5/21/2010

Global Research & Technology Centre/ GRTC Training Department

Drilling Fluids: Design & Selection

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Key elements of a successful Drilling Fluid Operation

HS&E Tender Drilling Fluid Design & Selection

Rig & Mud Plant Specs

Successful Drilling Fluid Process

Personnel

Drilling Fluid Design & Selection

Quality Control Solids Control

Technical Service

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There are only two reasons why we drill a hole in the ground:

To collect geological and reservoir data

To successfully exploit and produce oil & gas

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Primary operational goals

Deliver quality geological and reservoir data Minimise reservoir damage to optimise oil & gas recovery

Secondary operational goals

Achieve technical limit drilling performance

Note: The considerable reduction in operational costs as a consequence of technical limit drilling performance is valid only to the degree that the primary operational goals are successfully met! Appropriate drilling fluid design and selection is a prerequisite in order to fully meet both our primary and secondary goals
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Primary factors that impact drilling fluid design & selection

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Primary functions of a drilling fluid

Minimise fluid invasion into formations Maintain a stable in gauge well bore Minimise shale hydration & dispersion Efficiently transport cuttings to surface Minimise reservoir damage

Prevent the flow of oil and gas while drilling Lubricate the drill string Lubricate & cool the drill bit Transmit Hydraulic Horsepower (HHP) to the bit

Maximise Rate or Penetration (ROP)

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Drilling fluid design & selection considerations

Do you want to be first to try something new? Risk management Formation damage Lubrication Waste disposal options Local regulations Shale inhibition Completion design Who has the fluids contract? What has worked before? Who needs to be involved? Temperature and pressure
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Are mud losses expected?

Cost of Fluid

Mud weight

Company policy

Primary drilling fluid design and selection GOALS

To fully meet all regulatory and internal HSE guidelines and goals. To provide a stable wellbore to facilitate the successful running / retrieval of quality geological and reservoir data. To minimise reservoir damage and thereby optimise well productivity and profitability. To optimise drilling performance and thereby reduce overall drilling

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Framework for drilling fluid design, testing & selection

Test, evaluate and select drilling fluid systems that will fully meet all regulatory and internal HSE guidelines.

This is especially applicable to synthetic oil based muds.

Test & analyse the physical & electro-chemical characteristics of the clays, shales, mudstones and reservoir sequences to be drilled. Design & test for the best synergy between the clays, shales or mudstones with various water based mud system options in order to minimise hydration & control dispersion.

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Framework for drilling fluid design, testing & selection

Test various water based and / or synthetic oil based mud formulations for their tolerance to: Drill solids Barite weight up Applicable drilling fluid contaminants including cement Temperature stability at anticipated BHT On the basis of the test results evaluate, optimise and then select the appropriate water based or synthetic oil based mud system to meet your well specific drilling and reservoir challenges.

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Thoroughly review the following key elements

Environmental regulations & guidelines. Offset well data, ie well programs / well summaries and drilling fluid specific programs / summaries. Reservoir data: offset reverse permeability test data mercury injection data for reservoir pore throat size range prognosed in-situ shales or shale beds present in reservoir sands anticipated pore pressure gradient and temperature gradient in the reservoir

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Thoroughly review the following key elements

Logging plan, ie duration & prognosed maximum bottom hole temperature. Testing plan, ie special fluid and kill pill requirements. Development well - completion plan, ie perforated liner, expandable or fixed screens, sliding sleeve, etc. Well clean up and fluid design program to be based on completion design criteria.

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Thoroughly review the following key elements

Potential for the presence of acid gasses, CO2 & H2S. Prognosed fractured and / or faulted zones with the potential for lost circulation Maximum prognosed temperature for each hole section.

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Thoroughly review the following key elements

Deep water wells: Seabed depth Seabed temperature In-situ gas hydrates potential for formation of gas hydrates Drilling fluid lubricity: A key element in terms of potential torque & drag limitations when planning to drill a long reach step out well. Note: Lubricity is also a significant factor when drilling deviated wells through hard rock, eg granite.

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Thoroughly review the following key elements

Exploration well, ie wildcat or mature exploration area. Detailed lithology profile. Casing design options. Hole sizes / depths MD & TVD as applicable. Directional plan inclination & azimuth. Wellbore stress modeling data, ie in-situ vertical stress & minimum / maximum horizontal stress prediction.

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Thoroughly review the following key elements

Pore pressure prediction, ie mud weight range for each hole section. Data sources used to predict pore pressure gradient: Sonic / resistivity logs, seismic data analysis, micro hydraulic fracturing (MDT), drilling records and bore hole modeling. Offset well leak off & F.I.T. test data. Mud plant capacities / warehouse facilities, product availability and lead times. Rig specifications / limitations, ie tank capacities, solids control equipment and rig mixing / delivery systems.

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Risk management in drilling fluid design & selection

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Risk management in drilling fluid design & selection

Management of risk
Lower
O P TI M U M D RI LL IN G P E R F O R M A N C E

Overall well costs

Risk
Choice of drilling fluid systems: Synthetic oil based mud Enhanced KCL / Polymer / Glycol & Surfactants KCL / Polymer / Glycols Silicates Dispersed muds

Higher Higher
C R IT I C A L F A IL U R E LI N E

Lower

Poor shale inhibition Hole stability problems Stuck pipe Low ROPs Consequences of poor drilling practices

I N C R E A S E D H & S R I S K S

Exception: Dispersed muds are often the most economical low risk option for drilling shallow, young, weakly consolidated shales

Brine systems Fully dispersed fresh water / lignosulfonate / Lime / gyp muds Bentonite muds / spud muds SW / viscous sweeps

Failure to run & retrieve quality logging data Reservoir damage, etc

Higher

Inhibitive properties

Lower

Evaluate risk ie potential value of success vs the potential cost of failure

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Risk management in drilling fluid design & selection

Management of risk
C R I T I C A L F A I L U R E L I N E
160 140 120 100

Example lost time analysis for an offshore well

80 60 40 20 0

I N C R E A S E D H & S R I S K S

Hours

The cost of failure !

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Advantages & disadvantages of SBM & WBM

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Advantages & disadvantages of SBM & WBM

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Advantages & disadvantages of SBM & WBM

WBM
Environmental
Moderate environmental impact. Dependant upon type of WBM system.

SBM
Environmental
Moderate to significant environmental impact, however this impact can be managed, e.g. cuttings re-injection, ship to shore, etc.

Hole stability & hole gauge

Open hole stability sustainable for long periods of time. Close to gauge well bore.

Hole stability & hole gauge

Open hole stability very time dependent. From close to gauge to out of gauge well bore dependent upon appropriate water based mud system design & selection requirements.

Accretion / bit balling

Minimal to zero accretion / bit balling.

Accretion / bit balling

Severe to minimal accretion/ bit balling problems. Dependant upon appropriate water based mud system design & selection.

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Advantages & disadvantages of SBM & WBM

SBM
ROPs
Higher ROPs in most drilling environments.

WBM
ROPs
Lower Rops in most drilling environments.

Torque & drag

Lower torque & drag values.

Torque & drag

Higher torque & drag values.

Temperature stability
High thermal stability 450F +

Temperature stability
Lower thermal stability, ie above 280 F require special H.T. products for thermal stability to +/400 F. Potential problems maintaining stable mud properties at very high temperatures.

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Advantages & disadvantages of SBM & WBM

SBM
ROPs
Higher ROPs in most drilling environments.

WBM
ROPs
Lower Rops in most drilling environments.

Torque & drag

Lower torque & drag values.

Torque & drag

Higher torque & drag values.

Temperature stability
High thermal stability 450F +

Temperature stability
Lower thermal stability, ie above 280 F require special H.T. products for thermal stability to +/400 F. Potential problems maintaining stable mud properties at very high temperatures.

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Advantages & disadvantages of SBM & WBM

SBM
Lubricity
Lower coefficient of friction = good lubricity
0.45 0.4

WBM
Lubricity
Higher coefficient of friction = poor lubricity

Coefficient of Friction

0.35 0.3 0.25 0.2 0.15 0.1 0.05 0

SBM SBM

WBM with lubricant WBM + lubricant

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Metal to sandstone

Metal to shale

Advantages & disadvantages of SBM & WBM

SBM
Risk of unscheduled events
Low risk of costly unscheduled events, e.g. hole stability problems, stuck pipe, etc. Subject to good drilling practices due to close to gauge hole.

WBM
Risk of unscheduled events
Much higher risk of costly unscheduled events, e.g. hole stability problems, stuck pipe, etc.

Long reach step out wells

Extended long reach step out range (distance) due to the lower co-efficient of friction ie lubricity significantly reduces torque & drag values.

Long reach step out wells

Diminished long reach step out range (distance) due to the higher co-efficient of friction ie higher torque & drag values and potential hole stability problems related to time!

Stuck pipe
Generally easier to recover from mechanically stuck pipe and twist off type incidents, i.e lubricious, stable & close to gauge well bore conducive to more successful jarring/ fishing operations.

Stuck pipe
Generally more difficult to recover from mechanically stuck pipe and twist off type incidents, i.e less lubricious, hole stability time dependant and possibility of out of gauge well bore results in a more challenging jarring/ fishing environment.

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Advantages & disadvantages of SBM & WBM

SBM
Hole stability (time)
Extended time period before the onset of hole instability problems. Especially significant when unscheduled events are encountered, eg pipe twist off, rig shut down for cyclones, etc.

WBM
Hole stability (time)
Limited time period before onset of open hole stability problems. High risk of unscheduled events resulting in stuck pipe and probable requirement to side track.

Fluid loss
Low invasion rates ( fluid loss properties) moderate the rate at which the rock matrix weakens followed by hole stability problems.

Fluid loss
Higher invasion rates ( fluid loss properties) accelerates the rate at which the rock matrix weakens followed by hole stability problems.

Tools Corrosion & frictional wear

Minimal corrosion and frictional wear of tools & equipment due to a lower co-efficient of friction and the preferential oil wetting of steel surfaces.

Tools Corrosion & frictional wear

Increased corrosion rates and higher frictional wear on tools and equipment due to a higher co-efficient of friction and a water / seawater environment.

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Advantages & disadvantages of SBM & WBM

SBM
Fluid loss
Low invasion rates ( fluid loss properties) moderate the rate at which the rock matrix weakens followed by hole stability problems.

WBM
Fluid loss
Higher invasion rates ( fluid loss properties) accelerates the rate at which the rock matrix weakens followed by hole instability problems.

PPA spurt loss & total fluid loss SBM vs WBM

18 16 14 12 10 8 6 4 2 0
FL Value, dP 500psi @300F - cc

16.8

HtHp fluid loss graphs SBM

WBM

3.2 0.2 0.6

Bridging agent PSD optimised to minimise invasion at assumed 60 micron pore throat size
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Advantages & disadvantages of SBM & WBM

SBM
Fluid loss
Low invasion rates ( fluid loss properties) moderate the rate at which the rock matrix weakens followed by hole stability problems.

WBM
Fluid loss
Higher invasion rates ( fluid loss properties) accelerates the rate at which the rock matrix weakens followed by hole instability problems.

HtHp fluid loss SBM vs KCL / Glycol / polymer WBM

FL Value, dP 500psi @250F - cc

12 10 8 6 4 2 0

11.0

SBM

WBM

1.0
Mud weight 10 ppg - High-mod prima clay 35 ppb Hot rolled @ 250 deg F for 16 hrs

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Advantages & disadvantages of SBM & WBM

SBM
Inhibition & dispersion properties
Continuous oil phase is non-polar, ie does not react with clays, shales and mudstones.

WBM
Inhibition & dispersion properties
Continuous water phase does react with clays, shales and mudstones, resulting in significant hydration and dispersion. The degree of hydration and dispersion depends upon the type of WBM system selected.

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Shale in oil

Shale in fresh water

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Advantages & disadvantages of SBM & WBM

SBM
Logging
Petrophysical log evaluation more demanding. However gauge hole & minimal invasion / filter cake thickness requires less rigorous correction & correlation of log data, e.g. neutron density, gamma ray, resistivity, sonic, etc. New logging tools have been successfully developed to provide reasonable image log quality.

WBM
Logging
Enhanced petrophysical log evaluation. However, out of gauge hole & higher invasion / filter cake thickness requires careful and rigorous correction & correlation of log data, e.g. neutron density, gamma ray, resistivity, sonic, etc. * Hole gauge depends upon type of WBM system used. Excellent image log quality.

Mud weight
Generally lower mud weight overbalance required to maintain well bore pressure support over time. Minimal invasion = low pore pressure penetration.

Mud weight
Generally higher mud weight overbalance required to maintain well bore pressure support over time, ie higher invasion rates = higher pore pressure penetration. Invasion rates are dependant upon type of WBM system.

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Advantages & disadvantages of SBM & WBM

SBM
Gasses
High hydrocarbon gas solubility in oil at down hole pressures. Minimal reaction time due to rapid expansion of gas near surface. H2S soluble in oil but comes out of solution when mud alkalinity is depleted, ie excess lime content. Serious health & safety implications for rig personnel if H2S is not managed properly at surface.

WBM
Gasses
Hydrocarbon gasses insoluble. Acid gasses H2S & CO2 soluble in water, resulting in serious mud problems together with H2S health and safety implications for rig personnel.

1600 1400 G a sO il R a tio (s c f/s tb ) 1200 1000 800 600 400 200 0

Gas solubility in mineral oil, ester & olefin Olefin Mineral oil Ester

Bubble point, ie gas coming out of solution near the surface as the pressure diminishes
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2000

4000

6000 Pressure (psi)

8000

10000

12000

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Advantages & disadvantages of SBM & WBM

SBM
Identifying hydrocarbons
Some difficulty identifying hydrocarbon shows but can be managed with preparatory GC scan and analysis of synthetic oil properties.

WBM
Identifying hydrocarbons
Less difficulty identifying hydrocarbon shows but some WBM additives can interfere with hydrocarbon analysis.

Elastomers (rubber parts)

Low elastomer resistance to solvents in SBM. Requirement for rigorous testing of selected base oil at maximum prognosed BHT.

Elastomers (rubber parts)

Higher elastomer resistance to most WBM additives.

Temperature conductivity
Temperature conductivity high. Significant mud temperature increases when drilling and circulating mud at high pump rates for long periods of time.
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Temperature conductivity
Temperature conductivity lower. Not as significant when drilling and circulating at high pump rates for long periods of time.

Advantages & disadvantages of SBM & WBM

SBM
Drill solids tolerance
High tolerance to drill solids. SBM drill solids contamination test
60 50 40 30 20 10 0 60 50 40

WBM
Drill solids tolerance
Low tolerance to drill tolerance. WBM drill solids contamination test YP

YP PV YP PV

30 20 10 0

YP PV PV

Base mud SCOMI OILTOOLS

+ 45 ppb Drill Solids

Base mud

+ 45 ppb Drill Solids

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Advantages & disadvantages of SBM & WBM

SBM
Sensitivity to common drilling fluid contaminants
SBM impervious to most common contaminants. Exceptions: - Ester oil / cement contamination will cause the ester to hydrolise ie waxing out - Substantial / rapid influx of water can lead to severe water wetting of drill solids and barite as a result of severe emulsion instability.

WBM
Sensitivity to common drilling fluid contaminants
High, but dependant upon type of WBM selected. Examples:
Reaction to clays, shales and mudstones - Potential for clays, shales and mudstones to hydrate and disperse Calcium contamination (eg cement, anhydrite) - Retards performance of most polymers - Flocculates Bentonite based systems Carbonate/bicarbonate contamination - Flocculates Bentonite based systems

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Advantages & disadvantages of SBM & WBM

SBM

versus

WBM
Potentially good drilling performance. Hole stability time dependant & dependant upon appropriate mud system design

Optimum drilling performance

?
Lower overall risks and well costs in challenging drilling environments

Higher overall risks and well costs in challenging drilling environments

Moderate to significant environmental impact. Various options available to manage environmental impact, eg dependant upon type of base oil and physical environment, ie seawater temperature, seawater current activity, depth of deposition, etc
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Moderate environmental impact dependant upon type of WBM system used

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