Drilling of Reactive Clays in the Offshore Region of Southeastern Mexico – High

Performance Water-Based Drilling Fluid

Christian Ferreira and Mario Serrano, Halliburton

SUMMARY

Drilling the highly reactive shale formations of the Cretaceous formation offshore Mexico is
generally carried out with inverse emulsion fluids. The logistical requirements demanded by the
use of these types of fluids and the environmental risks associated with their use makes the use
of a water-based fluid necessary. The inhibitive water-based fluids commonly used as an
alternative to inverse emulsions have produced a poor inhibitive effect on the reactive shale and
very low penetration velocities, which caused a substantial increase in the drilling costs.

An extensive laboratory study was developed as a point of departure for the selection, design
and formulation of the water-based drilling fluid utilized for the drilling of reactive clays in the
offshore region of Mexico. In this study, the mineral characteristics of the clays found in the
formations that were to be drilled was determined, and their response to the interaction with the
various water-based and oil-based fluids was evaluated. Subsequently, the fluids with the best
laboratory results were selected, and their formulas were adjusted to design a fluid with the best
inhibitive properties, the lowest environmental impact, and the best theoretical properties for
obtaining high penetration velocities.

In this paper, the laboratory study that was developed and the results obtained are shown. The
subsequent application of these results is demonstrated with the progress curves (footage) of
the first wells drilled with that system, and compared to the progress curves of some of the wells
in the area that were drilled with traditional mud systems.
INTRODUCTION

When designing the fluid that was used for drilling the highly reactive shale of the Cretaceous
formation offshore Mexico, the drilling problems experienced in the area while using traditional
fluids were taken into consideration. Based on these problems, the fundamental characteristics
that would be contained in the ideal fluid for that area were identified. These characteristics
would comply with the following objectives, among others:

• A high inhibition of the formations drilled.

• A reduction in the logistics for the preparation and maintenance of the fluid and the
transportation and disposal of cuttings.
• A reduction of drilling time.
• An environmentally friendly fluid.

Prior to the development of the laboratory work, the field was selected. An interval of 17.5” was
identified for the application of the new fluid. This interval has the greatest number of logistical
requirements due to the great volumes of fluid utilized, and the greatest problems associated
with the reactivity of the clays and low penetration velocities, which were experienced with the
water-based fluids traditionally utilized.

Subsequently, channel samples were taken of the drill cuttings from a well being drilled in the
field. These samples were analyzed in the laboratory to determine their characteristics.

Additionally, the historical drilling behavior of several wells in that field drilled with traditional
fluids was evaluated, and their progress curves were charted. The bits and hydraulics utilized
and the properties of the fluids utilized also were evaluated.

Once the types of clays present in the formations that would be drilled were identified, the
various seawater-based fluids were evaluated. The HYDROGUARD® water-based system was
chosen as the best alternative, considering that it is a high-inhibition fluid with no impact on the
environment, with good rheological characteristics and a low content of colloidal solids that
guarantee high penetration velocities. Several formulations of the system were subsequently
tested in the laboratory. The effect of those fluids on the clay samples collected in the field was
studied. Their performance was compared with that of the fluids previously utilized, including oil-
based fluids, and the formula was adjusted according to the laboratory results obtained with the
clays from the field.

Once the laboratory study was concluded, the platform for the utilization of the system was
assigned by the operator. A complete evaluation of the solids control equipment then was
developed by the Baroid Surface Solutions group, and recommendations were made to obtain
the highest efficiency in the removal of solids in the equipment.

Finally, the application of the system was made in the first well. The results were as had been
expected, with a significant reduction in drilling time for the section from an average of 25 days
to 14 days, and a drilling operation free of non-productive time associated with the drilling fluid.

BODY OR DEVELOPMENT OF THE WORK

Laboratory work

One of the objectives of the laboratory study was to determine the fluid that would best preserve
the integrity of the rock with the best inhibition properties in the cuttings.

The laboratory work was in two phases. The first phase was carried out to determine the
characteristics of the clays that would be drilled, which included X-ray diffraction tests. The
second phase consisted of rock-fluid interaction tests, which included clay erosion/dispersion
tests, adherence tests, and linear swelling tests, among others. Several water-based systems
were evaluated, including low-limestone based systems, KCL-based systems, and oil-based
systems.

X-ray Diffraction Tests.

The X-ray diffraction tests showed an average 28% content of smectite in the upper part of the
interval, 7% of illite, and 14% of calcite. The results are shown in Figure 1.

Figure 1. X-ray Diffraction Results

Erosion and Dispersion Tests

Erosion and dispersion tests evaluate the tendency of the cuttings to erode and disperse in the
drilling fluid. The results obtained with the HYDROGUARD system were the best, showing the
lowest tendency of the cuttings to disperse in the fluid, which indicates its high capacity for
maintaining the integrity of the cuttings. This test was realized under dynamic conditions for 16
hours at 150 °F, with cutting samples duly strained and selected at an initial humidity of 5%.
Table 1 shows the comparative results between the HYDROGUARD system and the low-lime
based fluid in the comparison wells.

Table 1. Erosion and Dispersion Test Results

Fluid System: Initial Weight Final Weight Percentage of

(gr) (gr) Erosion
HYDROGUARD 30 26.66 6.45%
HYDROGUARD/KCl 30 26.75 6.14%
Low Lime System 30.05 21.15 29.62%
Adherence Tests

Adherence tests of the fluid were carried out to evaluate the tendency of the fluid to cause the
clogging of the bit and of the down-hole assembly. Again, the results showed the best values for
the HYDROGUARD fluid with the lowest amounts of clay adhering to the test pipes. As can be
seen, the amounts are lower than those experienced with oil-based fluids. See Table 2.

Table 2.- Adherence Test Results

Fluid System: % Adhered clay

HYDROGUARD system 4.00%

Low-lime system 14.60%
OBM 4.20%

Linear Swelling Tests

The final linear swelling tests were carried out using three HYDROGUARD formulas, one
PERFORMADRIL® fluid formula, and one inverse emulsion formula, as shown in Table 3
below.
Table 3. Linear Swelling Tests - Formulas
Additives HYDRO 15% NaCl/ 5% KCl / PERFOR 80/20 OBM
GUARD HYDRO HYDRO MADRIL 250,000
system GUARD GUARD system ppm CaCl2
system system WPS
Seawater, m³ 0.97 0.915 0.927 0.97
KCl, kg ---- ---- 50 ----
NaCl, kg ---- 150 ---- ----
Diesel Oil, m³ 0.72
EZ-MUL NT™,kg 12
INVERMUL NT™, kg 12
DURATONE HT™, kg 15
Cal, kg 9
Water, m³ 0.18
GELTONE II™, kg 12
CLAY SYNC™, kg 6 6 6 -----
CLAY GRABBER®, kg 5 5 5 ----
PERFORMATROL®, ---- ---- ---- 32
kg
BARAZAN D PLUS™, 3 3 3 3
kg
FILTER CHEK, kg 6 6 6 6
PAC-L, kg 6 6 6 6
Barite, kg 240 150 233 240 369
NaOH, kg 0.5 0.5 0.5 0.5
CLAYSEAL™ PLUS, 0.03 0.03 0.03 0.03
m³
CaCl2 , kg 62.7

The clays were hydrated at an initial humidity of 12% in weight, and then compressed into
cylinders at 1000 and 10,000 psi before exposing the fluids to the linear swelling test.

The inverse emulsion fluid, with an oil-water ratio of 80 / 20, and with a salinity of the aqueous
phase of 250,000 ppm CaCI2, showed negative volume change values in the tablet samples
prepared at different compression. The most compressed tablets (10,000 psi) showed negative
volume change values of 6 to 8%. The cores prepared at a lesser compression showed a
reduction in their volume of 1.2%. Negative values indicate a loss of humidity in the cuttings due
to osmotic pressure from the high salinity of the fluid utilized during the test. See Table 4.

Table 4 – Lineal Swelling Test Results

Change of Volume Change of Volume Fluids evaluated
– clay compressed – clay compressed
at 10,000 psi at 1,000 psi
- 6.8 % - 1.2 % 80/20 Oil base - 250,000 ppm CaCl2 salinity
1.74 % 0.80 % 5% KCl / HYDROGUARD system – Seawater base
2.43 % 3.47 % PERFORMATROL system in seawater
2.65 % 0.31 % 15% NaCl / HYDROGUARD system
4.9 % 4.4 % HYDROGUARD system in seawater

The HYDROGUARD water-based fluid with 5% KCl showed the lowest change in volume in the
linear swelling test in the two types of tablets evaluated. Therefore, this fluid should work very
well in both the surface part of the interval, in which the clay is less consolidated, as well as in
the deeper part of the interval where the clays are more consolidated (more compressed).
Figure 3 shows the swelling curves for a period of 4.5 days.
Figure 3. Linear Swelling Results

Lineal Swelling Test Results

Linear swelling test results

10

9
HYDRO-GUARD
Initial humidity of clay = 12% 15% NaCl / HYDROGUARD
8 Sample compressed at 10,000 psi 5% KCl / HYDRO GUARD
Volume cahnge of clay

Test temperature = 150º F

PERFORMADRIL
7

0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Time (days)

Application in the field

The system was successfully used in several wells in different fields of the offshore region.
Table 5 shows the first five wells in which the system was used. Well No. 3 was drilled with a
fluid density of 1.92 SG

Table 5.- Wells – Intervals drilled with the HYDROGUARD system

Name of Interval Meters drilled Drilling hours
Well Inches
Well – 1 17 1/2 1748 265.19
Well – 2 17 1/2 2200 539
Well – 3 12 1/4 800 67.8
Well – 3 8 1/2 471 69.5
Well – 3 6 1/2 345 29.5
 Well – 4 17 1/2 675 80.5
Well – 5 17 1/2 1335 316.5

In every case, the drilling time for these wells was below the time programmed for each interval.
Additionally, there were no problems of lost time associated with drilling fluid problems.

Figure 4 shows the progress curves of several wells in the area drilled with oil-based or water-
based fluids and the progress curve of the first well drilled with the HYDROGUARD system.

Figure 4. Drill Rate Curves

Progress Curves
0 10 20 30 Days 40 50 60 70
500
Comparison well 1 – Water based
Comparison well 2 – Water based
HYDROGUARD system well
1000
Fishing Comparison well 3 – Oil based
Depth ( meters )

1500

2000

2500

3000

3500

Fluid Properties
The fluid properties remained stable during the drilling of the intervals in which the fluid was
utilized. Figure 5 shows some of these properties and their behavior during the drilling of the
first interval of the first well drilled.
Figure 5.- Properties of the HYDROGUARD fluid in the first well drilled

PROPERTIES VS. DEPTH, WELL -1

40

35 GEL 30'
PROPERTY/CONCENTRATION

30 GEL 10' MBT

YP
25
VP

20

V KCL GEL 1O"

15

10
CLAYSEAL

5 CLAY SINC
CLAY
GRABBER
DENS.
0
1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,600 2,800 3,000

DEPTH, METERS

CONCLUSIONS

• The preliminary laboratory study and the analysis of the historical information of the
wells drilled in the area were fundamental in the selection of the HYDROGUARD fluid.

• The drilling of the 17.5” interval phase was realized without drilling problems caused by
the drilling fluid.

• The penetration velocities were very good, and the interval was drilled in less time than
the time programmed. A total length of 1748 meters was drilled in 265.19 hours.

• The properties of the fluid remained within the programmed parameters, with an
exception of the increase of the MBT. This was caused principally by initial
contamination during the displacement due to the lack of a spacer between the
displaced mud and the HYDROGUARD system.
• Problems occurred in the solids control equipment used on the rig, which was not
efficient in the removal of solids. This caused an increase in the content of clay and
colloids in the fluid.

• There were no problems in cleaning the hole, or clogging problems of the bit or
stabilizers. This demonstrates the great inhibiting properties of the fluid.

• The trip operations to change the bit were carried out without problems. Additionally,
there were two incidents of breakage in the drill pipe, and the fishing operations were
carried out with complete normality, showing that there was excellent stability of the
hole.

• The results obtained with the utilization of the HYDROGUARD system in the next four
wells confirmed the great performance of the fluid, which can be summarized in the
following points:
o Excellent stability of the hole
o Improved penetration velocity
o Stability of the fluid in a high range of densities
o Ease of removal of cuttings on the surface
o Reduction in the logistics of preparing the fluid
o Reduction in the volume of fluids – less volumes of dilution
o No problems with clogging of the bit or the drillstring.