. .
SPE
SPE7749
DRILLING
OF GULFOF SUEZEVAPORATES
by F. Khalaf, Cairo U.; and
H. M. El Shennawy, Gulf of Suez
Petroleum Co., Members S?E-AIME
~Copyrqh! 1979 Society ot Petroleum Engmeefs
Th!soapef waspresenled allha Middle East Oil Technical Conference of the SKlety7: Delroleum Eng!neersheld lnManama Bahra!n.25-~ March 1979The male!lallssubject tocorrecllon by fheaulhor
Permission tocopyls reslflcted loan abslracl ofnolmofe lhan3OOwords WrNe SF ,6200 Norlh Central Expressway .Oallas. Texas 75206 USA Telex 7309S9(SPEOALl
ABSTRACT
The Miocene evaporates of Guif of Suez area
comprise salt, anhydrite and, rarely, gypsum. Th@Y
are mainly found south of 290N latitude line. Salt
pillows and diapirs are common in the southern half
of Gulf of Suez and may be associated with upward
salt creep.
Hole enlargement, key seating,high pressure
salt water flows, hole instability and drillability con-
Lrasts are some problems associated with the drill-
ing of these evaporates . Careful preplanning tak-
ing into account in-situ behavior of evaporates, re -
duces the chances of developing any of the problems
associated with their drilling.
INTRODUCTION
Since initial discovery of oil in Egypt, Gemsa
field in 1910, extensive exploration has been carried
out commencing with on shore drilling on both east
and west coasts of the Gulf of Suez ( GOS ). Offshore
exploration in the Gulf commenced in the early six-
ties and is still among the most active offshore ar@m
of the Middle East. Gulf of Suez Petroleum Com-
pany (GUPCO) drilled its first offshore well in
1964 and to date more than 200 wells have been drill -
ed including ~.bout 60 exploratory ventures. Total
footage driiled by GUPCO exceeds two miilion feet
and is increasing rapidly with 9 currently active
rigs involved in exploration, workover and develop-
ment drilling operations. c
The southern region of GOS has a very charac -
teristic Miocene evaporite section which has a
direct i mpad on VFpliplanning. and drilling practices , tion inmxcess of 3050 meters (about 10,000 feet ) of
— moved upward to form pillows and swells near July &
References and illustrations at end of paper.
Many problems are encountered while drillingthese
evaporite sections. The object ofthis paper isto
highiight the major problems ~r taining to the speci -
fic mechanical and physical characteristics of the
rocks comprising the Miocene evaporates.
This paper presents a brief discussion abut the
geology of the Miocene evaporates in the GOS area.
Problems pwed by hole enlargement, drillability
variations and hole instability are discussed. Detaiis
are given regarding potential key seating and salt
water flows. Also the repercussion of these prob-
lems in regard to casing aild cementing program is
summarized. An outline of a typical drilling prog---
ram for these evaporates is contained in the appen -
dix.
QEOLOGY OF (30S EVAPORATES
Miocene evaporates are very distinctive sedi -
ments of the GOS area. They comprise salt, anhydrit{
and, rarely. gypsum. The rock salt is mainly com -
posed of sodium chloride. Evaporite thickness varies
from 25 to in excess of 50% of the total Miocene and
Post Miocene Sediments.
Miocene evaporates in the GOS are main? y found
south of 29°N latitude line and cover essentially all
of the graben of Gulf cif Suez. They occupy the
whole southern part of the Gulf . Miocene evapo -
rites have been recently found as far as the Sudan-
es e border . Fig, 1 shows their location.
Generally, the evaporite thickness increases to -
wards the centre and south of (303. Very rapid thinn-
ing occurs near 29°N latitude. Conversely, a sec -
Miocene evaporates was encountered in Tawila Island
WellN!LZ 1. Salts have under prevailing stresses
12 DRILLING OF GULF OF SUEZ EVAPORATES .
Ramadan Fields and piercement diapirs in the south
near Areal block 2, 3. There are also areas, within
the southern Gulf, in which the possibility of salt
creep is well supported. In Fig. 1, a sectional view
across the Gulf illustrates a typical subsurface pic -
tur; of the area.
The bottom of the Miocene evaporates is affected
by the P re-Miocene tensional faults; however, these
faults usually terminate inside the salt, particularly
when massive salt sections are present. Normal
tensional faults that cross the top of salt are beli ev-
ed to be mainly relief faults, resulting from read-
justments to tectonics prevailing inside the salt.
Some of these relief faults seem to be active. Fold-
ing has played a minor role in the P re-Miocene
structures but it has a significar,t effect in de-
termining present Miocene structures of the Gulf
of Suez Area.
The massive salt sections of the GOS area limit
the use of seismic data to accurately predict litholo-
w and/or structures underlying the salt as well as
techniques for detection of formation pressure.
DISCUSSION
.—— OF DRILLING ‘“ROBLEMS
Drilling of the Miocene evaporates of the GOS dis-
plays a certain category of problems related to their
physical and mechanical properties. A discussion
of these specific problems and their repercussions
on the drilling operations is given below.
Hole Enlargement
At normal bottom hole temperatures of 60 to 80°C
(140 to 175°F), a salt saturated mud requires around
380 kg of salt/ m30f water (about 200,000 ppm chlo -
rides ) for saturation .This is difficult to achieve with
out additives or special treatment nreeded to maintain
such a high concentration with lower temperatures at
the surface. Actual salt concev~ ration of mud at sur-
face ranges between 320 and 340 kg/ m3(175, 000 to
185,000 ppm chlorides). W some leaching of the
salt formation takes place due to the mud being un -
dersaturatwi. In general washouts and ledges are
very common particularly in salt anhydrite sections
and near kauge holes are the exception rather than
the rule.
When the drill string becomes stuck across a salt
section, a common and effective technique used by
GUPCO is to spot low chlorides water around the bot-
tom hole assembly to free it. However f .equent use
of this technique aggravates hole enlargements: in
12:” holes, washouts may attain 18” to 24” ( 0.45 to
0.6 m) in diameter. Hole enlargement is evidenced
by variations in drag while tripping with the drill
string or running casing through these evaporite
sections.
Hole enlargement in the salt and the presence of
anhydrite ledges are important parameters to con-
sider while analyzing the following :
S P E 7749
- Mud displacement, preflush and slurry dis -
placement rates during cementing operation.
- Occasional key seating problems .
- Mud and cement requirements.
- Directional drilling considerations .
- Existence of concentrated forces on casing,
particularly in salt-anhydrite sections.
Even when formation fracture pressures or slurry
pumpabilities are not a problem , hole enlarge-
ment dictates the use of filling materials to increase
slurry yield because of the limited cement storage
capacities of most of the offshore rigs operating in
the GOS area. Prehydrated gel is added to cement
fcr cementing 9-5/ 8“ casing opposite the Zeit
and overlying formations .
Key Seating
Key seats usually form in deviated holes when
drilling sections of salt, shales and anhydrites. While
building angle, the effects of hole washouts, dog legs
hole curvature and drillability contrasts can com-
bine to cause severe key seats leading, if ,not de-
tected in time, to serious hole problems that would
eventually lead to plugging the hoie anti sidetrack-
ing.
To prevent formation of key seats while drill-
ing in and below the Miocene evaporates, a key
seat wiper is constantly kept in the drill string
until the 9 5/8” casing is set, Weight on bit va-
riations are monitored, particularly when drilling
with iimber 8“ bottom hole assemblies or pendu -
lum assemblies. Routine running of single shot
directional surveys helps to detect zones of dog
. legs in the hole which can lead to key seating.
Severe dog legs usually require plugging back and
redrilling instead of attempting lengthy key seat
wiping: this is justified by the relative ease with
which sidetracks can be accomplished in the salt
and the high rate of penetration achieved while
drilling salt.
Salt Water Flows
High pressure salt water ilow is a common
phenomenon in the Miocene evaporates. Extent of
eal flows experienced vary from a fraction of
dm i /s to 40 dm3/s (few l/h to 900 bbl/h). Mud
weights of 14 to 18 N/din !?(12 to 15.4 ppg)are
used to control flows in many of El Morgan wells ,
Mud weights up to 20.5 N/dm3(17. 5 ppg) have
been used in some wells and resulted in loss of
circulation when the fracture gradients of weaker
formations were exceeded4
These high pressure reservoirs are scattered
throughout the GOS area. Recent drilling by
ES!X2 confirms that salt water flows also exist in
the Miocene evaporit es of the Red Sea5. Flow be-
havior varies considerably from one location to
the next and it is improbable that continuous
communication exists between these reservoirs.
SPE 7749 F. KHALAF and H. EL SHENNAWY
Occasional, salt water-flows are encountered
in sands, fractured anhydrites, gypsum or lime -
stones. Also, these flows frequently occur along
the bedding planes between salt and “fractured “
anhydrites of South Gharib Salt section and Middle-
Miocene Formations. No significant correlation is
evident between salt water flows and fault zones
crossed by wells. All flows from Miocene evap -
orites are salt saturated at the bottom hole temp-
erature. The majority of encountered high pres -
sure salt water reservoirs deplete quickly when
allowed to flow:they are generally not associated
with large quantities of gas. If the flow does not
deplete, the well is killed and drilling continues
with the high mud weight. Setting of protective
9-5/8” casing is necessary before drilling under-
lying low pressure Miocene horizons or reaching
the fracture gradient at the 13 3/ 8“ shoe. The
use of formation water as a drilling fluid has been
discontinued after losing a well due to preci -
pitatidn of salt uphole where temperatures are
reduced and the same degree of salt saturation
cannot be maintained. Current policy consists of
controlling salt water flows through kill mud and/
or anticipated ruining of protective 9-5/ 8“casing.
Hole Instability
Major hole instability problenis are encount -
ered in Belayim Salts. and Lower Salts of the
South Gharib Formatior~. These salts have well
developed time-dependent plastic ( creeping-plas -
tic or viscoplastic ) behavior due to bottom hole
overburden stresses and temperatures. Due to
this specific behavior, tight hole i +quiring exten-
sive reaming and/or even stuck bottom hole as -
semblies are very frequent while these sections
are open. When the stuck pipe is believed to
result from sah movement toward the well bore,
a calculated amount of sea water is spotted oppo -
site the bottom hole assembly, left for a while
to saturate and dissolve the salt in this area.
After this, water is circulated out of the hole
without affecting the upper sections. Special a~-
ention is made to limit deterioration of mud pro-
perties,particularly when shale bodies are pres-
ent. Also, stuck pipe in the salt while making a
connection sometimes results from accumulation
of salt cuttings around the bit and stabilizers.
Adequate circulation prior to a connection, parti -
ctiarly in fast drilling salts , is effective in elimin -
sting this type of sticking problem.
Radial salt movement towards Lie center of
the borehole is not the only type of salt move -
ments . Microscopic examination of the crystalline
structure in some salt cores indicates that very
slow upward salt flow does exist in certain areas ,
pa.rticu,larly in the borders of large diapirs and
pillows2 . . Even though this type of sWt fiow is
too slow to affect drilling operations, it can with
time affect casing integrity leading to casing de-
formation and collapse. It is ~elieved that where
thin salt sections less than 100 feet exist between
13
anhydrite streaks very little creep is evident.
With regard to salt movement no direc; down
hole measurements are made by SUPCO, o] any
other company working in the area, to show salt
movements. However, lack of information defin -
ing the nature of salt creep does not hamper act-
ual drilling operations directly. Conversely, ccrn-
.plete information on salt movement is essential
for the proper design of casing to cover the salt.
The time lapse between drilling salt and sett -
ing and cementing protective casing has a direct
impact on the frequency of stuck pipe specially in
the massive salt sections of the South Gharib and
Belayim Formation . Hole condition deteriorates
when pipe is stuck several times. Setting a pro-
tective casing string is advisable to minimize
potential associated hole problems .
Salt movement behind casing could lead to
confusion with regard to the interpretation of ce -
ment bond logs which have been obtained sometime
after the protective string is set (for example ,
when logs are run for ?“ liner and protective 9-5/8
inch casirg after reaching Total Depth). Due to the
creeping-plastic nature of the deep-massive salt
sections, it has been observed that although practi
tally no cement exists behind pipe, the bond log
indicates excellent bonding.
Drillability of Evaporates
Drillability of rock salt in the Miocene evapo -
rites is independent of depth; however anhydrites
are more difficult to drill as depth increases, with
the hardest anhydrite stringers commonly being
those of the Belayim Formation. The variation in
drillability between salt and anhydrite does pre -
sent problems when pendulum or limber assem-
blies Are used. Usually, these evaporates are drill-
sd with a sealed bearing bit for soft or medium
hard formations .
While deep salts have a very distinctive visco
plaetic nature which would initially permit exces -
sive penetration rates , careful drilling with ade w
quate circulation and periodic reamiiig is used b
check probable salt creep.
Drilling curves for a development well in July
Field are represented in Fig. 2. I t illustrates drill-
ing progress, mud weights and casing points. Most
of the problems pertaining to the evaporates are
present in this well. Recently, a side track oper-
ation was success.%lly conducted in this well ; a
complete casing collapse was observed, one year
after completion and commencement of production ~
in the C-95 53.5 lb/ft casing opposite South
Gharib and Belayim Salts .
14 DRILLING OF GULF OF SUEZ EVAPORATES
EFFECTS OF EVAPOR~ES ON WELL PLANNING
Kick Off and Side Track Operations
Massive salt bodies are excellent points for
directional kick off and side track operations using
positive-displacernent down hole motors. Gener-
ally there is a sufficient salt thickness to build
angle without being’ hindered by relatively hard an-
hydrite stringers. For side tracking collapsed
wells, a casing window of 50 to 60’(15. 25 to 18. 3m)
is cut in 9-5/ 8“ casing near the top of South Gha -
rib Salt Form&.ti~n. Since salt I caching behind the
,window while sick mmking is very common, ce -
ment squeeze arowd window side track point to
anchor the casing is found to be effective in reduc -
ing problems associated with side tracking through
unsupported casing. Additional drilling with slick
bottom hole assemblies can avoid hanging of sta-
bilizers in the window *.bile tripping out of hole.
Similarly, where casing deformation is a proved
problem in an area and there is a chance that it
might occur while drilling the open hole below the
protective string, it is prudent to drill to total
depth without excessive stabilization. In certain
cases a compromise is made since stabilization is
required for holding angle and also to reduce the
risk of differential sticking in underlying, part-
ially depleted, Miocene porosities.
Effects on Casing Program
Adequate reaming of the lower evaporite
salts prior to running the 9 5/8’’casing is essen -
tial. Undergauge hole in the lower salt can result
in stressing the bottom of the casing under com-
pression causing it to bow out in washed zor,es
and induce high contact stresses against anhy-
drites. The hole conditions of the plastic salts
and washouts in the upper salts mask indications
based on drag values which might induce buck-
ling of casing while running in hole.
Casing design opposite salt formations assu~
mes that a collapse pressure gradient of about 230
KPa/ m(lpsi/ft)is acting orI empty pipe. Proper
cement placement in these sections is often diffi-
cult, particularly in deviated holes. Beneficial xne-
:hanical effects rf the cement around the casing
are therefore igno. ed. 9-5/ 87 S-95 53.5 lb/ft cas-
ing is now used across the entire &mth Gharib
For mation. However, during 1977 /78 several
casing deformations in this high grade casing were
ubserved while drilling or during workover opera-
tions. The majority of these deformations
occurred in the lower part of the Miocene eva-
porites, close to suspected fault traces6, 7.
Currently 9-5/ 8“casing strings are designed
using a rwvised design program7 which adds dog
leg considerations to the conventional design cri -
teria. Prior to well completion a 7“scab liner is
run zmd cemented inside the 9-5/ 8“prot ective
striilg to provide a double protective string
SP E;49
against the collapse opposite the salts. This pro-
c edure is effective and offers a solution without
major deviation from existing drilling and com-
pletion practices.
The anhydrite of the Miocene evaporates pro-
vides good casing seats. High leak off tests are
obtained when the shoe is well cement&d with neal
class “G” cement or cement plus silica flour.
Setting the casing shoe in the massive salt for the
purpose o a high leak off test was tried twice
elsewhere 6 . Results of the leak off test were
discouraging primarily due to the fact that the
cement se~l behind the shoe was defective; wash-
out of sfilt around casing shoe in this case rep-
rcaents a great risk .
EIfects on Cementing Program
P dehydrated gel added to dry cement was
initially used to cement both stages of the protec -
tive 9-5/8’’casing. Recently, prehydrated gel has
been replaced by silica flour to improve both phy -
sical and mechanical properties of the cement
against South Gharib and Balayim Salts. This is
particular used wh~n hole Temperatures opposite
salt approaches 110 C (230 OF); flowing well head
temperatures exceeding 105 C (221 F) are common
in deep wells of GUPCO Fields. Prehydrated gel
is still in use as extender in primary cementing
jobs opposite the Zeit Formation.
Multistage cementing was found to insure
better cement placement and minimum slurry con-
lamination, particularly in deviated holes. Two
stage cementing is widely used to improve cement-
ing quality below and against the evaporite section.
The two stage cementing collar is set 100m(about
300 feet)above the top of &mth Gharib Formation.
If a chance of losing cement in the underlying for-
mations exists, the stage collar is placed at the
base of South Gharib. Recently, a three stage
cement job was accomplished on a well with a
lengthy open hole section below the Miocene eva.
porites. The stage cementing collars were placed
below and above the &uth Gharib evaporates.
Putting a stage cementing collar below the evapo-
rites is believed to improve cement placement in
the overlying salt section.
Spring-bow centralizers are positioned on cas
ing, one per joint, througlmut the entire salt sec -
tion, particularly for $eviated wells with drift
angles in excess of 15 . One stop collar is used
per centralizer within the bow-spring. No scrat-
chers are installed in the Miocene evaporates.
A spacer of 250 to 300m(about 800 to 1000
feet) weighted to two pg(about 2. 4N/dm3) above
the drilling mud weig f t is used during cementing.
Viscosity of the spacer is adjusted “to insure plug
flow between the casing and open hole, it is diffi-
cult to achieve turbulent flow for both slurry and
spacer due to hole enlargement. Bottom~ and
3P plugs are used in single and multistage EGPC -Fifth Production Seminar, Cairo, Dec.,
ementing. 1978.

;ONCLUSIONS 7 Pattillo, P., and Rankin, T. E.: “casing

Design Through Salt i~ the Gulf of Suez”’, un-
A number of drilling and hole protection published report no. F 78-P 39, Oct. 3rd, 1978.
u’oblems pertaining to the Miocene evaporates of Amoco Production Company-Research Dept.
he Gulf of Suez area are present, which affect
)ell planning considerably. Most of the pro- APPENDIX
—.—
llems originate from the presence of deep vi sco -
~lastic salt sections associated with frequent bands Excerpts from a typical drilling program to
f hard anhydrites. Associated problems include drill through Gulf of Suez evaporates are given
asing deformation, tight holes and stuck pipe. here below:
:alt water flows are numerous; common abnormal
u’essure detection techniques are not effective in Geology
letecting abnormally high pressures.
Zeit Salt, Anhydrite, Shale
In exploratory drilling, the massive salt S. Gharib Salt, Anhydrite
iections limit the use of seismic data to predict Belayim Salt, Anhydrite, Marl, Shale
ithology of the underlying sediments. Hard rocks
.nd abnormal pressures at shallow depths, in con- Mud Program ( 12$’ hole ) .
junction with lost circulation and pressure rever-
uls below the evaporates sections results in low Low Solids salt saturated mud ( prehydrated gel,
.verage penetration rates and high cost per foot starch /polymer )
~alues. weight 12-12,4 N/dm3 (10. 2-10.5 Ppg )
viscosity 32-48 s/ dm3
In development drilling, casing deformation yield point 24-.48 pa (5-lo lb/100 ft2 )
gainst vi sco-plastic salts is a great challenge. water 10ss 20-30 CC
;areful well planning and operationa?. procedures
‘educe the chances of developing any of the Bit Program (12?” hole)
Associated problems.
Formation IADC WOB RPM
ACKNOWLEDGEMENTS
Zeit 1-2-4,1-3-4 40-60,000 120-150
The authors wish to thank the Management of S, Gharib 1-1-4,1-3-4 40-60,000 120-150
klf of Suez Petroleum Company and Amoco Inter- Belayim 1-3-1,2-1-4 60-70,000 80-120
national Company for permission to publish this
}aper. They also wish to express their gratitude Sealed bearing bits are used when available iOpti -
o colleagues in Gupco’s drilling and operation mum bit weights and RPM are determined by
Departments who assisted in the preparation, re- running drill off tests.
tision and typing of the paper.
Hydraulics
—. (12~” hole)
references
Pump pressure 2700 to 3000 psi
Said, R.: “The Geology of Egypt”, Elsvier Pub, Rate 580 to 550 gpm
lishing Co. (1962), pp. 183 and 303. Jet horse power 4.4-4.6 HP/sq inch
Nozzles 13-13-13 or 14-14-14
2 Buchanan, R,: G~f of Suez Petroleum Co. ,
Cairo Egypt, Personal Communication, Production Seminar, Cairo, May 1974.

3 Hagras, M. : “The Distribution and The Nature 5 Brown, P. :” “Deep Sea Drilling in the Red Sea
of the Miocene Sediments in the Gulf of Suez”, Area”, EGPC -Fifth Production Seminar, Cairo,
EGPC-Fifth Exploration Seminar, Cairo, 1976. .Dec. , 1978.

4 Agiza, M. N.: “High Pressure Salt Water Flo 6 Akl, Ii., and El Kholy, Y.: “collapsed casing
in Gulf of Suez Offshore Wells. ” EGPC-Third in El Morgan Oil Field-Gulf of Suez Area”,
 .

c ●

WEST EAST

ZEIT
\

JULT FKL

‘\
t

solm. \
)
---EXTENSION W 00S EVAPORATES

MIOC6NE wdpokms - ZE1T4 SOurn mMRi4 FoRMArloNs

FIG, 1 - SCHEMATIC CROSS SECTION IN SOUTH HALF OF GULF OF SUEZ SHOWING TYPICAL TYPES OF SALT DIAPERS &WELLS,

●
0mLLIR6 711C. am smct sw IR
40 50 so 70 80 90
-o~ T I Uuo *. VP8 [

b 11~—-l 1 1 1 I 1 r. 1
i

I ‘07’”W(O’’s’t’H0”:i
I
I I I 1 I I I
I
I
I
I
I
1
I
1
I
I
I
11
1 1

‘.

FIG, 2 - DRILLING CURVES AND PROBLEMS,