HIGH TEMPRATURE AND HIGH PRESSURE KCL K-LIGNITE DRILLING FLUID

Report submitted to Banasthali University, Banasthali for the partial fulfillment award of the degree of

Bachelor of Technology
by Sushmita Sati

To

Dr.SatishShukla& A Prof. Wahid Ali & AProf. ShilpiShrivastava

DEPARTMENT OF CHEMICAL ENGINEERING BANASTHALI UNIVERSITY, BANASTHALI 19 Sept 2011

CERTIFICATE

CONTENTS Topics 1) Introduction of Drilling Fluid i) Functions ii) Classifications iii) Problems iv) Properties 2) HTHP Drilling Fluids 3) KCL Polymer in Drilling Mud i) Properties ii) Applications 4) K Lignite Polymer in Drilling Mud i) Properties ii) Application 5) Experimental Procedure i) Drilling Fluid Formulation ii) Observations at HTHP iii) Conclusion 6) Reference 11 12 13 14 10 3 4 5 6 8 9 Page no

INTRODUCTION Drilling Fluids

In geotechnical engineering, drilling fluidis a fluid used to aid the drilling ofboreholes into the earth.The drilling fluid is related either directly or indirectly to almost every drilling problem. It is a part of the drilling process and should be used to complement all other facts of the operation.Liquid drilling fluid is often called drilling mud The objective in planning a mud program is the selection of a mud that will minimize the amount of lost time in the drilling operation. Generally, a good drilling fluid is simple and contains a minimum number of additives. Planning of the mud program begins with acquisition of all pertinent geologic and offset well information. This includes pore pressure and fracture gradient profiles, formation characteristics, intervals of possible borehole instability, location of soluble salt beds, and the possibility of sour gas or saltwater flows. The mud and casing programs should be integrated. The only solution to some problems is to isolate them behind casing. This is especially true when two problems that require opposite mud properties occur at the same time. For instance, a lost-returns zone and a high-pressure sand or sloughing shale open at the same time lead to a conflict that cannot be resolved by the mud alone. The mud program should be planned for each casing interval with a contingency plan for deviations from the casing Program.
1.1. Basic Functions of Drilling Fluids:

To cool and lubricate the bit and drill string. To remove and transport cuttings from bottom of the hole. To carry cuttings to the surface. To suspend cuttings during time when circulation is stopped. To control subsurface pressure and formation pressure. To seal permeable hole and to wall with an impermeable filter cake. To stabilize bore hole and to maintain hole integrity. To minimize corrosion of the drill string, casing and tubing. To minimize torque, drag, pipe sticking and contamination problem. To maintain optimum penetration rate. To minimize formation damage. (1)

1.2 CLASSIFICATION OF DRILLING FLIUD

A drilling fluid can be classified by the nature of its continuous fluid phase. There are three types of drilling fluids: Water Based Mud Oil Based Mud Gas Based Mud

1.2.1 Water Based Mud- These are fluids where water is the continuous phase. The water may be fresh, brackish or seawater, whichever is most convenient and suitable to the system or is available. The following designations are normally used to define the classifications of water based drilling fluids: Non-dispersed - Inhibited Non-dispersed-Non inhibited Dispersed - Non-inhibited Dispersed - Inhibited

1.2.2 Oil Based Mud An oil based mud system is one in which the continuous phase of a drilling fluid is oil. When water is added as the discontinuous phase then it is called an invertemulsion. These fluids are particularly useful in drilling production zones, shaleand other water sensitive formations, as clays do not hydrate or swell in oil. Temperature stability Lubricity Corrosion resistance Stuck pipe prevention Contamination 1.2.3 Gas Based Mud There are four main types of gas based fluids: Air Mist Foam Aerated Drilling fluid. (2)

1.3. DRILLING FLUID PROBLEMS

A number of major drilling-problems are directly related to the drilling fluid and drilling practices. Solution to these problems often requires adjustments of mud composition, mud properties, and operational procedures such that all facets of the problem are relieved.

Pipe Sticking Pipe sticking is one of the more costly drilling problems that we encounter. It occurs from any of these several different causes: Differential pressure sticking. Accumulation of cutting or sloughing in the hole, due to inadequate hole cleaning. Plastic flow into the hole, such as salt. Key seats in crooked holes. Mechanical obstructions. Sudden settling of barite, due to such things as barite stripping from gas flow or Inversion of oil-mud emulsionn. Collapse of weak or unconsolidated formation, due to sudden reduction in hydrostatic head from lost circulation.

Lost Circulation Lost circulation is defined as the loss of whole mud to a formation. It results from two basic causes: Seepage loss to vugular zones, coarse gravel beds, and shell deposits. Hydraulic fracturing.

These are not common systems as they have limited applications such as the drilling of depleted reservoirs or aquifers where normal mud weights would cause severe loss circulation. In the case of air the maximum depth drillable is currently about 6-8,000 ft because of the capabilities of the available compressors. Water if present in the formation is very detrimental to the use of gas-based mud as their properties tends to break down in the presence of water. (3)

1.4. PROPERTIES OF DRILLING FLUIDS: The nature of the solids also plays an integral role in the properties of drilling fluids, which in turn affect the properties of the solids and the performance of the equipment. Any change made to one of these affects the other two, and those in turn affect all three, and so on. To optimize a drilling operation, it is important to understand how the solids affect bulk mud properties, particularly rheology, hole cleaning, filtration, drilling rate (rate of penetration [ROP]), along with surface properties such as shale inhibition potential, lubricity, and wetting characteristics. Rheology is the study of the deformation and flow of matter. Drilling fluids that can exhibit elasticity as well as viscosity are known as viscoelastic fluids. 1.4.1 Density: Mud density is the weight per unit volume of mud and normally it is reported in Pound Per Gallon (PPG). Mud density is used for providing hydrostatic pressure to control well for drilling operation.

1.4.2 Viscosity: It is defined as the internal resistance of fluid flow. There are two types of
viscosity which are funnel viscosity and plastic viscosity. 1.4.2.1 Funnel viscosity: It is time, in seconds for one quart of mud to flow through aMarsh funnel which has a capacity of 946 cm3 (See Figure 1). A quart of waterexits the funnel in 26 seconds. This is not a true viscosity, but serves as aqualitative measure of how thick the mud sample is. The funnel viscosity is usefulonly for relative comparisons. 1.4.2.2 Plastic viscosity (pv): A parameter of the Bingham plastic rheological model. PV is the rate plot above the yieldslope of the shear stress-shearpoint (See Figure 4). Viscometer is equipment to measure Plastic Viscosity. Plastic Viscosity is derived from the 600 rpm reading minus the 300 rpmreading and PV is in centipoises (cp). A low PV indicates that the mud is capableof drilling rapidly because of the low viscosity of mud exiting at the bit. High PV is caused by a viscous base fluid and by excess colloidal solids. To lower PV, areduction in solids content can be achieved by dilution. There are many rheology models. Normally Bingham Plastic Model is used todescribe mud properties as Plastic Viscosity and Yield Point. 1.4.2 Gel Strength- The gel strength is a measurement of the shear stress necessary to initiate flow of a fluid that has been quiescent for period of time. It is caused by electrically charged particles that link together to form a rigid structure in the fluid. (4)

Shear stress and Shear rate:

When a fluid flows, it exerts a frictional drag called the shear stress on the surface of the conduit. The magnitude of shear stress depends on frictional dragbetween adjacent layers of fluids travelling at different velocities, and the difference in velocities of different layers next to the wall of conduit. The rate of difference in velocities between adjacent layers is called the shear rate. In the mud circulating system we are interested in the flow behavior of mud at the bit where shear rate are extremely high, in the annulus where shear rates are relatively low, and in the pits where shear rates are almost zero. The variation between shear stress and shear rate for Bingham plastic fluid is shown in the fig 1(iv).

Fig 1(iv)

(5)

(2) HTHP DRILLING FLUIDS

High Temperature and High Pressure, usually deep and often corrosive wells, impose the most severe constraints on drillers and well testing engineers. HTHP present special challenges to drill and test. Predominantly gas producers HTHP wells may yield significant reserves in some areas. But the wells stretch conventional equipment beyond normal operational capacities. To safely meet these extreme conditions, traditional procedures have been modified and extra operational controls devised.

HPHT Fluid Systems The main HTHP fluid options are: Water Base Drilling Fluids. Oil Base Drilling Fluids. Synthetic Base Drilling Fluids Formate Base Fluids Synthetic Polymer Treated Water Base Fluids.

1) Water base Fluid:Standard water-based drilling fluid additives start to degrade thermally at approximately 250F (121C). For higher temperature applications a flexible water-based drilling fluid system designed for high temperature and hostile environments, where conventional drilling fluids are impractical or uneconomical. Features: Stability in extreme temperatures up to 600F (316C). Handles densities up to 19.4 ppg Environmentally compliant, technically viable alternative to oil-based muds.

2) Oil Base Fluid-It is designed for maximum versatility delivers optimized drilling performance, including excellent penetration rates, enhanced lubricity, and superior wellbore stability. Features. Specifically designed for the use of commonly available aromatic-free base.

Minimal occupational hygiene exposure.

(6)

3) Synthetic Base Fluid-In these drilling fluids,the mineral oil is replaced by synthetic base fluids. The main advantage of this is that it is Environmental friendly. 4)Formate Base FluidThese are the clear brines of Sodium, Potassium, and Caesium Formates. These drilling fluids are compatible with PAC and Xanthum Gum. They also enhance thermal stability. They are clay-free and noon-damaging and Eco-Friendly. Choosing Oil or Water Base Mud The stability- as defined by rheology and fluid loss control of oil base mud at high temperature is a clear advantage in HPHT wells. Most are stable at leastup to 450F or 230 C in 16 hours lab test., Greatest disadvantage of oil base mud is solubility of gas under HPHT condition in base fluid, which makes kick detection more difficult. The thermal expansion of oil base mud is higher than water base mud, which can lead to pressurization of annulus.

(3) KCL/POLYMER MUDS

The basic component of potassium chloride(KCL)/Polymer muds are: Fresh water or sea water. KCL Inhibiting polymer Viscosity building polymer Stabilized starch or CMC Caustic soda or caustic potash Lubricants etc.

The KCL/polymer mud is suitable for drilling shale sections due to its superior sloughing inhibiting properties resulting from the use of KCl and the inhibiting polymer.Inhibition by KCL is attributed to the replacement of sodium ions in shales by potassium ions which are more tightly held. (7)

This mud type is also suitable for drilling potentially productive sands which are amendable to permeability damage by fresh water. Due to its low solid contents,this mud is often described as non-dispersed mud. It prevents the shale from coming in contact with the water. Due to their low tolerance of solids ,KCL/polymer muds require the use of efficient desanders and desilters to remove the very fine cuttings. The advantage of this mud includes: High shear thinning behaviour facilitating solids removal through the shale shaker, desanders and desitiers. High true yield strength Improved borehole stability Good but hydraulics and reduced circulating pressure losses

NOTE : The disadvantage is their instability at temperature above 250 degree F. (4) K-LIGNITE IN DRILLING MUD
GLO KL 1000- Potassium Lignite It is specially formulated modified lignite compound compatible with all water based mud system but it is developed specially for use in potassium based mud system APPLICATIONS: It contributes the potassium ion to the mud system and improves rheological properties. It reduces formations in reservoir damage by limiting the migration of clay. It reduces, washouts and improves well caliper by base exchange. Aids in controlling temperature stability of muds by reducing floucculation and gelation. It improves rheological properties of water based system. (8)

(4) EXPERIMENTAL WORK

The experimental work was carried out as a three stage process involving systematic design preparation evaluation approach. Before the experimental work on preparation and evaluation of drilling fluids wasstarted using polymers, the available polymeric additives were tested for their thermal stability in bentonite suspension alone. This evaluation of thermal stabilityof additives was done by hot rolling of the treated bentonite suspension at 236 Cfor 20 hours. The thermal stability tests were carried out in fresh waterenvironment.

PROCEDURE

4.1. Drilling fluid preparation 1. The drilling fluid was prepared using heavy duty mixer for 25-30 minutes. 2.The drilling fluid mixture then formed was stirred in Hamilton beach Mixer for 15 minutes. 3.After hot rolling the D/fluid was stirred in Hamilton beach mixer for 15minutes.

Plastic viscosity and yield point measurement 1. The sample is placed in a suitable container and the rotor sleeve is immersed exactly to the scribed line. 2. The plastic viscosity (PV) in centipoises equals the 600rpm reading minusthe 300 rpm reading. PV = 600rpm dial reading 300rpm dial reading.

3. The yield point (YP) in lbf/100ft2 equals the 300rpm reading minus theplastic viscosity. The temperature of the sample is reported in degrees F (orC). YP = 300rpm dial reading PV. 4.Apparent Viscosity- AV = (600rpm reading/2)

(9)

4.2. Observation
(A)Drilling Fluid formation-1 5cp Bentonite+ 3% KCL+ 3% K-Lignite+ 2%RL+1.5% SA+1% PAC+ 800gm Barite.

TABLE 1 A :
Parameters at ambient Temperature PH Sp Gr. AV PV YP Gel0 (lb/ 100ft2) Gel10 (lb/ 100ft2) Fluid loss (ml)

10.5

1.80

13

16

26

10

15

TABLE 1 B :
Parameters after hot roll at 200C for 16 hours

PH

Sp Gr.

AV

PV

YP

Gel0 (lb/ 100ft2) 12

Gel10 (lb/ 100ft2)

Fluid loss (ml)

1.80

32

18

16

35

Remarks:Fluid Loss at HTHP is very high.

(10) (B)Drilling fluid formulation 2 5cp Bentonite+ 3% KCL+ 3% K-Lignite+ 2%RL+1.5% SA+0.5% HTHP Deflocculant + 800gm Barite.

TABLE -2A :
Parameters at ambient temperature PH Sp Gr. AV PV YP Gel0 (lb/ 100ft2) Gel10 (lb/ 100ft2) Fluid loss (ml)

10.2

1.84

59

49

22

12

TABLE 2B :
Parameters after Hot Roll at 200C for 16 hours

PH

Sp Gr.

AV

PV

YP

Gel0
(lb/ 100ft2)

Gel10 (lb/ 100ft2)

30

Fluid loss (ml)

7

9.1

1.84

59

50

21

18

Remarks :Fluid was quite stable and has fluidity.

4.3. CONCLUSION Experiment were performed with different composition at 200 C.From the data presented in tables it is evident that normal fluid loss reducing chemicals and deflocculant were not effective in controlling the fluid loss andrheology at elevated temperature of 200 C HTHP deflocculant and Fluid Loss reducing polymers are useful in controllingfluid loss and rheology at higher temperature and thus for successful drilling of HTHP wells.

(11)

(5) Reference
Drilling Fluid Rheology and Hydraulics. Well Engineering and Construction, H.Rabia. Petroleum Engineering-Drilling and Well Completions, CarlGatlin. http:// www.fann.com. http://www.spe.org/jpt.

(12)