SPE 128810

A Derivation of Drilling Fluid Modeling for PR # 2 Well (KG Basin - India) in

Terms of Geo-pressure Gradient and Geo-mechanical Stress for Extra
Wellbore Stability of its over pressured Highly Reactive – Water Sensitive
Shale column of 1225 Mtrs in 8-½ inch borehole from 2883 Mtrs to 4108 Mtrs
TVD: A Critical Analysis of Shear Failure Pressure and Chemical Osmosis during Fluid – Shale Interactions
Jagdish P. N. Giri, ONGC

Copyright 2010, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Oil and Gas India Conference and Exhibition held in Mumbai, India, 20–22 January 2010.

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 any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract: Success of achieving extra well-bore stability in highly reactive shale column of 1225 mtrs, in PR#2,
is attributed to adequate pre-well planning, execution of drilling plan and guidelines, and the K+Cl –Polymer Drilling
fluid chemistry. Well-bore cleaning and hydraulic modeling in an integrated geo–pressure gradient and critical
analysis of shear failure pressure due to chemical osmosis and fluid – shale interaction was the significant attribute
on well-bore stability. Pre well modeling of well-bore stability in problematic shale – zones and hole cleaning in its
deeper final phase, contributed to stable hole behavior during unexpectedly longer durations on non – drilling
downtime for frequent surface equipment failures, etc. Paper critically analyzes shear failure pressure and
chemical osmosis during fluid – shale interaction to improve better well construction - design and drilling fluid
modeling for productive oil – field economics in entire KG Basin - India. Key conclusions drawn from such a critical
analysis of water based K+Cl – K+ Lignite/PHPA Polymer mud system include:
• Hole cleaning and hydraulic model derived in this analysis, proved to be quite useful in the pre well
planning process as well as in post - well analysis on high bore-hole stability.
• Chemical osmosis and shale – fluid interaction further demonstrated the pore pressure transmission, and
geo-pressure variance, and its integration with geo-mechanical stress and shear failure pressure derived
the well-bore stability modeling.
The case study presented compares original mechanical stability and hydraulic- fracturing estimates with the
critical mud weight identified for successfully completing this difficult operation. Descriptions of well-bore stability
and fluid losses are presented along with drilling fluid parameters used to combat them. Method used for
estimating formation pore pressure, in-situ stresses and formation rock properties are also described. Additionally,
possible explanations for differences between planned and actual stability estimates are explored with future
recommendations for similar operations.

Background: An Exploratory PR # 2 well, was drilled in Pendurru Structure of KG Basin - India, to delineate the
gas show of PR # 1 well geology in its dominant deeper shale lithology, beyond 3000 mtrs depth in the same
basin. Initially, the well was planned as a deep well of 4100 mtrs (Target Depth) of an exposed deep shale lithology
of approximately 1100 mtrs between 3000 mtrs – 4100 mtrs in 8-½ inch borehole interval, however is was finally
drilled for 1225 mtrs of open hole interval of highly reactive shale, in its 8-½ inch gazed hole diameter and
significantly stable hole condition, from 2883 mtrs to 4108 mtrs. The shale encountered in most of the Krishna –
Godavari sedimentary deeper basins, are some of the most chemically reactive and highly water sensitive found in
any drilling area, all around the world; they contain high percentages of mixed – layer of illite/smectite clays, which
are prone to swelling and dispersion, and can lead to diminished control of mud rheological properties, due to its
high Cation Exchange Capacity (CEC), and exchangeable cation characteristics. In early days of exploratory
drilling during 1985 to 1995, in nearby Bantumuli, Nandigama and Lingala structures of KG Basin - India, the
troublesome deeper shale was drilled with Oil Based Drilling Fluids, however, applications of water - based K+Cl –
K+ -Lignite Polymer Mud Systems to drill Highly Reactive and Water Sensitive Shale and Clay sections, of almost
all deeper wells in Krishna–Godavari Basin, replacing Oil Based Drilling Fluids, as a need to supplement
2 SPE 128810

environment protection and prevent environmental hazards in oil / gas field drilling operations of KG Basin, during
past one decade after 1995, has necessitated, to analyze critically the well-bore stability of open hole shale and
clay lithology, in terms of variance in geo-pressure gradient, geo-mechanical stress, shear failure pressure during
chemical osmosis and fluid - shale / clay interactions on a drilling fluid modeling of KCl – K+-Lignite Polymer mud,
used successfully for drilling, PR # 2 well, in Pendurru structure of Krishna-Godavari Basin, and to derive its extra
well-bore stability in 8-1/2 inch (1225 mtrs deep), exposed shale and clay section from 2883 mtrs to 4108 mtrs
(Measured Depth), that resulted in smooth drilling and well - logging operations, in spite of frequent surface
equipment failures almost every day during drilling and longer duration of tripping cycles and more than a week
days time of waiting on well - logging, for a total drilling - logging period of more than 60 days ( out of that less than
40 % time, i.e., only 24 days were actually productive drilling period ), beyond 2883 mtrs in 8 – ½ inch shale
section to the drilled depth of 4108 mtrs (Measured Depth). The choice of using, proven water – based K+Cl – K + -
Lignite Polymer mud system for drilling this well was based on following well construction and drilling fluid design
parameters:
1. Shale inhibition, prevention of formation damage and formation analysis;
2. Prevention of solid build up and solid dispersion in mud system;
3. Mud weight optimization to supplement geo pressure gradient and geo mechanical stresses;
4. Extra well bore stability through Chemical Osmosis and improved Reflection Coefficient;
5. Hole Cleaning Efficiency in terms of Hydraulics and HCE Modeling;
6. Pore Pressure Transmission and change in Geo- pressure gradient;
7. Geo-mechanical stress and shear failure pressure due to shale hydration; and
8. Drilling - Fluid system Performance.
The success of achieving extra well – bore stability in highly reactive shale column of 1225 mtrs, can be attributed
to adequate pre-well planning, execution of the drilling plan and guidelines, and the K+Cl – Polymer Drilling fluid
chemistry on one hand and hole cleaning and hydraulic modeling in an integrated geo –pressure gradient and
critical analysis of shear failure pressure due to chemical osmosis and fluid – shale interaction, on the other.
Extensive pre- well modeling of well – bore stability in problematic shale zones and of hole cleaning in its deeper
final phase, contributed to the stable well bore behavior during unexpectedly longer durations on non – drilling
downtime for frequent surface equipment failures, etc. In detail, the paper critically analyzes shear failure pressure
and chemical osmosis during fluid – shale interaction to improve better well construction design and drilling fluid
modeling for productive oil – field economics in entire KG Basin - India. A water based mud such K+++Cl – Polymer
mud system with a rheological profile of API – PV = 15 – 18 ( cp ), yield point ( YP ) = 24 – 25 ( lbf/ 100100 sq.ft )
, and funnel viscosity of 42 seconds, as maintained in drilling of PR # 2 shale is recommended for effective hole
cleaning. However, use of high viscosity fluids should be avoided, particularly in high angled or deviated sections.
In addition, the following considerations are significant;
1. The particle diameter of the drilled cuttings was demonstrated to be an important factor for Hole Cleaning
Efficiency. Less aggressive PDC bits with reduced cutter diameters were recommended and can be used so
smaller cuttings would be cut and cleaned from the well bore more efficiently.
2. A maximum ECD of 1.65 g/ lit – 1.67 g/ lit was predicted in pre well drilling plan while drilling with 1.60 g/ lit –
1.62 g/ lit mud, moreover, the ECD measured near the bottom of the 8 -½ inch shale section, agreed quite
closely with those estimated in pre well planning.
3. Extensive well – bore stability and hydraulic modeling in the pre well planning phase can greatly increase the
likelihood of success in non – routine drilling situations.

Introduction: Hydratable shale often lead to a variety of drilling problems such as well – bore instability, stuck –
pipe, and solids build – up in drilling fluids. Shale is fine – grained sedimentary rocks that contain significant
amount of clay minerals. The types and amounts of clays as well as the degrees of its hydration have important
effects on the chemical and mechanical behavior of shale during water – based fluid- interactions. During drilling,
knowledge of swelling - clay content or shale - factor is significantly useful in determining the type and amount of
shale inhibitors required for drilling fluids to provide well – bore stability. The swelling clay content also provides
valuable information about drilling problems such as well – bore instability, stuck-pipe, bottom – hole fill, bit balling,
torque, drag, and solids build-up in the drilling fluids. Well completion problems, such as formation damage in shaly
sands, logging and coring failures, hole wash outs, and poor cement jobs are attributable to the hydratable clay
content of the reactive and water sensitive shale formations. It is further, a proved estimation, world over in
general, that the drilling problems due to the well – bore instabilities are responsible for about 10 % - 20 % of total
drilling cost of a well, however, under KG Basin especially, while drilling through dispersive and reactive formations
such as shale or clay in deeper sections, well - bore instabilities cost even more. Further broad statistical analysis
of KG Basin - wells, in particular, reveals that 80 % to 90 % of these instabilities occur when drilling through water
sensitive shale or compact clays. It has been established in early seventies itself, that chemical reactions and
shale interactions with aqueous drilling fluids were at the origin of shale swelling, which would in turn facilitate the
destabilization of well bore wall, while drilling. Over the years since 1970s onwards, various techniques and water
SPE 128810 3

based - drilling fluid designs, aimed at inhibiting such reactions / interactions between drilling fluids and shale, have
been developed and tried in practice with various degrees of success. As an example K+Cl – K+-Lignite - Polymer
mud system pioneered in seventies proved to be very effective to replace or substitute Oil – Based Drilling Fluids,
earlier used to drill most of the reactive shale or clay formations world over, as a need to prevent environmental
degradation and environmental - hazards in oil field drilling operations. Since past one decade, K+Cl –K+-Lignite -
Polymer mud systems have been successfully applied for drilling of deeper shale in KG Basin as well, which are
some of the most chemically reactive and highly water sensitive found in any drilling area, all around the world ;
they contain high percentages of mixed – layer illite / smectite clays, which are prone to swelling and dispersion,
and can lead to diminished control of mud rheological properties, due to its high Cation Exchange Capacity (CEC),
and exchangeable cation characteristics. In parallel with these developments in the area of drilling fluid inhibition
modeling, the understanding of the mechanisms leading to borehole instabilities has been improved and a recent
advancement in this area has been derived in terms well – bore stability model, incorporating physico – chemical
interactions between shale and drilling fluids, leading to chemical osmosis and pore pressure transmission through
shale permeability, that resulted in increase in geo-pressure gradient, and finally, a failure in shear pressure,
causing well –bore destabilization. Further drilling in the shale – sand reservoir section would be through reactive
shale and unconsolidated sands : thus, three high priority requirements were perceived to – (1) shale inhibition, (2)
borehole stability while drilling, and (3) sand exclusion while producing. In view of the foreseen requirements, the
optimum drilling fluid for such a shaly reservoir would need to represent the best compromise with respect to shale
inhibition, hole-stability, lubricity and ability to improve drilling – rate.

The case study depicts a derivation of Drilling Fluid Modeling for PR # 2 Well (KG Basin - India) in terms of Geo-
pressure Gradient and Geo-mechanical Stress for extra well – bore Stability of its Highly Reactive – Water
Sensitive Shale column of 1225 Mtrs in 8-½ inch bore - hole from 2883 Mtrs to 4108 Mtrs, ( Measured Depth ). As
an Exploratory oil / gas well, PR # 2 well, was drilled in Pendurru Structure of KG Basin - India, to explore and
delineate the gas show of PR # 1 well – geology in its dominant deeper shale – lithology, beyond 3000 mtrs depth
in the same basin. Initially, the well was planned as a deep well of 4100 mtrs (Target Depth) of an exposed deep
shale lithology of approximately 1100 mtrs between 3000 mtrs – 4100 mtrs in 8 – ½ inch borehole interval,
however the well was finally drilled for 1225 mtrs of open hole interval of highly reactive shale, in its 8 – ½ inch
gazed hole diameter and significantly stable hole condition, from 2883 mtrs to 4108 mtrs. The derived well -
stability model further incorporates a critical Analysis of Shear Failure Pressure and Chemical Osmosis during
Fluid – Shale Interactions to elaborate borehole stability mechanism. The effective drilling fluid performance of the
water - based KCl – K+-Lignite Polymer mud used successfully for drilling, PR # 2 well, resulted in extra - well-
bore stability in its 8-1/2 inch (1225 mtrs deep ),
 The Schematic Graphics of Geo-pressure Variance of PR # 2 ( KG Basin )
Depth In Well Mud
Fracture
Meters Construction weight
Pressure PIT/ LOT

250
Pore Pressure
Variance 500 400.50 1.05

750 1.378
LOT
1000 1.10
Gas – Show during
Geo-pressure 1250
Drilling
(MW –equivalent)

1500

1750
Background Gas
(0.1% - 8.0) 1904.00
2000 1.20
1.64
LOT
2250 2232.00

2500

2750
Trip Gas 2883.70
1.28
( 0.1 % - 100 % )
3000 8-1/2 inch
10 Hole 1.35
90 3250
Dominantly
Shale
12 3500 Lithogy
100
75 % 29 3750
100 % 95 50 %25 % 4000 0.25 0.50 0.75 1.00 1.251.411.46 1.501.541.75
0
Pressure in mud weight equivalent

4
 Mechanism of Well – bore Stabilization for Hydratable Shale
An Explanation of well bore stability of PR # 2 well in its 8-1/2 inch
Shale section……

Mud Pressure /
Hydrostatic Head

Fluid /Filtrate Invasion Differential Pressure for

filtrate invasion Filtrate Invasion
= Mud Pressure – Pore Pressure
Pressure / Pore Pressure
Shale Hydration……..=
Well-bore support stress = Hydrostatic Head – Pore Pressure
---------------Depth ---------------
Well – bore stabilization

An ideal situation of stable and non – hydration of shale, where Pore pressure is not
changing; Pore- Pressure Transmission due to shale hydration is zero and Reflection Coefficient
for filtrate molecules is almost one.

Mud – Pressure /
Hydrostatic Head

Invaded or hydrated shale zone

Shale hydration
Elevation in Increased
beyond
Pore Pressure Well bore stress
Support

Pressure

Shale Hydration and Well-bore destabilization

----------- Depth ---------

5
6 SPE 128810

Drilling Fluid Selection: Summarized Best Practices:

Operational Stage Type Of Drilling Fluid Drilling – Fluid Parameters
Drill – in Fluid. KCl – K+ - Lignite Polymer Shale – Inhibition.
Mud Prevention of Clay –
Dispersion / Solid Build – up.
Prevention in Pore Pressure
Transmission,
Reduction in Shale Hydration.
Mud – Weight Optimization. KCl – K+ - Lignite Polymer Prevention Of Formation
Mud Damage.
Well-bore stability, balancing
hydrostatic head, and reducing
formation influx, such as
background gas etc. while
drilling.

Over the years, since seventies onwards, continuing efforts are being made to develop most effective water based
drilling fluid that can provide the osmotic membrane behavior and well – bore stability, comparable to a highly
effective oil based drilling fluid. Consequently, a pore pressure transmission technique is developed and in use for
several years as a tool to measure osmotic behavior and changes in permeability and pore pressure in response to
interactions of shale / clay with aqueous drilling fluids. Basically three different types of “osmotic membranes” are
postulated to describe the interaction of various drilling fluids with shale.
1. Type – 1, membranes are generally characterized by coupled flows of water and solutes between drilling
fluids and shale – fluids.
2. Type – 2, membranes greatly reduce the near well – bore permeability of shale and restrict the flow of both
water and solutes, and
3. Type -3, membranes transport water more selectively : Invert – emulsion fluids tend to form more efficient
selective osmotic membranes of type -3, however, under certain conditions, the invert – emulsion fluids
can yield lower capillary pressures than anticipated, and can invade the interstitial fabric of high
permeability shale.
And furthermore, over the years, several water – based mud formulations in combination of various cellulose-
polymer additives and sodium, potassium as well as silicate, magnesium and aluminum, salts, have been
developed, that achieve approximately one-quarter to one-half of the measured osmotic pressure of a typical oil –
based mud (OBM ), and resulted in applications of a variety of water –based mud ( WBM ) systems, for drilling
even highly reactive and water – sensitive deeper shale. Shale - Membrane efficiency in restraining the passage of
solutes or fluids between mud system and shale fluid, is further quantified by a measurable behavior of shale-
membrane, in analogy with optical reflections as “Reflection Coefficient – sigma”. All solutes of a solution to which
a shale - membrane is exposed will be fully or partially reflected, leading to quantify the reflection coefficient
between zero to one (ideal semi-permeable membrane that allows the passage of solvents only is denoted by
reflection coefficient 1, whereas non – ideal membranes, allowing partial or complete passage of solutes as well,
will have a reflection coefficient between 1 to 0). Such a measurable quantity of reflection coefficient leads to a
“leakiness factor” between shale and drilling fluid interactions. Clay – based materials in dominant shale lithology
have intrinsic membrane behavior with reflection coefficients between 0 and 1, depending on the fluid contacting
the clay surface in a compact shale matrix. High permeability sand, on the other hand, does not exhibit semi-
permeable osmotic properties, and its reflection coefficient is essential zero. For a shale lithology at thermal and
electrical equilibrium, osmosis across a semi-permeable clay membrane in its matrix consists of water transport
from higher to lower water activity, and this water flow will continue unless or until osmotic pressure is balanced by
the hydraulic pressure. For an ideal semi-permeable membrane, that is the extent of osmosis, however for a leaky
clay membrane in the shale matrix, solute species will also flow and can flow in both directions. Furthermore
hydrated species will carry water with them, leading to countercurrent flow of water and dispersed solids. For shale
in contact with typical salt-based aqueous drilling fluid such as, K+Cl - K+-Lignite Polymer mud system, water will
flow from the shale into drilling fluid, but opposing hydrated cations and anions will flow from the drilling fluid into
the shale matrix. Additionally, hydrated salt species in the pore network of the shale will tend to flow into the drilling
fluid. Further complicating the picture is the resulting exchange of ions on the clay. These substitutions cause clay
surfaces in a compact shale matrix to have a net negative surface charge, and its electrical neutrality is preserved
by attraction of cations from the drilling fluid. The charged clay surface with counter – ions in the pore water form
the diffused double layer, resulting in inhibition of anions into the pores. In practice, morphology of the clay
SPE 128810 7

structure in the dominant shale lithology and fluid / pore water interaction play significant role in the construction
and maintenance of all three membrane types. Membrane ideality of an exposed natural clay / shale depends on
several factors, and the most important are mentioned below:
• Clay Type – Clay with high negative charge, expressed as the Cation Exchange Capacity (CEC), generally
provide superior semi-permeable osmotic membranes, than clays with lower CEC, because the double
layer is “thicker”.
• Clay / Shale Porosity – the more compact the clay / shale, the more double layers overlap to form a
contiguous membrane.
• Salt concentration of the pore water of the clay – lower salt concentration also results in a “thicker” double
layer and more ideal membrane.
• Drilling fluid composition – the nature of the clay / fluid interface is strongly influenced by physical and
chemical interactions of dispersed solids in the mud with the clay surface and / or dilution of bound water
by drilling fluid solvent.

The interactions of drilling fluids with formation shale may be categorized in terms of formation of three types of
membranes, shown in the following table. It should be emphasized that the term “membrane” is used here solely
for the purpose of illustrating, how the drilling fluid – shale interface affects the flow behavior of chemical species
between the drilling fluid and the shale.

Drilling Fluid – Shale Interaction: Formation of Osmotic Membrane and Membrane Type
Type – I Type – II Type – III
This type of membrane This type of This type of membrane is
is formed within the membrane is associated with invert –
shale. For this efficiently laid down emulsion based drilling fluids
membrane type, drilling as a relative and does not depend upon a
fluid filtrate, shale / impermeable deposited or precipitated
clay, and pore fluid deposits or solid film. A mobile film of the
chemistry, as well as precipitates continuous phase in
Membrane pore dimension, filtrate external to or within association of surfactants of
viscosity, permeability, the near – well bore the drilling fluid bridges and
clay components, and shale matrix. This separates the internal
shale cementation can type of membrane aqueous phase of the drilling
all contribute to the is typical to KCl – fluid from water – filled shale
development of K+-Lignite Polymer pores.
membrane effect and a Mud – Systems.
more ideal reflection
coefficient.
Position Internal Primarily External Primarily External
Character Dynamic, not Static, fixed Dynamic, not permanent.
permanent durable.
Clay/ shale Dependent Independent. Independent.
Effects.

The application of KCl – K+-Lignite Polymer mud system for drilling deeper shale of PR # 2 well under KG Basin
has demonstrated superior shale – stability. The issue here was the ability to maintain an open hole of 1225 mtrs
deep through sensitive shale for days or weeks allowing extended trouble-free drilling with water – based KCl –
polymer drilling fluid, and it has proved to maintain high borehole stability during more than 60 % of non – drilling
period due to downtime on surface equipment failures and longer tripping cycles. The lignosulfonates mixed in KCl
– Polymer at concentrations of greater than 4 % weight, effectively reduced shale permeability by 50 % to 70 % in
pore – fluid based formulations. This supports old claim that drilling fluids with high concentrations of
lignosulfonates provide shale stabilization. Particularly Type – II membranes are produced, at fluid – shale
interface, to prevent penetration of drilling filtrate through the osmotic membranes formed externally on well – bore
shale matrix. The maintained composition of the mud system, as tabulated below, during 8-1/2 inch drilling in 1225
mtrs deeper section of shale of PR # 2 well, significantly reduced fluid flow into the shale, resulting in reservoir
pressure stabilization and maintaining pore pressure gradient to provide extra borehole stability.
8 SPE 128810

Chemical Composition of the KCl – K+-Lignite Polymer Mud System Used for
Drilling of PR # 2 well
S. N. Name of the Chemical Maintained % by weight of the
chemical.
1. Bentonite 08%
2. KOH ( pH – 9.5 ) .01%
3. KCl 05.00%
4. K- Lignite 03.00%
5. Lignosulfonate – Polymer 03.00%
6. Chrome- lignite 02.50%
7. Resinated - Lignite nil
8. Sulphonated Asphalt. 04.00%
9. Surfactant ( D D ) 01.00%
10. Cellulose – Polymer. 03.00%

Hole Cleaning Efficiency in terms of Hydraulics and HCE Modeling:

The key parameters involved to hole cleaning modeling include:
• Mud Density.
• Fluid Rheological Parameters.
• Cuttings size and Shape.
• Pump Rate.
• Hole Geometry.
• Drill-pipe Eccentricity.
• Hole Angle.
• Drill-pipe Rotation.
• Rate of Penetration (ROP).

In order to derive Hole Cleaning Efficiency Modeling of KCl – K+-Lignite Polymer mud system, the following
important items are calculated:
• The fluid rheological parameters are calculated with the Herschel – Bulkley Rheological Model.
• A fine – mesh grid scheme valid for eccentric well – bores is used to model the hydraulics and annular
Hole Cleaning Efficiency.
• For the entire drilled shale section the circulating pressure drop is determined by numerical methods that
give the correct annular velocity.
• With estimated values for drill – pipe eccentricity, the point velocities in the entire column of annulus are
calculated.
• Particle settling velocities for both static and dynamic conditions are calculated.
• The volume of cuttings removed by drip-pipe rotation for the input drilling conditions is predicted as the
function of the ROP.

• With the effect of drill cuttings taken into account, the calculated pressure drops and circulating annular
mud densities for the entire drilled shale section of 8-1/2 inch well-bore are integrated to arrive at a final
annular mud weight and equivalent circulating density ( ECD ).

Hole – Cleaning Parameters:

The goal of optimizing hole cleaning parameters is to determine the ranges of drilling – fluid behavior and
operational parameters that would provide good hole cleaning efficiency, while drilling with reactive formations and
keeping the ECD at less than the fracture gradient at 9-5/8 inch casing shoe for drilling of 8-1/2 inch shale lithology.
Pump capacity on the rig provided for the maximum rate of ……….liters / minute at 90 % pump efficiency and 2000
psi Stand Pipe Pressure. Values for key parameters used in HCF Modeling included,

Hole Diameter = 8- ½ inch.

Drill – pipe size = 5- ½ inch.
Hole Deviation = Zero degree (vertical).
Average Cuttings Diameter = 0.25 to 0.75 inch.
Drill – pipe rotation sped (RPM) = 60 – 90 rpm.
SPE 128810 9

The water based KCl – K+-Lignite Polymer mud with following maintained rheological properties and mud density
served as the principal component for HCF Modeling. Because this fluid was a water based mud, subjected only
to moderate temperature and pressure conditions down hole, the surface fluid density and rheological properties
were not adjusted to down hole conditions. It was observed that the maintained rheological properties of the drilling
fluid was well enough for good hole cleaning.

Drilling Fluid Properties Maintained for Effective Bottom – Hole Cleaning:

Fluid Property Numerical Value
600 rpm 60
300 rpm 45
6 rpm 08
3 rpm 07
API – PV (cp ) 15
API – Yield Point YP 15
H – B “n” -
H – B “k” -
H – B “ t” -
Mud – Weight 1.34

For efficient Hole - Cleaning Modeling, the drill-pipe rotation speed was optimized at 80 rpm; however it was
varying between 60 rpm to 90 rpm during entire section of drilling. The optimized 80 rpm was chosen as the rig
was capable of achieving this rotation speed at the minimum, while drilling, as well as, HCEs at 80 rpm provided a
good operational base-line from which to evaluate drilling fluid performance.
• Further, particle size can significantly affect particle slip velocity under static conditions, and the effect is
even greater under dynamic conditions. It has been observed through Hole Cleaning Modeling that the
cleaning efficiency decreases with increasing particle size and that effect is more pronounced in deviated
or angled hole. The result also indicated that the less aggressive bit that would produce smaller cuttings
would be preferred given the operational constrains of rig and pump capacity, such as pump pressure
limits etc.
• As a part of fluid behavior optimization, the effect of increasing fluid rheological properties on the hole
cleaning efficiency was also analyzed. Velocity – modeling in eccentric well – bores have clearly
demonstrated that there can be wide divergence in fluid velocity above and below the eccentric drill – pipe.
Increased rheological properties serve to exacerbate the resulting flow diversion, often resulting in little to
no flow under the drill – pipe. With no fluid movement under the drill – pipe, cleaning suffers at elevated
hole angles. It is also an useful outcome that the cleaning efficiency of a higher viscosity fluid is only 25 %
to 33 %, as compared to a relatively less viscosity fluid, which cleaned the hole up to 70 % at high pump
rate.
• A number of significant observations were made on the basis of hole cleaning modeling results of K+Cl –
K+-Lignite Polymer mud system:
• It is apparent that annular velocity and Hole Cleaning Efficiency would be greatly improved by reducing bit
diameter alone, moreover it was further assumed that the hole may be washed out somewhat, because of
the dispersive nature of the formation when drilled with a water – based mud system,
• The higher the deviation, the more difficult the hole cleaning, even when the cuttings are small. With the
higher annular velocity, the hole is somewhat easier to clean and improvements are seen with high pipe
rotation,
• The larger the cuttings, the less efficient the hole cleaning,
• More viscous drilling fluid does not improve hole cleaning, particularly in deviated or high angled section,
• Pore Pressure Transmission and change in Geo- pressure gradient, and
• Geo-mechanical stress and shear failure pressure due to shale hydration,

Drilling - Fluid system Performance:

The overall KCl – K+-Lignite Polymer mud system was found exceptionally good on the basis of extra -stable and
highly gazed hole - condition of 1225 mtrs exposed shale section in 8-1/2 inch - final phase, and more stable mud
properties during drilling of this interval from 2883 mtrs to 4108 mtrs. Shale - inhibition and solid - dispersion in
term of a measured mud parameter on Cation Exchange Capacity (CEC), was one of the key parameters,
monitored and controlled by water - dilution and solid control equipments. The CEC value was effectively
maintained at less than 25 lbm / bbl bentonite equivalent, and was successfully achieved simply by water dilution
while drilling through more reactive formations. Further the mud system was found to be extremely tolerant of
dispersed solids, as reflected by the acceptable rheological properties for a mud weight of 1.62 sp. gr. (gm/liter)
10 SPE 128810

with a methylene Blue Content (MBC) or CEC 2.5 or 25 lbm/bbl bentonite equivalents. The accurately specified 4
% – 5 % of KCl concentrations and above 3 % of lignite / lignoslfonate concentrations in 9.5 mud pH, was
undoubtedly instrumental in providing the solid dispersal tolerance and shale stabilizing drilling detergent
treatments also appear to have made significant contribution to the overall well – bore stability.
• While drilling the KCl concentration was maintained at 3 % to 4 % for upper part of the hole interval, till
3600 mtrs and was subsequently increased to 4 % - 5 % in the lower part beyond 3600 mtrs up to drilled
depth of 4108 mtrs. However, it was not possible to further increase the KCl content in the lower part of the
drilled interval, to the planned 6 % KCl level, because of the severe depletion of K + ions under 72 0 C to
78 0 C bottom hole temperature. The maintained 4 % - 5 % of KCl content was well programmed and was
quite instrumental in KCl – K+ - Lignite Polymer mud system performance and the resultant excellent hole
condition.
• There were many significant accomplishments during drilling a deep well of 4100 mtrs, by a 25 years old
rig for such a deeper and chemically reactive interval of high pressured gas zone, with water – based
drilling - fluid system :
• There was minimal over-pull / tight-pull on trips, which was attributed to good hole cleaning and extra well
– bore stability of exposed shale section,
• There was no downtime , because of mud related incidents : the interval was effectively drilled during
productive drilling within the prescribed timeframe, as the total productive drilling time was only 40 % of
total consumed period of more than 60 days for drilling this interval – most of the non drilling time was
consumed on surface equipment failures and extra tripping time.,
• Hole conditions and drilling cuttings integrity were excellent through out the drilled shale interval – shale
heaving, sloughing or caving were not observed at all, and the hole was more or less gazed. Even with the
background gas of 5 % - 10 %, the pore pressure was effectively balanced with the optimized hydrostatic
head, and in 70 %– 100 % trip gas accumulations, the hole fill was significantly nil, and
• There was absolutely no downtime on the rig related to mud system – mud dilution, solid or background
gas control.

Conclusions:
The key conclusions that can be drawn from such a critical analysis of water based KCl – K+-Lignite Polymer mud
system include:
• The success of deriving extra bore-hole stability and efficient hole cleaning for drilling of highly reactive
and water sensitive deeper shale of PR # 2 well, can be attributed to adequate pre well planning,
execution of drilling plan and guidelines, and the KCl – Polymer Drilling Fluid Chemistry.
• The hole cleaning and hydraulic model derived in this analysis, proved to be quite useful in the pre - well
planning process as well as in post - well analysis.
• Chemical osmosis and shale – fluid interaction further demonstrates the pore pressure transmission, and
geo-pressure variance, and its integration with geo-mechanical stress and shear failure pressure derives
the well-bore stability modeling.
• A water based mud such K+Cl – Polymer mud system with a rheological profile of API – PV = 15 – 18,
yield point 24 – 25, and funnel viscosity of 42, as maintained in drilling of PR # 2 shale is recommended
foe effective hole cleaning. However, use of high – viscosity fluids should be avoided, particularly in high
angled or deviated sections.
• The particle diameter of the drilled cuttings was demonstrated to be an important factor for Hole Cleaning
Efficiency. Less aggressive PDC bits with reduced cutter diameters were recommended and can be used
so smaller cuttings would be cut and cleaned from the well –bore more efficiently.
• A maximum ECD of 1.65 – 1.67 was predicted while drilling with 1.60 – 1.62 mud, moreover, the ECD
measured near the bottom of the 8 – ½ inch shale section, agreed quite closely with those estimated in pre
well planning.
• Extensive well – bore stability and hydraulic modeling in the pre well planning phase can greatly increase
the likelihood of success in non – routine drilling situations.

Acknowledgement:
The author expresses his sincere thanks to the Management of ONGC, and more specifically to Shri I. M. Hashim
– DGM (Chemistry) – I/C – Sectoral HSE, ONGC, Chennai for providing all support and cooperation in preparing
the manuscript of the paper.
SPE 128810 11

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