High Pressure High Temperature

Drilling Fluids

Baroid Drilling Fluids

 Hostile Environments (HPHT)
Halliburton/Baroid Presence
North Sea
Russia
Norway
Kazakhstan
and UK
Gulf of Mexico Tengiz

China
Hainan Island
Mexico
Indonesia
Bolivia and
Venezuela

Baroid Drilling Fluids

Source: IHS Energy International Database
HPHT Drilling Fluids
• Drilling Fluids Capabilities
– HT Non Aqueous Fluids
– HT WBM
– Completion Fluids
– Acid Gas
– Barite Sag
– DFG - ECD Modeling

Baroid Drilling Fluids

 HPHT Fluids Issues

• Thermal/Pressure Stability of additives

• Downhole Pressure Management
• Differential Sticking/Mud Losses
• Completion Fluids/Metallurgy
• Fluid Testing and Monitoring
• Barite Sag

Baroid Drilling Fluids

 Stability While Drilling

• Optimize/Control Mud Rheology

– a) Minimize BHP fluctuations
– b) Prevent Barite Sag

• Stability and Tolerance to Contaminants

• Low HPHT Filtrate - Thin Filter Cake
• Tight Stable Quality Emulsion (Inverts)

Baroid Drilling Fluids

 Stability While Static

• Same Criteria as Drilling Plus :

– Minimize Long Term Gellation
– Prevention of Barite Settlement
– Longer Term Stability of System and Products at max T & P

Baroid Drilling Fluids

 HPHT Fluids Issues

Pressure Management

• Narrow band between pore pressure and fracture gradient

• Must understand the T & P behaviour of the system used

• Know and Control pressures exerted on the well

• Utilise pressure tools and proven software packages to

manage / predict pressure drops

Baroid Drilling Fluids

 HPHT Fluids Issues

Pressure Management

• Failure to control can cause:

– Well breathing/ supercharging

– Use of additives to seal formation fractures
– Influx
– Loss of well

Baroid Drilling Fluids

 HPHT Fluids Issues

Pressure Management
• Solutions:

• Stable fluids with lowest practicable rheologies and gels

• Use of additives to “strengthen” formation
• Monitoring via tools/ software
• Good operational procedures

Baroid Drilling Fluids

 HPHT Fluids Issues

Barite Sag

• Experienced over range of well types

• Effects of
– Fluid/product quality
– Well Profile
– Rheology profile -Surface vs Downhole
– Static and semi-static periods

Baroid Drilling Fluids

 HPHT Fluids Issues

Barite Sag
• Select fluid with stable rheology under downhole conditions
• Single function products
• Optimize base fluid/water ratio
• Viscosity and gel building via quality viscosifiers
• Quality emulsifier and fluid loss package
• Weighting agent with optimum sizing and density
• Utilize high density brine based system - field proven to 330
F, 16 ppg for drilling. 400 F and 18.2 ppg for completion
Baroid Drilling Fluids
 HPHT Fluids Issues

Differential Sticking and Seepage Loss

• Porous Sands: Prone to high seepage losses and

differential sticking

• High differential pressures

• Inadequate bridging/ filtercake material

Baroid Drilling Fluids

 HPHT Fluids Issues

Differential Sticking and Seepage Loss

• Effective bridging material treatment and monitoring

strategy
• Additive optimization for maximum sealing with
minimum increase in rheology
• Optimize rheology to minimize ECD and dynamic
overbalance
• Employ good drilling practices

Baroid Drilling Fluids

 Completion Fluids

• Long Term Stability Requirement

• Compatible with metallurgy
• Resistant to reservoir components- H2S, CO2
• Additives should be sulphur-free
• Utilize biocides
• Oxygen scavenger to extend polymer life
• Corrosion inhibitor

Baroid Drilling Fluids

 Fluid Testing

• Design and test fluids for most demanding

conditions
• Optimize rheology to ensure downhole pressures
created remain within operating window
• Check fluids compatibility with formation, drilling and
completion components

Baroid Drilling Fluids

 HPHT Fluids Issues
Fluid Testing
• Special testing of field fluid samples:
– Bridging tests on Aloxite Disks/Slotted Disks
– Particle Size Analysis
– Fann 70 (HPHT Rheometer) Rheology Tests
– Fann 90 Dynamic filtration
– Sag testing

Baroid Drilling Fluids

 HPHT Fluids Issues
Conclusions

• HPHT Wells are challenging

• Can severely stress fluids used
• Design and test fluids to be fit for purpose
• Regularly monitor fluids throughout well
• Use best practices
• Ensure Well Team Trained & Competent in HPHT

Baroid Drilling Fluids

Baroid HPHT Experience
500
ExxonMobil Pemex
Mobile Bay Mexico
450

Elgin/Franklin China
400
North Sea
Temperature (F)

Saudi
350
Arabia
Tuscaloosa
300

High Island
250

ChevronTexaco East Cameron

200 West Cameron

150
0 5,000 10,000 15,000 20,000 25,000
Pressure (PSI)

Baroid Drilling Fluids

HPHT Gulf Coast and GOM
GOM:
BHT’s up to 420 degree F and BHP’s up to 15,000 PSI
• Tuscaloosa Trend
• Mobil Bay
• West Cameron

Baroid Drilling Fluids

 Mud Cooling
Mud Coolers and Insulated Drill pipe

Baroid Drilling Fluids

 Mud Cooling Technology
Insulated Drill pipe

Baroid Drilling Fluids

 Slides that could be added or
incorporated into the presentation

Baroid Drilling Fluids

HPHT Issues

• HSE and Quality

• Thermal Stability of Fluid
• Differential Sticking
• Filtration and Evaporation
• Lost Circulation
• Quantifying impact of Temperature and Pressure
• Barite Sag
• Testing and Completions
• Future Developments

Baroid Drilling Fluids

HSE

• Safe and Successful Operations

– Stable Mud Properties
• Risk Analyses and Hazard Mitigation
– Differential Sticking, Induced Fracture (LOC), Hole
Stability, Hazardous Gases,
• User Friendly Mud Systems
• Environmental Protection
– Base Oil Development

Baroid Drilling Fluids

Safety

• Estimated flow line mud temperatures: 140o to

185o F
• At these temperatures, some water and base oil
evaporation will occur
• Ensure good ventilation in all hot mud
processing areas
• Ensure the drilling fluid flash point is higher than
the anticipated flow line temperature (nb: the
drilling fluid flash point will normally be higher
than that of the base fluid)
• Wear protective clothing

Baroid Drilling Fluids

Thermal stability while drilling

• Components - Thermogravimetric analysis

• System - Hot Roll and Static Age
• Control PV, YP and Gels
• Low HPHT Filtrate and Filter Cake
• Tight Stable Emulsion (Inverts)
• Stability and Tolerance to Contaminants

Baroid Drilling Fluids

Thermal stability while static

• Same Criteria as Drilling Mud + :

– Minimize Long Term Gellation
– Prevent Barite Settlement
– Stability of System and Products to
Temperature at High Density
– Prevent Oil Separation (Inverts)

Baroid Drilling Fluids

Base Fluid Requirements

• Low Kinematic Viscosity

– Lower PV values ( Reduced ECD )
– High low end Rheology ( Hole cleaning )
– Lower synthetic/water ratios for given mud
weight ( less synthetic on cuttings & less
discharge )

Baroid Drilling Fluids

Base Fluid Properties
Mineral n-
Ester ALKANE IAO LAO PAO ACETAL
Oil

S.G. 0.77-0.8 0.86 0.76 0.78 0.78 0.8 0.84

K.
3 6 1.7-1.75 3.6 2.28 6-7 3.5-6
Visc

Flash
71-105 179 >93 >134 113 160 129
Point

Temp
>200 >175 >200 >200 >200 >200 180-200
Stab

Baroid Drilling Fluids

Differential sticking & seepage loss

• Porous Sands: Prone to high seepage losses

and differential sticking
• High differential pressures
• Small tolerance between fracture gradient
and ECD
• Major cost savings and performance
improvements realised by preventative
measures and techniques

Baroid Drilling Fluids

Differential sticking & seepage loss -
Prevention
• Effective bridging material treatment and
monitoring strategy
– Additive optimisation for maximum sealing with
minimum increase in rheology
• Lubricants reduce torque and drag and facilitate
freeing differentially stuck pipe
• Minimise PV’s and ECD’s
• Pipe Movement

Baroid Drilling Fluids

Differential sticking & seepage loss -
Lab testing and monitoring

• Bridging Tests using Aloxite Disks/Slotted Disks

• HPHT cell and Permeability Plugging Apparatus
• Particle Size Analysis
• Fann 90 Dynamic Filtration Tests
• Fann 70 Rheological Properties under Downhole
Conditions

Baroid Drilling Fluids

Fracture Gradient versus ECD
• Difference of 0.5 - 1.0 ppg is likely between ECD
and static mud weight
• May only be a narrow band between ECD and
fracture gradient at the casing shoe
• Importance of casing seat selection
• May need two separate mud systems: Drilling
mud and Tripping mud
• Avoid rapid pipe movements to minimise surge
and swab pressures
• Use DFG WIN to understand/monitor all
pressures
Baroid Drilling Fluids
Fracture Gradient versus ECD
• Stage into the hole, circulating at least once before bottom, to
break gels and heat mud
• Mud in riser will be cooler, heavier and thicker after trips,
resulting in increased ECD
• Rotate pipe before breaking circulation
• Use mud density calculations corrected for temperature and
pressure to monitor mud weight downhole:
• Use downhole rheology corrected for temperature and pressure
for ECD, surge/swab calculations:
• If losses occur, reduce pump rate, monitor loss rate and
implement planned action to cure losses
• Displacement procedures - defined and agreed

Baroid Drilling Fluids

Induced Lost Circulation

• Often occurs during a trip into the hole due to:

– Increased density caused by cold mud in
annulus and slug pumped before trip
– Surge pressure of BHA on small diameter gauge
hole
– High initial pump pressure & ECD caused by
cooler mud when breaking circulation
– Mud gellation & barite settling

Baroid Drilling Fluids

Thermal expansion in Invert Emulsions
• Thermal expansion reduces mud density and rheology
• Always record temperature of rheology and density
measurements
• After a trip, a slow stand-pipe pressure drop occurs as
the mud heats up and thins out
• This can resemble a drillstring washout
• Coarser shaker screens will be needed until the mud
heats up and thins

Baroid Drilling Fluids

Impact of temperature & pressure -
Invert Emulsion Fluids

T V , 

P
V,

T , P  V ?, 
?

Baroid Drilling Fluids

Impact of temperature & pressure

• Quantify impact on down hole rheologies, ECD’s,

Surge and Swab. Do not generalise to predict
trends:
• Critical Impact on density and bottom hole
pressures
• Density increase of cold mud (pits and riser)
versus hot mud, especially after trips

Baroid Drilling Fluids

Barite Sag
• Effects of
– Hole Angle
– Well Profile
– Static and semi-static periods
• Rheology-Surface vs Downhole
• Type and quality of fluid loss reducers, viscosifiers, base
fluid, emulsifiers, particle distribution, density and
quantity of the weight material, chemical contamination,
reaction of chemical thinners
• Monitor using FANN 70 & HAST

Baroid Drilling Fluids

Impact of Quality
• Quality usually provides the most cost effective solutions
to HPHT wells
• Use base fluid with the lowest practicable kinematic
viscosity
• Reliable emulsifier, fluid loss reducer and viscosifier
package
• Premium barite to tailored specifications
• Products to provide hole cleaning, barite suspension
whilst ensuring the lowest practicable rheologies

Baroid Drilling Fluids

Barite Quality
• Higher SG - API specs 4.2 SG, suggest 4.23-4.30 SG.
• Importance of low carbonates and sulphides content
especially with WBM’s. No API specs. Suggest less
than 3000 mg/l, typical 1200-2000 mg/l
• Environmental impact from heavy metals content.
• Effect of grind size
– API - Max 30% below 6 micron and 4% above 74 micron
– Suggest - Max 17 - 25% below 6 micron

Baroid Drilling Fluids

Routine Lab Testing
• Regular testing of field mud samples:
– Complete API mud check
– Static ageing tests at estimated BHT
– HAST sag tests
• Special testing of field mud samples:
– Bridging tests on Aloxite Disks/Slotted Disks
– Particle Size Analysis
– FANN 70 (HPHT Rheometer) Rheology Tests
• Test mud compatibility with testing, completion or packer fluids
• Regular calibration of testing equipment

Baroid Drilling Fluids

Routine Lab Testing
• Test HPHT filtrate at estimated BHT
• Test rheology at standard temperature, eg 120 oF
• Calibrate test equipment regularly, eg. mud
balance can be checked with 18 ppg calcium
bromide/zinc bromide brine
• Static ageing tests at estimated BHT can be done
on rig

Baroid Drilling Fluids

Pit level monitoring

• Particularly in lower sections, there will be a

small margin between formation pore
pressure and casing shoe fracture gradient
• Mud loggers, drillers, derrickmen and mud
engineers must monitor pit levels closely
• Hold regular pit drills
• Regularly check pit level sensor calibration

Baroid Drilling Fluids

Well Control

• Add base oil or barite treatment via reserve

pit whenever possible to minimise density
variations in the well
• The ECD (Equivalent Circulating Density) will
be very close to the fracture gradient and the
static mud weight will be very close to the
formation pressure
• Minimize ECD and surge/swab pressures by
all available methods
Baroid Drilling Fluids
Well Testing
• With oil mud in use require:
– Long term stability
• Balance between barite suspension and
thickening
• Dense, solids free invert emulsion perforating
pill
• Use of clear brine
– Displacement and clean-up
– Associated cost and rig time

Baroid Drilling Fluids

Lost Circulation

• Reduce delta T
– mud/formation
– heat surface fluid
– periodically break circulation
• Reduce overbalance
• Reduce fluid loss control
– increase API (OBM/WBM)
– increase HPHT (OBM/WBM)
– consider differential sticking implications

Baroid Drilling Fluids

Lost Circulation

• Utilize effective LCM

– BAROFIBRE
– BXR/BXR-L
– STEELSEAL
• Stabilize rheological character
• Stabilize gel structure with low and flat
character

Baroid Drilling Fluids

Lost Circulation

• Select mud type with consideration to

contaminants
• Minimize ECD, utilize model that incorporates
downhole rheology/density validated with
downhole pressure measurements

Baroid Drilling Fluids

Support Tools

• FANN-70 - Dynamic and static rheologies

under downhole temperature and pressure
conditions
• FANN-90 - Dynamic filtration under downhole
temperature and pressure conditions
• Particle Plugging Tester
Bridging – 2000 psi and 260oC
• DFG+ WIN - Modelling of downhole rheology,
ECD, swab & surge pressures

Baroid Drilling Fluids

 Questions?

Baroid Drilling Fluids