2 Aramco Awareness

Drilling Fluids Awareness

Workshop Series

WORKSHOP 1

BASIS OF DESIGN

June 2009 Drilling Technical Department

DRILLING FLUIDS AWARENESS
DRILLING TECHNICAL DEPARTMENT WORKSHOP 1 : BASIS OF DESIGN

BASIS OF DESIGN

Set of conditions, needs, and requirements taken into
account in designing a mud program.

“Mud represents 5 – 15% of drilling costs but can cause 100% of
drilling problems.”
‐West Texas Mud Engineer (Unknown)


Table of Contents
1.1 Design Criteria
1.1.1 General Drilling Fluid Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Reservoir Drill‐In Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1.3 Overbalance Drilling Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1.4 High Performance Water Base Mud Technology . . . . . . . . . . . . . . . . . . 15

1.2 Risk Assessment, Contingencies, and Mitigations
1.2.1 Well Bore Risks related to Geology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2 Operational Geologic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3 Drilling Problems related to Drilling Fluids . . . . . . . . . . . . . . . . . . . . . . . 27
Bit Balling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mud Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mud Cap Drilling . . . . . . . . . . . . . . . . . . . . . . . . . 53
Hole Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wellbore Stability . . . . . . . . . . . . . . . . . . . . . . . . 64
Stuck Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2.4 Drilling Mud Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.3 Well Site Equipment
1.3.1 Drilling Rig Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.3.2 Drilling Rig Specification Database Link . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.3.3 Mud Laboratory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3.4 Solids Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.4 HSE (Health, Safety and Environmental)
1.4.1 H2S Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.4.2 Mud Chemicals Safety Handling Guidelines . . . . . . . . . . . . . . . . . . . . . . 145
1.4.3 Marine Biotoxicity Testing – LC50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.4.4 Links to Saudi Aramco Environmental Standards, Procedures, & G.I.’s . 152

1.5 Knowledge Management
1.5.1 Drilling Information Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5.2 ShareK – Knowledge Sharing Platform . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.5.3 Useful Technical Web Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.5.4 Operational Meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5.5 Post Well Mud Recaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.5.6 Drilling Alert Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161


Chapter 1.1

DESIGN CRITERIA
1 June 2009

Example of Drilling Fluid BOD – Offshore Development well
Drilling Fluids - Design Criteria
Development Wells
Potential Risks/Technical Key Performance
Well Schematic Hole Size Objectives Assumptions and Boundaries
Challenges
Mitigations/Actions Proposed Fluid Offset Experience Fluids Related
Indicators
Drill 28" pilot hole and open it to Potetial lost circulation above RUS Keep planned density KARN 8 - Lost returns while running csg
None formation Bbls Mud lost/ft
28x34" 34" wihtout problems. If returns are lost, drill with SW and SPUD MUD KARN 7 - lost 100% returns at 1047 ft
Unconsolidated sand in the Neogene
Gel slips KARN 2 - 100% losses at 830 ft
30"
1145' MD/1145' TVD
Keep the planned MW to control
water flow
Possible water flow and lost KARN 6 - lost complete returns at 1550 ft
Add sealing agents to the drilling fluid
Drill to 3338 ft into Ahmadi if losses are experienced while circulation from UER KARN 8 - casing got stuck at 3685 ft
28" Hole Member without problems and keep filtration value low SPUD MUD Bbls mud lost/ft
cementing, pump 50% excess Tigh hole and swelling in KARN 5 - Total losses at 1689 ft, switch
Keep good mud rheology if hole
Aruma shale to SW
cleaning is an issue due to wellbore
instability in Aruma
24" Casing
3338' MD/3334' TVD
Possibility of using a vibration sub Keep planned MW

KARN 6 - Bit balling at 4120 ft
Drill to 6449 ft without problems Arab formations are expected to Lost circulation in Wasia Keep high dilution rate Bbls mud lost/ft
22" Hole Maximie bit HSI to reduce bit KARN 7 - 100% losses prior to drilling
be productive Water flow in lower Ratawi Add Wallnut and CONDET (Soap) or LSND with KCL Non Productive time
Shu'aiba
balling tendency Casing point may change if hole Bit balling in Wasia shales glycol for bit balling allocated to mud losses
KARN 4 - Lost 100% returns at 5331 ft
problems are experienced Keep enough volume of fluid
18 5/8" Csg
6449' MD/6445' TVD

Have enough LCM material on
Casing point planned at 30 TVD
Drill to the kick off point at 6604 ft into base Jilh Dolomite location, particulate and cross link KARN 6 - Partial losses at 6964 ft
Possible lost circulation in Bbls mud lost/ft
polymers. Be ready to pump cement KARN 7 - Well flowed at 9100 ft
Hold 52 degrees of inclination to DST data from KARN 1 Hanifa Non Productive time
16" Hole plugs LSND KARN 1 - Lost Returns with 77 PCF at
TD (10672 ft) indicated EMW of 69.7 PCF to Possible gas in Jilh Dolomite allocated to mud losses
Keep the planned density at all times 6576 ft
balance Manifa
and monitor mud pit levels closely for
13 3/8" Csg any kick
9223' MD/8870' TVD Hold 52 degrees inclination to TD, Abnormal gas and /or KARN 6 - Well flowing at 10248 ft with
The slurry density and design Have plenty barite on the rig NPT allocated to well
12" Hole top of Khuff formation will depend on Jilh pressure
saltwater flow in lower Jilh
Have enough LCM materiial on the rig
LSND 112 PCF
control issue
Casing will be set at the top of Khuff Tigh hole/swelling shales KARN 7 - No major problems observed
Control fluid rheology when weighting
12898' MD/11115' TVD regardless of high Jilh pressure across Kilh, Sudair and Khuff
Lost circulation in Khuff Use lowest practical MW
Hold 52 degrees inclination to TD. Vibration data can be used in reservoirs Minimize ECD by using low pump KARN 6 - Drilling at 10908 ft, well flowed Bbls of mud lost/ft
7" Liner 8 3/8" Hole Run open hole logs without thsi section for optimizing H2S in the Khuff reservoirs rates.Karn 6 succesfully drilled with LSND with 95 PCF NPT allocated to stuck
problems performance Possible tigh hole/sticking in 250 gpm KARN 7 - Stuck at 13935 ft while reaming pipe
Khuff formations Monitor pressure closely while drilling
15500' MD/12704' TVD
2 June 2009

DRIILING FLUIDS AWARENESS
DRILLING TECHNICAL DEPARTMENT WORKSHOP 1: BASIS OF DESIGN

1.1.1 GENERAL DRILLING FLUIDS TYPES
¾ Drilling fluids are classified by the type of base fluid used: water or oil.
¾ “Water based” can be fresh water, sea water or any concentration of
various brine types such as sodium or potassium chloride, calcium chloride
or bromide, or sodium or potassium formate.
¾ “Oil based” can be any hydrocarbon based fluid including diesel, mineral
oil, synthetic oil, or even crude oil.
¾ Different base fluids are used to prepare drilling fluid types depending on
requirements for hole stability, density, temperature of the wells as well as
environmental guidelines.
¾ Drilling fluids selection ‐‐ determined by the cost effectiveness of the
system to achieve the required objectives of the well or project

3 June 2009


Typical Drilling Fluid Components – Water Base Mud

4 June 2009


Typical Drilling Fluid Components – Oil Base Mud

5 June 2009


Common Drilling Fluids – Saudi Aramco
Spud mud
Water and gel sweeps
Low –Solids Non-Dispersed
Oil-based Mud
Reservoir Drill-In Fluids
Cost-effective drilling fluids formulations

and sound field practices should apply
Typical Mud Selection ‐ Onshore

22” Hole Section Spud Mud
17” Hole Section Spud Mud or KCl LSND
12-1/4” Hole Section

LSND or OBM or DOE
6-1/8” Hole Section WBM Reservoir DIF

6 June 2009


Typical Mud Selection Onshore ‐ e.g. Manifa ERD Wells Onshore

17” Hole Section KCl LSND
12-1/4” Hole Section OBM (hole stability &

lubricity in long reach
8-1/2” Hole Section sections)
NaCl based Reservoir

DIF

Typical Mud Selection Onshore ‐ e.g. Shaybah Wells Onshore

16” Hole Section LSND
12-1/4” Hole Section Water and Gel Sweeps

–Lost Circulation
8-1/2” Hole Section Oil-based Mud due to hole

instability and lubricity problems
6-1/8” Hole Section NaCl brine-based DIF

7 June 2009


Typical Mud Selection Offshore
28” Hole Section

Spud Mud
22” Hole Section
16” Hole Section Water and Gel sweeps

Oil-based Mud due to
hole instability reasons
6-1/8” Reservoir Hole Oil-based Mud

(Or 8-1/2”) Section Reservoir Drill In Fluid

Additional Oil Base Mud Types Used in Saudi Aramco

DIRECT OIL‐IN‐WATER EMULSION ALL OIL SYSTEM

• Oil emulsified in water
• Designed to protect the Reservoir
• Utilizing simple oil‐in‐water emulsifier • Ensures proper reservoir rock
• Oil volume percentage up to 45% protection especially for horizontal
• Fluid density can be as low as 56 ‐ 58 drain holes in clastic reservoirs.
pcf. • Fluid density can be as low as 56 pcf
• Minimize potential losses across and can be increased with sized
typically Weak formations in Wasia calcium carbonate or barite for non‐
and Shuaiba by getting lower payzone drilling.
densities.

NOTE: Synthetic Oil Base mud (SOBM) is considered a separate system from Oil Based
Mud (OBM) by the industry.

8 June 2009

DRIILING FLUIDS AWARRENESS
DRILLIN
NG TECHNICA
AL DEPARTM
MENT WORKSHOP 1:
W 1 BASIS OF DESIGN

1.1
1.2 RESERV
VOIR DRILL‐IN FLUID
D (DIF) – ALLL AREAS
a. Reservoir Drill‐In Fluid Compo
onents

Reservoir Drill‐In Fluids arre the most important muds we use
u becausee they have DIRECT
IMPACT o
on how mucch productio on or injectio
on we achievve from a weell.
“THEE COMPLETIION STARTSS WHEN THEE BIT HITS TH
HE RESERVO
OIR.”
WB
B Reservoir D
Drill In Fluid
Waterr
XC Pollymer
Modiffied Starch
NaOH or MgO
NaCl o
or other salt
Sized C
CaCO3 blend

¾ BRINE: Brine es are defineed as an aqueous solutio on at any con ncentration of any comb bination
of typical saltts generally u
used to achieve solids frree density oor shale inhibition.
o Brines ccan be comp posed of a sin
ngle salt or aa combinatioon of 2 or 3 d
different sallts.
¾ SAALT: Defineed, not just aas sodium ch
hloride (NaC Cl), but as an
ny type of salt used to buuild
drilling or commpletion fluids.
¾ There are 2 classes of salts commonly used in ou ur industry:
1) Inorganic salt – Sodium m, potassiumm, calcium, o or ammoniu um chloride; sodium, calcium or
ziinc bromide; potassium sulfate
2) Organic saalt – Sodium, potassium or cesium fo ormate; potassium acetate

Oil Base Resservoir Drill IIn Fluid
Mineral Oil
Primary Emulsifier
Secondaary Emulsifier
Organop
philic clay
Organop
philic lignite
Lime
CaCl2
CaCO3 sized
Water

9 Junee 2009


b. Reservoir Drill‐In Fluid ‐ Design of Bridging Materials

** Bridging the production zone is the key to A rule of thumb for estimating an unknown
minimizing formation damage. CaCO3 blend pore diameter is to use the square root of
must be calculated to properly bridge the the permeability of the zone in millidarcies.
pore throats of the reservoir and build an
To effectively bridge off the zone, 20 – 30%
external filter cake with low lift off pressure.
by weight of the bridging material (CaCO3)
The big challenge is in maintaining this blend
should be 1/3 of the pore size in microns.
while drilling.

c. Reservoir Drill‐In Fluid Maintenance this addition is 300 lbs to as much as
¾ Run PPA (Particle Plugging Apparatus) 2000+ lbs added per hour required to
2‐4 times a day when drilling the maintain the designed Particle Size
reservoir. Maintain PPA values equal Distribution (PSD) of the mud.
to or less than the original newly ¾ Utilize centrifuges and dump and
mixed mud. dilute practices as necessary to help
¾ If available, monitor the active drilling maintain the PSD.
mud with a Particle Size Analyzer ¾ Use modified HT starches in the
several times a day while drilling with reservoir for fluid loss control. They
onsite equipment or by sending are known to cause less formation
samples to the Aramco Lab for damage.
maximum 24 hour turnaround on ¾ Do not use asphaltic products (Soltex,
results. Blacknite, etc.) in the reservoir and
¾ Control ROP when in the reservoir to avoid or minimize bentonite or barite
no faster than needed to maintain the if possible in the mud.
designed properties of the Drill‐In ¾ Avoid typical grease pills containing
fluid. Typically this is around 80 ft/hr. diesel, mineral oil, bentonite, and
¾ Maintain continuous additions of barite in the reservoir. Glycol pills are
larger CaCO3 while drilling to preferred first steps in freeing the
counteract the continual grinding pipe along with reducing mud weight
down of the CaCO3 to fine, zone‐ if possible to minimize formation
damaging sizes by the BHA. Typically damage.

“THE KEY TO GOOD DRILL‐IN FLUID AND MINIMUM FORMATION DAMAGE IS
GOOD WELL SITE MUD ENGINEERING.”
10 June 2009

MATCHING BRINE COMPLETION FLUIDS TO THE BRINE BASED DRILLING FLUID

MONOVALENT BRINES = NACL;KCL,NA OR K FORMATE

DIVALENT BRINES = CACL2; CABR2 PCF
64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106
IF YOUR MUD IS NACL OR KCL BASED TO 73 PCF: Note: Completion Brine Densities

NACL, KCL OR BLEND PLUS CACO3 MUD are typically 2 PCF > Drilling Mud
Density to achieve the same
YOUR COMPLETION FLUID, SHOULD BE: hydrostatiic pressure due to temp
NACL NEVER USE DIVALENT BRINES and pressure effects on brines.
IF YOUR MUD IS NACL OR KCL BASED TO 85 +/- PCF:

NACL, KCL OR BLEND PLUS CACO3 MUD TO 85 +/- PCF
YOUR COMPLETION FLUID, SHOULD BE:
SODIUM / POTASSIUM FORMATE NEVER USE DIVALENT BRINES
IF YOUR MUD IS CACL2 BASED TO 86 PCF: CaCl2 Mud is not

recommended
CACL2 PLUS CACO3 MUD TO 86 +/- PCF for use unless
Formate is not
YOUR COMPLETION FLUID, SHOULD BE: available.
CACL2 NEVER USE MONOVALENT BRINES
IF YOUR MUD IS SODIUM FORMATE BASED TO 90 +/- PCF:

SODIUM FORMATE PLUS CACO3 MUD TO 90 +/- PCF
SODIUM / POTASSIUM FORMATE (WITH PROPER CRYSTALLIZATION POINT) NEVER USE DIVALENT BRINES
IF YOUR MUD IS CACL2 BASED TO 95 PCF: CaCl2 Mud is not

recommended
CACL2 PLUS CACO3 MUD TO 95 +/- PCF for use unless
Formate is not
YOUR COMPLETION FLUID, SHOULD BE: available.
CACL2/CABR2 BLEND (WITH PROPER CRYSTALLIZATION POINT) NEVER USE MONOVALENT BRINES
IF YOUR MUD IS SODIUM / POTASSIUM FORMATE BASED TO 106 +/- PCF:

SODIUM / POTASSIUM FORMATE PLUS CACO3 MUD TO 106 +/- PCF
SODIUM / POTASSIUM FORMATE TO 95 PCF / ABOVE 95 PCF HAVE TO COMPLETE WITH MUD FOR OPTIMUM SALT COMPATIBILITY
NEVER USE DIVALENT BRINES
11 June 2009


PROCEDURE FOR TESTING CRYSTALLIZATION TEMPERATURE OF A BRINE
12 June 2009


1.1.3 OVERBALANCE DRILLING FLUIDS

• Drilling through depleted zones of
relatively high permeability creates a
higher risk for differential sticking.

• Drilling through multiple zones of different
pressure regimes over one interval, e.g.
Arab‐A, B, C and D reservoirs in 8‐1/2”
section creates a higher risk for
differential sticking.

• How much differential pressure is
considered high overbalance? It
depends – on permeability, inclination, formation type, etc. Generally speaking, normal
mud can handle up to 500 psi without special efforts.

Prevention Mechanism

These systems utilize mud pressure isolation techniques by creating an ultra‐low permeable, finely
packed and slick filter cake across zones of different pressure regimes. The mud additives used to
build this filter cake will be selected based on whether we are drilling in the reservoir or not.

¾ Particle packing

• Sized graphitic additives (RGC (resilient
graphitic carbon e.g. Steelseal or LC Lube) –
Able to seal large pore throats and remain in
place with changing pressures in the well (the
particles deform with increased pressure and
return to original size as pressures reduce,
such as with surge and swab pressure
changes.
• Sized CaCO3 (fine and medium) – pack and
bridge small pore throats
• Micronized fibre – fibre micelles seal small
pore throats (e.g. Barofibre) RGC (Resilient
Graphitic Carbon)
¾ Polymers
• Starches, PAC’s, latex
• Deforms and seals in small pore‐throats
• Coats well bore.
13 June 2009


¾ System Examples ‐ Non‐Reservoir Applications

MAXBRIDGE (Baker Hughes) HYDRO‐GUARD (Baroid)
9 Resilient Graphitic Additives (LC 9 Resilient Graphitic Additives
Lube) ‐ key (Steelseal) ‐ Key
9 Polymer 9 Polymer
9 Sized Calcium Carbonate 9 Sized Calcium Carbonate
9 Micronized Fibers 9 Micronized Fibers

¾ Reservoir Applications
WBM or OBM can be used in high overbalance reservoir applications without graphitic
additives. Special care is required in managing a properly bridged particle size relative to the
formation pore throats and appropriate filtration polymers to achieve a thin, impermeable
cake during the entire drilling operation. Proper cake management is more critical without
the aid of graphite and sealing polymers.

Examples (Reservoir Applications – WBM or OBM)
9 Polymers
9 Sized Calcium Carbonate

14 June 2009


1.1.4 HIGH PERFORMANCE WATER‐BASED MUD TECHNOLOGY

¾ Definition: Water Base Mud system that can emulate Oil Base or Synthetic Oil Base Fluid
performance while meeting environmental regulations.

Characteristics Chemistry

• Highly inhibitive • Shale/Hole Stability & Clay Inhibition by
• Primarily Polymeric unique chemistry, e.g. silicates, aluminum
• High cost per barrel complexes, polyamines
• Engineering intensive • Cuttings encapsulation polymers
• Lower dilution rates due to increased • ROP enhancing, minimal bit balling, lower
cuttings inhibition torque & drag by utilizing synthetic oil
mixture

600°, 30,000 PSI RHEOMETER

¾ HPWBM’s seek to achieve wellbore stability by developing semi‐permeable membranes
with unique chemistry however the best Semi‐membrane efficiency is with oil‐based mud.

¾ VENDOR EXAMPLES ‐ HPWBM
PERFORMAX™ Baker Hughes Drilling Fluids
ULTRADRIL ™ M‐I SWACO
HYDRO‐GUARD™ Baroid Drilling Fluids
PERFORMA‐DRIL Baroid Drilling Fluids
HYPR‐DRILL ™ SCOMI

15 June 2009


16 June 2009

DRILLIING TECHNICAL DEPARTMENT WORKSHOP 1: BASIS OF DESIGN

Chapter 1.2

RISK ASSESSMENT,
CONTINGENCIES AND
MITIGATION

17 June 2009

DRILLIN
NG FLUIDS AWARENESS
A S
DRILLIING TECH
HNICAL DEPA
ARTMENT WORKSHHOP 1: BASIS
S OF DESIGN
N

1
1.2.1 WELLL BORE RISSKS RELATED TO GEO
OLOGY

3Aquifers 3 HP Waater Flow
3Lostt Circulation 3 Hard, abrasive Sandstone
3Unsttable Hole, C
Caving 3 Sour G
Gas
3Swe
elling Shales 3 Reactiive Shales
3Hard
d Anhydrites 3 Oil Flo
ows
3Tecttonics, Bit Stticking 3 Gas
18 June 2009


19 June 2009


20 June 2009


21 June 2009


1.2.2 OPERATIONAL GEOLOGIC CHART
22 June 2009


23 June 2009


24 June 2009


25 June 2009


26 June 2009


1.2.3 DRILLING PROBLEMS

Bit Balling

Bit balling is defined as the tendency of drilled solids to adhere together and cling to the metal
surface of the bit and BHA. The clay adhesion is a function of the electro‐chemical attraction of
clay to clay and clay to metal (surface tension). Bit balling can be minor to severe causing
problems from simply decreased ROP to not being able to pull the BHA through the previous
casing and thus being stuck in the open hole.

Generally bit balling is classified into two types;
1) Primary Balling – occurs on the cutting surface of the bit
2) Secondary Balling – occurs above the cutting surface of the bit such as the BHA and Junk Slot.

Bit balling occurs under the following conditions:
1) Drilling into water sensitive or reactive clay formation ‐ (rock type)
2) Usually drilling with Water Based Mud System‐ (mud design)
3) Cuttings are compressed , using aggressive bit like PDC ‐ (bit design and depth of cut)
4) Clay plasticity relative to bottom hole pressure ‐ (effect of Pressure)
5) Poor Bit hydraulics and hole cleaning
6) Electrochemical attraction of clay to metal surface

The diagram below describes the state of the clay that promotes bit balling.

27 June 2009


¾ Prevention
Bit balling can be prevented by optimizing the following mechanisms:
1) Prevent water movement from the mud to the shale by controlling fluid loss
2) Change surface tension between the metal surface and the cuttings –( detergent; glycol)
3) Minimize clay content in the mud system
4) Use of inhibitive mud systems (clay inhibitor, clay hydration suppressant, shale stabilizer,
cation exchanger and osmotic control)
5) Optimize Bit design and Bit hydraulics ( High blade standoff, large junk slot areas and
good flow area with proper nozzle size)
6) Use anti bit balling agent – (detergent; glycol)
7) Good hole cleaning practice (Sweeps and wiper trip)

¾ Identification
Bit balling indicators:
1) A sudden decrease in ROP which cannot be improved by changing drilling parameters
2) An increase in hydraulic pressure drop across the bit due to plugging of the nozzles
3) High overpulls and a tendency to swab the well when tripping out

¾ Cures
1) Dispersing the balled material‐ pump highly dispersive pills like caustic pill,
lignosulfonate, SAAP and drilling detergent
2) Eroding the balled material‐ pump nutplug or walnut pill to blast the sticky clay from the
face of the bit
3) Pumping non‐polar material such as anti‐bit balling agent (Glycols, detergents, etc)
4) HCl pill (15%) has been used to break up some calcareous clay balling in Saudi Arabia
5) When the balling is persistent and the material is hard to get off of the bit, the bit needs
to be pulled and cleaned manually.

Recommended Treatments
Option 1
• Drilling Detergent (CONDET). Treatment is 5 gals/40 bbl ‐ SAP # 1000021975
Option 2
• Caustic Soda pill ( 5 ppb) in Drill water
Option 3
• Pump a 50 bbl (Mud from the system) + with 50 ppb Wallnut pill (if downhole tools allow it)
Option 4
• High concentration pill of Chrome free lignosulfonate or any other dispersant available
Option 5
• PolyGlycol or Lube 167, 1 ‐ 4% by volume in the mud will help prevent bit balling.
Option 6
• 10 – 15% HCl acid pill can break up calcareous clay ball

28 June 2009


Mud Losses

Lost circulation is one of the major events causing non productive time and high cost to
our drilling operation in Saudi Arabia. Lost circulation has historically been one of the
primary contributors to high mud costs. Other hole problems such as wellbore instability,
stuck pipe and even blowouts have been the result of lost circulation.
Besides the obvious benefits of maintaining circulation, preventing or curing mud losses
is important to other drilling objectives such as obtaining good quality formation
evaluation and achieving an effective primary cement bond on casing.

Lost circulation occurs in one of two basic ways:
1) Invasion: Mud loss to cavernous, vugular, fractured or unconsolidated formations.
2) Fracturing: Mud loss due to hydraulic fracturing from excessive induced pressures

a
Typical lost‐circulation formations:

a: High‐permeability unconsolidated sands and
d gravel.

b
b: Cavernous or vugular zones in carbonates
(limestone or dolomite).
a

d c : Natural fractures, faults and transition zones

in carbonates or hard shale.

d: Induced fractures from excessive pressure
c

Lost circulation severity can be classified into 4 categories:
¾ Seepage Losses – Usually less than 10 bbls per hour
¾ Partial Losses – More than 10 bbls per hour with partial returns to surface
¾ Severe Losses – More than 100 bbls per hour with some returns to surface
¾ Total Losses – Fluid level in hole may not be visible

While Prevention is the first consideration, when Lost Circulation occurs, the solution should
follow a 3 STEP PROCESS:
1) Locate the Loss Zone
2) Identify the mechanism and assess the severity of the losses
3) Curing the losses
29 June 2009


¾ Preventing Lost Circulation
Good planning and proper drilling practices are the keys to preventing lost circulation by
minimizing excessive pressures on the formation. Several measures can be taken to prevent or
minimize lost circulation:
1. Set the casing in the appropriate zone so the fracture gradient of the formation at the casing
shoe will be sufficient to support the hydrostatic head of heavier muds required to balance
pressures in the formations below.
2. Minimize downhole pressures.
a. Pipe movement should not exceed

critical speeds when tripping. When the drill
string is run in the hole, there is a surging
pressure from the piston effect of the bit and
collars increasing the pressure exerted on the
bottom of the hole. Good drilling practices will
keep these pressure surges within the fracture
and formation pressure, as shown at left. Many
wells experience lost circulation while running
pipe or casing into the hole. The length of pipe
in the hole affects the magnitude of the surge.
Tests show that the flow of mud along the pipe
creates most of the pressure surge. The longer the
pipe, the greater the surge. Therefore, the deeper the well, the
slower the pipe should be run into the hole as the depth of the bit increases. Smaller
annular clearances also increase surge pressures much in the same way annular pressure
losses are increased as annular clearances decrease.
Rapid movement of pipe while circulating also causes even greater pressure surges. Rapid
“spudding” of the pipe or fast reaming while circulating can create large surges.

30 June 2009


b. Very high ROP loads the annulus with cuttings, thus increases the ECD, making any further
surging on connections more likely to cause fracturing. It is important to control the ROP
and circulate prior to making connections when the ECD is near the fracture pressure.
Maintain the cuttings concentration in the annulus below 4% to minimize the effect of
cuttings on ECD.
c. Rapid starting or stopping of the mud pumps can cause pressure surges. Starting the
pumps too rapidly will create a pressure that can cause lost circulation, especially when
breaking circulation on bottom after a trip. Part of the surge is caused by pressure required
to break the gel structure of the mud. Rotating the pipe when starting circulation will aid
breaking the gel strengths and greatly reduce the surge pressure. The other part of the
surge is the pressure required to accelerate the mud column to the normal circulating rate.
Maintaining low gel structure and gradually increasing the pump rate will reduce this type
of surge pressure. Breaking circulation at several intervals when tripping in hole is another
way to minimize these pressures.
d. Use enough drill collars to keep the neutral point in the Bottom‐Hole Assembly (BHA) to
minimize drill string whipping.
e. During the planning phase of the well, casings and drill string design should be engineered
for proper and safe operation, and also to optimize hydraulics for good hole cleaning and
minimum ECD, especially in sensitive areas.
f. Wash and ream cautiously through bridges.
g. Control mud properties in the proper ranges.
i. High viscosity and gel strengths increase surge pressures each time circulation is
interrupted and restored. They also increase the ECD while drilling. These values
should be optimized to ensure good hole cleaning and solids suspension, and minimize
ECD, surge and swab pressures. Many times mud properties cannot be kept at a level
which will provide adequate hole cleaning due to other operational considerations.
Higher flow rates and aggressive drill pipe rotation are the best methods to improve
hole cleaning. Sweeps are recommended in such cases where good hole cleaning is
questionable.
ii. Control drill solids at the minimum practical level and add proper treatment to
minimize filter‐cake build‐up. Anything that reduces the annular clearance causes a
pressure increase. Balling of the bit, collars, stabilizers or tool joints decreases the
annular clearance. In the case of extensive bit and/or stabilizer balling, a significant
pressure will be exerted on the formation. An increase in drag or swabbing on
connections is possible indicators of balling. Sometimes a ball can be pumped off a bit,
but if that fails, the common practice of spudding the bit should be avoided. The
combination of the reduced annular clearance and the pipe surge can cause the
pressure to exceed the fracture pressure.
iii. High fluid‐loss muds deposit a thick filter cake that can reduce the annular clearance.
Smaller annular space increases the ECD which can induce or increase mud losses.
Therefore, fluid loss and filter‐cake thickness should always be controlled in the proper
range. Mud that develops a thin, strong filter cake is more effective in preventing lost
circulation to small fractures or pores.

31 June 2009


iv. Drill with minimum mud density as possible. This not only enhances the ROP but also
diminishes other mud‐related effects.
v. Pre‐treatment with a good selection of the proper size of bridging materials can help
reduce and eliminate whole mud losses into porous formations. The choice of such
bridging agents will depend on the formation characteristics. Generally, particles that
are one‐third to one‐half the square root of the permeability in millidarcies (md)
should be able to bridge such formations. Common pre‐treatment recipes are 5 – 20
lbs/bbl mica, walnut or fine fiber material. This material would be maintained in the
active system by continuous treatment and monitoring of product concentrations.

¾ Curing Losses – The 3 Step Process

When lost circulation is first noted, the conditions at the time the loss occurred should be
accurately recorded and studied. The time of the occurrence (while drilling, circulating or
tripping), the type of the loss (seeping, partial or complete) and the severity of the loss with
respect to the exposed formations are the key factors in determining why the loss occurred,
where in the hole the loss occurred and the best remedy for the situation.

Step 1 ‐ Locate the Loss Zone

The probable location of the loss zone may be determined from knowledge available at the
rig site. Globally, most losses do not occur at the bottom of the hole, however, in Saudi Arabia,
the majority of losses appear to occur as fractured carbonates are exposed while drilling, often as
soon as the fractures are drilled. The following subjects will help in determining the location of
the losses:
a) Formation Information.
1) Carbonate formations contain cavernous and vugular zones. This type of loss would be
indicated if the loss was swift, large and accompanied by a drop in the drill string.
2) Shale formations tend toward fracturing that may be a slower type of loss. This loss
needs to be controlled quickly, as continued losses will enlarge the fracture and com‐
promise formation integrity.
3) A change in the drill rate may indicate a formation change with possible change in
formation integrity.
b) Operational Information.
1) Some type of hydraulic‐pressure‐induced lost circulation would be indicated if the mud
weight was being increased at the time of loss. This type of loss may seal itself
(seepage) or require treatment (induced fracture) depending on the severity of the loss.
2) Rapid movement of the drill string will cause pressure surges that can induce fractures
or reopen previously sealed loss zones. Unless a previously sealed loss zone has been
pressure tested it should always be assumed this area remains a potential source of
32 June 2009


losses. The rate of pipe movement during trips and while reaming should be adjusted to
compensate for this weakness. A more informed decision can be made regarding the
proper steps to eliminate the losses with the information gathered above.
c) Logging methods
a) Spinner survey.
b) Temperature survey.
c) Radioactive tracer survey.
d) Hot wire survey.
e) Pressure transducer survey.

Step 2 ‐ Identifying the Mechanism of Losses and Assessing the Severity

a) Invasion
In many cases, lost circulation cannot be prevented in formations that are cavernous,
vugular, fractured or unconsolidated. Depleted low‐pressure formations (usually sands)
are similar relative to lost‐circulation potential.
1) Coarse, unconsolidated formations
2) Potential loss zone is in depleted formations.
3) Cavernous or vugular zones are usually associated with low‐pressure carbonate.
The volume and persistence of this kind of loss depends on the degree to which
the vugs are interconnected. Cavernous and vugular formations are often easily
traceable from offset wells and predictable from mud logs and lithology.
4) Fissures or fractures in wells where no coarsely permeable or cavernous
formations exist. These fissures or fractures may occur naturally, or may be
initiated or extended by hydraulically imposed pressures.
b) Fracturing
Hydraulic fracturing is initiated and lost circulation occurs when some critical
fracture pressure is reached or exceeded. Once a fracture is created or opened by
an imposed pressure, it may be difficult to repair (heal) and it may never regain the
original formation strength. Lost circulation may persist even though the pressure
is later reduced. This is one reason why it is better to pre‐treat for, and prevent,
lost circulation than to permit it to occur.
Lost circulation resulting from induced fracturing is usually caused by one of two
situations:
1) Setting intermediate casing in the wrong place.
2) Excessive downhole pressures, which are the result of many conditions including:
i) Mechanical forces.
ii) Improper hydraulics: Excessive pump rates and velocities causing high
Equivalent Circulating Density (ECD) pressures.
iii) Increasing pump rates too rapidly after connections and trips. This can be extremely
important when dealing with oil‐base fluids.

33 June 2009


iv) Raising or lowering the pipe too fast (surge/swab).
v) Spudding bridges.
vi) Excessive Rate of Penetration (ROP) for a given flow rate will result in high cuttings
concentration in the annular fluid causing a high ECD.
vii) Pipe whipping.
viii) Hole conditions.
a) Sloughing shale or increased solids loading in the annulus and high equivalent
circulating density.
b) Accumulation of cuttings in a washed‐out portion of the hole or in the mud.
c) Cuttings beds, barite sag/slumping forming on the low side of a directional well.
d) Bridges.
e) Kicks and well‐control procedures.
ix) Mud condition.
a) Excessive viscosities and gel strengths.
b) Buildup of drilled solids.
c) Thick filter cakes that reduce the hydraulic diameter of the wellbore.
d) Excessive mud density or increasing mud density too fast.
e) Unbalanced mud columns.
f) Barite sag.
c) Assessing the Severity
¾ Seepage Losses – Usually less than 10 bbls per hour
¾ Partial Losses – More than 10 bbls per hour with partial returns to surface
¾ Severe Losses – More than 100 bbls per hour with some returns to surface
¾ Total Losses – Fluid level in hole may not be visible

Continued drilling
exposes new fractures
Point of Loss
Reduce Pump Rate

34 June 2009


Step 3 ‐ Curing the Losses

Choosing the LCM Recipe and Spotting Technique
The best approach to control lost circulation is to make an assessment of the severity of a
loss zone and match the remedial material and technique to it in terms of both the size of the
material and its function.

NOTE: Losses to Non‐Reservoir zones are handled differently than Reservoir Zones simply
by applying the rule “Only use Acid Soluble Material or Non‐Damaging Material in the Payzone”.

1. Seepage losses can occur in any formation type when the bridging agents are not large enough
to form a seal, or when there are no fine particles to complete the seal.
a. Generally it is acceptable to continue drilling while adding 5 – 25 lbs/bbl of fine to
medium LCM to the mud on a continual basis (Fiber, calcium carbonate, Nut plug, etc.)
b. If losses continue or increase, stopping and spotting an LCM slurry containing fine to
medium bridging agents (fibers, granular and flakes) with a total concentration of 40
lbs/bbl (if motors or jetted bits are in the hole) to 200 lbs/bbl if possible, should be
considered.
c. Reduce mud weight if possible.
2. Partial losses occur in gravel, small natural fractures and barely opened induced fractures.
a. The pull‐up‐and‐wait technique should be the first technique used to attempt to regain
full returns (see pull‐up‐and‐wait technique).
b. If the hole will not stand full while waiting, the technique of mixing an LCM slurry
containing fine to medium bridging agents (fibers, granular and flakes) or utilizing a an
alternative, more aggressive solution (high concentration LCM pill; crosslink pill) should be
considered.
c. Reduce mud weight if possible.
3. Severe losses
a. The pull‐up‐and‐wait technique should be the first technique used.
b. If the hole will not stand full while waiting, an LCM pill containing large bridging agents
(up to 200 lbs/bbl), a cross‐link pill or a high fluid loss pill should be prepared.
c. If returns are not regained with this technique, a hard plug such as a cement or diesel‐
oil‐bentonite‐cement is recommended (see techniques for cement slurries).
d. Reduce mud weight and/or pump pressure if possible.
35 June 2009


4. Complete losses occur to long, open sections of gravel, long intervals of small natural fractures,
large natural fractures or open induced fractures.
a. The pull‐up‐and‐wait technique should be the first technique used to attempt to regain
full returns (see pull‐up‐and‐wait technique).
b. If regain of lost circulation is not required, proceed to Mud Cap drilling technique.
c. If regain of circulation is required, use an aggressive LCM pill consisting of a combination
of large sizes of particles, fibers and flakes, a cross‐link pill or a high filtration loss pill.
d. If returns are not regained with this technique, a hard plug such as a cement or diesel‐
oil‐bentonite‐cement is recommended (see techniques for cement slurries).
e. Reduce mud weight if possible.(Be aware of any well control issue)

Causes for Failure to Regain Circulation
Some of the most usual causes, directly or indirectly, for failure to control loss of
circulation are:
1. The location of the loss zone is not correctly established many times, resulting in attempts
to place materials at the wrong spot. Loss zones are usually on bottom, especially when drilling
natural fractured formations.
2. Lost‐circulation materials are not systematically matched to the type and severity of the
loss zone. There must be a mixture of particle sizes to initiate and complete an effective seal. The
most effective pills contain a combination of particles, fibers and flakes.
3. There is sometimes a reluctance to proceed to the technique required to match the severity
of the loss zone (i.e. drilling blind and setting pipe).
4. Failure to study and follow lessons learned from offset wells in dealing with similar loss
situations.
5. In cementing, the columns are not balanced and drilling mud breaks through the plug before
it sets. In addition, when the pipe is withdrawn from the hole after placement, the mud level in
the annulus goes down and mud from the formation can break through the freshly placed slurry.
Balanced columns and plug‐dropping techniques should be employed.
6. The formation strength or natural fracture is too weak to support the hydrostatic pressure
of the fluid column needed to control the pressure in other exposed zones. To be effective, the
lost‐circulation techniques and materials must be functionally related to the losses they cure.

36 June 2009


Pull‐Up‐and‐Wait Technique
Drilling and circulation should be stopped at the first indication of lost circulation when
partial losses and losses to induced fractures are experienced, except for sudden, complete losses
to limestones where large fractures, vugs or caverns occur. The bit should be pulled to a point of
safety and the hole permitted to remain static for a period of time. Carefully monitor the well for
signs of intruding fluids and risk of a kick. After the waiting period, good drilling techniques must
be followed in getting back to bottom to keep minimum pressures on the formations.
On the speculation that returns will not be obtained by waiting, a 100‐bbl LCM slurry or a
similar LCM treatment can be mixed during the waiting period. If it is anticipated that a WBM LCM
pill will remain in storage for any length of time a biocide should be added to prevent bacterial
degradation of any organic components.
Fractured shales exposed to water‐base muds will often heal and circulation can be
regained, especially if pressures can be reduced with improved hydraulics and drilling practices.
Oil‐base fluids typically do not exhibit this self‐healing behavior to the same extent. This technique
is particularly applicable to deep‐induced fractures.

Drilling Blind (Mud Cap Technique)
Drill blind through the loss zone (Mud Cap drilling technique) and set pipe. Use this
technique against severe complete losses. In the case of very severe loss zones such as big caverns
(with or without water movement) or long (500 to 1,000 ft) zones of honey‐combed vugs or
fractures, drilling blind (Mud Cap drilling technique) through all the loss zones and then setting
pipe is often the only technique that can succeed. (See Page 54 for more information on Mud Cap
Drilling.)

Typical Plugging and Bridging Agents (LCM)
Fibers Flakes
¾ Cellulosic (wood) Fibers ¾ Flake (cellophane).
¾ Mineral fiber ¾ Mica (fine and coarse).
¾ Synthetic fiber ¾ Calcium Carbonate flakes
Granular Hard and Soft Plugs
¾ Walnut Shells (nut shells ‐ fine, medium ¾ Cement
and coarse). ¾ High‐filter‐loss squeeze (EZ Squeeze / DE)
¾ Resilient Graphitic Carbon (Fine, Medium ¾ Diesel‐Oil/Bentonite (DOB –“Gunk Plug”).
and Coarse) ¾ Crosslinked polymers (X Link, etc.).
¾ Sized Calcium carbonate Blends ¾ Diesel‐oil/bentonite/cement (hard plug).
¾ Blend of fibrous, granular and flake ¾ OBM High‐filter‐loss squeeze (DE).
material in a 1 sack product. ¾ Gunk squeeze for oil muds (Organophilic
Clay in water).
37 June 2009


¾ Incorporating Lost Circulation Material into the System – Pre‐Treatment Technique
Incorporating “large” concentrations of lost‐circulation materials into the whole system
will increase the equivalent circulating density, increasing the potential of further losses. This
often compounds the lost‐circulation problem instead of solving it. However, there are cases
where seepage losses can be temporarily stopped or minimized by carrying small concentrations
of lost‐circulation materials in the system.
&Rule of Thumb: Recommended materials and concentrations for pre‐treating systems can be 5
to 8 lb/bbl of cellulosic fibers (Baro‐Fiber, Frac‐Seal, Tru‐Seal, Cedar fiber) and 5 to 10 lb/bbl of
fine and medium granular and/or flake material (calcium carbonate, walnut, mica, graphite).

Use of Plugging or Bridging Agents
This technique should be used against seepage and partial losses and the less severe
complete losses. A blend of bridging agents in the mud is mixed and applied as follows:
1. Establish the approximate point of the loss, type of formation taking the mud, height the
mud stands in the hole and the rate of loss.
2. Use open‐ended drill pipe for placement of the LCM pill if possible. Otherwise use a bit
with no nozzles or a Paul B. Lee circulating sub (PBL).
If an LCM pill must be pumped through a bit with jets or MWD/LWD tools, medium‐to‐fine,
sized bridging agents should be used to prevent plugging the bit.
&Rule of Thumb: Typical maximum limits for LCM concentrations when pumping through
MWD/LWD tools is 40 ppb (However, higher concentrations of graphite to 120 lbs/bbl have been
used extensively).
NOTE: Use only acid soluble materials for losses to the reservoir.
3. Mix a 100 to 300 bbl LCM slurry. Sacks of blended coarse, medium and fine granular, fiber
and flake bridging agents are commercially available and could be substituted for those added
separately. Use mud from the circulating system or mix LCM in a fresh prepared, viscous,
bentonite slurry. The combination of LCM can be similar to the recipe below:
¾ 15 ‐30 lb/bbl of coarse Walnut Shells.
¾ 5 ‐ 20 lb/bbl coarse‐to‐medium fibers (Baro‐fiber, Frac‐Seal, Tru‐Seal).
¾ 5 – 20 lb/bbl of medium‐to‐fine fibers (Cedar fiber,Baro‐Fiber, Frac‐Seal, Tru‐Seal).
¾ 0.25 – 1.0 lb/bbl of coarse fibers (Cedar fiber, SunSweep, SuperSweep)
¾ 5 – 60 lb/bbl of medium to coarse resilient graphite carbon (SteelSeal, LC Lube)

38 June 2009


¾ 5 – 40 lb/bbl of medium to coarse calcium carbonate
¾ 5 – 30 lb/bbl of mica flakes
The total concentration of material in these pills can vary from 30 to 200+ lbs/bbl.
&Rule of Thumb: Good mud engineering and constant visual observance of the high
concentration pills while mixing is critical to adjust viscosity and ensure the pill is still pumpable.
For high concentration pills, start with a thin mud.
NOTE: The size of the bridging material must be tailored to the severity of loss since the size of
the openings where the mud is going is seldom known. This logic is based on the knowledge that
low rates of loss occur through small openings and higher rates of loss occur through larger
openings.
When selecting the size of materials to use, the size of the nozzles in the bit and other
possible restrictions (e.g. MWD tools, mud motors) must always be considered.

4. Pump the LCM slurry out the drill pipe opposite the loss zone. Pump at a slow rate until the
entire LCM pill is out of the drill pipe and across the loss zone.
If the initial pill does not cure the losses, repeat as necessary. Consider changing the
formulation or employing other pill types. If the hole fills, close the blowout preventers (rams)
and squeeze the annulus with 50 psi for 30 min. Measure the pressure on the annulus using a 0‐
to 300‐psi gauge. LCM slurries containing a blend of materials are most effective.
&Rule of Thumb: LCM pills are most effective when they contain granular, fibrous and flake LCM
materials. A useful LCM mixture is 3 to 6 parts granular, 2 parts fibrous and 1 part flake material.

¾ Hard and Soft Plugs
Various hard cement plugs are often effective against complete losses and severe
complete losses.
The composition and application of the cement slurry being used to combat lost circulation must
be functionally adequate if the job is to succeed.
1. Cement slurry composition
Cement, or cement plus bentonite, is an important lost‐circulation remedy because these
slurries will often seal vugular loss zones. Four Portland cement slurries are recommended: neat,
thixotropic, bentonite, filamentous fiber. These have been chosen because a wide variety of
properties can be obtained and they are usually available.
Neat‐Portland cement: This slurry is a dense fluid and develops high‐compressive strength.

39 June 2009


Thixotropic cement: Proprietary thixotropic additive(s) from cementing companies can be
added to low density cement slurry to obtain fast gellation properites. The thixotropic cement
slurry can be used to squeeze highly fractured or vugular zones.
Bentonite or gel cement. Bentonite cement formed by adding cement to water containing
prehydrated bentonite gives optimum properties. This slurry has low density and high gel
strength. It also has a higher set strength than a slurry formed by adding water to a dry mixture of
bentonite and cement.
In mixing the slurry, treat the freshwater to be used with 1‐4 lb/bbl of soda ash and 1‐4
lb/bbl of caustic to remove calcium and magnesium ions. Add 10 lb/bbl of bentonite and allow
this to yield. Use this bentonite slurry to mix a 108 to 112 pcf bentonite‐cement slurry.
Use 100 sacks of cement or more for large hole sizes.
Fiber‐Cement : Low concentration of filamentous fibers can be added to a conventional
low density cement slurry . Such filamentous fibers will form a net work across the losses zones to
combat the lost circulation.

Techniques for applying cement (Balanced‐Column Method)
1. If possible, drill without returns through the entire lost‐circulation zone.
2. Pull out of the hole. Measure the static mud level using a sonic echo fluid level meter.
3. Choose a cement slurry according to the severity of the loss zone.
4. Locate the loss zone (Step 1 – Curing the Losses).
5. Run the drill pipe and cementing sub past the loss zone to make sure it is exposed. Pull
up the cementing sub at a point 50 ft above the top of the loss zone.
6. Calculate the slurry volume of cement needed to be spotted. Mix and pump the cement
until the desired volume is pumped. Displace the drill pipe at ±10 bbl/min. Leave enough
cement inside the drill string to balance the plug in the annulus. This will eliminate the U‐
tube effect and minimize cement contamination.
7. Slowly pull out of the hole. As the pipe is withdrawn, the mud level in the annulus will
fall and cause an imbalance of pressure from the formation to the hole. This may cause
mud or formation fluids to break through the cement slurry. To prevent this, very carefully
add mud to the annulus through the fill‐up line. Adding too much mud to the annulus will
force mud from the annulus into the formation through the cement slurry before it has a
chance to set. The amount of mud pumped must match the volume displacement (not
capacity) of the pipe. If it is done carelessly, it can do more harm than good. Pump the
required amount of mud every 10 stands. Wait on cement at least 8 hr.
40 June 2009


8. Measure fluid level. If it is lower or higher than the original static level, do not attempt
to adjust. If it is higher and another plug is run, adjust by adding proportionately less mud
as the pipe is withdrawn.
2. Diesel‐Oil/Bentonite/Cement Slurry Squeeze. This pill can be used against complete losses
and severe complete losses. These steps should be used in applying this technique:
1. If possible, drill without returns through the entire lost circulation zone.
2. Pull out of the hole. Measure static mud level as previously mentioned.
3. Locate the loss zone (Step 1 – Curing the Losses).
4. After locating the loss interval, set the bottom of the mixing sub 50 ft above it. Set a
maximum squeeze pressure.
5. Pump in a 10‐bbl cushion of water‐free diesel oil ahead of the slurry.
6. Mix 100 sacks of regular cement and 100 sacks of bentonite with 50 bbl of diesel oil. For
volumes other than 50 bbl, mix two, 96‐lb sacks of cement and two, 100‐lb sacks of
bentonite with each barrel of diesel oil. For large fractures or long sections of
honeycombed vugs, 300 sacks of each material should be used. For large batches, use a
cementer and mix the dry materials with the diesel oil continuously. For small batches use
a suitable tank. This mixture will yield 1.39 bbl of slurry for each barrel of diesel oil. This
slurry will weigh 86 pcf.
7. Displace the slurry down the drill pipe and follow it with 5 bbl of diesel oil.
8. Start pumping drilling mud into the annulus when the 10‐bbl cushion of diesel oil
reaches the mixing sub. Close the rams. Control the pumping rates so the ratio of the
slurry volume to the mud volume is 2:1. Pump rates of 4 bbl/min down the drill pipe and 2
bbl/min down the annulus will usually be satisfactory with 4 1/2‐in. drill pipe in 7 7/8‐in.
and larger holes.
9. Displace one‐half of the slurry into the formation at this fast pumping rate. The drill pipe
may occasionally be reciprocated slowly to indicate whether the slurry might be moving up
the annulus. If the weight indicator shows any increased drag, break the connections and
raise the pipe until it is free. Make connections and continue displacement. There is no
need for concern over short shutdown periods since the slurry has no pumping time
limitation inside the pipe.
10. Displace the next quarter of volume of slurry / mud at one‐half the rate used in Step 9.
11. Displace the remaining quarter volume of slurry at 1/2 of the rates used in Step 10. If
the hole fills, as shown by pressure on the annulus, attempt (by a hesitation squeeze) to
obtain a pressure buildup using rates of 1 bbl/min into drill pipe and 0.5 bbl/min into
annulus.
41 June 2009


NOTE: One barrel of slurry should be left in the drill pipe at the completion of the squeeze, if
pressure has developed. Balance columns if no pressure develops. Do not attempt to reverse
circulate because mud will contact the slurry and gel up inside the drill pipe.
12. After the squeeze job, pull out of the hole and wait a minimum of 8 hr for the cement to
set before drilling out. If the first attempt is unsuccessful, repeat the procedure after waiting
on the cement for 8 hr.
Precautions
Avoid contamination of the slurry with mud or water in the suction lines and pumps. The
following steps will minimize the possibility of contamination.
1. Field test for diesel‐oil suitability.
a. Fill a sand content tube to the 20% line with the diesel oil.
b. Add water to the “mud to here” line.
c. Shake vigorously for 10 sec and allow to stand for 10 min.
d. If the oil and water separate into two distinct layers, the diesel oil is suitable for use.
However, if the fluid separates into three layers with the oil on top, the water on
bottom and a white emulsion between, the diesel oil is not suitable and should not be
used.
2. Drain all water and mud out of all pumps, lines and tanks prior to mixing.
NOTE: Use diesel oil to thoroughly flush the pumps, lines and mixing facilities prior to
mixing.
3. Crosslinked‐Polymer Squeezes.
Several companies offer crosslinked‐polymer‐squeeze pills in addition to the gunk and
high‐fluid‐loss squeezes designed for lost‐circulation applications. M‐I’s FORM‐A‐SET/PLUG, Baker
Hughes Drilling Fluids’ X‐LINK and Baroid’s N‐SQUEEZE/N‐PLEX are crosslinked polymers and LCM
slurries. These pills are usually a blend of polymers and lost‐ circulation materials that crosslink
with temperature and time to form a rubbery, spongy ductile consistency that effectively stops
loss of fluid by sealing fractures and vugular formations. These pills may also be used to
prevent water flow and consolidate loose gravels. Depending on the manufacturer, the product
may be a one‐sack additive containing polymers and lost‐circulation materials or be individually
packaged.
¾ Techniques for Treating Lost Circulation in Oil‐Base Muds
Although there should be no difference between water and oil‐base muds in the pressure
needed to initiate a hydraulic fracturing of the formation, there is a significant difference once the
fractures are formed. Water‐base fluids typically have a higher “spurt” fluid loss causing an almost
42 June 2009


instantaneous filter cake to form that aids in formation sealing in permeable formations. Oil‐base
fluids do not display the same characteristics. Once a fracture is initiated by an oil‐base fluid, the
pressure necessary to propagate the fracture is much smaller by comparison. This is compounded
by lack of a significant pressure drop across the filter cake of most oil‐base fluids. This allows
changes in wellbore pressures to be transmitted to the formation more readily and further
propagate the fracture. Studies have shown that the pressure required to re‐open a fracture is
also lower when using an oil‐base fluid. A further complication is introduced if the lost‐circulation
material being used acts to prop open the fracture.

The major issues with OBM and lost circulation are:
Flow property differences caused by temperature. After a bit trip, it may be necessary to
operate at a reduced flow rate until a full hole cycle is complete. This allows the mud to heat to
normal circulating temperature and viscosity, preventing unnecessarily high equivalent circulating
densities. Pump pressure differences in excess of 100 psi in heavier fluids are not uncommon as
the fluid heats up.
Increased fluid expansion in comparison to water‐base fluids. The mud weight of OBM will
often increase as the fluid cools on surface as during a trip. Again, these differences are magnified
at higher mud weights. For this reason, the temperature at which mud is weighed should always
be recorded. The temptation to reduce the mud weight in the pits during a trip should be resisted
unless the weights were taken at the same temperature.
Certain products reduce electrical stability. In oil base muds, small concentrations of fine
Walnut Shells, mica (5 to 10 lb/bbl) and fine Resilient Graphitic Carbon additives (RGC, 2–5 lb/bbl)
may be used but be aware that these tend to cause water‐wetting and loss of electrical stability.
The oil mud system should be monitored for their effects and treated accordingly. Pretreating
with an oil‐wetting agent may minimize these effects.
¾ Oil‐base‐mud squeezes.
These have proven to be an effective method of sealing a loss zone. These squeezes should
be of a volume sufficient to at least fill the hole 50 ft above and below the loss zone. The following
squeezes have been most effective in sealing loss zones when oil‐base muds are used.
4. Resilient Graphite/Calcium Carbonate/Fiber Squeeze
1. Mud from the active system can be used as the base for this slurry. To the base mud,
add 8 ‐ 10 lb/bbl Resilent Graphite Carbon (RGC), 10 ‐ 25 lb/bbl Mica, 10 to 25 lb/bbl
medium Wallnut Shells, 10 to 20 lb/bbl Calcium Carbonate (medium to coarse) and 10 ‐ 20
lb/bbl Cellulosic Fibers (as an example). The quantity of material mixed in the pill will
depend on several conditions and if a PBL sub is run with the drilling assembly:
43 June 2009


a. The current mud weight. As fluid density increases, the quantity of lost‐ circulation
material that can be added and maintain a pumpable fluid decreases.
b. Restrictions in the drill string. The size of the bit nozzles, internal restrictions from
MWD, motors and other tools affect permissible lost‐circulation material concentrations.
c. Always check if the pumps or pumping units are equipped with suction screens. If so,
the screens may need to be removed prior to pumping the pill.
2. Set the bit at the top of, or opposite, the loss zone. Displace the slurry to the end of the
drill pipe.
3. Close the rams. Gently squeeze (50 psi maximum) material into the loss zone at a rate of
1 bbl/min.
Hold the squeeze pressure 2‐4 hrs, or as desired, or until it dissipates. Measure the squeeze
pressure on the annulus using a 0‐ to 300‐psi gauge.
To avoid fracturing other zones, safe squeeze pressures in excess of mud hydrostatic pressure
should be used.
For example: Depth (ft) Squeeze Pressure (psi)
0 ‐ 1,000 0 ‐ 200

1,000 ‐ 5,000 100 ‐ 500

5,000 and deeper 500

NOTE: Surface pressure plus mud‐column pressure should never exceed the fracture
pressure (1 psi/ft).

5. Gunk Squeeze for Oil Muds
A typical placement example is given below.
1. If possible, drill without returns through the entire lost‐circulation zone.
2. Pull out of the hole. Measure the static mud level as previously described.
3. Locate the loss zone (Step 1).
4. After locating the loss interval, set the bottom of the mixing sub 50 ft above it. Set a
maximum squeeze pressure.
5. Pump in a 10‐bbl cushion of water ahead of the slurry.
6. Mix 1/2 lb/bbl of XC Polymer and 250 lb/bbl of Oil Mud Viscosifier (Organophilic clay,
GELTONE/VG69) in water to the desired volume of slurry.
44 June 2009


7. Displace the slurry down the drill pipe and follow it with 10 bbl of water.
8. Start pumping oil‐base mud into the annulus when the 10‐bbl cushion of water reaches
the mixing sub. Close the rams. Control the pumping rates so the ratio of slurry volume to
the oil mud volume is 2:1. Pump rates of 4 bbl/min down the drill pipe and 2 bbl/min down
the annulus will usually be satisfactory with 4 ½ in. drill pipe in 7‐7/8 in. and larger holes.
9. Displace one half of the slurry into the formation at this fast pumping rate. The drill pipe
may occasionally be reciprocated slowly to indicate whether the slurry might be moving up
the annulus. If the weight indicator shows any increased drag, break the connections and
raise the pipe until it is free. Make connections and continue displacement. There is no
need for concern over short shut down periods since the slurry has no pumping time
limitation inside the pipe.
10. Displace the next quarter volume of slurry and mud at one‐half the rate used in Step 9.
11. Displace the remaining quarter volume of slurry at 1/2 of the rates used in Step 10. If
the hole fills, as shown by pressure on the annulus, attempt (by a hesitation squeeze) to
obtain a pressure buildup using rates of 1 bbl/min into drill pipe and 0.5 bbl/min into
annulus.
NOTE: One barrel of slurry should be left in the drill pipe at the completion of the squeeze.
Do not attempt to reverse circulate because mud will contact the slurry and gel up inside
the drill pipe.
12. In instances where the hole cannot be filled, a packer should be set in the bottom of
the casing. Oil‐base mud and slurries should be displaced down the drill pipe in alternate
batches of 20 bbl of slurry to 5 bbl of oil‐base mud using a spacer of 1 or 2 bbl of oil
between slurries.
13. After the squeeze job, pull out of the hole and wait on the slurry to set a minimum of 2
hr before drilling out. If the first attempt is unsuccessful, repeat the procedure.

PRECAUTIONS
Avoid contamination of the slurry with oil‐base mud or water in the suction lines and
pumps. The following steps will minimize the possibility of contamination.
1. Drain all oil mud out of all pumps, lines and tanks prior to mixing.
2. Use water to thoroughly flush the pumps, lines and mixing facilities prior to mixing.

45 June 2009


Losses
Typical LCM Pill Formulations
Severity
Non-Reservoir Reservoir
In the active system: In the active system:
Calcium Carbonate Fine: 10 ppb Calcium Carbonate Fine: 10 ppb
Seepage Calcium Carbonate Medium: 10 ppb Calcium Carbonate Medium: 10 ppb
losses Hourly additions to the active sytem Hourly additions to the active
Calcium Carbonate F: 150 lbs/hr sytem
(< 10 bbl/hr) Calcium Carbonate M: 150 lbs/hr Calcium Carbonate F : 150 lbs/hr
NUT PLUG Fine: 3 sx/hr Calcium Carbonate M :150 lbs/hr
Fiber Fine: 3 sx/hr
Calcium Carbonate Fine: 10 ppb Calcium Carbonate Fine: 10 ppb
Calcium Carbonate Medium: 10 ppb Calcium Carbonate Medium: 10 ppb
Partial losses Fiber Medium: 5 ppb N-Seal: 5 ppb
Graphite Regular: 5 ppb Hourly additions to the active
> 10 BPH Hourly additions to the active sytem system
NUT PLUG Fine: 3 sx/hr Calcium Carbonate F: 250 lbs/hr
Mica Medium: 3 sx/hr Calcium Carbonate M : 250 lbs/hr
Fiber Medium: 3 sx/hr N-Seal: 2 sx/hr
Calcium Carbonate Fine: 10 ppb Calcium Carbonate F: 10 ppb
Calcium Carbonate Medium: 10 ppb Calcium Carbonate M: 10 ppb
Calcium Carbonate Coarse: 10 ppb Calcium Carbonate Coarse: 10 ppb
Severe
Fiber Coarse: 5 ppb SoluFlake: 5 ppb
Losses Graphite Coarse: 5 ppb N-Seal: 5 ppb
Hourly additions to the active sytem Hourly additions to the active
(> 100 bbl/hr) NUT PLUG Coarse: 3 sx/hr system
Mica Medium: 3 sx/hr Calcium Carbonate F: 150 lbs/hr
Fiber Coarse: 3 sx/hr Calcium Carbonate M : 150 lbs/hr
Spot Cross Link pills (See formulations in this Soluflake: 3 sx/hr
section) N-Seal: 3 sx/hr
Calcium Carbonate Medium: 10 ppb Calcium Carbonate Medium: 10 ppb
Calcium Carbonate Coarse: 10 ppb Calcium Carbonate Coarse: 10 ppb
TOTAL
Marble Chips (2000 microns) : 5 ppb SoluFlake: 5 ppb
Losses Fiber Coarse: 5 ppb N-Seal: 5 ppb
Graphite Coarse: 5 ppb Spot Acid soluble plugs and/or
(No returns) Spot Cross Links pills, Gun Squeeze pills, Flash cement plugs
set plugs or cement (See formulations in this
section)
Ensure that pill particles will not plug down hole equipment.
If the pill is ineffective, increase the particle size.
N- Seal is 98% soluble in 60:40 blend of 10% HCl and 3% Acetic acid.
46 June 2009


Size Data for Conventional Lost Circulation Materials
Product Type Product Name Fine Medium Coarse
D50 = 37μm D90 = 1362 μm

Baro-Fiber D50 = 60 μm

Cellulose fiber Frac-Seal
Median size 44 - Median size 104- Median size
True-Seal
74 μm 149 μm 420-840 μm
Sun Sweep
Synthetic Fiber Super Sweep 1.5 cm
Baro-Lift
Mica MICA D90 = 850 μm D90 = 1.4 mm D90 = 4.75 mm
Nut shells Wallnut D50 = 418μm D50 = 1148μm D50 = 1727μm
Product Type Product Name Blend
Graphite Steel-Seal BDF-398

D50 = 55 μ
Steel-Seal Fine
D50 = 78 μm
Steel-Seal Reg
D50 = 343 μm
LC-LUBE
Cross-linking polymer pill X-Link D50 = 180 μm
Fine (ARAMCO) D50 = 8 – 12 μm

Medium (ARAMCO) D50 = 130 – 170 μm
Coarse (ARAMCO) D50 ≈ 600 μm
Chips D50 = 3800 μm
Bara-Carb 5
Calcium Carbonate D50 = 5 μm
Bara-carb 25
D50 = 25 μm
Bara Carb 50
D50 = 50 μm
Bara-Carb 600 D50 = 600 μm

Bara-Carb 2300 D50 = 2300 μm
Acid Soluble Fiber N-Seal D50 = 1300 μm

47 June 2009

48 June 2009

49 June 2009


LCM products Taxonomy
LCM PLANT

HIGHLIGHTED products are approved in the Saudi
Aramco system and should be available for use. M-I-X II (F, M. C) – M-I
Barofiber (F, C) - Baroid
Chek-Loss, Chel-Loss-C &- Plus -Baker
Fiber, cellulosic Sized, Micronized
Fibro-Seal (F, M C) - KMC
Fracseal (F, M, C) – Summit
Truseal (F, M, C) – Petro Chem
Barolift (Baroid)
Fiber, filamentous Sun Sweep (Sun Drilling)
Fibrous

Super Sweep ( M-I)
Fiber, cedar Cedar fiber (most compan ies)
Fiber & seed hull Cottonseed Hulls (most companies)
Fiber, treated oil-wet Vinseal (M-I)
Plant

Nut Plug (F, M, C)- most companies
Granules Nutshells
Nutshells, walnut – most companies

Blend of
fibers,
granules and
flakes
Kwikseal – most companies
MI Seal (MI)
MIL-Seal (Baker)
Baro-Seal (Baroid)
50 June 2009

LCM MINERAL
Aramco system and should be available for use. BaraCarb series -5, 25, 50, 150

Aramco CaCo3-Fine & Medium
Sized, Micronized SafeCarb series- 5, 20, 40, 100
Mil-Carb series – 5, 25, 50, 150 & 450

Calcium Carbonate Opta-Carb series 5, 20, 50, 100.

Flakes Solu-Flakes (Baker)

Fine,d50=30m
Granular Petroleum Coke Sized, Micronized C-Seal
Regular, d50=130m

Steel Seal-400 (d50 = 400 micron)
Steel Seal-100 (d50 = 100 micron)

BDF-398 (d50 = 50 micron)
LC Lube (d50 = 325 micron)
Synthetic Graphites Sized, Micronized LC Lube Fine (d50 = 165 micron)

G-Seal Fine (d50= 50 micron)
Mineral G-Seal (d50=130 micron)
G-Seal- Plus (d50=200 micron)

Magma Fiber Fine
Fibrous Fiber, Mineral Sized Magma Fiber Reg
N-Seal

Solubridge
Resinous Resins Sized Solubridge-CRS

Solubridge-Fine

Cellophane Cellophane Flakes
Plastic Flakes

Mica Fines
Mica
Mica Coarse
51 June 2009


LCM BLEND SQUEEZE

High Fluid Loss & High Solids Slurry Form-A-Squeeze or Form-A-Set (M-I)
Squeeze
N-Squeeze (Baroid)
DIASEAL-M (Drilling Specialty )
Solu-Squeeze (Baker)

Form-A-Plug II/Form-A-Set/ Form-A-set-
Cross-Linked Polymer Gel Plug +
Graded LCMs - Non acid soluble. N-Squeeze /N-plex (Baraid)
(cross linking reaction adjusted with X-Link (Baker)
Accelerator or Retarder)
Bor-Plug (Tanajib, 3rd Party)

Blend, High TekPlug* XL (BJ)

Fluid Loss or Cross-Linked Polymer Gel-Like plug
for fluid loss control in completion Safe – Link (M-I)
Reinforcing
Plugs/or Slurries K-Max (Baroid)

Cross-Linked Cement-Like Polymer ThermaTek RSP (Baroid)
plug – 95% Acid soluble
Magneset (BJ)

Hydrating Polymer Blend
Hydro-Plug (Baroid)

Flex Plug (Baroid)

Chemical Sealant Fuse-IT (Baroid)
Versapac (M-I)

Shear Thickening Special Polymer
LCM Slurry with fibers, flakes &
LCP-2000 (Impact Solution)
granules


Aramco system and should be available for use.

52 June 2009


Mud Cap Drilling
Definition: A non conventional drilling technique to maintain a floating “cap” of weighted mud in
the annulus across a sensitive or high pressure hydrocarbon zone while drilling ahead with
complete mud losses.
How it works?
When drilling with a floating mud cap, circulation continues down the drill string, usually with
water and gel sweeps while weighted mud (75 – 95 pcf) is pumped down the annulus periodically.
When to use it?
Used in a total loss scenario to control wellbore
stability or a high pressure zone above the lost
zone and allow continued drilling.
Rules for Mud Cap Drilling
• Once this option is taken, DO NOT
REGAIN CIRCULATION. If circulation is regained
in this condition, the drill water will mix with
the mud cap and will lighten the annular
column causing a potential well control issue if
high pressure zones are exposed. Also, the
water in the annulus will contact the sensitive
shales and quickly destabilize them, possibly
causing hole collapse.
• Mud cap MUST cover zone of risk at all
times
• Discontinue use of LCM (Do not attempt
to regain circulation)

Fluid Type used as mud cap
Water based muds are used as a mud cap. The mud cap can be treated with 3 – 5% KCl and starch
to be inhibitive if necessary and also weighted to control any high pressure zone or unstable shale.
The mud cap density will be calculated based on the hydrostatic pressure needed.
Drilling Fluid
The cheapest fluid available that can keep up with the rate of pumping while drilling – almost
always water with regular high viscosity, bentonite‐based sweeps.
53 June 2009

DRILLING FLUID
F S AWAR
RENESS
DRILLIING
G TECHNICA
AL DEPARTM
MENT WORKSHOP 1:
W 1 BASIS OF DESIGN

Ho
ole Cleanin
ng

Hole ccleaning is of the utmostt importancee to the succcess of any d drilling operaation. Regular size
bit cuttin
ngs to fine, p
packed cuttinngs beds to llarge “rocks”” from unco onsolidated fformations tthat
have caved into the w well must bee effectivelyy removed. TThe results oof ineffectivee hole cleaning can
vary fromm packing offf to high ECDD’s and resu ultant mud lo osses to stucck pipe.

There are various proceduress and techniq ques used to o ensure andd enhance ho ole cleaning. While
flow ratee (annular veelocity) and m
mud weight are the bigggest factors, hole angle will dictate the
mud design for swee eps and evenn the active mud. High vviscosity sweeeps are recommended for
sections from verticaal to 35˚, where high den nsity sweepss are proven n to be the m
most effectivve in
sections greater than n 35˚. The m
most critical mmud parameeters to achieve consisteent hole cleaaning in
highly deeviated sections are the low shear rh heology valu ues (6/3 rpm
m; low shear YP). As is offten
said and proven, swe eeps are nott even necesssary for effeective hole ccleaning if th
he mud is in ggood
shape an nd flow rate and pipe rottation are op ptimized.
&Rule of Thumb: For optimumm hole cleanning sweeps,, use High Viscosity Pills for <35° holle
angles; H dem Low Viss/High Densiity for > 35° hole angle.
High Density Pills or Tand
¾ Criticcal parametters: The listt below iden
ntifies variables that ne
eed to be op
ptimized to h
have
effecctive hole cle
eaning:
Hyddraulics
¾ annular velocity
v
¾ annular velocity
v
profile
¾ flow regimme
Drilling Param
meters
¾ bit type
¾ penetratio on rate
¾ pipe rotattion
Mud Properties
¾ mud weig ght
¾ viscosity,, especially
y
at low sheear rates
¾ gel strenggths
¾ inhibitiveeness

5
54 June 2009

DRILLING FLUID
F S AWAR
RENESS
DRILLIING
G TECHNICA
AL DEPARTM
MENT WORKSHOP 1:
W 1 BASIS OF DESIGN

¾ Indicators of hole cleaning p problems
o The first and most importtant source of informatiion is to visu ually evaluate cutting retturns,
th
he observed amount of cuttings hass to reflect th he relative h
hole size and
d ROP. Roun nded
cuuttings indiccate long ressidence timee downhole aand poor cleeaning.
o Torque and D Drag: Erratic increases orr higher thann expected u upward trennds.
o Pick‐Up and SSlack‐Off weeights: Reducction in dow wn weight can indicate cu uttings bed b
buildup.
o Connections: fill after con nnections; higher rotaryy torque; preessure surges while breaaking
ciirculation indicates cuttiings accumu ulation.
o Pressure tren nds: can indicate annular obstruction ns due to a h
higher amou unt of cuttings in
annulus.
o Tripping: High her drag; improper holee fill‐up on trrips; and incrreased presssure when bbreaking
ciirculation caan be an indiicator of poo
or hole cleanning.

Position of Drill Strin
ng

In horrizontal or hiighly deviateed wells, thee pipe is typically on low side of the hole which m means
the path of least flow
w resistance is on the higgh side of th he hole. Thiss is why high
h viscosity pills have
poor performance in n horizontal wwells since tthe thick mu ud will favor the path of least resitannce.

5
55 June 2009


Performance of High Density vs High Viscosity Sweeps

1 Cuttings Transport Efficiency
MC 127 Sidetrack #3
0.8
0.6
Drilling Fluid
0.4
Hi‐Viscosity Fluid
Transport Efficiency
0.2
Weighted Fluid
0
0 200 400 600 800 1000 1200 1400
Flow Rate (gpm)
‐0.2
‐0.4
‐0.6
‐0.8
‐1

Transport efficiency is a modified slip velocity approach that analyses the average fluid velocity
in the narrow gap region of an eccentric annulus and is compared to the settling velocity of
individual cuttings particles. The output from this model is given as transport efficiency.

High density pills (15 – 30 pcf > active mud weight) have proven to be much more effective in
effectively flushing a horizontal hole clean due to buoyancy effects, reduced cuttings settling
velocity and the ability to stay more intact than high viscosity pills during high flow rate.

In industry flow loop and field studies since 1979, mud weight always proved to have a stronger
effect on hole cleaning than mud rheology.

A 200 annular foot sweep, 30 pcf higher than the active mud weight in a 10,000 ft. well
increases hydrostatic less than 0.6 pcf equivalent.
&Rule of Thumb: High Density Sweeps should be 15 – 30 pcf > Active Mud Weight, used alone
or preceded by a Low Vis Pill. High Density Pills should never be of a higher viscosity than the
active mud weight. Sweeps should be 200‐500 annular feet in size depending on ECD impact.
56 June 2009


Rotation of Drill String & Rheology is Critical!

Low Rheology High Rheology
High Velocity Fluid Low Velocity Fluid

Area of high velocity shrinks and
areas of low velocity flow increases
GOOD!
BAD!

No Rotation With Rotation
High Velocity Fluid
Low Velocity Fluid

Cuttings on low side will not be disturbed by fluid
unless stirred by pipe rotation or higher velocity
With rotation, cuttings pulled up into high velocity
fluid mechanically and due viscous coupling
or turbulence effect

BAD! GOOD!
Settling / Avalanching ‐ While Oil Base and Water Base Muds perform about the same with
respect to hole cleaning, cuttings beds slide/avalanche much more in Oil Base Muds.

1 2 3

1) Cuttings particles are suspended when drilling with pipe rotation.
2) Once circulation and rotation stop, cuttings begin to settle to the low side of the
annulus creating a pressure imbalance which drives the lighter, upper fluid upwards.
3) Once a critical mass has been exceeded the cuttings avalanche, leading to a pack-off.

57 June 2009


Tools to improve hole cleaning
• Increased flow rate – Most effective
• Increased mud density
• Changes in fluid rheological properties (Improve low shear rheology in deviated wells)
• Increased DP rotation
• Drilling fluid sweeps (<35° ‐ Use high viscosity; >35° ‐ Use Low vis / High density)
• Increased DP size [for ECD and AV]
• Cuttings bed impellers [CBI]

¾ Best Practices for Highly Deviated or Horizontal Holes
Ensure high enough flow rate [Q] to give adequate AV in open hole
Hole Size, in Annular Velocity, Comment
ft/min
Even with these AV’s, hole cleaning problems can
Larger diameters 125‐140 be expected. The use of specially designed
sweeps is mandatory
13 ½ +/‐ 200
12 ¼ +/‐ 180
9 ½ +/‐ 170‐175
8 ½ +/‐ 150‐165
These AV values assume you are rotating the drill pipe at a 'normal' rpm speed (100‐120
rpm). For Transport efficiency, use 40% (2.5 bottoms up to remove cuttings from the hole)
as a minimum.

Minimize the number of sweeps – Optimize mud parameters & flow rate/rotation for consistent
Hole Cleaning!
&Rule of Thumb: For horizontal/highly deviated wells, the 6 RPM rheology reading should
be 1.2 – 1.5 X the Hole Size. Example: For an 8‐1/2” hole, 6 RPM should be 10 – 13.

Detrimental Effects of Too Many Sweeps:
• Viscosity increase in system • Additional cost to control mud
• Density increase in system • Additional rig time required

58 June 2009


If annular velocity is inadequate, consider increasing pump rate or even changing DP size.
o 5‐in to 5.5‐in
o 5‐in to 5.875‐in [special string]
o 5.5‐in to 6.625‐in
Avoid backreaming as hole cleaning tool because it causes the following effects:
o Excessive pressures on wellbore wall
o Damage to filter cake on borehole wall
o Wellbore instability issues
o Increases incidents of pack‐offs and stuck pipe
o Complicates PWD interpretation
&Rule of Thumb: If Backreaming is required, always backream to at least a <35° section and
circulate the hole clean.
Use of sweeps as hole cleaning tools
o Best hole cleaning tool is flow rate/velocity
o Sweeps are purely secondary tools, not primary tools
Tandem sweeps are NOT recommended when wellbore stability problems are
expected. The low viscosity part can be easily put in turbulent flow and scours wall
cake off the borehole wall, thus allowing more fluid to be pushed into the rock matrix.
However, in stable hole, tandem sweeps have been used successfully.
o High viscosity for vertical / near‐vertical wells < 35 deg
o High density for high‐angle wells – Recommended 15 – 30 PCF above fluid density
o DP rotation enhances sweep performance
&Rule of Thumb: For deviated wells, a single bottoms up is never enough. Up to 2.5 times
bottoms‐ up are required to clean the well.
Minimize or eliminate sliding

Causes of Poor Hole Cleaning while Sliding
o Poor cleaning with no DP rotation
o DP lies against low side of hole

Possible solutions for Hole Cleaning while Sliding
o Drill with rotary steerable assemblies
o Control ROP

59 June 2009


Tripping Procedures
o Assume tight hole caused by cuttings bed first. Avoid back‐reaming and pumping out
to help clean hole. Take the time to properly clean the hole before beginning the trip
out
o Back‐reaming should be avoided so that pack‐offs associated with Boycott settling are
not induced or the drill string is not dragged through a cuttings bed accumulating
cuttings across tool joints, the BHA or the bit.
o Determine Over‐pull limit before pulling out of hole.
o If back‐reaming is performed, do not stop backreaming until the BHA is in a section
with less than 35° deviation
o Watch torque and drag trends as these can be an indication of cuttings loading in the
annulus. Stop and circulate hole until hole clean (Minimum 2.5 bottoms up)

Use Sweep Sheets to Document Sweep Performance
Sweep Sheets should be used to document details of every sweep pumped and the results
of the sweep in order to develop a best performance trend and lessons learned for future
wells.
Use the example Sweep Sheet on the following page.

60 June 2009


SWEEP SHEET
Date / Time: Depth : Hole angle: Av. ROP:
Sliding / Rotation:
Active mud density, PV/YP, 6/3 RPM:
MWD tool in hole (type/company):
Circulating sub in hole (yes/no):
Pump rate during sweep: Pipe rotation during sweep (Yes/No):
Bbls Density PV YP
High Vis only
High Density only
Tandem Sweep
Lo-vis
Hi-vis
Fiber-enhanced Sweep
Before After Remarks
Pump Pressure (psi)
Torque (off btm)
String Weight:
Up:
Down:
Sweep Effects: (% cuttings increase, pump pressure increase during sweep, cuttings size/appearance, etc.)

61 June 2009


Circulation Prior To Tripping
Due to the fact that cuttings move more slowly than the circulating mud, it is essential that
sufficient bottoms‐up are circulated prior to tripping, especially in a highly deviated/horizontal
hole. A SINGLE BOTTOMS‐UP IS NEVER ENOUGH!
The minimum on bottom circulation time prior to tripping will be influenced by hole size,
inclination and flow history (i.e. mud properties and flow rate). These factors will affect the height
of any residual cuttings beds. Industry studies show that the volume of cuttings left behind during
normal drilling operations can be considerable. Studies recommend selection of bits/BHA’s with
large bypass areas to facilitate tripping out of the hole.
Before tripping, monitor the shakers to ensure the cuttings return rate is reduced to an
acceptable background level. The figures in the table below are guidelines based on simple slip
velocity considerations and field experience:
WELL INCLINATION SECTION LENGTH FACTOR
RANGE 17‐1/2” HOLE 12‐1/4” HOLE 8‐1/2” HOLE
0° ‐ 10° 1.5 1.3 1.3
10° ‐ 30° 1.7 1.4 1.4
30° ‐ 60° 2.5 1.8 1.6
60° + 3.0 2.0 1.7

Since in practice not all of the section back to surface will be deviated at the same angle, the
overall minimum circulation time prior to tripping should be apportioned in direct relation to the
relative lengths of section at each angle. This is illustrated in the following example for tripping
out of 17‐1/2 inch hole at 7,710 ft. (2,350 m)

Procedure:
1. Effective Length = Section length x section length
factor

∑ Effective Length
2. Circulation Time = X B/U
Actual Length

Example:
Number of Circulations:
5,350 m
=
2,350 m
= 2.2 * B/U

62 June 2009

DRILLING FLUID
F S AWAR
RENESS
DRILLIING
G TECHNICA
AL DEPARTM
MENT WORKSHOP 1:
W 1 BASIS OF DESIGN

Cuttings build‐up wh
hile pulling p
pipe

ROTTATION is a K
Key Factor to disturb th
he cuttings b
beds

¾
¾
¾
¾

¾ Itt is very imp
portant to identify any w
wellbore stability proble
ems that are
e affecting th
he hole
clleaning befo
ore making sseveral chan
nges to the iinitially plan
nned hole cle
eaning strattegy.
6
63 June 2009


Wellbore Stability

Drilling in complex geological environments, such as faults, joints, fractures, layered formations,
weak bedding planes, etc., usually leads to expensive borehole stability problems. Here, a deep
understanding of the mechanics and mechanisms of rock fracture becomes a key element in
solving such problems involving geotectonic structures.

Wellbore instability can occur as a result of a mechanical effects, chemicals effects or a
combination of both.
In simple terms, mechanical effects are usually related to mud weight (too high or too low) or
drilling practice (Rate of penetration, vibration effects, torque and drag and frequency of trips),
whereas chemical effects are mud type related (inappropriate mud type or inhibition level for the
problematic formation being drilled).
Misconceptions about Wellbore Stability
“Many people in our industry believe that well control purposes alone dictate the required
mud weight. They often also assume that the hole collapse is simply a result of drilling with
insufficient mud weight”
“It is common to assume that increasing mud weight is always the answer to hole instability
problems. This is not always correct. Sometimes, increasing it can make the problem worse.”
“Many people believe that the use of an oil based mud will prevent any problems occurring
while drilling in shales. Hole instability can still occur particularly if mud weight or water phase
salinity is inappropriate.”
Signs Of Wellbore Instability
• Hole washout / hole enlargement
• Tight hole or creep
• Altered, damaged, or plastic zones
• Unusual hole calipers
• Formation fracturing / lost circulation
• Wellbore breathing (losses followed by gains)
• Bedding plane slippage
• Stable wellbore while drilling, unstable while preparing to run and cement casing
64 June 2009


Rock Failure Mechanisms
¾ Exceeding tensile strength (fracture gradient)
This event occur when the tensile strength of the rock is exceeded due to high ECD
(Equivalent Circulating Density), high surge pressures while tripping or running casing or
when the well is strongly shut down for a well control situation.
Drilling fluid Lost is experienced when the tensile strength of the rock is exceeded. The
figure below shows a fracture process (Similar to a LOT)
Lost Returns Fracture Process is

Identical to LOT Fracture Process
3. Stable Crack Growth 4. Stop Pump

Continued increase due to
pressure drop down crack 5. Initial Shut-in
Initial fracture pressure
2. Leak-Off
Small, stable 6. Width Declines
crack opens Fracture closes due to filtrate
ISIP
P re s s u re
losses in fracture face
7. Minimum Stress
Final pressure at crack
closed on mud solids 8. Pressure Declines
Filtrate losses continue
1. No Open Crack after fracture closure, but
Linear drilling fluid compression. only into the smaller area
exposed in the borehole
V o lu m e SI Time

Prevention
o Be aware of the mud density limitation (Based on LOTs data from offset wells,
historical mud losses or rock data analysis).
o When drilling in fractured formations, the weakest point in the hole section IS NOT
below the casing shoe. You have to rely on the mud losses history. A good MW /ECD
tracking of the mud losses scenarios is very important.
o Do not rely just on surface density, the ECD (Equivalent Circulating Density) is the one
affecting the formation while drilling. In OBM, the difference between the surface and
bottom hole density is considerable due to the compressibility effect.
o When drilling long horizontal sections, the difference between the mud density and
the ECD is much bigger than drilling vertical wells. Plan to reduce this ECD to a
minimum by controlling the flow rate, ROP and fluid rheology.
65 June 2009

DRILLING FLUID
F S AWAR
RENESS
DRILLIING
G TECHNICA
AL DEPARTM
MENT WORKSHOP 1:
W 1 BASIS OF DESIGN

¾ Exxceeding co
ompressive sstrength (Ho ole collapse)

This event o
occurs when n the compreessive strenggth of the ro ock is exceed
ded which caan occur
w
when lower f fluid densitiees than requ
uired for rockk stability arre used.
There are o d to wellboree collapse, like swabbing while tripp
other scenariios that lead ping out
or a sudden rig pumps shut
s down. All of abovee should bee avoided to
o minimize wellbore
w
coollapse.
Effects of Compressiive Failure
¾ Hole size
e reduction ddue the plasttic flow of th
he rock into the boreholle (boreholee
collapse)), which causses repeatedd requiremeents of reaming, difficulties to run in hole,
pull out o
of hole or stuck pipe.
¾ Hole enlaargement due to rock ffailing in a brittle manneer and falling into the b borehole
(break‐out), which results in poor
p directional contro
ol, poor cem
menting job
bs, poor
logging aand formatioon evaluation.
“Highly devviated wells require high
her mud den
nsities to maaintain the w
wellbore staability”

“IIn a deviated well, the d
drilling wind
dow is narro
owing as the
e hole angle increases”
6
66 June 2009


Prevention

o Use the recommended mud density based on wellbore stability analysis or offset
wellsIf the recommended mud density for wellbore stability cannot be used for well
control issues or potential down hole losses, be prepared for wellbore collapse and
packing off events. An efficient hole cleaning and ROP control are mandatory in this
scenario.
o Treat the well gently, especially when tripping or shutting pumps down to minimize
the swabbing effect.
o Condition the drilling fluid prior to running casing and control pipe speed while
tripping.
• Do not make drastic mud density reduction, since it may cause a wellbore
collapse (Especially in unconsolidated or weak formations).
¾ Bedding plane slippage
This event occurs in certain formations that once they are drilled, the rock will slip on a
defined plane. Blocky cavings are typical of this bedding plane slippage scenario.
Prevention
o Use bridging material in the drilling fluid to fill the cracks presented in these
formations and have a good filtration control. This formation will try to fall as soon
it is drilled and it is recognized by blocky type cavings on the shakers.
o Maintain a good hole cleaning efficiency and ROP control to minimize the risk of
pack off.

¾ Interaction with drilling fluid at wellbore wall (Chemical instability)
Chemical wellbore instability is due to chemical interaction between the rock being drilled
and the drilling fluid. The water phase of the drilling fluid reacts with the formation
(Especially shale) and weakens it.
When shales react with water, they can soften, disperse, swell and crack.
These effects can cause a wide range of operational problems such as tight hole, hole
enlargement, ledging, bit balling and caving.
67 June 2009


Prevention
o Use inhibitive drilling fluids that minimize the amount of water going into the shale.
Good filtration control is required.
• Low HTHP values dependent on many variables (BHT, mud type, overbalance,
etc.)
• Cake Thickness ‐ 1 ‐ 4/32” for WBM; <2/32” for OBM

o For Oil base muds, the salinity of the water phase should be minimum in balance
or higher than the formation water salinity. Higher salinity in the OBM will prevent
the shale to get water, swell and slough.
o The interfacial film surrounding the emulsified water droplets in an oil mud act as a
semi‐permeable membrane and provide a mechanism for osmosis. Osmosis is the
flow of water from a less concentration salt solution into a more concentrated
solution through a semi‐permeable membrane. This is why OBM are the best option
for shale inhibition.
o For WBM (Water Based Muds), the shale inhibition mechanism is achieved by:
• Salinity of its continuous phase (Water). NaCl, KCL are commonly used in our
operation. KCL brine (3 – 5% by wt) is preferred, especially when drilling shales
which have a high Smectite/Illite content.
• Polymers as filtration control agents (PAC, Starch, N‐Drill HT, etc). These
polymers delay (through their viscosity) the water flow from the mud filtrate to
the shale.
• Encapsulation: It is a chemical and physical interaction with the clays surfaces.
Long chain polymers such as PHPA and modified carboxymethylcellulose, are
believed to wrap around the clay particles. This aids in control of surface
hydration and reduces the tendency to disperse and disintegrate
• Physical plugging, in some of the brittle shales, ionic inhibition and
encapsulation may not sufficiently reduce shale instability.Even a slight
hydration of microfractures will make the formations unstable. Asphaltenes
have been used effectively to seal micro‐fractures. Gilsonite is another mineral
product used to maximize shale stabilization. Soltex, Blacknite are commonly
used in our operation for this purpose for non‐payzones.
• PolyGlycols are also used as clay inhibitor due to their ability to retain water.
(GEMGP, etc). MEG and TEG ‐ typical Aramco glycols, are not effective as clay
inhibitors and should not be used for this purpose.
68 June 2009


69 June 2009


Stuck Pipe

¾ Stuck Pipe events are one of the highest causes of downtime in all drilling operations. They
can range from minor incidents increasing costs slightly, to major, catastrophic complications,
such as loss of drill strings and expensive down hole equipment to even complete loss of the
well.

Industry studies reveal the following information concerning stuck pipe:
Vertical and Low Angle holes have the best success rates for freeing
Hole Angle:
stuck pipe.
Success rate for freeing stuck pipe was slightly higher for larger than
Hole Size:
smaller holes.
The chance of freeing stuck pipe is higher in wells requiring lower
Mud Weight:
mud weights.
The quicker the spot is applied, the higher the chance of success.
Spotting Time:
Delay reduces success rapidly.
Open hole length does not consistently affect the success rate for
Open Hole:
freeing stuck pipe.
Operation during 60% of stuck pipe incidents.
Reaming/Backreaming:

Effective Soaking time
24 hours for directional wells; 30 hours for vertical wells
for Pills
36% of stuck pipe incidents typically occur within the first 2 hours of
crew change
People Factor ¾ People are the critical element to prevention of stuck pipe – proper
training, awareness of the goals, attention to detail and best practice
application are the best insurance for success.

Causes of Stuck Pipe

Drill strings or casing strings can become stuck by two basic mechanisms:
¾ Mechanical sticking
¾ Differential sticking

From 1999 – 2004, 39% of Saudi Aramco Deep Gas Wells experienced Stuck Pipe. In a
study of 115 of these stuck pipe incidents, conclusions were that 58% were differentially
stuck and 42% were mechanically stuck.

70 June 2009


Mechanically stuck pipe

Causes of Mechanically Stuck Pipe – 2 Categories

Hole Packoff and Bridges caused by:
1. Settled Cuttings and Cuttings Beds
2. Shale Instability
3. Unconsolidated Formation
4. Cement or junk
5. Tectonics
Well bore Geometry Interferences caused by:
1. Key Seats
2. Undergauge Hole
3. Stiff Drilling Assembly
4. Mobile Formation
5. Ledges and Doglegs
6. Casing Failures

Differential Sticking
Many incidents of stuck pipe are caused by differential
pressure effects. Excessive differential pressures across lower‐
pressure permeable zones can cause the drill string, or
casing, to pull the drill pipe into the filter cake.
Differential Sticking should be properly addressed in the
pre‐planning stage and proper preventive measures
should be taken to avoid substantial cost penalties.
Preventive measures include pre‐treatment to prevent
sticking and a pre‐agreed action plan should sticking occur.
Experience has shown that differential sticking can occur
with a minimum overbalance and should always be considered a
hazard when drilling permeable formations such as sandstone and/or Limestone.

Differential Sticking is a 2 Part Problem

¾ High overbalance across a permeable zone

¾ Filter cake “grows” as filtration continues to

“glue” the pipe in place

71 June 2009


Causes of Differential Sticking
A major cause of differential sticking is excessive overbalance in a permeable zone. The
overbalance may be necessary because of an open hole section containing reactive, pressurized
shales that require a high mud weight to impart stability.
This may be further complicated where wells are deviated, requiring higher mud weights
(compared to vertical wells) to stabilize the shales combined with an increase in equivalent
circulating density (ECD) and in most cases a lower fracture gradient.
Differential sticking may result when the specific requirements for casing design expose sands
to excessive overbalance, e.g. deep high temperature ‐ high pressure (HTHP) wells or development
wells where the formation changes from shales to reservoir sands. A pressure reversal or depleted
zones may cause differential sticking.
Excessive overbalance can be a result of poor hole cleaning and/or excessive rates of
penetration (ROP) resulting in an increase of annular mud weight. Other causes include poor
quality filter cake, excessive fluid loss, poor hydraulics and rheology resulting in high ECDs and
poor drilling practices such as leaving drill string stationary in a permeable zone.

¾ Prevention ‐ General
o Well Planning is Key – Identify zones with high probability of stuck pipe
o Training – Hold team/well site Stuck Pipe Prevention meetings
o Design BHA’s for minimum wall contact
o Design/drill with optimum trajectories to minimize dogleg severity (tortuosity)
o Minimize mud overbalance
o Keep the pipe moving
o Optimize mud to maintain thin, impermeable mud cakes
o Minimize reaming/backreaming
o If backreaming, always continue to a vertical section to ensure good hole cleaning
o Develop trend charts of torque/drag and pipe pick up/slack off

¾ Prevention of Stuck Pipe ‐ Mud Condition
o Maintain good hole cleaning rheology and minimize annular cuttings loading
o Control ROP – do not out‐drill the capability of maintaining mud quality.
o Ensure low filtrates and thin, tough, impermeable filter cakes.
o Use lubricity agents (lubricants, plastic beads) as necessary
o Maintain <5% by volume low gravity drill solids
o Employ specialty Overbalance Drilling Fluids in extreme cases
72 June 2009


&Rule of Thumb: Maintain <5% low gravity drill solids in the mud; < 3% in a Reservoir Drill
In Fluid or High Density Mud (>120 pcf) for best control of mud parameters, minimizing
formation damage and minimizing risk of stuck pipe. Studies show that over 10% low gravity
solids almost guarantees stuck pipe.

Stuck Pipe ‐ The Importance of Proper Bridging Materials

Using a high quality properly sized bridging material will effectively bridge across porous sands
minimizing filtrate and whole mud invasion, filter cake build up, seepage loss, differential sticking
and formation damage.
Bridging material type and optimum concentration should be determined through testing with
the Particle Plugging Apparatus and FANN® 90 to determine the combination of products that will
provide the lowest spurt and fluid loss. It is important to bridge and seal pore spaces with the
initial loss of filtrate. This minimizes filtrate loss and filter cake build up and resulting stuck pipe.
Dynamic filtration can be evaluated in the laboratory under a variety of conditions. These
include various shear rates, pressures, and temperatures and filter medium permeability. The lab
requires details about the size and permeability of sand to be drilled. Ideally, the tests should be
completed far enough in advance so the treatment can be implemented and the active system
tested to confirm the lab results prior to drilling the sands.

¾ Prevention of Stuck Pipe ‐ Connection Guidelines
There is a history of sticking problems when making connections. These guidelines are to
remind everyone of good drilling practices which minimize potential problems during connections.
These guidelines assume top drive drilling.
• All Drillers should be familiar with these connection procedures.
• Wipe, at least, the last joint prior to making a connection. If erratic or high torque is
experienced prior to the connection, clean the hole.
• At “Kelly Down” always allow the weight on bit (WOB) to drill off prior to picking up off
bottom, especially when drilling with high WOB.
• Have a single in the “V”door in case downward motion is required to free the pipe after a
connection.
• Avoid starting and stopping the mud pumps suddenly. This may disturb the wellbore
downhole (shock loading effect). Take a whole minute to bring the pumps up to speed.
• Minimize the period without circulation during a connection.
• After drilling or reaming, cuttings should be circulated above the open hole section and/or
the horizontal section prior to picking up to make a connection.
73 June 2009


• If differential sticking is suspected to be a risk; maximize pipe motion, consider rotation of
string with slips set while picking up the next stand.
• Connections should only be made if hole condition is good. Never make a connection with
any overpull onto the slips.
• Set slips high enough to allow downward movement. If hole conditions are sticky, extra stick
up may be required, taking care not to bend pipe.
• Always confirm circulation after a connection prior to moving pipe.
• Always begin pipe motion downwards once slips are pulled.

¾ Prevention ‐ Reaming and Back‐Reaming Guidelines
It is now accepted that reaming contributes to increased hole deterioration. In addition,
reaming and back reaming account for over 60% of stuck pipe incidents. Reaming in the hole has
the greatest risk of sticking associated with it due to the fact that the BHA continues run in hole
(RIH) past "stirred up" cuttings beds and can therefore pack‐off.
The preferred practice is to work the string past a tight spot as a first option. However, overpull
limits must be known and used. Work up to the overpull limit in stages, ensuring free movement in
the other direction at each stage.
Understanding the geology and hole condition is important. Different actions may be required
in different formations (e.g. undergauge sand, ledges or sticking balling formations).

• Always plan the trip. Have an up‐to‐date mudlog on the rig floor, know where high doglegs
exist and note troublesome areas from past trips.
• A tripping speed plot should be available on the rig floor. A good understanding of this plot
will assist in safer and quicker trips.
• Ensure that the Driller knows what actions to take in the event of problems. Are overpull
limits, freeing procedures and reaming practices understood? Are written instructions for
the driller prepared and updated regularly?
• If reaming is required, control the speed of reaming operations. Large volumes of settled
cuttings or new cave‐ins can be introduced to the hole while reaming. It is critical that this
material is circulated out (4 stands an hour can be used as a rule of the maximum speed).
• Reaming operations should be conducted as smoothly as possible. Rotation speed should be
dictated by torque and kept as low as possible.
• Prior to heavy reaming, slow rotation (<80 rpm) should be attempted to "walk" the pipe
through ledges.
• Reaming weight and speed should be kept low (< 10 ‐ 15 Klb) either up or down. This
reduces the chance of sidetracking the well and is less damaging to the drill string.
• When the top drive stalls out during reaming operations, there is a great deal of stored
energy in the torqued up drill string. Always release this torque slowly.
• If consistent parameters can be used for reaming operations, this assists in identification of
changes in torque and pressure trends.

74 June 2009


• Increase in drag, torque, or pressure may indicate that the annulus is loaded up and a pack‐
off may be forming. Take time to clear up the hole.
• The shakers must be monitored continuously, and the volume of solids being removed from
the wellbore should be recorded. Reaming speed and circulation time should be adjusted if
volume rate dictates.
• Drill floor personnel should get into the habit of calling the Mud loggers before making
connections to check that everything is OK.

Treatment
Once the pipe becomes stuck, whether it is the drill pipe assembly or casing/liner, the
reaction plan should be as follows:

1. Determine the type of sticking mechanism. Use the following table to help.
2. Immediately apply efforts to work the pipe properly and use spotting pills.

& Rule of Thumb: The surest way to free stuck pipe is to ALWAYS BE PREPARED. Preplanning

is essential and must include having proper mud additives and chemicals at the well site
before drilling a high risk section.

75 June 2009


How to determine if the pipe is Differential or Mechanically stuck

PIPE MOTION PRIOR PACK‐OFF/ WELLBORE
DIFFERENTIAL
TO STICKING? BRIDGE GEOMETRY
Moving Up 2 0 2
Rotating Up 0 0 2
Moving Down 1 0 2
Rotating Down 0 0 2
Static 2 2 0
PIPE MOTION AFTER
STICKING?
Down Free 0 0 2
Down Restricted 1 0 2
Down Impossible 0 0 0
PIPE ROTATION
AFTER STICKING?
Rotate Free 0 0 2
Rotate Restricted 2 0 2
Rotate Impossible 0 0 0
CIRCULATING
PRESSURE AFTER
STICKING?
Circulating Free 0 2 2
Circulating Restricted 2 0 0
Circulating Impossible 2 0 0
TOTALS
INSTRUCTIONS:
Answer the shaded questions by circling all the numbers in the row with the correct answer.
Add the columns; the column with the highest number indicates the sticking mechanism.

76 June 2009


77 June 2009


Spotting Fluids Classification

Filter Cake
Brine Surfactant Lubricant Degrading Glycol Acidic Solvents
Dehydrate the Change Reduces friction Degrades the Dehydrate the Dissolve Dissolve
filter cake and as wettability of between drill filter cake (Can be filter cake and filter cake asphalt based
a spacer between filtercake to pipe and weighted) lubricate. It and possibly material
the mud and allow action of formation and cannot be weaken
other spacers acid or other filter cake weighted formation
spotting fluid integrity at
stuck point
• CaCl2 • Lo Surf‐259 • Radiagreen • Coastal Spot • MEG/TEG • Citric Mutual

• CaBr2 • W‐54 EME Salt • EZ SPOT • Polyglycol • HCL Solvent
• F‐103 • Lube 167 • Pipe Lax Ethers • Formic (EGMBE)
• Teq‐Lube II • Musol
• BaroLube • SA‐64
Gold Seal • U‐66

High Weight High Viscosity (HWHV) spacer: Brine or drilling fluid spacer that has a density and viscosity sufficiently higher than the
spotting fluids and displacement mud to minimize interface mixing and improve displacement efficiency. Density should be 10 – 12 pcf
higher than the fluid being displaced.
78 June 2009


Spotting Fluid Types, Actions and Material Requirements
Note: It is critical to have a spotting fluid readily available and apply it as soon as possible.
** If spotted within the first 6 hours, statistically there is a 90% chance of getting free. After
that time, the success rate goes down exponentially.

¾ General Action of a Stuck Pipe Spotting Fluid:
• To dehydrate, disturb or degrade the filter cake
• Allow a lubricant to penetrate the filter cake and reduce pipe/cake adhesion

A. Brine Pre‐Sweep or Soak Pill to precede Lubricating Pills
Purpose:
o To dehydrate and degrade the filter cake by osmotic pressure
o If pumped around the stuck pipe fast, in turbulent flow, may wash and thin the cake
o If soaked, will further dehydrate the filter cake. Optimum soak time ‐ 16 hours.

When and How to Use:
o 30 – 50+ bbls pumped as first pill in a lubricant, glycol or cake degradation pill train
o Pumped as fast as possible past stuck zone OR spotted and soaked up to 16 hours prior
to moving second pill into place.
Formulation for 100 bbls: CaCl2, NaCl or CaBr2
a. CaCl2 – 10.5 big bags (2200 lbs/bag) for 236 lbs/bbl for 86 pcf
b. NaCl ‐ 10 big bags (2200 lbs/bag) for 110 lbs/bbl for 75 pcf
c. CaBr2 – 95 drums for 106 pcf
d. Potassium formate – 15.4 tote tanks (275 gal each) for 98 pcf
B. Surfactant Pills
Purpose:
o To change to or ensure water wet surface area of stuck pipe zone prior to placing acid
or glycol spot

o If OBM 1 – 2% by volume in first pill pumped in a lubricant, glycol or cake degradation
pill train
o Pumped as fast as possible past stuck zone OR spotted and soaked up to 16 hours prior
to moving second pill into place.
79 June 2009


Formulation for 100 bbls:
a. CaCl2 – 10.5 big bags (2200 lbs/bag) for 236 lbs/bbl for 86 pcf
b. NaCl ‐ 10 big bags (2200 lbs/bag) for 110 lbs/bbl for 75 pcf
c. CaBr2 – 95 drums for 106 pcf
d. Potassium formate – 15.4 tote tanks for 98 pcf

C. Lubricant Pills ‐ High concentration Lubricity Pill – Components = active mud, lubricant,
weight material as required
Purpose:
o To lubricate area around stuck zone and reduce adhesion of pipe/cake
o Recommended soaking time – 12 – 30 hours
o Density can be adjusted for any hydrostatic requirement

o Only when it is the quickest response pill to the stuck pipe event. Filter cake
degradation pills are preferred since they perform the same lubricating function plus
other benefits.

a. 90 bbls Active Mud
b. 20 bbls (14 drums) Lubricant ‐ Lube 167, TeqLube II, Radiagreen, or BaroLube Gold
Seal

D. Filter Cake Degradation Pills – Pills containing filter cake degradation chemistry and a high
degree of lubricity. Usually recommended as first response pills. Can be weighted up.
Purpose:
o To degrade filter cake and lubricate area around stuck zone to reduce adhesion of
pipe/cake

o Recommended as first response pills due to multiple benefits

80 June 2009


1) EZ Spot – Components = Water, diesel, EZ Spot, weight material
i. 6 drums EZ Spot
ii. 44 – 64 bbls diesel (depending on density required)
iii. 10 – 28 bbls water (depending on density required)
iv. Barite or CaCO3
2) Pipe Lax – Components = Water, diesel, Pipe Lax, weight material
i. 6 drums Pipe Lax
ii. 44 – 64 bbls diesel (depending on density required)
iii. 10 – 28 bbls water (depending on density required)
iv. Geltone, VG‐69 – 12 – 15 sacks
v. Barite or CaCO3
3) Coastal Spot – Components = Coastal Spot tote tanks, NaCl, SX Plus
i. 3300 gal (12 tote tanks) Coastal Spot
ii. 1210 lbs. NaCl
iii. 26 sacks SX Plus
iv. 580 gal water (depends on density required)
v. Barite or CaCO3 to required density

E. Glycol Pills – Pills containing filter cake degradation chemistry and a high degree of
lubricity. Usually recommended as first response pills. Can be weighted up.
Purpose:
o To degrade/dehydrate filter cake and lubricate area around stuck zone to reduce
adhesion of pipe/cake
o Density CANNOT be adjusted. Are used in neat solution, no viscosifiers.
o Glycol or glycol cocktail pill density will be 68 +/‐ pcf. Check before pumping.

o Also recommended as first response pills, especially in Gas Drilling, due to multiple
benefits and history of success.
o Use when in horizontal wells or maintaining hydrostatic pressure is not critical.

81 June 2009


1) Glycol Neat – Components = Aramco Glycol (MEG or TEG)
i. 77 drums Aramco Glycol (MEG or TEG)

2) Glycol Formulation – Components = Aramco Glycol (MEG or TEG, lubricants, Pipe‐Lax)
a. Basic components per 100 bbls
ii. 65 drums (80 bbls) Aramco Glycol (MEG or TEG)
iii. 12 drums Lubricant (15 bbls) Lube 167, TeqLube II, Radiagreen, or BaroLube
Gold Seal)
iv. 4 drums (5 bbls) Pipe‐Lax

F. Acid Pills
Purpose:
o To dissolve filter cake and near borehole rock to reduce pipe/cake adhesion.

o Citric acid is a low strength acid for use when stuck in carbonate.
o Primary usage is HCl (hydrochloric acid) when stuck in carbonates or to dissolve
carbonate based filter cake in sandstones.
o HCl/HF (hydrofluoric) acid blends are available for sandstone applications but extra
safety precautions must be taken as HF has high HSE risks.
o HCl has been used successfully to relieve severe shale balling causing pipe sticking
when shale ball contains carbonate chips.
o Corrosion inhibitor addition is mandatory.
o Recommended soaking time – 30 minutes – 2 hours
o Density CAN be adjusted by mixing acid in various brines although HCl is commonly
used in 15 – 20% concentrations with water.

1) Citric Acid Pill – Components = Water, 12 – 20 lbs/bbl citric acid (dry)
a. Basic components per 100 bbls
i. 98 bbls water
ii. 36 sacks (25 kg) citric acid
2) HCL – Components = water, 31.5% HCL, corrosion inhibitors
*Consult with Cement Company representative for formulation and supply of acid
and corrosion inhibitors. Confirm formulation with Aramco Mud Specialist.
3) HF acid blends – Commonly referred to as “mud acid”. It is a specialty formulation
and should be planned case by case by the Cement Company acid specialists.

82 June 2009


F. Solvent Pill
Purpose:
o To dissolve any material containing asphaltenes (tar) which have contributed to a
stuck pipe incident.

o When stuck pipe is suspected to be across a “tar” zone. Tar cuttings are often
noticed on the shaker.
o Mutual Solvent (Musol, SA‐64, U‐66 ‐ EGMBE) mixed at 15 – 20% in base oil.

i. 5 – 10 bbls base oil spacer either side of mutual solvent/base oil pill
ii. 85 bbls Base oil ‐ (Low tox mineral oil, Diesel)
iii. 12 drums Mutual Solvent – 15% by volume
Spotting Procedure
Follow the Stuck Pipe Action Plan on page 77 for determination of what type of pill train
to use. Specific volumes and spotting procedures should be written for the particular well as a part
of contingency planning.

Soaking Time of Stuck Pipe Pills

¾ Acid pills react rapidly with carbonates. The reaction can be considered complete in as little
as 30 minutes to 1 hour. This action may be retarded down hole if rock is previously coated
with OBM or a grease pill thus enforcing the importance of using mutual solvents and
surfactants in the pill formulations to convert the rock/filter cake to a water wet condition.
¾ For all “grease” type or glycol/ lubricant pills, the recommended effective soak time is a
minimum of 12 hours with the pill in place to 30+ hours. The action of these pills is to
degrade/crack the filter cake in place around the stuck zone and allow the lubricious phase
of the fluid to soak into the area between the pipe and release pressure. Basically, a fluid is
soaking into rock, which takes time.

83 June 2009


1.2.4 DRILLING FLUID CONTAMINATION

Definition:
Drilling Fluid Contaminants are defined as any external source that changes the chemical or
physical behavior of the fluid system.
¾ Contaminants in fluids can be broken down into three major categories as listed below:

o Contaminants in water based mud
o Contaminants in oil based (or synthetic) mud
o Contaminants in workover and completion brines
Typical Drilling Fluid Contaminants or Undesirable Conditions
9 Carbonates/bicarbonates
9 Salt
9 Calcium from cement
9 Calcium from other sources
9 Magnesium
9 H2S
9 Low Gravity Solids
9 Air entrapment
9 Bacterial Degradation
9 Corrosion
9 Foaming
9 Hydrocarbon Influx
9 Thermal Instability
9 Emulsion breaking
9 Water wetting
9 Barite sag
9 Iron

¾ Some of the previously mentioned contaminants can be prevented by pretreatment of the
fluids system; however some of other forms of contaminants can only be treated as a post
treatment. The points below outline the method for prevention and mitigation.

84 June 2009


Identification and Treatment of Common Contaminants
1) Carbonates (Detected by an increase in Mf‐Pf)
I. Insoluble carbonates such as Calcium Carbonate (limestone) do not pose a problem in the
mud. Soluble carbonates will give rise to high Yield Points and Gels.
II. 3 potential causes of carbonate contamination are Carbon Dioxide from the formation,
degradation of polymers, and excessive additions of Soda Ash or Bicarb to the mud.
III. Pre or post treatment is made with Lime [Calcium Hydroxide – Ca(OH)2] to precipitate
Calcium Carbonate.
2) Salt (Detected by increase in Cl ‐)
I. Salt can be introduced as a contaminant from a saltwater flow, or from drilling salt which
dissolves in the mud.
II. There is no practical means to treat salt out of the mud, other than by massive dilution. If
the source of the salt is drilled salt, dilution is counterproductive since more salt may well
go into solution.
III. Good drilling practice should limit the quantities of salt from a saltwater flow. If major salt
sections are to be drilled, a salt‐saturated mud system should be used.
3) Calcium from Cement (Detected by increase in Pm)
I. Drilling cement (especially green cement) wiII cause the pH of the mud to rise.
II. Treatment is by Bicarb (Sodium Bicarbonate – NaHCO3) which Will react with and
precipitate Calcium from the cement as Calcium Carbonate. and also reduce the alkalinity.
III. Treat the system with thinner
4) Calcium from other sources (Detected by increase in Ca++)
I. Possible sources would be from drilling Gypsum/ Anhydrite. A more likely source is the
make‐up water for the mud.
II. Treatment: is by Soda Ash (Sodium Carbonate – Na2CO3) which will also precipitate calcium
carbonate, but without lowering the alkalinity.
5) Magnesium (Detected by increase in Mg++)
I. Magnesium contamination from the formation is extremely rare. The normal source of
Magnesium contamination is seawater used to mix mud.
II. Treatment is by Caustic Soda (Sodium Hydroxide ‐ NaOH), KOH, or Lime [Calcium Hydroxide
‐ Ca(OH)2). All of these products precipitate Magnesium Hydroxide [Mg(OH)2] as a Gel. If
high Magnesium levels are to be treated. this gel will cause very high viscosities, and
treatment with a flocculants may be necessary to settle the gel.

85 June 2009


6) Hydrogen Sulphide (Detected by decrease in pH, increase in Sulphides)
I. H2S is by far the most dangerous contaminant. It is colourless and although it has a strong
odour it kills the sense of smell at low concentrations, It is extremely toxic. With air it forms
explosive mixtures over a wide range of concentrations. .
II. In the mud it causes flocculation, accompanied by a rapid fall in pH, due to reaction with
Caustic Soda. As an immediate measure, the mud should be treated with Caustic Soda to
raise the pH, and to maintain the H2S in solution. The mud should also be treated with an
H2S Scavenger such as Zinc Carbonate, Zinc Oxide, or Iron Oxide to remove dissolved
sulphides.
III. Treatment with Caustic Soda alone is not recommended, since all that the Caustic does is
to ensure that the H2S remains dissolved in the mud. Further intrusions of H2S will lower
the pH, and allow all the dissolved H2S to break out.
IV. It is recommended that ail rigs working in potential H2S zones be equipped with proper H2S
detectors, and that all personnel receive proper H2S safety training.
7) Low gravity solids (Detected by increase in retort solid content)
I. Optimize solid control equipment
II. Dilute with water or base oil
8) Air entrapment (Detected by increase bubble in the system)
I. Minimize surface air entrapment such as aeration process
II. Treat system with defoaming agent
9) Bacterial degradation (Detected by increase in carbonate alkalinity)
I. Add biocide or lime
II. Increase pH and treat system with fresh polymer
10) Corrosion (Detected by external or internal pitting on drill pipe)
I. Raise pH to between 11 to 11.5
II. Treat the system with suitable corrosion inhibitor
11) Foaming (Decrease in mud weight and foam on surface of mud pits)
I. Add suitable defoamer to the system
II. Spray water on the surface
III. Add viscosifier and reduce mechanical aeration
12) Hydrocarbon Influx (increase in pit volume and reduction in mud weight)
I. Increase mud weight
II. Operate degasser
III. Shut‐in well and follow proper kill procedures

86 June 2009


13) Thermal instability (increase in fluid rheology and system flocculate)
I. Treat mud with deflocculants or thinner
II. Use thermally stable polymer and covert to HTHP system
III. Dilute the system with water or base fluid
14) Emulsion breaking (presence of water in HTHP filtrate)
I. Treat mud with primary or secondary emulsifier
II. Treat system with fluid loss reducer
III. Add lime to the system
15) Water wetting (presence of water wet solid sag in thermo‐cup)
I. Treat mud with secondary emulsifier or wetting agents
II. Treat system fresh mud
III. Add water to solubilize excess salt
16) Barite sag (presence of barite settle in thermocup & decrease in mud weight)
I. Treat mud system with viscosifier. Usually the mud needs a small amount of bentonite (2 –
6 lbs/bbl) to alleviate this problem. Polymer viscosifiers are less effective.
II. Treat system low end rheology modifier
17) Iron (Change of brine color to greenish or rusty)
I. Treat brine system with caustic for monovalent brine and filter the brine
II. Treat system iron scavenger
III. Displace the brine system with fresh uncontaminated filtered brine

87 June 2009


88 June 2009


89 June 2009


90 June 2009


Section 1.3

WELL SITE EQUIPMENT
91 June 2009


1.3.1 DRILLING RIG SPECIFICATIONS

In the basis of design process, rig specifications are very important to plan the job ahead and
have all the contingencies needed prior to start drilling. Mud pits capacities, solids control
equipment availability and additional storage is some of the key information necessary for drilling
fluids planning.

The rig circulating and solids control equipment system should be audited by a qualified service
company and any recommended improvements implemented prior to the start of drilling.

1.3.2 DATA BASE CONTAINING ALL RIG EQUIPMENT FOR EACH RIG

Use the following link to access the rig specifications.
http://eccweb.enp.aramco.com.sa/drilling/NewDIH/Drilling_Manuals/DataFiles/Rig%20Specifications.pdf

92 June 2009


1.3.3 MUD LABORATORY EQUIPMENT AUDIT REPORTS
Rig Mud Lab Audit Report
Check List for Water-Base Mud Testing Equipment
Report No. Well: Rig:
Date:
Comments
Retort Kit
Calibration Yes/No S/N:

Viscometer & Thermocup
Calibration Yes/No Viscometer S/N :

HTHP Filtrate Yes/No HTHP Filtrate S/N:

Yes/
Condition
Required Chemicals and Equipment for Testing Water‐based Drilling Fluids No
1‐ Atmospheric Mud balance
2‐ Pressurized Mud balance
3‐ Marsh Funnel, Graduated Cup (one quart) and Thermometer 220° F
4‐ Six‐speed Viscometer (600,300,200,100 and 6 & 3 rpm) and thermocup.
5‐ API Filter Press (Low‐Temperature/Low‐Pressure cell).
6‐ HTHP Filter Press (High‐Temperature/High‐Pressure)
7‐ Retort instrument (50‐ml).
8‐ 200‐mesh sieve, funnel and glass measuring tube (Sand content set).
9‐ Methylene blue capacity (MBT).
10‐ pH meter (0‐14), for 150 F, resolution 0.1 unit and calibration pH
standards.

93 June 2009


Yes/
Condition
Required Chemicals and Equipment for Testing Water‐based Drilling Fluids No
11‐ pH Paper (0‐14).
12‐ Hydrogen sulfide detection kit (Lead acetate paper discs).
13‐ Chemical analysis kit for all alkalinity and lime content.
14‐ Chemical analysis kit for chlorides.
15‐ Chemical analysis kit for total hardness (calcium and magnesium).
16‐ Chemical analysis kit for calcium sulphate.
17‐ Chemical analysis kit for calcium and magnesium.
18‐ Chemical analysis kit for monitoring the biocide treatment (Aldehyde).
19‐ Pilot Test Kit (Balance, Hamilton Beach Mixer, etc.).
20‐ Garrett Gas Train and Dragger tubes for low and high CO2 and H2S.
21‐ Chemical analysis kit for monitoring potassium ion concentration > 5000
mg/I.
22‐ PPT
Name and Signature of

Saudi Aramco
Name and Signature of Mud Engineer: Representative:

94 June 2009


Rig Mud Lab Audit Report

Check List for Oil-Base mud testing equipment
Report No. Well: Rig: Date:

Retort Kit Aramco Rep. Comments
Electrical Stability Tester

HTHP Filtrate Yes/No

S/N:
Chemical & Equipment for Testing Oil-Based Drilling Fluids

Most of the field-testing equipment used for water-based mud can also be used for oil-
based mud. However, in addition to the water-based equipment mentioned above, the
following field testing equipment for oil-based mud is required.
1- Chemical analysis kit for oil-based mud to measure “excess” lime
2- Electrical stability meter with calibration resistors / diodes
3- Hand held scientific calculator.
4- Samples of oil-based mud products to be included in the Pilot Test Kit.
5- PPT
Name & Signature of Saudi Aramco

Name & Signature of Mud Engineer: Representative:

95 June 2009

Mud Balance Model Mud Balance Model
Constructed of premium metals for durability,

accuracy and ease of use
The Mud Balance provides a simple, practical method
for accurate determination of fluid density. It is one of
the most sensitive and accurate field instruments
available for determining the density or weight-per-unit-
volume (specific gravity) of drilling fluids. An outstanding
advantage of this Mud Balance is that the temperature
of the sample does not materially affect the accuracy of
readings. A high impact plastic case protects the
balance during transport and provides a secure base in
1 its working position.
The Mud Balance is constructed with an easy-to-read
beam which is graduated into four scales:
• pounds per gallon
• specific gravity
• pounds per cubic foot
• pounds per square inch per 1,000 feet of depth
The volume of space occupied by entrapped gas or air
bubbles in a sample fluid may distort the accuracy of the
fluid density measurement. This distortion can be
significantly reduced by pressurizing the fluid. The
density of a fluid containing entrained air or gas can be
determined more accurately by using a pressurized fluid
density balance.
Pressurized Mud Balance
Pressurized Mud Balance The Pressurized Mud Balance is an instrument for
measuring the absolute density of a fluid sample. The
density of a fluid sample, such as cement slurry, can be
measured in a fixed volume sample under pressure. By
pressurizing the sample cup the entrained air or gas can
be decreased to a negligible volume, thus providing a
slurry density measurement more closely in agreement
with the true density which will be realized under down-
2 hole conditions.
Fann density balances are constructed of premium
metals for durability, accuracy and ease of use. A high
impact plastic case protects the balance during
transport and provides a secure base in its working
position.
96 June 2009

Marsh Funnel Viscometer

Marsh Funnel Viscometer
The Marsh Funnel is a simple device for indicating
viscosity on a routine basis. When used with a
measuring cup the funnel gives an empirical value for
the consistency of a fluid. The number obtained
depends partly on the effective viscosity at the rate of
shear prevailing in the orifice, and partly on the rate of
gelation.
The Marsh Funnel Viscometer and Measuring Cup are
made of rugged, break-resistant plastic that resists
temperature change deformation. The Measuring Cup,
graduated in cubic centimeters and fluid ounces, is
designed specifically for use with the Marsh Funnel.
This easy to operate equipment is used for making
rapid, on the spot measurements of fluids viscosity.
3 The Marsh Funnel readings are only general
measurements, but the frequent reporting of the Marsh
Funnel Viscosity will indicate changes in the fluid
viscosity that could require corrective action.
Funnel Viscosity is the ratio of the speed of the sample
fluid as it passes through the outlet tube (the Shear
Rate) to the amount of force (the weight of the fluid)
that is causing the fluid to flow (the Shear Stress).
Marsh Funnel Viscosity is reported as the number of
seconds required for one quart of sample fluid to flow
out of a full Marsh Funnel.
In addition to the Marsh Funnel, the viscosity
measurement procedure requires a graduated
container (Measuring Cup) to receive the fluid as it
flows out of the funnel, a means to measure elapsed
time (Stopwatch), and a thermometer for measuring the
temperature of the sample

97 June 2009

pH Meters – Digital pH Meters – Digital

Easy to operate
The Digital pH Meter is easy to operate, rugged, portable and
compact, measuring only 3" by 6". It is battery operated and
has a 5/16" high LCD display that is easy to read in all lighting
conditions. The meter is packaged in a rugged carrying case
with one 9-volt alkaline battery, permanently sealed
combination probe, pH 4, 7 and 10 buffer capsules, plastic
buffer bottles, and a comprehensive manual.
Each Digital pH Meter is inspected and tested to provide
reliable and trouble free operation. It is accurate and
4 repeatable to +.02 pH and has solid state integrated circuitry
with temperature stable components. The meter includes a
standardizing knob for calibration and slope control, which
matches the meter to the probe for optimum accuracy.
The meter operates with a range of 0 to 14 pH and has a
complete line of accessories. With its low battery indicator,
optional 115-volt and 230-volt AC adapters, and optional car
adapter, the Digital pH Meter is ready for field and lab
operation.

Electrical Stability Tester (EST)

Electrical Stability Tester (EST)
Electrical Stability
The electrical stability (ES) of an oil-based drilling fluid is
related to the stability of the emulsion and oil-wetting
capability. ES is determined by applying a voltage-ramped,
sinusoidal electrical signal across a pair of parallel flat-plate
electrodes that are immersed in the mud. The resulting
current remains low until a threshold voltage is reached,
whereupon the current rises very rapidly
The Electrical Stability Tester (EST) is a battery powered
5 portable instrument that conforms to the test
procedure described in API Recommended Practice 13B-2
The Model 23D EST is calibrated in peak volts which is the
maximum voltage that the fluid experiences between the two
electrodes. Peak voltage may be converted to Root Mean
Square (RMS) voltage by multiplying the peak voltage by
0.7071
98 June 2009

Viscometer Model 35 Viscometer Model 35
Widely known as the Standard of the Industry for drilling

fluid viscosity measurements
Fann produces a range of true Couette coaxial cylinder
rotational viscometers. The test fluid is contained in the
annular space or shear gap between the cylinders. Rotation of
the outer cylinder at known velocities is accomplished through
precision gearing. The viscous drag exerted by the fluid
creates a torque on the inner cylinder or bob. This torque is
transmitted to a precision spring where its deflection is
measured and then related to the test conditions and
instrument constants. This system permits the true simulation
of most significant flow process conditions encountered in
6 industrial processing.
Direct Indicating Viscometers combine accuracy with simplicity
of design, and are recommended for evaluating materials that
are Bingham plastics. These instruments are equipped with
factory installed R1 Rotor Sleeve, B1 Bob, F1 Torsion Spring,
and a stainless steel sample cup for testing according to
American Petroleum Institute Specification RP 13B. Other
rotor-bob combinations and/or torsion springs can be
substituted to extend the torque measuring range or to
increase the sensitivity of the torque measurement. Shear
stress is read directly from a calibrated scale. Plastic viscosity
and yield point of a fluid can be determined easily by making
two simple subtractions from the observed data when the
instrument is used with the R1-B1 combination and the
standard F1 torsion spring.

The most effective means of determining the

Filter Press API (LPLT) filtration properties of drilling muds and cement
slurries
The Series 300 APT Low Pressure Low Temperature
(LPLT) Filter Press consists of a mud reservoir
mounted in a frame, a pressure source, a filtering
medium, and a graduated cylinder for receiving and
measuring filtrate. The basic unit has a cell
assembly constructed of rustproof anodized aluminum
7
and chrome plated brass, and includes the required
screen and gaskets.
Working pressure is 100 psig and the filtering area is
7.1-in2, as specified in the American Petroleum
Institute, API Recommended Practice 13B-1 and 13B-
2.
99 June 2009

Filter Press HPHT 175 ml

175 ml HPHT Filter Press units can be pressurized to 1800
psig on the cell and 750 psig on the back pressure receiver.
Maximum operating temperature is 350°F.
HPHT Filter Presses are available in various component
configurations to allow for greater flexibility in choosing the
system and options that suite each individual need.
Pressurization with CO2 Cartridges, bottled Nitrogen, or an
in-house (user provided) source.
Single or double opening cells that accept different filter
media.
Filter media that includes the API standard Filter Paper,
Ceramic Discs of several calculated porosities, and various
8 mesh sized screens.
Filter Press HPHT
The 3-Way Valve with Valved Quick Disconnect Stabilizer

Regulator helps address our concerns relating to safer high
pressure equipment. The features include a unique 3-way
valve attached to a hex nipple going into the HTHP cell to
isolate gas from regulator and fluid under pressure. The 3-
way valve is turned and not the entire valve stem. Valved
quick-disconnect couplings allow the streamlined and
lightweight Stabilizer regulator to be removed for cleaning
the cell after testing.
The Hydrometer Kit The Hydrometer Kit
The Hydrometer Kit measures the true specific gravity of

liquids in the range of 0.700 to 2.000 specific gravity. The
kit consists of eight 265 mm/10.5 inch glass hydrometers
and a thermometer range -30 to 120°F in 1° divisions, all
packed in a protective foam-lined carrying case. The
9 hydrometer scale is standardized at 60°F. For maximum
efficiency, special hydrometer cylinders are available in 250
ml and 500 ml sizes. Other specific gravity ranges and
types of hydrometers are available upon request.
Size: 13.5 x 10 x 2.5 inches (34.3 x 25.4 x 6.4 cm)
Weight: 2 lbs 10 oz (1.2 kg)
100 June 2009


Chloride, Alkalinity and Water Chloride, Alkalinity and Water Hardness Test Kit
Hardness Test Kit
The Filtrate Analysis Kit contains all equipment and
reagents required to test for chloride content, alkalinity,
calcium content, and hardness by the Versenate Method,
according to API Recommended Practice 13B-1. All testing
apparatus and reagents are contained in a specially
designed stainless steel carrying case.
10

Mud Test Kit – Basic Mud Test Kit – Basic
The Basic Mud Test Kit is designed to provide the basic

drilling fluid testing equipment required for field testing of
water based drilling fluids according to API
Recommended Practice 13B-1. All testing apparatus and
reagents are contained in a specially designed stainless
steel case.
11
101 June 2009

Mud Test Kit - Oil Mud Kit Model Mud Test Kit - Oil Mud Kit Model 866
866
Oil Mud Test Kits are designed as a compliment to the
Basic Mud Testing Kit by providing all necessary drilling
fluid testing equipment required for field testing of oil
based drilling fluids according to API Recommended
Practice 13B-2. All testing apparatus and reagents are
contained in a specially designed stainless steel case.
12
Methylene Blue Test Kit Methylene Blue Test Kit
Shows the amount of reactive clays (bentonite and/or

drill solids) present in drilling fluid
The Methylene Blue Test Kit containing all reagents,
glassware and hardware required to perform the
methylene blue test according the API recommended
practice. All items are neatly packaged in a rugged
Stainless Steel carrying case.
13

102 June 2009


Retort Oil and Water 50ml Kit Retort Oil and Water 50ml Kit
A retort, sometimes called a still, is used to determine the
quantity of liquids and solids in a drilling fluid. In a retort
test, a measured sample of fluid is placed in a cup and
heated until the liquid components have been vaporized.
The vapors are passed through a condenser and collected
in a graduated cylinder or centrifuge tube that has been
calibrated to record the volume of the condensed liquids at
20°C. The distillate is read directly as volume percent of the
solids sample's original volume.
Suspended and dissolved solids are determined by
14 subtracting these from 100 percent of the initial sample. For
fresh-water fluids, the relative amount of barite and clay can
be estimated. Corrections must be made for salt in the
calculation for solids content by volume.
The Oil and Water Retort provides a simple, direct field
method for determining the percent by volume of oil and
water in samples in drilling mud or in core samples of the
formation. The Retort has been found to be especially
useful in determining the oil content of emulsion muds.
Garrett Gas Train Test Garrett Gas Train Test

Measures the concentration of soluble sulfides and
soluble carbonates
The Garrett Gas Train (GGT) measures the concentration
of sulfides or carbonates in drilling fluids and drilling fluid
filtrates. This measurement gives a quantitative indication
of the rate and amount of intrusion of hydrogen sulfide or
carbon dioxide from the formation in the drilling fluid.
The Garrett Gas Train kit contains all hardware and
reagents required to conduct the procedure according to
API Recommended Practice 13B-1, ANSI/API 13B-1/ISO
10414-1. Two types of Dräeger tubes are supplied to
15
adequately span the range of hydrogen sulfide
concentrations that may be found in water based drilling
fluid filtrates and in oil based drilling fluids. CO2 Dräeger
tubes and 1 liter gas bags are supplied for determination of
carbonate concentration. Inert carrier gases, both CO2 and
NO2 are supplied for all tests. All items are securely
packaged in a waterproof, high-impact plastic carrying
case.
Hydrogen Sulfide Test Paper discs (supplied) can be used
in the Garrett Gas Train to give a qualitative indication of
the presence of sulfide. If the presence of sulfide is
indicated by darkening of the paper disc, a Dräeger tube
should be used for quantitative analysis.

103 June 2009

Mixers - Multi-Mixer Mixers - Multi-Mixer
Five-Spindle Multi-Mixer® mixer is recommended for

use in general purpose mixing of drilling fluids in
preparation for laboratory tests of mud materials. This
mixer conforms to American Petroleum Institute
Specification 13A and is supplied with the API
recommended mud impeller blade for mixing water-
based and oil-based drilling fluids. This mixer can be
used to mix cement for field or laboratory testing.
16
Shearing Device / Dispersator Shearing Device / Dispersator
The High Shear Mixer (Dispersator) utilizes a

patented mixing head that pumps material into the
hollow mixing chamber and outward through the
chamber openings. The blades on the mixing
head are designed to draft material from above
and below the mixing head and pull it into the
chamber. The suction of the blades and flow
through the chamber provide a more
homogeneous material mix compared to other
17 mixers which rely exclusively on centrifugal force.
This mixer achieves a higher shear in less time
and maintains a homogeneous material mix
without shear degradation. The mixing head is
easily disassembled for cleaning and the head
and shaft are replaceable

104 June 2009

Aging cell Aging cell
Most drilling fluid formulations contain a base

liquid and additives which must be dissolved or
mechanically dispersed into the liquid to form a
homogenous fluid. The resulting fluid may
contain one or more of the following:
• Water-dispersible (soluble) polymers or
18 resins
• Clays or other insoluble but dispersible
fine solids
• Soluble salts
The fluids are mixed or sheared for times
appropriate to achieve a homogenous mixture
and are then set aside to age. Aging is done
under conditions which vary from static to
dynamic and from ambient to highly elevated
temperatures.

The Portable Malvern Mastersizer Micro

The Malvern Mastersizer Micro
The Malvern Mastersizer Micro particle size

analyzer was developed to provide a simple-
to-use compact particle analysis solution
capable of being operated at or near the
production line as well as in the laboratory.
Sample handling and dispersion is simplified

by the use of standard 600 to 1000 ml
19
laboratory beakers in place of a fixed tank. Its
robust construction and relatively small size
have made the Micro very popular for offshore
and mineral exploration applications.
Single Measurement range.

Measures materials from 0.3 µm to 300 µm.

105 June 2009


Permeability Plugging Permeability Plugging Apparatus (PPA)

Apparatus (PPA) 5,000 psig Working Pressure
The Permeability Plugging Apparatus (PPA) is designed to

provide accurate simulation and measurement of down‐hole
static filtration. This 5,000 psig rated PPA is ideal for predicting
how a drilling fluid can form a permeable filter cake to seal off
depleted/under pressure intervals. The PPA utilizes a
conventional HTHP Heating Jacket to simulate reservoir
20 temperature. The fluid cell is inverted, with pressure applied
from the bottom of the cell and filtrate collected out the top.
Pressure is transferred to the mud by a small hydraulic hand
pump through a small floating piston within the cell. The PPA
employs a ceramic filter disc, which is available in varying
porosities. The disc offers a more authentic representation of
the formation.
‐ Pressure rating: 5,000 psig (34,473 kPa)
‐ Temperature rating: 500°F (260°C)

106 June 2009


1.3.4 SOLIDS CONTROL
“IF YOU CONTROL THE SOLIDS, YOU CONTROL THE MUD.”
Ancient Mud Philosopher

Solids in drilling fluids are a complex balance of desirable and undesirable components. The
science and art required to maintain this balance begins with good well planning. The right solids
control equipment (SCE) must be on location and the expertise must be available to operate,
maintain and evaluate this equipment properly during the entire course of the well.

Failure to maintain the proper balance of solids in the drilling fluid can result in many negative
effects:
1. Increased viscosity and filtration
2. High chemical and dilution costs
3. Uncontrollable mud and costly replacement of the entire system
4. Reduced ROP
5. Excess torque and drag
6. Downhole tool failure
7. Excess pump wear
8. Damage to production zones
9. Stuck pipe
10. Rig downtime

Designing a Pre‐Well Plan for Solids Control – Drilling Engineer, Mud Specialist
1. Plan the mud type and density
2. Develop solids targets for each interval and mud density
3. Understand low gravity solids (LGS) targets and tolerance of the mud systems selected
4. Understand the costs of dilution vs realistic goals of solids control equipment
5. Determine if and when centrifuges may be needed and a projected operation plan
(Solids Removal or Barite Recovery mode, how many hours per day recommended)
6. Check on availability of additional SCE required (centrifuges)
7. Develop a plan for evaluation of solids control equipment (SCE)
8. Plan logistics to accommodate dilution/equipment discharge volumes
9. Consider environmental impact of excessive dilution/discharge
10. Develop a Shaker Screen Program for each interval
11. Determine when hydrocyclones and centrifuges are cost effective
12. Consider the effect bit choices have on solids content in mud and the resultant
dilution/ cost impact
13. Request a Solids Control Program for the well from a company specializing in SCE
&Rule of Thumb: Every one (1) barrel of solids removed by mechanical means saves twenty (20)
barrels of dilution / displacement fluid to maintain 5% Low Gravity Solids.
bbls of solids removed / Target LGS = bbls of dilution required
Ex. – 1 bbl of solids removed / 0.05 = 20 bbls dilution required

107 June 2009


? Can the same results for maintaining solids content be achieved with dilution /
displacement versus that expensive solids control equipment?
NO – Dilution / displacement is a random dump of all solids of all particle sizes. The net effect
is poor particle size distribution of the system producing poor quality rheology, filtration
control and potential formation damage.

? Why is Mechanical Solids Control significantly better than a random dump of solids?
Mechanical Solids Control is the employment of various pieces of equipment to remove solids
of a particular size range, type and density (specific gravity), with some limitations. The effect
is to maintain a desirable particle size distribution to aid in controlling rheology, filtration and
damage to producing formations.

? When are centrifuges most commonly used?
1.Wells > 10,000 feet or highly deviated/horizontal wells
2.High bottom hole temperatures
3.High density muds
4.Expensive muds
5.Producing zones sensitive to formation damage plugging
6.Environmentally sensitive areas

Pros: Drivers for additional Mechanical Solids Control
o Mud Performance
o Mud / disposal / transportation costs
o Minimizing mud volumes to limit environmental impact
o Minimizing formation damage
Cons: More sophisticated SCE does not pay off in:
o Shallower wells / shorter drilling days
o Lack of time for solids accumulation
o Economics of simpler drilling fluids
o Lesser degree of drilling difficulty where mud performance is less critical
o Minimal environmental constraints

Solids control equipment has limitations. The most practical solids control method is a
combination of mechanical solids removal first and maintaining with minimal dilution second.

Develop a Well Site Plan for SCE Implementation – Rig Foreman, Mud Engineer
1. Review the Solids Control Well Plan thoroughly
2. Request a rig audit of SCE by a qualified mud specialist or SCE company
3. Implement recommended repairs of any equipment that is not optimized before spud
4. Ensure adequate inventory of recommended shaker screens, fittings or spare
equipment for planned equipment
5. Coordinate with any planned SCE vendors to supply equipment and qualified operators
6. Have training sessions for pit/shaker hands to cover SCE responsibilities
7. Post equipment maintenance plan/procedures in mud pit shack
108 June 2009

DRILLING FLUID
F S AWAR
RENESS
DRILLIING
G TECHNICA
AL DEPARTM
MENT WORKSHOP 1:
W 1 BASIS OF DESIGN

Mud Soliids – What aare they?

Some industry spe ecialists defiine them as “The Good, The Bad and d The Ugly”..

“The GGood” – Com mmercial So olids – Solids added to give specific eeffects such as bentonitee,
polymerss, weighting agents, LCM M plus severaal more.
“The BBad” – Sand Size Solids –– Drilled Solids which prroduce the n negative effeects previously
mentioneed and are tthe easiest to o remove.
“The UUgly” – Collooidal Size Soolids – The greatest challenge. Theyy have tremeendous surfaace
area, can
n be very reaactive, are th
he same sizee as many coommercial so olids, have th
he strongestt
negative effect on m
mud propertiees and are th he most diffficult, if not iimpossible to remove.

TYP
PES OF SOLLIDS IN DRIILLING FLU
UID
120
Barrite
100
Grround
M
Marble
Relative Volume
80
DRILLED
D
60 SOLIDS
DEN
NSITY
40
SOLIDS Graphite
Bentonite
e
20 BR
RIDGING
S
SOLIDS
Polymer//Starch
0
1 10 100 1000
Partticle Size (microns)

From this comparrison it is cleear that “deesirable” soliids such as tthose used ffor bridging and

density have
h consideerable overllap in size with “undesi
w irable” solids from drilliing. This makes
the selecction and management
m of solids co
ontrol equip
pment very important to be tailoreed to
the type of mud and d type of formmation being drilled. Th his comparisson also illusstrates the p point
that a weell designed bridging mu ud (PSD) neeed not have aa high solidss content to be effectivee.

109 Jun
ne 2009


Drilling Fluid Solids

Classification by Type
Dissolved Solids Suspended Solids Colloidal Solids
Ultra Fine Solids
Salts Drill Solids Mud Additives
(< 2 – 3 microns)
• NaCl • Clays • Barite Usually powder fluid additives used for
• CaCl2 • Sand • Bentonite filtration control like lignite. They will
• KCl • Carbonates • Polymers disperse in solution, will not settle, are
• Sodium/Potassium • Anhydrite • CaCO3 not removable by standard SCE
Formate • Dolomite • LCM
• Organophilic Clay

Classification by Specific Gravity
Low Gravity Solids High Gravity Solids
(1.6 – 2.9 SG) (> 4.2 SG)
Drilled Solids Barite Hematite
Calcium Carbonate
Most fluid additives

Effect/Impact on Drilling Fluid Properties
If undesirable solids accumulate in the fluid, changes in the fluid properties are noted. Depending upon
the size and shape of the solids, fluid loss may either increase or decrease. In general, the quality of the
filter cake will deteriorate (i.e., become thicker and softer). The most immediate changes will be noted in
the fluid rheological properties.
Plastic Viscosity is largely due to mechanical friction between solids particles in the drilling fluid. This
property depends primarily on the size, shape and number of solids in the fluid. Progressive increases in
plastic viscosity can indicate a build‐up of drilled solids.
Yield Point and Gel Strength indicate the degree of attractive forces between particles in the fluid.
These attractive forces are related to the distance between the particles. When yield values and gel
strength become excessive, treatment with a dispersant or deflocculant is required.
“The removal of very fine particles from the fluid produces a greater reduction in viscosity than does the
removal of an equivalent volume of coarser solids due to the difference in surface area.”
The Effect of Solids on the Fluid Flow Regime and Hole Cleaning

110 June 2009


How do I Evaluate the Solids Content of My Mud?

Commonly referred to as a loaded question or as one grizzly oil field hand said – “It’s as
complicated as Women’s Shoes.” Simply said, it is a mathematical calculation based on several
variables including mud density, retort readings, specific gravity of weight material in use, salinity,
specific gravity of an oil recorded, type of salt in use and amount of added commercial solids in
the mud. The best way to evaluate the solids content is to rely on experience, refer to prepared
rule of thumb graphs or require a competent mud engineer with computer software to produce
the numbers. A solids analysis for the mud in use is reported on the Daily Mud Report.

Solids Content Definitions

¾ Retort Solids – Represents the total solids in the mud as read directly from the retort tube
and includes soluble solids.
¾ Corrected Solids – Represents the total solids in the mud MINUS the soluble salt.
¾ Low Gravity Solids (LGS) – Represents the corrected solids in the mud MINUS high gravity
weight material. This value also includes low density weight material added such as
calcium carbonate (CaCO3).
¾ Drill Solids – Represents the total solids in the mud MINUS soluble salt, any weight
material and chemical additives.

An example of Solids Calculations from a Daily Mud Report

MUD PROPERTIES
Sample Source Flow Line
Time 1:58
Flow Line Temp. F 160 Note: Another value of solids
Depth ft 5,430.00
Mud Weight
Mud Gradient
lb/ft3
psi/ft
83.00
0.58
measurement reported daily is ASG of
Funnel Viscosity sec/Qrt 73
600 RPM 99 Solids in the mud (average specific
300 RPM 61
200 RPM
100 RPM
47
30
gravity). In a barite weighted mud
6
3
RPM
RPM
10
8
(barite S.G. = 4.2), the closer to 4.2 the
Rheology Temp. F 120
PV cP 38 ASG is, the cleaner the mud is
YP lb/100ft2 23
LSYP
Gel Strength(10s)
lb/100ft2
lb/100ft2
6
11
indicating that the solids are
17
Gel Strength(10m)
API Fluid Loss
lb/100ft2
ml/30min predominantly barite.
HTHP Filtrate ml/30min 2
Cake API/HTHP 1/32nd in 1
Sand Content Vol %
Retort Oil
Retort Water
52
23
In a mud weighted with CaCO3 (S.G.
Retort Solids 25
Alkalinity Mud (Pom) 4 2.7), the formulas cannot differentiate
Excess Lime ppb 6
Emulsion Stability
Oil Water Ratio
V 950
69/31
ASG of weight material solids from drill
Cl-
BIT HYDRAULICS
mg/l 310 k
SOLIDS ANALYSIS
solids due to the similar specific
AV / DP ft/min 134.98 CaCl2 Vol % 3.63
AV / DC ft/min 200.01 CaCl2 % wt 36.2 gravity.
AV / RISER ft/min CaCl2 mg/l 488,763

na / ka 0.3771 / 4.6 Av.sp.Gr.Solids 2.62
np / kp 0.6982 / 0.83Corrected SolidsVol % 21.37
BIT HHSI hp/in2 0.97 Avg. Sp. Gr. of Salt Wa 1.35
BIT PRESSURE LOSS psi 267.2 LGS Vol % 1.72
NOZZELS VELOCITY ft/sec 173.4 LGS ppb 15.34
ECD @ Bit lb/ft3 83.93 HGS Vol % 19.66
ECD @ Casing Shoe lb/ft3 83.75 HGS ppb 189.46
&Rule of Thumb: Low Gravity Solids = 5 – 8% for a barite mud. 3 – 4% for a reservoir drill in fluid
111 June 2009


Target Solids Percent for Muds that do not Contain Barite

82.3
If mud contains oil:
A. For each 1% oil in mud (as measured in retort) add 0.1 to solids
80.8 content. (Based on oil @ 0.84 Sp. Gr.)
If mud contains over 10,000 ppm salinity:

79.3 B. For each 10,000 ppm increase in salinity (as measured in filtrate
test), Subtract 0.3 from solids content. (This is approximate and will vary
slightly for various concentrations of salt and percent solids..
77.8
Example: Mud Wt. 71.8 pcf, oil 12%, 18,000 ppm chlorides
(Solids from graph) 9.5 + 1.2 {See A. re: oil content} - 0.54 {See B. *0.3
76.3 x 1.8 salinity*} = 10.16 % Target Solids
74.8
Mud Weight pcf
73.3
71.8
70.3
68.8
Solids based on 2.6 Sp. Gr
67.3
65.8
64.3
62.8
0 2 4 6 8 10 12 14 16 18 20
Solids Percent by Volume
112 June 2009


OIL BASE MUD

MUD WEIGHT Vs TOTAL SOLIDS%
No Drill Solids - CaCO3 Weight Material
Mud Weight pcf
70 75 80 85 90 95
5
6
7
8
9
10 CORRECTED SOLIDS
11
12
13
14
15
16
17
Solids %
18
19
20 UNCORRECTED SOLIDS
21
22
23
24 GUIDELINES FOR IDEAL UNCORRECTED SOLIDS vs DENSITY - OBM
25
26 NOTE: PARAMETERS USED FOR THESE TARGETS ARE:
OIL/WATER RATIO - 65/35
27 SALINITY - 350,000 using 77% PURITY CaCl2
28 WEIGHTING MATERIAL - CaCO3
29 *Variations on typical oil/water ratios or salinity of Aramco muds
will vary these targets by +/-1 - 4%.
30
31
32

113 June 2009


Density of Water & Diesel Emulsion with 3% LGS

100%

95%

90%

% Water % Diesel 85%

80%
75%
70%
65%
60%
55%
%OIL 10% 20% 30% 40%
50%

45%

40%
35%
30%
25%
20%
15%
10%

5%
0%
65.5 65.0 64.5 64.0 63.5 63.0 62.5 62.0 61.5 61.0 60.5 60.0 59.5

PCF

114 June 2009

DR
RILLING FLUIDS AWARENESS
D
DRILLIING TECH
HNICAL DEPART
TMENT WORKSHOP 1: BASSIS OF DESIGN
67 75 82
2 90 97 105 11
12 120 127 135 142 150 157 165
Mu
ud Weightt pcf
115 JJune 2009


Another Tool for Evaluating Solids Content – Trend Charting

Mud engineers should maintain a daily graph of critical parameters directly related to solids
content during the course of drilling a well. A visual representation of these daily values for Plastic
Viscosity, mud density, solids content, low gravity solids, etc. can help in identifying trends in mud
properties that can go unnoticed from day to day. Targets can also be included to help follow the
plan. It is a simple method to ensure prevention of associated problems that are developing.
Some examples are below.

Solids Trend Chart

45

40

35

30
Maximum PV
25

Target Solids
20

15

10

5
Target LGS
0
12-May 13-May 13-May 14-May 14-May 15-May 15-May 16-May 16-May 17-May 17-May
Density/10 PV Solids LGS
Solids Analysis Trend Chart

PD-XXX / XXXX-1

38
36
34

32
30

28
26
24
22 Density/10
20 The squares in red indicate an excellent decrease in Low Gravity PV
Solids over the last f ew days to about 5% today. PV conf irms drop in solids.
18 Excellent work! Solids
16 LGS
14
12

10
8 Target LGS

6
4
2
0
13-Aug 15-Aug 17-Aug 19-Aug 21-Aug 23-Aug 25-Aug 27-Aug

Date
116 June 2009


Another Tool to ‘quick check’ your Solids Content – Compare to Other Rigs
Simply check the Mud Summary on the Drilling Information Highway and find similar muds to
see how your mud solids content compares to other wells.

117 June 2009


Solids Control Equipment
¾ The design objective of any solids control system should be to achieve step‐wise removal of
progressively finer drilled solids.

Typical Equipment and Layout
The Optimum Solids Control System consists of:

¾ An adequate number of shakers to handle the full circulating volume
¾ High efficiency centrifuges to control fine solids and to facilitate barite recovery

• A typical system may include hydrocyclones:
• These should ONLY be used with spud mud

It generally is not economical to run desanders, desilters and mud cleaners from a solids
removal and mud cost standpoint unless the shale shakers are not operating efficiently. In fact,
they can aggravate a solids problem since their centrifugal pump systems are proven to grind
solids to smaller, harder to remove sizes.

How do I know what equipment to run for my mud type and when to run it?
118 June 2009


SOLIDS CONTROL EQUIPMENT GUIDELINES – WHAT AND WHEN?
LSND, 67 ‐ 100 pcf
Spud mud,w/ LSND, 100 ‐150 LSND, with fine to OBM/SBM, 75 ‐
Spud mud, 65 ‐ 72 NO BARITE OBM/SBM, 68 ‐ 75 All Oil, 57 ‐ 70 pcf
10 ‐ 40 ppb pcf WITH medium graphite 140+ pcf WITH
pcf (Reservoir Drill‐In pcf NO BARITE NO BARITE
LCM BARITE (RGC) or LCM BARITE
Fluid)
Shaker 1 100‐ 230 50 ‐ 100 170 ‐ 230 180 ‐ 220 120 ‐ 170 As fine as possible As fine as possible As fine as possible
Shaker 2 100‐ 230 50 ‐ 100 170 ‐ 230 180 ‐ 220 120 ‐ 170 As fine as possible As fine as possible As fine as possible
Shaker 3 170 ‐ 230 100‐ 230 170 ‐ 230 180 ‐ 220 120 ‐ 170 As fine as possible As fine as possible As fine as possible
Shaker 4 170 ‐ 230 110 ‐220 170 ‐ 230 180 ‐ 220 120 ‐ 170 As fine as possible As fine as possible As fine as possible
Desander Yes No No No No No No No
Desilter Yes No No No No No No No
Yes, 200 ‐ 270 Yes, as shaker only, Yes, as shaker only, Yes, 200 ‐ 270 Yes, as shaker only,

Mud Yes/blanked as mesh, if no no hydrocyclones, no hydrocyclones, mesh, if no no hydrocyclones,
No No
Cleaner desilter centrifuge screen as fine as screen as fine as centrifuge screen as fine as
available possible possible available possible
On TSR to hold
Centrifuge Yes, Total Solids Yes, Barite Yes, Barite
No No desired MW when Yes, TSR mode Yes, TSR mode
1 Removal (TSR) recovery recovery
needed
On TSR to hold
Centrifuge Yes, Total Solids Yes, Barite Yes, Barite
No No desired MW when Yes, TSR mode Yes, TSR mode
2 Removal (TSR) recovery recovery
needed
Notes: ALL SHAKER SCREENS ABOVE CONFORM TO API RP 13 C SIZES.
1. All shakers should be running with the finest screens possible. THERE IS NO SUCH THING AS A SPARE SHAKER!
2. Pool of mud on the screen MUST be maintained at 75 ‐ 80% coverage on the screens (referred to as the "pond".)
3. Mud cleaner should be used as a secondary desilter for spud muds (blank screen) or used as additional shaker, except at higher mud weights and with OBM.
4. Mud cleaner with >= 250 mesh screens should be run on OBM/SBM to help in water wet solids removal.
5. Centrifuges should be run in total solids removal mode at lower mud weights and in barite recovery in higher mud weights.
6. If LCM is used in OBM, large mesh screens should only be used until full returns are gained then the LCM should be screened out.
7. If possible, run mud from the centrifuge recovering barite over shaker or mud cleaner screen before it returns to the system.
8. In certain cases the centrifuges can be used to advantage with spud mud, as when drill water is in short supply and you wish to reduce the dilution rate.
9. When keeping sized CaCO3 and graphite in the mud system, the shaker screens should be matched to the particle sizes that are to be kept in the system.
10. Most important is to ensure that no cuttings or whole mud bypasses shaker screens through holes, gaps between screens or around skirts at the discharge end.
Key to achieving this is to have someone reliable watching, maintaining the shakers and changing or plugging screens at all times while circulating.
119 June 2009


HOW TO QUICK CHECK YOUR SOLIDS CONTROL EQUIPMENT OPERATION IN 30 MINUTES OR LESS!
¾ Shale Shakers
Do I have 75% pool on shaker?
Holes in screens? During connections turn off shakers and check shaker screens one by one.
Are motors running in right direction? With no mud on shaker, put glove on back and it should vibrate to
front and off. Not stay in the middle of the shaker.
Check for leaks around the seals of the shaker screens.
Are the crown rubbers/seal strips in good condition? Check when screens are off. If change one, change all.
Is grease schedule being followed (Brandt shakers)?
Based on ROP and hole size, is the right amount of cuttings consistently coming off the shaker?
Ensure there is no shaker bypass. This will build up solids further downstream.
Check oil level in sight glass on side of Derrick Shaker motors.
Are crank up bolts tight?
Are screen tension bolts tight?
Are the springs in good condition (rusted or sagging)?
Are the rubber vibration dampeners in good condition? (Cracked, swollen, hard?)
Is the basket level (side to side)? Check with spirit level laid on front of shaker.
Is rubber curtain in place at front of shaker (to keep solids from falling back under shaker)?
Is there excess or unusual sounds coming from the shaker?
When screens are being changed, notify mud engineer to be there to inspect all parts under screen.
If VSM 300, bladder pressure to hold in screen should be +/‐ 90 psi.

¾ Degasser
Check if float arm is free.
Check that suction is free of solids build‐up around it.
Run for 2 – 5 minutes. Check vacuum gauge. Should be 0.5 psi.
Do not bypass degasser pit when going to a short system.

¾ Desilter, Desander & Mud Cleaner
Is the pressure correct? Should read 35 – 40 psi (or 3 times the mud weight in ppg)
Cone discharge spray or rope? Should be spray.
Take cones off and compare to a new cone for wear.

¾ Centrifuge
When was unit last serviced? Ask to see maintenance schedule kept by centrifuge operator.
Look at grease nipples. Should see excess fresh grease to indicate recent service.
Rig foreman and mud eng. to be with the centrifuge operator during regular maintenance rounds.
Look at solids being discharged. How much? Wet or dry? Should not be mud/fluid. Should not be real dry.
Should be medium sludge like humus.
Any unusual noise or vibration? Unit should be “zinging” noise and no excess vibration.
If pump smells like burnt rubber, have vendor check.
Check all hoses and fittings for leaks or dry rot.
Check pump for excess leakage.
Is centrifuge getting flushed out during shutdown? WBM ‐ flush with water till water comes out clean.
OBM ‐ flush with base oil or lower to 500 RPM and flow with base mud to “wash” out.
Visually check for water / base oil hook‐up for flushing. There is a connection ‐ is a hose hooked to it?
What is unit RPM? Barite recovery 1,500–1,900 rpm, total solids removal 2,400–3,200 rpm.

120 June 2009


Without a centrifuge and using Rig SCE, Solids are left in the system.

Optimum Solids Removal is Achieved by use of Multiple Current Generation Shakers and
Centrifuges

¾ Shale Shakers
Shale shakers are the first line of defense in the Solids Control Chain
• The shaker’s strategic position at the flow line allows it to remove large amounts of solids
before the mud is circulated through the surface mud system. Efficient operation of the
shaker leads to better performance of downstream separation equipment.

• Most shale shakers operate at a high speed with an elliptical vibratory motion. Two
vibrators (motors) which provide power to the shaker drive the machine. The vibrators are
attached to the screen deck and transmit vibration to the screens.

• Most shale shakers are equipped with a unique basket tilting mechanism providing up to a
5‐degree inclination for fluid retention with no interruptions in service.

&Rule of Thumb: A shaker operating properly has 75 – 80% of the screen area covered in mud.
121 June 2009


Shaker / Screen Best Practices
• The most common error in running shakers is not running a full pool of mud on the
screens. The pool of mud should cover at least 75% of the total screen area. Minor mud
losses over the screen are acceptable and often beneficial.
• Inspect shakers on a regular basis. Routine maintenance on screen rubbers and regular
greasing of movable parts results in longer screen life and better solids removal.
• Shakers are only as good as the grade, installation and maintenance of the screens.
• Shaker screens do not make an absolute cut based on the screen size. As screens remove
solids, a filter bed effect (FBE) develops which effectively becomes a fine filter on top of the
screen surface. The larger the hole, the faster the ROP, the thicker an FBE becomes,
trapping, piggy‐backing and removing more solids. The effect can be an unexpected
removal of barite over a screen which theoretically, barite should pass through easily.

Shaker performance is affected by:

• Vibration patterns and dynamics
• Number of decks
• Deck size
• Deck angle
• Screen type and mesh
• Mud Rheology
• Flow rate and solids loading

Shale Shaker Adjustments:

Deck angle

• Generally the easiest/fastest adjustment
• Do not use as a long term adjustment

During normal operations the deck angle should be adjusted to zero degrees with 75% Coverage
over the screen area. This is when you know the proper screen size has been selected

Flow distribution

• Depending on design/availability and conditions
• Generally limited by flow rate and number of shakers
• Can be changed during operations
• One shaker flow should always be fully opened

122 June 2009


Motion type

• Linear Motion
o G‐force linear motion up to 6 G’s
o Speeds solids conveyance
o Increases shaker‐fluid capacity
o Enables shaker to process heavier solids loads
o Enhances cuttings‐processing volume

• Elliptical Motion
o Reduces G‐force (5 G’s maximum)
o Optimizes solids removal
o Maximizes drilling‐fluids recovery
o Drier cuttings
o Extends screen life
• G‐Force Boost
o Only used in linear motion up to 6 G’s

Screen choice

• Significant impact on solids size removal
• Can be done during operations depending on conditions
• Many rigs only stock multiple size, not multiple platform or mesh types

The separation performance of a shale shaker screen is normally represented by the
percentage of drill solids removed and the screen life. Grading the screens will vary from
manufacturer to manufacturer, but the best way to compare is to look at fluid volume capacity
versus solids‐removal efficiency.

• Screen Blinding; what do we do?

First Determine if Blinding or Solids Bed (build‐up of cuttings not conveyed off the
shaker)
1) If Solids Bed
o Lower Deck angle to improve conveyance
o If dual motion shaker use Linear Motion
2) Blinding
o Screen up (finer cut point)
o Change mesh weave or to a platform type screen

‘G Force’ Factor
• Counterweight settings – Not readily changed during operations
• Boost mode – Very fast change, downside is current designs do not have deck angle
adjustment
123 June 2009


Shaker screens are comprised of two elements:

• A media to separate the drilling mud from the cuttings (mesh type)
• A method to attach the media to the shale shaker (platform type)

Based on the drilling application, a specific combination of the two will optimize solids separating
efficiency.

Mesh Count
n = Starting at the center of one wire and counting the number of openings along the screen grid
to the next wire center, one linear inch away.

Screen Opening Size

Distance between wires measured along the screen grid, expressed in either fraction of an inch or
in microns
1 inch = 25400 microns
D = 25400 [(1/n) – d]
D = Opening Size (microns)
n = Mesh Count (number of wires / inch)
d =Wire Diameter (inch)

Effects of Wire Diameter

124 June 2009


Screen labeling (API RP 13C)
• Screen Name
‐ API Number
o Does not coincide with mesh count!
• Cut Point
‐ D100 micron cut point
o Specifies what size particle it will remove 100% of the time.
• Conductance
‐ Measured in KD/mm
o The ease in which fluid can flow through a unit area of screen.
• Non Blanketed Area
‐ Measured in Square Feet
o Takes into consideration screen support rails, backing material, ect.

What is API RP 13C (ISO 13501)?
• A new physical testing and labeling procedure for shaker screens. To be API RP 13C
compliant, a screen must be tested and labeled in accordance with the new recommended
practice.
• Two tests were devised: cut point and conductance. The tests describe a screen without
predicting its performance and can be performed anywhere in the world.
• After identifying the cut point and conductance, complying with API RP 13C requires
application of a permanent tag or label to the screen in a position that will be both visible
and legible. Both cut point expressed as an API number and conductance shown in kD/mm
is required on the screen label.
• Internationally, API RP 13C is ISO 13501.
• The new procedure is a revision of the previous API RP 13E, which was based on optical
measurements of the screen opening using a microscope and computer analysis. Under API
RP 13E, screen designations were based on individual manufacturer test methods,
producing inconsistent labeling.
API RP 13C Required Screen Labeling Information
After identifying the cut point and conductance, complying with API RP 13C requires application
of a permanent tag or label to the screen in a position that will be both visible and legible. Both cut
point expressed as an API number and conductance shown in kD/mm is required on the screen
label. Previously, screens were labeled in accordance with manufacturer specifications.

125 June 2009


126 June 2009


127 June 2009


128 June 2009


129 June 2009


¾ Hydrocyclones

Â Desanders Â Desilters Â Mud Cleaners

Performance Variables Cone Diameter
¾ Cone Diameter (inches) ¾ Diameter determines processing capacity.
¾ Feed Pressure (inlet manifold) ¾ Larger cones can handle more volume.
¾ Solids Size Distribution (feed) ¾ Smaller cones can remove very fine solids.
¾ Plastic Viscosity (feed)

Desander Desilter
• Capacity 500 gpm • Capacity 75 gpm per cone
• Cut Point >90 µ • Cut Point >60 µ
• Cone diameter 12 in. • Cone diameter 4 in.
• Ft of Head Req. 75 ft. (20‐30 psi) • Ft of Head Req. 90 ft. (30 – 40 psi)
• Practical Cut Point = 100 mesh screen • Practical Cut Point = 150 mesh screen

Mud Cleaner
The mud cleaner is a bank of hydrocyclones mounted over a shaker. In some installations,
there are desander and desilter cones mounted in such a way that the unit can be used as a mud
cleaner or as a shaker and hydrocyclone unit separately.
¾ Mud Cleaners were introduced in the 1980’s to remove finer solids from the mud than the
shakers could remove, at this time shakers were using 30 to 120 mesh screens.
¾ With the volume of solids & particle size left in the mud from the older design of shakers, the
mud cleaners were effective.
¾ With today’s finer‐screening shakers that have higher overall efficiency rates than the
traditional linear‐motion shakers, the applications for mud cleaners are limited and generally
not necessary.
¾ When running a screen above 200 mesh, a mud cleaner will only remove a very small
percentage of solids, and during this process it will grind the solids that are in the mud into
ultra fine solids.
¾ Useful in closed‐looped, waste processing systems to “dry” hydrocyclone discharges.

130 June 2009


Feed Pressure ‐ Feet of Head
¾ Hydroclones are designed to process a fixed volume of mud at a specific head
¾ If the head pressure is less than required, volume processed will also be less and velocity of
the mud entering the cone will produce insufficient “G‐Force’’.
¾ It is generally not economical to run desanders, desilters and mud cleaners from a solids
removal and mud cost standpoint unless the shale shakers are not operating efficiently. In
fact, they can aggravate a solids problem by grinding up solids to smaller, harder to remove
sizes.

Spray Discharge ‐ Optimum Desired Flow

Rope Discharge – Not optimized!

131 June 2009


Disadvantages of Using Hydrocyclone Equipment (Desanders, Desilters, Mud Cleaners)

Industry research proved that centrifugal pumps
used for the hydrocyclone equipment ground up
solids and made them more difficult to remove.
Courtesy Amoco Research

More Surface Area of Solids means More Chemical Cost to Treat
Hydrocyclone equipment loses valuable chemicals and liquid mud.

132 June 2009


¾ Centrifuges

Application
The primary benefit of centrifuge utilization is to control fine solids that contribute to
undesirable mud density and rheology.

• Total Solids Removal Mode ‐ Discard drill solids from un‐weighted mud
• Barite Recovery Mode ‐ Reclaim Barite while discarding drill solids
• Dual Centrifuging Mode – Reclaim barite and recover liquid from a dual centrifuge
system
• De‐watering applications using chemical flocculants

Centrifuge Processing Rates
Centrifuges Should Process 5‐25% of Circulating Volume/Day. Typically, these rates are 15 – 25
gpm for Barite Recovery Mode and 30 – 60 gpm for Total Solids Removal Mode.

Processing rate decreases as mud density increases
Barite Recovery Mode
• The process of salvaging barite, the most expensive component of many weighted mud
systems.
• The term Barite Recovery is misleading since the actual goal is to remove and discard as
many colloidal fines as possible while saving the barite. Removing the colloidal fines is
the most effective way to reduce viscosity (PV and progressive gel strengths).
• Reducing viscosity‐creating colloids without increasing volume through dilution is where
the economics of a centrifuge pays off.
• Rheology control is the reason we operate a centrifuge in barite recovery mode.
• The unit should only be operated when unwanted viscosity increases are noticed.
• Over‐centrifuging for barite recovery may needlessly discard liquid and additives.
133 June 2009


How do we determine when to operate the centrifuge for barite recovery?

Plastic Viscosity (PV) is a good indicator of the total solids volume, the nature of their size,
reactivity, and ability to produce viscosity. Plastic Viscosity is an indicator of mechanical friction
between solids particles in the fluid and thus an increase in PV will indicate an increase in solids
concentration indicating the need for a centrifuge.

Barite Recovery Efficiency
• Except at the lowest mud densities, 85‐95% of barite processed should be recovered as a
3.8 ‐ 7.6 gpm sludge.
• Adjust feed and pond settings to achieve a 9.5 ppg / 30 – 35 funnel viscosity on the effluent
discard.
• Increasing feed rate will sacrifice cut point. Reduced feed rate gives better separation.
• Once PV is stabilized, run unit continuously at lower volumes to maintain the system.

Total Solids Removal Mode
• The goal is defined as the name implies – Remove as many solids as possible to maintain
the minimum mud weight.
• The centrifuge will be run at higher RPM (2,500 – 3,200 rpm)
• Larger bowl centrifuges are more efficient for this purpose.
• It is recommended to run the unit at 75 – 80% capacity to avoid approaching torque limits.
By avoiding capacity limits, the most common centrifuge problem – torque overload
(plugging) can be avoided. Run conservatively and steady and downtime will not happen.
• Add your system dilution water at the centrifuge feed pipe which will reduce feed viscosity
and enhance centrifuge efficiency.
• Important! Avoid running the unit in hourly intervals. Lower GPM for longer intervals will
maintain more consistent mud properties and longer unit life without problems.

Dual Stage Mode
Consists of a 2 centrifuge system to accomplish the following:
1) Barite recovery mode on first centrifuge. Effluent sent to second centrifuge.
2) Stripping effluent stream of ultra‐fines to discharge and return of cleaned fluid to the
active system.

Recommended Operating Practice:
• Run continuously at 75 – 80% capacity around the clock to achieve minimum mud weight.
• Do not shut unit down if goals are achieved. Continue to process low volume to maintain
minimum weight.

134 June 2009


Notes on Dual Centrifuge systems
•
Centrifuging weighted mud for barite recovery can save many times the centrifuges cost
•
Liquid fractions of new mud types often cost as much or more than barite. (chemical,
synthetic, oil, etc.)
• Recovery of expensive liquid and chemical is cost effective for many modern mud systems.
• Installation and operating parameters are critical for successful dual centrifuging
• Highly recommended for weighted oil base mud to recover the expensive oil fraction and
minimize environmental impact from liquid discharges.

Dual Centrifuge Process

Dual Centrifuging Weighted Mud
F lo w Schem atic fo r
Dual Centrifu ge Parallel Op eratio n s

1 18 5 0 Ce ntrifu ge
2 51 8 C en tr ifug e
1

3
Ce ntrifu ge Fee d P um p
2
A 18 50 C en trifug e Fe ed
B So lid s
C Di h e
Cen trifug
D 51 8 CedO
OF ntri fugfle Fee d
E So lid s D ischa rg e
3

E

A
B

C
D
3

Figur e 1

135 June 2009


Flow Schematic for
Dual Centrifuge Series-Parallel Operations
1 1850CENTRIFUGE
2 518 C ENTRIFUGE 1
3 Centrifuge Feed Pump
4 Feed Pump
5 Barite Recovery Jet Hopper 4
6 Barite Recovery Jet

7 Liquid Phase Catch Tank
J
A 1850CENTRIFUGE Feed 5 2
J
B 518 C ENTRIFUGE Feed 6
C 518 C ENTR IF UGE Feed from Active (Optional )
D 1850CENTR IF UGE Solids Dis card (Opt ional )
E B arit e Return to Active B
F Overflow t o Acti ve Syst em G
G 518 CENTRIFUGE Soli ds Discard
H Dil ution to 1850C ENTRIFUGE F eed H
J Liquid Phase from Centrifuges 3
7
A
D
E
F
3
C
Figure 2

Notes on Centrifuging Un‐weighted Mud
Because of processing limitations the smaller processing rate centrifuges are effective solids
control devices only under certain conditions:
• Installed and operational prior to increasing the mud weight with barite.
• Low Circulation Rates
o Bowl RPM can be increased for a finer cut point
• With un‐weighted mud systems we never know on a real time basis at what particle sizes
exist in the mud system, only that their average specific gravity is 2.6.
• As formation types change the centrifuge needs to be adjusted for the goal of maximum
solids discard.

To Discard Large volumes of Coarse Solids:
• Run minimum bowl rpm
• Use unit with maximum Bowl/Conveyor ÕThese adjustments are necessary to
Differential reduce bowl/conveyor torque and
• Feed Tube fully retracted prevent packing off the unit.
• Reduced feed rate

136 June 2009


To Discard Large volumes of Ultra‐Fine Solids:
• Maximum Bowl rpm
• Minimum Bowl/Conveyor RPM Diff.
• Feed Tube fully inserted
• Adjust the feed rate for maximum discard

¾ Principles of Operation ‐ Centrifuges

Centrifugal ‐ Separation

• Based on the principle of accelerated gravity
o ‐ An object whirled about a central point is forced away from that central point
• The degree of rotational force generated is:
o ‐ A function of the rotational speed and the distance of the object from the
rotational point

Decanting Centrifuge

• A bowl is rotated about its central point at some speed, with the outer surface (I.D.) of the
bowl from the central point being defined as the bowls radius.
• The degree of Centrifugal Force generated is a function of the rotating speed and the bowls
radius.
• This is expressed as G‐Force in multiples of the earth gravitational force (1 “G”)

G‐Force = Bowl Diameter (inches) X RPM2 X 0.0000142

• When a suspension of solids is fed into the rotating bowl, solids strive to move outward
through the liquid toward the internal surface of the bowl
• The effective force generated by the particles as they move to the internal surface of the
bowl is determined by their density in relation to the liquid, and their physical size

Particle Mass and Separation Time

• Larger more dense particles move through the liquid with the greatest force, making
immediate separation.
• Smaller less dense particles move through the liquid to the interior surface of the bowl
with less force, taking more time to separate.
• The smaller the particle the greater the separation time.

137 June 2009


Performance Adjustments
Adjustable in five ways:
• Bowl Speed (RPM)
• Bowl/Conveyor Speed (RPM) Differential
• Pool Depth (inches)
• Feed Tube Placement
• Feed Rate (gpm)

Centrifuge Bowl
Parameters affecting Separation:
• Bowl Rotating Speed (RPM)
‐ Units (1,900‐ up to 4,000 rpm)Bowl Diameter (inches)
‐ Units (up to 70 Inches)
¾ Increased bowl speed will result in greater solids removal

Centrifuge Bowl Speed
Centrifuge Models vary in size in speed.

Bowl Speed “G” Force
• 1900 RPM 720
• 2500 RPM 1250
• 3250 RPM 2100

“G” Force = RPM 2 x Bowl Dia. x 0.0000142

Recommended “G” Force Range – General Requirements
1) Barite Recovery – 600 – 700 “G’s”
2) Solids Removal – 1,000 – 3,000 “G’s”

Mud type, weight, economics, bowl length and process volume can vary these numbers.

138 June 2009


Example of Savings by Using Centrifuges
Section Comparison WDYH 2 & WDYH 3
139 June 2009

140 June 2009

141 June 2009


142 June 2009


Section 1.4

HEALTH, SAFETY AND
ENVIRONMENTAL
(HSE)

143 June 2009


1.4.1 H2S AWARENESS

Characteristics
• Hydrogen Sulphide in gaseous form
• Colorless
• Flammable
• Highly Toxic
• Associated with the biological degradation of organic matter with sulfides by bacteria in an
anaerobic environment

H2S Danger Recap

Concentration Concentration Effect

% ppm
0.001 10 Can smell, "safe" for up to 8 hours
0.01 100 Kills sense of smell in 3-15 minutes; may burn eyes and
throat
0.02 200 Kills sense of smell quickly; stings eyes and throat
0.05 500 Loss of balance; respiratory difficulty in 30-45 minutes,

leading to pulmonary edema
0.07 700 Unconscious in less than 15 minutes; immediate artificial
respiration needed, otherwise death will occur
0.1 1000 Permanent brain damage inflicted in single breath; If not
rescued, death will occur quickly

144 June 2009


1.4.2 MUD CHEMICALS SAFETY HANDLING GUIDELINES

You can find chemical hazard information for chemicals used by Aramco in the
following link:
http://epdapps.aramco.com.sa/Publications/Hazcom/default.asp

145 June 2009


1.4.3 MARINE BIOTOXICITY TESTING – LC50

Saudi Aramco has taken a proactive step in implementing a program for routine monitoring of
drilling fluid toxicity in the marine environment by application of a globally accepted standard test
used by many countries. As of May, 2009 all offshore drilling and workover operations are
required to follow the Saudi Aramco LC50 protocol.

In addition to this publication, the RIG OPERATOR shall have readily available for reference to drilling or
workover personnel the most recent publications as follows:‐
SAES‐A‐103 Discharges to the Marine Environment
1.0 PURPOSE
1.1 This procedure provides a detailed description of the process and document requirements
for sampling and shipping drilling fluid samples for LC50 toxicity testing.

2.0 SCOPE
2.1 The scope of this process is applicable to offshore drilling and workover rigs.

3.0 RESPONSIBILITIES
3.1 The Project Supervisor (Saudi Aramco Drilling Superintendent) or other designated
personnel will ensure that all procedures and documents have been completed according
to the procedure described below.
3.2 The Project Supervisor shall establish the sample collecting schedule and notify the Aramco
Liaisonman on the rigs.
3.3 The Project Supervisor is responsible to provide the materials mentioned in section 4 to the
rigs for collecting samples.
3.4 The Aramco Liaisonman on a rig is responsible to ensure that samples are collected and
shipped as per sections 5.1, 5.2 & 5.3.
3.5 Testing Agency (currently KFUPM) is responsible to ensure that samples are received in
good order and perform the LC50 toxicity testing as stipulated in section 5.4. Ensure that
Saudi Aramco is notified of the test results as soon as possible.

4.0 MATERIALS
4.1 The following standard items shall be used for the collection and shipping of drilling fluid
samples;
4.1.1 Shipping container (ice chest, box, or buckets)
4.1.2 Chain of Custody (COC)
4.1.3 Sample container (plastic cubitainers, plastic or glass jars, plastic or metal buckets)
provided by Testing Agency.
4.1.4 Coolants (ice and/or gel packs)
4.1.5 Sample Receipt Logbook

146 June 2009


5.0 PROCEDURE
The following guidelines are to be implemented to ensure that uniform, representative drilling fluid
samples are collected for compliance testing as required by Saudi Aramco Environmental
Guidelines.
5.1 Collecting Drilling Fluid Samples
5.1.1 Collect the drilling fluid sample from the return flowline under the shale shaker. If
there are no returns across the shaker, sample must be taken (for a location &
time) that is representative of the overall (average) mud system to be discharged.
5.1.2 Be sure that water is not being sprayed on the shaker during sample collection.
5.1.3 Do not collect the sample just after a connection has been made; pipe dope could
contaminate the sample.
5.1.4 Bioassay tests are very sensitive and depend in part on the stability of the system
emulsion. To ensure that a representative sample is collected, do not collect the
sample after the following events:
• Just after a cementing operation.
• Just after a heavy chemical operation.
• Just after a trip.
• Just after displacement to a water base system with Mineral Oil‐Based Mud
(MOBM).
5.1.5 It is critical to allow the emulsion to heal and for the system to re‐stabilize after any
of these events. It is necessary to adequately circulate any drilling fluid system after
one of these events has occurred before a sample is collected. Depending on the
event, circulation may be required for more than 48 hours before a sample should
be collected. For MOBM in particular, it is NOT advisable to sample immediately
after a fresh batch of fluid is built.
5.1.6 Spotting Fluids:
• Collect a drilling fluid sample before placing a spotting fluid in the well.
This first sample is needed to establish that the mud discharges were in
compliance before the spotting fluid was used.
• After the spotting fluid has been recovered, collect a second sample of
drilling fluid. This sample is used to determine the amount of the spotting
fluid recovered, to determine the oil content of the mud system, and to
determine any effect of the spotting fluid on the system’s toxicity.
• If most of the spotting fluid is not recovered and becomes mixed with the
drilling fluid system, it could greatly increase the toxicity of the mud
system. The drilling fluid system may have to be contained until the system
is safely in compliance. In addition, if certain oils are used in the spotting
fluid, it may cause the mud discharges to produce a sheen which is
prohibited.
5.1.7 Upsets – Kicks:
5.1.7.1 When a kick occurs, collect a sample before the invading fluid reaches the
surface. There are different Saudi Aramco rules governing this event and
the operator may not be out of compliance in this situation. In any case, it
is important to be able to show that the drilling fluid was in compliance
before the influx altered its toxicity. After the kick has been resolved and
drilling continues, collect a sample as in Step 5.1.1.

147 June 2009


5.2 Shipping of Samples
5.2.1 If the samples are Water‐Based drilling fluids, refrigerate the filled containers prior
to shipping until the temperatures of the drilling fluid samples are approximately
40°F. Do not freeze the samples. Oil‐Based drilling fluids can be maintained at
ambient temperature during transport.
5.2.2 Place BOTH of the drilling fluid sample containers back in the shipping cooler.
Surround the samples with frozen packs of reusable gel ice. One of the samples
from the first container will be sent for complete LC50 testing and the second
container will be kept in a secure location at KFUPM in case of problems during
shipment until the laboratory analyses have been completed and confirmed. After
confirmation of results, the back‐up sample may be discarded unless a second test
is required. At the rig, while awaiting shipment back to the base, WBM must be
kept refrigerated at (40°F); MOBM may be kept at ambient temperature.
5.2.3 The reusable GEL ICE must be frozen prior to use in the shipping cooler.
5.2.4 Complete the Sample Identification part of the COC (see above) as shown on page
7. Record and sign to release the sample for shipment. Place the COC in the plastic
pouch and tape it to the side of the cooler. EACH PERSON THAT TAKES CUSTODY
OF THE SAMPLE IS REQUIRED TO SIGN THE RECORD DOCUMENTING HANDOVER OR
RECEIPT OF THE SAMPLE.
5.2.5 If a sample is to be detained for later shipment, refrigerate (40°F) WBM samples
and re‐freeze the reusable gel ice packs.
5.2.6 Ship samples and all paper work in cooler/container to the Saudi Aramco shore
base labeled as follows:

KING FAHD UNIVERSITY OF PETROLEUM & MINERALS
CENTER FOR ENVIRONMENT AND WATER, RESEARCH INSTITUTE
BLDG. # 15
DHAHRAN 31261
Attention: DR. K. P. MANIKANDAN / Phone‐(03) 860‐7606 / 056‐220‐5323

5.2.7 Label Samples as “Drilling Fluids” NOT “Drilling Muds” to expedite processing by US
Customs.
5.2.8 Follow the instructions for “SAMPLING/SHIPPING” the drilling fluid sample found in
each bioassay sample kit.

5.3 Sampling Frequency for Water Based and Mineral Oil Based Drilling Fluids
5.3.1 Saudi Aramco regulations require that toxicity monitoring shall be performed at
least once per well for both the daily minimum and the monthly average value(s).
In addition, an end‐of‐well sample is required for a daily minimum. A minimum of
two samples at minimum will need to be collected for any given well in order to
comply with the regulations.

• If a well starts and finishes in one calendar month, two samples will need to
be collected during that month. The second sample will be taken at the
end of the drilling operations for that well.

148 June 2009


• If operations continue during two or more calendar months, the sample
collected at the end of drilling operations can also be used as the
compliance sample for that same month.
5.3.2 According to current Saudi Aramco regulations, it is NOT necessary to collect a
sample at the beginning of drilling operations. However, it is a good idea to collect
a sample of the relatively non‐toxic spud drilling fluid for the first toxicity testing
event. It is also NOT necessary, according to current Saudi Aramco regulations, to
collect a sample each time the drilling fluid system is changed or altered.
EXCEPTION: When changing from water‐based to mineral oil based systems,
additional samples may be recommended and/or required.

5.4 Testing of Samples:
5.4.1 KFUPM will arrange for the sample to be shipped to the contract laboratory (until
KFUPM has commissioned its own compliance lab for their own) for compliance
toxicity testing (LC50 test) on submitted samples for Saudi Aramco.
5.4.2 96‐hour Mysid LC50 tests will be performed with Water‐Based and MOBM.
5.4.3 If the sample used for the monthly compliance toxicity test passes the 96‐hour
permit toxicity limit (>30,000 ppm SPP), any weekly samples collected prior to the
test can be discarded. If the sample fails the permit toxicity limit, additional
retained samples will be tested to determine average toxicity. The proposed
laboratory should be made aware of testing requirements prior to sample
collection and shipment.
5.4.4 Specialty Products:
Products that may produce low LC50 values (high toxicity) are usually:
• Lubricants
• Defoamers (some)
• Spotting Fluids
• Corrosion Inhibitors
• Oils
• Surfactants
• Potassium based products (some, at K+ levels > 3%)
For WBM, check on the toxicity of these products or any products from product
toxicity databases as available. Most of these products can be used safely at
certain concentrations before producing unacceptable toxicity levels. All base oils
do not produce the same toxicity levels. Therefore, for MOBMs, check with Saudi
Aramco mud specialists to determine which base oil should be recommended for
your situation.
5.4.5 All test results received by Testing Agency will be communicated to Project
Supervisor immediately as identified on the chain of custody record.

149 June 2009


6.0 COMPLIANCE AND REPORTING

To ensure full and proper compliance with this procedure, the following measures will be
implemented as part of the sampling procedure:

6.1 Drilling rig is to report in the remarks section of the morning report that an LC50 sample was
taken on the date of collection.
6.2 Testing Agency will submit a monthly report to HSE Core Group identifying all samples
received in that month.
6.3 Testing Agency will submit a monthly report to HSE Core Group providing LC50 results
received in that month.
6.4 HSE Core Group will provide a periodic report to Management documenting toxicity testing
compliance.

150 June 2009


Test Results are to be reported back to Project Supervisor ____________________
(Name)
HSE 012 5/20/2009
151 June 2009


1.4.4 LINKS TO SAUDI ARAMCO ENVIRONMENTAL STANDARDS, PROCEDURES AND GI’S
ENVIRONMENTAL STANDARDS, PROCEDURES AND GI’s RELATED TO DRILLING AND WORKOVER FLUIDS
ACTIVITIES

Description G.I. or SAES or D & Web Sites
WOSD Procedures
Government Environmental Standards Document No. 1409‐0 http://epd.aramco.com.sa/epd

Corporate Environmental Protection Policy INT‐5 http://epd.aramco.com.sa/epd
Corporate Environmental Protection Policy GI‐ .2.714 http://epd.aramco.com.sa/epd
Implementation
EPA Procedures SAEP ‐ 32 http://epd.aramco.com.sa/epd
Land Use Permit Procedures GI. – 2.716 http://epd.aramco.com.sa/epd
Waste Management – This doc provides direction and GI‐ 430.001 http://epd.aramco.com.sa/epd
guidance to Company organizations on the proper Ö Company Standards
handling and disposal of wastes. Ö Environmental Protection
Ö Waste Management
Borrow Pit Requirements SAES – A‐ 111 http://epd.aramco.com.sa/epd
Solid Waste Landfill Standard SAES‐S‐007 http://epd.aramco.com.sa/epd
Ambient Air Quality & Source Emission Standard SAES – A‐102 http://epd.aramco.com.sa/epd
Processing and Handling of Hazardous Material CU 22.01 http://epd.aramco.com.sa/epd
Handling Bulk/Non‐Bulk Chemicals CU 22.05
Discharge to the Marine Environment SAES‐A‐103 http://epd.aramco.com.sa/epd
¾ Discharges from Drilling Operations Clause 4.5, Ö Company Standards
o Guidelines on the discharges of OBM, alternative Sub‐Clauses 4.5.1, Ö Wastewater & Marine Protection
OBM and water base drilling fluids and cuttings. Ö Discharges to the Marine Environment
4.5.2, 4.5.3, 4.5.4,
4.5.5.
Offshore Oil Spill Contingency Plan G.I. 2‐400 http://epd.aramco.com.sa/epd

Leak and Spill Reporting‐Arabian Gulf G.I. 2.104 Ö Company STandards
Ö Wastewater & Marine Protection
152
June 2009

ENVIRONMENTAL STANDARDS, PROCEDURES AND GI’s RELATED TO DRILLING AND WORKOVER FLUIDS
ACTIVITIES (cont’d)
Wastewater Treatment, Reuse and Disposal SAES‐A‐104 http://epd.aramco.com.sa/epd

Onshore Well site Environmental Management D&WOSD http://eccweb.enp.aramco.com.sa/drilling/NewDIH/DWOSD_web/Web

Operations Procedure Environmental Page/DwosdPro.html
¾ This doc provides guidelines for handling /disposal of Procedure June 2006.
drilling wastes including spent drilling fluids, cutting
solids –sands, clays, limestone, mud sludge, drilling
supply water and flare pit material, associated with
onshore D&WO activities.
Inland Oil Spill Contingency Plan G.I.2.401 http://epd.aramco.com.sa/epd
Ionizing Radiation Protection G.I. 150.003 http://epd/epd/epd/contentAction.do?name=COMPANYSTANDARD
Fishing For Radioactive Tools Chapter 5 Section C http://eccweb.enp.aramco.com.sa/drilling/NewDIH/Drilling_Manuals/D
ataFiles/Manuals%20Interface.pdf
Abandonment Guidelines For Radioactive Tools Chapter 2 Section G http://eccweb.enp.aramco.com.sa/drilling/NewDIH/Drilling_Manuals/D
Sub‐section 3.0 ataFiles/Manuals%20Interface.pdf
Radiation Protection Requirements for Downhole Well Draft
Logging Incidents

153
June 2009

154
June 2009

Section 1.5

KNOWLEDGE
MANAGEMENT

155
June 2009

1.5.1 DRILLING INFORMATION HIGHWAY

156
June 2009

1.5.2 SHAREK – KNOWLEDGE SHARING PLATFORM
157
June 2009

1.5.3 USEFUL TECHNICAL WEB LINKS

DIH http://eccweb.enp.aramco.com.sa/drilling/NewDIH/index.html

Drilling Rig http://eccweb.enp.aramco.com.sa/drilling/NewDIH/Drilling_Manuals/DataFiles/Rig%
Specifications 20Specifications.pdf

In House Technical http://eccweb.enp.aramco.com.sa/drilling/NewDIH/Drilling%20Library/2009_In‐
courses Catalog House_Technical_Courses.pdf

Special mud http://eccweb.enp.aramco.com.sa/drilling/NewDIH/EngineeringHelp/Datafiles/Gene
products ral%20Drilling%20Info/SPECIAL%20MUD%20PRODUCTS%20and%20SYS.pdf

Environmental EPD website: http://epd.aramco.com.sa
standards
Saudi Aramco http://shedgum1.com/safetyhandbook/
Safety Handbook

Baroid http://www.halliburton.com/ps/default.aspx?navid=3&pageid=97&prodgrpid=MSE%
3a%3a1045760282883590

MI SWACO http://www.miswaco.com/

Baker fluids http://www.bakerhughesdirect.com/cgi/bhdf/myHomePage/welcome.jsp?func=cert
&goto=%2fresources%2fExternalFileHandler.jsp&linkNames=Drilling+Flu

TETRA http://www.tetratec.com

Chemical Hazard http://epdapps.aramco.com.sa/Publications/Hazcom/default.asp
Products Bulletin

158
June 2009

1.5.4 OPERATIONAL MEETINGS

Meetings between Aramco Fluids personnel and service companies directly
involved in the various wells should be held to review the drilling fluids operations.
The following format is typical for these meetings.

Proposed Agenda
Monthly Operational/Technical Meeting
1. Safety/Quality moment (5 mins)
2. Main Operational Problems (Drilling Fluid Management)
3. Drilling Fluid Technical Issues
4. Cost Management
5. Personnel Performance
6. Action Tracker

159
June 2009

1.5.5 POST WELL MUD RECAPS (PHASE REPORT EXAMPLE)

MUD PHASE REPORT
Well : Rig : Phase : 12 1/4"

Depth MD TVD Deviation Drilled feet Volume drilled Phase duration From To
11386 ft 7879 ft 62.00 5281 770 bbl 10 days 29-Jun-07 9-Jul-07
Last CSG Dia.: 13 3/8" Shoe : 6072 ft Current CSG Dia.: 9 5/8" Shoe : 11373 ft
End phase status: Completion Abandonment Suspension
FLUID TYPE 30-Jun-07 3-Jul-07 5-Jul-07 6-Jul-07 7-Jul-07 Solids treatment Drilling data
Depth ft 6105 9286 11386 11386 11386 Shaker screens : 170 x 4 Drilling: 3.13 day
Pit temp. °F 100 130 125 110 110 Shaker screens : 200 x 4 Tripping: 1.92 day
Flo-line temp. °F n/a 142 138 Shaker screens : 170 x 4 Logging:
Check Temp °F Shaker screens: 200 x 4 Casing: 0.08 day
Mud weight lb/gal 9.2 9.25 9.4 9.4 9.4 Mud cleaner n/a Rig Up/Service: 0.75 day
Solids % 6 8 8 8 8 Condition Hole:
Oil % 1 1 Desander : hrs.
Water % 94 91 92 91 92 Desilter : 71 hrs.
O/W ratio Centrifuge 01 : 83 hrs. Reaming:
Sand out % Centrifuge 02 : 83 hrs. Condition Mud: 0.58 day
Sand in % LOT@ last csg shoe: 13 EMW
Marsh Visc. s/qt 75 65 62 65 65 Max. temp. at TD : 180 °F Dilution Factor: 1 bbls/bbl of formation
Fann 600 rpm 75 68 77 75 75 Initial hole vol.: bbls Formation bbls
Fann 300 rpm 56 52 63 61 61 Initial tank vol.: bbls Dumped Sweeps 210 bbls
Fann 200 rpm 47 44 56 54 54 Received vol.: 1012 bbls Dumped 3603 bbls
Fann 100 rpm 35 34 46 44 44 Made up vol.: 5907 bbls Trip Loss 128 bbls
Fann 6 rpm 11 14 18 17 17 SCE: 1433 bbls
Fann 3 rpm 9 11 16 15 14 Cuttings Retention 272 bbls
Gel 0 lb/100ft² 11 12 17 18 16 Abandon bbls
Gel 10 min. lb/100ft² 13 16 21 20 19 Left in Hole bbls
Gel 30 min. lb/100ft² 15 18 23 22 21 Tot handled vol.: 6919 bbls Total lost vol.: 5646 bbls
App. Visc. cP 37.5 34.0 38.5 37.5 37.5 Transferred volume (out of rig): n/a bbls
Plastic Visc. cP 19 16 14 14 14 Reusable volume (well+tanks): 1276 bbls
Yield value lb/100ft² 37 36 49 47 47 Cost and consumption Currency: US$
n. 0.42 0.39 0.29 0.30 0.30 Products Amount Unit Price Total Cost ppb
K lb·s^n/100ft² 4.05 4.66 10.37 9.52 9.52 Barite 41 1. MT $20.00 $5,432.50 13.06
Filtrate API cc 4.8 5.8 6.1 6.6 6.6 Bentonite Gel 2 1. MT $20.00 $270.40 0.64
HP/HT Filtrate 500 psi - 230° F Bentonite Wyoming 45 100. LB $20.00 $517.50 0.65
PPA Spurt (35µ) Total Vol. Caustic Soda 162 25. KG $20.00 $3,418.20 1.29
pH 10.2 10.1 10.1 10.2 10.2 Defoam 5 25. LT $20.00 $353.00 0.04
Pm 2.2 2.8 2.5 3.8 3.6 Biocide 48 25. LT $20.00 $3,189.60 0.42
Pf 0.5 0.4 0.5 0.7 0.7 Pac UL 210 25. KG $20.00 $14,836.50 1.67
Mf 1.7 2 1.6 2.5 2.5 Polysal 472 25. KG $20.00 $11,092.00 3.76
Cl- mg/l 23000 23000 24000 25000 25000 SAPP 2 25. KG $20.00 $85.80 0.02
Ca++ mg/l 600 720 640 400 400 Soda Ash 259 25. KG $20.00 $3,651.90 2.06
Mg++ mg/l 200 291 48 121.5 121.5 Sodium Bicarbonate 40 25. KG $20.00 $496.00 0.32
MBT ppb 7.5 5 5 5 5 XCD 190 25. KG $20.00 $37,297.00 1.51
Excess sulfide mg/l 50 150 150 150 150
H2S n/a n/a n/a n/a n/a
Conqor 404 mg/l 1500 1200 2000 1800 1800
Hach n/a n/a n/a n/a n/a
Hole Angle deg 58 60 58 58 58
Oil SG
K+
NaCl 1.1 1.1 1.1 1.1 1.1
KCl
CaCl2
LGS % 4.3 6.7 6.5 5.9 6.5
HGS % 0.3 1.0 0.4 0.9 0.3
Solids (corr.) % 7.0 5.9 6.9 6.8 6.8
Vsalt
%salt wt.
SG
INTERVAL OVERVIEW
The mud system, used for this section was a Seawater bassed, PHB, polymer system. 1012bbls of mud
was carried over from xxx-1, and reconditioned for use in this section. New mud was also built at
program specs, and once initial displacement begain, mud warmed and sheared through the bit, then the
tweaking of mud properties was addressed. Initialy shakers were dressed with 110mesh, and 140 mesh
Total Product Cost: $148,715.85
screens, then later swaped to 170's and 200's which handled the flow rather well. No FIT was conducted
due to hard cement, so drilling ahead comensed.Highler then normal Calcium levels were noted from the UNIT COSTS Per bbl mud Per ft drilled Per bbl drilled
begining and constant increaesd concnetrations of US$ 21.49 28.16 193.10
Soda Ash was needed to control this. Caustic was used for alkalinityand maintaining the PH at 10-10.2 was achieved through contiunous additions of caustic Soda. 70bbl Seawater Sweeps were pumped every 200ft
drilled, and brought up between 200-300% increase in cuttings for upwards of 2 minutes at a time. ROP increased substantialy while drilling through the Arab formations, with averagess of 200-300ft hr. 2469ft was
drilled in 24 hrs, which was a success, however maintainining PH, and Ca levelels while drilling anhydrite was a challange, and maintaining Mud weight at 9.2ppg, difficult. Constant dillution rates of 40-70bbl/hr of
premix was needed and periodic dumping of sandtraps, for volume and weight control, needed. The centrifuges were run non-stop while drilling this section, with a flow rate of 70gal/min, and 3200RPM bowl speed.
They worked well, cutting the mud weight from 9.3ppg, to 8.9ppg, with a discarded weight of 15.6ppg, on average. The corrosion program was followed with the istalation of 1 corrosion ring in the drill string, and
regular mud maitnence of Conqor 404, and Os1-L. High torque was expereinced early on so initialy 1% volume of starglide was added to the mud, then increased to 2 % once drilling into the ARL formation. Proved to
ease torque, and maintain ROP. MBT was brought down to 5lb/bbl, and XCD used as the main source for Rheology control, with average 6RPM reading kept between 17-18. Drilled to 11297ft, and expereinced tight
hole. Worked pipe and jarred free, increased starglide concentration, and also increased mud weight to 9.4ppg, and weight kept at 9.4ppg to TD. ROP slowed down to 10-15ft/hr and the desion was made at 11386ft, to
establish TD, casing point. Circulated BU, pumping 2.0lb/bbl SAPP sweep at td, and circulated out. Wiper trip to shoe, then back to bottom were 3 x BU was pumped along with 2 60bbl Seawater sweeps then POOH
for running 9 5/8'' liner. Liner was run succssessfully, no fill on bottom and cemented at 11373ft, with TOL set at 5565ft. Cement job was succssessfull, with excess cement Dumped at surface.
Reminder Include:Comments, Solids Control, Problems, Reccomendations, and Lessons Learned

Mud contractor : Made on: 9-Jul-07 By:
160
June 2009

1.5.6 DRILLING ALERT REPORT

161
June 2009

2 Aramco Awareness

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3338' MD/3334' TVD

Possibility of using a vibration sub Keep planned MW

6449' MD/6445' TVD

Water and gel sweeps

Low –Solids Non-Dispersed

Reservoir Drill-In Fluids

Cost-effective drilling fluids formulations

17” Hole Section Spud Mud or KCl LSND

12-1/4” Hole Section

6-1/8” Hole Section WBM Reservoir DIF

17” Hole Section KCl LSND

12-1/4” Hole Section OBM (hole stability &

NaCl based Reservoir

16” Hole Section LSND

12-1/4” Hole Section Water and Gel Sweeps

8-1/2” Hole Section Oil-based Mud due to hole

6-1/8” Hole Section NaCl brine-based DIF

28” Hole Section

16” Hole Section Water and Gel sweeps

12-1/4” Hole Section

6-1/8” Reservoir Hole Oil-based Mud

MATCHING BRINE COMPLETION FLUIDS TO THE BRINE BASED DRILLING FLUID

IF YOUR MUD IS NACL OR KCL BASED TO 73 PCF: Note: Completion Brine Densities

IF YOUR MUD IS NACL OR KCL BASED TO 85 +/- PCF:

IF YOUR MUD IS CACL2 BASED TO 86 PCF: CaCl2 Mud is not

IF YOUR MUD IS SODIUM FORMATE BASED TO 90 +/- PCF:

IF YOUR MUD IS CACL2 BASED TO 95 PCF: CaCl2 Mud is not

CACL2/CABR2 BLEND (WITH PROPER CRYSTALLIZATION POINT) NEVER USE MONOVALENT BRINES

IF YOUR MUD IS SODIUM / POTASSIUM FORMATE BASED TO 106 +/- PCF:

a. Pipe movement should not exceed

D50 = 37μm D90 = 1362 μm

Synthetic Fiber Super Sweep 1.5 cm

Mica MICA D90 = 850 μm D90 = 1.4 mm D90 = 4.75 mm

Nut shells Wallnut D50 = 418μm D50 = 1148μm D50 = 1727μm

Product Type Product Name Blend

Graphite Steel-Seal BDF-398

Fine (ARAMCO) D50 = 8 – 12 μm

Bara-Carb 600 D50 = 600 μm

Truseal (F, M, C) – Petro Chem

Fiber, cedar Cedar fiber (most compan ies)

Fiber & seed hull Cottonseed Hulls (most companies)

Fiber, treated oil-wet Vinseal (M-I)

Steel Seal-100 (d50 = 100 micron)

Cellophane Cellophane Flakes

Blend, High TekPlug* XL (BJ)

Active mud density, PV/YP, 6/3 RPM:

MWD tool in hole (type/company):

Circulating sub in hole (yes/no):

Pump rate during sweep: Pipe rotation during sweep (Yes/No):

High Vis only

High Density only

Before After Remarks

Pump Pressure (psi)

Torque (off btm)

Lost Returns Fracture Process is

3. Stable Crack Growth 4. Stop Pump

losses in fracture face

& Rule of Thumb: The surest way to free stuck pipe is to ALWAYS BE PREPARED. Preplanning

• CaCl2 • Lo Surf‐259 • Radiagreen • Coastal Spot • MEG/TEG • Citric Mutual

Name and Signature of

Rig Mud Lab Audit Report

Report No. Well: Rig: Date:

Electrical Stability Tester

HTHP Filtrate Yes/No