Lecture For Production Well Planning
Lecture For Production Well Planning
Lecture For Production Well Planning
OVERVIEW
OF COMPLETION
FLUIDS
SYSTEMS IN
ONGC
Sapna Rathi
Sr. Chemist
IDT, Dehradun
Completion Fluids (CF) are special purpose fluid placed against the producing
formation during well completion & remedial workover operations (WO) such as
well killing, cleaning out, plugging back or perforating etc.
CF is a low solid mud or salt solution (brine) used for well testing & upon a
well's completion.
Completion fluids are typically brines (chlorides, bromides & formates), but in
theory could be any fluid of proper density with flow characteristics.
The fluids for Completion and Workover operations will mostly be the same.
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Function of Completion Fluids
Must Control the Formation Pr. during completion & intervention operations,
Circulate & transport the solids,
Protect the productive zones, down hole & surface equipment,
Inhibitive Nature
Stable at surface & downhole conditions,
Be safely handled,
Environment friendly or used with controlled exposure,
Enabling repair operations as a circulating or kill fluid medium,
As packer fluids,
Avoid damaging the well after completion, or repair;
Allow other well operations to be conducted.
Low or Nil corrosive nature
Pumpability over long period of time
Reusable
Cost effective.
• Brines are the salt solutions in water that are generally used for Completion /
Workover operations in oil well
• Typical operations in which clear brines are used are Well kills, Fishing,
Perforating, Drilling, Gravel Packing and as Packer fluids.
• The commonly used completion / workover fluid can be grouped under following
broad categories.
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Clean, Solid-Free Brines
They are the most commonly used fluids in completion and workover operations.
These brines are true solutions, meaning that they contain only water &
dissolved salts (ions), with no un-dissolved solids.
Salt when dissolved in water, yields clear brine — as long as it is below
saturation.
They may be used as single-salt brines or mixture of two or three different salt
compounds.
Advantages of clear brines solution are;
Solids-free
Inhibitive
Available in a wide density range.
Capable of being reclaimed for reuse.
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Soluble Salts used as Brines
Category of Salts
Inorganic Salts Organic Salts
Monovalent salts Monovalent salts
Sodium Chloride (NaCl) Sodium Formate (HCOONa)
Potassium Chloride (KCl) Potassium Formate (HCOOK)
Sodium Bromide (NaBr) Cesium Formate (HCOOCs)
Potassium Bromide (KBr)
Divalent Salts
Calcium Chloride (CaCl2)
Calcium Bromide (CaBr2)
Zinc Bromide (ZnBr2)
Type of Brines
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Brine Density Range
A) Single Salt Brine (Inorganic Salt): These brines are made with fresh water &
one salt.
• Used up to 1.41 S.G. (11.8 ppg), but dissolution in water gives high heat,
• Dry salt must be added very slowly to prevent boiling.
• Compatibility should be ensure with reservoir fluids due to the divalent Ca++.
• More corrosive compare to KCl brine & require a corrosion inhibitor.
• Hygroscopic in nature.
• At higher densities there may be operating problem in winter because of
freezing of the solution.
• At a density of 11.6 ppg (1.39 SG) the freezing point of CaCl2 brine is 44 deg
F (6.6 degC).
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Type of Brines
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Type of Brines
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Type of Brines
C) Mixed Salt Brine (Inorganic Salt): When the brine densities greater than 11.6
ppg (1.39 SG) are required, the use of two or more salts is usually preferred instead
of single salt due to economics.
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Type of Brines
Density
Viscosity
pH
Saturation
Crystallization
Turbidity
Corrosion
Pressure
Temperature
Compatibility with formation pressure
Environmental impact
Economics
Institute of Drilling Technology
Properties of Brine
Viscosity:
A. Marsh Funnel
Measured by viscometer
The Apparent Viscosity in centipoise equals the 600 RPM reading divided by 2.
AV = Ø 600/2 In Centipoise
Friction force between two particles is known as plastic viscosity reading at 600
RPM - reading at 300 RPM.
PV = Ø 600 - Ø 300 in Centipoise
pH :
• The pH of the Cl- & Br- salts of sodium, potassium & calcium is neutral, i.e. 6 – 8.
•
• The pH of ZnBr2 is acidic due to the hydrolysis of water by the Zinc ion.
• The pH of 2.30 SG (19.2 ppg) stock zinc-calcium bromide brine is about 1 – 1.5.
•
• 17.5 ppg blend of 19.2 ppg Zn-CaBr2 and 15.1 ppg CaCl2-ZnBr2 should have a pH
equal to about 3.5.
• The formate brines are alkaline solutions & have a pH of greater than 9.5.
• In fact, these solutions need to maintain the pH above 9.5 to prevent
precipitation of the less soluble biformate solid.
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Properties of Brine
Saturation
Salt Solubilty (%) Density in PPG Specific Gravity
KCl 24 9.7 1.164
NaCl 26 10.0 1.200
CaCl2 40 11.8 1.416
NaBr2 46 12.7 1.525
HCOONa 50 11.1 1.329
CaBr2 57 15.3 1.837
HCOOK 78 13.3 1.595
Crystallization
Increasing the salt concentration is possible until the salt reaches saturation.
The temp. at which the salt is saturated is called its crystallization temperature
(TCT – True or Thermodynamic crystallization temperature).
In some situations, the crystallization point was raised above its TCT by the
pressure exerted by a combination of pump pressure & hydrostatic column.
Each individual brine, has its own crystallization / freezing temperature, under
this temperature the fluid will freeze.
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Properties of Brine
• It represents the lowest point on the Crystallization curve & includes the
cooling under the TCT referred as the super-cooling effect.
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Properties of Brine
• In such situations, the crystallization point was raised above its TCT by the
pressure exerted by a combination of pump pressure & the hydrostatic
column.
• The total pressure on the cool fluid (38 °F at the sea floor), caused the TCT
to be greater than 35 °F, which was its target TCT when the fluid was
formulated at the brine plant
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Properties of Brine
Turbidity :
• Turbidity (Clarity) are representative properties for clear brines, turbidity is a function of fluid
cleanliness,
• The technique of beaming light on a sample, and measuring the amount of light scattered at a
certain angle,
• If a fluid contains drill solids, undissolved salts, etc., the turbidity will be high,
• The NTU value will drop by cleaning the fluid, thus a brine with a low NTU will be preferred.
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Properties of Brine
Turbidity Meter
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Properties of Brine
Corrosion:
• Corrosion affects & deteriorates the metal, from the start of the well till the
abandonment stage; pipes, casing, tools, containers, etc.; &
• From the surface equipment (ex: lines, pumps, pits, pipes, etc.) to bottom
hole equipment.
• Brines have a corrosive effect on all kinds of metal drilling equipment and
casing strings.
Wellbore temperature;
• The density of brine will decrease as the temperature increases due to thermal
expansion, and thus the well stability may suffer if the brine can’t handle the
formation pressure.
• In below Figure the density reduction of a CaCl2 Brine due to thermal expansion
can be observed .
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Properties of Brine
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Properties of Brine
• Formation
• Formation water and
• Hydrocarbon;
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Properties of Brine
Environmental impact:
• Salts and brines can harm the persons who will handle them;
• Some of them are extremely hygroscopic – the ability to absorb water from all
kind of sources (ex. leather boots, skin, air, etc.)
• When come in contact with skin will cause burns;
• Dry calcium salts are highly exothermic – they release heat when added to water,
around 180-200 oF,
• Special measures should be put in place when handling these brines,
• Use PPE like slicker suits, rubber gloves, rubber boots, goggles plus a face
shield;
• Rinse with plenty of fresh water immediately & seek medical attention, If comes
in contact with skin and eyes
• If in the event of spills, it must be diluted before removal.
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Properties of Brine
Economics:
• All data collected from the well is simulated in a computer program – Virtual
Completion Solutions (VCS)) that will plan & design simulations of multiple
operations & scenarios, establish pump rates, flow regimes and chemical clean-
up efficiency and displacements;
• Plans & designs Brine systems that needs to be used for the well with minimal
impact,
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Costing of Brine
Are solid free – Relying on the dissolved salts for their density
Have a wide density range from 1.16 – 2.5 SG (.4 to 21.0 ppg)
Are inhibitive.
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OIL
• It is usually non-corrosive and does not cause clay swelling in producing zones.
• It weighs about 7 ppg, which is excellent for low pressure oil field.
Disadvantages :
• Usually contains wax, fine particles of sand, solid or asphalts that can
damage the formation.
• It is corrosive if H2S or CO2 is present.
• It is a fire hazard and difficult to handle
• Oil may not be compatible with the reservoir oil if it is obtained elsewhere in
the field.
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OIL BASE FLUIDS
• The thin, low-permeability filter cake also prevent solids into producing zone.
• The filtrate is also oil, so that sensitive clays are not affected.
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OIL BASE FLUIDS
Advantages Disadvantages
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Latest Development in Completion Fluid
2. HGS based CF
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HPHT Formulations Designed by IDT
Potassium Formate and Tri Manganese
Tetra Oxide based completion fluid with
indigenous chemicals (182°C/1.97
SG/16.4ppg).
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Formulations Designed by IDT for Sub Hydrostatic Wells
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
Depth - 4836m
BHP - 10923 psi
BHT - 360º F (182º C)
Drilling Fluid - 14.6 ppg LTSOBM
Testing Fluid - 14.6 ppg CaBr2 -Micromax
Objects Tested - 05
Testing Services - M/s Halliburton
Testing fluid Cost - $ 1.75 million
Status - Gas Producer
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
Five objects were smoothly tested without any hindrance and the
activation was instantaneous – indicated no reservoir damage.
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
• Excellent HT rheology,
• Thermal stability and endurance after prolonged usage.
• The fluid showed no sag,
• Good pressure communication to operate down hole DST tools.
• Packer setting and release were smooth.
• The well produces gas
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
After testing the well GSS041NAA-C this brine became the property
of ONGC which was transported to east cost & tested another HTHP
well YS-6-2 SUB thus reducing the over all cost of fluid drastically.
The HTHP well YS-6-2 SUB is a substitute of the previous well which
had to be abandoned with unsuccessful testing due to extreme
HTHP conditions.
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
The entire testing fluid cost of the well GSS041NAA#C was around $
1.75 million, which is only 23.8% of the rental cost of cesium formate
brine.
The re-use of the same brine in YS-6-2 SUB has brought down the
testing fluid cost to $ 0.29 million.
Benefits:
Still left over completion fluid further can be used in future well.
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
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Alternate HPHT Completion / Testing Fluid of Cesium Formate
and Zinc Bromide
The well NSG-AA was successfully tested with this new completion fluid
and the permanent packer was set in the very first attempt.
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Update / formulation of procedure and guidelines
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IDT Capability
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Thank You