Mud DF System

DRILLING
FLUIDS
SYSTEMS
Key elements of a successful Drilling Fluid Operation
HS&E
Drilling
Tender Fluid
Design &
Selection
Successful Drilling Fluid

Rig & Mud
Drilling Personnel
Plant Specs
Fluid
Design &
Process Selection
Quality Technical
Control Service
Solids
Control
DRILLING FLUIDS SYSTEMS
Choice of Drilling Fluid
Suitability for the formations to be drilled?

Inhibition
Rheology
Fluid Loss
Temperature limitations
Cost
Environmental concerns
Safety
Availability
Storage
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

Drilling fluid design & selection considerations
Are mud losses expected?

Do you want to be first to try something new?
Risk management
Cost of Fluid
Formation damage
Lubrication
Waste disposal options
Local regulations
Shale inhibition
Completion design Mud weight Company policy
Who has the fluids contract?

What has worked before?
Who needs to be involved?
Rheology Temperature and pressure
Inhibition Ranking A Reminder
Lower Overall well costs Higher Very high

O Examples of failures
P
Lower Risk Higher
C I
TI
Choice of drilling fluid systems: R
M N
U I
M Synthetic oil based mud T Poor shale inhibition C
I Hole stability problems R
D C E
Enhanced KCL / Polymer / Stuck pipe
R
IL Glycol & Surfactants A A
L Low ROPs
LI
KCL / Polymer / Glycols S
N Consequences of poor E
G
Silicates F
drilling practices D
A
P
E
Dispersed muds I
R Brine systems L H
Exception: U
F
Dispersed muds are often Fully dispersed fresh water / Failure to run & &
O
lignosulfonate / Lime / gyp R S
the most economical low
R
risk option for drilling muds E retrieve quality logging
M
A shallow, young, weakly data
consolidated shales
Bentonite muds / spud muds
L R
N Reservoir damage, etc I
C I
E SW / viscous sweeps N S
E K
Higher Lower S
Inhibitive properties
Evaluate risk ie potential value of success vs the potential cost of failure
KMC Oiltools Systems
Water Base Systems

High Solids Dispersed Mud Systems
Spud Mud
Seawater Muds
Lignite/Lignosulfonate
Gyp-Lignosulfonate
Lime Muds
Inhibited Low Solids Polymer Systems
Hydro-Foil KCl Polymer PHPA
Hydro-Foil Gen 1 Glycol Mud Systems
Hydro-Foil Gen 2 Highly Inhibitive Low Salt
System
Hydro-Foil S8 Silicate System
Specialist Water Base Fluids
Hydro-Therm High Temperature System

Opta-Flo Drill-In Fluids (DIF)
Rheo-Plex Mixed Metal Hydroxide (MMH)
Formates Alternative Salt Systems
Non Aqueous Fluids

Oil based and Synthetic Based Mud Systems
Confi-Drill Invert Emulsion Mud

Confi-Dense HTHP Invert Emulsion
Confi-Deep Deepwater Emulsion
Extra-Vert Environmentally Friendly Invert
Opta-Vert Drill-In Fluid
Opta-Vert 100 100% Oil Fluid (Coring, DIF)
Bentonite Spud Mud
Requirements :
High Viscosity (FV 100 sec+)
Low Cost
Hi-vis sweeps or circulating system
Bentonite Spud Mud

Requires fresh water to prehydrate Bentonite
May be a circulating system or seawater - sweep system
Bentonite Spud Muds

To mix prehydrated Bentonite (DRILL-GEL) (PHG or PHB))
Fill tanks with fresh water (chlorides less than 1000 mg/l)
Add Soda ash to reduce total hardness to below 150 mg/l
Add 0.5 - 1 ppb caustic soda to increase pH above 9.5
Add 25 - 35 ppb API Bentonite or 35-45 ppb OCMA/Euro Bentonite
Allow to hydrate at maximum shear for 6 hours if possible
Dilute with water / sea-water (final Bentonite concentration = 15 -25

ppb)
Add 0.2 ppb Lime just prior to pumping (sweep system only)
Guar Spud Mud

Guar Gum yields in sea-water and drill water
Normally used only as a sweep Clean out tanks
Add drill water or sea water
Add :
3 - 4 ppb GUAR @ 5 - 10 min/sx

Pump immediately or add biocide over top of pits (1
litre/m3)
High yield and viscosity in any brackish and salty water makes
this option cost effective in some situations
Lower solids keeps hydrostatic down

Engineering Comments Spud Muds
Fill all pits with PHG if necessary prior to spudding
Pump 50 bbls every 2/3 connections
Pump further sweeps if tight hole or hole fill is observed
At TD pump 100 bbl sweep around hole, observe returns
Displace hole to Hi Vis mud (+ excess) prior to POOH for

casing
Weighted standby mud may be required if shallow gas is

expected
Bentonite Muds
1. Fresh water Bentonite muds.

2. 2. Sea water Bentonite muds.
3. 3. High chloride concentration Bentonite muds.
PROPERTIES - as required. Normally PV as low as possible. YP 12 - 20.
Fluid loss as required.
MIXING INSTRUCTIONS - The Bentonite concentration will normally be 15

to 20 ppb. For systems 2 and 3 the Bentonite will need to be prehydrated
in fresh water and then diluted back with sea water to attain the desired
concentration.
To increase the viscosity, increase the Bentonite concentration.

To decrease the viscosity :
Decrease the Bentonite concentration by dilution or adding new
premix.
Decrease the solids content.
Fluid Loss Control
Fresh and sea water systems should use :
CMC (up to 2 ppb) - Deflocculates system

PAC (up to 2 ppb) - Deflocculates system
Starch (up to 6 ppb) - Will not deflocculate
system
or use a combination of the above
At higher chloride levels the CMCs become less effective

so only starches and PACs should be used.
Lignite & Lignosulfonate Systems
Advantages Inexpensive, easy to control system for drilling 17 1/2 and

12 1/4 intervals which can be inhibited
Disadvantages Dispersed, High Solids System.
Temperature limitations on polymers & Lignosulfonates,
Density Barite
Viscosity Bentonite, PAC, Xanthan, CMC HV, Prehydrated Bentonite
Fluid Loss Starch, CMC-LV, PAC, Lignite, Lignosulfonate, Bentonite
Inhibition Seawater, saturated salt, KCl, PAC, PHPA (encapsulation)
pH Caustic, KOH
Thinner FCL, Calcium Lignosulphonate, Lignite, (dispersants)
Mainly used on land wells rather an old fashioned mud system

Mixing Procedure
Mixing order (fresh water), add :

Prehydrated Bentonite in fresh water with caustic and soda ash
Adjust volume of water to obtain correct gel conc.
FCL / Calcium Lignosulphonate and adjust pH
Polymer viscosifiers and fluid loss additives, 10-15 min/sack
Barite
Mixing Procedure
Mixing order (Inhibited systems):
1. Prehydrated Bentonite in fresh water with caustic and/or soda

ash; adjust pH
2. Hydrate maximum quantity of Bentonite by adding FCL or
Calcium Lignosulphonate to aid dispersion.
3. Mix salt water with appropriate salt (NaCl, KCl, etc) and adjust
pH.
4. Add Prehydrated Bentonite to Salt water until desired
viscosity/rheology is obtained. (Shoot high as Bentonite will fall
back somewhat as the system breaks over.
5. Mix Polymer viscosifiers and fluid loss additives, 10-15 min/sack
6. Barite
7. Maintain Rheological properties with periodic additions of
Prehydrated Bentonite.
Engineering Comments
Pretreat with bicarbonate of soda or SAPP prior to drilling out cement or
drill out with water.
Increase viscosity with PHG additions, Long chain polymers will also
increase viscosity but will be more expensive.
Foaming problems can be reduced by adding defoamer, minimizing use
of starch and maintaining the minimum acceptable pH.
Increase inhibition by increasing the salt content.
Increase encapsulation of solids with additions of PAC or PHPA.
Minimize dispersion by running minimum pH with maximum inhibition.
It will be necessary to dump and dilute to maintain the correct solids and
MBT conc. so minimize dumping by running solids control equip.
Further additions of thinner may be necessary with Barite additions
At high mud weights replace long chain polymers with short chains
Reduce gels and YP prior to logging or running casing.
Gypsum / Lignosulphonate System

Advantages Economical fluid with moderate inhibition
Disadvantages Moderate inhibition, temperature limitations, Dispersed,
high solids system.
Density: Barite, hematite, galena, CaCO3
Viscosity: Bentonite, PAC,XCD, CMC HV
Fluid Loss: CMC LV, Lignosulfonate, starch, PAC
Inhibition: Gypsum CaSO4
pH: Caustic
Thinner: Lignosulphonate, Polymer thinners, DESCO (Lignites do
not like Calcium)
Soluble calcium ions partially convert sodium montmorillonite into the
less hydratable calcium form.
CaSO4 2H2O <=> Ca + SO4 + 2H2O
Mixing Procedure
Mixing order, add :
Prehydrate Bentonite in fresh water w/ caustic, and soda ash
Adjust volume of water to obtain correct gel conc.
FCL / Calcium Lignosulphonate and adjust pH
Polymer viscosifiers and fluid loss additives, 15 min / sac
Gypsum
Barite
To convert (Breakover) to a gyp system, reduce LGS below 5%.
Dispersants may need to be added before or with the gypsum.
Engineering Comments (Gyp System)

Increase viscosity with PHG additions, Long chain polymers will
also increase viscosity but will be more expensive.
Foaming problems can be reduced by adding defoamer and
maintaining the correct pH.
Increase inhibition by reducing the pH, increasing the chloride
conc. or maximizing soluble calcium levels.
Dump and dilute to maintain the correct solids and MBT conc.
Optimal Solids Control equipment is important with this system.
Further additions of thinner may be necessary with Barite
additions.
At high mud weights replace hi-vis polymers with low vis polymers.
Reduce gels and YP prior to logging or running casing.
Maintain excess Gypsum at 2-4 ppb
Lime Muds
High lime content muds - > 5 ppb excess lime.

Low lime content muds - < 5 ppb excess lime.
pHs are normally 11-12, calcium filtrate levels are 75 - 200 mg/l
High lime content muds were used for drilling mud making (reactive)
shales.
Low lime content muds are used where higher temperatures are
encountered.
Lime is only partially soluble in water :
Ca(OH)2 < Ca2+ + 2OH-
Caustic additions will increase the insoluble or excess lime.
Lime muds replace sodium cations with calcium cations thus reducing
the hydratablity of clays and shales.
Lime Muds Breakover and Maintenance

Start with a normal Bentonite mud.
Reduce low gravity solids to below 4%.
Add the following simultaneously to the mud during 1-2 circulations :

2 - 3 ppb caustic
2 - 4 ppb lignosulfonate (Lig-Sperse, Lig-Sperse NC or equivalent)
4 - 8 ppb lime
Control fluid loss with PAC, CMC or starch.
Further caustic and thinner additions should be made together with equal
weights of each.
The excess lime is controlled using the formula :

Excess lime = 0.26 [Pm - (Pf -Wf) ]
Wf = water fraction of the mud.
Caustic is added to increase the Pf. Lime is added to increase the Pm.
Viscosity is increased by increasing the gel strength and is reduced by
lowering the solids content, by greater dilution or by adding a thinner
Limitations of Calcium Treated Muds
At high temperatures (above 275F) severe gelation or

solidification may occur. The effect is more severe at high
LGS levels.
The gelation or solidification is caused by the reaction

between the hydroxyl ion, the calcium ion and the clays. An
irreversible reaction occurs forming a calcium alumino-silicate
or simple cement
Gyp muds are less susceptible to gelation than lime muds.

Non-Dispersed Polymer System
The majority of Water Base Mud Systems today are

Polymer based
Advantages Disadvantages
Greater degrees of inhibition
than a dispersed mud Some polymers are attacked
Flexibility by bacteria
Logistics Temperature limitations of
Less Damaging to formation polymers
Increased ROP Polymers are more
Optimum rheological expensive per sack
characteristics Requires care in mixing
Resistant to contaminating procedures
ions
Non Dispersed Basic Polymer System

Additives
Density: Calcium Carbonate or Barite
Viscosity: PAC, Xanthan Gum, CMC
Fluid Loss: CMC LV, PAC LV, Starch
Inhibition: Gypsum, Lime, Salts, plus encapsulation with PAC
pH: Caustic or KOH

Bactericide: As required
Sometimes a little PHG is added instead of polymers to :

Give viscosity at a cheaper price and to provide plate-like material to
reduce initial fluid loss
Mixing Procedure
Mixing order, add :

Adjust pH of make-up water with caustic/KOH
Fluid loss additives 15 min / sack (Low vis polymers first)
XCD, PAC @ 15-20 min/sack (Viscosifiers)
Gypsum / Lime / Salt (Inhibitive compounds)
Bactericide
Barite / Calcium Carbonate
Minimise viscosifying polymer addition until after

displacement to minimize screen blinding. Add additional
polymer as drilling proceeds.
Displace to new mud system after drilling out cement.
Effects of cement contamination will be worse in a fresh water system.

Add Bicarb or to treat it out
Mud losses at the shakers are likely if coarse screens not fitted to start
with
Reduce circulation rates or use larger screens for 1-2 circulations
Dump and dilute to maintain correct solids and MBT conc.

Watch fluid properties for product depletion
Add Xanthan to improve YP and low end rheology.

At high mud weights replace hi vis polymers with low vis polymers.
Polymer thinners will be required in addition to PAC for very low
fluid losses.
Bacterial attack is possible :
Add initial kill dose and daily treatment
Increase pH to 10.5 and increase chlorides if necessary
Add defoamer if necessary
To salt saturate :
Reduce MBT to < 10 to minimize flocculation effects
Add a slight excess of salt to ensure saturation at downhole
conditions
HYDRO- FOIL - KCl PHPA Polymer Systems

Advantages
Low Solids, inhibitive mud - better gauge hole
Stabilizes shales by replacing sodium with potassium ion on
exchange site
PHPAs minimize dispersion (via encapsulation)
Increased solids removal efficiency
All the other advantages of non-dispersed polymer systems
Disadvantages
Lubricity is not as good as NAF
Possible Temperature limitations
Bacterial degradation potential depending upon polymer.
Generally not for high Ca++ environments
HYDRO- FOIL - KCl PHPA Polymer Systems

Additives
Density CaCO3 or Barite
Salt KCl
Viscosity PAC, Xanthan, CMC HV
Fluid Loss CMC LV, PAC LV
Inhibition PHPA (encapsulation) + KCl
pH KOH or Caustic
Bactericide
HT Polymer may be added as required to extend limits of system

Mixing Procedure
Mixing order, add :
Increase pH with KOH or caustic

Fluid loss additives, 15 min / sack (Lo Vis polymers first)
Viscosifiers @ 15-20 min/sack
Potassium Chloride
Barite / Calcium Carbonate
Add the PHPA slowly at the suction pit
Minimize polymer additions until after displacement to minimize

screen blinding and precipitation of polymer with Ca++
Pretreat for cement contamination with Bicarb
All the comments on non dispersed polymer systems apply
PHPA should only be added after cement is drilled, due to sensitivity

to Ca++ & Mg++ ions
NB. PHPA hydrolyses at high pH and gives off Ammonia
PHPA concentration should be maintained at 1 lb/bbl excess in the

filtrate
Potassium depletion should be monitored closely
Bacterial degradation is unlikely at chloride concentrations above

100 g/l, add biocides if necessary
Due to depletion add 1 drum (25 kg) of PHPA every 30 -100 ft as per
program (or as required). Add slowly at suction pit. Note that Liquid
PHPS is only 35% PHPA so adjust additions accordingly.
If cuttings are sticky increase KCl concentration.
If cuttings are brittle reduce KCl concentration.
Use ROP Enhancer, drilling detergent, nut plug to solve bit balling.
Mix slugs with KCl if possible due to density limitations.
KCl and PHPA can be added to a non dispersed mud to convert it to

a KCl/PHPA system. This is only cost effective at low solids
concentrations.
Hydro-Foil Gen 1 Glycol system
A glycol-based drilling fluid system designed as an effective and

environmentally safe alternative to traditional oil and synthetic
fluids for drilling troublesome shales.
Utilises cloud-point glycols, operating in conjunction with PHPA

and other polymeric additives to provide enhanced inhibition.
HYDRO-FOIL GEN 1 can be specially formulated to meet

individual well applications
Basically this is an enhanced KCl/PHPA system which shows the

flexibility of polymer systems
This system will be detailed in a separate module

HYDRO-FOIL GEN 1
Visualisation of Polyol Behaviour as a Function of Temperature
Polyol and Solution is

water heated until the
together at polyol reaches
cloud point
ambient and becomes
temperature; insoluble. A
the polyol is thermally
100% water activated micro
soluble emulsion forms
HYDRO-FOIL GEN 1
Schematic of Cloud Point Activity for a Glycol Mud
Mud pits and solids control:

Glycol in solution
Temperature
reduction
lowers the
Glycol back
below its
cloud point
Downhole Glycol forms
droplets or micelles
which coat out on
wellbore and cuttings
HYDRO-FOIL GEN 1
HYDRO-FOIL GEN 1 COMPONENTS

The HYDRO-FOIL GEN Gen I system achieves its inhibition
through the synergistic action of four key components:
Cloud Point Polyol: CIRRUS,STRATUS, CUMULUS and

NIMBUS
Polymer ENCAPSUL-8 & ENCAPSUL-8L shale

encapsulators
Salt: Brine NaCl, KCl, K2SO4, K2CO3,
NaCOOH, KCOOH etc.
Cation: Potassium or calcium
HYDRO-FOIL GEN 1
Typical Formulation of a HYDRO-FOIL GEN 1 system

HYDRO-FOIL HYDRO-FOIL
Product Function GEN 1 GEN 1
BHCT = 40C BHCT = 90C
Drillwater (bbl/bbl) Base Fluid 0.85 0.75
Water activity &
KCl (lb/bbl) Cation 30 30
Exchange
Caustic Soda / Potash Alkalinity
to pH 8.5 9.5 to pH 8.5 9.5
(lb/bbl) Control
XC-EED (lb/bbl) Viscosifier 0.75 1.25 0.75 1.25
Fluid Loss
HYDRO-PAC UL (lb/bbl) 1.0 2.0 1.0 2.0
Control
Cuttings
ENCAPSUL-8 (lb/bbl) 2.0 2.0
Encapsulator
Shale
CIRRUS CPG (v/v%) 3.0
Stabilisation
Shale
STRATUS CPG (v/v %) 3.0
Stabilisation
DRILL-BAR (lb/bbl) Weighting Agent 68 206
HYDRO-FOIL GEN 1
Typical Properties of a HYDRO-FOIL GEN 1 system
HYDRO-FOIL HYDRO-FOIL
Properties GEN 1 GEN 1
BHCT = 40C BHCT = 90C
Density (ppg) 10.5 13
Plastic
Viscosity 15 - 25 25 - 35
(cP)
Yield Point
15 - 25 20 - 30
(lb/100ft2)
Gels
+/- 6 /10 +/- 8 / 14
(lb/100ft2)
API Fluid Loss
<5 <5
(cc/30min)
HYDRO-FOIL GEN 2
The HYDRO-FOIL GEN 2 system was developed in response to

environmental regulations, particularly onshore, whereby high salinities
water based fluids, are not acceptable for discharge, yet highly
reactive, hydratable shales still need to be stabilised whilst drilling.
Furthermore, it is well established that drilling shales rich in Kaolinite

with potassium based drilling fluids destabilises the clay lattice,
resulting in decreased rock strength and potential failure.
The HYDRO-FOIL GEN 2 is a fresh to low salt based drilling fluid

containing a polyamine derivative that mitigates hydration and swelling
of reactive clays. Inhibition is achieved by restricting water adsorption
and providing improved cuttings integrity.
By reducing water adsorption into the clay matrix and prevents them
from becoming plastic, thereby providing a secondary benefit of
reducing the tendency for bit-balling.
HYDRO-FOIL GEN 2
Features and Benefits
Highly Inhibitive for both freshwater to saturated brines
Reduced dilution rates and improved solids removal efficiency
Lubricious
High ROPs achievable
Environmentally acceptable
Ease of mixing
HYDRO-FOIL GEN 2
IMMUNE-8 is the key additive to system performance and is a blend
of primary, secondary and tertiary amines reacted with an acid.
Therefore, it has both acidic and basic properties. It is preferentially
is adsorbed on to the cation exchange sites electrostatically binding
clay platelets together and mitigates a clays tendency to absorb
water.
Shale Cutting using
Affect of IMMUNE-8 on Bentonite Hydration HYDRO-FOIL GEN 2
HYDRO-FOIL GEN 2
IMMUNE-8 is liquid additive and the recommended concentration of is

2 - 3% v/v, and will vary based on hole size, rates-of-penetration and
reactivity of the formation being drilled.
IMMUNE-8 will deplete upon reaction with hydratable clays and

additional product should be added via whole mud or neat product
dilution to maintain appropriate product concentrations.
Cuttings integrity and MBT levels are indicators of sufficient IMMUNE-

8 concentration. Drilled cuttings should be firm and loss of integrity,
combined with increased MBT levels, may be indicators of insufficient
product concentrations.
Typical Formulation of a HYDRO-FOIL GEN 2 system

HYDRO-FOIL GEN
Product Function
2
Drillwater (bbl/bbl) Base Fluid 0.83
DRILL-GEL* Viscosifier 5.0
Water activity &
NaCl (lb/bbl) 10
Cation Exchange
Caustic Soda (lb/bbl) Alkalinity Control to pH 8.0 9.0
LIG-SPERSE Deflocculant 1.5
XC-EED (lb/bbl) Viscosifier 0.5 0.75
HYDRO-PAC UL (lb/bbl) Fluid Loss Control 1.0
ENCAPSUL-8 (lb/bbl) Cuttings Encapsulator 1.0
Hydration
IMMUNE-8 (v/v %) 2.5
Suppressant
DRILL-BAR (lb/bbl) Weighting Agent 141
Drilled Solids (lb/bbl) Drilled Solids 20
Typical Properties of a HYDRO-FOIL GEN 2 system
Properties
Density (ppg) 11.5
Plastic Viscosity (cP) 20 - 30
Yield Point (lb/100ft2) 30 - 35
Gels (lb/100ft2) +/- 14 / 30
API Fluid Loss

<7
(cc/30min)
SILICATES HYDRO- FOIL S8

HYDRO-FOIL S8 is essentially a HYDRO-FOIL system that utilises 5
15% v/v Sodium or Potassium Silicate solution to enhance inhibition and
mechanical wellbore stability, particularly in highly fractured or
unconsolidated formations.
The system pH is engineered to +/- 12 which has an adverse affect on

certain polymer additives.
The system is formulated using most conventional polymers, with the

exception of ENCAPSUL-8 (PHPA) Silicate enhanced systems are
designed to drill very reactive shale
They strongly minimize shale hydration and improve formation integrity
These systems can be used as an economic and environmental

replacement for oil-base mud
This system is also detailed in a separate module

SILICATE SYSTEM
Sealing of Microfractured Shales by Silicates
Fracture propagation
Mp Fp
Mp FLUID Fp Non-inhibitive
Non inhibitive Fluid
INGRESS
Mp > Fp Mp = Fp = Mechanical Failure
Silicate gel/precipitate
Mp
Mp FLUID Fp HYDRO-
HYDRO-FOIL S8 Fluid
INGRESS Fp
Mp > Fp Mp > Fp = Mechanical Stability

DRILLING
SILICATE
FLUIDS
SYSTEM
SYSTEMS
Inhibition Mechanisms of Silicates
H2O May Penetrate But Ions Are Excluded
Ca
Ca
H2O Ca Ca
SHALE PORE
Ca
Ca
~ GELLED/PRECIPITATED SILICATES
SILICATE SYSTEM
Typical Formulation of a HYDRO-FOIL S8 system

HYDRO-FOIL
Product Function HYDRO-FOIL S8
S8
Drillwater (bbl/bbl) Base Fluid 0.74 0.65
Water Activity &
KCl (lb/bbl) Cation 30 25
Exchange
Caustic Soda / Potash Alkalinity
to pH 12 12.5 to pH 12 12.5
(lb/bbl) Control
Hardness
Soda Ash to < 400 mg/L to < 400 mg/L
Control
XC-EED (lb/bbl) Viscosifier 0.75 1.0 0.75 1.25
Fluid Loss
HYDRO-PAC UL (lb/bbl) 2.5 2.5
Control
HYDRO-STAR CMS Fluid Loss
2.0 2.0
(lb/bbl) Control
Shale
SILIC-8S (v/v%) 11.0 9.0
Stabilisation
Oxygen
SCAV-OX (lb/bbl) 1.0 1.5 1.0 1.5
Scavenger
SILICATE SYSTEM
Typical Properties of a HYDRO-FOIL S8 system
Properties
Density (ppg) 12 15
Plastic Viscosity (cP) 20 - 30 25 - 35
Yield Point (lb/100ft2) 15 - 25 20 - 30
Gels (lb/100ft2) +/- 6 /10 +/- 8 / 14
API Fluid Loss

<6 <6
(cc/30min)
Pf/Mf 20/25 - 35/40 20/25 - 35/40
SiO2/Na2O 40-50 / 20-25 40-50 / 20-25
pH 12 12.5 12 12.5
High Temperature Polymer System HYDRO-THERM
The HYDRO-THERM System is an extremely flexible drilling fluid

system used when temperature, contaminants, and/or borehole
instability make conventional systems impractical or uneconomical.
The actual composition will vary depending on specific

requirements.
HYDRO-THERM is a synthetic polymer based system that is stable
to > 230C (450F).
The use of the HYDRO-THERM system allows for the conversion of

conventional mud systems e.g. HYDRO-FOIL systems, to a
HYDRO-THERM HTHP drilling fluid without the need for complete
displacement.
Advantages
Temperature stability to > 230C (450F).
Low solids
Non Dispersed System
Disadvantages
Calcium and salinity limitations may limit choices
More expensive than High Temperature Bentonite
System

Product Description Function
Barite, Micro-Max, Weight Materials

Hematite
THERMO-TROL AMPS/AM HTHP filtration control
copolymer
THERMO-PLEX Divalent Silicate Supplemental HTHP
Complex Viscosifier
HYDRO-THIN HT Sodium salt of Thermal stability
maleic anhydride
copolymer
DRISCAL D Proprietary HTHP filtration control
THERMO-SPERSE Modified sodium HTHP filtration control

salt of sulfonated Deflocculation
lignin
T-REX Resinated Lignin HTHP filtration control

Features and Benefits
Thermal stability
Flexibility that extends conventional systems beyond their
normal limits
Shale stability
Excellent return permeability
Reduced corrosion rates
Lubricity
Environmentally acceptable
Economical
Typical Formulation of a HYDRO-THERM system

HYDRO-
THERM HYDRO-THERM
Product Function BHST = BHST = 165C
193C
Seawater (bbl/bbl) Base Fluid 0.73
Aw & Cation
KCl (lb/bbl) 30
Exchange
Caustic Soda / Potash Alkalinity Control to pH 9.0
to pH 9.0 10.0
(lb/bbl) 10.0
DRILL GEL (lb/bbl) Viscosifier 8.0 12.0 3.0 6.0
DRISCAL D (lb/bbl) HTHP Fluid Loss 1.0 2.0
THERMO-TROL (lb/bbl) HTHP Fluid Loss 2.0 3.0 2.0
T-REX (lb/bbl HTHP Fluid Loss 5.0 8.0
THERMO-PLEX (lb/bbl) HT Viscosifier 1.5 3.0
Shale
CUMULUS CPG (v/v %) 3.0
Stabilisation
DRILL-BAR (lb/bbl) Weighting Agent 347 450
Typical Properties of a HYDRO-THERM system
Properties
Density (ppg) 15.0 17.2
Plastic Viscosity (cP) 30 - 40 40 - 50
Yield Point (lb/100ft2) 15 - 25 20 - 30
Gels (lb/100ft2) +/- 15 /40 +/- 12 / 25
API Fluid Loss (cc/30min) <4 <4
HTHP Fluid Loss 300F/

< 25 < 20
500 (cc/30 min)
Mixing Procedure
Mixing order, add :

Adjust pH with caustic or KOH
Fluid loss additives @ 15-20 min/sack
Polymer viscosifiers and fluid loss additives, 15 min / sack
Inhibitor salt
High Temperature dispersants if required
Barite
Minimize viscosifying polymer addition until after displacement to

reduce screen blinding
For high mud weights add half water requirement initially, then add
remaining water when adding Barite.
Displace to new mud system after drilling out cement if possible
Effects of cement contamination will be worse in a fresh water system

Add bicarb, gypsum and calcium chloride may also be required
Prehydrate HT Polymers in Fresh Water
Mud losses at the shakers are likely

Reduce circulation rates or use larger screens for 1-2 circulations
Dump and dilute to maintain correct solids and MBT conc.

Watch fluid properties for product depletion
High bit temperatures may cause product breakdown

Likely while turbo drilling with low flow rates
High temperature muds dehydrate due to
evaporation/filtration
Small additions of water may be required just below shakers
Carbonate contamination results in high viscosities
Add lime and dispersants if necessary
Drill-In Fluids
Fluids used to construct wellbore in the producing formation.
A drill-in fluid can be defined as a fluid that possesses the

desirable properties of a good drilling fluid but will also provide
the necessary attributes of a completion fluid.
Its primary attribute is the development of a filter cake which

effectively prevents formation damage and is easily
removed
Drill-In Fluids will be covered in detail in a separate

module (Inclsuing Opta-Flo, Rheo-Plex and NAF
Drill-In Fluid
Drill-In Fluids
Drill-in fluids can be:
Untreated mud held over from the previous

section
Treated mud held over from the previous section
New fluid formulated specifically for the producing

formation
DRILL-IN FLUIDS
OPTA-FLO Engineered Calcium Carbonate/Polymer system
OPTA-FLO drill-in fluids are custom designed to provide minimal

reservoir damage over a wide range of porosities and permeabilitys,
whilst at the same time providing an easily removable filtercake on
drawdown that typically requires no breakers or acid clean-ups.
The system is custom designed for each individual reservoir and uses
a range of high-quality components and design tools to facilitate the
design process.
One such tool is the Synthe-Sizer software program that allows the
fluids engineer to optimise the concentration and particle size
distribution of the bridging agent to ensure solids are deposited across
the pore throats with minimum invasion, yet seal off the reservoir with a
thin, compact and resilient filtercake
DRILL-IN FLUIDS
The key products in the OPTA-FLO system are
Product Description Function

OPTA-VIS Scleroglucan / clarified Viscosity
xanthum gum Control
OPTA-STAR Modified Starch Fluid Loss
Derivative Control
OPTA-CARB Custom sized Calcium Bridging agent
Carbonate
HYDRO- Proprietary Lubricity
LUBE
DRILL-IN FLUIDS
Typical Formulation
Product Function OPTA-FLO

Aw & Cation
KCl (lb/bbl) 22.0
Exchange
Caustic Soda / Potash Alkalinity Control
to pH 8.5 9.0
(lb/bbl)
OPTA-VIS (lb/bbl) Viscosifier 1.0 2.0
OPTA-STAR (lb/bbl) Fluid Loss control 3.0 5.0
OPTA-CARB (lb/bbl) Bridging Agent 30.0 50.0
HYDRO-CIDE (gal/100bbl) Biocide 3.0 5.0

DRILL-IN FLUIDS
Typical Properties
Properties
Density (ppg) 9.4
Plastic Viscosity (cP) 12 - 18
Yield Point (lb/100ft2) 15 - 25
6 rpm Reading
7 - 12
(lb/100ft2)
Gels (lb/100ft2) 6 - 12
API Fluid Loss (cc/30m) < 4.0
HTHP Fluid Loss (200F/
< 8.0
500psi)
DRILL-IN FLUIDS
RHEO-PLEX MMO / MMH System
Advantages
Viscosity Bentonite plus Excellent hole
MMO/MMH cleaning rheology
Avoids erosion of soft
Fluid loss Carboxymethyl formations
Starch (CMS), PAC Minimal loss into
fractures
Fluid Loss
Control Additive Disadvantages
Sensitive to
Density CaCO3 or contamination by
CaCO3 and barite many mud polymers
Not compatible with
Clean-up None? high KCl levels
Acid Poor acceptance of
bentonite as drill-in
Brine wash fluid additive
Breaker wash Poor fluid loss control
compared with
polymer muds
DRILL-IN FLUIDS
RHEO-PLEX is a mixed metal oxide system that delivers

a highly thixotropic (shear thinning) water-based fluid in
an environmentally and cost effective package. The
system exhibits a unique rheological profile that makes it
ideal for a wide variety of applications, such as;
Milling operations
Drilling fractured and vugular lost-circulation zones.
Stabilizing unconsolidated formations.
Coiled tubing drilling
High-angle
Horizontal wells (Drill-In Fluid)
DRILL-IN FLUIDS
Typical Flow Profile

Formate Systems
Recent Alternative to standard brine systems NaCl, KCl,

CaCl2
Advantages
Non damaging drilling in / completion fluid
Also used for workover / packer fluids
Temperature stability to 350F and very resistant to
contamination
Suitable for slim hole drilling
Non corrosive, Non toxic, Non scaling
Disadvantages
Cost, especially at high mud weights Cesium Formate is
extremely expensive
Applications for Formate Based Fluids
Reservoir drill-in and completion - to improve ECD,

production rates and minimize corrosion.
Narrow bore drilling - to improve circulating hydraulics in
slim hole and CT operations.
Shale drilling - to improve inhibition and minimize
environmental impact.
High temperature/high pressure drilling - to avoid
excessive solids, barite sag and stuck pipe.
High temperature/high pressure completions and
workovers to improve safety with solids free fluids.
Underbalanced drilling - to control density with solids free
fluids.
Drilling of Hydrates - to control dissociation.
Basic Properties of Formate Based Fluids
The formate salts of alkali metals

are very soluble in water and form Cesium Formate
brines of very high densities and
low crystallization temperatures. O-Cs
Cesium formate is the most
soluble of the three formate H-C
brines, the others being Sodium O
and Potassium formate.
- Preferred application of formates is as near saturated (water is bound

up with ions at a near 1:1 basis) fluids.
- Formate Based Fluids are made from; Na, K or Cs Formate and
blends of Na+K or K+Cs for density range from 1.0 to 2.3 s.g.
Basic properties of Formate Based Fluids

Formate Systems
Additives
Density: - Potassium Formate (10.8 ppg saturated brine)

- Sodium Formate (13.1 ppg saturated brine)
- Cesium Formate (19.2 ppg saturated brine)
- Increase up to 2 ppg with CaCO3
Viscosity - Xanthan
Fluid Loss - PAC
Inhibition - Salts,
pH Buffer
Bridging agents -CaCO3 150, Sized salts NaCl, etc.
Do not use starch products with Formates
Do not retort at normal settings
Formates decompose at 350F
Retort at 200F
Do not use Barite
Formate systems solubilise barite giving toxic barium

Invert Emulsion Systems NON AQUEOUS FLUIDS (NAF)

THREE PHASE SYSTEM
Base Fluid - Diesel, Mineral Oil, Linear Paraffin, Internal
Olefin, Esters This is the continuous phase,
WATER This is the internal phase is in the form of
emulsified droplets. All water soluble additives will be
found in this phase (CaCl2, soluble lime)
SOLIDS - barite, organophilic clays, drill solids, fluid loss
control products, LCM, etc. All solids are surrounded by
the continuous phase and are thus, oil-wet.
NAF will be covered in detail in a separate module

NON AQUEOUS FLUIDS
BASE FLUIDS INCLUDE

CRUDE
DIESEL
MINERAL OILS (LMO)
OLEFIN BLENDS (PAO, LAO)
LINEAR PARAFFINS (LP)
ISO PARAFFINS (IP)
INTERNAL OLEFINS (IO)
ESTERS OF PALM OIL ESTER
NON AQUEOUS FLUIDS

Advantages Disadvantages
High ROP High Cost

Long bit life Electric log difficulties
Excellent inhibition Oil water emulsion blocks in gas reservoirs
Thermally stable Lost circulation is $$$$$$$
Low reservoir damage Poor cement bonds possible
High lubricity, low torqueGas kick detection difficulties
Low corrosion Logistics
Gauge hole Messy working environment
Low fluid loss Difficult to detect crude (Geochem)
Reduced chance of stuck pipe Poor hole cleaning at high temperatures
High solids tolerance Fire hazard
Salt not dissolved Fumes
Good coring fluid Pollution Environmental Compliance
Using OBM can reduce total well cost by 25%

Emulsions
Internal Phase
Oil in water Brine in oil
Continuous Phase
Typical Formulation of a CONFI-DRILL (LP) system
Product 1 2
Linear Paraffin(bbl/bbl) 0.68 0.43
CONFI-MUL P (lb/bbl) 6 6
CONFI-MUL S (lb/bbl) 2.5 2.5
CONFI-GEL HT (lb/bbl) 6 3
LIME (lb/bbl) 3 3
CONFI-TROL (lb/bbl) 8 8
Drillwater (lb/bbl) 0.175 0.109
Calcium Chloride 22 13
DRILL-BAR (lb/bbl) 120 635

Typical Formulation of a CONFI-DRILL (LP) system
Product 1 2
Linear Paraffin(bbl/bbl) 0.68 0.43
CONFI-MUL P (lb/bbl) 6 6
CONFI-MUL S (lb/bbl) 2.5 2.5
CONFI-GEL HT (lb/bbl) 6 3
LIME (lb/bbl) 3 3
CONFI-TROL (lb/bbl) 8 8
Drillwater (lb/bbl) 0.175 0.109
Calcium Chloride 22 13
DRILL-BAR (lb/bbl) 120 635

Typical Properties of a CONFI-DRILL (LP) system
Properties 1 2
Density (ppg) 9.5 18.7
Plastic Viscosity (cP) +/- 15 +/- 80
Yield Point (lb/100ft2) +/- 12 +/- 30
Gels (lb/100ft2) +/- 6 /10 +/- 15 / 25
HTHP Fluid Loss (cc/30min) <2 < 3.5
SWR 80/20 80/20

Mud DF System

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DRILLING

Successful Drilling Fluid

Choice of Drilling Fluid

Suitability for the formations to be drilled?

To collect geological and reservoir data

To successfully exploit and produce oil & gas

Are mud losses expected?

Completion design Mud weight Company policy

Who has the fluids contract?

Lower Overall well costs Higher Very high

KMC Oiltools Systems

Water Base Systems

KMC Oiltools Systems

Specialist Water Base Fluids

Hydro-Therm High Temperature System

KMC Oiltools Systems

Non Aqueous Fluids

Confi-Drill Invert Emulsion Mud

Bentonite Spud Mud

Bentonite Spud Mud

Bentonite Spud Muds

Add Soda ash to reduce total hardness to below 150 mg/l

Add 0.5 - 1 ppb caustic soda to increase pH above 9.5

Add 25 - 35 ppb API Bentonite or 35-45 ppb OCMA/Euro Bentonite

Allow to hydrate at maximum shear for 6 hours if possible

Dilute with water / sea-water (final Bentonite concentration = 15 -25

Guar Spud Mud

Normally used only as a sweep Clean out tanks

Add drill water or sea water

3 - 4 ppb GUAR @ 5 - 10 min/sx

Lower solids keeps hydrostatic down

Engineering Comments Spud Muds

Fill all pits with PHG if necessary prior to spudding

Pump 50 bbls every 2/3 connections

Pump further sweeps if tight hole or hole fill is observed

At TD pump 100 bbl sweep around hole, observe returns

Displace hole to Hi Vis mud (+ excess) prior to POOH for

Weighted standby mud may be required if shallow gas is

1. Fresh water Bentonite muds.

MIXING INSTRUCTIONS - The Bentonite concentration will normally be 15

To increase the viscosity, increase the Bentonite concentration.

Fluid Loss Control

Fresh and sea water systems should use :

CMC (up to 2 ppb) - Deflocculates system

or use a combination of the above

At higher chloride levels the CMCs become less effective

Lignite & Lignosulfonate Systems

Advantages Inexpensive, easy to control system for drilling 17 1/2 and

Mainly used on land wells rather an old fashioned mud system

Mixing order (fresh water), add :

Adjust volume of water to obtain correct gel conc.

FCL / Calcium Lignosulphonate and adjust pH

Polymer viscosifiers and fluid loss additives, 10-15 min/sack

Mixing order (Inhibited systems):

1. Prehydrated Bentonite in fresh water with caustic and/or soda

Gypsum / Lignosulphonate System

Engineering Comments (Gyp System)

High lime content muds - > 5 ppb excess lime.

Lime Muds Breakover and Maintenance

Add the following simultaneously to the mud during 1-2 circulations :

The excess lime is controlled using the formula :

Limitations of Calcium Treated Muds

At high temperatures (above 275F) severe gelation or