e h t g n i t r o p p u S a e S a n i h C h t u So Robert Schlemmer, Scomi Oiltools, GRTC, Malaysia, gives an overview of how to minimise fluid losses and reduce drilling costs in the South China Sea. D rilling in cold deep water or cold weather situations can cause a 3 - 4 fold increase in viscosity of conventional invert emulsion drilling fluids. Mud losses due to induced fracture are likely if that viscosity increase occurs when the mud weight window is narrow. Typical invert emulsion drilling fluids become viscous and do not flow easily at seabed temperatures; the resulting increase in resistance to flow due to frictional losses increases the apparent fluid column hydraulic pressure when circulating. Any increase in column hydraulic pressure can overcome the wellbore horizontal stress or fracture gradient, which then results in costly loss of drilling fluid, severe reservoir damage, and loss of wellbore integrity. OILFIELD TECHNOLOGY NOVEMBER 2008 35 www.oilfieldtechnology.com Table 1. Comparison of formulations ‘System R’ and ‘CONFI-DEEP’ Components System ‘R’ concentration lb/bbl CONFI-DEEP component CONFI-DEEP concentration lb/bbl Surfactants 7-8 cDEEP-MUL 7 - 11 Wetting agent 1-2 Lime 3-5 Lime Polymer 0.5 - 1 cDEEP-MOD Rhelogical modifier 0.3 -1 1st line organoclay 1-2 2nd line organoclay 0.4 - 0.7 Filtration control 2-4 Mud plant viscosity As needed Thinner As needed Total components System ‘R’ 10 basic components not needed 8 1-2 not needed cDEEP-TONE 0-2 mud plant and transport procedures, elimination of three components, and training of drilling and mud engineers. CONFI-DEEP techniques and components were carefully developed; their application was properly planned in detail; and the system was put to work with surprisingly few problems. The first application was a complete success. The cost CONFI-DEEP’s reduced contribution to ECD and subsequent potential whole mud losses directly reduces non-productive rig costs. The flat rheology Not needed fluid’s ability to increase clearance of cuttings allows dependable increased ROP and reduced drilling hours. CONFI-DEEP like other flat rheology drilling CONFI-DEEP only 4 basic components fluids provides higher drilling efficiency and can reduce formation damage due to whole mud losses to reservoir rock. CONFI-DEEP, unlike other flat rheology drilling fluids, improves rheological properties with fewer additives and much easier mud plant and transport handling. Overall performance is generally superior to that of systems introduced in the Gulf of Mexico. Environmental considerations Figure 1. Rheological properties of conventional and flat rheology drilling fluids. Data collected using Fann 75. The challenge A fluid is needed which will reduce the likelihood of circulating losses to induced fractures by providing improved flow properties at low temperature. This problem occurs when mud hydraulic pressure approaches the minimum horizontal rock stress (fracture gradient). The problem is difficult to control with conventional lost circulation material and may be addressed more fundamentally by introduction of unique additives which: l Maintain uniform maximum limit of rheological properties over a broad temperature range extending from near zero to bottom hole temperature approaching 250 ˚F. l Maximise hole cleaning and minimise sag by providing controlled minimum limit of rheological properties over that same range of temperatures. l Make a fluid system that is easy to mix and transport, and stable and robust. l Combine to form a very special fluid, which does not increase equivalent circulating density (ECD) under extreme deepwater drilling conditions. An engineered solution The simple robust CONFI-DEEP ‘flat rheology’ drilling fluid has exceeded expectations. CONFI-DEEP, a simple formulation applying only one unique proprietary polymer with off the shelf components, was refined over 18 months and is now confidently and routinely used in deep offshore waters of the South China Sea. An extended development period allowed invention of novel CONFI-DEEP is an extremely robust system, which is uniquely solids tolerant. The surfactant package and special polymer support actually improve rheological properties as drilled solids increase. CONFI-DEEP is immune to cement contamination. CONFI-DEEP remains stable with seawater intrusion. Disposal losses due to contaminants are minimal. Less dilution is required and the system can be reused across several wells. The relatively low rheological properties of a flat rheology fluid with circulation of bottoms up or when using a booster pump do not interfere with use of fine shaker screens. Mud is not lost over the shakers on bottoms up. It is not necessary to bypass shakers because of excessive fluid viscosity. API 270 mesh screens have been routinely installed when HyPR-BAR fine grind barite has been used. The solids tolerant CONFI-DEEP combined with HyPR-BAR fine grind barite can be well managed using primary solids control equipment, the shale shaker. Material balance measurements have shown that mass difference between fine grind barite and drilled solids allows a high speed centrifuge to more efficiently partition barite and drilled solids for additional separation. Oil on cuttings is efficiently removed and offshore compliance will not be compromised in many parts of the world. History of development Scomi Oiltools Global Research and Technology Center (GRTC) in Shah Alam, Malaysia, has engineered a unique non-aqueous drilling fluid. CONFI-DEEP flat rheology drilling fluid, unlike traditional invert emulsion systems, has relatively unchanging viscosity and controlled gelation characteristics when exposed to the full range of temperatures from coldest deep seabed to moderately hot reservoir. Work began on CONFI-DEEP in 2006 specifically to satisfy a customer’s request for such a fluid. A workable formulation was quickly achieved and was tested by the operator against design specifications in their Houston laboratory. The fluid was also tested on what has become the industry standard sag test flow loop using both API barite and HyPR-BAR fine grind barite variants. Basic fluid performance was as expected and sag performance as reported by the sag engineering lab was surprisingly good. 36 OILFIELD TECHNOLOGY www.oilfieldtechnology.com NOVEMBER 2008 Despite these positive initial results, testing and development continued. The delay in rig availability allowed the Scomi GRTC laboratory to investigate in detail: l Fluid performance and formulation requirements with both reduced and higher bottom hole temperature: All the original work had been performed assuming maximum sustained temperature of 190 ˚F. It was quickly understood that a 130 ˚F formulation required significantly less emulsifier to achieve desired ideal properties. A more economical formulation can be put to use before higher temperature reservoir rock is reached. This practice has been put to use in the field. The system was also tested for sustained stability at temperatures up to 250 ˚F. l Mud plant procedures: It was discovered in laboratory modelling of the extended low temperature aging (as would be experienced in a liquid mud plant, and during storage and transport) produced a much more stable fluid for later application in a well. This lower temperature lower shear mixing and simulated aging regime is now included in the CONFI-DEEP procedure manual and has resulted in more economical formulations. l Use of special mud plant viscosifiers: It was found that use of special fatty acid based emulsifier/viscosifiers typically used in competitive flat rheology systems and in conventional invert emulsion muds causes extended complications to CONFI-DEEP properties and presumably all similar flat rheology muds. As simple fatty acid emulsifiers degrade with temperature they begin to act as thinners and increase the required concentration of polymeric viscosifier cDEEP-MOD and cDEEP-TONE organophyllic clay. The use of fatty acid viscosifier materials is no longer recommended and the result is a longer lived more stable flat rheology fluid and extended economical and efficient performance of cDEEP-MOD and cDEEP-TONE. l Mix technique in absence of special viscosifiers: To substitute for the temporary viscosifier, a modest adjustment in the mud plant formulation was developed and applied on the first offshore job. It worked flawlessly. No additional materials were required; a yield point of 45 - 50 lb/100 ft2 was achieved. No barite sag was reported at the mud plant or on the boat during transport. l Use of system thinners: cDEEP-THIN, a proprietary thinner, was originally developed for the CONFI-DEEP system. This thinner is extremely potent, matching the performance of similar material used in competing systems. It was found again that use of such a chemical causes ongoing depression of correct properties of a flat rheology system which can be time consuming and expensive to compensate. It has been eliminated from Scomi’s procedure manual as a standard product. Thinners such as cDEEP-THIN can be recommended only in the very unlikely event that rheological properties get out of control due to mistaken and extreme additions of organophyllic clay. Loss of rheological control is very unlikely in the CONFI-DEEP system. The primary viscosifier of the CONFI-DEEP system is polymeric cDEEP-MOD. Depending upon synthetic or mineral oil used from 0 - 2 lb/bbl CONFI-TONE organophyllic clay is required. l Use of supplemental polymeric rheological modifiers: cDEEP-RM was originally proposed to supplement and partially replace a portion of cDEEP-MOD. This substitution results in incremental loss of rheological ‘flatness’ and is no longer recommended. Nor is cDEEP-RM needed to supplement rheological properties in a mud plant mix in the mix scheme applied for CONFI-DEEP. Figure 2. Detailed Pressure Analysis Performed using ‘HyPR-CALC’. l Summary of component elimination work: cDEEP-THIN and the mud plant viscosifier as well as a proposed secondary rheological modifier, cDEEP-RM, are not needed nor recommended if CONFI-DEEP’s very simple preparation and maintenance procedures are followed. In addition, because the cDEEP-MUL emulsifier is fully reacted and does not depend upon formation of calcium soap, lime was omitted from the early formulation. However, lime was soon discovered to play a primary role in temperature stability of the system as brine phase buffer and polymer solubility regulator. Lime, 8 lb/bbl, is now recommended for every formulation. Excess lime should be maintained at 4 lb/bbl or more. Rheological properties, details Traditional invert emulsion muds are viscosified using relatively large concentrations of oil dispersible clays and polymers to efficiently transport cuttings from the well at elevated temperature. A derivative of that viscosity is expressed as ‘yield point’. Invert emulsion muds which rely on dispersible organophyllic clay with a yield point of 20 - 25 lb/100 ft2, may exhibit very high plastic viscosity of 150 cP or more at deep seabed temperature of 39 ˚F (4 ˚C). CONFI-DEEP does not rely on cDEEP-TONE organophyllic clay as a primary viscosifier and gellant at higher temperature. A very small amount, if any, cDEEP-TONE is used as a low temperature viscosifier. The small quantity of cDEEP-TONE recommended has little or no impact on rheological properties above 80 ˚F. For higher temperature range of rheological control cDEEP-MOD, 2 lb/bbl, is most typically added to the CONFI-DEEP system. cDEEP-MOD has little or no effect on rheological properties below approximately 60 ˚F. This small combination addition of cDEEP-TONE organophyllic clay and cDEEP-MOD polymer provide balanced rheological properties as the temperature of the CONFI-DEEP system changes as it is circulated in the well, through the cold water riser, and the pits. This improved viscosity profile of CONFI-DEEP flat rheology drilling fluid supports efficient improved clearance of drilled cuttings from the deepening wellbore. Drilled cuttings detrimental contribution to the actual average density of the drilling fluid is thus reduced. It may seem paradoxical, but the yield point is more easily controlled at a relatively high value than the yield point of a conventional invert emulsion drilling fluid, yet the fluid frictional losses calculated or measured for the flat rheology fluid are typically significantly less. OILFIELD TECHNOLOGY NOVEMBER 2008 37 www.oilfieldtechnology.com The fundamental benefit of the balanced flat rheological profile of CONFI-DEEP is excellent hole cleaning across the full range of temperatures experienced in deepwater wells or in cold environments. Efficient cuttings removal can be achieved with the maximum plastic viscosity limited to approximately 50 cP or so, approximately one half to one third of what will be experienced with a conventional invert emulsion drilling fluid prepared from the same base fluid. Conventional invert emulsion muds must often sacrifice hole cleaning to reduce the ECD component caused by severe thickening of the mud due to cold temperature viscosity and gelation. Conventional invert emulsion muds are run with less viscosity. Unfortunately this can lead to cuttings accumulation in the fluid column and increased ECD due to actual density increase of the solids laden drilling fluid itself. Alternatively penetration rate must be slowed and controlled to prevent overloading the annulus with cuttings. Rheological properties, hole cleaning and rate of penetration The goal in every drilling interval is to manage flow rates and fluid characteristics so that the mass of cuttings removed by the shakers and other surface equipment matches the mass of the cuttings generated at the bit. However, accelerated penetration rates in every case lead to some degree of increase in concentration of cuttings load in the annulus (all other factors remaining constant). This increase in cuttings load absolutely causes an increase in mud density and ECD and can lead to mud losses to induced fractures if not controlled by ether adjustment of rate of penetration or rheological properties. Aggressive rates of penetration can lead to actual accumulation of cuttings at rheological transition regions or in washouts in the wellbore. During connections, the cuttings will fall collecting around the bottom hole assembly or drill string tool joints. At the very least, pressure spikes will result when circulation is restarted. Fractures can be initiated or extended by those pressure spikes. A worst case result of collection of cuttings, which are not uniformly removed, is packoff of the hole, stuck pipe, and total and often intractable induced losses. The very consistent rheological properties of CONFI-DEEP supports use of increased drill rate. The easily maintained yield point and 6 rpm values of the CONFI-DEEP system assure consistent and more reliable hole cleaning. A dependable non-progressive gel is sufficient to prevent settling of solids when the drilling fluid is static during connections. Dynamic rheological measurements are most critical while drilling but CONFI-DEEP gel strength must also be considered. CONFI-DEEP’s low clay content and high surfactant concentration guarantees low and non-progressive gel strengths. Gels are sufficient to maintain suspension of barite and cuttings when the mud is static but the pressure spikes on connections seen with conventional invert emulsion drilling fluids are essentially eliminated. development and performance comparisons with conventional invert emulsion muds. ECD predictions by hydraulics models constructed last year have been within 0.1 lb/gal. of PWD data later available. Hydraulics modelling first called attention to the potential for reduction in standpipe pressure. The reduction in use of organophyllic clay and low temperature rheological properties leads to a sometimes dramatic reduction in standpipe pressure resulting from CONFI-DEEP’s flat rheolgical properties. Studies have shown reductions of up to 600 psi depending on pump rate and ID of the tubulars. With reduced pressure drop in the drillstring more hydraulic horsepower is available to the mud motor and bit. The higher potential pump rate and fluid volume can also contribute to hole cleaning without a significant change in overall hydraulic pressure and ECD. These advantages are dependent on booster pump rate and resulting pump suction temperature. Dramatically improved flow properties thus reduce the ECD and subsequent losses to induced fractures in three ways: l Yield point is easily maintained contributing to efficient cuttings clearance. l Potentially increased pump output can also improve hole cleaning and reduce cuttings load. l A flat viscosity profile assures lowest possible frictional losses in the annulus and minimum hydraulic contribution to ECD. By reducing hydraulic contribution and cuttings load contribution to ECD, CONFI-DEEP delivers higher penetration rate (ROP); as much as 30 ft/hr higher than a conventional invert emulsion drilling mud prepared from the same synthetic base fluid. The drilling rate can be increased without necessarily increasing the ECD beyond designated limits. In the initial trial of a flat rheology system, the 17.5 in. section was reportedly drilled with penetration rates as high as 150 ft/hr with no mud losses. Conclusion CONFI-DEEP is a simple, more stable, and better designed system than competing flat rheology drilling fluids. The basic characteristics of the flat rheology drilling fluid and CONFI-DEEP significantly decrease the chance of losses due to fracture induction. CONFI-DEEP provides stable rheological properties; yield point, 6 rpm viscosity, and gel strengths that are nearly temperature independent. CONFI-DEEP improves hole cleaning with its high yield point without accompanying higher plastic viscosity and gels. CONFI-DEEP supports use of higher penetration rates than conventional invert emulsion muds. CONFI-DEEP reduces the chance of whole mud loss and formation damage to productive reservoir rock. CONFI-DEEP is an environmentally acceptable drilling fluid and can meet stringent US Gulf Coast environmental criteria. CONFI-DEEP is the superior member of the new generation of flat rheology drilling fluids. O T Rheological properties, hydraulics Scomi Oiltools performed detailed hydraulic modelling of the drilling fluids using Fann 75 data collected over the full range of temperatures and pressures expected in the South China Sea well. Both Presmod and Scomi Oiltools proprietary ‘HyPR-CALC’ modelling software were used for fluid design 38 OILFIELD TECHNOLOGY www.oilfieldtechnology.com NOVEMBER 2008
© Copyright 2024