Design, Qualification and Field Deployment of Low ECD Organoclay-Free Invert Emulsion Drilling Fluids
Design, Qualification and Field Deployment of Low ECD Organoclay-Free Invert Emulsion Drilling Fluids
Design, Qualification and Field Deployment of Low ECD Organoclay-Free Invert Emulsion Drilling Fluids
Vikrant Wagle, Abdullah Yami, and Michael Onoriode, Saudi Aramco; Jacques Butcher, Halliburton
This paper was prepared for presentation at the SPE Russian Petroleum Technology Conference originally scheduled to be held in Moscow, Russia, 12-14 October
2020. Due to COVID-19 the physical event was postponed until 26 – 29 October 2020 and was changed to a virtual event. The official proceedings were published
online on 26 October 2020.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
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Abstract
High pressure and high temperature (HPHT) wells especially those with narrow pore / fracture pressure
gradient margins present challenges in drilling. Maintaining optimum and low rheology for such wells
becomes a challenge where a slight change in the bottom-hole pressure conditions can lead to non-
productive time. However maintaining low viscosity profile for a drilling fluid can pose a dual challenge in
terms of maintaining effective hole-cleaning and barite-sag resistance.
This paper describes the formulation of 95pcf medium-density organoclay-free invert emulsion drilling
fluids (OCIEF). These fluids were formulated with acid-soluble manganese tetroxide as weighting agent
and specially designed bridging-agent package. The fluids were hot rolled at 300°F and their filtration and
rheological properties were measured. The paper describes the static-aging, contamination, HTHP rheology
measurements and filter-cake breaking studies of the fluids at 300°F. Particle plugging experiments were
performed on both the fluids in order to determine the invasion characteristics and the non-damaging nature
of the fluids. These organoclay-free invert emulsion fluids were then field-trialed in different wells with
good results.
The OCIEFs showed optimum rheology and filtration properties. The fluids gave lower PV, which
ensured that the fluid presents low ECD contribution while drilling/circulating. Sag factor analysis for
the fluids after static aging for 24 and 48hours showed excellent stability and minimal sag propensity.
HTHP rheology showed that the fluids had consistent PV and YP values across a range of temperatures and
pressures. Contamination studies showed that the effect of contaminants on the organoclay-free fluid was
minimal and any change in properties can be easily controlled using conventional treatments. The paper
thus demonstrates the superior performance of the developed fluid in achieving the desired lab and field
performance.
Field deployment of the 95pcf organoclay-free invert emulsion fluid helped to maintain the required
hole stability in the HTHP well. The well was displaced to 95pcf production screen test (PST) fluid and
completed with a 4 ½" sand screen.
2 SPE-201847-MS
Introduction
High pressure, high temperature (HPHT) wells which operate on a narrow window between pore-pressure
and fracture gradient usually need effective management of equivalent circulating density (ECD). A drilling
fluid required for effective ECD management needs to have lower viscosity (Taugbol, 2005). However
maintaining low viscosity profile for a drilling fluid can pose a dual challenge in terms of maintaining
effective hole-cleaning and barite-sag resistance.
Invert emulsion drilling fluids are generally preferred over their water-based counterparts for drilling
HPHT wells. Although the water-based drilling fluids are cheaper as compared to the invert-emulsion
fluids, advantages such as well-bore stability, higher thermal stability and lower friction coefficients make
the invert emulsion drilling fluids more cost-effective. (Bland, 2006). However, the main drawback of the
conventional organoclay-based invert emulsion drilling fluids is their tendency for barite sag. (Herzhaft,
2003 and Saasen, 2002). This increased tendency to sag has been attributed to the limited gel network
between the organophilic clays and the invert emulsion internal phase (Herzhaft, 2003). Thus, the use of
organoclay-based invert emulsion drilling fluids having the right rheology profile to give long-term stability
as well as better ECD management in HTHP wells has been difficult. Thus, a two-pronged approach has
been used to develop a drilling fluid that not only has the right rheology profile for better ECD management
but also shows good thermal stability.
The first approach was to formulate an organoclay-free invert emulsion drilling fluid by replacing the
organophilic clay and organophilic lignite with a polymeric viscosifier and filtration control agent. The
removal of these low gravity solids with the polymeric additives would help to reduce and optimize the
overall rheology of the fluid. This reduced rheology would in turn also reduce the strong surge and swab
effects which would help in better ECD management. The use of polymeric additives in the organoclay-
free invert emulsion fluids would help to form a gel-structure required to achieve the necessary viscosity
control. This viscosity control would help to increase the sag-resistance and the cuttings-carrying capacity
of the fluid (Carbajal, 2009). As the organoclay-free invert emulsion fluids have low solid content, these
fluids provide a higher rate of penetration as compared to the conventional organoclay-based fluid systems.
Another advantage of the organoclay-free invert emulsion drilling fluids is the fragile gel structure that they
provide (Burrows, 2004). In static conditions, the organoclay-free fluid forms a gel structure rapidly, that
breaks instantaneously on applying low shear or after resuming circulation. Such a behavior not only results
in lower equivalent circulating densities but also would reduce downhole mud losses as compared to the
organoclay-based invert emulsion drilling fluids.
The second approach was to formulate the organoclay-free invert emulsion fluids with acid-soluble
micronized weighting agent viz. manganese tetraoxide. Formulations with micronized weighting agents
have been known to give fluids with enhanced sag resistance and better ECD control (Nicora, 2001 and
Maroni 2008). The settling rate of micronized particles in a viscous medium is much lower as the sag-
resistance of such smaller particles is higher. Also, manganese tetroxide has a higher specific gravity of
4.8 as compared to the conventional weighting agent viz. barite (SG 4.2). The use of manganese tetroxide
would help to decrease the solids loading as compared to a conventional organoclay-free invert emulsion
fluid formulated with barite as the weighting agent. This decreased solids loading would results in a lower
plastic viscosity and improved rheology profile, which subsequently would result in a lower equivalent
circulating density (Wagle, 2015).
The present paper describes the results of the formulation of an acid-soluble, low ECD organoclay-
free invert emulsion drilling fluid formulated with acid-soluble manganese tetroxide and a specially
designed bridging package. The fluid developed for field deployment has been designed to offer stable
filtration properties and optimum particle size distribution (PSD) for drilling thereby maximizing well
productivity. The non-damaging novel fluid has superior rheology resulting in lower ECD, excellent
SPE-201847-MS 3
suspension properties for effective hole cleaning and barite-sag resistance while also reducing the risk of
stuck pipe and pack off.
The weight material selected for the OCIEF fluids was a manganese tetraoxide due to the inherent high
density (4.8SG) and non-damaging nature. Previous work (Wagle, 2015) has indicated the acid solubility
of the manganese tetraoxide. The micronized, spherical nature of the manganese tetraoxide is believed to
be support ease of flow back through permeable formation when wells are produced.
The OCIEF fluids were formulated with 70/30 oil water ratio (OWR). Shale inhibition would be achieved
with a calcium chloride brine internal phase and the water phase salinity (WPS) matched to offset field
experience of 180,000ppm - 230,000ppm.
• Registered and available additives with diesel base fluid. Utilizing same additives as OCIEF fluid
for compatibility.
• Ease of mixing and application.
• Non-impairment characteristics to flow through and flow back, through the pore sizes of the lower
completion tool.
4 SPE-201847-MS
The 95pcf OCIEF fluid formulations based on differences in bridging package for laterals of varying
length. From an initial design perspective it was considered paramount to have two formulations developed
so that the final fluid selected for field deployment would offer stable filtration properties and particle size
distribution (PSD) for drilling and offering maximum well productivity.
The use of one emulsifier proved adequate for developing stable emulsification of the external phase and
providing sufficient wetting of weight material additions as well as associated solids.
The 95pcf OCIEF Fluids were formulated with one polymeric filtration control additive. The selection of
a single polymeric filtration control additive was based on proven high sealing efficiency at high overbalance
conditions and lower impact on high end rheology values.
Two suspension agents were included in the 95pcf fluid formulations, with Rheology Modifier 2
supporting higher initial gel structure.
95pcf OCIEF #1 was developed with a bridging package of various sized ground marbles specifically
for short laterals and applications with lower differential pressures. The sized ground marble has higher
hardness and tighter modality values than commodity calcium carbonate grades.
The acid solubility of the bridging package was considered to be an additional benefit of the OCIEF #1
fluid formulation.
An alternative OCIEF #2 fluid formulation (Table 1) was developed with sized ground marble, sized
resilient graphite and fiber for longer laterals where increased mechanical attrition (Kumar et al. 2010) of
bridging solids would be expected.
A bridging package with improved PSD stability for longer slim hole lateral sections would provide
greater assurance for mitigating the risk of differential sticking in higher over balance applications and when
drilling formations with wide permeability ranges.
The sized resilient graphitic materials are not acid soluble, but the sizing relative to test media (and
expected formation permeability) and low concentration on a volume by volume basis was considered to
present negligible damage potential. The sized resilient graphitic materials would form an integral part of
SPE-201847-MS 5
the external filter cake. The inclusion of a fiber in the bridging package was considered advantageous due
to the high aspect ratio of fibers in developing a filter cake relative to the graphites and ground marble.
The 95pcf PST fluid was developed for ease of mixing and handling in the field with a focus on achieving
flow through properties, target density, proven emulsion stability and adequate suspension of micronized
weight material. The 95pcf PST fluid formulation detailed in Table 1 includes a low concentration of
rheology modifiers to provide suspension of micronized weight material. A low rheological profile was
desireable to minimize fluid friction losses during production screen testing (PST) and flow back during
production.
Note that the polymeric fluid loss control additive was not added to the 95pcf PST fluid formulation. The
potential risk and mitigation of experiencing lost circulation from damaged filter cakes during the trip out of
hole with the clean out assembly were not considered at the time that the 95pcf PST fluid was formulated.
• OCIEF fluids were mixed in batches of 4 lab barrels on the Silverson mixer.
• The OCIEF additives (exclusive of the bridging materials) were mixed for a total of 60 minutes at
6,000rpm in order of addition detailed in Table 1.
• A water bath was used as a heat sink to ensure the temperature of the 2 liter stainless steel mixing
cup did not exceed 150°F during the fluids mixing.
• The OCIEF fluids were decanted into ageing cells and a 150psi nitrogen header pressure was
applied to the cells prior to loading into the pre heated hot roll ovens
• The OCIEF fluids were hot rolled in the roller ovens for 16 hours at 300°F.
• After the dynamic ageing period had elapsed, the ovens were switched off and the cells were
removed. The ageing cells were allowed to cool to ambient temperature for 60 minutes in a water
bath.
• The ageing cells were depressurized and the contents of the ageing cells decanted into the mixing
cup.
• The hot rolled OCIEF fluids were mixed on the Silverson mixer at 11,500rpm for 5 minutes.
• The bridging materials were added to the hot rolled OCIEF fluids and mixed on the Silverson
Mixer for 8 minutes at 6,000rpm.
• The PST fluids were mixed in batches of 4 lab barrels on the Silverson mixer. A total of 5 liters
of fluid required for the PST test.
• The PST additives were mixed for a total of 60 minutes at 6,500rpm. The additives were mixed
according to the sequence indicated in Table 2.
• The PST fluid was mixed for a further 60 minutes on the Silverson mixer at 6,500rpm to simulate
extended shearing time expected during deployment
• A water bath was used as a heat sink to ensure the temperature of the 2 liter stainless steel mixing
cup did not exceed 150°F during the fluids mixing.
6 SPE-201847-MS
Temperature F 300 °F
Test Results BHR AHR ASA 24hrs ASA 48hrs 10% Water 35ppb
Contamination Synthetic
Drill Solids
contamination
θ300 41 47 49 46 67 71
θ200 32 36 38 35 52 55
θ100 22 23 25 23 35 37
θ6 8 7 8 7 11 13
θ3 7 6 7 6 10 11
Total [2V30], mL ml 3
Spurt [4V7.5-2V30] ml 1
Sag Testing
Free Oil, ml 0 0
Temperature F 300 °F
Test Results BHR AHR ASA 24hrs ASA 48hrs 10% Water 35ppb
Contamination Synthetic
Drill Solids
contamination
Clashach synthetic core material was used for the regain permeability study as formation core
was not available. Clashach sandstone had comparable minerology, porosity and permeability to
the formation in which the organoclay-free fluid was going to be used. Clashach was considered to
be a suitable standard based on XRD and thin section analysis which indicated fewer constituent
minerals and smaller clay fraction The bulk rock XRD analysis of Clashach core material indicated
that quartz was the dominant mineral (95.4%) with potassium feldspar (3.4%) and illite/mica
(1.2%) also detected.
The core samples were subject to submerged solvent cleaning techniques to prevent damage to
clay minerals. Solvents were replaced until all residues or brine, filtrate and oil were removed from
the core samples. Core samples were dried in a low temperature oven to prevent collapse of any
delicate clay minerals. Rock flour was removed from the end faces (where appropriate) by acid
peel technique. On completion of the cleaning phase, the base parameters were measured.
The core samples were 100% saturated in simulated formation brine (11.8% CaCl2, pH 8.5) in
a pressure saturator.
ii. 95pcf OCIEF Application and Drawdown
▪A base permeability measurement with (synthetic) formation brine was taken in the formation
to wellbore direction at low flow rate and with 400psi confining pressure.
▪ The core samples were then prepared to irreducible brine saturation using an ultracentrifuge
(this process generated the appropriate capillary pressure to force CO2 to replace formation
brine by drainage).
▪ Once the core samples had achieved irreducible brine saturation, the cores were loaded into
the HTHP core holders and effective pressure was gradually increased to 11,420psi (effective
wellbore pressure).
▪ At expected reservoir conditions (300°F) the base effective permeability measurement at
5,300psi pore pressure and 16,270psi overburden pressure was performed in the formation
to wellbore direction with CO2 @ 5ml/min.
▪ Under the described reservoir conditions, the OCIEF fluids were applied dynamically across
the wellbore face of the core samples at 4,500psi overbalance pressure and 3.33ml/minute
for a 24 hour period. Cumulative filtrate volume measurements were recorded versus time
over the dynamic OCIEF application period.
▪ Following the OCIEF application, the drawdown to (simulated) production phase CO2 was
performed by flowing the gas through the sample in the direction of formation to wellbore
at 5ml/minute while recording the differential pressure measurements. Drawdown continued
until stable flow conditions were achieved. On completion of the drawdown phase, an
effective permeability measurement to CO2 at residual saturation was made in the formation
to wellbore direction.
▪ The core samples were removed from the core holders and visually inspected, prior to
removing OCIEF mud and filter cake remnants.
▪ The cleaned cores were then reloaded into the test equipment and recalibrated to reservoir
conditions. An effective permeability to CO2 was established in the formation to wellbore
direction.
▪ The core samples were again unloaded from the core holder and spun down with an ultra
centrifuge.
▪ The cores were then re-equilibrated to reservoir pressure conditions and an effective
permeability to CO2 at residual saturation was measured in the direction of formation to
wellbore.
E. Micro-CT scan of synthetic core material
SPE-201847-MS 9
Micro-CT scanning of the Clashach core samples before and after completing the coreflood
procedure. The 2-D and 3-D analysis of sub sampled regions of the core (post coreflood) provided
unique depiction of the filtrate invasion and spatial distribution during the coreflood procedure.
The PST fluids were tested according to RP API-13 B2 and Company PST test procedures. Select
properties were evaluated as follows:
A. Density, rheology, gel strengths were determined on fresh mixed fluid (BHR)
B. PST testing was performed on 5 × 1 liter samples of fresh mixed PST fluid. The PST tests were
performed against 250µ screens with 10psi header pressure.
C. A PST test was performed on a solids contaminated 94pcf PST fluid (1pcf lower than target density
of 95pcf recorded). The resulting density of 98pcf was measured after 5ppb Ground Marble 25µ
and 45ppb Ground Marble 50µ was added to the 94pcf PST fluid and mixed for 10 minutes on the
Silverson Mixer at 6,500rpm.
The PST test on the solids contaminated sample was also performed on 5 × 1 liter sample against a 250µ
screen with a 10 psi header pressure
Note that no ageing tests were considered as the PST fluids would be mixed on surface and spotted in open
hole. The PST fluids had inferred stability as the PST fluid was developed from qualified OCIEF fluids.
Temperature F 300 °F
Test Results BHR AHR ASA 24hrs ASA 48hrs 10% Water 35ppb
Contamination Synthetic
Drill Solids
contamination
θ600 66 74 76 76 106 -
θ300 41 45 47 46 66 -
θ200 32 33 36 65 51 -
θ100 22 22 25 23 34 -
θ6 8 8 8 8 11 -
θ3 7 7 7 77 10 -
Temperature F 300 °F
Test Results BHR AHR ASA 24hrs ASA 48hrs 10% Water 35ppb
Contamination Synthetic
Drill Solids
contamination
Spurt [4V7.5-2V30] ml 0
Sag Testing
Free Oil, ml 0 0
Filtration characteristics of both 95pcf OCIEF fluids are extremely tight as evidenced by
low spurt and total filtrate recorded during the Particle Plugging Apparatus (PPA) Testing. The
efficiency of the polymeric filtration control additive in combination with sized bridging materials
were confirmed with successful tests on 10μ and 40μ aloxite discs with differential pressures of
3,000psi – 4,500psi.
The validation of the sealing performance against two different permeable media was based
on potentially intersecting formations that exhibit heterogeneity in lithology or potentially wide
or uncertain porosity and permeability ranges. Drilling formations with uncertainties at high
overbalance presents risk of differential sticking events.
iii. Emulsion stability
Emulsion stability of the 95pcf OCIEF fluids is evidenced by the all oil filtrate observed in the
HTHP Fluid loss test performed at 300°F. The lack of free fluid and sag factor results can (in part)
be attributed to the emulsion stability of the formulations.
The emulsion stability is further validated by the fact that there is sufficient free emulsifier in
the 95pcf OCIEF #1 that the 10% water contamination test also presented no breakout (water) in
the HTHP filtrate.
iv. Fluid Stability: Static Ageing
Sag testing was performed on the 24 hour and 48 hour static aged 95pcf OCIEF fluids. Sag
factors of 0.51 with no free fluid were observed after 48 hours. The 48 hour fluids did not exhibit
thermal gelation tendencies when samples were drawn for the sag tests.
The stability of the 95pcf OCIEF fluids can be attributed to the selection of the emulsifier and
rheology modifiers and low settling propensity of micronized weight material (Stoke’s Law).
The negligible difference in sag factors observed between the test periods suggests low
probability of sag occurrence during an extended static period under similar ageing conditions.
B. Contamination Testing:
i. 10% Fresh Water Contamination
The 95pcf OCIEF fluids were contaminated with 10% fresh water, which resulted in increased
rheology and gel strength values recorded. The higher rheology and gel strengths can be attributed
to the larger internal phase and expected reduction in relative solids wetting.
The 95pcf OCIEF fluids exhibit adequate resilience to the 10% water contamination with a
tolerable increase in rheology whilst maintaining tight filtration control of 2.4ml (HTHP @ 300°F
on filter paper). No free water was observed in this testing. A reduction in electrical stability was
observed in the case of both 95pcf OCIEF fluids contaminated with 10% water addition.
10% water contamination could be effectively treated with additions of Emulsifier 1.
ii. 35ppb Synthetic Drill Solids Contamination
The 95pcf OCIEF #2 fluid was contaminated with 35ppb synthetic drill solids to simulate
contamination by reactive clays. The rheology and gel strengths of the contaminated 95pcf OCIEF
fluids increased primarily due to the reactive nature of the sodium montmorillonite as compared
to the volume addition of the solids.
The electrical stability values increased due to the higher solids content and fluid viscosity
(Growcock, et al. 1994). Increased HTHP filtration properties were also observed in the solids
contaminated fluid and can be attributed to the higher rheology and filter cake building nature of
the additional colloidal size clay particles.
Note that the 35ppb synthetic drill solids contamination would be considered an extreme solids
contamination test. The disproportionately high contamination level with reactive clays would not
be expected in a sandstone reservoir drilled horizontally with a slim hole drilling assembly.
12 SPE-201847-MS
The elevated rheology and gel strengths could be trimmed to within specification with a higher
OWR pre-mix volume inclusive of increased concentrations of Emulsifier 1.
C. HTHP Rheology
The HTHP Rheology of the 95pcf OCIEF fluids were evaluated on the Fann 75 HTHP Rheometer.
Both OCIEF fluids were subject to the same HTHP Rheology test protocol.
Test temperatures and pressures were determined for 95pcf OCIEF #1 and OCIEF #2 based on
points of interest in the well architecture and test results are detailed in Table 4 and Table 5 respectively.
The HTHP rheology values are consistent between 95pcf OCIEF #1 and OCIEF #2 and validate
that there is negligible change in rheology and no fluid thickening is observed when fluids are subject
to varying temperatures and pressure regimes. Both test fluids exhibit satisfactory dynamic suspension
characteristics across the range of defined HTHP conditions defined in the tests. The HTHP Rheology
values indicate that the OCIEF Fluid formulations have low inherent ECD potential for expected
application
Note that the elevated HTHP rheology values observed in 95pcf OCIEF #2 at 1,954psi and 3,457psi
test points can not be explained. Considering that all other test data collected during the HTHP
Rheology test on OCIEF #2 is comparable to equivalent test points recorded with OCIEF #1, the
HTHP Rheology values recorded at 1,954psi and 3,457psi is considered to be an artifact of testing.
D. Regain Permeability Testing of 95pcf OCIEF Fluids
The test results for the OCIEF application and drawdown are detailed below and summarized in
Table 6 and Figures 1 and 2.
• After the base parameters were established the core materials were saturated in brine. The cores
were loaded in the core holder and 400psi confining pressure applied.
• Base permeability was established to formation brine in the formation to wellbore direction at low
flow rate: Core V3/95pcf OCIEF #1 Kw = 98.6mD and Core V14/95pcf OCIEF #2 Kw = 131mD.
• Irreducible formation brine saturation was attained using an ultracentrifuge
• The cores were loaded in the core holder and equilibrated to reservoir conditions and base effective
measurement to CO2 at irreducible formation brine saturation was undertaken in the formation to
wellbore direction: Core V3/95pcf OCIEF #1 Kg@Swi = 91.6mD and Core V14/95pcf OCIEF #2
Kg@Swi = 129mD.
• OCIEF fluids were dynamically applied across the wellbore face of the core sample at overbalance
pressure for 24 hours. Cumulative filtrate volume loss: Core V3/95pcf OCIEF #1 = 1.383ml and Core
V14/95pcf OCIEF #2 = 1.648ml.
• The core samples underwent drawdown to CO2 in the formation to wellbore direction at
constant flow rate and initial/final pressures were recorded as follows: Core V3/95pcf OCIEF #1 =
89.4psi/1.53psi and Core V14/95pcf OCIEF #2 = 70.4psi/0.79psi.
• An intermediate, effective permeability to CO2 was then undertaken in the formation to wellbore
direction at residual saturation post drawdown was recorded as follows: Core V3/95pcf OCIEF #1
Kg@Sr = 36.5mD and Core V14/95pcf OCIEF #2 Kg@Sr = 70.4mD.
• After cleaning the cores of mud/filter cake, the core samples were reloaded and re-equilibrated
to reservoir conditions. An intermediate effective permeability to CO2 at residual saturation minus
fluid/cake was undertaken in the formation to wellbore direction. Core V3/95pcf OCIEF #1 Kg@Sr
= 37mD and Core V14/95pcf OCIEF #2 Kg@Sr = 83mD.
• The core materials were removed from the core holders and spun down in an ultracentrifuge and
total filtrate volumes spun out of the core materials were recorded as follows: Core V3/95pcf OCIEF
#1 = 0.65ml and Core V14/95pcf OCIEF #2 = 0.4ml.
• The core samples were again reloaded into the core holders and re-equilibrated to reservoir
conditions. A final effective permeability measurement to CO2 was undertaken in the formation to
SPE-201847-MS 13
wellbore direction at residual saturation after spin down as follows: Core V3/95pcf OCIEF #1 Kg@Sr
= 88.7mD and Core V14/95pcf OCIEF #2 Kg@Sr = 126mD.
The low filtrate values recorded at high overbalance test conditions validates the efficiency of the
bridging materials and filter cake building additives within the 95pcf OCIEF fluids.
The spin down procedure with the ultracentifuge gives is more representative of radial, long term
production after the back production has swept all the filtrate from the near wellbore area. In both tests
there was an almost complete regain in permeability for the 95pcf OCIEF #1 and #2 fluids. The only
slightly damaging mechanism that caused a a reduction in permeability were any retained filtrate/fluid
additives blocking some pore spaces in the wellbore face end of the core samples.
The 95pcf OCIEF #2 fluid does have marginally better final regain permeability (and higher regain
permeability after drawdown and after cake removal) than the 95pcf OCIEF #1.
E. Micro-CT Scanning
Micro-CT can analysis was performed on Clashach core (V3) before the coreflood experiment as
indicated in Figure 3.
The (black) low x-ray density features represent open pore spaces throughout the subsampled body
of the core sample. The (light) high x-ray intensity features represent high density grains or patches
of cementation.
Temperature (°F) 150 150 150 150 267 267 311 311 331 331
Pressure (psi): 0 0 1,954 3,457 5,059 7,272 6,628 8,469 7,617 9,733
Rheology @ 150°F
θ600 74 74 88 98 53 61 49 54 48 55
θ300 45 46 51 57 34 38 32 36 31 34
θ200 33 36 40 42 27 30 25 28 25 28
θ100 22 25 28 28 19 20 18 20 19 21
θ6 8 9 10 9 7 7 7 7 8 7
θ3 7 7 7 7 5 5 5 5 6 5
Temperature (°F) 150 150 150 150 267 267 311 311 331 331
Pressure (psi): 0 0 1,954 3,457 5,059 7,272 6,628 8,469 7,617 9,733
Rheology @ 150°F
θ300 47 50 61 68 36 42 33 37 33 35
θ200 36 38 45 50 30 35 28 30 27 29
θ100 23 26 30 32 23 25 20 23 19 20
θ6 7 9 9 9 10 11 7 10 7 8
θ3 6 7 6 7 7 8 5 7 5 5
Temperature (°F) 150 150 150 150 267 267 311 311 331 331
Pressure (psi): 0 0 1,954 3,457 5,059 7,272 6,628 8,469 7,617 9,733
Effective
Effective
Base Specific Base Effective Effective Permeability
Total Filtrate Permeability
Permeability Permeability Permeability to CO2 After
Volume to CO2 Minus
Core Sample Pore Volume Fluid Applied to Formation to CO2 to CO2 after Spindown
Loss (ml) Drilling
Brine Kg@Swi Drawdown Kg@Sr (mD)
(Pore Vol.) Mud Cake
Kw (mD) (mD) Kg@Sr (mD) Filtrate
Kg@Sr (mD)
Out [ml]
V3 2.873 95pcf 1.383 (0.440) 98.6 91.6 36.5 (-60.2%) 37.0 (-59.6%) 88.7 (-3.17%)
OCIEF #1 [0.65]
V14 3.046 95pcf 1.648 (0.574) 131 129 70.4 (-45.4%) 83.0 (-35.7%) 126 (-2.33%)
OCIEF #2 [0.40]
The 2D Micro-CT scan image (Figure 4, upper image), indicated that within the sub sampled region of
the wellbore end of the core sample exposed to 95pcf OCIEF #1, the filtrate invaded just the first few pore
spaces to a depth of ~1mm from the wellbore face after spin down.
Figure 4—2-D and 3-D Micro-CT scan of core sample after spin down (95pcf OCIEF #1)
The top image is a 2-D slice through the subsampled region and (white) high intensity features represent
the OCIEF filtrate invasion into the pore spaces at the wellbore end. The (black) low intensity features
represent pore spaces in the core sample.
The observation of low invasion is also shown by the 3-D visualization of the invaded filtrate in Figure
4 (lower image). The image indicates the spatial distribution of filtrate (blue) invasion. Note that the rock
matrix has been removed in this image but the white boundary lines indicate the core sample outline.
The Micro-CT scan supports the results of the regain permeability study and tight filtration characteristics
of the 95pcf OCIEF Fluid.
Density pcf 94 98
θ600 48 54
SPE-201847-MS 17
θ300 32 36
θ200 26 29
θ100 18 20
θ6 6 8
θ3 5 7
1 liter 10 10
1 liter 10 Aborted
The 98pcf (contaminated) PST fluid also indicated that the fluid would pass through the screen coupon
and the full test was aborted after the 3rd liter passed through the screen with consistent timing. The
fractional increase in PST time per 1 liter volume passed with the 98pcf (contaminated) PST fluid may be
due to the slight increase in frictional forces of the higher viscosity fluid relative to the 94pcf fluid.
• Non damaging fluid formulation to optimize production from an open hole completion
• Ensure zero stuck pipe incidents during drilling and completions operations
• Run 4 ½" sand screens without incident and set at target depth
The 8 ⅜" interval would be drilled with 109pcf conventional OBM. The well design had the 7" liner set
at an 89° inclination. The 5 ⅞" interval was planned to be drilled through the target reservoir holding 89°
inclination and 302° azimuth. Based on offset experience in the field, low ROP was expected for the well.
The well would be completed with 4 ½" sand screens.
A detailed Mud Program was prepared for the candidate well based on the pre drill data, offset analysis,
risk assessments, fluids qualification, agreed KPI’s and hydraulics modelling.
An 85pcf OCIEF fluid was initially planned for use on the 5 ⅞" interval. The 85pcf OCIEF was required
for wellbore stability and presented a 2,810psi static overbalance across the reservoir section.
The contingency for higher mud weights of up to 95pcf was included in the Mud Program if the additional
wellbore stability was required.
Drilling resumed and the density of the OCIEF was increased to 95pcf in response to formation breakouts
evidenced from LWD data.
The 5 ⅞" interval was drilled with low ROP and the following typical drilling parameters: 100rpm, WOB
6,000 - 7,400kftlbs, flow rates of 200 – 264gpm, torque 10,000 -17,000 ftlbs and SPP ranged from 2,450
- 3,800psi. Tandem hole cleaning pills were pumped with no notable increase in cuttings observed when
circulated out of hole.
The hole was relogged and the assembly was run back in hole on elevators to bottom. A trip out of hole
was planned to change out the MWD tools and test BOPs. The assembly was pulled out on elevators and
no over-pull or drag was observed in open hole.
A 5 ⅞" directional assembly with MWD and LWD was run back in hole and various depths were re-
logged while running in hole to bottom. A sweep was pumped and circulated out of hole prior to performing
a wiper trip to the 7" shoe. The drilling assembly was run back to bottom and hole swept clean with tandem
pills prior to pulling out of hole.
Logging tools were picked up and run back in hole. Caliper data indicated hole enlargement of 12"
below the 7" shoe. Another section of enlarged hole of 9" was observed at depth corresponding to where
initial instability was observed. Reservoir temperature was recorded at 294°F. Both wash out zones had high
gamma ray readings confirming predominant argillaceous siltstone.
The logging tools were pulled out of hole. Due to concerns regarding the risks associated with running a
stiff lower completion in unstable and enlarged open hole, the decision was made to cut TD short.
A 9 ⅝" × 7" scraper assembly was made up and run in hole. The hole was swept with tandem pills and
the scraper assembly was pulled out of hole.
A 5 ⅞" cleanout assembly was picked up and run in hole on elevators. Hole conditions were good as
no tight spots were recorded in open hole. The hole was swept clean with tandem pills. The assembly was
pulled to the 7" shoe while the fluids engineers prepared the 95pcf PST fluid for spotting in the open hole.
The 5 ⅞" cleanout assembly was run back to bottom freely and a viscous spacer was pumped ahead of the
120 bbl 95pcf PST fluid that was spotted in the open hole section. The cleanout assembly was pulled inside
the 7" liner. The cased hole volume of 95pcf OCIEF fluid was circulated over fine shaker screens to remove
LGS. The shale shakers were dressed with 270/325 mesh screens and the active system was circulated until
the OCIEF fluid was deemed PST compliant. The cleanout assembly was pulled out of hole.
The 4 ½" sand screens were picked up and run in hole to bottom without issue and the 4 ½" tubing hanger
was set successfully.
Conclusions
• The shearing unit mobilized to the drilling location supported the efficient mixing of fresh fluid
and eliminated any flat time to shear fluid prior to drilling out the 7" casing.
• The 8 ⅜" interval was drilled with 109pcf OBM and 7" casing was run and set. Whilst 88pcf OCIEF
minimized static overbalance, it was evident from hole enlargement observed below the 7" shoe
that the density of the OCIEF was insufficient for wellbore stability. The final 95pcf fluid density
was adequate for wellbore stability as subsequent trips were performed on elevators. No hole
enlargement was observed at depths beyond the fluid weight up to 95pcf. The formations drilled
with 95pcf OCIEF had comparable gamma ray readings as observed in the previously referenced
(two) wash out zones.
• The increased emulsifier additions and increased oil content after weight up of the OCIEF to 95pcf
presented some notable reduction to plastic viscosity and stand pipe pressure. The rapid change
to OWR while drilling did however present some practical challenges to managing mixing and
volumes as well as maintaining fluid properties. Heavy mud should be stored in reserve pits and
transferred to active for more efficient management of fluid properties.
• The combination of emulsifiers, polymers and sized bridging materials provided effective bridging
and sealing characteristics such that the fluid system could drill a high angle section with up to
3,773psi over balance (95 pcf).
• 95pcf PST fluid should be reformulated with the inclusion of low concentrations of polymeric
fluid loss control additives. The PST formulation should present a mitigation for risks associated
with potential damage to the filter cake that may arise from tripping out of hole with the clean
out assembly.
• Well production exceeded expectations validating the fluid design and deployment
Nomenclature
AHR After Hot Roll
ASA After Static Ageing
BHR Before Hot Roll
CT Computed Tomography
ECD Equivalent Circulating Density
HPHT High Pressure High Temperature
LCM Lost Circulation Material
LGS Low Gravity Solids
OCIEF Organoclay-free Invert Emulsion Fluid
OWR Oil Water Ratio
PSD Particle Size Distribution
PPA Particle Plugging Apparatus
PST Production Screen Test
PV Plastic Viscosity
ROP Rate of Penetration
UoM Unit of Measure
YP Yield Point
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