PET 315: DRILLING FLUID

TECHNOLOGY
BY
ENGR. DR. E.E. OKORO
&
ENGR. (MRS) K.B. ORODU 1
DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 DRILLING
PROBLEMS

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU 2

 DRILLING PROBLEMS
• It is not uncommon to have problem in any field of activity

• The degree and the magnitude of the problems, however, vary to

the nature of the causes of the problems

• Drilling problems and the respective causes by their nature are

very much complicated

• Since the problems occur out of our sight, below our feet and
deep in the subsurface, most of the time the problem
identification step is performed by mere speculation
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 THE MOST COMMON DRILLING PROBLEMS

• Loss of circulation

• Cave-in hole (collapse)

• Bridging in wells

• Crookedness of wells/deflection of wells

• Pollution and corrosion in wells

• Mud cake formation 4

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 CAUSES AND EFFECTS OF THE PROBLEMS

• A problem well identified can be considered as partially solved

• Hence to identify any problem developing, sound analytical

approach becomes an indispensable task

• The logical relationship of cause and effect must be well

organized to the identified problems

• Mixing their logical relationship may lead to hampering further

problem analysis tasks
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 EXAMPLE - CAUSES AND EFFECTS OF THE PROBLEMS
• Problem
• Loss of circulation

• Causes
• Natural or intrinsic fractures, induced or created fractures, highly permeable
formations, clogging of the opening of the drill bit are the main subsurface causes
for circulation loss problem

• Effects
• Partial or full interception of the drilling fluid which finally result in staking of the
bit and the pipe may occur
• In addition to this, at times, collapse of the borehole wall in unconsolidated
formation may occur
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 STUCK PIPE / PIPE STICKING
• When part of the drill pipe or collar are stuck in the hole

• If pipe cannot be rotated or pulled and circulation is good, then

pipe is probably wall stuck

• Causes of pipe sticking:

• Differential / wall sticking

• Mechanical sticking
• Key seating

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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 STUCK PIPE / PIPE STICKING
Differential Pressure

• A portion of the drill string is embedded in the mud cake on the

walls of the hole

• It is held there by the pressure difference between in hole and

the formation

• The pull force to free the pipe is a function to the differential

pressure, coefficient of friction and the total contact area of the
pipe on the hole wall. The coefficient of friction is a function of
the mud

• An oil based mud with have a μ of 0.04, a water based mud up

to 0.35

• The contact area, Ac, is expressed in terms of arc length, ψarc,

and the length 8
DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 STUCK PIPE / PIPE STICKING
The causes of differential sticking When it happens
• Unnecessary high differential pressures • Spot oil around the stuck portion
• Thick mud cake (continuous high fluid loss to formation) • Lower mud weight
• Low-lubricity mud cake (high coefficient of friction) • Back-off above the stuck portion then wash-over
it
• Excessive embedded pipe length (time delay in operations) • Place a packer above it

Ways to minimize differential sticking Mechanical Sticking

• Proper mud characteristics (weight, fluid loss) • High Accumulation of cuttings in the annulus
• Collar shape (spiral or square collars) • Borehole Instability – hole caving, sloughing,
plastic squeezing
• Keep drilling solids low in the mud • Key Seat
• Keep rotating the drill string

Indications

• Increase in torque and drag

• Inability to move the pipe
• Circulation of drill fluid is not interrupted 9
DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 DRILLING PROBLEMS
Accumulation of Cuttings Borehole Instability

• It can occur in wells that do not have the • These problems are common in shale sections
adequate hole cleaning of the hole
• This is common in directional or horizontal • Shale can plastically flow inward or slough
wells
causing mechanical sticking
• Increasing circulating pressure while drilling,
or increase in drag when tripping are • Any formation can collapse if the mud weight
indications of a problem is not high enough to control it
• It is a good idea to circulate bottoms up • Indications of trouble are an increase in the
before tripping the pipe as this cleans the torque, increase in circulating pressure or
hole
even the blocking of returns to the surface.
Minimizing
Minimizing
• Proper drilling hydraulics, rate and viscosity • Proper mud design, weight and water loss
• High rotation rate in directional holes
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 DRILLING PROBLEMS
A key seat

• A key seat is formed by the drill string pressing against the side of the hole and cutting
groove
• This happens when the hole is not straight
• The problem occurs when pulling out of the hole the BHA will catch on this groove

Minimizing

• Keeping the hole in proper alignment

When it happens
• First define the problem, what is causing the stuck
• Rotating and reciprocate the drill string if possible
• Increase the pump rate, watch the pressure
• Increase mud weight for hole instability
• Back off, use jars
• Wash-over
• Worse case, sidetrack 11
DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 DRILLING PROBLEMS
Lost Circulating

• The uncontrolled flow of drilling fluids into a downhole formation

• This can be either a partial lost, some returns to the surface or a complete loss with no returns to the surface
• This happens when the drilling encounters a highly fracture zone, one with low pressure-high permeability or a cavern
• If drilling is continued with no returns it is called Dry or Blind drilling

Prevention

• Maintain proper mud weight

• Minimize annular friction pressure
• Maintain adequate hole cleaning
• Set casing to protect weaker formations
• If anticipated, treat mud with lost circulation materials

If it happens

• Pump lost circulation materials in the mud

• Seal the zone with cement or other blockers
• Set casing
• Dry drill (clear water)
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
FLUID LOSS INTO THE FORMATION

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

 LOSS CIRCULATION

• Lost circulation can happen either by pressure induced fractures or through

encountering naturally existing fractures and/or vugs

• The first type of the lost circulation can happen as results of a

• Narrow pore-fracture window

• Tight casing/hole clearances and negative impacts of pressure
• Temperature on rheological properties

• Different techniques and LCM types are applied to mitigate lost circulation problem

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

LOSS CIRCULATION TYPES

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

 PREVENTIVE MEASURES

• Crew Education

• Good Mud Program

• Study Wells in Area

…to be prepared

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

 REMEDIAL MEASURES

• Use Lost Circulation Material as Mud Additive (fibrous or

granular)

• Drill Through Troublesome Interval and Case Off

• Decrease Mud Weight

• Decrease Circulation Rate

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

 LOSS OF CIRCULATION FORMATION TYPES

• Coarsely permeable unconsolidated formations such as;

• Sand, pea gravel and some coarse gravel beds, shell beds and reef deposits

• Vugular and cavernous formations such as;

• Reefs, limestone, chalk and dolomite formations

• Fissures or fractures, both natural and induced

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

ILLUSTRATIONS OF LOST CIRCULATION ZONES

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

MANAGING LOST CIRCULATION: A 4-TIERED STRATEGY
 LOST CIRCULATION EXAMPLE
• This Example shows how to determine the mud weight that can be supported by the
formation and also the mud weight that will control the subsurface pressure.

• Well depth = 16,000 ft

• Protective casing seat = 12,500 ft
• Mud Weight = 17.0 lb/gal
• Drillpipe size = 4.5 in.
• Hole size, casing I.D. = 8.5 in.
• Annulus volume = 0.05 bbl/ft
• Water required to fill hole = 20 bbl

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

EXAMPLE - SOLUTION

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

EXAMPLE – SOLUTION CONT’D

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

EXAMPLE – SOLUTION CONT’D

DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU

 DRILLING PROBLEMS
Hole Deviation

• When the hole deviates from the vertical or planned Drill Pipe Failures - Common Failures
course
• The bit tends to walk while drilling. Formation dip
and rock properties can influence the path of the bit • Twist off
• This can cause both technical and legal problems • Parting
• Burst or collapse
Causes
• Fatigue
• Heterogeneous nature of the rock • Leaking
• Drill string characteristics
• Applied WOB • Most of these are prevented by starting
• RPM of the drill string with a good string
Remedies
• Drill pipe and collars should be constantly
• Lower WOB inspected, and regularly tested
• Slow the rotation
• Change the BHA, add stabizers etc
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 DRILLING PROBLEMS
Borehole Instability - Causes

• Mechanical in situ stresses

• Erosion due to drilling fluids
• Chemical interaction of fluids and formations

Problems
Problems
• Hole Closure
• Increase in torque and drag • Fracturing
• Pipe sticking • Lost circulation and kick potential
• Running and seating casing
• Collapse
• Hole Enlargement
• Pipe sticking
• Difficulty in cementing • Loss of the hole
• Increase chance of hole deviation
• Hydraulic problems in cleaning the hole
• Trouble logging the well
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 DRILLING PROBLEMS
Producing Formation Damage Hole cleaning
• It is “the impairment of the unseen by the inevitable, causing
unknown reduction in the un-quantifiable.” • Problems
• A reduced permeability near the wellbore caused by drilling, • Pipe sticking
cementing or workover fluids • Premature bit wear
• This is called skin • Slow drilling
• Formation damage – fracturing
Mechanisms • Excessive torque and drag
• Solids plugging • Trouble in logging and cementing
• Clay particle swelling or dispersion
Factors
• Saturation change
• Annular velocity
• Emulsion blockage
• Hole inclination angle
• Filtrate blockage • Flow rate max’s @ 65-67o
• Precipitation of soluble salts • Drill string rotation
• ROP
Remedies • Drilling fluid properties
• Lower mud weight • Characteristics of the cuttings
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• Water loss control DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 CORROSION
• Corrosion may be defined as the destruction of a metal or an alloy because
of chemical or electrochemical reaction with its surrounding environment
or medium

• Corrosion is becoming an increasing global threat to the integrity of oil and

gas facilities whose major component is steel with its attendant economic
wastages and associated environmental hazards

• These facilities include pipelines, platforms, vessels (storage tanks), drill pipes
and well casings

• The economic wastages include but are not limited to downtimes,

production losses, contamination and equipment failures; whilst
environmental hazards include pollution, spill, destruction of flora and fauna,
fire outbreak and fatalities
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 CORROSION
• During the drilling operation, O2, H2S, CO2, and other chemicals diffuse and
contaminate the mud
• Oxygen enters the mud from the air; H2S contaminates the mud from the
reservoir and the breakup of the additives
• H2S will promote pitting corrosion and also may cause hydrogen degradation:

• The pitting corrosion acts as stress concentration to lead to wash-out, while H

embrittlement will promote corrosion fatigue

• H2CO3 from reservoir will also induce uniform corrosion:

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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 CORROSION

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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
CORROSION CHEMISTRY OF STEELS

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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 CORROSION PROCESS

Loss of positive metal ions from the Anode causes At the Cathode, excess electrons are neutralized or taken up by
a release of free electrons. This process is called ions in the electrolyte. This process is called Reduction. As long as
Oxidation. reduction reactions predominate, no metal is lost at the cathode
but the anode will continue to corrode
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 EFFECTS OF CORROSION
Losses are economic and safety:

• Reduced Strength

• Downtime of equipment

• Escape of fluids

• Lost surface properties

• Reduced value of goods

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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
CORROSION PREVENTION

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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU
 BACKGROUND

 Problem:

Corrosion and Erosion caused by corrosive factors (i.e chemical) and erosive factors
(i.e. sand) in oil and gas industry

 Solution:

Continuous, on-line corrosion/erosion monitoring system including transmitters,

probes, coupons, access & retrieval equipment, communication equipment, corrosion
server and software
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DR. OKORO E. E. SCHOOL OF PETROLEUM ENGR. CU