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IPTC-21407-MS Handling High-Intensity Brine Influxes Using Flow-While-Drilling FWD Techniques in A Salt Formation in Chinarevskoye Field
IPTC-21407-MS Handling High-Intensity Brine Influxes Using Flow-While-Drilling FWD Techniques in A Salt Formation in Chinarevskoye Field
IPTC-21407-MS Handling High-Intensity Brine Influxes Using Flow-While-Drilling FWD Techniques in A Salt Formation in Chinarevskoye Field
This paper was prepared for presentation at the International Petroleum Technology Conference held virtually on 23 March - 1 April 2021. The official proceedings
were published online on 16 March 2021.
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Abstract
This case study describes the approach taken when drilling an 11 5/8-in. hole section through a salt formation
on the Chinarevskoye field in the West Kazakhstan Oblast region where high-intensity brine influxes and
subsequent flow had been encountered. The intensity of the brine flow, when encountered, had ranged from
5,000 to 6,000 L/min at an equivalent kick density of 2.2 SG, and it is believed to be among the most intense
brine flow experienced in the world during drilling operations.
Standard well control measures proved to be inefficient because of the narrow margin between pore
pressure and fracture pressure gradients. Several techniques were applied to combat such influxes in a safe
manner with minimum associated nonproductive time (NPT). The high-pressured formation in this hole
section is associated not only with brine influxes, but also with losses and gas increase scenarios. As a result,
the company adopted unconventional drilling techniques with a combination of planned flow-while-drilling
(FWD) and mud-cap drilling techniques to reach total depth (TD).
These two techniques created a viable and cost-effective solution to mitigate such challenges, helped
the company to drill to the planned section TD, and consequently complete the well within the defined
authorization for expenditure (AFE) without associated NPT. The paper will cover and emphasize
techniques, along with details on running casing and cementing the hole section, which required an
unconventional approach for success. The paper will also briefly outline the equipment used, such as rotating
control devices (RCDs), a choke manifold, and a separator when drilling this section and their limitations.
Despite the complications, the well was successfully drilled, and this experience provided an opportunity
for learning.
The marked improvements in well control, loss management, and cementation displayed that combining
knowledge and experience can reduce the negative impact on well costs when drilling similar cases.
2 IPTC-21407-MS
Field Background
Chinarevskoye is an oil and gas-condensate field discovered in 1991. It is considered one of the world's most
challenging fields to drill because of its unique geological structure, characterized by a complex tectonic-
sedimentary nature and highly stressed carbonate deposits. It is located at the northern edge of the Pre-
Caspian Basin.
One of the challenges associated with Chinarevskoye field is the fact that layered pay zones underlie
plastic salt formations. To reach these reserves, it is necessary to drill through the salt and case it off. Such
№ Well Depth (m) MW(SG) Influx Rate (m3/hr) NPT (hrs) Notes
1 B 2,025 1.42 11 100 Could not drill further with brine influx
9 J 2,450 1.47 90 622.5 Could not drill further with brine influx
10 K 2,314 1.47 150 605 Could not drill further with brine influx
12 M 2,457 1.37 24 N/A Could not drill further with brine influx
16 Q 1,280 1.47 250 to 280 312 Drilled further with brine influx
19 "A" 1,142 1.57 300 to 360 135.5 Drilled further with brine influx
Brine influxes occur in 10% of the wells when drilling the 11 5/8-in. hole section, and the first problematic
intervals were noticed in the range of 1,800 to 1,900 m with formation pressure up to between 260 and 270
atm (EMW 1.52 SG with a 5% margin). The second challenging interval was from 2,020 to 2,050 m, and
the third one was in the range of 2,420 to 2,490 m.
The major issues encountered when drilling through the salt formations were the following:
• Borehole closure and stuck drillstrings because of salt creep after drilling.
• Washouts and challenges with cementing because of the presence of highly soluble squeezing salts
and high magnesium content in the brine.
Parameter Value
pH 4 to 6
Several preliminary actions were planned for the ability to control drilling fluid parameters when facing
severe calcium/magnesium contamination. Before drilling the 11 5/8-in. section, some volume of kill fluid
with a 2.2 to 2.4 SG and bentonite slurry are mixed and stored in reserve pits. Pre-hydrated bentonite or
dry attapulgite is used to maintain rheological properties and prevent barite from settling when a partial
gain of ≤ 5 m3/hr is experienced. To control filtration properties, the drilling fluid is treated with standard
polymers, such as starch. Polyanionic cellulose is mixed and dispersed also in advance. No special, high
hardness resistant polymers are required in case of having ≤ 50% of high hardness brine in the system. If
the rate of influx is high or the well is mostly displaced with brine over time, then there is no need to treat
the fluid to bring the parameters back to the programmed range.
General Applications
The 11 5/8-in. hole section is associated not only with brine influxes, but also with loss of circulation
scenarios. As a result, Nostrum Oil & Gas (NOG) has adopted a combination of mud cap drilling and flow
while drilling (FWD) to the brine pit techniques to combat the mentioned challenges. In summary, the
methods adopted during drilling of the subject hole section on Chinarevskoye field are listed below:
• Drilling while flowing brine to the surface (flow while drilling [FWD]).
IPTC-21407-MS 5
Conventional well kill procedures are typically applied in an attempt to control the well. However, killing
the well conventionally is not always effective. Thus, depending on the flow intensity of the brine, the well
would be switched either to FWD or mud cap drilling. One of the alternative techniques that was evaluated
by NOG was the possibility of using a conventional MPD application with constant bottomhole pressure
(CBHP) by using a semi-automated MPD manifold. The CBHP technique could minimize brine kicks at
The fluid influx consists of brine, which flows plastically under stresses such as overburden pressure to
a more passive region. When the kick intensity is very high and killing the well is impossible, the option
that would allow safely drilling the sections is FWD. Brine fluid from the well is recirculated and is used as
a sacrificial drilling fluid, which is unloaded and fills up the brine pits on the surface before commencing
drilling in FWD mode.
The objective of FWD is to control the well at the surface with the means of surface control equipment.
Drilling operations should be designed to hold the maximum safe underbalanced condition and to avoid all
unnecessary interruptions while allowing the well to flow on the surface safely.
6 IPTC-21407-MS
Surface Equipment
One of the advantages of FWD and MCD techniques is that they do not involve the use of a lot of equipment.
Specific surface equipment is required for safe and efficient drilling operations through the salt formations.
Fig. 3 and Fig. 4 show the basic equipment layout, including an RCD, a choke manifold, and brine pits.
Choke Manifold
The choke manifold is necessary to maintain a safe operating backpressure and control the flow rate from
the return side. A typical FWD choke manifold should handle the maximum expected volumes with dual
chokes that allow redundancy. Using dual chokes enables one to be quickly isolated and cleaned if plugged
with cuttings while the backup choke operates. During FWD, the chokes will essentially be fully opened
and will gradually be closed, as necessary, to control fluid rates and pressures at the surface. It is imperative
that the annular pressure does not exceed the maximum rated working pressure of the RCD during choking.
Brine Pits
Brine pits should be prepared before a rig move during the well construction phase with the minimum
volume capacity of 5,000 m3. Brine pits are used to accommodate the brine from the well and eventually
used as a sacrificial fluid to drill the section further.
8 IPTC-21407-MS
A total of two bits runs was made to drill the 11 5/8-in. hole section in well A with an average rate
of penetration (ROP) of 34.9 m/hr. The BHA included a low-speed fluid hammer with a polycrystalline
diamond compact (PDC) bit to drill the section and maximize performance because of the low ROP. The
PDC bit was re-run after it was pulled out of the hole for a bottomhole assembly change. Overall, it was
managed to drill through the brine kick zone to the section TD of 2,460 m with no failures.
IPTC-21407-MS 11
Non-Casing Running
Description Make-Up Time Slips In to Slips In
Crew Operation
The cement bond log performed at the end of the 8 1/2-in. section demonstrated intact, solid cement on
the upper section of the brine influx interval.
• Plan the well with the rig crews in mind and prepare for the operations with a detailed drilling-
the-well-on-paper (DWOP) strategy.
• When drilling with brine influxes, the well was unloaded frequently to obtain brine as a sacrificial
drilling fluid, which created a potential risk of the choke washing out. Ensure the availability of
a backup choke before drilling the section.
• Brine pits need to be constructed in advance with a total volume capacity of at least 5,000 m3. This
may differ dependent on anticipated brine flow.
• Pre-prepare and keep kill mud (heavy mud) available to avoid losing time for mud preparation
during drilling operations.
• Ensure corrosion-resistant BHA components are planned for and in place. Use H2S scavenger and
corrosion inhibition in the drilling fluid.
• It is recommended to use only non-ported float valves in every section because of the high risk
of plugging the bit nozzles. Keep additional Texas Iron Works (TIW) valves available on the rig
floor during drilling in case float valves fail.
• Experience from several wells drilled with BHA designs with long gauge bits showed that they
keep well verticality very efficiently. It is therefore recommended to reduce survey frequency and
perform an inclination survey only every four stands while drilling in the 11 5/8-in. hole section.
• It is recommended to conduct a temperature log right after the first cementing stage to check the
TOC and to see if additional cement is required for the second stage because of possible washouts.
IPTC-21407-MS 13
• Hold kick and RCD drills with both rig crews before drilling into the expected brine influx zone
or zones.
Conclusion
The FWD method is successful in many applications when it is not technically or economically feasible
to drill with other managed pressure drilling techniques. Conventional drilling in salt involves complexity,
risks, and high costs, so it was decided to drill using this technique on Chinarevskoye field to provide a
Aknowledgement
The authors of this paper would like to express their gratitude to Nostrum Oil & Gas management for the
support and permission to publish this manuscript. In addition, they wish to thank Weatherford for great
cooperation and the successful implementation of the project.
Nomenclature
AFE – Authorization for expenditure
AROP – Average rate of penetration
BHA – Bottomhole assembly
BOP – Blowout preventer
CBHP – Constant bottomhole pressure
CM – Choke manifold
DWOP – Drilling-the-well-on-paper
EMW – Equivalent mud weight
FIT – Formation integrity test
FWD – Flow while drilling
H2S – Hydrogen sulphide
HMR – High magnesium resistance
KMW – Kill mud weight
MCD – Mud cap drilling
MPD – Managed pressure drilling
MW – Mud weight
NOG – Nostrum oil and gas
NPT – Nonproductive time
PDC – Polycrystaline diamond
PMCD – Presurized mud cap drilling
POOH – Pull out of hole
RCD – Rotating control device
ROP – Rate of penetration
SBP – Surface backpressure
SG – Specific gravity
TD – Target depth
TIW – Texas Iron Works
14 IPTC-21407-MS
References
1. M. D Williamson, S. J. Murray. A Review of Zechstein Drilling Issues // Society Of Petroleum
Engineers, European Conference, Aberdeen. – 1997. – No. 38483.
2. M.H.A.A. Zijp, M.A. Huijgen, M. Wilpshaar, R. Bouroullec, J.H. Ter Heege. Stringers in Salt as
a Drilling Risk// TNO Report. – 22 May 2018. – TNO2018 R10975.
Appendix 1
IPTC-21407-MS