Front-End Engineering
Mud Design
Allen Haryanto Lukmana
2019 - Allen H Lukmana
Mud Design
• What Type of Mud?
• How Much Mud Weight (ppg)?
• What additive must be added?
• How Much (Sack) barrite and Additve use to drill well?
• How many price?
2019 - Allen H Lukmana
Drilling Fluid Formula
• Bulk Density of Cuttings by using Mud Balance
• Decrease oil water ratio
• Determine oil water ratio from a retort analysis
• Determine the density of oil/water mixture
• Dilution to control LGS
• Increase mud weight by adding Barite
• Increase mud weight by adding Calcium Carbonate
• Increase mud weight by adding Hematite
• Increase oil water ratio
• Mixing Fluids of Different Densities with Pit Space Limitation
• Mixing Fluids of Different Densities without Pit Space Limitation
• Plastic Viscosity (PV) and Yield Point (YP) from mud test
• Reduce mud weight by dilution
• Solid Density From Retort Analysis
2019 - Allen H Lukmana
Bulk Density of Cuttings by
using Mud Balance
Ref books:
1. Lapeyrouse, N.J., 2002. Formulas and calculations for drilling,
production and workover, Boston: Gulf Professional publishing.
2. Bourgoyne, A.J.T., Chenevert , M.E. & Millheim, K.K., 1986. SPE
Textbook Series, Volume 2: Applied Drilling Engineering, Society of
Petroleum Engineers.
3. Mitchell, R.F., Miska, S. & Aadny, B.S., 2011. Fundamentals of drilling
engineering, Richardson, TX: Society of Petroleum Engineers.
2019 - Allen H Lukmana
Bulk Density of Cuttings by using Mud Balance
• Wet cutting coming over shale shakers can be used to determine
cutting bulk density.
• This slide demonstrates you how to find bulk density (specific
gravity) in specific gravity of cutting using mud balance, so please
read and understand procedure to determine resulting
weight with cutting plus water (RW) and then use RW to
determine specific gravity of cutting bulk density.
(OilfieldPix.com, 2017)
2019 - Allen H Lukmana
Procedure to obtain resulting weight
with cuttings plus water (RW):
1. Cuttings must be washed free of mud. In oil base mud,
diesel oil can be used instead of water.
2. Set mud balance at 8.33 ppg.
3. Fill the mud balance with cuttings until a balance is
obtained with the lid in place.
4. Remove lid, fill cup with water (cuttings included),
replace lid and dry outside of mud balance.
5. Move counterweight to obtain new balance.
6. This value is “Rw” = resulting weight with cuttings plus
water in ppg.
2019 - Allen H Lukmana
The specific gravity of cutting is calculated as :
SG = 1 ÷ (2 – (0.12 x Rw))
• Where;
SG = specific gravity of cuttings – bulk density
Rw = resulting weight with cuttings plus water in ppg
2019 - Allen H Lukmana
The specific gravity of cutting is calculated as :
Example:
Determine the bulk density of cuttings:
Rw = 14.0 ppg
SG = 1 ÷ (2 – (0.12 x Rw))
SG= 1 ÷ (2 – (0.12 x 14.0))
SG = 3.13
Moreover, if you can to convert specific gravity to mud
weight (ppg and lb/ft3) and pressure gradient (psi/ft).
2019 - Allen H Lukmana
Calculate Oil-Water Ratio from
Retort Data
Ref books:
1. Lapeyrouse, N.J., 2002. Formulas and calculations for drilling,
production and workover, Boston: Gulf Professional publishing.
2. Bourgoyne, A.J.T., Chenevert , M.E. & Millheim, K.K., 1986. SPE
Textbook Series, Volume 2: Applied Drilling Engineering, Society of
Petroleum Engineers.
3. Mitchell, R.F., Miska, S. & Aadny, B.S., 2011. Fundamentals of drilling
engineering, Richardson, TX: Society of Petroleum Engineers.
2019 - Allen H Lukmana
Calculate Oil-Water Ratio from Retort Data
• Oil Water Ratio (OWR) is a figure representing the
fraction of oil and water in oil based drilling mud.
• Generally speaking, it is a ratio between the
percent oil in liquid phase and the percent water
in liquid phase.
• In order to determine OWR, volume of
oil/water/solid in drilling mud comes from a retort
analysis.
• A sample of oil based mud is controlled burnt in
a retort kit at required temperature.
• When the mud is heated, water and oil will be
extracted out and solid is left in the retort kit.
• The retort analysis report shows percentage of
each component by volume so we use data from
the retort analysis to determine oil water ratio. Retort kits, OilfieldPix.com 2017
2019 - Allen H Lukmana
The formulas below
a) % oil in liquid phase = (% by volume oil x 100) ÷ (% by
volume oil + % by volume water)
b) % water in liquid phase = (% by volume water x 100) ÷ (%
by volume oil + % by volume water)
Result: The oil/water ratio equals to the percent oil in liquid
phase and the percent water in liquid phase.
2019 - Allen H Lukmana
Example:
Determine oil water ratio from following information
• Data from a retort analysis:
• % by volume oil = 56
• % by volume water = 14
• % by volume solids = 30
2019 - Allen H Lukmana
Solution:
a) % oil in liquid phase = (56 x 100) ÷ (56+14) % oil in liquid phase = 80
b) % water in liquid phase = (14 x 100) ÷ (56+14) % water in liquid phase
= 20
c) According to this retort report, the oil/water ratio equals to 80/20
2019 - Allen H Lukmana
Determine the density of oil and
water mixture
Ref book:
Drilling Formula Book Formulas and Calculations for Drilling,
Production and Workover, Second Edition
2019 - Allen H Lukmana
Determine
the density of oil and water mixture
normally get the oil/water ratio from a retort so you can use
these numbers to determine density oil and water mixture
by the following formula.
(V1)(D1) + (V2)(D2) = (V1 + V2)DF
Where;
• V1 = percentage of oil
• V2 = percentage of water
• D1 = density of oil
• D2 = density of water
• DF = final density of mixed fluid between oil and water
2019 - Allen H Lukmana
Determine
the density of oil and water mixture
Example:
• If the oil/water (o/w) ratio is 80/20 (80% oil and 20%
water), please determine the density of mixed fluid
between oil and water from the retort. Oil density = 7.0 ppg.
Water density = 8.33 ppg.
2019 - Allen H Lukmana
Example
• V1 = 0.8
• V2 = 0.2
• D1 = 7.0
• D2 = 8.33
(V1)(D1) + (V2)(D2) = (V1 + V2)DF
• (0.8)(7.0) + (0.2)(8.33) = (0.8 + 0.2) DF
• 5.60 + 1.67= 1.0 DF
• 7.27 = DF
• The density of the oil/water mixture = 7.27 ppg
2019 - Allen H Lukmana
Dilution of Mud System to
Control Low Gravity Solid by
Adding Mud
Ref book:
Drilling Formula Book Formulas and Calculations for Drilling,
Production and Workover, Second Edition
2019 - Allen H Lukmana
Dilution of Mud to Control LGS by Adding Mud
• Adding bbl of drillingfluid can help control low gravity
solid (LGS) in mud system.
• However, this is different from the way to control LGS by
adding base fluid as base oil or water because mud that is
added into system has some Low Gravity Solid (LGS).
• Hence, when we calculate it, we need to account for Low
Gravity Solid (LGS) of new mud into the calculation as well.
• This post will demonstrate you how to determine barrels
of drilling fluid required to achive the desired Low Gravity
Solid (LGS).
2019 - Allen H Lukmana
Formula, used to calculate dilution of mud system
Vwm = Vm x (Fct – Fcop) ÷ (Fcop – Fca)
Where;
• Vwm = barrels of dilution water or base fluid
• Vm = total barrels of mud in circulating system
• Fct = percent low gravity solids in system
• Fcop = percent total low gravity solids desired
• Fca = percent low gravity solids bentonite and/or chemicals
added in mud
2019 - Allen H Lukmana
Example:
• Determine how much barrels of oil base mud to diluate
total 2000 bbl of mud in system from total LGS = 7 % to
desired LGS of 3.5 %. The oil base mud has 2% of bentonite
slurry.
Vwm = Vm x (Fct – Fcop) ÷ (Fcop – Fca)
2019 - Allen H Lukmana
Example:
• Determine how much barrels of oil base mud to diluate
total 2000 bbl of mud in system from total LGS = 7 % to
desired LGS of 3.5 %. The oil base mud has 2% of bentonite
slurry.
Vwm = Vm x (Fct – Fcop) ÷ (Fcop – Fca)
Vwm = 2000 x (7 – 3.5) ÷ (3.5-2)
Vwm = 4667 bbl
In order to dilute total of 2000 bbl of the original mud with 7% LGS down to 3.5%
LGS, 4667 bbl of mud that has 2% bentonite is requied to add into the system.
2019 - Allen H Lukmana
Increase mud weight by adding
Barite, calcium carbonate,
hematite
Ref books:
• Lapeyrouse, N.J., 2002. Formulas and calculations for drilling,
production and workover, Boston: Gulf Professional publishing.
• Bourgoyne, A.J.T., Chenevert , M.E. & Millheim, K.K., 1986. SPE Textbook
Series, Volume 2: Applied Drilling Engineering, Society of Petroleum
Engineers.
• Mitchell, R.F., Miska, S. & Aadny, B.S., 2011. Fundamentals of drilling
engineering, Richardson, TX: Society of Petroleum Engineers.
2019 - Allen H Lukmana
Increase mud weight
• Weighting up is the critical operation while drilling so we
need to know how much weighting agent such as barite,
calcium carbonate, hematite, etc required in order to get
proper weight to prevent a well control situation.
• average specific gravity of barite – 4.2
• The maximum practical mud weight attainable with calcium
carbonate is 14.0 ppg, (Mud weight increase with calcium
carbonate (SG – 2.7))
• Hematite , its average specific gravity +/- 4.8, to weight up your
mud system.
2019 - Allen H Lukmana
The formula for weight up with barite
Sacks of Barite per 100 bbl of mud
= 470 x (W2 – W1) ÷ (35 – W2)
Sacks of calcium carbonate per 100 bbl of mud
= 945 x (W2 – W1) ÷ (22.5 – W2)
Sacks of Hematite per 100 bbl of mud
= 1680 x (W2 – W1) ÷ (40 – W2)
Where;
• W1 = current mud weight
• W2 = new mud weight
2019 - Allen H Lukmana
The formula for weight up with barite
Example:
Determine the number of sacks of barite required to increase
the density of 500 bbl of 10.0 ppg (W1) mud to 13.0 ppg (W2):
Sacks of Barite per 100 bbl of mud = 1470 x (13.0 – 10.0) ÷ (35 –
13.0)
Sacks of Barite per 100 bbl of mud = 201 sacks (round up)
If you have total volume of 500 bbl of mud, the barite required to
increase mud weight from 10.0 ppg to 13.0 ppg is 1,003 sacks
(201×500/100).
2019 - Allen H Lukmana
The formula for weight up with barite
Example:
Determine the number of sacks of barite required to
increase the density of 500 bbl of 10.0 ppg (W1) mud to 13.0
ppg (W2):
Sacks of Barite per 100 bbl of mud =
1470 x (W2 – W1) ÷ (35 – W2)
2019 - Allen H Lukmana
The formula for weight up with barite
Example:
Determine the number of sacks of barite required to increase the
density of 500 bbl of 10.0 ppg (W1) mud to 13.0 ppg (W2):
Sacks of Barite per 100 bbl of mud = 1470 x (13.0 – 10.0) ÷ (35 – 13.0)
Sacks of Barite per 100 bbl of mud = 201 sacks (round up)
If you have total volume of 500 bbl of mud, the barite required to increase
mud weight from 10.0 ppg to 13.0 ppg is 1,003 sacks (201×500/100).
2019 - Allen H Lukmana
Example
• Determine the number of sacks of Hematite per l00 bbl
required to increase the density from 10.0 ppg (W1) to 13.0
ppg (W2):
• Determine the number of sacks of calcium carbonate per
l00 bbl required to increase the density from 10.0 ppg (W1)
to 13.0 ppg (W2):
2019 - Allen H Lukmana
Calculate Inner Capacity and
Annular Capacity
2019 - Allen H Lukmana
Calculate inner capacity of open hole/inside cylindrical objects
• Inner Capacity in bbl/ft = (ID in.)2 ÷1029.4
• Inner Capacity in gal/ft = (ID in.)2 ÷24.51
• Inner Volume = Inner Capacity x Length
2019 - Allen H Lukmana
• Example: Determine inner capacity in bbl/ft of a 6-1/8 in.
hole:
Inner Capacity in bbl/ft = 6.1252÷1029.4
Inner Capacity in bbl/ft = 0. 0364 bbl/ft
• Example: Determine inner capacity in gal/ft of 6-1/8 in.
hole:
Inner Capacity in gal/ft = 6.1252÷ 24.51
Inner Capacity in = 1.53 gal/ft
2019 - Allen H Lukmana
• Annular capacity, which is one
of basic values that you really
need to understand, is volume of
fluid between two diameter of
cylindrical objects per length or
length per volume.
2019 - Allen H Lukmana
a) Calculate annular capacity in bbl/ft
Annular capacity in bbl/ft = (Dh2 – Dp2) ÷1029.4
b) Calculate annular capacity in ft/bbl
Annular volume can be determined by this following formula;
Annular volume in bbl = annular capacity (bbl/ft) x length of annulus (ft)
Note: annular volume can be expressed in several unit depending on unit that you
use in the calculation.
2019 - Allen H Lukmana
a) Calculate annular capacity in bbl/ft
Annular capacity in bbl/ft = (Dh2 – Dp2) ÷1029.4
Example: Hole size (Dh) = 6-1/8 in.
Drill pipe OD (Dp) = 3.5 in.
Annular capacity in bbl/ft = (6.1252 – 3.5 2) ÷1029.4
Annular capacity = 0.0245 bbl/ft
b) Calculate annular capacity in ft/bbl
Annular volume can be determined by this following formula;
Annular volume in bbl = annular capacity (bbl/ft) x length of annulus (ft)
Note: annular volume can be expressed in several unit depending on unit that you use in the calculation.
Example:
Annular capacity = 0.0245 bbl/ft
Length of annulus = 1000 ft
Annular volume = 1000 x 0.0245 = 24.5
2019 - Allen H Lukmana
Slug mud
Mud Design
2019 - Allen H Lukmana
What is slug mud? How much
volume and weight of slug mud
should be?
2019 - Allen H Lukmana
Slug Mud
Slug Mud:
• It is heavy mud which is used to push
lighter mud weight down before pulling
drill pipe out of hole.
• Slug is used when pipe became wet while
pulling out of hole.
• Normally, 1.5 to 2 PPG over current mud
weight is a rule of thumb to decide how
much weight of slug should be.
• For example, current mud weight is 10 PPG.
Slug weight should be about 11.5 to 12 PPG.
• Normally, slug is pumped to push mud
down approximate 200 ft (+/2 stands) and
slug volume can be calculated by applying
a concept of U-tube (see a figure below)
2019 - Allen H Lukmana
• Volume of slug can be calculated by this following equation:
• This equation expresses that the higher slug volume, the
deeper of dry in drill pipe is met. As per the above equation,
length of dry pipe can be substituted by 200 ft.
• In normal practice, slug volume pumped to clean drill pipe is
around 15-25 bbl depending on drillpipe size. Moreover, it also
depends on situations because sometime mud in annulus side
may be heavier than measured MW due to cutting, drilling
solid contaminated in mud, hence more slug volume is needed.
2019 - Allen H Lukmana
Barrels of slug required for desired length of dry pipe
• Volume of slug required for required length of dry pipe can be
calculated by this following equations:
Step 1: Determine hydrostatic pressure required to give desired drop
inside drill pipe:
Hydrostatic Pressure in psi = mud weight in ppg x 0.052 x ft of dry pipe
Step 2: Determine difference in pressure gradient between slug weight
and mud weight:
Pressure gradient difference in psi/ft = (slug weight in ppg – mud
weight in ppg) x 0.052
Step 3: Determine length of slug in drill pipe:
Slug length in ft = Hydrostatic Pressure in psi (in step 1) ÷ Pressure
gradient difference in psi/ft (step 2)
Step 4: Slug volume required in barrels:
Slug volume in barrel = Slug length in ft x drill pipe capacity in bbl/ft
2019 - Allen H Lukmana
Example:
• Determine the barrels of slug required for the following:
• Desired length of dry pipe = 200 ft
• Drill pipe capacity = 0.016 bbl/ft
• Mud weight = 10.0 ppg
• Slug weight = 11.5 ppg
2019 - Allen H Lukmana
Example:
• Determine the barrels of slug required for the following:
• Desired length of dry pipe = 200 ft
• Drill pipe capacity = 0.016 bbl/ft
• Mud weight = 10.0 ppg
• Slug weight = 11.5 ppg
• Step 1 Hydrostatic pressure required:
• Hydrostatic Prssure in psi = 10.0 ppg x 0.052 x 200 ft
• Hydrostatic Prssure in psi = 104 psi
• Step 2 differences in pressure gradient between slug weight and mud weight:
• Pressure gradient difference in psi/ft = (11.5 ppg – 10.0 ppg) x 0.052
• Pressure gradient difference in psi/ft = 0.078 psi/ft
• Step 3 length of slug in drill pipe:
• Slug length in ft = 104psi ÷ 0.078
• Slug length in ft = 1,333 ft
• Step 4 Slug volume required in barrels:
• Slug volume required = 1333 ft x 0.016 bbl/ft
• Slug volume required = 21.3 bbl
2019 - Allen H Lukmana
Weight of slug required for desired length of dry
pipe with set volume of slug
• You can determine how much
slug weight required in order
to achieve desired length of
dry pipe with certain slug
volume that you will use.
2019 - Allen H Lukmana
Please follow these steps of calculation below;
• Step 1 Determine Length of slug in drill pipe in ft:
• Length of slug in drill pipe in ft = slug volume in bbl ÷ drill pipe
capacity in bbl/ft
• Step 2 Determine hydrostatic pressure required to give
desired dry pipe drill pipe:
• Hydrostatic Pressure in psi = mud weight in ppg x 0.052 x
desired length of dry pipe ft
• Step 3 Determine slug weight needed in ppg:
• Slug weight in ppg = (Hydrostatic Prssure (from step 2) ÷ 0.052 ÷
Length of slug in ft (step1)) + mud weight, ppg, in hole
2019 - Allen H Lukmana
• Example: Determine slug weight required for the following
data:
• Desired length of dry pipe = 200 ft
• Mud weight in hole = 12.0 ppg
• Drill pipe capacity = 0.016 bbl/ft
• Volume of slug = 20 bbl
2019 - Allen H Lukmana
• Step 1 – Determine Length of slug inside drill pipe in ft:
• Slug length = 20 bbl ÷ 0.016
• Slug length = 1250 ft
• Step 2 – Determine hydrostatic pressure required to give
desired dry pipe drill pipe
• Hydrostatic Pressure in psi = 12.0 x 0.052 x 200
• Hydrostatic Pressure in psi = 124.8 psi
• Step 3 – Determine slug weight needed in ppg:
• Slug weight in ppg = (124.8 ÷ 0.052 ÷ 1250) + 12.0
• Slug weight in ppg = 13.92 ppg
2019 - Allen H Lukmana
