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Copyright 2005, Society of Petroleum Engineers Inc. the primary agent in an effort to cool the bit, to remove
This paper was prepared for presentation at the SPE International Symposium on Oilfield cuttings from the face of the bit, and to carry those cuttings to
Corrosion held in Aberdeen, United Kingdom, 13 May 2005. the surface. There are several drilling processes that fit this
This paper was selected for presentation by an SPE Program Committee following review of definition: (1) dry air drilling; (2) mist drilling; and (3) foam
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to drilling (It can be detailedly classified stable foam drilling and
correction by the author(s). The material, as presented, does not necessarily reflect any rigid foam drilling ).
position of the SPE, their officers, or members. Electronic reproduction, distribution, or storage
of any part of this paper for commercial purposes without the written consent of the Society of During the dry air drilling or dusting process, dry air is
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
injected into the drillstring and cutting carrying capacity for a
conspicuous acknowledgment of where and by whom the paper was presented. Write particular application is determined by borehole annulus air
Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
velocity. This method is used when no formation liquids are
present in the wellbore.
In mist drilling some water is injected along with the air
Abstract into the drillstring, but air remains the continuous phase while
Simulating corrosion condition of air foam drilling, corrosion water is the discontinuous phase. This practice can be used to
inhibition performance and foaming properties of stable foam handle relatively small water flows into the wellbore.
are evaluated. Corrosion product layer images and composites Corrosion inhibitor and a surfactant solution are commonly
are investigated by scanning electron microscope, energy injected along with the water in this method.
dispersion spectrometer and x-ray diffraction analysis. The For foam drilling, enough water and foaming agent are
results show that corrosion pitting with sodium chloride injected along with the air to make air the discontinuous phase
crystalline grain forms on the surface of steel corroded by and water the continuous phase. Foam has a cuttings carrying
formation water. Foam can retard corrosion, particles in foam capacity superior to that of any other system, including liquid
uniformity, thinness and tightness. After adding foam and drilling systems, yet it retains most of the advantages common
inhibitor no obvious corrosion phenomenon happens but to all air drilling procedures. In additional, it can be used to
existing tiny trace originating from washing and erosion. handle water influxes that are too large to be handled with
Foam corrosion inhibition mechanism is first put forward mist drilling. Air drilling types and peremeter show in Table 1.
through laboratory data and theoretical analysis, which mostly
consists in foam agent absorption on steel surface; viscosifier Advantages of foam drilling. Drilling speed is high and
complexing characteristic; oxygen isolation; foam enwrapping there is no obvious corrosion phenomenon of drilling tools
sands, reducing erosion. Adding inhibitor and oxygen using dry air or natural gas drilling without formation water. If
scavenger, foam corrosion inhibition ability is improved formation water invads into the annulus during drilling,
further. Indoor experiment and field application show foam drilling tools were corroded severely, hence the dry air drilling
drilling substituting for dry air drilling and adjusting pH value should be substituted for foam drilling, which can not only
and adding inhibitor reduce sharply corrosion of drilling tools. carry the formation water to ground effectively, but also
Special formula in Western Gasfield of China X-14 well is sharply reduce the corrosion of drilling tools. The foam
2.0%F4 +0.3%HPAM + 0.2%XC + 0.5%CT2 + 0.05%Na2SO3. drilling is based on the dry air drilling in addition adding
Practice proved that this method effectively restrained drilling foamer, viscosifier and some other surfactants, which can
tools corrosion and improved economic benefits. produce stable foam, enwrap water and drill cuttings in foam
This paper is the first in a series of studies designed to or foam-like structure, take away the formation water as
bring forward foam corrosion inhibition in air foam drilling. carrying the solid particles consequently eliminate the
The goal is to better understand the mechanism of foam formation water effectively. Compared with dry air drilling,
corrosion inhibition, to be able to select the proper inhibitor foam drilling can reduce erosion of drilling tools due to less
and extend air foam drilling techniques in suit region. air output and lower return velocity, and cut down contact of
air and drilling tools by foam enwrapping air, at the same time
Introduction through synergetic function of high pH and inhibitor, the
Definition of Air Drilling1-2. An air drilling operation can be corrosion of drilling tools is reduced3-4. Besides, foam drilling
defined as any drilling process that utilizes compressed air as can potentially result in increased profit margins due to its
2 LIpING WAN AND YINGFENG MENG SPE 94469
advantages. These include: (1) avoidance of lost circulation is foamer mixed dodecyl alcohol sulfonate with dodecyl
problems; (2) minimizing damage to sensitive pay zones; (3) dimethyl tertiary amine oxide, HPAM is viscosifier which is
higher penetration rates and bit life; (4) immediate and modified from polyacrylamide, XC biopolymer is foam
continuous evaluation of cuttings for hydrocarbon shows; and stabilizer, CT2 is quaternary ammonium imidazoline inhibitor,
(5) production while drilling. Na2SO3 is oxygen scavenger.
Test temperature is 60 , air pressure 1.0 Mpa, the
Experimental Procedures amount of drill cuttings 30%, the rotate speed of electromotive
Main Experiment Equipment. GSH-1/10 high-intensity 150r/min, corrosion reaction time 48h. Surveying the dynamic
magnetic agitation and high temperature high pressure corrosion rate of foam in high pressure vessel, moreover
(HTHP) action vessel; Waring Blender; HITACHI S-450 measuring quality and half life of the foam in Waring Blender,
scanning electron microscope (SEM); OXFORD ISIS energy the result as is shown inTable 4.
dispersion spectrometer (EDS); D/max-2400 X-Ray Conclusion is obtained as follow: foam has corrosion
diffraction (XRD). inhibition ability to a certainty, which can be improved after
In order to factually simulate air foam drilling process, adding inhibitor. This conclusion provides a powerful
the HTHP reaction vessel is rebuilt. First adding a tri-wheel laboratory support for that the corrosion of drilling tools
metal leaf in the bottom of central rotation pole can stir reduces when the foam drilling substitutes for dry air drilling.
cuttings deposited in bottom, which realistically simulates Corrosion phenomenon shows that: when adding foaming
cuttings erosion to drilling tools and connection abrasion. agent into corrosion medium, viscosity of solution enhances,
Second reaction vessel is not set uprightly but lain down (two non uniform corrosion of test coupon is translated into
setting methods form an angle of 90 degree), which ensures uniform corrosion, the superficial layer is covered by high
the contact of drill cuttings and corroded steel is interim. If viscosity film, which is yellowish-brown, can be washed by
reaction vessel setting uprightly most of cuttings subsided to water, the inside layer black corrosion product. Corrosion rate
bottom, thus contact of cuttings and corroded steel is of test steel falls to 1.475mm/a from 2.195mm/a, and
continuous, which can not agree with field air foam drilling. inhibition ratio reaches 32.8%. Inhibition ability of foam
In practical air foam drilling operation, cuttings carried by principally consists in foaming agent absorption on steel
airflow bump and erode drilling tools at intervals, so reaction surface. Adding inhibitor into foam system, viscosity of
vessel should be lain down. Finally air holes in vessel lid are solution increases, uniform corrosion. The superficial layer is
plugged up with filter mesh, preventing cuttings jamming covered by high viscosity films which are yellowish-brown.
holes. The black scales of the inside layer decreases evidently, and
corrosion rate ulteriorly drops. The inhibition ratio of corroded
Corroded Materials and Medium. Test material: S135 drill coupon arrives at 82.5%, which reaches the aim of corrosion
pipe steel (API standard), chemical element and metallurgical inhibition initially. The reason lies in that CT2 is quaternary
analysis are listed in Table 2. Material element and mechanics ammonium imidazoline inhibitor, the atom N of imidazoline
performance conform to the standard of API SPEC 5D. can be connected with quaternary ammonium, then change
Machining dimension: 50mm H 25mm H 3mm, round hollow into great molecular weight cation, which is easy to form
diameter 3mm. steady coordination bond with free d orbit on the surface of
Abrasion medium: Using outcropped rocks of X-14 well steel, and then reducing corrosion rate of anode. After
nearby simulate sands or drill cuttings. These rocks are adding the oxygen scavenger, the stable performance of the
smashed into 20, 55 and 75 grid fine grain. Adding quantity is foam system declines slightly, but its inhibition ability is
10% respectively, so tatal quality of cuttings accounts for 30% improved. In appointed temperature, oxygen scavenger can
of formation water. remove dissolved oxygen in a great measure from corrosion
The corrosion medium is simulating formation water of medium, so corrosion inhibition ability is improved a lot. As
ChangQing Gasfield X-14 well. According to the element for the stability decrease of foam system, it maybe is that the
percentage of the formation water in the depth of 1126m- reduction of dissolved oxygen of medium leads to the decrease
1180m, representative water is prepared. The water type is of gas phase percentage of foam system, then quality and half
CaCl2, and the content of Cl- is 41641mg/L, the salinity is life reduce subsequently. The amount of dissolved oxygen in
relatively high, the flowout amount of formation water is foam system is lower compared with the air, as a result, even
about 90m3/h. The specific water quality analysis result is adding oxygen scavenger, the quality and half life is not
showed in Table 3. reduced dramatically.
Results and Discussion X-Ray diffraction analysis and other surface experiments.
Weight Loss Corrosion Experiment. One major aspect Watching the corrosion images of S135 steel in three different
concerning the applicability of a foaming system is the corrosion environments : blank solution; 2.0%F4+0.3%
stability of the foam in downhole condition. An important HPAM+0.2%XC; 2.0%F4+0.3%HPAM+0.2%XC+0.5%
point to be investigated is the optimization of the system
CT2+0.05%Na2SO3. The morphology of corrosion scales is
regarding the proper choice of the foamer agent and its optium
shown in Figs. 1, 2 and 3. It showed that corrosion pitting
concentration5. Through indoor experiments, the optimal
forms on the surface of steel corroded by formation water with
formula of new style anticorrosion stable foam is ascertained
sodium chloride crystal grain; particles uniformity, thinnesse
2.0%F4+0.3%HPAM+0.2%XC+0.5%CT2 +0.05%Na2SO3. F4
and tightness after adding foam; no obvious corrosion
SPE 94469 DISCUSSION OF FOAM CORROSION INHIBITION IN AIR-FOAM DRILLING 3
The complexing characteristics of foam stabilizer and Field Application and Prevention Measures
viscosifier HPAM and XC biopolymer. Foam stabilizer and Field application. X-14 well drilling from ground to 1126m
viscosifier HPAM and XC biopolymer have the similar with dry air, formation water first flows out, the content of Cl-
characteristics of complexing agent which complex metal ion is 41641mg/L.Then enhances air output adopting mist drilling
such as Ca2+ Mg2+ Fe3+, then form aqueous soluble to 1970m, next formation water is countered, the content of Cl-
complexing substance, as shown in Figs. 7 and 8. On the one is 127834mg/L, salinity is close to saturation brine. Lifting up
hand it avoids these metal ions reacting with the surfactant drilling tools, severe corrosion phenomenon is observed, red
which has the anion characteristic to creat insoluble substance, loose rust in surface layer, black compact product in inner
on the other hand the percentage of Ca2+ Mg2+ Fe3+ in layer, which is consistent with HTHP corrosion phenomenon.
corrosion medium is reduced, accordingly the salinity of Then adopting stable foam drilling to goal. Fig.10 shows
formation water is cut down, thereby the content of surface corrosion image of S135 drilling string in X-14 well
2Na.Mg.Fe(SO4)(CO3)2 and CaCO3 in corrosion product layer (1970m). Fig.11 shows 8 inch vibration corrosion image in
decreases. formation water. From above two pictures, we can realize
4 LIpING WAN AND YINGFENG MENG SPE 94469
severe corrosion of drilling tools in dry air drilling or mist that corrosion of drilling tools reduces when foam drilling
drilling when encountering formation water. Fig.12 shows substituting for dry air drilling.
mushy protective layer in stable foam drilling. Foam drilling 2.Foam corrosion inhibition mechanism consists in
substituting dry air drilling, mushy protective layer made up absorption of foam agent on steel surface; the complexing
of low return velocity cuttings forms on surface of drilling characteristics of foam stabilizer and viscosifier HPAM and
tools, prevent drilling tools corrosion. XC biopolymer; oxygen isolation; foam wrapping
Indoor experiment and field observation show that the sands and reducing erosion. Adding inhibitor (CT2) and
main corrosive factors of drilling tools are acid formation oxygen scavenger (Na2SO3), foam corrosion inhibition ability
briny electro-chemical corrosion in high temperature; is improved further.
oxidation corrosion of dissolved oxygen in high pressure air; 3.Through the practical experience and theoretical analysis, it is
oxidizing film shedding creating erosion, for cuttings carried considered as a good method to solve the corrosion problem
by airflow bump and erod drilling tools intervally. In order to of drilling tools in formation water that taking foam drilling
prevent drilling tools corrosion, formulating high pH value substituts for air drilling, adding inhibitor, oxygen scavenger,
and adding inhibitor stable foam proceeding air foam drilling, and improving pH of foam properly.
reduce direct contact air with drilling tools; neutralize acid
substance deriving from air and formation water; and reduce Acknowlegement
return velocity of foam in annulus, slow corrosion and erosion The authors would like to thank the management of Tubular
to drilling tools. Special formula in Western gasfield is Goods Research Center of CNPC and State Key Laboratory of
2.0%F4+0.3%HPAM+0.2%XC+0.5%CT2+0.05%Na2SO3.This Oil and Gas Reservoirs Geology and Exploitation in SWPI for
method effectively restrains drilling tools corrosion and their technical support and permission to present this paper.
improves economic benefits.
References
Prevention measures. On the one hand air drilling can not 1. Supon,S.B., Adewumi,M.A. and Fairchild,N.: Measure
deviate from dry air, and it is impossible to clear oxygen from and Analysis of the Pressure Drop in a Vertical Annulus
air (except adopting N2, but high cost should be considered), in a Simulated Air drilling Operation, paper SPE 17039
on the other hand air column exerts a hydrostatic pressure that presented at the 1987 SPE Eastern Regional Meeting,
is much lower than the hydrostatic pressure exerted by a Pittsburgh, Pennsylvania,Oct.21-23.
conventional drilling mud column of the same height, so
formation fluids can easily inpour wellbore. According to 2. E.Y.Nakagawa and Valter Silva Jr.: Comparison of
wellbore situation, adopting reasonable measures to protect Aerated Fluids/Foam Drilling Hydraulics Simulators
drilling tools from corrosion, not only utilizing air drilling Against Field Data, paper SPE 54319 presented at the
advantages, at the same time reducing drilling tools corrosion 1999 SPE Asia Pacific Oil and Gas Conference and
to least dgree. Combining past experiment air drilling should Exhibition, Jakarta, Indonesia, Apr.20-22.
adopt hereinafter measures to protect drilling tools:
3. Scott,S.L., Wu,Y.and Bridges,T.J.: Air Foam Improves
(1) Dry zones drill using pure air; low water influx zones
Efficiency of Completion and Workover Operation in
using dry foam; high water influx zones using foam. From the
Low Pressure Gas Wells paper SPE 27922 presented at
mechanism of corrosion, water is the most important in
the 1994 SPE Mid-Continent Gas Symposium, Amarillo,
drilling tools corrosion induced by air (oxygen and carbon
Texas, May 22-24.
dioxide). Air can not produce corrosion in dry environment.
But in humidity (wet) circumstance, even oxygen content is 4. A.L.Martins, A.M.F.Louren and C.H.M.Dens: Foam
very low ( 1mg/L)which can bring severe corrosion. So dry Property Requirments for Proper Hole Cleaning While
air drilling can be performed in dry, rigid zones. When Drilling Horizontal Wells in Underbalanced
countering formation water, mist drilling can be carried out Conditiond, paper SPE 64382 presented at the 2000 SPE
through increasing air output. If formation water influx is great Asia Pacific Oil and Gas Conference and Exhibition,
and salinity is high, above two drilling methods can not be Brisbane,Australia, Oct.16-18.
operated. It is necessary to adopt foam drilling. Thus not only 5. Samuel Campbell,Sunder Rama Chandran and Keith
descending air output and return velocity of annulus, reducing Bartrip: Corrosion Inhibition/Foamer Combination
drilling tools erosion, but also using foam wrapping air, Treatment to Enhance Gas Production, paper SPE 67325
decreasing contact opportunity of drill pipe and medium. presented at the 2001 SPE Production and Operation
(2) Surface treatment. For instance, zincification or Symposium, Oklahoma, Mar.24-27.
coating oxidation films.
(3) During stop drilling, wash duly all foam channels, 6. Marek Pakulski and Richard Martin: Synergism and
drilling tools and equipment. Antagonism of Foaming Agents and Corrosion
(4) Preparing high pH value foam agent and adding some Inhibitors, paper SPE 65016 presented at the 2001 SPE
protection agents. International Symposium on Oilfield Chemistry,
Houston, Texas, Feb.13-16.
Conclusions and Recommendations
1.The dynamic corrosion experiment in HTHP indicats that
foam owns the ability of inhibition, which is stronger after
adding inhibitor. It gives a powerful laboratory support for
Fig. 1-SEM of corrosion scales in blank solution Fig. 2-SEM of corrosion scales in foam (2.0%F4+0.3%HPAM+0.2%XC)
Hydrophobic group
C12H25
Hydrophilic group
SO3H
Steel S135
Fig. 6-Schematic diagram of foam agent absorption on the surface of S135 steel
2+
Fig. 7 -Sketch map of HPAM complexing Ca
2+ -
low concetration [Ca ] and [-coo ] complexing inside of molecule forming collapse chain;
2+ -
high concetration [Ca ] and [-coo ] complexing first inside of molecule forming mutual chain;
2+ -
high concetration [Ca ] and [-coo ] collecting second in mutual molecule forming congeries
8 LIpING WAN AND YINGFENG MENG SPE 94469
M: Na K+ 1/2Ca2+ 1/2Mg2+
AC: CH2CO-
2+
Fig. 8 -Sketch map of XC complexing Ca
drill cuttings
Fig. 9-Schematic diagram of foam netlike structure and fixing drill cuttings
SPE 94469 DISCUSSION OF FOAM CORROSION INHIBITION IN AIR-FOAM DRILLING 9
Fig. 10- Corrosion image of S135 drilling string in X-14 well (1970m)
Content(%) 0.37 0.94 1.01 0.22 0.016 0.02 0.032 0.028 1083 1148
API standard --- --- --- --- 0.03% 0.03% --- --- 931~1138 1000
Concentration 2034 18461 6280 1072 41641 1274 3085 6.3 1.07 73847
Fe Mn Cr Si S Ca P Cl Mg
blank solution 82.71 2.13 0.63 1.40 0.73 10.14 0.44 0.81 ---
2.0%F4+0.3%HPAM+0.2%XC 80.11 2.55 1.99 1.14 1.75 7.98 --- 0.68 1.45
2.0%F4+0.3%HPAM+0.2%XC+0.5%CT2+0.05%Na2SO3 75.92 2.27 0.47 0.94 0.70 3.09 1.09 0.53 0.54