the hole size, the well geometry and the effective annular velocity.
FLUID LOSS CONTROL
Maintain Fluid Loss control by treatment with PAC material. However, all conventional fluid loss
polymers can be used with the Glycol system. Treatment concentrations are dependent on the fluid
loss specification.
Note that the freshly prepared solids-free fluid will exhibit relatively high fluid loss values, until drill
solids have been incorporated.
KCL CONCENTRATION
Maintain KCL concentration within the recommended range with additions of brine concentrate or
the direct addition of powdered KCL.
Monitor and record the in and out potassium concentrations on a regular basis while drilling to
determine depletion rate and treatment requirements. Increase the KCL concentration as per hole
condition dictate.
BACTERIAL DEGRADATION
The KCL/Glycol system uses conventional polymers (biopolymers, poly-anionic cellulose polymers,
and starches) to maintain fluid properties. The use of a bactericide is recommended to prevent
bacterial degradation of the polymers.
SOLID CONTROL
The inhibition of the glycol system contributes to optimum performance from the solids control
equipment. Solids removal is enhanced as a consequence of the large inhibited cuttings that are
generated with the Glycol system, and the shear-thinning nature of the Xanthan-base polymer
system.
Use all available Solids Control Equipment as efficiently as possible to minimize undesirable mud
weight increase from drilled solids accumulation and to reduce dilution requirements. Use the finest
shaker screens, which can handle the circulation mud on shale shakers. Run other solids control
equipments as and when required.
Maintenance:
1. The appearance of cuttings at the shale shakers should be closely monitored to ensure there is
Sufficient inhibition. The effects on other drilling parameters such as tight hole, torque, etc. should
also be considered. Maintain constant inspection of cuttings integrity at the shaker. Glycol & KCL
concentrations should be altered according to firmness and increased as hole condition dictate.
2. Selecting the proper fluid density is critical. The mud weight required for the system is based on
the pore pressure and tectonic stress of the formation(s). Fluid density is a key element contributing
to the effective borehole stability of the system and also is a critical requirement for effective
inhibition performance. . This is particularly critical in high angle wells or in areas where
tectonic stress is a key factor.
3. Any premium grade Xanthan Gum, is recommended to provide shear-thinning viscosity for the
KCL/Glycol system. Minimum hydraulics is achieved through the low plastic viscosity and shear-
thinning rheology profile. Optimum cuttings transport and solids suspension is provided with the
proper low-shear rheology values. The 6 RPM and 3 RPM specification depends on hole size, well
geometry, the bottom hole assembly and drill-string design, and the annular velocity.
4. The prudent use of wiper trips is important to facilitate cuttings transport and to ensure the caliper
of the well bore. This is especially important when using a stiff BHA. Monitor over-pull on trips for
indications of inadequate hole cleaning or tight hole. If over-pull is a major problem, then
consideration should also be given to a change in the BHA assembly.
5. Before pulling out of the hole it is critical to remove all the cuttings from the well bore. This is
especially important because of the gauge well bore and larger cuttings typically obtained with glycol
fluids. The circulation time can be determined based on hole cleaning algorithms, but the ultimate
observation is at the shaker. If any over-pull is observed on a trip, then additional circulation time
and/or wiper trips are recommended.
6. Calcium carbonate must be added at concentration 5-10 ppb to ensure a good external filter cake
across the sand faces and provide good bridging for these sand which will reflect in minimizing down
hole losses and formation damage.
7. HOLE CLEANING MUD RHEOLOGY. Proper rheology is extremely important. The system uses
biopolymers to provide optimum low-shear-rate-viscosity (LSRV) for superior hole cleaning, wellbore
stability and optimum hydraulics. The inhibitive, non-dispersed glycol/polyamine fluid maintains the
integrity of the cuttings and the LSRV values are maintained higher than conventional polymer fluids
to provide adequate hole cleaning performance. Elevated flat, fragile gel strengths are important to
ensure suspension of solids. Proper rheology is even more critical in high angle wells to prevent the
formation of cuttings beds and the degradation of the large, inhibited cuttings. The use of high
density-viscous sweeps should only be used to ensure adequate hole cleaning; proper rheology is
the key to efficient solids removal.
8. HOLE CLEANING - DRILLING PRACTICES. Controlled ROP, maximum circulation rates,
maximum pipe rotation, and LSRV mud rheology all of these factors are critical to ensure drill
solids removal from the wellbore in vertical and especially in a high angle wellbore. This is critical
because of the improved cuttings integrity.
9. WIPER TRIPS. This fluid will provide a gauge hole and, therefore, it is important to utilize wiper
trips. The prudent use of wiper trips is important to facilitate cuttings transport and to ensure the
caliper of the wellbore. This is especially important when using a stiff BHA. Monitor over-pull on trips
for indications of inadequate hole cleaning or tight hole. If over-pull is a major problem, then
consideration should also be given to a change in the BHA assembly.
10. SOLIDS CONTROL. Optimum solids removal and minimum system dilution are characteristic of
the Glycol fluid. It is important to ensure that the solids removal system is properly designed and
sized to ensure optimum performance. The key with regard to solids removal is the primary solids
removal equipment the shale shaker system. An adequate number of high performance shale
shakers to process the required flow rates and to handle the required rheology is mandatory.
.
11. While drilling this section attention should be paid to maintain the solids content within
programmed limits by; upgrading shakers screen size & installing the finer mesh, and dumping
sand trap periodically beside running all the solids control equipment with its full efficiency
continuously and diluting the system with fresh mud to reduce the effects of high concentration
of low gravity solids. Shaker screens should be inspected regularly, and damaged screen has to
be changed immediately to keep the solid content as lowest possible.
VOLUME ESTIMATE BBL
SURFACE VOLUME
9 5/8 casing VOLUME
TOTAL VOLUME
MAINTAINENCE VOLUME
Old Mud Received
New Mud Built
Mud Remaining
600
279
605
1484
2300
3784
0
3784
1484
Material Estimation
PRODUCT UNIT
SIZE
Baryte
Soda ash
XC-Polymer
PAC_LV
PAC_R
PHPA
GLYCOL
SOLTEX
BIOCIDE
KOH
EPLUBE
POLYAMINE
CaCO3
KCl
50 Kg
50 Kg
25Kg
25 Kg
25 Kg
25 kg
200 Lt
25 KG
20 LTS
50 Kg
200 lt
200 lt
50Kg
50Kg
1200
19
79
316
79
79
131
343
17
30
4
103
515
1279
8.5 Interval: 1700M 3000M
NonDamaging Fluids
Common Causes of Limited Producing Rate
High oil viscosity
Formation damage
Wellbore design restrictions
Low reservoir pressure
Low reservoir permeability
Inadequate or improper artificial lift
Some of the most common ways of damaging a formation include pay zone invasion
and plugging by fine particles, formation clay swelling, commingling of incompatible fluids,
movement of dislodged formation pore-filling particles, changes in reservoir rock wettability, and
formation of emulsions or water blocks. Once one of these damage mechanisms diminishes the
permeability of a reservoir, it is seldom possible to restore it to its original condition.
Except when drilling underbalanced, the hydrostatic pressure in the wellbore is greater
than the reservoir pressure. When the drill bit penetrates and crushes the permeable pay zone,
the drilling fluid is forced to move into the rock pores, carrying with it the fine drilled solids and
the suspended weighting materials, clays, polymers, lost circulation materials, cement particles,
rust, pipe dope, or precipitates. Any of these contaminants can wreak havoc upon the
productivity of oil and gas wells.
Suspended particles larger than the formation pores are generally swept away in the
mud stream and lifted out of the well; smaller-than-pore particles tend to invade the formation
and can become trapped on the face of the wellbore, forming a permeable wall cake that allows
fluids to filter through. This wall cake can allow fluids to continuously filter through as long as a
deferential pressure is applied towards the formation. Simply, any subsurface permeable zones
should be considered as effective depth filters for any wellbore fluids.
Loss of large volumes of fluids to permeable producing formations (lost circulation) is one of the
most common problems encountered when drilling or completing a well. Lost circulation can
severely impair productivity and undermine profitability. Production can be seriously impeded if
all the invading fluid is not produced back into the wellbore.
Design criteria for non-damaging fluids.
Fundamentally, a non-damaging fluid is a clean fluid that causes little or no loss of the natural
permeability of the pay zone targeted for development, while providing superior hole cleaning
and easy clean-up. In addition to being safe and economical for the application, it must be
compatible with the reservoirs native fluids, so as to avoid precipitation of salts or production of
emulsions.
A suitable non-damaging fluid should establish a filter cake on the face of the formation, but not
penetrate too far into the formation pore pattern. This can be accomplished by the addition of
sized particles of a durable bridging solid into the fluid system. Generally speaking, the median
size of the bridging solids should be equal to at least one-third of the diameter of the mean pore-
throat diameter and the size distribution of the particles should be wide. Optimal particle size
distribution and tight filtration control also help significantly reduce differential sticking forces
while drilling. Another factor that should be considered when formulating a drill-in fluid is
achieving a low filter cake lift-off pressure as the well is flowed in the production direction.
The fluid filtrate should inhibit or prevent swelling of reactive clay particles within the pore
throats. Important factors for optimum filtration control are low spurt loss, low total filtrate loss,
and maintenance of a thin cake to avoid excessive erosion and to reduce the risk of stuck pipe.
Non-damaging KCl-Glycol-Polyamine Polymer Mud system
As a general rule, monovalent and divalent salts should not be mixed together. However,
monovalent salts and some two-salt combinations-for example, sodium chloride and potassium
chloride, sodium chloride and sodium bromide, potassium bromide and potassium chloride, and
sodium bromide and potassium bromide-may be blended as brine-salt solutions to densities of
up to 13 pounds per gallon (ppg). Looking into all the above criteria, we are proposing a non
damaging KCl-Glycol-Polyamine Polymer mud system to drill the 8.5 hole by using two salts KCl
and NaCl, acid soluble polymers, filter cake, weighing materials etc.
INTERVAL DISCUSSION
CLAY FREE MUD SYSTEM FROM 1700 M TO3000M
Fluid
The utilization of CLAY FREE SYSTEM to obtain minimum reservoir damage and
to enhance the fluid capability to inhibit the drilled shales as well as providing an
enhanced environment for mechanical and chemical bore stabilization and control
formation characteristics for the entire section.
Provide shale inhibition by chemically and mechanicallyand maintain
well-bore stability to ensure the use of minimum mud weights.
Losses while running casing/Formation damage
Solutions Maintain6 RPM in recommended range
Control drilling rate to avoid overloading annulus
Maintain thin, tough filter cake
Maintain the bridging material to avoid formation damage
CaCO3
XC-Polymer
PG STARCH
PAC-LV
KCL
SODIUM CHLORIDE
CP Glycol
Polyamine
Bridging Material, Weighing
Primary Viscosifying agent
Fluid loss control
Fluid Loss Control
Inhibitor
Weighing material
Inhibitor
Inhibitor
20-50ppb
1.0 ppb
7.0 ppb
4ppb
33ppb
20-50 ppb
14PPB
12ppb
Sized Calcium carbonate
Clarified Xanthan gum
1.15
Modified starch
Polyanionic Cellulose
Potassium chloride
Sodium chloride
Glycol
Polyamine
Mud Weight
9.5-10.5 ppg As hole condition dictate
Funnel Viscosity
chances of losses
PV
YP.
LSRV(6 RPM)
25-30
8-9
Ib/100 ft2 To be calculated for maximum hole cleaning
For better hole cleaning
API FluidLoss
<5 ml To arrest formation invasion
KCL
33 ppb For inhibition
pH
9-9.5
PREPARATION:
All pits and flow lines should be thoroughly cleaned prior to mixing the CLAY-FREE system using base
fluid. All dump valves should be checked and secured. The shale shaker system should be fitted with new
screens keeping in mind that initial sizing should avoid excessive loss of polymer and carbonate which
will occur from the fluid being cold and not fully sheared. 84 mesh is recommended. Add Defoamer if
required and biocide before any other mud products. Always check the pH of brines before mixing other
products.
1. Fill up desired drill water in the pit and then add salt in drill water. Check pH and reduce to between pH
7 and 8.
2. Add the PG Starch, through the hopper using maximum shear.
3. Add the XC Polymer at 10 minutes per sack or slower to avoid forming fish eyes.
4. Add KCl.
5. Add Cloud Point Glycol slowly
6. Add the CaCO3 fine as fast as possible to required weight.
7. Add Polyamine slowly to avoid the flocculation
Note: Finally add the caustic Soda to adjust the pH to 9.5 or slightly higher if require. Normally
Polyamine system does not require addition of caustic soda. The polymers will fully yield in the higher pH
and after some temperature from shearing.
Mixing Products while drilling
In order to maximize product yield and avoid sub-standard mud properties the following guidelines
should be followed when adding products to the system:
Adjust pH to the correct range before adding XC Polymer as low or high pH reduces yield,
adjusting the pH after the addition of a polymer may result in a viscosity hump.
Always add viscosifiers to the system at 30 minutes per sack to avoid viscosity humps. Maintain
the micronized CaCO3 concentration by continuous slow addition to the active while drilling rather
than let it deplete, by removal on the solids control equipment.
CHANGE OVER
The procedure is designed for displacing the casing from a water based mud used to drill the previous
hole section. The previous mud system or water should be used to drill the cement and float equipment
down to 2 meters above the shoe.
General Consideration
The aims of a successful displacement are to remove completely the previous drilling fluid prior to use of
CLAYFREE, or the removal of CLAYFREE fluid and associated solids in the case of completion brine. To
do this efficiently whilst maintaining the integrity of the CLAYFREE or brine, taking into consideration rig
time and environmental impact. Displace conditioned WBM with the following pills in sequence using
conventional circulation.
Rig Site Execution
Execution of displacement and clean up requires good preparation at the rig site. Review the planned
procedure with the rig crew and adjust as necessary based on their recommendations. Floaters have
special design considerations, simple pit logistics and maintaining the required pump rates are the most
important factors to ensure the job is carried out successfully. Write a detailed plan with contingencies for
contaminated returns; also indicate the most important aspects of the job such as pump rate etc. Get the
mud loggers (If available) to record the displacement and to indicate when the pills return to surface.
Make sure the sequence and timing of events is communicated during the job. Check spacer properties
after mixing and before pumping. Check all valves and connections involved as well as pit condition prior
to the job.
Procedure sequence
1) 50 BBL dense, viscous pill built using water. Weighted with Barite to a 10% higher density than the
mud to be displaced. Viscosified using XC Polymer so the 100 Fann RPM reading is 20% greater than
the mud to be displaced.
2) 50 BBL caustic surfactant pill (3 lb/bbl caustic soda).
3) 50 BBL viscous pill (2.5 ppb of XC Polymer in water) pumped ahead of the CLAYFREE fluid.
Do not stop pumping while displacing old mud to CLAYFREE. Flow rates should be high enough to
ensure turbulence of the second pill and water pumped. Rotation and reciprocation should also be
employed throughout the displacement. Over displacement is recommended to minimize contamination.
Return fluid density should be within 0.25 ppg/0.03gm/cc of mud weight before taking returns back to the
system.
MAINTAINANCE
Drill out cement with water (if possible), or pre-treat the CLAYFREE mud with Soda ash and
Sodium bicarbonate to eliminate Calcium contamination.
Ensure all solids control equipment is working efficiently, as maintaining the low gravity solids
content and MBT equivalents will be extremely important through the reservoir section.
The appearance of cuttings at the shale shakers should be closely monitored to ensure there
insufficient inhibition. The effects on other drilling parameters such as tight hole, torque, etc.
should also be considered. Maintain constant inspection of cuttings integrity at the shaker. The
KCL concentrations should be altered according to firmness and increased as hole condition
dictate.
The mud density should be kept as lowest possible whilst drilling the 8 section to minimize the
chance of differential sticking
HOLE CLEANING MUD RHEOLOGY. Proper rheology is extremely important. The system
uses biopolymers to provide optimum low-shear-rate-viscosity (LSRV) for superior hole cleaning,
wellbore stability and optimum hydraulics. Elevated flat, fragile gel strengths are important to
ensure suspension of solids. Proper rheology is even more critical in high angle wells to prevent
the formation of cuttings beds and the degradation of the large, inhibited cuttings. The use of high
density-viscous sweeps should only be used to ensure adequate hole cleaning; proper rheology
is the key to efficient solids removal.
HOLE CLEANING - DRILLING PRACTICES. Controlled ROP, maximum circulation rates,
maximum pipe rotation, and LSRV mud rheology all of these factors are critical to ensure drill
solids removal from the wellbore in vertical and especially in a high angle wellbore. This is critical
because of the improved cuttings integrity.
WIPER TRIPS. The CLAYFREE fluid will provide a gauge hole and, therefore, it is important to
utilize wiper trips. The prudent use of wiper trips is important to facilitate cuttings transport and to
ensure the caliper of the wellbore. This is especially important when using as stiff BHA. Monitor
over-pull on trips for indications of inadequate hole cleaning or tight hole. If over-pull is a major
problem, then consideration should also be given to a change in the BHA assembly.
Engineering Guide lines
Formation Damage
The most important parameter of the system that will require regular monitoring is the fluid loss across a
porous medium in particular the spurt volume measured after 20 seconds. If the values indicate a rising
trend then additions of micronized CaCO3 should be added. PG Stach and PAC LV should be added to
reduce the final filtrate value. Pilot testing is recommended prior to any system treatment. Addition of
Barite considered only if require and after confirmation from the ONGC.
Solids Control
To minimize formation damage it is necessary to retain carbonate particle size up to 200 microns in the
active system. Based on screen opening size this would mean shaker screens finer than 84 meshes
could not be used while drilling. With 84 mesh shaker screens however 90% of the micronized CaCO3
will be retained but only 60% of the formation sand will be removed, possibly allowing sand content of the
drilling fluid to affect surface equipment. With 140 mesh shaker screens 85%of the formation sand will be
removed but only 80% of the micronized CaCO3 will be retained, below the effective particle size
required to effectively bridge the formation sand.
It is recommended to run the shaker screens as fine as possible preferably 120 mesh screens while
replacing the top cut calcium carbonate removed by the shakers with additions of Gel white. This will help
to maintain the correct particle size distribution without compromising filter cake quality. It is not
recommended that centrifuges be used with this system as they will remove all the bridging
material.
Drilling rates can be high in reservoir sections. If shales of a dispersible nature are encountered this may
result in a deterioration of the filter cake properties from incorporation of plastic clays. Clay content as
measured by MBT should be kept less than 5 ppb. Potassium content should be measured at regular
intervals and sufficient reserve volume and mixing capability should be available at all times. Consider
increasing the KCl content of the brine phase or in pre-mix if depletion occurs with clay hydration. Regular
monitoring of the drilled solids content and type is essential. Maintaining a drilled solid target of 3%
maximum with 7% bridging material (160 kg/m3) will mean a total LGS solid content of 10%. The sand
content of the fluid should be monitored to check that it contains carbonate as well as silica. The CaCO3
coarse bridging carbonate will appear as sand in this test but is acid soluble. Volume percent carbonate
measured in the sand tube can be multiplied by 2700 to give kg/m3 of coarse bridging material. There
should be at least 2% carbonate in the sand content to maintain the correct bridging concentration.
Lost Circulation:
Loss of whole fluid will most likely be related to encountering highly permeable zones with an
overbalance. Bridging with the correct range of particle sizes will reduce losses. A NON DAMAGING pill
composed of all the grades of carbonate(140-215 kg/m3 (50-75 ppb) CaCO3) ranging from super fine (<
5 micron) to coarse (350 micron) particle sizes should be pumped to reduce losses.
Hole Cleaning:
If the hole angle is more than 45 degrees hole cleaning will become more challenging. The excellent
rheological profile of CLAYFREE makes it an excellent choice for deviated wells, as the high low shear
rate viscosity (LSRV) inherent in this fluid helps to ensure excellent hole cleaning. By maintaining the
program rheological profile, providing sufficient annular velocity and rotating the pipe should ensure
cuttings removal.
However, high instantaneous ROPs may lead to poor hole cleaning. Poor hole cleaning may also be
observed after periods of sliding. Ream and circulate connections prior to re-orienting. In the event that
poor hole cleaning is suspected and correct rig procedures have been followed, then consider pumping a
high viscosity pill (50 bbl). Monitor returns for signs of increased returns. This would be an indication that
higher viscosity is required for cleaning the low angle section of the hole.
Note: Low viscosity pills are not recommended as generally they require large volumes to be effective
and are counterproductive if pipe rotation and pumping is stopped even for a short period. Avoid pumping
several hi-vis sweeps, as this will affect the rheological profile of the mud. The pipe must be rotated and
pumping should not stop while circulating pills.
Before pulling out for a trip circulate the hole clean with rotation. Cuttings transport will take longer than
expected for the high angle sections, a clean shaker does not necessarily mean a clean hole. Be aware
of the possibility of cuttings beds further up the hole in hole angles between 50 and 60 degrees, back-
ream out if necessary with high pipe rotation. Since the main viscosifier is a biopolymer and the solids
content is relatively low the rheological behavior of the system is best predicted by the Power Law model.
The fluid exhibits shear thinning behavior at annular and pipe shear rates as well as visco-elastic
behavior at shear rates below 1 sec-1. This results in low system pressure loss, flatter flow profile in the
annulus with higher wall shear rates and sufficient solids suspension at very low shear rates. In order to
preserve these advantages the n and K indices of the system should be monitored and controlled by
addition of XC Polymer.
Adding XC Polymer will increase K at the same time as lowering n, enhancing Power Law behavior.
Since PAC R also contributes to K its use should be restricted to controlling fluid loss. The n should be
kept in the range 0.2 to 0.5 by addition of XC Polymer. Calculating n and K from 200 and 100 Fann 35
readings will increase accuracy of fluid characterization. A check on the ECD value while circulating and
the swab value while tripping is recommended as a safety precaution as the system rheology is higher
than conventional reservoir fluids.
After drilling to TD circulate bottoms up with 50-60 RPM rotation. Perform a wiper back to the shoe and
circulate bottoms up. Run back to TD and circulate the hole clean with rotation. It is important to ensure
the hole is clean of cuttings to prevent damage to the completion when it is run in the hole.
VOLUME ESTIMATE BBL
SURFACE VOLUME
9 5/8 casing VOLUME
TOTAL VOLUME
MAINTAINENCE VOLUME
Old Mud Received
New Mud Built
Mud Remaining
600
408
329
1338
1300
2638
600
2038
1338
Material Estimation
PRODUCT UNIT
SIZE
Xanthum Gum
KCL
Soda Ash
Mod.Starch
Salt
Calcium carbonate
Biocide
PAC LV
C P Glycol
25Kg
50 Kg
50Kg
25Kg
50Kg
50Kg
200 Lt
25Kg
200Lt
61
657
8
282
1237
600
15
172
71
Polyamine
Soltex
EP Lube
Biocide
200Lt
25Kg
200Lt
20Lt
61
185
4
20
Contingencies:
1. Lost circulation: Losses of partial or whole mud to subsurface formations is called lost
circulationor lost returns. Lost circulation has historicallybeen one of the primary contributors to high
mud costs. Other hole problems such as wellbore instability, stuck pipe and even blowouts have been
the result of lost circulation. Besides the obvious benefits of maintaining circulation, preventing or
curing mud losses is important to other drilling objectives such as obtaining good quality formation
evaluationand achieving an effective primarycement bond on casing. Lost circulation occurs inone of
twobasic ways:
1. Invasionor mud loss to formationsthat are cavernous, vugular, fracturedor unconsolidated.
2. Fracturingwhich is mud loss due tohydraulic fracturing from excessiveinduced pressures.
It is important to have a good stock of both fibrous flake & granular NON DANAGINGLCM available on
the rig at all times. The volumes in the pits must be monitored closely at all times, and losses
understood quickly to avoid breaking down any formations down-hole. This section is provided to give
guidance on the best remedial action to stem down-hole losses. I t is recommended loss treatments
based on the severity of down-hole losses; these can be ranked as Seepage Losses, Partial Losses, or
Severe/Total Losses. It is recommend using conventional lost circulation products initially, but should
these fail to cure the losses, special pills may be tried and at last cement plug is the final solution.
Seepage Losses: Losses of up to 10 bbl/hr are normally considered as seepage losses. Seepage type
losses are frequently cured by the simple action of reducing or stopping the pump rate and allowing the
formation to heal and become sealed off by the development of a filter cake. The pump rate can be
gradually increased after the losses have stopped. Seepage losses can sometimes progress to partial or
total losses if remedial action is not taken. If seepage losses are expected during drilling through a
certain formation, treating the whole mud system with LCM before entering the loss zone can be
recommended. Such a treatment will depend on pore/fracture size distribution in the actual formation,
not to mention the tolerance to LCM of down-hole tools.
Partial losses: Losses from 10 bbl/hr to 25 bbl/hr are referred in this particular case as partial losses.
The situation will usually require treatment. The LCM pill should be spotted in the thief zone, and
allowed to soak: If this pill does not heal the losses, the pill given under total losses of returns should
be pumped. If that one also fails, one of the soft plugs or reinforcing plugs should be pumped.
Total Losses of Returns: The priority will usually be well control, so the annulus must be filled from the
top with either drilling fluid, base oil or other lightweight liquid. Unless the fracture is induced, losses
can normally not be stopped by pumping conventional LCM pills. However, a pill of LCM is often the first
choice since it gives quick response if it works and it is easy to do. Recommended pill to pump should
contain as much LCM as possible, but not more than 75 ppb total LCM concentration If this pill does not
heal the fracture, a specialized pill (cross-linking or reinforcing plug) should be set across the loss zone
containing a mixture of fine particle sizes to plug deep fractures, faults, and vugular formations. The flow
chart below shows the generalized course of action recommended in the event of down-hole losses.
Recommended Course of Action Based on Severity of Down-Hole Losses
Losses on
surface
Locate and stop
osses
Record shut in
pressure. Kill the well
Premix 10 ppb mica in the
whole system.
If no reduction in loss rate spot
pill:
micaI 15 lb/bbl
wall nut 15 lb/bbl
If no reduction in loss rate go to
partial losses recommended
tratment.
Spot pill:
mica 10 lb/bbl
wallnut 20 lb/bbl
saw dust 20 lb/bbl
Volume:
100 bbl mimimum
Spot specialized pill:
Yes
No
Yes
No
No
success
Losses
Stopped?
Drill Ahead.
No
success
Spot pill:
mica 20
lb/bbl
wallnut 20
lb/bbl
saw dust 20
lb/bbl
Volume:
100 bbl
minimum
Losing fluid while drilling
Stop drilling and observe
levels
Well flowing?
Seepage losses < 10
bbl/hr
Measure rate of loss
Partial losses 10-25
bbl/hr
Total loss
No
success
Differential StickingThe vast majority of stuck pipe problems arise from differential pressure
sticking. Differential pressure sticking can be defined as the force that holds pipe against the wall of the
hole, due to the differential between formation pressure and hydrostatic pressure.
In order for differential pressure to exist, certain criteria are required:
Hydrostatic pressure must exceed formation pressure.
A zone of permeability must exist, over which a thick filter cake has been deposited.
Theremust be contact area between the pipe and the filter cake.
Since formations with permeability will be encountered, differential sticking is a possibility. The
following information will deal with the remedies available to free differential pressure stuck
pipe. The area of contact increases as the filter cake thickens with time, thus producing greater
sticking forces.
Because of this, a quick determination of the cause followed by an immediate remedial step is imperative.
2.1 Work pipe by tripping the jars both up and downifpossible.
2.2 Attempt to rotate.
2.3 Spot a Pipe-Lax soak solutionquickly. The probability of freeing differentially stuck pipe with a
soak solution is inversely proportional to the time between actual sticking and final spotting of the
solution. Reduce mud weight if possible.
2.4 Run a drill stem test tool and relieve pressure.
2.5 Pump a slug of water down the drill string then let it U-Tube.
2.6 Pump some air to reduce the hydrostatic head.
PIPE-LAX(NW)FORMULATION:
1 Dump the slug pit
2 Take Diesel
3 Mix3-4%PIPE LAX spotting Fluid, shear.
4 Displace around the stuck point against DC. Assuming that the stuck point is against the
D/C, enough Sp. Fluid should be prepared to cover the twice the DC.
5 Displace and keep 1M3 inD/string. Work on string.
PIPE-LAX (Weighted) FORMULATION:for 1M3
Sp. Gr 1.20 1.44 1.68 1.72
Pipe-Lax-W 115Lts 115Lts 115Lts 115Lts
HSD 545Lts 490Lts 455Lts 485Lts
Water 295Lts 270Lts 245Lts 135Lts
Baryte 354Kg 663Kg 950Kg 1280Kg
Note: Before Pipe-lax is mixed, make sure that the tank is agitated completely to ensure no settling.
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